Komatsu WA270-8 Manual

CEAM031701
Operation&Maintenance
Manual
WA270 -8
WHEEL LOADER
SERIAL NUMBERS WA270-8 A28001 and up
ENGINE 6D107E-3
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
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
July 2016 Komatsu America Corp.

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CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some ofits
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and
related accessories contain lead
and lead compounds, chemicals
known to the State of California
to cause cancer, birth defects and
reproductive harm.
Wash hands after handling.
FOREWORD
1-1
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BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the in-
dicated location so that all relevant personnel can read it at any
time.
Keep it in the box for the Operation and Maintenance Manual
(1) on the left side of the operator's seat.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.
BEFORE READING THIS MANUAL FOREWORD
1-2
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SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
1-3
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INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
• Digging work
• Leveling work
• Dozing work
• Loading work
For details of the work procedure, see “RECOMMENDED APPLICATIONS (3-191)”.
DIRECTIONS OF MACHINE
(A) Front
(B) Rear
(C) Left
(D) Right
(E) Bucket
(F) Operator's seat
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from
the operator's seat in the direction of travel (front) of the machine.
VISIBILITY FROM OPERATOR'S SEAT
This machine complies with the visibility standard (ISO5006).
This machine maintains a proximity visibility of a height of 1.5 m {4 ft 11 in} at a point 1 m {3 ft 3 in} away from
the outside surface of the machine, and a visibility for a radius of 12 m {39 ft 4 in}.
Protective structures
This machine is equipped with a structure to protect the operator (ROPS) conforming to ISO3471.
INTRODUCTION FOREWORD
1-4
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ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS
EMISSION
About Engine Technology
This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EPA Tier4 Final emission regulation in North America.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the aqueous urea solution for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, that is API (American Petroleum Institute) certified and fulfills the quality requirements in ac-
cordance with ISO 22241-1, is to be used. The certified DEF has the API DIESEL EXHAUST FLUID Certifica-
tion Mark shown as follows. Look for the API DEF Certification Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade mark of
API (American Petroleum Institute).
FOREWORD ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
1-5
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PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-
AL NO. PLATE
This is located at the center of the front frame on the right side of the machine.
The design of the nameplate differs according to the district.
LOCATION OF ENGINE NUMBER PLATE
This is located at the right top of the engine rear part on the right side of the machine.
PRODUCT INFORMATION FOREWORD
1-6
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SERVICE METER LOCATION
It is at the center bottom of the machine monitor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Distributor name
Address
Phone/Fax
Service personnel
FOREWORD PRODUCT INFORMATION
1-7

TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
BEFORE READING THIS MANUAL ......................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-3
INTRODUCTION ...................................................................................................................................... 1-4
MAIN USE OF MACHINE .................................................................................................................. 1-4
DIRECTIONS OF MACHINE.............................................................................................................. 1-4
VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-4
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION..................................................... 1-5
PRODUCT INFORMATION....................................................................................................................... 1-6
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........ 1-6
LOCATION OF ENGINE NUMBER PLATE ........................................................................................ 1-6
SERVICE METER LOCATION........................................................................................................... 1-7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................................................. 1-7
SAFETY........................................................................................................................................................... 2-1
SAFETY.................................................................................................................................................... 2-2
SAFETY LABELS ..................................................................................................................................... 2-4
LOCATION OF SAFETY LABELS...................................................................................................... 2-5
CONTENTS OF SAFETY LABELS .................................................................................................... 2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-15
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-15
PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-18
DO NOT GET CAUGHT................................................................................................................... 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-21
UNAUTHORIZED MODIFICATION .................................................................................................. 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING..................................................... 2-21
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-22
PRECAUTIONS FOR JOBSITE....................................................................................................... 2-22
START ENGINE............................................................................................................................... 2-24
PRECAUTIONS FOR OPERATION ................................................................................................. 2-26
PRECAUTIONS FOR TRANSPORTATION...................................................................................... 2-31
TOWING AND BEING TOWED........................................................................................................ 2-32
PRECAUTIONS FOR MAINTENANCE................................................................................................... 2-33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-33
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-36
TIRES .............................................................................................................................................. 2-41
PRECAUTIONS FOR DEF...................................................................................................................... 2-42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING .................................................. 2-42
PRECAUTIONS FOR ADDING........................................................................................................ 2-42
PRECAUTIONS FOR STORING...................................................................................................... 2-42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE .................................................................... 2-42
OTHER PRECAUTIONS.................................................................................................................. 2-42
OPERATION .................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES................................................................................................. 3-3
OTHER EQUIPMENT NAME............................................................................................................. 3-7
EXPLANATION OF COMPONENTS....................................................................................................... 3-10
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................. 3-10
SWITCHES...................................................................................................................................... 3-90
CONTROL LEVERS AND PEDALS............................................................................................... 3-105
OTHER EQUIPMENT .................................................................................................................... 3-108
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-145
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-145
TABLE OF CONTENTS FOREWORD
1-8

METHOD FOR STARTING ENGINE.............................................................................................. 3-171
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-175
METHOD FOR STOPPING ENGINE ............................................................................................. 3-178
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE, AND SHIFTING GEAR)
AND STOPPING MACHINE ....................................................................................................... 3-179
METHOD FOR STEERING MACHINE........................................................................................... 3-187
METHOD FOR OPERATING WORK EQUIPMENT ....................................................................... 3-188
PRECAUTIONS FOR OPERATION ............................................................................................... 3-190
RECOMMENDED APPLICATIONS................................................................................................ 3-191
METHOD FOR ADJUSTING WORK EQUIPMENT POSTURE...................................................... 3-196
REMOTE POSITIONER................................................................................................................. 3-196
METHOD FOR PARKING MACHINE............................................................................................. 3-201
METHOD FOR CHECKING AFTER FINISHING WORK................................................................ 3-203
LOCK............................................................................................................................................. 3-203
HANDLE TIRE ............................................................................................................................... 3-206
HANDLE AIR CONDITIONER............................................................................................................... 3-208
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-209
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-214
HANDLE RADIO ................................................................................................................................... 3-218
EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-218
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-220
TRANSPORTATION.............................................................................................................................. 3-223
TRANSPORTATION PROCEDURE............................................................................................... 3-223
LOADING AND UNLOADING WITH TRAILER .............................................................................. 3-223
METHOD FOR LIFTING MACHINE............................................................................................... 3-226
COLD WEATHER OPERATION............................................................................................................ 3-229
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-229
PRECAUTIONS AFTER DAILY WORK COMPLETION ................................................................. 3-230
PRECAUTIONS IN COLD WEATHER ........................................................................................... 3-230
AFTER COLD WEATHER SEASON .............................................................................................. 3-230
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-231
PREPARATION FOR LONG-TERM STORAGE............................................................................. 3-231
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-231
STARTING MACHINE AFTER LONG-TERM STORAGE............................................................... 3-231
TROUBLES AND ACTIONS ................................................................................................................. 3-233
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-233
PRECAUTIONS FOR TOWING MACHINE.................................................................................... 3-233
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-236
OTHER TROUBLE......................................................................................................................... 3-239
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR ADDING DEF ................................................................................................. 4-2
PRECAUTIONS FOR WELDING ....................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-2
PRECAUTIONS FOR SCR ASSEMBLY ............................................................................................ 4-3
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
FOREWORD TABLE OF CONTENTS
1-9

CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-4
CLOSE ENGINE SIDE COVER SECURELY...................................................................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.............................................................. 4-10
MAINTENANCE SCHEDULE.................................................................................................................. 4-12
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-12
MAINTENANCE PROCEDURE .............................................................................................................. 4-14
INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) .................................. 4-14
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-14
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ........................ 4-14
WHEN REQUIRED .......................................................................................................................... 4-14
CHECKS BEFORE STARTING........................................................................................................ 4-40
EVERY 50 HOURS MAINTENANCE ............................................................................................... 4-41
EVERY 100 HOURS MAINTENANCE ............................................................................................. 4-41
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-45
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-52
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-56
EVERY 2000 HOURS MAINTENANCE ........................................................................................... 4-61
EVERY 4000 HOURS MAINTENANCE ........................................................................................... 4-77
EVERY 4500 HOURS MAINTENANCE ........................................................................................... 4-80
EVERY 8000 HOURS MAINTENANCE ........................................................................................... 4-80
EVERY 9000 HOURS MAINTENANCE ........................................................................................... 4-80
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
SPECIFICATIONS:WA270-8.............................................................................................................. 5-2
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
BUCKET AND TIRE SELECTION............................................................................................................. 6-2
HANDLE HYDRAULIC TYPE QUICK COUPLER ..................................................................................... 6-3
EXPLANATION OF COMPONENTS ON MACHINES WITH QUICK COUPLER................................ 6-3
METHOD FOR REMOVING ATTACHMENT ...................................................................................... 6-4
METHOD FOR INSTALLING ATTACHMENT..................................................................................... 6-5
HANDLE FORK ........................................................................................................................................ 6-8
EXPLANATION OF COMPONENTS ON MACHINES WITH FORK ................................................... 6-8
MACHINE OPERATIONS AND CONTROLS ..................................................................................... 6-9
PCS(PROPORTIONAL CONTROL SWITCH)......................................................................................... 6-15
LCD UNIT ........................................................................................................................................ 6-15
METHOD FOR SETTING PCS ........................................................................................................ 6-17
REPLACEMENT PARTS.................................................................................................................................. 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2
DEFINED LIFE PARTS LIST.............................................................................................................. 7-2
CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS LIST............................................................................................................. 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-4
LUBRICATION CHART...................................................................................................................... 7-5
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-7
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-8
INDEX.............................................................................................................................................................. 8-1
TABLE OF CONTENTS FOREWORD
1-10

SAFETY
Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.
2-1

SAFETY
SAFETY LABELS ............................................................................................................................................ 2-4
LOCATION OF SAFETY LABELS............................................................................................................. 2-5
CONTENTS OF SAFETY LABELS ........................................................................................................... 2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-15
ENSURE SAFE OPERATION .......................................................................................................... 2-15
UNDERSTAND THE MACHINE ....................................................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION ............................................................................................ 2-15
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ................................................................. 2-15
INSPECT MACHINE........................................................................................................................ 2-15
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT............................................. 2-15
KEEP MACHINE CLEAN ................................................................................................................. 2-15
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT ...................................................... 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ................................................................... 2-16
IF ANY PROBLEM IS FOUND ......................................................................................................... 2-16
PRECAUTIONS TO PREVENT FIRE...................................................................................................... 2-16
ACTIONS IF FIRE OCCURS ........................................................................................................... 2-16
PREVENT FIRE............................................................................................................................... 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.................................................................... 2-18
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE..................................... 2-18
NO JUMPING ON OR OFF MACHINE............................................................................................. 2-18
NO PEOPLE ON ATTACHMENTS................................................................................................... 2-19
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT.............................................. 2-19
PRECAUTIONS WHEN LEAVING MACHINE .................................................................................. 2-19
EMERGENCY EXIT FROM OPERATOR'S CAB.............................................................................. 2-20
PRECAUTIONS FOR CLEANING CAB GLASS............................................................................... 2-20
DO NOT GET CAUGHT.......................................................................................................................... 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-21
UNAUTHORIZED MODIFICATION ......................................................................................................... 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ........................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING............................................................ 2-21
PRECAUTIONS FOR OPERATION ............................................................................................................... 2-22
PRECAUTIONS FOR JOBSITE.............................................................................................................. 2-22
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS................................................................. 2-22
PRECAUTIONS WHEN WORKING ON LOOSE GROUND............................................................. 2-22
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................................ 2-22
ENSURE GOOD VISIBILITY............................................................................................................ 2-23
CHECK SIGNS AND SIGNALMAN'S SIGNALS............................................................................... 2-23
BEWARE OF ASBESTOS DUST..................................................................................................... 2-23
START ENGINE...................................................................................................................................... 2-24
USE WARNING TAGS ..................................................................................................................... 2-24
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ........................................................ 2-24
PRECAUTIONS WHEN STARTING ENGINE .................................................................................. 2-25
IN COLD WEATHER........................................................................................................................ 2-25
START ENGINE WITH JUMPER CABLES ...................................................................................... 2-25
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-26
CHECKS BEFORE OPERATION..................................................................................................... 2-26
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE............................................... 2-26
PRECAUTIONS WHEN TRAVELING............................................................................................... 2-27
PRECAUTIONS WHEN TRAVELING ON SLOPES ......................................................................... 2-27
METHOD OF USING BRAKES........................................................................................................ 2-28
PRECAUTIONS WHEN OPERATING MACHINE............................................................................. 2-28
PROHIBITED OPERATIONS ........................................................................................................... 2-29
PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES.................................. 2-30
PRECAUTIONS WHEN PARKING MACHINE ................................................................................. 2-30
PRECAUTIONS FOR TRANSPORTATION............................................................................................. 2-31
SAFETY SAFETY
2-2

PRECAUTIONS WHEN LOADING AND UNLOADING.................................................................... 2-31
TOWING AND BEING TOWED............................................................................................................... 2-32
PRECAUTIONS FOR TOWING AND BEING TOWED..................................................................... 2-32
PRECAUTIONS FOR MAINTENANCE.......................................................................................................... 2-33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-33
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ....................................... 2-33
KEEP WORK PLACE CLEAN AND TIDY ........................................................................................ 2-33
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE .......................................... 2-33
ONLY AUTHORIZED PERSONNEL................................................................................................. 2-33
APPOINT LEADER WHEN WORKING WITH OTHERS .................................................................. 2-33
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ........................... 2-33
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................... 2-35
TURN OFF ECSS SWITCH BEFORE PERFORMING INSPECTION AND MAINTENANCE ........... 2-35
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS...................... 2-35
PRECAUTIONS FOR WORKING AT HIGH PLACES ...................................................................... 2-36
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT .......................... 2-36
USE PROPER TOOLS .................................................................................................................... 2-36
PRECAUTIONS FOR CHECK AND MAINTENANCE ............................................................................. 2-36
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION....................................................... 2-36
PRECAUTIONS FOR WELDING ..................................................................................................... 2-37
HANDLE BATTERY ......................................................................................................................... 2-37
PRECAUTIONS WHEN USING HAMMER ...................................................................................... 2-38
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT ............................................................... 2-38
PRECAUTIONS FOR HIGH-TEMPERATURE OIL........................................................................... 2-38
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS..................................................................... 2-38
PRECAUTIONS FOR HIGH-PRESSURE OIL.................................................................................. 2-38
PRECAUTIONS FOR HIGH-PRESSURE FUEL .............................................................................. 2-39
HANDLE HIGH-PRESSURE HOSES AND PIPING ......................................................................... 2-39
PRECAUTIONS FOR NOISE........................................................................................................... 2-39
HANDLE ACCUMULATOR AND GAS SPRING............................................................................... 2-39
PRECAUTIONS FOR COMPRESSED AIR...................................................................................... 2-40
MAINTENANCE OF AIR CONDITIONER ........................................................................................ 2-40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS .......................................................... 2-40
METHOD FOR SELECTING WINDOW WASHER FLUID................................................................ 2-40
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS................................................................. 2-40
TIRES ..................................................................................................................................................... 2-41
HANDLE TIRES............................................................................................................................... 2-41
PRECAUTIONS FOR STORING TIRES .......................................................................................... 2-41
PRECAUTIONS FOR DEF............................................................................................................................. 2-42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING ......................................................... 2-42
PRECAUTIONS FOR ADDING............................................................................................................... 2-42
PRECAUTIONS FOR STORING............................................................................................................. 2-42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE ........................................................................... 2-42
OTHER PRECAUTIONS......................................................................................................................... 2-42
SAFETY SAFETY
2-3

SAFETY LABELS
kk
WARNING
Be sure that you fully understand the correct position, content and how to avoid a danger shown in the
safety labels.
Handle the warning signs and safety labels used on this machine as follows.
• Always keep the safety labels clean so that you can read it properly. When cleaning the safety labels, do
not use organic solvents or gasoline. These may cause the labels to peel off.
• If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details
of the part numbers for the safety labels, see this manual or the actual label, and place an order to your
Komatsu distributor.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the
same way.
SAFETY LABELS SAFETY
2-4

LOCATION OF SAFETY LABELS
SAFETY SAFETY LABELS
2-5

(1) Caution before operating
(2) Caution when leaving operator's seat
(3) Caution when traveling in reverse
(4) Caution for electric cables
(5) Prohibition of trespassing
(6) Caution for frame lock bar
(7) Caution for high-temperature coolant
(8) Caution for high-temperature oil and hydraulic oil
(9) Caution for handling battery cable
(10) Caution for explosion
(11) Caution for explosion
(12) Prohibition of getting on or off fender
(Machines equipped with rear full-length fender)
(13) Caution while engine is running
(14) Caution for nearing machine
(15) Prohibition of entering beneath work equipment
(16) Caution for modification of ROPS/FOPS
(17) Prohibition of start by short-circuiting
(18) Caution for cleaning cooler core
(19) Emergency escape
(20) Caution when closing emergency escape right
window
(21) Caution for high-temperature turbocharger
(22) Caution for hot exhaust pipe
(23) Caution for high-pressure common rail
(24) Caution for blast site
(Machines equipped with KOMTRAX)
(25) Caution for handling battery
(26) Caution when traveling in reverse
(Machine with rearview camera)
(27) Caution for handling DEF
SAFETY LABELS SAFETY
2-6