Komatsu WA180-3 Manual

CEAM001302
Operation&Maintenance
Manual
WA180 -3
WA180L -3
WHEEL LOADER
SERIAL NUMBERS WA180-3 A80001and up
WA180L-3 54001and up
ENGINE 6D102E-1
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2016 Komatsu
Printed in U.S.A.
Komatsu America Corp.
April 2016

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PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENTOWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS
IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
Engine and Chassis ..................................................... BEPB002100
PARTS BOOK - MICROFICHE:
Engine and Chassis ..................................................... BEPM002100
OPERATION & MAINTENANCE MANUAL:
Chassis .............................................................. CEAM001300
SHOP MANUAL:
Chassis .............................................................. CEBM001100
Engine ............................................................... SEBM010002
SAFETY MANUAL .......................................................... WLT70-1
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,
USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTEM
(PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D
IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
PUBINFO.KOM 121296
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PURCHASE ORDER NO.
ORDER DATE
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO << Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. [phone]
Tel No. [phone]
COMPANY NAME
ATTN.
STREET ADDRESS
CITY, STATE, ZIP CODE
COUNTRY
SHIP TO <<
TYPE or PRINT
ONLY <<
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
PARTS BOOK
M-Microfiche
PUBLICATION
DESCRIPTION
KDC91D 121296 CURRENT PRICES WILL BE CHARGED
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0-1
INTRODUCTION
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INTRODUCTION
0-2
1. FORWARD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will
help the operator and maintenance personnel realize peak performance through effective, economical and safe
machine operation and maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not
be read, request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this
manual. Consult your local distributor or Komatsu America International Company for the latest available information
on your machine or for questions regarding information in this manual.
WARNING
!! Improper operation and maintenance of this machine can be hazardous and could result in serious injury
or death.
!! Operators and maintenance personnel must read this manual thoroughly before operating or maintaining
this machine.
!! This manual should be kept near the machine for reference and periodically reviewed by all personnel
who come across it.
!! Some actions involved in operation and maintenance can cause a serious accident, if they are not
performed in the manner described in this manual.
!! The procedures and precautions given in this manual apply only to intended uses of the machine. If you
use your machine for any unintended uses that are not specifically prohibited, you must be sure that it
is safe for you and others. In no event should you or others engage in prohibited uses or actions as
described in this manual.
!! Komatsu America International Company delivers machines that comply with all applicable regulations
and standards of the country to which it has been shipped. If this machine has been purchased in
another country or purchased from someone in another country, it may lack certain safety features and
specifications that are necessary for use in your country. If there is any question about whether your
productcomplies with the applicable standards and regulations of your country, consult your local
distributor or Komatsu America International Company before operating the machine.
!! The description of safety is given in SAFETY INFORMATION on page 0-2 and in SAFETY from page 1-1.
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INTRODUCTION
0-3
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the
machine before performing maintenance and machine operations.
To identify safety messages in this manual and on machine product graphics, the following signal words are used.
DANGER! - This word is used on safety messages and product graphics where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages and product graphics usually describe precautions that must be taken to
avoid the hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
WARNING! - This word is used on safety messages and product graphics where there is a
potentially dangerous situation, which could result in serious injury or death if the
hazard is not avoided. These safety messages and product graphics usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard may
also result in serious damage to the machine.
CAUTION! - This word is used on safety messages and product graphics for hazards, which could
result in minor or moderate injury if the hazard is not avoided. These safety messages
and product graphics might also use this word for hazards where the only result could
be damage to the machine.
NOTICE - This word is used for precautions that must be taken to avoid actions, which could shorten
the life of the machine.
Safety precautions are described in SAFETY beginning on page 1-1.
Komatsu America International Company cannot predict every circumstance that might involve a potential hazard in
operationand maintenance. Therefore the safety message in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are
used, you must be sure that you and others can do such procedures and actions safely and without damaging the
machine. If you are unsure about the safety of some procedures, contact your local distributor or Komatsu America
International Company.
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INTRODUCTION
0-4
3. INTRODUCTION
3.1 INTENDED USE
This WHEEL LOADER is designed to be used mainly for the following work:
!Digging
!Leveling
!Pushing
!Loading
For details of the operating procedures, see "12.13 WORK POSSIBLE USING WHEEL LOADER" on page 2-46
3.2 FEATURES
!Curved glass and improved sealing for reduced noise, low vibration cab.
!Console and steering post with unencumbered foot area providing the same comfortable feeling as in an
automobile
!Maintenance-free, wet-type disc parking brake (acts also as emergency brake).
!One-touch panel control and air conditioner with new refrigerant installed.
!Full fender system installed to help prevent mud or water from splashing on or around the machine.
!Light touch lever operations through use of electrical transmission control lever
!Pleasant operators compartment with low vibration and noise levels
!Large gull-wing side panels and a rear grill that opens fully for ease of maintenance
!Large safety lock lever for work equipment to ensure that operator does not forget to apply safety lock
!New engine that meets exhaust gas emission of 96 EPA & carb.
3.3 BREAKING IN A NEW MACHINE
Your machine has been thoroughly adjusted and tested before shipment. However, operating the machine under
severe conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter).
During breaking in:
!After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation.
!Avoid operation with heavy loads or at high speeds.
!Avoid sudden starts or acceleration, unnecessarily abrupt stops and sharp steering except in cases of emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply
when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this
manual, Komatsu America International Company cannot bear any responsibility for safety. All consideration of safety
in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstance.
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INTRODUCTION
0-5
4. LOCATIONOF PLATES, TABLE TO ENTER SERIAL NO. AND
DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
(A) Position of plate
On the center right of the front frame.
(B) Position of stamp
This is stamped on the center of the front frame on the right hand side of
the machine.
4.2 ENGINE SERIAL NO. PLATE POSITION
Position of plate
As viewed from the right hand side of the machine.
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
REMARKS

INTRODUCTION
0-6
5. CONTENTS
INTRODUCTION
1. FORWARD .............................................................................. 0-2
2. SAFETY INFORMATION ................................................................... 0-3
3. INTRODUCTION ......................................................................... 0-4
3.1 INTENDED USE ........................................................................ 0-4
3.2 FEATURES ............................................................................ 0-4
3.3 BREAKING IN A NEW MACHINE .......................................................... 0-4
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ...................... 0-5
4.1 MACHINE SERIAL NO. PLATE POSITION ................................................... 0-5
4.2 ENGINE SERIAL NO. PLATE POSITION .................................................... 0-5
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR .......................................... 0-5
5. CONTENTS ............................................................................. 0-6
SAFETY
6. GENERAL PRECAUTIONS ................................................................. 1-2
7. PRECAUTIONS DURING OPERATION ....................................................... 1-8
7.1 BEFORE STARTING ENGINE ............................................................. 1-8
7.2 AFTER STARTING ENGINE ............................................................. 1-11
7.3 TRANSPORTATION .................................................................... 1-20
7.4 BATTERY ............................................................................ 1-21
7.5 TOWING ............................................................................. 1-24
8. PRECAUTIONS FOR MAINTENANCE ....................................................... 1-25
8.1 BEFORE CARRYING OUT MAINTENANCE ................................................ 1-25
8.2 DURING MAINTENANCE ................................................................ 1-30
8.3 TIRES ............................................................................... 1-35
9. POSITION FOR ATTACHING SAFETY LABELS ............................................... 1-37
9.1 POSITION FOR ATTACHING SAFETY LABELS ............................................. 1-37
OPERATION
10. GENERAL VIEW ......................................................................... 2-2
10.1 GENERAL VIEW OF MACHINE .......................................................... 2-2
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ........................................... 2-3
11. EXPLANATION OF COMPONENTS .......................................................... 2-5
11.1 METER, LAMPS ...................................................................... 2-5
11.2 SWITCHES .......................................................................... 2-9
11.3 CONTROL LEVERS, PEDAL ........................................................... 2-15
11.4 CAP WITH LOCK .................................................................... 2-19
11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK ............................... 2-19
11.5 SAFETY BAR ........................................................................ 2-19
11.6 TOWING PIN ........................................................................ 2-20
11.7 GREASE PUMP CLAMP AND RUBBER RING ............................................. 2-20
11.8 BACKUP ALARM ..................................................................... 2-20
11.9 FUSE .............................................................................. 2-21
11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT ............................................ 2-21

INTRODUCTION
0-7
11.10 SLOW BLOW FUSE ................................................................ 2-22
11.11 STORAGE PLACE FOR THIS MANUAL ................................................ 2-23
11.12 AUXILIARY POWER SOURCE ........................................................ 2-23
11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB ........................................ 2-23
12. CHECK BEFORE STARTING ENGINE ...................................................... 2-24
12.1 WALK AROUND CHECK .............................................................. 2-24
12.2 CHECK BEFORE STARTING ........................................................... 2-27
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT ........................................... 2-27
12.2.2 CHECK FUEL LEVEL, ADD FUEL ................................................... 2-27
12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL ..................................... 2-28
12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK ..................................... 2-28
12.2.5 CHECK DUST INDICATOR ......................................................... 2-29
12.2.6 CHECK ELECTRICAL WIRING ...................................................... 2-29
12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR ........................... 2-30
12.2.8 CHECK EFFECT OF PARKING BRAKE ............................................... 2-30
12.2.9 CHECK EFFECT OF WHEEL BRAKES ............................................... 2-31
12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM ..................................... 2-31
12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE ........................ 2-31
12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND ..................................... 2-31
12.2.13 CHECK OPERATIONS OF GAUGES ................................................. 2-31
12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING ................ 2-31
12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE ............ 2-31
12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB .................... 2-31
12.3 ADJUSTMENT BEFORE OPERATION ................................................... 2-32
12.3.1 OPERATOR'S SEAT .............................................................. 2-32
12.3.2 ADJUST SEAT BELT .............................................................. 2-34
12.3.3 ADJUST REAR VEIW MIRRORS .................................................... 2-35
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE ................................. 2-36
12.5 STARTING ENGINE .................................................................. 2-37
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS ................. 2-37
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE ............ 2-38
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS .......................... 2-38
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL ............................ 2-38
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE .................................. 2-39
12.7 MOVING MACHINE OFF ............................................................... 2-40
12.8 CHANGING GEAR SPEED ............................................................. 2-42
12.9 CHANGING DIRECTION .............................................................. 2-42
12.10 TURNING ......................................................................... 2-43
12.11 STOPPING MACHINE ............................................................... 2-44
12.12 OPERATION OF WORK EQUIPMENT .................................................. 2-45
12.13 WORK POSSIBLE USING WHEEL LOADER ............................................ 2-46
12.13.1 DIGGING OPERATIONS WITH ROCK PILES .......................................... 2-46
12.13.2 DIGGING OPERATIONS ON LEVEL GROUND ......................................... 2-47
12.13.3 LEVELING OPERATION ........................................................... 2-48
12.13.4 PUSHING OPERATIONS ........................................................... 2-48
12.13.5 LOAD AND CARRY OPERATIONS ................................................... 2-48
12.13.6 LOADING OPERATIONS ........................................................... 2-49
12.14 PRECAUTIONS FOR OPERATION .................................................... 2-50
12.14.1 PERMISSIBLE WATER DEPTH ..................................................... 2-50
12.14.2 IF WHEEL BRAKE DOES NOT WORK ................................................ 2-50
12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES ............................... 2-50
12.14.4 PRECAUTIONS WHEN DRIVING MACHINE ........................................... 2-51
12.15 ADJUSTING WORK EQUIPMENT POSTURE ........................................... 2-52
12.15.1 ADJUSTING BOOM KICKOUT ...................................................... 2-52
12.15.2 ADJUSTING BUCKET POSITIONER ................................................. 2-53
12.15.3 BUCKET LEVEL INDICATOR ....................................................... 2-53
12.16 PARKING MACHINE ................................................................ 2-54
12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION ................................ 2-55

INTRODUCTION
0-8
12.18 STOPPING ENGINE ................................................................ 2-55
12.19 CHECKS AFTER STOPPING ENGINE ................................................. 2-56
12.20 LOCKING ......................................................................... 2-56
12.21 HANDLING THE TIRES .............................................................. 2-57
12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES ........................................ 2-57
12.21.2 TIRE PRESSURE ................................................................. 2-57
13. TRANSPORTATION ..................................................................... 2-59
13.1 LOADING, UNLOADING WORK ........................................................ 2-59
13.2 PRECAUTION FOR LOADING ........................................................ 2-60
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE ........................................... 2-60
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS ...................... 2-61
13.3.2 WEIGHT LIST .................................................................... 2-61
13.3.3 LIFTING PROCEDURE ............................................................ 2-62
14. COLD WEATHER OPERATIONS ........................................................... 2-63
14.1 PRECAUTIONS FOR LOW TEMPERATURE .............................................. 2-63
14.1.1 FUEL AND LUBRICANTS .......................................................... 2-63
14.1.2 COOLANT ....................................................................... 2-63
14.1.3 BATTERY ....................................................................... 2-64
14.2 PRECAUTIONS AFTER COMPLETION OF WORK ......................................... 2-65
14.3 AFTER COLD WEATHER ............................................................. 2-65
15. LONG TERM STORAGE .................................................................. 2-66
15.1 BEFORE STORAGE .................................................................. 2-66
15.2 DURING STORAGE .................................................................. 2-66
15.3 AFTER STORAGE ................................................................... 2-66
16. TROUBLESHOOTING .................................................................... 2-67
16.1 WHEN MACHINE RUNS OUT OF FUEL .................................................. 2-67
16.2 TOWING THE MACHINE .............................................................. 2-68
16.2.1 WHEN ENGINE CAN BE USED ..................................................... 2-70
16.2.2 WHEN ENGINE CANNOT BE USED ................................................. 2-70
16.3 IF BATTERY IS DISCHARGED ......................................................... 2-71
16.3.1 REMOVAL AND INSTALLATION OF BATTERY ........................................ 2-71
16.3.2 PRECAUTIONS FOR CHARGING BATTERY .......................................... 2-72
16.3.3 STARTING ENGINE WITH BOOSTER CABLE ......................................... 2-73
16.4 OTHER TROUBLE ................................................................... 2-75
16.4.1 ELECTRICAL SYSTEM ............................................................ 2-75
16.4.2 CHASSIS ........................................................................ 2-76
16.4.3 ENGINE ......................................................................... 2-79
MAINTENANCE
17. GUIDES TO MAINTENANCE ............................................................... 3-2
18. OUTLINES OF SERVICE ................................................................... 3-5
18.1 OUTLINE OF OIL, FUEL, COOLANT ...................................................... 3-5
18.1.1 OIL .............................................................................. 3-5
18.1.2 FUEL ............................................................................ 3-6
18.1.3 COOLANT ........................................................................ 3-6
18.1.4 GREASE ......................................................................... 3-7
18.1.5 STORING OIL AND FUEL ........................................................... 3-7
18.1.6 FILTERS ......................................................................... 3-7
18.2 OUTLINE OF ELECTRIC SYSTEM ....................................................... 3-8
19. WEAR PARTS LIST ....................................................................... 3-9
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ......... 3-10

INTRODUCTION
0-9
20.1 ENGINE OIL SPECIFICATIONS ......................................................... 3-11
20.2 DIESEL FUEL SPECIFICATIONS ........................................................ 3-12
20.3 COOLANT SPECIFICATIONS .......................................................... 3-13
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ................................... 3-19
21.1 INTRODUCTION OF NECESSARY TOOLS ............................................... 3-19
21.2 TORQUE LIST ....................................................................... 3-20
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ..................................... 3-22
23. MAINTENANCE SCHEDULE CHART ....................................................... 3-26
23.1 MAINTENANCE SCHEDULE CHART .................................................... 3-26
24. SERVICE PROCEDURES ................................................................. 3-30
24.1 INITIAL 250 HOURS SERVICE .......................................................... 3-30
24.1.1 REPLACE FUEL FILTERS .......................................................... 3-30
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT ..................................... 3-30
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT ...................................... 3-30
24.2 WHEN REQUIRED ................................................................... 3-31
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT ............................... 3-31
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL ......................................... 3-33
24.2.3 CHECK AXLE OIL LEVEL , ADD OIL ................................................. 3-34
24.2.4 CLEAN THE AXLE CASE BREATHER ................................................ 3-35
24.2.5 CLEAN RADIATOR FINS ........................................................... 3-35
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES .......................................... 3-36
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED) ........................................... 3-37
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED) ........................................... 3-38
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED) .......................... 3-39
24.2.10 CHECK WINDOW WASHING FLUID ................................................. 3-39
24.2.11 ADJUST PARKING BRAKE ......................................................... 3-40
24.2.12 REPLACE SLOW BLOW FUSE ...................................................... 3-41
24.2.13 CHECK AIR INTAKE HEATER ...................................................... 3-41
24.3 CHECK BEFORE STARTING ........................................................... 3-42
24.4 EVERY 50 HOURS SERVICE ........................................................... 3-43
24.4.1 CHECK THE TIRE INFLATION PRESSURE ........................................... 3-43
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK ....................................... 3-43
24.5 EVERY 100 HOURS SERVICE ......................................................... 3-44
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL .................................... 3-44
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER ............................ 3-45
24.5.3 LUBRICATING ................................................................... 3-46
24.6 EVERY 250 HOURS SERVICE ......................................................... 3-47
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER ................... 3-47
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN ................................... 3-48
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER ...................... 3-48
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST .................... 3-49
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL ............................................ 3-50
24.6.6 CHECK AIR INTAKE SYSTEM ...................................................... 3-50
24.6.7 LUBRICATING ................................................................... 3-51
24.7 EVERY 500 HOURS SERVICE ......................................................... 3-52
24.7.1 REPLACE FUEL FILTERS .......................................................... 3-52
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT ..................................... 3-54
24.7.3 LUBRICATE ..................................................................... 3-55
24.8 EVERY 1000 HOURS SERVICE ........................................................ 3-56
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER ............................. 3-56
24.8.2 CLEAN TRANSMISSION CASE BREATHER ........................................... 3-57
24.8.3 LUBRICATE ..................................................................... 3-58
24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT ......... 3-59
24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE ......................................... 3-60
24.8.6 CHECK FAN BELT TENSION ....................................................... 3-61

INTRODUCTION
0-10
24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT ..... 3-61
24.9 EVERY 2000 HOURS SERVICE ........................................................ 3-62
24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM .................... 3-62
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT .................................. 3-65
24.9.3 CHANGE AXLE OIL ............................................................... 3-65
24.9.4 CHECK BRAKE DISC WEAR ....................................................... 3-66
24.9.5 CHECK ALTERNATOR ............................................................ 3-66
24.9.6 CHECK STARTER MOTOR ......................................................... 3-66
24.9.7 CHECK VIBRATION DAMPER ...................................................... 3-66
24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER
................................................................................ 3-66
24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE ......................................... 3-67
SPECIFICATONS
25. SPECIFICATIONS ........................................................................ 4-2
OPTIONS, ATTACHMENTS
26. AVAILABLE ATTACHMENTS ............................................................... 5-2
27. HEATER AND AIR CONDITIONING (IF EQUIPPED) ............................................ 5-4
27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL ............................... 5-4
27.2 COOL BOX COMPARTMENT ........................................................... 5-5
28. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) ....................... 5-6
28.1 STRUCTURE AND FUNCTION OF E.C.S.S. ............................................... 5-6
28.2 METHOD OF OPERATING E.C.S.S. ...................................................... 5-7
28.3 PRECAUTIONS WHEN OPERATING E.C.S.S. ............................................. 5-7
28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR ....................................... 5-8

1-1
SAFETY
WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional
equipment and attachments.

SAFETY WARNING: For reasons of safety, always follow
these safety precautions.
1-2
6. GENERAL PRECAUTIONS
SAFETY RULES
!ONLY trained and authorized personnel should be allowed to operate and service this machine.
!Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
!The owner and/or operator must replace any and all safety and warning product graphics if they are defaced
or removed from the machine.
!Think before you act. Careful operators and service personnel are the best insurance against accidents.
!Do not rush. Hurrying can lead to accidents. Haste, carelessness and lack of training are the primary causes
of equipment-related injuries.
!The operator must be alert, physically fit and free from the influences of alcohol, drugs and medications that
might affect his eyesight, hearing or reactions.
!Safety must always be the operator's most important concern. He must refuse to operate when he knows it is
unsafe and consult his supervisor when safety is in doubt.
!When working with another operator or a person on worksite traffic duty, be sure all personnel understand all
hand signals that are to be used.
SAFETY FEATURES
!Be sure all guards and covers are in their proper position. Be sure to replace them after servicing the machine.
Have guards and covers repaired immediately if damaged.
Proper position öö "See 12.1 WALK-AROUND CHECK" on page 2-24.
!Use safety features such as safety lock lever and seat belt properly.
!A seat belt is required by OSHA in almost all applications. DO NOT operate
this machine without a seat belt.
!NEVER remove any safety features. ALWAYS keep them in good operating
condition.
Safety lock lever öö See "12.16 PARKING MACHINE" on page 2-54.
Seat belts öö See "12.3.2 ADJUSTMENT BEFORE OPERATION" on page 2-34.
!Improper use of safety features could result in serious bodily injury or death.
!Be sure the machine has the correct equipment required by local rules and regulations.
UNAUTHORIZED MODIFICATION
!Any modification made without authorization from Komatsu America International Company can create
hazards.
!Before making a modification, consult your local distributor. Komatsu America International Company will not
be responsible for any injury or damage caused by any unauthorized modification.

WARNING: Failure to follow these safety precautions
may lead to a serious accident. SAFETY
1-3
CLOTHING AND PERSONAL PROTECTIVE ITEMS
!Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause
serious injury or death. Also, do not wear oily clothes because they are flammable.
!Also do not wear oily clothes, because they are flammable.
!Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine.
Always wear safety goggles, hard hat and heavy gloves if your job involves scattering metal chips or minute
materials - this is particularly important when driving pins with a hammer and when cleaning the air cleaner
element with compressed air. Also check that there are no other personnel near the machine.
!Check that all protective equipment functions properly before using.
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT
!When standing up from the operator's seat, always place the safety lock lever securely in the LOCK position. If
you accidentally touch the equipment levers when they are not locked, the machine or work equipment may
move and cause serious injury or damage.
!When leaving the machine, lower the work equipment completely to the ground, set the safety lock lever to the
LOCK position and the parking brake pedal to the LOCK position then stop the engine and use the key to lock
all the equipment locks. Always take the key with you.
Work equipment posture öö See "12.16 PARKING MACHINE" on page 2-54.
Locks öö See "12.20 LOCKING" on page 2-56.

SAFETY WARNING: For reasons of safety, always follow
these safety precautions.
1-4
MOUNTING AND DISMOUNTING
!NEVER jump on or off the machine. NEVER get on or off a moving machine.
!When mounting or dismounting, always face the machine and use the handrails and steps.
!Do not use the machine's controls or hoses as handrails when climbing on or off the machine. Controls and
hoses can move and do not provide solid support. Movement of the controls may cause unexpected machine
movement and injury.
!Ensure safety by always maintaining at least three-point contact of hands and feet with the handrails and
steps.
!Always remove any oil or mud from the handrails and steps. If they are damaged, repair them and tighten any
loose hardware.
FIRE PREVENTION FOR FUEL AND OIL
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
!Keep any flame away from flammable fluids.
!Stop the engine and do not smoke when refueling.
!Tighten all fuel and oil caps securely.
!Refueling and oiling should be made in well ventilated areas.
!Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES