Wa200 6

TEN00471-07
WHEEL LOADER WA200 -6

SERIAL NUMBERS 71006 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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READ THIS MANUAL FOREWORD
READ 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 perform 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 System of 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))
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 or death 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 used.
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 3-125)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
(A) Front (E) Bucket

(B) Rear
(C) Left
(D) Right
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.
VISIBILITY FROM OPERATOR'S SEAT

This machine complies with the visibility standard (ISO 5006).
This machine maintains a close visibility of a height of 1.5 m (4 ft 11 in) at a point 1 m (3 ft 3 in) away from the outside
surface of the machine, and a visibility for a circumference of 12 m (39 ft 4 in).
1-4
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FOREWORD NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, contact 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 on the side face of the engine on the right side of the machine.
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NECESSARY INFORMATION FOREWORD
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
1-6
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FOREWORD CONTENTS
CONTENTS
FOREWORD 1- 1
READ 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- 4
NECESSARY INFORMATION 1- 5
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 5
ENGINE SERIAL NO. PLATE 1- 5
POSITION OF SERVICE METER 1- 6
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 6
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- 12
PRECAUTIONS BEFORE STARTING OPERATION 2- 12
PREPARATIONS FOR SAFE OPERATION 2- 12
FIRE PREVENTION 2- 14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 15
DO NOT GET CAUGHT IN ARTICULATING PORTION 2- 18
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 18
UNAUTHORIZED MODIFICATION 2- 18
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 18
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 19
PRECAUTIONS FOR OPERATION 2- 20
PRECAUTIONS FOR JOBSITE 2- 20
STARTING ENGINE 2- 22
OPERATION 2- 24
TRANSPORTATION 2- 31
TOWING 2- 32
PRECAUTIONS FOR MAINTENANCE 2- 33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 33
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 38
TIRES 2- 43
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- 5
MACHINE MONITOR 3- 5
SWITCHES 3- 42
CONTROL LEVERS, PEDALS 3- 56
STEERING TILT LOCK LEVER 3- 61
CAP AND COVER WITH LOCK 3- 61
FRAME LOCK BAR 3- 62
TOWING PIN 3- 63
1-7
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CONTENTS FOREWORD
GREASE PUMP 3- 63
OPENING, CLOSING CAB DOORS, WINDOWS 3- 64
FUSE 3- 68
SLOW BLOW FUSE 3- 70
POWER OUTLET 3- 71
STORAGE BOX 3- 71
AM/FM RADIO-CASSETTE STEREO 3- 72
AIR CONDITIONER 3- 80
HANDLING CAB WIPER 3- 87
OPERATION 3- 88
CHECK BEFORE STARTING ENGINE, ADJUST 3- 88
STARTING ENGINE 3-106
CHECKS AFTER STARTING ENGINE 3-110
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-111
STOPPING ENGINE 3-114
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE 3-115
TURNING 3-121
OPERATION OF WORK EQUIPMENT 3-123
WORK POSSIBLE USING WHEEL LOADER 3-125
PRECAUTIONS FOR OPERATION 3-131
ADJUSTING WORK EQUIPMENT POSTURE 3-133
PARKING MACHINE 3-135
CHECKS AFTER COMPLETION OF OPERATION 3-137
LOCKING 3-137
HANDLING THE TIRES 3-138
TRANSPORTATION 3-140
TRANSPORTATION PROCEDURE 3-140
LOADING, UNLOADING WORK WITH TRAILERS 3-140
LIFTING MACHINE 3-144
COLD WEATHER OPERATION 3-146
PRECAUTIONS FOR LOW TEMPERATURE 3-146
PRECAUTIONS AFTER COMPLETION OF WORK 3-147
AFTER COLD WEATHER 3-147
LONG-TERM STORAGE 3-148
BEFORE STORAGE 3-148
DURING STORAGE 3-148
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 3-152
OTHER TROUBLE 3-155
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
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
1-8
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FOREWORD CONTENTS
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED 4- 16
SERVICE PROCEDURE 4- 17
EVERY 10 HOURS SERVICE (ONLY FOR FIRST 50 HOURS) 4- 17
INITIAL 250 HOURS SERVICE 4- 17
INITIAL 1000 HOURS SERVICE 4- 17
WHEN REQUIRED 4- 18
CHECK BEFORE STARTING 4- 45
EVERY 50 HOURS SERVICE 4- 46
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING BUCKET AND TIRES 6- 2
HANDLING HYDRAULIC QUICK COUPLER 6- 3
REMOVING ATTACHMENT 6- 3
INSTALLING ATTACHMENT 6- 5
METHOD OF USING 2 LEVERS 6- 7
EXPLANATION OF COMPONENTS 6- 7
KOMTRAX 6- 9
POWER SUPPLY FOR KOMTRAX 6- 9
INDEX 7- 1
1-9
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2-1
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SAFETY SAFETY
SAFETY
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12

PRECAUTIONS BEFORE STARTING OPERATION 2- 12
ENSURING SAFE OPERATION 2- 12
UNDERSTANDING THE MACHINE 2- 12
PREPARATIONS FOR SAFE OPERATION 2- 12
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 12
INSPECTING MACHINE 2- 12
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2- 12
KEEP MACHINE CLEAN 2- 13
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT 2- 13
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2- 13
IF ANY PROBLEM IS FOUND 2- 13
FIRE PREVENTION 2- 14
ACTION IF FIRE OCCURS 2- 14
PRECAUTIONS TO PREVENT FIRE 2- 14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 15
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 2- 15
NO JUMPING ON OR OFF MACHINE 2- 15
NO PEOPLE ON ATTACHMENTS 2- 15
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT 2- 16
PRECAUTIONS WHEN LEAVING MACHINE 2- 17
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 17
PRECAUTIONS WHEN CLEANING CAB GLASS 2- 17
DO NOT GET CAUGHT IN ARTICULATING PORTION 2- 18
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 18
UNAUTHORIZED MODIFICATION 2- 18
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 18
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 19
2-2
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SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 20

PRECAUTIONS FOR JOBSITE 2- 20
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 20
WORKING ON LOOSE GROUND 2- 20
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 21
ENSURE GOOD VISIBILITY 2- 21
CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 21
BEWARE OF ASBESTOS DUST 2- 22
STARTING ENGINE 2- 22
WARNING TAGS 2- 22
INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE 2- 23
PRECAUTIONS WHEN STARTING ENGINE 2- 23
PRECAUTIONS IN COLD AREAS 2- 23
STARTING WITH BOOSTER CABLES 2- 24
OPERATION 2- 24
CHECKS BEFORE OPERATION 2- 24
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 25
PRECAUTIONS WHEN TRAVELING 2- 26
TRAVELING ON SLOPES 2- 27
METHOD OF USING BRAKES 2- 27
PRECAUTIONS WHEN OPERATING 2- 28
PROHIBITED OPERATIONS 2- 29
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 2- 29
PARKING MACHINE 2- 30
TRANSPORTATION 2- 31
LOADING AND UNLOADING 2- 31
TOWING 2- 32
PRECAUTIONS WHEN TOWING 2- 32
2-3
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SAFETY SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 33

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 33
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 33
KEEP WORKPLACE CLEAN AND TIDY 2- 33
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 33
ONLY AUTHORIZED PERSONNEL 2- 33
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 33
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 34
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 36
TURNING E.C.S.S. SWITCH OFF BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 36
INSTALLING, REMOVING, OR STORING ATTACHMENTS 2- 37
PRECAUTIONS WHEN WORKING AT HIGH PLACES 2- 37
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2- 37
PROPER TOOLS 2- 37
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 38
PRECAUTIONS WHEN WELDING 2- 38
HANDLING BATTERY 2- 38
PRECAUTIONS WHEN USING HAMMER 2- 39
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2- 39
PRECAUTIONS WITH HIGH-TEMPERATURE OIL 2- 39
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 40
PRECAUTIONS WITH HIGH-PRESSURE FUEL 2- 40
HANDLING HIGH-PRESSURE HOSES AND PIPING 2- 40
NOISE 2- 40
HANDLING ACCUMULATOR AND GAS SPRING 2- 41
PRECAUTIONS WITH COMPRESSED AIR 2- 41
MAINTENANCE OF AIR CONDITIONER 2- 41
DISPOSING OF WASTE MATERIALS 2- 41
METHOD OF SELECTING WINDOW WASHER FLUID 2- 41
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 42
TIRES 2- 43
HANDLING TIRES 2- 43
PRECAUTIONS WHEN STORING TIRES 2- 44
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 (09651-03001)
(2) Caution for leaving the operator's seat (09654-03001)
(3) Caution when traveling in reverse
Please request part number 418-93-42271 for this safety label.
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(4) Caution for going close to electric cables (09801-13001)
(5) Caution to keep away from movable parts (09162-23000)
(6) Caution for frame lock bar (09161-23000)
(7) Caution when coolant is at high temperature

(09668-03001)
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(8) Caution when oil is at high temperature (09653-03001)
(9) Caution for handling battery cable (09808-03000)
(10) Explosion warning (09659-53000)
(11) "Do not climb on fender" sign (09805-03000)

(Machine equipped with rear fender)
(12) Caution when opening while engine is running (09667-03001)
2-8
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(13) Caution to prevent entry of ether (421-93-A1510)
(14) "Do not come near machine" sign (09812-13000)
(15) "Do not go under work equipment" sign (09807-C0883)
(16) Certification for ROPS/FOPS (09620-A2001, 09620-A2171)
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(17) Prohibited to start by short-circuiting (09842-A0481)
(18) Precautions when cleaning cooler core (418-93-43341)
(19) Escape (425-93-51110)
(20) Precautions when closing emergency escape right window

(421-926-4990)
2 - 10
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(21) Caution blast site (09845-00480)

(only when equipped with KOMTRAX)
(22) Caution when handling battery (09664-30014)
2 - 11
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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 performing
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 performing 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 protective eyeglasses, 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 - 12
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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
KEEP MACHINE CLEAN

If you get on or off the machine or perform 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 components.
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 observe the following to prepare for action if any injury or death 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 emergencies.
Perform periodic inspection and maintenance to ensure that the
fire extinguisher can always be used.
Provide a first aid kit in the storage point. Perform 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 machine 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 - 13
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FIRE PREVENTION
ACTION IF FIRE OCCURS

Turn the starting 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 open flame 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 open 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 combustible 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 performing 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 combustible 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 death.
2 - 14
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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 or death caused by slipping or falling off the machine, always observe the following.
Use the handrails and steps marked by arrows in the figure on
the right when getting on or off the machine.
Always face the machine and maintain at least 3 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 and off the machine, check the handrails and steps if there is any oil, grease, or mud on them.
Wipe it off immediately not to slip if any. In addition, tighten any loose bolt of the handrails and steps.
If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu
distributor to perform this work.
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
2 - 15
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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 operator's seat), always lower the work equipment to
the ground, set work equipment lock lever (1) to the LOCK position,
pull parking brake lever (2) fully to the LOCK position while
stepping the brake pedal, make sure the machine is completely
stopped even when releasing the brake pedal, and then stop the
engine.
If you accidentally touch the levers when they are not locked, there
is a hazard that the machine may suddenly move and cause
serious personal injury or death.
2 - 16
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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 observe the following.
When leaving the machine, always lower the work equipment to
the ground, set work equipment lock lever (1) to the LOCK
position, pull parking brake lever (2) fully to the LOCK position
while stepping the brake pedal, make sure the machine is
completely stopped even when releasing the brake pedal, and
then stop the engine.
Use the key to lock all the equipment.
Always remove the key, take it with you, and keep 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 a good view when operating.
When cleaning the cab glass, check that the foothold is safe.
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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 perform 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. Any
modification is prohibited.
If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced
and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
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
If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety
and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as
machine strength and visibility. Before making any modifications, please consult your Komatsu distributor.
Komatsu cannot take any responsibility for accidents, failures, or damage caused by modifications not authorized
by Komatsu.
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

Any injuries or death, 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
consult 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 performing operations near combustible materials such as attatched 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 observe the following.
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 100 V, 200 V Over 2 m (7 ft)
machine and the electric cable. Check with the local power 6,600 V Over 2 m (7 ft)
company about safe operating procedure before starting 22,000 V Over 3 m (10 ft)
operations. 66,000 V Over 4 m (14 ft)
To prepare for any possible emergencies, wear rubber shoes 154,000 V Over 5 m (17 ft)
and gloves. Lay a rubber sheet on top of the seat, and be careful
187,000 V Over 6 m (20 ft)
not to touch the chassis with any exposed part of your body.
275,000 V Over 7 m (23 ft)
Use a signalman to give warning if the machine approaches too
close to the electric cables. 500,000 V Over 11 m (36 ft)
When performing 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 performing 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 performing operations in places with poor visibility, always observe the following.
Position a signalman if there are areas where the visibility is not good.
Only 1 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 1 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 improper 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 performing inspection and maintenance
of the machine. If the warning sign is ignored and the machine is
operated, there is danger that the person performing 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

Perform 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 performed 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 3-88)" 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 perform 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
NEUTRAL position.
Before starting up the engine, check that the work equipment lock lever is in LOCK position.
Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See "ADJUST
REAR VIEW MIRROR (PAGE 3-103)".
Check that there are no persons or obstacles above, below, or in the area around the machine.
Check that the parking brake lever is in LOCK position.
Check that frame lock bar (1) is fixed securely at FREE position.
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

Perform 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 observe the
following.
Always wear protective eyeglasses and rubber gloves when
starting the engine with booster cable.
When connecting a normal machine to a failed machine with
booster cables, always use a normal machine with the same
battery voltage as the failed machine.
When starting with a booster cable, perform the starting
operation with 2 workers (1 worker sitting in the operator's seat
and the other working with the battery).
When starting from another machine, do not allow the nomal
machine and failed machine.
When connecting the booster cables, turn the starting switch to
OFF position for both the normal machine and failed 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
3-153)" in the OPERATION section.
OPERATION
CHECKS BEFORE OPERATION

If the checks before starting are not performed 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 performing 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 fasten 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, perform repairs immediately.
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Before driving the machine or starting operations, check that

frame lock bar (1) is securely fixed at FREE position.
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 perform 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 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 performing 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 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, consult your Komatsu distributor.
When the machine is traveling on flat ground or down a slope, NEVER set the directional lever to 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
2 - 26
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TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always observe the following.
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.
When traveling downhill, use the braking force of the engine, and always use the right brake pedal at the same
time.
Set to the lock-up and use the braking force of the engine.
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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 1 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 over.
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 perform 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.
2 - 29
.
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, pull parking brake lever (2) fully to the LOCK
position while stepping the brake pedal, make sure the machine
is completely stopped even when releasing the brake pedal, and
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 observe the following.
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, consult your
Komatsu distributor to have the work performed.
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 3-140)".
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 observe the following.
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 idle (MIN) and drive the machine slowly (4) Angle of ramps: Max. 15 deg.
at low 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 the machine 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 3-140)".
When it is necessary to remove handrails and steps, take care not to lose removed handrails and steps.
Install the removed handrails and steps securely.
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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 performing inspection and maintenance
of the machine. If the warning sign is ignored and the machine is
operated, there is danger that the person performing 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: 09963-03001
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 perform 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 ON, operate
work equipment control lever (1) fully to RAISE and LOWER
positions 2 or 3 times to release the remaining pressure in the
hydraulic circuit, then set work equipment lock lever (2) to LOCK
position.
After releasing the remaining pressure in the hydraulic circuit,
turn the starting switch to OFF position.
2 - 34
.
Apply parking brake by pulling parking brake lever (3) fully to the
LOCK position while stepping the brake pedal, make sure the
machine is completely stopped, even when releasing the brake
pedal, then put chocks under the front and the rear of the wheels
to prevent the machine from moving.
Lock the front and rear frames with frame lock bar (4).
2 - 35
.
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent personal injury, do not perform maintenance with the engine running. If maintenance must be performed
with the engine running, perform the operation with at least 2 workers and observe the following.
1 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 performing 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 to prevent the
work equipment from moving.
Pull parking brake lever (2) to LOCK position to apply the

parking brake, then put blocks under the front and the rear of 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.
TURNING E.C.S.S. SWITCH OFF BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
For machines equipped with the E.C.S.S. (if equipped), lower the bucket to the ground, turn the E.C.S.S. switch
OFF, and stop the engine before starting inspection or maintenance. NEVER turn the switch ON during inspection
or maintenance.
2 - 36
.
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 performed safely.
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT

Make sure the hoists or hydraulic jacks you use are in good
repair and strong enough to handle the weight of the
component. Never use hydraulic jacks at places where the
machine is damaged, bent, or twisted. Never use if the element
wire of wire rope is frayed, twisted or pinched. 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 or death.
2 - 37
.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
PRECAUTIONS WHEN WELDING

Welding operations must always be performed by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when performing welding, so never allow any unqualified personnel
to perform welding.
HANDLING BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to 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 or death, explosion, or fire, so
always observe the following.
Do not use or charge the battery if the battery electrolyte is
below LOWER LEVEL mark. This will cause explosion.
Always perform periodic inspection of the battery electrolyte
level, and add distilled water (or commercially available
battery filler solution) to UPPER LEVEL mark.
Do not use a dry wipe to clean the battery. A wet wipe will
prevent fire or explosion from static electricity.
Do not smoke or bring any open 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
perform 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 or death, explosion, or fire, so
always observe the following.
When handling the battery, always wear protective
eyeglasses 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 performing electric welding, turn the starting switch OFF. Wait for
approximately 1 minute, then remove the negative (-) battery cable to stop the flow of electricity.
2 - 38
.
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 observe the following.
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 area.
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 protective eyeglasses 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 - 39
.
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 performing 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 observe the following.
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 2-34)".
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 perform inspection, wear protective eyeglasses 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 medical attention.
On machines equipped with an E.C.S.S. system, the pressure
in the E.C.S.S. circuit is stored by an accumulator. Do not
remove the E.C.S.S. piping or components.
If it is necessary to remove them, please ask your Komatsu
distributor to carry out the removal operation.
PRECAUTIONS WITH HIGH-PRESSURE FUEL

When the engine is running, high-pressure is generated in the engine fuel piping. When performing 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, 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 performing 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 - 40
.
HANDLING ACCUMULATOR AND GAS SPRING

This machine is equipped with an accumulator. Even after the engine stops, if the work equipment control lever is
operated soon after stop of the engine in the direction to lower the work equipment, the work equipment goes down
under its own weight.
After stopping the engine, set the work equipment lock lever and the parking brake lever to the LOCK position.
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.
Do not disassemble the accumulator.
Do not bring it near open 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.
Ask your Komatsu distributor to have this work performed.
PRECAUTIONS WITH COMPRESSED AIR

When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by
flying dust or particles.
When using compressed air to clean the filter element or radiator, wear protective eyeglasses, 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 - 41
.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To enable this machine to be used safely for a long period, always perform periodic replacement of safety critical
parts that have a particularly close relation to safety, such as hoses and the seat belt.
For details of the replacement of safety critical parts, see "PERIODIC REPLACEMENT OF SAFETY CRITICAL
PARTS (PAGE 4-13)".
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 - 42
.
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 perform these
operations.
Always use the tires specified by Komatsu and maintain the
specified inflation pressure.
Suitable tire inflation pressure: see "HANDLING THE TIRES
(PAGE 3-138)"
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 performing operations under
heavy load.
Never perform 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 - 43
.
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 deg. to 70 deg.
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 - 44
.
3-1
.
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
(1) Bucket (8) Turn signal lamp

(2) Bell crank (9) Head lamp
(3) Front wheel (10) Lift cylinder
(4) Bucket cylinder (11) Lift arm
(5) Front working lamp (12) Rear working lamp
(6) ROPS cab (13) Rear combination lamp
(7) Rear wheel
3-2
.
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES
(1) Rear wiper switch (16) Cigarette lighter

(2) Front wiper switch (17) Variable shift control switch
(3) Machine monitor mode selector switch 1 (18) Speed range selector switch
(4) Machine monitor mode selector switch 2 (19) Starting switch
(5) E.C.S.S. switch (if equipped) (*) (20) Quick coupler attachment switch (if equipped)
(6) Directional lever (21) Cooling fan auto reverse rotation switch
(7) Horn button (22) Directional selector switch actuation switch
(8) Steering wheel (23) Traction control switch
(9) Lamp switch (24) Work equipment lock lever
(9) Turn signal lever (25) Accelerator pedal
(9) Dimmer switch (26) Brake pedal
(10) Front working lamp switch (27) Parking brake lever
(11) Rear working lamp switch (28) Rear heated wire glass switch
(12) Hazard lamp switch (29) Air conditioner panel
(13) Max. traction switch (30) Radio (if equipped)
(14) Directional selector switch (31) Room lamp switch
(15) Work equipment control lever
(*)E.C.S.S.: Electronic Controlled Suspension System
3-3
.
GENERAL VIEW OPERATION
MACHINE MONITOR
(1) Central warning lamp (19) Preheating pilot lamp

(2) Brake oil pressure caution lamp (20) Directional selector pilot lamp
(3) Engine oil pressure caution lamp (21) Economy operation display lamp
(4) Water separator caution lamp (22) S mode operation pilot lamp
(5) Radiator coolant level caution lamp (23) Shift hold pilot lamp
(6) Engine oil level caution lamp (24) Traction control operation pilot lamp
(7) HST oil filter clogging caution lamp (25) Travel speed range selector switch position pilot
(8) Air cleaner clogging caution lamp lamp
(9) Parking brake pilot lamp (26) Directional lever position pilot lamp
(10) Brake oil temperature caution lamp (27) HST oil temperature gauge
(11) Quick coupler operation pilot lamp (28) HST oil temperature caution lamp
(if equipped) (29) Engine coolant temperature gauge
(12) Cooling fan reverse rotation pilot lamp (30) Engine coolant temperature caution lamp
(13) Maintenance caution lamp (31) Speedometer
(14) Parking brake reminder caution lamp (32) Turn signal pilot lamp
(15) Battery charge circuit caution lamp (33) Head lamp high beam pilot lamp
(16) Steering oil pressure caution lamp (34) Meter display pilot lamp
(if equipped) (35) Fuel level caution lamp
(17) Emergency steering pilot lamp (if equipped) (36) Fuel gauge
(18) Character display portion
3-4
.
OPERATION EXPLANATION OF COMPONENTS
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 portion (E) Pilot display portion

(B) Emergency stop items (F) Meter display portion
(C) Caution items (G) Centralized warning lamp
(D) Inspection and maintenance items
NOTICE
When turning the starting switch to the ON position before starting the engine, the centralized 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 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.
3-5
.
EXPLANATION OF COMPONENTS OPERATION
When the starting switch is turned ON, if the following conditions A and B are not met, the central warning lamp lights
up and the alarm buzzer sounds intermittently. If this happens, set the controls to condition A or B, and the central
warning lamp will go out.
Condition A
Directional selector actuation switch (1): OFF position
Directional lever: Neutral position
Condition B
Directional selector actuation switch (1): ON position
Directional lever: Neutral position
Directional selector switch (2): Neutral position
3-6
.
TYPES OF WARNING
If an abnormality occurs on the machine, or if any switch or lever is
operated accidently, the machine 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 centralized 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 centralized 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 centralized 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 machine monitor lights up. At the same time, action code "E01" is displayed on
character display (1).
With this warning, the centralized warning lamp does not light up and the alarm buzzer does not sound.
CENTRALIZED 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 (4) Failure code display

(2) Engine speed or travel speed (5) Filter, oil replacement time display
(3) Action code 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
The top line of this display portion (1) shows the total time that the
machine has been running.
The service meter advances while the engine is running, even if
the machine is not moving.
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,
engine speed, or machine travel speed will be displayed if top part
(U) of machine monitor mode selector switch 1 is kept pressed.
NOTICE
When the starting switch is at the OFF position, if the service meter, engine speed, or travel speed is being displayed even thought
the top part (U) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the equipment, so
please ask your Komatsu distributor to carry out inspection.
3-8
.
ENGINE SPEED OR TRAVEL SPEED

The bottom line of this display portion (2) shows the engine speed.
If the speedometer is displaying the engine speed, it can be
switched so that the bottom line will display the machine travel
speed.
To have the speedometer display (travel speed or engine speed)
switched, see "METHOD OF SWITCHING TRAVEL
SPEED/ENGINE SPEED DISPLAY (PAGE 3-40)".
Even if the starting switch is at the OFF position, the service meter,
engine speed, or machine travel speed will be displayed if top part
(U) of machine monitor mode selector switch 1 is kept pressed.
NOTICE
When the starting switch is at the OFF position, if the service meter, engine speed, or travel speed is being displayed even thought
the top part (U) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the equipment, so
please ask your Komatsu distributor to carry out inspection.
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 (3).
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 centralized 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 3-36)".
3-9
.
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.
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 being displayed on the character display of
this display portion (4), press top part (>) of machine monitor
selector switch 2(A).
The action code will switch 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
ENG Engine controller
HST HST 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 (5) 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 3-35)".
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
Transfer oil 1000 TRANSF OIL 25
HST oil filter 1000 HST FILT 26
Hydraulic filter 2000 HYD FILT 04
HST drain filter 2000 HST FILT 43
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 4-56)"
Engine oil filter

"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-56)"
Fuel pre-filter
"REPLACE FUEL PREFILTER CARTRIDGE (PAGE 4-58)"
Fuel main filter

"REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-62)"
Transfer oil
"CHANGE OIL IN TRANSFER CASE (PAGE 4-60)"
HST oil filter

"REPLACE HST OIL FILTER ELEMENT (PAGE 4-64)"
Hydraulic filter
"CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-66)"
HST drain filter

"REPLACE HST DRAIN FILTER (PAGE 4-68)"
Hydraulic oil
"CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-66)"
Axle oil
"CHANGE AXLE OIL (PAGE 4-69)"
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 centralized 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 (if equipped)
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), this lamp lights up,
but when the engine is started, it goes out.
During operation (engine running)

If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and centralized 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 centralized 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.

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 centralized
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.

light up.

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

(if equipped)
(Red)
This lamp (4) lights up when the steering oil pressure has dropped.
During check before starting (with the starting switch at the ON

position and the engine stopped), the lamp is lit.
When the engine is started, the lamp goes out.

If the steering oil pressure goes down during operation, the
steering oil pressure caution lamp and centralized 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) HST oil temperature caution lamp
(2) Quick coupler operation pilot lamp (5) Engine coolant temperature caution lamp
(if equipped) (6) Fuel level caution lamp
(3) Parking brake reminder caution lamp
BRAKE OIL TEMPERATURE CAUTION LAMP

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

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 centralized 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. Let the accelerator pedal back to reduce the speed.
2. Avoid using the brake.
1) Do not keep the brake pedal depressed continuously; use the brake only intermittently.
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.
3 - 17
.
QUICK COUPLER OPERATION PILOT LAMP

(if equipped)
This lamp (2) lights up and the buzzer sounds intermittently when
the quick coupler is released. At the same time, "PIN
DISCONNECT" is displayed on the bottom line of the character
display.
When releasing the quick coupler, press the quick coupler
attachment switch to apply the lock, then operate the work
equipment attachment lever.
If this lamp is lighted up at any time except when the quick coupler
is being released, it means that there is a problem in the quick
coupler solenoid actuation circuit. Move the machine immediately
to a safe place, stop the engine, then carry out inspection.
PARKING BRAKE REMINDER CAUTION LAMP

If the engine is stopped and the parking brake is not applied, this
parking brake reminder caution lamp (3) lights up together with the
centralized warning lamp, and the alarm buzzer sounds
intermittently to warn the operator.
At the same time, "APPLY PKG BRAKE" is displayed on the
bottom line of the character display, so pull the parking brake lever
fully to apply the parking brake.
When the parking brake is applied, the lamp goes out and the
buzzer stops.
HST OIL TEMPERATURE CAUTION LAMP

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

light up.

When the HST oil temperature goes up, the HST oil temperature
caution lamp and centralized warning lamp light up, and the alarm
buzzer sounds intermittently.
At the same time, "E02" is displayed on the character display and
"HST OVERHEAT" is displayed on the bottom line, so stop the
machine and run the engine at a mid-range speed under no load
until the lamp goes out.
3 - 18
.
ENGINE COOLANT TEMPERATURE CAUTION LAMP

This lamp (5) lights up to warn the operator that the engine coolant

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 centralized warning
lamp will light up and the alarm buzzer will sound intermittently.
At the same time as the centralized 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 out.
FUEL LEVEL CAUTION LAMP

This lamp (6) lights up if the amount of fuel remaining in the fuel
tank goes below 21.5 liters (5.68 US gal).
If it lights up, check and add fuel as soon as possible.
REMARK
Even if the caution lamp lights up, action code "E02" is not
displayed on the character display.
3 - 19
.
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED

When the travel speed goes above 36 km/h (22.4 MPH), the
central warning lamp lights up and the alarm buzzer sounds.
At the same time, "OVERRUN PROTECT" is displayed on the
If the alarm buzzer sounds, let the accelerator pedal back to
reduce speed.
TRAVEL SPEED LIMIT FUNCTION

When the machine travel speed goes above 36 km/h (22.4 MPH), the limit function to limit the travel speed is
automatically actuated.
3 - 20
.
INSPECTION AND MAINTENANCE ITEMS

CAUTION
If these lamps light up, stop operations quickly and carry out the following action.
(1) Water separator caution lamp (4) HST oil filter clogging caution lamp
(2) Radiator coolant level caution lamp (5) Air cleaner clogging caution lamp
(3) Engine oil level caution lamp (6) Maintenance caution lamp
WATER SEPARATOR CAUTION LAMP

This lamp (1) warns of a rise in the water level in the water
separator. When it lights up, drain water from the water separator.
The water separator is combined with the fuel pre-filter and they
are located in the lower part.
For draining water from the water separator, see "CHECK WATER
SEPARATOR, DRAIN WATER (PAGE 3-94)".
3 - 21
.
RADIATOR COOLANT LEVEL CAUTION LAMP

This lamp (2) lights up to warn the operator that the coolant level in
the radiator has gone down.

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 (3) is not used.
HST OIL FILTER CLOGGING CAUTION LAMP

When the engine is running, this lamp (4) lights up if the HST oil
filter is clogged.

light up.

This lights up if the HST oil filter is clogged.
At the same time, "E01" is displayed on the character display and
"HST FILTER CLOGGED" is displayed on the bottom line, so
replace the oil filter.
REMARK
The lamp may light up in cold temperatures, but it should go out when the HST oil temperature gauge indicator
enters the white range.
AIR CLEANER CLOGGING CAUTION LAMP

3 - 22
.
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 filter or oil change is reached, this lamp (6)
flashes or lights up for approximately 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 3-35)".
3 - 23
.
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 (8) Shift hold pilot lamp
(2) Cooling fan reverse rotation pilot lamp (9) Traction control operation pilot lamp
(3) Emergency steering pilot lamp (if equipped) (10) Travel speed range selector switch position pilot
(4) Preheating pilot lamp lamp
(5) Directional selector pilot lamp (11) Directional lever position pilot lamp
(6) Economy operation display lamp (12) Turn signal pilot lamp
(7) S mode operation pilot lamp (13) Head lamp high beam pilot lamp
PARKING BRAKE PILOT LAMP

This lamp (1) lights up when the parking brake is applied.
3 - 24
.
COOLING FAN REVERSE ROTATION PILOT LAMP

This lamp (2) lights up when the direction of rotation of the cooling
fan is reversed.
At the same time, "COOLING FAN REVERSE" is displayed on the
character display.
When the direction of rotation of the fan is reversed, the cooling fan
reverse rotation pilot lamp flashes.
For details of the method of operation, see "COOLING FAN AUTO

REVERSE ROTATION SWITCH (PAGE 3-45)".
EMERGENCY STEERING PILOT LAMP

(if equipped)
(Green)
If this lamp (3) lights up when the engine is running or when the
machine is operating, it indicates that the condition is normal.
If it does not light up, an abnormality has occurred in the

emergency steering circuit.
Move the machine immediately to a safe place, stop the engine,
and check the condition.
PREHEATING PILOT LAMP

This lamp (4) 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.
DIRECTIONAL SELECTOR PILOT LAMP

This lamp (5) lights up when the directional selector switch
actuation switch on the right switch panel is turned ON.
It shows that it is possible to switch the direction of travel of the
machine between FORWARD and REVERSE with the directional
selector switch installed to the work equipment control lever.
For details, see "CHANGING DIRECTION (PAGE 3-117)".
3 - 25
.
ECONOMY OPERATION DISPLAY LAMP

This lamp (6) lights up when the economy mode is used.
S MODE OPERATION PILOT LAMP

This lamp (7) lights up when the S mode is selected.
Use the traction control switch to select S mode.
REMARK
When the S mode has been selected, if the traction cancel switch
is pressed, the S mode is cancelled and the lamp (7) goes out.
To set again to S mode and light up lamp (7), press the traction
cancel switch again or change the position of the directional lever.
SHIFT HOLD PILOT LAMP

TRACTION CONTROL OPERATION PILOT LAMP

This lamp (9) lights up when traction control ON is selected.
Use the traction control switch to select traction control ON.
REMARK
When traction control ON has been selected, if the traction cancel
switch is pressed, traction control ON is cancelled and lamp (9)
goes out.
To turn the traction control ON again and light up lamp (9), press
the traction cancel switch again or change the position of the
directional lever.
3 - 26
.
TRAVEL SPEED RANGE SELECTOR SWITCH POSITION PILOT LAMP

This lamp (10) shows the position of the travel speed range
selector switch.
DIRECTIONAL LEVER POSITION PILOT LAMP

This lamp (11) indicates the position of the directional lever.
F lights up: FORWARD

N lights up: NEUTRAL
R lights up: REVERSE
TURN SIGNAL PILOT LAMP

When the turn signal lamp flashes, this lamp (12) also 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 (13) lights up when the head lamp is at high beam.
3 - 27
.
METER DISPLAY PORTION
(1) HST oil temperature gauge (4) Meter display pilot lamp
(2) Engine coolant temperature gauge (5) Fuel gauge
(3) Speedometer
HST OIL TEMPERATURE GAUGE

This meter (1) indicates the HST oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside
the HST oil temperature gauge will light up. At the same time, the
centralized warning lamp lights up and the alarm buzzer sounds
intermittently. In addition, "E02" is displayed on the top line of the
character display and "HST 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 centralized 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).
3 - 28
.
SPEEDOMETER
This meter (3) indicates the travel speed of the machine.
The display unit is indicated on meter display pilot lamp (4).
It is also possible to show the engine speed on this meter (3) by
switching the display.
To have the speedometer display (travel speed or engine speed)
switched, see "METHOD OF SWITCHING TRAVEL
SPEED/ENGINE SPEED DISPLAY (PAGE 3-40)".
METER DISPLAY PILOT LAMP

This lamp (4) displays the unit for the travel speed or engine
tachometer.
FUEL GAUGE
This meter (5) indicates the amount of fuel remaining in the fuel
tank.
If the indicator is at the F position, it indicates that the tank is full.
If the indicator is at the E position, it indicates that there is little fuel
remaining. When the amount of remaining fuel goes below 21.5
liters (5.68 US gal), caution lamp (A) inside the fuel gauge lights up.
If it lights up, check the fuel level and add fuel.
3 - 29
.
OTHER FUNCTIONS OF MACHINE MONITOR

The machine monitor also has the following functions. Use them if necessary.
When the () portion of the machine monitor mode selector switch 1 is pressed from the standard screen (service
meter display) or warning screen, the display changes to "TRACTION LEVEL". Press the (>) or (<) portion of the
machine monitor mode selector switch 2 and move to the following menus.
To return from each menu to the standard menu, press the () of the machine monitor mode selector switch 1.
3 - 30
.
METHOD OF SELECTING TRACTION LEVEL

Use this when selecting the maximum traction level from A, B, and
C. The traction level cannot be switched if the traction control
switch is not at the traction control ON position (position (b)).
1. Set the traction control switch to the traction control ON position (position (b)).
2. 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.
3. Press part (U) of machine monitor mode selector switch 1 to
display "TRACTION LEVEL".
3 - 31
.
4. Press part (U) of machine monitor mode selector switch 1.

Default level B is displayed on the line below "LEVEL (A-C)".
Repeatedly press part (U) of machine monitor mode selector
switch 1 to switch the traction levels in the order B -> C -> A ->
B.
5. To complete the change, press part (t) of machine monitor mode selector switch 1 twice, then turn the starting
switch OFF.
3 - 32
.
METHOD OF SELECTING HST CHANGING FUNCTION

When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use
this when changing the selection.
Speed range selector switch position

Function
3rd position 4th position
A (default setting) F3, R3 F4, R4
B F3, R2 F4, R2
1. Press part (U) of machine monitor mode selector switch 1 to display "TRACTION LEVEL".
2. Press part (>) or (<) of machine monitor mode selector switch
2 to display "HST SELECT".

The HST function (default setting A) is displayed.
Repeatedly press part (U) of machine monitor mode selector
switch 1 to switch the HST function in the order A -> B -> A ->
B.
4. To complete the change, press part (t) of machine monitor mode selector switch 1 twice, then turn the starting
switch OFF.
3 - 33
.
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 to display "ODO" (odometer).
4. After checking the screen, press the () portion of the machine monitor mode selector switch 1 or turn the
starting switch OFF.
3 - 34
.
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 to display "MAINTENANCE MONITOR".
3. Press the () portion of the machine monitor mode selector

switch 1. The screen switches to the display shown on the
right.
The replacement interval is shown on the bottom line at the left
and the number of times of replacement is shown on the right.
4. Press the (>) or (<) portion of the machine monitor mode
selector switch 2 to display the filter or oil item that has been
replaced.
For details of the items to reset, see "FILTER, OIL
REPLACEMENT TIME DISPLAY (PAGE 3-12)".
right.
"RESET" and "ITEM TO RESET" are displayed on the top line
in turn.
6. When resetting the replacement interval, press the (>) or (<)
portion of the machine monitor mode selector switch 2, set the
cursor on "YES", then press the () portion of the machine
monitor mode selector switch 1. The time is reset and the
screen returns to the previous screen.
To abort the operation, set the cursor on "NO", then press the
() portion of the machine monitor mode selector switch 1.
7. When resetting the replacement interval for another item, repeat the procedure from Step 4. After completing
the resetting operation, press the () portion of the machine monitor mode selector switch 1 twice or turn the
3 - 35
.
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.


selector switch 2 to display "TEL".

right.
Once the telephone number has been input, the number will
always be displayed on the screen.
4. The telephone number can be displayed up to 12 digits. Input

in order starting from the first digit on the left.
The cursor is displayed at the input position. Press the (>) or (
<) portion of the machine monitor mode selector switch 2 to
input "0 to 9". To leave a blank, input "*".
After selecting the input value, press the () portion of the
machine monitor mode selector switch 1. The input value is
accepted and the cursor moves to the next digit.
5. Repeat the procedure in Step 4 until the last digit has been input. At the last digit, press the () portion of the
machine monitor mode selector switch 1. The input values are accepted and the screen returns to the previous
screen.
If the wrong number is input or the input operation is to be aborted, press the () portion of the machine monitor
mode selector switch 1. The screen returns to the previous screen.
6. After completing the operation, press the () portion of the machine monitor mode selector switch 1 twice or turn
the starting switch OFF.
3 - 36
.
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.


2 to display "LANGUAGE".

switch 1. The presently selected language is displayed.
selector switch 2 to select the desired language.
The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.
5. After selecting the desired language, press the () portion of
the machine monitor mode selector switch 1.
When the language is changed, "LANGUAGE" is displayed.
6. After completing the operation, press the () portion of the
machine monitor mode selector switch 1 twice or turn the
3 - 37
.
METHOD OF ADJUSTING MONITOR BRIGHTNESS
Do as follows to adjust the brightness of the machine monitor.


2 to display "BRIGHTNESS ADJUST".

"MONITOR PANEL" is displayed on the bottom line and it
becomes possible to adjust the brightness of the monitor
except for the liquid crystal display.
The brightness can be adjusted separately for the liquid crystal

display (LCD) portion and the monitor panel itself, excluding the
liquid crystal portion.
To adjust the liquid crystal display (LCD) portion, press part (>) or
(<) of machine monitor mode selector switch 2 to switch to "LCD
PANEL ".
3 - 38
.

switch 1. The screen switches to the display shown on the right
and it becomes possible to adjust the brightness.
selector switch 2 to adjust the brightness between L and H (7
levels).
6. After selecting the desired brightness, press the () portion of
the machine monitor mode selector switch 1.
The brightness is set and the screen returns to the previous
screen.
7. After completing the operation, press the () portion of the
machine monitor mode selector switch 1 twice or turn the
3 - 39
.
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 to display "SELECT r/min" or "SELECT SPEEDOMETER".
When the meter and meter display pilot lamp are displaying the
travel speed (km/h, MPH), "SELECT r/min" is displayed; when
they are displaying the engine speed, "SELECT
SPEEDOMETER" is displayed.
3. If part (U) of machine monitor mode selector switch 1 is pressed when "SELECT r/min" is being displayed, the
"X100 r/min" portion of the meter display pilot lamp lights up and the meter display switches to the engine speed.
In addition, the display on the character display switches to "SELECT SPEEDOMETER".
If part (U) of machine monitor mode selector switch 1 is pressed when "SELECT SPEEDOMETER " is being
displayed, the "km/h" or " MPH" portion of the meter display pilot lamp lights up and the meter display switches
to the travel speed.
In addition, the display on the character display switches to "SELECT r/min".
CAUTION
In areas where traffic regulations require the travel speed to be displayed, this menu is not displayed and the meter cannot be
switched to display the engine speed.
3 - 40
.
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 "MPH ON → OFF".
To set to no display for the travel speed or engine speed on the
character display, display "rpm OFF → ON" or "MPH 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 - 41
.
SWITCHES
(1) Starting switch (13) Horn button

(2) Speed range selector switch (14) Lamp switch
(3) Variable shift control switch (14) Turn signal lever
(4) Quick coupler attachment switch (14) Dimmer switch
(if equipped) (15) Front working lamp switch
(5) Cooling fan auto reverse rotation switch (16) Rear working lamp switch
(6) Directional selector switch actuation switch (17) Hazard lamp switch
(7) Traction control switch (18) Rear wiper switch
(8) Max. traction switch (19) Directional selector switch
(9) Front wiper switch (20) Cigarette lighter
(10) Machine monitor mode selector switch 1 (21) Room lamp switch
(11) Machine monitor mode selector switch 2 (22) Rear heated wire glass switch
(12) E.C.S.S. switch (if equipped) (*)
(*)E.C.S.S.: Electronic Controlled Suspension System
3 - 42
.
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 to the charging circuit, lamp
circuit, and accessory circuit.
Keep the starting switch key at the ON position while the engine is
running.
(C): START position

Always turn the key to this position when starting the engine. Set the key to this position while cranking (initial
rotation of starting motor), and after starting the engine, put your hand off from the key immediately. The key will
return to ON position (B).
SPEED RANGE SELECTOR SWITCH

Use this switch (2) to switch the speed range.
Use 1st and 2nd for operations, and 3rd and 4th for travel.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
REMARK
When traveling in 3rd or 4th at high speed (travel speed: 8 km/h (4.97 MPH) or more), even if the speed range is
switched to 1st or 2nd, the engine overrun prevention function will act to prevent the speed range from shifting to
1st or 2nd.
If this happens, the centralized warning lamp lights up and the alarm buzzer sounds. At the same time, "OVERRUN
PREVENTION" is displayed on the bottom line of the character display.
There are the following ways to cancel the alarm buzzer.
Reduce the travel speed to less than 7 km/h (4.34 MPH). The speed range will shift to 1st or 2nd and the alarm
buzzer will be cancelled.
Return the speed range selector switch to 3rd or 4th.
3 - 43
.
VARIABLE SHIFT CONTROL DIAL

When the speed range is in 1st, it is possible to use this dial (3) to
set the maximum speed as desired.
Turn the dial to the right to increase the setting; turn it to the left to
decrease the setting.
The conditions for use may differ according to the condition of the road surface.
Installed tire Max. speed [km/h (MPH)]

Standard tire (17.5-25) 4.0 to 13.0 (2.5 to 8.1)
Large-diameter tire (20.5-25) 4.4 to 14.3 (2.7 to 8.9)
QUICK COUPLER ATTACHMENT SWITCH

(if equipped)
Use this switch (4) when installing or removing the attachment or
when connecting or releasing the attachment and coupler.
Position (a): Release

Push the switch in to this position, then pull lock (A) in
the direction of the arrow (c) and release the
connection.
Position (b): Connect
3 - 44
.
COOLING FAN AUTO REVERSE ROTATION SWITCH

This switch (5) is used to rotate the cooling fan in the reverse
direction when cleaning the radiator.
Position (a): Auto reverse rotation function ON
The fan automatically rotates in reverse for 2 minutes
every 2 hours.
The pilot lamp inside the switch and the cooling fan
reverse rotation pilot lamp on the machine monitor
light up.
Position (b): Manual reverse rotation switch ON
When the fan is rotating in the normal direction, if the
switch is pressed once for more than 0.5 seconds, the
fan will rotate in reverse; if the switch is pressed again
for more than 0.5 seconds, the fan will rotate in the
normal direction. When the fan is rotating in the
reverse direction, the cooling fan reverse rotation pilot
lamp on the machine monitor lights up. When the
switch is pressed, the fan will continue to rotate in the
reverse rotation for approx. 10 minutes. For details of
the procedure when cleaning, see "CLEAN
RADIATOR FINS AND COOLER FINS (PAGE
4-29)".
When operating the manual reverse rotation switch,
press position (b) of the switch for more than 0.5
seconds and check that the cooling fan reverse
rotation pilot lamp on the machine monitor flashes.
Position (c): Neutral (OFF)
The cooling fan is constantly set to normal rotation.
Run the engine at idling when operating the switch.
REMARK
When operating the manual reverse switch, hold the switch at position (b) for at least 0.5 seconds, then release
it.
When the fan rotation direction is switched, the reverse rotation pilot lamp flashes.
To protect the machine, the fan rotation direction may not change when the fan is operating under high load or
in low temperatures. (For details, see Conditions for switching fan rotation.)
When the engine is stopped, the fan rotation direction returns to the normal direction.
If the switch is set to position (b) (manual reverse rotation ON), the switch will return to position (c) (Neutral) when
the switch is released.
Even if position (b) of the switch is not kept pressed, the fan will rotate in the reverse direction for a fixed time,
so there is no need to keep the switch pressed at position (b).
During reverse rotation of the fan, if the engine cooling water, boost, or HST oil overheat (the oil temperature
caution lamp on the machine monitor lights up), the reverse rotation of the fan is forcibly stopped and the fan
switches to rotation in the normal direction.
It is possible to adjust the following of the automatic reverse rotation functions:
Cycle fan automatic reverse rotation (Standard: 2 hours)
Continuous time fan automatic reverse rotation (Standard: 2 minutes)
Please ask your Komatsu distributor to carry out the adjustment
3 - 45
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Conditions for switching fan rotation
When using manual reverse rotation function
Switching from normal rotation to reverse rotation

The fan will switch from normal rotation to reverse rotation only if all the following conditions are fulfilled.
If the direction is switched, the cooling fan reverse rotation pilot lamp on the machine monitor will change from
flashing and will stay lighted up.
If all the conditions are not fulfilled, the fan direction will not change.
If the direction is not switched, the cooling fan reverse rotation pilot lamp on the machine monitor will continue to
flash.
Conditions
Position (b) of the cooling fan auto reverse rotation switch is pressed once.
The engine speed is between Li and 1200 rpm.
(If the HST oil temperature is above 30°C (86°F), the engine speed condition does not apply.)
The engine water temperature is less than 102°C (215.6°F).
The HST oil temperature is below 100°C (212°F).
At least 30 seconds has passed since the engine was started.
Switching from reverse rotation to normal rotation

The fan will switch from reverse rotation to normal rotation if any of the following conditions are fulfilled.
If the direction is switched, the cooling fan reverse rotation pilot lamp on the machine monitor will change as follows:
Lighted up -> flashing -> OFF.
If none of the conditions are fulfilled, the fan direction will not change.
If the direction is not switched, the cooling fan reverse rotation pilot lamp on the machine monitor will change from
being lighted up to flashing and will continue to flash.
Conditions
If the HST oil temperature is above 20°C (68°F), the following engine speed conditions do not apply.
At least 10 minutes has passed since the fan switched to reverse rotation and the engine speed is less than 1200
rpm.
Position (a) of the cooling fan reverse rotation switch was pressed again during reverse rotation of the fan and
the engine speed is less than 1200 rpm.
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.
When using automatic reverse rotation function
Switching from normal rotation to reverse rotation

The fan will switch from normal rotation to reverse rotation only if all the following conditions are fulfilled.
If the direction is switched, the cooling fan reverse rotation pilot lamp on the machine monitor will change from
flashing and will stay lighted up.
If all the conditions are not fulfilled, the fan direction will not change.
OFF to flashing and will continue to flash.
Conditions
Position (a) of the cooling fan auto reverse rotation switch is pressed.
The engine water temperature is less than 102°C (215.6°F).
The HST oil temperature is above 13°C (55.4°F) and below 100°C (212°F).
The boost temperature is below 80°C (176°F).
At least 30 seconds has passed since the engine was started.
The specified time for switching has passed.
Switching from reverse rotation to normal rotation

The fan will switch from reverse rotation to normal rotation if both of the following conditions are fulfilled.
If the direction is switched, the cooling fan reverse rotation pilot lamp on the machine monitor will change as follows:
Lighted up -> flashing -> OFF.
If neither of the conditions are fulfilled, the fan direction will not change.
being lighted up to flashing and will continue to flash.
Conditions
A position other than position (a) of the cooling fan auto reverse rotation switch is pressed during reverse rotation
of the fan.
After completion of the time for continuous running of automatic fan reverse operation.
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH

When this switch (6) is turned ON, the function of the directional
selector switch is actuated.
Position (a): ON
The directional selector switch is actuated.
The directional selector pilot lamp on the machine
monitor lights up.
Position (b): OFF
The directional selector switch is turned off.
REMARK
Turn this switch ON when the directional lever and directional
selector switch are at the neutral position. At any other position,
this switch does not work.
Even if the directional selector switch is functioning, when the
directional lever is operated, the operation of the directional
lever is given priority.
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TRACTION CONTROL SWITCH

Use this switch (7) to actuate the traction control and make it possible to reduce the maximum traction.
Position (a): Traction control OFF (MAX)
The traction control is not actuated.
Position (b): Traction control ON
The traction control is actuated.
When the traction control is actuated, the traction
control operation pilot lamp on the machine monitor
lights up. It becomes possible to select the maximum
traction level on the machine monitor from A, B, and
C.
For details of the method of selecting the traction
level, see "METHOD OF SELECTING TRACTION
LEVEL (PAGE 3-31)".
Position (c): S mode
The S mode is actuated.
If the S mode is actuated, the S mode operation pilot lamp on the machine monitor lights up.
If the S mode is actuated, it becomes possible to select the most suitable drive power when operating
on extremely slippery roads, such as during snow-clearing operations, and this makes it possible to
reduce tire slip and carry out the operation easily. In addition, it also suppresses the sudden movement
when driving forward and allows the machine to move off smoothly.
REMARK
Using the traction control switch and traction level selector function makes it possible to carry out efficient operations
with reduced tire slip by selecting the most suitable maximum traction to match the job conditions.
If the traction is too great for the operating conditions:
It will become more difficult to raise the lift arm and tire slip will be more likely to occur. If tire slip becomes
common, the working efficiency will become poor and the life of the tires will also be reduced.
If the traction is too small for the operating conditions:
It will become impossible to thrust the bucket in sufficiently into the materials being loaded, and the working
efficiency will become poor.
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MAX. TRACTION SWITCH

Use this switch (8) to cancel the traction control or S mode.
Use the traction control switch to select traction control ON or S
mode.
When the traction control ON or S mode selection is active, if
switch (8) pressed, the traction control or S mode is cancelled and
the maximum traction becomes larger. At the same time, the
traction control operation pilot lamp or S mode operation pilot lamp
on the machine monitor goes out.
To return to the traction control ON or S mode status, press switch
(8) again or change the position of the directional lever.
REMARK
Use this function for scooping-up operations or other operations
where the maximum traction is desired.
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FRONT WIPER SWITCH

When rotary switch (E) of this switch (9) 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
MACHINE MONITOR MODE SELECTOR SWITCH 1

This switch (10) is used to switch the function of the character
display.
When the switch is released, it automatically returns to its original
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 (11) is used to switch the function of the character
display.
When the switch is released, it automatically returns to its original
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
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E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) SWITCH

(if equipped)
WARNING
If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned ON, the work equipment
will move.
If operations are carried out with the E.C.S.S. switch at the ON position, the moment the E.C.S.S. is actuated, the work
equipment may move.
Never turn the E.C.S.S. switch ON during inspection or maintenance. The work equipment will move and this will create a
dangerous situation.
NOTICE
Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S. switch.
When carrying out inspection and maintenance, first lower the work equipment to the ground, then turn the E.C.S.S. switch OFF
before starting the inspection and maintenance operation.
When carrying out leveling work, turn the E.C.S.S. switch OFF.
The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb the vibration of the chassis
during travel, allowing the machine to travel smoothly at high speeds.
This switch (12) is used to turn the E.C.S.S. ON and OFF.

Position (a): ON
The pilot lamp (A) lights up and the E.C.S.S. is
actuated.
Position (b): OFF
The E.C.S.S. is not actuated.
REMARK
If the travel speed goes above 5 km/h (3.1 MPH), the E.C.S.S. is automatically actuated; when the travel speed goes
below 4 km/h (2.5 MPH), the travel damper is automatically turned off (when 17.5-25 tires are used).
If you want to adjust the travel speed for actuation and non-actuation, please consult your Komatsu distributor.
HORN BUTTON
When the horn button (13) in the center of the steering wheel is
pressed, the horn will sound.
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LAMP SWITCH
CAUTION
When the front lamps are lit, the surface of the front lamp is at high temperature. Always turn the lamp switch OFF before washing
the lamp.
This switch (14) is used to light up the front lamps, side clearance
lamps, tail lamps, and machine monitor.
Position (a): OFF
Position (b): Side clearance lamps, tail lamps, and machine
monitor 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 (14) 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.
DIMMER SWITCH
This switch (14) is used to switch the head lamps between high
beam and low beam.
Position (L): Low beam
Position (H): High beam
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FRONT WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
This switch (15) is used to light up the front working lamp.

Position (a): Working lamp and pilot lamp (A) light up
Position (b): Working lamp goes out
REAR WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
This switch (16) is used to light up the rear working lamp.

Position (a): Working lamp and pilot lamp (A) light up
Position (b): Working lamp goes out
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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 (17) is used in emergencies, such as when the

machine breaks down and has to be parked on the road.
Position (a): Direction indicator lamp and directional indicator pilot

lamp flash, and pilot lamp (A) lights up at the same
time
Position (b): Lamps go out
REAR WIPER SWITCH

When lever (E) of this switch (18) 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
DIRECTIONAL SELECTOR SWITCH

This switch (19) is used to switch the direction of travel of the
machine between forward and reverse.
F Position: FORWARD
N Position: Neutral
R Position: REVERSE
Before operating this switch, check that the condition is as follows.
Directional lever is at N
Directional selector switch actuation switch is at ON
If the condition is not as above, the switch will not work.
For details, see "CHANGING DIRECTION (PAGE 3-117)".
3 - 54
.
CIGARETTE LIGHTER
This is used to light cigarettes.
After cigarette lighter (20) is pushed in, it will return to its original
position after a few seconds, then you may pull it out and light a
cigarette.
ROOM LAMP SWITCH

This switch (21) 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).
REAR HEATED WIRE GLASS SWITCH

When this switch (22) is pressed, electric current flows through the
heated wire glass at the rear and the mist is removed from the
glass.
Position (a): ON (removes mist from glass)
Pilot lamp (A) also lights up.
Position (b): OFF
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CONTROL LEVERS, PEDALS
(1) Directional lever (4) Accelerator pedal

(2) Work equipment control lever (5) Brake pedal
(3) Work equipment lock lever (6) Parking brake lever
DIRECTIONAL LEVER
This lever (1) 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 N position,
the engine will not start.
Position (a): FORWARD
Position N: NEUTRAL
Position (b): REVERSE
REMARK
When the starting switch is turned to the ON position, if the
directional lever is not at the N position, the centralized warning
lamp lights up and the alarm buzzer sounds intermittently.
When the directional lever is set to the N position, the centralized
warning lamp goes out and the alarm buzzer stops.
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WORK EQUIPMENT CONTROL LEVER

Use this lever (2) to operate the lift arm and bucket.
NOTICE
Do not use FLOAT position when lowering the bucket. Use FLOAT position
when leveling, see "LEVELING OPERATIONS (PAGE 3-127)".
Position (a): RAISE

When the work equipment control lever is pulled
further beyond 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 and bucket stop and remain in the same
position.
Position (c): LOWER
Position (d): FLOAT
The lift arm moves freely under external force.
Position (e): TILT

further beyond 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 (f): DUMP
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WORK EQUIPMENT LOCK LEVER
WARNING
Before leaving the operator's seat, set the work equipment lock lever securely to LOCK position. If the work equipment lock
lever is not at LOCK position, and work equipment control lever is touched by mistake, it may lead to a serious accident.
If the work equipment lock lever is not placed securely at LOCK position, the work equipment control lever may move, and this
may lead to a serious accident or personal injury. Check that the lever is in LOCK position.
When operating the work equipment lock lever, check that the work equipment control lever is held securely at HOLD position.
When pulling up or pushing down the work equipment lock lever, be careful not to touch work equipment control lever.
This lever (3) is a lock device for the work equipment control lever.
Push the work equipment lock lever down to lock it.
REMARK
If the work equipment lock lever is at the LOCK position, the work
equipment will not move even when the work equipment control
lever is operated.
ACCELERATOR PEDAL
This pedal (4) controls the engine speed and output.
The engine speed can be freely controlled between low idle and
high idle.
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BRAKE PEDAL
WARNING
When traveling downhill, always use the right brake pedal, and use the braking force of the engine together with the brake.
Do not use the brake pedal excessively. If the brake is used too frequently, the brake will overheat. If this happens, the brakes
will not work and may lead to a serious accident.
Do not put your foot on the brake pedal unless necessary.
These pedals (5) operate the brakes.

Use the brake pedal for normal braking operations.
The left and right pedals are interconnected and work together.
Inching function
When the brake pedal is depressed slightly, the HST inching
function is actuated and it becomes possible to reduce speed or
stop the machine without reducing the engine speed.
Use the inching function when raising the lift arm and
approaching the dump truck.
REMARK
When using the brake pedal and accelerator pedal together (applying the brake and easing the accelerator) to
reduce the travel speed or stop the machine, it is more convenient to use the left brake pedal.
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PARKING BRAKE LEVER
WARNING
Always apply the parking brake when leaving the machine or when parking it.
NOTICE
Never use the parking brake lever to slow the machine 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 (near the maximum speed), contact
your Komatsu distributor to have the parking brake checked for any abnormality.
This lever (6) operates the parking brake.

Pull the lever up to the LOCK position to actuate the parking brake.
At the same time, the parking brake pilot lamp will light up.
To release the brake, pull the lever, then press button (A) at the tip
of the lever and return the lever to the FREE position. At the same
time, the parking brake pilot lamp will go out.
REMARK
If the directional lever is placed at the FORWARD or REVERSE
position with the parking brake still applied, the centralized
warning lamp will light up and the buzzer will sound.
Before operating the directional lever, check that the parking brake
lever is at the FREE position.
When the parking brake is applied, the machine will not move even
if the directional lever is operated.
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STEERING TILT LOCK LEVER

WARNING
Stop the machine 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 allows the steering column to be tilted forward or

backward.
The amount of adjustment is 8° to the front and 10° to the rear
(stepless) from the neutral position.
1. Set the lever (1) to FREE position (a).
2. Set the steering wheel (2) to the desired position, then set lever
(1) to LOCK position (b).
CAP AND COVER WITH LOCK

Use the starting key to open and close the locks on the caps and
covers.
For details of the locations of the caps and covers with locks, see
"LOCKING (PAGE 3-137)".
Insert the key as far as it will go to the shoulder (A). If the key is
turned before it is inserted all the way, it may break.
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.
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METHOD OF OPENING AND CLOSING COVER WITH LOCK
TO OPEN THE COVER

1. Insert the key into the key slot.
2. Turn the key counterclockwise and open the cover by pulling
the cover grip.
(A): OPEN
(B): LOCK
TO LOCK THE COVER

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and take the key out.
FRAME LOCK BAR

WARNING
When carrying out maintenance or transporting the machine, always set the frame lock bar to 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.
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TOWING PIN
1. Align protrusion (1) in the towing pin with groove (2) in the
counterweight, then insert the pin and turn it 180°.
2. To prevent the towing pin from turning, fold the handle of the
towing pin and set it in position.
Reverse this operation to remove the pin.
GREASE PUMP
Open the top cover (1) at the front of the engine hood. The grease
pump is stored in storage box (2).
After using, wipe off all the grease stuck to the pump, set the pump
in storage box (2), then fit band (3) to prevent the box from moving.
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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.
CAB SLIDING WINDOW LOCK RELEASE KNOB

(LEFT, RIGHT)
Use this knob when you want to move the glass in the window of
the 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).
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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 cab.
1. Lift open lock knob (1) up.
3 - 66
.
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.
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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.
Remove cover (1). The fuse boxes are (A) and (B).
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.
FUSE CAPACITY AND NAME OF CIRCUIT
FUSE BOX A
(C): Front of machine
No. Fuse capacity Name of circuit

(1) 10A Radio
(2) 20A Wiper
(3) 10A Boom
(4) 15A HST control
(5) 10A Reverse lamp, brake lamp
(6) 10A Turn signal lamp
(7) 10A Head lamp, right
(8) 10A Head lamp, left
(9) 10A Auxiliary power source
(10) 10A Radio
(11) 10A Monitor
(12) 30A Engine cut
(13) 15A HST control
(14) 10A Hazard lamp
(15) 20A Starting switch
FUSE BOX B
(C): Front of machine
No. Fuse capacity Name of circuit

(1) 5A Engine control
(2) 10A Monitor accessory
(3) 10A Rear working lamp
(4) 10A Front working lamp
(5) 10A Clearance lamp, right
(6) 10A Clearance lamp, left
(7) 10A Horn
(8) 10A Parking brake
(9) 10A DC converter
(10) 20A Auxiliary power source KEY ON 24V
(11) 10A Load meter
(12) 20A Heated wire glass
(13) 20A Rotating lamp
(14) 5A Air conditioner compressor
(15) 20A Air conditioner blower
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SLOW BLOW FUSE

If the power does not come on when the starting switch is turned to
the ON position, there is probably a disconnection in the slow blow
fuse, so inspect and replace it.
The slow blow fuse is on the left side of the machine at the side of
the engine.
1. Open the cover (1).
2. Open the cover of slow blow fuse box (2) and inspect.
For details of the method of replacing the slow blow fuse, see
Section "REPLACE SLOW BLOW FUSE (PAGE 4-39)".
SLOW BLOW FUSE

(A) 80A: Chassis power source
(B) 120A: Engine preheating power source
(C) 50A: Battery power source (starting switch, hazard)
3 - 70
.
POWER OUTLET
NOTICE
There are 2 power sources: 12 V and 24 V
Check the voltage of the electrical equipment and select the appropriate power source.
Mistaken use, such as using 24 V as the power source for 12 V equipment, will cause failure of the equipment.
When using the electric power source, do not install 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: 3.5A (84W)
Electric power source (2) can be used as a 12V power source.

Maximum amperage: 5A (60W)
STORAGE BOX
This is under the operator's seat.
Use this box to keep small items and tools.
REMARK
The storage box is not waterproof. When washing the floor,
remove all documents and other items that may be damaged by
water, and keep them in a waterproof bag.
3 - 71
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AM/FM RADIO-CASSETTE STEREO

(if equipped)
(1) Power switch/volume (8) Cassette door

(2) Auto-store/preset scan button (9) Fast forward, rewind buttons
(3) Bass control knob (10) Preset buttons
(4) Treble control knob (11) Metal tape button
(5) Loudness button (12) Manual tuning buttons
(6) Time/radio display selector button (13) Seek tuning buttons
(7) Tape eject button (14) Band selector button
(A) Band display (E) Tape direction display

(B) Metal tape display (F) Preset channel display
(C) FM stereo reception display (G) Time/frequency display
(D) Loudness display
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POWER SWITCH/VOLUME
Turn this knob (1) to the right until it clicks to turn the power on.
Turn it further to increase the volume.
AUTO-STORE/PRESET SCAN BUTTON

Use this button (2) to actuate the preset scan and auto-store
functions.
Auto-store
Each time this button is pressed for more than 2 seconds while
in radio reception, this auto-store function automatically starts to
search for the desired station within a receivable band, and
memorize the frequency in the preset memory. During this
scanning process, the frequency shown in the right side of
display continues to change. This indicates that each frequency
is memorized in the auto-store.
REMARK
The auto-store function cannot be used when the channel display
is flashing.
When the display is flashing, the preset scan function is being
used.
Preset scan
If this button is pressed for less than 0.5 seconds while in radio reception, programs from the 6 preset stations
in the same band will be broadcast 1 after another for 5 seconds each, starting from No. 1 through No. 6 stations
consecutively.
When the desired station is found, press the button again. This stops the preset scan tuning process and switches
to ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.
BASS CONTROL KNOB

Turn this button (3) to the left to reduce the low tones; turn it to the
right to emphasize the low tones.
Direction (a): Low tone reduced
Direction (b): Low tone emphasized
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TREBLE CONTROL KNOB

Turn this button (4) to the left to reduce the low tones; turn it to the
right to emphasize the high tones.
Direction (a): High tone reduced
Direction (b): High tone emphasized
LOUDNESS BUTTON
This button (5) is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when the
low tones are weak.
Push button: Actuated (ON)
Push button again: Canceled (OFF)
TIME/RADIO DISPLAY SELECTOR BUTTON

This button (6) is used to switch between "Radio/tape display" and
"Time display".
Correcting the time

Press the button to set the time display.
(A) Correcting hour:
Keep DISP button pressed and press the bottom (H) of
TUNING button to correct the hour.
(B) Correcting minute:
Keep DISP button pressed and press the top (M) of TUNING
button to correct the minute.
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TAPE EJECT BUTTON

This button (7) is used to stop the tape and to eject the cassette.
When this button is pressed, the tape is ejected and the radio
plays.
CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right
side and insert it through the cassette door (8).
FAST-FORWARD, REWIND BUTTONS

These buttons (9) are used to fast-forward or rewind the tape.
Fast-forward/rewind
If you press the button pointing in the same direction as the lit
arrow indicating the direction of play, the tape will be
fast-forwarded; if you press the button pointing in the opposite
direction, the tape will rewind.
To stop the tape, lightly press the button that is not locked. The
fast-forward or rewind operation will be canceled.
If the fast-forward and rewind buttons are pressed at the same
time, the tape will change sides.
PRESET BUTTONS
These buttons (10) are used to call up the broadcast station
frequencies preset in memory for each of buttons No. 1 to No. 6.
It is possible to preset 18 stations (FM: 12; AM: 6) with these
buttons.
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METAL TAPE BUTTON

(used also for preset button No. 5)
This button (11) is used when playing a metal or chrome tape. This
button is also used for preset button No. 5. When it is pressed,
"MTL" appears on the display.
MANUAL TUNING BUTTONS

These buttons (12) are used for manual tuning.
When "TUN ∧" button is pressed, the frequency goes up; when
"TUN ∨" button is pressed, the frequency goes down. If the button
is pressed down and held, the frequency will change continuously.
SEEK TUNING BUTTONS

These buttons (13) are used to seek tuning.
When "SEEK UP" button is pressed, the search automatically
goes up; when "SEEK DN" button is pressed, the search
automatically goes down.
When the next station that can be received is found, it
automatically stops.
BAND SELECTOR BUTTON

When this button (14) is pressed, the band is switched between
FM1, FM2, and MW (AM). The band is shown on the display.
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METHOD OF OPERATION
METHOD OF SETTING PRESET BUTTONS

It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations).
REMARK
If you are playing the cassette, press the tape eject button to stop the tape.
METHOD OF AUTO PRESET

1. Use band selector button (1) to select MW (AM), FM1 or FM2.
2. Press auto-store/preset scan button (2) for less than 0.5
seconds.
3. The preset scan tuning function automatically searches for the
desired station within the same band and can memorize as
many as 6 stations in the preset memory.
METHOD OF MANUAL PRESET

2. Press manual tuning buttons (2) or seek tuning buttons (3).
3. Press preset button (4) of the number to be preset for 2
seconds while the frequency display is being shown on the
display. (The preset channel and frequency are displayed and
the presetting is completed).
4. Repeat the steps explained in Item 2 and 3 above to preset
other stations to the subsequent numbers.
5. If you want to preset a station in the other bands, follow the
steps explained in Item 1 through 4 above.
REMARK
Also, use Steps 2 and 3 when changing the setting of a preset
switch to another station.
When the power is disconnected, such as when the battery is
replaced, all the settings are deleted, so preset the stations
again.
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LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch (1) ON.
3. Select the station with the preset buttons (3).
REMARK
In case you do not promptly remember the number assigned to a
certain preset station, press auto-store/preset scan button (4) for
less than 0.5 seconds. The preset 6 stations will broadcast one
after another for 5 seconds each. When the desired station
broadcasts, press the button again and scan tuning stops.
4. If you want to tune in to a station that is not preset, use either

seek tuning button (5) or manual tuning button (6).
5. Adjust the volume, balance, and tone as desired.
6. When turning the radio OFF, turn power switch (1) to the left
until it clicks.
REMARK
To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape.
If you insert a cassette when listening to the radio, the tape will start to play.
LISTENING TO CASSETTE TAPE

1. Turn the starting switch ON, then turn power switch (1) ON.
2. Set the cassette with the exposed portion of the tape on the
right side and push it past the cassette door. The tape will
automatically start playing.
If the arrow indicating the direction of play is pointing to the
right, the top side is being played; if the arrow is pointing to the
left, the bottom side is being played.
When the tape reaches the end, it is automatically reversed
and the other side starts to play.
3. When finished with the tape, press the cassette eject button to
eject the tape and automatically switch to the radio.
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REVERSING TAPE
When listening to the tape, press both FAST FORWARD,
REWIND buttons (A) and (B) at the same time lightly.
When this is done, the tape direction display will be reversed.
PRECAUTIONS WHEN USING

WARNING
If a voltage greater than the specified voltage is input, it may cause fire, electrocution, or other failure. Never input any voltage
other than the specified voltage.
Places inside the radio are under high voltage. Do not remove the cover.
Do not perform any modifications. This may cause fire, electrocution, or other failure.
If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your
Komatsu distributor to make repairs without delay.
Stow the antenna when traveling in places with low overhead clearance.
To ensure safety, adjust the sound to a level where it is possible to hear outside sounds during operation.
If water gets inside the speaker case or radio (auto tuning), it may cause a serious problem, take care not to let
water get in these items.
Do not wipe the scales or buttons with solvent such as benzene or thinner. Wipe with a dry soft cloth. If the dirt
cannot be removed easily, soak the cloth with alcohol.
NOTICE
Handling cassette tape
Clean the tape head approximately once a month with a commercially available head cleaning tape.
Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place where
there is a magnetic field.
Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the machine.
If the tape is slack, it easily gets caught up inside the machine. Use a pencil to wind in the tape to remove any slack.
Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to get
the tape out of the machine.
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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
(A) Face vent (C) Defroster vent

(B) Foot vent
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.
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.)
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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"
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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 FRESH/RECIRC 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 FRESH/RECIRC 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 FRESH/RECIRC 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.
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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 4-37)".
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.
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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 combustible 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, perform
repairs.
5. Check for oil leakage from HST piping, transfer case, axle, hydraulic tank, hoses and 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,
4.34 to 7.23 lbft}
Tightening torque for portion B: 11.8 to 19.6 Nm {1.2 to 2.0
kgm, 8.68 to 14.5 lbft}
12. Check for damage to the seat belt and mounting clamps.
WARNING
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.
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.
3 - 89
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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 figure 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.
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.
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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 ON position (B).
2. Check that all the monitors, gauges, and the centralized

warning lamp is lit for approximately 2 seconds, and that the
alarm buzzer sounds for approximately 2 seconds.
If the lamps do not light up, there is probably a failure or
disconnection. Contact your Komatsu distributor for
inspection.
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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 top cover (1) at the front of the engine hood.
2. Check that the coolant level is between the FULL and LOW
marks on radiator sub-tank (2). If the coolant level is low, add
coolant through the coolant filler of sub-tank (2) to the FULL
level.
3. After adding coolant, tighten the cap securely.
NOTICE
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 4-21)", 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.
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.
OPERATION OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they
have cooled down before starting the work.
1. Open the engine side cover on the right side of the machine.
2. Take out dipstick (G) and wipe off the oil with cloth.
3. Fully insert dipstick (G) into dipstick pipe, then remove it.
4. The oil level should be between H and L marks on dipstick (G).
If the oil level is below L mark, add oil through oil filler port (F).
5. If the oil is above the H line, open drain valve (P), drain the
excess engine oil, then 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.
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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 transparent 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 transparent
cup.
Do not bring fire close.
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 cup (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, 0.14 to
0.36 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.
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 cup (3) is dirty and the contents cannot be easily seen, clean transparent cup (3) when
replacing the filter.
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.
OPERATION OPERATION
When washing, if plug (2) is removed, coat the O-ring with grease, then tighten by hand until it contacts
the bottom.
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 eyeglasses, dust mask, and other protective equipment.
2. If the yellow piston in the display portion of dust indicator (1)
enters the red position (7.5 kPa), clean the element.
For details of the method of cleaning the element, see
"CLEANING OUTER ELEMENT (PAGE 4-18)".
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
"REPLACING ELEMENT (PAGE 4-20)".
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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 4-63)".
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. If the fuel level is low, open rear grill (1) and add fuel through
the filler port (F) to fill the tank.
For details of the method for opening and closing the cap, see
"METHOD OF OPENING AND CLOSING CAP WITH LOCK
(PAGE 3-61)".
3. After adding fuel, tighten the cap securely.
Fuel tank capacity: 177 liters (46.76 US gal)
3 - 96
.
OPERATION OPERATION
CHECK ELECTRIC WIRING
CAUTION
If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu
distributor to locate the cause and make the repair.
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 clear 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 3-138)" 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, 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
Failures may occur at interval shorter than the periodical replacement interval of "2 years or 4000 hours".
Operate the horn switch and check that the horn sounds normally, or its sound quality is normal.
If there is any abnormality, ask your Komatsu distributor for the inspection and repair.
CHECK DEFROSTER FUNCTION

Operate the air conditioner and check that the air blows out properly onto the front glass.
If there is any abnormality, ask your Komatsu distributor to carry out inspection and repair.
Operate the rear heated wire glass switch and check that the rear glass surface is heated properly.
If there is any abnormality, ask your Komatsu distributor to carry out inspection and repair.
CHECK LOCKS
Check that all places can be locked properly.
(For details of the locations that can be locked, see "LOCKING (PAGE 3-137)".)
If any abnormality is found, ask your Komatsu distributor to carry out inspection and repair.
3 - 97
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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.
3 - 98
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OPERATION OPERATION
ADJUSTMENT
SEAT ADJUSTMENT
WARNING
When adjusting the position of the operator's seat, always set the work equipment lock lever to 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.
AIR SUSPENSION SEAT

(A) Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then release
the lever.
Fore-and-aft adjustment: 120 mm (4.7 in)
(B) Adjusting seat angle

Move lever (2) up and push down on the rear of the seat to tilt it
backward.
Move lever (2) down and push down on the front of the seat to tilt
it forward.
Adjustment range: 13 degrees (Tilt forward/tilt back angle)
(C) Adjusting height of seat

Move lever (2) up or down to move the seat up or down. This lever
is also used to adjust the seat angle. Adjust the seat angle and
height.
Amount of adjustment: 50 mm (2.0 in)
(D) Setting seat for weight

Knob (3) controls the air suspension system's air valve. Push or
pull the knob to adjust the suspension's strength and compensate
for operator weight and/or preference.
(E) Adjusting reclining angle

Move lever (4) up and move the backrest to the front or rear.
Adjustment range: Front 24 degrees , Rear 3 degrees
(F) Lumbar support

Turn grip (5) to adjust the tension applied to the lower back.
3 - 99
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OPERATION OPERATION
(G) Adjusting headrest height

Move the headrest (6) up or down.
(H) Adjusting headrest angle

Rotate the headrest (6) to the front or rear.
Adjustment range: 60 degrees
(I) Adjusting armrest angle

Armrest (7) can be operated by hand to spring up approx. 90
degrees (both left and right).
In addition, dial (8) under the armrest can be operated by hand to
make fine adjustments of the armrest in the up or down direction
(left side only).
Adjustment range: forward tilt 25 degrees, backward tilt 5 degrees
3 - 100
.
OPERATION OPERATION
MECHANICAL SUSPENSION SEAT

(if equipped)
(A) Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then release
the lever.
Fore-and-aft adjustment: 120 mm (4.7 in)
(B) Adjusting seat angle

Move lever (2) up and push down on the rear of the seat to tilt it
backward.
Move lever (2) down and push down on the front of the seat to tilt
it forward.
Adjustment range: 13 degrees (Tilt forward/tilt back angle)
(C) Adjusting height of seat

Move lever (2) up or down to move the seat up or down. This lever
is also used to adjust the seat angle. Adjust the seat angle and
height.
(D) Setting seat for weight

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

Move lever (4) up and move the backrest to the front or rear.
Adjustment range: Front 24 degrees , Rear 3 degrees
(F) Lumbar support

Turn grip (5) to adjust the tension applied to the lower back.
(G) Adjusting headrest height

Move the headrest (6) up or down.
(H) Adjusting headrest angle

Rotate the headrest (6) to the front or rear.
Adjustment range: 60 degrees
(I) Adjusting armrest angle

Armrest (7) can be operated by hand to spring up approx. 90
degrees (both left and right).
In addition, dial (8) under the armrest can be operated by hand to
make fine adjustments of the armrest in the up or down direction
(left side only).
Adjustment range: forward tilt 25 degrees, backward tilt 5 degrees
3 - 101
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OPERATION OPERATION
ADJUST SEAT BELT

Always wear the seat belt.
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 sooner.
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.
FASTENING AND REMOVING BELT

Fastening seat belt
Hold grip (2) and pull the belt out from wind-in device (1), check that
the belt is not twisted, then insert tongue (3) into buckle (4)
securely.
When doing this, pull the belt lightly to check that it is properly
locked.
Removing belt
Press button (5) in buckle (4), and remove tongue (3) from buckle
(4).
The belt is automatically wound in, so hold grip (2) and return the
belt slowly to wind-in device (1).
ADJUST LEVER STAND
ADJUST HEIGHT OF WRIST REST

Loosen lock lever (2) and adjust the height of wrist rest (1).
REMARK
Keep button (3) pressed and operate lock lever (2) to the FREE
position. The lever can be turned in the desired direction.
3 - 102
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OPERATION OPERATION
ADJUST REAR VIEW MIRROR
WARNING
When adjusting the angle of the mirror, prepare a scaffold first in order to provide a safe working platform.
If you try to work standing on the counterweight, there is always a danger of serious injury or death due to falling off from the
machine.
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 machine.
Mirrors C
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.
Install the mirrors at the position and dimensions shown in the

figure. 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 2.5Nm (0.2 to 0.25 kgm, 1.45 to 1.81 lbft)
Mirrors C :8.8 to 12.7Nm (0.9 to 1.3 kgm, 6.51 to 9.4 lbft)
If the tightening torque cannot be controlled, ask your Komatsu

distributor for tightening the bolts.
3 - 103
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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 lever (1) is at the LOCK position.
2. Check that directional lever (2) is at N position.
REMARK
If directional lever (2) is not set to the N position, the engine will
not start.
When directional selector switch actuation switch (3) is ON, the
engine will not start if directional lever (2) and directional
selector switch (4) are not both at the N position.
3 - 104
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OPERATION OPERATION
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.
4. Check that work equipment lock lever (5) is at the LOCK
position.
5. Insert the key in starting switch (6), turn the key to the ON
position (B), and check that the machine monitor system
works.
When the starting switch is turned to ON position before

starting the engine, monitors, gauges, and centralized warning
lamp light up for approximately 2 seconds, and the alarm
buzzer sounds for approximately 2 seconds.
If any machine monitor does not light up, there is probably a
failure or disconnection. Contact your Komatsu distributor for
inspection.
3 - 105
.
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 injury, death 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 lit depends on the
Ambient temperature Lighting time
ambient temperature as shown in the table on the right.
(°C (°F)) (sec.)
Above -4
0
(Above 24.8)
-4 to -15
5 to 30
(24.8 to 5)
Below -15
30
(Below 5)
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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).
3 - 107
.
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 injury, death 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 (-4°
F), 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 lit depends on the
Ambient temperature Lighting time
ambient temperature as shown in the table on the right.
(°C (°F)) (sec.)
Above -4
0
(Above 24.8)
-4 to -15
5 to 30
(24.8 to 5)
Below -15
30
(Below 5)
3 - 108
.
OPERATION OPERATION
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 start.
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 approximately 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 40 °C (104 °F), the automatic warming-up
operation (engine speed:1000 rpm or 900 rpm, depending on the engine water temperature) is carried out, and is
cancelled when the engine water temperature goes above 50 °C (122 °F). (Engine speed: 825 rpm)
It is also cancelled when the directional lever is operated to the FORWARD or REVERSE position.
(X) :Engine speed (rpm)

(Y) :Water temperature (°C)
3 - 109
.
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, 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, 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 at idle 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 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, contact your Komatsu distributor for inspection and repair.
3 - 110
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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.
NOTICE
When the hydraulic oil temperature is low, do not operate under heavy load or at high speed. There is danger that the pump may
break.
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.
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OPERATION OPERATION
NORMAL OPERATION
After the engine starts, do not start operating the machine immediately. 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 approximately 5 minutes.
To warm up the hydraulic oil in cold areas, do as follows.

2. After completing the warming-up operation, check that the
engine rotation is smooth, then check that the work equipment
control lever is at the HOLD position and set work equipment
lock lever (2) to the FREE position.
3. Operate work equipment control lever (3) to TILT position (e)

and return it to HOLD position (b) to warm up the hydraulic oil.
The relief time at the tilt position (e) should be a maximum of 10
seconds.
With this operation, the oil will reach the relief pressure and this
will warm up the hydraulic oil more quickly.
3 - 112
.
OPERATION OPERATION
4. Slowly operate the steering wheel to the left and the right approximately 10 times to warm up the hydraulic oil
inside the steering valve.
WARNING
If the steering wheel is operated and stopped while the oil temperature is
low, there may be a time lag before the machine stops turning.
In this case, use the frame lock bar to ensure safety, and perform the
warm-up operation in a wide place.
Do not relieve the hydraulic oil in the circuit 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 pilot lamps are normal.
If there is any abnormality, carry out maintenance or repair.
Run the engine under a light load until engine coolant
temperature gauge (4) and HST oil temperature gauge (5) are
in the white range.
6. Check for abnormal exhaust gas color, noise, or vibration. If
any problem is found, contact your Komatsu distributor.
3 - 113
.
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 apart
from 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 (MIN) for approximately 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).
3 - 114
.
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, 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 particular attention to the blind spot at the rear of the machine when traveling in reverse.
MOVING THE MACHINE

1. Check that caution lamp (1) is not lit.
2. Check that the work equipment control lever (3) is at the HOLD
position, then set work equipment lock lever (2) to the FREE
position.
3 - 115
.
OPERATION OPERATION
3. Operate work equipment control lever (3) to set the work

equipment to the travel posture shown in the figure on the right.
(A): 40 to 50 cm (16 to 20 in)
4. Depress brake pedal (4) and turn parking brake lever (5) to the
FREE position to release the parking brake.
Keep brake pedal (4) depressed.
5. Set speed range selector switch (6) to the desired position.

Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
6. Set directional lever (7) to the desired position.

Position N: NEUTRAL
Check that the backup alarm sounds when the directional

lever is set to REVERSE. If the backup alarm does not
sound, contact your Komatsu distributor for repairs.
7. Release brake pedal (4), then depress accelerator pedal (8) to

move the machine.
3 - 116
.
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: 13 km/h (8.1 MPH))
There is no need to stop the machine even when switching

between FORWARD and REVERSE.
Place directional lever (1) in the desired position.
Position N: NEUTRAL
Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not
sound, 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.
If an attempt is made to switch the direction between FORWARD

and REVERSE while traveling at high speed, if the travel speed
and engine speed are in the hatched range shown in the figure, the
centralized warning lamp will light up and the alarm buzzer will
sound.
At the same time, "OVERRUN PROTECT" is displayed on the
If the alarm buzzer sounds, return the directional lever immediately
to its original position, depress the brake pedal to reduce speed,
then operate the directional lever to switch between FORWARD
and REVERSE.
(X): Travel speed (km/h)
(Y): Engine speed (rpm)
3 - 117
.
OPERATION OPERATION
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE
WARNING
When the directional selector switch actuation switch (3) is at the ON
position, if the directional lever (1) is operated to FORWARD or REVERSE,
the machine will travel in forward or reverse according to the operation of
the directional lever, regardless of the position of the directional selector
switch (2).
Priority is given to the operation of the directional lever, so be careful when
operating.
1. Place the directional lever (1) at the N position.
2. Place the directional selector switch (2) at the N position.
3. Place the directional selector switch actuation switch (3) at the

ON position (a).
3 - 118
.
OPERATION OPERATION
4. Place the directional selector switch (2) at the F (forward) or R

(reverse) position.
REMARK
When the directional selector switch actuation switch (3) is at the ON position, if the directional lever (1) is operated
to FORWARD or REVERSE, the machine will travel in forward or reverse according to the operation of the
directional lever, regardless of the position of the directional selector switch (2).
Priority is given to the operation of the directional lever.
When using directional selector switch (2) again, set directional lever (1) and directional selector switch (2) to the
N position.
If the directional selector pilot lamp on the machine monitor

flashes, the switch or the lever is in one of the following conditions.
Set it to the correct position.
When directional lever is not at N position
If the directional lever is not at the N position, the pilot lamp
flashes, and at the same time, the central warning lamp lights up
and the alarm buzzer sounds.
In this condition, the machine will move forward or in reverse
according to the set position of the directional lever.
Return the directional lever to the N position.
When directional selector switch is at F or R when engine is
started
If the directional selector switch is at F or R, the pilot lamp
flashes, and at the same time, the central warning lamp lights up
and the alarm buzzer sounds.
In this condition, the engine will not start, so set the directional
selector switch to N.
3 - 119
.
OPERATION OPERATION
STOPPING THE MACHINE

WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Even if the parking brake lever is pulled and set to the LOCK position,
there is a danger of the machine moving until the parking brake pilot
lamp lights up, so keep the brake pedal depressed.
NOTICE
Never use the parking brake lever to slow 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) and directional selector switch (5) in

N (neutral) position.
3. Pull parking brake lever (4) and set it to the LOCK position to
apply the parking brake.
3 - 120
.
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 steering becomes heavy, so never stop the engine while traveling.
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.
3 - 121
.
OPERATION OPERATION
EMERGENCY STEERING
(if equipped)
CAUTION
Never actuate the emergency steering except during emergencies.
When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH).
Emergency steering pilot lamp (green) (2) lights up to inform the

operator that the emergency steering system is normal.
The emergency steering system is provided to enable the machine

to be steered under the following conditions.
Traveling when there is a failure in the steering system
Coasting with the engine stopped
REMARK
The emergency steering does not work when the machine is
stopped.
When the emergency steering system detects lack of oil pressure in the steering system, steering oil pressure
caution lamp (red) (3) and centralized warning lamp (4) light up, and the alarm buzzer sounds intermittently.
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.
When the emergency steering system detects that the oil pressure in the steering circuit has been restored, the
actuation of the emergency steering system is stopped.
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OPERATION OPERATION
OPERATION OF WORK EQUIPMENT

WARNING
Never raise the boom with the bucket fully loaded when the machine is articulated. There is danger that the machine may tip over.
Work equipment control lever (1) can be used to operate the lift arm
and bucket as follows.
LIFT ARM OPERATION
NOTICE
Position (a): RAISE

further beyond 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
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OPERATION OPERATION
BUCKET OPERATION
Position (e): TILT
further beyond 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 (f): 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
Never dig or scoop with the machine articulated. There is danger that the machine may tip over.
Never raise the boom with the bucket fully loaded when the machine is articulated. There is danger that the machine may tip
over.
When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch (if equipped) is turned ON,
the work equipment will move.
If operations are carried out with the E.C.S.S. switch (if equipped) left at the ON position, the moment that the travel damper
switch is turned ON, the work equipment will move.
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
LOADING PILED SOIL

Scoop up the piled soil by moving the machine forward as shown below. If the tires begin slipping under heavy
load, raise the bucket slightly to reduce the load.
1. Force the bucket into the pile of soil while moving the machine
forward.
2. Thrust the bucket fully into the soil, then drive the machine
forward and operate the work equipment control lever to raise
the lift arm. In addition, operate the work equipment control
lever occasionally to tilt the bucket so that the bucket can be
fully loaded.
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
3. If it is difficult to thrust the bucket into the soil, operate the work
equipment control lever to the left and right to move the cutting
edge of the bucket up and down.
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 work equipment

control lever forward to cut a thin layer of the surface each time
when excavating the soil.
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OPERATION OPERATION
3. Operate the work equipment 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.
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-dump angle to more than 20 degrees.
Turn the E.C.S.S. switch (if equipped) OFF when carrying out leveling
operations.
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.
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OPERATION OPERATION
PUSHING OPERATION
CAUTION
Never set the bucket to 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.
When the machine is traveling or the work equipment is raised, the
moment that the E.C.S.S. switch (if equipped) is turned ON, the work
equipment will move.
If operations are carried out with the E.C.S.S. switch (if equipped) left at
the ON position, the moment that the travel damper is actuated, the
work equipment will move.
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
3-139)".
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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 jobsite flat, and do not operate the steering wheel suddenly or apply the brakes suddenly when the lift arm is
raised with a loaded bucket. This is dangerous.
Never thrust the bucket in when traveling at high speed (when loading soil or crushed rock). This is dangerous.
When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch (if equipped) is turned ON,
the work equipment will move.
If operations are carried out with the E.C.S.S. switch (if equipped) left at the ON position, the moment that the travel damper is
actuated, the work equipment will move.
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 deg. 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 DUMP position when piling-up loads.
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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 points.
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

If the brake pedal is used frequently when traveling downhill, the brake will overheat and may be damaged. Release
the accelerator pedal to make full use of the braking force of the engine when traveling downhill.
Use the right brake pedal for braking.
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 3-17)" in EXPLANATION OF COMPONENTS.
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 and directional selector switch 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.
When traveling on a paved road surface using normal tires (17.5-25-12 PR), the guideline for the appropriate tire
inflation pressure and travel speed is as follows.
Tire inflation pressure: 300 kPa (3.0 kg/cm2, 42.6 PSI)
Travel 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, pull parking brake lever to the LOCK
position while stepping the brake pedal, then make sure the machine is
completely stopped.
Put blocks under the front and the rear of the tires.
Secure the front and rear frames with the frame lock bar.
Always attach the warning tag to the work equipment control lever.
Do not go under the work equipment when the arm is raised. To support
the work equipment securely, use a strong support that can withstand
the weight of the work equipment and prevent the arm coming from
down.
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 height, set the work equipment
control lever at HOLD, then set the work equipment lock lever
to the LOCK position and 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: 14.7 to 19.6 Nm (1.5 to 2.0 kgm , 10.8 to
14.5 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.
For details of the method of returning the control lever automatically to the HOLD position, see "WORK
EQUIPMENT CONTROL LEVER (PAGE 3-57)".
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.
OPERATION OPERATION
ADJUSTING BUCKET POSITIONER

1. Lower the bucket to the ground, set to the desired digging
angle, return the work equipment control lever to HOLD, then
set the work equipment lock lever to the LOCK position and
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 nuts (5), 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.
Tightening torque: 14.7 to 19.6 Nm (1.5 to 2.0 kgm , 10.8 to
14.5 lbft)
4. After adjusting, start the engine and raise the lift arm. Operate
the bucket control lever to DUMP position, then operate it to
TILT BACK position and check that the lever is automatically
returned to HOLD position when the bucket reaches the
desired digging angle.
For details of the method of returning the control lever
automatically to the HOLD position, see "WORK EQUIPMENT
CONTROL LEVER (PAGE 3-57)".
REMARK
When checking, depress the accelerator pedal to the same angle
as when carrying out actual operations.
Depending on the engine speed, the position where the bucket
stops may differ within a range of 1 - 2°.
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 deg. 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 lever is pulled and set to the LOCK position,
there is a danger of the machine moving until the parking brake lamp
lights, therefore keep the brake pedal depressed.
NOTICE
Never use the parking brake lever to slow 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) and directional selector switch (7) in

N (neutral) position.
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.
OPERATION OPERATION
3. Pull parking brake lever (4) to the LOCK position while

stepping the brake pedal (2), then make sure the machine is
completely stopped.
4. Operate work equipment control lever (5) to lower the bucket to

the ground.
5. Check that the work equipment control lever (5) is at the HOLD
position, then set work equipment lock lever (6) to the LOCK
position.
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.
OPERATION OPERATION
CHECKS AFTER COMPLETION OF OPERATION
BEFORE STOPPING ENGINE

Check the engine water temperature, engine oil pressure, HST oil temperature, and fuel level with the meters and
lamps.
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.
LOCKING
Always lock the following parts.
(1) Fuel filler cap
(2) Rear grill
(3) Engine side cover (2 places)
(4) Cab door
(5) Cover of air conditioner FRESH air filter.
REMARK
The starting switch key is used as the key for locks (1) - (5).
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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 approximately 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.
Consult 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): approximately 15 to 25 %
When digging (rear wheels off ground): approximately 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 (kgf/cm2, PSI)

Tire size
Soft ground Normal road When shipped from
(Pattern)
(sandy ground) Stockpile Digging factory
180 to 320 180 to 350 200 to 350
17.5-25-12PR Front and Rear Tire:
(1.8 to 3.2, (1.8 to 3.5, (2.0 to 3.5,
(L2: Traction) 300 (3.0, 42.6)
25.6 to 45.5) 25.6 to 49.7) 28.4 to 49.7)
180 to 320 180 to 350 200 to 350
(1.8 to 3.2, (1.8 to 3.5, (2.0 to 3.5,
(L3: Rock) 300 (3.0, 42.6)
25.6 to 45.5) 25.6 to 49.7) 28.4 to 49.7)
190 to 330 190 to 330 210 to 350
(1.9 to 3.3, (1.9 to 3.3, (2.1 to 3.5,
(L2: Traction) 280 (2.8, 39.8)
27.0 to 46.9) 27.0 to 46.9) 29.8 to 49.7)
190 to 330 190 to 330 210 to 350
(1.9 to 3.3, (1.9 to 3.3, (2.1 to 3.5,
(L3: Rock) 280 (2.8, 39.8)
27.0 to 46.9) 27.0 to 46.9) 29.8 to 49.7)
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.
3 - 139
.
TRANSPORTATION OPERATION
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 deg.
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 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 deg.
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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.
OPERATION TRANSPORTATION
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.
3. Pull parking brake lever to the LOCK position while stepping

the brake pedal, then make sure the machine is completely
stopped.
4. Turn the starting switch to the OFF position to stop the engine,
and pull out the starting switch key.
5. Set the frame lock bar to the LOCK position 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. 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 deg.
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.
5. Start the engine.
Warm the engine up fully.

position, then set the work equipment lock lever to the FREE
position.
7. Depress brake pedal (6) and turn parking brake lever (7) to the
FREE position to release the parking brake.
Keep brake pedal (6) depressed.
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 lever to the LOCK 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
This method of lifting applies to the standard specification machine.
The method of lifting differs according to the attachments and options installed.
For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor.
For 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, set the machine horizontal, and set the work
equipment in the travel posture (see "MOVING THE
MACHINE (PAGE 3-115)").
(A): 40 to 50 cm (16 to 20 in)

position, then set the work equipment lock lever to the LOCK
position.
3. Stop the engine, check that the area around the operator's
compartment is safe, then lock with the frame lock bar so that
the front frame and rear frame do not articulate.
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.
For machines equipped with a rear full fender, remove the rear full fender before carrying out the operation.
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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.
COLD WEATHER OPERATION 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 follows.
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 4-9)".
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 cooling water containing coolant that has been drained during repair of
radiator, contact your Komatsu distributor or request a specialist company to perform the operation. Coolant is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
NOTICE
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).
For details of the density of coolant and the interval for changing the coolant, see "CLEAN INSIDE OF COOLING
SYSTEM (PAGE 4-21)".
3 - 146
.
OPERATION COLD WEATHER OPERATION
BATTERY
WARNING
The battery generates flammable gas. Do not bring open flame 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. 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 4-9)".
3 - 147
.
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than 1 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 separately.
Set the work equipment lock lever to 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, perform the rust prevention operation 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, charge the battery as well.
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 (MIN) when doing this.
In addition, check the refrigerant level twice a year.
PROCEDURE FOR RUST PREVENTION OPERATION
1. Check the safety around the machine, and check for any problem on the machine (leakage of coolant and oil).
2. Check the oil level and coolant level on each part.
Check them in the following order.
(1) Sub-tank coolant level
(2) Engine oil level
(3) Hydraulic oil level
3. Start the engine and run it at low idle for 5 minutes.
4. Check for abnormality on the machine monitor and machine.
If any abnormality (noise, vibration, etc.) is found, stop the engine immediately, and ask your Komatsu distributor
for inspection and maintenance.
5. Check the oil level in the transfer or transmission.
6. Depress the accelerator pedal to the midpoint in order to run the engine at a medium speed, and fully extend and
fully retract each hydraulic cylinder repeatedly 5 times.
7. To lubricate the axle, drive the machine forward and reverse (forward and reverse travel of 10 m {32 ft 10 in} for
3 times).
8. Set the machine in the parking posture and stop the engine to park the machine.
3 - 148
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OPERATION LONG-TERM STORAGE
AFTER STORAGE
NOTICE
If the machine has been stored without performing 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 again after running out of fuel, fill with fuel, then bleed the air from the fuel system before
starting the engine.
For details of bleeding the air, see "PROCEDURE FOR BLEEDING AIR (PAGE 4-59)".
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, 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 2 machines
to within 30 deg.
3 - 150
.
OPERATION TROUBLESHOOTING
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.
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
figure 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 transfer 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 2 machines of at least the
same class as the machine being towed. Connect 1 machine each to the front and rear of the machine being
towed, then remove the blocks from the tires and tow the machine.
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, contact your Komatsu distributor to have the machine moved.
NOTICE
Always request your Komatsu distributor to carry out the emergency travel operation.
3 - 151
.
IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery 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 OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do nothing 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 protective eyeglasses 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 installing the terminal, securely install it.
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: 5.9 to 9.8 Nm
{0.6 to 1.0 kgm, 4.3 to 7.2 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 - 152
.
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 3-147)" 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 LOWER LEVEL line. This may cause an explosion.
Check the battery electrolyte level periodically and add distilled
water to bring the electrolyte level to 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 performing 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 protective
eyeglasses 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.
NOTICE
Use a booster cable and clip of a thickness to match the size of the battery.
The battery on the normal machine must be the same capacity as the battery on the failed machine.
Check that there is no breakage or corrosion of the cable or clip.
Connect the clip securely.
Check that the work equipment lock levers on both the machines are at LOCK position and that the parking brake is applied.
Check that all levers are at Neutral position.
3 - 153
.
CONNECTING THE BOOSTER CABLE

Keep the starting switch of the normal machine and failed machine in OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the figure.
1. Connect the clip of booster cable (A) to the positive (+) terminal
of battery (C) on the failed 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 LOCK position, regardless of whether the machine is working normally
or has failed. Check also that all the control levers are in 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 (MAX).
3. Turn the starting switch of the problem machine to 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 (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (C) on the failed machine.
3 - 154
.
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, ask 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 Check, Adjust alternator driving
Lamp flickers while engine is tension belt tension
running For details, see EVERY 1000
HOURS SERVICE
Even when the engine is rotating, Defective alternator ( Replace)
the battery charge circuit caution Defective wiring ( Check, repair)
pilot lamp does not go out Defective adjustment of alternator Check, Adjust alternator driving
driving belt tension belt tension
For 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
Defective starting motor ( Check, repair)
Pinion of starting motor keeps Insufficient battery charge Charge
going in and out Defective starting motor ( Replace)
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, preheating ( Replace)
water temperature sensor
Defective preheating pilot lamp ( Replace)
Even when engine is stopped, the Defective wiring ( Check, repair)

battery charge circuit caution pilot Defective monitor ( Replace)
lamp does not light up (starting Defective alternator ( Replace)
switch at ON position)
Even when engine is stopped, Defective lamp ( Replace)
engine oil pressure caution lamp Defective lamp switch ( Replace)
does not light up (starting switch Defective monitor ( Replace)
at ON position)
3 - 155
.
CHASSIS

HST
Engine is running but machine Parking brake is applied Release parking brake
does not move Directional lever is not shifted Shift lever properly
properly
No electricity is flowing to Check fuse and wiring harness
directional lever (electrical type) connector
Lack of oil in hydraulic tank Add oil to specified level. See
EVERY 100 HOURS SERVICE
Even when engine is run at full Lack of oil in hydraulic tank Add oil to specified level. See
throttle, machine only moves EVERY 100 HOURS SERVICE
slowly and lacks power Hydraulic oil temperature is low Carry out warming-up operation
Oil overheats Too much oil or too little oil in Add or drain oil to specified level
hydraulic tank See EVERY 100 HOURS
SERVICE
Clogged oil cooler core Clean oil cooler core
Noise generated Lack of transfer oil 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
Air in brake line ( Bleed air)
Brake drags or not applied Defective adjustment of brake ( Check, repair)
pedal linkage
Vent hole of brake valve is clogged Clean
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
over-use of brake
Parking brake
Poor braking effect Linkage is loose Adjust
Disc is worn ( Replace disc)
Steering
Steering wheel is heavy Lack of oil in hydraulic tank Add oil to specified level. See
There is play in steering wheel Steering cylinder pin is loose Grease bearing. Or replace pin
and bushing where there is play
3 - 156
.

Hydraulic system
Bucket lacks lifting power Lack of oil in hydraulic tank Add oil to specified level. See
Bucket takes time to go up Clogged hydraulic filter Replace cartridge, see EVERY
2000 HOURS SERVICE
Excessive bubbles in oil Poor quality oil Replace with good quality oil
Air entering oil line Bleed air. See EVERY 2000
HOURS SERVICE
Lack of oil pressure Lack of oil in hydraulic tank See EVERY 100 HOURS
causes pump to suck in air SERVICE for details of adding oil,
then see EVERY 2000 HOURS
SERVICE for details of bleeding
air
Irregular movement of cylinder Lack of oil in hydraulic tank Add oil to specified level. See
Squeaking noise comes from Lack of grease at roller portion Carry out greasing
accelerator pedal
3 - 157
.
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 Check, add coolant, repair, see
Low coolant level, leakage of water
radiator (pressure valve) WHEN REQUIRED
Defective fan pump motor
Engine coolant temperature ( Check, repair)
Dirt or scale accumulated in
gauge is in red range Change coolant, clean inside of
cooling system
Engine coolant temperature cooling system, see WHEN
caution lamp lights up REQUIRED
Clogged radiator fin or damaged
Clean or repair, see WHEN
fin
REQUIRED
Defective thermostat
( Replace thermostat)
Loose radiator filler cap (high
Tighten cap or replace packing
altitude operation)
Defective monitor
( Replace)
Engine coolant temperature Defective thermostat ( Replace thermostat)
gauge is in white range Defective monitor ( Replace)
Engine does not start when Add fuel, see CHECK BEFORE
Lack of fuel
starting motor is turned STARTING
Repair place where air is sucked
Air in fuel system
in
Fuel filter with fuel. See EVERY
No fuel in fuel filter
500 HOURS SERVICE
( Replace pump or injector)
Defective injection pump or injector
Starting motor cranks engine too
See ELECTRICAL SYSTEM
slowly
Starting motor does not turn
Preheating pilot lamp does not
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
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 ( Wash turbocharger or replace)
Combustion noise occasionally Defective injector ( Replace injector)
makes breathing sound
3 - 158
.

Abnormal noise generated Low grade fuel being used Change to specified fuel
(combustion or mechanical) Overheating Refer to "Engine coolant
temperature gauge is in red
range" as above
Damage inside muffler ( Replace muffler)
Excessive valve clearance ( Adjust valve clearance)
3 - 159
.
.
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:

For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity
according to the ambient temperature.
ALWAYS USE CLEAN WASHER FLUID:

Use automobile window washer fluid, and be careful not to let any dirt get into it.
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 perform 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 approximately 1 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 ft 3 in) 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 perform 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.
BLEED 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 4-66)".
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 death. Always observe 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 2-36)" 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 parts)
Transfer case Power train oil TO10 (Komatsu genuine parts)
Hydraulic oil system Engine oil EO10W30-DH (Komatsu genuine parts)
Axle Axle oil AXO80 (Komatsu genuine parts)
Radiator SUPERCOOLANT (AF-NAC) (Komatsu genuine parts) (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 capacity 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,
consult 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, consult 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 perform 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.
The ASTM diesel fuel recommended by Komatsu may contain 5% or less of biofuel. The EN diesel fuel may contain 7% or less of
it. Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible.
When the diesel fuel is changed to the one mixed with the bio-fuel, replace the fuel prefilter cartridge and the fuel main filter
cartridge with new ones.
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 2 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 4-21)".
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.
PERFORMING 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 performed 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 5 μm or more, enabling
early detection of failures.
Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity,
if necessary, to enable a highly precise diagnosis of the machine and the components' condition.
4-6
.
MAINTENANCE OUTLINES OF SERVICE
OIL SAMPLING
Sampling interval
500 hours
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, 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,
consult 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, consult 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
Fuel main filter 600-319-3750 Cartridge 1
HST filter 418-18-34160 Cartridge 1 EVERY 1000 HOURS
Transfer strainer 07000-73042 O-ring 1
HST drain filter 417-18-34130 Cartridge 1
Hydraulic filter 418-60-55151 Cartridge 1
Hydraulic tank breather 417-60-15380 Element 1 EVERY 2000 HOURS
fresh 426-07-32441 Element 1
Air conditioner filter
recirc 426-07-32441 Element 1
Every 2 years or 4000
425-62-23751 Accumulator 1
PPC accumulator hours, whichever comes
(07002-12034) (O-ring) (1)
sooner
Air cleaner 600-185-2500 Element ass'y 1
421-43-27920 Strainer 1
Brake circuit strainer (07002-15234) (O-ring) (1)
(02896-11012) (O-ring) (1)
417-815-3210 Center edge 1 -
417-815-1220 Side edge 2
Bolt on cutting edge (02090-11475) (Bolt) (8)
(02290-11422) (Nut) (8)
(01643-32260) (Washer) (8)
Fuel breather filter 421-60-35170 Element 1
4-8
.
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
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 the Operation and Maintenance Manual 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 amount of oil
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 0.5% or more, change the oil and oil filter according to the following table.
Sulfur content (%) Oil change interval Oil filter change interval
Less than 0.5 500 hours 500 hours

0.5 to 1.0 250 hours 250 hours
1.0 and up (*) (*)
* 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 perform periodic engine inspection by distributor's expert since change interval of periodic
replacement parts and overhaul interval are also shorter.
4-9
.
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
ASTM: American Society of Testing and Material
Reservoir Axle
Engine oil Transfer Hydraulic Cooling
(front and rear) Fuel tank
pan case system system
Capacity (each)
Liters 17 7.0 120 18 17 177
Specified
US gal 4.49 1.85 31.70 4.76 4.49 46.76
Liters 15.5 5.0 58 18 - -
Refill
US gal 4.09 1.32 15.32 4.76 - -
4 - 10
.
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
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.
The ASTM diesel fuel recommended by Komatsu may contain 5% or less of biofuel. The EN diesel fuel may contain 7% or less of
it. Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible.
When the diesel fuel is changed to the one mixed with the bio-fuel, replace the fuel prefilter cartridge and the fuel main filter
cartridge with new ones.
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).
If only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
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 4-21)".
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 - 11
.
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE
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 to 14.7 1.2 to 1.5 8.7 to 10.8
8 13 31 3.2 23.1 27 to 34 2.8 to 3.5 20.3 to 25.3
10 17 66 6.7 48.5 59 to 74 6.0 to 7.5 43.4 to 54.2
12 19 113 11.5 83.2 98 to 123 10.0 to 12.5 72.3 to 90.4
14 22 172 17.5 126.6 153 to 190 15.5 to 19.5 112.1 to 141.0
16 24 260 26.5 191.7 235 to 285 23.5 to 29.5 170.0 to 213.4

18 27 360 37.0 267.6 320 to 400 33.0 to 41.0 238.7 to 296.6
20 30 510 52.3 378.3 455 to 565 46.5 to 58.0 336.3 to 419.5
22 32 688 70.3 508.5 610 to 765 62.5 to 78.0 452.1 to 564.2
24 36 883 90.0 651.0 785 to 980 80.0 to 100.0 578.6 to 723.3
27 41 1295 132.5 958.4 1150 to 1440 118.0 to 147.0 853.5 to 1063.3

30 46 1720 175.0 1265.8 1520 to 1910 155.0 to 195.0 1121.1 to 1410.4
33 50 2210 225.0 1627.4 1960 to 2450 200.0 to 250.0 1446.6 to 1808.3
36 55 2750 280.0 2025.2 2450 to 3040 250.0 to 310.0 1808.3 to 2242.2
39 60 3280 335.0 2423.1 2890 to 3630 295.0 to 370.0 2133.7 to 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 34 to 63 3.5 to 6.5 25.3 to 47.0
11/16 -16UN 22 74 7.5 54.2 54 to 93 5.5 to 9.5 39.8 to 68.7
13/16 -16UN 27 103 10.5 75.9 84 to 132 8.5 to 13.5 61.5 to 97.6
1 -14UNS 32 157 16.0 115.7 128 to 186 13.0 to 19.0 94.0 to 137.4
13/16 -12UN 36 216 22.0 159.1 177 to 245 18.0 to 25.0 130.2 to 180.8
4 - 12
.
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
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.
Ask your Komatsu distributor to replace the critical parts.
No. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (fuel tank - fuel pre-filter) 1

2 Fuel hose (fuel pre-filter - supply pump) 1
3 Fuel hose (supply pump - fuel main filter) 1
4 Fuel hose (fuel main filter - supply pump) 1
5 Fuel hose (supply pump - common rail overflow) 1
6 Fuel hose (engine - fuel tank) 1
7 Steering hose (pump - priority valve) 1
8 Steering hose (priority valve - orbitrol valve) 1
9 Steering hose (orbitrol valve - steering cylinder) 6
10 Steering hose (steering cylinder line - cushion valve) 2 Every 2 years or
every 4000 hours,
11 Packings, seals, O-rings of steering cylinder 2
whichever
12 Brake hose (gear pump - master cylinder) 1 comes first
13 Brake hose (master cylinder - front brake) 2
14 Brake hose (master cylinder - rear brake) 2
15 Brake hose (master cylinder - accumulator) 2
16 Brake hose (accumulator - charge valve) 2
17 Brake hose (master cylinder - hydraulic tank) 1
18 Brake hose (charge valve - hydraulic tank) 1
19 O-rings and oil seals of brake valve 7
20 Accumulator (For PPC) 1
21 Alarm 2
22 Engine high-pressure piping clamp 1set
Every 8000 hours
23 Fuel spray prevention cap 1set
Every 3 years after beginning
to use or 5 years after
24 Seat belt 1
manufacturing of seat belt,
whichever comes sooner
4 - 13
.
MAINTENANCE SCHEDULE CHART MAINTENANCE
MAINTENANCE SCHEDULE CHART

If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the bio-fuel, the
replacement interval of the fuel filter is changed as well. See "MAINTENANCE INTERVAL WHEN DIESEL FUEL
MIXED WITH BIO-FUEL IS USED (PAGE 4-16)".
MAINTENANCE SCHEDULE CHART
EVERY 10 HOURS SERVICE (ONLY FOR FIRST 50 HOURS)

LUBRICATING 4- 55
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
REPLACE HST OIL FILTER ELEMENT 4- 64
REPLACE HYDRAULIC TANK FILTER ELEMENT 4- 66
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS)
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 72
WHEN REQUIRED
CLEAN, REPLACE AIR CLEANER ELEMENT 4- 18
CLEAN INSIDE OF COOLING SYSTEM 4- 21
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL 4- 24
CHECK AXLE OIL LEVEL, ADD OIL 4- 26
CLEAN AXLE CASE BREATHER 4- 27
CLEAN AIR CONDITIONER CONDENSER 4- 28
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID 4- 29
CLEAN RADIATOR FINS AND COOLER FINS 4- 29
TURN, REPLACE BOLT-ON CUTTING EDGE 4- 34
REPLACE BUCKET TEETH 4- 35
CHECK AIR CONDITIONER 4- 37
REPLACE SLOW BLOW FUSE 4- 39
CHECKING FUNCTION OF ACCUMULATOR 4- 40
SELECTION AND INSPECTION OF TIRES 4- 41
CLEAN, REPLACE FUEL BREATHER FILTER 4- 43

DRAIN WATER, SEDIMENT FROM FUEL TANK 4- 46

LUBRICATE REAR AXLE PIVOT PIN 4- 47
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER 4- 48
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 4- 49

CHECK BATTERY ELECTROLYTE LEVEL 4- 50
CHECK PARKING BRAKE 4- 51
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 4- 52
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN 4- 53
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 4- 54
4 - 14
.
MAINTENANCE MAINTENANCE SCHEDULE CHART

LUBRICATING 4- 55

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 56
REPLACE FUEL PREFILTER CARTRIDGE 4- 58

CHANGE OIL IN TRANSFER CASE 4- 60
CLEAN TRANSFER CASE BREATHER 4- 61
REPLACE FUEL MAIN FILTER CARTRIDGE 4- 62
REPLACE HST OIL FILTER ELEMENT 4- 64
LUBRICATING 4- 65
CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS 4- 65
CHECK ALTERNATOR DRIVING BELT TENSION AND AUTO-TENSIONER, REPLACE
AUTO-TENSIONER 4- 65

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT 4- 66
REPLACE HYDRAULIC TANK BREATHER ELEMENT 4- 67
REPLACE HST DRAIN FILTER 4- 68
CHANGE AXLE OIL(*) 4- 69
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER 4- 69
CLEAN BRAKE CIRCUIT STRAINER 4- 70
CHECK BRAKE DISC WEAR 4- 71
CHECK ALTERNATOR 4- 72
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 72
CHECK VIBRATION DAMPER 4- 72
*: 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- 73
CHECK WATER PUMP 4- 73
CHECK STARTING MOTOR 4- 73
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER 4- 74
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4- 74

REPLACE HIGH-PRESSURE PIPING CLAMP 4- 75
REPLACE FUEL SPRAY PREVENTION CAP 4- 75
4 - 15
.
MAINTENANCE SCHEDULE CHART MAINTENANCE
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED

If the diesel fuel which does not include the bio-fuel is changed to the diesel fuel mixed with bio-fuel, set the
maintenance interval as follows.
Replace the fuel prefilter cartridge
When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed
with bio-fuel, and when the machine is operated further 250 hours.
After that, replace it within 500 hours as a periodic replacement by the service meter reading.
Replace the fuel main filter cartridge
When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed
with bio-fuel, and when the machine is operated further 250 hours.
After that, replace it within 1000 hours as a periodic replacement by the service meter reading.
Maintenance interval after the diesel fuel has been changed to the diesel fuel mixed with bio-fuel
Operating hours of the machine Service meter

Every 500 hours Every 1000 hours
250 hours 500 hours Within 500 After 500 Within 500 After 500
When
after after operating operating operating operating
changed
changing changing hours after hours after hours after hours after
changing changing changing changing
Fuel prefilter
Replace Replace Replace - Replace - Replace
cartridge
Fuel main
Replace Replace Replace - - - Replace
filter cartridge
4 - 16
.
MAINTENANCE SERVICE PROCEDURE
SERVICE PROCEDURE
EVERY 10 HOURS SERVICE (ONLY FOR FIRST 50 HOURS)
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.
Replace HST oil filter element

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 - 17
.
SERVICE PROCEDURE MAINTENANCE
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 eyeglasses, dust mask, and other protective equipment.
CLEANING OUTER ELEMENT

1. If the yellow piston at the display portion of dust indicator (1)
becomes red (7.5 kPa), clean the element.
For inspection method, see "CHECK AIR CLEANER (PAGE
3-95)".
3. Remove 3 clips (2), then remove cover (3).
NOTICE
Never remove inner element (5). If it is removed, dust will enter and cause
engine trouble.
4. Remove outer element (4).
5. Clean the interior of the air cleaner body, cover (3) and
vacuator valve (6).
4 - 18
.
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.
6. Direct dry compressed air (less than 0.2 MPa {2.1 kg/cm2, 30.0
PSI}) to the outer element from inside along its pleats, then
direct it from outside along its pleats and again from inside.
1) Replace any outer element which has been cleaned 6
times or used for 1 year. Replace the inner element at the
same time.
2) Even if the outer element has not been cleaned 6 times, if the yellow piston in the display portion of dust
indicator (1) enters the red position (7.5 kPa) immediately after cleaning, replace both the inner and outer
elements.
7. 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 (3), check O-ring (7) and replace it if there are any scratches or damage.
8. Set the cleaned outer element in position, then secure cover (3) with mounting clips (2).
9. Press the dust indicator button to return the yellow piston to its
original position.
10. Close the engine side cover on the right side of the machine.
If the yellow piston enters the red position (7.5 kPa) immediately after cleaning, replace both the inner and outer
elements.
4 - 19
.
REPLACING ELEMENT
2. Remove 3 clips (2), then remove cover (3).
3. Remove outer element (4).

Do not remove inner element (5) at this time, however.
4. Clean the interior of the air cleaner body, cover (3) and
vacuator valve (6).
5. Remove inner element (5), then install a new inner element immediately.
6. Fit new outer element (4), replace O-ring (7) with a new part, install cover (3), then secure with clips (2).
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 - 20
.
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
LOCK position.
For details of starting the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-88)" and "STARTING ENGINE
(PAGE 3-106)" 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.
Stop the machine on level ground when cleaning or changing the coolant.
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 2 years or every 4000 hours
SUPERCOOLANT
whichever comes sooner
(AF-NAC)
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 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 2 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 approximately 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, contact your Komatsu distributor.
4 - 21
.
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
Density (%) 30 36 41 46 50 54 58 61 64
WARNING
Coolant is toxic. Be careful not to get coolant on you when opening the drain valve.
If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Ask a specialist company or contact your Komatsu distributor for performing the change of coolant or disposal of the cooling
water containing coolant that has been drained during repair of radiator. 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 refilling 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. Place a container in position to catch the coolant, then open

drain valve (2) at the bottom of the radiator and drain the
coolant.
5. After draining the coolant, close drain valve (2) and fill with tap
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 valves (2), drain the water, then
tighten them again.
8. After draining the water, clean it with detergent liquid.
For the cleaning method, follow the instruction for the detergent liquid.
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 remove the air in the coolant, run the engine at Low idle (MIN) for 5 minutes, and then run at High idle (MAX)
for a further 5 minutes. (When doing this, leave the radiator cap off.)
4 - 22
.
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 level.
12. Stop the engine, wait for approximately 3 minutes, add coolant
up to the mouth of the filler port, and tighten the cap.
4 - 23
.
CHECK OIL LEVEL IN TRANSFER CASE, 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 transfer case.
1. Start the engine and carry out the warming-up operation for the transfer. When the warming-up operation of the
transfer is completed, run the engine at low idle for at least 5 minutes.
REMARK
"When the warming-up operation of the transfer is completed" means the condition where the transfer oil
temperature has been warmed up to a temperature of approx. 40 - 60°C (104 - 140°F). As a guideline, this condition
is usually reached when the machine travels under its own power for 30 - 40 minutes.
As a guideline if the ambient temperature is low (below 0°C (32°F)), the transfer is warmed up when the machine
travels under its own power for approx. 1 hour.
2. When the engine is running at low idle, open the cap of oil filler
port (F), pull out dipstick (G), and wipe off the oil with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out again.
4. The oil level should be between the (A) and (B) marks on the
"HOT IDLE" side of dipstick (G).
If the oil level does not reach the (B) mark, add oil through oil
filler port (F).
4 - 24
.
5. If the oil level is above the (A) mark on the "HOT IDLE" side,
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.
NOTICE
The oil level differs according to the oil temperature, so check the oil level after completing the warming-up operation of the
transfer.
If the transfer oil level is low, the oil level may go below the (B) mark on the "HOT IDLE" side when the engine is running at low
idling.
(If the oil level is correct, the oil level will be between the (A) and (B) marks on the "HOT IDLE" side when the transfer oil is
warmed up.)
Checking Oil Level with Engine Stopped

When the oil level is checked with the engine stopped, as a
guideline, the oil level should be between the (C) and (D) marks
on the " COLD STOP" side of dipstick (G).
When checking the oil level with the engine stopped, stop the
engine and wait for at least 2 hours before checking.
When making the final check of the oil level, complete the
warming-up operation of the transfer, then follow Steps 1 - 6
above and check the oil level with the "HOT IDLE" side of
dipstick (G).
4 - 25
.
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 dipstick attached to
plug (1).
3. Set the dipstick (G) as shown in the right figure.

(2): Axle
(3): Spot facing face)
4. The oil level should be between the two lines (H) and (L) on the
dipstick.
If the oil is below the (L) line, add axle oil through oil filler port
(F).
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: 93 to 123 Nm (9.5 to 12.5 kgm , 68.7 to 90.4
lbft)
4 - 26
.
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 2 places (front
and rear).
After removing the breather, take steps to prevent dirt or dust from
entering the mount.
4 - 27
.
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
1. Open the engine side covers on the left and right sides of the
machine.
2. Remove mounting bolts (2) (left side of machine) and (3) (right
side of machine) of condenser (1).
3. Hold the top of condenser (1) and tip it over to the front. A gap
will be made between radiator (4) and condenser (1).
4. Wash with water through the gap.
5. Return condenser (1) to its original position and install bolts (2)
and (3).
4 - 28
.
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID

1. Open the top cover at the front of the engine hood.
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 protective eyeglasses, dust mask, or other protective equipment.
Clean the radiator fins if any mud or dirt is stuck to the radiator.
CLEAN FINS BY ROTATING COOLING FAN IN REVERSE
NOTICE
When rotating the fan in reverse, be careful of flying dust, and be careful
not to let any cloth get caught in the fan.
Dust may rise, so check that there is no one in the surrounding area when
rotating the fan in reverse.
On jobsites where dirt tends to stick to the radiator or cooler, set

cooling fan auto reverse rotation switch (1) to the ON position to
rotate the fan in reverse and blow out the dirt stuck to the radiator
and cooler. This will extend the cleaning interval.
MANUAL FAN REVERSING METHOD
NOTICE
Never rotate the fan in reverse by hand when carrying out the operation.
Before operating the fan reverse rotation switch, run the engine at low idling.
1. Set the directional lever to the Neutral position.

2. Set the parking brake lever to the LOCK position, then apply the parking brake securely.
3. Run the engine at low idle.
4 - 29
.
4. Press portion (a) (manual reverse rotation ON) of the cooling

fan auto reverse rotation switch (1).
5. After the cooling fan reverse rotation pilot lamp on the machine
monitor flashes, check that it lights up. At the same time,
"COOLING FAN REVERSE" is displayed on the character
display and the fan is set to rotate in reverse.
6. Run the engine at high idle.

Select the time for running the engine at High idle (MAX) as follows according to the condition of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
7. When the cleaning is completed, run the engine at low idle.
8. Press portion (a) (manual reverse rotation ON) of the cooling
9. After the cooling fan reverse rotation pilot lamp on the machine
monitor flashes, check that it goes out. The fan is set to rotate
in the normal direction.
10. Run the engine at low idle for approximately 10 seconds.
4 - 30
.
AUTOMATIC FAN REVERSING METHOD
1. Run the engine at low idle.

2. Press portion (a) (auto reverse rotation function ON) of cooling
3. Check that pilot lamp inside of the switch and the cooling fan
reverse rotation pilot lamp on the machine monitor light up.
The fan automatically rotates in reverse for 2 minutes every 2
hours.
REMARK
When the fan direction is switched, the reverse rotation pilot lamp flashes.
When the machine is operating under high load or in low temperatures, the direction of rotation of the fan may not
change. This is to protect the machine.
Run the engine at low idling and wait for the oil temperature or water temperature to go down before operating the
switch.
4 - 31
.
CLEAN FINS WITH COMPRESSED AIR
WARNING
Before opening the fan guard, stop the engine, and hang a warning tag on the work equipment control lever.
CLEANING WITH REAR GRILL OPEN

1. Open rear grill (1).
2. Remove bolts (3) and open fan guard (2).
3. Use compressed air to blow out any mud, dirt, or leaves

clogging radiator fins (4). It is also possible to use steam or
water in place of compressed air.
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.
4. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by aging.
Also, check hose clamps for looseness.
5. After cleaning, close fan guard (2) and install bolts (3).
4 - 32
.
CLEANING WITH ENGINE SIDE COVER OPEN

1. Open the engine side covers on the left and right sides of the
machine.
2. Remove mounting bolts (2) (left side of machine) and (3) (right
side of machine) of condenser (1).
3. Hold the top of condenser (1) and tip it over to the front.
4. Insert the steam jet nozzle through the gap between the
radiator, oil cooler, aftercooler (4) and the air conditioner
condenser (1), and carry out cleaning.
5. Use an air jet nozzle to blow out to the front of the machine all
the mud and dirt that has dropped down. Use an air jet nozzle
also to blow out to the front of the machine the mud and dirt that
has accumulated on top of the fuel tank.
It is also possible to use steam or water in place of compressed
air.
6. Return condenser (1) to its original position and install bolts (2)
and (3).
4 - 33
.
TURN, REPLACE BOLT-ON CUTTING EDGE

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.
Set the bottom of bucket to be level, and put a block under the
bucket at the center.
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: 637 to 853 Nm
(65 to 87 kgm , 470 to 629 lbft)
6. Tighten the mounting bolts again after operating for several hours.
4 - 34
.
REPLACE BUCKET TEETH

(if equipped)
ONE-PIECE TOOTH
When the bucket teeth are worn, replace them as follows.
2. Remove the bolt and nuts (1), then remove bucket tooth (2).
3. Clean the installation surface of bucket tooth (2).
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) temporarily,
then hit the tip of the teeth with a hammer.
Tightening torque for mounting bolt: 863 to 941 Nm (88 to 96 kgm , 637 to 694 lbft)
6. After operating the machine for a few hours, tighten the mounting bolts again.
4 - 35
.
BUCKET WITH TIP TOOTH
WARNING
If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area.
There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as protective
eyeglasses and gloves.
Replace the teeth before they wear down as far as the adapter.
2. Remove pin (2) installed to the bucket, then remove tooth (1).
Put a rod (slightly narrower than the pin) in contact with the
hatched portion (either left or right) and tap pin (2) out to the
opposite side.
3. Fit new tooth (1) in adapter (3), push in pin (2) partially by hand,
then knock it in with a hammer.
4. After operating the machine for a few hours, check that the pin
does not come out.
5. If mounting bolts (4) of adapter (3) are loose, tighten them.

Tightening torque for mounting bolt: 863 to 941 Nm (88 to 96 kgm , 637 to 694 lbft)
4 - 36
.
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 open flame close to any point where the refrigerant gas is leaking.
1. Start the engine and set the engine speed to approx. 1500 rpm.
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. Open up the engine side cover on the left side of the machine.
8. Use sight glass (6) (inspection window) of receiver drier (5) to

check the condition of the refrigerant gas (Hydrofluorocarbons
HFC-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 - 37
.
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
4 - 38
.
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.
The slow blow fuse is at the side of the engine on the left side of the
machine.
1. Turn the starting switch to the OFF position.
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
(A) on the body as a fulcrum and levering the catch of the cover
with a flat-headed screwdriver to release it.
4. Loosen screws (4) and (5), and remove.
When screws (4) and (5) are removed, slow blow fuse (6) will
also come off together with electric wiring (7) and (8).
5. Using screws (4) and (5), install a new slow blow fuse together
with electric wiring (7) and (8) to the slow blow fuse box, then
close covers (1), (2), and (3).
6. Install the slow blow fuse box to the chassis.
4 - 39
.
CHECKING FUNCTION OF ACCUMULATOR

For details of handling the accumulator, see Section "HANDLING ACCUMULATOR AND GAS SPRING (PAGE
2-41)".
ACCUMULATOR FOR TRAVEL DAMPER

When the travel damper switch is ON, the hydraulic spring effect of the accumulator absorbs the up-and-down
motion of the machine during travel and reduces the swaying.
Drive the machine and compare the up-and-down movement of the machine during travel when the travel damper
switch is ON and when it is OFF.
If there is no change in the up-and-down movement of the machine, the gas pressure in the accumulator has
probably dropped.
Please contact your Komatsu distributor to have the accumulator inspected.
REMARK
Carry out the inspection when the machine is traveling at a speed of at least 10 km/h (6.2 MPH). Even if the travel
damper switch is ON, the travel damper is not actuated if the travel speed is less than 5km/h (3.1 MPH).
ACCUMULATOR FOR BRAKE DAMPER

When the brake pedal is depressed, the hydraulic spring effect of the accumulator actuates the brake smoothly.
If any change is felt in the smoothness of the brake operation during daily operations, the gas pressure in the
accumulator has probably dropped.
REMARK
Even if there is any change in the smoothness, there is no drop in the braking force or brake performance.
4 - 40
.
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.
Tire size Maximum load [kg (lb)]

Standard Front and Rear 17.5-25-12PR 6,070 (13,384)
Option Front and Rear 20.5-25-12PR 6,775 (14,939)
4 - 41
.
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

Front tire: 300 kPa (3.0 kg/cm2, 42.6 PSI)
Standard 17.5-25-12PR
Rear tire: 300 kPa (3.0 kg/cm2, 42.6 PSI)
17.5-25-16PR
Option
20.5-25-12PR
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-138)".
4 - 42
.
CLEAN, REPLACE FUEL BREATHER FILTER

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. Open rear grill (1).

2. Loosen nut (3) at the top of fuel breather (2) at the top right 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 - 43
.
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).
Tightening torque: 10 to 14 Nm {1.0 to 1.4 kgm, 7.2 to 10.1 lbft}
NOTICE
If the element is excessively dirty, or if it is damaged, replace it with a new part.
4 - 44
.

For the following items, see "CHECK BEFORE STARTING (PAGE 3-91)".
Check machine monitor

Check coolant level, add coolant
Check oil level in engine oil pan, add oil
Check water separator, drain water
Check air cleaner
Check fuel level, add fuel
Check electric wiring
Check inflation pressure of tires
Check condition of window washer spray
Check wiping efficiency of wiper
Check horn
Check defroster function
Check locks
Check emergency exit
4 - 45
.
DRAIN WATER, SEDIMENT FROM FUEL TANK

Loosen valve (1) on the left side of the tank so that the sediment
and water will be drained together with fuel.
4 - 46
.

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

(2 places)
1. By 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.
4 - 47
.
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).
For details of the method of opening and closing the cover, see
"METHOD OF OPENING AND CLOSING COVER WITH
LOCK (PAGE 3-62)".
2. Raise knob (5), 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 pleats. Then blow
the compressed air from the outside along the pleats, 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 - 48
.
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until
they have cooled 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
Do not add oil above the H level. This will damage the hydraulic circuit or
cause the oil to spurt out. If oil has been added to above the H level, stop
the engine and wait for the hydraulic oil to cool down, then drain the excess
oil from drain plug (P).
2. If the oil is below the L level, add oil to the hydraulic tank as
follows.
1) Remove cover (1).
2) Keep grip (2) pulled, then turn the cap of oil filler (F)
counterclockwise and remove it.
3) Refill the specified quantity of oil through oil filler (F).
4) After adding oil, install the cap of oil filler (F) and cover (1).
4 - 49
.

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

Perform this procedure before operating the machine.
WARNING
Do not use the battery if the battery electrolyte level is below 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 open flame 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 UPPER LEVEL line. If the electrolyte
level is too high, it may leak and cause damage to the paint surface or corrode other parts.
Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static electricity.
NOTICE
If there is a fear that the battery water may freeze after refilling with purified water (e.g. commercially available replenishment water
for a battery), do the replenishment before the day's work on the next day.
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 UPPER
LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
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.
4 - 50
.
REMARK
If distilled water is added to above UPPER LEVEL (U.L.) line, use a syringe to lower the level to 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.
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 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 appear bent.
(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. On dry downhill slopes, use the brake pedal to stop the
machine.
2. Pull the parking brake lever fully to the LOCK position, and
check if the parking brake can hold the machine in position.
3. If any problem is found, contact your Komatsu distributor.
4 - 51
.
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
CHECKING
2. Standard deflection "a" between air conditioner compressor
pulley (1) and drive pulley (2) when pressed with a thumb
(approx. 98 N (10 kg)) should be approx. 11 to 14.5 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 "a" between air conditioner compressor pulley (1) and fan pulley (2) when pressed with a
thumb (approx. 98 N (10 kg)) should be approx. 8 to 11 mm (0.32 to 0.4 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.
4 - 52
.
ADJUSTING
2. When adjusting, loosen bolt (1), turn adjustment bolt (2) and
the lock nut (3), and move the compressor and bracket (4) to
adjust.
3. After adjusting, tighten locknut (3) of adjustment bolt (2) and
bolt (1).
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 1 hour of operation.
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: 785 to 980 Nm (80 to 100 kgm, 578.6 to
723.3 lbft)
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.
4 - 53
.
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.

2-41)".
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 - 54
.
LUBRICATING
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. Put the work equipment horizontally in contact with the ground,

2. By using a grease pump, pump in grease through the grease
fittings marked by the arrows.
(1) Bucket pin (2 places)

(2) Bucket link pin (2 places)
(3) Dump cylinder pin (2 places)

(4) Lift cylinder pin (4 places)
(5) Lift arm pivot pin (2 places)
(6) Bell crank pin (1 place)
(7) Steering cylinder pin (4 places)
4 - 55
.

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: 15.5 liters (4.1 US gal)

Prepare a filter wrench
2. Remove oil filler cap (F).
3. Place a container to catch the oil under drain plug (P).
4. Loosen drain plug (P) and drain the oil. Be careful not to get oil
on yourself.
5. Check the drained oil, and if there are excessive metal
particles or foreign material, contact your Komatsu distributor.
6. Tighten 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.
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.
4 - 56
.
11. After replacing the filter cartridge, add oil through oil filler (F)
until the oil level is between the H and L marks on the dipstick
(G).
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 3-93)".
4 - 57
.
REPLACE FUEL PREFILTER CARTRIDGE

WARNING
Immediately after the engine is stopped, all parts are still very hot. Accordingly, wait until they have cooled down before
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
Do not bring any open 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 performing 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 located at the front 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.
5. Using a filter wrench, turn filter cartridge (2) counterclockwise
on remove it.
4 - 58
.
6. Take water separator transparent cup (3) installed to the

bottom of the cartridge and turn it to the left to remove it. (This
transparent cup is used again. If it is damaged, replace it with
a new part.)
7. Install transparent cup (3) to the bottom of the new fuel pre-filter
cartridge.
When doing this, always replace the O-ring with a new part.
Tightening torque for transparent cup: 10 Nm {1.02 kgm, 7.38
lbft}
When replacing the O-ring, coat the surface with clean fuel
before installing it.
8. Check that drain plug (4) at the bottom of transparent cup (3)
of the fuel pre-filter is tightened securely.
Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.046 kgm, 0.14 to
0.36 lbft}
9. Clean the filter holder.
NOTICE
When filling the filter cartridge with fuel, perform 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 head, 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 main filter cartridge (EVERY 1000 HOURS), replace the
cartlidge and bleed the air. For details, see "REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-62)".
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 approximately 10 minutes at low idle.
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 prefilter 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 - 59
.

Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time.
CHANGE OIL IN TRANSFER CASE

WARNING
Refill capacity: 5 liters (1.32 US gal)
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).
3. Loosen bolt (1), remove cover (2), then take out strainer (3).
4. Remove any dirt stuck to strainer (3), then wash it with flushing
oil. If the strainer is damaged, replace it with a new part.
5. Replace O-ring (4) of cover (2) with a new part, then install.
6. Refill the specified quantity of oil through oil filler (F).
4 - 60
.
7. After refilling with oil, check that the oil is at the specified level.
For details, see "CHECK OIL LEVEL IN TRANSFER CASE,
ADD OIL (PAGE 4-24)".
NOTICE
Before starting the engine, check that the oil level is between the (C) and
(D) marks on the " COLD STOP" side of dipstick.
When checking the oil level, complete the warming-up operation of the
transfer, then use the "HOT IDLE" side of dipstick to make the final
check of the oil level. For details, see "CHECK OIL LEVEL IN TRANSFER
CASE, ADD OIL (PAGE 4-24)".
8. Check that there is no oil leakage from the transfer case.
CLEAN TRANSFER CASE BREATHER

1. Remove cover (1).
2. Remove the mud and dirt from around the breather (2), then
remove breather (2).
After removing the breather, take steps to prevent dirt or dust
from entering the mount.
3. Soak the breather (2) in washing liquid and wash it.
4 - 61
.
REPLACE FUEL MAIN FILTER CARTRIDGE

WARNING
Immediately after the engine is stopped, all parts are still very hot. Accordingly, wait until they have cooled down before
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
Do not bring any open 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 performing 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. By using a filter wrench, turn filter cartridge (1)
counterclockwise on remove it.
4. Clean the filter holder.
Replace inner seal (2) with a new part.
4 - 62
.
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.
7. When installing, tighten until the packing surface contacts the seal surface of the filter head, 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 4-63)".
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 to 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 to 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 prefilter 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 - 63
.
REPLACE HST OIL FILTER ELEMENT

WARNING
2. Using a filter wrench, turn filter cartridge (2) to the left to remove
it.
3. Install the new filter cartridge.
Tighten it until the packing surface contacts the seal surface of
the filter holder, then tighten it 1/2 of a turn.
Tightening torque: 29 to 39 Nm (3.0 to 4.0 kgm , 21.7 to 28.9
lbft)
4. Run the engine at low idle for 5 minutes to bleed the air from the
HST circuit.
5. Check that the hydraulic oil is at the specified level. For details,
see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
(PAGE 4-49)".
6. 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 approximately 100 mm (3.9 in) before the end of
stroke).
NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder
may cause damage to the piston packing.
7. Operate the steering, bucket, and lift arm cylinders to the end of their stroke 3 to 4 times, then stop the engine
and loosen filler cap to bleed the air from the hydraulic tank.
8. Check that the hydraulic oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL (PAGE 4-49)".
9. After completing the air bleed operation, install cover (1).
Replace the HST filter element if the HST oil filter clogging warning pilot lamp lights up, even if 1000 hours or 1 year
has not passed.
4 - 64
.
LUBRICATING
1. By using a grease pump, pump in grease through the grease fittings marked by the arrows.
(1) Center hinge pin (2 places)
CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS

Ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger -
aftercooler - engine.
CHECK ALTERNATOR DRIVING BELT TENSION AND AUTO-TENSIONER, REPLACE

AUTO-TENSIONER
As the alternator driving belt tension is automatically adjusted by auto-tensioner (belt tensioner), no belt tension
adjustment is required.
Special tools are required for the inspection and replacement of auto-tensioner.
Ask your Komatsu distributor to perform this work.
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 - 65
.

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
Refill capacity: 58 liters (15.32 US gal)
1. Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.
2. Remove covers (1) and (2).
3. Keep grip (3) pulled, then turn the cap of oil filler (F)
counterclockwise and remove it.
4. Set a container to catch the oil under drain plug (P).
5. Loosen drain plug (P), drain the oil, then tighten drain plug (P)
again.
6. By using a filter wrench, turn cartridge (4) to the left to remove
it.
7. Clean the filter holder, fill the new filter cartridge with oil, then
coat the seal and thread of the filter cartridge with oil (or coat
thinly with grease) and install.
When installing the seal, tighten it until its surface comes into
contact with the filter holder, then tighten it 1/3 turn more.
8. Refill the specified quantity of oil through oil filler (F).
(PAGE 4-49)".
stroke).
NOTICE
12. Check that the hydraulic oil level and add oil to the specified level. For details, see "CHECK OIL LEVEL IN
HYDRAULIC TANK, ADD OIL (PAGE 4-49)".
13. Next, raise the engine speed and follow the procedure in Step 11 to bleed the air. Repeat this process until no
more air comes out.
14. After completing the air bleed operation, install cover (1) and (2).
4 - 66
.
REPLACE HYDRAULIC TANK BREATHER ELEMENT

WARNING

2. Loosen bolt (2) at the top of the filler cap, then remove cap
cover (3).
3. Remove element (4).
4. Coat O-ring (5) of the new element with grease, then install.
5. Align cap cover (3) with the grooves in the body, then tighten
with bolt (2).
6. Install cover (1).
4 - 67
.
REPLACE HST DRAIN FILTER

WARNING
2. Using a filter wrench, turn filter cartridge (2) to the left to remove
it.
3. Install the new filter cartridge.
Bring the packing surface into contact with the seal surface of
the filter holder, then tighten 3/4 turns.
Tightening torque: 11.7 - 15.6 Nm (1.2 - 1.6 kgm, 8.68 - 11.6
lbft)
(PAGE 4-49)".
stroke).
NOTICE
7. Check that the hydraulic oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL (PAGE 4-49)".
8. After completing the air bleed operation, install cover (1).
4 - 68
.
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 and rear, each): 18.0 liters (4.76 US gal)
A: Front B: Rear
1. Set a container to catch the oil under drain plug (P).

2. Remove plug (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 (1) hole at the refill level.
5. After adding oil, check that the oil is at the specified level. For
details, see "CHECK AXLE OIL LEVEL, ADD OIL (PAGE
4-26)".
REMARK
For operations where the brake is used frequently, change the axle oil at shorter intervals.
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 4-54)".
For details of cleaning the fresh air filter, see "CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER
(PAGE 4-48)".
4 - 69
.
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 left 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 - 70
.
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.
Prepare an inspection gauge.
1. Remove check plug (1).
2. With the brake pedal depressed, insert inspection gauge (2)

into the tooth portion of piston (3) and plate (4).
3. If the inspection gauge can be inserted into the tooth portion,
the disc has reached the wear limit.
Please ask your Komatsu distributor to carry out the
replacement.
4. After checking, install check plug (1).
Tightening torque: 127 to 177 Nm (13 to 18 kgm , 94.0 to 130.2
lbft)
4 - 71
.

2-41)".
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.
Replace the accumulator every 4000 hours or every 2 years.
CHECK ALTERNATOR
Ask your Komatsu distributor to have the alternator checked.
If the engine is started frequently, have this inspection performed 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 - 72
.

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
LUBRICATING
1. By using a grease pump, pump in grease through the grease fittings marked by the arrows.
(1) Front drive shaft (2 places)
(2) Rear drive shaft (2 places)
(3) Drive shaft spline (1 place)
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

Ask your Komatsu distributor to have the starting motor checked.
If the engine is started frequently, have this inspection performed every 1000 hours.
4 - 73
.
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, ask your Komatsu distributor to perform replacement.
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
The fuel spray prevention caps (8 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 - 74
.

Maintenance for every 50, 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time.
REPLACE HIGH-PRESSURE PIPING CLAMP

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

Ask your Komatsu distributor to have the fuel spray prevention cap replaced.
4 - 75
.
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit With bolt on cutting edge
Machine weight
kg(lb) 9,890(21,807)
(With bolt on cutting edge)
Normal load kg(lb) 3,200(7,056)
3
Bucket capacity Heaped m (cu.yd) 2.0(2.6)
Engine model - Komatsu SAA4D107E-1 diesel engine
Flywheel horsepower kW(HP)/rpm 94(126)/2,000
A Overall length mm(ft in) 6,895(22'7")
B Overall height mm(ft in) 3,110(10'2")
C Max. dimension when shaking bucket mm(ft in) 4,885(16')
D Overall width mm(ft in) 2,375(7'10")
E Min. ground clearance mm(ft in) 425(1'5")
F Bucket width mm(ft in) 2,550(8'4")
Dumping clearance
G Cutting edge [BOC tip] mm(ft in) 2,760(9'1")
(*1)
H Dumping reach (*1) Cutting edge [BOC tip] mm(ft in) 1,000(3'3")
I Bucket dump angle (max.height) degrees 45
Out of chassis mm(ft in) 5,850(19'2")
Min. turning radius
Center of outside tire mm(ft in) 5,100(16'9")
Permissible towing load kg(N) 7,250(71,100)
1st km/h(MPH) 4.0 - 13.0(2.5 - 8.1)
2nd km/h(MPH) 13.0(8.1)
Forward
3rd km/h(MPH) 20.0(12.4)
4th km/h(MPH) 34.5(21.4)
Travel speed
1st km/h(MPH) 4.0 - 13.0(2.5 - 8.1)
2nd km/h(MPH) 13.0(8.1)
Reverse
3rd km/h(MPH) 20.0(12.4)
4th km/h(MPH) 34.5(21.4)
*1:Indicates the value at the 45 degree 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

Loading and Light material bucket 17.5-25-12PR(L3: Rock)
carrying (with bolt-on cutting edge) General ground
20.5-25-12PR (L3: Rock)
products 2.4 m3 (3.1 cu.yd)
17.5-25-12PR (L2: Traction)
Leveled ground
Soft ground
Loading Excavating bucket 17.5-25-12PR (L3: Rock)
products and (with bolt-on cutting edge) General ground
20.5-25-12PR (L3: Rock)
crushed rock 1.7 m3 (2.2 cu.yd)
17.5-25-12PR (L3: Rock)
Hard ground
20.5-25-12PR (L3: Rock)
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
.
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC QUICK COUPLER
HANDLING HYDRAULIC QUICK COUPLER

WARNING
Before operating the machine, check that the attachment is correctly connected. If it is not correctly installed, the attachment may
fall off and cause serious injury.
Check that the quick coupler attachment switch is at the CONNECT position.
Check that the coupler plunger is completely inserted into the attachment.
REMOVING ATTACHMENT
1. Tilt the attachment.
2. Keep the control lever at the TILT position, pull lock (A) of the
quick coupler attachment switch in the direction of the arrow
(c), and push in to RELEASE position (a) to release the
connection.
3. Check that the coupler plunger is completely pulled in.
6-3
.
HANDLING HYDRAULIC QUICK COUPLER ATTACHMENTS, OPTIONS
4. Lower the attachment completely to the ground and set it in a

stable position.
5. Tilt the coupler forward slowly and lower it slowly so that it

separates from the attachment hook.
6. Drive the machine slowly in reverse and separate the
attachment from the machine.
7. Push in the quick coupler attachment switch to CONNECT

position (b).
6-4
.
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC QUICK COUPLER
INSTALLING ATTACHMENT
1. Pull lock (A) of the quick coupler attachment switch in the
direction of the arrow (c), and push in to RELEASE position (a).
2. Check that the coupler plunger is completely pulled in.
3. Tilt the coupler forward, drive the machine slowly forward and
set so that the attachment hook is aligned with the puller tube.
4. Raise the coupler slowly, connect the coupler tube to the

attachment hook, then raise the coupler until the attachment
rises slightly off the ground.
5. Check that the attachment is horizontal to the left and right and
that each hook is correctly inserted.
6-5
.
HANDLING HYDRAULIC QUICK COUPLER ATTACHMENTS, OPTIONS
6. Tilt the coupler fully.
7. Keep the control lever at the TILT position, and push in the
quick coupler attachment switch to CONNECT position (b).
8. Check that the coupler plunger is completely inserted.
6-6
.
ATTACHMENTS, OPTIONS METHOD OF USING 2 LEVERS
METHOD OF USING 2 LEVERS

(1) Bucket control lever (3) Max. traction switch

(2) Lift arm control lever
BUCKET CONTROL LEVER

This lever (1) 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
6-7
.
METHOD OF USING 2 LEVERS ATTACHMENTS, OPTIONS
LIFT ARM CONTROL LEVER

This lever (2) is used to operate the lift arm.
NOTICE
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
MAX. TRACTION SWITCH

Use this switch (3) to cancel the traction control or S mode.
Use the traction control switch to select traction control ON or S
mode.
When the traction control ON or S mode selection is active, if
switch (3) pressed, the traction control or S mode is cancelled and
the maximum traction becomes larger. At the same time, the
traction control operation pilot lamp or S mode operation pilot lamp
on the machine monitor goes out.
To return to the traction control ON or S mode status, press switch
(3) again or change the position of the directional lever.
REMARK
Use this function for scooping-up operations or other operations
where the maximum traction is desired.
6-8
.
ATTACHMENTS, OPTIONS KOMTRAX
KOMTRAX
WARNING
Never disassemble, repair, modify, or move the wireless communication terminal, antenna, or cables. This may cause failure
or fire on the wireless equipment or the machine itself.
An explosion may mistakenly occur if any wireless equipment is used near the blasting jobsite. It may result in serious
personal injury or death. Disconnect the power supply cable of the wireless communication device before starting the work if
you have to operate the machine within 12 m {39 ft 4 in} from the remote-controlled blasting device.
KOMTRAX is a vehicle management system that remotely manages the machines equipped with the KOMTRAX
device by using satellite communication or portable radio communication.
The GPS (Global Positioning System), receiver, and communication system are equipped in the vehicle
management system.
The machine information such as the machine maintenance, maintenance management, operating situation
management, and machine location management is gathered from the inside network of the machine. It can be
useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above machine
information for supply of service to the customers, improvement of our products and service, etc.
The type of information which is sent from the machine may vary depending on the machine. For the radio station
establishment of KOMTRAX, consult your Komatsu distributor.
POWER SUPPLY FOR KOMTRAX

Even when the starting switch is in OFF position, KOMTRAX system consumes a small amount of electric power.
It is recommended to start the engine periodically to charge the battery. See "LONG-TERM STORAGE (PAGE
3-148)" when storing the machine for a long term.
If the power supply cable of KOMTRAX system device has to be disconnected, contact your Komatsu distributor.
6-9
.
.
INDEX
INDEX
<A> GENERAL VIEW 3- 2

ADJUSTING WORK EQUIPMENT GENERAL VIEW OF CONTROLS AND
POSTURE 3-133 GAUGES 3- 3
AIR CONDITIONER 3- 80 GENERAL VIEW OF MACHINE 3- 2
AM/FM RADIO-CASSETTE STEREO 3- 72 GREASE PUMP 3- 63
GUIDES TO MAINTENANCE 4- 2
<C>
CAP AND COVER WITH LOCK 3- 61 <H>
CHECK BEFORE STARTING ENGINE, HANDLING CAB WIPER 3- 87
ADJUST 3- 88 HANDLING HYDRAULIC QUICK
CHECKS AFTER COMPLETION OF COUPLER 6- 3
OPERATION 3-137 INSTALLING ATTACHMENT 6- 5
COLD WEATHER OPERATION 3-146 REMOVING ATTACHMENT 6- 3
AFTER COLD WEATHER 3-147 HANDLING OIL, FUEL, COOLANT, AND
PRECAUTIONS AFTER PERFORMING OIL CLINIC 4- 4
COMPLETION OF WORK 3-147 HANDLING THE TIRES 3-138
PRECAUTIONS FOR LOW
TEMPERATURE 3-146 <I>
CONTROL LEVERS, PEDALS 3- 56 INTRODUCTION 1- 4
FRONT/REAR, LEFT/RIGHT
<E> DIRECTIONS OF MACHINE 1- 4
ENGINE SERIAL NO. PLATE 1- 5 USE OF MACHINE 1- 4
EXPLANATION OF COMPONENTS 3- 5 VISIBILITY FROM OPERATOR'S
SEAT 1- 4
<F>
FRAME LOCK BAR 3- 62 <K>
FUSE 3- 68 KOMTRAX 6- 9
POWER SUPPLY FOR KOMTRAX 6- 9
<G>
GENERAL PRECAUTIONS COMMON <L>
TO OPERATION AND MAINTENANCE 2- 12 LIFTING MACHINE 3-144
DO NOT GET CAUGHT IN LOADING, UNLOADING WORK WITH
ARTICULATING PORTION 2- 18 TRAILERS 3-140
FIRE PREVENTION 2- 14 LOCKING 3-137
PRECAUTIONS BEFORE STARTING LONG-TERM STORAGE 3-148
OPERATION 2- 12 AFTER STORAGE 3-149
PRECAUTIONS RELATED TO BEFORE STORAGE 3-148
ATTACHMENTS AND OPTIONS 2- 18 DURING STORAGE 3-148
PRECAUTIONS RELATED TO
PROTECTIVE STRUCTURES 2- 18 <M>
PRECAUTIONS WHEN GETTING ON MACHINE MONITOR 3- 5
OR OFF MACHINE 2- 15 MAINTENANCE SCHEDULE CHART 4- 14
PRECAUTIONS WHEN RUNNING MAINTENANCE INTERVAL WHEN
ENGINE INSIDE BUILDING 2- 19 DIESEL FUEL MIXED WITH BIO-FUEL
PREPARATIONS FOR SAFE IS USED 4- 16
OPERATION 2- 12 METHOD OF USING 2 LEVERS 6- 7
UNAUTHORIZED MODIFICATION 2- 18 EXPLANATION OF COMPONENTS 6- 7
7-1
.
INDEX
MOVING THE MACHINE <S>

(DIRECTIONAL, SPEED), STOPPING SAFETY 2- 2
THE MACHINE 3-115 SAFETY INFORMATION 1- 3
SAFETY LABELS 2- 5
<N> LOCATION OF SAFETY LABELS 2- 5
NECESSARY INFORMATION 1- 5 SAFETY LABELS 2- 6
SELECTING BUCKET AND TIRES 6- 2
<O> SERVICE PROCEDURE 4- 17
OPENING, CLOSING CAB DOORS, CHECK BEFORE STARTING 4- 45
WINDOWS 3- 64 EVERY 100 HOURS SERVICE 4- 47
OPERATION 3- 88 EVERY 1000 HOURS SERVICE 4- 60
OPERATION OF WORK EQUIPMENT 3-123 EVERY 2000 HOURS SERVICE 4- 66
OPERATIONS AND CHECKS AFTER EVERY 250 HOURS SERVICE 4- 50
STARTING ENGINE 3-111 EVERY 4000 HOURS SERVICE 4- 73
OUTLINE OF ELECTRIC SYSTEM 4- 7 EVERY 50 HOURS SERVICE 4- 46
OUTLINES OF SERVICE 4- 4 EVERY 500 HOURS SERVICE 4- 56
<P> INITIAL 250 HOURS SERVICE 4- 17
PARKING MACHINE 3-135 WHEN REQUIRED 4- 18
PERIODIC REPLACEMENT OF SAFETY SLOW BLOW FUSE 3- 70
CRITICAL PARTS 4- 13 SPECIFICATIONS 5- 2
POSITION OF SERVICE METER 1- 6 STANDARD TIGHTENING TORQUES
POWER OUTLET 3- 71 FOR BOLTS AND NUTS 4- 12
PRECAUTIONS FOR MAINTENANCE 2- 33 STARTING ENGINE 3-106
PRECAUTIONS BEFORE STARTING STEERING TILT LOCK LEVER 3- 61
INSPECTION AND MAINTENANCE 2- 33 STOPPING ENGINE 3-114
PRECAUTIONS FOR INSPECTION STORAGE BOX 3- 71
AND MAINTENANCE 2- 38 SWITCHES 3- 42
TIRES 2- 43
PRECAUTIONS FOR OPERATION 2- 20 <T>
OPERATION 2- 24 TABLE TO ENTER SERIAL NO. AND
PRECAUTIONS FOR JOBSITE 2- 20 DISTRIBUTOR 1- 6
STARTING ENGINE 2- 22 TORQUE LIST 4- 12
TOWING 2- 32 TOWING PIN 3- 63
TRANSPORTATION 2- 31 TRANSPORTATION 3-140
PRECAUTIONS FOR OPERATION 3-131 TRANSPORTATION PROCEDURE 3-140
PRODUCT IDENTIFICATION NUMBER TROUBLESHOOTING 3-150
(PIN)/MACHINE SERIAL NO. PLATE 1- 5 IF BATTERY IS DISCHARGED 3-152
METHOD OF TOWING MACHINE 3-150
<R> OTHER TROUBLE 3-155
READ THIS MANUAL 1- 2 WHEN MACHINE RUNS OUT OF
RECOMMENDED FUEL, COOLANT, FUEL 3-150
AND LUBRICANT 4- 9 TURNING 3-121
RECOMMENDED BRANDS,
RECOMMENDED QUALITY FOR <W>
PRODUCTS OTHER THAN WEAR PARTS 4- 8
KOMATSU GENUINE OIL 4- 11 WEAR PARTS LIST 4- 8
USE OF FUEL, COOLANT AND WORK POSSIBLE USING WHEEL
LUBRICANTS ACCORDING TO LOADER 3-125
AMBIENT TEMPERATURE 4- 10
7-2
.
.
WA200-6 WHEEL LOADER

Form No. TEN00471-07
©
2019 KOMATSU
All Rights Reserved
Printed in Japan 03-19

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TEN00471-07

WHEEL LOADER WA200 -6

READ THIS MANUAL FOREWORD

READ 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

(A) Front (E) Bucket

VISIBILITY FROM OPERATOR'S SEAT

FOREWORD NECESSARY INFORMATION

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

ENGINE SERIAL NO. PLATE

NECESSARY INFORMATION FOREWORD

POSITION OF SERVICE METER

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Engine serial No.

Product identification number (PIN)

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12

PRECAUTIONS FOR OPERATION 2- 20

PRECAUTIONS FOR MAINTENANCE 2- 33

SAFETY SAFETY LABELS

LOCATION OF SAFETY LABELS

SAFETY LABELS SAFETY

(2) Caution for leaving the operator's seat (09654-03001)

(3) Caution when traveling in reverse

Please request part number 418-93-42271 for this safety label.

SAFETY SAFETY LABELS

(4) Caution for going close to electric cables (09801-13001)

(5) Caution to keep away from movable parts (09162-23000)

(6) Caution for frame lock bar (09161-23000)

(7) Caution when coolant is at high temperature

SAFETY LABELS SAFETY

(8) Caution when oil is at high temperature (09653-03001)

(9) Caution for handling battery cable (09808-03000)

(10) Explosion warning (09659-53000)

(11) "Do not climb on fender" sign (09805-03000)

(12) Caution when opening while engine is running (09667-03001)

SAFETY SAFETY LABELS

(13) Caution to prevent entry of ether (421-93-A1510)

(14) "Do not come near machine" sign (09812-13000)

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

(16) Certification for ROPS/FOPS (09620-A2001, 09620-A2171)

SAFETY LABELS SAFETY

(17) Prohibited to start by short-circuiting (09842-A0481)

(18) Precautions when cleaning cooler core (418-93-43341)

(19) Escape (425-93-51110)

(20) Precautions when closing emergency escape right window

SAFETY SAFETY LABELS

(21) Caution blast site (09845-00480)

(22) Caution when handling battery (09664-30014)

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION AND

PRECAUTIONS BEFORE STARTING OPERATION

ENSURING SAFE OPERATION

UNDERSTANDING THE MACHINE

PREPARATIONS FOR SAFE OPERATION

PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT