KOMATSU WA250-M Maintenance Manual

VEAM290100

Operation & Maintenance Manual

WHEEL LOADER

SERIAL NUMBERS WA250H60051 AND UP

DANGER

Incorrect operation and maintenance of this machine may be hazardous and cause injuries. The operator and maintenance personnel must read this manual before commencing operation or maintenance. Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals.

-5H

NOTE

Komatsu has had the operating and maintenance instructions

translated into all the languages of the European Union.

Should you require a copy in another language please inquire

at your local dealer’s

FOREWORD

Foreword FOREWORD

Foreword 0.

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.

WARNING

Operators and maintenance personnel must always do as follows before beginning operation or maintenance.

Always be sure to read and understand this manual thoroughly before performing operation and

maintenance.

Read the safety messages given in this manual and the safety labels affixed to the machine thor-

oughly and be sure that you understand them fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

Storage location for the Operation and Maintenance Manual:

Pocket (1) at rear of operator's seat

1-2

FOREWORD Foreword

EU Directives 0.

Machines supplied by us fulfil the Directive for Machinery 89/392/EEC and its supplements. If the machine is being used in another country, it is possible that certain safety regulations and specifications may not be fulfilled for use in that country. For example, priority vehicle warning lamps may be used in some countries, but are forbidden in others. Please contact our dealer before using the machine if you have any questions regarding the fulfilment of standards and regulations in a specific country.

Notes on subsequent installation of electrical and electronic equipment and components

Electrical and electronic equipment and/or components which have been installed subsequently, emit electromagnetic radiation which can influence the function of the electronic components and sections of the machine. This can have an influence on the safety of the machine and endanger persons. For this reason, please ensure that the following safety instructions are observed. If you are installing electrical or electronic equipment and/or components in the machine and connect them to the vehicle electrical system, you must check at own responsibility that the installations do not cause any disturbance to the vehicle’s electronic system or other components. Above all, you must ensure that any subsequently installed electrical and electronic components comply with the EMV Directive 89/336/EEC in its current edition and bear the CE mark. The following requirements also have to be met for subsequent installation of mobile communication systems (e.g. radio, telephone):

Only equipment approved by national legislation (e.g. BZT approval for Germany) may be used The unit must be fixed in position Portable or mobile units may only be used inside the vehicles if they are connected to a fixed outside

antenna

The transmitter unit must be spatially separated from the vehicle’s electronic system Make sure when installing the antenna that this is installed correctly with good earth connection between

antenna and vehicle mass Also observe machine manufacturer’s installation instructions for wiring, installation and maximum permitted power consumption.

1-3

Safety information FOREWORD

Safety information 0.

To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This word is used also to alert against unsafe practices that may cause property damage.

Example of safety message using signal word

WARNING

When standing up from the operator's seat, always place the safety lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know.

NOTICE

REMARKS

This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine. This word is used for information that is useful to know.

1-4

FOREWORD Safety information

Safety labels

Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses “Safety labels using pictograms“ to indicate safety procedures.

Safety labels using pictogram

Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))

1-5

Introduction FOREWORD Directions of machine

Introduction 0.

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 on page 3-84“.

Directions of machine 0.

Front

Bucket

RightLeft

Rear

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.

1-6

FOREWORD Necessary information

Machine serial No. plate and position

Necessary information 0.

When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.

Machine serial No. plate and position 0.

On the center right of the front frame.

Engine serial No. plate and position 0.

This is on the side face of the engine cover on the right side of the machine.

EPA: Environmental Protection Agency, U.S.A.

1-7

Necessary information FOREWORD Position of service meter

Position of service meter 0.

It is at the center bottom of the machine monitor.

Table to enter serial No. and distributor 0.

Machine serial No.

Engine serial No.

Distributor name

Address

Service Personnel

Phone/Fax

1-8

FOREWORD Contents

Contents 0.

FOREWORD

Foreword.............................................................................................................................................................. 1-2

Safety information............................................................................................................................................... 1-4

Introduction ......................................................................................................................................................... 1-6

Directions of machine ...................................................................................................................................... 1-6

Necessary information ....................................................................................................................................... 1-7

Machine serial No. plate and position .............................................................................................................. 1-7

Engine serial No. plate and position ................................................................................................................ 1-7

Position of service meter.................................................................................................................................. 1-8

Table to enter serial No. and distributor ........................................................................................................... 1-8

Contents............................................................................................................................................................... 1-9

......................................................................................................................................................................... 1-9

Dimensions, weights and operating data ....................................................................................................... 1-15

WA250PT-5H: Dimensions, weights and operating data............................................................................... 1-15

CE-conforming equipment............................................................................................................................... 1-16

CE-conforming equipment ............................................................................................................................ 1-16

Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 .......................... 1-17

SAFETY

Safety labels ........................................................................................................................................................ 2-3

Location of safety labels .................................................................................................................................. 2-3

Presentation of safety labels............................................................................................................................ 2-4

General precautions ........................................................................................................................................... 2-7

Safety rules ...................................................................................................................................................... 2-7

Precautions for operation ................................................................................................................................2-16

Starting engine............................................................................................................................................... 2-16

Operation ....................................................................................................................................................... 2-17

Transportation................................................................................................................................................ 2-24

Battery............................................................................................................................................................ 2-25

Towing ........................................................................................................................................................... 2-27

Precautions for maintenance........................................................................................................................... 2-28

Safety instructions.......................................................................................................................................... 2-28

Precautions with tires....................................................................................................................................... 2-35

Handling tires ................................................................................................................................................. 2-35

Precautions when storing tires....................................................................................................................... 2-35

OPERATION

General view ........................................................................................................................................................ 3-3

General view of machine ................................................................................................................................. 3-3

General view of controls and gauges............................................................................................................... 3-4

Explanation of components............................................................................................................................... 3-6

Machine monitor .............................................................................................................................................. 3-6

Monitor system............................................................................................................................................ 3-7

Types of warning......................................................................................................................................... 3-8

Central warning lamp .................................................................................................................................. 3-9

1-9

Contents FOREWORD

Character display portion .......................................................................................................................... 3-10

Emergency stop item ................................................................................................................................ 3-14

Caution items ............................................................................................................................................ 3-16

Warning/limit functions for travel speed .................................................................................................... 3-18

Inspection and maintenance item ............................................................................................................. 3-19

Pilot display portion ................................................................................................................................... 3-21

Meter display portion................................................................................................................................. 3-24

Other functions of machine monitor .......................................................................................................... 3-26

Switches......................................................................................................................................................... 3-30

Control levers, pedals .................................................................................................................................... 3-38

Steering tilt lock lever ..................................................................................................................................... 3-41

Cap and cover with lock ................................................................................................................................. 3-42

Safety bar....................................................................................................................................................... 3-43

Towing pin...................................................................................................................................................... 3-43

Grease pump ................................................................................................................................................. 3-43

Cab door inner lock ........................................................................................................................................ 3-44

Cab door open lock ........................................................................................................................................ 3-44

Cab window open lock cancel knob ............................................................................................................... 3-44

Fuse ............................................................................................................................................................... 3-45

Fuse capacity and name of circuit ............................................................................................................ 3-45

Slow blow fuse ............................................................................................................................................... 3-46

Power outlet ................................................................................................................................................... 3-47

Air conditioner ................................................................................................................................................ 3-48

General locations and function of control panel ........................................................................................ 3-48

Method of operation .................................................................................................................................. 3-51

Precautions when using ............................................................................................................................ 3-52

Handling cab wiper......................................................................................................................................... 3-53

Preventing damage to wiper arm bracket ................................................................................................. 3-53

Operation ........................................................................................................................................................... 3-54

Check before starting engine, adjust.............................................................................................................. 3-54

Walk-around check ................................................................................................................................... 3-54

Check before starting ................................................................................................................................ 3-57

Adjustment ................................................................................................................................................ 3-62

Operations and checks before starting engine ......................................................................................... 3-66

Starting engine ............................................................................................................................................... 3-68

Operations and checks after starting engine.................................................................................................. 3-70

Breaking-in the machine ........................................................................................................................... 3-70

Normal operation ...................................................................................................................................... 3-70

Stopping engine ............................................................................................................................................. 3-72

Moving the machine (Directional, speed), stopping the machine...................................................................3-73

Moving the machine .................................................................................................................................. 3-73

Changing direction .................................................................................................................................... 3-75

Stopping the machine ............................................................................................................................... 3-78

Turning ........................................................................................................................................................... 3-79

Emergency steering .................................................................................................................................. 3-79

Operation of work equipment ......................................................................................................................... 3-80

Handling hydraulic quick coupler ................................................................................................................... 3-81

Installing the attachment ........................................................................................................................... 3-81

Removal and installation of the attachment .............................................................................................. 3-83

Precautions for use ................................................................................................................................... 3-83

Precautions when removing the attachment ............................................................................................. 3-83

Work possible using wheel loader.................................................................................................................. 3-84

Digging operations .................................................................................................................................... 3-84

Leveling operations ................................................................................................................................... 3-86

Pushing operation ..................................................................................................................................... 3-86

Load and carry operations ........................................................................................................................ 3-86

Loading operations ................................................................................................................................... 3-87

Precautions for operation ............................................................................................................................... 3-89

Permissible water depth............................................................................................................................ 3-89

1-10

FOREWORD Contents

If wheel brake does not work .................................................................................................................... 3-89

Precautions when driving up or down slopes............................................................................................ 3-89

Adjusting work equipment posture................................................................................................................. 3-90

Adjusting boom kickout............................................................................................................................. 3-90

Adjusting bucket positioner ....................................................................................................................... 3-91

Adjusting fork positioner............................................................................................................................ 3-92

Bucket level indicator................................................................................................................................ 3-92

Parking machine ............................................................................................................................................ 3-93

Check after stopping engine .......................................................................................................................... 3-95

Checks after completion of operation ............................................................................................................ 3-95

Locking........................................................................................................................................................... 3-95

Handling the tires ........................................................................................................................................... 3-96

Precautions when handling tires ............................................................................................................... 3-96

Tire pressure............................................................................................................................................. 3-96

Precautions for using load and car method .............................................................................................. 3-97

Transportation................................................................................................................................................... 3-98

Transportation procedure............................................................................................................................... 3-98

Loading, unloading work with trailers ............................................................................................................. 3-98

Loading ..................................................................................................................................................... 3-98

Securing machine ..................................................................................................................................... 3-99

Unloading.................................................................................................................................................. 3-99

Lifting machine ............................................................................................................................................. 3-100

Location of lifting position mark............................................................................................................... 3-101

Weight table ............................................................................................................................................ 3-101

Lifting procedure ..................................................................................................................................... 3-102

Cold weather operation .................................................................................................................................. 3-103

Precautions for low temperature .................................................................................................................. 3-103

Fuel and lubricants.................................................................................................................................. 3-103

Coolant ................................................................................................................................................... 3-103

Battery .................................................................................................................................................... 3-104

Precautions after completion of work ........................................................................................................... 3-105

After cold weather ........................................................................................................................................ 3-105

Warming-up operation for steering hydraulic circuit in cold weather ........................................................... 3-105

Long-term storage .......................................................................................................................................... 3-106

Before storage ............................................................................................................................................. 3-106

During storage ............................................................................................................................................. 3-106

After storage ................................................................................................................................................ 3-106

Troubleshooting.............................................................................................................................................. 3-107

When machine runs out of fuel .................................................................................................................... 3-107

Towing the machine ..................................................................................................................................... 3-107

When engine can be used ...................................................................................................................... 3-108

When engine cannot be used ................................................................................................................. 3-108

If battery is discharged................................................................................................................................. 3-109

Removal and installation of battery......................................................................................................... 3-109

Precautions for charging battery ............................................................................................................. 3-110

Starting engine with booster cable.......................................................................................................... 3-110

Other trouble ................................................................................................................................................ 3-112

Electrical system ..................................................................................................................................... 3-112

Chassis ................................................................................................................................................... 3-113

Engine..................................................................................................................................................... 3-115

MAINTENANCE

Guides to maintenance....................................................................................................................................... 4-2

Outlines of service .............................................................................................................................................. 4-4

Handling oil, fuel, coolant and performing oil clinic .......................................................................................... 4-4

Oil ............................................................................................................................................................... 4-4

1-11

Contents FOREWORD

Fuel ............................................................................................................................................................. 4-4

Coolant........................................................................................................................................................ 4-4

Grease ........................................................................................................................................................ 4-4

Carrying out KOWA (Komatsu Oil Wear Analysis) ..................................................................................... 4-5

Storing oil and fuel ...................................................................................................................................... 4-5

Filters .......................................................................................................................................................... 4-6

Biodegradable hydraulic oil and lubricants ................................................................................................. 4-6

Outline of electric system ................................................................................................................................. 4-6

Wear parts............................................................................................................................................................ 4-7

Wear parts list .................................................................................................................................................. 4-7

Fuel, coolant and lubricants .............................................................................................................................. 4-8

Lubrication chart............................................................................................................................................... 4-8

Proper selection of fuel, coolant and lubricants ............................................................................................... 4-9

Standard tightening torques for bolts and nuts............................................................................................. 4-13

Torque list ...................................................................................................................................................... 4-13

Periodic replacement of safety critical parts.................................................................................................. 4-15

Safety critical parts......................................................................................................................................... 4-15

Maintenance schedule chart ............................................................................................................................ 4-17

Service schedule............................................................................................................................................ 4-17

Service procedure............................................................................................................................................. 4-19

Initial 250 hours service (only after the first 250 hours) ................................................................................. 4-19

When required................................................................................................................................................ 4-20

Check, clean, or replace air cleaner element............................................................................................ 4-20

Dust pre-extractor "Turbo II": check, clean ............................................................................................... 4-23

Clean inside of cooling system ................................................................................................................. 4-24

Check oil level in transfer case, add oil..................................................................................................... 4-27

Check axle oil level, add oil....................................................................................................................... 4-28

Clean axle case breather .......................................................................................................................... 4-29

Clean air conditioner condenser ............................................................................................................... 4-29

Check window washing fluid level, add fluid ............................................................................................. 4-30

Clean radiator fins and cooler fins ............................................................................................................ 4-30

Clean transfer oil cooler fins ..................................................................................................................... 4-31

Check electrical intake air heater.............................................................................................................. 4-31

Replace bolt on cutting edge .................................................................................................................... 4-31

Replace bucket teeth ................................................................................................................................ 4-32

Check air conditioner ................................................................................................................................ 4-33

Replace slow blow fuse ............................................................................................................................ 4-34

Selection and inspection of tires ............................................................................................................... 4-35

Check before starting ..................................................................................................................................... 4-37

Every 50 hours service................................................................................................................................... 4-38

Drain water, sediment from fuel tank ........................................................................................................ 4-38

Every 100 hours service................................................................................................................................. 4-39

Lubricate rear axle pivot pin...................................................................................................................... 4-39

Clean element in air conditioner fresh air filter.......................................................................................... 4-39

Check oil level in hydraulic tank, add oil ................................................................................................... 4-40

Every 250 hours service................................................................................................................................. 4-41

Check battery electrolyte level .................................................................................................................. 4-41

Check parking brake ................................................................................................................................. 4-43

Check air conditioner compressor belt tension, adjust ............................................................................. 4-43

Check for loose wheel hub bolts, tighten .................................................................................................. 4-44

Clean element in air conditioner recirculation filter ................................................................................... 4-45

Lubricating ................................................................................................................................................ 4-46

Every 500 hours service................................................................................................................................. 4-47

Change oil in engine oil pan, replace engine oil filter cartridge................................................................. 4-47

Replace fuel filter cartridge ....................................................................................................................... 4-48

Clean water separator strainer.................................................................................................................. 4-49

Every 1000 hours service............................................................................................................................... 4-50

Change oil in transfer case ....................................................................................................................... 4-50

Clean transfer case breather .................................................................................................................... 4-51

1-12

FOREWORD Contents

Replace HST oil filter element .................................................................................................................. 4-52

Lubricating ................................................................................................................................................ 4-53

Check tightening parts of turbocharger..................................................................................................... 4-53

Check play of turbocharger rotor .............................................................................................................. 4-53

Check alternator driving belt tension and replacement............................................................................. 4-53

Every 2000 hours service .............................................................................................................................. 4-54

Change oil in hydraulic tank, replace hydraulic filter element ................................................................... 4-54

Replace hydraulic tank breather element ................................................................................................. 4-55

Change axle oil ......................................................................................................................................... 4-56

Replace element in air conditioner recirculation air filter, fresh air filter.................................................... 4-56

Check alternator, starting motor................................................................................................................ 4-56

Check engine valve clearance, adjust ...................................................................................................... 4-56

Check brake disc wear.............................................................................................................................. 4-57

Clean and check turbocharger.................................................................................................................. 4-57

Check accumulator gas pressure ............................................................................................................. 4-57

Check vibration damper ............................................................................................................................ 4-57

Every 4000 hours service .............................................................................................................................. 4-58

Lubricating ................................................................................................................................................ 4-58

Check water pump .................................................................................................................................... 4-58

TECHNICAL DATA

Technical data ..................................................................................................................................................... 5-2

Noise emission levels ......................................................................................................................................... 5-4

Vibration level...................................................................................................................................................... 5-4

ATTACHMENTS, OPTIONS

Selecting bucket and tires.................................................................................................................................. 6-2

Handling fork tool ............................................................................................................................................... 6-3

Explanation of components.............................................................................................................................. 6-3

Work equipment lever................................................................................................................................. 6-3

Operation ......................................................................................................................................................... 6-4

Loading operation ....................................................................................................................................... 6-4

Method of using 3 levers.................................................................................................................................... 6-7

Explanation of components.............................................................................................................................. 6-7

Lift arm control lever ................................................................................................................................... 6-7

Bucket control lever .................................................................................................................................... 6-8

Auxiliary control lever .................................................................................................................................. 6-8

Directional selector switch .......................................................................................................................... 6-8

Directional selector actuation switch........................................................................................................... 6-9

Operation ....................................................................................................................................................... 6-10

Using switch to change between forward and reverse ............................................................................. 6-10

Central lubrication system ............................................................................................................................... 6-12

Operating the central lubrication system........................................................................................................ 6-12

Display and control unit.................................................................................................................................. 6-12

Led-display................................................................................................................................................ 6-12

Pushbuttons .............................................................................................................................................. 6-13

Changing the lubrication interval times .......................................................................................................... 6-13

INDEX

Index..................................................................................................................................................................... 7-3

1-13

Contents FOREWORD

1-14

FOREWORD Dimensions, weights and operating data

WA250PT-5H: Dimensions, weights and operating data

Dimensions, weights and operating data 0.

WA250PT-5H: Dimensions, weights and operating data 0.

˚ 5 5

4 5

E D C

Measurements, operating data

Bucket capacity to ISO 7546 m³ 2,0

Material density t/m³ 1,8 Bucket weight without teeth kg 883 Static tipping load, straight kg 8.672 Static tipping load, 40° angle kg 7.548 Breakout force, hydraulic kN 109 Lifting capacity, hydraulic, on ground kN 61

Operating weight *) kg 12.880 a Reach at 45° discharge mm 1.023 b Dumping height at 45° discharge mm 2.887 c Lift height, hinge pin mm 3.959 d Height to upper edge of bucket mm 5.514 e Digging depth mm 90 A Overall length, bucket on ground mm 7.424 B Wheel base mm 2.900 C Bucket width mm 2.540 D Width over tyres mm 2.460 E Gauge mm 1.930 F Ground clearance mm 450 H Overall height mm 3.188

F B

WA250PT-Abm

These values refer to machines with 20,5 R25 XHA

*) Machine without additional counterweight

1-15

CE-conforming equipment FOREWORD CE-conforming equipment

CE-conforming equipment 0.

CE-conforming equipment

12345–

Type Pa rt N o .

Bucket WA250PT-5H

Volu m e

m³

418-70-H2710 2,0 - - 884

418-70-H2700 2,0 - - 981

418-70-H2720 2,1 - - 1004

418-70-H2850 - - 625

Load

Capacity

Hydraulic

pressure

bar

Weight

GK100392

1-16

FOREWORD CE-conforming equipment

Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900

Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 0.

The responsibility for observing valid regulations in the case of wheel loaders with "interchangeable equipment" (e.g. bucket or fork-lift) which was not supplied from works lies with the customer which was subsequently fitted to the machine. The directives for CE conformity and road-traffic registration are deemed to have been fulfilled when the manufacturer of the equipment confirms fulfilment of the form 421-93-H1900 alongside. The certification must be sent to the customer and the wheel loader manufacturer. The CE conformity declaration for a specific wheel loader is only legally valid once this has taken place. The dimensions X1, X2, Y1 and Y2 must be provided by the customer for approval for use on public roads. (valid in Germany) The dimension Sh (smallest tyre radius) must be added to the dimension D2. The figure G (in kg) represents the maximum load (equipment and operating load) which may act upon this point.

1-17

CE-conforming equipment FOREWORD Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900

1-18

FOREWORD CE-conforming equipment

Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900

WA250PT-5H 421-93-H1900

A1 Distance: bucket pivoting point - front axle, horizontal A2 Distance: bucket pivoting point - front axle, vertical Sh Distance: road level - front axle B1 Distance: driver's eye (1) - front axle, horizontal B2 Distance: driver's eye (1) - front axle, vertical C1 Distance: centre steering wheel - centre front axle,

horizontal

C2 Distance: center steering wheel - centre front axle,

horizontal D1 Distance: headlight - centre front axle, horizontal D2 Distance: headlight - centre front axle, vertical G Weight of equipment and working load H1 Distance: bucket pivoting point - bucket upper edge, verti-

cal (carrying position) H2 Distance: bucket pivoting point - vision line, vertical (carry-

ing position) J Distance: road level - bucket bottom edge (carrying posi-

tion) X1 Distance: cutter protection - front axle, horizontal X2 Distance: cutter protection - road level, vertical Y1 Distance: teeth protection - front axle, horizontal Y2 Distance: teeth protection - road level, vertical b1 Bucket connection dimension, boom width inside b2 Bucket connection dimension, boom arm b3 Bucket connection dimension, tilt rod b4 Bucket connection dimension, temporary size c Bucket connection dimension between d1 and d2, vertical d1 Bucket connection dimension, bolt (3) for boom d2 Bucket connection dimension, bolt (3) for tilt rod e Bucket connection dimension d1 - d2, horizontally dis-

placed h Distance: bucket bottom edge - boom bolt hole l Distance: centre of bolt -- centre of fastening screw

A1 2.184

A2 1.960

Sh -

B1 1.910

B2 2.190

C1 1.415

C2 1.720

D1 435

D2 1.450

G 4.400

H1 1.257

H2 1.498

J270

X1 2.530

X2 1.080

Y1 2.710

Y2 1.220

b1 955 ± 4

b2 -

b3 -

b4 -

c595

50,5

+ 0,5

61,5

+ 1

e 159,5

h220

1 Driver’s eye

2 Vision line

3Bolts

Tyres

Bucket

MICHELIN

20.5R25 XHA

2,0 m³ 418-70-H2700

1-19

CE-conforming equipment FOREWORD Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900

1-20

SAFETY

WARNING

Please be sure that you fully understand this manual and the precautions related to safety for the machine. When operating or servicing the machine, always follow these precautions strictly.

SAFETY

2-2

SAFETY Safety labels

Location of safety labels

Safety labels 0.

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 0.

2-3

Safety labels SAFETY Presentation of safety labels

Presentation of safety labels 0.

1 Precautions before starting operation, inspec-

tion and maintenance (421-93-H1250)

WARNING!

Read the Operator’s Manual before startung operation, inspection, maintenance or transportation.

3 Precautions when traveling in reverse

(421-93-H1360)

2 Precautions before leaving the machine

(421-93-H1290)

Sign indicates a hazard of unexpected moving of stopped machine.

Lower working device to ground, move safety lever to lock position and take engine key with you before leaving machine.

4 Use Komatsu oil only

(421-93-H1390)

Sign indicates to prevere severe injury or death

Honk to alert people nearby. Be sure no one is on or near machine. Use spotter if view is obstructed.

2-4

SAFETY Safety labels

Presentation of safety labels

5 Do not enter (421-93-H1320) 6 Precautions for safety bar (421-93-H1330)

Sign indicates a crush hazard between the articulating parts of the vehicle.

Keep away from the vehicle when it is move.

7 Precautions when coolant is at high tempera-

ture (421-93-H1280)

Sign indicates a burn hazard from spurting hot water if radiator is uncapped while hot.

Sign indicates a crush hazard between the articulating parts of vehicle.

Lock vehicle with lock bar to avoid movement during maintenance, inspection and transportation.

8 Precautions when oil is at high temperature

(421-93-H1280)

Sign indicates a burn hazard from spurting hot water if radiator is uncapped while hot.

Allow radiator to cool before removing cap.

9 Precautions when handling battery cable

(421-93-H1310)

Sign indicates a hazard of falling.

Do not stand on this place here.

Allow radiator to cool before removing cap.

10 High pressure warning (421-93-H1300)

Sign indicates a hazard of rotating parts, such as belt.

Turn off engine before inspection and maintenance.

2-5

Safety labels SAFETY Presentation of safety labels

11 Do not climb on fender (421-93-H1400) 12 Do not open when engine is running

(09667-A0880)

Sign indicates a hazard of falling.

Do not stand on this place here.

13 “Do not come under machine“ sign

(421-93-H1370)

Sign indicates a hazard of being run over by moving vehicle.

Sign indicates a hazard of rotating parts, such as belt.

Turn off engine before inspection and maintenance.

14 “Do not go under work equipment“ sign

(421-93-H1380)

Sign indicate a crush hazard from falling off of working device.

Keep a safe distance from vehicle when it is moving.

16 Only start machine from driver's seat

(09842-A0481)

Keep away when the working device is raised.

17 Safety measures before starting work

(421-93-H1340)

2-6

421-93-H1340

SAFETY General precautions

Safety rules

General precautions 0.

Safety rules 0.

Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the

machine.

If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may

be severly impaired putting yourself and everyone else on your jobsite in danger.

When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-

stand all hand signals that are to be used.

If abnormalities are found 0.

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

Clothing and personal protective items 0.

Do not wear loose clothing and accessories. There is a haz-

ard that they may catch on control levers or other protruding parts.

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.

Always wear a hard hat and safety shoes. If the nature of

the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the machine.

Check that all protective equipment functions properly

before using it.

Fire extinguisher and first aid kit 0.

Always follow the precautions below to prepare for action if any injury or fire should occur: The fire extinguisher can be fastened to the inside cabin

wall on the left.

If, in the course of certain operations, there is danger of fire,

fire extinguishers must be at hand. Familiarise with the use of the fire extinguishers.

Inform yourself on measures to be taken in the event of a

fire.

The first-aid kit can be positioned on the right of the cabin's

interior.

Make sure that you know all telephone numbers of the per-

sons that you need to contact in an emergency.

Fastening points

2-7

General precautions SAFETY Safety rules

Safety features 0.

Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if

they are damaged.

Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition.

Keep machine clean 0.

If water gets into the electrical system, there is a hazard that

it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors).

If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean.

Inside operator’s compartiment 0.

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 parts or tools lying around the operator's com-

partment.

Do not stick suction pads to the window glass. Suction pads

act as a lens and may cause fire.

Do not use cellular telephones inside the operator's com-

partment when driving or operating the machine.

Never bring any dangerous objects such as flammable or

explosive items into the operator's compartment.

2-8

SAFETY General precautions

Safety rules

Always apply lock when leaving operator’s seat 0.

Before standing up from the operator's seat (such as when

adjusting the operator's seat), always lower the work equipment completely to the ground, set safety lock lever (1) to the LOCK position, pull parking brake lever (2) to the LOCK position, 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 injury or property damage.

When leaving the machine, always lower the work equip-

ment completely to the ground, set safety lock lever (1) to the LOCK position, pull parking brake lever (2) to the LOCK position, 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.

Free

Lock

9EA04394A

Lock

Free

9EA04395A

2-9

General precautions SAFETY Safety rules

Handrails and steps 0.

To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the dia-

gram on the right when getting on or off the machine.

To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself.

When entering the cab, open the cab door, push the door

securely into catcher (1) to hold in position, then use the handrail on the inside to get on the machine. For details of the method of releasing the door lock, see “Cab door open lock on page 3-44“.

Do not grip the control levers 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.

Before getting on or off the machine, check the handrails

and steps, and if there is any oil, grease, or mud on them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.

Do not get on or off the machine while holding tools in your

hand.

2-10

SAFETY General precautions

Safety rules

Mounting and dismounting 0.

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 0.

Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering serious injury.

Do not get caught in articulated portion 0.

If the clearance at the articulating portion changes, it will

lead to serious personal injury. Do not allow anyone to come inside the articulation range.

Never enter or put your hand, arm, or any part of your body

in the movable portion between the work equipment and machine or between the cylinder and the work equipment. If someone operates the control levers by mistake, the gap between the work equipment and machine and between the cylinder and work equipment will change, and you, your hand, or arm will be caught and you may suffer serious injury. If you have to go into a movable portion, always take action to secure the work equipment and ensure that it cannot move.

Preventions of burns 0.

Hot coolant

To prevent burns from hot water or steam spurting out when

checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Hot oil

To prevent burns when checking or draining the oil, wait for

the oil to cool to a temperature where it is possible to touch the plug by hand before starting the operation. Even when the oil has cooled down, loosen the plug slowly to relieve the internal pressure before removing the plug.

2-11

General precautions SAFETY Safety rules

Fire prevention 0.

Fire caused by fuel or oil

Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following:

Do not smoke or use any flame near fuel or oil. Stop the engine before refueling. Do not leave the machine while adding fuel or oil. Tighten all fuel and oil caps securely. Do not spill fuel on overheated surfaces or on parts of

the electrical system.

Use well-ventilated areas for adding or storing oil and

fuel.

Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.

After adding fuel or oil, wipe up any spilled fuel or oil. When carrying out grinding or welding work on the chas-

sis, move any flammable materials to a safe place before starting.

When washing parts with oil, use a non-flammable oil.

Diesel oil and gasoline may catch fire, so do not use them.

Put greasy rags and other flammable materials into a

safe container to maintain safety at the work place.

Do not weld or use a cutting torch to cut any pipes or

tubes that contain flammable liquids.

Fire caused by accumulation of flammable material.

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

Fire coming from electric wiring

Short circuits in the electrical system can cause fire.

Always keep 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 hydraulic line

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. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-

explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause serious injury.

When taking the electrical power for the lighting from the machine itself, follow the instructions in this man-

ual.

Action if fire occurs 0.

If a fire occurs, escape from the machine as follows.

Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine.

Window washer liquid 0.

Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

2-12

SAFETY General precautions

Safety rules

ROPS (Roll Over Protective Structure) 0.

The roll-over protection system (ROPS) protects the operator and absorbs load and impact energy, if the

machine should roll over.

The ROPS is a fixed component of the cab. The machine must not be operated without this roll-over protection

system.

The ROPS meets the regulations of all member states of the EU. If, however, the ROPS is modified, damaged,

or repaired without permission, its stability is impaired. In this case, the ROPS must be replaced, since its correct function can no longer be guaranteed.

The ROPS can only provide maximum protection, if the driver wears the safety belt correctly. For this reason,

the safety belt is to be worn when the machine is in operation.

Attachment for protection against falling objects (FOPS) 0.

NOTICE FOPS is a fixed component of the cab.

When you work on a site where there is danger of falling rocks or other objects, the machines must be equipped with a FOPS. If the FOPS is modified without permission or damaged, its stability is impaired. In this case, the FOPS must be replaced, since its correct function can no longer be guaranteed.

Precautions for attachments 0.

When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-

fore contact your Komatsu distributor for advice.

Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not

be the responsibility of Komatsu.

When installing and using optional attachments, read the instruction manual for the attachment, and the gen-

eral information related to attachments in this manual.

Unauthorized modification 0.

Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting

from modifications made without authorization from Komatsu.

Safety at worksite 0.

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there

is a hazard of fire, so be careful when operating.

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.

Do not carry out operations at places 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 action to prevent unauthorized people from approach-

ing the jobsite. When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians.

When traveling or operating in shallow water or on soft

ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.

In order that travel operations can be carried out safely,

always keep the roads on the jobsite properly maintained.

2-13

General precautions SAFETY Safety rules

Working on loose ground 0.

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.

Do not go close to high-voltage cables 0.

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows: Before starting work near electric cables, inform the local

power company of the work to be performed, and ask them to take the necessary action.

Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations.

To prepare for any possible emergencies, wear rubber

shoes and gloves. Lay a rubber sheet on top of the seat,

Nominal Voltage

up to 1000 V 1 m

over 1 kV up to 110 kV 3 m

Safety

Distance

and be careful not to touch the chassis with any exposed part of your body.

Use a signalman to give warning if the machine approaches

too close to the electric cables.

When carrying out operations near high voltage cables, do

over 110 kV up to 220 kV 4 m

over 220 kV up to 380 kV 5 m

with unknown nominal voltage 5 m

not let anyone come close to 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 come close to the machine.

Ensure good visibility 0.

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely. Always do as follows.

Position a signalman if there are areas at the rear of the machine where the visibility is not good. 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.

2-14

SAFETY General precautions

Safety rules

Ventilation for enclosed areas 0.

Exhaust fumes from the engine can kill. If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

Checking signalman’s signals and signs 0.

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if

necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

Only one signalman should give signals. Make sure that all workers understand the meaning of all signals and signs before starting work.

Emergency exit from operator’s cab 0.

Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open, escape from the door on the other side.

Be careful about asbestos dust 0.

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 when cleaning. Do not

use compressed air for cleaning.

If there is danger that there may be asbestos dust in the air,

always operate the machine from an upwind position. All workers should use an approved respirator.

Do not allow other persons to approach during the opera-

tion.

Always observe the rules and regulations for the work site

and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts.

Gas, dust, and inflammable vapours 0.

Do not operate combustion engines in an environment that may contain inflammable gases or vapours. These gases, dusts, or vapours may ignite or be sucked in by the suction system, thus causing a rise in engine speed or an exceeding of the engine's maximum rpm. This may lead to a fire, an explosion, and major damage to property. It may also happen that the engine cannot be switched off anymore.

Mirrors, windows and lighting 0.

Clean the windows and the headlights to ensure maximum sight. Adjust the rear-view mirror in such a way that you have an excellent view of the rear from the driver's seat.

Keep the mirrors clean. See "Adjust rear view mirror on page 3-65".

Ensure that the complete lighting system operates properly and that it is correctly adjusted. Immediately replace broken window panes by new ones.

2-15

Precautions for operation SAFETY Starting engine

Precautions for operation 0.

Starting engine 0.

If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers.

9JA04836-1

Checks before starting engine 0.

Carry out the following checks before starting the engine at the beginning of the day's work.

Remove all dirt from the surface of the window glass to ensure a good view. Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and

check that they light up correctly.

Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and

check for damage to the electric wiring.

Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake

pedal, and check that the pedals work properly.

Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-

age or wear to the seat belt or mounting clamps.

Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-

trol levers are all at the neutral position.

Before starting the engine, make sure that the safety lock lever is in the LOCK position. Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See “Adjust rear

view mirror on page 3-65“.

Check that there are no persons or obstacles above, below, or in the area around the machine.

Precautions when starting 0.

Only start and operate the machine from the seat. Never try to start the engine by hot-wiring the ignition. This

can cause fire, grave injuries or death.

When starting the engine, sound the horn as a warning. Do not allow anyone apart from the operator to ride on the machine. For machines equipped with a back-up alarm, check that the alarm works properly.

Precautions in cold areas 0.

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control

levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.

There is a hazard that this will ignite the battery and cause the battery to explode. Before charging or starting the engine with a different power source, melt the battery electrolyte and check that there is no leakage of electrolyte before starting.

2-16

SAFETY Precautions for operation

Operation

Operation 0.

Checks before operation 0.

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine.

Always fasten your seat belt. Check the operation of travel, steering and brake systems,

and work equipment control system. Check for any abnormality in the sound of the machine,

vibration, heat, smell, or gauges; check also that there is no

leakage of oil or fuel.

If any abnormality is found, carry out repairs immediately.

Before driving the machine or starting operations, check

that safety bar (1) is securely fixed at the FREE position.

Precautions when traveling in foreward or reverse 0.

Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles. Before travelling, sound the horn to warn people in the area. Always operate the machine only when seated. Do not allow anyone apart from the operator to ride on the machine. Check that the back-up alarm (alarm buzzer when machine travels in reverse) works properly. Always lock the door and windows of the operator's compartment in position (open or closed).

On jobsites where there is a hazard of flying objects or of objects entering the operator's compartment, check

that the door and windows are securely closed. If there is an area to the rear of the machine which cannot

be seen, position a signal person. Take special care not to

hit other machines or people when turning or swinging the

machine. Always be sure to carry out the above precautions even when the machine is equipped with mirrors.

2-17

Precautions for operation SAFETY Operation

Precautions when traveling 0.

Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the

machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal immediately to stop the machine.

When traveling on level ground, keep the work equipment at

height of 27 cm from the ground. 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.

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.

27 cm

9JA04632-1

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. Never travel over obstacles which make the machine tilt strongly to one side.

When traveling or carrying out operations, always keep a

safe distance from people, structures, or other machines to avoid coming into contact with them.

When passing over bridges or structures, check first that the

structure is strong enough to support the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions.

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 work equipment hit anything.

Always obey the traffic regulations when traveling on public

roads. This machine travels at a lower speed than normal automobiles, so keep to the side of the road and be careful to leave the center of the road free for other vehicles.

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 an extremely large destructive force, and this may cause serious injury or accident. If you are going to travel continuously, please consult your Komatsu distributor.

Height limitation 0.

When working in areas with height limitations, e.g. in tunnels, beneath bridges or power transmission lines, or in garages, pay attention that the work unit does not touch or damage these facilities.

2-18

SAFETY Precautions for operation

Operation

Traveling on slopes 0.

To prevent the machine from tipping over or slipping to the side, always do as follows: When traveling on slopes, keep the bucket at height “A“ of

approximately 20 to 30 cm (8 to 12 in) above the ground. In

case of emergency, quickly lower the bucket to the ground

to help the machine to stop.

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 trans-

mission 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.

2-19

Precautions for operation SAFETY Operation

Prohibited operations 0.

It is dangerous to excavate the bottom of a rock face. Never

do this.

It is dangerous to use the bucket or lift arm for crane opera-

tions, so do not carry out such operations.

Do not pass the bucket over the head of other workers or

over the operator's seat of dump trucks or other hauling equipment. The load may spill or the bucket may hit the dump truck and cause serious injury or property damage.

Emergency lowering system 0.

When the engine is not running, you can lower the work unit by means of the pilot control lever. PPC control lever To achieve this, slowly press the pilot control lever (2) forward to the "LOWER" position.

EPC control lever

1. Turn the key in ignition switch (1) to ON.

2. Then slowly press the pilot control lever (2) forward to the "LOWER" position.

9JA04954-2A

2-20

9JA04954-1A

SAFETY Precautions for operation

Operation

Precautions when operating 0.

When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to

the work equipment, do not exceed the maximum permitted load or performance of the machine.

If the engine cannot be started again after it has stopped, immediately operate the work equipment control

levers to lower the work equipment to the ground. (After the engine stops, the accumulator allows the work equipment to be operated for a limited time.)

Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when

dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.

The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of

a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure to reduce the speed.

When the bucket is fully loaded, never start, turn, or stop the

machine suddenly. There is danger of the machine turning 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 damage.

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 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.

Methods of using brake 0.

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. If necessary, use the brake pedal at the same time.

2-21

Precautions for operation SAFETY Operation

Operate carefully on snow 0.

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.

If the machine enters deep snow, there is a hazard that it

may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift.

When clearing snow, the road shoulder and objects placed

beside the road are buried in the snow and cannot be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.

When traveling on snow-covered roads, always fit tire

chains.

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 bucket to the ground to stop the machine.

2-22

SAFETY Precautions for operation

Operation

Parking machine 0.

Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.

Lower the work equipment completely to the ground.

When leaving the machine, set safety lock lever (1) to the

LOCK position, pull parking brake lever (2) to the LOCK position, then stop the engine.

Always close the operator's cab door, and use the key to

lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place.

Free

Lock

If it is necessary to park the machine on a slope, set blocks

under the wheels to prevent the machine from moving.

9EA04394A

Lock

Free

9EA04395A

2-23

Precautions for operation SAFETY Transportation

Transportation 0.

The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out.

Loading and unloading 0.

When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follow:. Perform loading and unloading on firm, level ground only.

Maintain a safe distance from the edge of the road or cliff.

Always use ramps of adequate strength. Be sure that the

ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off.

Be sure the ramp surface is clean and free of grease, oil, ice

and loose materials. Remove dirt from machine-tracks. On a rainy day, in particular, be extremely careful since the ramp surface is slippery.

Run the engine at low speed and travel slowly. Never correct your steering on the ramps. If necessary,

drive off the ramps, correct the direction, then enter the ramps again.

When loading or unloading to an embankment or platform,

make sure that it has suitable width, strength, and grade.

For machines equipped with a cab, always lock the door

after boarding the machine. If this is not done, the door may suddenly open during transportation. Refer to “Transportation on page 3-98“.

Ramp

Distance between ramps

Block

Blocks

9ER01312A

Shipping 0.

When shipping the machine on a trailer, do as follows: The weight, transportation height, and overall length of the

machine differ according to the work equipment, so be sure to confirm the dimensions.

When passing over bridges or structures on private land,

check first that the structure is strong enough to support the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions.

Lock the frame with the safety bar to prevent the machine

from articulating.

For details of the shipping procedure, see “Transportation

on page 3-98“ in the OPERATION section.

2-24

SAFETY Precautions for operation

Battery

Battery 0.

Battery hazard prevention 0.

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions: Do not use or charge the battery if the battery electrolyte

level is below the LOWER LEVEL line. This may cause an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.

When working with batteries, always wear safety glasses

and rubber gloves.

Never smoke or use any flame near the battery.

If you spill acid on your clothes or skin, immediately flush

the area with large amount of water.

If acid gets into your eyes, flush them immediately with

large amount of water and seek medical attention.

Before working with batteries, turn the starting switch to the

OFF position.

As there is a hazard that sparks will be generated, always do as follows: Do not let tools or other metal objects make any contact

between the battery terminals. Do not leave tools or other metal objects lying around near the battery.

Always disconnect the negative (-) terminal (ground side)

first when removing the battery; when installing the battery, connect the positive (+) terminal first, and connect the ground last.

Attach the battery terminal securely. Flammable hydrogen gas is generated when the battery is

charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it.

Tighten the battery caps securely. Install the battery securely to the determined place.

2-25

Precautions for operation SAFETY Battery

Starting with booster cables 0.

If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows: When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the operator's seat and the other working with the battery).

When starting from another machine, do not allow the two

machines to touch.

When connecting the booster cables, turn the starting

switch OFF for both the normal machine and problem machine. There is a hazard that the machine will move when the power is connected.

Be sure to connect the positive (+) cable first when installing

the booster cables. Disconnect the negative (-) cable (ground side) first when removing them.

When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch the machine.

Always wear safety goggles and rubber gloves when start-

ing the engine with booster cables.

When connecting a normal machine to a problem machine

with booster cables, always use a normal machine with the same battery voltage as the problem machine.

For details of the starting procedure when using booster

cables, see “Starting engine with booster cable on page 3110“ in the OPERATION section.

2-26

SAFETY Precautions for operation

Towing

Towing 0.

When towing 0.

Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see “Towing the machine on page 3-107“.

Always wear leather gloves when handling wire rope. During the towing operation, never stand between the tow-

ing machine and the machine being towed.

Never tow a machine on a slope.

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.

2-27

Precautions for maintenance SAFETY Safety instructions

Precautions for maintenance 0.

Safety instructions 0.

Warning tag 0.

Always attach the “DO NOT OPERATE“ warning tag to the

work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.

9JA04836-1

Warning tag

Keep this warning tag in the tool box while it is not used. If there is not the tool box, keep the tag in the operation manual pocket.

If others start the engine, or touch or operate the work

equipment control lever while you are performing service or maintenance, you could suffer serious injury or property damage.

Keep work place clean and tidy 0.

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

Appoint leader when working with others 0.

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

2-28

SAFETY Precautions for maintenance

Safety instructions

Maintenance with engine running 0.

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

landslides, or of flooding if the land is low.

Lower the work equipment completely to the ground and

stop the engine.

After stopping the engine, operate work equipment control

lever (1) 2 to 3 times fully to the RAISE and LOWER positions to release the pressure inside the hydraulic circuit, then set safety lock lever (2) to the LOCK position.

Pull parking brake lever (3) to the LOCK position, then put

blocks under the front and the rear of the tires.

Lock the front and rear frames with safety bar (4).

Free

Lock

9EA04401A

Lock

Free

9EA04402A

Lock

Free

9EA04785A

2-29

Precautions for maintenance SAFETY Safety instructions

Two workers for maintenance when engine is running 0.

To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows: One worker must always sit in the operator's seat and be

ready to stop the engine at any time. All workers must maintain contact with the other workers.

When carrying out operations near the fan, fan belt, or other

rotating parts, there is a hazard of being caught in the parts, so be careful not to come close.

Never drop or insert tools or other objects into the fan or fan

belt. Parts may break or be sent flying.

Set safety lock lever (1) to the LOCK position to prevent the

work equipment from moving. Then pull parking brake lever (2) to the position to prevent the machine from moving.

Do not touch any control levers. If any control lever must be

Free

operated, give a signal to the other workers to warn them to move to a safe place.

Lock

9EA04394A

Lock

Free

9EA04395A

Inspection and maintenance after turning E.C.S.S. switch OFF 0.

For machines equipped with a E.C.S.S. 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.

Proper tools 0.

Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury.

2-30

SAFETY Precautions for maintenance

Safety instructions

Accumulator 0.

WARNING

Danger of injury! Pressure accumulator is filled with highly pressurised nitrogen. Do not open or damage the pressure accumulator.

The accumulator is charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage. For this reason, always observe the following precautions:

Do not disassemble the accumulator. Do not bring it near flame or dispose of it in fire. Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be

released. Please contact your Komatsu distributor to have this work performed.

Personnel 0.

Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer.

Attachments 0.

Appoint a leader before starting removal or installation oper-

ations 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.

2-31

Precautions for maintenance SAFETY Safety instructions

Working under the raised boom 0.

WARNING

Danger of injury! The raised boom may suddenly fall! For safety reasons, a raised boom must be secured against dropping before you pass or stand under it.

The boom must be secured against moving if any work is to

be carried out under it when it is in a raised position. For this purpose you should use a supporting prop (1) which is to be positioned below the boom.

Park the machine on level, solid ground. Apply the parking brake. Place wheel chocks in front of the wheels to prevent the

machine from inadvertently rolling away.

Lift the arm far enough to allow the supporting prop to be

placed beneath the boom.

Switch off the engine. With the engine switched off, lower the boom slowly until it

rests on the supporting prop.

Set the control lever to "NEUTRAL" and secure it with the

safety lever (2) (locked).

Free

Lock

9EA04401A

2-32

SAFETY Precautions for maintenance

Safety instructions

Precautions when using hammer 0.

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. 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 injury. Always wear safety goggles and gloves.

When hitting pins or bucket teeth, there is a hazard that bro-

ken pieces might be sent flying and injure people in the surrounding area. Always check that there is no one in the surrounding area.

There is a hazard that the pin hit with strong force may fly

out and injure people in the surrounding area.

Repair welding 0.

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.

Removing battery terminal 0.

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the battery to prevent the flow of current.

Precautions with high-pressure oil 0.

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury, so always do as follows. When carrying out inspection and maintenance of the pressure, release the pressure before starting. For

details, see “Maintenance with engine running on page 2-29“. Do not carry out inspection or replacement work with the circuit under pressure.

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the pip-

ing and hoses and for swelling in the hoses. When carry out inspection, wear safety glasses and leather gloves.

There is a hazard that high-pressure oil leaking from small

holes may penetrate your skin or cause blindness if it contacts your 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.

Precautions for high-pressure fuel 0.

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting inspection or maintenance.

2-33

Precautions for maintenance SAFETY Safety instructions

Handling high-pressure hoses 0.

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious

injury or property damage. If any loose bolts are found, stop work and tighten to the specified torque.

If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace all hoses every six years at the latest. The shelf life of the hose should not exceed 2 years. Hoses must be replaced as soon as the following damage is noticeable:

damage to the outer layer through to the intermediate layer, brittleness in the outer layer, distortions in pressurised or unpressurised state not conforming with the original shape of the installed hose, leakages, damage to the hose fittings or to the connection between fittings and hose, storage damage.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. See also "Periodic replacement of safety critical parts on page 4-15".

Waste materials 0.

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.

Maintenance of air conditioner 0.

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause

frostbite. Never touch refrigerant.

Compressed air 0.

When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,

and other protective equipment.

Periodic replacement of safety critical parts 0.

In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service

and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship to safety, such as hoses and seat belts, must be replaced at periodic intervals. Replacement of safety critical parts: see "Periodic replacement of safety critical parts on page 4-15".

The material of these components naturally changes over time, and repeated use causes deterioration, wear,

and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or 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 time speci-

fied interval.

Replace all hoses every six years at the latest. The shelf life of the hose should not exceed 2 years.

2-34

SAFETY Precautions with tires

Handling tires

Precautions with tires 0.

Handling tires 0.

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 serious injury or death. To maintain safety, always do as follows: Maintenance, disassembly, repair, and assembly of the tires

and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations.

Always use the tires specified by Komatsu and maintain the

specified inflation pressure. Suitable tire inflation pressure: see “Handling the tires on page 3-96“.

When pumping up the tires, check that no other person is

standing near the tire, and install an air chuck with a clip that can be secured to the air valve. To prevent the tire inflation pressure from becoming too high, measure the pressure from time to time with an air gauge while pumping up the tire.

If the tire pressure goes down abnormally or the rim parts

do not fit the tire, there is a problem with the tire or rim parts. Always contact your Komatsu distributor for repairs.

If the rim parts are not fitted properly when the tire is being

pumped up, there is danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand beside the tread when pumping up the tire.

Do not adjust the tire inflation pressure immediately after

traveling at high speed or carrying out operations under heavy load.

Never carry out welding or light a fire near the tire.

Precautions when storing tires 0.

Tires for construction equipment are extremely heavy, so they may cause serious personal injury. As a basic rule, store the tires in a warehouse which unau-

thorized 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, and block it securely so that it

cannot roll or fall over if any person should touch it. Do not lay the tire on its side. This will deform the tire and cause it to deteriorate.

If the tire should fall over, do not attempt to stop it. Get out

of the way quickly.

Block

AW63748-A

2-35

Precautions with tires SAFETY Precautions when storing tires

2-36

OPERATION

WARNING

Please read and make sure that you understand the safety volume before reading this section.

OPERATION

3-2

OPERATION General view

General view of machine

General view 0.

General view of machine 0.

(1) Bucket (8) Turn signal lamp

(2) Tilt lever (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

3-3

General view OPERATION General view of controls and gauges

General view of controls and gauges 0.

(1) Parking brake lever (16) Auxiliary control lever

(2) Rear wiper switch (17) Variable shift control switch

(3) Front wiper switch (18) Speed range selector switch

(4) Front working lamp switch (19) Start switch

(5) Rear working lamp switch (20) Traction control switch

(6) Hazard lamp switch (21) Attachment selection switch

(7) Directional lever (22) Dump speed switch

(8) Horn switch (23) E.C.S.S. switch

(9) Steering wheel (24) Directional selector actuation switch

(10) Lamp switch (25) Safety lock lever

(10) Turn signal lever (26) Accelerator pedal

(10) Dimmer switch (27) Brake pedal

(11) Monitor panel mode selector switch 1 (28) Rear heated wire glass switch

(12) Monitor panel mode selector switch 2 (29) Air conditioner panel

(13) Cigarette lighter (30) Radio

(14) Directional selector switch (31) Room lamp switch

(15) Work equipment control lever

3-4

OPERATION General view

General view of controls and gauges

Machine monitor 0.

(1) Pilot lamp for speed range selector switch position (13) Brake oil pressure caution lamp

(2) Steering oil pressure caution lamp (14) Parking brake reminder caution lamp

(3) Emergency steering pilot lamp (15) Axle oil temperature caution lamp

(4) Preheating pilot lamp (16) Radiator coolant level caution lamp

(5) Directional lever position pilot lamp (17) Maintenance caution lamp

(6) HST oil temperature gauge (18) HST oil filter clogging caution lamp

(7) Engine coolant temperature gauge (19) Battery charge circuit caution lamp

(8) Speedometer (20) Engine oil pressure caution lamp

(9) Turn signal pilot lamp (21) Central warning lamp

(10) Head lamp high beam pilot lamp (22) Meter display pilot lamp

(11) Fuel gauge (23) Character display

(12) Parking brake pilot lamp

3-5

Explanation of components OPERATION Machine monitor

Explanation of components 0.

The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays.

Machine monitor 0.

A: Character display E: Pilot display

B: Emergency stop items F: Meter display

C: Caution items G: Central warning lamp

D: Inspection and maintenance items

3-6

OPERATION Explanation of components

Machine monitor

Monitor system 0.

Testing actuation of machine monitor system 0.

NOTICE When the starting switch is in the ON position before starting the engine, lamps (1) in the diagram on the right light up for approx. 3 seconds and the alarm buzzer sounds for approx. 3 seconds. After 3 seconds all lamps except lamps (2) go out. Lamps (2) go out after the engine starts. If any lamps do not light up there is probably a failure or a disconnection, so please ask your Komatsu distributor to carry out inspection.

When the starting switch is turned ON, if the directional

lever is not at the neutral position, the central warning lamp lights up and the alarm buzzer sounds intermittently. If this happens, return the directional lever to the neutral position. The lamp will go out and the buzzer will stop.

Directional lever: Neutral position

Directional selector actuation switch (3): ON position Directional selector switch (4): Forward or Reverse position

When the starting switch is turned to the ON position with the levers and switches in the following condition, all directional lever positional pilot lamps (5) will go out. If directional selector switch (4) is then set to the N position, directional lever positional pilot lamps (5) display the normal condition “N“.

3-7

Explanation of components OPERATION Machine monitor

Types of warning 0.

If an abnormality occurs on the machine, or if any switch or lever is operated accidently, the monitor display and buzzer give a warning to inform the operator. Following are the types of warning depending on the level of danger.

REMARK For details of action codes “E03“ to “E00“, see “Action code display on page 3-11“.

Emergency stop 0.

This warning is given if there is a serious failure that affects the normal operation of the machine or if the setting is incorrect. The central warning lamp on the monitor and the caution lamp for the location of the abnormality light up, and at the same time, the alarm buzzer sounds and action code “E03“ is displayed on character display (1).

Caution 0.

This warning is given if the cooling water or lubricating oil overheat. The central warning lamp on the monitor and the individual caution lamps light up, and at the same time, the alarm buzzer sounds and action code “E02“ is displayed on character display (1).

MIistaken operation 0.

This warning is given if any switch or lever is operated mistakenly. The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time. In addition, if the travel speed is too high, action code “E00“ is displayed on character display (1).

Inspection and maintenance 0.

This warning is given if it is necessary to carry out inspection and maintenance of wear parts, or if it is necessary to check the oil or cooling water level. The individual caution lamp on the monitor lights up, and at the same time, action code “E01“ is displayed on character display (1). In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound.

3-8

OPERATION Explanation of components

Machine monitor

Central warning lamp 0.

This display portion (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 content of the display and carry out the specified action for the item.

3-9

Explanation of components OPERATION Machine monitor

Character display portion 0.

(1) Service meter (4) Filter, oil replacement time display

(2) Action code display

(3) Failure code display

Normally, the service meter is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action. When the time for replacing the filter or changing the oil is reached, after completion of the system check with the starting switch at the ON position, the maintenance monitor caution lamps flash or light up, and at the same time, 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 0.

This meter (1) shows the total time that the machine has been operating. While the engine is running, the service meter advances 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 will display as long as the top part () of monitor panel mode selector switch 1 is being pressed.

NOTICE When the starting switch is at the OFF position, if the service meter is displayed even though the top () of monitor panel mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection.

3-10

OPERATION Explanation of components

Machine monitor

Action code display 0.

WARNING

If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see “Failure code display on page 3-12“. Inform your Komatsu distributor of the failure code and ask for repairs.

If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or maintenance must be carried out, action code E00, 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, E00. In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning lamp lights up.

If action codes E00, 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 immedi-

ately, check the failure code, and contact your Komatsu distributor for repairs.

REMARK “E03 CALL“ is displayed on the character display, and then “CHECK RIGHT NOW“ and “E03 CALL“ are displayed in turn for 3 seconds each.

E02: If overrun related information is displayed, reduce the

engine speed and the speed of the machine while continu-

ing operations. If the overheat related display is given, stop the machine and run the engine under no load at a mid-range speed.

If an action code is still displayed after doing this, check the

failure code and contact your Komatsu distributor for

repairs.

REMARK “E02“ is displayed on the character display, and then the condition of the machine related to the overheating or overrun is displayed in turn with “E02“ for 3 seconds each.

E01: When a failure occurs in the mechanical system, such as

a drop in the level of the engine cooling water, the mainte-

nance location is displayed. If the maintenance caution

lamp lights up at the same time, carry out inspection and

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 character display, and then “MAINTENANCE“ or the part of the machine requiring inspection, filling of fluid, or replacement is displayed on the bottom line.

3-11

Explanation of components OPERATION Machine monitor

E00: If travel speed overrun is displayed, ease the accelerator

pedal back to reduce speed.

REMARK “E00“ is displayed on the character display, and then “OVERRUN PREVENTION“ and “E00“ are displayed in turn for 3 seconds each.

Failure code display 0.

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, please inform your distributor of the failure code.

Method of displaying failure code

1. If an action code is displayed on the character display of display portion (4), press the top (>) of monitor panel mode selector switch 2 (A). The action code will change to the failure code. The failure code is displayed with the first 6 digits on the

left side 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 failure code and the component causing the failure

are displayed on the character display in turn for 3 seconds each.

Top right code Controller detecting failure code

MON Machine monitor

HST HST controller

2. Press the top (>) of monitor panel 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.

Filter, oil replacement time display 0.

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 on page 3-27“.

3-12

OPERATION Explanation of components

Machine monitor

REMARK The ID number and item name of the item needing replacement are displayed on the character display,

and then the remaining time to replacement and the number of times of replacement are displayed in turn for 3 seconds each.

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, they are displayed repeatedly in turn. 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 999 hours. When more than 999 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

Item

Engine oil 500 ENG OIL 01

Engine oil filter 500 ENG FILT 02

Fuel filter 500 FUEL FILT 03

Transfer oil 1000 TRANSF OIL 25

HST oil filter 1000 HST FILT 26

Hydraulic filter 2000 HYD FILT 04

Hydraulic oil 2000 HYD OIL 10

Axle oil 2000 AXLE OIL 15

REMARK See the section below for details of the procedure for replacing the filter and oil: Engine oil:

See "Change oil in engine oil pan, replace engine oil filter cartridge on page 4-47".

Engine oil filter:

See "Change oil in engine oil pan, replace engine oil filter cartridge on page 4-47".

Fuel filter: See "Replace fuel filter cartridge on page 4-48".

Replacement

interval (H)

Character display ID number

Transfer oil: See "Change oil in transfer case on page 4-50".

HST oil filter: See "Replace HST oil filter element on page 4-52".

Hydraulic filter:

See "Change oil in hydraulic tank, replace hydraulic filter element on page 4-54".

Hydraulic oil:

See "Change oil in hydraulic tank, replace hydraulic filter element on page 4-54".

Axle oil: See "Change axle oil on page 4-56".

3-13

Explanation of components OPERATION Machine monitor

Emergency stop item 0.

CAUTION

If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the applicable location.

If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for the location of the abnormality and the central warning lamp will light up. At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then 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

Brake oil pressure caution lamp 0.

This lamp (1) lights up when the brake oil pressure goes below the specified value.

During checks before starting (starting switch at the ON position, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.

During operation (engine running) If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection. If the brake oil pressure caution lamp lights up, the footbrake may not work, so keep the parking brake applied to prevent the machine from moving. 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.

3-14

OPERATION Explanation of components

Machine monitor

Engine oil pressure caution lamp 0.

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

During checks before starting (starting switch at the ON position, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.

During operation (engine running) If the engine lubricating oil pressure goes down during operation, the engine lubricating oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection.

Battery charge circuit caution lamp 0.

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

During checks before starting (starting switch at the ON position, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.

During operation (engine running) If an abnormality occurrs in the charging circuit during operation, the battery charge circuit caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection.

Steering oil pressure caution lamp 0.

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

During checks before starting (starting switch at the ON position, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.

During operation (engine running) If the steering oil pressure goes down during operation, the steering oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection.

3-15

Explanation of components OPERATION Machine monitor

Caution items 0.

CAUTION

If these lamps light up, stop operations quickly and carry out the following action.

(1) Axle oil temperature caution lamp (4) Hydraulic oil temperature caution lamp

(2) Torque converter oil temperature caution lamp (5) Fuel level caution lamp

(3) Engine cooling water temperature caution lamp

AXLE OIL TEMPERATURE CAUTION LAMP 0.

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

During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

During operation (engine running) In continuous heavy-duty operations or when traveling long distances downhill where the brake is used frequently, the axle oil temperature becomes high, so the axle oil temperature caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E02“ and “BRAKE OVERHEAT“ are displayed on the character display in turn, so take the following action:

1. Release the accelerator pedal and move the speed range selector switch down one range to reduce the travel speed.

2. Avoid using the brake. 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 axle oil temperature will go down and the caution lamp will go out.

3-16

OPERATION Explanation of components

Machine monitor

Parking brake reminder caution lamp 0.

This lamp (2) lights up when engine is stopped but the parking brake is not applied. At the same time, the central warning lamp lights up and the alarm buzzer sounds intermittently. When the parking brake is applied, the lamp goes out and the buzzer stops.

HST oil temperature caution lamp 0.

This lamp (3) lights up to warn the operator that the HST oil temperature has risen.

During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

During operation (engine running) When the HST oil temperature goes up, the HST oil temperature caution lamp and central warning lamp light up, and the alarm buzzer sounds intermittently. At the same time, “E02“ and “HST OVERHEAT“ are displayed on the character display in turn, so stop the machine and run the engine at a midrange speed under no load until the lamp goes out.

Engine cooling water temperature caution lamp 0.

This lamp (4) lights up to warn the operator that the engine cooling water temperature has risen.

During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

During operation (engine running) If the engine cooling water temperature rises, the engine cooling water temperature caution lamp only will light up. If the water temperature rises further, the central warning lamp will light up and the alarm buzzer will sound intermittently. At the same time, “E02“ and “ENGINE OVERHEAT“ are displayed on the character display in turn, so stop the machine and run the engine at a midrange speed under no load until the lamp goes out.

3-17

Explanation of components OPERATION Machine monitor

Fuel level caution lamp 0.

This monitor (5) lights up if the amount of fuel remaining in the fuel tank goes below 26 liters (6.87 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.

Warning/limit functions for travel speed 0.

When the travel speed goes above 40.0 km/h (24.9 MPH), the central warning lamp lights up and the alarm buzzer sounds. At the same time, “E00“ is displayed on the character display, and then “OVERRUN PREVENTION“ and “E00“ are displayed in turn for 3 seconds each. If the alarm buzzer sounds, ease the accelerator pedal back and reduce speed.

Travel speed limit function 0.

The travel speed is automatically controlled so that it does not go above approx. 42 km/h (26.1 MPH).

3-18

OPERATION Explanation of components

Machine monitor

Inspection and maintenance item 0.

CAUTION

If these lamps light up, stop operations quickly and carry out the following action.

(1) Radiator water level caution lamp (3) HST oil filter clogging caution lamp

(2) Maintenance caution lamp

Radiator coolant level caution lamp 0.

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

During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor lights up if the coolant level in the radiator is low. At the same time, “E01“ and “COOLANT LOW“ are displayed on the character display in turn, so check the coolant level in the radiator sub-tank, and add coolant. Use a suitable climbing aid (for example a ladder) to climb up the back of the machine and unscrew the radiator cap.

During operation (engine running) If the water level in the radiator becomes too low, the radiator coolant level caution lamp will light up. At the same time, “E01“ and “COOLANT LOW“ are displayed on the character display in turn, so stop the engine, check the coolant level in the radiator sub-tank, and add coolant.

3-19

Explanation of components OPERATION Machine monitor

Maintenance caution lamp 0.

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 and oil change is reached, this monitor (2) flashes or lights up for approx. 30 seconds after completion of the system check when the starting switch is at the ON position.

REMARK The maintenance caution lamp flashes when there is less than 30 hours to the replacement time, and after the replacement time has passed, it stay on.

For details of the items covered by filter and oil replacement, see “Filter, oil replacement time display on page 312“. After replacing the filter or changing the oil, reset time for the replacement. For details, see “Reset method for filter, oil replacement time on page 3-27“.

HST oil filter clogging caution lamp 0.

When the engine is running, this lamp (3) lights up if the HST oil filter is clogged.

During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

During operation (engine running) This lights up if the HST oil filter is clogged. At the same time, “E01“ and “HST OIL FILTER“ are displayed on the character display in turn, 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.

3-20

OPERATION Explanation of components

Machine monitor

Pilot display portion 0.

When the starting switch is ON, the pilot display lights up when the display items are functioning.

(1) Parking brake pilot lamp (5) Pilot lamp for speed range selector switch position

(2) Preheating pilot lamp (6) Turn signal pilot lamp

(3) Emergency steering pilot lamp (7) Head lamp high beam pilot lamp

(4) Directional lever position pilot lamp

Parking brake pilot lamp 0.

This lamp (1) lights up when the parking brake is applied.

Preheating pilot lamp 0.

This lamp (2) 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, and when the preheating is completed, it goes out. The preheating time differs according to the engine water temperature.

3-21

Explanation of components OPERATION Machine monitor

Emergency steering pilot lamp 0.

(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.

Directional lever position pilot lamp 0.

This lamp (4) indicates the position of the directional lever.

F lights up: FORWARD N lights up: NEUTRAL R lights up: REVERSE

REMARK In the following conditions, it indicates the position of the directional selector switch. Directional selector actuation switch (3): ON position Directional lever: Neutral position

Pilot lamp for speed range selector switch position 0.

This lamp (5) indicates the position of the speed range selector switch.

Turn signal pilot lamp 0.

When the turn signal lamp flashes, this lamp (6) also flashes.

REMARK If there is a disconnection in the turn signal lamp, the flashing interval becomes shorter.

3-22

OPERATION Explanation of components

Machine monitor

Head lamp high beam pilot lamp 0.

This lamp (7) lights up when the head lamp is at high beam.

3-23

Explanation of components OPERATION Machine monitor

Meter display portion 0.

(1) HST oil temperature gauge (4) Speedometer

(2) Engine coolant temperature gauge (5) Meter display pilot lamp

(3) Fuel gauge

HST oil temperature gauge 0.

This meter (1) indicates the HST oil 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 HST oil temperature gauge lights up. At the same time, the central warning lamp lights up and the alarm buzzer sounds. In addition, “E02“ and “HST OVERHEAT“ are displayed on the character display in turn. Run the engine at a midrange speed under no load and wait for the indicator to return to the white range (A).

Engine coolant temperature gauge 0.

This meter (1) indicates the engine coolant temperature. During normal operations, the indicator should be in the white range (A). If the indicator enters red range (B) during operations, caution lamp (C) inside the engine coolant temperature gauge lights up. At the same time, the central warning lamp lights up and the alarm buzzer sounds. In addition, “E02“ and “ENGINE OVERHEAT“ are displayed on the character display in turn. Run the engine at a midrange speed under no load and wait for the indicator to return to the white range (A).

3-24

OPERATION Explanation of components

Machine monitor

Fuel gauge 0.

This meter (3) 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 26 liters (6.87 US gal), caution lamp (A) inside the fuel gauge lights up. If it lights up, check the fuel level and add fuel.

Speedometer 0.

This meter (4) indicates the travel speed of the machine.

Meter display pilot lamp 0.

This lamp (5) displays the unit for the travel speed.

3-25

Explanation of components OPERATION Machine monitor

Other functions of machine monitor 0.

The machine monitor also has the following functions: Odometer, filter/oil replacement time reset, language selection, HST selector function.

Method of displaying odometer 0.

Use this when checking the total distance that the machine has traveled.

1. Check that the character display is showing the service meter or the action code. If it is giving any other display, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display to be given.

2. Press the () of monitor panel mode selector switch 1. It displays the odometer.

3. When completing the operation, press () of monitor panel mode selector switch 1 or turn the starting switch OFF.

3-26

OPERATION Explanation of components

Machine monitor

Reset method for filter, oil replacement time 0.

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.

1. Press the () of monitor panel mode selector switch 1, and display the odometer.

2. Press (>) or (<) of monitor panel mode selector switch 2 and display “MAINTENANCE MONITOR“.

3. Press the () of monitor mode selector switch 1. The item is displayed, and then the replacement interval is displayed in the center and the number of times of replacement is displayed on the right in turn for 3 seconds each.

4. Press the (>) or (<) of monitor panel mode selector switch 2 to display the item (filter or oil) which has reached the replacement time.

5. Press the () of monitor mode selector switch 1. [RESET] and [YES <> NO] are displayed in turn.

6. When resetting the replacement time, press (>) or (<) of monitor panel mode selector switch 2, align the cursor with “YES“, then press () of machine monitor mode selector switch 1. It will reset and return to the previous screen. To abort, align the cursor with “NO“, then press () of monitor panel mode selector switch 1.

7. When resetting the replacement time for another item, carry out the procedure from Step 4. After completing, press () of monitor panel mode selector switch 1 twice or turn the starting switch OFF.

3-27

Explanation of components OPERATION Machine monitor

Method for selecting language 0.

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.

1. Press the () of monitor panel mode selector switch 1, and display the odometer.

2. Press (>) or (<) of monitor panel mode selector switch 2 and display “LGUAGE“.

3. Press the () of machine mode panel selector switch 1. The presently selected language is displayed.

4. Press (>) or (<) of monitor panel mode selector switch 2 and select the language. The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.

5. After selecting the language, press the () of monitor mode selector switch 1. This confirms the language. To abort, press the () of monitor mode selector switch 1.

6. When completing the operation, press () of monitor panel mode selector switch 2 twice or turn the starting switch OFF.

3-28

OPERATION Explanation of components

Machine monitor

Method of selecting HST changing function 0.

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.

Function

A (default setting) F3, R3 F4, R4

B F3, R2 F4, R2

1. Press the () of monitor panel mode selector switch 1, and

display the odometer.

2. Press (>) or (<) of monitor panel mode selector switch 2 and display “SELECT HST“.

3. Press the () of monitor mode selector switch 1. The present HST selection is displayed.

4. Press the (<) or (>) of monitor mode selector switch 2, and align the cursor with A or B.

5. Press the () of monitor mode selector switch 1. The HST selection is confirmed and the screen returns to the previous screen.

6. When completing the operation, press () of monitor panel mode selector switch 2 twice or turn the starting switch OFF.

Speed range selector switch position

3rd position 4th position

3-29

Explanation of components OPERATION Switches

Switches 0.

(1) Starting switch (11) Front working lamp switch (2) Speed range selector switch (12) Rear working lamp switch (3) Variable shift control switch (13) Monitor panel mode selector swiitch 1 (4) Directional selector switch (14) Monitor panel mode selector swiitch 2 (5) Directional selector actuation switch (15) Front wiper switch (6) Traction control switch (16) Rear wiper switch (7) E.C.S.S. switch (17) Cigarette lighter (8) Lamp switch

Turn signal lever Dimmer switch

(9) Horn button (21) Dump speed switch (10) Hazard lamp switch

(18) Room lamp switch (19) Rear heated wire glass switch (20) Attachment selection switch

Starting switch 0.

This switch (1) is used to start or stop the engine.

OFF position In this position, it is possible to insert or remove the starting switch key. All the electric system switches are off, and the engine will stop.

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.

START position This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to the ON position when released.

3-30

OPERATION Explanation of components

Switches

Speed range selector switch 0.

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

Variable shift control switch 0.

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 (20.2-25) 4.0 - 13.0 (2.5 - 8.1)

Small diameter tire (17.5-25) 3.6 - 11.7 (2.2 - 7.3)

Directional selector switch 0.

This switch (4) 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 on page 3-75“.

Directional selector switch actuation switch 0.

When this switch (5) is turned on, the directional selector switch is actuated. Position (a): ON

The directional selector switch is actuated.

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.

3-31

Explanation of components OPERATION Switches

Switch for traction control 0.

The traction control is switched on by means of this switch (6). When the traction control is on, the drive force that is transferred to the wheels is reduced in the 2nd to 4th gears. Position (ON): ON Position (OFF): OFF

Reduction

Drive force

Travelling speed

E.C.S.S. switch 0.

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.

switch is operated, 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 and allows the machine to travel smoothly and at high speed.

This switch (7) 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 The travel damper is automatically actuated when the travel speed becomes more than 6 km/h (3.7 MPH); when the travel speed goes below 5 km/h (3.1 MPH) it is automatically disengaged (when 20.5-25 tires are used).

3-32

OPERATION Explanation of components

Switches

Lamp switch 0.

This switch (8) is used to light up the front lamps, side clearance lamps, tail lamps, and instrument panel. Position (a): OFF

Lamps go out.

Position (b): Side clearance lamps, tail lamps, and instrument

panel light up.

Position (c): Head lamps light up in addition to lamps at (b) position.

REMARK The lamp switch can be operated regardless of the position of the lever.

Turn signal lever 0.

This switch (8) is used to operate the turn signal lamp. (a) position : LEFT TURN (Push lever FORWARD.) (b) position : OFF (c) position : RIGHT TURN (Pull lever BACK.)

REMARK When the lever is operated, the pilot lamp turn signal

pilot lamp also flashes.

When the steering wheel is turned back, the lever auto-

matically returns to its original position. If it does not return, return it manually.

Dimmer switch 0.

This switch (8) is used to switch the head lamps between high beam and low beam. Position (a): Low beam Position (b): High beam

Horn button 0.

When the horn button (9) in the center of the steering wheel is pressed, the horn will sound.

3-33

Explanation of components OPERATION Switches

Hazard lamp switch 0.

WARNING

Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators.

This switch (10) 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

Front working lamp switch 0.

WARNING

Always turn the working lamp off before traveling on public roads.

This switch (11) 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

REMARK If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light up.

Rear working lamp switch 0.

WARNING

Always turn the working lamp off before traveling on public roads.

This switch (12) 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

REMARK If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light up.

3-34

OPERATION Explanation of components

Switches

Monitor panel mode selector switch 1 0.

This switch (13) 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.

Monitor panel mode selector switch 2 0.

This switch (14) 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.

Front wiper switch 0.

When rotary switch (A) of this switch (15) is turned, the front wiper will move. If push button (B) is pressed, washer liquid will be sprayed out onto the front glass while the button is being pressed.

Display

window Position(a): (OFF) stop Position(b): (INT) Intermittent wiper Position(c): Low-speed wiper Position(d): High-speed wiper

Push button

Rotary switch

9EM00795A

Rear wiper switch 0.

When lever (C) of this switch (16) 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.

Lever

9EM00796A

3-35

Explanation of components OPERATION Switches

Cigarette lighter 0.

This is used to light cigarettes. After cigarette lighter (17) 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 0.

The switch (18) is used to turn the room lamp ON and OFF.

Position (a): OFF Position (b): Lights up when the cab door opens Position (c): Lights up

REMARK The room lamp lights up even when the main switch is

OFF, so when leaving the operator's compartment, turn the switch to position (a) (OFF) or (b).

When operating with the cab door fully open, set the

switch to position (a) (OFF).

Rear heated wire glass switch 0.

When this switch (19) 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) Position (b): OFF

3-36

OPERATION Explanation of components

Switches

Attachment selection switch 0.

This switch (20) switches the bucket positioner and fork positioner.

Position (a): When using the bucket, set to this position. Position (b): When using the fork, set to this position.

Dump speed switch 0.

Use this switch (21) to select the bucket dump speed.

Position (a): High speed Position (b): Low speed

REMARK The bucket tilt speed is not affected by this switch.

3-37

Explanation of components OPERATION Control levers, pedals

Control levers, pedals 0.

(1) Directional lever (5) Brake pedal

(2) Safety lock lever (for work equipment lever) (6) Accelerator pedal

(3) Work equipment lever (7) Parking brake lever

(4) Auxiliary control lever

DIRECTIONAL LEVER 0.

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 the 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 central warning lamp lights up and the alarm buzzer sounds intermittently. When the directional lever is set to the N position, the central warning lamp goes out and the alarm buzzer stops.

3-38

OPERATION Explanation of components

Control levers, pedals

Safety lock lever (for work equipment lever) 0.

WARNING

Before leaving the operator's seat, set the safety lock lever securely to the LOCK position. If the

safety lock lever is not at the LOCK position, and work equipment control lever is touched by mistake, it may lead to a serious accident.

If the safety lock lever is not placed securely at the 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 the LOCK position.

When pulling up or pushing down the safety lock lever, be careful not to touch work equipment con-

trol lever.

This lever (2) is a lock device for the work equipment control lever. Push the safety lock lever down to lock it.

REMARK If the safety lock lever is at the LOCK position, the work equipment will not move even when the work equipment control lever is operated.

Free

Lock

9EA04443A

Work equipment lever 0.

Use this lever (3) to operate the lift arm and bucket.

NOTICE Do not use the FLOAT position when lowering the bucket. Use the FLOAT position when leveling, see “Leveling operations on page 3-86“.

Position (a): RAISE

When the work equipment 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 and bucket stop and remain in the same posi-

tion. Position (c): LOWER Position (d): FLOAT

The lift arm moves freely under external force.

Position (e): TILT

When the work equipment 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 (f): DUMP

3-39

Explanation of components OPERATION Control levers, pedals

Auxiliary control lever 0.

(When multi-purpose bucket is installed) This lever (4) operates the clam on the multi-purpose bucket.

Position (a): Clam closes Position (b): HOLD The clam stops and remains in the same position. Position (c): Clam opens

Brake pedal 0.

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.

REMARK When using the brake pedal and accelerator pedal together to reduce the travel speed or stop the machine when carrying out the operation, it is more convenient to use the left brake pedal.

Accelerator pedal 0.

This pedal (6) controls the engine speed and output. The engine speed can be freely controlled between low idling and full speed.

3-40

OPERATION Explanation of components

Steering tilt lock lever

Parking brake lever 0.

WARNING

Always apply the parking brake when leaving the machine or when parking it.

NOTICE Never use the parking brake lever to brake 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 max-

imum speed), contact your Komatsu distributor to have the parking brake checked for any abnormality.

This lever (7) 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.

Lock

REMARK If the directional lever is placed at the FORWARD or REVERSE position with the parking brake still applied, the central 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.

Free

9EA04447A

Steering tilt lock lever 0.

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).

3-41

Explanation of components OPERATION Cap and cover with lock

Cap and cover with lock 0.

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 on page 3-95“. Insert the key as far as it will go, then turn it. If the key is turned before it is inserted fully, it may break.

Shoulder

AW35805B-A

Method of opening and closing cap with lock 0.

(For the fuel tank filler port)

To open the cap 0.

1. Insert the key into the key slot.

2. Turn the key clockwise, align the key slot with the match mark on the cap, then open the cap.

Match mark

Lock

Open

AW36171B-A

To lock the cap 0.

1. Turn the cap until tight, then insert the key into the key slot.

2. Turn the key counterclockwise and take the key out.

Method of opening and closing cover with lock 0.

(Engine side cover)

To open the cover 0.

1. Insert the key into the key slot.

2. Turn the key counterclockwise and open the cover by pulling the cover grip.

Open

Lock

9EH00425A

To lock the cover 0.

1. Close the cover and insert the key into the key slot.

2. Turn the key clockwise and take the key out.

3-42

KOMATSU WA250-M Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

Foreword FOREWORD

Safety information FOREWORD

Introduction 0.

Directions of machine 0.

FOREWORD Necessary information

Machine serial No. plate and position

Engine serial No. plate and position 0.

Position of service meter 0.

Table to enter serial No. and distributor 0.

Contents............................................................................................................................................................... 1-9

FOREWORD Dimensions, weights and operating data

WA250PT-5H: Dimensions, weights and operating data

CE-conforming equipment 0.

CE-conforming equipment

SAFETY

SAFETY Safety labels

Location of safety labels

Presentation of safety labels 0.

SAFETY General precautions

Safety rules

Precautions for operation 0.

Starting engine 0.

Operation

Transportation 0.

Battery

Towing

Precautions for maintenance 0.

Safety instructions 0.

SAFETY Precautions with tires

Handling tires

Precautions when storing tires 0.

OPERATION

OPERATION General view

General view of machine

General view of controls and gauges 0.

Explanation of components 0.

Machine monitor 0.

Monitor system 0.

Types of warning 0.

Central warning lamp 0.

Character display portion 0.

Emergency stop item 0.

Caution items 0.

Warning/limit functions for travel speed 0.

Inspection and maintenance item 0.

Pilot display portion 0.

Meter display portion 0.

Other functions of machine monitor 0.

Switches 0.

Control levers, pedals 0.

Steering tilt lock lever

Cap and cover with lock 0.