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May 2006 Copyright 2006 Komatsu

Published in USA

Komatsu America Corp.

CEAM017200

Operation and Maintenance

Manual

WA380-6WHEEL LOADER

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordancewith written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes oradd improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-mended that customers contact their distributor for information on the latest revision.

SERIAL NUMBERS WA380-6 A53001 and UP

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0-1

0INTRODUCTION

WA380-6

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INTRODUCTION

0-2 WA380-6

FOREWORD

This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help theoperator and maintenance personnel achieve peak performance through effective, economical and safe machine operation andmaintenance.

Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and cannot be read, request a replacement manual from your local distributor.

If you sell the machine, be sure to give this manual to the new owner.

Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual.

Consult your local KOMATSU distributor or for the latest available information on your machine or for questionsregarding information in this manual.

This manual may contain attachments and optional equipment that are not available in your area. Consult your localKOMATSU Distributor or for those items that you may require.

❉ Storage location for Operation and MaintenanceManual is in the pocket (1) at rear of operators seat back

rest.

Improper operation and maintenance of this machine can be hazardous and could result in serious injury

or death.

• Operators and maintenance personnel must read this manual thoroughly before operating or

maintaining this machine.

• This manual should be kept near or with the machine for reference and periodically reviewed by all

personnel who operate it.

• Some actions involved in operation and maintenance can cause a serious accident, if they are not

performed in the manner described in this manual.

• The procedures and precautions given in this manual apply only to the intended uses of this machine.

If you use your machine for any unintended uses that are not specifi cally prohibited, you must be surethat it is safe for you and others. In no event should you or others engage in prohibi ted uses or actions

as described in this manual.

• KOMATSU delivers machines that comply with all applicable regulations and standards of the country

to which it has been shipped. If this machine has been purchased in another coun try or purchased

from someone in another countr y, it may lack certain safety features and specifications that are

necessary for use in your countr y. If there is any question about whether your product complies with

the applicable standards and regulations of your countr y, consul t your local distributor or KOMATSU

before operating the machine.

• The safety description is given in SAFETY INFORMATION and in the SAFETY section 1

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WA380-6 0-3

SAFETY INFORMATION

Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine.To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations.

To identify safety messages in this manual and on machine product graphics, the following signal words are used:

DANGER! - This word is used on safety messages and product graphics where there is a high probability of serious injury ordeath if the hazard is not avoided. These safety messages and product graphics usually describe precautions thatmust be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the machine,

injury or even death.

WARNING! - This word is used on safety messages and product graphics where there is a potentially dangerous situation,which could result in serious injury or possibly death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this

hazard may result in serious damage to the machine or possible injury.

CAUTION! - This word is used on safety messages and product graphics for hazards, which could result in minor or moderate injury if the hazard is not avoided. These safety messages and product graphics might also use this word for

hazards where the only result could be damage to the machine.

Remark

This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage

the machine.

Safety precautions are described in SAFETY section (01-1)

KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Thereforethe safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some procedures, contact your local KOMATSU Distributor.

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0-4 WA380-6

APPROVED AND NON-APPROVED USES

The Komatsu WHEEL LOADER described in this manual has been designed and constructed to be used mainly for thefollowing functions, any non-approved used may void the warranty, damage the machine or possibly injure the operator.

APPROVED• Loading operations.• Excavating.

• Grading.

• Pushing

Installation of optional equipment can also be used in the following applications, use only KOMATSU approved equipment.

• Handling of materials (bucket - pallet forks).

NON-APPROVED

This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for any particular application other than those approved above, it is

important to contact your Authorized Komatsu Dealer before carrying out the work operations.

• Use of machine for lifting or transporting personnel in any manner.

• Transportation of flammable liquids.

• Lifting, moving or transporting other machines with the front end equipment.

• Towing other equipment with the tractor unit or work equipment.

• Using the loader as a hammer or for striking or driving objects.

• Towing the machine at high speeds

• Traveling at high speeds.

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WA380-6 0-5

PRODUCT IDENTIFICATION

The serial numbers and model numbers on the components are the only numbers that your dealer will need when requiringassistance or ordering replacement parts. It is a good idea to record this information in this manual on page 0-7 (Serial Number And Dealer Information). All views indicated below are viewed from the operators sitting position.

MACHINE SERIAL NUMBER

The machine serial number is stamped on the right side center of the front frame.

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ENGINE SERIAL NUMBER AND EMISSION LABEL

The engine serial number is on a plate located on the left side of the machine.

SERVICE METER LOCATION

The service meter is located in the center bottom of the machines monitor bezel.

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WA380-6 0-7

SERIAL NUMBERS AND DEALER INFORMATION

Model: WA400-5L

Machine #

Engine #

Dealer:

Address:

Phone #

Contacts:

NOTES:

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CONTENTS

INTRODUCTION

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

APPROVED AND NON-APPROVED USes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 NON-APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6SERVICE METER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6

SERIAL NUMBERS AND DEALER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8

SAFETY

SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2LOCATION OF SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12GENERAL SAFETY AT JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

FIRE CAUSED BY FUEL OR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . . . . . . . . . . . 1-14FIRE COMING FROM ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15FIRE COMING FROM HYDRAULIC LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

ACTION IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . 1-17

PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17EMERGENCY ESCAPE FROM OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17LEAVING OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18KEEP OPERATOR'S COMPARTMENT CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

ASBESTOS HAZARD ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

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WA380-6 0-9

WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21WORKING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

SAFETY HANDLING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32PRECAUTION FOR HIGH FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32HIGH TEMPERATURES AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33INFLATING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

OPERATION

GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2OUTSIDE VIEW OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2INSIDE VIEW OF THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 2-4INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

SWITCH PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2-6

INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6TYPES OF WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

MACHINE ELECTRONIC MONITORING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8MONITOR MODE SELECTOR SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

MONITOR DISPLAY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9SERVICE METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9ACTION CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

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INTRODUCTION

0-10 WA380-6

FAILURE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11SERVICE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12SELECTING LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

EMERGENCY STOP WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15BRAKE PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15ENGINE OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

BATTERY CHARGE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16STEERING OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16CAUTION ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

AXLE OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17TORQUE CONVERTER CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18COOLANT TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18FUEL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . 2-20RADIATOR COOLANT LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20ENGINE OIL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

BATTERY ELECTROLYTE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21MAINTENANCE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21AIR CLEANER CLOGGING CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22WATER SEPARATOR CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22TRANSMISSION FILTER CLOGGING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

MODE ALERT LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23PARKING BRAKE PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23COOLING FAN REVERSE ROTATION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24EMERGENCY STEERING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24OUTPUT MODE PILOT LAMP (POWER MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24PREHEATING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

SEMI AUTO DIGGING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25AUTO-GREASING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25JOYSTICK PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25ECONOMY OPERATION DISPLAY LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25AUTO-SHIFT PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25LOCKUP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26SHIFT HOLD PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26SHIFT LEVER POSITION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26TURN SIGNAL PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26HEAD LAMP HIGH BEAM PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28TORQUE CONVERTER OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28ENGINE TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29HYDRAULIC TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29METER DISPLAY PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30DISPLAYING ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30RESET FOR FILTER, OIL REPLACEMENT TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

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INTRODUCTION

WA380-6 0-11

ENTERING A TELEPHONE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31SELECTING A LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32ADJUSTING MONITOR BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

MACHINE SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

POWER MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35TRANSMISSION MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36TRANSMISSION CUT-OFF SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37TURN SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37DIMMER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38HAZARD LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38FRONT WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

REAR WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39MONITOR PANEL MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40MONITOR PANEL MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40KICKDOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41FRONT WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41REAR WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42REAR DEFROSTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42E.C.S.S. SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

EMERGENCY STEERING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43COOLING FAN REVERSE ROTATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

OPTIONAL SOUND SYSTEM AND AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2-45SOUND SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

POWER SWITCH/VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46AUTO-STORE/PRESET SCAN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46BASS CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46TREBLE CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46LOUDNESS BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47TIME/RADIO DISPLAY SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

TAPE EJECT BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47CASSETTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47FAST-FORWARD, REWIND BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48METAL TAPE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48MANUAL TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48SEEK TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48BAND SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49SETTING PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49


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AUTO PRESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49MANUAL PRESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49LISTENING TO RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50LISTENING TO CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50REVERSING TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51PRECAUTIONS WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

HANDLING CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51AIR CONDITIONER SYSTEM CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52MAIN POWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52FAN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53AIR CONDITIONER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54FRESH/RECIRC SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54COOLING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54HEATING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55DRYING-HEATING AND DEMISTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

PRECAUTIONS WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55PRECAUTIONS FOR INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 2-55CONTROL LEVERS, PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

GEAR SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58GEAR SHIFT LEVER STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58SAFETY LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59BUCKET CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59LIFT ARM CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

STEERING TILT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61SECURITY AND LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

IGNITION KEY LOCKED AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62CAB DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62ENGINE ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63FUEL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63LOCKING LOCATIONS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65PASSIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

ROLL-OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

CAB FRONTAL GUARD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

ACTIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66EQUIPMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

MACHINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

CAB DOOR OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68CAB WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69


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CAB LEFT WINDOW OPEN LOCK RESET KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69CAB RIGHT WINDOW OPEN LOCK RESET KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69RESET RIGHT WINDOW OPEN LOCK FOR ESCAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71FUSE CAPACITY AND NAME OF CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

MACHINE CAB AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73SEAT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73LUMBAR SUPPORT TYPE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73REMOVAL AND INSTALLATION OF HEADREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74HANDLING CAB WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75GREASE PUMP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

PERFORM A WALK AROUND CHECK OF YOUR MACHINE . . . . . . . . . . . . . . . . . . . . 2-76UNDER THE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

CHECK COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

CHECK WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79CHECK AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80CHECK ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80CHECK ENGINE OIL LEVEL, ADD OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81REAR-VIEW MIRROR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

IN THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83SEAT BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83ADJUST LEVER STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85CHECK FUEL LEVEL, ADD FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85CHECK THE BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

CHECK THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86FINAL CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92BREAKING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

NORMAL START-UP AND WARM-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

TRAVELING, STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

TURNING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98CHANGING GEAR SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

CHANGING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99WHEN USING AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100WHEN USING AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103ADJUSTING THE TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104STOPPING WHEN TRANSMISSION CUT-OFF IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106USING THE EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106


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EMERGENCY STEERING SELF-CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108LIFT ARM LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108BUCKET LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

SCOOPING A LOAD OR CUTTING A GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

LOADING PILED SOIL OR BLASTED ROCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110CUTTING A GRADE ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112LEVELING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113PUSHING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113LOAD AND CARRY OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114

CROSS DRIVE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114V-SHAPE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114PRECAUTIONS WHEN PILING UP LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114LOADING TRUCKS OR HOPPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

PERMISSIBLE WATER DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116IF WHEEL BRAKE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

BRAKING ON DOWNHILL SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116IF THE ENGINE STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116PRECAUTIONS FOR USING LOAD AND CARRY METHOD . . . . . . . . . . . . . . . . . . . . 2-116

PRECAUTIONS WHEN DRIVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117PRECAUTIONS REGARDING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117

WORK EQUIPMENT AND MACHINE POSTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118ADJUSTING BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118

BOOM KICKOUT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118

BUCKET POSITIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119

TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

UNLOADING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122

LIFTING LOCATIONS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122USING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123

PRE LIFTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123LIFTING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125

TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126

COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127PRECAUTIONS AFTER COMPLETION OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127AFTER COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127

BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128WHEN MACHINE RUNS OUT OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128

TOWING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128WHEN ENGINE CAN BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129WHEN ENGINE CANNOT BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129


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RELEASING PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129METHOD OF RELEASING WITH ADJUSTMENT SCREW . . . . . . . . . . . . . . . . . . . . . . 2-132EMERGENCY TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132

IF BATTERY IS DISCHARGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134

PRECAUTIONS FOR CHARGING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134STARTING ENGINE WITH BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135CONNECTING THE BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136DISCONNECTING THE BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-140

LONG-TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141

AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141MAINTENANCE

GUIDES TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2CHECK SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2KOMATSU GENUINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2KOMATSU GENUINE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2ALWAYS USE CLEAN WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2ALWAYS USE CLEAN OIL AND GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS . . . . . . . . . 3-2FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2DO NOT DROP THINGS INSIDE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3DUSTY WORKSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3AVOID MIXING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3LOCKING INSPECTION COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3BLEEDING AIR FROM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3CHECKS AFTER INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

HANDLING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4SERVICE LIMITS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

OUTLINES OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . . . . . . . . . . . . . . 3-6

OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

PERFORMING KOWA (Komatsu Oil Wear Analysis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8KOWA ANALYSIS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

OIL SAMPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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STORING OIL AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

OUTLINE OF ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . 3-11

RECOMMENDED BRANDS, OTHER THAN KOMATSU GENUINE OIL . . . . . . . . . . . . . . 3-12STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES . . . . . . . . . . . . . . . . . . 3-13TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16GENERAL MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16EVERY 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16EVERY 100 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16EVERY 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

EVERY 500 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17EVERY 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17EVERY 2000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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