Komatsu WA75-3 User manual

VEAM950600
Operation&Maintenance
Manual
WA75 -3
WA85 -3
WHEEL LOADER
SERIAL NUMBERS WA75-3 HA950857 – HA951433
WA75-3 H21408 and up
WA85-3 HA960166 – HA960218
WA85-3 H20219 and up
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 2005 Komatsu
Printed in U.S.A.
Komatsu America Corp.
December 2004

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KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
OPERATION & MAINTENANCE MANUAL:
Chassis
SHOP MANUAL:
Engine
Chassis
SAFETY MANUAL:
VEAM950600
YMHINSHI-H8013
VEBM950102
WLT70-1
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0-1
TABLE OF CONTENTS 0
INTRODUCTION
FORWORD ................................................................................................................................................... 1-2
SAFETY INFORMATION .............................................................................................................................. 1-3
INTRODUCTION ........................................................................................................................................... 1-5
FEATURES ............................................................................................................................................ 1-5
BREAKING IN A NEW MACHINE ......................................................................................................... 1-5
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ..................................... 1-6
MACHINE SERIAL NO. PLATE POSITION ........................................................................................... 1-6
ENGINE SERIAL NO. PLATE POSITION .............................................................................................. 1-6
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR .......................................................................... 1-6
EMISSION CONTROL WARRANTY ............................................................................................................ 1-7
EMISSION CONTROL WARRANTY STATEMENT
(APPLIES TO CANADA ONLY) .............................................................................................................. 1-7
ENGINE DATA PLATE ................................................................................................................................. 1-8
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ................................................................................... 1-9
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULE-
MENT): ................................................................................................................................................... 1-9
ENGINE DATA PLATE ................................................................................................................................. 1-11
WHY YOU SHOULD READ THESE OPERATING INSTRUCTIONS .......................................................... 1-12
NOTES ON SAFETY REGULATIONS ......................................................................................................... 1-14
CORRECT USE ..................................................................................................................................... 1-14
SAFETY NOTES IN THE OPERATING INSTRUCTIONS ..................................................................... 1-14
EQUIPMENT ................................................................................................................................................. 1-15
LOADING AND TRANSPORTING THE MACHINE
LOADING AND TRANSPORTING THE MACHINE ..................................................................................... 2-2
SECURING THE ARTICULATED STEERING ...................................................................................... 2-2
LIFTING THE MACHINE ....................................................................................................................... 2-2
DRIVING MACHINE ONTO LOADING AREA OF TRANSPORT VEHICLE .......................................... 2-4
SECURING THE MACHINE DURING TRANSPORT ............................................................................ 2-5
AFTER TRANSPORT ............................................................................................................................ 2-5
SAFETY
GENERAL SAFETY MEASURES ................................................................................................................ 3-3
SAFETY INSTRUCTIONS ..................................................................................................................... 3-3
SAFETY DEVICES ................................................................................................................................ 3-3
EMERGENCY EXIT ............................................................................................................................... 3-3
CLOTHING AND PERSONAL PROTECTION ....................................................................................... 3-4
MACHINE MODIFICATIONS ................................................................................................................. 3-4
BEFORE YOU LEAVE THE DRIVER'S SEAT ....................................................................................... 3-4
MOUNTING AND DISMOUNTING ........................................................................................................ 3-5
FIRE PREVENTION AND FIRE FIGHTING ........................................................................................... 3-6
FIRE EXTINGUISHER AND FIRST-AID KIT ......................................................................................... 3-7
PROTECTION AGAINST ASBESTOS DUST ....................................................................................... 3-7
PROTECTION AGAINST INJURIES ..................................................................................................... 3-8
WORKING AT HIGH TEMPERATURES ................................................................................................ 3-8
ROLL-OVER PROTECTION SYSTEM (ROPS) .................................................................................... 3-9
ATTACHMENT FOR PROTECTION AGAINST FALLING OBJECTS (FOPS) ...................................... 3-9
ATTACHMENTS .................................................................................................................................... 3-9
BATTERY .............................................................................................................................................. 3-10

0-2
SAFETY MEASURES DURING OPERATION ............................................................................................. 3-11
BEFORE YOU START THE ENGINE .................................................................................................... 3-11
WORKPLACE SAFETY .................................................................................................................. 3-11
IN THE DRIVER'S CAB .................................................................................................................. 3-11
IN-DOOR OPERATION .................................................................................................................. 3-12
GAS, DUST, AND INFLAMMABLE VAPOURS .............................................................................. 3-12
MIRRORS, WINDOWS, AND LIGHTING ....................................................................................... 3-12
MACHINE OPERATION ........................................................................................................................ 3-13
BEFORE YOU START THE ENGINE ............................................................................................. 3-13
REVERSING ................................................................................................................................... 3-13
DRIVING ......................................................................................................................................... 3-14
DRIVING ON SLOPES ................................................................................................................... 3-14
EMERGENCY LOWERING SYSTEM ............................................................................................ 3-15
WORKING CLOSE TO OVERHEAD POWER TRANSMISSION LINES ........................................ 3-15
LOADING ........................................................................................................................................ 3-16
GOOD VISION ................................................................................................................................ 3-16
WORKING ON SNOW .................................................................................................................... 3-16
HEIGHT LIMITATION ..................................................................................................................... 3-17
BRAKES ......................................................................................................................................... 3-17
WORKING ON LOOSE SOIL ......................................................................................................... 3-17
WORKING WITH THE FORKLIFT TRUCK ATTACHMENT ........................................................... 3-18
PARKING THE MACHINE .............................................................................................................. 3-19
TRANSPORT ......................................................................................................................................... 3-20
LOADING AND UNLOADING THE MACHINE ............................................................................... 3-20
TRANSPORT .................................................................................................................................. 3-21
SAFETY MEASURES DURING MAINTENANCE ........................................................................................ 3-22
PERSONNEL ......................................................................................................................................... 3-22
PRIOR TO START OF MAINTENANCE MEASURES .......................................................................... 3-22
WARNING SIGN ............................................................................................................................. 3-22
TOOLS ............................................................................................................................................ 3-22
SAFETY-RELATED PARTS ........................................................................................................... 3-22
PRIOR TO START OF INSPECTION AND MAINTENANCE ......................................................... 3-23
SECURING THE ARTICULATED STEERING ............................................................................... 3-23
SUPPORTING THE BOOM ............................................................................................................ 3-24
DURING MAINTENANCE ...................................................................................................................... 3-25
ATTACHMENTS ............................................................................................................................. 3-25
WORKING UNDER THE MACHINE ............................................................................................... 3-25
KEEPING THE MACHINE CLEAN ................................................................................................. 3-25
SPECIFIC MEASURES .................................................................................................................. 3-25
REFUELING AND TOPPING OFF OIL ........................................................................................... 3-26
COOLANT ....................................................................................................................................... 3-26
USE OF LIGHTING ......................................................................................................................... 3-27
HIGH-PRESSURE HOSES ............................................................................................................ 3-27
HANDLING HIGH-PRESSURE OIL ................................................................................................ 3-27
HANDLING OF THE PRESSURE ACCUMULATOR ...................................................................... 3-28
FAN AND BELTS ............................................................................................................................ 3-28
WASTE MATERIAL ........................................................................................................................ 3-28
TIRES .................................................................................................................................................... 3-29
STORING TIRES ............................................................................................................................ 3-30
LABELING .................................................................................................................................................... 3-31
POSITION OF SAFETY LABELS ........................................................................................................... 3-31
INFORMATION LABELS ....................................................................................................................... 3-33

0-3
CONTROLS AND INDICATORS
OVERALL VIEW OF MACHINE ................................................................................................................... 4-2
CONTROLS AND INDICATORS .................................................................................................................. 4-3
SWITCHES AND CONTROLS ....................................................................................................... 4-4
INSTRUMENT PANEL ................................................................................................................... 4-5
WARNING LIGHTS ........................................................................................................................ 4-6
CONTROL LAMPS ................................................................................................................................ 4-9
MEASURING INDICATORS .................................................................................................................. 4-13
SWITCHES ............................................................................................................................................ 4-15
CONTROL LEVERS, PEDALS .............................................................................................................. 4-22
ARTICULATED STEERING CATCH ..................................................................................................... 4-28
TRACTION DEVICE ............................................................................................................................... 4-28
SOCKET ................................................................................................................................................ 4-28
DOOR UNLOCKING SYSTEM .............................................................................................................. 4-29
ALARM HORN FOR REVERSE DRIVING ............................................................................................ 4-29
OPERATION
RUNNING IN THE MACHINE ....................................................................................................................... 5-2
PREPARING THE MACHINE START .......................................................................................................... 5-3
VISUAL CHECKS .................................................................................................................................. 5-3
BEFORE YOU START THE ENGINE ............................................................................................ 5-3
BEFORE STARTING WORKING WITH THE MACHINE ............................................................... 5-3
ADJUSTMENTS PRIOR TO MACHINE START .......................................................................................... 5-6
ADJUSTING THE DRIVER’S SEAT ...................................................................................................... 5-6
ADJUSTING THE STEERING COLUMN .............................................................................................. 5-7
ADJUSTING THE ARMREST ................................................................................................................ 5-7
ADJUSTING THE REAR-VIEW MIRRORS ........................................................................................... 5-7
ADJUSTING THE HEATING AND VENTILATION SYSTEM ................................................................. 5-8
ADJUSTING THE VENTILATION SYSTEM ................................................................................... 5-8
ADJUSTING THE HEATING SYSTEM .......................................................................................... 5-9
OPERATING THE AIR CONDITIONING ............................................................................................... 5-10
SWITCHING ON THE AIR-CONDITIONING .................................................................................. 5-10
PUTTING ON THE SAFETY BELT ........................................................................................................ 5-12
PUTTING ON THE SAFETY BELT ................................................................................................ 5-12
TAKING OFF THE SAFETY BELT ................................................................................................. 5-12
STARTING AND SWITCHING OFF THE ENGINE ...................................................................................... 5-13
STARTING THE ENGINE ...................................................................................................................... 5-13
WARMING UP THE ENGINE ................................................................................................................ 5-14
SWITCHING OFF THE ENGINE ...........................................................................................................5-15
DRIVING ....................................................................................................................................................... 5-16
START-UP ............................................................................................................................................. 5-16
STARTING THE MACHINE ON SLOPES ...................................................................................... 5-18
DRIVING WITH THE HIGH-SPEED GEAR .................................................................................... 5-18
CHANGING THE DRIVING DIRECTION ............................................................................................... 5-19
REVERSE DRIVING .............................................................................................................................. 5-20
TURNING ............................................................................................................................................... 5-20
TURNING ON SLOPES, EMBANKMENTS OR HILL FLANKS ...................................................... 5-20
BRAKING ..................................................................................................................................................... 5-21
PULLING THE PARKING BRAKE ......................................................................................................... 5-21
RELEASING THE PARKING BRAKE ............................................................................................. 5-21
BRAKING WITH THE SERVICE BRAKE ....................................................................................... 5-21
IF THE SERVICE BRAKE BREAKS DOWN .................................................................................. 5-22
BRAKING ON SLOPES .................................................................................................................. 5-22
STOPPING ............................................................................................................................................ 5-23
PARKING THE MACHINE ON A SLOPE ....................................................................................... 5-23
LONGER-DISTANCE DRIVING ............................................................................................................ 5-24

0-4
OPERATING THE MACHINE ....................................................................................................................... 5-25
PREPARING THE WORK EQUIPMENT ............................................................................................... 5-25
SELECTING A WORK UNIT ........................................................................................................... 5-25
PICKING UP THE WORK UNIT (EXCEPT MULTI-PURPOSE BUCKET) ..................................... 5-25
REMOVING THE WORK UNIT ....................................................................................................... 5-26
PICKING UP THE MULTI-PURPOSE BUCKET ............................................................................. 5-26
REMOVING THE MULTI-PURPOSE BUCKET .............................................................................. 5-28
TIRE SERVICE LIFE ............................................................................................................................. 5-29
LEVEL INDICATOR FOR THE BUCKET ............................................................................................... 5-29
ADJUSTING THE BUCKET POSITIONER ............................................................................................ 5-30
LOADING ............................................................................................................................................... 5-31
REMOVING PILED UP SOIL .......................................................................................................... 5-31
EXCAVATION WORKS .................................................................................................................. 5-33
TRANSPORTING ................................................................................................................................... 5-34
DUMPING / UNLOADING ...................................................................................................................... 5-34
LOADING IN DIAGONAL DIRECTION ........................................................................................... 5-34
V-SHAPED LOADING .................................................................................................................... 5-35
PILING UP MATERIAL ................................................................................................................... 5-35
PLANING ............................................................................................................................................... 5-36
FILLING UP .................................................................................................................................... 5-36
TAKING OFF SOIL ......................................................................................................................... 5-36
CUTTING THE GROUND ............................................................................................................... 5-37
WORKING WITH THE FORKLIFT TRUCK ATTACHMENT .................................................................. 5-38
PICKING UP THE LOAD ................................................................................................................5-38
PRECAUTIONS FOR SPECIAL OPERATIONS .................................................................................... 5-39
WORKING IN WATER .................................................................................................................... 5-39
WORKING ON SNOW .................................................................................................................... 5-39
DUMPING ON STEEP SLOPES .................................................................................................... 5-39
WORKING IN THE VICINITY OF ELECTRICAL OVERHEAD LINES ............................................ 5-39
OPERATION ON SLOPES ............................................................................................................. 5-39
WORKING ON LOOSE SOIL ......................................................................................................... 5-39
AFTER THE WORK IS FINISHED ......................................................................................................... 5-39
INSTRUCTIONS FOR WINTER OPERATION ............................................................................................. 5-40
BEFORE THE COLD SEASON ...................................................................................................... 5-40
AFTER OPERATION ...................................................................................................................... 5-40
AFTER THE COLD SEASON ......................................................................................................... 5-41
LONGER STANDSTILL PERIODS OF THE MACHINE ........................................................................ 5-42
BEFORE THE STANDSTILL .......................................................................................................... 5-42
DURING THE STANDSTILL ........................................................................................................... 5-42
AFTER THE STANDSTILL ............................................................................................................. 5-43
TROUBLESHOOTING
TROUBLESHOOTING .................................................................................................................................. 6-2
WARNING LIGHTS AND INDICATORS ................................................................................................ 6-2
ELECTRICAL SYSTEM ......................................................................................................................... 6-3
ENGINE ................................................................................................................................................. 6-4
HYDRAULIC SYSTEM ........................................................................................................................... 6-7
BRAKES ................................................................................................................................................. 6-9
AXLES ................................................................................................................................................... 6-10
DRIVER’S CAB ...................................................................................................................................... 6-10
EMERGENCY STEERING CHARACTERISTICS ................................................................................. 6-11
EMERGENCY LOWERING SYSTEM .................................................................................................... 6-11
STARTING THE ENGINE WITH A BATTERY JUMPER CABLE .......................................................... 6-12
CONNECTING THE JUMPER CABLE ........................................................................................... 6-12
STARTING THE ENGINE ...............................................................................................................6-13
DISCONNECTING THE BATTERY JUMPER CABLE ................................................................... 6-13
TOWING THE MACHINE ....................................................................................................................... 6-14
TOWING A MACHINE WITH DEFECTIVE BRAKES ..................................................................... 6-15

0-5
INADEQUATE BRAKING EFFECT ........................................................................................................ 6-16
CHECKING THE PARKING BRAKE .............................................................................................. 6-16
CHECKING THE SERVICE BRAKE ............................................................................................... 6-17
MAINTENANCE
MAINTENANCE BASICS ............................................................................................................................. 7-2
PREPARING THE MACHINE FOR MAINTENANCE ............................................................................ 7-2
CLEANING THE MACHINE ................................................................................................................... 7-3
PRECAUTIONARY MEASURES WHEN CLEANING THE MACHINE .......................................... 7-3
FIRE PREVENTION ....................................................................................................................... 7-3
WORKING-AREA-DEPENDENT MAINTENANCE ................................................................................ 7-4
MUDDY OR WET WORKING AREAS ........................................................................................... 7-4
DUSTY WORKING AREAS ............................................................................................................ 7-4
LUBRICANTS AND OPERATING AGENTS .......................................................................................... 7-5
DRAINING HOT LUBRICANTS AND FLUIDS ............................................................................... 7-5
CHECKING THE OIL LEVEL AND CHANGING OIL ...................................................................... 7-5
CHANGING FILTERS ..................................................................................................................... 7-5
REFUELLING AND TOPPING OFF OIL ........................................................................................ 7-5
OIL .................................................................................................................................................. 7-6
LUBRICATING GREASE ................................................................................................................ 7-6
BIODEGRADABLE HYDRAULIC OIL AND LUBRICATING GREASE ........................................... 7-6
FUEL ............................................................................................................................................... 7-7
STORAGE OF OIL AND FUEL ....................................................................................................... 7-7
COOLANTS .................................................................................................................................... 7-8
WINDSCREEN WASHER LIQUID ................................................................................................. 7-8
TABLE OF LUBRICANTS AND OPERATING AGENTS ................................................................ 7-10
LUBRICATION CHART .................................................................................................................. 7-11
AXLES ................................................................................................................................................... 7-12
RELEASED AXLE OIL BRANDS .................................................................................................... 7-12
REPLACING SAFETY-RELATED PARTS ............................................................................................. 7-12
WELDING INSTRUCTIONS .................................................................................................................. 7-13
SPARE PARTS AND CONSUMABLE COMPONENTS ........................................................................ 7-14
ELECTRICAL SYSTEM ......................................................................................................................... 7-15
FUSES ............................................................................................................................................ 7-16
FUSE ASSIGNMENT ..................................................................................................................... 7-16
SLOW-BLOWING FUSES .............................................................................................................. 7-17
TIRES .................................................................................................................................................... 7-18
TIRE COMPONENTS ..................................................................................................................... 7-18
CHECKING THE TIRES ................................................................................................................. 7-18
CHECKING THE TIRE PRESSURE ............................................................................................... 7-18
TORQUE FOR STANDARD NUTS AND BOLTS ................................................................................... 7-20
MAINTENANCE SCHEDULE ....................................................................................................................... 7-22
MAINTENANCE PRIOR TO START ............................................................................................................ 7-24
VISUAL CHECKS .................................................................................................................................. 7-24
COOLING SYSTEM, CHECKING THE COOLANT LEVEL, TOPPING OFF COOLANT ....................... 7-24
ENGINE, CHECKING THE OIL LEVEL, TOPPING OFF OIL ................................................................. 7-25
ENGINE, DRAINING OFF OIL ............................................................................................................... 7-26
CHECKING THE FUEL LEVEL, REFUELING ....................................................................................... 7-27
CHECKING THE CONTROLS ............................................................................................................... 7-28
CHECKING THE ELECTRICAL CONNECTIONS ................................................................................. 7-28
HEATER / AIR CONDITIONING: CHECKING RATE OF AIR FLOW .................................................... 7-29
OTHER MAINTENANCE MEASURES PRIOR TO START ................................................................... 7-29
MAINTENANCE UPON DEMAND ............................................................................................................... 7-30
CHECKING THE AIR-CONDITIONING SYSTEM ................................................................................. 7-30
CHECKING THE COOLANT LEVEL .............................................................................................. 7-30
MAINTENANCE EVERY 10 OPERATING HOURS ..................................................................................... 7-31
LUBRICATION ....................................................................................................................................... 7-31

0-6
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS .................................................................. 7-32
ENGINE, CHANGING OIL AND REPLACING THE OIL FILTER CARTRIDGE .................................... 7-32
REPLACING THE OIL FILTER CARTRIDGE ................................................................................. 7-33
V-BELT, CHECKING THE CONDITION ................................................................................................ 7-34
V-BELT, CHECKING AND ADJUSTING THE TENSION ....................................................................... 7-34
HYDRAULIC SYSTEM, REPLACING THE FILTER INSERT ................................................................ 7-35
CHECKING AND TIGHTENING THE WHEEL NUTS ............................................................................ 7-36
FRONT AND REAR AXLE, CHANGING OIL ......................................................................................... 7-37
PLANET GEAR ............................................................................................................................... 7-37
DIFFERENTIAL .............................................................................................................................. 7-37
TRANSFER GEAR - CHANGING OIL .................................................................................................... 7-38
MAINTENANCE EVERY 50 OPERATING HOURS ..................................................................................... 7-40
CHECKING COOLING SYSTEM, COOLANT LEVEL IN THE RADIATOR AND EXPANSION TANK .. 7-40
DRAINING OFF WATER AND DIRT DEPOSITS FROM THE FUEL TANK .......................................... 7-41
CHECKING THE SERVICE BRAKE AND OIL LEVEL, REFILLING OIL ............................................... 7-41
CHECKING THE BATTERY AND ACID LEVEL .................................................................................... 7-42
RE-CHARGING A BUILT-IN BATTERY ......................................................................................... 7-43
LUBRICATION ....................................................................................................................................... 7-44
LUBRICATING POINTS OF THE WORK EQUIPMENT ................................................................. 7-44
MAINTENANCE EVERY 100 OPERATING HOURS ................................................................................... 7-45
DRAINING THE WATER SEPARATOR, REMOVING WATER AND DIRT DEPOSITS ........................ 7-45
MAINTENANCE EVERY 250 OPERATING HOURS ................................................................................... 7-46
CHANGING THE ENGINE OIL AND OIL FILTER CARTRIDGE ........................................................... 7-46
CHECKING THE V-BELT CONDITION ................................................................................................. 7-46
CHECKING AND ADJUSTING THE V-BELT TENSION ........................................................................ 7-46
FRONT AND REAR AXLE, CHECKING THE OIL LEVEL ..................................................................... 7-47
PLANET GEAR ............................................................................................................................... 7-47
DIFFERENTIAL .............................................................................................................................. 7-48
AIR FILTER, REMOVING/RE-INSTALLING AND CHECKING/CLEANING THE FILTER INSERT ...... 7-49
STRUCTURE OF THE AIR FILTER ............................................................................................... 7-49
MAINTENANCE DEMAND ............................................................................................................. 7-49
REMOVING THE FILTER CARTRIDGE ......................................................................................... 7-49
CLEANING OR EXCHANGING THE FILTER CARTRIDGE .......................................................... 7-50
CHECKING THE FILTER CARTRIDGE ......................................................................................... 7-51
ASSEMBLING THE AIR FILTER CARTRIDGE .............................................................................. 7-51
CLEANING THE RADIATOR SEGMENTS ............................................................................................ 7-51
LUBRICATION ....................................................................................................................................... 7-52
MAINTENANCE EVERY 500 OPERATING HOURS ................................................................................... 7-53
CHANGING THE FUEL FILTER AND FILTER ELEMENT .................................................................... 7-53
BLEEDING THE FUEL SYSTEM .................................................................................................... 7-54
CHANGING THE FILTER CARTRIDGE OF THE HYDRAULIC SYSTEM ............................................ 7-55
CLEANING THE WATER SEPARATOR ............................................................................................... 7-55
LUBRICATION ....................................................................................................................................... 7-56
TRANSFER GEAR, CHECKING THE OIL LEVEL AND REFILLING OIL .............................................. 7-56
AIR FILTER, REPLACING THE FILTER INSERT, REPLACING THE SAFETY FILTER ...................... 7-57
REPLACING THE FILTER INSERT ............................................................................................... 7-57
REPLACING THE SAFETY FILTER ............................................................................................... 7-57
HEATER/AIR CONDITIONING: CLEAN FILTER FLEECE OF HEATER UNIT ..................................... 7-58
HEATER/AIR CONDITIONING: CLEANING THE CONDENSER ......................................................... 7-59
MAINTENANCE EVERY 1000 OPERATING HOURS ................................................................................. 7-60
COOLING SYSTEM, EXCHANGING COOLANT AND CLEANING THE SYSTEM ............................. 7-60
DRAINING OFF THE COOLANT .................................................................................................... 7-61
CLEANING THE COOLING SYSTEM ............................................................................................ 7-61
FILLING OFF COOLANT ................................................................................................................ 7-61
FRONT AXLE, OIL CHANGE ................................................................................................................ 7-62
REAR AXLE, OIL CHANGE ................................................................................................................... 7-62
TRANSFER GEAR, OIL CHANGE ......................................................................................................... 7-62

0-7
SERVICE BRAKE .................................................................................................................................. 7-62
CHANGING OIL .............................................................................................................................. 7-62
CHECKING TUBES AND LINES .................................................................................................... 7-62
CHECKING THE BRAKE DISKS FOR WEAR AND TEAR ............................................................ 7-62
ADJUSTING THE CLEARANCE OF THE BRAKE DISKS ............................................................. 7-62
CHECKING AND ADJUSTING SYSTEM PRESSURES ....................................................................... 7-62
CHECKING AND ADJUSTING THE VALVE CLEARANCE ................................................................... 7-62
CHECKING/ADJUSTING THE INJECTION NOZZLES, NOZZLE PRESSURE/FUEL-JET PATTERN 7-63
CHECKING THE ACCUMULATOR GAS PRESSURE .......................................................................... 7-63
MAINTENANCE EVERY 2000 OPERATING HOURS ................................................................................. 7-64
HYDRAULIC SYSTEM, OIL CHANGE .................................................................................................. 7-64
BLEEDING THE HYDRAULIC OIL TANK .............................................................................................. 7-65
COOLING SYSTEM, CHECKING THE ANTIFREEZE CONTENT OF THE COOLANT ....................... 7-65
CHECKING THE COOLING SYSTEM .................................................................................................. 7-65
CHECKING THE FUEL PUMP .............................................................................................................. 7-65
CHECKING THE FUEL AND COOLANT TUBES, REPLACING THE TUBES (IF REQUIRED) ............ 7-65
CHECKING THE WATER PUMP ........................................................................................................... 7-66
CHECKING AND ADJUSTING THE FUEL INJECTION AND INJECTION TIME .................................. 7-66
TECHNICAL DATA
TECHNICAL DATA ...................................................................................................................................... 8-2
NOISE EMISSION LEVELS ................................................................................................................... 8-3
VIBRATION LEVEL ................................................................................................................................ 8-3
LIMIT VALUES FOR SLOPES ............................................................................................................... 8-3
MAXIMUM SLOPE ANGLE FOR OPERATING THE MACHINE .................................................... 8-3
SPECIAL EQUIPMENT AND ATTACHMENTS
ALS-ELECTRONICS .................................................................................................................................... 9-2
STRUCTURE AND FUNCTIONING PRINCIPLE OF THE ALS-ELECTRONICS ................................. 9-2
PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS-ELECTRONICS ........................... 9-2
OPERATION OF THE ALS-ELECTRONICS ......................................................................................... 9-3
SWITCHING ON THE ALS-ELECTRONICS .................................................................................. 9-3
SWITCHING OFF THE ALS-ELECTRONICS ................................................................................ 9-3
HANDLING OF THE PRESSURE ACCUMULATOR ............................................................................. 9-4
INDEX

0-8

INTRODUCTION 1

FORWORD
1-2
FORWORD
This manual describes procedures for operation, handling, lubri-
cation, 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 periodi-
cally. 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.
• 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 refer-
ence 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 ap-
ply 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 prohib-
ited uses or actions as described in this manual.
• Komatsu America International Company delivers ma-
chines 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
purchase from someone in another country, it may lack
certain safety features and specifications that are neces-
sary for use in your country. If there is any question about
whether your product complies with the applicable stan-
dards and regulations or your country, consult your local
distributor or Komatsu America International Company
before operating the machine.
• The description of safety is given in "Safety Information"
and in chapter "Safety".

SAFETY INFORMATION
1-3
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.
• This word is used on safety messages and product graph-
ics 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.
• This word is used on safety messages and product graph-
ics 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.
• This word is used on safety messages and product graph-
ics 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 haz-
ards where the only result could be damage to the ma-
chine.
☞
• 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 important additional information.
Safety precautions are described in chapter "Safety".
Komatsu America International Company cannot predict every
circumstance that might involve a potential hazard in operation
and maintenance. Therefore the safety message in this manual
and on the machine may not include all possible safety precau-
tions. If any procedures, tools, actions, work method, or operat-
ing technique not specifically recommended or allowed in this

SAFETY INFORMATION
1-4
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.

INTRODUCTION
1-5
INTRODUCTION
FEATURES
• Maximum flexibility of usefulness.
• Improved sealing for reduced noise, low vibration cab.
• Console and adjustable steering column with unencum-
bered foot area provides a comfortable feeling.
• Light touch lever operations through use of electrical trans-
mission control lever.
• Pleasant operators compartment with low vibration and
noise levels.
• Excellent view from the cabin to all sides.
• Engine hood opens fully for ease of maintenance.
• Safety lock lever for work equipment.
• New engine that meets exhaust gas emission of 96 EPA &
carb.
BREAKING IN A NEW MACHINE
Your machine has been thoroughly adjusted and tested before
shipment. However, operating the machine under severe condi-
tions 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.
During breaking in:
• After starting, let the engine idle for 5 minutes to allow prop-
er 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, mainte-
nance, 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 re-
sponsibility of the user.
Operations that are prohibited in this manual must never be car-
ried out under any circumstance.

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
1-6
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND
DISTRIBUTOR
MACHINE SERIAL NO. PLATE POSITION
1. POSITION OF PLATE
On the center right of the front frame.
2. POSITION OF STAMP
ENGINE SERIAL NO. PLATE POSITION
1. POSITION OF PLATE
2. POSITION OF EPA - LABEL
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
REMARKS
2
1
Machine serial No.:
Engine serial No.:
Distributor name:
Address:
Service personnel for your machine:
Phone:
Fax:

EMISSION CONTROL WARRANTY
1-7
EMISSION CONTROL WARRANTY
EMISSION CONTROL WARRANTY STATEMENT
(APPLIES TO CANADA ONLY)
1. PRODUCTS WARRANTED
Komatsu America International Company, Komatsu Mining
Systems Inc. and Komatsu Utility Corporation (collectively
"Komatsu") produce and/or market products under brand
names of Komatsu, Dresser, Dressta, Haulpak and Galion.
This emission warranty applies to new engines bearing the
KomatsunameinstalledintheseproductsandusedinCan-
ada in machines designed for industrial off-highway use.
This warranty applies only to these engines produced on or
after January 1, 2000. This warranty will be administered by
Komatsu distribution in Canada.
2. COVERAGE
Komatsu warrants to the ultimate purchaser and each sub-
sequent purchaser that the engine is designed, built and
equipped so as to conform, at the time of sale by Komatsu,
with all U.S. Federal emission regulations applicable at the
time of manufacture and that is free from defects in work-
manship or material which would cause it not meet these
regulations within five years or 3,000 hours of operation,
whichever occurs first, as measured from the date of deliv-
ery of the engine to the ultimate purchaser.
3. LIMITATIONS
Failures, other than those resulting from defects in materials
or workmanship, are not covered by this warranty. Komatsu
is not responsible for failures or damage resulting from what
Komatsu determines to be abuse or neglect, including, but
not limited to: operation without adequate coolant or lubri-
cants; over fueling; over speeding; lack of maintenance of lu-
bricating, cooling or intake systems; improper storage,
starting, warm-up, run-in or shutdown practices; unautho-
rized modifications of the engine. Komatsu is also not re-
sponsible for failures caused by incorrect fuel or by water,
dirt or other contaminants in the fuel. Komatsu is not respon-
sible for non-engine repairs, "downtime" expense, related
damage, fines, all business costs or other losses resulting
from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warran-
ties, are the sole warranties of Komatsu. THERE ARE NO
OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.

ENGINE DATA PLATE
1-8
ENGINE DATA PLATE
IMPORTANT ENGINE INFORMATION
6150-82-2112
THIS ENGINE CONFORMS TO 1996 MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
WARNING
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AN APPLICATION.
ENGINE MODEL SERIAL NO.
ENGINE FAMILY DISPLACEMENT LITERS
EXHAUST EMISSION
CONTROL SYSTEM FIRING ORDER 1-5-3-6-2-4
ADV. LOAD OUTPUT Kw ( HP) RPM
VALVE LASH
COLD (mm)
IN. EX. FUEL RATE
AT ADV.
mm³/STROKE
IDLE SPEED RPM FAMILY EMISSION LIMIT
INITIAL INJECTION
TIMING
DEG. BTDC DATE OF MANUFACTURE
KOMATSU LTD.
MADE IN JAPAN