Operation & Maintenance

VEAM120100

Manual

WHEEL LOADER
SERIAL NUMBERS WA115H30051 AND UP

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

NOTE
© 2001 Komatsu Hanomag Aktiengesellschaft
Komatsu has had the operating and maintenance instructions
All Rights Reserved
translated into all the languages of the European Union.
Printed in Europe Should you require a copy in another language please inquire
11.2001 at your local dealer’s.
Introduction

1-1
1.1. Foreword Introduction

1.1. Foreword
This manual takes into account legal directives and regulations
necessary to ensure the safe and effective use of the machine.
Keep this manual within reach at all times and ensure that
operating personnel read it at regular intervals. Call Komatsu or
your local Komatsu dealer and request a replacement if this
manual is lost or is no longer legible because of soiling. Pass the
manual on to the new owner if selling the machine.

Our constant efforts to improve the design of our machines can

result in changes to construction which may differ slightly from the
details in this manual. Please contact Komatsu or your local
Komatsu dealer if you require the latest available information on
your machine or if you have questions regarding the contents of
this manual.

Auxiliary equipment and accessories named in this manual may

not be available in your region. If this is so, please contact
Komatsu or your local Komatsu dealer with enquiries about the
equipment you require.

DANGER

Incorrect operation and maintenance of this machine can
be dangerous and lead to injury.

The operator and maintenance personnel must read this

manual before commencing operation or maintenance.

The procedures and preventative measures named in

this manual apply only for the intended use of the
machine. If you use the machine for any other purpose
than its intended function, you are responsible for
ensuring that no danger is caused to you or others.
Under no circumstances may you carry out work or
functions which are explicitly forbidden in this manual.

Safety regulations can be found under section

"1.2. Safety information" on page 1-5 and in the chapter
"2. Safety" on page 2-1".

1-2
Introduction 1.1. Foreword

EU Directives

This machine is labelled with the CE mark indicating that it meets

all basic requirements concerning safety and protection of health
of the EU Machinery Directive 89/392/EEC, its supplements 91/
368 EEC and 93/44 EEC for Europe, and the regulation 95/27/
EEC. In addition, the harmonised European standards EN 292-2
and EN 474/1 of 1994, and EN 474-3 of 1996 were applied for
manufacture of the machine. This fact is documented in the EU
Declaration of Conformity (CE) which is supplied together with the
machine.

This means that in those cases in which the machine is modified

in such a way that safety of the machine is affected, the person
responsible for safety of the machine is the one who has
arranged for the machine to be modified. If you use the machine
for any other purpose than that defined as correct use, you are
the person who has to ensure that safety is maintained.
Modifications of the machine or use of the machine for any other
purpose than that specified as correct use may require a new CE
mark and thus new issuing of an EU Declaration of Conformity.

If a machine is used in other countries than Germany, it may be

possible that special national safety devices and specifications
are missing which may be required for the application in the
relevant country. For example, for Komatsu machines, the
manufacturer has to design the cab roof in such a way that a
warning beacon can be attached to the roof. However, when
driving the machine on roads, this warning beacon must be
covered.

Please contact our dealer before using the machine if you have
any questions regarding the fulfilment of standards and
regulations in a specific country.

In addition to the operating instructions, you must also adhere to

all legal regulations on public traffic and all applicable regulations
on prevention of accidents. A corresponding leaflet "Notes on
Operation of Komatsu Construction Machines in Public Traffic" -
applying to operation of construction machines with a speed of
more than 20 km/h on German public roads - has been handed
over to the dealer together with the machine papers.

The expert inspection for earthmoving machines has to be

performed according to VBG 40 § 50 (VBG: German
Administrative Professional Association). The requirements for
this expert inspection are defined in the paragraphs 1 to 3 as
follows:

1. Prior to first commissioning and after major modifications,

earthmoving machines must be inspected by an expert before
they are put into service again.

2. Earthmoving machines must be inspected by an expert at

least once every year. Moreover and depending on the
respective operating and local conditions, they must
additionally be inspected by an expert, when required.

3. The inspection results must be recorded in writing and stored

at least until the next inspection is due.

1-3
1.1. Foreword Introduction

Notes on subsequent installation of electrical and electronic

equipment and components

Electrical and electronic equipment and/or components which

have been installed subsequently, emit electromagnetic radiation
which can influence the function of the electronic components
and sections of the machine. This can have an influence on the
safety of the machine and endanger persons. For this reason,
please ensure that the following safety instructions are observed.

If you are installing electrical or electronic equipment and/or

components in the machine and connect them to the vehicle
electrical system, you must check at own responsibility that the
installations do not cause any disturbance to the vehicle’s
electronic system or other components. Above all, you must
ensure that any subsequently installed electrical and electronic
components comply with the EMV Directive 89/336/EEC in its
current edition and bear the CE mark.

The following requirements also have to be met for subsequent

installation of mobile communication systems (e.g. radio,
telephone):

Only equipment approved by national legislation (e.g. BZT

approval for Germany) may be used

The unit must be fixed in position

Portable or mobile units may only be used inside the vehicles

if they are connected to a fixed outside antenna

The transmitter unit must be spatially separated from the

vehicle’s electronic system

Make sure when installing the antenna that this is installed

correctly with good earth connection between antenna and
vehicle mass

Also observe machine manufacturer’s installation instructions for

wiring, installation and maximum permitted power consumption.

1-4
Introduction 1.2. Safety information

1.2. Safety information

Most accidents are cause by failure to observe fundamental
safety regulations during the operation and maintenance of the
machines. Please read the safety and warning instructions in this
manual and on the machine before operating or servicing the
machine and observe them at all times in order to avoid any
accidents.

The following words are used in this manual and on stickers on

the machine to signify safety instructions and enable them to be
recognized as such at a glance:

DANGER
This word is used for safety messages and safety label
where there is a probability of serious injury if the danger is
not avoided. The safety instruction or sticker contains
precautions which must be observed in order to avoid the
danger. Failure to do so can also result in damage to the
machine.

WARNING
This word is used for safety messages and safety label
where there is a potentially dangerous situation which could
lead to serious injury if the danger is not avoided. The safety
instruction or sticker contains precautions which must be
observed in order to avoid the danger. Failure to do so can
also result in damage to the machine.

CAUTION
This word is used for safety messages and safety label in the
event of danger which could result in minor or partly serious
injuries if the danger is not avoided. It may also relate to
dangers which may only result in damage to the machine.

NOTE
This word is used for precautions which have to be taken in
order to avoid situations which could result in shortening the
service lift of the machine.

1-5
1.2. Safety information Introduction

The safety instructions are listed in the chapter "2. Safety" on

page 2-1 and following.

We cannot foresee all circumstances which could result in

potential danger during maintenance and operation. The safety
instructions in this manual and on the machine, therefore, do not
necessarily contain all possible safety precautions. If you are
using a procedure or measure not explicitly permitted and
recommended in this manual, you must ensure that you and
anyone else can use any such procedure without any danger or
damage to the machine whatsoever. Please contact your local
Komatsu dealer if you have any doubts about the safety of any
procedures.

1-6
Introduction 1.3. Introduction

1.3. Introduction

1.3.1. Intended use

This loader is a machine with independent transmission, moving
on wheels. Driving in forward direction, the loader can load or dig
material using its attachments intended for loading operations
(i.e. bucket).

The standard operation cycle of a loader includes filling up and

loading of the bucket, transporting the material and emptying the
bucket.

In combination with the forklift truck attachment the picking up,

transporting and putting down of stacked material is also
considered to be part of the machine’s intended use.

If you use the machine for any other purpose than specified
above, we will not accept any responsibility for safety. All
considerations concerning safety will then be up to the owner or
the operating and maintenance personnel. In any case, neither
you nor any other person are/is authorised to perform work and
functions explicitly prohibited in these operating instructions.

Refer to chapter "3.6.6. Working with the wheeled loader" on

page 3-65 for more details.

1-7
1.3. Introduction Introduction

1.3.2. Breaking-in the machine

Your Komatsu machine has been thoroughly adjusted and tested
before shipment. However, operating the machine under severe
conditions at the beginning can adversely affect the performance
and shorten the machine life.

Be sure to break in the machine for the initial 100 hours (as
indicated by the service meter.)

During breaking in:

Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.

Avoid sudden starts, sudden acceleration, sudden steering

und sudden stops except in cases of emergency.

The precautions given in this manual for operating, maintenance,

and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a
purpose that is not listed in this manual Komatsu cannot bear any
responsibility for safety. All consideration of safety in such
operations is the responsibility of the user.

Operations that are prohibited in this manual must never be

carried out under any circumstances.

1-8
Introduction 1.4. Location of plates

1.4. Location of plates

1.4.1. Machine identification plate

Position of the identification plate (see enlargement)

Machine identification plate

1.4.2. Vehicle identification number

Serial no. stamp marking (1)

115_Typ2

1.4.3. Engine name-plate with serial no.

Engine name-plate (2) with serial no.

EPA label (3)

1-9
1.4. Location of plates Introduction

1.4.4. Table to enter serial no. and distributor

Must be filled in before machine is put into service:

Machine serial No.:

Engine serial No.:

Name of Dealer: Phone:

Address: Fax:

Service Personnel for your machine: E-mail

1-10
Introduction 1.5. Table of contents

1.5. Table of contents

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

1.1. Foreword....................................................................................................................................................... 1-2
EU Directives............................................................................................................................... 1-3

1.2. Safety information ....................................................................................................................................... 1-5

1.3. Introduction .................................................................................................................................................. 1-7

1.3.1. Intended use ..................................................................................................................................... 1-7
1.3.2. Breaking-in the machine ................................................................................................................... 1-8

1.4. Location of plates ........................................................................................................................................ 1-9

1.4.1. Machine identification plate .............................................................................................................. 1-9
1.4.2. Vehicle identification number............................................................................................................ 1-9
1.4.3. Engine name-plate with serial no...................................................................................................... 1-9
1.4.4. Table to enter serial no. and distributor .......................................................................................... 1-10

1.5. Table of contents ....................................................................................................................................... 1-11

1.6. Dimensions, weights and operating data ................................................................................................ 1-19

1.7. CE-conforming equipment........................................................................................................................ 1-20

1.7.1. CE-conforming equipment – part 1................................................................................................. 1-20
1.7.2. CE-conforming equipment – part 2................................................................................................. 1-21
1.7.3. CE-conforming equipment – part 3................................................................................................. 1-21
1.7.4. Manufacturer-supplied CE-conforming equipment, according to document 42R-93-19080........... 1-23

1.8. Loading and securing................................................................................................................................ 1-26

2. Safety ........................................................................................................... 2-1

2.1. General safety measures ............................................................................................................................ 2-2
2.1.1. Safety instructions ............................................................................................................................ 2-2
2.1.2. Safety devices .................................................................................................................................. 2-2
2.1.3. Emergency exit ................................................................................................................................. 2-2
2.1.4. Clothing and personal protection ...................................................................................................... 2-3
2.1.5. Machine modifications ...................................................................................................................... 2-3
2.1.6. Before you leave the driver's seat .................................................................................................... 2-3
2.1.7. Mounting and dismounting................................................................................................................ 2-4
2.1.8. Fire prevention and fire fighting ........................................................................................................ 2-5
2.1.9. Protection against asbestos dust...................................................................................................... 2-7
2.1.10. Protection against injuries................................................................................................................. 2-7
2.1.11. Working at high temperatures........................................................................................................... 2-8
2.1.12. Roll-over protection system (ROPS)................................................................................................. 2-9
2.1.13. Attachment for protection against falling objects (FOPS) ................................................................. 2-9

1-11
1.5. Table of contents Introduction

2.1.14. Attachments with auxiliary function................................................................................................... 2-9

2.1.15. Battery ............................................................................................................................................ 2-10

2.2. Safety precautions during operation ....................................................................................................... 2-11

2.2.1. Prior to daily starting up .................................................................................................................. 2-11
Workplace safety ....................................................................................................................... 2-11
In the driver's cab ...................................................................................................................... 2-11
Indoor operation......................................................................................................................... 2-12
Gas, dust, and inflammable vapours ......................................................................................... 2-12
Mirrors, windows and lighting .................................................................................................... 2-12
2.2.2. Machine operation .......................................................................................................................... 2-13
Before you start the engine........................................................................................................ 2-13
Reversing................................................................................................................................... 2-13
Driving........................................................................................................................................ 2-14
Driving on slopes ....................................................................................................................... 2-14
Emergency lowering system...................................................................................................... 2-15
Working close to power lines ..................................................................................................... 2-16
Loading ...................................................................................................................................... 2-17
Good vision................................................................................................................................ 2-17
Working on snow ....................................................................................................................... 2-17
Height limitation ......................................................................................................................... 2-18
Brakes........................................................................................................................................ 2-18
Working on loose soil................................................................................................................. 2-18
Working with the forklift truck attachment .................................................................................. 2-19
Parking the machine .................................................................................................................. 2-21

2.3. Safety measures during transport............................................................................................................ 2-22

2.3.1. Loading and unloading the machine............................................................................................... 2-22
2.3.2. Transport ........................................................................................................................................ 2-23

2.4. Precautions for maintenance.................................................................................................................... 2-24

2.4.1. Personnel........................................................................................................................................ 2-24
2.4.2. Before carrying out maintenance.................................................................................................... 2-24
2.4.3. During maintenance........................................................................................................................ 2-28
2.4.4. Tyres............................................................................................................................................... 2-33

2.5. Labels on the machine .............................................................................................................................. 2-35

2.5.1. Positions and order numbers of safety labels ................................................................................. 2-35
2.5.2. Positions and order numbers of information labels......................................................................... 2-36

1-12
Introduction 1.5. Table of contents

3. Operation ..................................................................................................... 3-1

3.1. General view................................................................................................................................................. 3-2
3.1.1. General view of the machine ............................................................................................................ 3-2
3.1.2. Controls and Indicators..................................................................................................................... 3-3

3.2. Controls ........................................................................................................................................................ 3-4

3.2.1. Switches ........................................................................................................................................... 3-4
Instrument Panel ......................................................................................................................... 3-4
Switches – Cab top left/right........................................................................................................ 3-7
Switches – on direction indicator lever ........................................................................................ 3-9
Switches – on the multifunction lever .........................................................................................3-11
Switches – to the right of the driver’s seat................................................................................. 3-12
Switches – to the left of the driver’s seat ................................................................................... 3-14
Switch – battery main switch ..................................................................................................... 3-16
3.2.2. Operating and control levers........................................................................................................... 3-17
3.2.3. Pedals............................................................................................................................................. 3-21
3.2.4. Miscellaneous controls ................................................................................................................... 3-23

3.3. Control lamps, measuring indicators und warning lights ..................................................................... 3-24
3.3.1. Overview......................................................................................................................................... 3-24
3.3.2. Control lamps.................................................................................................................................. 3-26
3.3.3. Measuring indicators....................................................................................................................... 3-30
3.3.4. Warning lights ................................................................................................................................. 3-32

3.4. Description of individual elements .......................................................................................................... 3-34

3.4.1. Safety bar ....................................................................................................................................... 3-34
3.4.2. Towing pin ...................................................................................................................................... 3-34
3.4.3. Alarm horn for reverse driving – option........................................................................................... 3-35
3.4.4. Fuses .............................................................................................................................................. 3-36
3.4.5. Slow-Blowing Fuses ....................................................................................................................... 3-37
3.4.6. Heater and ventilation system ....................................................................................................... 3-38

3.5. Checks and adjustments prior to starting work ..................................................................................... 3-39

3.5.1. Visual inspection............................................................................................................................. 3-39
3.5.2. Control checks ................................................................................................................................ 3-41
Cooling system – checking the coolant level, topping up coolant ............................................. 3-41
Checking the engine oil level – topping up oil ........................................................................... 3-42
Checking the fuel level – refuelling............................................................................................ 3-43
Checking the controls ................................................................................................................ 3-44
Checking the electrical connections .......................................................................................... 3-44
Heater/air conditioning – checking rate of air flow..................................................................... 3-45
Miscellaneous tests before starting work................................................................................... 3-45
3.5.3. Adjustments .................................................................................................................................... 3-46
Adjusting the driver’s seat ......................................................................................................... 3-46
Adjusting the steering column ................................................................................................... 3-47
Adjusting the armrest................................................................................................................. 3-48
Adjusting the rear-view mirrors.................................................................................................. 3-48
Putting on the safety belt ........................................................................................................... 3-49

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1.5. Table of contents Introduction

3.6. Operation .................................................................................................................................................... 3-50

3.6.1. Starting the engine.......................................................................................................................... 3-50
Warming up the engine.............................................................................................................. 3-51
3.6.2. Switching off the engine.................................................................................................................. 3-52
3.6.3. Driving with the machine................................................................................................................. 3-53
Start-up ...................................................................................................................................... 3-53
Switching high-speed gear on/off – option................................................................................. 3-54
Changing the driving direction ................................................................................................... 3-55
Turning and steering .................................................................................................................. 3-56
Braking....................................................................................................................................... 3-57
Stopping..................................................................................................................................... 3-59
Longer-distance driving ............................................................................................................. 3-60
3.6.4. Actuating working attachment......................................................................................................... 3-61
Multifunctional lever ................................................................................................................... 3-61
Control lever for auxiliary functions............................................................................................ 3-62
3.6.5. Raise/lower working attachment ..................................................................................................... 3-63
Select working attachment......................................................................................................... 3-63
Raise working attachment ......................................................................................................... 3-63
Lower working attachment......................................................................................................... 3-64
3.6.6. Working with the wheeled loader .................................................................................................... 3-65
Tyre-appropriate operation ........................................................................................................ 3-65
Level indicator for the bucket..................................................................................................... 3-65
Adjusting the bucket positioner.................................................................................................. 3-66
Loading work ............................................................................................................................. 3-67
Removal work ............................................................................................................................ 3-67
Excavation work......................................................................................................................... 3-69
Transporting............................................................................................................................... 3-70
Unloading................................................................................................................................... 3-70
Planing....................................................................................................................................... 3-72
Working with the forklift truck attachment .................................................................................. 3-73
3.6.7. Precautions For Special Operations ............................................................................................... 3-74
Permissible water depth ............................................................................................................ 3-74
Working on snow ....................................................................................................................... 3-74
Dumping on steep slopes .......................................................................................................... 3-74
Working in the vicinity of electrical overhead lines .................................................................... 3-74
Operation on slopes................................................................................................................... 3-74
Working on loose soil................................................................................................................. 3-74
3.6.8. If wheel brake fails to work ............................................................................................................. 3-74
3.6.9. Check after stopping the engine ..................................................................................................... 3-75
3.6.10. Locking ........................................................................................................................................... 3-75
3.6.11. Tyre handling .................................................................................................................................. 3-76
Precautionary measures when handling tyres........................................................................... 3-76
Tyre pressure............................................................................................................................. 3-76

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Introduction 1.5. Table of contents

3.7. Transport .................................................................................................................................................... 3-78

3.7.1. Securing the articulated steering .................................................................................................... 3-78
3.7.2. Loading and securing the machine ................................................................................................ 3-79
3.7.3. Driving machine onto loading area of transport vehicle.................................................................. 3-81
3.7.4. Securing machine for transport....................................................................................................... 3-83
3.7.5. Transporting the machine ............................................................................................................... 3-84
3.7.6. After Transport................................................................................................................................ 3-84

3.8. Cold weather operation ............................................................................................................................. 3-85

3.8.1. Precautions for low temperatures ................................................................................................... 3-85
Fuel and lubricants .................................................................................................................... 3-85
Coolant ...................................................................................................................................... 3-85
Battery ....................................................................................................................................... 3-86
3.8.2. Precautions after completion of work.............................................................................................. 3-87
3.8.3. After the cold weather period.......................................................................................................... 3-87

3.9. Long-term storage ..................................................................................................................................... 3-88

3.9.1. Before storage ................................................................................................................................ 3-88
3.9.2. During storage ................................................................................................................................ 3-88
3.9.3. After storage ................................................................................................................................... 3-89

4. Troubleshooting ......................................................................................... 4-1

4.1. When the machine runs out of fuel ............................................................................................................ 4-2

4.2. Towing the machine .................................................................................................................................... 4-3

4.3. If battery is discharged................................................................................................................................ 4-6

4.3.1. Precautions for charging the battery................................................................................................. 4-7
4.3.2. Starting the engine with a booster cable........................................................................................... 4-8

4.4. For insufficient braking effect .................................................................................................................. 4-10

4.4.1. Checking the brake function ........................................................................................................... 4-10
4.4.2. Checking the parking brake function .............................................................................................. 4-10

4.5. Emergency steering properties ................................................................................................................ 4-11

4.6. Emergency lowering.................................................................................................................................. 4-11

4.7. Other troubles ............................................................................................................................................ 4-12

4.7.1. Electrical system............................................................................................................................. 4-12
4.7.2. Engine ............................................................................................................................................ 4-13
4.7.3. Hydraulic system ............................................................................................................................ 4-16
4.7.4. Brakes ............................................................................................................................................ 4-18
4.7.5. Steering .......................................................................................................................................... 4-18
4.7.6. Axles ............................................................................................................................................... 4-19
4.7.7. Driver's Cab .................................................................................................................................... 4-19

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1.5. Table of contents Introduction

5. Maintenance ................................................................................................5-1
5.1. Maintenance guide....................................................................................................................................... 5-2

5.2. Maintenance basics ..................................................................................................................................... 5-6

5.2.1. Oil, fuel and coolant specifications ................................................................................................... 5-6
Oil ................................................................................................................................................ 5-6
Fuel.............................................................................................................................................. 5-7
Coolant ........................................................................................................................................ 5-8
Grease ......................................................................................................................................... 5-8
Storing oil and fuel ....................................................................................................................... 5-9
Filters ........................................................................................................................................... 5-9
Biodegradable hydraulic oil and lubricants .................................................................................. 5-9
5.2.2. Specifications of the electrical system ............................................................................................ 5-10

5.3. Wearing parts list ....................................................................................................................................... 5-11

5.4. Lubricants, fuels and filling capacities .................................................................................................... 5-12

5.5. Tools and standard tightening torques (bolts, nuts).............................................................................. 5-13

5.5.1. Introduction of recommended tools ................................................................................................ 5-13
5.5.2. Torque list ....................................................................................................................................... 5-14

5.6. Periodical replacement of safety-critical parts ....................................................................................... 5-16

5.7. Maintenance schedule chart ..................................................................................................................... 5-17

5.8. Service procedure...................................................................................................................................... 5-19

5.8.1. Pre-start checklist .......................................................................................................................... 5-19
Cooling system – checking the coolant level, toping up coolant................................................ 5-19
Checking the engine oil level – topping up oil............................................................................ 5-19
Checking the fuel level – refuelling ............................................................................................ 5-19
Checking the controls ................................................................................................................ 5-19
Checking the electrical connections .......................................................................................... 5-19
Heater/air conditioning – checking rate of air flow ..................................................................... 5-19
Miscellaneous tests before starting work ................................................................................... 5-19
5.8.2. Maintenance upon demand ............................................................................................................ 5-20
Checking the air-conditioning system ........................................................................................ 5-20
Checking the window washing-fluid level, adding fluid .............................................................. 5-21
5.8.3. Maintenance after first 50 service hours ........................................................................................ 5-22
Engine – changing oil and replacing the oil filter cartridge ........................................................ 5-22
Check condition of V-belt ........................................................................................................... 5-22
Check tension of generator V-belt and adjust............................................................................ 5-22
Check and adjust tension of air conditioning (option) compressor V-belt .................................. 5-22
Hydraulic system – replacing the filter insert ............................................................................. 5-22
Check and tighten wheel nuts.................................................................................................... 5-22
Front and rear axle – oil change ................................................................................................ 5-22
Transfer box gearing – changing oil .......................................................................................... 5-22

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Introduction 1.5. Table of contents

5.8.4. Maintenance every 50 operating hours .......................................................................................... 5-23

Cooling system – checking the cooling system, coolant level in the radiator
and expanion tank ..................................................................................................................... 5-23
Fuel tank – draining off water and dirt deposits ......................................................................... 5-24
Service brake – checking the oil level, refilling oil ..................................................................... 5-25
Battery – checking the acid level ............................................................................................... 5-26
Battery – re-charging the battery ............................................................................................... 5-27
Check and tighten wheel nuts .................................................................................................. 5-27
Lubrication ................................................................................................................................. 5-28
5.8.5. Maintenance every 100 operating hours ........................................................................................ 5-29
Water separator – removing water and dirt deposits ................................................................. 5-29
5.8.6. Maintenance after the first 250 operating hours ............................................................................. 5-30
Engine – changing oil and replacing the oil filter cartridge ........................................................ 5-30
Check condition of V-belt........................................................................................................... 5-32
Check tension of generator V-belt and adjust............................................................................ 5-33
Check and adjust tension of air conditioning (option) compressor V-belt ................................ 5-34
Front and rear axle – checking the oil level ............................................................................... 5-35
Air filter – checking and cleaning the filter insert ....................................................................... 5-36
Radiator – cleaning the radiator segments ................................................................................ 5-39
Lubrication ................................................................................................................................. 5-40
5.8.7. Maintenance every 500 operating hours ........................................................................................ 5-42
Fuel filter – changing the fuel filter and filter element ................................................................ 5-42
Purging the fuel system ............................................................................................................. 5-42
Cleaning the water separator .................................................................................................... 5-43
Transfer box gearing – checking the oil level and refilling oil .................................................... 5-44
Air filter – replacing the filter insert, replacing the safety filter ................................................... 5-45
Heater/air conditioning – cleaning/replacing filter fleece or cleaning condenser....................... 5-46
ALS-pressure accumulator (Option) - checking gas pressure.................................................. 5-47
Lubrication ................................................................................................................................. 5-48
5.8.8. Maintenance every 1000 operating hours ...................................................................................... 5-49
Cooling system – exchanging coolant and cleaning the system .............................................. 5-49
Hydraulic – ventilating the hydraulic oil tank.............................................................................. 5-52
Hydraulic system – replacing the filter insert ............................................................................. 5-52
Checking the tightening parts of the turbo-charger.................................................................... 5-53
Checking the play of the turbo-charger rotor ............................................................................. 5-53
Service Brake – checking, testing, changing oil ........................................................................ 5-53
System pressures – checking and adjusting ............................................................................. 5-53
Valve play – checking and adjusting.......................................................................................... 5-53
Injection nozzles – checking and adjusting the , nozzle pressure and fuel-jet pattern .............. 5-53
Check pressure accumulator – gas pressure ............................................................................ 5-53
Front and rear axle – oil change................................................................................................ 5-54
Transfer box gearing – changing oil .......................................................................................... 5-56

1-17
1.5. Table of contents Introduction

5.8.9. Maintenance every 2000 operating hours ...................................................................................... 5-57

Hydraulic system – oil change ................................................................................................... 5-57
Cooling system – checking the antifreeze content of the coolant.............................................. 5-59
Checking the cooling system ..................................................................................................... 5-59
Checking the fuel pump ............................................................................................................. 5-59
Checking the fuel and coolant tubes, replacing the tubes (if required)...................................... 5-59
Checking the water pump .......................................................................................................... 5-59
Checking and adjusting the fuel injection and Injection time ..................................................... 5-59

6. Technical data .............................................................................................6-1

6.1. Technical data .............................................................................................................................................. 6-2

6.2. Noise emission levels.................................................................................................................................. 6-3

6.3. Vibration level............................................................................................................................................... 6-3

6.4. Limit values for slopes ................................................................................................................................ 6-3

7. Special equipment and attachments.........................................................7-1

7.1. ALS-electronics............................................................................................................................................ 7-2
7.1.1. Structure and functioning principle of the ALS-electronics ............................................................... 7-2
7.1.2. Precautionary measures for switching on the ALS-electronics......................................................... 7-2
7.1.3. Operating the ALS-electronics.......................................................................................................... 7-3
Switching ON the ALS-electronics............................................................................................... 7-3
Switching OFF the ALS-electronics ............................................................................................. 7-3
7.1.4. Precautions when handling the accumulator .................................................................................... 7-4

7.2. Air condition ................................................................................................................................................. 7-5

8. Index.............................................................................................................8-1

1-18
Introduction 1.6. Dimensions, weights and operating data

1.6. Dimensions, weights and operating data

H
D I
T2 B
T1 L
A

GK100878

Measurements, operating data

Bucket capacity to ISO 7546 m³ 1.3
Material density t/m³ 1.8
Static tipping load, straight kg 6,060
Static tipping load, 40° angle kg 5,270
Working load without CTW kg 3,200
Working load with CTW kg –
The 1.1 m³ standard bucket given in the table is
Breakout force, hydraulic kN 7,330
also available with blade attachment.
Lifting capacity, hydraulic, on ground kN 7,650
Operating weight *) kg 7,460
Turning radius over bucket mm 5,150 Special buckets:
L Bucket length in transport position mm 6,040 see chapter "1.7.1. CE-conforming equipment –
A Bucket length during planing mm 6,160 part 1" on page 1-20.
T1 Width with bucket mm 2,300
T2 Width without bucket (above wheels) mm 2,160 These values refer to machines with
G Height, including ROPS mm 3,030 455/70 R24, SPT9, DLP
D Track (front section) 1,700
mm
Track (rear section) 1,700
CTW =additional counterweight
B Width over tyres mm 2,450
H Distance articulated steer. - front axle mm 1,150
Ground clearance, axle /transfer gear 395
E mm
ground clearance, cardan shaft 540
F Centre of gravity,height above axle centre mm 548,20
I Centre of gravity, distance to front axle mm 1573,80

1-19
1.7. CE-conforming equipment Introduction

1.7. CE-conforming equipment

1.7.1. CE-conforming equipment – part 1

CE-conforming equipment

1 2 3 4 –

Hydraulic
Volume Weight
Type Part No. pressure
m³ kg
bar

Standard bucket
42R-70-12100 1.3 – 557
(without teeth)

Standard bucket
42R-70-12110 1.3 – 604
(with teeth)

Multiple-purpose
42R-70-12050 1.2 210 850
bucket

Bucket for light

WA115-3 42R-70-12140 1.5 – 607
material

Bucket for light

42R-70-12080 2.2 – 860
material

Bucket with carry

42R-70-12070 1.7 210
position

Side-dump bucket 42R-70-12170 1.2 210

Mulch grab bucket 42R-70-12180 1.3 210

1-20
Introduction 1.7. CE-conforming equipment

1.7.2. CE-conforming equipment – part 2

CE-conforming equipment

1 2 3 4 –

Work load of Work load of

fork carrier fork carrier Weight
Type Part No.
STD with CTW kg
kg / pair kg / pair

Fork carrier WA115-3 42R-70-120 3,200 – 358

STD Machine in standard version

CTW Machine with counterweight

1.7.3. CE-conforming equipment – part 3

CE-conforming equipment

1 2 3 4 –

Load Load
Weight
Type Part No. Capacity Capacity
kg
mm/kg mm/kg

Crane boom WA115-3 42R-70-12160 1,200 1,400 395

1-21
1.7. CE-conforming equipment Introduction

1-22
Introduction 1.7. CE-conforming equipment

1.7.4. Manufacturer-supplied CE-conforming equipment, according to

document 42R-93-19080
The responsibility for observing valid regulations in the case of
wheel loaders with "interchangeable equipment" (e.g. bucket or
fork-lift) which was not supplied from works lies with the customer
which was subsequently fitted to the machine.

The guidelines for CE Conformity and road-traffic registration are

deemed to have been fulfilled when the manufacturer of the
equipment confirms fulfilment of the document 42R-93-19080.

The certification must be sent to the customer and the wheel

loader manufacturer. The CE conformity declaration for a specific
wheel loader is only legally valid once this has taken place.

The dimensions X1, X2, Y1 and Y2 must be provided by the

manufacturer of the equipment for approval for use on public
roads. *)

The dimension Sh (smallest tyre radius) must be added to the

dimension D2.

The figure G (in kg) represents the maximum load (equipment

and operating load) which may act upon this point.

*) valid in Germany

GK100952

1-23
1.7. CE-conforming equipment Introduction

GK100879

1-24
Introduction 1.7. CE-conforming equipment

Manufacturer-supplied CE-conforming equipment, according

to document 42R-93-19080
WA115-3 42R-93-19080
A1 Distance: bucket pivoting point - front axle, horizontal
A2 Distance: bucket pivoting point - front axle, vertical A1 1,745
B1 Distance: driver's eye (1) - front axle, horizontal A2 1,230
B2 Distance: driver's eye (1) - front axle, vertical
Sh 590
D1 Distance front axle- lower edge of headlights, horizontal
D2 Distance front axle- lower edge of headlights, vertical B1 2,045

G Weight of equipment and working load B2 2,085

H1 Distance: bucket pivoting point - bucket upper edge, vertical C1 1,538
(carrying position)
H2 Distance: bucket pivoting point - vision line, vertical C2 1720
(carrying position) D1 340
J Distance: road level - bucket bottom edge
(carrying position) D2 1,135

Sh Distance: road level - front axle G 2,950

X1 Distance cutter protection - front axle, horizontal H1 1,040
X2 Distance cutter protection - road level, vertical
H2 1,595
Y1 Distance teeth protection - front axle, horizontal
Y2 Distance teeth protection - road level, vertical J 270

a Tip-in angle X1 –
b1 Bucket connection dimension, boom width inside X2 –
c Bucket connection dimension between d1 and d2, vertical
Y1 –
d1 Bucket connection dimension, bolt (3) for boom
d2 Bucket connection dimension, bolt (3) for tilt rod Y2 –

e Bucket connection dimension d1 - d2, horizontally a 51°

displaced
b1 960
h Distance: bucket bottom edge - boom bolt hole
c 550

d1 40
d2 40

e 205

h 250
Tyre 455/70 R24, SPT9, DLP

1-25
1.8. Loading and securing Introduction

1.8. Loading and securing

Observe all safety instructions carefully in order to prevent
accidents with severe injury

Covering must be removed

DANGER

Always secure articulated joint if maintenance or repair
work is to be carried out or if the machine is going to be
lifted or transported.

An articulated joint may jack-knife unexpectedly if not

secured. Danger of injury if joint jack-knifes.

1-26
Introduction 1.8. Loading and securing

Position machine as if driving in forward direction and secure

articulated joint against jack-knifing, using the articulated-joint
lock. Always secure securing bar in either position using bolt and
spring pin
1
Position 1 Articulated steering locked
Position 2 Articulated steering unlocked

NOTE
Due to safety reasons and to avoid consequential damages,
it is prohibited to attach other points (such as axles, cardan
shafts, articulated joint, bucket teeth) than those specified
for lifting and securing. It is also prohibited to attach ropes 2
etc. to the driver's cabin.

1-27
1.8. Loading and securing Introduction

1-28
Safety

DANGER
Failure to adhere to these safety instructions can lead to
accidents with serious injuries!
Read and adhere to all safety instructions.

This chapter also contains safety instructions for special

equipment and attachments.

2-1
2.1. General safety measures Safety

2.1. General safety measures

2.1.1. Safety instructions

Do not operate or service the machine unless you have been
trained and are authorised to do so.

Always adhere to all instructions, measures, and safety

instructions when operating or servicing the machine.

When working together with other persons, agree beforehand

on all hand signals that you want to use to avoid accidents
due to misunderstandings.

2.1.2. Safety devices

Check that all safety devices and covers of the machine are
correctly installed.

Ensure that damaged safety devices and covers are repaired

before you start the machine.

Use all safety devices as prescribed, e.g. the safety lever for
the work hydraulic system and the safety belt.

Safety lever for working hydraulics:

Position 1 working hydraulics locked

Position 2 working hydraulics released

Do not remove any of the safety devices. Safety devices

must be kept in perfect condition.
GK100835

2.1.3. Emergency exit

The door on the direction of travel’s right-hand side of the cab can
be used as an emergency exit in hazardous situations.

2-2
Safety 2.1. General safety measures

2.1.4. Clothing and personal protection

Do not wear loose-fitting clothing, jewellery, or open long hair.
There is a danger that you will get caught by control elements
or moving parts, leading to serious injuries.

Immediately replace clothing stained with highly inflammable

substances.

When operating and servicing the machine, wear the

appropriate protective equipment, e.g. safety helmet, safety
goggles, safety shoes, dust protection mask, and safety
gloves.
A0055010

Always wear safety goggles, safety helmet, and protective
clothing, if it is likely that chippings or splinters will be
produced while operating the machine (e.g. when removing
or driving in bolts or cleaning with compressed air).

Ensure that no unauthorised person is within the danger

zone.

2.1.5. Machine modifications

Komatsu will not be liable for modifications performed without
prior expressed consent by the manufacturer.

Komatsu will not be liable for any injuries or damage resulting

from unapproved modifications.

2.1.6. Before you leave the driver's seat

1. Lower the work unit onto the ground.

2. Press slowly the multi-function lever to the front into position

'S'. The remaining hydraulics pressure will be reduced.

3. Switch off the engine.

4. Remove the ignition key before you leave the driver's seat.
Store the ignition key in a safe place.

5. Close the cabin door.

75_016

2-3
2.1. General safety measures Safety

2.1.7. Mounting and dismounting

Do not jump on or off the machine. Do not mount on or
dismount from a moving machine.

Always use the handle bars and tread steps for mounting or
dismounting the machine. Do not hold onto the control levers
while mounting and dismounting.

To ensure safe hold, hold the handle bar with one hand and
stand on the tread steps with both feet. Optionally, stand on
the tread steps with one foot and hold the handle bars with
both hands.

AL187320

2-4
Safety 2.1. General safety measures

2.1.8. Fire prevention and fire fighting

Fuel, oil, and antifreezing compound are highly inflammable
and could cause a fire.

Do not approach inflammable material with naked light.

Prior to refuelling, switch off the engine and stop smoking.

Refuelling and refilling of oil are to be performed in sufficiently

ventilated places.

Store oil and fuel in special places appropriate for this

purpose. Ensure that unauthorised persons do not have
access to these places.

Tightly close all cover caps.

Check the fuel system, the lubrication system, and the

hydraulic system for leaks. Have leaks repaired. Remove any
excess oil, fuel, or other inflammable substances.

Carefully and completely remove wooden chippings, leaves,

paper, and other highly inflammable materials that may have
collected in the engine compartment, since they could cause
a fire. A0055030

Do not operate the machine in the vicinity of naked light.

2-5
2.1. General safety measures Safety

Fire extinguisher and first-aid kit

A fire extinguisher can be stored in the compartment under

the driver's seat. Two appropriate fastening points are already
attached to the back of the compartment.

A fully operational fire extinguisher must be available at hand.

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

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

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

GK100893

The first-aid kit can be stored in the compartment under the
driver's seat next to the fire extinguisher.

Make sure that you know all telephone numbers of the

persons that you need to contact in an emergency.

2-6
Safety 2.1. General safety measures

2.1.9. Protection against asbestos dust

Asbestos dust is a health hazard if breathed in. This machine is
free of any parts containing asbestos.

When handling material that may contain asbestos fibres, strictly

adhere to all legal instructions and regulations. Furthermore,
adhere to the following protective measures for your own
protection:

Work, if possible, with a following wind.

While working, wear an approved dust protection mask.

After work, clean the machine with water to minimise

formation of dust. Do not use compressed air for cleaning.

2.1.10. Protection against injuries

Do not insert any part of your body in the operating range of
moving parts, such as work unit and cylinder, or machine and
work unit. Never stand in a dangerous area. Distances vary when
the work unit or steering are operated, this may lead to serious
injuries.

2-7
2.1. General safety measures Safety

2.1.11. Working at high temperatures

Directly after operating the machine, the engine coolant, the
engine oil, and the hydraulic oil are extremely hot and under
pressure. Do not try to unscrew caps, drain water or oil, or
replace filters directly after operating the machine, since this
may lead to severe burns due to hot fluids or hot machine
parts. Wait until the temperature has fallen. Strictly adhere to
the described procedures when performing the required
measures.

Lower the work equipment.

Switch off the engine and wait for the radiator to cool down
before you unscrew the radiator cap. Slowly turn the radiator
cap until it reaches the first catch to let the pressure escape.
Then, proceed turning the cap further and remove it. If you do
not let the pressure escape, boiling water may spurt out when
you remove the radiator cap.

Switch off the engine. Allow the hydraulic oil to cool down
before you unscrew the cap of the hydraulic tank to drain the
hydraulic oil. Slowly turn the cap of the hydraulic tank to let
the pressure escape from the tank. If you do not let the
pressure escape, oil may spurt out when you remove the cap
of the hydraulic tank.

2-8
Safety 2.1. General safety measures

2.1.12. Roll-over protection system (ROPS)

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

The ROPS is a fixed component of the cab. The machine

must not be operated without this roll-over protection system.

The ROPS meets the regulations of all member states of the

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

The ROPS can only provide maximum protection, if the driver

wears the safety belt correctly. For this reason, the safety belt
is to be worn when the machine is in operation.

2.1.13. Attachment for protection against falling objects (FOPS)

NOTE
FOPS is a fixed component of the cab.

When you work on a site where there is danger of falling rocks or

other objects, the machines must be equipped with a FOPS.

If the FOPS is modified without permission or damaged, its

stability is impaired. In this case, the FOPS must be replaced,
since its correct function can no longer be guaranteed.

2.1.14. Attachments with auxiliary function

Prior to assembly and operation of an additional attachment,
read the attachment's manual and strictly adhere to the
instructions on assembly and operation.

Do not use attachments that have not been approved of by

Komatsu or the responsible Komatsu dealer.

If you use attachments which have not been approved of,

safety, correct operation, and service life of the machine may
be impaired.

Komatsu are not liable for injuries, accidents, and damage

resulting from the use of attachments that have not been
approved.

2-9
2.1. General safety measures Safety

2.1.15. Battery
The batteries are filled with sulphuric acid (battery acid).

Always wear safety goggles when handling batteries.

Contact of battery acid with eyes can cause blindness. If acid

should get into your eyes, immediately rinse your eyes with
ample water and call for medical help. Rinse your eyes with
water until a doctor arrives or you are able to visit an
ophthalmologist or go to a hospital.

Sulphuric acid that gets into contact with skin or clothing may
cause acid burns. Immediately rinse the area that has come
into contact with the acid with ample water.

When working in the area of the battery, your hands may

unintentionally get in touch with acid. For this reason, do not
touch your eyes while working in the area of the battery.
Always wash your hands after work.

Batteries produce detonating gas. Detonating gas is

extremely explosive and may be ignited even by the
smallest spark.

Do not disconnect the battery while the engine is still running.

Prior to start of work on batteries, set the start switch to '0'.

Set the main switch of the battery (if installed) to 'Off'.

Avoid any short-circuits via the poles or the pole terminals of

the battery due to unintentional touching with metal objects,
such as tools.

When removing or inserting the battery, note which of the

poles is the positive (+) and which is the negative (-) one.
Always disconnect the mass cable first and reconnect it last.

Tightly fasten the pole terminals. Loose pole terminals may

produce sparks and thus cause explosions. Ensure that the
cover of the positive pole (+) is always mounted.

Tighten the cover caps.

When repairing the electrical system or performing electric

welding, disconnect the negative (-) pole terminal from the
battery to interrupt the electric circuit.

2-10
Safety 2.2. Safety precautions during operation

2.2. Safety precautions during operation

2.2.1. Prior to daily starting up

Workplace safety

Before you start operation, check the working area for

dangerous working conditions.

Inspect the surface of the soil in the working area and

determine the optimum and safest procedure.

Determine the required safety measures against dangers on

public roads in co-operation with the owners, users, and
responsible authorities.

On sites where there are underground water pipes, gas

pipes, or conduits for high voltage cables, contact the AE060770

responsible supply company to determine the lines' positions.

Ensure that these facilities will not be damaged.

When working with water or crossing sand banks, first check

the subsoil and depth and flow rate of the water. Ensure that
the permitted water depth will not be exceeded.

In the driver's cab

Do not leave any tools or spare parts lying around in the cab.
These may actuate, damage, or block control levers, pedals,
or switches. Store these parts in the tool box.

Keep the cab floor, the control elements, the tread steps, and
the handrails free of oil, grease, and excessive dirt.

Immediately repair any damage. Tighten loose screw

connections.

Check the safety belt, the belt buckle, and the fastening
elements for damage and wear. Replace worn or damaged
parts.

2-11
2.2. Safety precautions during operation Safety

Indoor operation

Do not operate machines in-door unless these areas are

sufficiently ventilated (e.g. workshops).

CAUTION
Danger of intoxication!

Gas, dust, and inflammable vapours

Do not operate combustion engines in an environment that may

contain inflammable gases or vapours. These gases, dusts, or
vapours may ignite or be sucked in by the suction system, thus
causing a rise in engine speed or an exceeding of the engine's
maximum rpm. This may lead to a fire, an explosion, and major
damage to property. It may also happen that the engine cannot be
switched off anymore. Also refer to section "Indoor operation" on
page 2-12.

Mirrors, windows and lighting

Clean the windows and the headlights to ensure maximum

sight.

Adjust the rear-view mirror in such a way that you have an

excellent view of the rear from the driver's seat. Keep the
mirrors clean.

Ensure that the complete lighting system operates properly

and that it is correctly adjusted.

Immediately replace broken window panes by new ones.

2-12
Safety 2.2. Safety precautions during operation

2.2.2. Machine operation

Before you start the engine

Walk around the machine to check whether persons or

objects are in the way before you get on the machine.

Do not start the engine, if a warning sign has been attached

to the control lever or another point. (see section 1
"2.4.2. Before carrying out maintenance" on page 2-24).

Sound the horn just before you start the engine.

Start and operate the machine only from the driver's seat.

Apart from the operator, no other person is permitted in the

driver's cab or the vicinity of the machine.

If the machine is provided with a reversing warning system,

you must ensure that it operates correctly. 2

Before you start the machine, check that

 the articulated steering is unlocked (position '2'),

 the locking bar is attached to the frame by means of bolts
and spring bolts.

Always wear the safety belt when operating the machine.

Reversing

These rules must be observed for all machines, i.e. also for those
machines equipped with a reversing warning system:

Check that there is nobody near the machine or in the way.

Before you start reversing, sound the horn to warn persons

within or near the operating area.

When working in potentially dangerous areas or areas with

obstructed view, ask another person to regulate and
supervise traffic.

2-13
2.2. Safety precautions during operation Safety

Driving

When driving, set the bucket to the transport position.

The two red arrows on the bucket cylinder will line up next to
each other.

When driving on uneven ground, drive slowly and avoid

sudden steering movements

GK100884

Driving on slopes

Keep sufficient distance to ridges and steep slopes. There is

danger of the machine tipping over or sliding down on steep
slopes, embankments, or hill flanks (approx. 200 to 300 mm).
The limiting values are defined in chapter "6.4. Limit values
for slopes" on page 6-3.

To keep the centre of gravity as low as possible when driving

on slopes, embankments, and hill flanks, you must set the
bucket to a position just above the ground. In an emergency,
quickly lower the bucket to the ground to stabilise the
machine.
AE060800

Do not turn on a slope or drive across a slope. Turn or cross

the section only level ground.

When driving on slopes, avoid driving on grass, fallen leaves,

or steel plates. Driving sideways on these surfaces may result
in the machine sliding. Drive very slowly and carefully.

When driving down a slope, use the braking power of the

engine and drive slowly.

If the engine stops while you are driving on a slope,

immediately apply the service brake to stop the machine.
Then apply the parking brake. Lower the work unit. AE060810

When driving on a hill with a load, drive

 uphill: in forward direction

 downhill: in reverse direction

2-14
Safety 2.2. Safety precautions during operation

Emergency lowering system

The machine is provided with a pressure accumulator for the work

hydraulic system. If the engine is not running, you can lower the
work unit with the multi-function lever.

NOTE
If you have secured the work hydraulic system with the locking
lever of the work hydraulic system, you cannot lower the work
unit.

Position 1 = working hydraulics locked

Position 2 = working hydraulics released

GK100835

1. Make sure that nobody is standing below the work unit.

Press slowly the multi-function lever into position 'P'. The

work unit is lowered.

75_016

2-15
2.2. Safety precautions during operation Safety

Working close to power lines

A voltage overspill may occur, if you or the machine get too

close to power lines. For this reason, always heed the
required safety distance between the machine and the power
lines.

Nominal Voltage Safety Distance

up to 1,000 V 1m

over 1 kV up to 110 kV 3m
A0060820
over 110 kV up to 220 kV 4m

over 220 kV up to 380 kV 5m

with unknown nominal voltage 5m

The safety distances given here reflect the German safety

standards. You can find the safety distances applying to your
country in the relevant national regulations.

Before you start work, obtain information about line voltages

from your supply company.

When estimating the distance, take into account all possible

movements of the machine, the work unit, and the line. An
uneven surface may result in the machine swaying, or wind
may move the lines, etc.

Should the work unit come into contact with a power line,
proceed as follows:

1. Do not leave the driver's cab. The driver's cab is a "Faraday

cage" protecting you from electric shock.

2. Warn other persons and tell them to stay far away from both
the power line and your machine.

3. Try to move the machine out of the range of influence of the

power line by moving it away from the line, moving away the
work unit, etc.

4. Have the power in the line switched off.

2-16
Safety 2.2. Safety precautions during operation

Loading

Proceed as follows to fill embankments, to backfill ditches, or

to deposit earth over the edge of a hill:

1. First, dump a heap of earth in front of the hill.

2. Fill the bucket with earth again and drive the machine into
the heap of earth. Dump the bucket contents behind the
first heap of earth.

After the first heap of earth has been pushed over the hillside,
the thrust required for the earthmoving operation is reduced –
with the result that the speed of the wheeled loader suddenly
increases unexpectedly. For this reason, you should drive
slowly and cautiously at such locations.

If possible, perform all load operations with a following wind to

protect yourself against dust and impaired vision.

Avoid sudden starts, turns, or stops when the bucket is full.

Good vision

When working in dark areas, switch on the working lights of

the machine and provide additional lighting for the working
area.

If vision is impaired, e.g. due to mist, snow, or rain, interrupt

work and wait until vision has improved to such an extent that
safe work is ensured again.

Working on snow

When working on snow or ice-covered surfaces, there is

danger of the machine starting to skid even at a very flat
angle. For this reason, drive slowly and avoid sudden starts,
turns, or stops.

Very often snow hides the edges of roads and other objects.
For this reason, proceed very carefully when removing snow.

When driving on hill flanks covered with snow do not brake

abruptly to stop the machine. To stop the machine, lower the
bucket onto the ground.

The load may vary considerably, depending on the structure

of the snow. For this reason, reduce the load and pay
attention that the machine does not start to skid.

2-17
2.2. Safety precautions during operation Safety

Height limitation

When working in areas with height limitations, e.g. in tunnels,

beneath bridges or power transmission lines, or in garages, pay
attention that the work unit does not touch or damage these
facilities.

Brakes

Use the brake pedal only for braking, do not use the brake
pedal as a foot rest.

Do not step repeatedly onto the brake pedal, unless it is

absolutely necessary.

When driving downhill, use the engine as a brake and use the
brake pedal, if necessary.

Working on loose soil

Do not drive the machine too close to edges of hills,

overhangs, and deep ditches.

If the soil starts to sag at these locations, the machine may tip
over, fall down, or roll over, thus injuring you severely.

Take into account that the soil is wet and soft after heavy
rainfall, or very loose after blasting.

2-18
Safety 2.2. Safety precautions during operation

Working with the forklift truck attachment

Check daily, before starting operation, the fork tines of the

machine for visual damages (e.g. fissures, cracks, abrasion).

Also the protective device for unintentional removing or

shifting of the fork tines may have no faults. Never operate
with a damaged forklift truck attachment.

Before inserting the forklift truck attachment into the quick-

change unit, check whether it is appropriately locked in.

Make sure that the distance between the individual fork tines
is sufficient.

Never exceed the maximum permitted loading capacity of the

forklift truck attachment.

It depends on the condition of the ground on which the work is 500 mm

to be performed and the stroke height. The values specified in
chapter "1.7. CE-conforming equipment" on page 1-20 refer
to the most unfavourable stroke position with the boom in 500 mm
horizontal position.

The centre of gravity of the load lies 500 mm from the fork
75_156
back and the fork tines (see drawing).

Transports palettes only individually.

If you are instructed by the responsible colleague to transport

more than one box palette, which are also piled up, you must
make sure in any case that the locations under which the
forklift truck attachment is gripping for transporting are in
perfect condition.

The overall height of the palette pile must not exceed 2 m.

Make sure that the fork tines are adapted to the length of the
load. Move the fork tines so far under the load that the load
comes to a rest at the fork back.

Make sure that the fork tines are adapted to the length of the
load.

Move the fork tines so far under the load that the load comes
to a rest at the fork back.

If you are transporting a load which is impairing your sight on

the route, you must drive the machine into a direction in which
you have free sight. If it cannot be avoided, drive backwards.
If this is not possible, ask a colleague to assist you by clearing
your way and indicating to you any obstacle.

In this case, drive very slowly and extremely careful.

2-19
2.2. Safety precautions during operation Safety

During transporting, lower the boom to its transport position.

Both red arrows of the transport position marking (see

adjacent figure) on the bucket cylinder must be next to each
other.

Incline the load slightly to the back during the transport.

Always drive slowly when you are transporting loads (speed

range 1).

If you are driving on slopes or hills, transport the load always GK100884

in such a way that it is pointing to uphil.

The boom performs a semicircular movement during the

lifting.

Lift the boom to the desired transporting height only shortly

before approaching the deposit surface. This prevents that
the load is damaged during the lifting.

Lower the forklift truck attachment completely to the ground

before quitting the driver's cab.

2-20
Safety 2.2. Safety precautions during operation

Parking the machine

If possible, park the machine on an even surface.

If you have to park the machine on a slope, you must park the
machine with the work unit pointing down the slope.

Lower the work unit until it firmly touches the ground, or let
the cutting edge of the bucket sink deeply into the soil.

Block the wheels with wheel chocks to ensure that the

machine cannot roll away.

Adhere to all regulations on parking vehicles and securing

building sites. GK100883

Before you leave the machine, completely lower the work unit
onto the ground.

Secure the control lever of the work hydraulic system against

accidental operation.

Switch off the motor.

Lock all points that can be locked and store the key in a safe
place.

2-21
2.3. Safety measures during transport Safety

2.3. Safety measures during transport

2.3.1. Loading and unloading the machine

Loading and unloading is potentially dangerous. For this reason,
proceed with extreme care.

Load and unload the machine only on solid and level ground.
Keep a safety distance to the edge of the road.
3

Block the wheels of the transport vehicle (1) and place
support blocks (2) under both ramps before driving the
machine onto the transport vehicle.
4 1

Only use ramps (3) with appropriate carrying capacities and
widths. The ramps must be long enough to ensure that the 5 Max. 15° 2 GK100205
maximum loading gradient (4) of 15° is not exceeded.

Ensure that the ramps are positioned and fastened safely and
that both sides have the same height. Set the distance
between the ramps to the distance between the wheel tracks
(5).

Ensure that the surfaces of the ramps are clean and free of
grease, oil, ice, and loose material. Remove any dirt adhering
to the wheels.

When loading and unloading the machine, keep the engine

speed low and drive slowly.

Do not carry out steering movements on the ramps. If

required, drive off the ramps again, correct alignment of the
machine, and drive up again.

After loading, i.e. when the machine is on the transport 1

vehicle, apply the parking brake.

Block the wheels of the machine with wheel chocks.

Set the steering wheel of the machine to straight driving.

Secure the articulated steering with the locking bar.

Position 1 Articulated steering locked
Position 2 Articulated steering unlocked
2
Always secure the locking bar with the bolt and the spring bolt
in both positions.

Secure the machine on the transport vehicle by means of

appropriate fastening equipment. Only use the attachment
points on the machine for lifting and securing. For safety
reasons, do not use any other points for fastening (e.g. axle,
cardan shaft, articulated steering, bucket teeth, or strapping
around the cab).

2-22
Safety 2.3. Safety measures during transport

2.3.2. Transport

When moving the machine on a transport vehicle, adhere to
all applicable motor vehicle traffic regulations.

Determine the transport route, taking into account the width,

length, height, and weight of the load and, if necessary, have
this approved by the responsible authorities.

2-23
2.4. Precautions for maintenance Safety

2.4. Precautions for maintenance

2.4.1. Personnel
Do not service or repair the machine unless you are an
appropriately qualified technician or have been appropriately
instructed by a qualified technician.

2.4.2. Before carrying out maintenance

Warning sign

While the machine is being serviced, the engine must not be

started and the control elements must not be actuated without
prior agreement, since this could cause accidents with serious
injury.

Always attach the warning sign to the control lever for the work
hydraulic system to warn other persons that work is being
performed on the machine. If required, put up additional warning
signs around the machine.

You may purchase these warning signs from your Komatsu

dealer.

Tools

Only use tools which are suitable for the task you want to carry
out. If you use damaged or makeshift tools or tools which are of
inferior quality, injuries may occur.

2-24
Safety 2.4. Precautions for maintenance

Safety-related parts

The quality of these parts is subject to normal wear and tear. For
this reason, replace safety-related parts by new ones at regular
intervals, regardless of whether they are defective or not.

Safety-related parts are:

Fuel system:

 fuel hose,
 overflow hose,
 tank cap

Hydraulic system:

 all hydraulic hoses

Immediately replace defective parts, even if the interval for
replacement has not elapsed.

Replace hydraulic hoses every 6 years.

Prior to start of inspection and maintenance

Prior to start of inspection and maintenance operations, park the

machine on solid, even ground. Lower the work unit.

If your machine is provided with ALS electronics, you must switch

off the ALS electronics.

Switch off the engine and safeguard the machine.

If the engine has to be running during maintenance, e.g. for

pressure checks of the hydraulic system, proceed with particular
care. Carry out such measures with two persons with whom you
have arranged clear hand signs beforehand.

One person must be seated on the driver's seat to ensure that the
engine can be immediately switched off, if required. This person
must always ask the second person before actuating the control
levers.

The person performing the maintenance measures must take

care not to touch or get caught by moving parts.

2-25
2.4. Precautions for maintenance Safety

Securing the articulated steering

WARNING

Use the articulated steering lock to lock the articulated
steering when performing maintenance or lock the
machine when transporting it.

Release the articulated steering lock under normal 1

operating conditions as shown.

The articulated steering lock is used during maintenance when

lifting with a crane or when transporting the machine. It serves to
lock the articulated steering and prevents the machine from
jackknifing.

Position 1 = Articulated steering locked

2
Position 2 = Articulated steering unlocked

Always use the bolts and spring connectors at both positions

when securing the lockup rod.

2-26
Safety 2.4. Precautions for maintenance

Securing the working attachment

DANGER
Risk of injury! The attachment may fall suddenly when in
raised position! For safety reasons, a raised attachment
must be secured against dropping before you pass or stand
under it.

The working attachment must be secured against moving if any

work is to be carried out under it when it is in a raised position. For
this purpose you should use either a supporting prop (1) which is
to be positioned below the lifting arms, or support braces (2) 1
which are mounted around the piston rods.

The support braces are available as optional extras.

Order No.: 42U-98-12030

NOTE
AE418280
Please note: 2 support braces are necessary for every
machine; one for the left-hand lifting ram and one for the
right-hand lifting ram.
3
When using the support braces the following procedure is to be
adhered to at all times:

1. Park the machine on level, solid ground.

2 2
2. Apply the parking brake.

3. Place wheel chocks in front of the wheels to prevent the

machine from inadvertently rolling away.

4. Lift the arm far enough to allow the support braces (2) to be
placed on the lifting ram’s piston rods.

5. Switch the engine off. F

6. Mount the support braces on the piston rods without standing N
under the lifting arm and tighten the screws (3) with your
fingers. R
7. With the engine switched off, lower the arm slowly until it
rests on the supports.
GK100809

8. Set the driving direction switch to 'N' and move the safety
lever for the working hydraulics to position '1'.

Position 1 = working hydraulics locked

Position 2 = working hydraulics released

GK100835

2-27
2.4. Precautions for maintenance Safety

2.4.3. During maintenance

Attachments

Attachments removed from the machine must be put down in a

safe location in such a way that they cannot tip over.

CAUTION
Risk of injury!

Working under the machine

Always lower all movable work units onto the ground or set
them to their lowest positions before you start to perform
maintenance or repair measures under the machine.

Block the wheels of the machine using wheel chocks.

Do not work under a machine that is not appropriately

supported.

Keeping the machine clean

Always keep the machine clean and tidy.

Oil, grease, and tools lying around involve danger, since they
may cause slipping or tripping over.

Do not clean sensors, plugs, and the interior of the driver's

cab with water or steam. If water seeps into the electric
system, there is danger of uncontrolled and unintentional
movement of the machine which may cause accidents.

Specific measures

Always wear appropriate safety clothes and safety goggles when

you perform grinding, welding, use a sledge hammer or carry out
similar work.

2-28
Safety 2.4. Precautions for maintenance

Refuelling and topping up of oil

Spilled fuel or oil involves danger of slipping and fire. For this
reason, immediately remove any spilled liquid.

Always refuel and top up oil in a place that is sufficiently

ventilated.

After refuelling and topping up, close the filling openings with
cover caps.

Do not use fuel for rinsing or cleaning of components.

Ensure that neither oil nor fuel can seep into the soil or water.
Dispose of used substances according to the relevant
environmental regulations.

If the machine is provided with a fuel sieve in the tank

opening, do not remove this fuel sieve before you start
refuelling.

A0055030

Coolant

The machine is provided with an aluminium cooling system.

Apply only coolants in the prescribed mixing ration.

Caution, antifreeze is highly inflammable.

To check the coolant level, first switch off the engine and wait
for the cooling system to cool down. Then, check the coolant
level in the expansion tank.

Slowly unscrew the cap to let the pressure escape.

If required, top up water in the expansion tank.

2-29
2.4. Precautions for maintenance Safety

Use of lighting

Always use explosion-proof lighting when checking fuel, oil,

coolant, or battery acid.

High-pressure hoses

Neither bend high-pressure hoses nor hit them with hard

objects. Do not use piping or hoses with fissures, cracks, or
bends, since they may burst during operation.

Immediately replace any loose or damaged fuel or oil hoses.

Leaking fuel or oil involves danger of fire and slipping.

Replace all hoses every six years at the latest.

Handling high-pressure oil

Always take into account that the hydraulic lines are

subjected to high pressure.

Do not top up oil, drain oil, or perform maintenance or

inspection measures unless the work unit is completely
lowered and the system is depressurised.

If oil comes out under high pressure, this involves danger of

an oil jet penetrating the skin or getting into the eyes. For this
reason, always wear safety goggles and thick safety gloves,
and use a piece of cardboard or wood when checking for oil
leaks.

If you have been hit by an oil jet, immediately go and see a

doctor and explain what has happened.

2-30
Safety 2.4. Precautions for maintenance

Handling of pressure accumulators

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

Immediately inform your Komatsu dealer, if you detect

malfunctions or defects of pressure accumulators.

Filling the pressure accumulator with gas or topping up gas in

the pressure accumulator is strictly limited to persons
authorised to handle highly pressurised gas.

Do not hit against the pressure accumulator.

Keep naked light and sources of heat away from pressure

accumulator.

Do not drill holes into the pressure accumulator.

Do not weld parts to the pressure accumulator.

The service technicians must depressurise the hydraulic

system before they can remove the pressure accumulator.

The service technician must let the gas escape before they
can disassemble the pressure accumulator.

2-31
2.4. Precautions for maintenance Safety

Fan and belts

Always keep sufficient distance from rotating parts and pay

attention that nothing gets within the operating range of
rotating parts.

There is danger that parts getting caught by the fan or the belt
are cut off or hurled away.

Do not wear loose clothing, neckerchiefs or the like, or open,

long hair that might get caught.

Waste material

Do not pour used oil into the sewage system, rivers, etc.

Collect used oil of the machine in appropriate containers. Do

not let oil flow out onto the ground.

Adhere to all applicable laws and regulations when disposing

of harmful substances, such as oil, fuel, coolant, solvents,
filters, batteries, etc.

2-32
Safety 2.4. Precautions for maintenance

2.4.4. Tyres

Handling of tyres

(also refer to chapter "3.6.11. Tyre handling" on page 3-76)

Tyres may burst and the resulting blast wave or parts whirling
around may cause severe injury or damage. Make sure that the
applicable procedures for servicing and replacing of wheels or
tyres are fully understood and that only correct procedures are
used.

To ensure safety and reduce wear and tear, always adhere to the
following instructions:

Inflate tyres up to the defined pressure.

 If the tyre pressure is too low, the tyres may heat up and
burst.

 If the tyre pressure is too high, there is also danger that

the tyre may burst.

If a tyre heats up considerably, inflammable gases are

produced. A burning tyre may burst very easily, thus
spreading fire over a large area.

Check the tyre pressure when the tyres are still cold. Do not
let off pressure, when the pressure in a warm tyre has
increased.

Do not light a fire and do not carry out welding near the tyre.

Keep the working area free of pointed or sharp objects that

may damage the tyre.

Avoid any overload.

The values for tyre pressure and permitted speed given in this
manual correspond to the manufacturers' values.

Please refer to your local dealer or the tyre manufacturer for

details.

2-33
2.4. Precautions for maintenance Safety

Storing tyres

Basically, tyres must be stored in a protected room that

cannot be accessed by unauthorised persons.

Place the tyres on an even surface and incline them 60° to

70° (2) against a solid stopper. Secure the tyres with wheel
chocks (1) so that they cannot roll away, tip over, or slip.

If, however, a tyre tips over despite this safety measure, do

not try to stop it, but get out of the way as quickly as possible,
since tyres for construction machines are very heavy and
may cause serious injuries.

Q
R
60˚ – 70˚ GK100224

2-34
Safety 2.5. Labels on the machine

2.5. Labels on the machine

All safety labels must be kept clean all times. Missing or damaged
safety labels must be replaced.

2.5.1. Positions and order numbers of safety labels

2-35
2.5. Labels on the machine Safety

2.5.2. Positions and order numbers of information labels

2-36
Operation

3-1
3.1. General view Operation

3.1. General view

3.1.1. General view of the machine

1 2 3

GK100881

8 7 6 5 4

1 Tipping lever 5 Lift cylinder

2 Bucket cylinder 6 Front wheel
3 Indicator lamp, Headlamp 7 Boom
4 Rear wheel 8 Bucket

3-2
Operation 3.1. General view

3.1.2. Controls and Indicators

1 Parking brake
2 Unlocking left door 8
3 Inch brake pedal 7
9
4 Direction indicator lever
6 10
5 Light switch
6 Horn button 5 11
7 Instrument panel
4
8 Steering column adjustment
9 Driving direction switch 3
10 Multifunction lever
2
11 Control lever for auxiliary functions
12 Safety lever for working hydraulics
13 12
13 Accelerator 1
14 Unlocking of right door 14
15 Power socket (12 V) 15
16 Vehicle radio (option) GK100813
16

17 High speed gear warning light – option

18 Brake fluid reservoir warning light 19 20 21 22 23 24 25
18 26
19 Air filter warning light 17 27
20 Parking brake warning light
21 Charging current warning light 39 28
22 Direction indicator switch warning light
23 Engine oil pressure warning light 38 29
24 Flasher signal warning light
37 30
25 Intake air pre-heater warning light
26 Heated rear window warning light
27 ALS electronics warning light – option GK100802

28 Working lights switch warning light 36 31

29 Driving range switch up to 20 km/h 35 32
30 High speed gear switch – option
31 Coolant temperature indicator
32 Operating hour recorder, speedometer 34 33
33 Main beam warning light
34 Low beam warning light
35 High speed gear warning label
36 Fuel gauge
37 Wiper and washer system switch
(Rear window)
38 Wiper and washer system switch GK100806

(Windscreen)
39 Hazard warning lights switch 40 41 42
40 ALS electronics switch – option
41 Air conditioning switch – option
42 Warning beacon switch – option
43 Starter switch GK100807

48 49
44 Blower rotary switch (ventilation and heating)
43 44 45 46 47
45 Temperature rotary switch (heater)
46 Heated rear window rotary switch
47 Power socket (12 V)
48 Reverse flow fan rotary switch – option
49 Lock striker for working attachments rotary switch

3-3
3.2. Controls Operation

3.2. Controls

3.2.1. Switches

Instrument Panel

3 4

2 5

1 6

GK100811

1 Switch of rear windscreen wiper and washer 5 Switch for driving range up to 20 km/h
2 Switch of front windscreen wiper and washer (with control lamp)
3 Hazard flasher switch (with control lamp) 6 High-speed gear switch
4 Working lights switch (with control lamp) (with control lamp) – option

1. Switch of rear windscreen wiper and washer

This switch is used to switch on/off the rear windscreen wiper and
washer.

The switch has two switching stages:

Switching stage '1' locks in permanently and is used to switch

on/off the windscreen wiper. GK100814

If you hold the switch pressed in switching stage '2', the

windscreen washer is only operated for the time you keep the
switch pressed.

3-4
Operation 3.2. Controls

2. Switch of front windscreen wiper and washer

This switch is used to switch on/off the front windscreen wiper and
washer.

The switch has two switching stages:

Switching stage '1' locks in permanently and is used to switch

on/off the windscreen wiper. GK100814

If you hold the switch pressed in switching stage '2', the

windscreen washer is only operated for the time you keep the
switch pressed.

3. Hazard flasher switch (with control lamp)

This switch is used to switch on/off the hazard flasher.

You may switch on the hazard flasher only in an emergency

situation.

If you switch on the hazard flasher, all direction indicators of the

machine will start to flash. At the same time, the control lamp of GK100815
the hazard flasher switch and the direction indicator control lamp
start to flash.

4. Working lights switch (with control lamp)

CAUTION
The front working lights may blind oncoming traffic! Before
driving on public roads, turn off the working lights.

GK100816
This switch is used to switch on/off the working lights.

5. Switch for driving range up to 20 km/h (with control lamp)

This switch is used to change between the machine’s two speed

ranges.

If you operate the switch, the machine will drive in speed

range '2' (up to 20 km/h).

If the switch is set to OFF, the machine drives in speed range GK100817
'1' (up to 7.5 km/h).

3-5
3.2. Controls Operation

6. High-speed gear switch (with control lamp) – option

The high-speed gear switch is a feature of machines from the

“high-speed version” series.

This switch is used to change between the machine’s standard

speed ranges and the high-speed gear.

If you switch on the high-speed gear, the control lamp in the GK100818
switch goes out and the machine can be driven up to a speed
of 35 km/h in the high-speed gear.

If the high-speed gear is switched off, the control lamp lights

up in the switch and the machine can be driven up to a speed
of 20 km/h in the standard speed-range.

3-6
Operation 3.2. Controls

Switches – Cab top left/right

0 8

0
1 0 2 GK100829
10
GK100806

7 Switch for inside lighting

8 Air conditioning switch (with control lamp) – option
9 ALS-electronics switch (with control lamp) – option
10 Warning beacon switch (with control lamp) – option

7. Switch for inside lighting

The inside lighting has three different switch settings:

Switch setting 1 = Steady light 0

Switch setting 0 = Off
Switch setting 2 = Steady light

0
NOTE 1 0 2 GK100829
You can also switch on the inside lighting, if the start switch
is in stop position '0'. For this reason, switch off the inside
lighting before you leave the driver’s cab.

8. Air conditioning switch (with control lamp) – option

The air conditioning switch with control lamp is only installed on

machines which have been fitted with air conditioning.

If you turn the air conditioning and the blowers on with this
switch, the control lamp shines blue and the air conditioning is
in operation.

If the blowers are switched off, the blue control lamp in the
switch goes out and the air conditioning is no longer in GK100820
operation.

3-7
3.2. Controls Operation

9. ALS-electronics switch (with control lamp) – option

The ALS-electronics switch is only installed in machines which

are provided with ALS-electronics.

If you switch on the ALS-electronics with this switch, the green

control lamp lights up in this switch.

If the machine drives faster than 5 km/h, the ALS-electronics

is automatically activated and the ALS-electronics control
lamp lights up on the instrument panel. GK100819

If the machine drives slower than 5 km/h, the ALS-electronics

is switched off and the control lamp on the instrument panel
goes out. However, the control lamp in the ALS-Electronics
switch remains lit in green.

10. Warning beacon switch (with control lamp) – option

The warning beacon switch is only installed in machines which

are provided with a warning beacon.

If you switch on the warning beacon, the green control lamp in the
switch lights up.

GK100821

3-8
Operation 3.2. Controls

Switches – on direction indicator lever

11

12 GK100812

11 Horn button
12 Light switch

11. Horn button

The horn sounds when you press the horn button.

GK100822

3-9
3.2. Controls Operation

12. Light switch

The light switch is used to switch on/off the main headlights, the 1
side lamps and the taillights. 0

Switching off the lights
Switch in '0' position 2

Switching on the parking light
Turn the light switch to the front until it reaches position '1'.
The side lamps and the taillights light up. GK100824

Switching on the low beam

Continue to turn the light switch until it reaches position '2'. All
lights which were already switched on in position '1' (parking
light) remain lit. In addition, the low beam is switched on. The
low beam control lamp lights up.

How to flash one’s lights (high beam)

In order to flash your lights, you need to draw the lever briefly
in the direction of the steering wheel. The high beam is only
switched on as long as you draw the lever. The high beam
control lamp will also light up for that time.

Switching on the high beam

In order to switch on the high beam you must press the lever
completely down. In this position the lever locks in and the
high beam control lamp lights up. GK100823

3-10
Operation 3.2. Controls

Switches – on the multifunction lever

13

F
N
R

GK100809

13 Driving direction switch

13. Driving direction switch

You can change the driving direction of the machine with the
driving direction switch..
F
Position F = Forward driving
N
Position N = Neutral position R
Position R = Reverse driving

GK100809
NOTE
You can only start the engine if the driving direction switch is
switched to the neutral position 'N'.

3-11
3.2. Controls Operation

Switches – to the right of the driver’s seat

GK100807

14 15 16 17

14 Start switch
15 Fan rotary switch for ventilation and heating
16 Temperature rotary switch
17 Heated rear windscreen switch

14. Start switch

You can start and switch off the engine with the start switch.

'0': Stop position

In this position, the engine is switched off, permitting you to
remove the ignition key. All functional circuits are interrupted
in the stop position.

'I': Operating position GK100825

The control lamps light up in the operating position 'I' and the
air preheater is in operation. All functional circuits are
activated. The ignition key remains in this position with the
engine running.

'II': Start position

In start position 'II', the engine starts.

NOTE
You may only start the engine, if the driving direction switch
is set to the neutral position 'N'.

3-12
Operation 3.2. Controls

15. Fan rotary switch for ventilation and heating

This rotary switch permits to regulate the fan step by step. 4

3
Position 1 = Fan off
Position 2 = Low air flow 2
Position 3 = Medium air flow
Position 4 = High air flow 1

GK100826

16. Temperature rotary switch

The temperature rotary switch permits to adjust continuously the

capacity of the heating system from 'cold' (heating OFF) to
'warm'.

GK100827

17. Heated rear windscreen switch

This rotary switch is used to switch on/off the heated rear

windscreen.

GK100828

3-13
3.2. Controls Operation

Switches – to the left of the driver’s seat

18 19

18 Lock striker for working attachments rotary switch

19 Reverse flow fan rotary switch – option

18. Lock striker for working attachments rotary switch

A B
The lock striker for working attachments rotary switch serves for
simple and easy mounting of working attachments. The standard
switch setting is position 'A'; to extend the lock strikers you have
to move the switch to position 'B' and hold it there. When
released, the switch will return to position 'A'.

Position A = Lock strikers locked

Position B =
Lock strikers released
By holding the switch in position 'B', the lock
strikers can be retracted using the control lever
for auxiliary functions, see section "Control
lever for auxiliary functions" on page 3-62.

3-14
Operation 3.2. Controls

19. Reverse flow fan rotary switch – option

A B
The reverse flow fan rotary switch enables you to reverse the
fan’s flow direction in order to clean it.

NOTE

Reversing the flow direction may only be conducted
when the machine’s driving direction switch is set to the
'N' (neutral) position and the machine’s engine is idling.

The fan may not be sped up using the accelerator until

after it has been reversed.

The standard switch setting is position 'A'; to reverse the fan’s

flow direction you have to move the switch to position 'B' and hold
it there. When released, the switch will return to position 'A'.

Position A = Forwards (normal position)

Position B = Reverse

3-15
3.2. Controls Operation

Switch – battery main switch

20

20 Battery main switch – option

20. Battery main switch – option

Do not operate the battery main switch with the engine running!

The battery main switch disconnects the power supply of the

machine’s electrical system. The switch is situated next to the
battery in the rear section of the machine.

If the machine is to be taken out of service for a longer time, you

must switch off the battery main switch and remove the ignition
key.

3-16
Operation 3.2. Controls

3.2.2. Operating and control levers

3
4
5

2
7

8
1

GK100813

1 Parking brake
2 Door unlocking system – left door
3 Direction indicator lever
4 Steering column adjustment
5 Multifunctional lever
6 Control lever for special equipment
7 Safety lever for the work hydraulic system
8 Door unlocking system – right door

3-17
3.2. Controls Operation

1. Parking brake

The parking brake is a mechanical device for operating the two

multi-disk brakes in the rear axle.

As soon as you pull the parking brake lever from its normal
position, the braking action comes into effect. If the start switch is
set to the 'I' operating position, the parking brake warning light
lights up in the instrument panel. The machine will drive again, if
you re-loosen the parking brake.
GK100830

NOTE
You cannot start the machine with the parking brake being
applied. If you set the driving direction switch to the 'F'
position (forward driving) or 'R' (reversing) with the parking
brake still being applied, the alarm buzzer will sound.

2. Door unlocking system – left door

Both doors have a locking mechanism which locks in if you open

the door completely, preventing that the door closes while driving.
In order to be able to re-close the door, you must draw the
respective door unlocking system to the back.

GK100830

3. Direction indicator lever

The direction indicator lever is used to switch on/off the direction

1
indicators.

Indicate right turn = Press direction indicator lever to the front

(1)
Indicate left turn = Draw direction indicator lever to the back
(2)
2 GK100831

After you have passed the bend, the direction indicator lever
automatically returns to its home position and the direction
indicator will be switched off.

4. Steering column adjustment

The lever for adjusting the steering column position permits to

incline the steering column smoothly in two directions (front or
back). The adjustment range is 125 mm.

Proceed as described in section "Adjusting the steering column"

on page 3-47.

3-18
Operation 3.2. Controls

5. Multifunctional lever

The work unit is operated with the multifunctional lever. The

multifunctional lever has 6 positions which control the work unit as
follows:

SW Float
â The multifunctional lever is locked in
this position.
The floating position is provided for
planing operations
(removing subsoil).
In this switch position, the work unit is GK100810

lowered by its own weight, and can be

freely operated by external parties.

ç
S Lower The boom is lowered in this position.
If the engine is switched off, you can
lower the boom in this position.

0 Hold
å The boom is held in position.

ã
H Raise The boom is raised in position.

ä
E Titt In this position, the bucket is tilted.

à
A Dump In this position, the bucket is dumped.

3-19
3.2. Controls Operation

6. Control lever for auxiliary functions

NOTE
The control lever may not be moved to positions '1', '2' or '3'
if a working attachment with auxiliary function is not
connected. In this case, the working hydraulics would be
operating against overpressure and the oil would be heated
up unnecessarily.

The control lever for the auxiliary functions has four switching GK100833
positions, the functions of which are dependent upon the types of
working attachment used and the position of the lock striker for
working attachments rotary switch (see section "18. Lock striker
for working attachments rotary switch" on page 3-14).

A detailed description is available in section "Control lever for

auxiliary functions" on page 3-62.

7. Safety lever for the work hydraulic system

The safety lever for the work hydraulic system protects the work
hydraulic system against unintentional activation. Before driving
on streets or beginning maintenance operations, it is required to
block the work hydraulic system with this safety lever.

Position 1 = working hydraulics locked

Position 2 = working hydraulics released

GK100835

8. Door unlocking system – right door

Both doors have a locking mechanism which locks in if you open

the door completely, preventing that the door closes while driving.
In order to be able to re-close the door, you must draw the
respective door unlocking system to the back.

GK100830

3-20
Operation 3.2. Controls

3.2.3. Pedals

GK100805

1 Inch-Brake pedal
2 Accelerator pedal

1. Inch-Brake pedal

WARNING

If you are driving downhill, let the engine run and use the
braking effect of the engine. If required, brake
additionally using the brake pedal.

Danger of accidents due to unintentional braking!

Do not use the brake pedal as a foot rest.

The brake is operated via a combined brake/inch pedal. The GK100805

brake has an effect on the two multi-disk brakes in the rear axle.
The inching exerts an additional braking effect on the hydrostatic
drive system.

3-21
3.2. Controls Operation

2. Accelerator pedal

The accelerator pedal regulates the speed (r.p.m.) and

performance of the engine.

GK100805

3-22
Operation 3.2. Controls

3.2.4. Miscellaneous controls

GK100807

1 Socket (12 V)

1. Socket (12 V)

CAUTION

Danger of accidents!
Electrical devices may interfere with the on-board
electronics.

For this reason, connect only the working lamp to the

GK100807
socket.

You may connect a working lamp to the socket.

3-23
3.3. Control lamps, measuring indicators und warning lights Operation

3.3. Control lamps, measuring indicators und warning

lights

3.3.1. Overview

C A
A A C

GK100802

A
In the cap, top right

GK100806

3-24
Operation 3.3. Control lamps, measuring indicators und warning lights

The instrument panel can be divided in

(A) Control lamps

(B) Measuring indicators
(C) Warning lights

In the following sections of this chapter, all elements required for

an efficient machine operation are explained in detail.

Control lamps
This group includes the control lamps for high beam, low beam,
heated rear window, intake air pre-heater, direction indicators,
driving direction switch, ALS electronics (option), high speed gear
(option), hazard warning lights, working lights, warning beacon
(option), air conditioning (option), driving range.

Measuring indicators
This group comprises the fuel gauge, the operating hour meter
and the temperature indicator of the coolant.

Warning lights
This group comprises the warning lights for charging current,
parking brake, air filter, engine oil-pressure and brake fluid supply.

3-25
3.3. Control lamps, measuring indicators und warning lights Operation

3.3.2. Control lamps

2 3 4 5 6 7

1 8
7
9

10

GK100802

In the cap, top right

15 14
GK100806

13 12 11

1 Control lamp in hazard warning lights switch

2 High-speed gear control lamp (only activated for "high-speed”) – option
3 Driving direction switch indicators
4 Direction indicator control lamp
5 Air preheater control lamp
6 Heated rear windscreen indicator
7 ALS-electronics control lamp (only activated for installed ALS electronics) – option
8 Control lamp in working lights switch
9 Control lamp in driving range switch up to 20 km/h
10 Control lamp in the high-speed gear switch – option
11 Control lamp in the warning beacon switch – option
12 Control lamp in the air conditioning switch – option
13 Control lamp in ALS electronics switch – option
14 Main beam control lamp
15 Low beam control lamp

3-26
Operation 3.3. Control lamps, measuring indicators und warning lights

1. Control lamp in hazard warning lights switch

The control lamp flashes when the hazard warning lights are
switched on.

GK100815

2. High-speed gear control lamp (only activated for

"high-speed”) – option

The high-speed gear control lamp is a feature of machines from

the “high-speed version” series.

It lights up if the high-speed gear is switched on. GK100842

3. Driving direction switch indicators

The indicators of the driving direction switch indicate which driving

direction you have selected:

left arrow lights up:

Machine drives backwards GK100836
(driving direction switch in 'R' position)

right arrow lights up:

Machine drives forward
(driving direction switch in 'F' position)

If the driving direction switch is set to the 'N' neutral position, both
control lamps will go out.

4. Direction indicator control lamp

The direction indicator control lamp flashes if you have switched

on the right or left direction indicators or the hazard flashers.

If the direction indicator control lamp flashes in very short

intervals, a fault has occurred in the direction indicator system. In
GK100837
this case, proceed as described in chapter "4. Troubleshooting"
on page 4-1.

5. Air preheater control lamp

The control lamp lights up, if you set the start switch to the 'I'
operating position and if the air preheater is running.

It will go out if the heating cycle is over. The running period of the
air preheater depends on the ambient temperature. GK100838

You can start the engine, after the control lamp has gone out.

3-27
3.3. Control lamps, measuring indicators und warning lights Operation

6. Heated rear windscreen indicator

The control lamp of the heated rear windscreen lights up, if you
have switched on the heated rear windscreen.

GK100839

7. ALS-electronics control lamp (only activated for installed

ALS electronics) – option

The ALS-electronics control lamp on the instrument panel is only

active if the ALS-electronics is installed.

It lights up, when the ALS-electronics is switched on and when GK100844

the machine drives faster than 5 km/h.

8. Control lamp in working lights switch

The control lamp illuminates when the working lights are switched
on.

GK100816

9. Control lamp in driving range switch up to 20 km/h

The control lamp illuminates when the '2' speed range is switched
on.

GK100817

10. Control lamp in the high-speed gear switch – option

The high-speed gear switch with control lamp is a feature of

machines from the “high-speed version” series.

It lights up if the high-speed gear is switched off.

GK100843

11. Control lamp in the warning beacon switch – option

The warning beacon switch with control lamp is only installed in

machines which are provided with a warning beacon.

The control lamp in the switch lights up in green when the warning
beacon is switched on. GK100846

3-28
Operation 3.3. Control lamps, measuring indicators und warning lights

12. Control lamp in the air conditioning switch – option

The air conditioning switch with control lamp is only installed on

machines which have been fitted with air conditioning.

The control lamp shines blue when the air conditioning is

switched on. GK100845

13. Control lamp in ALS electronics switch – option

The ALS-electronics switch with control lamp is only installed in

machines equipped with ALS electronics.

The control lamp in the switch flashes green when the ALS
electronics are switched on. GK100844

14. High beam control lamp

The high beam control lamp illuminates when the high beam
lights are switched on.

The control lamp also illuminates when you press the headlamp
flasher. GK100840

15. Low beam control lamp

The low beam control lamp lights up if you have switched on the
low beam.

GK100841

3-29
3.3. Control lamps, measuring indicators und warning lights Operation

3.3.3. Measuring indicators

GK100811

1 2 3 4

1 Fuel level indicator

2 Operating hour meter
3 Speedometer
4 Coolant temperature indicator

1. Fuel level indicator

If you set the start switch to the 'I' operating position, the fuel
gauge indicates the available fuel supply.

1 = The tank is full

R = The tank is in the critical range

During operation, it is recommended to keep the fuel supply

GK100847
between 'R' and '1'. If only the lowest 'R' LED lights up, it is time to
refill fuel.

If there is no electric contact between the fuel gauge and the fuel
level indicator, only the top LED lights up.

2. Operating hour meter

The operating hour meter indicates the total hours of operation. It

only counts the hours with the engine running, no matter whether
the machine is actually driving or not. If the operating hour meter
is ON, the icon on top of the operating hour meter is flashing.

GK100957

3-30
Operation 3.3. Control lamps, measuring indicators und warning lights

3. Speedometer

The speedometer indicates the speed of the machine at any

given time.

GK100957

4. Coolant temperature indicator

The coolant temperature indicator shows the temperature of the

coolant.

If you set the power switch to the 'I' position with the coolant
being warmer than 70° C, the temperature indicator will show
the current coolant temperature.

If the temperature is normal during operation, the green range

GK100849
of the temperature indicator lights up.

If the coolant is too hot, the top red LED of the temperature
indicator starts to flash. At the same time, the acoustic warner
starts to sound.

In this case, you must stop the machine and let the engine
run idle at medium speed until the indicator returns to the
green range.

Proceed as described in chapter "4. Troubleshooting" on

page 4-1.

If there is no electric contact applied to the sensor, only the

top LED lights up.

3-31
3.3. Control lamps, measuring indicators und warning lights Operation

3.3.4. Warning lights

1 2 3 4 5

GK100811

1 Brake fluid warning light

2 Air filter warning light
3 Parking brake warning light
4 Charging current warning light
5 Engine oil-pressure warning light

1. Brake fluid warning light

If the brake fluid supply is too low, the brake fluid warning light
lights up in red.

In this case you must immediately stop the machine and switch
off the engine. Proceed as described in chapter
GK100850
"4. Troubleshooting" on page 4-1.

2. Air filter warning light

If the air filter is polluted, the air filter warning light lights up in red.

In this case, you must clean or exchange the air filter. Proceed as
described in chapter "Air filter – checking and cleaning the filter
insert" on page 5-36. GK100851

3-32
Operation 3.3. Control lamps, measuring indicators und warning lights

3. Parking brake warning light

The parking brake warning light lights up in red if you set the start
switch to the 'I' operating position while the parking brake is
applied.

In addition, the acoustic warner sounds if you set the driving

GK100852
direction switch to forward or reverse driving with the parking
brake applied.

4. Charging current warning light

Before you start up the engine:

The charging current warning light must light up if you set the
start switch to the 'I' operating position.

With the engine running: GK100853

As soon as the engine runs, the generator starts to generate
current and to charge the battery. At the same time, the
charging current warning light will go out. A fault is present, if
the charging current warning light does not go out while the
engine is running.

In the latter case, proceed as described in chapter

"4. Troubleshooting" on page 4-1.

5. Engine oil-pressure warning light

Before you start up the engine:

The engine oil-pressure warning light must light up if you set
the start switch to the 'I' operating position. At the same time,
the acoustic warner will sound.
GK100854

With the engine running:
After starting the engine, the lubricating pressure builds up
and the lamp goes out. If the engine oil-pressure warning light
does not go out with the engine running or if it suddenly lights
up during operation, while the acoustic warner sounds at the
same time, a fault has occurred in the oil-pressure system.

In both cases, you must immediately stop the machine and switch
off the engine. Proceed as described in the chapter
"4. Troubleshooting" on page 4-1.

3-33
3.4. Description of individual elements Operation

3.4. Description of individual elements

3.4.1. Safety bar

WARNING

Always apply the safety bar while performing
maintenance operations and while transporting the
machine.

Always remove the safety bar during normal operations. 1

The safety bar is used during maintenance or when transporting

the machine. It locks the front frame and rear frame, and prevents
the front and rear frame from bending.

Position 1 = Articulated steering locked

Position 2 = Articulated steering unlocked
2
Always use the bolts and spring connectors at both positions
when securing the lockup rod.

3.4.2. Towing pin

1. Insert the bolts (1) into the counterweight’s bore.
1
2. Use the locking pin (2) attached to the chain to secure the
bolt.

To remove the pin proceed in reverse order.

GK100855

3-34
Operation 3.4. Description of individual elements

3.4.3. Alarm horn for reverse driving – option

The horn sounds if you have set the driving direction switch to the
reverse/backwards position.

GK100856

3-35
3.4. Description of individual elements Operation

3.4.4. Fuses

CAUTION

Parts of the electrical system may be damaged, if you
replace fuses with the ignition switched on!

Turn the start switch to switching position '0' (OFF),

before starting to replace fuses.

Fuses with wrong amperages may cause fires due to

electrical faults or may immediately blow again!

Only replace defective fuses with fuses of the same

rating.

The fuses protect the electrical system. Replace defective,

corroded, or loose fuses.

The fuses are located under the cover. To access the fuses,
remove the screws fixing the cover and remove the cover. Then
remove the cover caps of the fuse boxes.

Electrical circuits and amperage of fuses

No. Electrical circuit designation Amperes Electrical circuit designation Amperes

Starter Gear
1 Shut off solenoids, 20 A Solenoids 10 A
socket Main hydraulic

Interior light, Flashing light,

2 10 A 10 A
radio Horn

3 Hazard warning flasher 10 A Main monitor 10 A

Wash / Wipe
4 20 A Working light 20 A
Front and rear
Brake light,
Position light left,
5 back up alarm, 10 A 10 A
licence light
rotating beacon

Blower fan,
6 fresh air, 20 A Position light right 10 A
heater

Heated
7 Rear window, 20 A Headlight high beam 10 A
Compressor

Solenoid
8 Fast version, 10 A Headlight low beam 10 A
ALS (option)

3-36
Operation 3.4. Description of individual elements

3.4.5. Slow-Blowing Fuses

If the power supply fails, the reason for this may be that one of the
slow-blowing fuses (1) has blown. Check the electrical system
and replace defective fuses.

F3 80 A Main Power Supply / Starter

F4 100 A Intake Air Heater
F5 30 A Engine Stop F3, F4, F5

3-37
3.4. Description of individual elements Operation

3.4.6. Heater and ventilation system

Adjusting the ventilation system

When the ventilation system is operated, air is blown into the

driver's cab. If the cabin is closed, a light overpressure is built up,
preventing dust from outside to settle down in the cab. To
increase the volume of filtered fresh air, you can open the
ventilation grid a little.

GK100858

The air is distributed via the air ventilation nozzles on the left-
hand and right-hand side of the steering column.

You may open or close the nozzles individually. The exhaust

direction can be varied using the diffusing disks.

You can direct the air ventilation nozzles onto the front
windshield and the air ventilation nozzles onto the side
windows.

Adjusting the heating system

The heating capacity depends on the coolant temperature of the

engine. Full heating capacity is only realised, if the engine is
completely warmed up.

1 Blower rotary switch

2 Temperature rotary switch

You can realise maximum heating inside the cabin, if you open all
GK100860
air ventilation nozzles, set the temperature rotary switch to
maximum heating power while switching on the fan with its
highest level. 1 2

You may realise a comfortable temperature, if you open all air

ventilation nozzles, set the temperature rotary switch to a
comfortable temperature and set the fan to an appropriately low
air throughput.

To cool down the temperature inside the cabin, open all air
ventilation nozzles, set the temperature rotary switch to position
'Cold' and set the fan to its highest level.

To prevent premature tiredness due to lack of oxygen, it is

recommended to open the door a little from time to time and to
lock it in this position. Optionally, you may leave open the
ventilation grid above the side window.

3-38
Operation 3.5. Checks and adjustments prior to starting work

3.5. Checks and adjustments prior to starting work

3.5.1. Visual inspection

WARNING

Danger of fire! Oil or fuel leaking out or accumulated
combustible materials may catch fire at hot parts of the
machine, e.g. the exhaust!

Prior to starting the machine, check the oil and fuel lines
for leaks and immediately repair any leaks. Store
combustible material in a safe place.

Check that there are no loose nuts or screws lying around the
machine. Check that neither oil, nor fuel nor coolant are leaking
out. Check the condition of the work unit and the hydraulic
system. Check that there are no loose cables and accumulated
dirt. Remove accumulated dirt and eliminate faults.

The following tasks should be performed on a daily basis:

1. Check work unit

Check work unit, cylinder, connecting rods, and hoses for

cracks, premature wear and tear, and play. Repair damaged
parts.

2. Remove dirt and dust

Check the area around the engine and the radiator for
accumulated dirt or dust. Additionally check whether
combustible material has accumulated near the battery or
near hot parts of the machine, e.g. the exhaust. Remove
completely any accumulated dirt or dust.

3. Check engine and cooling system

Check that there is no oil leaking out of the engine and that
the cooling system and the fuel supply system are not
leaking. Repair damaged parts.

4. Check the gear unit, axles, hydraulic tank and hoses and
the connecting points

Check whether oil is leaking out of the gear unit, axles,

hydraulic tank and hoses, and connecting points Repair
damaged parts.

5. Check brake hoses

Check that there is no oil leaking out at the brake hoses.

Repair damaged parts.

3-39
3.5. Checks and adjustments prior to starting work Operation

6. Check wheels

Check the tyres for cracks, damages and wear and tear.
Check the wheel rims and lock rings for cracks, damage, and
wear and tear. Tighten loose wheel nuts. Repair damaged
parts. Replace missing valve caps.

7. Check handrails

Check handrails for damage and loose screws. Repair

damaged parts and tighten loose screws.

8. Check measuring and control indicators

Check measuring and control indicators for damage and

loose screw connections. Replace defective parts. Remove
dirt from surfaces.

9. Check air filter

Check the fastening screws of the air filter. Tighten loose

screws.

10. Check battery terminals

Tighten loose battery terminals.

11. Check the automatic seat belt

If the aut omat ic seat belt has been subject ed to

excessive loads, e.g. full braking manoeuvre or if the
machine rolls over, the automatic seat belt must be
replaced.

Check the belt, the mountings and the seat belt’s buckle.

If the seat belt system’s belt, mountings or buckle have been

damaged the automatic seat belt must be replaced.

Check that the mounting’s fastening screws are securely

fixed in place.

Tighten any loose screws. Tightening torque: 25 - 30 Nm

12. Check ROPS

Check whether screws are loose or damaged. Have loose

screws tightened and damaged screws replaced by a
Komatsu-dealer. Loose screws must only be tightened with
the specified tightening torque. Damaged screws must only
be replaced by original parts.

13. Check cab windows

Prior to start of work, clean the cab windows.

3-40
Operation 3.5. Checks and adjustments prior to starting work

3.5.2. Control checks

Cooling system – checking the coolant level,

topping up coolant

CAUTION

A wrong water/coolant mixing ratio will damage the
radiator! Always mix water and coolant in the ratio 50 :
50. This also applies to countries with a hot climate.

Danger of fire! Coolant may ignite at hot engine!

Do not top up coolant, unless the engine has cooled

down sufficiently.

1. Open the bonnet.

2. Check that the coolant level in the expansion tank is between

the FULL and LOW markings. If the coolant level does not
reach up to the LOW marking, top up coolant.

3. Therefore remove the cover cap of the expansion tank.

4. Top up coolant until the level reaches up to the FULL

marking.

5. After topping up, firmly close the cover cap.

6. Usually, the radiator needs not to be opened. However, for

safety reasons it is required to check the refrigerant level in
the radiator after 50 operating hours (see chapter
"5.8.4. Maintenance every 50 operating hours" on
page 5-23).

If the expansion tank is empty again after a short period of time,

immediately have the cooling system checked for leaks and have
any leaks repaired in the garage.

3-41
3.5. Checks and adjustments prior to starting work Operation

Checking the engine oil level – topping up oil

NOTE
After you have switched off the engine, wait at least 5
minutes before you check the engine oil level. The machine
must stand on an even surface.

1. Pull out the oil dipstick (1) and wipe off the oil with a clean
cloth. 1
GK100864
2. Completely re-insert the oil dipstick and pull it out again after
a few seconds. The oil level must be between the (H) and (L)
markings on the oil dipstick.

3. If the oil level does not reach up to the (L) marking, top up
engine oil. For detailed information on recommended oils, see
section "5.4. Lubricants, fuels and filling capacities" on
page 5-12.
2
NOTE
Do not fill in too much oil in one go via the filler!

4. Wait three minutes before you check the oil level again.

If the oil level is above the (H) marking, drain off some oil.

5. Close the oil filler (2).

Draining engine oil

If you have topped up too much oil, you must drain off the excess
oil. Have an oil trough with a sufficient capacity ready.

1. Loosen the screw (3) at the bottom cover plate (4) and swivel
the cover plate to the side. 3
2. Put the oil trough under the drain screw.

3. Remove the cover cap (5) from the drain valve.

4. Screw on the drain hose (6) on the drain valve (7). This will 4
cause the drain valve to open.

5. Drain the oil.

6. Remove the drain hose (6) from the drain valve (7). This will 7
cause the drain valve to close.

7. Check oil level again. 5

8. Fit cap (5) back onto drain valve.

4
9. Fasten the bottom cover plate (4) with the screw.
6

GK100866

3-42
Operation 3.5. Checks and adjustments prior to starting work

Checking the fuel level – refuelling

WARNING

Danger of fire! Fuel that has spilled over may ignite!

Immediately remove fuel that has spilled over.

1. Turn the start switch to the operating position 'I' and check the
fuel level indicated on the fuel level indicator.

2. Then, return the start switch to the stop position '0'.

GK100825

GK100867

3. If required, refuel via the filler .

For detailed information on fuels, see section

"5.4. Lubricants, fuels and filling capacities" on page 5-12.

4. After refuelling, firmly close the filler.

3-43
3.5. Checks and adjustments prior to starting work Operation

Checking the controls

1. Turn the start switch to the operating position 'I'.

An alarm buzzer sounds until the machine is started.

GK100825

2. Check that the following alarm and control indicators are on

until the engine is started: 1 2 3 4

1 Parking brake
2 Charging current
3 Engine oil level
4 Intake air preheater

3. Check that the fuel level indicator (5) indicates the fuel level in
the fuel tank. GK100867
5

NOTE
Contact your responsible Komatsu dealer, if one or several
of the indicators do not light up.

Do not only use the indicators to perform the checks prior to start.
Always perform the work described as regular maintenance, too.

Checking the electrical connections

CAUTION

Danger of ignition! Inflammable material (leaves, twigs,
grass, etc.) may ignite within the electrical system!

Remove inflammable material from the electrical system.

NOTE
If a fuse blows, or if there are any signs of a short-circuit
within the electrical system, inform your responsible
Komatsu dealer.

Regularly check that the terminals are fastened tightly, retighten

loose terminals.

3-44
Operation 3.5. Checks and adjustments prior to starting work

Heater/air conditioning – checking rate of air flow

1. Turn start switch to position 'I'.

GK100825

2. Switch blower on.

1 1
3. Check whether sufficient air flows out of the air outlet nozzles
(1).

Caution: the recirculation nozzles (2) must be open!

4. If insufficient air is coming out of the jets, either the filter 2 2

fleece in the heating/air conditioning unit is dirty and will have
to be cleaned or replaced or the condenser in the air
conditioning system is dirty and will have to be cleaned; see
" 5.8.7. Main te nance ever y 500 oper ating hour s" on
page 5-42.
GK100805

Miscellaneous tests before starting work

Check that the brake fluid in the brake fluid tank (2) reaches
the marking.

To do so open the bonnet and then open the maintenance 1

flap on the left-hand side of the machine by pulling on the ring
(1).

Check that the contacts at the float of the brake oil container
are tightened correctly.

Check that the lighting equipment operates correctly; check it

for dirt and damage.

Check the measuring instruments.

Check both the horn and the reversing warning horn.

Check both clearance and operation of the steering wheel.

Check the function of the rear-view mirror; check it for dirt and
damage.

3-45
3.5. Checks and adjustments prior to starting work Operation

3.5.3. Adjustments

Adjusting the driver’s seat

After each change of the driver, newly adjust the driver’s seat.
Before you start operation, check that the seat is adjusted in such
a way that you can fully floor the brake pedal when you lean
against the backrest.

Proceed as follows to adjust the seat according to your

requirements:

(1) Weight adjustment

Turn the handwheel (1) to set the vibration absorbing system

to the weight of the driver.

(2) Adjustment of horizontal position

To adjust the horizontal seating position, pull the lever (2) and
slide the seat forward or backward. To lock the position of the
seat, release the lever again.

(3/4)Adjusting height and angle of inclination

5
You may adjust the height and the angle of inclination of the
driver’s seat with the spring-supported levers (3) and (4). 1
4
Use lever (3) to set the front part of the seat, use lever (4) to
set the rear part of the seat. .
GK100868 3
Adjusting the seat’s height 2
Adjust the front and the rear section of the seat uniformly.

For this purpose, pull lever (3) and hold it in this position. To
lift up the front part of the seat, it is necessary to relieve your
weight from the front section of the seat cushion by standing
up. Then, sit down on the front part in order to press down the
front section of the seat. Release the lever if you have
reached the right position. The seat is now locked in its
position.

Then, pull lever (4) and hold it in this position. To lift up the
rear part of the seat, it is necessary to relieve your weight
from the rear section of the seat cushion by standing up.
Then, sit down on the rear part in order to press down the
rear section of the seat.

Release the lever if you have reached the right position. The
seat is now locked in its position.

Adjusting the angle of inclination of the seat

Adjust the front and rear section of the seat with different
settings.

Proceed as described above.

3-46
Operation 3.5. Checks and adjustments prior to starting work

(5) Adjusting the backrest

To adjust the position of the backrest, slightly lean against the

backrest, pull lever (5) and hold it in this position.

Relieve the backrest in order to bend it to the front. Press it to

the back in order to bend it to the back.

Release lever (5) if the backrest is in the desired position.

The backrest will lock in automatically in this position.

Adjusting the steering column

WARNING

Do not change the angle of inclination of the steering
column while you are driving, since this may lead to
severe accidents!

Stop the machine, before you change the angle of

inclination of the steering column.

You may use this lever for continuous adjustment of the steering
column’s (1) angle of inclination. (Adjustment range 125 mm)

Proceed in the following manner:

1. Release the locking lever (2).

2. Adjust it in such a way that you can reach the steering wheel
from a comfortable seating position while at the same time 1
having an optimum view of the work unit. Hold the steering
wheel in this position. 2

3. You can lock the steering column in this position by tightening

the locking lever again.

3-47
3.5. Checks and adjustments prior to starting work Operation

Adjusting the armrest

Proceed as follows to adjust the height of the armrest (1):

1 2
1. Loosen the screw (2).

2. Either pull out or push back the armrest to reach the

multifunctional lever.

Your forearm should rest on the armrest at an angle of 90° to

your upper arm.

3. Re-tighten the screw.

GK100869

Adjusting the rear-view mirrors

Sit down on the driver’s seat and adjust the rear-view mirrors to
their required positions. You should be able to view the traffic
coming from behind without having to change your seating
position.

3-48
Operation 3.5. Checks and adjustments prior to starting work

Putting on the safety belt

WARNING

Danger of injury! A damaged safety belt, a safety belt that
has been stretched in an accident, or a safety belt the
belt fixings or fastening screws of which have not been
mounted correctly will not protect you sufficiently in
case of accident!

Replace the safety belt, if it is damaged, or if the machine

has been involved in an accident. Check that the belt
fixings and fastening screws are in perfect condition,
before you put on the safety belt.

If you have not put on the safety belt and are involved in
an accident, this may lead to severe injuries!

Put on the safety belt, before you start work and do not
take it off during work. Put on the safety belt in such a
way that it is not twisted and fits tightly.

The machine is provided with a lap belt which automatically

retracts. When pulled slowly, automatic belts ensure full freedom
of action, but block immediately, if you suddenly brake or
accelerate, or if you drive downhill or take corners.

Putting on the safety belt

1. Sit down on the driver's seat.

2. Slowly and continuously pull out the belt.

3. Insert the lock tongue into the lock socket until the lock
engages.

4. Then, pull the belt to check whether or not the lock tongue is
fully engaged.

The belt cannot be pulled out unless it is completely wound

up

Taking off the safety belt

Press the orange button to release the lock of the safety belt and
allow the belt to wind up.

3-49
3.6. Operation Operation

3.6. Operation

3.6.1. Starting the engine

1. Pull the parking brake lever.

2. Set the drive direction switch to its neutral position 'N'.

You may only start the engine, if the driving direction switch is
set to the neutral position 'N'.

CAUTION

Unintentional start-up of the engine may lead to severe GK100830
accidents!

Before starting up the engine, make sure that there are

no persons or obstacles near the engine. In addition, F
sound the horn before you start the engine.
N
R

GK100809

3. Turn the ignition key to operating position 'I'.

 Fuel level (1) displayed.

 The parking brake warning light (2) illuminates when the
parking brake is applied.

 The charging current (3) and engine oil pressure (4)

warning lights illuminate. GK100825

 The air intake preheater control lamp (5) illuminates when

2 3 4 5
the air intake preheater is running.

The running period of the air preheater depends on the

ambient temperature. If the ambient temperature is low, the
preheating process may take more time.

4. Press down slightly the accelerator pedal.

5. If the control lamp of the air preheater has gone out, you can
turn the ignition key to the start position 'II' in order to start up GK100867
the engine.
1
NOTE
Do not operate the starter for longer than 15 seconds. If the
engine does not start up, wait at least two minutes before
trying a restart. If the engine does not start up after several
tries, find out the cause using the information indicated in
the chapter "4. Troubleshooting" on page 4-1.

3-50
Operation 3.6. Operation

6. Release the ignition key as soon as the engine started. It

automatically returns to the operating position 'I'.

7. Check whether all warning lights have gone out.

NOTE
For starting up the engine in cold weather, see chapter:
"3.8.1. Precautions for low temperatures" on page 3-85.

Warming up the engine

NOTE
You must not accelerate the engine abruptly before the
warm-up phase is finished. Do not let the engine run idle for
longer than 20 minutes at its lower or top speed. If it is
necessary to let the engine run idle for a longer time, you
must load the engine briefly from time to time or let it run at
medium speed.

Do not immediately begin with work after starting the engine. Prior
to operation, perform the following preparations and checks:

1. Press down slightly the accelerator pedal and let the engine
run without load at medium speed for approx. 5 minutes.

2. Proceed as follows in order to heat up the hydraulic oil at low

ambient temperatures:

Allow the engine to run consistently during the warm-up

phase. For warming the hydraulic oil, reset the multi-function
lever for the work hydraulic system in short intervals from GK100810
position '0' (holding) into position 'E' (tip-in position). Then
reset it to its '0' position.

Make sure not to exceed the maximum time (10 seconds)

permitted for the multi-function lever in the tip-in position.

3. While the engine is warming up, observe all measuring

instruments and warning lights and eliminate immediately any
fault.

4. Let the engine run with lightweight load further until the GK100867
engine coolant temperature indicator (1) lights up in the green
range. 1

5. Ensure that the exhaust gas colour is normal and that the
exhaust pipe produces neither abnormal noises nor
vibrations. Eliminate possible defects.

3-51
3.6. Operation Operation

3.6.2. Switching off the engine

NOTE
If you switch off the engine abruptly after heavy operations
without prior cool down period, the service life of the engine
may be severely impaired. It is recommended to switch off
the engine abruptly only in the event of an emergency.

1. Check the temperature of the engine with the help of the

coolant temperature indicator (1).

2. If the engine is overheated, you must let it run at medium

speed or 5 minutes before you switch it off, so that the engine
can cool down sufficiently.

3. Lower the work unit.

4. Turn the ignition key into its stop position '0' in order to switch GK100867
off the engine.
1
5. Pull the key from the start switch.

3-52
Operation 3.6. Operation

3.6.3. Driving with the machine

Start-up

CAUTION
Careless driving may lead to accidents!
Before starting to drive, ensure that no persons are near the
machine and sound the horn before you drive up.

1. Start the engine as described in chapter "3.6.1. Starting the

engine" on page 3-50.

2. Make sure that the parking brake is on.

The parking brake warning light illuminates. GK100884

3. Raise the working attachment to the transport position.

4. When the working attachment reaches the transport position,

the two red arrows on the bucket cylinder will line up with
each other.

5. Turn the working hydraulics safety lever to position ‘1’. The

boom is then blocked while driving on the road and cannot be
moved.

Position 1 = working hydraulics locked

Position 2 = working hydraulics released
GK100835

6. Press the brake pedal and hold it down.

7. Release the parking brake.

The parking brake warning light extinguishes.

8. Set the drive direction switch to the desired direction setting..

Position F = Driving forward

Position N = Neutral
Position R = Reversing GK100830

If you set the drive direction switch in to forward or reverse

driving, without having released the parking brake, the horn
will sound.

9. Release the brake pedal and press down the accelerator

F
pedal at the same time in order to start the machine. N
R

GK100809

3-53
3.6. Operation Operation

Switching high-speed gear on/off – option

CAUTION
Switching the high-speed gear on or off during driving may
lead to gearbox damages!
Ensure that the machine stands still and that the engine is
running, before you switch the high-speed gear on or off.

Switching on the high-speed gear

Push the switch lock (1) to the right, hold it in this position and
press the switch. If the high-speed gear is switched on, control
lamp (2) goes out and control lamp (3) lights up.

If the high-speed gear should not engage, control lamp (3)

remains unlit while control lamp (2) remains lit. In this case,
repeat the switching procedure or activate briefly the control lever
for the work hydraulic system.

GK100871
1 2
Switching off the high-speed gear

Push the switch lock (1) to the right, hold it in this position and
press the switch. If the high-speed gear is switched off, control 3
lamp (3) goes out and control lamp (2) lights up.

If the high-speed gear should not disengage, control lamp (2)

remains unlit while control lamp (3) remains lit. In this case,
repeat the switching procedure or activate briefly the control lever
for the work hydraulic system.

GK100867

3-54
Operation 3.6. Operation

Changing the driving direction

WARNING
Careless changes of the driving direction may cause severe
accidents!
Before you change the driving direction from forward to
reverse driving or vice versa, you must make sure that no
persons or obstacles are in your way.

CAUTION
The engine may be damaged if you are driving at a high
speed and then change abruptly from forward to reverse
driving or vice versa!
Brake until the machine has nearly come to a standstill
before you change the driving direction.

The drive direction switch is used to switch between forward and

reverse gear or vice versa. The machine may still roll, if you
change the driving direction.
F
Position F = Driving forward N
Position N = Neutral
Position R = Reversing R

Reverse Driving
GK100809

The machine can drive forward or backwards (reversing) at the

same speed.

Before driving backwards, make sure that nobody is in your way.

If necessary, rely on another person for aid. Sound the horn
before starting to drive to make sure, that anybody who might be
in your way is appropriately warned.

While driving backwards, turn your head into the driving direction.
It is not sufficient to rely on the rear view mirrors.

3-55
3.6. Operation Operation

Turning and steering

NOTE

The machine may fall over if you turn abruptly at a high
speed.

If the machine is halted during the ride, the servo-

assisted steering will be deactivated. You may then only
proceed with steering the machine with considerably
higher effort.

Turning on slopes, dams or hills

Keep sufficient distance to ridges and steep slopes. There is

danger of the machine tipping over or sliding down on steep
slopes, embankments, or hill flanks. The limiting values are
defined in chapter "6.4. Limit values for slopes" on page 6-3.

Do not turn on a slope or drive across a slope. Turn or cross the

section only level ground. When driving on slopes, avoid driving
on grass, fallen leaves, or steel plates. Driving sideways on these
surfaces types may result in the machine sliding. Drive very
slowly and carefully.

To keep the centre of gravity as low as possible when driving on AE060800

slopes, embankments, and hill flanks, you must set the bucket to
a position just above the ground (approx. 200 to 300 mm). In the
event of an emergency, displace the bucket fast on the bottom in
order to stabilise the engine.

AE060810

3-56
Operation 3.6. Operation

Braking

While driving, you may reduce your speed with the service brake
(1).
1 3
After the machine has stopped, you must secure it with the
parking brake (2).

Pulling the parking brake

1. Pull on the parking brake lever.

The control lamp for the parking brake then illuminates.

Releasing the parking brake

1. Pull parking brake slightly upwards and pull lock towards 2 GK100805

handle.

2. Push parking brake lever down.

The control lamp for the parking brake then extinguishes.

Braking with the service brake

If the braking delay is not sufficient by relieving the pressure from

the accelerator pedal, you must brake the machine with the
service brake. For this purpose, press down the brake pedal.

The service brake (1) can also be used to adapt the driving speed
to the respective driving and operating situation (3), independent
of the accelerator pedal position.

If it is required to press down the accelerator pedal completely, in

order to be able to use the full-load output of the engine of the
work hydraulic system, you can nevertheless use the brake pedal
to reduce the speed of the machine or to stop it completely.

If the service brake breaks down

If the machine is not stopped after pressing down the brake

pedal, you must use the parking brake.

3-57
3.6. Operation Operation

Braking on slopes

CAUTION

The service brake may overheat and be damaged while
driving downhill!
Let the engine run while driving downhill. If required,
brake in addition using the brake pedal.

Danger of accidents due to unintentional braking!

Do not use the brake pedal as a foot rest.

If you use the service brake too often while driving downhill, it
may overheat and be damaged.

You can avoid this by driving downhill in the lower speed range
and by using the braking effect of the engine.

In the lower speed range the high-speed gear switch (1) is

switched off and the control lamp (2) extinguished.

GK100871
1 2

3-58
Operation 3.6. Operation

Stopping

Avoid abrupt stopping. Proceed as follows, if you want to stop the

machine:

1. Release the accelerator pedal and press down the brake

pedal.

2. Set the drive direction switch into its neutral position 'N'. F
3. Apply the parking brake. N
4. Lower the work unit onto the ground. R
5. Protect the work hydraulic system against unintentional
activation by turning the locking lever of the work hydraulic GK100809
system into position ‘1’..

Position 1 = working hydraulics locked

Position 2 = working hydraulics released

WARNING

Unintentional activation of the multifunctional-lever or
moving of the equipment may lead to accidents!

Before you leave the cab, turn the locking lever for the
work hydraulic system into position '1'. As a result, the
work hydraulic system is blocked. GK100835

Parking the machine on a slope

Whenever possible, stop the machine on level ground. If you

have to park the machine on a slope, it is required that you
park it in such a way that the front section (work unit) points
downhill.

Lower the work unit onto the ground.

Block the wheels with wheel chocks.

GK100883

3-59
3.6. Operation Operation

Longer-distance driving

If the machine is driven over long routes at a high speed and

without having adapted the tyre pressure, the tyres will become
very hot.

This leads to premature wear and tear of the tyres which should
be avoided if possible. Adhere to the following instructions if you
must drive the machine over a long distance:

Perform all pre-start checks before starting to drive (see

chapter "3.5. Checks and adjustments prior to starting work"
on page 3-39.

Fix supplementary hand tools before starting to drive.

The required tyre pressure, the driving speed or the tyre type
may vary depending on the condition or structure of the road
o be used. Contact the responsible Komatsu trader or the tyre
dealer to obtain the required information.

The required tyre pressure can be found in the tyres and tyre
pressure table in chapter "3.6.11. Tyre handling" on
page 3-76.

Check the tyre pressure with the tyres being cold before
driving.

Lower the work unit to its transport position and move it

completely to its rear limit stop position.

Always drive with empty bucket or empty forklift truck

attachment.

Adhere to the valid motor vehicle traffic regulations and drive

very careful. Make sure that the working lights and the
warning beacon are turned off while driving on public roads.

Take a 30 minute break after driving for one hour. Check the
tyres and all particularly strained parts during driving on
public roads whether they are still fully functioning or
damaged.

3-60
Operation 3.6. Operation

3.6.4. Actuating working attachment

Multifunctional lever

The work unit is operated with the multifunctional lever. The

multifunctional lever has 6 positions which control the work unit as
follows:

SW Float
â The multifunctional lever is locked in
this position.
The floating position is provided for
planing operations (removing
subsoil).
In this switch position, the work unit is
lowered by its own weight, and can be
GK100810
freely operated by external parties.

ç
S Lower The boom is lowered in this position.
If the engine is switched off, you can
lower the boom in this position.

0 Hold
å The boom is held in position.

ã
H Raise The boom is raised in position.

ä
E Tilt In this position, the bucket is tilted.

à
A Dump In this position, the bucket is dumped.

In addition to the work described below further tasks can be

performed using various working attachments.

3-61
3.6. Operation Operation

Control lever for auxiliary functions

NOTE
The control lever may not be moved to positions '1', '2' or '3'
if a working attachment is not connected. In this case, the
working hydraulics would be operating against overpressure
and the oil would be heated up unnecessarily.

The control lever has four switching positions, the functions of

which are dependent upon the types of working attachment used
and the position of the lock striker for working attachments rotary
switch (see section "18. Lock striker for working attachments
rotary switch" on page 3-14).
GK100833

Function for simultaneous actuation of lock striker for

working attachments rotary switch A B

The lock striker for working attachments rotary switch serves for
simple and easy mounting of working attachments. The standard
switch setting is position 'A'; to retract the lock strikers you have to
move the switch to position 'B' and hold it there. When released,
the switch will return to position 'A'.

Position 1 = Lock strikers for working attachment retracted

(Hold rotary switch in position 'B')
Position 0 = Neutral position
Lock strikers retracted; in this position you can
raise the working attachment
Position 2 = Lock strikers for working attachment extended

Function on working attachments which require a constant

oil flow (e.g. sweepers, rotary snow ploughs)

Position 1 = Working attachment turns in reverse motion

Position 0 = Neutral position
Position 2 = Working attachment turns forwards
Under constant operation the working
Position 3 =
attachment turns forwards
(Lever engaged)

Function for deployed multiple-purpose bucket

Position 1 = Close multi-purpose bucket

Position 0 = Neutral position
Position 2 = Open multi-purpose bucket

3-62
Operation 3.6. Operation

3.6.5. Raise/lower working attachment

Select working attachment

The approved working attachments are listed in chapter

"1.7.1. CE-conforming equipment – part 1" on page 1-20.

Raise working attachment

1. Start the engine.

2. Raise the boom slightly by moving the multifunction lever (1)

to position 'H'. 1

3. Tilt the quick-change attachment slightly forwards by moving

the multifunction lever (1) to position 'A'.

GK100810

4. Move the machine up to the working attachment until the

quick-change attachment is positioned directly above the
working attachment’s mounting hooks.

Raise the boom far enough until the quick-change attachment

is hooked into place.

5. Tilt the quick-change attachment inwards, so that the working 2

attachment makes contact with the stops on the quick-change
attachment by moving the multifunction lever (1) to position
'E'.
GK100872

6. Switch the engine off.

7. If necessary, connect the hydraulic hoses for the working

attachment.

8. Start the engine again.

9. Lock the quick-change attachment in place by moving the

auxiliary function control lever (3) to position '2'. 3
The lock strikers (2) are visible.

10. Make sure that the working attachment is locked correctly in

place by using the multifunction lever (1) to tilt and dump it.

WARNING
If the working attachment is not properly locked in place, it GK100833
may suddenly drop down and cause serious injuries!
Make sure that the working attachment is locked properly.

3-63
3.6. Operation Operation

Lower working attachment

1. Lower the working attachment onto level ground.

A B
2. Switch the engine off.

3. Disconnect the hydraulic hoses from the working attachment.

4. Start the engine again.

5. Switch the lock striker for working attachments rotary switch

1
(1) to position 'B' and hold the rotary switch in this position.

6. Unlock the quick-change attachment by moving the auxiliary

function control lever (2) to position '1'. 2
The lock strikers (3) are retracted and release the working
attachment.

GK100833

GK100872

7. Use the multifunction lever (4) to switch the quick-change

attachment to the dumping position (A) until the quick- 4
change attachment is released from the working attachment’s
mounting hooks.

8. Make sure that no one is standing behind the machine and

reverse the machine away from the working attachment.

GK100810

3-64
Operation 3.6. Operation

3.6.6. Working with the wheeled loader

Tyre-appropriate operation

Removing heaps of loose soil or rock debris may cause

premature wear and tear of the tyres due to cracks and small
fissures. As a result, the service life of the tyres is reduced.

Proceed as follows to avoid unnecessary wear and tear of the

tyres:

Try to work on level ground and remove any rocks and large
stones which are sticking out of the surface.

Always drive in straight direction into the heap or slope. This

ensures that you have always the largest intrusive force while
reducing tyre wear and tear at the same time.

Drive slowly when removing agglomerated material and when

loading blasted solid rock (speed range 1).

For removing operations, lift the bucket as soon as you drive

into the heap or slope. This procedure permits to increase the
load of the front wheels, prevents slipway of the front wheels
and reduces wear and tear of the tyres.

Lower the bucket slowly onto the ground. If the bucket

touches the ground too fast, the front wheels may be lifted
from the ground, thus leading to premature wear and tear of
the rear tyres.

To prevent the front wheels from skidding, it is recommended

to set the ground pressure of the front wheels as high as
possible. Therefore, immediately lift the bucket a little after
running into the heap or slope.

Level indicator for the bucket

On both sides of the bucket the upper edges (see arrow) are
arranged in parallel to the bucket edge and can be used as a level
indicator for the bucket.

You can recognise the position of the cutting edge of the bucket
from the driver’s seat with the help of the level indicators.

GK100873

3-65
3.6. Operation Operation

Adjusting the bucket positioner

1 1

1. Lower the bucket to the ground and set the bucket to the
desired digging angle. Set the bucket control lever to HOLD,
stop the engine and adjust as follows.

2. Remove the two bolts (1) and set the angle (2) so that the end
of the angle (2) lies in a line with the centre point of the
switch’s (3) scanning area. Tighten the bolts in order to hold
the bracket in position.

A gap of 6 to 8 mm must be set between the angle (2) and the

switch’s scanning surface (3).

Tightening torque: 15 - 20 Nm

3. After the adjustment, start the engine and raise the lift arm.

Move the bucket control lever to the DUMP position 'A', then
to TILT position 'E' and check that the bucket control lever is
automatically returned to HOLD 'H' when the bucket reaches
the desired angle.

GK100810

3-66
Operation 3.6. Operation

Loading work

CAUTION
Danger of accidents! The machine may fall over if you
transport a load with the bucket lifted too high!
Lower the bucket during transporting loads in order to lower
the centre of gravity of the machine.

The loading operation of wheel loaders is based on the following

cycle:

Removing or digging
Transport
Dumping

In the following sections, the individual operation steps of this
cycle are explained.

Removal work

CAUTION
If you perform removal operations with bent machine, you
may damage the articulated steering and the cardan shaft!
Always drive into the material which you want to remove in
straight direction.

For removal operations, adhere to the instructions in section

"Tyre-appropriate operation“. For removal operations, proceed as
follows:

1. Drive in straight line to the piled up soil.

30 cm
2. While driving forward, lower the bucket rapidly until it reaches
a height of approx. 30 cm over the ground and hold the
bucket in this position.

NOTE GK100297

If the bucket touches the ground, the front wheels may be

lifted from the ground, resulting in premature wear and tear
of the rear wheels.

3. Then, proceed with slowly lowering the bucket onto the

ground.

4. Brake right in front of the material to be removed using the

service brake, while pressing down the accelerator pedal at
the same time.

5. Press down the accelerator pedal and drive the bucket into
the material to be removed. In order to remove the material, it
is required that you align horizontally the cutting edge of the
bucket while driving into the material. GK100295

3-67
3.6. Operation Operation

When you are loading rock debris, it is necessary to dump the

bucket slightly down.

While removing rock debris, ensure that no rock gets under

the bucket. This may lead to the front wheels being lifted from
the ground, thus resulting in premature wear and tear of the
rear wheels.

Always hold the load in the centre of the bucket. If the load is
shifted to one side, the equilibrium of the machine will be
impaired.

GK100296

6. To prevent that the bucket dig in too deep into the material to
be removed, you must lift the boom while driving into the
material. Lifting the boom ensures a sufficient thrust force.

AD061910

7. Tip in the bucket.

AD061920

If too much material is loaded on to the bucket then simply

"shake" the bucket to and fro several times. At the same time
lower the boom.

This removes excess material, takes the load off the bucket and
prevents any spillage of material during transportation.

AD061930

3-68
Operation 3.6. Operation

Excavation work

During excavation work, ensure that you do not load the bucket
only on one side, as the equilibrium of the machine may be
impaired.

1. Drive up to the soil heap in a straight line.

2. Slow down the machine using the service brake while

keeping the accelerator pedal pressed down at the same
time.

3. Bend the bucket edge slightly down.

AE061940

4. While driving forward, move slightly the multi-function lever of

the boom in order to remove only a thin layer of the surface of
the soil to be removed.

AE061950

5. Move the multi-function lever of the boom slightly up and

down to reduce the resistance during driving forward.

While removing, ensure that the digging force is not applied

only on one side of the bucket.

AE061950

3-69
3.6. Operation Operation

Transporting

Make sure that the transport route is in perfect condition and that
nobody is in your way. Remove any rocks or large stones which
have fallen down out of the operating range (see chapter "Tyre-
appropriate operation" on page 3-65“). Hold the bucket in tip-in
position. Lower the boom to its transport position. If the boom is in
transport position, the two red arrows of the transport position
marking on the bucket cylinder will be next to each other.

GK100884

Unloading

Always select the dumping/unloading type with the smallest

turning circle and driving effort in order to work as efficiently as
possible.

WARNING
Danger of accidents! If you turn or brake abruptly with the
lifted load, the load may fall out of the bucket and cause
accidents!
Turn slowly with the load lifted and brake cautiously.

CAUTION
The bucket and the machine are damaged if you drive into a
heap of soil or rocks with high speed!
Drive slowly into a heap of soil or rocks.

Avoid any excessive shaking of the bucket. Always operate with

respect to the condition of the tyres (see section "Tyre-
appropriate operation" on page 3-65).

Loading in diagonal direction

Align the machine in rectangular position to the heap. Drive the

machine backwards in straight line after you have filled the
bucket. Then, let the dump truck drive between heap and
machine. Drive up to the dump truck and unload the material.

This operation requires not much time and reduces considerably

the cycle times.

AE061990

3-70
Operation 3.6. Operation

V-shaped loading

Position the dump truck in such a way that the angle between the
dump and the dump truck is approx. 60°. Fill the bucket and
shake it. This leads to a better distribution of the cargo in the
bucket and prevents that material falls down to the back. Drive
the machine backwards from the heap and align the machine with
the dump truck. Raise the bucket to its maximum height. Drive up
forward to the dump truck and unload the material.

If you keep the turning angle of the machine as small as possible,

AE062000
the work will be more efficiently.

Piling up material

Do not position the bucket in its maximum tip-in or dumping

position while piling up material. Instead, use the required mining
angle. The rear counterweight must not touch the ground.

AE062010

3-71
3.6. Operation Operation

Planing

Planing operations are required for levelling the ground. For this
purpose, a straight bucket without claws is suitable. Planing
includes two operation steps - filling up and taking off ground.

Filling up

It may be necessary to fill up the uneven ground in front of the

machine with soil. Proceed as follows:

NOTE
For fill-up operations, lower the bucket max. by 15° to the
front.

Fill the bucket with soil. Drive slowly forward with the machine and
distribute the soil little by little from the bucket. If you must fill up
particularly large uneven surfaces, you should place additional
soil in front of the bucket, which will be distributed when the
machine is driving forward.

Taking off soil

If the surface is filled up, you may level the ground.

WARNING
Danger of accidents! Careless reverse driving may lead to
severe accidents!
Before you drive backwards, make sure that nobody is
behind the machine. Warn persons who are in your way by
sounding the horn.

Dump the bucket slightly down. Drive backwards and draw the
bucket over the ground.

In order to receive a particularly even surface, you must lower the

boom to its floating position. Drive slowly backwards and draw the
bucket with its plane underside over the ground.

Prospecting

Prospecting is a special type of planing. It is used to wear off the

top layer of soil. AE061970

CAUTION
The bucket teeth and bucket are damaged if you mine with
the bucket in dumping position!
For prospecting operations, align the underside of the
bucket until it is in parallel to the ground surface.

Always drive in the lower speed range while performing

prospecting operations.

3-72
Operation 3.6. Operation

Working with the forklift truck attachment

Operations with an forklift truck attachment on a wheel loader

differ from operations with the bucket or a forklift truck. Take into
account the following notes and the instructions indicated in the
chapter "2. Safety" on page 2-1.

Do not take up loads which are so high that you cannot see
onto the route.

Hold the fork tines of the forklift truck attachment as horizontal

as possible when you take up the load.

During the ride, hold the load as low as possible in order to

have free sight onto the route.

Always drive slowly (speed range 1) with the load.

The boom performs a semicircular stroke while performing

the lifting movement. Raise the boom only immediately in
front of the place at which you want unload to the height at
which you want to unload. In such a way, you prevent that you
damage the load while lifting it.

Hold the forklift truck attachment as horizontal as possible

while piling up.

Picking up the load

1. Drive slowly up to the load to be picked up.

CAUTION 500 mm
Danger of accidents! If the load does not lie in centre of
gravity, the stability of the machine is impaired.
Drive under the load until it is touching the fork back of the 500 mm
forklift truck attachment.

75_156

2. Drive so far under the load until it touches the fork back of the
forklift truck attachment.

3. Tip in slightly the forklift truck attachment so that the load

cannot fall down.

4. Lower the boom to its transport position. The two red arrows
of the transport position marking on the bucket cylinder will
then be lined up next to each other.

5. Then lift the load to the appropriate height only shortly before
you reach the stacking surface. Raise the load a little higher
than necessary.
GK100884
6. Set the load surface slowly and from above onto the stacking.

7. Slowly lower the boom so far that you can pull out the fork
tines below the load.

8. Make sure that nobody is behind the machine and drive off
backwards from the stacking surface.

3-73
3.6. Operation Operation

3.6.7. Precautions For Special Operations

Permissible water depth

While operating in water or on swampy ground, the water must

not reach the underside of the axle housing.
Axle housing
Wash the machine after the work has been finished and check the
lubricating points.

Working on snow

Adhere to the instructions in the chapter "Working on snow" on

page 2-17. GK100874

Dumping on steep slopes

Adhere to the instructions in the chapter "Loading" on page 2-17.

Working in the vicinity of electrical overhead lines

Adhere to the instructions in the chapter "Working close to power

lines" on page 2-16.

Operation on slopes

Adhere to the instructions in the chapter "Driving on slopes" on

page 2-14.

Working on loose soil

Adhere to the instructions in the chapter "Working on loose soil"

on page 2-18.

3.6.8. If wheel brake fails to work

If the machine does not stop after depressing the brake pedal,
use the parking brake instead.

NOTE
If the parking brake has been used as an emergency brake,
contact your Komatsu distributor to have the parking brake
checked for any abnormality.

3-74
Operation 3.6. Operation

3.6.9. Check after stopping the engine

1. Walk around the machine and check the work equipment,
body work, and undercarriage, and check also for leakage of
oil and water. If any leakage or abnormality is found, carry out
repairs.

2. Fill the fuel tank.

3. Remove any waste paper or dead leaves from inside the

engine room. These may cause a fire.

4. Remove any mud stuck to the undercarriage.

3.6.10. Locking
Lock the following places:

1 Cab doors
2 Engine hood
3 Lockable storage compartment in cab

NOTE
The ignition key fits all locks. 2 1

NOTE
The maintenance flaps on the right and left-hand sides of the
machine can be opened after opening the engine hood.
To do so pull on the respective release ring (A).

3-75
3.6. Operation Operation

3.6.11. Tyre handling

Precautionary measures when handling tyres

If the following defects are found in tyres, they must be replaced

Tread
for safety reasons.
Breakers

Bead wire is broken or bent, or the tyre is greatly deformed. Sidewalls

Excessive wear and the carcass ply (excluding breaker) is

exposed for more than 1/4 of the circumference.

Damage to the carcass exceeds 1/3 of the tire width.

Beads

Tyre layers are separated.
GK100306
Carcass

Radial cracks reach the carcass.

Deformation or damage which makes the tyre unsuitable for

use.

Tyre pressure

Measure the tyre pressure before starting the machine operation,

when the tyres are cool.

If the tyre inflation pressure is too low, there will be overload; if it is

too high, it will cause tyre cuts and shock burst. To prevent these
problems, adjust the tyre inflation pressure according to the table
on the next page.

For operations on normal road surfaces, rock digging

operations:

____________ Upper range values in air pressure chart

Stockpile operations on soft ground:

____________ Average pressure values in air pressure chart

Operations on sand (operations not using much digging

force)

____________ Lower range values in air pressure chart

H–h
Deflection ratio = ------------- × 100
H

As a guideline for visual inspection, the deflection ratio of the front

tyre (deflection/free height) is as follows:
When carrying normal load (lift arm horizontal): approx. 15 - 25%
When digging (rear wheels off ground): approx. 25 - 35%

3-76
Operation 3.6. Operation

When checking the tyre inflation pressure, check also for small
scratches or peeling of the tire, for nails or pieces of metal which
may cause punctures, and for any abnormal wear.

Clearing fallen stones and rocks from the working area and
maintaining the surface will extend the tyre life and improve the
economical case of the machine.

TYRES RECOMMENDED AIR PRESSURE

for road driving when working

Manufacturer Designation Tread Front axle Rear axle Front axle Rear axle

bar psi bar psi bar psi bar psi

DUNLOP 470/70 R24 SP T9 1.5 22 2.75 40 3.0 44 2.75 40

DUNLOP 15.5-25 TL EM11 1.5 22 1.75 25 2.5 36 1.75 25

DUNLOP 455/70 R24 SP T9 1.5 22 2.0 29 3.0 44 2.0 29

DUNLOP 405/80 R25 SP T9 1.5 22 2.5 36 3.25 47 2.5 36

DUNLOP 16/70-24 E 91-2 1.5 22 2.0 29 2.25 32 2.0 29

DUNLOP 15.5 R25 TL PG33U 1.5 22 2.25 32 3.0 44 2.25 32

MICHELIN 445/70 R24 XM 47 1.5 22 2.0 29 3.5 51 3.0 44

MICHELIN 15.5 R25 L2 XTLA 2.0 29 2.0 29 2.5 36 2.5 36

MICHELIN 15.5 R25 L3 XHA 2.0 29 2.0 29 2.5 36 2.5 36

Correct inflation pressure levels have a significant impact on the

service life and efficiency of the tyres. Only correct inflation
pressures protect the tyres from getting damaged. Should the
pressure rise as a result of heating, do not deflate the tyres.
Check and adjust inflation pressures before moving off, i.e., with
the tyres cold.

In extremlely severe applications and in load and carry

applications involving lenghty hauls, the correct inflation pressure
should be determined by the respective tyre manufacturer or an
authorised service outlet on the spot.
If the deflection of the tyre is excessive, raise the inflation
pressure accordingly (see section "Tyre pressure" on page 3-76).

3-77
3.7. Transport Operation

3.7. Transport
If you have to transport the machine over far distances, either use
a low bed loader or a railway wagon. You may lift the machine
onto the transport vehicle. Optionally, you may drive it onto the
low bed loader or railway wagon via loading ramp (also refer to
"Safety Measures During Operation, Transport"). Before you start
driving, check that the following requirements are fulfilled: the
roads are broad enough, the bridges are wide enough, the
clearance heights of tunnels and the like are sufficient, the
carrying capacities of roads and bridges are sufficient.

3.7.1. Securing the articulated steering

Secure the articulated steering before you lift up the machine
or start to perform repair measures.

1. Set the machine to straight driving.

1
2. Loosen the spring bolt and remove the bolt.

3. Turn the locking bar from position '1' to position '2'..

Position 1 = Articulated steering locked

Position 2 = Articulated steering unlocked

4. Insert the bolt and secure it with the spring bolt.

3-78
Operation 3.7. Transport

3.7.2. Loading and securing the machine

DANGER

Danger of pinching! An unlocked articulated steering
may suddenly move!
Secure the articulated steering before you lift up the
machine.

Danger of accidents! Carrying ropes with insufficient

carrying capacities may tear so that the machine may fall
down!
Only lift up the machine using carrying ropes with
sufficient carrying capacities.

Hoisting equipment with insufficient carrying capacities

may suddenly bend and cause severe accidents!
Only use hoisting equipment capable of carrying the
machine's operating weight.

Objects lying on the machine may fall down and cause

injuries when the machine is lifted up!
Remove all loose objects from the machine before you
lift up the machine.

CAUTION
Incorrectly attached ropes may damage the machine!
Only fasten the eye hooks of the carrying ropes at the
marked attachment points.

There are two attachment points each at the front part and the
rear part of the machine. These attachment points are shown in
the following figure. Information signs attached to the machine
indicate the attachment points.To avoid damage to the machine,
attach the eye hooks only to the attachment points.

Observe the machine’s service weight when selecting the hoisting

gear. If the hoisting gear’s loading capacity is insufficient serious
injuries may occur! Additionally, you should use carrying cables
which have sufficient load-carrying capacity for the machine’s
service weight. Carrying cables with insufficient load-carrying
capacity may break when lifting the machine and cause serious
accidents. The machine’s service weight is dependent upon the
mounted working attachment.

3-79
3.7. Transport Operation

Covering must be removed

3-80
Operation 3.7. Transport

3.7.3. Driving machine onto loading area of transport vehicle

WARNING

If the transport vehicle or the loading ramp starts
skidding while you are driving up the loading ramp, the
machine may f all off the ramp and cause severe
accidents!

Secure the transport vehicle against accidental

movement.

Secure the wheels of the low bed loader with wheel

chocks or wedges.

The transport vehicle for the machine must have an appropriate

work load. The operating weight of the machine depends on the
attached equipment. The operating weights of the machine can
be found in the respective table in the chapter "1.6. Dimensions,
weights and operating data" on page 1-19.

The articulated steering must be unlocked before the machine is

driven onto the transport vehicle to ensure that the machine
remains steerable.

Remove any mud, snow, or ice adhering to the wheels to ensure

that you can drive onto the ramps without danger of skidding.

Do not load the machine via landing stage unless you have
checked that the landing stage is broad enough and that its
strength is sufficient to carry the load.

Loading and unloading is potentially dangerous. For this reason,

proceed with extreme care.

Load and unload the machine only on solid and level ground.
Keep a safety distance to the edge of the road.

Block the wheels of the transport vehicle (1) and place

support blocks (2) under both ramps before driving the
machine onto the transport vehicle.

Only use ramps (3) with appropriate carrying capacities and

widths. The ramps must be long enough to ensure that the
maximum loading gradient (4) of 15° is not exceeded. 3

Ensure that the ramps are positioned and fastened safely and
that both sides have the same height. Set the distance
between the ramps to the distance between the wheel tracks
(5). 4 1

Ensure that the surfaces of the ramps are clean and free of 5 Max. 15° 2 GK100205

grease, oil, ice, and loose material. Remove any dirt adhering
to the wheels.

When loading and unloading the machine, keep the engine

speed low and drive slowly.

3-81
3.7. Transport Operation

Do not carry out steering movements on the ramps. If

required, drive off the ramps again, correct alignment of the
machine, and drive up again.

After loading, i.e. when the machine is on the transport

vehicle, apply the parking brake.

Block the wheels of the machine with wheel chocks.

Set the steering wheel of the machine to straight driving.

Secure the articulated steering with the locking bar.

Position 1 Articulated steering locked
Position 2 Articulated steering unlocked
1
Always secure the locking bar with the bolt and the spring bolt
in both positions.

Secure the machine on the transport vehicle by means of

appropriate fastening equipment. Only use the attachment
points on the machine for lifting and securing.

For safety reasons, do not use any other points for fastening
(e.g. axle, cardan shaft, articulated steering, bucket teeth, or
strapping around the cab).
2

3-82
Operation 3.7. Transport

3.7.4. Securing machine for transport

DANGER

If the machine is insufficiently secured, it may start to
skid or fall off the transport vehicle and cause severe
accidents!

Always secure the machine with ropes and wheel chocks

or wedges to avoid falling down and skidding.

CAUTION

Stay ropes that are incorrectly attached may damage the
machine!

Only fasten the eye hooks of the stay ropes at the

marked attachment points.

When the machine is on the loading area of the transport

vehicle, secure the articulated steering as described in the
chapter "3.7.1. Securing the articulated steering" on
page 3-78 .

Then, block the wheels of the machine with wheel chocks or

wedges and secure the machine with ropes in such a way
that it will neither start to skid nor tip over during transport.

To avoid damage to the machine, only fasten the eye hooks

of the stay ropes at the marked attachment points. The
attachment points to be used are the two eye hooks at the
front frame and the tie bolt at the rear frame of the machine.

The positions of the attachment points are shown in the figure

on the previous page. "3.7.2. Loading and securing the
machine" on page 3-79.

3-83
3.7. Transport Operation

3.7.5. Transporting the machine

When moving the machine on a transport vehicle, adhere to
all applicable motor vehicle traffic regulations.

Determine the transport route, taking into account the width,

length, height, and weight of the load and, if necessary, have
this approved by the responsible authorities.

3.7.6. After Transport

After transport, remove all securing devices, such as wheel
chocks or wedges and ropes.

Remove the catch of the articulated steering before you drive

the machine off the transport vehicle.

For this purpose, reverse the steps 1 through 4 described in

the chapter "3.7.1. Securing the articulated steering" on
page 3-78 in reverse order.

3-84
Operation 3.8. Cold weather operation

3.8. Cold weather operation

3.8.1. Precautions for low temperatures

Under low temperatures, the engine is difficult to start and the
coolant may freeze. In this case, proceed as follows:

Fuel and lubricants

Use fuel and oil with low viscosity for all components which is
suitable for low-temperature operation. For details of the specified
viscosity, see section "5.4. Lubricants, fuels and filling capacities"
on page 5-12.

Coolant

WARNING
Keep antifreeze fluid away from open fire. Never smoke when
using antifreeze.

NOTE

Never use antifreeze on methanol, ethanol or propanol
basis.

Absolutely avoid using any water leak preventing agent

irrespective of wether it is used independently or mixed
wih an antifreeze.

Do not mix different brands of antifreeze.

For details of the antifreeze mixture when changing the coolant,

see section "5.8.2. Maintenance upon demand" on page 5-20.

NOTE
Where no permanent antifreeze is available, an ethylene
glycol antifreeze without corrosion inhibitor may be used
only for the cold season. In this case, clean the cooling
system twice a year (in spring and autumn). When refilling
the cooling system, add antifreeze in autumn, but do not add
any in spring.

3-85
3.8. Cold weather operation Operation

Battery

WARNING

To avoid gas explosions, do not bring fire or sparks near
the battery.

Battery electrolyte is dangerous. If it gets in your eyes or

on your skin, wash it off with large amounts of water, and
consult a doctor.

When the ambient temperature drops, the capacity of the battery

will also drop. If the battery charge ratio is low, the battery
electrolyte may freeze. Maintain the battery charge as close as
possible to 100%, and insulate it against cold temperature so that
the machine can be started easily the next morning.

NOTE
Measure the specific gravity and calculate the rate of charge
from the following conversion table:

Temperature of fluid
Rate of
charge
20°C 0°C -10°C -20 °C

100% 1.28 1.29 1.30 1.31

90% 1.26 1.27 1.28 1.29

80% 1.24 1.25 1.26 1.27

75% 1.23 1.24 1.25 1.26

3-86
Operation 3.8. Cold weather operation

3.8.2. Precautions after completion of work

Always observe the following precautionary measures to prevent
mud, water, or the undercarriage from freezing which would result
in inhibiting the machine operation on the following morning:

Mud and water on the machine body should be completely

removed. This is to prevent damage to the seal caused by the
water in mud or dirt get inside the seal and freeze.

Park the machine on hard, dry ground. If this is impossible,

park the machine on wooden boards. The boards help to
protect the tracks from freezing in the soil so that the machine
can start the next morning.

Open the drain valve in the fuel tank and allow the collected
water to drain off.

As the battery capacity drops significantly in low

temperatures, cover the battery or remove it from the
machine, keep it in a warm place, and install it again the next
morning.

3.8.3. After the cold weather period

When season changes and the weather becomes warmer,
proceed as follows:

Replace the fuel and oil for all parts with oil of the specified
viscosity.
For details, see section "5.4. Lubricants, fuels and filling
capacities" on page 5-12.

If for any reason permanent antifreeze cannot be used, and

an ethyl glycol based antifreeze (winter, one season type) is
used instead, or if no antifreeze is used, drain the cooling
system completely, then clean out the inside of the cooling
system thoroughly, and fill with fresh water.

3-87
3.9. Long-term storage Operation

3.9. Long-term storage

3.9.1. Before storage

When storing the machine for a long time, take the following
precautions:

After every part is washed and dried, store the machine in a

dry building. Never leave it outdoors.
If the machine must be left outdoors, park it on well-drained
concrete and cover it with canvas, etc.

Completely fill the fuel tank, lubricate, and change the oil
before storage.

Apply a thin coat of grease to the metal surface of the

hydraulic piston rods.

Disconnect the negative terminals of the battery and cover it,

or remove it from the machine and store it separately.

If the ambient temperature is expected to drop below 0°C,

always add antifreeze to the cooling water.

Lock the control lever for working hydraulics in place and

apply the parking brake by actuating the toggle switch on the
steering column.

3.9.2. During storage

CAUTION
If, for any reason, it is unavoidable to perform the rust-
prevention operation indoors, open the doors and windows
to improve ventilation and to prevent gas poisoning.

Operate the engine and move the machine over a short distance
once a month so that a new film of oil will be applied to movable
parts and component surfaces.

At the same time, also charge the battery.

Before operating the work equipment, wipe off the grease on the
hydraulic piston rod.

3-88
Operation 3.9. Long-term storage

3.9.3. After storage

NOTE
If the machine is stored without performing the monthly rust
prevention operation, call your Komatsu distributor for
service.

Carry out the following procedure before operating the machine

after long-term storage:

Wipe off the grease from the hydraulic piston rods.

Add oil and grease to all places.

Degreasing machine, see chapter "5.7. Maintenance

schedule chart" on page 5-17.

3-89
3.9. Long-term storage Operation

3-90
Troubleshooting

4-1
4.1. When the machine runs out of fuel Troubleshooting

4.1. When the machine runs out of fuel

If the fuel system is run dry the system has to be vented.

WARNING

Fire risk! Spilled fuel may ignite! Remove carefully any
spilled fuel. 1

Fuel in the injection system is under pressure.

Carry goggles and rubber gloves if you work on the

injection pump. If you are hit by a high-pressure fuel
beam, immediately go into medical treatment.

1. Refuel.

2. For maintenance operations, park and secure machine as

2
described in chapter "5.1. Maintenance guide" on page 5-2.

3. Loosen the vent screw (1) at the water separator.

3
4. Unlock the fuel pump (2) by pressing the cover down and
swivelling it out of the way.

5. Operate fuel pump until bubble-free fuel leaks out at the vent
screw.

6. Re-tighten the vent screw. 4

7. Loosen the vent screw (4) at the fuel filter (3).

8. Operate the fuel pump until bubble-free fuel leaks out at the
vent screw.

9. Re-tighten vent screw.

10. Re-lock the cover of the fuel pump.

3

WARNING
Danger of injury! When the engine is running, you may hurt
yourself on the movable components inside the engine 5
room.
Do not perform any operation in the engine room with the
engine running.

11. Start up the engine and purge the lines (5), one after the
other, with the engine running until the engine is running
regularly.

4-2
Troubleshooting 4.2. Towing the machine

4.2. Towing the machine

WARNING
Towing with a traction machine that is too light may result in
accidents!
Use a traction machine which has at least the same weight as
the machine that you want to tow off.

CAUTION
Towing to start the engine will damage the hydrostatic drive
system! Do not give the machine a tow to start the engine.
T hi s w il l n ot s ta rt the e ngi ne , but m a y d a ma ge t he
hydrostatic drive system.

To avoid damage to the hydrostatic drive system, do not tow the

machine for more than 1 km. The towing speed must not exceed
2 km/h.

Perform towing using a machine weighing at least as much as the

machine that you want to tow off. Connect both machines with
appropriate towing attachments.

CAUTION
Tow bars which are attached to incorrect points may damage
the machine! Use only the intended attachments points for
attaching the tow bar.

At the front part of the machine, fasten the towing attachment at

the marked eyes. At the rear part of the machine, fasten the
towing attachment at the hitch.

Before you tow a machine with a hydrostatic drive system,

establish a short-circuit connection between the high-pressure
side and the low-pressure side of the variable pump.

1. Set the driving-direction switch to position 'N'.

F
N
R

GK100809

4-3
4.2. Towing the machine Troubleshooting

2. Remove protecting caps from the valves.

3. Hold the valve (1) in position, using a wrench. 3

4. Loosen the counter-nut (2) an re-insert the threaded stud (3)

2
clockwise, using a hexagonal socket head wrench, until it
reaches the top edge of the counter-nut (2).
1
5. Re-tighten firmly the counter-nut (2). Perform these
operations on both valves.

After having town another machine loosen the counter-nut (2) and
the threaded stud (3) by turning it anti-clockwise until it reaches
the limit stop. Hold the valve (1) in position using a wrench an re-
tighten firmly the counter-nut (2). Perform these operations on
both valves.
1
NOTE
2
When the engine is switched off, the power-assisted steering GK100958
is not operational, i.e. you have to apply much more force to
3
steer the machine.

If you lift up the rear axle of the machine with a lorry-mounted

crane, you can tow off the machine over longer distances and at
speeds exceeding 2 km/h. Before you do this you must, however,
remove the cardan shaft of the front axle. In addition, secure the
articulated steering with the locking bar, in the same way as it is
required for transport of the machine on a low bed loader or by
train.

Towing a machine with edefective brakes

WARNING
If the brakes of the machine that you want to give a tow are
defective, uncontrolled movement of the machine may cause
a crash while it is being towed!
Always use two machines to tow off a machine with defective
brakes. Connect all three machines with appropriate towing
attachments.

If you want to tow a machine with defective brakes, or if you have

to tow a machine driving downhill, use two machines for towing.

Attach the machine that you want to give a tow to a larger

machine with sufficient tractive and braking force. Attach a
second machine to the rear part of the machine that you want to
give a tow. In this way, you avoid uncontrolled movement of the
machine.

Towing can be performed under various conditions. Thus, it is

impossible to determine all the requirements that may apply to a
particular condition.

4-4
Troubleshooting 4.2. Towing the machine

When towing on an even and horizontal surface, the tractive force

that you need is much less than the tractive force that you need
when towing on a slope or uneven surface.

Please ask your responsible Komatsu dealer for details, if you

want to give a particular machine a tow.

4-5
4.3. If battery is discharged Troubleshooting

4.3. If battery is discharged

WARNING

Before checking or handling the battery, stop the engine
and turn the starter switch key to the OFF position.

Before starting the engine, use a damp cloth to wipe off

the dust accumulated on the top of the battery.

The battery generates hydrogen gas,so there is the

danger of an explosion. Do not bring lit cigarettes near
the battery and avoid anything that will cause sparks.

Battery electrolyte is dilute sulphuric acid, which will

attack your clothes and skin. If it gets on your clothes or
on your skin, wash it off immediately with large amounts
of water. If it gets in your eyes, wash it out with fresh
water, and consult a doctor.

When handling the battery, always wear protectives

goggles.

When removing the battery, first disconnect the cable

from the ground ( no rmally, f rom the negative (-)
terminal). When installing the battery, install the positive
(+) terminal first. If a tool touches the cable connecting
1
the positive terminal and the chassis, there is the danger
of spark information.

If the terminals are loose the defective contact may 2

generate sparks that will cause an explosion. When
installing the terminals, install them tightly.
GK100314

When removing or installing the battery, check which is
the positive (+) terminal and negative (-) terminal.

Make sure that the cover of the positive terminal (+) is

mounted.
2

GK100315

4-6
Troubleshooting 4.3. If battery is discharged

4.3.1. Precautions for charging the battery

Charging with the battery installed in the machine

Before charging, disconnect the cable from the negative (-)

terminal of the battery. Otherwise, an unusually high voltage
will damage the alternator.

While charging the battery, remove all battery plugs for a

sufficient ventilation.
To avoid gas explosions, do not bring fire or sparks near the
battery.

If the electrolyte temperature exceeds 45°C, stop charging for

a while.

Turn off the charger as soon as the battery is charged.

Overcharging the battery may cause the following:

 Overheating of the battery

 Decreasing the quantity of electrolyte
 Damaging the electrode plate.

Do not mix the cables (positive (+) to negative (-) or negative
(-) to positive (+)), as this will damage the alternator.

When performing any service to the battery besides checking

the electrolyte level or measuring the specific gravity,
disconnect cables from the battery.

4-7
4.3. If battery is discharged Troubleshooting

4.3.2. Starting the engine with a booster cable

For starting the engine with a booster cable, proceed as follows:

Precautions for connecting and disconnecting the booster

WARNING

When connecting the cables, never contact the positive
INCORRECT
(+) and negative (-) teminals.

When starting the engine with a booster cable, always

wear safety goggles.

Be careful not to let the normal machine and defective

machine contact each other. This prevents sparks from
being generated near the battery which could ignite the
hydrogen gas leaking from the battery. If hydrogen gas
explodes, it may cause serious injury.
AE063650

Make sure that there is no mistake in the booster cable
connections. The final connection is made to the engine
block of the defective machine, but sparks will be
generated when this is done, so connect it to a place as
far as possible from the battery.

Be careful when removing the cables from the machine

that has been started. Do not allow the cable ends to
contact each other or the machine to avoid hydrogen
explosion.

NOTE

The size of the booster cable and clip should be suitable
for the battery size.

The battery of the normal machine must have the same

capacity as that of the engine to be started.

Check the cables and clips for damage or corrosion.

Make sure that the cables and clips are firmly connected.

4-8
Troubleshooting 4.3. If battery is discharged

Connecting the booster cables

Keep the start switch set to OFF.

Connect the booster cable as follows, in the order of the numbers A
marked in the diagram. 2 1

1. Make sure that the start switches of the normal and defective
machine are both set to OFF.
3
2. Connect one clip of booster cable (A) to the positive (+) Battery of the Battery of the
terminal of the defective machine. normal machine B problem machine
4
3. Connect the other clip of booster cable (A) to the positive (+) Engine block of the
terminal of the normal machine. problem machine GK100876

4. Connect one clip of booster cable (B) to the negative (-)

terminal of the normal machine.

5. Connect the other clip of booster cable (B) to the engine block
of the defective machine.

6. Let the engine run with a high speed.

Starting the engine

1. Make sure the clips are firmly connected to the battery

terminals.

2. Turn the start switch of the defective machine to the START

position and start the engine. If the engine does not start at
first, wait for at least 2 minutes before trying again.

Disconnecting the booster cables

After the engine has started, disconnect the booster cables in

reverse order in which they were connected. A
3 4
1. Remove one clip of booster cable (B) from the engine block of
the defective machine.

2. Remove the other clip of booster cable (B) from the negative 2
(-) terminal of the normal machine. Battery of the Battery of the
normal machine B problem machine
3. Remove one clip of booster cable (A) from the positive (+) 1
terminal of the normal machine. Engine block of the
problem machine GK100876
4. Remove the other clip of booster cable (A) from the positive
(+) terminal of the defective machine.

4-9
4.4. For insufficient braking effect Troubleshooting

4.4. For insufficient braking effect

4.4.1. Checking the brake function

Drive the machine at a speed of 20 km/h on a dry flat concrete
road surface, and check whether the stopping distance is less
than 5 m.

NOTE
All repairs conducted on the braking system must be
conducted at a Komatsu workshop.

4.4.2. Checking the parking brake function

1. Start the engine, set the machine to straight driving, and drive
the machine with an empty bucket up a gradient of 25%.

2. Stop the machine with the service brake and do not release F
your foot again to keep the service brake applied.
N 1

3. Lower the bucket.

R
4. Set the driving direction switch (1) to its neutral position 'N'.

5. Switch off the engine. GK100809

6. Apply the parking brake (2) and slowly release the pedal of
the service brake.

The machine must stand still. 2

1
NOTE
All repairs conducted on the braking system must be
conducted at a Komatsu workshop.

GK100830

4-10
Troubleshooting 4.5. Emergency steering properties

4.5. Emergency steering properties

You can continue to steer the machine even if the engine cuts out
during a journey. This will require more force however.

If the engine cuts out, move over straight to the side of the road,
switch on the hazard warning lights and secure the machine.

4.6. Emergency lowering

The machine is equipped with a pressure accumulator for the
working hydraulics. If the engine is not running you can lower the
working attachment to the ground using the multifunction lever –
once only (emergency lowering).

NOTE
If you have secured the working hydraulics with the safety
lever, you will however be unable to lower the working
attachment.

Position 1 = working hydraulics locked

Position 2 = working hydraulics released

GK100835

1. Make sure that no one is standing underneath the working

attachment.

2. Move the multifunction lever slowly into position 'S'.

The working attachment is lowered.

GK100810

4-11
4.7. Other troubles Troubleshooting

4.7. Other troubles

4.7.1. Electrical system

If faults or causes of faults are not listed below, have them
rectified by a local dealer.

ELECTRICAL SYSTEM

Fault Fault cause Remedy

Warning light charging current:

warning light charging current is
Electrical connection without *) Check terminals, connections,
off, when the engine is switched off
function and cables
and the start switch is set to its
operating position 'I'

Electrical connection without *) Check terminals, connections,

function and cables
Warning light charging current:
warning light charging current does *) Check function of generator;
Generator without function
not go out when engine is running replace defective generator

Tension generator drive belt to low Tension drive belt

Generator produces unusual noise Generator defective Replace generator

Electrical connection without *) Check terminals, connections,

function and cables

Starter does not start the engine Re-charge battery

Battery charge insufficient
*) Check function of battery;
replace defective battery

Starter pinion repeatedly engages Battery charge insufficient Re-charge battery

and disengages Starter defective *) Replace starter

Battery charge insufficient Re-charge battery

Starter turns engine only slowly
Starter defective *) Replace starter

Starter disengages before engine Battery charge insufficient Re-charge battery

is started Starter defective *) Replace starter

*) Have this work performed by local dealer.

4-12
Troubleshooting 4.7. Other troubles

4.7.2. Engine
If faults or causes of faults are not listed below, have them
rectified by local dealer.

ENGINE

Fault Fault cause Remedy

Oil level in engine too low Top up engine oil

Engine oil filter (filter cartridge) Replace engine oil filter (filter
dirty cartridge)

Check lines and hoses (visual

check: oil leaks)
Lines or hoses of engine
lubricating system damaged
Warning light engine oil pressure: *) Replace defective lines and
with the engine running the hoses
warning light is on and an acoustic
alarm signal is given Check line and hose connections
(visual check: oil leaks)
Line or hose connections of engine
lubricating system leaky
*) Repair leaky line and hose
connections

*) Check function of oil pressure

Oil pressure switch without
switch; replace defective oil
function
pressure switch

Vapour is let off at the pressure Top up coolant

Coolant level in radiator too low
valve of the radiator cap (make sure mixture ratio is correct)

Check lines and hoses (visual

check: coolant leaks)
Coolant level too low Leak in cooling system
*) Replace defective lines and
hoses

*) Have this work performed by local dealer.

4-13
4.7. Other troubles Troubleshooting

ENGINE (continued)

Fault Fault cause Remedy

Let the engine run idle without

load, until the engine has
sufficiently cooled down and the
Engine is overheated
temperature indicator of the
coolant has returned to the green
range

Tension of fan's drive belt too low Tension drive belt

Temperature display coolant:
temperature display coolant in red Internal surface of engine cooling *) Clean internal surface of engine
zone, top LED is flashing, acoustic system furred or dirty cooling system
alarm is given
Radiator (radiator surfaces, fins) Clean radiator (radiator surfaces,
dirty fins)

*) Check function of thermostat;

Thermostat without function
replace defective thermostat

Radiator cap either defective or Replace defective radiator cap; re-

loose tighten loose radiator cap

Temperature display coolant:

with the engine at operating *) Check function of temperature
Temperature display without
temperature, the temperature display; replace defective
function
display coolant does not indicate a temperature display
temperature

Refill fuel and bleed fuel system

Bleed fuel system
*) Replace injection pump or
Fuel tank empty
injection nozzles
See ""Electrical System""
*) Check tappet clearance
Engine does not start Air in fuel system Bleed fuel system
Injection pump or injection nozzles *) Replace injection pump or
without function injection nozzles

Starting speed too low See "Electrical System"

Engine compression too low *) Check tappet clearance

Oil level in engine too high Correct oil level

Exhaust fumes colour white or blue
Wrong fuel Use prescribed fuel

Air filter insert dirty Clean or replace air filter insert

Exhaust fumes colour temporarily
Injection nozzle defective *) Replace injection nozzles
black
Engine compression too low *) Check tappet clearance

Temporarily, combustion sounds

Injection nozzles defective Replace injection nozzles*)
like breathing

*) Have this work performed by local dealer.

4-14
Troubleshooting 4.7. Other troubles

ENGINE (continued)

Fault Fault cause Remedy

Wrong fuel Use prescribed fuel

Allow engine to cool down

Unusual combustion noise Engine temperature too high
(engine overheated) See "Engine - temperature display
coolant"

Defective silencer *) Replace silencer

Unusual mechanical noise
Tappet clearance too wide *) Adjust tappet clearance

Engine fails to start or goes out

during operation and the top fuel Fuel tank empty Refill fuel and bleed fuel system
gauge LED starts to flash

Warning light air filter:

Clean or replace filter insert of air
warning light air filter is on when Air filter of filter insert dirty
filter
engine is running

*) Have this work performed by local dealer.

4-15
4.7. Other troubles Troubleshooting

4.7.3. Hydraulic system

If faults or causes of faults are not listed below, have them
rectified by local dealer.

HYDROSTATIC DRIVE UNIT

Fault Fault cause Remedy

Parking brake applied

Oil level in hydraulic oil tank too Release parking brake
low

Driving direction switch in position Set driving direction switch to

Machine does not drive 'N' either position 'F' or 'R'

Driving direction switch without *) Check function of driving

function direction switch

Oil level in hydraulic oil tank too

Top up hydraulic oil
low

Check hydrostatic motor for

contamination; clean dirty
Hydrostatic motor motor does not hydraulic motor
swivel
*) Check function of hydrostatic
motor

*) Check function of on-off valve;

On-off-valve without function
replace defective on-off-valve

Hydrostatic pump defective *) Replace hydrostatic pump

*) Check control pressure; reset, if

Machine does only drive slowly Wrong control pressure
required
and performance is poor
*) Check high pressure; reset, if
Wrong high pressure
required
*) Check setting of inch valve
Inch valve defective or set
incorrectly
*) Replace defective inch valve

Replace filter element of hydraulic

Hydraulic filter dirty
filter

*) Check function of switching

Switching relay without function relay; repair or replace defective
switching relay

*) Have this work performed by local dealer.

4-16
Troubleshooting 4.7. Other troubles

HYDROSTATIC DRIVE UNIT (continued)

Fault Fault cause Remedy

*) Check function (pressure) of

charge pump
Clean hydraulic oil radiator
(radiator surfaces, fins)
Faulty operation of charge pump
Check tension of drive belt
Replace filter element of hydraulic
filter
Correct oil level in hydraulic oil tank
Hydrostatic drive unit overheated Hydraulic oil radiator (radiator Clean hydraulic oil radiator
surfaces, fins) dirty (radiator surfaces, fins)

Faulty operation of radiator Check tension of drive belt

Replace filter element of hydraulic
Hydraulic filter dirty
filter

Oil level in hydraulic oil tank either

Correct oil level in hydraulic oil tank
too high or too low

Oil level in hydraulic oil tank too

Top up hydraulic oil
low
Unusual noise Inclusions of air in lines and units
of the hydraulic system (faulty Bleed hydraulic system
bleeding)

HYDRAULIC SYSTEM

Fault Fault cause Remedy

Lifting power too low Oil level in hydraulic tank too low Top up hydraulic oil
Filter insert of hydraulic oil filter Replace filter insert of hydraulic oil
Lifting power too slow
dirty filter

Oil level in hydraulic oil tank too

Air bubbles in hydraulic oil Top up hydraulic oil
low

Oil level in hydraulic oil tank too

Cylinders move jerky Top up hydraulic oil
low

*) Have this work performed by local dealer.

4-17
4.7. Other troubles Troubleshooting

4.7.4. Brakes
If faults or causes of faults are not listed below, have them
rectified by local dealer.

BRAKES

Fault Fault cause Remedy

Multi-disks of brake worn *) Replace multi-disks of brake

Brake has no effect
Air in brake system *) Bleed brake system

Top up brake oil

Warning light brake oil reserve: Brake oil level in brake oil tank too
Check brake system for damage
warning light brake oil reserve is on low
and leaks (visual check: brake oil
leaks)

PARKING BRAKE

Fault Fault cause Remedy

Parking brake's brake lever is too

*) Adjust parking brake
Brake is ineffective loose
Brake's multi-disks are worn *) Replace multi-disks

*) Have this work performed by local dealer.

4.7.5. Steering
If faults or causes of faults are not listed below, have them
rectified by local dealer.

STEERING

Fault Fault cause Remedy

*) Check function of hydraulic

Steering reacts slowly Hydraulic system malfunctions
system

*) Check fastenings of steering

Clearance of steering cylinder bolt
cylinder; replace defective cylinder
too large
Steering wobbles bolt.

Faulty operation of hydraulic *) Check function of hydraulic

system system

*) Have this work performed by local dealer.

4-18
Troubleshooting 4.7. Other troubles

4.7.6. Axles
If faults or causes of faults are not listed below, have them
rectified by local dealer.

AXLES

Fault Fault cause Remedy

Noise Oil level in axle too low Top up oil

*) Have this work performed by local dealer.

4.7.7. Driver's Cab

If faults or causes of faults are not listed below, have them
rectified by local dealer.

DRIVER'S CAB

Fault Fault cause Remedy

Blower: insufficient air flow Blower filter clogged Clean or replace filter

*) Have this work performed by local dealer.

4-19
4.7. Other troubles Troubleshooting

4-20
Maintenance

5-1
5.1. Maintenance guide Maintenance

5.1. Maintenance guide

Maintenance work is to be conducted by skilled personnel only.
See section "2.4. Precautions for maintenance" on page 2-24.

Perform maintenance work on hard, flat ground.

Always move the machine to the proper maintenance and repair

position.

The machine must be positioned as follows for maintenance,

unless other specifications are expressly provided.

Lower the working attachment onto the ground.

Move the multifunction lever to the HOLD '0' position.

GK100810

Switch the working hydraulics safety lever to position ‘1’.

Position 1 = working hydraulics locked

Position 2 = working hydraulics released

Apply service brake

Lock the centre pivot steering when performing maintenance

work by using the centre pivot steering locking lever.

Place chocks before and behind the wheels. GK100835

Check service meter

Check the service meter every day to see if any maintenance is

due.

Komatsu original replacement parts

Only use Komatsu original parts specified in the Parts Book as

replacement parts.

Oils and grease GK100882

Use only original oils and grease by Komatsu. Choose oils and
grease with the specified viscosity depending on the ambient
temperature.

Use only clean oil and grease. Keep also containers for oil and
grease clean. Be careful not to operate with foreign substances in
the vicinity of oil and grease.

Washer fluid

Use automobile window washer fluid and make sure it is not

contaminated with dust or dirt.

5-2
Maintenance 5.1. Maintenance guide

Keep the machine clean

Always keep the machine clean. This facilitates troubleshooting

considerably. In particular, keep grease fitting, breathers and oil
level gauges clean and avoid any contamination with foreign
materials.

Be careful with hot fluids

Draining hot oils and coolants and removing their filters

immediately after stopping the engine are hazardous. Allow the
engine to cool before.

If the oil has to be drained when it is cold, warm it up to a suitable

temperature (approx. 20 - 40°C), then drain!

Check for foreign particles in drained oil and on filters

After oil is changed or filters are replaced, check the oil and filters
for metallic particles and foreign materials. If large quantities of
metallic particles or foreign materials are found, consult your
Komatsu dealer.

Refilling fuel or oil, fuel strainer

Refill only fuel or oil in sufficiently ventilated places. If your

machine is equipped with a fuel strainer, do not remove it while
fueling. Re-close it after fueling.

Spilled fuel or oil may cause accidents due to slipping. It may also
ignite. For this reason, always remove any spilled oil or fuel.

Never use fuel for cleaning or rinsing parts. Be careful not to

contaminate soil or water with oil or fuel. Dispose oil and fuel in an
appropriate manner.

Oil check or change

Check or change oils only in dust-free places to keep foreign

particles away from oils.

Warning tag

Attach the warning tag to the start switch or other related control
elements to avoid that somebody starts the engine during
maintenance.

The warning tag is supplied together with the tools.

Safety labels

During the operation, always observe the precautions on the

safety label attached to the machine.

5-3
5.1. Maintenance guide Maintenance

Welding instructions

Turn off the engine start switch (OFF position).

Disconnect the negative terminal on the battery.

Do not apply more than 200V continuously.

Connect grounding cable within 1 m from the area to be

welded.

No seals or bearings may be between the area to be welded

and the grounding point.

Never weld any pipe or tube containing fuel or oil.

Keep a safety distance of min. 1 m between the area to be

welded and the battery.

Fire prevention

Use nonflammable cleaners or light oil for cleaning parts. Keep

flame or cigarette light away from light oil.

Clamp faces

When O rings or gaskets are removed, clean the clamp faces and
replace the O rings and gaskets with new ones. Be sure to fit O
rings and gaskets during re-assembly!

Objects in your pockets

Keep your pockets free of loose objects which can fall out and
drop into the machine (especially when bending over the
machine).

Tyres check

When working in rocky areas, check the tyres for damage and for
looseness, flaws, wear and tear. Re-tighten loose bolts and nuts.

Precautions when washing the machine

Place the machine on a plane, even surface.

Lower the work equipment to the ground.

Apply the parking brake.

Lock the wheels using support wedges to prevent the

machine from rolling away.

Proceed the following general measures, if you want to clean the

machine:

Never spray steam or water directly on the radiator.

Do not allow water to get on any electrical component.

5-4
Maintenance 5.1. Maintenance guide

Pre- and post-work checks

Before starting work in mud, rain, snow or at the seashore, check

plugs and valves for tightness. Wash the machine immediately
after the work to protect components from rusting.

Lubricate components more frequently than usual. Be sure to

lubricate work equipment pins daily if they are submerged in
water.

On worksites where heavy-duty operations are common, reduce

the maintenance and lubricating intervals.

Dusty worksites

When working at dusty worksites, take the following precautions:

Inspect the air cleaner clogging warning lamp to see whether

the air cleaner is blocked. Clean the air cleaner more
frequently than specified.

Clean the radiator core frequently to avoid clogging.

Clean and replace the fuel filter frequently.

Clean electrical components, especially the starter and

alternator to avoid accumulation of dust.

Avoid mixing oils

Never mix oils of different brands. If you have only oil which is
different from the oil brand used in the machine, do not add it but
replace the entire oil.

5-5
5.2. Maintenance basics Maintenance

5.2. Maintenance basics

5.2.1. Oil, fuel and coolant specifications

Oil

Oil is used in the engine and work equipment under extremely

severe conditions (high temperature, high pressure), and it
deteriorates with use.
Always use oil that matches the grade and temperature given
in the Operation and Maintenance Manual. Even if the oil is
not dirty, always replace the oil after the specified interval.

Oil can be compared to blood in the human body, so always

be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from penetrating.
The majority of problems with machines are caused by the
entry of such impurities.
Take particular care not to let any impurities penetrate when
storing or adding oil.

Never mix oils of different grades or brands. If only an oil is

available which does not match the oil grade/brand in the
machine then do not top up the oil, but replace all of it.

Always add the specified amount of oil.

Having too much oil or too little oil may both cause problems.

If the oil in the work equipment is not clear, there is probably

water or air getting into the circuit. In such cases, please
contact your Komatsu distributor.

When changing the oil, always replace the related filters at

the same time.

We recommend to have an analysis of the oil made

periodically to check the condition of the machine. Those who
wish to use this service, are requested to their Komatsu
distributor.

5-6
Maintenance 5.2. Maintenance basics

Fuel

The fuel pump is a precision instrument; if fuel containing

water or dirt is used, it cannot work properly.

Be extremely careful not to let impurities penetrate when

storing or adding fuel.

Always use the fuel specified in the Operation and

Maintenance Manual.
Fuel may congeal depending on the temperature (particularly
at low temperatures below -15°C), so change to a fue
matching this temperature.

To prevent the moisture in the air from condensing and

forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.

Before starting the engine, or when 10 minutes have passed

after adding fuel, drain the sediment and water from the fuel
tank.

If the engine runs out of fuel, or if the filters have been

replaced, you must fill up the fuel pre-filter with fuel and may
then restart the engine. For details, see "4.1. When the
machine runs out of fuel" on page 4-2.

If the fuel sulphur content is between 0.5 and 1.0%, the oil
change interval must be 1/2 normal.
If the fuel sulphur content is more 1.0%, the oil change
interval must be 1/4 normal.

5-7
5.2. Maintenance basics Maintenance

Coolant

River water contains large amounts of calcium and other

impurities, so if it is used, scale will stick to the engine and
radiator causing a defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions

given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-

freeze in the coolant when the machine is shipped.
This anti-freeze prevents corrosion in the cooling system.
Therefore, it can be used as it is even in hot areas.

Anti- freeze is flammable, so be extremely careful not to

expose it to open flame or fire.

The proportion of anti-freeze to water differs according to the

ambient temperature.
For details of the mixing ratios, see "Cooling system –
exchanging coolant and cleaning the system " on page 5-49.

If the engine overheats, wait for the engine to cool before

adding coolant.

If the coolant level is low, it will cause overheating and

corrosion due to the air in the coolant.

Grease

Grease is used to prevent twisting and noise at the joints.

The nipples not included in the maintenance section are

nipples for overhaul, so they need not be lubricated.
If any part becomes stiff after being used for a long time, add
grease.

Always wipe off all of the old grease that is pushed out when
greasing. Be particularly careful to wipe off the old grease in
places where sand or dirt in the grease would cause the
rotating parts to wear.

5-8
Maintenance 5.2. Maintenance basics

Storing oil and fuel

Keep oil and fuel indoors to prevent any water, dirt or other
impurities from penetrating.

When keeping barrels for a long period, lay down the barrel
on its side so that the filler port is at the side (to prevent
moisture from being sucked in).
If barrels have to be stored outside, cover them with a
waterproof sheet or take other measures to protect them.

To prevent any change in quality during long term storage, be

sure to use in the order of 'first in - first out' (use the oldest oil
or fuel first).

Filters

Filters are extremely important safety parts. They prevent

impurities in the fuel and air circuits from entering important
equipment and causing problems.

Replace all filters periodically. For details, see the Operation

and Maintenance Manual.
However, when working under severe conditions, it is
necessary to consider replacing the filters at shorter intervals
according to the oil and fuel (sulfur content) being used.

Never try to clean the filters (cartridge type) and use them
again. Always replace with new filters.

When replacing oil filters, check if any metal particles are

stuck to the old filter. If any metal particles are found, please
contact your Komatsu distributor.

Do not open packs of spare filters until just before they are to
be used.

Always use original Komatsu filters.

Biodegradable hydraulic oil and lubricants

The use of biodegradable hydraulic oils and lubricants - on the

basis of synthetic esters - for Komatsu machines is permitted. For
information on the products cleared for use and best suited for
your application contact our authorized service workshops.

5-9
5.2. Maintenance basics Maintenance

5.2.2. Specifications of the electrical system

If the wiring gets wet or the insulation is damaged, the
electrical system leaks resulting in hazardous malfunctions of
the machine.

Maintenance work at the electrical system includes:

1. check fan belt tension,

2. check damage or wear to the fan belt ,
3. check battery fluid level.

Never remove or disassemble any electrical components

installed in the machine.

Never install any electrical components other than those

specified by Komatsu.

Be careful to keep the electrical system free of water when

washing the machine or when it is raining.

When working on the seashore, carefully clean the electrical

system to prevent corrosion.

The optional power source must never be connected to the

fuse, start switch, or battery relay.

5-10
Maintenance 5.3. Wearing parts list

5.3. Wearing parts list

Wearing parts such as filter elements, air cleaner elements, bolt-
on edges, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits, are reached.
The wearing parts should be changed correctly in order to use the
machine economically.
For replacement, KOMATSU genuine parts of excellent quality
should be used.
When ordering parts, please check the part number in the parts
handbook.

The parts in parentheses are to be replaced at the same time.

Position Part no. Part name Q'ty Replacement interval

First maintenance after

50 operating hours
Engine Oil Filter YM 119005-35100 Cartridge 1
Maintenance every 250
operating hours

Maintenance every 500

Fuel Filter YM 119000-55600 Cartridge 1
operating hours

First maintenance
42U-62-13150 Filter Element 1 after 50 operating hours
Hydraulic Oil Filter (42U-62-H0P01) (O-Ring) (1)
(42U-62-H0P02) (O-Ring) (1) Maintenance every 500
operating hours

Engine Valve Cover YM 123900-11310 Gasket 1 Maintenance every 1000

Gasket YM 24311-000120 O-ring 4 operating hours

42U-01-H0P02 Filter Insert 1 Maintenance every 500

Air Filter
42U-01-H0P01 Safety Filter 1 operating hours

5-11
5.4. Lubricants, fuels and filling capacities Maintenance

5.4. Lubricants, fuels and filling capacities

LUBRICANTS, FUELS AND FILLING CAPACITIES

WA115-3 Approx. filling

Lubricants, fuel Temperature
BI code **) Quality grades Viscosity ranges capacity in
etc. ranges
litres

CCMC D4 or, if not

EO 1540 A -25° to 45°C SAE 15W-40 *)
available:
Engine Engine Oil EO EO 1030 A -20° to 30°C SAE 10W-30 14
API CE or
NRS -15° to 20°C SAE 05W-30
API CF -4 ²)
Transfer Gear Box
API-GL5 +LS – 1.6
Standard Type
Gear Oi GO GO 90 LS or SAE 90 LS
High Speed
MIL-L-2105D +LS – 1.0
Version
API-GL5 +LS SAE 90 LS *) Planet Gear: 2
Front Axle Gear Oi GO GO 90 LS or – SAE 85W-90 LS × 1.5
MIL-L-2105D +LS SAE 80W-90 LS Differential: 4.5
API-GL5 +LS SAE 90 LS *) Planet Gear:
Rear Axle Gear Oi GO GO 90 LS or – SAE 85W-90 LS 2 × 1.5
MIL-L-2105D +LS SAE 80W-90 LS Differential: 4.5
HYD 0530 -15° to 20°C ISO VG 46 *)
Hydraulic Oil HYD HYD 1030 HVLP, HVLP D -20° to 30°C ISO VG 68
HYD 1540 -15° to 45°C ISO VG 100
CCMC D4 or, if not
EO 1540 A -15° to 20°C SAE 15W-40 *)
Hydraulic system, available:
or Engine Oil EO EO 1030 A -20° to 30°C SAE 10W-30 85
steering, brakes API CE or
NRS -15° to 45°C SAE 05W-30
API CF -4 ²)
or HEES
Hydraulic Oil BIO- BIO-E-HYD 0530 (acc. to VDMA fluid -15° to 20°C ISO VG 46
E-HYD technology)
Automatic
AFT, Type A
Service Brake Transmission Gear AFT – – 0.7
Suffix A
Oil
Proportion of Mixture:
Cooling system Long-Time Antifreeze and 50% Coolant : 50% Water
SP-C 15.0
Coolant Corrosion Protection
Min. Freeze Proofing: -34° C
CFPP class B up to 0°C
CFPP class D up to -10°C
Fuel tank Diesel fuel ³) DIN-EN 590 120
CFPP class E up to -15°C
CFPP class F up to-20°C
Multi-purpose
Grease nipples,
grease MPG on a MPG-A KP2N-20 – NLGI 2
central lubrication
lithium base
R134a (CFC-free)
Coolant NRS 1.200 g
Air conditioning Refrigerating NRS 180 cm³
PAG
machine oil
(polyalkyleneglycol)
The specified filling capacities are approximate guidelines; test specifications are binding. The selection of the viscosity class depends on the
predominantly existing outside temperature. The temperature limits are to be regarded as guidelines which can be exceeded up or down for a
brief period.
*) Works filling
²) If no engine oil of the API CE or API CF-4 specification is available, API CC or API CD-classified engine oil can be used alternatively. The oil
change intervals must be split in half in this case, however.
³) If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. With a sulphur content of more than 1.0 %,
the oil change interval must be 1/4 normal.
**) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V. (BI).
The brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and Vehicles" can be
obtained from bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no. 3-7625-3102-1."

5-12
Maintenance 5.5. Tools and standard tightening torques (bolts, nuts)

5.5. Tools and standard tightening torques (bolts, nuts)

5.5.1. Introduction of recommended tools

No. Name of tool Part No. Remarks

Applicable width across flats

42T-09-H0450 8/10 mm
1 Wrench set 42T-09-H0460 13/15 mm
42T-09-H0470 17/19 mm
42T-09-H0440 24/27 mm
2 Screwdriver 421-98-H1120 –

3 Screwdriver 421-98-H1110 –

6 Grease gun 424-98-H1010 –

7 Hose 424-98-H1020 (for grease gun)

8 Grease cartridge 07950-90403 (Lithium base grease: 400g)

9 Hammer 421-98-H1140 –
10 Pocket 421-98-H1130 –

If any of the above tools are broken, please order them from your
KOMATSU distributor.

5-13
5.5. Tools and standard tightening torques (bolts, nuts) Maintenance

5.5.2. Torque list

Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.

The tightening torque is determined by the width across flats of

the nut and bolt.
b
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced..

a AD053380

Metric Fine Screw Thread - Strength Class 10.9

Tread diameter of Width across flat Steel Aluminium Cas

the bolt (mm) (mm)
(a) (b) Nm kgm Nm kgm

M6 10 14.0 1.4 7.7 0.77

M8 13 35.0 3.5 19.0 1.9

M10 17 (15) 70.0 7.0 37.0 3.7

M12 19 115.0 11.5 64.0 6.4

M14 22 185.0 18.5 101.5 10.15

M16 24 280.0 28.0 158.0 15.8

M18 27 390.0 39.0 218.0 21.8

M20 30 560.0 56.0 306.5 30.65

M22 32 750.0 75.0 416.0 41.6

M24 36 960.0 96.0 528.5 52.85

M27 41 1,400.0 140.0 774.0 77.4

M30 46 1,900.0 190.0 1,053.0 105.3

M33 50 2,600.0 260.0 – –

M36 55 3,300.0 330.0 – –

M39 60 4,300.0 430.0 – –

NOTE
When tightening panels or other parts having tightening
fixtures made of plastic, be careful not to use excessive
tightening torque: doing so will damage the plastic parts.

5-14
Maintenance 5.5. Tools and standard tightening torques (bolts, nuts)

Metric Fine Screw Thread - Strength Class 10.9

Tread diameter of Width across flat Steel Aluminium Cas

the bolt (mm) (mm)
(a) (b) Nm kgm Nm kgm

M8 × 1 13 35.0 3.5 20.0 2.0

M10 × 1 17 (15) 75.0 7.5 42.0 4.2

M10 × 1.25 17 (15) 70.0 7.0 39.0 3.9

M12 × 1.25 19 125.0 12.5 70.0 7.0

M12 × 1.5 19 120.0 12.0 67.0 6.7

M14 × 1.5 22 200.0 20.0 110.0 11.0

M16 × 1.5 24 300.0 30.0 167.5 16.75

M18 × 1.5 27 440.0 44.0 243.0 24.3

M18 × 2 27 420.0 42.0 230.0 23.0

M20 × 1.5 30 620.0 62.0 338.5 33.85

M20 × 2 30 – – 322.5 32.25

M22 × 1.5 32 820.0 82.0 454.5 45.45

M22 × 2 32 – – 436.0 43.6

M24 × 15 36 1,090.0 109.0 596.0 59.6

M24 × 2 36 1,040.0 104.0 573.0 57.3

M27 × 2 41 1,500.0 150.0 832.0 83.2

M30 × 2 46 2,120.0 212.0 1,158.0 115.8

M33 × 2 50 2,800.0 280.0 – –

M36 × 3 55 3,500.0 350.0 – –

M39 × 3 60 4,600.0 460.0 – –

5-15
5.6. Periodical replacement of safety-critical parts Maintenance

5.6. Periodical replacement of safety-critical parts

To ensure trouble-free operation of the machine, the user of the
machine must always carry out periodic maintenance. In addition,
to maintain safety standards, the user should also periodically
replace all safety related parts, which are particularly closely
connected to safety and fire prevention.

The standard service life under normal conditions should not

exceed 6 years.

Hoses must be replaced as soon as the following damage is

noticeable:

 damage to the outer layer through to the intermediate

layer,

 brittleness in the outer layer,

 distortions in pressurised or unpressurised state not
conforming with the original shape of the installed hose,

 leakages,
 damage to the hose fittings or to the connection between
fittings and hose,

 storage damage (the shelf life of the hose should not

exceed 2 years).

When replacing the hoses, always replace the O-rings, gaskets,

and other such parts at the same time.

Ask your Komatsu distributor to replace the safety critical parts.

5-16
Maintenance 5.7. Maintenance schedule chart

5.7. Maintenance schedule chart

Service Procedure see page

5.8.1 Pre-start checklist 5-19

Cooling system – checking the coolant level, toping up coolant 5-19
Checking the engine oil level – topping up oil 5-19
Checking the fuel level – refuelling 5-19
Checking the controls 5-19
Checking the electrical connections 5-19
Heater/air conditioning – checking rate of air flow 5-19
Miscellaneous tests before starting work 5-19
5.8.2 Maintenance upon demand 5-20
Checking the air-conditioning system 5-20
Checking the window washing-fluid level, adding fluid 5-21
5.8.3 Maintenance after first 50 service hours 5-22
Engine – changing oil and replacing the oil filter cartridge 5-22
Check condition of V-belt 5-22
Check tension of generator V-belt and adjust 5-22
Check and adjust tension of air conditioning (option) compressor V-belt 5-22
Hydraulic system – replacing the filter insert 5-22
Check and tighten wheel nuts 5-22
Front and rear axle – oil change 5-22
Transfer box gearing – changing oil 5-22
5.8.4 Maintenance every 50 operating hours 5-23
Cooling system – checking the cooling system, coolant level in the radiator and expanion tank 5-23
Fuel tank – draining off water and dirt deposits 5-24
Service brake – checking the oil level, refilling oil 5-25
Battery – checking the acid level 5-26
Battery – re-charging the battery 5-27
Check and tighten wheel nuts 5-27
Lubrication 5-28
5.8.5 Maintenance every 100 operating hours 5-29
Water separator – removing water and dirt deposits 5-29
5.8.6 Maintenance after the first 250 operating hours 5-30
Engine – changing oil and replacing the oil filter cartridge 5-30
Check condition of V-belt 5-32
Check tension of generator V-belt and adjust 5-33
Check and adjust tension of air conditioning (option) compressor V-belt 5-34
Front and rear axle – checking the oil level 5-35

5-17
5.7. Maintenance schedule chart Maintenance

Service Procedure see page

Air filter – checking and cleaning the filter insert 5-36

Radiator – cleaning the radiator segments 5-39
Lubrication 5-40
5.8.7 Maintenance every 500 operating hours 5-42
Fuel filter – changing the fuel filter and filter element 5-42
Purging the fuel system 5-42
Cleaning the water separator 5-43
Transfer box gearing – checking the oil level and refilling oil 5-44
Air filter – replacing the filter insert, replacing the safety filter 5-45
Heater/air conditioning – cleaning/replacing filter fleece or cleaning condenser 5-46
ALS-pressure accumulator (Option) - checking gas pressure 5-47
Lubrication 5-48
5.8.8 Maintenance every 1000 operating hours 5-49
Cooling system – exchanging coolant and cleaning the system 5-49
Hydraulic – ventilating the hydraulic oil tank 5-52
Hydraulic system – replacing the filter insert 5-52
Checking the tightening parts of the turbo-charger 5-53
Checking the play of the turbo-charger rotor 5-53
Service Brake – checking, testing, changing oil 5-53
System pressures – checking and adjusting 5-53
Valve play – checking and adjusting 5-53
Injection nozzles – checking and adjusting the , nozzle pressure and fuel-jet pattern 5-53
Check pressure accumulator – gas pressure 5-53
Front and rear axle – oil change 5-54
Transfer box gearing – changing oil 5-56
5.8.9 Maintenance every 2000 operating hours 5-57
Hydraulic system – oil change 5-57
Cooling system – checking the antifreeze content of the coolant 5-59
Checking the cooling system 5-59
Checking the fuel pump 5-59
Checking the fuel and coolant tubes, replacing the tubes (if required) 5-59
Checking the water pump 5-59
Checking and adjusting the fuel injection and Injection time 5-59

5-18
Maintenance 5.8. Service procedure

5.8. Service procedure

5.8.1. Pre-start checklist

Cooling system – checking the coolant level,

toping up coolant

See section "Cooling system – checking the coolant level, topping

up coolant" on page 3-41.

Checking the engine oil level – topping up oil

See section "Checking the engine oil level – topping up oil" on

page 3-42.

Checking the fuel level – refuelling

See section "Checking the fuel level – refuelling" on page 3-43.

Checking the controls

See section "Checking the controls" on page 3-44.

Checking the electrical connections

See section "Checking the electrical connections" on page 3-44.

Heater/air conditioning – checking rate of air flow

See section "Heater/air conditioning – checking rate of air flow"

on page 3-45.

Miscellaneous tests before starting work

See section "Miscellaneous tests before starting work" on

page 3-45.

5-19
5.8. Service procedure Maintenance

5.8.2. Maintenance upon demand

Checking the air-conditioning system

Check the air-conditioning system twice a year, in spring and

autumn.

Checking the coolant level

WARNING
If the liquid gets into your eyes or on your hands, it may
cause loss of sight or frostbite: Therefore never loosen any
part of the refrigerant circuit.

Operate the cooler of the air-conditioning system for 5 - 10

minutes, then touch the high pressure portion and low pressure
portion of the compressor (or high pressure hose and low
pressure hose joint) with your hand. At the same time, inspect the
flow of coolant (R134a) through the sight glass to check the gas
level.

Contact your Komatsu dealer for this inspection.

The sight glass is installed next to the receiver at the side of the
condenser. To this end the ladder at the right must be removed
and the condenser folded out.

Color condition Normal Abnormal

High pressure pipe is hot. High pressure pipe is
Amost no difference in
Temperature of high and Low presure pipe is cold. warm. Low pressure pipe is
temperature between high
low pressures pipes Clear difference in cold. Little difference in
and low pressure pipes.
temperature. temperature.
Almost transparent. All Bubbles are always visible. Opaque substance is
bubbles disappear if the Sometimes becomes visible in the fluid.
engine speed is increased transparent, or white
or reduced. bubbles appear.
Sight glass

Some parts contaminated Some parts heavily stained

Pipe connections Properly connected.
with oil. with oil.
Coolant level correct, no Ther may be a leak Almost all coolant has
General conditions of
abnormalitities. Ready for somewhere. Call service leaked out. Contact service
cooler
use. repair shop for inspection. repair shop immediately.

5-20
Maintenance 5.8. Service procedure

Checking the window washing-fluid level, adding

fluid

Check the washing-fluid level in washer tank. When the fluid has
run short, add window washing fluid for cars.

To prevent the nozzles from clogging, be careful not to let dust get
into the fluid.

5-21
5.8. Service procedure Maintenance

5.8.3. Maintenance after first 50 service hours

Engine – changing oil and replacing the oil filter

cartridge

See section "Engine – changing oil and replacing the oil filter
cartridge" on page 5-30.

Check condition of V-belt

See section "Check condition of V-belt" on page 5-32.

Check tension of generator V-belt and adjust

See section "Check tension of generator V-belt and adjust" on

page 5-33.

Check and adjust tension of air conditioning

(option) compressor V-belt

See section "Check and adjust tension of air conditioning (option)

compressor V-belt" on page 5-34.

Hydraulic system – replacing the filter insert

See section "Hydraulic system – replacing the filter insert" on

page 5-52.

Check and tighten wheel nuts

See section "Check and tighten wheel nuts" on page 5-27.

Front and rear axle – oil change

See section "Front and rear axle – oil change" on page 5-54.

Transfer box gearing – changing oil

See section "Transfer box gearing – changing oil" on page 5-56.

5-22
Maintenance 5.8. Service procedure

5.8.4. Maintenance every 50 operating hours

Cooling system – checking the cooling system,

coolant level in the radiator and expanion tank

WARNING

Danger of being burnt! The coolant is under pressure if
the engine is hot. Hot coolant may squirt out during
opening.

Check the coolant level only after the engine has

sufficiently cooled down. Open the cover of the radiator
(arrow) by turning it slowly so that the pressure can
escape.

DANGER

Danger of fire! Antifreeze may ignite at the hot engine!

Wait until the engine has cooled down, before refilling

antifreeze.

1. For maintenance operations, park and secure machine as

described in chapter "5.1. Maintenance guide" on page 5-2.

2. Stop the engine and let it cool down.

3. Open the engine cover.

4. Open maintenance flap on the right-hand side of machine.

5. Turn the radiator cap (arrow) slowly to the first stop and let
the pressure escape. Then press the cap down and turn
further to remove.

6. Check that the radiator is filled up to the overflow with

coolant. If not then top up to the overflow with coolant.

7. After tooping up, fit the radiator cap and tighten.

8. Check that the coolant level in the expansion tank is between

the marks FULL and LOW.

9. Top up to the full mark if required.

10. After tooping up, refit the tank cap and tighten.

5-23
5.8. Service procedure Maintenance

If coolant has been topped up:

11. Start the engine fully and open the heater.

12. Run the engine until warm.

13. Check points 2. to 7. again.

NOTE
If coolant has been toppe up regualry in the radiator or
expansion tank, then the system should be checkesd by your
local Komatsu dealer an repaired if required.

Fuel tank – draining off water and dirt deposits

14. Place a container under the drain plug of the fuel tank (see
arrow).

15. Open the drain plug, drain off water and dirt.

16. Close the drain plug when clean fuel starts to leak out.

5-24
Maintenance 5.8. Service procedure

Service brake – checking the oil level, refilling oil

WARNING

Danger of accidents! If the oil level is too low, the service
brake may break down!

If the brake fluid supply control lamp lights up, you must
immediately stop and check the oil level. GK100867

CAUTION

Danger of accidents! If you use usually available brake
fluid for filling up, the operational efficiency of the brake
system may be impaired!

Use only the prescribed oil for filling up! Do not use
brake fluid! Pay attention to utmost cleanness!

1. Position and secure the machine for maintenance work as

described in chapter "5.1. Maintenance guide" on page 5-2.

2. Open maintenance flap on the right-hand side of machine.

3. Check brake oil level on compensating tank (2). The oil level
must be below the upper edge of the compensation tank
(marking).
2
4. If the oil level is too low check the braking system.

5-25
5.8. Service procedure Maintenance

Battery – checking the acid level

WARNING

Danger of injury! The battery contains strongly
aggressive battery acid which may squirt out and burn
your eyes!

Carry goggles and rubber gloves if you work on the

battery. Immediately rinse your eyes or skin using plenty
of water and go to see a doctor.

Gases which may explode can form inside in the battery!

Go not come with open fire or sparks into proximity of

the battery. Do not smoke.

1. For maintenance operations, park and secure the machine as

described in chapter "5.1. Maintenance guide" on page 5-2.

2. Check the battery and pole terminals for proper fit.

3. Clean the environment of the plugs.

4. Remove all plugs and check whether the battery acid is at the
acid level markings. Refill distilled water if the acid level is too
low.

NOTE
In cold weather, refill distilled water only immediately before
the starting the machine. The water can then mix with the
battery acid and does not freeze.

5. Measure the specific density of the battery acid and read off
the battery charging using the following conversion table.

Temperature
Battery
20°C 5°C -10°C -25°C

Charge Specific Density (kg/l)

full 1,28 1,29 1,30 1,31

half 1,20 1,21 1,22 1,23
empty 1,12 1,13 1,14 1,15

6. Recharge insufficiently charged batteries.

7. Lock the cells with the cleaned plugs.

5-26
Maintenance 5.8. Service procedure

Battery – re-charging the battery

Disconnect cable from negative (-) battery terminal before

charging. Otherwise the generator will be damaged by
excessive voltage peaks.

Remove all battery plugs before re-charging to ensure

sufficient ventilation.

To prevent gas explosions, do not come near the battery with

fire and do not produce any sparks.

Interrupt the charging process if the temperature of the

battery acid exceeds 45°C.

Switch off the battery charger, as soon as the battery is re-

charged.If the battery is overloaded, the following situations
may occur:

 The battery may be overheated

 Decrease in the battery acid volume
 Damage of the electrode plates.

Do not mix up the cables (positive (+) and negative (-)).

Before performing maintenance operations, remove all cables

from the battery poles. Only exceptions: acid level check or
the measurement of the specific density.

Check and tighten wheel nuts

WARNING
Loose nuts can cause severe accidents!
Check the wheel nuts regularly and tighten them where
necessary.

Tighten loose wheel nuts.

Tightening torque: 450 - 500 Nm

NOTE
If a threaded bolt breaks, then all the threaded bolts of the
wheel in question must be replaced.

GK100915

5-27
5.8. Service procedure Maintenance

Lubrication

Lubrication points on boom

DANGER

If you perform maintenance operations at a machine
which is not properly parked and secured, severe
accidents may occur!

Park the machine on firm, level ground and secure it

before starting the maintenance operations.

1. Park and secure machine for the maintenance operations as

described in chapter "5.1. Maintenance guide" on page 5-2.

2. Clean the grease nipples which are indicated by the arrows.

3. Use a grease gun to press sufficient grease into the grease

nipples..

(1) Lifting cylinder right and left side (2 locations each )

(2) Rocker arm (2 locations)
(3) Boom right and left side (2 locations each )
(4) Tipping cylinder (2 locations)

4. Remove the old grease which is extruding at the bearings.

NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.

5-28
Maintenance 5.8. Service procedure

5.8.5. Maintenance every 100 operating hours

All maintenance operations to be performed after 50 hours of
operation fall also into this maintenance category.

Water separator – removing water and dirt

deposits

Keep a container ready for collecting the liquid from the water
separator (1).

1. Loosen the drain plug (2).

2. Let the water run off. 1

3. Screw in and tighten the drain plug.

4. Vent fuel system (see section "Purging the fuel system" on

page 5-42).

5-29
5.8. Service procedure Maintenance

5.8.6. Maintenance after the first 250 operating hours

All maintenance operations to be performed after 50 and 100
hours of operation fall also into this maintenance category.

Engine – changing oil and replacing the oil filter

cartridge

WARNING

Frequent skin contact with used engine oil may cause
skin lesions!
Thoroughly remove any engine oil adhering to your skin.

Hot engine oil may cause scalding!

Wear rubber gloves and place the oil trough under the
discharge opening in such a way that you do not get in
contact with the oil when it is running out.

CAUTION

There is danger of severe accidents, if you perform
maintenance work at a machine that has not been parked
and secured correctly!

Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.

Do not perform an oil change, unless the engine is switched off

and at operating temperature.

1. Before you start maintenance work, park and secure the

machine as described in the chapter "5.1. Maintenance 1
guide" on page 5-2.

2. Loosen the screw (1) at the bottom cover plate (2) and swivel
the cover plate to the side.
2
3. Put the oil trough under the drain screw (6).

4. Remove the cover cap (4) from the drain valve.

5. Screw on the drain hose (5) on the drain valve (6). This will
cause the drain valve to open. 6

6. Drain the oil.

4
7. Check the removed oil for metal parts or undesired material. If
the oil contains such particles, inform the responsible
3
Komatsu dealer.
5
8. Detach drain hose (5) from drain valve (6). This causes the
drain valve to close.
GK100866
9. Fit cap back onto drain valve.

5-30
Maintenance 5.8. Service procedure

10. Turn the filter screwdriver anti-clockwise to unscrew the filter

cartridge (7).

11. Clean the filter holder. Completely fill up the new filter
cartridge with engine oil. Slightly oil both the gasket and the
thread of the cartridge with engine oil. Screw in the filter
cartridge again. 7
12. When installing the filter cartridge, make sure that the sealing
surface of the cartridge slightly touches the filter holder. Then,
tighten the filter cartridge according to the filter
manufacturer's specification.

13. Tighten lower cover plate (2) again.

14. After changing the filter cartridge, pour clean engine oil into
the oil filler neck (8) until the oil level reaches the (H) marking
on the dipstick. 8
For details on recommended engine oils see section
"5.4. Lubricants, fuels and filling capacities" on page 5-12.

15. Close the oil filler.

16. Let the engine run in idle for about five minutes and check
whether oil is leaking out.

17. Switch off the engine.

18. Wait about ten minutes, then check the oil level again. The oil
level must be between the 'H' and 'L' markings on the oil
dipstick.

For further details see section "3.5. Checks and adjustments

prior to starting work" on page 3-39. 9
GK100864

5-31
5.8. Service procedure Maintenance

Check condition of V-belt

Check whether the generator’s V-belt or the air conditioning

compressor’s (option) V-belt shows any signs of cracks. permissible

Transverse cracks in the direction of the belt width are

permissible.

Longitudinal cracks in the direction of the belt length which do

not bisect the transverse cracks, missing sections or
damaged fabric layers are not permissible.
not
In such an instance the drive belt must then be changed.
permissible
GK100912

5-32
Maintenance 5.8. Service procedure

Check tension of generator V-belt and adjust

WARNING

There is danger of severe accidents, if you perform
maintenance work at a machine that has not been parked
and secured correctly!

Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.

Danger of injuries! When the engine is in operation, there

is danger of severe injuries by moving parts within the
engine compartment! Do not work within the engine
compartment, while the engine is in operation.

1. Before you start maintenance work, park and secure the

machine as described in the chapter "5.1. Maintenance 2
guide" on page 5-2.

2. Press down the V-belt in the middle of the longest straight

part (1). You should be able to press the V-belt down about
10 - 15 mm.

If you can press down the V-belt more than 10 - 15 mm,

adjust the tension as follows:
1
3. Remove V-belt covering.

4. Loosen the fastening screw (2) at the generator.

5. Loosen the connecting screw between the generator and the

guide rail.

6. Loosen the fastening screw at the guide rail.

7. Tilt the generator to adjust the tension of the V-belt.

8. Fasten the generator and the guide rail.

9. Check the tension of the V-belt and re-adjust it, if required.

5-33
5.8. Service procedure Maintenance

Check and adjust tension of air conditioning

(option) compressor V-belt

WARNING

There is danger of severe accidents, if you perform
maintenance work at a machine that has not been parked
and secured correctly!

Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.

Danger of injuries! When the engine is in operation, there

is danger of severe injuries by moving parts within the
engine compartment! Do not work within the engine
compartment, while the engine is in operation.

1. Position and secure the machine for maintenance work as

described in chapter "5.1. Maintenance guide" on page 5-2. 2
3
2. Press V-belt downwards at middle of longest straight section
(1). You should be able to press the V-belt down about
10 - 15 mm.

3. Loosen fastening screws on tensioner pulley (2) slightly. 1

4. Use the tensioning lever (3) to tension the compressor’s V-

belt. 2

5. Retighten fastening screws on tensioner pulley (2).

6. Check V-belt tension and re-adjust if necessary.

5-34
Maintenance 5.8. Service procedure

Front and rear axle – checking the oil level

CAUTION

There is danger of severe accidents, if you perform
maintenance work at a machine that has not been parked
and secured correctly!

Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.

Before you start maintenance work, park and secure the machine
as described in the chapter "5.1. Maintenance guide" on
page 5-2.

Planet gear

1. Start engine, raise work unit and drive the machine until the
oil level marking at the planetary gearing of the wheel which
you are checking is in horizontal position. Switch off engine.
Lower work unit and apply parking brake.

2. Unscrew the locking screw (1) of the drill hole.

3. Check the oil level. The oil level must reach up to the bottom
edge of the check drill hole.

4. If the oil level is too low, top up oil via the check drill hole of
the screw plug.
1
For details on recommended oils, see section
"5.4. Lubricants, fuels and filling capacities" on page 5-12.

5. Tightly screw in the screw plug.

2
6. Check the oil level at the other wheel of the front and rear
axle. For this purpose, proceed as described under points 2
through 5.

Differential

7. Unscrew the locking screw (2) of the drill hole at the front
axle. Check the oil level as described under points 3 through
in section "Planet gear".

8. Unscrew the locking screw (3) of the drill hole at the rear axle.
Check the oil level as described under points 3 through 5 in
section "Planet gear".

5-35
5.8. Service procedure Maintenance

Air filter – checking and cleaning the filter insert

Structure of the air filter

The air filter consists of the air filter housing, the dust exhaust
valve, the filter cartridge and the safety filter.

Maintenance demand

If the air filter warning indicator lights up, the air filter cartridge is
dirty. You must clean or exchange it immediately.

The filter insert has to be checked for perfect condition and be

cleaned every 250 operating hours, no matter whether the control
light is lit or not. If the filter insert is damaged or deformed, it must
be exchanged.

A dirty safety filter indicates that the filter cartridge is damaged. In

GK100867
this case, both - filter cartridge and safety filter - must be
exchanged.

Removing the filter cartridge

WARNING

Danger of injury! When the engine is running, you may
hurt yourself on the movable components inside the
engine room!

Do not perform any operation in the engine room with the

engine running!

1. For maintenance operations, park and secure machine as

described in chapter "5.1. Maintenance guide" on page 5-2.

2. Open maintenance flap on the left-hand side of machine.

3. Pull on air filter housing cap’s (1) lock, turn the cap to the left 1
and remove.

4. Pull out the filter cartridge (2).

5. Clean thoroughly the interior of the filter housing with a cloth.

5-36
Maintenance 5.8. Service procedure

Cleaning or exchanging the filter cartridge

Depending on the degree of contamination, the air-filter insert can

be cleaned using compressed air or water to which a mild
detergent can be added.

NOTE
The air-filter insert must be replaced, if the air-filter control
light lights up only short time after cleaning.

Do not clean the safety filter (see section "Air filter – replacing the
filter insert, replacing the safety filter" on page 5-45).

Cleaning with compressed air

CAUTION
Whirled up dust particles may hurt the eyes! Carry goggles if
you clean the filter cartridges with compressed air.
Dangerous dust particles may irritate the lung!
Carry a dust-protection mask if you clean the filter cartridges
with compressed air.

Blow out the air filter cartridge with dry compressed air (max.
6 bars) starting with the interior and then proceeding to the
outside. The air nozzle is to be moved up and down the paper
with a minimum distance of 3 cm. You can stop the cleaning if
no more dust comes out.

Do not clean the cartridge by hitting it or by beating it against

other objects.

Cleaning with water and cleaning agents

After the dust has been blown out, the filter cartridge can also
be additionally cleaned using warm water with a mild cleaning
agent (max. 50°C) to remove adhering oil, grease, soot, etc.
For this purpose, swing the cartridge back and forth in the
solution.

Then, rinse the filter cartridge with clean water starting with
the inside and then proceeding to the outside (max. 3 bars)
and let it dry at a temperature of max. 50°C.

5-37
5.8. Service procedure Maintenance

Checking the filter cartridge

Usually, it is required to check each air filter cartridge before it is

re-installed. For this purpose, insert a into the cartridge and
visually check the filter paper against the transmitted light. If you
detect small holes or spots on which the paper is thin, the insert is
defective and must be replaced.

Check filter cartridges for damaged seals.

NOTE
Also new filter cartridges must be checked before they are
assembled.

Assembling the air filter cartridge

1. Check the safety filter for proper fit.

2. Insert the filter cartridge into filter housing in such a way that
the seal of the insert locks firmly on the collar of the housing
rear panel.

3. Place cap of air filter housing such that the cap’s (3) support
faces downwards.

NOTE
If the control lamp lights up again after a short time, you
must replace both, the air filter cartridge and the safety filter
(refer to chapter "Air filter – replacing the filter insert,
replacing the safety filter" on page 5-45).

5-38
Maintenance 5.8. Service procedure

Radiator – cleaning the radiator segments

The radiator segments must be checked daily and cleaned with

compressed air, if required.

If your machine is equipped with a “reverse flow fan”, the cooler

fins can be cleaned by pressing the reverse flow fan rotary
control, see section "19. Reverse flow fan rotary switch – option"
on page 3-15.

NOTE
Do not hold the compressed air nozzle or water nozzle too
close to the radiator segments. Use no scrubber for cleaning
since the plates may be damaged.

5-39
5.8. Service procedure Maintenance

Lubrication

NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.

Lubrication points on articulated steering

DANGER

If you perform maintenance operations at a machine
which is not properly parked and secured, severe
accidents may occur!

Park the machine on firm, level ground and secure it

before starting the maintenance operations.

1. For maintenance operations, park the machine as described

in chapter "5.1. Maintenance guide" on page 5-2.

2. Clean the grease nipples which are indicated by the arrows.

1
3. Use a grease gun to squeeze as much grease into the
lubricating nipple until the grease begins to exit at the top and
bottom of the articulated steering.

(1) Articulated steering (1 Location)

4. Remove the old grease which is extruding at the bearings.

Lubrication points at steering cylinder

1. Position and secure the machine for maintenance work as

described in chapter "5.1. Maintenance guide" on page 5-2.

2. Clean the marked lubricating nipple.

3
3. Use a grease gun to squeeze a sufficient quantity of grease
into the lubricating nipple.

(2) Steering cylinder at front, right and left (1 location each ) 2

(3) Steering cylinder at rear, right and left (1 location each )
GK100928

4. Remove the old grease that has exited at the bearings.

5-40
Maintenance 5.8. Service procedure

Lubrication points at articulated shaft

1. Position and secure the machine for maintenance work as

described in chapter "5.1. Maintenance guide" on page 5-2. 4

2. Clean the marked lubricating nipples.

3. Use a grease gun to squeeze a sufficient quantity of grease

into the lubricating nipples.

(4) Front articulated shaft (1 Location)

(5) Rear articulated shaft (1 Location)

4. Remove the old grease that has exited at the bearings.

5-41
5.8. Service procedure Maintenance

5.8.7. Maintenance every 500 operating hours

All maintenance operations to be performed after 50 and 250
hours of operation also fall into this maintenance category.

Fuel filter – changing the fuel filter and filter

element

CAUTION

Danger of fire! Fuel may ignite on hot surfaces!

Only change the filter elements if the engine has

sufficiently cooled down. Stay away with open fire or
sparks while handling with fuel. Do not smoke.

1. For maintenance operations, park and secure machine as

described in chapter "5.1. Maintenance guide" on page 5-2 . 4

2. Clean the area around the fuel filter (1).

3. Unscrew the filter element counterclockwise with the filter

screwdriver.

4. Clean the filter head.

5. Fill up the new filter element with clean fuel.

6. Lubricate the sealing faces of the filter element lightly with

engine oil.

7. During reassembly, re-tighten the filter element manually, until

the seal is fitting. Then re-tighten the filter element. (Consider
the specifications of the filter manufacturer on the filter).

8. Then purge the fuel system (see section "Purging the fuel
system" on page 5-42).

9. Start the engine and check for leaks.

Purging the fuel system

See chapter "4.1. When the machine runs out of fuel" on

page 4-2.

5-42
Maintenance 5.8. Service procedure

Cleaning the water separator

Keep a container ready for collecting the liquid from the water
separator (1).

1. Loosen the drain plug (2).

2. Let the water and fuel run off. 1

3. Loosen the screw (4) at the bottom side.

4. Remove the housing (5) from the cover.

5. Remove the gasket (6).

6. Remove the filter element (7), the gasket (8) and the spiral
spring (9).

7. Remove water and dirt from the housing.

8. Clean the filter element and blow-dry it with compressed air.

2
9. Check the filter element and replace it, if it is damaged.

10. Re-insert the spiral spring, the gasket (8) and the filter
element.

11. Position the gasket (6) and the housing.

12. Insert a new o-ring (10).

13. Re-tighten the drain plug at the bottom side. 3

14. Remove the attachment screw (3).

15. Fill up the water separator with fuel.

6
16. Re-tighten firmly the attachment screw.

10

4
GK100932

5-43
5.8. Service procedure Maintenance

Transfer box gearing – checking the oil level and

refilling oil

NOTE
If the engine is not running, the oil level in the transfer box
can significantly rise. Therefore, only check the gear oil level
with the engine running idle at operating temperature. The
gearshift assembly must be in neutral position.

1. For maintenance operations, park and secure machine as

described in chapter "5.1. Maintenance guide" on page 5-2.
1
2. Clean the screw plug (1) and the adjacent environment.

3. Unscrew the screw plug.

4. Check the oil level. The oil level must be at the lower edge of
the control drill hole of the screw plug.

5. If the oil level is too low, fill up with oil using the control drill
hole of the screw plug.

6. Clean the screw plug and insert a new packing ring.

7. Re-tighten firmly the screw plug.

5-44
Maintenance 5.8. Service procedure

Air filter – replacing the filter insert, replacing the

safety filter

Replacing the filter insert

If the filter element is replaced for the third time in sequence, it is

required to replace also the safety filter.

1. Open the air filter and remove the air-filter insert (1). Proceed
as described in chapter "Air filter – checking and cleaning the
filter insert" on page 5-36.

2. Use a source of light (e.g. torch) to check the new air filter for
damages.

3. Re-install the air-filter insert as described in chapter "Air filter

– checking and cleaning the filter insert" on page 5-36. AE063690

Replacing the safety filter

If the filter element is replaced for the third time in sequence, it is

required to replace also the safety filter.

1. Open the air filter and remove the air-filter insert (1). Proceed
as described in chapter "Air filter – checking and cleaning the
filter insert" on page 5-36.

2. Pull out the safety filter (2).

3. In order to prevent that dust enters the interior of the engine, it

is required to the air aspiration opening of the engine with a
clean cloth or similar.

4. Clean the interior of the air-filter enclosure and remove the

cloth from the air aspiration opening.

5. Use a source of light (e.g. torch) to check the new safety filter
for damages. If it is in perfect condition, press it firmly into
place. 1 2

6. Re-install the air-filter insert as described in chapter "Air filter

– checking and cleaning the filter insert" on page 5-36.

5-45
5.8. Service procedure Maintenance

Heater/air conditioning – cleaning/replacing filter

fleece or cleaning condenser

Clean filter fleece of heater unit

NOTE
If the filter fleece is too dirty it must be replaced.

1. Remove screws on the front cover (1) on the driver's cab

(4 screws).

2. Withdraw filter (2) from the heater unit (3).

3. Clean the filter in warm water (30 - 40°C) which has had a
little household cleaning solvent added to it.

Caution: Neither rub the filter fleece nor wring it out.

1
4. Allow the filter fleece to dry.

5. Insert dried filter fleece (2) back into the heater unit (3).

2
3

6. Switch on the blower and check the air flow at the air-outlet
nozzles (4), (5) and (6) to the right and left of the steering
column. 4

Caution: The right and left circulating air jets (7) must be
open. 5
7
7. If the air flow is still too weak the filter fleece must be
replaced. 6

8. Screw front cover (1) back on.

5-46
Maintenance 5.8. Service procedure

Cleaning the condenser of air conditioning

NOTE
Do not wash the condenser with a steam cleaner. Otherwise,
the condenser will get hot and may break down.

If there is mud or dust sticking to the air conditioner condenser,

clean it with water.

If the water pressure is too high, the fins may get deformed. When
washing with a high pressure washing device, apply the water
from a reasonable distance.

Cleaning

1. Unscrew the steps on the right side (4 screws).

2. Swing out the steps together with condenser as far as it will

go.

3. Clean the condenser with water.

4. Screw the steps and condenser back into place (4 screws).

ALS-pressure accumulator (Option) - checking

gas pressure

Ask your Komatsu dealer to check the accumulator gas

pressure.(Gas pressure: 24 bar)

5-47
5.8. Service procedure Maintenance

Lubrication

NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.

Lubrication points on doors and engine hood

DANGER

If you perform maintenance operations at a machine
which is not properly parked and secured, severe
accidents may occur!

Park the machine on firm, level ground and secure it

before starting the maintenance operations.

1. For maintenance operations, park the machine as described

in chapter "5.1. Maintenance guide" on page 5-2.

2. Clean the lubrication points.

3. Lubricate the door and engine hood hinges.

Door hinges (4 Locations)

Engine hood hinges (2 Locations)

4. Remove the old grease.

5-48
Maintenance 5.8. Service procedure

5.8.8. Maintenance every 1000 operating hours

All maintenance operations to be performed after 50, 250 and 500
hours of operation fall also into this maintenance category.

Cooling system – exchanging coolant and

cleaning the system

WARNING

Danger of being burnt! The coolant is under pressure if
the engine is hot. Hot coolant may squirt out during
opening.

Check the coolant level only after the engine has

sufficiently cooled down. Open the cover of the radiator
(arrow) by turning it slowly so that the pressure can
escape.

DANGER
Danger of fire! Antifreeze may ignite at the hot engine! Wait
until the engine has cooled down, before refilling antifreeze.

NOTE

The coolant must be exchanged after max. two years.

While preparing the coolant, make sure to adhere to the

prescribed mixing proportions to ensure a freezing
protection up to -37°C! This is also valid for countries
with moderate climate.

The coolant has to consist of 50 vol.% coolant additive and

50 vol.% water. Only monoethylene glycol and dieethylene glycol
are permitted as coolant additives which are both contained in
commercially available standard coolants.

If the water contains too much lime, the cooling system may be
impaired. In this case, use a mixture of potable water and distilled
or deionized water.

5-49
5.8. Service procedure Maintenance

Draining off the coolant

1. Switch off the engine and let it cool down.

2. Open maintenance flap on the right-hand side of machine. 1

3. Swivel the radiator cap (1) slowly to the side, up to the first
fixed stop, and let the pressure escape. Then press down the
cover, while proceeding with swivelling. Then, remove the
cover.

4. Remove screw (2) on lower cover plate (3) and swivel cover
plate to one side.

The coolant drainage hose is located behind the cover plate.

2

5. Open the drain cock (4) and allow coolant to drain off.

6. Close drain cock.

7. Tighten cover plate (3) again.

4

5-50
Maintenance 5.8. Service procedure

Cleaning the cooling system

NOTE
The cooling system may only be filled slowly since otherwise
the included air cannot escape completely. After filling up,
wait approx. 3 minutes and refill liquid, if required.

1. Fill up the cooling system slowly with cleaning fluid

( Ad her e to the s pec ific ati ons of the cl eani ng agen t 1

manufacturer).

2. With the radiator cap (1) opened, let the engine run for 5
minutes with a coolant temperature of approx. 80°C.

3. After the cleaning, switch off the engine and open the drain
valve (4) to let the entire cooling system run empty.

4. Re-lock the drain valve (4) and slowly fill the cooling system
with clean water.

5. Let the engine run for five minutes with a coolant temperature
of approx. 80° C.

6. Then, let the cooling system run empty again. If the extruding
water is not clean, the cooling system must be re-flushed until
the extruding water is clean. 4

7. Close the drain valve (4).

Filling up coolant

1. Empty and clean the expansion tank (5).

2. Prepare the coolant as prescribed.

3. Fill up the coolant slowly into the cooling system up to the

overflow shoot of the radiator.

4. To purge the cooling system while the radiator cap is 5

removed, let the engine run idle for five minutes with its lower
speed (rpm) and then for another five minutes with its top
speed. Fill up with coolant if the coolant level in the radiator is
dropping.

5. Switch off the engine, wait approx. three minutes and then
refill coolant up to overflow shoot of the radiator.

6. Re-lock the radiator.

7. Fill up coolant into the expansion tank (5), until the coolant
level is between the FULL and LOW markings.

5-51
5.8. Service procedure Maintenance

Hydraulic – ventilating the hydraulic oil tank

8. Loosen the feeding and ventilation screw (1) by turning it a

couple of rotations.

9. Start up the engine.

10. Bring the boom into its highest position.

11. Bring bucket into its tip-in position (up to its limit stop).

12. Re-tighten the feeding and ventilation screw. 1

Hydraulic system – replacing the filter insert

WARNING

Frequent contact between used hydraulic oil and skin
may cause skin lesions and other physical damage!

Wear rubber gloves when changing the filter. Thoroughly

wash off any hydraulic oil adhering to your skin.

1. Lower the work unit onto the floor.

2. Switch off engine.

3. Open maintenance flap on the right-hand side of machine.

2
4. Turn the inlet and ventilation screw (1) several revolutions to
let the pressure escape.

5. Clean the surface of the filter cap (2) and the area around the
filter cap. 1

6. Unscrew the filter cap.

7. Withdraw filter element on plug-in handle from filter.

8. Pull the filter element off the handle and dispose of the filter
element.

9. Clean the inner surface of the filter housing. Before you start
cleaning, check that there is no undesired material in the filter
housing.

10. Put the handle onto the new filter element.

11. Insert the new filter element into the housing.

GK100913
12. Screw on the filter cap and tighten it with 20 Nm.

13. Ventilate the system at the tank according to the specification

(see section "Hydraulic – ventilating the hydraulic oil tank" on
page 5-52.

14. Perform a test run and check that the system is tight.

5-52
Maintenance 5.8. Service procedure

Checking the tightening parts of the turbo-charger

Contact your responsible Komatsu dealer to have the tightening

parts checked.

Checking the play of the turbo-charger rotor

Ask your responsible Komatsu dealer to check the play of the

turbo-charger rotor.

Service Brake – checking, testing, changing oil

All repairs on the brake system must be performed by a garage

which is authorised by Komatsu.

Changing oil

Checking tubes and lines

Checking the brake disks for wear and tear

Adjusting the clearance of the brake disks

System pressures – checking and adjusting

All repairs on the brake system must be performed by a garage

which is authorised by Komatsu.

Valve play – checking and adjusting

Have the valve play checked and adjusted at an authorised

Komatsu garage.

Injection nozzles – checking and adjusting the ,

nozzle pressure and fuel-jet pattern

Have the nozzle pressure of the injection nozzles and the fuel-jet
pattern checked and adjusted at an authorised Komatsu garage.

Check pressure accumulator – gas pressure

During maintenance work, have your local authorised Komatus

dealer check the gas pressure of the pressure accumulator every
1000 operating hours. (pressure: 20 bar)

5-53
5.8. Service procedure Maintenance

Front and rear axle – oil change

WARNING

Frequent contact between used hydraulic oil and skin
may cause skin lesions and other physical damage!

Wear rubber gloves when changing the oil. Thoroughly

wash off any hydraulic oil adhering to your skin.

DANGER

There is danger of severe accidents, if you perform
mainte-nance work at a machine that has not been
parked and secured correctly!

Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.

Planetary gearing

1. Start engine. Raise work unit and drive the machine until the
drain plug (1) for the planetary gearing on the wheel where
you want to change the oil has reached its lowest point.
Switch off engine. Lower work unit and apply parking brake.

2. Place drip pan or container underneath the drain plug (1).

3. Unscrew drain plug (1) and drain oil into container.

4. Drive machine until the planetary gearing drain plug hole (1)
is in a horizontal (3 o'clock") position.

5. Fill planetary gearing with oil until the oil reaches the lower lip
of the drain plug hole (1).

6. Clean drain plug and attach clean, undamaged (or new) 1

washer.

7. Screw drain plug in tight.

8. Change oil in other wheels of the front and rear axle following
the same procedure as described under no. 1 - 7 above.

5-54
Maintenance 5.8. Service procedure

Differential

1. Place a drip pan or container underneath the oil drain opening

(2). 1 2 3

Remove the filler screw (1), the 3 drain plugs of the drain
holes (2) and the 2 inspection hole screws (3). Drain off oil.

2. Clean drain plugs and attach clean, undamaged (or new)

washers.

3. Screw drain plugs (2) in tight.

4. Pour oil in through the filler hole (1) until it reaches the lower
lip of the inspection holes (3).

5. Insert filler screw (1) and inspection hole screws (3) and
screw tight.
2 2

5-55
5.8. Service procedure Maintenance

Transfer box gearing – changing oil

WARNING

Frequent contact between used oil and skin may cause
skin lesions and other physical damage!

Wear rubber gloves when changing the oil. Thoroughly

wash off any oil adhering to your skin.

DANGER

There is danger of severe accidents, if you perform
mainte-nance work at a machine that has not been
parked and secured correctly!

Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.

Have an oil trough with a sufficient capacity ready.

1. Before you start maintenance work, park and secure the 1

machine as described in the chapter "5.1. Maintenance
guide" on page 5-2.

2. Unscrew the screw plugs (1) and (2) .

3. Drain the oil. 2

4. Clean the screw plugs and replace the gaskets.

5. Tightly screw in the screw plug (2).

6. Fill in oil via the check drill hole (1), until the oil reaches up to
the bottom edge of the check drill hole.

7. Tightly screw in the screw plug (1).

5-56
Maintenance 5.8. Service procedure

5.8.9. Maintenance every 2000 operating hours

All maintenance operations to be performed after 50, 250, 500
and 1000 hours of operation also fall into this maintenance
category.

Hydraulic system – oil change

WARNING

Frequent skin contact with used hydraulic oil may cause
skin damages and other injuries! Wear rubber gloves for
exchanging the filter. Wash any spilled hydraulic oil
thoroughly from your skin.

Danger of being burnt! The hydraulics tank is under

pressure. Hot hydraulic oil may squirt out and cause
injuries! Wear rubber gloves and hold the oil trough
under the discharge hole in such a way that you cannot
come into contact with the extruding oil.

Keep a collecting container with sufficient capacity ready.

1. Park the machine on level ground.

2. Lower the work unit onto the ground.

3. Switch off the engine.

4. Secure the articulated steering with the articulated steering

lock (1).

5. Open maintenance flap on the right-hand side of machine.

6. Unlock the feeding and ventilation screw (2) by turning it

slowly to let the pressure escape.

5-57
5.8. Service procedure Maintenance

7. Loosen the screw plug (3) of the hydraulic oil tank and let the
oil run off.
3
8. Re-tighten the screw plug with its seal being in perfect
condition.

9. Unscrew the feeding and ventilation screw (2).

10. Fill up oil until the oil level is between the centre and top edge
of the inspection glass (4).

11. Start up the engine.

12. Raise and lower the work unit several times, while operating
the bucket at the same time.

13. Lower the bucket onto the ground and bring it into mining
position.
4
14. Check the oil level with the engine running idle in its low
speed position.

15. Ventilate the hydraulic oil tank (see section "Hydraulic –

ventilating the hydraulic oil tank" on page 5-52).

NOTE
Do not fill up with too much hydraulic oil! Otherwise, the
p r e s s u r e i n t h e h y d r a u l i c o i l c o n ta i n e r i n c r e a s e s
inadmissibly high.

5-58
Maintenance 5.8. Service procedure

Cooling system – checking the antifreeze content

of the coolant

Check the antifreeze content of the coolant. The mixing

proportion must always be adjusted to a temperature of -37°C -
even in countries with moderate climate. During filling up, pay
attention to the prescribed mixing proportion.

The coolant must contain antifreeze in all climate regions. The

antifreeze does not only decrease the freezing point but also
increases the boiling point. It lubricates movable components and
lip seals and prevents corrosion and foam formation.

Checking the cooling system

Let the cooling system check be performed at a garage which is

authorised by Komatsu.

Checking the fuel pump

Let the fuel pump be checked at a garage which is authorised by

Komatsu.

Checking the fuel and coolant tubes, replacing the

tubes (if required)

Have the fuel and coolant tubes checked and replaced, if

required, at an authorised Komatsu garage.

Checking the water pump

Let the water pump be checked at a garage which is authorised

by Komatsu.

Checking and adjusting the fuel injection and

Injection time

Let the injection time be checked at a garage which is authorised

by Komatsu.

5-59
5.8. Service procedure Maintenance

5-60
Technical data

6-1
6.1. Technical data Technical data

6.1. Technical data

WA115-3

Performance

Model YANMAR / S40 106E-IHC

Horsepower (ISO 9249) 65 kW (88 PS)

Torque, max. (DIN 70020) 330 Nm / 1,500 rpm

Engine
Starting motor 12 V / 39 kW
Alternator 12 V / 80 A

Battery 12 V / 92 Ah

Driving Speed 1st Driving Range 0 - 7 km/h

forward and backwards
2nd Driving Range 0 - 20 km/h
Standard type

Driving Speed 1st Driving Range 0 - 8 km/h

forward and backwards
2nd Driving Range 0 - 15 km/h
High speed version overdrive switched on

Driving Speed 1st Driving Range 0 - 15 km/h

forward and backwards
2nd Driving Range 0 - 35 km/h
High speed version overdrive switched on

Tractive force, max. 6,000 kg

Outside Counterweight 4.635 mm

Min. turning radius
Outer Edge Bucket, Standard 5.150 mm

Bucket, Standard 42R-70-12110 / 1,3 m³

6-2
Technical data 6.2. Noise emission levels

6.2. Noise emission levels

Two labels must be attached bearing details on the machine’s
noise level.

In accordance with ISO 6396:

1 plate for the sound pressure level LpA = 73 dB/A

In accordance with EC Directive 2000/14/EG:

1 plate for the sound power level LWA= 101 dB/A

No alterations may be made to the machine which could have an

influence on the noise emission levels.

6.3. Vibration level

When used for its intended purpose, levels of vibration for the
earthworking machine transmitted from the operator's seat are
lower or equal to the test vibrations for the relative machinery
class in compliance with ISO 7096. The actual accelaration value
of the upper limbs is less than 2.5 m/s². The actual acceleration
value for the body is less than 0.76 m/s². These values were
determined using a representative machine and with the help of
the measurement procedures that are defined in the directives
ISO 2631/1 and ISO 5349.

6.4. Limit values for slopes

Maximum slope angle for machine operation

If operating the machine on a slope, its angle must not exceed

35° uphill, downhill or sideways. If you angle the machine at more
than 35° during operation, the motor, transmission, hydraulic
system or axles, will not be supplied with sufficient oil and can be
damaged.

A uphill 35°
B downhill 35°
C sideways 35°

GK100880

6-3
6.4. Limit values for slopes Technical data

6-4
Special equipment and attachments

7-1
7.1. ALS-electronics Special equipment and attachments

7.1. ALS-electronics
Always read this section before installing and operating the ALS-
electronics as safe as possible.

7.1.1. Structure and functioning principle of the ALS-electronics

The ALS-electronics uses the hydraulic spring effect of the
hydraulic accumulator installed to the circuit at the lift cylinder
base end to absorb the vibration of the chassis when the
machine is travelling. This enables the machine to travel
smoothly at high speed.

The ALS-electronics consists of the ALS-electronics switch,

hydraulic accumulator and solenoid valves. When the travel
damper switch is turned ON, the solenoid valves open, the
circuit at the lift cylinder base end is connected with the
hydraulic accumulator.

7.1.2. Precautionary measures for switching on the ALS-electronics

WARNING
If the ALS system is switched on during a journey, or when
the working attachment is in raised position, it may move up
or down depending upon the bucket load.
For this reason, extreme caution is advised when operating
the switch.

When inspecting and servicing the machine, ALS lower the work
equipment to the ground then turn the ALS-electronics switch
OFF before beginning to service.

NOTE
The ALS system is activated when the transmission is
shifted in 2nd gear and the machine is traveling at a speed
higher than 5 km/h.

7-2
Special equipment and attachments 7.1. ALS-electronics

7.1.3. Operating the ALS-electronics

Switching ON the ALS-electronics

1. Precondition:

Speed range No. 2 must be switched on in order to ensure

that the ALS system can be activated. To do this, press the
"Driving range up to 20 km/h" button.

GK100871

2. Press the ALS-electronics switch.

The green control lamp in the switch lights up.

 If the machine drives faster than 5 km/h, the ALS-

electronics is automatically activated and the ALS-
electronics control lamp lights up on the dash panel.

 If the machine drives slower than 5 km/h, the ALS-

electronics is switched off and the control lamp on the
dash panel goes out. GK100819

 However, the control lamp in the ALS-electronics switch

remains lit in green.

NOTE

To ensure that the ALS system can remain fully effective
when the machine is underway, do not tilt the bucket all
the way through till it touches the limit stops.

Do not support the boom when on the road.

Switching OFF the ALS-electronics

1. Press the ALS-electronics switch.

The control lamp in the switch goes out.

7-3
7.1. ALS-electronics Special equipment and attachments

7.1.4. Precautions when handling the accumulator

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

Imme diatel y infor m y our K omatsu deal er, i f y ou de tect

malfunctions or defects of pressure accumulators.

Filling the pressure accumulator with gas or topping up gas in

the pressure accumulator is strictly limited to persons
authorised to handle highly pressurised gas.

Do not hit against the pressure accumulator.

Keep naked light and sources of heat away from pressure

accumulator.

Do not drill holes into the pressure accumulator.

Do not weld parts to the pressure accumulator.

The service technicians must depressurise the hydraulic

system before they can remove the pressure accumulator.

The service technician must let the gas escape before they
can disassemble the pressure accumulator.

7-4
Special equipment and attachments 7.2. Air condition

7.2. Air condition

NOTE
Only operate the air-conditioning with the engine running.
Run the air-conditioning for at least 10 minutes every month
irrespective of season. This prevents the compressor shaft
seal from drying out.

The windows and doors of the operator’s cab must be closed

when operating the air conditioning.

The circulating air jets (arrow) must be open.

We recommend ventilating the operator’s cab thoroughly first

when starting the machine and switching on the air conditioning if
the machine has been standing in bright sunshine for any length
GK100805
of time.

Switching on the air-conditioning

1. Start up the engine.

2. Turn the rotary switch (1) of the fan to position '4'.

3. Set the temperature control lever (2) to 'cold'.

4. Press the switch for the air conditioning.

The air conditioning system is now switched on and the

control lamp in the switch shines blue. GK100860

 The greatest cooling effect is achieved with this setting, 1 2

particularly if the engine is running at high revs.

 As soon as the required temperature has been reached,

turn the blowers down by one stage and carry out any
fur ther adju stment of the temper atur e us ing the
temperature control.

 The lowest blower setting can be used if only a low

cooling effect is required.

The air is distributed via the air ventilation nozzles on the left-
hand and right-hand side of the steering column.
GK100861

You may open or close the nozzles individually.

The exhaust direction can be varied using the diffusing disks.

7-5
7.2. Air condition Special equipment and attachments

7-6
Index

8-1
 Index

A Air-intake preheater ...................................... 3-27

Accelerator ..........................................................3-22 ALS electronics ............................................ 3-28
Adjusting driver’s seat .........................................3-46 Direction indicators ....................................... 3-27
Adjusting operator’s seat .....................................3-46 Driving direction switch ................................. 3-27
Air conditioning ......................................................3-7 Hazard warning lights ................................... 3-27
Adjusting compressor’s V-belt ......................5-34 Heated rear window ..................................... 3-28
Condenser ....................................................5-47 High beam .................................................... 3-29
Filter fleece ...................................................5-46 High speed ................................................... 3-27
Operation ........................................................7-5 Low beam ..................................................... 3-29
Air filter Warning beacon ........................................... 3-28
Changing air filter insert ................................5-45 Control lever .............................................. 3-17, 3-19
Changing safety filter ....................................5-45 Control lever for auxiliary functions ............ 3-20, 3-62
Cleaning filter insert ......................................5-36 Controls ................................................................ 3-4
ALS-electronics ..............................................3-8, 7-2 Control lamps ............................................... 3-24
Articulated steering lock ......................................3-34 Control lever ................................................. 3-17
Attachment Measuring indicators .................................... 3-24
Lowering .......................................................3-64 Operating lever ............................................. 3-17
Raising ..........................................................3-63 Pedals .......................................................... 3-21
Selecting .......................................................3-63 Warning lamps ............................................. 3-24
Automatic digging angle ......................................3-66 Controls and indicators (overview) ....................... 3-3
Automatic safety belt ...........................................3-49 Cooling system
Changing coolant ......................................... 5-49
B Checking antifreeze ...................................... 5-59
Battery Checking coolant level ........................ 3-41, 5-23
Battery main switch .......................................3-16 Cleaning coolant ........................................... 5-49
Charging .........................................................4-7 Cleaning cooler fins ...................................... 5-39
Checking acid level .......................................5-26 Temperature indicator .................................. 3-31
Connecting/disconnecting .............................2-10 Topping up coolant .............................. 3-41, 5-23
Safety instructions ........................................2-10
Booster cables ......................................................4-8 D
Brake pedal .........................................................3-21 Dimensions ......................................................... 1-19
Brakes Direction indicator lever ...................................... 3-18
Actuating .......................................................3-57 Driving
Braking on slopes .........................................3-58 Braking ......................................................... 3-57
Checking oil level ..........................................5-25 Braking on slopes ......................................... 3-58
Checking parking brake ................................4-10 Changing driving direction ............................ 3-55
Checking service brake ................................4-10 High speed ................................................... 3-54
Insufficient braking action .............................4-10 Long distances ............................................. 3-60
Parking brake ................................................3-18 Starting up .................................................... 3-53
Breaking in the machine ........................................1-8 Steering ........................................................ 3-56
Bucket level indicator ..........................................3-65 Stopping ....................................................... 3-59
Turning ......................................................... 3-56
C Driving direction switch ....................................... 3-11
CE-conforming equipment ..................................1-20
Changing driving direction ...................................3-55 E
Changing oil Emergency lowering .................................. 2-15, 4-11
Engine oil ......................................................5-30 Emergency steering ............................................ 4-11
Front axle ......................................................5-54 Engine
Hydraulics .....................................................5-57 Adjust generator’s V-belt .............................. 5-33
Rear axle ......................................................5-54 Changing engine oil ...................................... 5-30
Transfer box ..................................................5-56 Changing oil filter cartridge ........................... 5-30
Changing oil filter cartridge .................................5-30 Identification plate .......................................... 1-9
Control Starting ......................................................... 3-50
Control lever for auxiliary functions ...............3-62 Starting using booster cables ......................... 4-8
Multifunction lever .........................................3-61 Switching off ................................................. 3-52
Control lamp Technical details: ............................................ 6-2
Air conditioning .............................................3-29 Warm-up phase ............................................ 3-51

8-2
Index

Engine oil L
Checking oil level .......................................... 3-42 Lights
Draining ........................................................ 3-42 Headlamp flasher ......................................... 3-10
Top up .......................................................... 3-42 High beam .................................................... 3-10
EU Directives ........................................................ 1-3 Light switch .................................................. 3-10
Excavation work .................................................. 3-69 Low beam ..................................................... 3-10
Parking lights ................................................ 3-10
F Loading and securing ......................................... 1-26
Faults, in tabular form ......................................... 4-12 Loading work ...................................................... 3-67
Faulty brakes ....................................................... 3-74 Loading/securing the machine ............................ 3-79
Fire extinguisher .................................................... 2-6 Locking, machine ................................................ 3-75
Fire fighting ........................................................... 2-5 Low beam ........................................................... 3-10
Fire prevention ...................................................... 2-5 Lubricant, general ................................................. 5-6
First-aid kit ............................................................. 2-6 Lubricants, operating material
Forklift truck attachment ...................................... 3-73 and filling capacities ............................................ 5-12
Front axle Lubrication points
Changing oil .................................................. 5-54 Articulated shaft ........................................... 5-41
Checking oil level .......................................... 5-35 Articulated steering ...................................... 5-40
Fuel Attachment ................................................... 5-28
Checking fuel level ....................................... 3-43 Doors ............................................................ 5-48
Fuel gauge .................................................... 3-30 Engine hood ................................................. 5-48
Refuelling ...................................................... 3-43 Steering cylinder .......................................... 5-40
Winter operation ........................................... 3-85
Fuel system M
Fuel tank drain plug ...................................... 5-24 Machine
Replace filter cartridge .................................. 5-42 Breaking in ..................................................... 1-8
Venting ........................................................... 4-2 CE-conforming equipment ........................... 1-20
Fuses .................................................................. 3-36 Dimensions .................................................. 1-19
Driving .......................................................... 3-53
G Extended period of immobilisation ............... 3-88
Generator General view .................................................. 3-2
Adjusting V-belt ............................................ 5-33 Identification plate .......................................... 1-9
Loading/securing ................................. 3-78, 3-79
H Locking ......................................................... 3-75
Hazard warning lights ............................................ 3-5 Noise emission level ...................................... 6-3
Heated rear window ............................................ 3-13 Raising ......................................................... 1-26
Heating system ................................................... 3-38 Refuelling .............................................. 3-43, 4-2
High beam ........................................................... 3-10 Securing for transport ................................... 3-83
High speed .......................................................... 3-54 Shut down .................................................... 3-88
High speed gear .................................................... 3-6 Specifications ........................................ 1-9, 1-10
Horn ...................................................................... 3-9 Technical details: ........................................... 6-2
Hydraulics Towing ............................................................ 4-3
Changing filter insert ..................................... 5-52 Transport ...................................................... 3-84
Changing hydraulic oil .................................. 5-57 Transporting ................................................. 3-78
Venting hydraulic oil tank .............................. 5-52 Transporting with transport vehicle .............. 3-81
Vehicle identification number ......................... 1-9
I Weights ........................................................ 1-19
Identification plate Work units .................................................... 1-19
Engine ............................................................ 1-9 Machine specifications .......................................... 1-9
Machine .......................................................... 1-9 Machinery Directive .............................................. 1-3
Ignition lock ......................................................... 3-12 Main control panel ................................................ 3-4
Inside lighting ........................................................ 3-7 Maintenance
Instrument panel ................................................... 3-4 After 50 service hours .................................. 5-22
Intended use ......................................................... 1-7 Every 100 operating hours ........................... 5-29
Every 1000 operating hours ......................... 5-49
Every 2000 operating hours ......................... 5-57
K
Every 250 operating hours ........................... 5-30
Komatsu distributor, address .............................. 1-10
Every 50 operating hours ............................. 5-23
Every 500 operating hours ........................... 5-42

8-3
 Index

Maintenance chart ........................................5-17 Height limitation ............................................ 2-18

Maintenance guidelines ..................................5-2 High-pressure hoses .................................... 2-30
Maintenance flaps, opening ................................3-75 High-pressure oil .......................................... 2-30
Measuring indicators Lighting ......................................................... 2-30
Coolant temperature .....................................3-31 Loading ......................................................... 2-17
Fuel gauge ....................................................3-30 Mounting and dismounting ............................. 2-4
Operating hour meter ....................................3-30 Parking ......................................................... 2-21
Multifunction lever ......................................3-19, 3-61 Pressure accumulator .................................. 2-31
Adjusting armrest ..........................................3-48 Refuelling ..................................................... 2-29
Function ........................................................3-19 Roll-over protection system ............................ 2-9
Topping up of oil ........................................... 2-29
N Tyres ............................................................ 2-33
Noise emission level .............................................6-3 Waste material ............................................. 2-32
Working at high temperatures ........................ 2-8
O Working attachments with auxiliary function .. 2-9
Operating hour meter ..........................................3-30 Working on snow .......................................... 2-17
Operating lever ....................................................3-17 Working under the machine ......................... 2-28
Operating material, general ...................................5-6 Safety measures
Automatic safety belt .................................... 3-49
Cab ............................................................... 2-11
P
Emergency lowering ..................................... 2-15
Parking ................................................................3-59
General .................................................. 2-2, 2-12
Parking brake ......................................................3-18
Indoor operation ........................................... 2-12
Parking lights .......................................................3-10
Maintenance ................................................. 2-24
Parking on a slope ..............................................3-59
Operation ...................................................... 2-11
Pedals .................................................................3-21
Overhead power lines .................................. 2-16
Accelerator ....................................................3-22
Reversing ..................................................... 2-13
Brake pedal ...................................................3-21
Securing the articulated steering .................. 2-26
Power socket (12 V) ............................................3-23
Transporting ................................................. 2-22
Pressure accumulator .........................................2-31
Working hydraulics safety lever .................... 3-20
Pressure accumulator (ALS) .................................7-4
Workplace .................................................... 2-11
checking gas pressure ..................................5-47
Slopes, limits ......................................................... 6-3
Slow-blow fuses .................................................. 3-37
R Starter switch ...................................................... 3-12
Raising, machine .................................................1-26 Starting up .......................................................... 3-53
Refuelling .....................................................3-43, 4-2 Starting, engine ................................................... 3-50
Removal work .....................................................3-67 Steering column adjustment ...................... 3-18, 3-47
Reversing warning system ..................................3-35 Steering, machine ............................................... 3-56
Roll-over protection system ...................................2-9 Stopping .............................................................. 3-59
ROPS (roll-over protection system) ......................2-9 Supporting boom ................................................ 2-27
Supporting lifting arm .......................................... 2-27
S Switch ................................................................... 3-4
Safety belt ...........................................................3-49 Switching off, engine ........................................... 3-52
Safety information .................................................1-5
Safety instructions T
Asbestos dust .................................................2-7 Table of contents ................................................ 1-11
Attachments ..................................................2-28 Technical details: .................................................. 6-2
Battery ..........................................................2-10 Tension bolts ...................................................... 3-34
Boom ............................................................2-27 Tightening torques .............................................. 5-14
Braking ..........................................................2-18 Tools ................................................................... 5-13
Clothing ...........................................................2-3 Towing, machine ................................................... 4-3
Coolant .........................................................2-29 Transfer box
Driving ...........................................................2-14 Changing oil ................................................. 5-56
Driving on slopes ..........................................2-14 Checking oil level ......................................... 5-44
Emergency exit ...............................................2-2 Replenishing with oil ..................................... 5-44
Fan and belts ................................................2-32 Transporting ........................................................ 3-70
Fire fighting .....................................................2-5 Transporting the machine ................................... 3-78
Fire prevention ................................................2-5 Troubleshooting table
FOPS ..............................................................2-9 Axles ............................................................. 4-19
Forklift truck attachment ...............................2-19

8-4
Index

Brakes .......................................................... 4-18

Cab ............................................................... 4-19
Electrics ........................................................ 4-12
Hydraulics ..................................................... 4-16
Steering ........................................................ 4-18
Turning, machine ................................................ 3-56
Turob-charger ..................................................... 5-53
Tyre inflation pressure ......................................... 3-76

U
Unloading ............................................................ 3-70

V
V-belt
Adjusting (air conditioning compressor) ....... 5-34
Adjustment (generator) ................................. 5-33
Vehicle identification number ................................ 1-9
Ventilation system ............................................... 3-38
Venting
Fuel system .................................................... 4-2
Hydraulic tank ............................................... 5-52
Visual inspection ................................................. 3-39

W
Warm-up phase ................................................... 3-51
Warning beacon .................................................... 3-8
Warning lamps
Air filter ......................................................... 3-32
Brake fluid reservoir ...................................... 3-32
Charging current ........................................... 3-33
Engine-oil pressure ....................................... 3-33
Parking brake ............................................... 3-33
Washer system ..................................................... 3-4
Washing fluid ....................................................... 5-21
Water separator
Cleaning ....................................................... 5-43
Drain plug ..................................................... 5-29
Wearing parts list ................................................ 5-11
Weights ............................................................... 1-19
Wheel nuts .......................................................... 5-27
Winter operation .................................................. 3-85
Work units ........................................................... 1-19
Working hydraulics safety lever .......................... 3-20
Working lights ........................................................ 3-5
Working with the machine
Excavation work ........................................... 3-69
Forklift truck attachment ............................... 3-73
Loading work ................................................ 3-67
Removal work ............................................... 3-67
Transporting ................................................. 3-70
Unloading ..................................................... 3-70

8-5
 Index

8-6