Omm - Wa380z-6 PDF

PEN00665-00
WHEEL LOADER WA380Z -6

SERIAL NUMBERS 66847 and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
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1-1
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BEFORE READING THIS MANUAL FOREWORD
BEFORE READING THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety
rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance
of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the
location shown on the right so that all relevant personnel can read
it at any time.
Storage location for the Operation and Maintenance Manual:

Pocket (1) at rear of operator's seat
If this manual is lost or damaged, contact and tell your distributor about the machine model name and the serial No.
immediately to arrange for its replacement. For details regarding the machine model name and the serial No., see
the machine serial No. plate. In order to arrange the proper Operation and Maintenance Manual, you will need to
provide the machine model name and the serial No. to your Komatsu distributor.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used
in the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:1 → (1))
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, 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.
1-2
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced
if the precaution is not followed.
This word is used for information that is useful to know.
1-3
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INTRODUCTION FOREWORD
INTRODUCTION
USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Smoothing
Pushing work
Loading work
For details of the operating procedure, see "WORK POSSIBLE USING WHEEL LOADER (PAGE 3-124)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
(A) Front (E) Bucket
(B) Rear (F) Operator's seat
(C) Left
(D) Right
1-4
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FOREWORD INTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT

The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
VISIBILITY IN IMMEDIATE AREA

The visibility of this machine in the area 1 m (3 ft 3in) from the outside surface of the machine at a height of 1.5 m
(4 ft 11 in) is shown in the diagram below. The hatched area (A) shows the area where the view is blocked by part
of the machine when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are
places that cannot be seen when operating the machine.
When this machine is equipped with the rear under view mirror as optional, the visibility of the area 1 m from the
outside surface of the machine at a height of 1.5 m is secured.
12-M RADIUS VISIBILITY

The visibility on a circumference of 12 m of this machine is secured.
1-5
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NECESSARY INFORMATION FOREWORD
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

On the center right of the front frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE

This is at the top at the rear of the engine on the right side of the machine.
1-6
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FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER

It is at the center bottom of the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
1-7
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
BEFORE READING THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 4
USE OF MACHINE 1- 4
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR'S SEAT 1- 5
NECESSARY INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NO. PLATE 1- 6
POSITION OF SERVICE METER 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 14
PRECAUTIONS BEFORE STARTING OPERATION 2- 14
PREPARATIONS FOR SAFE OPERATION 2- 14
FIRE PREVENTION 2- 16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 17
DO NOT GET CAUGHT IN ARTICULATING PORTION 2- 20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 20
UNAUTHORIZED MODIFICATION 2- 20
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 20
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 21
PRECAUTIONS FOR OPERATION 2- 22
PRECAUTIONS FOR JOBSITE 2- 22
STARTING ENGINE 2- 24
OPERATION 2- 26
TRANSPORTATION 2- 33
TOWING 2- 34
PRECAUTIONS FOR MAINTENANCE 2- 35
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 35
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 39
TIRES 2- 44
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
MACHINE MONITOR 3- 6
SWITCHES 3- 41
CONTROL LEVERS, PEDALS 3- 52
STEERING TILT LOCK LEVER 3- 57
CAP WITH LOCK 3- 58
FRAME LOCK BAR 3- 60
TOWING PIN 3- 60
1-8
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FOREWORD CONTENTS
OPENING, CLOSING CAB DOORS, WINDOWS 3- 61

BACKUP ALARM 3- 65
FUSE 3- 66
SLOW BLOW FUSE 3- 67
POWER OUTLET 3- 68
AM/FM RADIO 3- 69
AIR CONDITIONER 3- 75
HANDLING CAB WIPER 3- 82
LOCATION OF FIRE EXTINGUISHER 3- 82
HANDLING MACHINES EQUIPPED WITH KOMTRAX 3- 83
OPERATION 3- 84
CHECK BEFORE STARTING ENGINE, ADJUST 3- 84
STARTING ENGINE 3-102
CHECKS AFTER STARTING ENGINE 3-106
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-107
STOPPING ENGINE 3-109
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE 3-110
TURNING 3-119
OPERATION OF WORK EQUIPMENT 3-122
WORK POSSIBLE USING WHEEL LOADER 3-124
PRECAUTIONS FOR OPERATION 3-131
ADJUSTING WORK EQUIPMENT POSTURE 3-133
PARKING MACHINE 3-135
CHECKS AFTER COMPLETION OF OPERATION 3-137
LOCKING 3-138
HANDLING THE TIRES 3-139
TRANSPORTATION 3-141
TRANSPORTATION PROCEDURE 3-141
LOADING, UNLOADING WORK WITH TRAILERS 3-141
LIFTING MACHINE 3-145
COLD WEATHER OPERATION 3-147
PRECAUTIONS FOR LOW TEMPERATURE 3-147
PRECAUTIONS AFTER COMPLETION OF WORK 3-148
AFTER COLD WEATHER 3-148
LONG-TERM STORAGE 3-149
BEFORE STORAGE 3-149
DURING STORAGE 3-149
AFTER STORAGE 3-149
TROUBLESHOOTING 3-150
WHEN MACHINE RUNS OUT OF FUEL 3-150
METHOD OF TOWING MACHINE 3-150
IF BATTERY IS DISCHARGED 3-155
OTHER TROUBLE 3-158
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
1-9
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CONTENTS FOREWORD
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10

LUBRICATION CHART 4- 11
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15
TORQUE LIST 4- 15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 16
MAINTENANCE SCHEDULE CHART 4- 18
MAINTENANCE SCHEDULE CHART 4- 18
SERVICE PROCEDURE 4- 20
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE) 4- 20
INITIAL 250 HOURS SERVICE 4- 20
INITIAL 1000 HOURS SERVICE 4- 20
WHEN REQUIRED 4- 21
CHECK BEFORE STARTING 4- 41
EVERY 100 HOURS SERVICE 4- 42
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING BUCKET AND TIRES 6- 2
INDEX 7- 1
1 - 10
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2-1
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SAFETY SAFETY
SAFETY
SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 14
PRECAUTIONS BEFORE STARTING OPERATION 2- 14
ENSURING SAFE OPERATION 2- 14
UNDERSTANDING THE MACHINE 2- 14
PREPARATIONS FOR SAFE OPERATION 2- 14
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 14
INSPECTING MACHINE 2- 14
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2- 14
KEEP MACHINE CLEAN 2- 15
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT 2- 15
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2- 15
IF ANY PROBLEM IS FOUND 2- 15
ACTION IF FIRE OCCURS 2- 16
PRECAUTIONS TO PREVENT FIRE 2- 16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 17
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 2- 17
NO JUMPING ON OR OFF MACHINE 2- 17
NO PEOPLE ON ATTACHMENTS 2- 17
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT 2- 18
PRECAUTIONS WHEN LEAVING MACHINE 2- 19
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 19
PRECAUTIONS WHEN CLEANING CAB GLASS 2- 19
DO NOT GET CAUGHT IN ARTICULATING PORTION 2- 20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 20
UNAUTHORIZED MODIFICATION 2- 20
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 20
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 21
2-2
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SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 22

PRECAUTIONS FOR JOBSITE 2- 22
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 22
WORKING ON LOOSE GROUND 2- 22
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 23
ENSURE GOOD VISIBILITY 2- 23
CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 23
BEWARE OF ASBESTOS DUST 2- 24
STARTING ENGINE 2- 24
WARNING TAGS 2- 24
INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE 2- 25
PRECAUTIONS WHEN STARTING ENGINE 2- 25
PRECAUTIONS IN COLD AREAS 2- 25
STARTING WITH BOOSTER CABLES 2- 26
OPERATION 2- 26
CHECKS BEFORE OPERATION 2- 26
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 27
PRECAUTIONS WHEN TRAVELING 2- 28
TRAVELING ON SLOPES 2- 29
METHOD OF USING BRAKES 2- 29
PRECAUTIONS WHEN OPERATING 2- 30
PROHIBITED OPERATIONS 2- 31
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 2- 31
PARKING MACHINE 2- 32
TRANSPORTATION 2- 33
LOADING AND UNLOADING 2- 33
TOWING 2- 34
PRECAUTIONS WHEN TOWING 2- 34
2-3
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SAFETY SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 35

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 35
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 35
KEEP WORKPLACE CLEAN AND TIDY 2- 35
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 35
ONLY AUTHORIZED PERSONNEL 2- 35
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 35
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 36
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 37
INSTALLING, REMOVING, OR STORING ATTACHMENTS 2- 38
PRECAUTIONS WHEN WORKING AT HIGH PLACES 2- 38
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2- 38
PROPER TOOLS 2- 38
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 39
PRECAUTIONS WHEN WELDING 2- 39
HANDLING BATTERY 2- 39
PRECAUTIONS WHEN USING HAMMER 2- 40
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2- 40
PRECAUTIONS WITH HIGH-TEMPERATURE OIL 2- 40
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 41
PRECAUTIONS WITH HIGH-PRESSURE FUEL 2- 41
HANDLING HIGH-PRESSURE HOSES AND PIPING 2- 41
NOISE 2- 41
HANDLING ACCUMULATOR AND GAS SPRING 2- 42
PRECAUTIONS WITH COMPRESSED AIR 2- 42
MAINTENANCE OF AIR CONDITIONER 2- 42
DISPOSING OF WASTE MATERIALS 2- 42
METHOD OF SELECTING WINDOW WASHER FLUID 2- 42
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 43
TIRES 2- 44
HANDLING TIRES 2- 44
PRECAUTIONS WHEN STORING TIRES 2- 45
2-4
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SAFETY SAFETY LABELS
SAFETY LABELS
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
To ensure that the content of these safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline.
These may cause the safety labels to peel off.
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part
numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
There are also other labels in addition to the safety labels. Handle these labels in the same way.
LOCATION OF SAFETY LABELS
2-5
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SAFETY LABELS SAFETY
SAFETY LABELS
(1) Caution before starting (09651-A0481)
(2) Caution for leaving the operator's seat (09654-C0481)
2-6
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(3) Caution when traveling in reverse (09802-D0880)
(4) Caution for going close to electric cables (09801-C0481)
2-7
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(5) Caution to keep away from movable parts (09162-C0641)
(6) Caution for frame lock bar (09161-C0641)
(7) Caution when canceling parking brake emergency

(423-93-41172)
2-8
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(8) Caution when coolant is at high temperature (09653-A0641)
(9) Caution when handling battery cable (09808-A1201)
(10) Explosion hazard (09659-A057B)
(11) Escape (425-93-51110)
2-9
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(12) "Do not open when engine is running" sign (09667-A0880)
(13) Caution for rotating fan (09667-A0481)
(14) "Do not come near machine" sign (09806-C0883)
2 - 10
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(15) "Do not go under work equipment" sign (09807-C0883)
(16) Caution blast site (09845-00480)

(only when equipped with KOMTRAX)
(17) Prohibition of engine start by short-circuiting (09842-A0481)
2 - 11
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(18) Caution for high temperature turbocharger (09817-A0753)
(19) Caution for high temperature exhaust pipe (09817-A0753)
(20) Caution for common rail high pressure (6754-71-1991)
2 - 12
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(21) Parking brake emergency cancel switch (423-93-41172)
(22) "Do not modify ROPS" sign (09620-A2000)
2 - 13
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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION AND

MAINTENANCE
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying
out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully
and obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION
ENSURING SAFE OPERATION

Only trained and authorized personnel can operate and maintain the machine.
Follow all safety, precautions, and instructions in this manual when operating or performing inspection or
maintenance on the machine.
If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate
or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
When working with another operator or with the person on the worksite traffic duty, discuss the content of the
operation beforehand and use the determined signals when carrying out the operation.
UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
PREPARATIONS FOR SAFE OPERATION
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT

Be sure that all guards, covers and mirrors 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.
INSPECTING MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

Do not wear loose clothes or any accessories. If these catch on
the control levers or protruding parts, there is danger that it may
cause the machine to move unexpectedly.
Always wear a hard hat and safety shoes. If the nature of the
work requires it, wear safety glasses, mask, gloves, ear plugs,
and safety belt when operating or maintaining the machine.
If you have long hair and it hangs out from your hard hat, there
is a hazard that it may get caught up in the machine, so tie your
hair up and be careful not to let it get caught.
Check that all protective equipment functions properly before
using it.
2 - 14
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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
KEEP MACHINE CLEAN

If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or
oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the
machine clean.
If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. If there is any
misoperation, there is danger that the machine may move
unexpectedly and cause serious personal injury or death.
When washing the machine with water or steam, do not allow
the water or steam to come into direct contact with electrical
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
Do not leave tools or a machine parts lying around inside the operator's compartment. If tools or parts get into
the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in serious
personal injury or death.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could cause serious personal injury or death.
Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read the
labels to ensure that you know how to use them in
Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
Provide a first aid kit in the storage point. Carry out periodic
checks and add to the contents if necessary.
IF ANY PROBLEM IS FOUND

If you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges,
smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge
and have the necessary action taken. Do not operate the machine until the problem has been corrected.
2 - 15
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FIRE PREVENTION
ACTION IF FIRE OCCURS

Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.
Do not jump off the machine. There is the danger of falling and suffering serious injury.
PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, COOLANT or window washer fluid
Do not bring any flame or fire close to flammable substances
such as fuel, oil, COOLANT or window washer fluid. There is
danger that they may catch fire. To prevent fire, always observe
the following:
Do not smoke or use any flame near fuel or other flammable
substances.
Stop the engine before adding fuel.
Do not leave the machine when adding fuel or oil.
Tighten all fuel and oil caps securely.
Be careful not to spill fuel on overheated surfaces or on parts
of the electrical system.
After adding fuel or oil, wipe up any spilled fuel or oil.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline. There is danger that they may
catch fire.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Determine well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the determined place and do not
allow unauthorized persons to enter.
When carrying out grinding or welding work on the machine,
move any flammable materials to a safe place before
starting.
Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
Fire coming from electric wiring

Short circuits in the electrical system can cause fire. To prevent fire, always observe the following.
Keep all electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair
or replace any damaged wiring.
Fire coming from piping

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or
2 - 16
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Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the handrails and steps marked by arrows in the diagram
on the right when getting on or off the machine.
Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one foot)
with the handrail and steps to ensure that you support yourself.
Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on
them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.
Do not grip the control levers and work equipment lock lever when getting on or off the machine.
Never climb on the engine hood or covers where there are no non-slip pads.
Never move from the step at the rear of the machine or the step at the side of the cab to stand on top of the tire.
Do not get on or off the machine while holding tools in your hand.
NO JUMPING ON OR OFF MACHINE

Never jump on or off the machine. Never get on or off a moving machine.
If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering
serious personal injury or death.
2 - 17
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PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

Before standing up from the operator's seat, such as when
adjusting the position of the seat, always lower the work
equipment completely to the ground, set work equipment lock
lever (1) to the lock position (L), set parking brake switch (2) to the
ON position (A), and stop the engine.
If the control levers are touched by mistake, the machine may
suddenly move and cause serious personal injury or death.
2 - 18
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PRECAUTIONS WHEN LEAVING MACHINE

If the proper procedures are not taken when parking the machine,
the machine may suddenly move off by itself, and this may lead to
serious personal injury or death. Always do the following.
When leaving the machine, always lower the work equipment
completely to the ground, set work equipment lock lever (1) to
the lock position (L), set parking brake switch (2) to the ON
position (A), and stop the engine.
In addition, lock all parts, always take the key with you, and
leave it in the specified place.
EMERGENCY EXIT FROM OPERATOR'S CAB

On machines fitted with a cab, a door is installed on the left side and an emergency escape door is installed on the
right side. If the door on the left side does not open, escape from the emergency door on the right side.
PRECAUTIONS WHEN CLEANING CAB GLASS

Clean the cab glass to ensure visibility during operation.
Make sure to clean the glass from the ground using a mop.
For details of the cleaning procedure, see "WALK-AROUND CHECK (PAGE 3-84)".
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DO NOT GET CAUGHT IN ARTICULATING PORTION

If the clearance at the articulating portion changes and you get
caught in it, you will suffer serious personal injury or death. Do
not allow anyone to come inside the articulation range.
The clearance in the area around the work equipment changes
according to the movement of the link. If you get caught, you
will suffer serious personal injury or death. Do not allow anyone
to come close to any rotating or extending/retracting portion.
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

The operator's compartment is equipped with a structure (such as
ROPS, FOPS) to protect the operator by absorbing the impact
energy. As for the machine equipped with ROPS, if the machine
weight (mass) exceeds the certified value (shown on the
ROLL-OVER PROTECTIVE STRUCTURE (ROPS)
CERTIFICATION plate), ROPS will not be able to fulfill its function.
Do not increase machine weight beyond the certified value by
modifying the machine or by installing attachments to the
machine. Also, if the function of the protective equipment is
impeded, the protective equipment will not be able to protect the
operator, and the operator may suffer injury or death. Always
observe the following.
If the machine is equipped with a protective structure, do not
remove the protective structure and carry out operations
without it.
If the protective structure is welded, or holes are drilled in it, or
it is modified in any other way, its strength may drop. Consult
your Komatsu distributor before carrying out any modifications.
If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced
and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu distributor for
advice on the method of repair.
Even if the protective structure is installed, always fasten your seat belt properly when operating the machine.
If you do not fasten your seat belt properly, it cannot display its effect.
UNAUTHORIZED MODIFICATION
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized
attachments or parts will not be the responsibility of Komatsu.
When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
contact your Komatsu distributor for advice.
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When installing and using optional attachments, read the instruction manual for the attachment, and the general
information related to attachments in this manual.
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

The engine exhaust gas contains substances that may damage
your health or even cause death. Start or operate the engine in a
place where there is good ventilation. If the engine or machine
must be operated inside a building or under ground, where the
ventilation is poor, take steps to ensure that the engine exhaust
gas is removed and that ample fresh air is brought in.
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PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR JOBSITE
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting
operations, always check the following to confirm that there is no danger on the jobsite.
When carrying out operations near combustible 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 operate where there is a hazard of landslides or falling rocks.
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.
In particular, if you need to operate on a road, protect
pedestrian and cars by designating a person for worksite traffic
duty or by installing fences around the worksite.
When traveling or operating in water or on soft ground, check
the water depth, speed of the current, bedrock, and shape of the
ground beforehand and avoid any place that will obstruct travel.
Maintain the travel path on the jobsite so that there is no
obstruction to travel operations.
WORKING ON LOOSE GROUND

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after
earthquakes is weak in these areas.
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the
machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe
and to prevent the machine from rolling over or falling.
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SAFETY PRECAUTIONS FOR OPERATION
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is
a hazard of electric shock, which may cause serious personal
injury or death. On jobsites where the machine may go close to
electric cables, always do as follows.
Before starting work near electric cables, inform the local power
company of the work to be performed, and ask them to take the
necessary action.
Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death. Always Voltage of Cables Safety Distance
maintain a safe distance (see the table on the right) between the 100V - 200V Over 2 m (7 ft)
machine and the electric cable. Check with the local power 6,600V Over 2 m (7 ft)
company about safe operating procedure before starting 22,000V Over 3 m (10 ft)
operations. 66,000V Over 4 m (14 ft)
To prepare for any possible emergencies, wear rubber shoes 154,000V Over 5 m (17 ft)
and gloves. Lay a rubber sheet on top of the seat, and be careful
187,000V Over 6 m (20 ft)
not to touch the chassis with any exposed part of your body.
275,000V Over 7 m (23 ft)
Use a signalman to give warning if the machine approaches too
close to the electric cables. 500,000V Over 11 m (36 ft)
When carrying out operations near high voltage cables, do not
let anyone near the machine.
If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not leave
the operator's compartment until it has been confirmed that the
electricity has been shut off.
Also, do not let anyone near the machine.
ENSURE GOOD VISIBILITY

This machine is equipped with mirrors to ensure good visibility, but even then there are places that cannot be seen
from the operator's seat, so be careful when operating.
When traveling or carrying out operations in places with poor visibility, it is impossible to check for obstacles in the
area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury
or death. When traveling or carrying out operations in places with poor visibility, always observe the following.
Position a signalman if there are areas where the visibility is not good.
Only one signalman should give signals.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to ensure
good visibility.
CHECKING SIGNS AND SIGNALMAN'S SIGNALS

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
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BEWARE OF ASBESTOS DUST

Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working
on jobsites handling demolition work or work handling industrial waste. Always observe the following.
Spray water to keep down the dust.
Do not use compressed air.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position, and make
sure that all workers operate on the upwind side.
All workers should use anti-dust masks.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and
environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always
use genuine Komatsu parts.
STARTING ENGINE
WARNING TAG
If there is any "DANGER! Do NOT operate!" warning tag
displayed, it means that someone is carrying out inspection and
maintenance of the machine. If the warning sign is ignored and
the machine is operated, there is danger that the person carrying
out inspection or maintenance may be caught in the rotating parts
or moving parts and suffer serious personal injury or death. Do not
start the engine or touch the levers.
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INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly problems may occur with
the operation of the machine, and there is danger that this may lead to serious personal injury or death.
Remove all dirt from the surface of the window glass to ensure a good view.
"WALK-AROUND CHECK (PAGE 3-84)" is surely executed.
Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and
check that they light up correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check
for damage to the electric wiring.
Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake
pedal, and check that the pedals work properly.
Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no damage
or wear to the seat belt or mounting clamps.
Check that the gauges work properly, check the angle of the mirror, and check that the control levers are all at
the Neutral position.
Before starting up the engine, check that the work equipment lock lever is in the LOCK position.
Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See "ADJUSTING
MIRRORS (PAGE 3-99)".
Check that there are no persons or obstacles above, below, or in the area around the machine.
Check that the parking brake switch is at the ON position.
Check that frame lock lever (1) is securely fixed at FREE
position(F).
PRECAUTIONS WHEN STARTING ENGINE

Start and operate the machine only while seated.
When starting the engine, sound the horn as a warning.
Do not allow anyone apart from the operator to ride on the machine.
Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious
Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
PRECAUTIONS IN COLD AREAS

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
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STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
Always wear safety goggles and rubber gloves when starting
the engine with booster cable.
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.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting switch to
the OFF position 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 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.
For details of the starting procedure when using booster cables,
see "STARTING ENGINE WITH BOOSTER CABLE (PAGE
3-156)" in the OPERATION section.
OPERATION
CHECKS BEFORE OPERATION

If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful
attention to the surrounding area. Do not allow anyone near the machine.
Always wear the seat belt. There is danger that you may be
thrown out of the operator's seat and suffer serious injury when
the brakes are applied suddenly.
Check the operation of travel, steering and brake systems, and
work equipment control system.
Check for any problem in the sound of the machine, vibration,
heat, smell, or gauges; check also that there is no leakage of oil
or fuel.
If any problem is found, carry out repairs immediately.
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Before driving the machine or starting operations, check that

frame lock bar (1) is fixed securely at FREE position (F).
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

Lock the cab door and windows securely, both when they are open and when they are closed.
Do not allow anyone apart from the operator to ride on the machine.
If there are any persons in the area around the machine, there
is danger that they may be hit or caught by the machine, and
this may lead to serious personal injury or death. Always
observe the following before traveling.
Always operate the machine only when seated.
Before moving off, check again that there is no person or
obstruction in the surrounding area.
Before moving, sound the horn to warn people in the
surrounding area.
Check that the backup alarm (alarm buzzer when machine
travels in reverse) works properly.
If there is an area to the rear of the machine which cannot be
seen, position a signalman.
Always be sure to carry out the above precautions even when the
machine is equipped with mirrors.
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PRECAUTIONS WHEN TRAVELING

Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the
machine is traveling, because the steering becomes heavy. There is danger that this will cause misoperation
of the steering wheel and may lead to serious personal injury or death. If the engine stops, depress the brake
pedal immediately to stop the machine.
When traveling or carrying out operations, always keep a safe distance from people, structures, or other
machines to avoid coming into contact with them.
When traveling on level ground, keep the work equipment at
height (A) 40 to 50 cm (16 to 20 in) from the ground. If the work
equipment is not sufficiently raised from the ground, there is
danger that the work equipment will contact the ground and
cause the machine to tip over.
When traveling, do not operate the work equipment control
levers. If the work equipment control levers have to be
operated, stop the machine first, then operate the levers.
Avoid traveling over obstacles when possible. If the machine
has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. There is more danger of
the machine tipping over to the left or right than tipping over to
the front or rear, so do not travel over obstacles which make the
machine tilt strongly to the left or right sides.
When traveling on rough ground, travel at low speed and do not
operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the ground
surface and cause the machine to lose its balance, or may
damage the machine or structures in the area.
When using the machine, to prevent personal injury caused by damage to the work equipment or by the machine
overturning due to overloading, do not exceed the permitted performance of the machine or the maximum
permitted load for the structure of the machine.
When passing over bridges or structures, check first that the structure is strong enough to support the weight of
the machine.
When operating in tunnels, under bridges, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the machine body or work equipment hit anything.
If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal
pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces a large
destructive force, and this may cause serious injury or death.
If you are going to travel continuously, please consult your Komatsu distributor.
When the machine is traveling on flat ground or down a slope, NEVER set the directional lever to the Neutral
position. Always set it to a transmission speed range.
If the transmission is at neutral, the engine brakes will not work and the steering wheel will become heavy,
so this creates a dangerous situation.
It may also cause damage to the transmission or other parts of the power train, and this may lead to serious
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TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
Keep the work equipment at height (A) 20 to 30 cm {8 to 12 in}
above the ground) so that it can be lowered immediately to the
ground to stop the machine in case of emergency.
Always travel straight up or down a slope. Traveling at an angle

or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that
the machine may slip.
If the engine stops, depress the brake pedal immediately, lower the bucket to the ground, and apply the parking
brake to stop the machine.
When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use the
braking force of the engine. Always place the transmission in a low gear before starting to travel downhill.
When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake
pedal to control the travel speed.
When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill. If the machine
travels with the bucket facing downhill, there is danger that the machine may tip over.
METHOD OF USING BRAKES

When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on the
pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
Do not depress the brake pedal repeatedly if not necessary.
Set to the lock-up and use the braking force of the engine.
When traveling downhill, use the engine brake while turning the transmission cut-off switch to the OFFposition.
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PRECAUTIONS WHEN OPERATING

When using the machine, to prevent personal injury caused by damage to the work equipment or by the machine
overturning due to overloading, do not exceed the permitted performance of the machine or the maximum
permitted load for the structure of the machine.
If the engine cannot be started again after it has stopped, immediately operate the work equipment control levers
to lower the work equipment to the ground. (After the engine stops, the accumulator allows the work equipment
to be operated for a limited time.)
Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when
dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.
The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of
a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure to reduce
the speed.
When the bucket is fully loaded, never start, turn, or stop the
machine suddenly. There is danger of the machine turning
When handling unstable loads, such as round or cylindrical

objects, or piled sheets, if the work equipment is raised high,
there is danger that the load may fall on top of the operator'
compartment and cause serious injury or death.
When handling unstable loads, be careful not to raise the work
equipment too high or tip the bucket back too much.
If the work equipment is suddenly lowered or suddenly stopped,
the reaction may cause the machine to tip over. Particularly
when carrying a load, be sure to operate the work equipment
carefully.
When operating in tunnels, under bridges, under electric wires,
or other places where the height is limited, be extremely careful
not to let the machine body or work equipment hit anything.
To prevent accidents caused by hitting other objects, always
operate the machine at a speed which is safe for operation,
particular in confined spaces, indoors, and in places where
there are other machines.
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PROHIBITED OPERATIONS
If the machine rolls over or falls, or the ground at the working point collapses, it may lead to serious personal injury
or death. Always observe the following precautions.
Do not excavate the work face under an overhangs. There is
danger that the work face will collapse.
When digging, never thrust the bucket into a load at an angle.
This will bring an excessive load to bear on the machine and will
reduce the service life of the machine.
It is dangerous to apply drive force when excavating a rock
face. In addition, an excessive load will be brought to bear on
the machine and this will cause damage to the machine.
Never carry out digging operations on a downhill slope. An
excessive load will be brought to bear on the machine and this
will cause damage to the machine.
Do not use the bucket or lift arm for crane operations. There is
danger that the machine will tip over and that the load will fall.
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 and
cause serious personal injury or death.
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over or make it impossible for the machine to escape.
When traveling on snow-covered roads, always fit tire chains.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations
carefully.
When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce the speed and use the
engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times).
If necessary, lower the work equipment to the ground to stop the machine.
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PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling
rocks, or flooding.
Lower the work equipment completely to the ground.
When leaving the machine, set work equipment lock lever (1) to
the LOCK position (L) and parking brake switch (2) to the ON
position (A), and stop the engine.
Always close the operator's cab door, and use the key to lock all
the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave it in the specified place.
If it is necessary to park the machine on a slope, set blocks

under the wheels to prevent the machine from moving.
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TRANSPORTATION
When the machine is transported on a trailer, there is danger of serious personal injury or death during
transportation. Always do as follows.
Always check the machine dimensions carefully. Depending on the work equipment installed, the machine
weight, transportation height, and overall length may differ.
Check beforehand that all bridges and other structures on the transportation route are strong enough to
withstand the combined weight of the transporter and the machine being transported.
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.
Lock the frame with the frame lock bar to prevent the machine from articulating.
Fit chains to the front frame and the rear frame to hold the machine securely in position.
For details of the procedure for transporting the machine, see "TRANSPORTATION (PAGE 3-141)".
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 the tire of the machine. On
(1) Blocks
a rainy day, in particular, be extremely careful since the ramp (2) Ramp
surface is slippery. (3) Width of ramps: Same width as tiers
Run the engine at low idling and drive the machine slowly at low (4) Angle of ramps: Max. 15°
speed. (5) Block
Never correct your steering on the ramps. 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 boarding the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-141)".
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TOWING
PRECAUTIONS WHEN TOWING

Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or
towing bar or in the method of towing a disabled machine may lead to serious personal injury or death.
For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-150)"
Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine
being towed.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing
machine and the machine being towed.
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SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE

If there is any "DANGER! Do NOT operate!" warning tag
displayed, it means that someone is carrying out inspection and
maintenance of the machine. If the warning sign is ignored and
the machine is operated, there is danger that the person carrying
out inspection or maintenance may be caught in the rotating parts
or moving parts and suffer serious personal injury or death. Do not
start the engine or touch the levers.
If necessary, put up signs around the machine also.
Warning tag part number: 09963-A1640
When not using this warning tag, keep it in the toolbox.
If there is no toolbox, keep it in the pocket for the Operation and
Maintenance Manual
KEEP WORKPLACE CLEAN AND TIDY

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely.
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

Stop the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling rocks, or flooding.
ONLY AUTHORIZED PERSONNEL

Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.
APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his instructions during the operation.
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.
PRECAUTIONS FOR MAINTENANCE SAFETY
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

Lower the work equipment completely to the ground and stop
the engine before performing any inspection and maintenance.
After stopping the engine, turn the starting switch to the ON

position, operate work equipment control lever (1) fully in the
RAISE and LOWER directions 2 or 3 times to release the
remaining pressure in the hydraulic circuit, then set work
equipment lock lever (2) to LOCK position (L).
After releasing the remaining pressure in the hydraulic circuit,
turn the starting switch to the OFF position.
Set parking brake switch (3) to the ON position (A) to apply the
parking brake, then put blocks in front of and behind the tires to
prevent the machine from moving.
2 - 36
.
Set frame lock bar (4) to lock position (L) to lock the front and
rear frames.
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried
out with the engine running, carry out the operation with at least two workers and do as follows.
One worker must always sit in the operator's seat and be ready
to stop the engine at any time. All workers must maintain
contact with the other workers.
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 careful not to come close.
Never drop or insert tools or other objects into the fan, fan belt,
or other rotating parts. There is danger that they may contact
the rotating parts and break or be sent flying.
Lower the work equipment completely to the ground, then set

work equipment lock lever (1) to lock position (L) to prevent the
machine from moving.
Set parking brake switch(2) to ON position(A) and put blocks

under the tires to prevent the machine from moving
Be careful not to touch the control levers or steering equipment.
If the control levers must be operated, always give a signal to
your partner and have your partner withdraw to a safe place.
2 - 37
.
INSTALLING, REMOVING, OR STORING ATTACHMENTS

Appoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine
in a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.
PRECAUTIONS WHEN WORKING AT HIGH PLACES

When working at high places, use a step ladder or other stand to ensure that the work can be carried out safely.
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT

Make sure the hoists or jacks you use are in good repair and
strong enough to handle the weight of the component. Never
use jacks at places where the machine is damaged, bent, or
twisted. Never use frayed, twisted or pinched wire rope. Never
use bent or distorted hooks.
If it is necessary to raise the work equipment or a component

and then go under it to carry out inspection or maintenance,
support the work equipment or component securely with blocks
and stands (1) strong enough to support the weight of the work
equipment or component.
If the work equipment or component are not supported, there is
a hazard that they may come down and that this may lead to
Never use concrete blocks for supports. They can collapse
under even light loads.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, deformed, or low quality tools, or
making improper use of the tools may cause serious personal
injury.
2 - 38
.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
PRECAUTIONS WHEN WELDING

Welding operations must always be carried out by a qualified welder and in a place equipped with proper
equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any
unqualified personnel to carry out welding.
HANDLING BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to the OFF position.
Danger of battery exploding

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire, so always
Do not use or charge the battery if the battery electrolyte is
below the LOWER LEVEL mark. This will cause explosion.
Always carry out periodic inspection of the battery electrolyte
level, and add distilled water (or commercially available
battery filler solution) to the UPPER LEVEL mark.
Do not smoke or bring any flame close to the battery.
Hydrogen gas is generated when the battery is being
charged, so remove the battery from the machine, take it to
a well-ventilated place, remove the battery caps, then carry
out the charging.
After charging, tighten the battery caps securely.
Danger from dilute sulphuric acid

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire, so always
When handling the battery, always wear protective goggles
and rubber gloves.
If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water. After that, get
medical attention immediately.
If battery electrolyte gets on your clothes or skin, wash it off
immediately with large amounts of water.
Removing battery cables

Before repairing the electrical system or carrying out electric welding, turn the starting switch OFF. Wait for
approx. 1 minute, then remove the negative (-) battery cable to stop the flow of electricity.
2 - 39
.
Danger of sparks
There is hazard that sparks will be generated, so always observe the following.
Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying
around near the battery.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing,
connect the positive (+) cable first, then connect the ground.
Tighten the battery cable terminals securely.
Secure the battery firmly in the specified position.
PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may be
scattered. This may lead to serious personal injury or death.
Always do as follows.
When hitting pins or bucket teeth, there is a hazard that broken
pieces might be sent flying and injure people in the surrounding
area. Always check that there is no one in the surrounding
If hard metal parts such as pins, bucket teeth, cutting edges, or
bearings are hit with a hammer, there is a hazard that pieces
might be scattered and cause serious personal injury or death.
Always wear safety glasses and gloves.
If the pin is hit with strong force, there is a hazard that it may fly
out and injure people in the surrounding area. Do not allow
anyone to enter the surrounding area.
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT

To prevent burns from boiling water or steam spurting out when
checking or draining the coolant, wait for the coolant to cool down
to a temperature where the radiator cap can be touched by hand.
Then loosen the cap slowly to release the pressure inside the
radiator, and remove the cap.
PRECAUTIONS WITH HIGH-TEMPERATURE OIL

To prevent burns from hot oil spurting out or from touching
high-temperature parts when checking or draining the oil, wait for
the oil to cool down to a temperature where the cap or plug can be
touched by hand. Then loosen the cap or plug slowly to release
the internal pressure and remove the cap or plug.
2 - 40
.
PRECAUTIONS WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pressure
when the engine is running and immediately after the engine is stopped. When carrying out inspection or
replacement of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not
done, it may lead to serious personal injury or death. Always do as follows.
Do not carry out inspection or replacement work with the circuit under pressure.
Always release the pressure before starting. For details, see "STOP ENGINE BEFORE CARRYING OUT
INSPECTION AND MAINTENANCE (PAGE 2-36)".
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping
and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause loss of sight if it
contacts your skin or eyes directly. If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately for
PRECAUTIONS WITH HIGH-PRESSURE FUEL

When the engine is running, high-pressure is generated in the engine fuel piping. When carrying out inspection or
maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal
pressure to go down before starting the operation.
HANDLING HIGH-PRESSURE HOSES AND PIPING

If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or misoperation, and lead to serious
personal injury, or death. If the hose or piping mounts are loose or oil or fuel is found to be leaking from the
mount, stop operations and tighten to the specified torque.
If any damaged or deformed hoses or piping are found, please consult your Komatsu distributor.
Replace the hose if any of the following problems are found.
Damaged hose or deformed hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
NOISE
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.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
2 - 41
.
HANDLING ACCUMULATOR AND GAS SPRING

This machine is equipped with an accumulator. Even after the engine has been stopped, it is possible to operate
the work equipment control lever in the LOWER direction for a short time to allow the work equipment to go down
under its own weight.
After stopping the engine, set the work equipment lock lever to the LOCK position and turn the parking brake switch
ON.
The accumulator and gas spring are charged with high-pressure nitrogen gas. If the accumulator is handled
mistakenly, it may cause an explosion that could lead to serious personal injury or death. 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.
PRECAUTIONS WITH COMPRESSED AIR

When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying
dust or particles.
When using compressed air to clean the filter element or radiator, wear safety glasses, anti-dust mask, gloves,
and other protective equipment.
MAINTENANCE OF AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause
frostbite. Never loosen any parts of the cooling circuit.
DISPOSING OF 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.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
METHOD OF SELECTING WINDOW WASHER FLUID

Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
2 - 42
.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To enable this machine to be used safely for a long period, always carry out periodic replacement of safety
critical parts that have a particularly close relation to safety, such as hoses and the seatbelt.
For details of the replacement of safety critical parts, see "PERIODIC REPLACEMENT OF SAFETY CRITICAL
PARTS (PAGE 4-16)".
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 personal injury or
death. 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 specified
replacement time.
2 - 43
.
TIRES
HANDLING TIRES
If tires or rims are handled mistakenly, there is danger that the tire
may explode or be damaged, or that the rim may fly off and cause
To maintain safety, always do as follows.
Maintenance, disassembly, repair, and assembly of the tires
and rims requires special equipment and special technology, so
always ask your Komatsu distributor to carry out these
operations.
Always use the tires specified by Komatsu and maintain the
specified inflation pressure.
Suitable tire inflation pressure: see "HANDLING THE TIRES
(PAGE 3-139)"
When pumping up the tires, check that no other person is
standing near the tire, and install an air chuck with a clip that can
be secured to the air valve.
To prevent the tire inflation pressure from becoming too high,
measure the pressure from time to time with an air gauge while
pumping up the tire.
If the tire pressure goes down abnormally or the rim parts do not
fit the tire, there is a problem with the tire or rim parts. Always
contact your Komatsu distributor for repairs.
If the rim parts are not fitted properly when the tire is being
pumped up, there is danger that the rim parts may fly off, so set
up a protective fence around the tire, and do not stand directly
in front of the rim. Stand beside the tread when pumping up the
tire.
Do not adjust the tire inflation pressure immediately after traveling at high speed or carrying out operations under
heavy load.
Never carry out welding or light a fire near the tire.
Always release all pressure from a single tire or from both tires of a dual assembly prior to removing any rim
components.
Before removing the tire from the machine for repairs, remove the valve partially to release the air from the tire,
then remove the tire.
2 - 44
.
PRECAUTIONS WHEN STORING TIRES

Tires for construction equipment are extremely heavy, it may lead
to serious personal injury or death. To maintain safety, always do
as follows.
As a basic rule, store the tires in a warehouse which
unauthorized persons cannot enter.
If the tires must be stored outside, always erect a fence and put
up "No Entry" signs.
Stand the tire on level ground at angle (A) of 60° - 70° and fit
blocks (1) securely so that the tire cannot roll or fall over if any
person should touch it. Do not lay the tire on its side. This will
deform the tire.
If the tire should fall over, do not attempt to stop it. Get out of the
way quickly.
2 - 45
.
.
3-1
.
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
(1) Bucket (9) Cab

(2) Bell crank (10) Rear wheel
(3) Front wheel (11) Lift cylinder
(4) Bucket cylinder (12) Lift arm
(5) Turn signal lamp (13) Rear working lamp
(6) Head lamp (14) Rear combination lamp
(7) Mirror (15) Step
(8) Front working lamp
3-2
.
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES
(1) Gearshift lever stopper (13) Bucket control lever

(2) Rear wiper switch (14) Kickdown switch
(3) Front wiper switch (15) Cigarette lighter
(4) Gearshift lever (16) Right switch panel
(5) Front switch panel (17) Starting switch
(6) Directional lever (18) Lift arm control lever
(7) Machine monitor (19) Hold switch
(8) Horn button (20) Work equipment lock lever
(9) Steering wheel (21) Accelerator pedal
(10) Hazard lamp switch (22) Steering tilt lock lever
(11) Lamp switch (23) Left brake pedal
(11) Turn signal lever (24) Right brake pedal
(11) Dimmer switch (25) Room lamp switch
(12) Parking brake switch (26) Armrest
3-3
.
GENERAL VIEW OPERATION
MACHINE MONITOR
(1) Central warning lamp (21) Auto-greasing pilot lamp

(2) Brake oil pressure caution lamp (22) Joystick pilot lamp
(3) Enigine oil pressure caution lamp (23) Directional selector pilot lamp
(4) Water separtor caution lamp (24) Shift indicator
(5) Radiator coolant level caution lamp (25) Auto-shift pilot lamp
(6) Engine oil level caution lamp (26) Torque converter lockup pilot lamp
(7) Transmission oil filter clogging caution lamp (27) Shift hold pilot lamp
(8) Air cleaner clogging caution lamp (28) Shift lever position pilot lamp
(9) Parking brake pilot lamp (29) Torque converter oil temperature gauge
(10) Brake oil temperature caution lamp (30) Torque converter oil temperature caution lamp
(11) Cooling fan reverse rotation pilot lamp (31) Engine coolant temperature gauge
(12) Maintenance caution lamp (32) Engine coolant temperature caution lamp
(13) Battery electrolyte level caution lamp (33) Speedometer or tachometer
(14) Battery charge circuit caution lamp (34) Turn signal pilot lamp
(15) Steering oil pressure caution lamp (35) Head lamp high beam pilot lamp
(16) Emergency steering pilot lamp (if equipped) (36) Meter display pilot lamp
(17) Character display portion (37) Hydraulic oil temperature caution lamp
(18) Power mode pilot lamp (P mode) (38) Hydraulic oil temperature gauge
(19) Preheating pilot lamp (39) Fuel level caution lamp
(20) Semi auto digging pilot lamp (40) Fuel gauge
(41) Economy operation display lamp
3-4
.
OPERATION GENERAL VIEW
SWITCH PANEL
Right switch panel Front switch panel

(1) Transmission shift mode selector switch (8) Machine monitor mode selector switch 1
(2) Transmission cut-off switch (9) Machine monitor mode selector switch 2
(3) Transmission cut-off set swtich (10) Front working lamp switch
(4) Emergency steering switch (if equipped) (11) Rear working lamp switch
(5) Power mode selector switch (12) Beacon lamp switch (if equipped)
(6) 2-stage low idle switch (if equipped)
(7) Starting switch
3-5
.
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
MACHINE MONITOR
(A) Character display (E) Pilot display portion

(B) Emergency stop items (F) Meter display portion
(C) Caution items (G) Central warning lamp
(D) Inspection and maintenance items
NOTICE
When turning the starting switch to the ON position before starting the engine, the central warning lamp, caution lamps, and pilot
lamps light up for 2 seconds to check the system.
After the alarm buzzer sounds for 2 seconds, it goes off if the condition is normal.
The shift indicator display shows "88" for 2 seconds.
The indicator gauges and meters are actuated after the above system check is completed.
The character display shows "KOMATSU" for 3 seconds.
If the lamps do not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection.
3-6
.
OPERATION EXPLANATION OF COMPONENTS
TYPES OF WARNING
If an abnormality occurs on the machine, or if any switch or lever
is operated accidently, the monitor display and buzzer give a
warning to inform the operator.
Following are the types of warning depending on the level of
danger.
REMARK
For details of action codes " E03 - E01", see "ACTION CODE
DISPLAY (PAGE 3-9)" in the OPERATION Section.
EMERGENCY STOP
This warning is given if there is a serious failure that affects the normal operation of the machine or if the setting
is incorrect.
The central warning lamp on the monitor and the caution lamp for the location of the abnormality light up. At the
same time, the alarm buzzer sounds and action code "E03" is displayed on character display (1).
CAUTION
This warning is given if the coolant or lubricating oil overheat.
The central warning lamp on the monitor and the individual caution lamps light up. At the same time, the alarm
buzzer sounds and action code "E02" is displayed on character display (1).
MISTAKEN OPERATION
This warning is given if any switch or lever is operated mistakenly.
The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time.
INSPECTION AND MAINTENANCE

This warning is given if it is necessary to inspect and maintain wear parts, or if it is necessary to check the oil or
coolant level.
The individual caution lamp on the monitor lights up. At the same time, action code "E01" is displayed on character
display (1).
With this warning, the central warning lamp does not light up and the alarm buzzer does not sound.
CENTRAL WARNING LAMP

This display (1) lights up if any emergency stop item, caution item,
or mistaken operation of any switch or lever occurs. At the same
time the alarm buzzer sounds.
Check the display content and perform the specified action for that
item.
3-7
.
CHARACTER DISPLAY PORTION
(1) Service meter (3) Failure code display

(2) Action code display (4) Filter, oil replacement time display
Normally, the service meter is displayed on the character display.

If the machine has failed, if there has been an excessive load on the machine, or if inspection and maintenance are
necessary, an action code is displayed to recommend suitable action.
When the time for replacing the filter or changing the oil is reached, the filter or oil to be replaced is displayed.
NOTICE
Information regarding the failure of the machine or maintenance is displayed on the character display when the starting switch
is at the ON position. Check the display to confirm that there is no abnormality before starting to travel.
SERVICE METER
This meter (1) shows the total time that the machine has been
operating.
The service meter advances while the engine is running, if the
machine is moving or not.
The meter advances by 1 for every hour of operation, regardless
of the engine speed.
Even if the starting switch is at the OFF position, the service meter
will display as long as the top part ( ) of machine monitor mode
selector switch 1 is being pressed.
NOTICE
When the starting switch is at the OFF position, if the service meter is displayed even though the top ( ) of machine monitor
mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor
for inspection.
3-8
.
ACTION CODE DISPLAY
WARNING
If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see "FAILURE CODE
DISPLAY (PAGE 3-11)".
Inform your Komatsu distributor of the failure code and ask for repairs.
If there is a failure on the machine, if it is necessary to change the method of operation, or if inspection or
maintenance must be carried out, action code E01, E02, or E03 is displayed on the character display in display
portion (2).
If different failures occur at the same time, the action code for the more serious problem is displayed.
The level of seriousness is as follows, starting with the most serious: E03, E02, E01.
In the case of action codes E02, and E03, the alarm buzzer sounds intermittently and the central warning lamp
lights up.
If action codes E01, E02, or E03 are displayed on the character display, stop operations, check the content of the
display, and take the following action.
E03: When this code is displayed, stop the machine immediately,

check the failure code, and contact your Komatsu distributor
for repairs.
REMARK
"E03" is displayed on the top line of the character display and
"CHECK RIGHT NOW" and "CALL" are displayed in turn on the
bottom line for 3 seconds each.
The telephone number is displayed to the right of "CALL". If no
telephone number has been set, the display is blank. For
details of the method of inputting the telephone number, see
Section "INPUT METHOD FOR TELEPHONE NUMBER
(PAGE 3-35)".
E02: If this code is displayed, stop the machine and run the engine
under no load at a mid-range speed.
If an action code is still displayed after taking the necessary
action, check the failure code and contact your Komatsu
distributor for repairs.
REMARK
The top line of the character display displays "E02" and the bottom
line displays the condition of the machine related to overheating.
3-9
.
E01: When a failure occurs in the mechanical system, such as a

drop in the level of the engine coolant, the maintenance
location is displayed. If the maintenance caution lamp lights
up at the same time, inspect and perform maintenance of the
item indicated after completion of the day's work or when
changing shifts. If "MAINTENANCE" is displayed together
with E01, check the failure code and ask for repairs to be
carried out.
REMARK
"E01" is displayed on the top line of the character display and
"MAINTENANCE" or the part of the machine requiring inspection,
filling of fluid, or replacement is displayed on the bottom line.
3 - 10
.
FAILURE CODE DISPLAY

If an action code is displayed on the character display, check the failure code according to the failure code display
method given below.
When contacting your Komatsu distributor to request repairs, inform your distributor of the failure code.
Method of displaying failure code

1. If an action code is displayed on the character display of
display portion (3), press the top (>) of machine monitor mode
selector switch 2 (A).
The action code will change to the failure code.
The failure code is displayed with the first 6 digits on the left
of the top line of the character display.
The code displayed after the space on the right side of the
failure code indicates the controller that detected the failure
code.
The component causing the failure is displayed on the
bottom line of the character display.
Top right code Controller detecting failure code

MON Machine monitor
TM Transmission controller
ENG Engine controller
2. Press the top (>) of machine monitor mode selector switch 2 (A) again.
If the condition is normal, the service meter is displayed for several seconds, then the display returns to the
action code.
If more than one failure has occurred at the same time, the next failure code is displayed.
3 - 11
.
FILTER, OIL REPLACEMENT TIME DISPLAY

After completion of the system check and when the starting switch
is in the ON position, if any filter or oil item is approaching the
replacement time, this display (4) shows the item for approx. 30
seconds. When this happens, the maintenance caution lamp also
flashes or lights up.
After replacing the filter or changing the oil, reset the time for
replacement. For details, see "RESET METHOD FOR FILTER,
OIL REPLACEMENT TIME (PAGE 3-34)".
REMARK
The top line of the character display shows the ID No. and item name for the item needing replacement; the
bottom line shows the time remaining until replacement and the total number of times the replacement has been
carried out.
If the replacement time has already passed, a minus (-) sign appears before the time.
After the display has been given for 30 seconds, it does not appear again until the starting switch is turned to
the ON position.
The message in the illustration above is not shown on the character display if an action code is being displayed.
If there are two or more items to be displayed, the display changes repeatedly every three seconds. If there are
more than 10 items, all the items are displayed once each, then the display returns to the normal display.
The display appears when there is 30 hours remaining until the filter or oil replacement time. If the replacement
time has passed, a minus (-) sign appears before the time for the first 30 hours. When more than 30 hours have
passed, the display is no longer given.
The maintenance caution lamp flashes as the replacement time approaches, and after the replacement time
has passed, it lights up.
Items for display of filter, oil replacement time
Replacement
Item Character display ID number
interval(H)
Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel pre-filter 500 FUEL P FILT 41
Fuel filter 1000 FUEL FILT 03
Transmission oil 1000 TM OIL 12
Transmission oil filter 1000 TM FILT 13
Hydraulic filter 2000 HYD FILT 04
Hydraulic tank breather element 2000 HYD BREATH 05
Hydraulic oil 2000 HYD OIL 10
Axle oil 2000 AXLE OIL 15
3 - 12
.
REMARK
See the section below for details of the procedure for replacing the filter and oil.
Engine oil
"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-50)"
Engine oil filter

"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-50)"
Fuel pre-filter
"REPLACE FUEL PRE-FILTER CARTRIDGE (PAGE 4-51)"
Fuel main filter

"REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-54)"
Transmission oil
"CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER (PAGE 4-55)"
Transmission oil filter

"CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER (PAGE 4-55)"
Hydraulic oil filter

"CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-58)"
Hydraulic tank breather element

"REPLACE HYDRAULIC TANK BREATHER ELEMENT (PAGE 4-60)"
Hydraulic oil
"CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-58)"
Axle oil
"CHANGE AXLE OIL (PAGE 4-61)"
3 - 13
.
EMERGENCY STOP ITEMS

CAUTION
If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the
applicable location.
If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp
for the location of the abnormality and the central warning lamp will light up.
At the same time, the top line of the character display displays "E03" and the bottom line displays "CHECK RIGHT
NOW" and "CALL" alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the
engine, and carry out inspection.
(1) Brake oil pressure caution lamp (3) Battery charge circuit caution lamp
(2) Engine oil pressure caution lamp (4) Steering oil pressure caution lamp
3 - 14
.
BRAKE OIL PRESSURE CAUTION LAMP

This lamp (1) lights up when the brake oil pressure goes below the
specified value.
During checks before starting (when the starting switch is turned

to the ON position but the engine is not started), the brake circuit
is not actuated while the engine is stopped, so the brake oil
pressure caution lamp and central warning lamp do not light up
and the alarm buzzer does not sound.
During operation (engine running)

If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and central warning lamp
light up and the alarm buzzer sounds intermittently.
If the brake oil pressure caution lamp lights up, the footbrake may not work. Keep the parking brake applied to
prevent the machine from moving.
In addition, when the accumulator is being charged immediately after starting the engine, the brake oil pressure
caution lamp will light up, but the central warning lamp remains OFF and the alarm buzzer does not sound.
Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and
the brake oil pressure caution lamp goes out.
ENGINE OIL PRESSURE CAUTION LAMP

This lamp (2) lights up to warn the operator that the engine
lubricating oil pressure has dropped.

to the ON position but the engine is not started), this monitor does
not light up.

If the engine lubricating oil pressure goes down during operation,
the engine lubricating oil pressure caution lamp and central
warning lamp light up and the alarm buzzer sounds intermittently.
3 - 15
.
BATTERY CHARGE CIRCUIT CAUTION LAMP

This lamp (3) lights up when the engine is running to warn the
operator that an abnormality has occurred in the charging circuit.

not light up.

If an abnormality occurs in the charging circuit during operation,
the battery charge circuit caution lamp and central warning lamp
light up and the alarm buzzer sounds intermittently.
STEERING OIL PRESSURE CAUTION LAMP

(Red)
This lamp (4) lights up to warn the operator that the steering oil
pressure has dropped.

not light up.
However, it lights up during the self-check of the emergency
steering.

If the steering oil pressure goes down during operation, the
steering oil pressure caution lamp and central warning lamp light
up and the alarm buzzer sounds intermittently.
3 - 16
.
CAUTION ITEMS
CAUTION
If these lamps light up, stop operations quickly and carry out the following action.
(1) Brake oil temperature caution lamp (4) Hydraulic oil temperature caution lamp
(2) Torque converter oil temperature caution lamp (5) Fuel level caution lamp
(3) Engine coolant temperature caution lamp
3 - 17
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BRAKE OIL TEMPERATURE CAUTION LAMP

This lamp (1) lights up to warn the operator that the brake oil
temperature has risen.

not light up.

In continuous heavy-duty operations or when traveling long
distances downhill where the brake is used frequently, the brake
oil temperature becomes high. The brake oil temperature caution
lamp and central warning lamp light up and the alarm buzzer
sounds intermittently.
At the same time, the top line of the character display displays "E02" and the bottom line displays "BRAKE
OVERHEAT", so take the following action.
1. Release the accelerator pedal and move the gearshift lever down one range to reduce the travel speed.
2. Avoid using the brake.
1) Do not keep the brake pedal depressed continuously; use the brake only intermittently.
2) Set the transmission cut-off switch to the ON position when carrying out operations.
If use of the brake is reduced for a short time in the way recommended above, the brake oil temperature will go
down and the caution lamp will go out.
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP

This lamp (2) lights up to warn the operator that the torque
converter oil temperature has risen.

not light up.

If the torque converter oil temperature rises, the torque converter
oil temperature caution lamp only will light up.
If the oil temperature rises further, the central warning lamp will
light up and the alarm buzzer will sound intermittently.
At the same time, "E02" is displayed on the top line of the
character display and "TC OVERHEAT" is displayed on the
bottom line. Stop the machine and run the engine under no load
at a mid-range speed until the lamp goes out.
3 - 18
.
ENGINE COOLANT TEMPERATURE CAUTION LAMP

This lamp (3) warns the operator that the engine coolant

not light up.

If the engine coolant temperature rises, only the engine coolant
water temperature caution lamp will light up.
If the coolant temperature rises further, the central warning lamp
will light up and the alarm buzzer will sound intermittently.
At the same time as the central warning lamp lights up, the top line
of the character display displays "E02" and the bottom line
displays "ENGINE OVERHEAT", so stop the machine and run the
engine under no load at a mid-range speed until the lamp goes
HYDRAULIC OIL TEMPERATURE CAUTION LAMP

This lamp (4) lights up to warn the operator that the hydraulic oil

not light up.

If the hydraulic oil temperature rises, the hydraulic oil temperature
caution lamp, the central warning lamp will light up, and the alarm
buzzer will sound intermittently.
At the same time, "E02" is displayed on the top line of the
character display and "HYD OVERHEAT" is displayed on the
bottom line. Stop the machine and run the engine under no load
at a mid-range speed until the lamp goes out.
FUEL LEVEL CAUTION LAMP

This lamp (5) lights up if the amount of fuel remaining in the fuel
tank goes below 27 liters (7.13 US gal).
If it lights up, check and add fuel and as soon as possible.
REMARK
Even if the caution lamp lights up, action code "E02" is not
displayed on the character display.
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INSPECTION AND MAINTENANCE ITEMS

CAUTION
If these lamps light up, stop operations quickly and carry out the following action.
(1) Radiator coolant level caution lamp (5) Air cleaner clogging caurion lamp
(2) Engine oil level caution lamp (6) Water separtor caution lamp
(3) Battery electrolyte level caution lamp (7) Transmission oil filter clogging caution lamp
(4) Maintenance caution lamp
3 - 20
.
RADIATOR COOLANT LEVEL CAUTION LAMP

This lamp (1) lights up to warn the operator that the coolant level
in the radiator has gone down.

to the ON position but the engine is not started), this monitor lights
up if the coolant level in the radiator is low.
At the same time, the top line of the character display displays
"E01" and the bottom line displays "COOLANT LOW", so check
the water level in the radiator and add water.

If the coolant level in the radiator becomes too low, the radiator
coolant level caution lamp will light up.
At the same time, the top line of the character display displays "E01" and the bottom line displays "COOLANT
LOW", so stop the engine, check the water level in the radiator, and add water.
ENGINE OIL LEVEL CAUTION LAMP

This lamp (2) lights up to warn the operator that the oil level in the
engine oil pan has gone down.

to the ON position but the engine is not started), this monitor lights
up if the oil level in the engine oil pan is low.
"E01" and the bottom line displays "COOLANT LOW", so do not
start the engine. Check the oil level in the engine oil pan and add
oil.
REMARK
During checks before starting, if the engine is started with the engine oil level caution lamp lighted up, the lamp will
stay lighted up.
Stop the engine, check the oil level in the engine oil pan, and add oil.
BATTERY ELECTROLYTE LEVEL CAUTION LAMP

This lamp (3) is not used.
3 - 21
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MAINTENANCE CAUTION LAMP
CAUTION
If the caution lamp lights up, repair the problem as soon as possible. If this is left as it is, it will lead to failure.
When the time for oil change is reached, this lamp (4) flashes or
lights up for approx. 30 seconds after completion of the system
check when the starting switch is at the ON position.
REMARK
The maintenance caution lamp flashes when there are less than
30 hours to the replacement time, and after the replacement time
has passed, it stays on.
For details of the items covered by filter and oil replacement, see "FILTER, OIL REPLACEMENT TIME DISPLAY
(PAGE 3-12)".
After replacing the filter or changing the oil, reset time for the replacement. For details, see "RESET METHOD FOR
FILTER, OIL REPLACEMENT TIME (PAGE 3-34)".
AIR CLEANER CLOGGING CAUTION LAMP

This lamp (5) lights up if the air cleaner element becomes clogged
when the engine is running.

not light up.

The lamp lights up if the air cleaner element becomes clogged.
"E01" and the bottom line displays "AIR FILTER", so stop the
engine and clean or replace the element.
REMARK
It is possible to check the condition of clogging of the air cleaner with the dust indicator installed at the side of the
air cleaner.
3 - 22
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WATER SEPARATOR CAUTION LAMP

This lamp (6) lights up if water accumulates in the water separator
installed to the fuel pre-filter.
If it lights up, check the pre-filter. For details, see "REPLACE
FUEL PRE-FILTER CARTRIDGE (PAGE 4-51)"
TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP

3 - 23
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PILOT DISPLAY PORTION

When the starting switch is ON, the pilot display lights up when the display items are functioning.
(1) Parking brake pilot lamp (9) Directional selector pilot lamp
(2) Cooling fan reverse rotation pilot lamp (10) Economy operation display lamp
(3) Emergency steering pilot lamp (if equipped) (11) Shift indicator
(4) Power mode pilot lamp (P mode) (12) Auto-shift pilot lamp
(5) Preheating pilot lamp (13) Torque converter lock-up pilot lamp
(6) Semi auto digging pilot lamp (14) Shift hold pilot lamp
(7) Auto-greasing pilot lamp (15) Shift lever position pilot lamp
(8) Joystick pilot lamp (16) Turn signal pilot lamp
(17) Head lamp high beam pilot lamp
3 - 24
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PARKING BRAKE PILOT LAMP

This lamp (1) lights up when the parking brake is applied.
COOLING FAN REVERSE ROTATION PILOT LAMP

EMERGENCY STEERING PILOT LAMP

(If equipped)
(Green)
This lamp (3) lights up when the emergency steering is being
actuated.
If the engine stops when the machine is traveling or an
abnormality occurs in the steering oil pressure circuit, and the
machine is traveling at a speed of more than 2 km/h (1.2 MPH), the
emergency steering is automatically actuated and the lamp lights
If the lamp lights up, move the machine immediately to a safe
place, stop the engine, and check the condition.
In addition, the lamp flashes if the emergency steering is actuated continuously for one minute.
At the same time, "E02 EMR S/T OVERRUN" is displayed on the character display, so move the machine
immediately to a safe place, stop the engine, and check the condition.
There is an emergency steering self-check function. For details, see "EMERGENCY STEERING SELF-CHECK
FUNCTION (PAGE 3-121)" in the OPERATION section.
POWER MODE PILOT LAMP (P MODE)

This lamp (4) lights up when the P mode is selected.
Use the power mode selector switch to select the P mode.
3 - 25
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PREHEATING PILOT LAMP

This lamp (5) lights up when the engine preheating electric heater
is actuated.
In cold weather, when the starting switch is turned to the ON
position, this lamp lights up. It goes out when preheating is
completed.
The preheating time differs according to the ambient temperature.
SEMI AUTO DIGGING PILOT LAMP

AUTO-GREASING PILOT LAMP

JOYSTICK PILOT LAMP

DIRECTIONAL SELECTOR PILOT LAMP

ECONOMY OPERATION DISPLAY LAMP

This lamp (10) lights up when the economy mode is used.
SHIFT INDICATOR
This monitor (11) indicates the transmission gear range (actual
travel speed range).
3 - 26
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AUTO-SHIFT PILOT LAMP

This lamp (12) lights up when the auto-shift function is selected.
Use the transmission shift mode selector switch to select the shift
mode.
TORQUE CONVERTER LOCK-UP PILOT LAMP

SHIFT HOLD PILOT LAMP

This lamp (14) lights up when the shift hold is actuated.
SHIFT LEVER POSITION PILOT LAMP

This lamp (15) displays the transmission position of the gearshift
lever.
3 - 27
.
TURN SIGNAL PILOT LAMP

This lamp (16) flashes at the same time as the turn signal lamp
flashes.
REMARK
If there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
HEAD LAMP HIGH BEAM PILOT LAMP

This lamp (17) lights up when the head lamps are set to high
3 - 28
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METER DISPLAY PORTION
(1) Torque converter oil temperature gauge (4) Fuel gauge

(2) Engine coolant temperature gauge (5) Speedometer or tachometer
(3) Hydraulic oil temperature gauge (6) Meter display pilot lamp
3 - 29
.
TORQUE CONVERTER OIL TEMPERATURE GAUGE

This meter (1) indicates the torque converter oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside
the torque converter oil temperature gauge will light up. At the
same time, the central warning lamp lights up and the alarm
buzzer sounds intermittently. In addition, "E02" is displayed on
the top line of the character display and "TC OVERHEAT" is
displayed on the bottom line.
Run the engine under no load at a mid-range speed and wait until
the indicator goes down to white range (A).
ENGINE COOLANT TEMPERATURE GAUGE

This meter (2) indicates the engine coolant temperature.
During normal operations, the indicator should be in the white
range (A).
If the indicator enters red range (B) during operations, caution
lamp (C) inside the engine coolant temperature gauge lights up.
At the same time, the central warning lamp lights up and the alarm
buzzer sounds.
In addition, the top line of the character display displays "E02" and
the bottom line displays "ENGINE OVERHEAT".
Run the engine at a midrange speed under no load and wait for the
indicator to return to the white range (A).
HYDRAULIC OIL TEMPERATURE GAUGE

This meter (3) indicates the hydraulic oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside
the hydraulic oil temperature gauge will light up. At the same time,
the central warning lamp lights up and the alarm buzzer sounds
intermittently. In addition, "E02" is displayed on the top line of the
character display and "HYD OVERHEAT" is displayed on the
bottom line.
Run the engine under no load at a mid-range speed and wait until
the indicator goes down to white range (A).
FUEL GAUGE
This meter (4) indicates the amount of fuel remaining in the fuel
tank.
F: Full tank
E: Fuel level is low
When the remaining amount of fuel goes below 27 liters (7.13 US
gal), caution lamp (A) inside the fuel gauge lights up.
If it lights up, check and add fuel.
3 - 30
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SPEEDOMETER OR TACHOMETER
This meter (5) indicates the travel speed of the machine.
The display unit is indicated on meter display pilot lamp (6).
It is also possible to display the engine speed by switching meter
(5).
If you wish to switch between the speedometer and tachometer,
please contact your Komatsu distributor to have it switched.
METER DISPLAY PILOT LAMP

This lamp (6) displays the unit for the travel speed or engine
tachometer.
3 - 31
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OTHER FUNCTIONS OF MACHINE MONITOR

The machine monitor also has the following functions.
Odometer, filter/oil replacement time reset, telephone number input, language selection, monitor brightness
adjustment
3 - 32
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METHOD OF DISPLAYING ODOMETER

Use this when checking the total distance that the machine has traveled.
1. Check that the character display is displaying the service meter or an action code. If there is any other display,
turn the starting switch OFF, then turn the starting switch ON again and wait for the service meter display or
action code display to appear.
2. Press the ( ) portion of the machine monitor mode selector

switch 1 to display "ODO" (odometer).
3. When completing the operation, press () of machine monitor mode selector switch 1 or turn the starting switch
OFF.
3 - 33
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RESET METHOD FOR FILTER, OIL REPLACEMENT TIME

The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced,
reset the filter and oil change time.

2. Press (>) or (<) of machine monitor mode selector switch 2

and display "MAINTENANCE MONITOR".
3. Press the ( ) of machine monitor mode selector switch 1. It

will change to the display in the diagram on the right.
The bottom line shows two items: the replacement time on the
left and the total number of times the item has been replaced
on the right.
4. Press the (>) or (<) of machine monitor mode selector switch
2 to display the item (filter or oil) which has reached the
replacement time.
5. Press the ( ) of machine monitor mode selector switch 1. It

will change to the display in the diagram on the right.
The top line shows [Reset] and [Item to be reset] in turn.
6. When resetting the replacement time, press (>) or (<) of
machine monitor mode selector switch 2, align the cursor with
"YES", then press () of machine monitor mode selector
switch 1. It will reset and return to the previous screen.
To abort, align the cursor with "NO", then press () of machine
monitor mode selector switch 1.
7. When resetting the replacement time for another item, use the procedure in Step 4. After completing, press (
) of machine monitor mode selector switch 1 twice or turn the starting switch OFF.
3 - 34
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INPUT METHOD FOR TELEPHONE NUMBER

It is possible to display the telephone number on the right side of "CALL" displayed on the character display when
action code "E03" is generated.


and display "TEL".
3. Press ( ) of machine monitor mode selector switch 1. It will

change to the display in the diagram on the right.
Once the telephone number is input, the input number will be

displayed next time.
4. Up to 12 digits can be displayed for the telephone number.

Input from the first digits.
The cursor is displayed at the input position. Press (>) or (<)
of machine monitor mode selector switch 2 and display "0 to
9". To leave a blank, select "*".
When the input value is decided, press ( ) of machine
monitor mode selector switch 1. The cursor will move to the
next position.
5. Repeat the procedure in Step 4 until the last digit. At the last digit, press ( ) of machine monitor mode selector
switch 1 to return to the previous screen.
If there is a mistake in the input or the input is to be stopped, press () of machine monitor mode selector switch
1 to return to the previous screen.
6. When completing the operation, press () of machine monitor mode selector switch 1 twice or turn the starting
switch OFF.
3 - 35
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METHOD FOR SELECTING LANGUAGE

Use this when switching the language displayed on the character display.
The following explanation is for when English is set as the language for the character display.


and display "BRIGHTNESS ADJUST".
3. Press the ( ) of machine monitor mode selector switch 1.

The presently selected language is displayed.
and select the language.
The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.
5. After selecting the language, press the ( ) of machine
To confirm, set the cursor at "YES", then press the () of
machine monitor mode selector switch 1. The language will
be selected and the screen will return to the previous screen.
To abort, set the cursor at "NO", then press the () of machine
6. When completing the operation, press () of machine monitor
mode selector switch 1 twice or turn the starting switch OFF.
3 - 36
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METHOD OF ADJUSTING MONITOR BRIGHTNESS

Do as follows to adjust the brightness of the monitor.


and display "BRIGHTNESS ADJUST".

"MONITOR PANEL" will be displayed on the bottom line and
it will be possible to adjust the brightness of the monitor.
The brightness can be adjusted for the overall monitor or for the
liquid crystal display only.
To adjust only the brightness of the liquid crystal display, press the
(>) or (<) of machine monitor mode selector switch 2 to switch the
display to "LCD PANEL".
3 - 37
.

The screen will change to the display shown on the right and
it will be possible to adjust the brightness.
5. Press the (>) or (<) of machine monitor mode selector switch
2 to select a level between L and H (available range: 7 stages).
6. After selecting the brightness, press the () of machine
The brightness will be selected and the screen will return to
the previous screen.
7. When completing the operation, press () of machine monitor
mode selector switch 1 twice or turn the starting switch OFF.
3 - 38
.
METHOD OF SWITCHING TRAVEL SPEED/ENGINE SPEED DISPLAY

Use this when switching between the travel speed (km/h, MPH) and the engine speed display.

2. Press the (>) or (<) of the machine monitor mode selector

switch 2 to display "SELECT SPEED" or "SELECT r/min".

switch 1.
The display changes and returns to the service meter display.
3 - 39
.
METHOD OF SWITCHING TRAVEL SPEED/ENGINE SPEED DISPLAY/NON-DISPLAY

Use the following method to display the travel speed or engine speed or to have no display on the character display.

2. Press the (>) or (<) of the machine monitor mode selector

switch 2 to display "rpm ON → OFF" or "km/h ON → OFF".
To set to no display for the travel speed or engine speed on the
character display, display "rpm OFF → ON" or "km/h OFF →
ON".
3. Press the ( ) of the machine monitor mode selector switch 1.

The item that was being displayed changes to non-display,
and the item that was not displayed, is displayed, and the
screen returns to the service meter display.
3 - 40
.
SWITCHES
(1) Starting switch (11) Rear working lamp switch

(2) Power mode selector switch (12) Machine monitor mode selector switch 1
(3) Transmission shift mode selector switch (13) Machine monitor mode selector switch 2
(4) Transmission cut-off switch (14) Kickdown switch
(5) Transmission cut-off set switch (15) Hold switch
(6) Lamp switch (16) Front wiper switch
(6) Turn signal lever (17) Rear wiper switch (if equipped)
(6) Dimmer switch (18) Cigarette lighter
(7) Horn button (19) Room lamp switch
(8) Hazard lamp switch (20) Beacon lamp switch (if equipped)
(9) Parking brake switch (21) 2-stage low idle switch (if equipped)
(10) Front working lamp switch (22) Emergency steering switch (if equipped)
3 - 41
.
STARTING SWITCH
This switch (1) is used to start or stop the engine.
(A): OFF position

It is possible to insert and remove the starting switch key, all the
electric system switches are turned off, and the engine stops. In
addition, the parking brake is automatically applied.
(B): ON position
In this position, electric current flows in the charging and lamp
circuits.
Keep the starting switch key at the ON position while the engine is
running.
If the ambient temperature is low, when the engine is started, the preheating pilot lamp will light up automatically
and preheating will start.
The preheating time differs according to the ambient temperature when the engine is started.
If the preheating pilot lamp lights up, wait for it to go out, then turn the key to the START position.
(C): START position

This is the position to start the engine. Hold the key at this position while cranking the engine. Release the key
immediately after the engine has been started. The key will return to ON position (B) when released
POWER MODE SELECTOR SWITCH

This switch (2) can be used to switch the engine output to match
the purpose of the operation.
When the P mode is selected, the power mode pilot lamp (P mode)
on the machine monitor lights up.
Position (a): E mode (engine output low); operations with

emphasis on fuel economy, such as operations on
level ground where a maximum output is not needed
Position (b): P mode (engine output high); operations with
emphasis on productivity
REMARK
To carry out operations with effective fuel consumption, normally set to the E mode.
The maximum engine speed is set lower than in the P mode, but except for hard operations such as heavy-duty
digging of rock, it can display ample power and can also display good fuel consumption. Furthermore, by
pressing the accelerator pedal lightly, it is possible to reduce the fuel consumption.
Set to the P mode when carrying out heavy-duty digging operations of rock or operations where the speed is
required, or when traveling at high speed on flat ground or on slopes.
3 - 42
.
TRANSMISSION SHIFT MODE SELECTOR SWITCH

This switch (3) is used to change the shift point when the AUTO
SHIFT/MANUAL selector switch has been switched to auto shift.
At each of the L, H positions, the system switches to auto shift and
the auto shift pilot lamp on the machine monitor lights up.
Normally, set to auto shift.
MANUAL position: System is set to manual shift and speed range

is a position selected by gearshift lever
L position: Travel speed when shifting up is low (flat ground,
normal travel)
H position: Travel speed when shifting up is high (traveling uphill,
traveling at high speed)
If it is set to the L position when the work is mainly operations on flat ground, it is possible to shift up when the engine
speed is low. This is effective in reducing fuel consumption.
REMARK
For details of the manual shift, see "MANUAL SHIFT (PAGE 3-52)".
For details of the auto-shift, see "AUTOMATIC SHIFT (PAGE 3-53)".
TRANSMISSION CUT-OFF SWITCH
WARNING
When starting the machine off up a hill, turn the transmission cut-off switch to the OFF position, depress the brake pedal, then
gradually depress the accelerator pedal and release the brake slowly to allow the machine to start off. This makes it possible to
prevent the machine from rolling back.
Press this switch (4) to turn on and off the transmission cut-off
system.
When the switch is pressed, the pilot lamp lights up and the
system is turned ON. The transmission is shifted to neutral at the
adjusted brake pedal depression position.
Normally, keep the switch at the ON position.
For details of the method of adjusting the cut-off position, see

"ADJUSTING TRANSMISSION CUT-OFF POSITION (PAGE
3-118)" in the STOPPING MACHINE section.
Position (a): OFF
The brake pedal acts in the normal way for the brake.
Position (b): ON
In addition to acting in the normal way for the brake, the brake pedal returns the transmission to
Neutral at the same time.
REMARK
The brake pedal position where the cut-off system is actuated can be adjusted by using the transmission cut-off set
switch on the right switch panel.
3 - 43
.
TRANSMISSION CUT-OFF SET SWITCH
CAUTION
Apply the parking brake before adjusting the transmission cut-off position.
Turn this switch (5) ON to adjust the brake pedal position where
the transmission is automatically shifted to Neutral.
Position (a): ON
Cut-off position can be adjusted
When the switch is released, it automatically returns to its original

position.
For details of the method of adjusting the cut-off position, see

"ADJUSTING TRANSMISSION CUT-OFF POSITION (PAGE
3-118)" in the STOPPING MACHINE section.
LAMP SWITCH
This switch (6) 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): Head lamps light up in addition to lamps at (b) position
REMARK
The lamp switch can be operated regardless of the position of the
lever.
TURN SIGNAL LEVER

This lever (6) is used to operate the turn signal lamp.
(L) position: LEFT TURN (Push lever FORWARD.)
(N) position: OFF
(R) position: RIGHT TURN (Pull lever BACK.)
REMARK
When the lever is operated, the turn signal pilot lamp also
flashes.
When the steering wheel is turned back, the lever automatically
returns to its original position. If it does not return, return it
manually.
3 - 44
.
DIMMER SWITCH
This switch (6) is used to switch the head lamps between high
beam and low beam.
Position (L): Low beam
Position (H): High beam
HORN BUTTON
When the horn button (7) in the center of the steering wheel is
pressed, the horn will sound.
HAZARD LAMP SWITCH
WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine
operators.
This switch (8) is used in emergencies, such as when the machine

breaks down and has to be parked on the road.
Position (A): Turn signal lamps, turn signal pilot lamp flash, and
pilot lamp (C) lights up at same time.
Position (B): Lamps are OFF.
3 - 45
.
PARKING BRAKE SWITCH
WARNING
Always apply the parking brake when leaving the machine or when parking it.
Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal
depressed.
NOTICE
Never use the parking brake switch to apply the brakes when traveling, except in an emergency. The parking brake may be
damaged and this may lead to a serious accident. 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, contact your Komatsu distributor to
have the parking brake checked for any abnormality.
This switch (9) operates the parking brake.

Position (A): ON
The parking brake is applied, and the parking brake
pilot lamp lights up.
Position (B): OFF
The parking brake is released.
REMARK
When the parking brake is applied, the machine will not move off even if the directional lever is operated.
If the directional lever is placed at the F or R position with the parking brake still applied, the central warning
lamp will light up and the buzzer will sound.
Before starting the engine, turn the parking brake switch ON.
FRONT WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
This switch (10) is used to light up the front working lamp.

Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working
lamp circuit will be switched ON.
3 - 46
.
REAR WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
This switch (11) is used to light up the rear working lamp.

Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working
lamp circuit will be switched ON.
MACHINE MONITOR MODE SELECTOR SWITCH 1

This switch (12) is used to switch the function of the character
display.
position.
The basic operation is as follows.

Position ( ):
Press here to select (confirm) each mode or operation
Position ():
Press here to cancel each mode or operation
MACHINE MONITOR MODE SELECTOR SWITCH 2

This switch (13) is used to switch the function of the character
display.
position.
The basic operation is as follows.

Position (>): Press here to go on to the next screen, or to move the
cursor forward, or to increase the number when
entering numerals
Position (<): Press here to go back to the previous screen, or to
move the cursor back, or to reduce the number when
entering numerals
3 - 47
.
KICKDOWN SWITCH
When the gear shift lever is at F2, if switch (14) at the head of the
lift arm control lever is pressed, the transmission will shift down
one range.
Use this when you need to increase the drawbar pull in digging
operations.
When the transmission shift range is in FORWARD 1st (F1) and

the power mode selector switch is at E mode, if switch (14) is
pressed, it is possible to switch to P mode.
Use this function during scraping-up operations or during digging
operations when it is desired to further increase the lifting force.
When using E mode
2nd 1st 1st

E mode o E mode o P mode
When using P mode
2nd 1st
P mode o P mode
If the transmission is in auto-shift, and the travel speed is below 10.5 km/h (6.5 MPH) in any speed range when
traveling in either forward or in reverse, the kick-down switch is actuated and it is possible to shift down to 1st.
This makes it easy to carry out load and carry operations.
Even if the travel speed is more than 10.5 km/h (6.5MPH), this switch can be used to shift the transmission down.
Each time the kick-down switch is pressed, the speed range will shift down one range at a time (F4 -> F3 -> F2).
REMARK
When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be canceled
by operating the gearshift lever to any position other than 2nd. It is also possible to cancel the kick-down by
turning the starting switch OFF.
In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the auto-shift.
In auto-shift, when traveling at more than 18 km/h (11.2 MPH) in 3rd or at more than 28 km/h (17.4 MPH) in 4th,
even if the kick-down switch is pressed, the transmission will not shift down. This is to prevent overrun of the
engine.
3 - 48
.
HOLD SWITCH
To fix the speed range when traveling in automatic transmission,
press switch (15) at the side of the lift arm control lever knob. The
transmission will be fixed in the speed range displayed on shift
indicator (A) on the machine monitor and shift hold pilot lamp (B)
will light up.
When the switch is pressed again, the display goes out.
Use this function to select the desired speed range when traveling
up or down hills or when carrying out operations such as grading.
REMARK
When canceling the shift hold, operate the directional lever or
gearshift lever or operate the transmission shift mode selector
switch to MANUAL. It is also possible to cancel the hold shift by
turning the starting switch OFF.
FRONT WIPER SWITCH

When rotary switch (E) of this switch (16) is turned, the front wiper
will move.
If push button (F) is pressed, washer liquid will be sprayed out onto
the front glass while the button is being pressed.
It is possible to check the position of the switch in display window
(G).
Position (A): (OFF) Stop

Position (B): (INT) Intermittent wiper
Position (C): Low-speed wiper
Position (D): High-speed wiper
REAR WIPER SWITCH

When lever (E) of this switch (17) is turned, the rear wiper will
move.
Position (A): Washer liquid is sprayed out

Position (B): OFF
Position (C): Wiper is operated
Position (D): Washer liquid is sprayed out, wiper is operated
3 - 49
.
CIGARETTE LIGHTER
This is used to light cigarettes.
After cigarette lighter (18) is pushed in, it will return to its original
position after a few seconds, so pull it out and light your cigarette.
ROOM LAMP SWITCH

This switch (19) is used to light up the room lamp.
Position (A): OFF
Position (B): Lights up when cab door is opened
Position (C): ON
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) or (B).
When operating with the cab door fully open, set the switch to
position (A).
BEACON LAMP SWITCH

(If equipped)
This switch (20) is used to light up the beacon lamp.
Position (a): Beacon lamp lights up
Position (b): Beacon lamp goes out
2-STAGE LOW IDLE SWITCH

(If equipped)
When this switch (21) is pushed, the engine idle speed is
increased.
3 - 50
.
EMERGENCY STEERING SWITCH

(If equipped)
This switch (22) is the manual control switch for the emergency
steering.
Even when the engine has stopped, steering operations are made
possible by pressing this switch.
Position (a): ON
The pilot lamp inside the switch and the emergency
steering pilot lamp on the machine monitor light up
and it becomes possible to operate the steering.

position.
Actuate the emergency steering only in cases of emergency or when checking the function.
The time for operating the emergency steering continuously is a maximum of 60 seconds.
When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH).
For details, see "EMERGENCY STEERING (PAGE 3-120)" in the OPERATION section.
3 - 51
.
CONTROL LEVERS, PEDALS
(1) Gearshift lever (5) Bucket control lever

(2) Directional lever (6) Lift arm control lever
(3) Gearshift lever stopper (7) Brake pedal
(4) Work equipment lock lever (8) Accelerator pedal
GEARSHIFT LEVER
This lever (1) changes the speed range of the transmission.
MANUAL SHIFT
This machine has a 4-FORWARD, 4-REVERSE speed
transmission.
Place the gearshift lever in a suitable position to obtain the desired
speed range.
1st and 2nd speeds are used for working.
3rd and 4th speeds are used for traveling.
However, when the gearshift lever stopper is being used, it is
impossible to shift to 3rd or 4th. Disengage the gearshift lever
stopper before trying to shift gear.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
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.
AUTOMATIC SHIFT
Automatic gear shifting can be carried out in the 2nd through 4th
speed range of the four forward and reverse speeds depending on
the travel conditions.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
The range of speeds during automatic gear shifting is determined

Gear shift lever
by the position of the gearshift lever as shown in the chart on the Speed range
positions
right.
2nd 2nd
3rd 2nd <-> 3rd
4th 2nd <-> 3rd <-> 4th
REMARK
The 1st position for the gearshift lever fixes the transmission in
1st. There is no automatic shifting of the transmission.
When shifting down from 2nd to 1st, press the kick-down switch
on the lift arm control lever.
If the transmission is in auto-shift and the travel speed is below
10.5 km/h (6.5 MPH) in any speed range when traveling in
either forward or in reverse, the kick-down switch is actuated
and makes it possible to shift down to 1st.
This makes it easy to carry out load and carry operations.
Even if the travel speed is more than 10.5 km/h (6.5 MPH), this
switch can be used to shift the transmission down. Each time
the kick-down switch is pressed, the speed range will shift
down one range at a time (when in 4th: F4 -> F3 -> F2; when in
3rd: F3 -> F2).
To set to the desired speed range when traveling uphill or

downhill, or when carrying out grading, do as follows.
When fixing the speed range
Press the HOLD switch on the lift arm control lever.
The speed range is fixed at the speed range displayed on the
transmission indicator on the machine monitor.
When shifting up or down from set speed range
Shift gear with the gearshift lever.
REMARK
When the transmission has been shifted down from 2nd to 1st with the kickdown switch, it will shift up from 1st to
2nd when the travel speed increases.
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.
DIRECTIONAL LEVER
This lever (2) is used to switch the direction of travel of the
machine between forward and reverse.
When starting the engine, if the directional lever is not at the N
position, the engine will not start.
In this case, the central warning lamp will light up and the buzzer
will sound.
Return the directional lever to the N position and start the engine.
Position (F): Forward
Position (N): Neutral
Position (R): Reverse
GEARSHIFT LEVER STOPPER

This stopper (3) prevents the gearshift lever from entering the 3rd
or 4th positions when working.
Position (a): Stopper actuated.
Position (b): Stopper released.
WORK EQUIPMENT LOCK LEVER
WARNING
Before standing up from the operator's seat, set the work equipment lock lever securely to the LOCK position. If the work
equipment lock lever is not at the LOCK position, and work equipment control lever(A) is touched by mistake, it may lead to
a serious accident.
If the work equipment lock lever is not placed securely at the LOCK position, the work equipment may move, and this may lead
to a serious accident or personal injury. Check that the lever is in the position shown in the diagram.
When operating the work equipment lock lever, check that work equipment control lever(A) is at the HOLD position.
When operating the work equipment lock lever, be careful not to touch work equipment control lever(A).
This lever (4) is used to lock the work equipment control levers and
prevent operation of the work equipment.
Pull the work equipment lock lever towards the center of the
machine to set it to LOCK position (L).
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.
BUCKET CONTROL LEVER

This lever (5) operates the bucket.
Position (a): TILT

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
positioner, and the lever is returned to the HOLD
position.
Position (b): HOLD
The bucket is kept in the same position.
Position (c): DUMP
LIFT ARM CONTROL LEVER

This lever (6) is used to operate the lift arm.
NOTICE
Do not use the FLOAT position when lowering the bucket. Use the FLOAT
position when leveling, see "LEVELING OPERATIONS (PAGE 3-128)".
Position (a): RAISE

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 position
of the kickout, and the lever is returned to the HOLD
position.
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.
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.
BRAKE PEDAL
WARNING
When traveling downhill, turn the transmission cut-off switch OFF and
use the engine brake.
Do not use the brake pedal repeatedly more than necessary.
If the brake is used too frequently, it will overheat and will not work, and
that can cause a serious personal injury.
Do not put your foot on the brake pedal unless necessary.
These pedals (7) operate the brakes.
RIGHT AND LEFT BRAKE PEDAL

The brake pedal operates the wheel brakes.
Use the brake pedal for normal braking operations.
When the transmission cut-off switch is at the ON position, the brakes are applied, and the transmission is returned
to Neutral at the same time.
When the transmission cut-off switch is at the OFF position, the brakes are applied, but the transmission is not
returned to Neutral.
REMARK
When using the brake and accelerator together to reduce the machine travel speed or to stop the machine while
carrying out operations, set the transmission cut-off switch to the ON position and use the brake pedal.
ACCELERATOR PEDAL
This pedal (8) controls the engine speed and output.
The engine speed can be freely controlled between low idle and
full speed.
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.
STEERING TILT LOCK LEVER

WARNING
Stop the engine or apply the parking brake before adjusting the tilt of the steering wheel. If this operation (adjustment) is carried
out while the machine is moving, it may lead to a serious accident or personal injury.
This lever is used to hold the steering wheel in position.

Position (F): FREE
Steering wheel can be moved to front, rear, up, and
down.
Position (L): LOCK
Steering wheel is held in position.
The adjustment amounts are 9 degrees forward and 5 degrees
backward (stepless).
NOTICE
Do not operate the lever (1) continuously by excessive force. The lever (1) may become loose or get out of angle. In this case,
please ask your Komatsu distributor to carry out repairs.
The bolts (2) and (3) on steering column are the left-hand screw.
If they are screwed counterclockwise, it is not a loosening
direction but a tightening direction (A).
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.
CAP WITH LOCK

The fuel tank filler port and the hydraulic tank filler port are
equipped with locks.
Use the starting switch key to open and close the cap.
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)
TO OPEN THE CAP

1. Insert the key into the key slot.
2. Turn the key clockwise, align the key groove with mark (1) on
the cap, then open the cap.
Position (A): OPEN
Position (B): LOCK
TO LOCK THE CAP

1. Turn the cap until tight, then insert the key into the key slot.
2. Turn the starting switch key to LOCK position (B), then remove the key.
3 - 58
.
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAULIC TANK FILLER
PORT)
TO OPEN THE CAP

1. Insert the key into the key slot.
2. Turn the starting switch key counterclockwise and bring the
rotor groove in line with the aligning mark (1) on the cap. Turn
the cap slowly until a "clicking" sound is made. This releases
the lock and allows the cap to be opened.
Position (A): OPEN
Position (B): LOCK
TO LOCK THE CAP

1. Screw the cap into place.
2. Turn the starting switch key to LOCK position (B), then remove the key.
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.
FRAME LOCK BAR

WARNING
When carrying out maintenance or transporting the machine, always set the frame lock bar to the LOCK position.
Always remove the frame lock bar for travel operations. If it is not removed, the steering wheel cannot be used for steering,
and this may lead to serious damage or injury.
This is a device used to lock the front and rear frames during
maintenance or when transporting the machine. It prevents the
front and rear frames from articulating.
(L) LOCK position: Front and rear frames are locked and machine
cannot articulate. Set to this position when
carrying out inspection and maintenance.
(F) FREE position: Set to this position for normal operations.
TOWING PIN
1. Insert towing pin (1) into hole (2) in the counterweight.
2. Use linch pin (3) to set so that the towing pin does not come
out.
Reverse this operation to remove the pin.
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.
OPENING, CLOSING CAB DOORS, WINDOWS

CAUTION
Always check that the cab door is locked, both when it is open and when
it is closed.
Always stop the machine on level ground before opening or closing the
door.
Avoid opening or closing the door on a slope. There is danger that the
operating effort may suddenly change.
When opening or closing the door, always use door handle and knob.
Be careful not to get your hands caught by the front pillar or center
pillar.
When there is any person inside the cab, always call out a warning
before opening or closing the door.
LEFT DOOR OF CAB
DOOR HANDLE
1. If the door has not been locked with the key, it is possible to
pull door handle (1) and open the door fully.
DOOR OPEN KNOB

1. When door open knob (2) is pulled, it is possible to open the
door fully. It is possible to open the door in this way even when
the door is locked with the key.
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.
DOOR OPEN LOCK

When getting in or out of the operator's compartment, or when
operating with the door open, use this lock to hold the door in
position.
1. Push the door against catch (1) to lock it in position.
2. When attaching the door in position, lock it firmly to the catch.
3. When getting on or off the machine, hold the handrail on the
inside.
4. When closing the door from the operator's seat, push knob (2)
to release the catch.
5. When closing the door after getting off the machine, pull knob
(3) to release the catch.
SLIDING WINDOW LOCK RELEASE KNOB

Use this knob when you want to move the glass in the window of
the left door up or down to open or close it.
Grip lock release knob (1), release the lock, then move the glass
down to a lower lock position. Release lock release knob (1).
When the glass is moved down, there are 3 stages for lock
position (A).
3 - 62
.
OPEN LOCK KNOB FOR CAB EMERGENCY ESCAPE DOOR

CAUTION
The door on the right side of the cab is provided as an emergency escape door for use when it is impossible to exit from the
door on the left side. Do not use it as the door for normal entry and exit from the cab.
Never operate the machine with the door open to around 90 degrees. The door may extend beyond the maximum width of the
machine or it may suddenly close if the brakes are applied. This is extremely dangerous, so never operate the machine in this
condition.
Operate the machine with the door on the right side fully closed (lock) or partially opened (quarter lock).
Use this to fix the door on the right side at the open or closed position.
1. When open lock knob (1) is pushed down securely, the lock is
applied.
When using the air conditioner or heater, carry out operations
with the knob in this position.
2. If open lock knob (1) is lifted up, the door on the right will
partially open (quarter lock).
When taking in outside air on the right side, carry out
operations with the window in this position.
METHOD OF RELEASING A LOCK IN AN EMERGENCY

If the door on the left side of the cab will not open, or it is dangerous to get on or off the machine from the door on
the left side, release the open lock of the door on the right, open the door fully, then use it to leave the operator's
1. Lift open lock knob (1) up.
3 - 63
.
2. Grip open lock knob (1) and pull it towards the rear of the
machine.
3. Remove the open lock guide rail from the window pillar guide
to free the right window lock.
4. Open the right door fully and escape from the cab.
To return the open lock to its original position, hold open lock knob
(1) by hand and pull it gradually to align the open lock guide rail
with the guide, then push the open lock knob to the front.
Check that the rail is completely fitted into the guide, then push
open lock knob (1) down to set it securely to the LOCK position.
NOTICE
If you do not hold open lock knob (1) with your hand when closing the door,
the plastic portion of the lock lever and pin (2) of the cab side will hit each
other, and this may cause the plastic portion to break.
Always hold open lock knob (1) with your hand when closing the door.
3 - 64
.
BACKUP ALARM
This sounds an alarm when the directional lever is set to the R position. It is used to warn people behind the
machine that the machine will travel in reverse.
3 - 65
.
FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
If the fuse should blow, check for the cause and take the necessary action.
Inside rear console box

Loosen knob (1) at two places, then remove cover (2). The fuse
boxes are A and B.
FUSE CAPACITY AND NAME OF CIRCUIT
FUSE BOX A
Fuse
No. Name of circuit
capacity
(1) 10A Left front lamp
(2) 10A Right front lamp
(3) 10A Left clearance lamp
(4) 10A Right clearance lamp
(5) 20A Main lamp circuit
(6) 10A Instrument panel B
(7) 5A Air conditioner B
(8) 20A Air conditioner A
(9) 20A Wiper, washer
(10) 10A Backup lamp, brake lamp
(11) 10A Work equipment positioner
(12) 5A Emergency steering (if equipped)
(13) 5A Parking brake
(14) 10A Transmission control A
(15) 10A Horn
3 - 66
.
FUSE BOX B
Fuse
No. Name of circuit
capacity
(1) 5A Engine control B
(2) 20A Multi-coupler (if equipped)
(3) 10A Air suspension seat
(4) 20A Yellow rotating lamp (if equipped)
(5) 10A Turn signal indicator
(6) 20A Car radio, cigarette lighter
(7) 10A Rear working lamp
(8) 10A Front working lamp
(9) 10A Spare 1
(10) 30A Engine control A
(11) 5A Transmision control B
(12) 10A Room lamp
(13) 10A Instrument panel A
(14) 10A Hazard lamp
(15) 20A Starting switch, KOMTRAX
SLOW BLOW FUSE

If the power does not come on when the starting switch is turned
ON, the slow blow fuse may be blown. Check and replace it.
The slow blow fuse is beside the engine on the left side of the
machine.
SLOW BLOW FUSE

(1) 50A: Main power A
(2) 50A: Permanent power source
(3) 50A: Main power B
(4) 120A: Charging circuit
(5) 120A: Heater relay (electrical intake air heater)
3 - 67
.
POWER OUTLET
NOTICE
There is a 24V power source. Check the voltage of the electrical equipment to be connected.
Mistaken use, such as using 24V as the power source for 12V equipment, will cause failure of the equipment.
When using the electric power source, do not connect any equipment which will exceed the maximum amperage.
When cigarette lighter (1) is removed, the lighter socket can be

used as a 24V power source.
Maximum amperage: 9A (216W)
3 - 68
.
AM/FM RADIO
(If equipped)
EXPLANATION OF COMPONENTS
(1) Power switch/Volume (6) Preset switch

(2) Tone control knob (7) Seek
(3) Display (8) Band selector switch
(4) Clock button/Displaying frequency (9) Tuning switch
(5) AST
POWER SWITCH/VOLUME
When this switch (1) is turned to the right, it clicks and the power
is turned on. If it is turned further, the speaker volume is adjusted.
3 - 69
.
TONE CONTROL KNOB

If this knob (2) is turned to the right, the high tone is emphasized;
if it is turned to the left, the high tone is reduced.
DISPLAY
This display (3) shows the radio reception frequency and the
operating mode.
CLOCK BUTTON/DISPLAYING FREQUENCY

When this button (4) is pressed, the display changes to the time.
If it is pressed again, it displays the frequency.
AST
When this button (5) is pressed, the preset stations are called up
in turn.
When the desired broadcasting station is reached, press the
button again to stop it.
If the button is kept pressed continuously for 2 seconds, it is set to
auto memory.
3 - 70
.
PRESET SWITCH
With this switch (6), each button can be preset to one station each
for FM and MW (AM). (For details of the method of presetting, see
Section "METHOD OF PRESETTING STATION (PAGE 3-73)".)
SEEK
When this switch (7) ("SEEK") is pressed, it automatically
searches for stations that can be received, and when it receives a
station, it stops.
BAND SELECTOR SWITCH

When this switch (8) ("BAND") is pressed, the band is switched
between FM and MW (AM).
The reception band and frequency are displayed on the display.
TUNING SWITCH
When the "TUNE" button U of switch (9) is pressed, the frequency
goes up; when the V button is pressed, the frequency goes down.
If it is kept pressed, the frequency changes continuously.
3 - 71
.
METHOD OF OPERATION
LISTENING TO RADIO
1. Turn radio power switch (1) ON.
2. "BAND" switch (2) is used to select MW (AM) or FM.
3. Use the preset switch or tuning switch (3) to select the station.
4. Adjust the volume and tone as desired.
5. To turn the radio OFF, turn VOL knob (1) to the left until a click
is heard.
METHOD FOR SELECTING STATION AUTOMATICALLY

When the "SEEK" switch is pressed, it moves up to higher
frequencies and when it finds a station that can be received, it
stops automatically.
METHOD FOR SELECTING STATION MANUALLY

When the TUNE button U is pressed, the frequency goes up;
when the V button is pressed, the frequency goes down. If it is
kept pressed, the frequency changes continuously.
3 - 72
.
METHOD OF PRESETTING STATION

1. Select the desired preset station.
Use the "BAND" button to select MW (AM) or FM, and use the
"TUNE" button to select the frequency of the broadcasting
station.
2. Decide the number of the button to be preset, and keep it
pressed for 2 seconds. The number of the button will be
displayed and the presetting is completed.
3. Repeat Steps 1 to 2 to preset other broadcasting stations.
To change the setting of a preset switch to another station,
repeat Steps 1 to 2.
If the battery is replaced or the power is switched off, all the
preset settings are deleted. Carry out the presetting
operation again.
It is possible to preset 6 AM (MW) stations and 6 FM
stations.
METHOD OF USING AUTO MEMORY

If the "AST" button is pressed for 2 seconds, the broadcasting
stations that can be received in the area are called up in turn, and
the broadcasting stations are automatically saved in the preset
memory.
AUTOMATIC SWITCHING OF MONAURAL/STEREO RECEPTION

If the reception of the FM stereo broadcast being received is weak (when you are far from the broadcasting station
or are surrounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference.
When the stereo broadcast becomes stronger, it automatically switches back to stereo broadcasting.
3 - 73
.
METHOD OF SETTING TIME

1. Turn the power switch (1) of radio to the ON position. If the
display (2) shows the frequency, press the CLOCK button (3)
to display the time.
2. With CLOCK button (3) kept pressed:
Press U button (4) to set the minutes.
Press V button (5) to set the hours.
PRECAUTIONS WHEN USING

Stow the antenna when traveling in places with low overhead clearance.
To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation.
If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use
a cloth soaked in alcohol if the equipment is extremely dirty.
3 - 74
.
AIR CONDITIONER
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it
possible to provide a pleasant working environment even on dusty jobsites.
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL
(1) Main power switch (4) Temperature control switch

(2) Fan switch (5) FRESH/RECIRC selector switch
(3) Air conditioner switch (6) Display monitor
3 - 75
.
MAIN POWER SWITCH

Use the switch (1) to turn the main power of the air conditioner
ON/OFF.
When the switch is pressed, display monitor (A) lights up. The fan
begins operation.
When the switch is pressed again, the air conditioner is turned
OFF and the display monitor goes out. The fan stops.
(When the switch is turned ON, the setting displayed is the same
as when the air conditioner was turned OFF.)
3 - 76
.
FAN SWITCH
Use this switch (2) to adjust the air flow from the fan.
The air flow can be adjusted to 4 levels.
When this switch (A) is pressed, the air flow increases; when
switch (B) is pressed, the air flow decreases.
The setting for the air flow is displayed on the display monitor.
A: Monitor display
B: Air flow
a: Air flow "Lo"
b: Air flow "M1"
c: Air flow "M2"
d: Air flow "Hi"
3 - 77
.
AIR CONDITIONER SWITCH

Use this switch (3) to start and stop the cooling or dehumidifying
heating function.
When the main power switch is ON, if the air conditioner switch is
pressed, the air conditioner is turned ON and (A) is displayed on
the display monitor.
If the switch is pressed again, the switch is turned OFF and display
monitor (A) goes out.
TEMPERATURE CONTROL SWITCH

Use this switch (4) to adjust the temperature between low
temperature and high temperature.
When switch (A) is pressed, the temperature of the air blowing out
becomes higher; when switch (B) is pressed, the temperature of
the air blowing out becomes lower.
The setting (C) for the temperature is displayed on the display
monitor.
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.
FRESH/RECIRC SELECTOR SWITCH

Use this switch (5) to switch between recirculation of the air inside
the cab and intake of fresh air from outside.
When this switch is pressed, recirculation of inside air is selected
and (A) lights up on the display monitor.
If the switch is pressed again, intake of fresh air is selected and (B)
lights up on the display monitor.
Recirculation of air inside cab

Only the air inside the cab is circulated. Use this setting when
carrying out quick cooling or heating of the cab or when the outside
air is dirty.
Intake of fresh air from outside

Air from the outside is taken into the cab. Use this setting when
taking in fresh air from outside or when removing the mist from the
windows.
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.
METHOD OF OPERATION
COOLING OPERATION
1. Press main power switch (1) of the air conditioner to turn the
power ON.
2. Press fan switch (2) and set the air flow to "Hi".
3. Press temperature control switch (3) and set the display
monitor to COOL (A).
4. Press air conditioner switch (4) to turn the air conditioner
switch ON.
5. Press RECIRC/FRESH selector switch (5) to select RECIRC.
6. When the temperature inside the cab goes down, use the
temperature control switch and the fan switch to set to the
desired temperature.
REMARK
If the temperature control switch is pressed to set the display monitor to COOL (A) and the air conditioner is run with
the air flow at "Lo" for a long period, there is a slight risk that the evaporator will freeze.
If it freezes and no cold air comes out, turn the air conditioner switch OFF, raise the temperature setting, run the
air conditioner with the air flow at "Hi " for a short time, then turn the air conditioner switch ON again.
HEATING OPERATION
power ON.
monitor to HOT (A).
4. Press RECIRC/FRESH selector switch (4) to select FRESH.
5. When the temperature inside the cab goes up, use the
temperature control switch and the fan switch to set to the
desired temperature.
REMARK
Heating is carried out using the engine cooling water, so it can be carried out when the cooling water temperature
is high.
DRYING-HEATING AND DEMISTING OPERATION

power ON.
2. Press fan switch (2) and set the air flow to the desired setting.
3. Press temperature control switch (3) and set to the desired
temperature.
4. Press RECIRC/FRESH selector switch (4) to select FRESH.
5. Press air conditioner switch (5) to turn the air conditioner ON.
REMARK
When the outside temperature is below 0°C (32°F), the air conditioner (compressor) may not operate.
3 - 80
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PRECAUTIONS WHEN USING

To prevent any excessive load on the engine or compressor, use the air conditioner when the engine is running.
If the machine is used in places where there is dust or bad smell, recirculate the air inside the cab when using
the air conditioner.
To prevent leakage of refrigerant from the air conditioner cooling circuit, run the air conditioner for several
minutes 2 or 3 times a month, even during the off-season. If the machine is left for a long time when the
refrigerant is leaking, rust will form on the inside and this will cause failure.
To protect your health, do not make the inside of the cab too cool and do not let the cold air flow contact your skin
directly for long periods.
Ventilate the cab from time to time.
If the temperature inside the cab is high, open the door or window to let the hot air escape and let fresh air in
before starting operation of the air conditioner.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE

When carrying out inspection and maintenance of the air conditioner, follow the table given in "CHECK AIR
CONDITIONER (PAGE 4-35)".
To allow the air conditioner to show its full performance and provide a comfortable environment, have inspection
and maintenance carried out periodically.
When adding refrigerant or carrying out other maintenance, special tools and instruments are needed, so ask
your Komatsu distributor to carry out inspection and repair.
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HANDLING CAB WIPER
PREVENTING DAMAGE TO WIPER ARM BRACKET
NOTICE
When angling the wiper arm (1) to the front, check that the wiper blade is
hanging free.
When angling the wiper arm (1) to the front, such as when wiping
the glass clean, if the wiper arm (1) is angled with the wiper blade
(2) locked to the arm (the bottom of the blade is caught on the
arm), abnormal force is brought to bear on the mounting bracket
and the bracket may break.
LOCATION OF FIRE EXTINGUISHER

(If equipped)
A fire extinguisher is prepared at the rear part inside the operator's
cab.
The directions are described on the nameplate affixed to it. Just in
case, carefully read and grasp them beforehand.
3 - 82
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HANDLING MACHINES EQUIPPED WITH KOMTRAX

KOMTRAX is a machine management system that uses wireless communications.
A contract with your Komatsu distributor is necessary before the KOMTRAX system can be used. Any
customers desiring to use the KOMTRAX system should consult their Komatsu distributor.
The KOMTRAX equipment is a wireless device using radio waves, so it is necessary to obtain authorization and
conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used.
Always contact your Komatsu distributor before selling or exporting any machine equipped with KOMTRAX.
When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary,
it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to
stop communications.
If you do not obey the above precautions, neither Komatsu nor your Komatsu distributor can take any
responsibility for any problem that is caused or for any loss that results.
BASIC PRECAUTIONS
WARNING
Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This may cause failure or fire
on the KOMTRAX equipment or the machine itself. (Your Komatsu distributor will carry out removal and installation of
KOMTRAX.)
Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected
wires may cause failure or fire on the KOMTRAX equipment or the machine itself.
For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm (8.7 in) from the pacemaker.
The radio waves may have an adverse effect on the operation of the pacemaker.
Near the blasting jobsite, there may be a danger of unexpected explosion due to use of interactive wireless communication
device of KOMTRAX and resulting serious personal injury. Make sure to operate the machine away from the blasting jobsite.
If you have to operate the machine within 12 m (39 ft 4 in) from the blasting jobsite or the remote blasting device, ask your
Komatsu distributor to disconnect power source cable of KOMTRAX in advance.
If there are any restriction or law of the territory or country where the machine equipped with this device is used, such
restriction or law has a priority than this warning.
KOMTRAX specifications are as follows.
Rated horsepower: 5 - 10 W
Operating frequency: 148 - 150 MHz
NOTICE
Even when the key in the starting switch of the KOMTRAX system is at the OFF position, a small amount of electric power is
consumed. When putting the machine into long-term storage, take the action given in "LONG-TERM STORAGE (PAGE 3-149)".
Please contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
Be careful not to get water on the communications terminal or wiring.
REMARK
The KOMTRAX system uses wireless communications, so it cannot be used inside tunnels, underground,
inside buildings, or in mountain areas where radio waves cannot be received. Even when the machine is
outside, it cannot be used in areas where the radio signal is weak or in areas outside the wireless
communication service area.
There is absolutely no need to inspect or operate the KOMTRAX communications terminal, but if any
abnormality is found, please consult your Komatsu distributor.
3 - 83
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OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST
WALK-AROUND CHECK
Before starting the engine, check the area around and under the machine, check for loose nuts and bolts, damage
to any parts, leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic systems.
Check for looseness or play in electric wiring and check that there is no dust accumulated around high-temperature
parts.
WARNING
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts.
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu
distributor.
If the machine is at an angle, reposition it level before checking.

Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage and hoses.
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage or hoses. If
any abnormality is found, repair it.
2. Remove dirt and dust from around engine, battery and radiator.
Check if there is any dirt or dust accumulated around the engine or radiator. Also check if there is any
flammable material (dead leaves, twigs, etc.) accumulated around the battery or high temperature engine
parts, such as the engine muffler or turbocharger. Remove all such dirt or flammable material.
3. Check for coolant or oil leakage around the engine.

Check that there is no oil leakage from the engine or coolant leakage from the cooling system. If any problem
is found, repair it.
4. Check for leakage from fuel line.

Check that there is no leakage of fuel or damage to the hoses and tubes. If any problem is found, carry out
repairs.
5. Check for leakage of oil from transmission case, axle, hydraulic tank, hoses, joints.
Check that there is no oil leakage. If any abnormality is found, repair the leakage.
6. Check for oil leakage from the brake line.

Check that there is no oil leakage or damage to the hoses and tubes. If any problem is found, repair the oil
leakage and repair or replace the damaged parts.
7. Check for damaged or worn tires, wheels, and wheel hub bolts and nuts, check for loose wheel hub bolts and
nuts.
Check for cracks or peeling of the tires and for cracks or wear to the wheels (side rim, rim base, lock ring).
Tighten any loose wheel hub bolts or nuts. If any abnormality is found, repair or replace the part.
If any valve caps are missing, install new caps.
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OPERATION OPERATION
8. Check for damage and loose bolts on the handrail and steps.
Repair any damage and tighten any loose bolts.
9. Check for damage to gauges, lamps on the instrument panel and loose bolts.
Check for damage to the panel, gauges and lamps. If any problem is found, replace the parts. Clean off any dirt
on the surface. Tighten any loose bolts.
10. Check for loose air cleaner mounting bolts.

Check for the loose bolts. If loose, tighten them.
11. Check for loose battery terminals.

Tighten any loose terminal.
Tightening torque for portion A: 5.9 to 9.8 Nm {0.6 to 1.0 kgm,
0.82 to 1.36 lbft}
Tightening torque for portion B: 11.8 to 19.6 Nm {1.2 to 2.0
kgm, 1.63 to 2.71 lbft}
12. Check for damage to the seat belt and mounting clamps.
WARNING
Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged,
replace the seat belt.
Even if there are no signs of damage, replace belts in accordance with the following schedule:
5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Always wear the seat belt during operations.
Fit the seat belt so that it is not twisted.
REMARK
The date of seat belt manufacture attached to the seat belt is the
start of the 5-year period. It is not the start of the 3-year period of
actual usage.
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OPERATION 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: 24.5 ± 4.9 Nm {2.5 ± 0.5 kgm, 18.1 ± 3.6 lbft}
If the belt is damaged or fluff is starting to form, or if there is any

damage or deformation of the seat belt holders, replace the seat
belt.
13. Clean cab window.

Clean the cab window to ensure good visibility when operating the machine.
Cleaning from the top of the fender or platform is very dangerous.
Clean from the ground with a mop etc.
14. Inspect tires.
WARNING
If worn or damaged tires are used, they may burst and cause serious injury
or death.
To ensure safety, do not use the following tires.
Wear:
Tires with a tread grooves of less than 15% of that of a new tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage that has reached the cords (1), or with cracks in the
rubber
Tires with cut or pulled cords (1)
Tires with peeled (separated) surface
Tires with damaged bead (2)
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires, which do not
seem usable
15. Inspect rims.
WARNING
Check the rims (wheels) to confirm that there is no deformation of the ring, or damage caused by corrosion, or cracks.
In particular, check the side ring, lock ring, and rim flange thoroughly.
If any problem is found, replace the part.
3 - 86
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OPERATION OPERATION
CHECK BEFORE STARTING

Always perform the procedures in this section before starting the engine each day.
CHECK MACHINE MONITOR

1. Turn starting switch to the ON position (B).
2. Check that all the monitors, gauges, and the central warning
lamp light up for approx. 2 seconds, and that the alarm buzzer
sounds for approx. 2 seconds.
If the lamps do not light up, there is probably a failure or
disconnection. Contact your Komatsu distributor for
inspection.
3 - 87
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OPERATION OPERATION
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go
down, then turn the cap slowly to release the pressure before removing it.
CAUTION
When adding coolant, use the step and handrail provided. Support your body securely.
1. Open the engine side cover on the right side of the machine.
2. Check that the coolant level is between the FULL and LOW
range on sub-tank (1). If the coolant level is low, add coolant
through the water filler port of sub-tank (1) to the FULL line.
3. After adding coolant, tighten the cap securely.
4. If the sub-tank becomes empty, there is probably coolant
leakage. After checking, repair any abnormality immediately.
If no abnormality is found, check the level of the water in the
radiator. If it is low, add COOLANT of the same density in
radiator according to the COOLANT density table in "CLEAN
INSIDE OF COOLING SYSTEM (PAGE 4-25)", then add
COOLANT to the sub-tank.
If the volume of coolant added is more than usual, check for

possible leakage.
Confirm that there is no oil in the coolant.
3 - 88
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OPERATION OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
1. Open the inspection cover of the right side at the rear of the machine.
2. Take out the dipstick (G) and wipe off the oil with cloth.
3. Fully insert dipstick (G) into filler pipe, then remove it.
4. The oil level should be between the H and L marks on dipstick
(G).
If the oil level is below the L mark, add oil through oil filler port
(F).
5. If the oil is above the H mark, drain the excess oil from drain
plug (P), and check the oil level again.
6. If the oil level is correct, tighten oil filler cap (F) securely and
close the inspection window.
REMARK
Wait for at least 15 minutes, after stopping the engine, before
checking the oil level.
If the machine is at an angle, make it horizontal before
checking.
DRAIN WATER, SEDIMENT FROM FUEL TANK

Loosen valve (1) on the right side of the tank so that the sediment
and water will be drained together with fuel.
3 - 89
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OPERATION OPERATION
CHECK WATER SEPARATOR, DRAIN WATER
WARNING
Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt to drain cooling water or
remove the filter element cup.
High pressure is generated inside the engine fuel piping, while the engine is running. Wait for more than 30 seconds after the
engine stop for the engine to sufficiently cool down. Then start with draining cooling water or removing the filter element cup.
Do not bring fire close.
Check water separator, drain water and sediment.

The water separator (1) forms one unit with the fuel pre-filter,
and is at the bottom.
2. It is possible to judge the condition of water and sediment

through transparent cap (3). If water or sediment is
accumulated, set a container under drain hose (4) to collect
the discharged water.
3. Loosen plug (2) and drain the water.
4. Tighten plug (2) as soon as fuel starts to be discharged from
drain hose (4).
(Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.05 kgm, 0.03 to
0.06 lbft})
5. On this machine, sensor is installed to detect if water is accumulated at the bottom of the fuel pre-filter.
If water separator caution lamp on the machine monitor lights up, carry out the above Steps 1 - 4 to drain the
water.
3 - 90
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OPERATION OPERATION
REMARK
If plug (2) is stiff, coat O-ring (5) of plug (2) with grease.
1) Set a fuel container under drain hose (4).
2) Loosen plug (2), then drain all the sediment together with
the fuel from drain hose (4).
3) Check that nothing comes out from drain hose (4), then
remove plug (2).
4) Coat O-ring portion (5) with a suitable amount of grease.
When doing this, be careful not to let the grease get on the
drain valve water drain port (a) or the plug thread.
5) Screw in plug (2) by hand until it contacts the bottom.
6) Remove the fuel container.
If transparent cap (3) is dirty and the contents cannot be

easily seen, clean transparent cap (3) when replacing
the filter.
When washing, if plug (2) is removed, coat the O-ring
with grease, then tighten by hand until it contacts the
bottom.
3 - 91
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OPERATION OPERATION
CHECK ADDITIONAL WATER SEPARATOR, DRAIN WATER
WARNING
The engine fuel piping system is under high internal pressure when the engine is running. Always reduce the internal pressure
before draining water or replacing the element cup.
This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will
cause problems. If there is any dirt stuck to the fuel line, use fuel to wash it off completely.
The water separator serves to separate moisture mixed in the fuel.
NOTICE
If float (1) goes above level line (2), there is danger that the separated water
may be sucked into the engine.
Always drain the water before float (1) reaches level line (2).
Prepare a container to catch the water.
1. Open engine side cover (3) on the right side of the machine.
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OPERATION OPERATION
2. Check if there is any water accumulated in water separator (4).

3. If there is any water accumulated, loosen air bleeding plug (5)
(width across flats: 13 mm (0.5 in)), then loosen drain valve (6)
of the water separator and drain the water.
4. Tighten air bleeding plug (5) and drain valve (6).
Tightening torque
Air bleeding plug: 8.0 to 12.0 Nm {0.82 to 1.22 kgm, 1.11 to
1.86 lbft}
Drain valve: 2.0 to 3.0 Nm {0.2 to 0.31 kgm, 0.28 to 0.41
NOTICE
When the engine is started after adding fuel, the water separator and fuel pre-filter cup may become filled with water.
If they become full of water, drain the water.
CHECK AIR CLEANER
WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it.
Always stop the engine before carrying out these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use protective glasses, dust mask, and other protective equipment.
2. If the yellow piston in the display portion of dust indicator (1)
installed to the air cleaner enters the red range (7.5 kPa),
clean the element.
3. After cleaning, press the button of the dust indicator to reset it.
4. If the yellow piston enters the red range (7.5 kPa) soon after
the dust indicator is reset, it is necessary to replace the
element.
For details of the procedure for replacing the element, see
ELECTRIC AIR CLEANER CLOGGING SENSOR

If the yellow piston in the display portion of dust indicator (1) enters
the red range (7.5 kPa), or air cleaner clogging caution lamp (2) on
the machine monitor lights up, clean the air cleaner element.
NOTICE
Do not clean at the element until the air cleaner clogging caution lamp
lights up.
If the element is cleaned frequently before the air cleaner becomes
clogged, the air cleaner will not be able to provide its expected
performance and the cleaning efficiency will become poor.
In addition, dirt stuck to the element will drop inside the inner element
more frequently during the cleaning operation.
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OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When filling with fuel, do not add any more fuel after the fuel supply has automatically stopped. If too much fuel is added, there
is danger that the fuel may expand because of the rise in the ambient temperature and cause the fuel to overflow.
Spilled fuel may cause fire, so always wipe off any spilled fuel completely.
Fuel is highly flammable and a dangerous substance, so do not bring any fire or flame close.
NOTICE
If the engine has stopped because it has run out of fuel, it is necessary to bleed all the air from the circuit before starting again.
For details of the procedure for bleeding air, see "PROCEDURE FOR BLEEDING AIR (PAGE 4-55)".
Be careful not to let the engine run out of fuel.
If the engine has run out of fuel, the air bleeding procedure can be carried out more quickly if the fuel tank is full.
1. Turn the engine starting switch to the ON position (B) and

check the fuel level with fuel level gauge (G).
After checking, turn the switch back to the OFF position (A).
2. After completing work, fill the fuel tank through fuel filler port
(F).
Do not add any more fuel after the tank is filled.
For details of the method for opening and closing the cap, see
"CAP WITH LOCK (PAGE 3-58)".
3. After adding fuel, tighten the cap securely.
Fuel capacity: 300 liters (79.3 US gal)
3 - 94
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OPERATION OPERATION
CHECK ELECTRIC WIRING
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately
perform repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check that the fuses are not damaged, that the fuses are of the correct capacity, and that there are no signs of short
circuits or disconnections in the electric wiring. Check also that there are no loose terminals or connectors. Tighten
any loose parts.
In particular, check the wiring of the battery, starting motor, and alternator.
Be also sure to check that there is no flammable material accumulated around the battery. Remove any such
flammable material.
Please consult your Komatsu distributor about the repairs and causes of problems.
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 appropriate inflation pressure differs according to the type of work. See Section "HANDLING THE TIRES
(PAGE 3-139)" for details.
CHECK CONDITION OF WINDOW WASHER SPRAY

Operate the window washer and check that the washer fluid is sprayed out properly.
If the fluid does not spray out properly, clean the washer nozzle with a safety pin or thin wire.
If the condition is still not improved, please ask your Komatsu distributor to carry out inspection and repair.
CHECK WIPING EFFICIENCY OF WIPER

Operate the wiper and check that it wipes the window properly under each operating speed: Intermittent, low
speed, high speed.
Operate the window washer to make the glass wet when checking.
If the wiping condition is poor, it is necessary to clean the surface of the glass or replace the rubber wiper blade.
If the condition is still not improved, please ask your Komatsu distributor to carry out inspection and repair.
CHECK HORN
Operate the horn switch and check that the horn sounds.
If there is any abnormality, please ask your Komatsu distributor to carry out inspection and repair.
CHECK DEFROSTER FUNCTION

Operate the air conditioner and check that the air blows out properly onto the front glass.
Operate the rear heated wire glass switch and check that the rear glass surface is heated properly.
CHECK LOCKS
Check that all places can be locked properly.
(For details of the locations that can be locked, see "LOCKING (PAGE 3-138)".)
If any abnormality is found, please ask your Komatsu distributor to carry out inspection and repair.
3 - 95
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OPERATION OPERATION
CHECK EMERGENCY EXIT

Operate the knob for opening and closing the emergency exit, and check that it works properly.
If any abnormality is found, please ask your Komatsu distributor to carry out inspection and repair.
ADJUSTMENT
SEAT ADJUSTMENT
WARNING
When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any
accidental contact with the control levers.
Always adjust the operator's seat before starting each operation or when the operators change shift.
When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can
be fully depressed.
SUSPENSION SEAT
(A) Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then release
the lever.
Fore-aft adjustment: 160 mm (6.3 in)
(B) Adjusting reclining angle

Pull up lever (2) and set the backrest to a position that is
comfortable for operation, then release the lever.
Sit with your back against the seat backrest when adjusting. If your
back is not against the backrest, the backrest may suddenly move
forward.
REMARK
The seat can be reclined more when the seat is pushed to the
front. The amount of reclining decreases as the seat is pushed
back, so when moving the seat back, return the seatback to the
upright position.
(C) Setting seat for operator's weight

Turn grip (3) to adjust the strength of the suspension.
Adjustment range: (Target) 50 to 120 kg (110 to 265 lb)
(D) Adjusting armrest angle

Armrest can be operated by hand to spring up approx. 90 degrees.
In addition, dial (4) under the armrest can be operated by hand to make fine adjustments of the armrest in the up
or down direction.
(E) Adjusting headrest height

Move the headrest up or down.
Amount of adjustment: 50 mm (2.0 in)
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.
OPERATION OPERATION
(F) Adjusting headrest angle

Rotate the headrest to the front or rear.
Adjustment range: 60 degrees
ADJUST SEAT BELT

Always wear the seat belt.
WARNING
Before fastening the seat belt, check that there is no abnormality in the belt-mounting bracket or mounting of the belt. If the
belt is worn or damaged, replace it.
Even if there are no signs of damage, replace belts in accordance with the following schedule:
5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Fasten the seat belt before starting operations.
Always wear the seat belt during operations.
Make sure that the left and right belts are not twisted when fastening the seat belt.
REMARK
The date of seat belt manufacture attached to the seat belt is the start of the 5-year period. It is not the start of the
3-year period of actual usage.
FASTENING AND REMOVING BELT

Fasten the belt so that it is tight without being too tight.
1. Sit on the seat, depress the brake pedal fully, and adjust the
seat so that your back is pressed against the backrest.
2. Sit in the seat. Hold buckle (1) with your left hand and tongue
(2) with your right hand, and put tongue (2) into buckle (1). Pull
the belt to check that the belt has locked.
3. When removing the belt, raise the tip of buckle lever (1) to
release it.
Fasten the belt along your body without kinking it. Adjust the
lengths of the belt on both the buckle and the tongue sides so
that the buckle is located at the front, mid-point of your body.
ADJUST BELT LENGTH

To make the belt shorter: Pull the free end of the belt at the buckle
end or tongue end.
3 - 97
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OPERATION OPERATION
To make the belt longer: Set the belt holding the buckle or tongue
end at right angles to the buckle or
tongue, and pull.
ADJUST LEVER STAND
WARNING
When adjusting the lever stand, check that the work equipment lock lever is securely at the LOCK position.
If it is not at the LOCK position, and the work equipment control levers are touched by accident when adjusting the lever stand,
the work equipment may suddenly move and cause serious personal injury.
ADJUST HEIGHT AND ANGLE OF ARMREST

The height and angle of armrest (1) can be adjusted by loosen lock
lever (2).
Height adjustment amount: 30 mm (1.0 in)
Angle adjustment amount: 44 degrees
REMARK
Set lock lever (2) to the FREE position (F). The lock lever is
loosened.
Hold the armrest at the desired position and move the lock lever to
the LOCK position (L) to secure the armrest in position.
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OPERATION OPERATION
ADJUSTING MIRRORS
WARNING
Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be
injured or may injure someone seriously.
Mirrors A, B
Loosen bolt (1) of the mirror, then adjust the mirror to a position
which gives the best view from the operator's seat of the blind spot
at the left and right sides at the rear of the machine.
When installing the mirror, adjust so that it is possible to see
any person (or any object of a height of 1 m (3 ft 3 in) and
diameter of 30 cm (11.8 in) at the rear left or right of the
Mirrors C
(If equipped)
Adjust so that is possible to see the ground around the machine at

a range of 1 m (3 ft 3 in) from the operator's seat.
If the movement of the mirror is stiff when adjusting it, loosen

bolt (2) of the mirror.
Install the mirrors at the position and dimensions shown in the

diagram. The values below are reference values for the range of
visibility.
Range of view (left): 2500 mm (8 ft 2 in)

Range of view (right): 2500 mm (8 ft 2 in)
Mirror A: Must be possible to see hatched portion (A)
Mirror B: Must be possible to see hatched portion (B)
Mirror C: Must be possible to see hatched portion (C)
NOTICE
Tighten the mirror mounting bolts securely that they will not be
loosened and the mirrors will not come off.
Tightening torque
Mirrors A, B :2.0 to 2.5 Nm {0.2 to 0.25 kgm, 0.28 to 0.35 lbft}
Mirrors C :8.8 to 9.8 Nm {0.9 to 1.0 kgm, 1.22 to 1.36 lbft}
If the tightening torque cannot be controlled, ask your Komatsu

distributor for tightening the bolts.
3 - 99
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OPERATION OPERATION
OPERATIONS AND CHECKS BEFORE STARTING ENGINE

WARNING
When starting the engine, check that the work equipment lock lever are placed securely at the LOCK position. If the work
equipment control lever is touched by accident when the engine is started, the work equipment may move unexpectedly and
cause serious injury or damage.
1. Check that parking brake switch (1) is at the ON position (A).
2. Check that directional lever (2) is at the Neutral position (N).
REMARK
If directional lever is not set to the Neutral position (N), the engine
will not start.
3. Check that the bucket is completely lowered to the ground.

If it is not completely lowered, lower the bucket to the ground
as follows.
1) Check that the work equipment control lever is at the
HOLD position, then set the work equipment lock lever to
the FREE position.
2) Operate the work equipment control lever to lower the
bucket to the ground.
3) Check that the work equipment control lever is at the
HOLD position, then set the work equipment lock lever to
the LOCK position.
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OPERATION OPERATION
4. Check that work equipment lock lever (3) is at the LOCK

position (L).
5. Insert the key in starting switch (4), turn the key to the ON
position (B), and check that the machine monitor system
works.
When the starting switch is turned to the ON position before

starting the engine, monitors, gauges, and central warning
lamp light up for approx. 2 seconds, and the alarm buzzer
sounds for approx. 2 seconds.
If any monitor does not light up, there is probably a failure or
disconnection. Contact your Komatsu distributor for
inspection.
In addition, after all the monitors, gauges, and central warning
lamp light up, a self check is carried out to check that the
emergency steering function works properly. For details, see
"EMERGENCY STEERING SELF-CHECK FUNCTION
(PAGE 3-121)" in the OPERATION section.
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OPERATION OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
Sit down in the operator's seat before starting the engine.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious bodily injury or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not accelerate the engine suddenly before completing the
warming-up operation.
Do not keep the starting motor rotating continuously for more than 20
seconds.
If the engine does not start, wait for at least 2 minutes before trying to
start the engine again.
This machine is equipped with an engine automatic preheating device that functions to start the engine preheating
automatically.
If the ambient temperature is low, the preheating monitor will light up when the key in starting switch (1) is turned
to the ON position to inform the operator that preheating has been started automatically.
1. Turn the key in starting switch (1) to ON position (B).
If the ambient temperature is low, the preheating pilot lamp (2)

lights up and automatic preheating is carried out. Keep the
key in starting switch (1) at the ON position until the preheating
pilot lamp (2) goes out.
The time that the preheating pilot lamp (2) stays lighted up
Ambient temperature Lighting time
depends on the ambient temperature as shown in the table on the
right. -1 to -15 °C
0 to 30 seconds
(30.2 to 5 °F)
-15 °C (5 °F) or less 30 seconds
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OPERATION OPERATION
2. If the preheating pilot lamp (2) does not light up, or it lights up
and then goes out to inform that the engine preheating has
been completed, turn the key in starting switch (1) to the
START position (C).
3. The starting motor will continue to turn and the engine will start.
Keep the key in starting switch (1) at the START position (C) to keep the starting motor running until the engine
starts.
REMARK
In low temperatures, to ensure lubrication of the engine and to improve the durability, no fuel is supplied to the
engine for 3 seconds after the key in starting switch (1) is turned to the START position (C), so the engine will not
start during this time.
Therefore, keep the key in starting switch (1) at the START position (C) to keep the starting motor running until the
engine starts.
4. After the engine starts, release the key in starting switch (1).
The key will automatically return to the ON position (B).
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OPERATION OPERATION
STARTING IN COLD WEATHER

WARNING
Sit down in the operator's seat before starting the engine.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious bodily injury or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not suddenly accelerate the engine before the warming-up operation
is completed.
When starting the engine after the machine has been left for more than half a day in temperatures near -20°C, it
will take time for the engine to achieve complete combustion, so operate the starting switch as follows.
1. Turn the key in starting switch (1) to ON position (B).
If the ambient temperature is low, the preheating pilot lamp (2)

lights up and automatic preheating is carried out. Keep the
key in starting switch (1) at the ON position until the preheating
pilot lamp (2) goes out.
The time that the preheating pilot lamp (2) stays lighted up
Ambient temperature Lighting time
depends on the ambient temperature as shown in the table on the
right. -1 to -15 °C
0 to 30 seconds
(30.2 to 5 °F)
-15 °C (5 °F) or less 30 seconds
2. When preheating pilot lamp (2) goes out, turn the key in
starting switch (1) to the START position (C).
Keep the key in starting switch (1) at the START position (C)
to keep the starting motor running until the engine starts.
3. The starting motor will continue to turn and the engine will
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OPERATION OPERATION
4. Method of starting engine in temperatures of approx. -20°C (-4°F).

1) Keep the engine starting motor running for the max. 20 seconds, holding the key of engine starting switch
(1) in the START position (C), until the engine starts up.
2) If the engine fails to start up even after running the engine starting motor for about 20 seconds, stop the
engine starting motor once (release the engine starting switch (1) key), and try the same process again
after a pause for a minute or so.
3) If the engine still fails to start up after the second attempt, try the same process for the third time after a
pause for a minute or so.
5. When the engine has started up and the engine speed rises,
release the key of engine starting switch (1). The key will
automatically return to the ON position (B).
AUTOMATIC WARMING-UP OPERATION

After starting the engine, if the engine water temperature is below 20 °C (68 °F), the automatic warming-up
operation (engine speed: 1000 rpm) is carried out, and is cancelled when the engine water temperature goes above
30 °C (86 °F). (Engine speed: 850 rpm)
(X) :Engine speed (rpm)

(Y) :Water temperature (°C)
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OPERATION OPERATION
CHECKS AFTER STARTING ENGINE
CHECK PARKING BRAKE

Check that the parking brake works properly.
If there is any abnormality in the operation of the parking brake or the brake does not provide the proper braking
effect, please contact your Komatsu distributor for adjustment.
CHECK BRAKE PEDAL

Set to the machine on level ground with no obstacles in the surrounding area, then drive the machine slowly forward
and in reverse and check the braking effect of the brakes.
If there is any abnormality in the operation of the brakes, please ask your Komatsu distributor to carry out
adjustment.
CHECK TRAVEL OF BRAKE PEDAL

Depress the brake pedal fully and check the distance from the floor. Check that the pedal is not too close to the
floor and that there is no abnormal feeling when operating the brake pedal.
If any abnormality is found, please ask your Komatsu distributor to carry out adjustments.
CHECK FOR EASE OF STARTING ENGINE, ABNORMAL NOISE

When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and smoothly.
Check also that there is no abnormal noise when the engine is idling or when the revolution rises slightly.
When there is an abnormal noise at the engine startup and if that condition continues, the engine may be
damaged. In that case, ask your Komatsu distributor to check the engine as soon as possible.
CHECK ENGINE AT LOW SPEED AND WHEN ACCELERATING

Check that there is no irregularity in the engine speed and that the engine does not suddenly stop when the
machine is stopped during normal travel.
Check also that the engine accelerates smoothly when the accelerator pedal is depressed.
Carry out the inspection in a safe place and check that there is no one in the surrounding area.
If the condition at low speed or when accelerating is extremely poor and that condition continues, there is danger
that the engine may be damaged, that the operating feeling may become strange, that the braking effect may
deteriorate, or that an unexpected accident may happen, so please ask your Komatsu distributor to carry out
repairs as soon as possible.
CHECK LOCATION OF ABNORMALITIES FROM PREVIOUS DAYS

Check the places where problems occurred when using the machine on previous days.
If any abnormality is found, please contact your Komatsu distributor for inspection and repair.
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OPERATION OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE

WARNING
If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position.
If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the
movement of the control lever will be slow and the work equipment may not respond as the operator desires, so always carry
out the warming-up operation. Particularly in cold areas, be sure to carry out the warm-up operation completely.
BREAKING-IN THE MACHINE

CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe
conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
During break-in operations, follow the precautions described in this manual.
Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
NORMAL OPERATION
After starting the engine, do not immediately start operations. First, perform the following operations and checks.
NOTICE
Do not suddenly accelerate the engine before the warming-up operation is
completed.
Do not run the engine at low idle or high idle continuously for more than 20
minutes.
If it is necessary to run the engine at idle, apply a load from time to time or
run the engine at a mid-range speed.
1. Depress accelerator pedal (1) lightly and run the engine with
no load at midrange speed for about 5 minutes.
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OPERATION OPERATION
To warm up the hydraulic oil in cold areas, do as follows.

2. After carrying out the warming-up operation, check that the
engine rotation is smooth, then set the work equipment lock
lever to the FREE position (F).
3. Operate the bucket control lever to the TILT position (A) and
return it to the HOLD position (B) repeatedly to warm up the
hydraulic oil.
Relieve the circuit at the TILT position (A) for a maximum of 10
sec.
This brings the oil to the relief pressure and makes it quicker
warm up the oil.
4. Slowly operate the steering wheel to the left and the right about 10 times to warm up the hydraulic oil inside the
steering valve.
WARNING
If you turn the steering wheel and stop turning it while the oil temperature
is low, there may be a time lag before the machine stops after the steering
wheel stops turning.
In such case, set the frame lock bar to LOCK position (L) in order to secure
safety, and perform the warm-up operation in a large place.
In the warm-up operation, be sure not to perform hydraulic relief
continuously for more than 5 seconds.
NOTICE
Turn the steering wheel a little and stop in that position. Confirm that the machine turns by an angle equivalent to the amount that
the steering wheel is turned.
5. After carrying out the warming-up operation, check that the

gauges and caution lamps are normal.
If there is any abnormality, carry out maintenance or repair.
Run the engine under a light load until engine water
temperature gauge (2) and torque converter oil temperature
gauge (3) are in the green range.
6. Check for abnormal exhaust gas color, noise, or vibration. If
any problem is found, contact your Komatsu distributor.
REMARK
The rotating speed of the cooling fan differs according to the following conditions, but this does not indicate any
abnormality.
The cooling fan speed increases when the hydraulic oil temperature, engine coolant temperature, or transmission
oil temperature are high.
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OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has cooled down, engine life may
be greatly shortened. Consequently, do not abruptly stop the engine
except for an emergency.
In particular, if the engine has overheated, do not abruptly stop it but run
it at medium speed to allow it to cool gradually, then stop it.
1. Run the engine at low idle for about 5 minutes to cool down
gradually.
2. Turn the key of starting switch (1) to the OFF position (A) to
stop the engine.
3. Remove the key from starting switch (1).
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OPERATION OPERATION
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE

WARNING
Always remove the frame lock bar for travel operations. If it is not removed, the steering wheel cannot be used for steering,
and this may lead to serious damage or injury.
When moving the machine off, check that the area around the machine is safe, then sound the horn before starting.
Do not allow people to get near the machine.
Clear the machine's travel path of any obstacle.
Pay a particular attention to the blind spot at the rear of the machine, when traveling the machine in reverse.
When starting the machine off up a slope, set the transmission cut-off switch to the OFF position, depress the left brake pedal.
Then depress the accelerator pedal and gradually release the brake pedal to start the machine off. This makes it possible to
prevent the machine from rolling back.
MOVING THE MACHINE

1. Check that caution lamp (1) is not lighted up.
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OPERATION OPERATION
2. Check that the bucket control lever (2) and lift arm control lever
(3) is at the HOLD position, then set the work equipment lock
lever (4) to the FREE position (F).
3. Operate lift arm control lever (3) to set the work equipment to
the travel posture shown in the diagram on the right.
(A): 40 to 50 cm (16 to 20 in)
4. Depress right brake pedal (5) and turn parking brake switch (6)
to the OFF position (B) to release the parking brake.
Keep right brake pedal (5) depressed.
REMARK
If the parking brake is still actuated when parking brake switch (6)
is at the OFF position (B), turn the parking brake switch ON
position (A), then turn it OFF position (B) again.
5. Set gearshift lever (7) to the desired position.

Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
6. Set directional lever (8) to the desired position.

Check that the backup alarm sounds when the directional

lever is set to REVERSE. If the backup alarm does not
sound, please contact your Komatsu distributor for repairs.
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OPERATION OPERATION
7. Release right brake pedal (5), then depress accelerator pedal

(9) to move the machine off.
REMARK
When moving the machine off on a hill, turn transmission cut-off
switch (10) OFF, depress left brake pedal (11), operate the
gearshift lever to the low speed range, then depress accelerator
pedal (9) and gradually release left brake pedal (11) to let the
machine move off. This makes it possible to prevent the machine
from rolling back.
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OPERATION OPERATION
CHANGING GEAR SPEED

WARNING
When traveling at high speed, do not shift gear suddenly. Use the brake to reduce the travel speed before shifting gear.
Shift gear as follows.

Move the gearshift lever (1) to the desired position to shift gear.
When carrying out digging or loading operations, the operation is
carried out in 1st or 2nd, so use the gearshift lever stopper (2).
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
REMARK
If the gearshift lever is operated slowly or is stopped between gear positions, the central warning lamp may light
up and the alarm buzzer may sound. In this case, there is no failure, but try to operate the gearshift lever so that
the gearshifting is completed within 2 seconds.
This machine is equipped with kickdown switch (3). When traveling in 2nd, if kickdown switch (3) is pressed,
the transmission shifts down to 1st.
For operations carried out in 1st and 2nd, such as digging and loading, we recommend the use of the kickdown
switch. For details of the method of use, see Section KICKDOWN SWITCH (PAGE 3-48).
This machine is equipped with an auto-shift system that automatically shifts the gear. For details of the method
of use, see "TRANSMISSION SHIFT MODE SELECTOR SWITCH (PAGE 3-43)" and "AUTOMATIC SHIFT
(PAGE 3-53)".
When the machine is traveling at high speed, if the gear shift lever is shifted down to a lower speed, such as 4th
-> 3rd or 4th -> 2nd, with the accelerator still depressed, the transmission is not shifted down. This is to prevent
the engine from overrunning.
In this case, the central warning lamp lights up and the alarm buzzer sounds. At the same time, "OVERRUN
PROTECT" is displayed on the bottom line.
If the alarm buzzer sounds, release the accelerator pedal immediately and depress the brake pedal to reduce
speed, then carry out the gearshift operation.
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OPERATION OPERATION
CHANGING DIRECTION
WARNING
When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind
spot behind the machine, so be particularly careful when changing direction to travel in reverse.
Do not switch between FORWARD and REVERSE when traveling at high speed.
When switching between FORWARD and REVERSE, depress the brake to reduce the travel speed sufficiently, then change the
direction of travel. (Max.speed for changing direction: 12 km/h (7.5 MPH))
When coasting down a slope, set the directional lever to match the direction of travel of the machine. If the directional lever
is in the opposite direction to the direction of travel, there is danger that the engine may stall. This condition is extremely
dangerous.
There is no need to stop the machine even when switching

between FORWARD and REVERSE.
Place directional lever (1) in the desired position.
Check that the backup alarm sounds when the directional lever
is set to REVERSE. If the backup alarm does not sound, please
contact your Komatsu distributor for repairs.
REMARK
If the directional lever is operated slowly or is stopped midway between the forward and reverse directions, "E01
MAINTENANCE" may be displayed on the character display. In this case, there is no failure, but try to operate the
directional lever so that the change in direction is completed within 2 seconds.
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OPERATION OPERATION
If an attempt is made to switch the direction between FORWARD

and REVERSE while traveling at high speed (when using 3rd or
4th), if the travel speed and engine speed are in ranges (A) or (B)
in the chart, the central warning lamp will light up and the alarm
buzzer will sound.
At the same time, "OVERRUN PROTECT" is displayed on the
bottom line of the character display.
If the alarm buzzer sounds, depress the brake pedal immediately
to reduce speed, then operate the directional lever to switch
between FORWARD and REVERSE.
(X): Travel speed (km/h)
( ): Machines fitted with
(Y): Engine speed (rpm)
20.5-25 tires (if equipped)
WHEN USING AUTO-SHIFT

If an attempt is made to switch the direction between forward and reverse when the auto-shift is ON, normally, the
gearshift range will switch F3 -> R2, F4 -> R2, or R3 -> F2, R4 -> F2 to make it possible to move the machine off
quickly.
However, if an attempt is made to shift between forward and reverse when the machine is traveling at high speed,
such as shown in ranges (A) or (B) in the chart, the central warning lamp will light up and the buzzer will sound.
At the same time, "OVERRUN PROTECT" is displayed on the bottom line of the character display.
If the alarm buzzer sounds, depress the brake pedal immediately to reduce speed, then operate the directional
lever to switch between FORWARD and REVERSE.
In particular, if an attempt is made to switch between forward and reverse in range (B), the speed range will not
shifted to 2nd, but will switch F3 -> R3, F4 -> R4, or R3 -> F3, R4 -> F4. As a result, the reduction in speed will be
less than in range (A), so care is necessary.
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OPERATION OPERATION
STOPPING THE MACHINE

WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Even if the parking brake switch is turned ON, there is danger until the
parking brake pilot lamp lights up, so keep the brake pedal depressed.
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.
1. Release accelerator pedal (1), then depress brake pedal (2) to

stop the machine.
2. Place directional lever (3) in Neutral position (N).
3. Set parking brake switch (4) to the ON position (A) to apply the
parking brake.
REMARK
When the parking brake is applied, the transmission is
automatically returned to neutral.
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OPERATION OPERATION
TRANSMISSION CUT-OFF FUNCTION

When the transmission cut-off switch is turned ON, the pilot lamp
lights up and the following transmission cut-off function is
Position (a): OFF
Position (b): ON
When the brake pedal is depressed, the brakes are actuated and
the transmission is returned to Neutral when the brake pedal is
depressed to the set position.
REMARK
For details of the method of adjusting the set position for the amount that the brake pedal is depressed, see
"ADJUSTING TRANSMISSION CUT-OFF POSITION (PAGE 3-118)".
To match the following type of work, adjust the set position to cut off the transmission at a smaller or larger angle.
When carrying out scooping-up work, lower the brake pedal
depression position for the cut-off (transmission shifted to
neutral). In this setting, the transmission driving force is cut at
a point where there is ample braking force, so this prevents the
machine from slipping down.
When approaching dump trucks during loading operations,

raise the brake pedal depression position for the cut-off
(transmission shifted to neutral). In this setting, the fine control
of the braking immediately before dumping the load can be
carried out with the brake only, so this makes it easy to control
and allows the machine to be brought to a soft stop.
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OPERATION OPERATION
ADJUSTING TRANSMISSION CUT-OFF POSITION
CAUTION
Apply the parking brake before adjusting the transmission cut-off position.
Adjust the amount that the brake pedal is depressed.
1. Start the engine with starting switch (1), then set parking brake
switch (2) to the ON position.
2. Set transmission cut-off switch (3) to the ON position.
3. Depress brake pedal (4) and adjust the set position to return
the transmission to Neutral.
4. Press transmission cut-off set switch (5), then release it.

When the switch is released, the buzzer will sound with a
repeated short sound, and the cut-off position is set.
Method of canceling cut-off position

5. After the buzzer sounds in Step 4 of the adjustment procedure,
the transmission cut-off switch flashes for 2 seconds. While it
is flashing, press transmission cut-off set switch (5) again and
release it.
6. The buzzer will sound with a long sound and the adjusted
cut-off position is canceled.
STOPPING WHEN TRANSMISSION CUT-OFF IS ON
When the transmission cut-off switch is ON, if the brake pedal is depressed, the transmission is returned to Neutral
when the brake pedal is depressed to the set position.
REMARK
When the transmission cut-off switch is OFF, the transmission is not returned to Neutral.
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OPERATION OPERATION
TURNING
WARNING
Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes is dangerous. Do not
operate the steering wheel in such situations.
If the engine stops when the machine is traveling, the emergency steering is actuated. Note that this system is only for steering
in emergencies, so never stop the engine.
It is particularly dangerous if the engine stops when the machine is traveling on slopes, so never let the engine stop when
traveling on slopes.
If the engine stops, stop the machine immediately at a safe place.
When traveling, use steering wheel (1) to turn the machine.

With this machine, the front frame is joined to the rear frame at the
center of the machine by the center pin. The front and rear frames
bend at this point, and the rear wheels follow in the same track as
the front wheels when turning.
Turn the steering wheel lightly to follow the machine as it turns.
NOTICE
When the steering wheel is turned fully, if it reaches the end of its stroke,
do not try to turn it further.
Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in the steering
wheel. Check also that the steering works properly. If any abnormality is
found, please contact your Komatsu distributor for inspection.
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OPERATION OPERATION
EMERGENCY STEERING
(If equipped)
CAUTION
Never actuate the emergency steering except during emergencies or
when checking the function.
The emergency steering can be used continuously for a maximum of 60
seconds. Operating it continuously for more than 60 seconds may
damage the system.
When using the emergency steering, travel at less than 5 km/h (3.1
MPH).
If the steering becomes heavy, keep the emergency steering switch
pressed, move the machine immediately to a safe place, then stop the
machine.
During emergencies or when stopping the engine to check the

function, press emergency steering switch (1). Emergency
steering pilot lamp (green) (2) will light up and the steering can be
operated.
Emergency steering pilot lamp (green) (2) lights up to inform the

operator that the emergency steering system has been actuated.
The emergency steering system is provided to enable the machine to be steered under the following conditions.
The starting switch is at the ON position.
The steering oil pressure is low or there is no pressure.
(When the engine has stopped or there is a failure in the steering oil pressure pump, etc.)
When the starting switch is turned to the ON position, the emergency steering automatically carries out a self check
for 3 seconds. For details, see "EMERGENCY STEERING SELF-CHECK FUNCTION (PAGE 3-121)".
When the emergency steering controller detects lack of oil

pressure in the steering system, steering oil pressure caution lamp
(red) (3) and central warning lamp (4) light up, and the alarm
buzzer sounds intermittently.
When this happens, if the machine is traveling at a speed of more
than 2 km/h (1.2 MPH), the electric pump motor is automatically
actuated and emergency steering pilot lamp (green) (2) lights up.
Steering oil pressure caution lamp (red) (3) lights up to inform the
operator that there is a failure in the steering system.
If steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and stop it.
Locate the cause and do not operate the machine until it has been repaired.
REMARK
If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure
caution lamp (red) (3) may light up for a moment, but if the lamp goes out again soon, there is no problem.
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OPERATION OPERATION
When the emergency steering controller detects that the oil

pressure in the steering circuit has been restored, the actuation of
the emergency steering system is stopped.
On machines equipped with an emergency steering function, the

emergency steering switch is installed at the position shown in the
diagram (1).
EMERGENCY STEERING SELF-CHECK FUNCTION

When the starting switch is turned ON, the emergency steering is automatically actuated for approx. 3 seconds to
check that the emergency steering is functioning properly.
When this happens, steering oil pressure caution lamp (red) (1)
and emergency steering pilot lamp (green) (2) light up.
If the steering oil pressure caution lamp (red) or emergency
steering pilot lamp (green) do not light up, there is an abnormality,
so please ask your Komatsu distributor to carry out inspection.
CAUTION
If the machine is steered during the steering self-check, it may move.
Do not steer the machine during the steering self-check.
The emergency steering function check is not carried out in the following cases.
If the starting switch is turned ON, turned OFF again without starting the engine, and is then turned ON again.
If the starting switch is turned ON again immediately after stopping the engine when the steering oil pressure has
not gone down completely.
If the engine is being preheated.
If the engine is being preheated.

When preheating is being carried out, the emergency steering self- check function is not actuated.
To check the emergency steering function, press the emergency steering switch after completing the warming-up
operation.
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OPERATION OPERATION
OPERATION OF WORK EQUIPMENT

Lift arm control lever (1) and bucket control lever (2) can be used
to operate the lift arm and bucket as follows.
LIFT ARM CONTROL LEVER
NOTICE
Do not use the FLOAT position when lowering the bucket. Use the FLOAT
position when leveling, see "LEVELING OPERATIONS (PAGE 3-128)".
Position (a): RAISE

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 position
of the kickout, and the lever is returned to the HOLD
position.
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.
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OPERATION OPERATION
BUCKET CONTROL LEVER

Position (a): TILT
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
positioner, and the lever is returned to the HOLD
position.
Position (b): HOLD
The bucket is kept in the same position.
Position (c): DUMP
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OPERATION OPERATION
WORK POSSIBLE USING WHEEL LOADER

In addition to the following, it is possible to further increase the range of applications by using various attachments.
DIGGING OPERATIONS
WARNING
Always set the machine facing directly to the front when carrying out digging or scooping operations. Never carry out these
operations with the machine articulated.
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
LOADING PILED SOIL OR BLASTED ROCK

When loading piled soil or blasted rock,drive the machine forward as follows to load. To prevent cutting of the
tires caused by the tires slipping, be careful of the following points during the operation.
Always keep the operating jobsite flat, and remove any fallen rocks.
When working with stockpiles, operate the machine in 1st or 2nd gear; when loading blasted rock operate the
machine in 1st gear.
1. When driving the machine forward and lowering the bucket,

stop the bucket at height (A) approx. 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. Shift down immediately in front of the material to be loaded. When completing the shift down, depress the
accelerator pedal at the same time and thrust the bucket into the material.
REMARK
To reduce fuel consumption, depress the accelerator pedal the minimum possible amount. If it is depressed fully,
the fuel consumption will increase, but there will be no increase in the amount loaded.
3. When the material is in a stockpile, keep the cutting edge of the bucket horizontal; when loading blasted rock,
have the bucket tilting slightly down.
Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip.
Try to keep the load in the center of the bucket; if the load is on one side of the bucket, the load will be
unbalanced.
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OPERATION OPERATION
Stock pile
Blasted rock
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 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 of 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.
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OPERATION OPERATION
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.
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OPERATION OPERATION
DIGGING AND LOADING ON LEVEL GROUND

When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the
machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load.
This operation should be carried out in 1st gear.
CAUTION
Do not set the bucket facing down more than 20 degrees.
1. Set the edge of the bucket facing slightly down.
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 imposing the digging

force on one side of the bucket.
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OPERATION OPERATION
LEVELING OPERATIONS
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 degrees.
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 bucket teeth touching the ground and level the ground by back-dragging.
3. Scoop some more soil into the bucket, put the lift arm control lever in FLOAT position, level the bucket at ground
level, and smooth the ground by moving backward.
PUSHING OPERATION
CAUTION
Never set the bucket to the DUMP position when carrying out pushing operation.
When carrying out pushing operations, set the bottom of the bucket parallel to the ground surface.
LOAD AND CARRY OPERATIONS

WARNING
When carrying a load, lower the bucket to lower the center of gravity when
traveling.
The load and carry method for wheel loaders consists of a cycle of scooping -> hauling -> loading (into a hopper,
truck, etc.).
Always keep the travel path properly maintained.
When using the load and carry method, see "PRECAUTIONS FOR USING LOAD AND CARRY METHOD (PAGE
3-140)".
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OPERATION OPERATION
LOADING OPERATIONS
Select the method of operation which will give the minimum amount of turning and travel in order to provide the
most efficient method for the jobsite.
WARNING
Always keep the working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load. These
actions are dangerous.
It is also dangerous to drive the bucket at high speed into a stockpile or pile of rocks.
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
Avoid excessive bucket shaking.
CROSS DRIVE LOADING

Always set the wheel loader facing at a right angle to the stockpile.
After digging in and scooping up the load, drive the machine
straight back in reverse, then bring the dump truck in between the
stock pile and the wheel loader.
This method requires the least time for loading, and is extremely
effective in reducing the cycle time.
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OPERATION OPERATION
V-SHAPE LOADING
Position the dump truck so that the direction of approach of the
wheel loader is approx. 60 degrees 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.
PRECAUTIONS WHEN PILING UP LOADS

When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground.
Do not set the bucket to the DUMP position when piling-up loads.
REMARK
When using the transmission cut-off function, lower the cut-off position so that cut-off function is actuated, when
the brake pedal is deeply depressed, while ensuring ample braking force.
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OPERATION OPERATION
PRECAUTIONS FOR OPERATION
PERMISSIBLE WATER DEPTH

When working in water or on swampy ground, do not let the water
come above the bottom of the axle housing (1).
After finishing the operation, wash and check the lubricating
IF WHEEL BRAKE DOES NOT WORK

If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine.
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.
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES
LOWER THE CENTER OF GRAVITY WHEN TURNING

When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to
turn the machine suddenly on slopes.
BRAKING ON DOWNHILL SLOPE

When traveling downhill, if the footbrake is used frequently, the brake will overheat and may be damaged. To
prevent this, place the gearshift lever in a low speed range, turn the transmission cut-off switch OFF, and use the
engine brake.
If the brakes are used excessively, the brake oil temperature caution lamp may light up and the alarm buzzer may
sound intermittently. For details of the necessary action to take, see "BRAKE OIL TEMPERATURE CAUTION
LAMP (PAGE 3-18)" in EXPLANATION OF COMPONENTS.
If the speed range selected by the gearshift lever is not correct, the torque converter oil may overheat. If this
happens, shift down one gear range and reduce the oil temperature.
If the oil temperature does not return to the white range even when the gearshift lever is at 1st, stop the machine,
return the directional lever to the N position, and run the engine at a mid-range speed until the gauge returns to the
white range.
IF ENGINE STOPS
If the engine stops on a slope, apply the parking brake immediately, and lower the work equipment to the ground
and stop the machine. Then put the directional lever in neutral position, and start the engine again.
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OPERATION OPERATION
PRECAUTIONS WHEN DRIVING MACHINE

When the machine travels at high speed for a long distance, the tires become extremely hot. This causes early
wear of the tires and should be avoided as much as possible. If the machine must be driven for a long distance,
take the following precautions.
Follow the regulations related to this machine, and drive carefully.
Before driving the machine, carry out the checks before starting.
The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface.
Contact your Komatsu distributor or tire dealer for information.
The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard
tires. (23.5-25-16PR)
Tire pressure
Front wheel: 300 kPa {3.1 kg/cm2, 44.1 PSI}
Rear wheel: 300 kPa {3.1 kg/cm2, 44.1 PSI}
Speed:14 km/h {8.7 MPH}
Check the tire pressure before starting, when the tire is cool.
After traveling for one hour, stop the machine for 30 minutes and check the tires and all parts for any abnormality.
Check the oil level and coolant level also.
When stopping the machine in extremely cold areas, do as follows.
To prevent the radiator water temperature from rising suddenly, do not suddenly stop the engine. Gradually cool
the radiator water down before stopping the engine.
Always travel with the bucket empty.
Never put "calcium chloride" or "dry ballast" in the tires when traveling.
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OPERATION OPERATION
ADJUSTING WORK EQUIPMENT POSTURE

WARNING
Stop the machine on flat ground and put blocks in front of and behind
the tires.
Set the parking brake switch to the ON position (A) to apply the parking
brake.
Set the frame lock bar to LOCK position (L) to lock the front and rear
frames.
Always attach a warning sign to the work equipment control levers.
Do not go under the work equipment when the arm is raised.
The boom kickout makes it possible to set the bucket so that it automatically stops at the desired lifting height (lift
arm higher than horizontal) and the bucket positioner makes it possible to set the bucket so that it automatically
stops at the desired digging angle. The setting can be adjusted to match the working conditions.
ADJUSTING BOOM KICKOUT

1. Raise the bucket to the desired position, return the lift arm
control lever to the HOLD position, set the work equipment
lock lever to the LOCK position, then stop the engine.
2. Loosen two bolts (1), and adjust plate (2) so that the bottom
edge is in line with the center of the sensing surface of
proximity switch (3). Then tighten the bolts to hold the plate in
position.
3. Loosen two nuts (4) to make a clearance of 3 to 5 mm (0.118
to 0.197 in) between plate (2) and the sensing surface of
proximity switch (3). Then tighten the nuts to hold in position.
Tightening torque: 17.2 ± 2.5 Nm {1.75 ± 0.25 kgm, 12.7 ±
1.8 lbft}
4. After adjusting, start the engine and operate the lift arm control lever. Check that the lever is automatically
returned to HOLD when the bucket reaches the desired height.
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OPERATION OPERATION
ADJUSTING BUCKET POSITIONER

1. Lower the bucket to the ground, set it to the desired digging
angle, return the bucket control lever to the HOLD position, set
the work equipment lock lever to the LOCK position, then stop
the engine.
2. Loosen 2 bolts (1), adjust the position of mounting bracket (4)
of the proximity switch so that the rear tip of bar (2) is in line
with the center of the sensing surface of proximity switch (3),
then tighten bolts to hold the bracket in position.
3. Loosen 2 bolts (5), adjust so that the clearance between bar
(2) and support (6) is 0.5 to 2 mm (0.020 to 0.079 in), then
tighten bolts (5) to hold in position.
4. Loosen 2 nuts (7), adjust so that the clearance between bar (2) and the sensing surface of proximity switch (3)
is 3 to 5 mm (0.118 to 0.197 in), then tighten the nuts to hold in position.
5. After adjusting, start the engine and raise the lift arm. Operate the bucket control lever to the DUMP position,
then operate it to the TILT BACK position and check that the lever is automatically returned to the HOLD
position when the bucket reaches the desired digging angle.
BUCKET LEVEL INDICATOR

(A) and (B) at the top rear of the bucket are the level indicators.
They check the bucket angle during operations.
(A): Parallel with cutting edge
(B): 90 degrees to cutting edge
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OPERATION OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Do not park the machine on slopes.
If the machine has to be parked on a slope, set it facing directly down the
slope, then dig the bucket into the ground and put blocks under the tires
to prevent the machine from moving.
If the control lever is touched by accident, the work equipment or the
machine may move suddenly, and this may lead to a serious accident.
Before leaving the operator's compartment, always set the work
equipment lock lever securely to the LOCK position.
Even if the parking brake switch is turned ON, there is danger until the
parking brake pilot lamp lights up, so keep the brake pedal depressed.
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.
1. Release accelerator pedal (1), then depress brake pedal (2) to

stop the machine.
2. Place directional lever (3) in Neutral position (N).
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OPERATION OPERATION
3. Set parking brake switch (4) to the ON position (A) to apply the
parking brake.
NOTICE
When the parking brake is applied, the transmission is automatically
returned to neutral.
4. Operate lift arm control lever (5) to lower the bucket to the
ground.
5. Check that the lift arm control lever (5) and bucket control lever
(6) is at the HOLD position, then set the work equipment lock
lever (7) to the LOCK position (L).
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.
OPERATION OPERATION
CHECKS AFTER COMPLETION OF OPERATION
BEFORE STOPPING ENGINE

Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the
machine monitor.
If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to
cool down before stopping it.
AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, bodywork, and undercarriage, and check also for oil
and water leakage.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.
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OPERATION OPERATION
LOCKING
Always lock the following parts.
(1) Fuel tank filler cap (1 place)
(2) Engine side cover (2 places)
(3) Cab door (1 place)
(4) Hydraulic tank filler cap (1 place)
(5) Air-conditioner fresh air filter inspection cover (1 place)
(6) Transmission filter cover (1 place) (if equipped)
REMARK
The starting switch key is used also for locks (1) to (6).
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OPERATION OPERATION
HANDLING THE TIRES
PRECAUTIONS WHEN HANDLING TIRES

CAUTION
If a tire has reached any of the following service limits, there is danger that
the tire may burst or cause an accident, so to ensure safety, replace it with
a new tire.
Service limits for wear
When the remaining depth of the grooves on construction equipment
tires (at a point approx. 1/4 of the tread width) is 15% of the groove depth
on a new tire.
When the tire shows marked uneven wear, stepped wear or other
abnormal wear, or when the cord layer is exposed. (1) Side wall
Service limits for damage (2) Shoulder
When there is external damage extending to the cord or when the cord (3) Tread
is broken (4) Breaker or belt (cord layer)
When the cord is cut or there is dragging (5) Bead
(6) Inner liner
When the tire is peeling (there is separation)
(7) Carcass
When the bead is damaged
For tubeless tires, when there is air leakage or improper repair
Do not install a tire protector (mesh chain) to the rear tires.
Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without
taking due care.
TIRE PRESSURE
Measure the tire pressure before starting operations, when the tires are cool.
If the tire inflation pressure is too low, there will be overload; if it is too high, it will cause tire cuts and shock burst.
To prevent these problems, adjust the tire inflation pressure according to the table on the next page.
Deflection ratio = H - h / H x 100
As a guideline that can be checked visibly, the deflection ratio of the front tire (deflection/free height) is as follows.
When carrying normal load (lift arm horizontal): Approx. 15 to 25 %
When digging (rear wheels off ground): Approx. 25 to 35 %
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OPERATION OPERATION
When checking the tire inflation pressure, check also for small scratches or peeling of the tire, for nails or pieces
of metal which may cause punctures, and for any abnormal wear.
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 operations: High end of range in air pressure chart
Stockpile operations on soft ground: Average pressure in air pressure chart
Operations on sand (operations not using much digging force): Low end of range in air pressure chart
If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a
suitable deflection (see deflection ratio).
Inflation pressure [kPa {kg/cm2, PSI}]

H
Tire size Soft ground
Free height Normal road When shipped from
(Pattern) (sandy ground)
(mm) factory
Stockpile Stockpile Digging
23.5-25-16PR
424 (BS)
(L3: Rock)
423 (TOYO)
(Standard) 240 to 360 260 to 360 260 to 360
Front and Rear tire:
{2.4 to 3.6, {2.6 to 3.6, {2.6 to 3.6,
300 {3.1, 44.1}
23.5-25-16PR 34.1 to 51.2} 37.0 to 51.2} 37.0 to 51.2}
434 (BS)
(L2: Traction)
422 (TOYO)
(if equipped)
20.5-25-16PR
(if equipped)
387 (BS)
20.5-25-20PR
383 (TOYO)
(L3: Rock)
(if equipped) 260 to 380 280 to 450 280 to 450
Front and Rear tire:
{2.6 to 3.8, {2.8 to 4.5, {2.8 to 4.5,
20.5-25-16PR 350 {3.5, 49.8}
37.0 to 54.0} 39.8 to 64.0} 39.8 to 64.0}
(if equipped)
386 (BS)
20.5-25-20PR
385 (TOYO)
(L2: Traction)
(if equipped)
Stockpile operations mean the loading of sand and other loose

materials.
PRECAUTIONS FOR USING LOAD AND CARRY METHOD

When traveling continuously with load and carry operations, choose the correct tires to match the operating
conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so
contact your Komatsu distributor or tire dealer when selecting tires.
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OPERATION TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
When transporting the machine, choose the optimum transportation method in reference to the weight and
dimensions shown in "SPECIFICATIONS (PAGE 5-2)". Note that machine specifications (weight and dimensions)
vary depending on the kind of tire and bucket.
LOADING, UNLOADING WORK WITH TRAILERS

WARNING
When loading or unloading the machine, run the engine at low speed, travel at low speed, and operate slowly.
When loading or unloading the machine, stop the trailer on firm level ground.
In addition, keep well away from the road shoulder.
Use ramps of ample width, length, thickness, and strength, and install them securely at an angle of less than 15°.
When using an embankment, compact the fill soil thoroughly and make sure that the slope face does not collapse.
Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the ramps.
In addition, remove any water, snow, ice, grease, or oil from the ramps.
Never change direction on the ramps. There is danger that the machine may tip over.
If it is necessary to change direction, return to the ground surface or the trailer platform, correct the direction, and start again.
The position of the center of gravity of the machine will change suddenly at the connection of the ramp and trailer, and there
is danger of the machine losing its balance. Always drive slowly over this point.
When loading or unloading, always use ramps or a platform. Proceed as follows.
LOADING
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Apply the brakes on the trailer securely and insert blocks (1)
under the tires to hold the trailer in position.
Set the distance (3) between ramps (2) to match the distance
between the left and right tires, and make angle (4) of the
ramps a maximum of 15°.
If ramps (2) sag appreciably under the weight of the machine,
put wooden block (5) under the ramps to support them.
3. Determine the direction of the ramp, then slowly load the
machine.
4. Load the machine correctly in the specified position on the
trailer.
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TRANSPORTATION OPERATION
SECURING MACHINE
Load the machine onto a trailer as follows:
1. Lower the work equipment slowly.
2. Check that the work equipment control lever is at the HOLD
position, then set the work equipment lock lever to the LOCK
position (L).
3. Set the parking brake switch to ON position (A) to apply the

parking brake securely.
4. Turn the starting switch to the OFF position and stop the
engine.
Remove the key from the starting switch.
5. Set the frame lock bar to the LOCK position (L)to lock the front
frame and rear frame.
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.
6. Put blocks in front and behind the wheels, and secure the machine with chains or wire rope to prevent the
machine from moving during transportation.
In particular, attach the machine securely to prevent it from slipping sideways.
Fastening positions
7. Stow the antenna away.
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.
UNLOADING
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road.
2. Apply the brakes on the trailer securely and insert blocks (1)
under the tires to hold the trailer in position.
Set the distance (3) between ramps (2) to match the distance
between the left and right tires, and make angle (4) of the
ramps a maximum of 15°.
If ramps (2) sag appreciably under the weight of the machine,
put wooden block (5) under the ramps to support them.
3. Remove the chains and wire ropes fastening the machine.

4. Set the frame lock bar to FREE position (F).
5. Start the engine.
Warm the engine up fully.

position, then set the work equipment lock lever to the FREE
position (F).
7. Set the parking brake switch to OFF position (B) to cancel the
parking brake.
8. Determine the direction of the ramps, then drive the machine
slowly down the ramps to unload the machine.
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LIFTING MACHINE
WARNING
The person using the crane to carry out lifting operations must be a qualified crane operator.
Never carry out lifting operations if any person is on the machine being lifted.
Always use a wire rope that has ample strength for the weight of the machine being lifted.
Keep the machine horizontal when lifting it.
When carrying out lifting operations, do as follows to prevent the machine from moving unexpectedly.
Set the parking brake switch to the ON position.
Set the work equipment lock lever to the LOCK position.
Set the frame lock bar to the LOCK position.
Never enter the area under or around a raised machine.
There is danger of the machine losing its balance.
Use the procedure below to set the machine in the proper posture and use the lifting equipment when lifting the machine.
NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting
procedures, contact your Komatsu distributor.
For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".
LIFTING PROCEDURE
Lifting position
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.
Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the
machine in a horizontal place and do as follows.
1. Start the engine, make sure that the machine is horizontal,

then set the work equipment to the travel posture.
For details, see "MOVING THE MACHINE (PAGE 3-110)".
(A): 40 to 50 cm (16 to 20 in)

position, then set the work equipment lock lever to the LOCK
position (L).
3. Stop the engine, check that the area around the operator's
compartment is safe, then set the frame lock bar to the LOCK
position (L) to prevent the front frame and rear frame from
articulating.
4. Use wire ropes and slings that match the weight of the machine, and wind the wire rope and fix it to the lifting
points as shown in the figure.
NOTICE
Use protectors, etc. so that the wire ropes will not be broken at sharp edges or narrow places.
Use threaders and bars having sufficient width so that the slings and wire ropes will not touch the machine.
5. Before lifting up the machine, set the slings and float the machine to 100 to 200 mm (3.9 to 7.9 in) above the
ground. Make sure that the wire ropes are not slack and the machine is kept horizontally, and then lift up the
machine slowly.
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.
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION

PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as
FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-10)".
COOLANT
WARNING
COOLANT 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 amounts of fresh water and see a doctor at once.
When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
NOTICE
Please use Komatsu genuine SUPERCOOLANT (AF-NAC) for the COOLANT. As a basic rule, we do not recommend the use of any
COOLANT other than SUPERCOOLANT (AF-NAC).
COOLANT is already diluted with distilled water, so it is not flammable.

For details of the density of COOLANT and the interval for changing the coolant, see "CLEAN INSIDE OF
COOLING SYSTEM (PAGE 4-25)".
3 - 147
.
COLD WEATHER OPERATION OPERATION
BATTERY
WARNING
The battery generates flammable gas. 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 a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on 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 the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
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%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte
Temperature 20°C 0° C -10°C -20°C
Charging (68°F) (32°F) (14°F) (-4°F)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine,
store the battery in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the
day's work to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to
prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
Park the machine on hard, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.
AFTER COLD WEATHER

When the season changes and the weather becomes warmer, do as follows.
Replace all fuel and oil with fuel and oil of the specified viscosity. For details, see "RECOMMENDED FUEL,
COOLANT, AND LUBRICANT (PAGE 4-10)".
3 - 148
.
OPERATION LONG-TERM STORAGE
LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than one month), store as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level
ground and cover the machine with a sheet.
Completely fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it
Set the lock lever to the LOCK position to prevent the machine from moving.
To prevent rust, fill with COOLANT to give a density of at least 30% for the engine coolant.
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
During storage, operate and move the machine for a short distance once a month so that a new film of oil will
coat moving parts. At the same time, also charge the battery.
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month
to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In
addition, check the refrigerant level twice a year.
AFTER STORAGE
NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and
after starting the engine. If there is water in the oil, change all the oil.
Check that there is no rust on the engine pulley and no abnormality in the belt.
If there is excessive rust on the belt contact surface of the pulley, remove it with a wire brush.
3 - 149
.
TROUBLESHOOTING OPERATION
TROUBLESHOOTING
WHEN MACHINE RUNS OUT OF FUEL
WARNING
When starting the engine again, check carefully that the area around the engine is safe before cranking the engine.
When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.
For details of bleeding the air, see "PROCEDURE FOR BLEEDING AIR (PAGE 4-53)".
METHOD OF TOWING MACHINE

WARNING
Serious injury or death could result if there is any mistake in the selection
of wire rope or method of towing a disabled machine.
Always be sure to check carefully that the capacity of the wire rope used
for towing is ample for the weight of the towed machine.
Never use a wire rope which has cut strands (A), reduced diameter (B),
or kinks (C). There is danger that the rope may break during the towing
operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing machine
and the machine being towed.
Move the machine slowly and be sure not to apply any sudden load on
the wire rope.
If there is a failure in the brake line, the brakes cannot be used, so be
extremely careful when towing.
NOTICE
Only tow the machine for a short distances, such as to a place for inspection or maintenance.
The machine must not be towed for long distances.
For details of the permissible towing load for this machine, see Section "SPECIFICATIONS (PAGE 5-2)".
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.
Before releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are
not blocked, the machine may suddenly move.
When towing a machine, tow it at a low speed of less than 2 km/h (1.2 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.
If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the
machine.
Keep the angle of the towrope as small as possible. Keep the angle between the centerlines of the two machines
to within 30 degrees.
The towing machine should normally be of the same class as the machine being towed. Check that the towing
machine and towed machine both have ample braking power and that the towing machine has ample rimpull to
control both machines on the slopes or on the tow road.
3 - 150
.
OPERATION TROUBLESHOOTING
When towing a machine downhill, it may be necessary to connect another machine to the rear of the machine
being towed in order to provide ample rimpull and braking power. This makes it possible to prevent the machine
from losing control.
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 rim pull.
Connect a wire rope to the part indicated with the arrow in the
diagram at right.
WHEN ENGINE CAN BE USED

If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the
machine out of mud or to move it for a short distance to the edge of the road.
The operator should sit on the machine being towed and operate the steering in the direction that the machine
is towed.
WHEN ENGINE CANNOT BE USED

When towing a machine with the engine stopped, use the following procedure.
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.
2. The steering cannot be operated, so remove the steering cylinder.
Even if the brakes are in good condition, the brakes can only be used a limited number of times. There is no
change in the operating force for the brake pedal, but the braking force is reduced each time the pedal is
depressed.
3. Connect the towing equipment securely. When carrying out towing operations, use two machines of at least
the same class as the machine being towed. Connect one machine each to the front and rear of the machine
being towed, then remove the blocks from the tires and tow the machine.
4. Parking brake
The parking brake cannont be turned OFF. To release the parking brake, do as follows.
3 - 151
.
RELEASING PARKING BRAKE

WARNING
When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is
necessary to release the brake on a slope in an emergency, block the tires before starting the operation.
If the parking brake is released, the brake cannot be used, so check the safety carefully when moving the machine.
If the engine will not run for some reason, use the following methods to release the parking brake and tow the
machine.
METHOD OF RELEASING BRAKE BY USING EMERGENCY PARKING BRAKE CANCEL SWITCH
CAUTION
When the parking brake switch is at the OFF position and the emergency parking brake release valve is opened, the parking brake
is released immediately.
In this condition, even if you feel danger and try to stop the machine, the parking brake will not be applied immediately even if you
close the emergency parking brake release valve.
If the pressure in the brake accumulator is high, do as follows.

1. Turn the starting switch to the OFF position (A).
2. Turn locknut (1) of the release valve counterclockwise, then

turn grip (2) counterclockwise to open the release valve.
REMARK
The relief valve is located on the left front portion inside the rear
frame and secured to the accumulator mounting bracket.
3 - 152
.
3. Turn starting switch to the ON position (B).
4. Move the parking brake switch to the ON (A) position

(actuated), then move it to the OFF (B) position (released).
The parking brake is released.
5. To restore the function of the parking brake, turn grip (2) of the
release valve clockwise to close the release valve, then turn
locknut (1) clockwise to lock it.
Tightening torque
Grip (2): 20 ± 5 Nm {2.0 ± 0.5 kgm, 14.5 ± 3.6 lbft}
Locknut (1): 20 ± 5 Nm {2.0 ± 0.5 kgm, 14.5 ± 3.6 lbft}
6. Move the parking brake switch to the ON (a) position. The
parking brake is applied.
To release the parking brake again, repeat the procedure in
Steps 1 to 4.
REMARK
If the brake accumulator pressure is low, the parking brake warning lamp may not go out and the alarm buzzer may
sound (a long continuous sound). If this happens, release the brake. For details, see "METHOD OF RELEASING
WITH ADJUSTMENT SCREW (PAGE 3-154)"
3 - 153
.
METHOD OF RELEASING WITH ADJUSTMENT SCREW

If the brake accumulator pressure is low, do as follows.
1. Loosen bolt (2) and adjustment screw (1) at 3 places (A, B, C)
at the front of the transmission case.
2. Rotate lock plate (3) to release the lock, then tighten

adjustment screw (1) until it stops.
3. If this operation is carried out at the same time at A, B, and C,
the parking brake can be released.
EMERGENCY TRAVEL OPERATION

The normal gear shifting operation is carried out by electric signals. If there should be a failure in the electrical
system and the machine does not move, please contact your Komatsu distributor to have the machine moved.
NOTICE
Always request your Komatsu distributor to carry out the emergency travel operation.
3 - 154
.
IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery when installed on a machine. Make
sure that it is removed before charging.
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do anything that will
cause sparks.
Battery electrolyte is dilute sulfuric acid, and it will attack your clothes
and skin. If it gets on your clothes or on your skin, immediately wash it
off with a large amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
When handling batteries, always wear safety glasses and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger
that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
REMOVAL AND INSTALLATION OF BATTERY

1. Before removing battery, remove the ground cable (normally connected to the negetive (-) terminal). If any tool
touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the
nuts of the terminal and remove the wires from the battery.
2. After installing the battery, fix it with the battery hold down.
Tightening torque: 2 to 2.9 Nm
{0.2 to 0.3 kgm, 1.4 to 2.2 lbft}
3. When installing the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 5.9 to 9.8 Nm
{0.6 to 1.0 kgm, 4.3 to 7.2 lbft}
REMARK
The batteries are on both sides at the rear of the machine. The battery used for the ground is on the right side of
the machine.
3 - 155
.
PRECAUTIONS FOR CHARGING BATTERY

When charging the battery, if the battery is not handled correctly,
there is danger that the battery may explode. Always follow the
instructions in "BATTERY (PAGE 3-148)" and the instruction
manual accompanying the charger, and do as follows.
Do not use or charge the battery if the battery electrolyte level
is below the LOWER LEVEL line. This may cause an explosion.
Check the battery electrolyte level periodically and add distilled
water to bring the electrolyte level to the UPPER LEVEL line.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the correct voltage is not selected, the charger
may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the positive (+) terminal of the battery, then connect the
negative (-) charger clip of the charger to the negative (-) terminal of the battery. Be sure to attach the clips
securely.
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.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, wear safety glasses and
rubber gloves.
Be careful not to let the normal machine and problem machine contact
each other. This prevents sparks from generating near the battery
which could ignite the hydrogen gas given off by the battery.
Make sure that there is no mistake in the booster cable connections.
The final connection is to the engine block of the problem machine, but
sparks will be generated when this is done, so connect to a place as far
as possible from the battery.
When disconnecting the booster cable, take care not to bring the clips
in contact with each other or with the machine body.
NOTICE
The size 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 engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the work equipment lock levers and parking brake levers of both machines are in the LOCK position.
Check that each lever is in the NEUTRAL position.
3 - 156
.
CONNECTING THE BOOSTER CABLE

Keep the starting switch of the normal machine and problem machine in the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Connect the clip of booster cable (A) to the positive (+)
terminal of battery (C) on the problem machine.
2. Connect the clip at the other end of booster cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of booster cable (B) to the negative (-)
terminal of battery (D) on the normal machine.
4. Connect the clip at the other end of booster cable (B) to engine
block (E) on the problem machine.
STARTING ENGINE
WARNING
Always check that the work equipment lock lever is set to the LOCK position, regardless of whether the machine is working
normally or has failed. Check also that all the control levers are in the HOLD or NEUTRAL position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle speed.
3. 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.
DISCONNECTING THE BOOSTER CABLE

After the engine has started, disconnect booster cables in the reverse order in which they were connected.
1. Remove the clip of booster cable (B) from engine block (E) on
the problem machine.
2. Remove the clip of booster cable (B) from the negative (-)
3. Remove the clip of booster cable (A) from the positive (+)
4. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (C) on the problem machine.
3 - 157
.
OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Main causes Remedy

Lamp does not glow brightly even Defective wiring ( Check, repair loose terminals,
when the engine runs at high disconnections)
speed Defective adjustment of belt Adjust alternator belt tension For
Lamp flickers while engine is tension details, see EVERY 1000 HOURS
running SERVICE
Even when the engine is rotating, Defective alternator ( Replace)

the battery charge circuit caution Defective wiring ( Check, repair)
lamp does not go out Defective adjustment of alternator Adjust alternator belt tension For
belt tension details, see EVERY 1000 HOURS
SERVICE
Abnormal noise is generated from

Defective alternator ( Replace)
alternator
Starting motor does not turn when Defective wiring ( Check, repair)
starting switch is turned to ON Insufficient battery charge Charge
Pinion of starting motor keeps Insufficient battery charge Charge

going in and out
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
Starting motor disengages before Defective wiring ( Check, repair)

engine starts Insufficient battery charge Charge
Preheating pilot lamp does not Defective wiring ( Check, repair)

light up Defective heater relay, heater ( Replace)
controller, temperature sensor
Defective preheating pilot lamp ( Replace)
Even when engine is stopped, Defective wiring ( Check, repair)

battery charge circuit caution Defective monitor ( Replace)
lamp does not light up (starting
switch at ON position)
3 - 158
.
CHASSIS

Transmission
Engine is running but machine Parking brake is applied Release parking brake
does not move Directional lever is not shifted Shift lever 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. See
throttle, machine only move WHEN REQUIRED
slowly and lacks power Screen is clogged ( Disassemble, clean)
Oil overheats Too much oil or too little oil in Add or drain oil to specified level.
transmission case See WHEN REQUIRED
Machine is not traveling in correct Place in correct speed range
speed range
Torque converter is stalled for Reduce stall time
long periods
Engine is overheating ( Check engine)
Noise generated Lack of oil in transmission case Add oil to specified level. See
WHEN REQUIRED
Axle
Noise generated Lack of oil Add oil to specified level.
See WHEN REQUIRED
Improper oil used (for machines Change to specified oil
with limited-slip differential)
Brake
Brake is not applied when pedal is Disc has reached wear limit ( Replace disc)
depressed Lack of oil in hydraulic tank Add oil to specified level. See
EVERY 100 HOURS
Air in brake line Bleed air
Vent hole of brake valve is Clean

Brake drags or remains applied clogged
Brakes squeal Disc is worn ( Replace disc)

Large amount of water in axle oil Change axle oil
Deteriorated axle oil due to Change axle oil
overuse of brake
3 - 159
.

Steering
Steering wheel is heavy Lack of oil in hydraulic tank Add oil to specified level. See
EVERY 100 HOURS SERVICE
Steering wheel is loose Play in steering cylinder pin ( Grease bearing or replace pin
and bushing where there is
play)
Lack of oil in hydraulic tank Add oil to specified level. See
Parking brake
Braking effect is poor Disc is worn ( Replace disc)
Brake drags or remains applied Lack of oil in transmission case Add oil to specified level. See
WHEN REQUIRED
Screen is clogged ( Disassemble and clean)
Hydraulic system
Lack of lifting power for bucket Lack of oil in hydraulic tank Add oil to specified level. See
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
Lack of oil in hydraulic tank Add oil to specified level. See
Air in oil line Bleed air. See EVERY 2000
HOURS SERVICE
Hydraulic pressure is low Lack of oil in hydraulic tank Add oil to specified level. See
causes pump to suck in air EVERY 100 HOURS SERVICE
Then bleed air. See EVERY
2000 HOURS SERVICE
Movement of cylinder is irregular Lack of oil in hydraulic tank Add oil to specified level. See
3 - 160
.
ENGINE

Engine oil pressure caution lamp Low engine oil pan oil level Add oil to specified level, see
lights up (sucking in air) CHECK BEFORE STARTING
Clogged oil filter cartridge Replace cartridge, see EVERY
500 HOURS SERVICE
Defective tightening of oil pipe ( Check, repair)
joint, oil leakage from damaged
part
Defective monitor ( Replace)
Steam is emitted from top part of Low cooling water level, water Check, add cooling water, repair,
radiator (pressure valve) leakage see WHEN REQUIRED
Defective fan pump or motor ( Check, repair)
Engine water temperature gauge Dirt or scale accumulated in Change cooling water, clean
is in red range cooling system inside of cooling system, see
Engine cooling water temperature WHEN REQUIRED
caution lamp lights up Clogged radiator fin or damaged Clean or repair, see WHEN
fin REQUIRED
Defective thermostat ( Replace thermostat)
Defective thermostat seal ( Replace thermostat seal)
Loose radiator filler cap (high Tighten cap or replace packing
altitude operation)
Defective monitor ( Replace)
Engine water temperature gauge Defective thermostat ( Replace thermostat)

is in white range Defective monitor ( Replace)
Engine does not start when Lack of fuel Add fuel, see CHECK BEFORE
starting motor is turned STARTING
Air in fuel system Repair place where air is sucked
in
No fuel in fuel filter Fuel filter with fuel. See EVERY
1000 HOURS SERVICE
Defective injection pump or ( Replace pump or injector)
injector
Starting motor cranks engine too See ELECTRICAL SYSTEM
slowly
Starting motor does not turn See ELECTRICAL SYSTEM
Preheating pilot lamp does not See ELECTRICAL SYSTEM
light up
Defective valve clearance ( Adjust valve clearance)
(Defective compression)
Exhaust gas is white or blue Too much oil in oil pan Add oil to specified level, see
Improper fuel Change to specified fuel
3 - 161
.

Exhaust gas occasionally turns Clogged air cleaner element Clean or replace, see WHEN
black REQUIRED
Defective injector ( Replace injector)
Defective compression ( See defective compression
above)
Defective turbocharger ( Clean or replace turbocharger)
Combustion noise occasionally Defective nozzle ( Replace nozzle)

makes breathing sound
Abnormal noise generated Low grade fuel being used Change to specified fuel
(combustion or mechanical) Overheating Refer to "Water temperature
gauge is in red range" as above
Damage inside muffler ( Replace muffler)
Excessive valve clearance ( Adjust valve clearance)
3 - 162
.
4-1
.
GUIDES TO MAINTENANCE MAINTENANCE
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual.
CHECK SERVICE METER:

Check the service meter reading every day to see if the time has come for any necessary maintenance to be
performed.
KOMATSU GENUINE REPLACEMENT PARTS:

Use Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE OILS:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient
temperature.
ALWAYS USE CLEAN WASHER FLUID:

Use automobile window washer fluid, and be careful not to let any dirt get into it.
ALWAYS USE CLEAN OIL AND GREASE:

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS:

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out
suitable action.
FUEL STRAINER:
Do not remove the strainer from the filler port when adding fuel.
When adding fuel, be careful not to spill it. If any fuel should spill, wipe it up with a clean cloth.
Do not bring any lighted cigarette or flame close to the fuel.
WELDING INSTRUCTIONS:
Cut off power. Wait for approx. one minute after turning off the engine starting switch key, and then disconnect
the negative (-) terminal of the battery.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
DO NOT DROP THINGS INSIDE MACHINE:

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
.
MAINTENANCE GUIDES TO MAINTENANCE
DUSTY WORKSITES:
When working at dusty worksites, do as follows:
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
AVOID MIXING OIL:

If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade
of oil. Never mix different brand or grade of oil.
LOCKING INSPECTION COVERS:

Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly blow shut by the wind and cause
injury to the worker.
When closing the inspection cover, check that it is not locked with the lock bar.
If it is locked and a strong force is brought to bear on it, there is danger that it may become deformed.
BLEEDING AIR FROM HYDRAULIC CIRCUIT:

If the hydraulic oil equipments have been repaired or replaced and if the hydraulic hoses, pipes, etc. have been
disconnected, it is necessary to bleed air from the circuit. See "CHANGE OIL IN HYDRAULIC TANK, REPLACE
HYDRAULIC FILTER ELEMENT (PAGE 4-58)".
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES:

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist them or bend them sharply. If they are installed so, their service life will
be shortened extremely and they may be damaged.
CHECKS AFTER INSPECTION AND MAINTENANCE:

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do the following:
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been performed correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
Check when the engine is running
See "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-37)" in the section on
safety for checking when the engine is running. Pay attention to safety.
Check if the inspected and maintenance area is operating normally.
Increase the engine speed to check for fuel and oil leakage.
4-3
.
OUTLINES OF SERVICE MAINTENANCE
OUTLINES OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil.
When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the
old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the
small amount of oil remaining in the piping mixes with the new oil.)
Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed
in the table below.
item type
Engine oil pan Engine oil EO15W40-DH (Komatsu genuine)
Transmission case Power train oil TO10 (Komatsu genuine)
Hydraulic oil system Power train oil TO10 (Komatsu genuine)
Axle Axle oil AXO80 (Komatsu genuine)
Radiator SUPERCOOLANT (AF-NAC) (Komatsu genuine) (density: 30% or above)
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil at the specified interval.
Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil.
4-4
.
MAINTENANCE OUTLINES OF SERVICE
FUEL
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.
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified for the temperature in the Operation and Maintenance Manual.
If the fuel is used at temperatures lower than the specified temperature (particularly at temperatures below
-15°C (5°F), the fuel will solidify.
If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and this may
result in problems such as a drop in output.
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.
When adding fuel, be careful not to spill it. If any fuel should spill, wipe it up with a clean cloth. If there is any
sand or soil in the area where the fuel is spilled, remove the sand or soil.
NOTICE
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an
electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low
viscosity fuel with low lubricating ability is used, the durability may drop markedly.
COOLANT AND WATER FOR DILUTION

Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Komatsu machines are supplied with Komatsu SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC)
has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or
4000 hours.
As a basic rule, we do not recommend the use of any COOLANT other than SUPERCOOLANT (AF-NAC). If you
use another COOLANT, it may cause serious problems, such as corrosion of the engine and aluminum parts of
the cooling system.
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
COOLANT is already diluted with distilled water, so it is not flammable.
The density used for the COOLANT differs according to the ambient temperature.
For details of the density of the COOLANT, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)".
Even in the areas where it is not considered necessary to prevent freezing, always use COOLANT with a density
of over 30% in order to prevent corrosion of the cooling system.
COOLANT is diluted with distilled water that does not contain any ions or water-hardening substances. Never
dilute the COOLANT with ordinary water.
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 due to air entering
the coolant.
4-5
.
OUTLINES OF SERVICE MAINTENANCE
GREASE
Grease is used to prevent seizure and noises at the joints.
This construction equipment is used under heavy-duty conditions. Always use the recommended grease and
follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance
Manual.
Grease fittings not included in the maintenance section are grease fittings for overhaul, so they do not need
grease.
If any part becomes stiff after being used for long time, add grease.
Always wipe off all of 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.
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the
oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other
problems.
We strongly recommend you to use this service. The oil analysis is carried out at actual cost, so the cost is low,
and the results of the analysis are reported together with recommendations which will reduce repair costs and
machine downtime.
KOWA ANALYSIS ITEMS

Measurement of density of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of iron, copper, and other metal wear
particles in the oil.
Measurement of quantity of particles

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of iron particles of 5μm or more, enabling
early detection of failures.
Others
Measurements are made of items such as the ratio of water in the oil, density of the COOLANT, ratio of fuel in
the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
4-6
.
MAINTENANCE OUTLINES OF SERVICE
OIL SAMPLING
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Perform sampling at regular fixed intervals.
Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
STORING OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the
side to prevent moisture from being sucked in.
If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.
To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).
FILTERS
Filters are extremely important safety parts. They prevent impurities in the 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, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are
found, contact your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.
OUTLINE OF ELECTRIC SYSTEM

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This
will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of the
operator's cab with water. When washing the machine, be careful not to let water get into the electrical
components.
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and
checking battery fluid level.
Never install any electric components other than those specified by Komatsu.
External electro-magnetic interference may cause malfunction of the control system controller, before installing
a radio receiver or other wireless equipment, contact your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
The optional power source must never be connected to the fuse, starting switch, or battery relay.
4-7
.
WEAR PARTS MAINTENANCE
WEAR PARTS
Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of
the machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.
WEAR PARTS LIST

The parts in parentheses are to be replaced at the same time.
Item Part No. Part Name Q'ty Replacement frequency

Engine oil filter 6736-51-5142 Cartridge 1 EVERY 500 HOURS
Fuel pre-filter(*) 600-319-3610 Cartridge 1 EVERY 500 HOURS
Fuel main filter(*) 6754-71-6130 Cartridge 1 EVERY 1000 HOURS
Transmission oil filter 714-07-28712 Cartridge 1 EVERY 1000 HOURS
56D-15-19310 Strainer 1 -
Transmission strainer
(07000-75085) (O-ring) (1) EVERY 1000 HOURS
423-60-45460 Element 1
Hydraulic filter EVERY 2000ŽHOURS
(07002-15234) (O-ring) (1)
Hydraulic tank breather 285-62-17320 Element 1 EVERY 2000 HOURS
Hydraulic oil strainer 22B-60-11160 Strainer 1 -
Fuel tank breather 421-60-35170 Element 1 -
Air cleaner 600-185-5100 Element ass'y 1 -
Fresh 426-07-32441 Element 1 EVERY 2000 HOURS
Air conditioner filter
Recirc 426-07-32441 Element 1 EVERY 2000ŽHOURS
425-62-23750 Accumulator 1
PPC accumulator EVERY 4000ŽHOURS
(07002-12034) (O-ring) (1)
600-311-9921 Case 1
Additional water separator (600-311-9490) (O-ring) (1) -
600-311-9971 Screen 1
424-815-1111 Center edge 1
424-815-1131 Side edge 2
Standard
(02090-11485) (Bolt) (14) -
type
(02290-11422) (Nut) (14)
Bolt on cutting (01643-32260) (Washer) (14)
edge
421-838-1110 Edge 7
Segment (02091-11600) (Bolt) (14)
-
type (02290-11625) (Nut) (14)
(01643-22460) (Washer) (14)
423-70-13114 Tooth 6
(02090-11490) (Bolt) (18)
One-piece bucket tooth (09218-12219) (Nut) (18) -
(423-70-13130) (Shim: 0.5 mm (0.02 in)) (6)
(423-70-13120) (Shim: 1.0 mm (0.039 in)) (6)
4-8
.
MAINTENANCE WEAR PARTS
Item Part No. Part Name Q'ty Replacement frequency

423-70-13154 Right corner tooth 1
423-70-13144 Leftt corner tooth 1
(423-70-13160) (Bolt) (2)
(02090-11490) (Bolt) (4)
One-piece corner tooth (01643-32260) (Washer) (2) -
(02290-11422) (Nut) (2)
(09218-12219) (Nut) (4)
(423-70-13170) (Shim: 0.5 mm (0.02 in)) (2)
(423-70-13160) (Shim: 1.0 mm (0.039 in)) (2)
*: If the fuel filter gets clogged before its periodic replacement time is arrived at, replace both the fuel pre-filter and
fuel main filter together.
4-9
.
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
RECOMMENDED FUEL, COOLANT, AND LUBRICANT

Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment
and components.
In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the
instructions in this Operation and Maintenance Manual.
Failure to follow these recommendations may result in shortened life or excess wear of the engine, power train,
cooling system, and/or other components.
Commercially available lubricant additives may be good for the machine, but they may also cause harm.
Komatsu does not recommend any commercially available lubricant additive.
Use the oil recommended according to the ambient temperature in the chart below.
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity means
the amount of oil needed to refill the system during inspection and maintenance.
When starting the engine in temperatures below 0°C (32°F), be sure to use the recommended multi-grade oil,
even if the ambient temperature may become higher during the course of the day.
If the machine is operated at a temperature below -20°C (-4°F), a separate device is needed, so consult your
Komatsu distributor.
When the fuel sulfur content is less than 0.5%, change the engine oil according to the period inspection table
given in this Operation and Maintenance Manual.
If the fuel sulfur content is more than 0.5%, change the oil according to the following table.
Sulfur content (%) Oil change interval
Less than 0.5 500 hours

0.5 - 1.0 250 hours
1.0 and up Not recommendable (*)
* If these fuels are used, there is danger that serious trouble may occur because of early deterioration of the engine
oil or early wear of the internal parts of the engine. If the local situation makes it necessary to use these fuels,
always remember the following.
1) Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil
based on the result.
2) Always be aware that oil change interval is extremely shorter than standard.
3) Be sure to carry out periodic engine inspection by distributor's expert since change interval of periodic
replacement parts and overhaul interval are also shorter.
4 - 10
.
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
LUBRICATION CHART
The lubrication standard chart uses symbols to show the lubrication points and types of lubricant by each
lubrication
interval.
Even if the same symbol is used in the lubrication standard chart, the recommended genuine oil may differ
according to the location and the ambient temperature. For details, see "USE OF FUEL, COOLANT AND
LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-13)".
For details of lubrication, see "MAINTENANCE SCHEDULE CHART (PAGE 4-18)".
4 - 11
.
The symbols used in the lubrication standard chart are explained as follows.
4 - 12
.
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
4 - 13
.
Reservoir Axle
Engine oil Transmission Hydraulic Cooling
(front and rear) Fuel tank
pan case system system
Capacity (each)
Liters 25.5 47 210 40 29 300
Specified
US gal 6.7 12.4 55.5 10.6 7.7 79.3
Liters 23 38 139 40 - -
Refill
US gal 6.1 10.0 36.7 10.6 - -
NOTICE
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an
electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low
viscosity fuel with low lubricating ability is used, the durability may drop markedly.
Note 1: HTHS ( High-Temperature High-Shear Viscosity 150°C (302°F)), specified by ASTM D4741 must be equal
to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note .2: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
Note .3: Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip
Differential).
Note .4: When the ambient temperature is higher than 45°C (113°F) and the machine operation hour is longer than
12 hours/day, then the use of TO50 instead of AXO80 is recommended.
Squealing of the brakes may occur with TO50, but there is no problem with the brake performance or
durability.
For machines with LSD, use AXO80 regardless of the ambient temperature. Do not use TO50.
Note .5: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins
and bushings, the use of G2-T or G2-TE is recommended.
Note 6: COOLANT
1) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000
hours. SUPERCOOLANT (AF-NAC) is strongly recommended wherever available.
2) For details of the density of the COOLANT, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)".
COOLANT is supplied already diluted. In this case, add the pre-diluted fluid to keep the tank full. (Never dilute
the COOLANT with ordinary water.)
3) To maintain the anticorrosion properties of COOLANT, always keep the density of COOLANT between 30% and
64%.
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN

KOMATSU GENUINE OIL
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
4 - 14
.
MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

TORQUE LIST
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and
this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.
Thread Width Tightening torque

diameter across
Target value Service limit
of bolt flats
(a)(mm) (b)(mm) Nm kgm lbft Nm kgm 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 19 113 11.5 83.2 98-123 10.0-12.5 72.3-90.4
14 22 172 17.5 126.6 153-190 15.5-19.5 112.1-141
16 24 260 26.5 191.7 235-285 23.5-29.5 170.0-213.4

18 27 360 37 267.6 320-400 33.0-41.0 238.7-296.6
20 30 510 52.3 378.3 455-565 46.5-58.0 336.3-419.5
22 32 688 70.3 508.5 610-765 62.5-78.0 452.1-564.2
24 36 883 90 651 785-980 80.0-100.0 578.6-723.3
27 41 1295 132.5 958.4 1150-1440 118.0-147.0 853.5-1063.3

30 46 1720 175.0 1265.8 1520-1910 155.0-195.0 1121.1-1410.4
33 50 2210 225.0 1627.4 1960-2450 200.0-250.0 1446.6-1808.3
36 55 2750 280.0 2025.2 2450-3040 250.0-310.0 1808.3-2242.2
39 60 3280 335.0 2423.1 2890-3630 295.0-370.0 2133.7-2676.2
Apply the following table for Hydraulic Hose.
Width Tightening torque

Nominal -
across
No. of Target value Permissible range
flats (b)
threads (a)
(mm) Nm kgm lbft Nm kgm lbft
9/16 -18UNF 19 44 4.5 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0
11/16 -16UN 22 74 7.5 54.2 54 - 93 5.5 - 9.5 39.8 - 68.7
13/16 -16UN 27 103 10.5 75.9 84 - 132 8.5 - 13.5 61.5 - 97.6
1 -14UNS 32 157 16.0 115.7 128 - 186 13.0 - 19.0 94.0 - 137.4
13/16 -12UN 36 216 22.0 159.1 177 - 245 18.0 - 25.0 130.2 - 180.8
4 - 15
.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts listed in the table of important parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is required
to replace them with new ones regardless of their condition after a certain period of usage. This is important to
ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.
4 - 16
.
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
For standard specification
No. Safety critical parts Q'ty Replacement interval
1 Fuel hose (fuel tank - additional water separator) 1

2 Fuel hose (additional water separator - fuel pre-filter) 1
3 Fuel hose (fuel pre-filter - supply pump) 1
4 Fuel hose (supply pump - fuel main filter) 1
5 Fuel hose (fuel main filter - supply pump) 1
6 Fuel hose (supply pump - common rail overflow) 1
7 Fuel hose (engine - fuel tank) 1
8 Steering hose (pump - steering valve) 1
9 Steering hose (steering valve - steering cylinder) 6
10 Steering hose (steering valve - hydraulic tank) 2
11 Steering hose (steering valve - hydraulic tank: seal drain circuit) 2
12 Steering hose (steering valve - pump: LS) 1
13 Brake hose (pump - charge valve) 1
14 Brake hose (charge valve - hydraulic tank) 2 Every 2 years or 4000 hours,
15 Brake hose (charge valve - accumulator) 2 whichever comes sooner
16 Brake hose (accumulator - brake valve) 2
17 Brake hose (brake valve - front axle) 3
18 Brake hose (brake valve - rear axle) 2
19 Brake hose (brake valve - hydraulic tank) 1
20 Brake hose (accumulator - emergency release valve) 1
21 Brake hose (emergency release valve - transmission valve) 1
22 Transmission hose (pump - transmission valve) 1
23 Transmission hose (transmission valve - transmission filter) 1
24 Transmission hose (transmission filter - transmission main valve) 1
25 Transmission hose (transmission - torque converter cooler) 1
26 Transmission hose (torque converter cooler - transmission) 1
27 Accumulator (for PPC) 1
28 Alarm 2
29 Engine high-pressure piping clamp 1set
Every 8000 hours
30 Fuel spray prevention cap 1set
Every 3 years after beginning
to use or 5 years after
31 Seat belt 1
manufacturing of seat belt,
whichever comes sooner
4 - 17
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MAINTENANCE SCHEDULE CHART MAINTENANCE
MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)

LUBRICATING 4- 49
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
CHANGE TRANSMISSION OIL FILTER CARTRIDGE 4- 55
REPLACE HYDRAULIC TANK FILTER ELEMENT 4- 58
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS)
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 64
WHEN REQUIRED
CLEAN, REPLACE AIR CLEANER ELEMENT 4- 21
CHECK ADDITIONAL WATER SEPARATOR, CLEAN INSIDE OF CASE 4- 24
CLEAN INSIDE OF COOLING SYSTEM 4- 25
CHECK TRANSMISSION OIL LEVEL, ADD OIL 4- 28
CHECK AXLE OIL LEVEL, ADD OIL 4- 29
CLEAN AXLE CASE BREATHER 4- 30
CLEAN AIR CONDITIONER CONDENSER 4- 30
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID 4- 31
CLEAN RADIATOR FINS AND COOLER FINS 4- 31
TURN, REPLACE BOLT-ON CUTTING EDGE 4- 33
REPLACE BUCKET TEETH 4- 34
CHECK AIR CONDITIONER 4- 35
REPLACE SLOW BLOW FUSE 4- 36
SELECTION AND INSPECTION OF TIRES 4- 37
CLEAN, REPLACE BREATHER ELEMENT IN FUEL TANK 4- 39

LUBRICATE REAR AXLE PIVOT PIN 4- 42
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 4- 42
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER 4- 43

CHECK BATTERY ELECTROLYTE LEVEL 4- 44
CHECK PARKING BRAKE 4- 45
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 4- 46
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN 4- 47
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 4- 47
CHECKING FUNCTION OF ACCUMULATOR 4- 48
LUBRICATING 4- 49

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 50
REPLACE FUEL PRE-FILTER CARTRIDGE 4- 51
4 - 18
.
MAINTENANCE MAINTENANCE SCHEDULE CHART

REPLACE FUEL MAIN FILTER CARTRIDGE 4- 54
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER 4- 55
CLEAN TRANSMISSION CASE BREATHER 4- 56
LUBRICATING 4- 57
CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS 4- 57
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT 4- 57

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT 4- 58
REPLACE HYDRAULIC TANK BREATHER ELEMENT 4- 60
CHANGE AXLE OIL(*) 4- 61
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER 4- 62
CLEAN BRAKE CIRCUIT STRAINER 4- 62
CHECK BRAKE DISC WEAR 4- 63
CHECKING FUNCTION OF ACCUMULATOR 4- 64
CHECK ALTERNATOR 4- 64
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 64
CHECK VIBRATION DAMPER 4- 64
*: 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.

LUBRICATING 4- 65
CHECK WATER PUMP 4- 66
CHECK STARTING MOTOR 4- 66
CHECK AIR CONDITIONER COMPRESSOR, ADJUST 4- 66
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER 4- 67
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4- 67

REPLACE HIGH-PRESSURE PIPING CLAMP 4- 68
REPLACE FUEL SPRAY PREVENTION CAP 4- 68
4 - 19
.
SERVICE PROCEDURE MAINTENANCE
SERVICE PROCEDURE
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)
Carry out the following maintenance every 10 hours for the first 50 hours of operation of a new machine.
Lubricating
For details of the method of replacing or maintaining, see the section on EVERY 250 HOURS SERVICE.
INITIAL 250 HOURS SERVICE

Perform the following maintenance only after the first 250 hours.
Change transmission oil filter cartridge

Replace hydraulic tank filter element
For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS
SERVICE.
INITIAL 1000 HOURS SERVICE

Carry out the following maintenance only after the first 1000 hours.
Check engine valve clearance, adjust
For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.
4 - 20
.
MAINTENANCE SERVICE PROCEDURE
WHEN REQUIRED
CLEAN, REPLACE AIR CLEANER ELEMENT

WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it.
Always stop the engine before carrying out these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use protective glasses, dust mask, and other protective equipment.
For inspection method, see "CHECK AIR CLEANER (PAGE 3-93)".

When the yellow piston of the dust indicator enters the red range (7.5 kPa) or the air cleaner clogging caution lamp
of the machine monitor lights up, clean the air cleaner element.
CLEANING OUTER ELEMENT

2. Remove three clips (1), then remove cover (2).
NOTICE
Never remove inner element (4). If it is removed, dust will enter and cause
engine trouble.
3. Remove outer element (3).
4. Clean the interior of the air cleaner body, cover (2) and
evacuator valve (5).
4 - 21
.
NOTICE
The inner element must not be used again even after cleaning. When
replacing the outer element, replace the inner element at the same time.
5. Direct dry compressed air (less than 0.2 MPa {2.1 kg/cm2, 30.0
PSI}) to the outer element from inside along its folds, then
direct it from outside along its folds and again from inside.
6. If small holes or thinner parts are found on the element when

it is checked by shining a light through it after cleaning, replace
the element.
NOTICE
When cleaning the element, do not hit or beat it against anything.
Do not use an element whose folds, gasket or seal are damaged.
CAUTION
When installing the cover (2), check O-ring (6) and replace it if there are any scratches or damage.
7. Set the cleaned outer element in position, then secure cover (2) with mounting clips (1).
8. Press the dust indicator button to return the yellow piston to its
original position.
9. Close the engine side cover on the right side of the machine.
After cleaning, if the air cleaner clogging caution lamp lights up immediately or the yellow piston reaches the
red line (7.5 kPa), replace the inner and outer elements.
4 - 22
.
REPLACING ELEMENT
2. Remove three clips (1), then remove cover (2).
3. Remove outer element (3).

Do not remove inner element (4) at this time, however.
4. Clean the inside of the air cleaner body and vacuator valve (5).
5. Remove inner element (4), then install a new inner element immediately.
6. Fit new outer element (3), replace O-ring (6) with a new part, install cover (2), then secure with clips (1).
7. Press the dust indicator button to return the yellow piston to its
original position.
8. Close the engine side cover on the right side of the machine.
4 - 23
.
CHECK ADDITIONAL WATER SEPARATOR, CLEAN INSIDE OF CASE

WARNING
The engine fuel piping system is under high internal pressure when the engine is running. Always reduce the internal pressure
before draining water or replacing the element cup.
This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will
cause problems. If there is any dirt stuck to the fuel line, use fuel to wash it off completely.
NOTICE
When carrying out inspection and maintenance of the fuel system, the particularly careful not to let any dirt or dust get in. If
there is any dirt of dust around the fuel system, clean it off thoroughly with fuel before starting the operation.
To prevent dirt or dust from getting into the fuel circuit, remove all dirt and dust from the surrounding area before starting the
operation.
Prepare a container to catch the fuel.
1. Drain the water and fuel. For details, see "CHECK ADDITIONAL WATER SEPARATOR, DRAIN WATER
(PAGE 3-92)".
2. Loosen the ring nut (1), then remove case (2).
3. Pull screen (5) down to remove it from the water separator
holder (3).
4. Wash screen (5) in clean fuel.
Check screen (5) and replace it if it is damaged.
5. Wash the inside of case (2) with clean fuel.
Check case (2). If it is scratched or damaged, or so dirty that
the position of float (6) cannot be checked, replace case (2).
6. Wash the inside of water separator holder (3) with clean fuel.
7. Install screen (5) to the water separator holder.
8. Replace O-ring (7) with a new part.
9. Tighten plug (4) and insert in case (2). Be careful not to let
float (6) be at an angle.
Tightening torque: 2.0 to 3.0 Nm {0.20 to 0.31 kgm, 1.4 to 2.2
lbft}
10. Install case (2) to the water separator holder (3), then tighten ring nut (1).
Tightening torque: 23 to 27 Nm {2.4 to 2.8 kgm, 17.0 to 19.9 lbft}
11. After completing the inspection and cleaning, bleed the air. Use the same procedure as when replacing the fuel
filter cartridge.
For details of bleeding the air, see "PROCEDURE FOR BLEEDING AIR (PAGE 4-55)".
4 - 24
.
CLEAN INSIDE OF COOLING SYSTEM

WARNING
Immediately after the engine is stopped, the engine coolant is hot and the pressure inside the radiator is high. Removing the
cap and draining the water under this condition could cause burns. Allow the engine to cool down, then turn the cap slowly
to release the pressure.
Start the engine and flush the system. Before standing up or leaving the operator's seat, set the work equipment lock lever to
the LOCK position.
For details of starting the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-84)" and "STARTING ENGINE
(PAGE 3-102)" in the OPERATION section of the Operation and Maintenance Manual.
When the undercover is removed, there is danger of touching the fan.
Never enter the rear of the machine when the engine is running.
Clean the inside of the cooling system, change the coolant according to the table below.
Interval for cleaning inside of cooling system

Coolant
and changing antifreeze coolant
Komatsu genuine
Every two years or every 4000 hours
SUPERCOOLANT
whichever comes first
(AF-NAC)
Stop the machine on level ground when cleaning or changing the coolant.
Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours. As a
basic rule, we do not recommend the use of any COOLANT other than SUPERCOOLANT (AF-NAC). If you use
another COOLANT, it may cause serious problems, such as corrosion of the engine and aluminum parts of the
cooling system.
To maintain the anticorrosion properties of COOLANT, always keep the density of COOLANT between 30% and
64%.
When selecting COOLANT, investigate the lowest temperature in the past and decide the density for the
COOLANT from the COOLANT density table below. When actually deciding the density for the COOLANT, set it
about 10°C (18°F) below lowest temperature. The density must be over 30% at least. If the density of obtained
COOLANT is higher than the necessary density for lowest temperature, dilute it with adequate distilled water, and
then fill it into the tank.
If there is any unclear point, please contact your Komatsu distributor.
Coolant density table

°C Above -10 -15 -20 -25 -30 -35 -40 -45 -50
Minimum Temp
°F Above 14 5 -4 -13 -22 -31 -40 -49 -58
Concentration (%) 30 36 41 46 50 54 58 61 64
4 - 25
.
WARNING
COOLANT is toxic. When open the drain valve, be careful not to get coolant on you.
If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
COOLANT is already diluted with distilled water, so it is not flammable. (For details of the distilled water, see
"COOLANT AND WATER FOR DILUTION (PAGE 4-5)"). Check the density with a COOLANT tester.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to use when filling with coolant.
1. Stop the engine.

2. Check that the coolant temperature has gone down enough to
make it possible to touch the radiator cap surface by hand,
then turn radiator cap (1) slowly until it contacts the stopper to
release the pressure.
3. Following this, push radiator cap (1), turn it until it contacts the
stopper, then remove it.
4. Set a container in position to catch the coolant, then open

drain valve (2) at the left side of the fuel tank.
5. After draining the water, close drain valve (2) and fill with city
water.
6. When the radiator is full, start the engine, and run it at low idle.
Keep the engine running at low idle for 10 minutes until the
coolant temperature reaches more than 90°C (194°F).
7. Stop the engine, open drain valve (2), drain the water, then
tighten the drain valve again.
8. After draining the water, clean the cooling system with cleaning agent.
For the cleaning method, see the instructions for the cleaning agent.
9. Add coolant through the water filler port up to the mouth of the port. For details of the COOLANT density, see
"COOLANT DENSITY TABLE".
10. To bleed the air from the cooling system, run the engine at low idle for 5 minutes, and for a further 5 minutes
at high idle. (When doing this, leave the radiator cap off.)
4 - 26
.
11. After draining off the coolant of sub tank (3), clean the inside
of the sub tank and refill the water between FULL and LOW
12. Stop the engine, wait for approximately 3 minutes, add coolant
up to the mouth of the filler port, and tighten the cap.
4 - 27
.
CHECK TRANSMISSION OIL LEVEL, ADD OIL

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature
to go down before starting the work.
Carry out this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling
water.
1. Start the engine and run it for at least 5 minutes.
2. Open the cap of oil filler port (F), remove dipstick (G), and wipe
the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe, then remove it.
4. The oil level should be between the H and L marks on dipstick

(G).
If the oil level is below the L mark, add oil through oil filler port
(F).
5. If the oil is above the H mark, drain the excess oil from drain
plug (P), and check the oil level again.
6. If the oil level is correct, insert dipstick (G) in the dipstick guide,
then tighten the cap.
4 - 28
.
CHECK AXLE OIL LEVEL, ADD OIL

WARNING
When checking the oil level, apply the parking brake and secure the front and rear frames with the frame lock bar.
After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down before starting the
operation.
Perform this procedure if there is any sign of oil on the axle case.
Inspect the machine on a horizontal surface.
(If the road surface is at an angle, the oil level cannot be checked correctly.)
A: Front B: Rear
1. Stop the engine and remove oil level plug (1).
REMARK
Remove the mud and dirt from around plug (1), then remove the
plug.
2. With cloth, wipe off any oil adhering to the oil level gauge
attached to plug (1).
3. Set the oil level gauge (G) as shown in the right diagram.
(2): Axle
(3): Spot facing face)
4. The oil level should be between the two lines (H) and (L) on the
oil level gauge.
If the oil is below the (L) line, add axle oil through oil filler port
(F).
REMARK
For axles with ASD (Limited-Slip Differential), the brand of
lubricating oil is different. Use the specified lubricating oil.
5. If the oil level is above the (H) line, drain the excess oil through
drain plug (P), then check the oil level again.
6. If the oil level is correct, install plug (1).
Tightening torque: 127 to 177 Nm {13 to 18 kgm, 94.0 to 130.2
lbft}
4 - 29
.
CLEAN AXLE CASE BREATHER

WARNING
When cleaning the axle breather, apply the parking brake and secure the front and rear frames with the frame lock bar.
A: Front B: Rear
Remove all mud and dirt from around the breather with a brush.
After removing the mud or dirt from around the breather, remove
the breather, immerse it in cleaning fluid and clean it.
When cleaning the breather, clean the breathers at two places
(front and rear).
After removing the breather, take steps to prevent dirt or dust from
entering the mount.
CLEAN AIR CONDITIONER CONDENSER

WARNING
Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat.
If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear protective
glasses, dust mask, and other protective equipment.
If there is mud or dust on the air conditioner condenser, clean it with water.
If the water pressure is too high, the fins may get deformed. When washing with a high pressure washing machine,
apply the water from a reasonable distance.
WASHING METHOD
Open the engine side cover on the right of the machine and wash
the top of condenser (1) with water.
4 - 30
.
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID

Check the washing fluid levels in washer tank (1). When the fluid
has run low, add automotive window washing fluid.
Be careful not to let dust get into the fluid.
CLEAN RADIATOR FINS AND COOLER FINS

WARNING
Never open the engine side cover when the engine is running. Stop the engine completely before starting the cleaning
operation.
If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal injury.
Always wear safety glasses, dust mask, or other protective equipment.
Clean the radiator or cleaner if mud or dirt is stuck to it.
CLEAN FINS WITH COMPRESSED AIR

Insert the jet nozzle through the gap between the radiator, oil
cooler, aftercooler (1) and air conditioner condenser (2) to clean
the fins.
4 - 31
.
When cleaning the face behind the radiator, oil cooler, and
aftercooler (1), remove bolts (3) and plate (4), remove bolts (5) and
plate (6) in plate (4), then insert the steam jet nozzle through the
opening to clean the fins.
Steam or water can be used instead of compressed air. But, make sure to keep a reasonable distance when
performing washing with powerful steam (high-pressure washing) to heat exchange devices (radiator, cooler). If
steam washing (high pressure washing) is performed from point-blank distance, fins inside the heat exchange
device may deform which will cause clogging or damage on early stage.
Examine the rubber hoses, and if any hose is cracked or deteriorated, replace it. Check also that there are no loose
hose clamps.
4 - 32
.
TURN, REPLACE BOLT-ON CUTTING EDGE

(If equipped)
WARNING
It is dangerous if the work equipment moves by mistake during the turning or replacement operation.
Set the work equipment in a stable condition, stop the engine, then set the work equipment lock lever securely to the LOCK
position.
Turn or replace the cutting edge before the wear reaches the edge of the bucket.
1. Raise the bucket to a suitable height, then put blocks (A) under
the bucket to prevent the bucket from coming down.
Raise the bucket so that the bottom surface of the bucket is
horizontal.
2. Remove nuts and bolts (1), then remove cutting edge (2).
3. Clean the mounting surface of cutting edge (2).
4. Turn cutting edge (2) and install it to the bucket. When turning
the edge, install it to the opposite side (left edge to right side,
right edge to left side).
If both sides of the cutting edge are worn, replace with a new
part.
If the wear extends to the mounting surface, repair the
mounting surface before installing the cutting edge.
5. Tighten nuts and bolts (1) uniformly so that there is no gap between the bucket and cutting edge.
Tightening torque for mounting bolt: 745 ± 108 Nm {76 ± 11 kgm, 549.7 ± 79.6 lbft}
6. Tighten the mounting bolts again after operating for several hours.
4 - 33
.
REPLACE BUCKET TEETH

When the bucket teeth are worn, replace them as follows.
1. Raise the bucket to a suitable height, then put blocks (A) under
the bucket to prevent the bucket from coming down.
Raise the bucket so that the bottom surface of the bucket is
horizontal.
2. Remove the bolt and nuts (1) and (2), then remove bucket
tooth (3).
3. Clean the installation surface of bucket tooth (3).
4. Install new teeth to the bucket.
When doing this, insert shims so that there is no clearance
between the teeth and the top surface of the bucket.
Continue to add shims until it becomes impossible to add a 0.5
mm (0.02 in) shim.
If the mounting surface is worn, correct the mounting surface
before installing the teeth.
5. To prevent any gap from forming between the teeth and tip of the bucket, tighten bolts and nuts (1) and (2)
temporarily, then hit the tip of the teeth with a hammer.
Tightening torque of mounting bolt (1): 637 ± 853 Nm {65 ± 87 kgm, 470.1 ± 629.3 lbft}
(2): 618 Nm {63 kgm, 455.7 lbft}
6. After operating the machine for a few hours, tighten the mounting bolts again.
4 - 34
.
CHECK AIR CONDITIONER
CHECK LEVEL OF REFRIGERANT (GAS)
WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your
hands, it may cause loss of sight or frostbite. Do not touch the refrigerant.
Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is
leaking.
1. Start the engine and set the engine speed to approx. 1500
power ON.
monitor to COOL (A).
5. Open the door and window fully.
6. Press air conditioner switch (4) to turn the air conditioner
switch ON.
7. Use sight glass (6) (inspection window) of receiver drier (5) to
check the condition of the refrigerant gas (freon 134a) flowing
in the refrigerant circuit.
A: Quantity of refrigerant
B: Condition of sight glass
a: Proper: After air conditioner switch is turned ON, few bubbles
are seen and refrigerant becomes milk-white and then
becomes pale milk-white.
b: Insufficient refrigerant: After air conditioner switch is turned ON,
bubbles are seen continuously.
X: Condition of refrigerant flow

Y: Condition of sight glass
x: There are bubbles: Gas and liquid of refrigerant are mixed.
y: There are not bubbles: All refrigerant is liquefied and
transparent.
z: Refrigerant is milk-white: Oil and refrigerant are separated from
each other and their mixture is pale milk-white.
4 - 35
.
MAINTENANCE AND INSPECTION AND TIME TO EXECUTE THEM

Maintenance interval
Inspection location Item to check for Check before Replacement
6 months
operating interval
Filter Clogging, dirt Carry out check - 2 years
Condenser Clogging, dirt Carry out check - -
Belt Looseness, damage Carry out check - 2 years
Refrigerant gas Amount - Carry out check -
Piping Looseness, damage, leakage - Carry out check -
Receiver drier - - - 2 years
REPLACE SLOW BLOW FUSE
NOTICE
Always turn the power OFF when 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.
If the slow blow fuse should blow, check for the cause and take the
necessary action.
1. Turn the starting switch to the OFF position (A).

2. Remove the slow blow fuse box from the chassis.
3. Open covers (1), (2), and (3) of the slow blow fuse box.
Covers (2) and (3) can be removed easily by using protrusion
(4) on the body as a fulcrum and levering the catch of the cover
with a flat-headed screwdriver to release it.
4. Loosen screws (5) and (6), and remove.
When screws (5) and (6) are removed, slow blow fuse (7) will
also come off together with electric wiring (8) and (9).
5. Using screws (5) and (6), install a new slow blow fuse together
with electric wiring (8) and (9) to the slow blow fuse box, then
close covers (1), (2), and (3).
6. Install the slow blow fuse box to the chassis.
4 - 36
.
SELECTION AND INSPECTION OF TIRES

WARNING
If a tire or a rim is handled improperly, the tire may burst or may be
damaged and the rim may be broken and scattered, and that can cause
serious injury or death.
Since maintenance, disassembly, repair and assembly of the tires and
rims require special equipment and skill, be sure to ask a tire repair
shop to do the work.
Do not heat or weld the rim to which the tire is installed. Do not make a
fire near the tire.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and the weight of the attachments on the machine. Use only specified tires and
inflate them to the specified pressure.
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the
following table.
Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor
when using optional tires.
4 - 37
.
CHECK INFLATION PRESSURE OF TIRES
WARNING
When inflating a tire, check that no one will enter the working area. Use an
air chuck which has a clip and which can be fixed to the air valve.
While inflating the tire, check the inflation pressure occasionally so that
it will not rise too high.
If the rim is not fitted normally, it may be broken and scattered while the
tire is inflated. To ensure safety, place a guard around the tire and do not
work in front of the rim but work on the tread side of the tire.
Abnormal drop of inflation pressure and abnormal fitting of the rim
indicate trouble in the tire or rim. In this case, be sure to ask a tire repair
shop to carry out repairs.
Be sure to observe the specified inflation pressure.
Do not adjust the inflation pressure of the tires just after high-speed
travel or heavy-duty work.
CHECK
Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
INFLATION OF TIRES
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not
work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown below.
Tire size Inflation pressure

Standard 23.5-25-16PR Front Tire: 300 kPa {3.1kg/cm2, 44.1 PSI}
23.5-25-20PR Rear Tire: 300 kPa {3.1kg/cm2, 44.1 PSI}
Option 20.5-25-16PR Front Tire: 350 kPa {3.5kg/cm2, 49.8 PS}
20.5-25-20PR Rear Tire: 350 kPa {3.5kg/cm2, 49.8 PSI}
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-139)".
4 - 38
.
CLEAN, REPLACE BREATHER ELEMENT IN FUEL TANK

CAUTION
If inspection and cleaning is carried out with the engine running, dust will enter the fuel tank and this will lead to damage to the
engine. Always stop the engine before carrying out inspection or cleaning.
1. Remove rear grill (1).

2. Loosen nut (3) at the top of fuel tank breather (2) at the top left
of the fan guard, then remove.
3. Turn cover (4) counterclockwise and remove it.
4. Remove element (5) to the top.

5. Blow with dry compressed air from the inside of the element.
4 - 39
.
6. After cleaning, install the element to the breather.

When doing this, be careful not to mistake the direction of
installation.
Set so that the surface with the mark shown in (6) is at the top,
then install.
7. Install the cover (4).

8. Tighten nut (3).
9. Install rear grill (1).

NOTICE
If the element is excessively dirty, or if it is damaged, replace it with a new part.
4 - 40
.

For the following items, see "CHECK BEFORE STARTING (PAGE 3-87)".
Check machine monitor
Check coolant level, add coolant
Check oil level in engine oil pan, add oil
Drain water and sediment in fuel tank
Check water separator, drain water
Check additional water separator, drain water
Check air cleaner
Check fuel level, add fuel
Check electric wiring
Check inflation pressure of tires
Check window washer spray condition
Check wiping efficiency of wiper
Check horn
Check defroster function
Check locks
Check emergency exit
4 - 41
.

Maintenance for every 50 hours service should be carried out at the same time.
LUBRICATE REAR AXLE PIVOT PIN

(3 places)
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 was pushed out.
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the
temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
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 between the H and L marks.
NOTICE
If the oil has been added to above 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 H level, it will damage the hydraulic circuit or cause the oil
to spurt out.
2. If the level is below the L mark, add oil through oil filler (F).
4 - 42
.
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER

WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury.
Always wear protective glasses, dust mask, and other protective equipment.
If the air conditioner has been used, the air filter should be cleaned.
Stop the air conditioner before cleaning the element.
Articulate the machine fully to the right before replacing the air filter element.
1. Insert the starting key into key slot (1), release the lock, loosen
knob (2), and open cover (3).
2. Take out element (4) and clean it.

3. Blow dry compressed air (less than 0.2 MPa {2.1 kg/cm2, 30.0
PSI}) from the inside of the element along its folds. Then blow
the compressed air from the outside along the folds, and again
from the inside.
Replace the filter with a new part if the clogging cannot be
removed with compressed air, or if it has been used for 1 year.
4. After cleaning, return filter (4) to its original position and close
the cover. Use the starting switch key to lock the cover. Do
not forget to remove the starting switch key.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air
conditioner unit.
4 - 43
.

Maintenance for every 50 and 100 hours service should be carried out at the same time.
CHECK BATTERY ELECTROLYTE LEVEL

Perform this check before operating the machine.
WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is danger of explosion, 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 a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from
freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Open the cover of the battery box.
There are two battery boxes: One on each side at the rear of the machine.
2. 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.
3. If the electrolyte level is below the midway point between the

UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines,
remove cap (1) and add distilled water to the U.L. line.
4. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.
5. Clean the vents of the battery caps, then close the caps
securely.
Keep the top of the battery clean and wipe it with a wet cloth.
REMARK
If distilled water is added to above the UPPER LEVEL (U.L.) line, use a syringe to lower the level to the UPPER
LEVEL (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.
4 - 44
.
WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Open the cover of the battery box.
There are two battery boxes: One on each side at the rear of the machine.
2. Remove cap (1) at the top of the battery, look through the
water filler port (2), and check the electrolyte surface. If the
electrolyte does not reach the sleeve (3), add distilled water so
that the level reaches the bottom of the sleeve (UPPER
LEVEL line) without fail.
(A) Suitable level: Electrolyte level is up to bottom of
sleeve, so surface tension causes
electrolyte surface to bulge and poles
(B) Low: Electrolyte level is not up to bottom of sleeve, so
poles appear straight and not bent.
3. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.
4. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the bottom of the sleeve, use a
syringe 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.
WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
CHECK PARKING BRAKE

1. Stop the machine on a dry slope (downhill slope), set the
parking brake switch to the ON position (A), and check that the
brake holds the machine in that position.
2. If any problem is found, please contact your Komatsu
distributor.
4 - 45
.
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
CHECKING
The standard deflection between the air conditioner compressor
pulley and crank pulley when pressed with a thumb (approx. 98 N
{10 kg}) should be approx. 11 to 15 mm {0.4 to 0.6 in}.
When a belt tension gauge is used, the standard tension is within
a range of 353 to 530 N {36 to 54 kg}.
CHECK WHEN CHANGING THE V-BELT

The standard deflection between the air conditioner compressor pulley and fan pulley when pressed with a thumb
(approx. 98 N {10 kg}) should be approx. 8 to 11.5 mm {0.315 to 0.5 in}.
When a belt tension gauge is used, the standard tension is within a range of 530 to 745 N {54 to 76 kg}.
REMARK
When the belt has been replaced with a new part, a high tension is necessary, so the initial tension is in the value
given above.
ADJUSTING
1. Loosen bolt (1), then loosen locknut (2), tighten bolt (3), and
move compressor (4) to adjust.
2. Tighten bolt (1) and locknut (2) to hold compressor (4) in
position.
NOTICE
Check each pulley for damage, wear of the V-groove, and wear of the
V-belt. In particular, be sure to check that the V-belt is not touching the
bottom of the V-groove.
In case any of the following occurs, ask the Komatsu distributor in your
territory to replace the belts with new ones.
• The fan belt has elongated, leaving little allowance for adjustment.
• A cut or crack is found on the belt.
• Slipping or creaking sound is heard coming from the belt.
When the new V-belt is set, readjust it after one hour of operation.
4 - 46
.
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN

If wheel hub bolts (1) are loose, tire wear will be increased and
accidents may be caused.
1. Check for loose nuts, and tighten if necessary.
When checking for loose nuts, always turn the nuts in the
direction of tightening to check.
Tightening torque: 823 to 1,029 Nm
{84 to 105 kgm, 607 to 759 lbft}
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER

1. Loosen knob (1), then remove filter inspection cover (2).
2. Remove filter (3) in the direction shown by the arrow.

3. Use compressed air to clean the recirculated air filter in the
same way as for the fresh air filter.
Replace the filter with a new part if the clogging cannot be
removed with compressed air, or if it has been used for 1 year.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air
conditioner unit.
4 - 47
.
CHECKING FUNCTION OF ACCUMULATOR

For details of handling the accumulator, see Section "HANDLING ACCUMULATOR AND GAS SPRING (PAGE
2-42)".
BRAKE ACCUMULATOR
If the engine stops when the machine is traveling, the oil pressure in the accumulator can be used to apply the brake
as an emergency measure.
1. Stop the machine on level ground and lower the work equipment completely to the ground.
2. Apply the parking brake.
3. Start the engine, run it at a mid-range speed for 1 minute, then stop the engine.
4. Turn the starting switch key to the ON position and depress the brake pedal repeatedly.
If the brake oil pressure caution lamp does not light up even when the brake is depressed 6 times, the gas
pressure in the accumulator is normal.
If the brake oil pressure caution lamp lights up when the brake has been depressed 5 or less times, the gas
pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the
accumulator inspected.
REMARK
Carry out the check within 5 minutes after stopping the engine. If the machine is left with the engine stopped, the
accumulator pressure will drop and it will be impossible to check the cause of the problem.
4 - 48
.
LUBRICATING
1. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
NOTICE
When working on jobsites where heavy-duty operations are frequent or when working continuously for more than eight hours,
shorten the lubrication interval and carry out lubrication more frequently.
For the initial 50 hours, carry out lubrication every 10 hours.
(1) Bucket pin (2 places) (5) Lift arm pivot pin (2 places)
(2) Bucket link pin (2 places) (6) Bell crank pin (1 place)
(3) Dump cylinder pin (2 places) (7) Steering cylinder pin (4 places)
(4) Lift cylinder pin (4 places)
When carrying out greasing of bucket pin (1), lift arm pivot pin (5), and bell crank pin (6), set the work equipment
to the following posture.
Lower the bucket to the ground and set it horizontally.
4 - 49
.

Maintenance for every 50, 100 and 250 hours service should be carried out at the same time.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
Refill capacity: 23 liters (6.1 US gal)

Prepare a filter wrench
2. Open oil filler (F).
3. Place a container to catch the oil under drain plug (P).
4. Loosen drain plug (P), and drain the oil.
5. Check the drained oil, and if there are excessive metal
particles or foreign material, please contact your Komatsu
distributor.
6. Install drain plug (P).
7. Open the engine side cover on the left side of the chassis.
8. Using the filter wrench, turn filter cartridge (1)
counterclockwise to remove it.
In particular, if this operation is carried out immediately after
stopping the engine, a large amount of oil will come out, so
wait for 10 minutes before starting the operation.
9. Clean the filter holder, fill the new filter cartridge with engine
oil, then coat the seal and thread of the filter cartridge with
engine oil (or coat thinly with grease) and install.
10. When installing the seal, tighten it so its surface comes into
contact with the filter holder, then tighten another 3/4 turn.
11. After replacing the filter cartridge, add engine oil through oil
filler port (F) until the oil level is between the H and L marks on
the dipstick.
12. Run the engine at idle for short time, then stop the engine, and
check that the oil is between the H and L marks on the dipstick.
For details, see "CHECK OIL LEVEL IN ENGINE OIL PAN,
ADD OIL (PAGE 3-89)".
4 - 50
.
REPLACE FUEL PRE-FILTER CARTRIDGE

WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts
to cool down before starting the operation.
High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
Do not bring any fire or flame close.
NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection
pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is
stuck to any part, use fuel to wash it off completely.
2. The fuel pre-filter forms one unit with the water separator and is at the rear of the engine.
3. Remove connector (1).
After removing the connector, cover the connector terminals
with a vinyl bag or tape to protect them and prevent them from
becoming dirty.
4. Set the container to catch the fuel under the filter cartridge.
4 - 51
.
5. Using a filter wrench, turn filter cartridge (2) counterclockwise

on remove it.
6. Take water separator cup (3) installed to the bottom of the
cartridge and turn it to the left to remove it. (This cup is used
again. If it is damaged, replace it with a new part.)
7. Install cup (3) to the bottom of the new fuel pre-filter cartridge.
When doing this, always replace the seal ring with a new part.
Tightening torque for cup: 10 Nm {1.02 kgm, 1.38 lbft}
When replacing the seal ring, coat the surface with clean fuel
before installing it.
8. Check that drain plug (4) at the bottom of cup (3) of the fuel
pre-filter is tightened securely.
Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.05 kgm, 0.03 to
0.06 lbft}
9. Clean the filter holder.
NOTICE
When filling the filter cartridge with fuel, carry out the filling operation with
cap (A) fitted.
Cap (A) acts to prevent the entry of dirt or dust into the filter cartridge.
10. Fill the filter cartridge with clean fuel through the 8 small holes
(B) in the new filter cartridge.
11. Coat the packing surface of the filter cartridge with oil.
12. Remove filter cartridge cap (A) and install to the filter holder.
13. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
14. Connect connector (1).
15. When carrying out standard replacement of the fuel filter cartridge (EVERY 1000 HOURS), replace the
cartlidge and bleed the air. For details, see "REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-54)".
16. Start the engine, check that there is no leakage of fuel from the filter seal surface or water separator mounting
surface, then run for approx. 10 minutes at low idling.
4 - 52
.
PROCEDURE FOR BLEEDING AIR

1. Fill the fuel tank with fuel.
3. Loosen and pull out feed pump knob (1) and move it forward
and backward.
The plug on the side surface of the fuel pre-filter head does
not need to be removed.
Keep moving knob (1) until it becomes heavy.
4. After bleeding air, push in and tighten knob (1).
4 - 53
.

Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time.
REPLACE FUEL MAIN FILTER CARTRIDGE

WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts
to cool down before starting the operation.
High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
Do not bring any fire or flame close.
NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection
pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is
stuck to any part, use fuel to wash it off completely.
2. Set the container to catch the fuel under the filter cartridge.
3. Using a filter wrench, turn filter cartridge (1) counterclockwise
on remove it.
4. Clean the filter holder.
NOTICE
Do not fill the filter cartridge with fuel.
Cap (A) is installed to prevent dirt from entering the inside of the filter
cartridge.
A
5. Coat the packing surface of the filter cartridge with oil.
9JA07639
6. Remove filter cartridge cap (A) and install to the filter holder.
4 - 54
.
7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
8. After completing replacement of fuel filter cartridge (1), bleed the air from the system.
For details, see "PROCEDURE FOR BLEEDING AIR (PAGE 4-55)".
9. After completing the air bleeding, start the engine and check that there is no leakage of fuel from the filter seal
surface. If there is any leakage, check the tightening condition of the filter cartridge. If there is still fuel leakage,
repeat Steps 1 - 3 to remove the filter cartridge, then check the packing surface for damage or embedded dirt.
If any damage or embedded dirt is found, replace the cartridge with a new part and repeat Steps 4 - 8 to install
it.
PROCEDURE FOR BLEEDING AIR

1. Fill the fuel tank with fuel.
3. Loosen and pull out feed pump knob (1) and move it forward
and backward.
The plug on the side surface of the fuel pre-filter head does
not need to be removed.
Keep moving knob (1) until it becomes heavy.
4. After bleeding air, push in and tighten knob (1).
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER
WARNING

1. Set a container to catch the oil under drain plug (P), then
remove drain plug (P) and drain the oil.
To prevent the oil from pouring out suddenly, loosen drain plug
(P) and remove it gradually.
2. After draining the oil, install drain plug (P).
Tightening torque: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm, 50.6 ± 7.2
lbft}
3. Set a container to catch the oil under the transmission filter.
4 - 55
.
4. Remove drain plug (1) of the transmission filter, drain the oil,
then tighten the plug again.
5. Using a filter wrench, turn filter cartridge (2) to the left to
remove it.
6. Clean in the filter holder, coat the seal surface and thread of
the new filter cartridge with engine oil, then install it.
7. When the seal surface comes into contact with the filter holder,
tighten a further 2/5 turns with the filter wrench.
8. Remove 4 bolts (3), move tube (4), then remove strainer (5).
9. Remove any dirt stuck to strainer (5), then wash it in clean
diesel fuel or flushing oil. If strainer (5) is damaged, replace it
with a new part.
10. Install strainer (5) in the case.
Replace the O-ring of tube (4) with a new part, then install tube
(4).
11. Refill the specified quantity of oil through oil filler (F).
12. After filling with oil, check that the oil is at the specified level.
For details, see "CHECK TRANSMISSION OIL LEVEL, ADD
OIL (PAGE 4-28)".
13. Check that there is no leakage of oil from the transmission
case or oil filter.
CLEAN TRANSMISSION CASE BREATHER

1. Loosen bolt (1) and remove cover (2).
2. Remove all dirt and mud from around the breather, then
remove breather (3), soak it in flushing fluid, and wash it.
After removing the breather, take steps to prevent dirt or dust
from entering the mount.
4 - 56
.
LUBRICATING
1. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
(1) Center hinge pin (2 places)
(2) Drive shaft center support (1 place)
CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS

Please ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger
- aftercooler - engine.
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT

Since inspection and replacement of the fan belt requires special tools, contact your Komatsu distributor.
REMARK
The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
If the alternator drive belt is in the following condition, the belt must
be replaced. Please ask your Komatsu distributor to replace the
belt.
When horizontal scratch (1) crosses vertical scratch (2)
When there are tears (3) in part of the belt
In case (4) where there are horizontal scratches only, there is no
need to replace the belt.
4 - 57
.

Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT

WARNING
1. Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.
2. Remove oil filler cap (F).
3. Set a container to catch the oil under drain plug (2).

4. Remove drain plug (2).
5. Loosen drain valve (3), then gradually pull it out to drain the oil.
6. After draining the oil, close drain valve (3), install and tighten
drain plug (2).
Tightening torque
Drain plug (2): 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm, 50.6 ± 7.2 lbft}
Drain valve (3): 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm, 47.0 ± 10.8
4 - 58
.
7. Remove mounting bolts (5) (6 pieces) of filter cover (4) on the

top of the tank, then remove the cover.
When doing this, the cover may fly off under the force of spring
(6), so keep the cover pressed down while removing the bolts.
8. Remove spring (6) and bypass valve (7), then take out
element (8).
9. Check that there is no foreign material inside the tank, then
clean it.
10. Install new element (8), then set bypass valve (7), spring (6),
and cover (4) on the tank.
When doing this, check the cover O-ring. If it is damaged or
deteriorated, replace it.
11. Remove 6 bolts (10), then remove cover (9).

12. Pull the top of rod (11) from the top and remove strainer (12).
13. Remove any dirt stuck to strainer (12), then wash it in flushing
oil. If strainer (12) is damaged, replace it with a new part.
14. When installing the cover bolts, push down the cover and tighten the bolts evenly.
15. Add engine oil through oil filler port (F) to the specified level, then install cap (F).
16. Check that the hydraulic oil is at the standard level. For details, see "CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL (PAGE 4-42)".
17. Run the engine at low idle, and extend and retract the steering, bucket, and lift arm cylinders 4 to 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 stroke).
NOTICE
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.
4 - 59
.
18. Next, operate the steering, bucket, and lift arm cylinders fully
3 - 4 times, then stop the engine and loosen air bleed plug (13).
After bleeding the air from the hydraulic tank, tighten plug (13).
Keep the engine running at low idling when bleeding the air.
19. Check that the hydraulic oil is at the standard level. For details,
see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
(PAGE 4-42)".
20. Next, raise the engine speed, repeat the air bleeding procedure in Step 18, and continue the operation until no
more air comes out from plug (13).
21. After bleeding the air, tighten plug (13).
22. Check that the hydraulic oil is at the standard level. For details, see "CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL (PAGE 4-42)".
23. Check that there is no leakage of oil from the filter cover mount.
REPLACE HYDRAULIC TANK BREATHER ELEMENT

WARNING
1. Lower the bucket horizontally to the ground and turn the

parking brake switch ON.
2. Stop the engine and wait for the temperature at all parts to go
down.
3. Before removing the cap of oil filler (F), wipe off all the dirt from
around the breather.
4. Remove the cap of oil filler (F).
5. Remove snap ring (2) from breather (1), then remove breather
cap (3).
6. Replace filter element (4) with a new part, then install breather
cap (3) and snap ring (2).
7. Tighten the cap of oil filler (F).
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.
4 - 60
.
CHANGE AXLE OIL

WARNING
When changing the oil, apply the parking brake and secure the front and rear frames with the frame lock bar.
After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go
down before starting the operation.
When the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
Refill capacity
Front: 40 liters (10.6 US gal)
Rear: 40 liters (10.6 US gal)
A: Front B: Rear
1. Set a container to catch the oil under drain plug (P).

2. Remove front and rear oil filler plugs (1), then remove drain
plug (P) to drain the oil.
REMARK
Remove the mud and dirt from around plug (1), then remove the
plug.
3. After draining the oil, clean drain plug (P) and install it again.
4. Add oil through plug hole (1) at the refill level.
REMARK
Be sure to use the only specified lubricating oil for the axle with the
ASD (Anti-Slip Differential).
5. After adding oil, check at level plug (1) that the oil is at the
specified level. For details, see "CHECK AXLE OIL LEVEL,
ADD OIL (PAGE 4-29)".
REMARK
For operations where the brake is used frequently, change the axle oil at shorter intervals.
4 - 61
.
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER
Remove both the recirculation air filter and fresh air filter in the same way as when cleaning, and replace them with
new parts.
For details of cleaning the recirculation air filter, see "CLEAN ELEMENT IN AIR CONDITIONER
RECIRCULATION FILTER (PAGE 4-47)".
For details of cleaning the fresh air filter, see "CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER
(PAGE 4-43)".
CLEAN BRAKE CIRCUIT STRAINER

WARNING
After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go
down before starting the operation.
When the rubber hose is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
1. Remove a cover under the floor frame at the right side of

machine.
2. When rubber hose (1) and flange (2) are removed, oil will spill
out, so set a container (capacity: approx. 300 cc) in position to
catch the oil.
3. Remove rubber hose (1) and flange (2).
4. Remove strainer (3) and wash it in clean diesel oil.
5. Assemble strainer (3) in strainer case (4) with the strainer
protrusion side (O-ring side) facing the front and fix it with
flange (2).
6. Install rubber hose (1).
7. Install the cover.
4 - 62
.
CHECK BRAKE DISC WEAR

WARNING
When checking the brake disc wear, apply the parking brake and secure the front and rear frames with the frame lock bar.
Make sure that the brake oil temperature is less than 60°C (140°F) before checking the brake wear.
If the disc is near the wear limit, carry out inspection at shorter intervals, regardless of the specified inspection interval.
When checking the brake disc for wear, there are 4 places (front axle and rear axle, left and right), so use the same
procedure to check all 4 places.
1. Remove cap nut (1).
2. Depress the brake pedal and push in rod (2) fully.

3. Amount of wear (A) is the amount that end face (C) of the rod
protrudes from end face (D) of the guide. Measure the amount
of protrusion.
Permitted wear limit (B) of the disc is the point where groove
(E) of the rod is in line with end face (D) of the guide.
When this point is reached, please ask your Komatsu
distributor to carry out inspection and replacement of parts.
If the disc is near the wear limit, carry out inspection at
shorter intervals, regardless of the specified inspection
interval.
4. Install cap nut (1).
Tightening torque: 29.4 to 39.2 Nm {3.0 to 4.0 kgm, 21.7 to
28.9 lbft}
REMARK
On new machines, the position of the guide is adjusted so that the end face of rod (2) comes to the end face of
guide (3). For this reason, do not loosen locknut (4) except when replacing the disc.
Carry out the operation with two workers: one worker depresses the brake pedal and the other worker pushes
in rod (2).
4 - 63
.
CHECKING FUNCTION OF ACCUMULATOR

For details of handling the accumulator, see Section "HANDLING ACCUMULATOR AND GAS SPRING (PAGE
2-42)".
PPC ACCUMULATOR
If the engine stops with the work equipment raised, and it is impossible to start the engine again, it is possible as
an emergency measure to actuate the valve with the oil pressure stored in the accumulator and lower the work
equipment to the ground.
1. Apply the parking brake.
2. Raise the work equipment to the maximum height, then
operate the lift arm control lever to HOLD position (b).
3. Stop the engine.
4. Leave the work equipment lock lever in the FREE position.
5. Check that the area around the machine is safe, then operate
the lift arm control lever to FLOAT position (d) and lower the
work equipment to a point 1m above the ground.
6. When the lift arm comes to the 1m position, return the lift arm
control lever to LOWER position (c), and lower the work
equipment slowly to the ground.
REMARK
Carry out the check within 2 minutes after stopping the engine. If
the machine is left with the engine stopped, the accumulator
pressure will drop and it will be impossible to check the cause of
the problem.
If the work equipment stops while it is moving, the gas pressure in the accumulator has probably dropped.
Please contact your Komatsu distributor to have the accumulator inspected.
Replace the accumulator every 4000 hours or every 2 years.
CHECK ALTERNATOR
Contact your Komatsu distributor to have the alternator checked.
If the engine is started frequently, have this inspection carried out every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts, request your Komatsu distributor for service.
CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
4 - 64
.

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
LUBRICATING
Carry out the greasing once every two years, regardless of whether the 4000 hour interval has passed.
1. Using a grease pump, apply grease through the grease fittings marked by arrows.
3. When lubricating, stop the drive shaft so that the grease fitting of center drive shaft spline (1) will be as shown
in the figure and supply grease from under the machine.
At this time, the grease fitting is at the position indicated by the arrow at the circle below seen from the rear of
the machine.
(1) Center drive shaft spline (1 place)
View from rear of machine
(2) Front drive shaft (2 places)
4 - 65
.
(3) Rear drive shaft (2 places)
(4) Center drive shaft (2 places)
CHECK WATER PUMP

Check the water pump and its relative parts for water leak, and if anything abnormal is found, call on your Komatsu
distributor for repairs or replacement.
CHECK STARTING MOTOR

Contact your Komatsu distributor to have the starting motor checked.
If the engine is started frequently, have this inspection carried out every 1000 hours.
CHECK AIR CONDITIONER COMPRESSOR, ADJUST

As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.
4 - 66
.
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER
Check visually and touch by hand to check that there is no hardening of the rubber and no loose bolts of the
mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail. If there
are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out
replacement.
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
The fuel spray prevention caps (12 places) on the fuel injection piping and both ends of the high-pressure piping
act to prevent the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the
fuel should leak or spray out. Check visually and touch by hand to check that there are no missing caps, loose bolts
or hardening of the rubber. If there are any problems, the parts must be replaced. In this case, please ask your
Komatsu distributor to carry out replacement.
4 - 67
.

Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time.
REPLACE HIGH-PRESSURE PIPING CLAMP

Contact your Komatsu distributor to have the engine high-pressure clamps replaced.
REPLACE FUEL SPRAY PREVENTION CAP

Contact your Komatsu distributor to have the fuel spray prevention cap replaced.
4 - 68
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
WA380Z-6 (Standard)
Item Unit
(when using POWER mode)
Machine weight kg (lb) 17,130 (37,770)
Normal load kg (lb) 5,280 (11,642)
Bucket capacity Heaped m3(cu.yd) 3.1 (4.1)
Engine model - Komatsu SAA6D107E-1
Flywheel horse power kW (HP)/rpm 142 (191)/2,100
A Overall length mm (ft in) 8,295 (27'3")
B Overall height mm (ft in) 3,390 (11'1")
C Max.dimension when shaking bucket mm (ft in) 5,600 (18' 4")
D Overall width mm (ft in) 2,780 (9'1")
E Min. ground clearance mm (ft in) 455 (1' 6")
F Bucket width mm (ft in) 2,920 (9' 7")
Dumping clearance
G Cutting edge [tooth tip] mm (ft in) 3,035 (9' 11") [2,825 (9' 3")]
(*1)
H Dumping reach (*1) Cutting edge [tooth tip] mm (ft in) 1,105 (3'8") [1,240 (4'1")]
I Bucket dump angle (max.height) degrees 50
Out of chassis mm (ft in) 7,260 (23' 10")
Min. turning radius
Center of out side tire mm (ft in) 6,320 (20' 9")
Permissible towing load kN (kg) 115 (11,700)
1st km/h (MPH) 6.6 (4.1)
2nd km/h (MPH) 11.5 (7.1)
Forward
3rd km/h (MPH) 20.2 (12.6)
4th km/h (MPH) 34.0 (21.1)
Travel speed
1st km/h (MPH) 7.1 (4.4)
2nd km/h (MPH) 12.3 (7.6)
Reverse
3rd km/h (MPH) 21.5 (13.4)
4th km/h (MPH) 35.5 (22.1)
*1: Indicates the value at the 45 degrees bucket dump angle.
5-2
.
SPECIFICATIONS SPECIFICATIONS
5-3
.
.
6-1
.
SELECTING BUCKET AND TIRES ATTACHMENTS, OPTIONS
SELECTING BUCKET AND TIRES

Select the most suitable bucket and tires for the type of work and the ground conditions on the jobsite.
Type of work Bucket Ground conditions Tire

Stockpile bucket General ground
Loading (with bolt-on cutting edge) 23.5-25-16PR (L3 Rock)
conditions
products (3.3 m3 (4.3 cu.yd))
Stockpile bucket
Loading and (with teeth) Leveled ground 23.5-25-16PR (L2 Traction)
carrying (3.1 m3 (4.1 cu.yd))
products Light material bucket
(with bolt-on cutting edge) Soft ground 23.5-25-16PR (L2 Traction)
(4.0 m3 (5.2 cu.yd))
General ground
23.5-25-20PR (L3 Rock)
conditions
Excavating bucket 20.5-25-16PR (L3 Rock)

Soft ground
Loading (with segment edge) 23.5-25-16PR (L3 Rock)
crushed rock (2.7 m3 (3.5 cu.yd)) Ground with many
23.5-25-12PR (L3 Rock)
light rocks
Soft ground with
23.5-25-12PR (L3 Rock)
many light rocks
BOC indicates a bolt-on type cutting edge.
The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your
Komatsu distributor.
6-2
.
INDEX
INDEX
<A> PRECAUTIONS WHEN RUNNING

ADJUSTING WORK EQUIPMENT ENGINE INSIDE BUILDING 2- 21
POSTURE 3-133 PREPARATIONS FOR SAFE
AIR CONDITIONER 3- 75 OPERATION 2- 14
AM/FM RADIO 3- 69 UNAUTHORIZED MODIFICATION 2- 20
GENERAL VIEW 3- 2
<B> GENERAL VIEW OF CONTROLS AND
BACKUP ALARM 3- 65 GAUGES 3- 3
BEFORE READING THIS MANUAL 1- 2 GENERAL VIEW OF MACHINE 3- 2
GUIDES TO MAINTENANCE 4- 2
<C>
CAP WITH LOCK 3- 58 <H>
CHECK BEFORE STARTING ENGINE, HANDLING CAB WIPER 3- 82
ADJUST 3- 84 HANDLING MACHINES EQUIPPED
CHECKS AFTER COMPLETION OF WITH KOMTRAX 3- 83
OPERATION 3-137 HANDLING OIL, FUEL, COOLANT, AND
COLD WEATHER OPERATION 3-147 PERFORMING OIL CLINIC 4- 4
AFTER COLD WEATHER 3-148 HANDLING THE TIRES 3-139
PRECAUTIONS AFTER
COMPLETION OF WORK 3-148 <I>
PRECAUTIONS FOR LOW INTRODUCTION 1- 4
TEMPERATURE 3-147 FRONT/REAR, LEFT/RIGHT
CONTROL LEVERS, PEDALS 3- 52 DIRECTIONS OF MACHINE 1- 4
USE OF MACHINE 1- 4
<E> VISIBILITY FROM OPERATOR'S
ENGINE SERIAL NO. PLATE 1- 6 SEAT 1- 5
EXPLANATION OF COMPONENTS 3- 6
<L>
<F> LIFTING MACHINE 3-145
FRAME LOCK BAR 3- 60 LOADING, UNLOADING WORK WITH
FUSE 3- 66 TRAILERS 3-141
LOCATION OF FIRE EXTINGUISHER 3- 82
<G> LOCKING 3-138
GENERAL PRECAUTIONS COMMON LONG-TERM STORAGE 3-149
TO OPERATION AND MAINTENANCE 2- 14 AFTER STORAGE 3-149
DO NOT GET CAUGHT IN BEFORE STORAGE 3-149
ARTICULATING PORTION 2- 20 DURING STORAGE 3-149
PRECAUTIONS BEFORE STARTING <M>
OPERATION 2- 14 MACHINE MONITOR 3- 6
PRECAUTIONS RELATED TO MAINTENANCE SCHEDULE CHART 4- 18
ATTACHMENTS AND OPTIONS 2- 20 MOVING THE MACHINE
PRECAUTIONS RELATED TO (DIRECTIONAL, SPEED), STOPPING
PROTECTIVE STRUCTURES 2- 20 THE MACHINE 3-110
PRECAUTIONS WHEN GETTING ON
OR OFF MACHINE 2- 17 <N>
NECESSARY INFORMATION 1- 6
7-1
.
INDEX
<O> SELECTING BUCKET AND TIRES 6- 2

OPENING, CLOSING CAB DOORS, SERVICE PROCEDURE 4- 20
WINDOWS 3- 61 CHECK BEFORE STARTING 4- 41
OPERATION 3- 84 EVERY 100 HOURS SERVICE 4- 42
OPERATION OF WORK EQUIPMENT 3-122 EVERY 1000 HOURS SERVICE 4- 54
OPERATIONS AND CHECKS AFTER EVERY 2000 HOURS SERVICE 4- 58
STARTING ENGINE 3-107 EVERY 250 HOURS SERVICE 4- 44
OUTLINE OF ELECTRIC SYSTEM 4- 7 EVERY 4000 HOURS SERVICE 4- 65
OUTLINES OF SERVICE 4- 4 EVERY 500 HOURS SERVICE 4- 50
<P> INITIAL 250 HOURS SERVICE 4- 20
PARKING MACHINE 3-135 WHEN REQUIRED 4- 21
PERIODIC REPLACEMENT OF SAFETY SLOW BLOW FUSE 3- 67
CRITICAL PARTS 4- 16 SPECIFICATIONS 5- 2
POSITION OF SERVICE METER 1- 7 STANDARD TIGHTENING TORQUES
POWER OUTLET 3- 68 FOR BOLTS AND NUTS 4- 15
PRECAUTIONS FOR MAINTENANCE 2- 35 STARTING ENGINE 3-102
PRECAUTIONS BEFORE STARTING STEERING TILT LOCK LEVER 3- 57
INSPECTION AND MAINTENANCE 2- 35 STOPPING ENGINE 3-109
PRECAUTIONS FOR INSPECTION SWITCHES 3- 41
AND MAINTENANCE 2- 39
TIRES 2- 44 <T>
PRECAUTIONS FOR OPERATION 2- 22 TABLE TO ENTER SERIAL NO. AND
OPERATION 2- 26 DISTRIBUTOR 1- 7
PRECAUTIONS FOR JOBSITE 2- 22 TORQUE LIST 4- 15
STARTING ENGINE 2- 24 TOWING PIN 3- 60
TOWING 2- 34 TRANSPORTATION 3-141
TRANSPORTATION 2- 33 TRANSPORTATION PROCEDURE 3-141
PRECAUTIONS FOR OPERATION 3-131 TROUBLESHOOTING 3-150
PRODUCT IDENTIFICATION NUMBER IF BATTERY IS DISCHARGED 3-155
(PIN)/MACHINE SERIAL NO. PLATE 1- 6 METHOD OF TOWING MACHINE 3-150
OTHER TROUBLE 3-158
<R> WHEN MACHINE RUNS OUT OF
RECOMMENDED FUEL, COOLANT, FUEL 3-150
AND LUBRICANT 4- 10 TURNING 3-119
LUBRICATION CHART 4- 11
RECOMMENDED BRANDS, <W>
RECOMMENDED QUALITY FOR WEAR PARTS 4- 8
PRODUCTS OTHER THAN WEAR PARTS LIST 4- 8
KOMATSU GENUINE OIL 4- 14 WORK POSSIBLE USING WHEEL
USE OF FUEL, COOLANT AND LOADER 3-124
LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE 4- 13
<S>
SAFETY 2- 2
SAFETY INFORMATION 1- 3
SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
7-2
.
.
WA380Z-6 WHEEL LOADER

Form No. PEN00665-00
©
2013 KOMATSU
All Rights Reserved
Printed in Japan 04-13

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PEN00665-00

WHEEL LOADER WA380Z -6

BEFORE READING THIS MANUAL FOREWORD

BEFORE READING THIS MANUAL

Storage location for the Operation and Maintenance Manual:

FOREWORD SAFETY INFORMATION

This word is used for information that is useful to know.

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE

VISIBILITY FROM OPERATOR'S SEAT

VISIBILITY IN IMMEDIATE AREA

12-M RADIUS VISIBILITY

NECESSARY INFORMATION FOREWORD

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

ENGINE SERIAL NO. PLATE

FOREWORD NECESSARY INFORMATION

POSITION OF SERVICE METER

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Engine serial No.

Product identification number (PIN)

OPENING, CLOSING CAB DOORS, WINDOWS 3- 61

RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10

PRECAUTIONS FOR OPERATION 2- 22

PRECAUTIONS FOR MAINTENANCE 2- 35

SAFETY SAFETY LABELS

LOCATION OF SAFETY LABELS

SAFETY LABELS SAFETY

(2) Caution for leaving the operator's seat (09654-C0481)

SAFETY SAFETY LABELS

(3) Caution when traveling in reverse (09802-D0880)

(4) Caution for going close to electric cables (09801-C0481)

SAFETY LABELS SAFETY

(5) Caution to keep away from movable parts (09162-C0641)

(6) Caution for frame lock bar (09161-C0641)

(7) Caution when canceling parking brake emergency

SAFETY SAFETY LABELS

(8) Caution when coolant is at high temperature (09653-A0641)

(9) Caution when handling battery cable (09808-A1201)

(10) Explosion hazard (09659-A057B)

(11) Escape (425-93-51110)

SAFETY LABELS SAFETY

(12) "Do not open when engine is running" sign (09667-A0880)

(13) Caution for rotating fan (09667-A0481)

(14) "Do not come near machine" sign (09806-C0883)

SAFETY SAFETY LABELS

(15) "Do not go under work equipment" sign (09807-C0883)

(16) Caution blast site (09845-00480)

(17) Prohibition of engine start by short-circuiting (09842-A0481)

SAFETY LABELS SAFETY

(18) Caution for high temperature turbocharger (09817-A0753)

(19) Caution for high temperature exhaust pipe (09817-A0753)

(20) Caution for common rail high pressure (6754-71-1991)

SAFETY SAFETY LABELS

(21) Parking brake emergency cancel switch (423-93-41172)

(22) "Do not modify ROPS" sign (09620-A2000)

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION AND

PRECAUTIONS BEFORE STARTING OPERATION

ENSURING SAFE OPERATION

UNDERSTANDING THE MACHINE