O&M WA380-6 A53001 Up CEAM017200

CEAM017200
Operation and Maintenance

Manual
WA380-6
WHEEL LOADER
SERIAL NUMBERS
WA380-6
A53001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add 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 recommended that customers contact their distributor for information on the latest revision.
May 2006
Copyright 2006 Komatsu

Published in USA
Komatsu America Corp.
0INTRODUCTION
WA380-6
0-1
INTRODUCTION
FOREWORD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the
operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and
maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and can
not be read, request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual.
Consult your local KOMATSU distributor or for the latest available information on your machine or for questions
regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area. Consult your local
KOMATSU Distributor or for those items that you may require.
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 specifically prohibited, you must be sure
that it is safe for you and others. In no event should you or others engage in prohibited uses or actions
as described in this manual.
KOMATSU delivers machines that comply with all applicable regulations and standards of the country
to which it has been shipped. If this machine has been purchased in another country or purchased
from someone in another country, it may lack certain safety features and specifications that are
necessary for use in your country. If there is any question about whether your product complies with
the applicable standards and regulations of your country, consult your local distributor or KOMATSU
before operating the machine.
The safety description is given in SAFETY INFORMATION and in the SAFETY section 1
0-2
Storage location for Operation and Maintenance

Manual is in the pocket (1) at rear of operators seat back
rest.
WA380-6
INTRODUCTION
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 or
death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that
must be taken to avoid the hazard. Failure to avoid this hazard may 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. Therefore
the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some
procedures, contact your local KOMATSU Distributor.
WA380-6
0-3
INTRODUCTION
APPROVED AND NON-APPROVED USES

The Komatsu WHEEL LOADER described in this manual has been designed and constructed to be used mainly for the
following 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.
0-4
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.
WA380-6
INTRODUCTION
PRODUCT IDENTIFICATION
The serial numbers and model numbers on the components are the only numbers that your dealer will need when requiring
assistance 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.
WA380-6
0-5
INTRODUCTION
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.
0-6
WA380-6
INTRODUCTION
SERIAL NUMBERS AND DEALER INFORMATION

Model: WA400-5L
Machine #
Engine #
Dealer:
Address:
Phone #
Contacts:
NOTES:
WA380-6
0-7
INTRODUCTION
CONTENTS
INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPROVED AND NON-APPROVED USes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NON-APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE METER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERIAL NUMBERS AND DEALER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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0-3
0-4
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SAFETY
SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCATION OF SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
GENERAL SAFETY AT JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
FIRE CAUSED BY FUEL OR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . . . . . . . . . . . 1-14
FIRE COMING FROM ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE COMING FROM HYDRAULIC LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
ACTION IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
INSIDE OPERATORS COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . 1-17
PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
EMERGENCY ESCAPE FROM OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
LEAVING OPERATORS COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
KEEP OPERATOR'S COMPARTMENT CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
ASBESTOS HAZARD ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
0-8
WA380-6
INTRODUCTION
WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
WORKING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
SAFETY HANDLING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
PRECAUTION FOR HIGH FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
HIGH TEMPERATURES AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
INFLATING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
OPERATION
GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
OUTSIDE VIEW OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
INSIDE VIEW OF THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 2-4
INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
SWITCH PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2-6
INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
TYPES OF WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MACHINE ELECTRONIC MONITORING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
MONITOR MODE SELECTOR SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
MONITOR DISPLAY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
SERVICE METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
ACTION CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
WA380-6
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INTRODUCTION
FAILURE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STOP WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY CHARGE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . .
RADIATOR COOLANT LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY ELECTROLYTE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CLEANER CLOGGING CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER SEPARATOR CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION FILTER CLOGGING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODE ALERT LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING FAN REVERSE ROTATION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STEERING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT MODE PILOT LAMP (POWER MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREHEATING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEMI AUTO DIGGING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO-GREASING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JOYSTICK PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECONOMY OPERATION DISPLAY LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO-SHIFT PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCKUP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT HOLD PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT LEVER POSITION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAD LAMP HIGH BEAM PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER DISPLAY PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAYING ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET FOR FILTER, OIL REPLACEMENT TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-10
2-11
2-12
2-14
2-15
2-15
2-16
2-16
2-16
2-17
2-17
2-18
2-18
2-18
2-19
2-20
2-20
2-21
2-21
2-21
2-22
2-22
2-22
2-23
2-23
2-24
2-24
2-24
2-24
2-25
2-25
2-25
2-25
2-25
2-25
2-26
2-26
2-26
2-26
2-27
2-28
2-28
2-29
2-29
2-29
2-29
2-30
2-30
2-30
2-30
WA380-6
INTRODUCTION
ENTERING A TELEPHONE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
SELECTING A LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
ADJUSTING MONITOR BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
MACHINE SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
POWER MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
TRANSMISSION MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
TRANSMISSION CUT-OFF SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
TURN SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
DIMMER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
HAZARD LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
FRONT WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
REAR WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
MONITOR PANEL MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
MONITOR PANEL MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
KICKDOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
FRONT WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
REAR WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
REAR DEFROSTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
E.C.S.S. SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
EMERGENCY STEERING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
COOLING FAN REVERSE ROTATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
OPTIONAL SOUND SYSTEM AND AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2-45
SOUND SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
POWER SWITCH/VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
AUTO-STORE/PRESET SCAN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
BASS CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
TREBLE CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
LOUDNESS BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
TIME/RADIO DISPLAY SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
TAPE EJECT BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
CASSETTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
FAST-FORWARD, REWIND BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
METAL TAPE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
MANUAL TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
SEEK TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
BAND SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
SETTING PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
WA380-6
0-11
INTRODUCTION
AUTO PRESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL PRESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LISTENING TO RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LISTENING TO CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REVERSING TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN POWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRESH/RECIRC SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRYING-HEATING AND DEMISTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS FOR INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .
CONTROL LEVERS, PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SHIFT LEVER STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT ARM CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING TILT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECURITY AND LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION KEY LOCKED AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCKING LOCATIONS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASSIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROLL-OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB FRONTAL GUARD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIPMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB DOOR OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-12
2-49
2-49
2-50
2-50
2-51
2-51
2-51
2-52
2-52
2-53
2-53
2-54
2-54
2-54
2-54
2-55
2-55
2-55
2-55
2-56
2-56
2-58
2-58
2-59
2-59
2-60
2-60
2-61
2-61
2-62
2-62
2-62
2-62
2-63
2-63
2-63
2-65
2-65
2-65
2-65
2-65
2-66
2-66
2-66
2-67
2-68
2-68
2-68
2-69
WA380-6
INTRODUCTION
CAB LEFT WINDOW OPEN LOCK RESET KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
CAB RIGHT WINDOW OPEN LOCK RESET KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
RESET RIGHT WINDOW OPEN LOCK FOR ESCAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
FUSE CAPACITY AND NAME OF CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
MACHINE CAB AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
SEAT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
LUMBAR SUPPORT TYPE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
REMOVAL AND INSTALLATION OF HEADREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
HANDLING CAB WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
GREASE PUMP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
PERFORM A WALK AROUND CHECK OF YOUR MACHINE . . . . . . . . . . . . . . . . . . . . 2-76
UNDER THE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
CHECK COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
CHECK WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
CHECK AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
CHECK ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
CHECK ENGINE OIL LEVEL, ADD OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
REAR-VIEW MIRROR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
IN THE OPERATORS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
SEAT BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
ADJUST LEVER STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
CHECK FUEL LEVEL, ADD FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
CHECK THE BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
CHECK THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
FINAL CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
BREAKING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
NORMAL START-UP AND WARM-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
TRAVELING, STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
TURNING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
CHANGING GEAR SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
CHANGING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
WHEN USING AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
WHEN USING AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
ADJUSTING THE TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
STOPPING WHEN TRANSMISSION CUT-OFF IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
USING THE EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
WA380-6
0-13
INTRODUCTION
EMERGENCY STEERING SELF-CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT ARM LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCOOPING A LOAD OR CUTTING A GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOADING PILED SOIL OR BLASTED ROCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUTTING A GRADE ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVELING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUSHING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD AND CARRY OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CROSS DRIVE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-SHAPE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS WHEN PILING UP LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOADING TRUCKS OR HOPPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERMISSIBLE WATER DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IF WHEEL BRAKE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKING ON DOWNHILL SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IF THE ENGINE STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS FOR USING LOAD AND CARRY METHOD . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS WHEN DRIVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS REGARDING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WORK EQUIPMENT AND MACHINE POSTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOM KICKOUT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET POSITIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNLOADING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFTING LOCATIONS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRE LIFTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFTING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS AFTER COMPLETION OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFTER COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEN MACHINE RUNS OUT OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOWING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEN ENGINE CAN BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEN ENGINE CANNOT BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-14
2-107
2-108
2-108
2-108
2-109
2-110
2-110
2-112
2-113
2-113
2-113
2-114
2-114
2-114
2-114
2-115
2-116
2-116
2-116
2-116
2-116
2-116
2-116
2-117
2-117
2-118
2-118
2-118
2-119
2-119
2-120
2-120
2-121
2-122
2-122
2-123
2-123
2-125
2-126
2-127
2-127
2-127
2-127
2-127
2-128
2-128
2-128
2-129
2-129
WA380-6
INTRODUCTION
RELEASING PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
METHOD OF RELEASING WITH ADJUSTMENT SCREW . . . . . . . . . . . . . . . . . . . . . . 2-132
EMERGENCY TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
IF BATTERY IS DISCHARGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
PRECAUTIONS FOR CHARGING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
STARTING ENGINE WITH BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135
CONNECTING THE BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136
STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136
DISCONNECTING THE BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136
ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-140
LONG-TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
MAINTENANCE
GUIDES TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOMATSU GENUINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOMATSU GENUINE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALWAYS USE CLEAN WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALWAYS USE CLEAN OIL AND GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS . . . . . . . . .
FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DO NOT DROP THINGS INSIDE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUSTY WORKSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AVOID MIXING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCKING INSPECTION COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING AIR FROM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKS AFTER INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE LIMITS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINES OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . . . . . . . . . . . . . .
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMING KOWA (Komatsu Oil Wear Analysis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOWA ANALYSIS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL SAMPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WA380-6
3-2
3-2
3-2
3-2
3-2
3-2
3-2
3-2
3-2
3-3
3-3
3-3
3-3
3-3
3-3
3-3
3-4
3-4
3-4
3-6
3-6
3-6
3-6
3-7
3-7
3-8
3-8
3-8
0-15
INTRODUCTION
STORING OIL AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
OUTLINE OF ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . 3-11
RECOMMENDED BRANDS, OTHER THAN KOMATSU GENUINE OIL . . . . . . . . . . . . . . 3-12
STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES . . . . . . . . . . . . . . . . . . 3-13
TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
GENERAL MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
EVERY 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
EVERY 100 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
EVERY 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
GENERAL MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
INITIAL 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CLEANING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHECK AXLE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
WINDOW WASHING FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
CLEAN RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CLEAN FINS WITH COMPRESSED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CHECK ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
REPLACE BOLT-ON CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
REPLACE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
REPLACING SLOW-BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
INSPECTION OF TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
CHECKING FUNCTION OF ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
ACCUMULATOR FOR TRAVEL DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
ACCUMULATOR FOR BRAKE DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
EVERY SPECIFIC HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
EVERY 50 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
DRAIN SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
0-16
WA380-6
INTRODUCTION
LUBRICATE THE REAR AXLE PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL . . . . . . . . . . . . 3-36
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT . . . . . . . . . . . . 3-37
EVERY 250 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
CHECK PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . 3-40
WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
EVERY 500 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE . . . 3-43
REPLACING PRIMARY FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
EVERY 1000 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
REPLACING PRIMARY AND SECONDARY FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . 3-46
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER . . . . 3-48
CLEAN THE TRANSMISSION CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECKING PARTS OF TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHECK AND REPLACEMENT OF SERPENTINE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT . . . . . 3-51
REPLACE HYDRAULIC TANK BREATHER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
CHANGE THE AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
CHECKING BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CHECK ALTERNATOR, STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
CHECK ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
CHECK INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
CHECK VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
CHECK WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CHECK AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
REPLACE INJECTOR NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER
3-59
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
3-60
REPLACE HIGH-PRESSURE PIPING CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
REPLACE FUEL SPRAY PREVENTION CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
CHECK, REPLACE INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
SPECIFICATIONS
WA380-6
0-17
INTRODUCTION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4-2
4-2
4-3
4-3
4-4
4-4
OPTIONS, ATTACHMENTS
TORQUE CONVERTER LOCK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER LOCK-UP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVEL SPEED WARNING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVEL SPEED LIMIT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING BUCKET AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USING MACHINES EQUIPPED WITH KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-18
5-2
5-2
5-3
5-3
5-3
5-4
5-4
5-4
5-5
5-6
5-6
WA380-6
SAFETY
WARNING!
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional
equipment and attachments.
WA380-6
1-1
SAFETY
SAFETY AND WARNING DECALS

It is important that all safety and warning decals are in place, not damaged, covered up or removed. It is also important for
the operator to be aware of the decal content and location.
LOCATION OF THE SAFETY DECALS
1-2
Your Komatsu Dealer can supply you with new replacement decals if the ones on the machine are damaged or
missing.
When replacing damaged or missing decals, be sure they are placed in the proper location.
Additional safety or warning decals may be added to your machine if desired.
WA380-6
SAFETY
LOCATION OF SAFETY LABELS

The rear full fender is available as an option only; item 14 indicates that the machine is equipped with full fender.
SAFETY LABELS
(1) Precaution before starting (09651-A0481).
Warning! Read the manual before operation, maintenance, disassembly, assembly and
transportation.
(2) Precautions for safety lock lever (09654-C0481).

Sign indicates a hazard of unexpected moving of stopped machine.
Lower the working device to the ground, move the safety lever to the look position and
take the engine key with you before leaving the machine.
WA380-6
1-3
SAFETY
(3) Precautions when travelling in reverse (423-93-41150).
To prevent SEVERE INJURY or DEATH, do the following before
moving the machine or its attachments:
Honk horn to alert people nearby.

Be sure no on is on or near the machine.
Use a spotter if view is obstructed.
Follow the above even if the machine is equipped with back-up alarm
and mirrors.
(4) Precautions for going close to electric cables (09801-C0481).

Sign indicates an electrocution hazard if the machine is brought too near the
electric power lines.
Keep a safe distance from the electric power lines.
1-4
WA380-6
SAFETY
(5) Do not enter (09162-23000).
Sign indicates a crush hazard between the articulating parts of the
vehicle.
(6) Precautions for safety bar (09161-2300).

Sign indicates a crush hazard between articulating parts of
the vehicle.
(7) Caution when canceling parking brake emergency (423-93-41311)

Sign indicates if the release valve is set to RELEASE, a serious accident
may occur, as this operation releases the parking brake and the machine
may suddenly start to roll.
WA380-6
1-5
SAFETY
(8) Precautions when coolant is at high temperature (09653-03001).
Sign indicates a burn hazard from spurting hot water or oil if the
radiator or hydraulic tank is uncapped while hot.
Allow the radiator or hydraulic tank to cool before removing the

cap.
(9) Precautions when handling battery cables (09808-03000).

Sign indicates an electrical hazard from handling the cable. Read the
the manual for safe and proper handling.
(10) High-pressure warning (09659-5300).

There is the hazard of explosion causing injury.
Do not disassemble the accumulator, make holes in it, weld it, cut it,
hit it, roll it or bring it near the flame.
(11) Do not climb on fender (09805-03000)

(machines equipped with full rear fender)
Sign indicates a hazard of falling.
Do not stand on this place.
1-6
WA380-6
SAFETY
(12) Do not open when the engine is running (09667-03001).
Sign indicates a hazard of rotating parts, such as a belt.
Turn off before inspection and maintenance.
(13) Do not open when the engine is running (09667-03001).

Sign indicates a hazard of rotating parts, such as a belt.
Turn off before inspection and maintenance.
(14) Do not come near the machine (09812-13000).

Sign indicates a hazard of being run over by a moving
vehicle.
Keep a safe distance from the vehicle when it is moving.
WA380-6
1-7
SAFETY
(15) Do not work on equipment (09807-C0883).
Sign indicates a crush hazard from falling off of the working device.
Keep away when the working device is raised.
(16) Do not modify ROPS (09620-A2000)

Do not drill, cut, bend or modify ROPS in any way. If damaged,
replace the ROPS, do not repair.
(17) Jump start prohibited (09842-A0481)

Start the engine only after sitting in the operators seat
Do not attempt to start the engine by short circulating the starter motor circuit, serious
injury may result.
1-8
WA380-6
SAFETY
(18) Precautions for high temperature turbocharger (09817-A0753).
Sign indicates a burn hazard from touching heated parts, such as the
engine, motor or muffler during or right after operation.
Allow the hydraulic tank to cool before removing the cap.
(19) Precautions for high temperature exhaust (09817-A0753).

Sign indicates a burn hazard from touching heated parts, such as the
engine, motor or muffler during or right after operation.
Allow the hydraulic tank to cool before removing the cap.
(20) Caution for common rail high pressure (6217-71-93310)

Sign indicated extremely high fuel pressure in the system, never
loosen the injector lines when the engine is running.
WA380-6
1-9
SAFETY
(21) Parking brake emergency cancel switch (423-93-41311)
Sign indicates proper procedure for releasing the parking brake during
an emergency situation.
(22) Escape (425093-51110)

Sign indicates the areas to escape from the machine in an emergency.
1-10
WA380-6
SAFETY
GENERAL SAFETY RULES AND PRECAUTIONS

GENERAL SAFETY RULES
Only trained and authorized personnel shall be allowed to operate and service this machine.
Before operating this machine it is important to study the operators manual thoroughly and become familiar with all controls
and safety decals. Keep this manual with your machine at all times for easy and quick reference.
Safety must always be the operators most important concern. Never operate a machine that is unsafe or in poor operating
condition.
Always perform a pre-operational check on your machine before operating it.
If the machine is equipped with a seat belt and rollover protective structure, OSHA law requires the operator remain within the
confines of the rollover protective structure, with the seat belt fastened snugly around their waist before operating the machine.
OSHA law states if your equipment is designed for operation by one person, it is for one person only, never allow other
personnel to ride on your machine in any manor.
Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the
ground, set the parking brake, lock the controls and turn the engine off before exiting the operators compartment.
Be sure that all personnel are at least 12 m (40 ft) away from any point on the machine before moving or operating the
machine. Never allow anyone to stand near the machine while in operation. Remember, the larger the machine the more
restricted your visibility will be.
If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right away, and a loaded
or smaller machine has the right away over an unloaded machine.
Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result.
Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.
It is the owner and /or operators responsibility to replace any safety or warning decals if they are defaced or removed from the
machine.
Think before you act, study the job carefully. Careful operators and service personnel are the best insurance against accidents.
The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that
might affect there eyesight, hearing, or reactions.
When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand
signals that are to be used.
When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment
controls and lock and secure your machine properly to avoid tampering by other personnel.
Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you
approach them and acknowledge your approach.
Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.
WA380-6
1-11
SAFETY
UNAUTHORIZED MODIFICATIONS
If this machine is modified without permission from Komatsu, there is a danger that problems may occur with safety that may
lead to serious personal injury.
Modifications may have an adverse effect on items such as machine strength and visibility.
Before making any modifications, please consult your Komatsu distributor. Komatsu cannot take any responsibility for
accidents, failures, or damage caused by modifications not authorized by Komatsu.
GENERAL SAFETY AT JOB SITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Know your location to report an accident or fire. In case of an emergency, have a local emergency phone number available.
Be careful when operating around or near open burning operations.
Maintain the fire extinguisher on the machine and a second one at the job site
Keep the machine clean, especially from flammable materials such as trash, grease, oil or fuel.
Keep all safety equipment in good working condition.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not operate where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility company
and have them identify their locations.
Take action to prevent unauthorized people from approaching the job site.
When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the
depth and speed of flow of the water before starting operations.
Conduct periodic safety training and familiarize all personnel with emergency procedures.
WORKING ON LOOSE GROUND

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be
weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the
machine may fall or tip over.
Remember that the soil is loose after heavy rain or blasting or after earthquakes
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will
cause the soil to collapse.
Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.
1-12
WA380-6
SAFETY
SAFETY FEATURES
Be sure all guards and covers are in place especially after servicing the machine.
Have guards or covers repaired immediately if they are damaged. See STARTING THE ENGINE on page 2-89
Use safety equipment such as safety locks and seat belt properly.
Never remove any safety features. Always keep them in good operating condition.
Always secure the machine in a safe position: See STOPPING AND PARKING THE MACHINE on page 2-101
Seat belt: See INSIDE OPERATORS COMPARTMENT on page 1-17
Improper use of safety features could result in serious bodily injury or death.
Be sure the machine has the correct equipment required by local rules and regulations.
PERSONAL PROTECTIVE EQUIPMENT

If your machine is equipped with safety equipment OSHA law requires
this equipment to be used when operating your machine.
Avoid loose fitting clothing, jewelry and loose long hair. These can
catch on controls or in moving parts and cause serious injury.
Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine.
Always wear safety goggles, hard hat and heavy gloves, if your job
involves driving pins with a hammer or cleaning the air cleaner
element with compressed air.
Check to be sure no one is near your work area.
Check to be sure all personal protective equipment are in good
condition before using.
If you will be subject to loud noise always wear ear protection.
WA380-6
1-13
SAFETY
FIRE AND EXPLOSION PREVENTION

Fuel and oil are flammable. Fuel is particularly flammable and can be
hazardous. Always observe the following:
Keep any open flames, airborne sparks or burning embers away
from flammable fluids.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling or adding oil should be made in well ventilated areas.
Clean up any fluid spills.
FIRE CAUSED BY FUEL OR OIL

Fuel and oils are particularly flammable and can be hazardous.
To prevent fire, always observe the following:
Do not smoke or use any flame near fuel or oil.

Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Always inspect around the entire fuel tank for leaks and clean or
repair if needed.
Inspect fuel system for leak or seepage, this includes fuel lines, filters and injection system, clean or repair if required.
Do not spill fuel on overheated surfaces or on parts of the electrical
system.
Use well-ventilated areas for adding or storing oil and fuel.
Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chassis, move any flammable materials to a safe place before starting.
When washing parts with oil, use a non-flammable oil.
Diesel oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL
Remove any dry leaves, wood chips, pieces of paper, wood dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, air cleaner or battery, or inside the undercovers.
Be aware that operations such as logging, mulching, clearing, and landfill work may cause trash and debris to accumulate
on the machine. Always remove accumulated trash and debris on a daily basis.
Clean the machine after servicing the hydraulic system, engine or fuel system.
Operations near burn piles or other open burning may cause airborne sparks or glowing embers to cause a fire on the
machine.
1-14
WA380-6
SAFETY
FIRE COMING FROM ELECTRIC WIRING
Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage to the wire insulation.
Tighten any loose connectors or wiring clamps.

Repair or replace any damaged, pinched or chaffed wiring.
After market radios or other electrical operated equipment in the cab must be fused close to the power supply
FIRE COMING FROM HYDRAULIC LINE
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and
cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Check for oil leaks daily and repair them immediately.
WINDSHIELD WASHER FLUID
Use an automotive type washer fluid in the windshield washer system.

Never use flammable fluids in the windshield washer system
ACTION IF FIRE OCCURS
If a fire occurs, escape from the machine as follows:

Do not attempt to move the machine or continue operations.
Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.
Immediately call for help.
When using a fire extinguisher, always aim the extinguisher at the base of the fire
If an optional fire extinguishing system is in place be finality with its operating procedures.
FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if a fire or an injury should occur, always keep a fire
extinguisher and first aid kit on your machine and do as follows:
Be sure that fire extinguisher is in good condition and read the label
on it to ensure you know how to use it.
Keep a first aid kit in the storage area. Check the kit periodically
and make any additions if necessary.
Keep a list of emergency phone numbers in case of an accident.
WA380-6
1-15
SAFETY
MOUNTING AND DISMOUNTING

When mounting or dismounting this machine, always be sure the work
equipment is fully lowered to the ground and the engine is OFF.
Use all hand holds and step plates on your machine.
Never jump off or on to the machine.
Before getting on the machine, if there is any oil, grease, or mud on your
shoes, rails, steps or platforms, wipe it off immediately, always keep
these areas clean, and in good condition.
Never get on or off a moving machine. These actions may lead to
serious injury. Always bring the machine to a full stop.
Be sure machine is at a full stop, equipment lowered and parking brake
set before entering or exiting machine.
When getting on or off the machine, always face the machine and
maintain a Three Point Contact (both feet and one hand or one foot
and both hands) with the handrails, steps and platforms to ensure that
you support yourself properly.
When entering the cab and opening the cab door, push the door open
until it is securely into the door klatch (1) and held in position. Use the
hand rails on the inside of the door while entering or exiting the cab.
Never hold any control levers or the steering wheel when getting on or
off the machine.
1-16
WA380-6
SAFETY
INSIDE OPERATORS COMPARTMENT

When entering the operators compartment, always remove mud and oil from the
soles of your shoes. If you operate the brake pedal with mud or oil on your shoes,
your foot may slip and may cause an accident.
After using the ashtray, make sure matches or cigarettes are properly extinguished
and be sure to close the lid. If the ashtray is left open, there is danger of fire. Do not
leave lighters or aerosol cans lying around the operators compartment. If the
temperature inside the operators compartment gets too high, there is danger that the
lighter may explode.
Do not stick suction pads to the window glass. Suction pads may act as a lens and
could cause fire. Do not use cellular telephones inside the operators compartment
when driving or operating the machine.
After market radios or other electrically operated equipment in the cab must be fused close to the power supply
Never bring any dangerous objects such as flammable or explosive items into the operators cab. To ensure safety, do not
use the radio or music headphones when operating the machine. Keep the operators compartment clean, never allow
trash or tools to accumulate, these may hinder the operation of the controls or pedals.
When operating the machine, do not put your hands or head out of the window or beyond the protection of the ROPS.
Always use the seat belt equipped with your machine. Be sure the seat belt is fastened snugly around your waist before
operating the machine.
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

When standing up from the operator's seat, lower the work equipment,
set work equipment lock lever (1) to Lock position (L), parking brake
switch (2) to ON position (Heathen stop the engine. If you touch the
control lever, the machine may suddenly move and cause serious
personal injury or death.
PRECAUTIONS WHEN USING ROPS

The ROPS (Roll Over Protective Structure) must never be removed
from the machine. The ROPS is installed to protect
the operator if the machine should roll over. It is designed not only to
support the load if the machine should roll over, but
also to absorb the impact of the energy.
The ROPS fulfills all the regulations and standards for all countries, but if it is modified without authorization or is
damaged, the strength may be reduced and it may not able to fulfill its function properly. Never drill, cut or modify the
ROPS structure, if the ROPS structure should become damaged in any way, replace it immediately. Do not make repairs
to the ROPS structure its self.
EMERGENCY ESCAPE FROM OPERATOR'S CAB

If the door of the cab does not open or it is dangerous to get off the machine from the side where the door is, release the open
lock of the right window and use the right window as an emergency escape route. See CAB WINDOW on page 2-69
WA380-6
1-17
SAFETY
LEAVING OPERATORS COMPARTMENT

Below are listed procedures that must be followed when exiting the
operators cab.
1.
2.
Park the machine in a level area, lower all work equipment to the
ground.
Engage the parking brake in the (LOCKED) position.
3.
Place safety lock lever for loader control in the (LOCKED)

position.
4.
Turn the engine OFF, remove ignition key and keep the key with
you.
5.
Use the key to lock and secure all the equipment locks. This will
prevent other unauthorized personnel from tampering with your
machine. Keep in mind you are responsible for securing your
machine.
Remark
Never leave your machine running and unattended, even for a moment.
Work equipment posture: See STOPPING AND PARKING THE MACHINE on page 2-101
Lock: See WORK EQUIPMENT on page 2-108
KEEP OPERATOR'S COMPARTMENT CLEAN
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the
pedal with mud or oil on your shoes, your foot may slip and this may cause an accident.
Do not leave parts or tools lying around the operator's compartment.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
Never bring any dangerous objects such as flammable or explosive items into the operator's cab.
1-18
WA380-6
SAFETY
DUST HAZARD PRECAUTIONS

Dust can be hazardous to your health if inhaled. Komatsu does not use
asbestos in its products. There is a danger imitation products may contain asbestos. If you have to handle materials containing asbestos fibers
or other dust materials during demolition operations, always do as follows.
Never use compressed air for cleaning.
Use water to keep down the dust when cleaning.
If there is a danger there may be asbestos dust in the air, operate the
machine with the wind to your back whenever possible.
Use an approved respirator.
Do not allow any other person into the area during operation.
ASBESTOS HAZARD ALERT

Asbestos dust in the air can cause lung cancer if they are inhaled. There
is danger of inhaling asbestos materials when working on jobsites doing
demolition work or handling industrial waste. Always observe the following.
Spray water to keep down the dust when cleaning. Do not use
compressed air for cleaning.
If there is danger that there may be asbestos dust in the air, always
operate the machine from an upwind position. All workers should
use an approved respirator.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and
environmental standards.
CRUSH OR PINCH POINT DANGERS

Never stand in or place any part of your body between the movable
components such as the articulating portions of the machine or between
the machines work equipment.
Keep in mind, when the machine is operated, the clearance will change,
this may lead to serious personal injury or death.
Never drive up to any one standing in front of a solid object or your path
of travel. The brakes could fail or the machine could slide on a slippery
surface causing injury or even death.
WA380-6
1-19
SAFETY
PRECAUTIONS BEFORE STARTING OPERATIONS

As an operator of the machine, you are responsible for the safe operation of the machine at all times regardless of the
situation. Although KOMATSU cannot cover all operating conditions that pose a major hazard here are a few basic situations
to avoid when using the excavator during work or travel operations. It is advised to study these and always be aware of them
before starting your work operations. Failure to do so may result in damage to the machine or injury to the operator and other
personnel.
PRE-OPERATIONAL CHECKS
Before starting your work operations it is important to perform a Pre-operational Check to be sure your equipment is in safe
operating condition. If any problems are found during your Pre-operational Check, have them repaired immediately. Never
operate a machine that is unsafe, damaged or in need of repair. Failure to perform a pre-operational check before starting work
operations may result in damage to the machine or injury to the operator and other personnel.
Remark
It is important that a pre-operational check be performed at the beginning of your work shift, even if you are
taking the machine operations over from another operator, always perform a pre-operational check before you
start work.
STARTING YOUR WORK OPERATIONS
Before operating the machine, walk around it and check for people
or objects that might be in the way.
Do not start the engine if warning tags have been attached to the
steering wheel or control levers.
Sound your horn to warn others in the area before starting the
engine or moving the machine.
Operate the machine in a seated position only, with the seat belt
fastened snugly around your waist.
Do not allow anyone in the cab or on the machine during operations.
Be sure all personnel are clear from your work site before starting
any work operations.
Inspect for damaged hoses which may leak or spray fluids.
Before operating the machine, walk around it and check for people or objects that might be in the way.
Make sure the safety bar (1) is securely in place.
Do not start the engine if warning tags have been attached to the steering wheel or control levers.
Sound your horn to warn others in the area before starting the engine or moving the machine.
Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.
1-20
WA380-6
SAFETY
WORK SITE HAZARDS

Before proceeding with any excavating or grading operations it is
important to be aware of the hazards involved with this
operation. Below is a list outlining what to do to avoid some of
these hazards.
Before starting any excavating or grading operations,
contact all utility departments in your area and have them
identify and mark any underground system locations, (gas
lines, water lines, electrical lines, sewer lines, etc.).
Check your work area for any unusual ground conditions.
Make sure your work area is as level as possible and you
will be able to maneuver your work equipment or machine
easily.
If you will be working near a high traffic area, (pedestrians
or cars) have a dedicated worker available to direct traffic or
install safety fencing around your work site.
Always be aware of all your work site dangers or
distractions.
Operations such as logging, mulching, land clearing or landfill operations may cause trash and debris to accumulate on the
machine. Remove debris or trash on a daily or more frequent basis as necessary to prevent fire.
Always clean trash from the exhaust system compartments. The hot exhaust compartments may cause fire from contact
with flammable material.
Remove any leaves, wood chips, paper, wood dust or anything that could catch fire accumulated around the engine.
AVOIDING DANGEROUS SITUATIONS

Avoid traveling with the bucket raised. Rasing the bucket raises the
center of gravity on the machine. Traveling with a raised bucket,
especially a loaded bucket may result in loss of control or a rollover
situation. Never raise the bucket unless the machine is stopped.
When the bucket is raised and loaded, never make sharp turns or stop
the machine suddenly, this may cause the machine to tip forward.
WA380-6
1-21
SAFETY
Always handle unstable loads carefully, avoid tipping the bucket
back or raising the load too high. Be sure to operate the work
equipment carefully and keep the load as close to the ground as
possible.
Do not use the bucket or lift arms as a crane. The object you are
lifting may swing or shift causing the machine to tip, sway or
possibly rollover.
Never work under overhangs or excavated bank areas. These could

collapse and damage the machine or injure the operator.
WORKING CLEARANCES
It is always a good idea to be aware of your clearances around, in
front, behind and especially above your work area or travel rout.
.Some basic safety precautions to prevent risk are:
When working or traveling in an area where clearances are a
problem, travel at a slow cautious speed.
If you are not sure of your clearances, request the aid of another
person who can guide or warn you if you get too close to objects.
1-22
WA380-6
SAFETY
Be aware of the dangers when working around overhead

electrical lines, high humidity may pose an electrical hazard even
if your machine clears the overhead power lines.
If your machine should come in contact with overhead electrical
lines, stop the machine and remain on the machine until the
power company clears the lines and it is safe to get off or move
the machine.
If low power lines pose a greater hazard, ask the power company
to remove the lines until your work is finished.
Cable Voltage
WA380-6
Min. Safe Distance
6.6kV
3m
10 ft.
66.0kV
5m
16 ft.
275kV
10 m
33 ft.
500kV
11 m
36 ft.
1-23
SAFETY
RULES FOR ROAD TRAVEL

Traveling with your machine may pose some hazards. When traveling, always travel in a safe manor and remain alert at
all times A safety conscious operator is the most important insurance when traveling with the machine. Below are several
situations and information the operator should be aware of:
1.
Raise the loader bucket to a safe travel height of 40-50 cm

(16-20 in) from the ground, lock the loader control levers using
the safety lock equipped with the machine.
2.
Obey all traffic rules when traveling on local and state roads.
Always travel at a safe controllable speed.
3.
Never turn the ignition key off when traveling. If the engine
should stop, apply the brakes and stop the machine immediately.
4.
Always be aware of your clearances and road surface. Some

areas may not support the weight of your machine. Plan your
rout in advance. If necessary, obtain the aid of an escort to lead
or prepare your travel rout.
5.
Never travel at high speeds, loss of control or tire damage may result.
TRAVELING IN REVERSE
Traveling in reverse may pose several hazards. Below is a list if some
basic rules to follow when traveling in reverse:
Be sure the area behind you is clear of people or objects that
might be in the way
Before moving your machine, sound the horn to warn others in
your area you are moving.
When operating in areas that may pose a hazard or has poor
visibility, designate a person to direct your movements.
Do not rely totally on you machines mirrors, keep in mind there
are blind spot when using the mirrors.
TRAVELING ON ICY OR SNOW-COVERED SURFACES

If the ground is icy or covered with snow, the response of the machine to the movements of the steering wheel may not be
as precise as expected. To limit the risk resulting from reduced maneuverability, proceed as follows:
Travel at a slow safe speed. Avoid rapped accelerations or breaking.
Remember your stopping distances are reduced during slippery conditions.
WORKING ON LOOSE OR UNSTABLE GROUND

To limit the risk when working in these areas:
Avoid operating the machine too close too the edge of a cliff, open trenches or ditch lines. These areas may collapse
under the weight of your machine causing serious damage to the machine or injury to the operator.
Keep in mind after a heavy rain or thaw, the surface conditions become worse and less stable.
1-24
WA380-6
SAFETY
TRAVEL ON SLOPES
Traveling on slopes may pose a hazard. In order to prevent tipping
the machine or losing control it is important to follow some basic
simple rules:
.
Never turn the ignition key off when traveling up or down a slope.
If the engine should stop, apply the brakes and stop the machine
immediately.
When traveling over rough ground travel at a slow controllable
speed.
When traveling up or down slopes with an empty bucket it is
important to travel at a safe controllable speed with the bucket set in
position A 20 to 30 cm (8 to 12 in) above the ground.
When traveling up or down a slope with a load, always keep the

bucket 20 to 30 cm (8 to 12 in) above the ground and the load
facing the top of the hill.
Never travel up or down a slope with the load facing the bottom of
the hill. Loss of control may result when the brakes are applied.
WA380-6
1-25
SAFETY
Always travel straight up or straight down a slope, traveling at an
angle on a slope may cause the machine to tip or possibly rollover.
PARKING THE MACHINE

When parking the machine it is important to follow several basic
safety rules. Keep in mind you are responsible for the security of the
machine when it is parked. Below is a list if some basic rules to
follow when parking your machine.
1.
Always park the machine on a flat level location away from

moving equipment, pedestrians or traffic.
2.
Lower all work equipment on to the ground and neutralize all

controls.
3.
Remove the ignition key, set the parking brake in the PARK
mode and lock the controls.
See LEAVING OPERATORS COMPARTMENT on page 1-18
Be sure all access panels, cab, fuel and oil tanks are locked and
secure to prevent tampering with the machine while unattended.
4.
Avoid parking the machine on a slope of any kind. If you must

park on a slope, park with the bucket facing down the slope and
the wheels blocked to prevent any movement of the machine.
1-26
WA380-6
SAFETY
PRECAUTIONS DURING MAINTENANCE OPERATIONS

All maintenance performed on this machine must only be performed by trained and authorized personnel. When
performing maintenance it is important to follow the outlined maintenance procedures and safety information outlined in
this manual and in the Shop Manual for this machine.
WARNING TAGS
For machines equipped with the Electronically Controlled
Suspension System (ECSS) be sure the system is off before
proceeding with any maintenance procedures.
Before performing any maintenance operations on this machine,
position the machine on level and firm surface.
Lock the equipment controls, remove the ignition key and tag the
steering wheel.
Alert all personnel in your area that the machine is down for
maintenance. If necessary, tag the machine around specific
points to warn others that this machine is down for maintenance.
If the machine will be down for maintenance for a long period of
time, be sure to check and see if the warning tags are still in place
before you start your repair procedures the next day.
EQUIPMENT STORAGE
Always store optional or extra work equipment in a safe and secure
location.
Do not store flammable liquids or materials for any length of time.
WA380-6
1-27
SAFETY
Store equipment in such a way that it cannot fall or cause injury to
others.
WORKING UNDER THE MACHINE

Always use approved jack stands to support the machine when
performing maintenance under the chassis.
Never rely on hydraulic jacks or the machines work equipment to
support the machine when working under or on the machine.
Always lower the work equipment to the ground after raising the
machine for repairs.
When carrying out maintenance or repairs with the bucket raised,

always support the bucket safely with the proper support (1) as
shown in the illustration.
USING DROP LAMPS

Use only approved anti-explosion proof lamps when checking fuel,
oil, or batteries. Non-approved lamps can cause an explosion or fire.
1-28
WA380-6
SAFETY
KEEPING THE MACHINE CLEAN

Never use flammable liquids to clean your machine. Use only
approved non-flammable cleaning solvents to clean parts or the
machine itself.
Avoid using high pressure steam cleaners or caustic soaps to wash
the machine if possible. Steam cleaning or using caustic soaps may
damage paint, wiring or sensitive electrical components.
Never use high pressure water or flood the inside of the operators
cab. Doing so may damage sensitive electrical components.
When pressure washing, use high pressure hot water and mild grease
cutting soaps.
Always grease the machine after cleaning to push any water out of the pivot point connections.
Remove trash daily or more often as necessary. Never allow trash to accumulate on the machine.
RUNNING THE MACHINE DURING MAINTENANCE

If during maintenance the engine must be run have someone remain
in the operators seat while the engine is running. This is if the engine
must be shut down quickly.
Be sure all work equipment is LOCKED and the ECSS system
is off.
For machines equipped with the Electronically Controlled
Suspension System (ECSS) be sure the system is off before
proceeding with any maintenance procedures.
Set the parking brake in the LOCK mode and instruct the
person sitting in the cab not to operate any controls unless instructed
to.
WA380-6
1-29
SAFETY
Always lock the front and rear frames with the safety bar (1).
Be aware of rotating parts while the engine is running.
RULES FOR REFUELING THE MACHINE

Always clean up any spills. Grease, fuel, oil or coolant spills can pose
a trip hazard if not moped up immediately.
Be sure you are adding the correct fluids to the proper location.
Mixing fluids can cause damage to internal components.
When refueling or adding any fluids, be sure you are in a well
ventilated area. Never smoke or allow open flames near you while you
are refueling the machine.
Never mix gasoline with diesel fuel. Gasoline is extremely
flammable and could cause an explosion. Do not fill the fuel tank
completely, leave room for the fuel to expand.
COOLING SYSTEM PRECAUTIONS

Never add coolant to a hot or warm engine. Always allow the engine
time to cool down completely before opening the radiator cap.
Never dump used coolant on the ground, in a lake, stream or in a
sewer system. EPA Law requires these fluids to be captured and
recycled properly. Failure to do so is in violation of the law.
1-30
WA380-6
SAFETY
BATTERY PRECAUTIONS
When working on the electrical system, disconnect the negative (-)
battery cable first then the positive (+) battery cable last.
On completion of work, reconnect the positive (+) cable first then the
negative (-) cable last.
When using jumper cables to start the machine as shown below, hook
the positive (+) jumper up first, then the negative (-) jumper last to a
remote location on the chassis.
STARTING THE MACHINE

Never try to start the machine by tampering or shorting the starter
terminals. Accidental movements of the machine could cause injury
or even death.
Always start the machine seated in the operators cab using the
ignition switch.
See ELECTRICAL CIRCUITS on page 2-137
Never use a welder or a machine with a higher voltage system to jump start the machine. Using a
higher voltage to jump-start a machine may damage the machines electrical system or cause an
unexpected explosion or fire. Always jump-start a machine with equal voltages and never allow the
machines to touch each other when jump starting a machine.
WA380-6
1-31
SAFETY
HIGH PRESSURE HOSES

The hydraulic system is always under internal pressure. When
inspecting or replacing piping or hoses, always check that the pressure
in the hydraulic circuit has been released. If the circuit is still under
pressure, it will lead to serious injury, so always do as follows.
Do not carry out any inspection or replacement work when the hydraulic
system is under pressure.
If there is any leakage from the piping or hoses, the surrounding area
will be wet, so check for cracks in the piping and hoses and for swelling
in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small holes may
penetrate your skin or cause blindness if it contacts your eyes directly. If
you are hit by a jet of high-pressure oil and suffer injury to your skin or
eyes, wash the place with clean water, and consult a doctor immediately
for medical attention.
SAFETY HANDLING HIGH-PRESSURE HOSES

If oil or fuel leaks from high-pressure hoses, it may cause fire or
defective operation, which may lead to serious injury. If any loose bolts
are found, stop work and tighten to the specified torque. If any damaged
hoses are found, stop operations immediately and contact your Komatsu
distributor.
Replace the hose if any of the following problems are found.

Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
PRECAUTION FOR HIGH FUEL PRESSURE

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or
maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go
down before starting inspection or maintenance. Never loosen a fuel injector line while engine is running severe injury may
result from the high pressure fuel spray.
HIGH TEMPERATURES AREAS

When you stop the machine at the end of a job, remember the engine
coolant, oil, all engine parts, exhaust stack and the hydraulic system
is still hot and under pressure. If you attempt to drain engine coolant,
hydraulic fluid, or engine oil under these conditions, you expose
yourself to various dangers, including the risk of serious burns.
Carry out maintenance procedures described in this manual only
when the machine has had time to cool down.
1-32
WA380-6
SAFETY
DISPOSAL OF WASTE MATERIALS

Never dump waste fluids in a sewer system, on the ground in rivers,
etc.
Always drain fluids from your machine into the appropriate
containers.Never drain fluids directly onto the ground.
Obey appropriate laws and regulations when disposing of harmful
objects such as oil, fuel, filters, batteries, coolant, brake fluid and
hydraulic oil.
INFLATING TIRES
Always bear in mind that tires can burst while being inflated, causing
serious accidents. Before servicing the tires, observe the following
precautions:
Before inflating tires, always check the wheel rims, tire walls
and tread for cuts, broken cords, or other damage.
Have a tire expert perform checks and tire maintenance.
When inflating tires, use a protective cage, and a compressed air
gun with extension hose and pressure gauge.
Make sure there is nobody in the vicinity before starting to
inflate a tire. Stand at the tread side of the tire to inflate it.
DISPOSAL OF WASTE MATERIALS

Never dump waste fluids in a sewer system, on the ground in rivers,
etc.
Always drain fluids from your machine into the appropriate
containers.Never drain fluids directly onto the ground.
Obey appropriate laws and regulations when disposing of harmful

objects such as oil, fuel, filters, batteries, coolant, brake fluid and
hydraulic oil. Recycle when ever possible.
WA380-6
1-33
SAFETY
ACCUMULATOR
This machine is equipped with an accumulator charged with
high-pressure nitrogen gas. Before servicing the accumulator,
observe the following precautions:
Do not dissemble the accumulator.
Do not expose the accumulator to high heat or an open flame.
Do not weld on the accumulator.
Do not drill or cut the accumulator.
Do not strike or crush the accumulator.
When replacing or disposing of the accumulator, always release
the nitrogen pressure from the chamber.
CRITICAL PARTS
Periodically some parts must be replaced due to safety purpose. Even if
these parts seem to be in good condition and operating
properly they may fail at some point causing possible injury to the
operator or pedestrian. Listed are some of the systems
containing these components that may fail under extended use:
Seat belts.
Fuel supply and delivery hoses.
Hydraulic system: main delivery hoses and tubing.
Hydraulic hoses: all the hoses that feed and return the hydraulic
fluid to and from the work equipment.
For additional information: See PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS on page 3-15
HIGH VOLTAGE
When the engine is running or immediately after it has stopped, high
voltage is generated at the injector terminal and inside the engine
controller, so there is danger of electrocution.
Never touch the injector terminal or the inside of the engine controller.
If it is necessary to touch the injector terminal or the inside of the engine
controller, please contact your Komatsu distributor.
1-34
WA380-6
OPERATION
WA380-6
2-1
OPERATION
GENERAL VIEW OF MACHINE

OUTSIDE VIEW OF THE MACHINE
1.
2.
3.
4.
5.
6.
7.
2-2
Bucket
Tilt lever
Front wheel
Bucket cylinder
Front working lamp
ROPS cab
Rear wheel
8.
9.
10.
11.
12.
13.
Turn signal lamp

Head lamp
Lift cylinder
Lift arm
Rear working lamp
Rear combination lamp
WA380-6
OPERATION
INSIDE VIEW OF THE CAB
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Directional lever stopper

Rear wiper switch
Front wiper switch
Gear shift lever
Front switch panel
Directional lever
E.C.S.S. switch
Horn switch
Machine monitor
Steering wheel
Hazard lamp switch
Lamp switch, Turn signal lever, Dimmer switch
Parking brake switch
Cigarette lighter
WA380-6
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Kickdown switch
Lift arm control lever
Hold switch
Bucket control lever
Ignition switch
Right switch panel
Accelerator pedal
Right brake pedal
Steering tilt lock lever
Left brake pedal
Safety lock lever
2-3
OPERATION
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS

Before operating the machine it is important to understand all the functions equipped with your machines monitor.
Operating the machine without knowledge of all the alert systems may damage the machine, property or possibly cause
injury to the operator. Below is a description of all monitoring functions.
INSTRUMENT BEZEL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2-4
Central warning lamp

Brake oil pressure caution lamp
Engine oil pressure caution lamp
Water separator caution lamp
Radiator coolant level caution lamp
Engine oil level caution lamp
Transmission filter clogging caution lamp
Air cleaner clogging caution lamp
Parking brake pilot lamp
Axle oil temperature caution lamp
Cooling fan reverse rotation pilot lamp
Maintenance caution lamp
Battery electrolyte level caution lamp (if equipped)
Battery charge caution lamp
Steering oil pressure caution lamp
Emergency steering pilot lamp
Character display portion
Power mode pilot lamp (P mode)
Pre-heat pilot lamp
Semi auto digging pilot lamp (if equipped)
Lockup pilot lamp (if equipped)
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Joystick pilot lamp pilot lamp

Directional selector pilot lamp
Shift indicator
Auto-shift pilot lamp
Auto-greasing pilot lamp (if equipped)
Shift hold pilot lamp
Shift lever position pilot lamp
Torque converter oil temperature gauge
Torque converter oil temperature caution lamp
Engine coolant temperature gauge
Engine coolant temperature caution lamp
Speedometer
Turn signal pilot lamp
Head lamp high beam pilot lamp
Meter display pilot lamp
Hydraulic oil temperature caution lamp
Hydraulic temperature gauge
Fuel level caution lamp
Fuel gauge
Economy operation display lamp
WA380-6
OPERATION
SWITCH PANELS
These switches are used to control various functions relating to the machines operating system, it is important the operator
become familiar with the switch function and what system they control Without knowledge of all the switch controlled
systems damage the machine, property or possibly cause injury to the operator may result.
RIGHT SWITCH PANEL

1. Transmission shift mode selector switch
2. Transmission cut-off switch
3. Transmission cut-off set switch
4. Directional selector switch actuation switch
5. Emergency steering switch
(machines equipped with emergency steering)
6. Power mode selector switch
7. Torque converter lock-up switch (if equipped)
8. Cooling fan reverse rotation switch
9. Ignition switch
WA380-6
FRONT SWITCH PANEL

10.
11.
12.
13.
Monitor panel mode selector switch 1

Front working lamp switch
Rear working lamp switch
2-5
OPERATION
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM

Before operating the machine it is important to understand all the functions equipped with your machines monitor.
Operating the machine without knowledge of all the alert systems may damage the machine, property or possibly cause
injury to the operator. Below is a description of all monitoring functions.
INSTRUMENT BEZEL
A. Character display
E. Pilot display
B. Emergency stop items
F. Meter display
C. CAUTION items
G. Central warning lamp
D. Inspection and maintenance items
2-6
When turning the ignition switch to the ON position before starting the engine, the central warning lamp, caution lamps,
and pilot lamps light up for 2 seconds to check the system.
After the alarm buzzer sounds for 2 seconds, it goes off if the condition is normal.
The shift indicator display shows 88 for 2 seconds.
The indicator gauges and meters are actuated after the above system check is completed.
The character display shows KOMATSU for 3 seconds.
If the lamps do not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for
inspection.
WA380-6
OPERATION
TYPES OF WARNING
If an abnormality occurs on the machine, or if any switch or lever is operated mistakenly, the monitor display and buzzer alert
the operator. These are the following types of warnings depending on the level of warning.
EMERGENCY STOP
This warning is given if there is a serious failure that affects the
normal operation of the machine or if a setting is incorrect.
The central warning lamp on the monitor and the caution lamp for the
location of the abnormality will light up. At the same time, the alarm
buzzer sounds and action code E03 is displayed on the character
display (1).
CAUTION
This warning is given if the engine coolant or lubricating oil overheats.
The central warning lamp on the monitor and the individual caution
lamps light up also. At the same time, the alarm buzzer sounds and action code E02 is displayed on the alert display (1).
MISTAKEN OPERATION
This warning is given if any switch or lever is operated mistakenly.
The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time.
In addition, in the following case, action code E00 is displayed on character display (1).
When the machine has exceeded the travel speed limit.

When the work equipment lock lever is at the LOCK position and the EPC control lever is at any position other than
neutral. (Machines equipped with EPC)
INSPECTION AND MAINTENANCE

This warning is given if it is necessary to perform inspection and maintenance of wear parts, or if it is necessary to check the
oil or engine coolant level. The individual caution lamp on the monitor lights up. At the same time, action code E01 is
displayed on the character display (1).
In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound
CENTRAL WARNING LAMP

This display portion (1) lights up if any emergency stop item, caution
item, or mistaken operation of any switch or lever occurs. At the same
time, the alarm buzzer sounds.
Check the content of the display and perform the specified action for the
item.
WA380-6
2-7
OPERATION
MACHINE ELECTRONIC MONITORING DISPLAY

This display system electronically monitors several major functions, these functions include the amount of operating hours on
the machine, all operating alert and failure information and service intervals. These functions can be accessed by using the
mode selector switches (1) and (2). It is important for the operator of this machine to know how to access this
information and understand what this information contains
1.
2.
Service meter
Action code display
3.
4.
Failure code display

Filter, oil replacement time display
MONITOR MODE SELECTOR SWITCHES

In order to access information on the monitor, the mode selector
switches must be used in conjunction with each other. These
switches are located on the right hand side of the instrument panel as
shown in the illustration. They allow you to enter or exit a mode as
well as navigate within the mode. There operating function is
listed below:
2-8
WA380-6
OPERATION
MODE SELECTOR SWITCH 1
Mode selector switch (1) is used to switch the function of the character
display on the monitor screen. The basic operation is as follows.
Position:
To select, confirm or enter a mode or operation.
Position:
To exit or cancel mode or operation.
MODE SELECTOR SWITCH 2

Mode selector switch (2) is used to navigate within the chosen
display on the monitor screen. The basic operation is as follows.
Position:
To go on to the next screen or function, move the cursor forward, or
to increase the number when entering numerals
Position:
To go back to the previous screen or function, or to move the cursor
back, or to reduce the number when entering numerals
MONITOR DISPLAY INFORMATION

Once you know the operating functions of the mode selector switches (1) and (2) it is important to be able to access this
information and navigate within the mode you have selected, below is a list of these mode and how to access and navigate
within them.
SERVICE METER DISPLAY

An hour meter reading or an odometer reading can be displayed in this mode if desired.
Hour Meter Display
During normal operation display (1) shows the total time in hours
that the machine has been operating. While the engine is running, the
hour meter advances even if the machine is not moving. The hour
meter advances by 1 hour of operation, regardless of the engine
speed.
You can also access the hours on the machine with the ignition
switch in the OFF position simply by pressing the () button.
Remark
When the starting switch is at the OFF position, if the service
meter is displayed even though the top () of machine
monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please
contact your Komatsu distributor for inspection.
WA380-6
2-9
OPERATION
ACTION CODE DISPLAY
If an inspection or maintenance procedure must be performed, if there is a failure on the machine, or if it should become
necessary to change your operating methods, An action code E00, E01, E02, or E03 will be displayed on the monitor
display portion (3). If different failures should occur at the same time, the action code for the most serious problem is
displayed. The action code will be displayed first, then the system with the failure will be displayed at 3 second intervals.
The level of seriousness in the action code order is as follows, starting with the most serious: E03, E02, E01, E00. In the
case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning lamp lights up.
Action Code (E03)
This code is the most serious of all the codes, it usually indicates an
oil pressure loss or a malfunction in a safety related system. If this
code should appear on the monitor, stop and shut the machine down
immediately. Contact your Komatsu Dealer and do not operate the
machine until the problem is repaired.
Remark
E03 is displayed on the top line of the character display and
CHECK RIGHT NOW and CALL are displayed in turn on
the bottom line for 3 seconds each.
The telephone number is displayed to the right of CALL. If
no telephone number has been set, the display is blank. For details of the method of inputting the telephone
number, see ENTERING A TELEPHONE NUMBER on page 2-31.
Action Code (E02)
This code warns the operator of a potential failure if action is not
taken immediately. This would be an over heat condition or an
engine over speed. If this code should appear while operating the
machine, stop the machine and allow the system to cool down or
contact your komatsu distributor for repairs.
Remark
The top line of the character display displays E02 and the
bottom line displays the condition of the machine related to
overheating.
Action Code (E01)

This code alerts the operator of a problem in the system. This would
be low coolant level or a maintenance due item. If this code should
appear while operating the machine, take the machine to a
maintenance area so servicing can be carried out or the problem can
be checked.
Remark
E01 is displayed on the top line of the character display and
MAINTENANCE or the part of the machine requiring
inspection, filling of fluid, or replacement is displayed on the
bottom line.
2-10
WA380-6
OPERATION
Action Code (E00)
This code will appear if the parking brake is not fully released or the
machine is traveling at an excessive road speed or down hill at an
excessive speed. If this should occur, slow the machine down
immediately to a safe speed. Never over speed the engine, damage to the
engine will occur. If an item related to the work equipment control lever
is displayed, return the lever to the HOLD position. (Machines equipped
with EPC)
Remark
Action codes cannot be erased or canceled, after repairs
have been made the system will automatically reset its self
and the code will disappear.
FAILURE CODE DISPLAY

If an action code is displayed, check the failure code using the failure code display method given below.When
contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code.
Method Of Displaying Failure Code
If an action code is displayed on the monitor display portion (3),
press the mode selector switch (>)button.
1.
The action code will change to the failure code.
The failure code is displayed with the first 6 digits on the left
side of the character display.
The code displayed after the space on the right side of the
failure code indicates the controller that detected the
failure code.
The failure code and the component causing the failure are
displayed on the character display for 3 seconds each.
Top right code
The controller in the system detecting the failure will

be indicated.
MON
TM
WRK
Controller detecting failure code

Machine monitor
Transmission controller
Work equipment controller (if equipped)
Press the selector switch (>) button again. If the condition is normal, the service meter is displayed for several seconds,
then the display returns to the action code. If more than one failure has occurred at the same time, the next failure code is
displayed.
WA380-6
2-11
OPERATION
SERVICE DISPLAY
After a complete system check when the ignition switch is turned to the ON position, if any filter or oil related item is
approaching its replacement time, this display (4) shows the item for approx. 30 seconds. When this happens, the
maintenance caution lamp also flashes or lights up. If this should occur during operation of the machine, have the
maintenance performed as soon as possible. After replacing the filter or changing the oil, it is important to reset the
time for replacement.
Service Items List
Item
Service Interval (hrs.)
System Needing Service
System ID Number
Engine oil
500
ENG OIL
01
Engine oil filter
500
ENG FILT
02
Fuel pre-filter
500
FUEL P FILT
41
Fuel filter
500
FUEL FILT
03
Transmission oil
1000
TM OIL
12
Transmission filter
1000
TM FILT
13
Hydraulic filter
2000
HYD FILT
04
Hydraulic tank vent element
2000
HYD BREATH
05
Hydraulic oil
2000
HYD OIL
10
Axle oil
2000
AXLE OIL
15
Service Alert Display

The ID number and item name needing service are displayed on the
monitor display, the remaining time to service the item and the
number of times a service has been performed are displayed in 3
second intervals. If the service time has already passed, a minus (-)
sign appears before the time display. After the display has been on
for 30 seconds, it does not appear again until the ignition switch is
turned to the ON position again.
The service information in the illustration is not shown on the
monitor display if an action code is being displayed.
The top line of the character display shows the ID No. and item name
for the item needing replacement; the bottom line shows the time remaining until replacement and the total number of times
the replacement has been carried out.
If the replacement time has already passed, a minus (-) sign appears before the time.
After the display has been given for 30 seconds, it does not appear again until the starting switch is turned to the ON position.
The message in the illustration above is not shown on the character display if an action code is being displayed.
If there are two or more items to be displayed, the display changes repeatedly every three seconds. If there are more than 10
items, all the items are displayed once each, then the display returns to the normal display.
The display appears when there is 30 hours remaining until the filter or oil replacement time. If the replacement time has
passed, a minus (-) sign appears before the time for the first 30 hours. When more than 30 hours have passed, the display is no
longer given.
The maintenance caution lamp flashes as the replacement time approaches, and after the replacement time has passed, it lights
up.
2-12
WA380-6
OPERATION
Resetting Service Times After Servicing
Once an item has been serviced and the machine is ready to go back into operation it is necessary to reset the service time
interval. It is important to do this in order to keep track of when it will be time to perform service on the machine again.
Below is the procedure for resetting the service time interval.
1.
To enter reset mode the ignition key must be in the ON position.
2.
Press the () selector switch button and it will display the

odometer.
3.
Using the (>) selector switch button scroll thought the menu to
the [MAINTENANCE] display.
4.
Once the [MAINTENANCE] display is reached, press the ()

selector switch button to enter the system.
5.
Once in the system using the (< >)selector switch buttons you
can scroll through the eight service items listed on page 2-24.
6.
When you have found the item that was serviced, using the ()
selector button switch reset the service time interval, a
[00: RESET] will appear on the monitor display. 3 seconds
later a [YES <> NO ENTER] will appear.
7.
To reset the service interval, select YES or NO using the (< >)
selector switch buttons. Once you have chosen yes or no, use the
() selector button to reset the maintenance time interval If yes
is selected the service time interval is reset and a beep is heard.
If no is selected the service time is not reset.
WA380-6
2-13
OPERATION
SELECTING LANGUAGE
To switch the language on the mode display. The following explanation outlines the procedure for changing the
language to either English, Japanese, German, French, Italian, Spanish or Swedish.
To Select A Language
1.
To enter reset language mode the ignition key must be in the ON

position.
2.
Press the ()selector switch button and it will display the

odometer.
3.
Using the (>)selector switch button scroll through the menu to

the [LANGUAGE] display.
4.
Once the [LANGUAGE] display is reached, press the ()

selector switch button to enter the system. The current language is
displayed.
5.
Once in the system using the(< >)selector switch buttons you

can scroll through the seven languages.
6.
After selecting a language, press the () selector switch button.

This confirms the language. To abort, press the () selector
switch button. When completing the operation, press the ()
selector switch button twice or turn the ignition switch OFF.
2-14
WA380-6
OPERATION
EMERGENCY STOP WARNING SYSTEM

If any abnormality occurs in the (Emergency Stop Warning System), an audible alarm will sound intermittently. The lamp for
the location of the abnormality will light up also. If any of these lamps are illuminated during operation of the machine, park
the machine in a safe location, lower the work equipment, set the parking brake and shut the engine OFF. Contact your local
Komatsu Dealer for repairs.Do not operate the machine until repairs have been made.
1.
2.
Brake oil pressure caution lamp

Engine oil pressure caution lamp
3.
4.
Battery charge circuit caution lamp

Steering oil pressure caution lamp
BRAKE PRESSURE WARNING LAMP

This lamp (1) lights up when the brake oil pressure goes below the
specified value.
During checks before starting (when the starting switch is turned to the
ON position but the engine is not started), the brake circuit is
not actuated while the engine is stopped, so the brake oil pressure
caution lamp and central warning lamp do not light up and the
During operation (engine running)
If the brake oil pressure goes down during operation, the brake oil
pressure caution lamp and central warning lamp light up and the alarm
buzzer sounds intermittently.
At the same time, the top line of the character display displays E03 and the bottom line displays CHECK RIGHT NOW
and CALL alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the engine, and carry out
inspection.
If the brake oil pressure caution lamp lights up, the footbrake may not work. Keep the parking brake applied to prevent the
machine from moving.
In addition, when the accumulator is being charged immediately after starting the engine, the brake oil pressure caution lamp
will light up, but the central warning lamp remains OFF and the alarm buzzer does not sound.
WA380-6
2-15
OPERATION
Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and the brake oil
pressure caution lamp goes out. alarm buzzer does not sound.
ENGINE OIL PRESSURE WARNING LAMP

This lamp (2) lights up to warn the operator that the engine lubricating
oil pressure has dropped.
ON position but the engine is not started), this monitor does not light up.
If the engine lubricating oil pressure goes down during operation, the
engine lubricating oil pressure caution lamp and central warning lamp
light up and the alarm buzzer sounds intermittently.
At the same time, the top line of the character display displays E03
and the bottom line displays CHECK RIGHT NOW and CALL
alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the engine, and carry out inspection.
BATTERY CHARGE WARNING LAMP

This lamp (3) lights up when the engine is running to warn the operator
that an abnormality has occurred in the charging circuit.
If an abnormality occurs in the charging circuit during operation, the
battery charge circuit caution lamp and central warning lamp light up
and the alarm buzzer sounds intermittently.
and the bottom line displays CHECK RIGHT NOW and CALL
alternately for 3 seconds each, so stop the machine immediately in a
safe place, stop the engine, and carry out inspection.
STEERING OIL PRESSURE WARNING LAMP

(Red)
This lamp (4) lights up to warn the operator that the steering oil pressure
has dropped.
However, it lights up during the self-check of the emergency steering.
If the steering oil pressure goes down during operation, the steering oil
pressure caution lamp and central warning lamp light up and the alarm
buzzer sounds intermittently. At the same time, the top line of the
character display displays E03 and the bottom line displays CHECK RIGHT NOW and CALL alternately for 3 seconds
each, so stop the machine immediately in a safe place, stop the engine, and carry out inspection.
If any steering warnings should occur, do not operate the machine until diagnostics or repairs have been
made to this system. Operating the machine with a steering alert or warning could lead to loss of control
on the machine.
2-16
WA380-6
OPERATION
CAUTION ALERT WARNING SYSTEM

If an operator alert is required the (Caution Lamps), and an audible alarm will sound intermittently. The lamp for the
location of the alert as well as the central warning lamp will light up. If any of these lamps are illuminated during
operation of the machine, stop the machine in a safe location, lower the work equipment, set the parking brake and run
the engine at a low idle until the light goes out or check the system showing the problem. Contact your Komatsu Dealer
1.
2.
3.
Axle oil temperature caution lamp

Torque converter oil temperature caution lamp
Engine coolant temperature caution lamp
4.
5.
Hydraulic oil temperature caution lamp

Fuel level caution lamp
AXLE OIL TEMPERATURE CAUTION LAMP

This lamp (1) lights up to warn the operator that the brake oil
temperature has risen.
In continuous heavy-duty operations or when traveling long distances
downhill where the brake is used frequently, the axle oil temperature
becomes high. The axle oil temperature caution lamp and central
warning lamp light up and the alarm buzzer sounds intermittently.
and the bottom line displays BRAKE OVERHEAT, so take the following action.
1.
2.
Release the accelerator pedal and move the gearshift lever down one range to reduce the travel speed.
Avoid using the brake.
A. Do not keep the brake pedal depressed continuously; use the brake only intermittently.
WA380-6
2-17
OPERATION
B. When using the left brake pedal, turn the transmission cut-off switch ON to carry out operations. If use of the brake is
reduced for a short time in the way recommended above, the axle oil temperature will go down and the caution lamp
will go out.
TORQUE CONVERTER CAUTION LAMP

This lamp (2) lights up to warn the operator that the torque converter oil
ON position but the engine is not started), this monitor does not
light up.
If the torque converter oil temperature rises, the torque converter oil
temperature caution lamp only will light up. If the oil temperature rises
further, the central warning lamp will light up and the alarm buzzer will
sound intermittently. At the same time, E02 is displayed on the top
line of the character display and TC OVERHEAT is displayed on the
bottom line. Stop the machine and run the engine under no load at a mid-range speed until the lamp goes out.
COOLANT TEMPERATURE CAUTION LAMP

This lamp (3) warns the operator that the engine coolant temperature has
risen.
If the engine coolant temperature rises, only the engine coolant temperature caution lamp will light up. If the coolant temperature rises further,
the central warning lamp will light up and the alarm buzzer will sound
intermittently. At the same time as the central warning lamp lights up,
the top line of the character display displays E02 and the bottom line
displays BRAKE OVERHEAT, so stop the machine and run the
engine under no load at a mid-range speed until the lamp goes out.
HYDRAULIC OIL TEMPERATURE CAUTION LAMP

This lamp (4) lights up to warn the operator that the hydraulic oil
If the hydraulic oil temperature rises, the hydraulic oil temperature
caution lamp, the central warning lamp will light up, and the alarm
buzzer will sound intermittently. At the same time, E02 is displayed
on the top line of the character display and HYD OVERHEAT is
displayed on the bottom line. Stop the machine and run the engine under
no load at a mid-range speed until the lamp goes out
2-18
WA380-6
OPERATION
FUEL LEVEL CAUTION LAMP
Lamp (5) alerts the operator that the fuel in the tank is below 36 liters
(9.19 gal). Add fuel as soon as possible.
Remark
If the caution lamp lights up, action code E02 will not be
display on the character display.
WA380-6
2-19
OPERATION
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM

If there is need for service or inspection, the lamp for the location needing an inspection or service will light up. If any of
these lamps are illuminated during operation of the machine, take the machine to a service location immediately, lower
the work equipment, set the parking brake and shut the engine down. These items must be attended to immediately.
Failure to do so may result in a system break down. Contact your local Komatsu Dealer for service on these items. Do not
continue machine operations
1.
2.
3.
Radiator coolant level caution lamp

Engine oil level caution lamp
Battery electrolyte level caution lamp
(if equipped)
4.
5.
6.
7.
Maintenance alert lamp

Air cleaner clogging caution lamp (machines equipped with KOMTRAX)
Water separator caution lamp
Transmission filter clogging caution lamp (not available in North America)
RADIATOR COOLANT LEVEL CAUTION LAMP

This lamp (1) lights up to warn the operator that the coolant level in the
radiator has gone down.
ON position but the engine is not started), this monitor lights up if the
coolant level in the radiator is low.
and the bottom line displays COOLANT LOW, so check the water
level in the radiator and add water.
If the coolant level in the radiator becomes too low, the radiator coolant
level caution lamp will light up.
At the same time, the top line of the character display displays E01 and the bottom line displays COOLANT LOW, so
stop the engine, check the water level in the radiator, and add water.
2-20
WA380-6
OPERATION
ENGINE OIL LEVEL CAUTION LAMP
This monitor (2) lights up to warn the operator that the oil level in the
engine oil level has gone down.
During checks before starting (when the ignition switch is turned to the
ON position but the engine has not started), this monitor lights up if
the oil level in the engine oil level is low, and at the same time, the E01
ENG OIL LEV LOW is displayed on the character display. Do not start
the engine. Check the oil level in the engine and add oil.
Remark
During checks before starting, if the engine is started with the
engine oil level caution lamp lit up, the lamp will stay lit.
BATTERY ELECTROLYTE CAUTION LAMP

(If equipped)
This lamp (3) lights up to warn the operator that the battery electrolyte
level has gone down.
ON position but the engine is not started), this monitor lights up if the
battery electrolyte level is low.
and the bottom line displays COOLANT LOW, so do not start the
engine. Check the battery level.
If the battery electrolyte level becomes too low, the battery electrolyte level caution lamp will light up.
At the same time, E01 is displayed on the top line of the character display and BATTERY LEV LOW is displayed on the
bottom line, so check the electrolyte level and add distilled water.
MAINTENANCE CAUTION LAMP
If the caution lamp lights up, repair the problem as soon as

possible. If this is left as it is, it will lead to failure.
When the time for oil change is reached, this lamp (4) flashes or lights
up for approx. 30 seconds after completion of the system check when
the starting switch is at the ON position.
Remark
The maintenance caution lamp flashes when there are less
than 30 hours to the replacement time, and after the replacement time has passed, it stays on.
For details of the items covered by filter and oil replacement, SERVICE DISPLAY on page 2-12. After replacing the filter or
changing the oil, reset time for the replacement. For details, RESET FOR FILTER, OIL REPLACEMENT TIME on page 230.
WA380-6
2-21
OPERATION
AIR CLEANER CLOGGING CAUTION LAMP
This lamp (5) lights up to warn the operator that the air cleaner is
clogged.
During checks before starting (when the ignition switch is turned to the
ON position but the engine is not running), this monitor does not light
up.
If the air cleaner becomes clogged, the air cleaner clogging caution
lamp will light up, and at the same time, the E01 AIR FILTER is displayed on the character display. Stop the engine and clean or replace the
element.
Remark
Check the dust indicator installed at the side of the air cleaner.
WATER SEPARATOR CAUTION LAMP

This lamp (6) lights up if water accumulates in the water separator
installed to the fuel pre-filter.
If it lights up, check the pre-filter. For details, see REPLACING PRIMARY AND SECONDARY FUEL FILTER on page 3-47
TRANSMISSION FILTER CLOGGING LAMP

This lamp (7) is not used.
2-22
WA380-6
OPERATION
MODE ALERT LAMPS

These indicators alert the operator that the machine is in a certain operating mode or a function is operating. It is
important for the operator of this machine to pay close attention to these indications especially when the machines engine
is running or the machine is mobile, failure to do so may shorten the life of a component or inadvertently cause an
accident
1.
2.
3.
4.
5.
6.
7.
8.
9.
Parking brake pilot lamp

Cooling fan reverse rotation pilot lamp
Emergency steering pilot lamp
Output mode pilot lamp (power mode)
Preheating pilot lamp
Semi auto dig pilot lamp (if equipped)
Auto-grease pilot lamp (if equipped)
Joystick pilot lamp (if equipped)
Economy operation pilot lamp
10.
11.
12.
13.
14.
15.
16.
Shift indicator pilot lamp

Auto-shift pilot lamp
Lock-up pilot lamp (if equipped)
Shift hold pilot lamp
Shift lever position pilot lamp
Turn signal pilot lamp
Head lamp high beam pilot lamp
This feature is not used on Waste Handler applications
PARKING BRAKE PILOT LAMP

This monitor (1) lights up when the ignition switch is in the ON
position or when the parking brake is applied.
WA380-6
2-23
OPERATION
COOLING FAN REVERSE ROTATION PILOT LAMP
This monitor (2) lights up when the when the ignition switch is in the
ON position or when direction of rotation of the cooling fan is
reversed, and at the same time, the COOLING FAN REVERSE is
displayed on the character display.
EMERGENCY STEERING PILOT LAMP

position or when the emergency steering is being actuated.
If the engine stops when the machine is traveling or an abnormality
occurs in the steering oil pressure circuit, and the machine is traveling at
a speed of more than 2 km/h (1.2 mph), the emergency steering is
automatically actuated and the lamp lights up.
If the lamp lights up, move the machine immediately to a safe place,
stop the engine, and check the condition. The lamp flashes, if the
emergency steering is actuated continuously for one minute, and at the
same time, E02 EMR S/T OVERRUN is displayed on the character
display.
There is an emergency steering self-check function. For details, EMERGENCY STEERING SELF-CHECK FUNCTION on
page 2-107.
OUTPUT MODE PILOT LAMP (POWER MODE)

position or when the power mode is selected.
Use the power mode selector switch to select the output P mode.
PREHEATING PILOT LAMP

ON position or when engine preheating electric heater is actuated.
In cold weather, when the ignition switch is turned to the ON position,
this lamp lights up. When the preheating is completed, it goes out. The
preheating time differs according to the ambient temperature.
2-24
WA380-6
OPERATION
SEMI AUTO DIGGING PILOT LAMP
(If equipped)
AUTO-GREASING PILOT LAMP

(If equipped)
JOYSTICK PILOT LAMP

(If equipped)
ECONOMY OPERATION DISPLAY LAMP

This lamp (10) lights up when the economy mode is used.
SHIFT INDICATOR
This monitor (11) indicates the transmission gear range (actual travel
speed range).
AUTO-SHIFT PILOT LAMP

ON position or the auto-shift function is selected.
Use the transmission shift mode selector switch to select the shift mode.
WA380-6
2-25
OPERATION
LOCKUP PILOT LAMP
(if equipped)
ON position or the torque converter lock-up is engaged and the
transmission is set to direct drive.
For details, TORQUE CONVERTER CAUTION LAMP on page 218.
SHIFT HOLD PILOT LAMP

ON position or the shift hold is actuated.
SHIFT LEVER POSITION PILOT LAMP

This monitor (15) displays the transmission position of the gearshift
lever.
TURN SIGNAL PILOT LAMP

This monitor (16) flashes at the same time as the turn signal lamp
flashes.
If an open circuit exists in the turn signal indicator lamp system, the
flashing interval becomes shorter.
2-26
WA380-6
OPERATION
HEAD LAMP HIGH BEAM PILOT LAMP
This monitor (17) lights up when the head lamps are set to high beam.
WA380-6
2-27
OPERATION
GAUGE DISPLAY
These gauges allow the operator of the machine the ability to monitor the operating systems on the machine. It is
important for the operator to pay close attention to these gauges especially when the machines engine is running, mobile
or the working
1.
2.
3.
Torque converter oil temperature gauge

Engine water temperature gauge
Hydraulic temperature gauge
4.
5.
6.
Fuel gauge
Speedometer
Meter display pilot lamp
TORQUE CONVERTER OIL TEMPERATURE GAUGE

This meter (1) indicates the torque converter oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside the
torque converter oil temperature gauge will light up. At the same time,
the central warning lamp lights up and the alarm buzzer sounds
intermittently. In addition, E02 is displayed on the top line of the
character display and TC OVERHEAT is displayed on the bottom
line.
Run the engine under no load at a mid-range speed and wait until the
indicator goes down to white range (A).
2-28
WA380-6
OPERATION
ENGINE TEMPERATURE GAUGE
This meter (2) indicates the engine coolant temperature.
During normal operations, the indicator should be in the white range
(A).
If the indicator enters red range (B) during operations, caution lamp (C)
inside the engine coolant temperature gauge lights up. At the same time,
the central warning lamp lights up and the alarm buzzer sounds.
In addition, the top line of the character display displays E02 and
the bottom line displays ENGINE OVERHEAT.
Run the engine at a midrange speed under no load and wait for the
indicator to return to the white range (A).
HYDRAULIC TEMPERATURE GAUGE

This meter (3) indicates the hydraulic oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside the
hydraulic oil temperature gauge will light up. At the same time, the
central warning lamp lights up and the alarm buzzer sounds
intermittently. In addition, E02 is displayed on the top line of the
character display and HYD OVERHEAT is displayed on the bottom
line.
Run the engine under no load at a mid-range speed and wait until the
indicator goes down to white range (A)
FUEL GAUGE
This meter (4) indicates the amount of fuel remaining in the fuel tank.
F: Full tank
E: Fuel level is low
When the amount of remaining fuel goes below 27 liters (7.13 US gal),
the caution lamp (A) inside the fuel gauge lights up.
If it lights up, check and add fuel.
SPEEDOMETER
This meter (5) indicates the travel speed of the machine.
The display unit is indicated on meter display pilot lamp (6).
It is also possible to display the engine speed by switching meter (5).
If you wish to switch between the speedometer and tachometer, please
contact your Komatsu distributor to have it switched.
WA380-6
2-29
OPERATION
METER DISPLAY PILOT LAMP
This lamp (6) displays the unit for the travel speed or engine
tachometer.
MACHINE MONITOR
The machine monitor (1) also has the following functions:
Odometer, filter/oil replacement time reset, telephone number input,
language selection, and monitor brightness adjustment.
DISPLAYING ODOMETER
Use this when checking the total distance that the machine has traveled.
1.
2.
3.
Check that the character display is showing the service meter or the
action code. If it is giving any other display, turn the ignition switch
OFF, then turn the ignition switch to the ON position and wait
for the above display to be given.
Press the () of monitor panel mode selector switch 1. It displays
the odometer.
When completing the operation, press ( ) on the monitor panel
mode selector switch 1, or turn the ignition switch OFF.
RESET FOR FILTER, OIL REPLACEMENT TIME

The filter and oil replacement time is displayed on the character display,
so if the filter and oil have been replaced, reset the filter and oil change
time.
1.
2.
Press the () of monitor panel mode selector switch 1, and display

the odometer.
Press (>) or (<) of monitor panel mode selector switch 2 until
MAINTENANCE MONITOR is displayed.
2-30
WA380-6
OPERATION
3.
4.
5.
6.
7.
Press the () of monitor panel mode selector switch 1. It will

change to the display in the diagram on the right. The bottom line
shows two items: the replacement time on the left and the total
number of times the item has been replaced on the right.
Press the (>) or (<) of monitor panel mode selector switch 2 to
display the item (filter or oil) which has reached the replacement
time.
Press the () of monitor panel mode selector switch 1. It will

change to the display in the diagram on the right. The top line
shows [Reset] and [Item to be reset] in turn.
When resetting the replacement time, press (>) or (<) of machine
monitor mode selector switch 2, align the cursor with YES, then
press () of machine monitor mode selector switch 1. It will reset
and return to the previous screen. To abort, align the cursor with
NO, then press () of machine monitor mode selector switch 1.
When resetting the replacement time for another item, use the
procedure in Step 4. After completing, press () of machine
monitor mode selector switch 1 twice or turn the starting switch
OFF.
ENTERING A TELEPHONE NUMBER

It is possible to display the telephone number on the right side of
CALL displayed on the character display when action code E03 is
generated.
1.
2.
3.
4.
5.
6.

the odometer.
Press (>) or (<) of monitor panel mode selector switch 2 until TEL is displayed.
Press () of monitor panel mode selector switch 1. It will change
to the display in the diagram on the right. Once the telephone
number is entered, the number will be displayed next time.
Up to 12 digits can be displayed for the telephone number. The
cursor is displayed at the enter position. Press (>) or (<) of monitor
panel mode selector switch 2 to display 0 - 9". To leave a blank,
select *. When the input value is decided, press () of monitor
panel mode selector switch 1. The cursor will move to the next
position.
Repeat the procedure in Step 4 until the last digit. At the last digit, press () of monitor panel mode selector switch 1 to
return to the previous screen. If there is a mistake in the input or the input is to be stopped, press () of monitor panel
mode selector switch 1 to return to the previous screen.
When completing the operation, press () on the monitor panel mode selector switch 2 twice, or turn the ignition switch
ignition switch OFF.
WA380-6
2-31
OPERATION
SELECTING A LANGUAGE
Use this when switching the language displayed on the character
display.
The following is for when English is set as the language for the
character display.
1.
2.
3.
4.
Press the () on the monitor panel mode selector switch 1, and

display the odometer.
Press (>) or (<) of monitor panel mode selector switch 2 until
LGUAGE is displayed.
Press the () of machine mode panel selector switch 1. The

presently selected language is displayed.
Press (>) or (<) of monitor panel mode selector switch 2 and select
the language.
The available languages are English, Japanese, German, French, Italian,

Spanish, and Swedish.
5.
6.
After selecting the language, press the () of monitor panel mode

selector switch 1. To confirm, set the cursor at YES, then press
the () of monitor panel mode selector switch 1. The language will
be selected and the screen will return to the previous screen. To
abort, set the cursor at NO, then press the () of monitor panel
mode selector switch 1.
When completing the operation, press () of monitor panel mode
selector switch 2 twice, or turn the ignition switch OFF.
2-32
WA380-6
OPERATION
ADJUSTING MONITOR BRIGHTNESS
To adjust the brightness of the monitor.
1.
2.
3.

the odometer.
Press (>) or (<) on the monitor panel mode selector switch 2 until
BRIGHTNESS ADJUST is displayed.
Press the () of monitor panel mode selector switch 1.
MONITOR PANEL will be displayed on the bottom line and it
will be possible to adjust the brightness of the monitor.
The brightness can be adjusted for the overall monitor or for the liquid
crystal display only.
To adjust only the brightness of the liquid crystal display, press the (>)
or (<) of monitor panel mode selector switch 2 to switch the display to
LCD PANEL.
4.
5.
6.
7.
Press the () of monitor panel mode selector switch 1. The screen

will change to the display shown on the right and it will be possible
to adjust the brightness.
Press the (>) or (<) of the monitor panel mode selector switch 2 to
select a level between L and H (available range: 7 stages).
After selecting the brightness, press the () of monitor panel mode
selector switch 1. The brightness will be selected and the screen
will return to the previous screen.
When completing the operation, press () of monitor panel mode selector switch 2 twice, or turn the ignition switch
OFF.
WA380-6
2-33
OPERATION
MACHINE SWITCHES AND CONTROLS

Before operating the machine it is also important to understand all the functions of your machines controls and switches.
Operating the machine without full knowledge of all control systems may damage the machine, property or possibly
cause injury to the operator. Below is a description of all switch and controls functions.
SWITCH LOCATION
2-34
WA380-6
OPERATION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Ignition switch
Power mode selector switch
Transmission shift mode selector switch
Transmission cut-off switch
Transmission cut-off set switch
Lamp switch, Turn signal lever, Dimmer switch
Horn switch
Hazard lamp switch
Parking brake switch
Front working lamp switch
Rear working lamp switch
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Kickdown switch
Hold switch
Front wiper switch
Rear wiper switch
Cigarette lighter
Cab lamp switch
Rear defroster switch
E.C.S.S. switch
Emergency steering switch (if equipped)
Cooling fan reverse rotation switch
Lock-up switch
Air Conditioning controls
Radio (if equipped)
IGNITION SWITCH
This switch (1) is used to start or stop the engine.
OFF position
It is possible to insert and remove the ignition switch key, all the electric
system switches are turned off, and the engine stops. In addition, the
parking brake is automatically applied.
ON position
Electric current flows in the charging circuit, lamp circuit, and
accessory circuit. Keep the ignition switch key at the ON position
while the engine is running.
START position
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the
engine has been started. The key will return to the ON position when released.
POWER MODE SELECTOR SWITCH

This switch (2) can be used to switch the engine output to match the
purpose of the operation.
When the POWER mode is selected, the output mode pilot lamp
(P mode) on the machine monitor lights up.
NORMAL position (a): Normal mode (low engine output), operations
where emphasis is on fuel consumption, such as operations on flat
ground where high engine output is not needed.
POWER position (b): Power mode (high engine output), operations
where emphasis is on production.
Remark
For efficient fuel consumption, use the NORMAL mode.
The maximum engine speed is set lower than in the P mode, except for hard operations such as
heavy-duty digging of rock. Ample power and low fuel consumption can be obtained in the NORMAL mode.
Furthermore, by pressing the accelerator pedal lightly, it is possible to reduce fuel consumption.
Use the P mode when performing heavy-duty digging operations of rock or operations where speed is
required, or when traveling at speed under the machine's own power on flat ground or on slopes.
WA380-6
2-35
OPERATION
TRANSMISSION MODE SELECTOR SWITCH
This switch (3) is used to change the shift point when the AUTO
SHIFT/MANUAL selector switch has been switched to auto shift.
At each of the L and H positions, the system switches to auto shift and
the auto shift pilot lamp on the machine monitor lights up.
Normally, set to auto shift.
MANUAL position: System is set to manual shift and speed range is

position selected by gearshift lever
L position: Travel speed when shifting up is low (flat ground, normal
travel)
H position: Travel speed when shifting up is high (traveling uphill, traveling at high speed)
Remark
For details of the manual shift, see Manual Shift on page 2-56.
For details of the auto-shift, see AUTOMATIC SHIFT on page 2-57.
TRANSMISSION CUT-OFF SWITCH
When moving the machine on an uphill slope, set the transmission cut-off switch to the OFF position,
depress the accelerator pedal while keeping the left brake pedal depressed, then gradually release the
brake pedal and allow the machine to move. This way the machine can be prevented from traveling
backwards.
Turn this switch (4) ON and OFF.
When the switch is pressed, the pilot lamp lights up and the system is
turned ON. The transmission is shifted to neutral at the adjusted brake
depression position. Normally, keep the switch at the ON position.
For details of the method of adjusting the cut-off position,

ADJUSTING THE TRANSMISSION CUT-OFF on page 2-104.
Position (a): OFF
The left brake pedal acts in the same way as the normal brake (right
brake pedal).
Position (b): ON
The left brake pedal acts in the same way as the normal brake, and at the same time, sets the transmission to neutral.
Remark
The brake pedal position can be adjusted when the system is actuated with the transmission cut-off set switch
on the right switch panel.
2-36
WA380-6
OPERATION
TRANSMISSION CUT-OFF SET SWITCH
Apply the parking brake before adjusting the transmission cut-off position.
Turning the switch (5) to the ON position sets the transmission to

Neutral and sets the transmission cut-off function, which allows the
brake pedal applied position to be adjusted.
Position (a): ON
Cut-off position can be adjusted
When the switch is released, it automatically returns to its original
position.
For details of the method of adjusting the cut-off position,
ADJUSTING THE TRANSMISSION CUT-OFF on page 2-104.
LAMP SWITCH
This (6) is used to light up the head lamps, side clearance lamps, tail
lamps, and instrument panel lighting.
Position (a): OFF
Position (b): Side clearance lamps, tail lamps, and instrument panel
lights up
Position (c): Head lamps light up in addition to lamps at b position.
Remark
The lamp switch can be operated regardless of the position
of the lever.
TURN SIGNAL LEVER

This lever (6) operates the turn signal lamps.
Position (a): LEFT TURN: (Push lever FORWARD).
Position (b): RIGHT TURN (Pull lever BACK).
Remark
When the lever is operated, the turn signal pilot lamp will also
light up. When the steering wheel is turned to the neutral
position, the turn signal lever will return automatically to
OFF. If not, return the lever to OFF manually.
WA380-6
2-37
OPERATION
DIMMER SWITCH
This (6) switches the head lamp between high beam and low beam.
Position (a): Low beam
Position (b): High beam
HORN BUTTON
When the button (7) in the center of the steering wheel is pressed, the
horn will sound.
HAZARD LAMP SWITCH
Use the hazard lamp only in emergencies. Using the hazard

lamp when traveling could confuse the drivers of other
machines.
This switch (8) is used in emergencies, such as the case of emergency
parking on the street when the machine breaks down.
ON: All turn signal lamps flash.
PARKING BRAKE SWITCH
Always apply the parking brake when leaving the machine

or when parking it.
Even if the parking brake switch is turned ON, there is
danger until the parking brake pilot lamp lights up, so keep
the brake pedal depressed.
This switch (9) operates the parking brake.
Position (a): ON.
The parking brake is applied, and the parking brake pilot lamp lights up.
Position (b): OFF
The parking brake is released.
2-38
WA380-6
OPERATION
Never use the parking brake switch to apply the brakes when traveling, except in an emergency. The
parking brake may be damaged and this may lead to a serious accident. Apply the parking brake only
after the machine has stopped.
If the parking brake has been used as an emergency brake when traveling at high speed, contact your
Komatsu distributor to have the parking brake checked for any abnormality.
Remark
When the parking brake is applied, the machine will not move even if the directional lever is operated.
If the directional lever is placed at the F or R position with the parking brake still applied, the central warning
lamp will light up and the buzzer will sound.
Before starting the engine, turn the parking brake switch ON.
FRONT WORKING LAMP SWITCH
Always turn the working lamp off before traveling on public

roads.
When turning the front working lamp ON, operate the lamp switch to
turn the side clearance lamp ON or the head lamp ON, then operate
this switch (10).
Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched ON.
If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light up.
REAR WORKING LAMP SWITCH
Always turn the working lamp off before traveling on public

roads.
When turning the rear working lamp ON, operate the lamp switch to
turn the side clearance lamp ON or the head lamp ON, then operate
this switch (11).
Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched ON.
If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light up.
WA380-6
2-39
OPERATION
MONITOR PANEL MODE SELECTOR SWITCH 1
This switch (12) is used to switch the function of the character display.
position.
The basic operation is as follows.

Position (): press to select or confirm each mode or operation.
Position (): press to cancel each mode or operation.
MONITOR PANEL MODE SELECTOR SWITCH 2

This switch (13) is used to switch the function of the character display.
position.
The basic operation is as follows.

Position (>): Press here to go to the next screen, or to move the cursor
forward, or to increase the number when entering numerals
Position (<): Press here to go back to the previous screen, or to move the
cursor back, or to reduce the number when entering numerals
KICKDOWN SWITCH
When the gearshift lever is in 2nd, if switch (14) on the head of the left
arm control lever is pressed, the transmission will shift down to 1st.
This switch is used to increase the drawbar pull in digging operations.
If the transmission is in auto-shift, and the travel speed is below 10.5

km/h (6.5 mph) in any speed range when traveling in either forward or
in reverse, the kick-down switch is actuated and it is possible to shift
down to 1st.
This makes it easy to perform load and carry operations.
Even if the travel speed is more than 10.5 km/h (6.5 mph), this switch
can be used to shift the transmission down. Each time the kick-down switch is pressed, the speed range will shift down one
range at a time (F4 F3 F2).
When the torque converter is in the lock-up condition (if equipped), the lock-up is canceled.
Remark
When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be canceled by
operating the gearshift lever to any position other than 2nd. It is also possible to cancel the kick-down by
turning the ignition switch OFF.
In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the auto-shift.
In auto-shift, when traveling at more than 18 km/h (11.22 mph) in 3rd or at more than 28 km/h (17.4 mph) in
4th, even if the kick-down switch is pressed, the transmission will not shift down. This is to prevent overrun of
the engine.
2-40
WA380-6
OPERATION
HOLD SWITCH
To set the speed range when traveling in automatic transmission, press
switch (15) at the side of the left arm control lever knob. The
transmission will be set in the speed range displayed on shift indicator
(A) on the machine monitor and shift hold pilot lamp (B) will light up.
When the switch is pressed again, the display goes out.
Use this function to select the desired speed range when traveling up or
down hills or when performing operations such as grading.
Remark
When the torque converter is in the lock-up condition (if
equipped), the transmission cannot be set.
When canceling the shift hold, operate the directional lever or
gearshift lever or operate the transmission shift mode
selector switch to MANUAL. It is also possible to cancel the
hold shift by turning the ignition switch OFF.
FRONT WIPER SWITCH

When the rotary switch (A) of this switch (16) is turned, the front wiper
will move.
If button (B) is kept pressed, washer fluid will be sprayed out on to the
front glass.
Position (a): (OFF) stop

Position (b): (INT) Intermittent wiper
Position (c): Low-speed wiper
Position (d): High-speed wiper
REAR WIPER SWITCH

When lever (C) of this switch (17) is turned, the rear wiper will move.
Position (a): Washer liquid is sprayed out

Position (b): OFF
Position (c): Wiper is operated
Position (d): Washer liquid is sprayed out, wiper is operated.
WA380-6
2-41
OPERATION
CIGARETTE LIGHTER
This is used to light cigarettes.
After the cigarette lighter (18) is pushed in, its element will heat up and
return to its original position after a few seconds. Pull it out and light
your cigarette.
CAB LAMP SWITCH

The switch (19) is used to turn the cab lamp ON and OFF.
Position (a): OFF
Position (b): Lights up when the cab door opens
Position (c): Lights up
Remark
The cab lamp lights up even when the main switch is OFF,
so when leaving the operator's compartment, turn the switch
to position (a) (OFF) or (b).
When operating with the cab door fully open, set the switch to position (a) (OFF).
REAR DEFROSTER SWITCH

When this switch (20) is pressed, electric current flows through the
heated wire glass at the rear and the mist is removed from the glass.
Position (a): ON (removes mist from glass)
Position (b): OFF
2-42
WA380-6
OPERATION
E.C.S.S. SWITCH
If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned ON,
the work equipment will move.
If operations are performed with the E.C.S.S. switch at the ON position, the moment the E.C.S.S. switch
is operated, the work equipment may move.
Never turn on the E.C.S.S. switch during inspection or maintenance. The work equipment will move and
this will create a dangerous situation.
Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S. switch.
When performing an inspection and maintenance, first lower the work equipment to the ground, then turn the E.C.S.S.
switch OFF before starting the inspection and maintenance operation.
When carrying out leveling work, turn the E.C.S.S. switch OFF.
This switch (21) is used to turn the E.C.S.S. ON and OFF.

Position (a): ON
The pilot lamp lights up and the E.C.S.S. is actuated.
Position (b): OFF
The E.C.S.S. is not actuated.
Remark
The E.C.S.S. is a device that uses the hydraulic spring effect
of an accumulator to absorb the vibration of the chassis
during travel and allows the machine to travel smoothly and
at high speed.
When traveling in 1st, the E.C.S.S. is not actuated.
When the speed range is 2nd to 4th, and the travel speed becomes more than 5 km/h (3.1 mph), the E.C.S.S.
is automatically actuated; when the travel speed goes below 3 km/h (1.9 mph), it is automatically disengaged.
EMERGENCY STEERING SWITCH

This switch (22) is the manual control switch for the emergency
steering.
Even when the engine has stopped, steering operations are made
possible by pressing this switch.
Position (a): ON
The pilot lamp inside the switch and the emergency steering pilot lamp
on the machine monitor light up and it becomes possible to operate the
steering. When the switch is released, it automatically returns to its
original position.
Actuate the emergency steering only in cases of emergency or when
checking the function.The maximum operating time for continuous emergency steering is 60 seconds. When using emergency
steering, travel at a speed of less than 5 km/h (3.1 mph).
For details, see EMERGENCY STEERING on page 2-106.
WA380-6
2-43
OPERATION
COOLING FAN REVERSE ROTATION SWITCH
This switch (23) is used to rotate the cooling fan in the reverse direction
when cleaning the radiator.
Position (a): Manual reverse rotation switch ON

If the switch is pressed once when the fan is rotating in the normal
direction, the rotation of the fan is reversed. If the switch is pressed
again the fan returns to normal rotation. When the fan is rotating in
reverse, the cooling fan reverse rotation pilot lamp on the machine
monitor lights up. For details of the procedure for cleaning, see
CLEAN RADIATOR FINS on page 3-30.
Run the engine at idling when operating the switch.
Remark
When the direction of rotation of the fan switches, the reverse rotation pilot lamp flashes.
COOLING FAN AUTO REVERSE ROTATION SWITCH

(If equipped)
This switch (23) is used to rotate the cooling fan in the reverse direction
when cleaning the radiator.
Position (a): Auto reverse rotation function ON
The fan automatically rotates in reverse for 2 minutes every 2 hours.
The pilot lamp inside the switch and the cooling fan reverse rotation
pilot lamp on the machine monitor light up.
Position (b): Manual reverse rotation switch ON
If the switch is pressed once when the fan is rotating in the normal direction, the rotation of the fan is reversed. If the switch is pressed again, the
fan returns to normal rotation. When the fan is rotating in reverse, the
cooling fan reverse rotation pilot lamp on the machine monitor lights up. After the switch is pressed, the fan continues to rotate
in the reverse direction for approx. 10 minutes.
Position (c): Neutral (OFF)
The cooling fan is constantly set to normal rotation. Run the engine at idling when operating the switch.
When the direction of rotation of the fan is switched, the reverse rotation pilot lamp flashes.
When the machine is operating under high load or in low temperatures, the direction of rotation of the fan may not change.
This is to protect the machine.
When the engine is stopped, the fan returns to normal rotation.
When the switch is set to position (b) (Manual reverse rotation switch ON), if the switch is released, it returns to position
(c) (Neutral). Even if the switch is not kept pressed at position (b), the fan will continue to rotate in reverse direction for a
certain period, so there is no need to keep the switch pressed at position (b).
TORQUE CONVERTER LOCK-UP SWITCH

For details of the torque converter lock-up, see TORQUE CONVERTER LOCK-UP on page 5-2.
2-44
WA380-6
OPERATION
OPTIONAL SOUND SYSTEM AND AIR CONDITIONING SYSTEM

As an option your machine may be equipped with one of the listed premium sound system for your audio pleasure. Remember
safety has priority. Only operate your radio if the operating conditions allow. Familiarize yourself with the units before starting
your work operations. When listening to your radio, you should set the volume so you can hear what is going on around you.
SOUND SYSTEM COMPONENTS
1.
2.
3.
4.
5.
6.
7.
Power switch/Volume
Auto-store/preset scan button
Bass control knob
Treble control knob
Loudness button
Time/radio display selector button
Tape eject button
8.
9.
10.
11.
12.
13.
14.
Cassette door
Fast forward, rewind buttons
Preset buttons
Metal tape button
Manual tuning buttons
Seek tuning button
Band selector button
A. Band display
B. Metal tape display
C. FM stereo reception display
D. Loudness display
E. Tape direction display
F.
Preset channel display
G. Time/frequency display
WA380-6
2-45
OPERATION
POWER SWITCH/VOLUME
When this switch (1) is turned to the right, it clicks and the power is
turned on. If it is turned further, the speaker volume is adjusted.
AUTO-STORE/PRESET SCAN BUTTON

Use this button (2) to actuate the preset scan and auto-store functions.
Auto-store
Each time this button is pressed for more than 2 seconds while in radio
reception, this auto-store function automatically starts to search for the
desired station within a receivable band, and memorize the frequency in
the preset memory. During this scanning process, the frequency shown
in the right side of display continues to change. This indicates that each
frequency is memorized in the auto-store.
The auto-store function cannot be used when the channel display is flashing.
When the display is flashing, the preset scan function is being used.
Preset scan
If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations in the same
band will be broadcast one after another for 5 seconds each, starting from No. 1 through No. 6 stations consecutively.
When the desired station is found, press the button again. This stops the preset scan tuning process and switches to ordinary
broadcasting. The same process will be repeated continuously until the button is pressed again.
BASS CONTROL KNOB

Turn this button (3) to the left to reduce the low tones; turn it to the right
to emphasize the low tones.
Direction (a): Low tone reduced
Direction (b): Low tone emphasized
TREBLE CONTROL KNOB

Turn this button (4) to the left to reduce the low tones; turn it to the right
to emphasize the high tones.
Direction (a): High tone reduced
Direction (b): High tone emphasized
2-46
WA380-6
OPERATION
LOUDNESS BUTTON
This button (5) is used when playing at low volume. It makes it possible
to hear more easily by emphasizing the low tone when the low tones are
weak.
Push button: Actuated (ON)
Push button again: Canceled (OFF)
TIME/RADIO DISPLAY SELECTOR BUTTON

This button (6) is used to switch between the Radio/tape display and
the Time display.
Correcting the time press the button to set the time display.
(A) Correcting hour:
Keep the DISP button pressed and press the bottom (H) of the TUNING
button to correct the hour.
(B) Correcting minute:
Keep the DISP button pressed and press the top (M) of the TUNING
button to correct the minute.
TAPE EJECT BUTTON

This button (7) is used to stop the tape and to eject the cassette.
When this button is pressed, the tape is ejected and the radio plays.
CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right side and
insert it through the cassette door (8).
WA380-6
2-47
OPERATION
FAST-FORWARD, REWIND BUTTONS
These buttons (9) are used to fast-forward or rewind the tape.
Fast-forward/rewind
If you press the button pointing in the same direction as the lighted
arrow indicating the direction of play, the tape will be fast-forwarded; if
you press the button pointing in the opposite direction, the tape will
rewind.
To stop the tape, lightly press the button that is not locked.
The fast-forward or rewind operation will be canceled.
If the fast forward and rewind buttons are pressed at the same time, the tape will change sides.
PRESET BUTTONS
These buttons (10) are used to call up the broadcast station frequencies
preset in memory for each of buttons No. 1 to No. 6.
It is possible to preset 18 stations (FM: 12; AM: 6) with these buttons.
METAL TAPE BUTTON

(used also for preset button No. 5)
This button (11) is used when playing a metal or chrome tape.
This button is also used for preset button No. 5. When it is pressed,
MTL appears on the display.
MANUAL TUNING BUTTONS

These buttons (12) are used for manual tuning.
When TUN button is pressed, the frequency goes up; when TUN
button is pressed, the frequency goes down. If the button is
pressed down and held, the frequency will change continuously.
SEEK TUNING BUTTONS

These buttons (13) are used to seek tuning.
When the SEEK UP button is pressed, the search automatically goes
up; when the SEEK DOWN button is pressed, the search automatically goes down.
When the next station that can be received is found, it automatically
stops.
2-48
WA380-6
OPERATION
BAND SELECTOR BUTTON
When this button (14) is pressed, the band is switched between FM1,
FM2, and MW (AM). The band is shown on the display.
METHOD OF OPERATION
SETTING PRESET BUTTONS
It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6
stations, FM2: 6 stations).
If you are playing the cassette, press the tape eject button to stop the
tape.
AUTO PRESET
Use band selector button (1) to select MW (AM), FM1 or FM2.
A. Press auto-store/preset scan button (2) for less than 0.5 second.
B. The preset scan tuning function automatically searches for the
desired station within the same band and can memorize as
many as 6 stations in the preset memory.
MANUAL PRESET
Use band selector button (1) to select MW (AM), FM1 or FM2.
A. Press manual tuning buttons (2) or seek tuning buttons (3).
B. Press preset button (4) of the number to be preset for 2 seconds
while the frequency display is being shown on the
C. display. (The preset channel and frequency are displayed and
the presetting is completed).
D. Repeat the steps explained in Item 2 and 3 above to preset other stations to the subsequent numbers.
E. If you want to preset a station in the other bands, follow the steps explained in Item 1 through 4 above.
Remark
Also, use Steps 2 and 3 when changing the setting of a preset switch to another station. When the power is disconnected, such as when the battery is replaced, all the settings are deleted, so preset the stations again.
WA380-6
2-49
OPERATION
LISTENING TO RADIO
A. Turn the starting switch ON, then turn power switch (1) ON.
B. Use band selector button (2) to select MW (AM), FM1 or FM2.
C. Select the station with the preset buttons (3).
In case you do not promptly remember the number assigned to a certain
preset station, press auto-store/preset scan button (4) for less than 0.5
second. The preset 6 stations will broadcast one after another for 5 seconds each. When the desired station broadcasts, press the button again
and scan tuning stops.
D. If you want to tune in to a station that is not preset, use either
seek tuning button (5) or manual tuning button (6).
E. Adjust the volume, balance, and tone as desired.
F.
When turning the radio OFF, turn power switch (1) to the left
until it clicks.
Remark
To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape. If you insert
a cassette when listening to the radio, the tape will start to play.
LISTENING TO CASSETTE TAPE

A. Turn the starting switch ON, then turn power switch (1) ON.
B. Set the cassette with the exposed portion of the tape on the
right side and push it past the cassette door. The tape will
automatically start playing.
C. If the arrow indicating the direction of play is pointing to the

right, the top side is being played; if the arrow is pointing to the
left, the bottom side is being played.
D. When the tape reaches the end, it is automatically reversed and
the other side starts to play.
E. When finished with the tape, press the cassette eject button to
eject the tape and automatically switch to the radio.
2-50
WA380-6
OPERATION
REVERSING TAPE
When listening to the tape, press both FAST FORWARD, REWIND
buttons (A) and (B) at the same time lightly.
When this is done, the tape direction display will be reversed.
PRECAUTIONS WHEN USING
If a voltage greater than the specified voltage is input, it may cause

fire, electrocution, or other failure. Never input any voltage other
than the specified voltage.
Places inside the radio are under high voltage. Do not remove the
cover.
Do not carry out any modifications. This may cause fire, electrocution, or other failure.
If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your
Komatsu distributor to make repairs without delay.
Stow the antenna when traveling in places with low overhead clearance.
To ensure safety during operations, keep the volume at a level where it is possible to hear other machines.
If water gets inside the speaker case or radio (auto tuning), it may cause a serious problem, take care not to let water get in
these items.
Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a cloth
soaked in alcohol if the equipment is extremely dirty.
HANDLING CASSETTE TAPE
Clean the tape head approx. once a month with a commercially available head cleaning tape.
Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place
where there is a magnetic field.
Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the machine.
If the tape is slack, it easily gets caught up inside the machine. Use a pencil to wind in the tape to remove any slack.
Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to
get the tape out of the machine.
WA380-6
2-51
OPERATION
AIR CONDITIONER SYSTEM CONTROL PANEL

By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This action makes it possible
to provide a pleasant working environment, especially on dusty job sites
1.
2.
3.
Main power switch

Fan switch
Air conditioner switch
4.
5.
6.
Temperature control switch

FRESH/RECIRC selector switch
Display monitor
MAIN POWER SWITCH

Use the switch (1) to turn the main power of the air conditioner ON/
OFF.
2-52
WA380-6
OPERATION
When the switch is pressed, display monitor (A) lights up. The fan
begins operation.
When the switch is pressed again, the air conditioner is turned OFF and
the display monitor goes out. The fan stops. (When the switch is turned
ON, the setting displayed is the same as when the air conditioner was
turned OFF.)
FAN SWITCH
Use this switch (2) to adjust the air flow from the fan.
The air flow can be adjusted to 4 levels.
When this switch (A) is pressed, the air flow increases; when switch (B)
is pressed, the air flow decreases.
The setting for the air flow is displayed on the display monitor.
A: Monitor display
B: Air flow
a: Air flow Lo
b: Air flow M1
c: Air flow M2
d: Air flow Hi
AIR CONDITIONER SWITCH

Use this switch (3) to start and stop the cooling or dehumidifying
heating function.
WA380-6
2-53
OPERATION
When the main power switch is ON, if the air conditioner switch is
pressed, the air conditioner is turned ON and (A) is displayed on the
display monitor.
If the switch is pressed again, the switch is turned OFF and display
monitor (A) goes out.
TEMPERATURE CONTROL SWITCH

Use this switch (4) to adjust the temperature between low temperature
and high temperature.
When switch (A) is pressed, the temperature of the air blowing out
becomes higher; when switch (B) is pressed, the temperature of the air
blowing out becomes lower.
The setting (C) for the temperature is displayed on the display monitor.
FRESH/RECIRC SELECTOR SWITCH

Use this switch (5) to switch between recirculation of the air inside the
cab and intake of fresh air from outside.
When this switch is pressed, recirculation of inside air is selected and
(A) lights up on the display monitor.
If the switch is pressed again, intake of fresh air is selected and (B) lights up on the display monitor.
Recirculation of air inside cab
Only the air inside the cab is circulated. Use this setting when carrying
out quick cooling or heating of the cab or when the outside air is dirty.
Intake of fresh air from outside
Air from the outside is taken into the cab. Use this setting when taking
in fresh air from outside or when removing the mist from the windows.
METHOD OF OPERATION
COOLING OPERATION
1.
2.
3.
4.
5.
Press main power switch (1) of the air conditioner to turn the power
ON.
Press fan switch (2) and set the air flow to Hi.
Press temperature control switch (3) and set the display monitor to
COOL (A).
Press air conditioner switch (4) to turn the air conditioner switch
ON.
Press RECIRC/FRESH selector switch (5) to select RECIRC.
2-54
WA380-6
OPERATION
6.
When the temperature inside the cab goes down, use the temperature control switch and the fan switch to set to the desired
temperature.
If the temperature control switch is pressed to set the display monitor to COOL (A) and the air conditioner is run with the air
flow at Lo for a long period, there is a slight risk that the evaporator will freeze. If it freezes and no cold air comes out, turn
the air conditioner switch OFF, raise the temperature setting, run the air conditioner with the air flow at Hi for a short time,
then turn the air conditioner switch ON again.
HEATING OPERATION
1.
ON.
2. Press fan switch (2) and set the air flow to Hi.
3. Press RECIRC/FRESH selector switch (4) to select FRESH.
When the temperature inside the cab goes up, use the temperature control switch and the fan switch to set to the desired temperature.
Remark
Heating is carried out using the engine cooling water, so it
can be carried out when the cooling water temperature is
high.
DRYING-HEATING AND DEMISTING OPERATION

1.
ON.
2. Press fan switch (2) and set the air flow to the desired setting.
3. Press temperature control switch (3) and set to the desired
temperature.
4. Press RECIRC/FRESH selector switch (4) to select FRESH.
5. Press air conditioner switch (5) to turn the air conditioner ON.
When the outside temperature is below 0oC (32oF), the air conditioner
(compressor) may not operate.
PRECAUTIONS WHEN USING
To prevent any excessive load on the engine or compressor, use the air conditioner when the engine is running.
If the machine is used in places where there is dust or bad smell, recirculate the air inside the cab when using the air conditioner.
To prevent leakage of refrigerant from the air conditioner cooling circuit, run the air conditioner for several minutes 2 or 3
times a month, even during the off-season. If the machine is left for a long time when the refrigerant is leaking, rust will
form on the inside and this will cause failure.
To protect your health, do not make the inside of the cab too cool and do not let the cold air flow contact your skin directly
for long periods.
Ventilate the cab from time to time.
If the temperature inside the cab is high, open the door or window to let the hot air escape and let fresh air in before starting operation of the air conditioner.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
When carrying out inspection and maintenance of the air conditioner, follow the table given in CHECK AIR CONDITIONER (PAGE 4-35).
To allow the air conditioner to show its full performance and provide a comfortable environment, have inspection and
maintenance carried out periodically.
When adding refrigerant or carrying out other maintenance, special tools and instruments are needed, ask your Komatsu
distributor to carry out inspection and repair.
WA380-6
2-55
OPERATION
CONTROL LEVERS, PEDALS
1.
2.
3.
4.
Gear shift lever

Directional lever
Gear shift lever stopper
Safety lock lever
5.
6.
7.
8.
Bucket control lever

Lift arm control lever
Brake pedals
Accelerator pedal
GEAR SHIFT LEVER

This lever (1) controls the travel speed of the machine.
Manual Shift
This machine has a 4-FORWARD, 4-REVERSE speed transmission.
Place the speed control lever in a suitable position to obtain the desired
speed range.
1st and 2nd speeds are used for working.
3rd and 4th speeds are used for traveling.
However, when the speed control lever stopper is being used, it is
impossible to shift to 3rd or 4th. Disengage the speed control lever
stopper before trying to shift gears.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th.
2-56
WA380-6
OPERATION
Remark
The length of the lever can be adjusted to 3 stages (positions
A, B, C). To adjust the length, remove the screw at the bottom
of the lever knob, slide the knob to the desired position, then
tighten the screw again. The lever is installed to position B
when it is shipped from the factory.
AUTOMATIC SHIFT
Automatic gear shifting can be performed in the 2nd and 4th speed
range of the four forward and reverse speeds depending on the travel
conditions.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
The range of speeds during automatic gear shifting is determined by the

position of the gear shift lever as shown in the chart on the right.
Remark
The 1st position for the gearshift lever sets the transmission
in 1st. There is no automatic shifting of the transmission.
When shifting down from 2nd to 1st, press the kick-down
switch on the lift arm control lever.
If the transmission is in auto-shift and the travel speed is
below 10.5 km/h (6.5 mph) in any speed range when
traveling in either forward or in reverse, the kick-down switch
is actuated and makes it possible to shift down to 1st.
This makes it easy to perform load and carry operations.
Even if the travel speed is more than 10.5 km/h (6.5 mph),
this switch can be used to shift the transmission down. Each
time the kick-down switch is pressed, the speed range will shift
down one range at a time (when in 4th: F4 F3 F2; when in 3rd: F3
WA380-6
F2).
2-57
OPERATION
To set to the desired speed range when traveling uphill or downhill, or
when grading, do as follows.
When setting the speed range, press the HOLD switch on the lift
arm control lever.
The speed range is setting at the speed range displayed on the
transmission indicator on the main monitor.
When shifting up or down from set speed range, use the gear shift
lever to shift gears.
Remark
When downshifting the transmission from 2nd to 1st with the
kickdown switch, an upshift from 1st to 2nd occurs when
travel speed increases.
DIRECTIONAL LEVER
This lever (2) is used to change the direction of travel of the machine.
The engine cannot be started if the directional lever is not at N (neutral).
In this case, the central warning lamp will light up and the buzzer will
sound.
At the same time, E00 SHIFT LEVER NEUT is displayed on the
character display.
Return the gearshift lever to the N position and start the engine.
Position (a): Forward
Position N: Neutral
Position (b): Reverse
Remark
The length of the lever can be adjusted to 3 stages (positions
A, B, C). To adjust the length, remove the screw at the bottom
of the lever knob, slide the knob to the desired position, then
tighten the screw again. (The lever is installed to position B
when it is shipped from the factory.)
GEAR SHIFT LEVER STOPPER

This stopper (3) prevents the speed control lever from entering the 3rd
and 4th positions when working.
Position (a): Stopper actuated.
Position (b): Stopper released.
2-58
WA380-6
OPERATION
SAFETY LOCK LEVER
Before getting up from the operator's seat, set the safety lock lever securely to the LOCK position. If the
safety lock lever is not at the LOCK position, and work equipment control lever (A) is touched by mistake,
it may lead to a serious accident.
If the safety lock lever is not placed securely at the LOCK position, the work equipment may move, and
this may lead to a serious accident or personal injury. Check that the lever is in the position shown in the
diagram.
When pulling up or pushing down the safety lock lever, be careful not to touch work equipment control
lever (A).
This lever (4) is a locking device for the work equipment control lever.
Push the safety lock lever down to lock it.
Remark
This lever electrically locks the hydraulic circuit for the work
equipment, so if it is at the LOCK position, the work
equipment will not move even when work equipment control
lever (A) is operated.
If the work equipment control lever is operated when this
lever is at the LOCK position, the central warning lamp lights
up and the alarm buzzer sounds. At the same time, E00
WORK LEVER POSI is displayed on the character display.
BUCKET CONTROL LEVER

Lever (5) operates the bucket.
Position (a): TILT
When the bucket control lever is pulled further from the TILT position,
the lever is stopped in this position until the bucket reaches the preset
position of the positioner, and the lever is returned to the HOLD
position.
Position (b): HOLD

The bucket is kept in the same position.
Position (c): DUMP
WA380-6
2-59
OPERATION
LIFT ARM CONTROL LEVER
This lever (6) operates the lift arm.
This lever (6) operates the lift arm.

Position (a): RAISE
When the lift arm control lever is pulled further from the RAISE
position, the lever is stopped in this position. When the lift arm reaches
the preset position of the kick-out, the lever is returned to the HOLD
position.
Position (b): HOLD
The lift arm is kept in the same position.
Position (c): LOWER
Position (d): FLOAT
The lift arm moves freely under external force.
Do not use the FLOAT feature when traveling forward, the

bucket will dig in and raise the front of the machine. The
FLOAT feature should only be used in reverse.
BRAKE PEDAL
When traveling downhill, downshift the transmission to use

the engine as a brake.
When needed, use the right brake pedal. Do not use the
brake pedals repeatedly unless necessary.
Do not rest your foot on either the left or right brake pedal.
These pedals (7) operate the brakes.
Right Brake Pedal
The right brake pedal operates the wheel brakes, and is used for normal braking.
Left Brake Pedal
The left brake pedal operates the wheel brakes, and if the transmission cut-off switch is at ON, it also returns the
transmission to neutral.
If the transmission cut-off switch is at OFF, the left brake pedal acts in the same way as the right brake pedal.
Remark
When the accelerator is being used for operating the work equipment, always use the left brake pedal to slow
or stop the machine after putting the transmission cut-off switch to the ON position.
2-60
WA380-6
OPERATION
ACCELERATOR PEDAL
This pedal (8) controls the engine speed and output.
The engine speed can be freely controlled between low idling and full
speed.
STEERING TILT LOCK LEVER
Stop the machine before adjusting the angle of the steering

wheel. If the adjustment is made when the machine is
moving, serious injury may result.
This lever is used to set the steering wheel to the FREE position when
adjusting the position of the steering wheel to the front or rear or up or
down.
Pull the lever up, set the steering wheel to the desired position, then push the lever down to lock the steering wheel securely in
position.
The amount of adjustment is as follows.
Up-down
movement
When at
0 mm (0 in.)
When moved up to
40 mm (1.6 in.)
Tilt amount
0 - 105 mm
(0 - 4.1 in.)
0 - 130 mm
(0 - 5.1 in.)
WA380-6
2-61
OPERATION
SECURITY AND LOCKS

This machine is equipped with several security, locks and safety features designed to protect the operator, persons
performing service, repair or inspections on the machine as well as the general public when the machine is not in use and
unattended. It is important for the operator of the machine to know where these features are located and when to use them.
Failure to do so may result in damage to the machine or injury to personnel.
IGNITION KEY LOCKED AREAS

These areas require the ignition key to lock and secure them.
Whenever you leave the machine unattended for any length of time it
is advised to lock and secure the machine safely. Doing so will
prevent unauthorized personnel from accessing the machine.
CAB DOOR LOCKS

The left cab door is equipped with a key lock. Locking the cab
prevents access to the machine operating controls.
ENGINE ACCESS DOORS

Both sides of the engine access doors right and left are set up with a
security lock to prevent unauthorized access. Always keep these
doors locked to avoid the possibility of vandalism.
2-62
WA380-6
OPERATION
REAR GRILL
To access the fuel tank fill cap, both the rear grill and fuel cap are
locked. The lock for the rear grill is located on the lower portion of
the grill.
FUEL CAP
After refueling the machine lock the fuel tank (1) cap.
Insert the ignition key and turn the key to the OPEN position, remove
the key and unscrew the cap. To lock, fully install the cap, insert the
ignition key and turn the key to the LOCK position.
LOCKING LOCATIONS OVERVIEW

Always lock the following parts.
1.
2.
3.
4.
5.
Fuel tank filler cap

Engine side panel (2 points)
Cab door
Hydraulic tank
Rear grille
WA380-6
2-63
OPERATION
6.
Air conditioner fresh air filter
7.
Transmission filter cover
Remark
The starting switch key is used also for locks (1) to (7).
2-64
WA380-6
OPERATION
SAFETY FEATURES
Before performing any type of operation or maintenance on the machine it is important to know where and how to use the
safety features built into the machine. These safety features are of the passive type or active type.
PASSIVE SAFETY FEATURES

Passive safety features are built into the machine and need little or
no attention. It is important to inspect these safety features for
damage or ware occasionally.
ROLL-OVER PROTECTIVE STRUCTURE

(ROPS)
This is to protect the operator in a rollover situation or from falling
objects. When operating the machine, it is important to remain
within the ROPS structure to avoid any contact with falling objects
Never modify, cut or drill on any part of this structure. Doing so
may weaken the structure which could lead to possible failure in a
rollover situation.
CAB FRONTAL GUARD (OPTIONAL)

This feature is only available on machines used in severe
operations. It is designed to protect the operator from objects falling
back onto the cab and entering the operators compartment.
BACKUP ALARM
This sounds an alarm when the directional lever is set to the R
position. It is used to warn people behind the machine that the
machine will travel in reverse.
WA380-6
2-65
OPERATION
ACTIVE SAFETY FEATURES

Active safety features are safety devices that must be used by the operator in order to be effective. Failure to use these installed
features may lead to serious injury or even death.
When performing maintenance or transporting the machine, always lock the safety bar.
Always remove the safety bar for general travel operations. If it is not removed, the steering wheel will not
be able to turn the machine. This situation is extremely dangerous.
SAFETY BAR
The bar locks the front frame and rear frame to prevent the machine
from
bending during normal travel or when servicing or transporting the
machine.
SEAT BELT
The seat belt is installed to keep the operator in the seat within the cab
of the machine if the machine is ever in a rollover situation.
Always use the seat belt when operating the machine. It is important to
inspect this component for ware or damage. If the belt is worn or damaged, replace it
immediately.
Even if there appears to be no abnormality with the seat belt,

replace it once every three years.
Remark
The date of manufacture of the seat belt is marked on the belt
at the place indicated by the arrow in the diagram on the
right.
Check that the bolts that connect the seat belt to the machine are not
loose. Tighten if necessary.
Tightening torque: 24.5 4.9 Nm (18.1 3.6 lb. ft.)
2-66
WA380-6
OPERATION
If the belt is damaged or fluff is starting to form, or if there is any
damage or deformation of the seat belt holders, replace the seat belt with
a new one.
EQUIPMENT LOCK LEVER

Lever (4) is used to lock the equipment controls. By locking the
controls they cannot be operated inadvertently.
When leaving the operators cab or working within the cab always lock
the controls
WA380-6
2-67
OPERATION
MACHINE FEATURES
These features are important for the operator to know about. Although not safety related these features offer operator comfort
and convenience as well as easy care for the machine.
CAB DOOR
Always check that the cab door is locked, both when it is

open and when it is closed.
Always stop the machine on level ground before opening
or closing the door.
Avoid opening or closing the door on a slope. There is
danger that the operating effort may suddenly change.
When opening or closing the door, always use door
handle and knob.
Be careful not to get your hands caught by the front
pillar or center pillar.
When there is any person inside the cab, always call out
a warning before opening or closing the door.
CAB DOOR OPEN LOCK

When getting in or out of the operator's compartment, or when operating
with the door open, use this lock to hold the door in position.
1.
2.
3.
Push the door against catch (1) to lock it in position.

When attaching the door in position, lock it firmly to the catch.
When getting on or off the machine, hold the handrail on the inside.
4.
When closing the door from the operator's seat, push knob (2) to
release the catch.
When closing the door after getting off the machine, pull knob (3)
to release the catch.
5.
2-68
WA380-6
OPERATION
CAB WINDOW
CAB LEFT WINDOW OPEN LOCK RESET KNOB
Use this when raising or lowering the glass in the window of the left
door.
Grip lock release knob (1), release the lock, then remove the glass down
to the lower lock position. Release lock release knob (1).
When moving the glass down, there are 2 stages for lock position (A).
CAB RIGHT WINDOW OPEN LOCK RESET KNOB

Use this to keep the right window glass at the open or closed position.
Pull open lock knob (1) towards the inside of the machine to release the
lock, push open-lock knob (1) up along the rail to move to the lock position, then release the knob.
There are 2 lock positions: open and closed.
RESET RIGHT WINDOW OPEN LOCK FOR

ESCAPE
If the door of the cab does not open or it is dangerous to get off the
machine from the side where the door is, release the open lock of the
right window, open the right window fully, and use the right window as
an emergency escape route.
1.
Grip open lock knob (1) and pull it towards the rear of the machine.
2.
Remove the open lock guide rail from the window pillar guide to
free the right window lock.
WA380-6
2-69
OPERATION
3. Open the right window fully and escape through the window.
When returning the open lock knob to its original position, pull the
window to a position where it is possible to lock it, align the open lock
guide rail with the guide, then push in the open lock knob to the front.
Check that the rail is completely fitted into the guide, then secure at the
LOCK position.
It is dangerous to carry out operations with the emergency escape window lock released. The right window will extend beyond the outermost wheel.
There is also danger that the window may close suddenly when the brake is applied.
Always check that the open-lock knob for the right window glass is locked at the open or closed position
before driving the machine.
2-70
WA380-6
OPERATION
ELECTRICAL
FUSE
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is
loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
Loosen the knob (1) at two places, then remove cover (2). The fuse
boxes are A and B.
FUSE CAPACITY AND NAME OF CIRCUIT

FUSE BOX A
No.
Fuse
Capacity
Name Of Circuit
1.
10A
Left head lamp
2.
10A
Right head lamp
3.
10A
Left side clearance lamp
4.
10A
Right side clearance lamp
5.
20A
Main lamp circuit
6.
10A
Machine monitor A
Load meter (if equipped)
7.
5A
Air conditioner B
8.
20A
Air conditioner A
9.
20A
Wiper/washer
10.
20A
Backup lamp, brake lamp
11.
10A
Work equipment positioner

Work equipment controller (if equipped)
12.
5A
Emergency steering (if equipped)
13.
5A
Parking brake
14.
10A
Transmission control A
15.
10A
Horn
WA380-6
2-71
OPERATION
FUSE BOX B
No.
Fuse
Capacity
Name Of Circuit
1.
5A
Engine control B
2.
10A
Rear heater glass
3.
10A
KOMTRAX (if equipped)
4.
20A
Rotating beckon (if equipped)
5.
10A
Turn signal indicator
6.
20A
Radio, cigarette lighter, 12V power source

and air suspension seat (if equipped)
7.
10A
Rear work lamp
8.
10A
Front working lamp
9.
10A
Front working lamp
10.
30A
Engine controller A
11.
5A
Transmission control B, work equipment

control B (if equipped)
12.
10A
Cab lamp
13.
10A
Monitor B, A KOMTRAX (if equipped)
14.
10A
Hazard lamp
15.
20A
Ignition switch
If the power does not come on when the ignition switch is turned ON,
the slow-blow fuse may be blown. Check and replace it, if it is blown.
The slow-blow fuse is beside the engine on the left side of the machine.
1.
2.
3.
4.
50 A: Permanent power source

50 A: Main power A
50 A: Main power B
120 A: Heater relay (electrical intake air heater)
2-72
WA380-6
OPERATION
MACHINE CAB AND CHASSIS

SEAT ADJUSTMENT
When adjusting the operator's seat, stop the machine in a safe place before starting the operation.
Adjust the seat before starting operations for the day or when changing operators.
When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK
position to prevent any accidental contact with the control levers.
Adjustments (E), (J), and (K) use the air compressor built into the seat, turn the engine ignition switch to the ON position
when carrying out the adjustment.
LUMBAR SUPPORT TYPE SEAT
When pulling up levers (2) and (3), be careful not to pull up the switch box at the front by mistake. There is danger that the
switch box may be damaged.
When the left armrest is at the raised position, do not push down on the tip of the armrest with your hand to support your
weight. There is danger that the armrest mount may be damaged.
A. Fore-and-aft adjustment: Pull lever (1) up, set the seat to the
desired position, then release the lever.Amount of adjustment:
180 mm (7.1 in.) (10 mm (0.4 in.) x 18 stages)
B. Seat angle adjustment: Move lever (2) up and apply your
weight to the rear of the seat. The seat will tilt to the rear. Move
lever (3) up and apply your weight to the front of the seat. The
seat will tilt to the front. Amount of adjustment: 24 degrees
(front and rear tilt: 3 stages each)
C. Seat height adjustment: Move levers (2) and (3) up and move
the seat up or down to desired position. These levers are also
used for adjusting the seat angle, so adjust the seat angle to set
the seat to the desired height. Amount of adjustment: 65 mm
(2.6 in.)
D. Adjusting fore-and-aft position of seat cushion: Push lever (4)
in, set the seat cushion to the desired position, then release
lever. Amount of adjustment: 65 mm (2.6 in.)
E. Adjusting weight setting for seat: Sit on the seat, raise your
body slightly, then operate switch (5) to adjust the strength of
the suspension. Amount of adjustment: 50 - 130 kg (110 - 287 lb.)
F.
l
When + is pressed: Suspension becomes stronger
l
When - is pressed: Suspension becomes weaker
Reclining angle adjustment: Move lever (6) up and move the seat backrest to the front or rear. Push your back against
the backrest when carrying out this adjustment. If your back is not pressing against the backrest, the backrest may
suddenly spring forward.
l
Amount of adjustment: Front tilt: Free Rear tilt:40 degrees (2 degrees x 20 stages)
G. Head rest angle adjustment (if equipped): Rotate the headrest to the front or rear.
WA380-6
2-73
OPERATION
l
Amount of adjustment: Front tilt: 13 degrees Rear tilt: 13 degrees
H. Head rest height adjustment Move the head rest up or down. Amount of adjustment: 80 mm (3.2 in.)
I.
Arm rest angle adjustment: Rotate the knob (7) and adjust the angle of the arm rest. (Left side only) Amount of
adjustment: 73 degrees (front: 54 degrees; rear: 19 degrees) If the arm rest is turned, it will spring up. (Both left and
right sides)
J.
Lumbar support Operate switch (8) to give a suitable tension to the lower lumbar region. Operate switch (9) to give a
suitable tension to the upper lumbar region.
When + is pressed: Tension becomes stronger

When - is pressed: Tension becomes weaker
K. Side support: Operate switch (10) to give a suitable tension to the left and right lumbar region.
When + is pressed: Tension becomes stronger

When - is pressed: Tension becomes weaker
REMOVAL AND INSTALLATION OF HEADREST

REMOVAL
If the headrest is not needed, remove it as follows.
1.
2.
Pull up the headrest to the position where it stops.

From the top of the seat back, turn stopper (1) (under the material at
the top of the seat) of the headrest bar on one side in the direction of
the arrow, and pull up the headrest.
When stopper (1) is turned, it will come out of groove (2).
3.
Turn stopper (1) on the other side in the direction of the arrow, and
pull up the headrest.
When both stoppers (1) come out of groove (2), the headrest can be
removed.
INSTALLATION
Insert the bars into the holes in the top of the seat and push down.
2-74
WA380-6
OPERATION
HANDLING CAB WIPER
Remark
When angling the wiper arm (1) to the front, check that the
wiper blade is hanging free.
When angling the wiper arm (1) to the front, such as when wiping the
glass clean, if the wiper arm (1) is angled with the wiper blade (2)
locked to the arm (the bottom of the blade is caught on the arm),
abnormal force is brought to bear on the mounting bracket and the
bracket may break.
GREASE PUMP (IF EQUIPPED)

The grease pump is installed in the holder on the left radiator side of the
engine bulkhead at the rear of the machine. After using it, wipe off the
grease from its outside and install it in position. Insert the grease pump
in the holder and fix it with the rubber band. Hitch the tail chain of the
grease pump to the hook at the bottom of the holder.
WA380-6
2-75
OPERATION
PRECAUTIONS BEFORE STARTING WORK OPERATIONS

Before starting your work operations it is important to perform several procedures to be sure your equipment is in a safe
operating condition. It is also important to be aware of the hazards involved when operating your machine.
PRE-OPERATIONAL CHECKS
Before starting your machine and preceding with any work operations it is important to be sure your machine is safe to
operate. Below is a list of some basic items to check before any work is to begin. If any problems are found during your
Pre-operational Check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair.
PERFORM A WALK AROUND CHECK OF YOUR MACHINE

A. Look for any obvious missing or damaged items.
B. Check the condition of the loading bucket, look for loose or missing attachment pins, damaged surfaces
or missing parts.
C. Check the condition of all visible hydraulic hoses, look for worn or leaking fittings, cut, scuffed or cracked hose
surfaces. If any hose is found to be worn, cracked or leaking have it repaired or replaced immediately.
D. Check for leaking or damaged hydraulic cylinders. If any cylinder is damaged or leaking have it repaired
immediately.
E. Inspect the mechanical lift, dump and pivot points. Look for any loose or missing parts, cracked,
bent or damaged areas.
F.
Be sure all safety decals are in place and are not damaged. Be sure they are clean and visible for all personnel to see.
G. Check the condition of the front and rear tires. Look for excess wear or cut surfaces, objects imbedded in the tire or
under inflation.
If worn or damaged tires are used, they may burst and cause serious injury or death.
To ensure safety, do not use the following tires.
Wear:
Tires with a tread grooves of less than 15% of that of a new tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage that has reached the cords (1), or with cracks in the rubber
Tires with cut or pulled cords (1)
Tires with peeled (separated) surface
Tires with damaged bead (2)
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires, which do not seem usable
2-76
WA380-6
OPERATION
H. Inspect tires
I.
Inspect rims.
Check the rims (wheels) and rings for deformation, corrosion and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
J.
Check under the machine for any build-up of debris, trash or leaks. Remove any debris that is found and have the leak
checked by authorized personnel.
K. Inspect the fuel and hydraulic tanks for damage or leaks. Be sure the fill caps are installed and locked in place.
L. Be sure the steps are not damaged or covered with mud.
M. Check the condition of the cab. inspect the windows, mirrors, hand holds, work lights, directional and canopy for
any damage or missing parts. Be sure all locks are functional.
N. Check the exhaust stack, be sure it is not damaged, kinked or restricted in any way. Be sure the exhaust outlet is
facing away from the cab and is not restricted.
WA380-6
2-77
OPERATION
UNDER THE HOOD

A. Open the hood and check all fluid levels. be sure they are at the specified level outlined in the maintenance section.
B. Check the engine and radiator for any build up of trash, wood chips, rubbish, leaves or other flammable materials.
If flammable materials are found as well as excess build up of oil or dust, remove the flammable material or have
the engine cleaned.
C. Be sure the hood closes properly and will lock securely to prevent tampering by others.
CHECK COOLANT LEVEL
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to
cool down and check the sub tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high
internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of
burns. After waiting for the temperature to decrease, turn the cap slowly before removing it. This action
allows the pressure inside the radiator to release gradually.
When adding coolant, use the step and handrail to support yourself securely.
1.
2.
3.
4.
Open the side door of the engine hood on the right side of the
machine.
Check that the coolant level is between the FULL and LOW range
on sub-tank (1). If the coolant level is low, add coolant through the
water filler port of sub-tank (1) to the FULL line.
After adding coolant, tighten the cap securely.
If sub tank (1) is empty, check for water leakage, then check the
water level in the radiator. If the water level is low, add coolant to
the radiator, then add coolant to sub tank (1).
If the volume of coolant added is more than usual, check for possible
leakage.
Confirm that there is no oil in the coolant.
2-78
WA380-6
OPERATION
CHECK WATER SEPARATOR
Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt to
drain cooling water or remove the filter element cup.
High pressure is generated inside the engine fuel piping, while the engine is running. Wait for more than 30
seconds after the engine stop for the engine to sufficiently cool down. Then start with draining cooling
water or removing the filter element cup.
Do not bring fire close.
Check water separator, drain water and sediment.
1.
Open the engine side cover on the right side of the machine.
The water separator forms one unit with the fuel pre-filter, and is at
the bottom.
2.
3.
4.
It is possible to judge the condition of water and sediment through

transparent cap (3). If water or sediment is accumulated, set a
container under drain hose (4) to collect the discharged water.
Loosen plug (2) and drain the water.
Tighten plug (2) as soon as fuel starts to be discharged from drain
hose (4).
Tightening torque: 0.2 - 0.45 Nm (2 to 4 in/lbs)
5.
On this machine, sensor (5) is installed to detect if water is

accumulated at the bottom of the fuel pre-filter.
If water separator caution lamp (6) on the machine monitor lights
up, carry out the above Steps 1 - 4 to drain the water.
If plug (2) is stiff, coat O-ring (5) of plug (2) with grease.
6.
7.
Set a fuel container under drain hose (4).

Loosen plug (2), then drain all the sediment together with the fuel
from drain hose (4).
8. Check that nothing comes out from drain hose (4), then remove
plug (2).
9. Coat O-ring portion (5) with a suitable amount of grease.
10. When doing this, be careful not to let the grease get on the drain
valve water drain port (a) or the plug thread.
11. Screw in plug (2) by hand until it contacts the bottom.
12. Remove the fuel container.
If transparent cap (3) is dirty and the contents cannot be easily
seen, clean transparent cap (3) when replacing the filter.
When washing, if plug (2) is removed, coat the O-ring with grease, then tighten by hand until it contacts the bottom.
WA380-6
2-79
OPERATION
CHECK AIR CLEANER ELEMENT
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine
and damage it.
Always stop the engine before carrying out these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use protective glasses, dust mask, and other protective equipment.
1.
2.
3.
4.
5.
Open the engine side cover on the right side of the chassis.
If the yellow piston in the display portion of dust indicator (1)
installed to the air cleaner enters the red range (7.5 kPa), clean the
element.
After cleaning, press the button of the dust indicator to reset it.
If the yellow piston enters the red range (7.5 kPa) soon after the
dust indicator is reset, it is necessary to replace the element.
For details of the procedure for replacing the element, See
ENGINE AIR FILTER on page 3-19.
ELECTRIC AIR CLEANER CLOGGING SENSOR

(Machines equipped with KOMTRAX)
If the yellow piston in the display portion of dust indicator (1) enters the
red range (7.5 kPa), or air cleaner clogging caution lamp (2) on the
machine monitor lights up, clean the air cleaner element.
Remark
Do not clean at the element until the air cleaner clogging
caution lamp lights up.
If the element is cleaned frequently before the air cleaner
becomes clogged, the air cleaner will not be able to provide
its expected performance and the cleaning efficiency will
become poor.
In addition, dirt stuck to the element will drop inside the inner element more frequently during the cleaning
operation.
CHECK ELECTRIC WIRING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause
and immediately perform repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap to clean the breather hole.
Check for damage, wrong fuse capacity, and any sign of disconnection or short circuit in the electric wiring. Also, check and
tighten any loose terminals.
Particularly, check the wiring of the battery, starting motor and alternator carefully.
2-80
WA380-6
OPERATION
When checking around the battery, make sure there is no accumulation of flammable material. Remove all flammable
material.
Please contact your Komatsu distributor for investigation and correction of the cause.
CHECK ENGINE OIL LEVEL, ADD OIL
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious
burns. Wait for the temperature to go down before starting the operation.
1.
2.
3.
4.
5.
6.
7.
Open the inspection cover of the right side at the rear of the
machine.
Take out the dipstick (G) and wipe off the oil with cloth.
Insert dipstick (G) fully in the oil filler pipe, then take it out again.
The oil level should be between the H and L marks on dipstick (G).
If the oil level is below the L mark, add engine oil through oil filler
(F).
If the oil is above the H mark, drain the excess engine oil from drain
plug (P), and check the oil level again.
If the oil level is correct, tighten oil filler cap (F) securely and close
the inspection cover.
Remark
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine
before checking.
If the machine is at an angle, make it horizontal before
checking.
REAR-VIEW MIRROR ADJUSTMENT
Be sure to adjust the mirrors before starting work. If they are

not adjusted properly, you cannot secure the visibility and
may be injured or may injure someone seriously.
Mirrors A, B
Loosen bolt (1) of the mirror, then adjust the mirror to a position which
gives the best view from the operator's seat of the blind spot at the left
and right sides at the rear of the machine.
When installing the mirror, adjust so that it is possible to see

any person (or any object of a height of 1 m (3 ft 3 in) and diameter of 30 cm (11.8 in) at the rear left or right of the
machine.
WA380-6
2-81
OPERATION
Mirrors C
Adjust so that is possible to see the ground around the machine at a
range of 1 m (3 ft 3 in) from the operator's seat.
If the movement of the mirror is stiff when adjusting it, loosen

bolt (2) of the mirror.
Install the mirrors at the position and dimensions shown in the diagram.
The values below are reference values for the range of visibility.
Range of view (left): 2500 mm (8 ft 2 in)

Range of view (right): 2500 mm (8 ft 2 in)
Mirror A: Must be possible to see hatched portion (A)
Mirror B: Must be possible to see hatched portion (B)
Mirror C: Must be possible to see hatched portion (C)
Tighten the mirror mounting bolts securely that they will not be
loosened and the mirrors will not come off.
Tightening torque
Mirrors A, B: 2.0 to 2.5Nm (18 to 22 in/lbs)
Mirrors C: 8.8 to 9.8Nm (78 to 87 in/lbs)
If the tightening torque cannot be controlled, ask your Komatsu distributor for tightening the bolts.
2-82
WA380-6
OPERATION
IN THE OPERATORS CAB

A. Check the condition of the cab floor. Be sure it is clean and free from tools, objects, excess dirt, trash or grease.
B. Check to be sure both doors open and close properly. Be sure the right door is unlocked for safety purpose.
C. Check the windows for cleanliness, remove any stickers or objects pasted to the windows.
D. Make sure the fire extinguisher is in place and in operating condition.
E. Be sure the operators manual, safety manual and all cab safety decals are in place and in good condition.
F.
Check to be sure the seat belt and seat works properly.
SEAT BELT ADJUSTMENT

Always wear the seat belt.
Before fastening the seat belt, check that there is no abnormality in the belt mounting bracket or bolt. If the
belt is worn or damaged, replace it.
Fasten the seat belt before starting operations.
Always wear the seat belt during operations.
Make sure that the left and right belts are not twisted when fastening the seat belt.
Fastening And Removing The Belt

Fastening Belt
Hold grip (2) and pull the belt out from the retractor device (1), check
the belt to be sure it is not twisted then insert the tongue (3) into buckle
(4) securely. When doing this, pull the belt lightly to check to be sure it
is properly locked.
Removing belt
Press button (5) in the buckle (4) and remove tongue (3) from buckle
(4). The belt is automatically retracted. Hold grip (2) and return the belt
slowly into the re-wind device (1)
Belt Length Adjustment

To make the belt shorter: Pull the free end if the tether belt.
WA380-6
2-83
OPERATION
To make the belt longer: Set the fixed end of the tether belt at 90 degrees
to the holder and pull.
ADJUST LEVER STAND
When adjusting the lever stand, check that the work equipment lock lever is securely at the LOCK position.
If it is not at the LOCK position, and the work equipment control levers are touched by accident when
adjusting the lever stand, the work equipment may suddenly move and cause serious personal injury.
ADJUST HEIGHT AND ANGLE OF WRIST REST
The height of wrist rest (1) can be adjusted by loosening lock lever (2).
Amount of adjustment: 30 mm (1.2 in)
Angle: 44 degrees
Set lock lever (2) to the FREE position (F). The lock lever is loosened.
Hold the armrest at the desired position and move the lock lever to the
LOCK position (L) to secure the armrest in position.
ADJUST LEVER STAND FORWARD AND BACKWARD

Pull lever (1) up with your left hand, grip wrist rest (3) with your right
hand and move it to the front or rear, then release lever (1).
Amount of adjustment: 180 mm. (7 in)
2-84
WA380-6
OPERATION
START-UP PROCEDURES
When performing start-up checks, be sure your machine is in a well ventilated area.
1.
Turn the ignition switch to ON position.
CHECK MONITOR PANEL

2.
Check that all the monitor lamps, the gauges and the warning lamp
light up for about 2 seconds and the alarm buzzer sounds for about
2 second.
If the lamps do not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection.
Remark
It is important that a pre-operational check be performed at
the beginning of your work shift, even if you are
taking the machine operations over from another operator,
always perform a pre-operational check before you start
work.
CHECK FUEL LEVEL, ADD FUEL
When adding fuel, never let the fuel overflow. This action may cause a fire. If any fuel is spilled, wipe it up
completely. Never bring the flames near the fuel because it is highly flammable and dangerous.
Remark
If the engine has run out of fuel and has stopped, it is
necessary to operate the priming pump to bleed the air
completely from the fuel line before starting the engine again.
Take care not to let the engine stop because of lack of fuel.
If the engine has run out of fuel, the air bleeding operation
can be performed more quickly if the fuel tank is completely
filled with fuel.
WA380-6
2-85
OPERATION
1.
Ignition key must be in the ON position to check the fuel level

with fuel level gauge (G).
If necessary add fuel through fuel filler (F) to fill the tank. For
details of the method for opening and closing the cap, see
SECURITY AND LOCKS on page 2-62.
Fuel capacity: 300 liters (79.25 US gal.)
CHECK THE BRAKE PEDALS

Drive the machine forward and check the effect of the brakes.
If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted.
CHECK THE PARKING BRAKE

Check that the parking brake works properly.
If there is any abnormality in the operation of the parking brake or the brake does not provide the proper braking effect, please
contact your Komatsu distributor for adjustment.
2-86
WA380-6
OPERATION
FINAL CHECKS BEFORE STARTING THE ENGINE
Always set the safety lever securely to the LOCK position before starting the engine. If the control levers
are touched by accident at the time of starting the engine, the work equipment may move suddenly, which
may cause serious injury.
1.
Check to see if the parking brake switch (1) is in the A position.
2.
Check directional lever is in the N position.When starting the

engine, if directional lever (2) is not at the N position, the engine
will not start.
3.
Be sure the work equipment lock lever is in the LOCK position (L).
WA380-6
2-87
OPERATION
4.
Check that the bucket is completely lowered to the ground.

A. If it is not completely lowered, lower the bucket to the ground
as follows.
B. Check that the work equipment control lever is at the HOLD
position, then set the work equipment lock lever to the FREE
position.
C. Operate the work equipment control lever to lower the bucket
to the ground.
D. Check that the work equipment control lever is at the HOLD
position, then set the work equipment lock lever to the LOCK
position.
5.
Check that work equipment lock lever (3) is at the LOCK position
(L).
6.
Insert the key in starting switch (4), turn the key to the ON position
(B), and check that the machine monitor system works.
When the starting switch is turned to the ON position before starting the
engine, monitors, gauges, and central warning lamp light up for approx.
2 seconds, and the alarm buzzer sounds for approx. 2 sec.
If any monitor does not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection.
In addition, after all the monitors, gauges, and central warning lamp
light up, a self check is carried out to check that the emergency steering
function works properly. For details, See EMERGENCY STEERING
SELF-CHECK FUNCTION on page 2-107.
2-88
WA380-6
OPERATION
STARTING THE ENGINE
NORMAL STARTING
Start the engine only after sitting down in the operators seat with seat belt fastened around your waist.
Do not attempt to start the engine by short-ciruiting the engine starting circuit. Doing so may cause
serious bodily injury or fire.
Check to be sure that there are no persons or obstacles in the surrounding area, sound the horn and start
the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good
ventilation.
1.
With the key to the ON position. Preheating will automatically

start and preheating pilot lamp (2) will light up.
Remark
Do not accelerate the engine suddenly before completing the
warming-up operation.
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine does not start, wait for at least 2 minutes before trying to
start the engine again.
This machine is equipped with an engine automatic preheating device

that functions to start the engine preheating automatically.
If the ambient temperature is low, the preheating monitor will light up when the key in starting switch (1) is turned to the ON
position to inform the operator that preheating has been started automatically.
1. Turn the key in starting switch (1) to ON position (B).

If the ambient temperature is low, the preheating pilot lamp (2) lights up
and automatic preheating is carried out. Keep the key
in starting switch (1) at the ON position until the preheating pilot lamp
(2) goes out.
The time that the preheating pilot lamp (2) stays lighted up depends on
the ambient temperature as shown in the table on the
Ambient temperature
Heating time
-1 C to -15 C (30 F to 5 F) 0 seconds to 30 seconds

-15 C or less (5 F or less)
WA380-6
0 to 12 sec.
2-89
OPERATION
2.
3.
If the preheating pilot lamp (2) does not light up, or it lights up and
then goes out to inform that the engine preheating has been
completed, turn the key in starting switch (1) to the START position
(C).
The starting motor will continue to turn and the engine will start.
Keep the key in starting switch (1) at the START position (C) to
keep the starting motor running until the engine starts.
Remark
In low temperatures, to ensure lubrication of the engine and
to improve the durability, no fuel is supplied to the engine for
3 seconds after the key in starting switch (1) is turned to the
START position (C), so the engine will not start during this
time. Therefore, keep the key in starting switch (1) at the
START position (C) to keep the starting motor running until the
engine starts.
4.
When engine is started, release the key of ignition switch (1) and
the key will return automatically to ON.
STARTING IN COLD WEATHER
Do not suddenly accelerate the engine before the warming-up

operation is completed.
It takes some time to start up the engine when the machine is left unused
for more than half a day in the ambient temperature of approx. -20C (4F). In that case, use the engine starting switch in the following manner.
1.
Turn the key in starting switch (1) to ON position (B).
If the ambient temperature is low, the preheating pilot lamp (2) lights up
and automatic preheating is carried out. Keep the key in starting switch
(1) at the ON position until the preheating pilot lamp (2) goes out.
The time that the preheating pilot lamp (2) stays lighted up depends on
the ambient temperature as shown in the table on the right.
Ambient temperature
Heating time
-1 C to -15 C (30 F to 5 F) 0 seconds to 30 seconds

-15 C or less (5 F or less)
2-90
0 to 12 sec.
WA380-6
OPERATION
2.
When preheating pilot lamp (2) goes out, turn the key in starting
switch (1) to the START position (C).
Keep the key in starting switch (1) at the START position (C) to
keep the starting motor running until the engine starts.
3.
The starting motor will continue to turn and the engine will start.
Remark
In low temperatures, to ensure lubrication of the engine and
to improve the durability, no fuel is supplied to the engine for
3 seconds after the key in starting switch (1) is turned to the
START position (C), so the engine will not start during this
time.
Therefore, keep the key in starting switch (1) at the START
position (C) to keep the starting motor running until the engine starts.
4.
Method of starting engine in temperatures of approx. -20C (-4F).

A. Keep the engine starting motor running for the max. 20 seconds, holding the key of engine starting switch (1) in the
START position (C), until the engine starts up.
B. If the engine fails to start up even after running the engine starting motor for about 20 seconds, stop the engine starting motor once (release the engine starting switch (1) key), and try the same process again after a pause for a minute
or so.
C. If the engine still fails to start up after the second attempt, try the same process for the third time after a pause for a
minute or so.
5.
When the engine has started up and the engine speed rises, release
the key of engine starting switch (1). The key will automatically
return to the ON position (B).
AUTOMATIC WARMING-UP OPERATION

When the engine is started, if the engine water temperature is below 30
C (86F) the warming-up operation is carried out automatically (engine
speed: 1000 rpm). It is cancelled when the engine water temperature
goes above 50 C (122F). (Engine speed: 850 rpm)
(X): Engine speed (rpm)

(Y): Water temperature (C)
WA380-6
2-91
OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE

If any problems occur, turn the ignition switch to the OFF position.
If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the
movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always perform
the warm-up operation. Particularly in cold areas, be sure to perform the warm-up operation fully.
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 break-in operations, follow the precautions described in this manual.
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 and sudden stops except in cases of emergency.
NORMAL START-UP AND WARM-UP

After starting the engine, do not immediately start operations. First,
perform the following operations and checks.
Remark
Do not suddenly accelerate the engine before the warm-up
operation is completed.
Do not run the engine at low or high idle continuously for
more than 20 minutes.
If it is necessary to run the engine at idle, apply a load from
time to time or run the engine at a midrange speed.
1.
Depress the accelerator pedal (1) lightly and run the engine with no
load at midrange speed for about 5 minutes.
Remark
Do not use starting aids such as either to start a cold engine,
damage to the engine may result.
2-92
WA380-6
OPERATION
To warm up the hydraulic oil in cold areas, do as follows.
2.
After carrying out the warming-up operation, check that the engine
rotation is smooth, then set the work equipment lock lever to the
FREE position (F).
3. Operate the bucket control lever to the TILT position (A) and return
it to the HOLD position (B) repeatedly to warm up the hydraulic
oil.
Relieve the circuit at the TILT position (A) for a maximum of 10 sec.
This brings the oil to the relief pressure and makes it quicker warm up
the oil.
4.
Slowly operate the steering wheel to the left and the right about 10
times to warm up the hydraulic oil inside the steering valve
If the steering wheel is operated and stopped while the oil

temperature is low, there may be a time lag before the
machine stops turning.
In this case, use the frame lock bar to ensure safety, and
perform the warm-up operation in a wide place.
Do not relieve the hydraulic oil in the circuit continuously for
more than 5 seconds.
Turn the steering wheel a little and stop in that position. Confirm that
the machine turns by an angle equivalent to the amount that the steering wheel is turned.
Select the oil from the table of recommended oils below according to the ambient temperature.
If Komatsu EO10W30-DH is used in the cold season, replace it with Komatsu EO15W40-DH oil when the cold season
finishes.
Ambient temperature
Reservoir
Hydraulic fluid
WA380-6
Type of fluid
-22
-4
14
32
50
68
86
104
122oF
-30
-20
-10
10
20
30
40
50oC
Engine oil
2-93
OPERATION
5.
After carrying out the warming-up operation, check that the gauges
and caution lamps are normal.
If there is any abnormality, carry out maintenance or repair.
Run the engine under a light load until engine water temperature
gauge (2) and torque converter oil temperature gauge (3) are in the
green range.
6.
Check for abnormal exhaust gas color, noise, or vibration. If any

problem is found, contact your Komatsu distributor.
Remark
The rotating speed of the cooling fan differs according to the
following conditions, but this does not indicate any
abnormality.
The cooling fan speed increases when the hydraulic oil temperature, engine coolant temperature, or
transmission oil temperature are high.
However, when the cooling fan is rotating in reverse, it rotates at a fixed speed proportional to the engine
speed, regardless of any oil or coolant temperature.
STOPPING THE ENGINE

Remark
If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened.
Consequently, do not abruptly stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool
gradually, then stop it.
1.
2.
3.
Run the engine at low idling for about 5 minutes to cool down gradually.
Turn the ignition switch (1) to the OFF position to stop the
engine.
Remove the key from ignition switch (1).
After Stopping The Engine

4.
5.
6.
7.
Walk around the machine and check the work equipment, body and
undercarriage check for leakage of oil and coolant.
Fill the fuel tank.
Check the engine compartment for any debris. Clean out any debris
to avoid a fire hazard.
Remove any mud attached to the undercarriage.
2-94
WA380-6
OPERATION
TRAVELING, STOPPING AND PARKING THE MACHINE

Before traveling or moving the machine, it is important to know all the control functions and relevant safety regulations
for the area you will be traveling or moving the machine in. If you will be traveling on state or local roadways, observe all
traffic safety laws. Travel at a safe controllable speed.
TRAVELING
1.
Check that the warning pilot lamp (1) is not lit up.
2.
Set the safety lock of bucket control lever and lift arm
control lever to the FREE (F) position.
3.
Raise the work equipment to the travel posture shown in the

diagram on the right.
WA380-6
2-95
OPERATION
4.
Depress right brake pedal (5) and turn parking brake switch (6) to
the OFF (RELEASE) position to release the parking brake. Keep
right brake pedal (5) depressed.
Remark
If the parking brake is still actuated when parking brake
switch is at the OFF (RELEASE) position (B), turn the
parking brake switch ON (A), then turn it OFF again (B).
5.
Set the speed control lever to the desired speed range.

Position (a): 1st.
Position (b): 2nd.
Position (c): 3rd.
Position (d): 4th.
6.
Set the directional lever to the desired direction.
2-96
WA380-6
OPERATION
7.
After releasing the right brake pedal, depress the accelerator pedal
to begin moving the machine
Always travel at a safe controllable speed.
Remark
When moving the machine off on a hill, turn transmission cutoff switch (10) OFF, depress left brake pedal (11), operate the
gearshift lever to the low speed range, then depress accelerator pedal (9) and gradually release left brake pedal (11) to let
the machine move off. This makes it possible to prevent the
machine from rolling back.
When traveling, and turning the machine. Keep in mind the front
frame is joined to the rear frame at the center of the machine by the
center pin. Therefore, the front and rear frames bend at this point, and
the rear wheels follow in the same track as the front wheels when
turning. When turning, turn the steering wheel carefully to follow the
machine as it turns.
Remark
When the steering wheel reaches the end of its stroke, do
not try to turn it any further. Check the play it should be 50
to 100 mm (2.0 to 3.9 in) in the steering wheel. If any
abnormality is found, contact your Komatsu dealer for
inspection.
WA380-6
2-97
OPERATION
TURNING ON SLOPES
Traveling on slopes is dangerous in general. However, turning on a
slope can be fatal. When traveling on a slope never turn the steering
wheel. Always travel straight up or straight down a slope. If the
machine should start to tip, lower the bucket to the ground
immediately to stabilize the machine. Travel at a slow pace in the
lower speed ranges, avoid dragging the brakes when traveling down a
slope.
Remark
When starting to move the machine on a hill, turn
transmission cut-off switch (1) OFF, depress left brake
pedal (2), operate the gearshift lever to the travel position,
then depress accelerator pedal (3) and gradually release left
brake pedal (2) to let the machine move. This makes it possible to prevent the machine from rolling back.
CHANGING GEAR SPEED RANGES
When traveling at high speed, do not shift gears suddenly.

Use the brake to reduce the travel speed before shifting
gears.
Shift Gears As Follows.

Move the gearshift lever (1) to the desired position to shift.
When digging or loading, perform the operation in 1st or 2nd. Use the
gearshift lever stopper.
Position (a): 1st.
Position (b): 2nd.
Position (c): 3rd.
Position (d): 4th.
2-98
WA380-6
OPERATION
Remark
If the gearshift lever is operated slowly or is stopped between
gear positions, the central warning lamp may light up and the
alarm buzzer may sound. In this case, there is no failure, but
try to operate the gearshift lever so that the gear shifting is
completed within 2 seconds.
This machine is equipped with kick down switch (3). When
traveling in 2nd, if kick down switch (3) is pressed, the
transmission shifts down to 1st.
For operations carried out in 1st and 2nd, such as digging
and loading, we recommend the use of the kick down switch.
For details of the method of use, see KICKDOWN SWITCH
on page 2-40.
This machine is equipped with an auto-shift system that automatically shifts the gear. For details of the method
of use, see TRANSMISSION MODE SELECTOR SWITCH on page 2-36 and see WHEN USING AUTOSHIFT on page 2-100.
When the machine is traveling at high speed, if the gear shift lever is shifted down to a lower speed, such as
4th <-> 3rd or 4th <-> 2nd, with the accelerator still depressed, the transmission is not shifted down. This is to
prevent the engine from overrunning.
In this case, the central warning lamp lights up and the alarm buzzer sounds. At the same time, E00 is
displayed on the top line of the character display and OVERRUN PROTECT is displayed on the bottom line.
If the alarm buzzer sounds, release the accelerator pedal immediately and depress the brake pedal to
reduce speed, then carry out the gearshift operation.
CHANGING DIRECTION
When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe.
There is a blind spot behind the machine, so be particularly careful when changing direction to travel in
reverse.
Do not switch between FORWARD and REVERSE when traveling at high speed.
When switching between FORWARD and REVERSE, depress the brake to reduce the travel speed
sufficiently, then change the direction of travel. (Max.speed for changing direction: 12 km/h (7.5 mph))
There is no need to stop the machine even when switching between
FORWARD and REVERSE. Place the directional lever (1) in the
desired position.
Remark
The directional selector switch makes it possible to change
the direction of travel by operating a switch.
WA380-6
2-99
OPERATION
If an attempt is made to switch the direction between forward and
reverse while traveling at high speed (when using 3rd or 4th), if the
travel speed and engine speed are in ranges I or II in the chart on the
right, the central warning lamp will light up and the buzzer will sound.
At the same time, E00 OVERRUN PROTECT is displayed on the
character display.
If the alarm buzzer sounds, depress the brake immediately to reduce the
travel speed, then operate the directional lever to switch between
forward and reverse.
WHEN USING AUTO-SHIFT

If the directional lever is operated slowly or is stopped midway between
the forward and reverse directions, E01 MAINTENANCE may be
displayed on the character display. In this case, there is no failure, but
try to operate the directional lever so that the change in direction is
completed within 2 seconds.
If an attempt is made to switch the direction between FORWARD and
REVERSE while traveling at high speed (when using 3rd or 4th), if the
travel speed and engine speed are in ranges (A) or (B) in the chart, the
central warning lamp will light up and the alarm buzzer will sound.
At the same time, E00 is displayed on the top line of the character
display and OVERRUN PROTECT is displayed on the bottom line.
If the alarm buzzer sounds, depress the brake pedal immediately to reduce speed, then operate the directional lever to switch
between FORWARD and REVERSE.
(X): Travel speed (km/h)

(Y): Engine speed (rpm)
WHEN USING AUTO-SHIFT

If an attempt is made to switch the direction between forward and reverse when the auto-shift is ON, normally, the gearshift
range will switch F3 -> R2, F4 -> R2, or R3 -> F2, R4 -> F2 to make it possible to move the machine off quickly.
However, if an attempt is made to shift between forward and reverse when the machine is traveling at high speed, such as
shown in ranges (A) or (B) in the chart, the central warning lamp will light up and the buzzer will sound.
At the same time, E00 is displayed on the top line of the character display and OVERRUN PROTECT is displayed on the
bottom line.
If the alarm buzzer sounds, depress the brake pedal immediately to reduce speed, then operate the directional lever to switch
between FORWARD and REVERSE.
In particular, if an attempt is made to switch between forward and reverse in range (B), the speed range will not shifted to 2nd,
but will switch F3 -> R3, F4 -> R4, or R3 -> F3, R4 -> F4. As a result, the reduction in speed will be less than in range (A), so
care is necessary.
2-100
WA380-6
OPERATION
STOPPING AND PARKING THE MACHINE
Avoid stopping suddenly. Give yourself ample room when stopping.

Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up,
so keep the brake pedal depressed.
Remark
Never use the parking brake switch to brake the machine when traveling except in an emergency. Apply the
parking brake only after the machine has stopped.
1.
Release the accelerator pedal (1), then depress brake pedal (2) to
stop the machine.
2.
Brake and accelerator pedals
Place directional lever (3) in N (neutral).
WA380-6
2-101
OPERATION
3.
Turn the parking brake switch to the ON position to apply the

parking brake.
Remark
When the parking brake is applied, the transmission is
automatically returned to neutral.
4.
5.
Lower the lift arm and bucket to the ground.

Set safety lock lever to the LOCK position.
6.
Do not park the machine on slopes. If the machine has to be

parked on a slope, set it facing directly down the slope, then dig
the bucket into the ground and put blocks under the tires to
prevent the machine from moving.
7.
Allow the engine to run at a low idle for about 5 minutes to cool
down gradually. Never shut down an engine that is over heating
or has just finished work operations always allow it a time to
cool down before turning the ignition key to the OFF position.
2-102
WA380-6
OPERATION
Always lock the following parts.
1.
2.
3.
4.
5.
Fuel tank filler cap

Engine side panel (2 points)
Cab door
Hydraulic tank
Rear grille
TRANSMISSION CUT-OFF SWITCH

When the transmission cut-off switch is pressed, the pilot lamp lights
up, and the following transmission cut-off function is actuated.
Position (a): OFF
Position (b): ON
When the brake pedals are both depressed, the brake is actuated, and in
addition, the transmission is shifted to neutral at the pre-selected brake
pedal depression position.
Remark
The cut-off function is actuated only with the left and right
brake pedals are depressed.
For details of adjusting the brake pedal depression position,
see ADJUSTING THE TRANSMISSION CUT-OFF on
page 2-104.
Raise or lower the pre-selected brake pedal depression position to adjust the cut-off to match the type of work.
When carrying out scooping-up work, lower the brake pedal
depression position for the cut-off (transmission shifted to
neutral). In this setting, the transmission driving force is cut at
a point where there is ample braking force, so this prevents the machine from slipping down.
When approaching dump trucks during loading operations, raise the brake pedal depression position for the
cut-off (transmission shifted to neutral). In this setting, the fine control of the braking immediately before
dumping the load can be carried out with the brake only, so this makes it easy to control and allows the
machine to be brought to a soft stop.
WA380-6
2-103
OPERATION
ADJUSTING THE TRANSMISSION CUT-OFF
Apply the parking brake before adjusting the transmission

cut-off position.
In the transmission cut-off function, it is possible to adjust the
depression position of the left brake pedal used to shift the
transmission to neutral.
1.
2.
3.
4.
Start the engine with the ignition switch (1), then set the parking
brake switch (2) to the ON position.
Set the transmission cut-off switch (3) to the ON position.
Depress left brake pedal (4) and set it to the desired position to
shift the transmission to neutral.
Press the transmission cut-off set switch (5), then release it. When
the switch is released, the buzzer will sound with a repeated short
sound, and the cut-off position is set.
Method of canceling cut-off position
5.
6.
After the buzzer sounds in Step 4 of the adjustment procedure, the

transmission cut-off switch flashes for 2 seconds. While it is
flashing, press transmission cut-off set switch (5) again and release
it.
The buzzer will sound with a long sound and the adjusted cut-off
position is canceled.
STOPPING WHEN TRANSMISSION CUT-OFF IS ON

When the transmission cut-off switch is at the ON position and the left brake pedal is depressed, the transmission is shifted
to neutral at the pre-selected brake pedal depression position.
The transmission is also shifted to neutral when the right brake pedal is operated.
Remark
When the transmission cut-off switch is OFF, both brake pedals act in the same way, and the transmission is
not shifted to neutral.
2-104
WA380-6
OPERATION
TURNING
Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes is
dangerous. Do not operate the steering wheel in such situations.
If the engine stops when the machine is traveling, the emergency steering is actuated. This system is only
for steering in emergencies, so never stop the engine. It is particularly dangerous if the engine stops when
the machine is traveling on slopes, so never let the engine stop when traveling on slopes. If the engine
stops, stop the machine immediately at a safe place.
When traveling, use the steering wheel to turn the machine.
The center pin joins the front frame to the rear frame. The front and rear
frames pivot at the center point, and the rear wheels follow in the same
track as the front wheels when turning. Turn the steering wheel lightly
to follow the machine as it turns.
Remark
When the steering wheel is turned fully, if it reaches the end
of its stroke, do not try to turn it further. Check that there is a
play of 50 to 100 mm (2.0 to 3.9 in.) in the steering wheel.
Check also that the steering works properly. If any
abnormality is found, please contact your Komatsu distributor
for inspection.
WA380-6
2-105
OPERATION
EMERGENCY STEERING
Never actuate the emergency steering except during emergencies or when checking the function.
The emergency steering can be used continuously for a maximum of 60 seconds. Operating it continuously for more than
60 seconds may damage the system.
When using the emergency steering, travel at less than 5 km/h (3.1 mph).
USING THE EMERGENCY STEERING

During emergencies or when stopping the engine to check the function,
press emergency steering switch (1). Emergency steering pilot lamp
(green) (2) when the engine is running or when the machine is operated,
indicating the condition is normal.
The emergency steering system is provided to enable the machine to be
steered under the following conditions.
The ignition switch is at the ON position.
The steering oil pressure is low or there is no pressure.
(When the engine has stopped or there is a failure in the steering oil
pressure pump, etc.)
When Key SW is turned on, during the emergency steering motor is

running for automatic self-checking, it indicates that the
emergency steering system is functional. For details, see EMERGENCY STEERING SELF-CHECK FUNCTION on page 2-107.
When the emergency steering controller detects lack of oil pressure in

the steering system, steering oil pressure caution lamp (red) (3) and
central warning lamp (4) light up, and the alarm buzzer sounds
intermittently.
When this happens, if the machine is traveling at a speed of more than 2
km/h (1.2 mph), the electric pump motor is automatically actuated and
emergency steering pilot lamp (green) (2) lights up.
Steering oil pressure caution lamp (red) (3) lights up to inform the
operator that there is a failure in the steering system.
If steering oil pressure caution lamp (red) (3) lights up, move the
machine immediately to a safe place and stop it.
Locate the cause and do not operate the machine until it has been
repaired.
Remark
If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure
caution lamp (red) (4) may light up for a moment, but if the lamp goes out again soon, there is no problem.
When the emergency steering controller detects that the oil pressure in the steering circuit has been restored, the actuation of
the emergency steering system is stopped.
2-106
WA380-6
OPERATION
EMERGENCY STEERING SELF-CHECK FUNCTION
When the ignition switch is turned ON, the emergency steering is automatically actuated for approximately 3 seconds to
check that the emergency steering is functioning properly.
When this happens, steering oil pressure caution lamp (red) (1) and
emergency steering pilot lamp (green) (2) light up.
If machine is steered during the steering self-check, it may

move.
Do not steer the machine during the steering self-check.
The emergency steering function check is not performed in the
following cases.
If the ignition switch is turned ON, turned OFF again without

starting the engine, and is then turned ON again.
If the ignition switch is turned ON again immediately after
stopping the engine when the steering oil pressure has not gone down completely.
When automatic preheating is being carried out.
Remark
During automatic preheating, the emergency steering self-check function is not actuated.
To check the emergency steering function, press the emergency steering switch after completing the warm-up
operation.
WA380-6
2-107
OPERATION
STARTING YOUR WORK OPERATIONS
Do not start the engine if warning tags have been attached to the steering wheel or control levers.
Sound your horn to warn others in the area before starting the engine or moving the machine.
Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.
Check the area to be sure all personnel are clear of the machine and your work area.
WORK EQUIPMENT
1.
Lift arm control lever (1) and bucket control lever (2) can be used
to operate the lift arm and bucket as follows.
LIFT ARM LEVER

Position (a): RAISE
Position (b): HOLD
The lift arm is kept in the same position.
Position (c): LOWER
Position (d): FLOAT
The lift arm moves freely under external force.
When the lift arm control lever is pulled further from the raise position,
the lever is stopped in this position until the lift arm reaches the preset
kick-out position, and the lever is return to the hold position.
Remark
Do not use the FLOAT position when lowering the lift arm.
Use the FLOAT position when leveling in reverse direction
only.
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WA380-6
OPERATION
BUCKET LEVER
Position (a): TILT
Position (b): HOLD
The bucket is kept in the same position.
Position (c): DUMP
When the bucket control lever is pulled further from the TILT position,
the lever is stopped in this position until the bucket reaches the preset
position of the positioner, and the lever is returned to the HOLD
position.
WA380-6
2-109
OPERATION
SCOOPING A LOAD OR CUTTING A GRADE
Never perform digging or scooping operations with the machine articulated because the machine may tip
over.
The work equipment will move when the travel damper switch is turned ON (ECCS), regardless if the
machine is traveling or the work equipment is raised.
Remark
If the tires slip, tire life will be reduced. Do not allow the tires to slip during operation.
LOADING PILED SOIL OR BLASTED ROCK

When loading piled soil or blasted rock, drive the machine forward (as
follows) to load. To prevent the tires from getting cut caused by the tires
slipping, be careful of the following points during the operation.
1.
Always keep the operating job site flat, and remove any fallen
rocks.
When working with stockpiles, operate the machine in 1st or
2nd; when loading blasted rock operate the machine in 1st.
When driving the machine forward and lowering the bucket, stop
the bucket about 30 cm (12 in.) from the ground, then lower it
slowly.
Remark
If the bucket hits the ground, the front tires will come off the ground and the tires will slip.
2.
Downshift immediately in front of the material to be loaded. After

downshifting, depress the accelerator pedal at the same time and
thrust the bucket into the load.
Remark
To reduce fuel consumption, depress the accelerator pedal
the minimum possible amount. If it is fully depressed, the fuel
consumption will increase, but there will be no increase in the
amount loaded.
3.
When the material is in a stockpile, keep the cutting edge of the

bucket horizontal; when loading blasted rock, have the bucket
tilting slightly down.
Be careful not to get blasted rock under the bucket. This will make
the front tires come off the ground and slip.
Try to keep the load in the center of the bucket; if the load is on one
side of the bucket, the load will be unbalanced.
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WA380-6
OPERATION
4.
At the same time you are thrusting the bucket into the material,
raise the lift arm slightly to help keep the tires from slipping. While
continuing to enter the pile of material, roll the bucket back to fully
fill it.
5.
Once the bucket is full check the amount of material loaded into the
bucket, then operate the bucket control lever to tilt the bucket and
load back fully.
Remark
If the bucket edge is moved up and down while pushing in the
bucket and digging, the front tires will come off the ground
and this will cause the tires to slip.
6.
If there is too much material loaded in the bucket, dump and tilt the
bucket quickly to remove the excessive load. This prevents spillage
of the load during hauling.
WA380-6
2-111
OPERATION
CUTTING A GRADE ON LEVEL GROUND
When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward.
Always be careful not to load the bucket on one side and cause an unbalanced load. Perform this operation in 1st gear.
Do not set the bucket facing down more than 20 degrees.

1.
Set the edge of the bucket facing slightly down.
2.
Drive the machine forward and operate the lift arm control lever
forward to cut a thin layer of the surface each time when excavating
the soil.
3.
Operate the lift arm control lever slightly up and down to reduce the
resistance when driving the machine forward.
When digging with the bucket, avoid imposing the digging force
onto only one side of the bucket.
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WA380-6
OPERATION
LEVELING OPERATIONS
1.
2.
3.
Always operate the machine in reverse when carrying out leveling

operations.
If it is necessary to perform leveling operations when traveling
forward, do not set the bucket dumping angle to more than 20
degrees.
Turn the E.C.S.S. OFF carrying out leveling operations.
Scoop soil into the bucket. Move the machine backward while
spreading soil from the bucket little by little.
Go over the spread soil with the bucket teeth touching the ground
and level the ground by back-dragging.
Scoop some more soil into the bucket, put the lift arm in float, level
the bucket at ground level, and smooth the ground by moving backward.
PUSHING OPERATION
Never set the bucket to the DUMP position when pushing.
When pushing, set the bottom of the bucket parallel to the ground surface.
LOAD AND CARRY OPERATIONS
When carrying a load, lower the bucket to lower the center of gravity when traveling.
Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S.
switch.
When performing inspection and maintenance, first lower the work equipment to the ground, then turn
the E.C.S.S. switch OFF before starting the inspection and maintenance operation.
The load and carry method for wheel loaders consists of a cycle of
scooping hauling loading (into a hopper, truck, etc.)
Always keep the travel path properly maintained.
When using the load and carry method, see LOAD AND CARRY
OPERATIONS on page 2-113.
Remark
When approaching dump trucks during loading operations,
raise the brake pedal depression position for the cut-off
(transmission shifted to neutral). In this setting, the fine
control of the braking immediately before dumping the load
can be carried out with the brake only, so this makes it easy
to control and allows the machine to be brought to a soft stop.
WA380-6
2-113
OPERATION
LOADING OPERATIONS
Select the method of operation which will give the minimum amount of turning and travel in order to provide the most
efficient method for the job site.
Always keep the job site flat, and do not operate the steering wheel suddenly or apply the brakes suddenly
when the lift arm is raised with a loaded bucket. This action is dangerous.
Never thrust the bucket in when traveling at high speed (when loading soil or crushed rock). This action is
dangerous.
The work equipment will move when the travel damper switch is turned ON (ECCS), regardless if the
machine is traveling or the work equipment is raised.
CROSS DRIVE LOADING

Always set the wheel loader facing at a right angle to the stockpile.
After digging in and scooping up the load, drive the machine straight
back in reverse, then bring the dump truck in between the stock pile and
the wheel loader. This method requires the least time for loading, and is
extremely effective in reducing the cycle time.
Remark
If the tires slip, the life of the tires will be reduced. Do do not
allow the tires to slip during operation. Avoid excessive
bucket shaking also.
V-SHAPE LOADING
Position the dump truck so that the direction of approach of the wheel
loader is approximately 60 degrees from the direction of approach to the
stockpile. After loading the bucket, drive the wheel loader in reverse,
then turn it to face the dump truck and travel forward to load the dump
truck.
The smaller the turning angle of the wheel loader is, the more efficient
the operation becomes.
When loading a full bucket and raising it to the maximum height, first
shake the bucket to stabilize the load before raising the bucket. This will
prevent the load from spilling to the rear.
PRECAUTIONS WHEN PILING UP LOADS

When forming products into a pile, be careful not to let the rear
counterweight come into contact with the ground.
Do not set the bucket to the DUMP position when piling-up loads.
Remark
When scooping-up, avoid using the transmission cut-off
function as much as possible. It will prevent the machine from
moving back.
When using the transmission cut-off function, adjust the
cut-off position to match the amount that the brake pedal is
depressed in order to ensure ample braking force.
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WA380-6
OPERATION
LOADING TRUCKS OR HOPPERS
Approach the truck or hopper slowly and cautiously from the side
with the load low, arms 300mm (12 in) above the ground
When within 0.2~1.0 m (5~6 ft) of the truck or hopper, STOP the
machine and raise the load to the proper height keeping it as level
as possible.
When you have reached the proper height, slowly move toward the
truck or hopper in a straight line until the bucket is totally over the
truck body or hopper opening and stop the machine.
Carefully and slowly roll the bucket forward dumping the load.
After the load is completely out of the bucket, roll the bucket back
completely, back the machine away from the truck or hopper
0.2~1.0 m (5~6 ft) and lower the arms to the 300mm (12 in) above
the ground.
Never turn or maneuver machine with the load raised.

Never raise the load while approaching the truck or
hopper.
Never bang the bucket against the hopper or truck body
to loosen loads in the bucket.
Be sure the driver or operator of the truck or hopper are
aware of when you are loading.
WA380-6
2-115
OPERATION
PRECAUTIONS DURING OPERATION

PERMISSIBLE WATER DEPTH
When working in water or on swampy ground, do not let the water come
above the bottom of the axle housing.
After finishing the operation, wash and check the lubricating points.
IF WHEEL BRAKE DOES NOT WORK

If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine.
Remark
If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the
parking brake checked for any abnormality.
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES

BRAKING ON DOWNHILL SLOPE
If the footbrake is used frequently when traveling downhill, the brake will overheat and may be damaged. Place the gearshift
lever at a low speed range and use the braking force of the engine when traveling downhill.
Use the right brake pedal for braking.
If the brakes are used excessively, the axle oil temperature caution lamp may light up and the alarm buzzer may sound
intermittently. For details of the necessary action to take,
see AXLE OIL TEMPERATURE CAUTION LAMP on page 2-17.
If the speed range selected by the gearshift lever is not correct, the torque converter oil may overheat. If this situation happens,
downshift one gear range to reduce the oil temperature.
If the oil temperature does not return to the white range even when the gearshift lever is at 1st, stop the machine, return the
directional lever to the N position, and run the engine at a mid-range speed until the gauge returns to the white range.
IF THE ENGINE STOPS

If the engine stops on a slope, apply the parking brake immediately, lower the work equipment, then stop the work machine.
Put the directional lever in neutral, and start the engine again.
PRECAUTIONS FOR USING LOAD AND CARRY METHOD

When traveling continuously with load and carry operations, choose the correct tires to match the operating conditions, or
choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so contact your Komatsu
distributor or tire dealer when selecting tires.
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WA380-6
OPERATION
PRECAUTIONS WHEN DRIVING THE MACHINE

When the machine travels at high speed for a long distance, the tires become extremely hot. This action causes early wear of
the tires, so it should be avoided as much as possible. If the machine must be driven for a long distance, take the following
precautions.
Follow the regulations related to this machine, and drive carefully.

Before driving the machine, perform the checks before starting.
The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact
your Komatsu distributor or tire dealer for information.
The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard tires.
(23.5-25A)
Check the tire pressure before starting when each tire is cool
Front wheel: 310kPa (45 psi)
Rear wheel: 310kPa (45 psi)
Speed: 14 km/h (8.7 mph)
After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage; also check the oil and coolant
levels.
Always travel with the bucket empty.
Never put calcium chloride or dry ballast in the tires when traveling.
PRECAUTIONS REGARDING BRAKE FUNCTION

When traveling long distances continuously downhill, the frequency of using the brake may increase. As a result, depending
on the weight of the machine and the grade of the slope, the machine's braking capacity may be exceeded and the brakes may
overheat.
The table below shows a guideline of the values for this machine.
Braking capacity limit

Machine
weight
(t)
Slope
grade
(%)
17.3 - 19.5
(unloaded)
22.5 - 24.5
(loaded)
Average travel speed

limit
(km/h (mph))
Downhill
distance limit
(continuous)
(km)
10
40 (24.9)
1.9
20
38 (23.6)
0.6
10
38 (23.6)
1.5
20
32 (19.9)
0.5
If the braking capacity limit is exceeded, a forced cooling system for the brakes is needed. Please consult your Komatsu
distributor.
WA380-6
2-117
OPERATION
WORK EQUIPMENT AND MACHINE POSTURE
Stop the machine on flat ground and put blocks in front and behind the wheels.
Apply the parking brake.
Secure the front and rear frames with the safety bar.
Be sure to put a warning tag on work equipment control levers.
Do not go under the work equipment when the arm is raised.
ADJUSTING BUCKET
The kickout makes it possible to set the bucket so that it automatically stops at the desired lifting height (lift arm higher than
horizontal) and the bucket positioner makes it possible to set the bucket so that it automatically stops at the desired digging
angle. The setting can be adjusted to match the working conditions.
Set the parking brake i position (A)
Lock the frame of the machine
BOOM KICKOUT ADJUSTMENT

1.
2.
3.
Raise the bucket to the desired height, set the lift arm control lever
at HOLD and lock the lever in position with the safety lock lever.
Then stop the engine.
Loosen two bolts (1), and adjust plate (2) so that the bottom edge is
in line with the center of the sensing surface of proximity switch
(3). Then tighten the bolts to hold the plate in position.
Loosen two nuts (4) to make a clearance of 3 to 5 mm (0.118 to
0.197 in.) between plate (2) and the sensing surface of proximity
switch (3). Then tighten the nuts to hold in position.
Tightening torque: 17.2 2.5 Nm (12.7 1.8 lbft)
4.
After adjusting, start the engine and raise the lift arm. Check that
the bucket control lever is automatically returned to HOLD when
the lift arm reaches the desired height.
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WA380-6
OPERATION
BUCKET POSITIONER ADJUSTMENT
1.
2.
3.
4.
Lower the bucket to the ground and adjust the bucket to the desired
digging angle. Set the bucket control lever at HOLD, stop the
engine and adjust as follows.
Loosen the bolts (1), adjust the position of mounting bracket (4) of
the proximity switch so that the rear tip of bar (2) is in line with the
center of the sensing surface of proximity switch (3), then tighten
the bolts to hold the bracket in position.
Loosen the bolts (5), adjust so that the clearance between the bar (2)
and support (6) is 0.5 to 2 mm (0.020 to 0.079 in.), then tighten the
bolts (5) to hold in position.
Loosen the nuts (7), adjust so that the clearance between bar (2) and
the sensing surface of proximity switch (3) is 3 to 5 mm (0.118 to
0.197 in.), then tighten the nuts to hold in position.
Tightening torque: 17.2 2.5 Nm (12.7 1.8 lbft)
5.
After adjusting, start the engine and raise the lift arm. Operate the bucket control lever to the DUMP position, then operate
it to the TILT BACK position and check that the lever is automatically returned to the HOLD position when the bucket
reaches the desired digging angle.
BUCKET LEVEL INDICATOR

(A) and (B) at the top rear of the bucket are the level indicators, so the
bucket angle can be checked during operations.
(A): Parallel with cutting edge
(B): 90 degrees to cutting edge
WA380-6
2-119
OPERATION
TRANSPORTING THE MACHINE

Before transporting the machine be sure what you are using to transport the machine is capable of supporting the weight
and size of the machine. Be sure it is wide enough and rated for the load.
LOADING AND SECURING THE MACHINE

Load the machine onto a trailer as follows:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Be sure the area you will be loading the machine in is flat and
dry.
Be sure the machine is free of mud or debris that may hinder
loading.
Check the ramps and support surfaces for damage, week spots,
missing boards or excess ware. If these surfaces look unsafe, too
week or unstable do not load the machine. Be sure the loading
equipment and transportation equipment are in good condition
and rated for your load.
Lower the work equipment slowly.
Check that the work equipment control lever is at the HOLD
position, then set the work equipment lock lever to the LOCK
position (L).
Set the parking brake switch to ON position (A) to apply the parking brake securely.
Turn the starting switch to the OFF position and stop the engine.
Remove the key from the ignition switch.
Center the machines frame and lock the frame with the safety bar.
10. Block the wheels on the trailer (D) before attempting to load the
machine.
11. Locate the tie down and transportation brackets (A & C)on the
machine. Be sure they are in good condition.
12. Position the machine squarely on the deck. Raise the loader bucket
high enough to clear all surfaces.
13. Once the machine has been loaded, rest the front bucket on the
floor, set the machine in neutral and set the parking
brake and lock the controls.
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WA380-6
OPERATION
14. Secure the machine with tie-downs/chains (C) at the anchor points shown in illustrations (A).
To help keep the machine in position, place blocks (B) in front and behind the front and rear wheels for extra support.
Protect the exhaust stack from moisture if needed.
UNLOADING MACHINE
Load and unload on firm level ground only. Maintain a safe

distance from the edge of a road.
Apply the brakes on the trailer securely and insert locks (1) under
the tires to hold the trailer in position.
Set the distance (3) between ramps (2) to match the distance
between the left and right tires, and make angle (4) of the ramps a
maximum of 15.
Remove the chains and wire ropes fastening the machine.

Set the frame lock bar to FREE position (F).
Start the engine.
Warm the engine up fully.
Check that the work equipment control lever is at the HOLD
position, then set the work equipment lock lever to the FREE position (F).
Set the parking brake switch to OFF position (B) to cancel the parking brake.
Determine the direction of the ramps, then drive the machine
slowly down the ramps to unload the machine.
WA380-6
2-121
OPERATION
LIFTING THE MACHINE

Lifting hooks (A) are located in 4 places on the machine as shown in the diagram below. Use only these 4 places when
lifting; do not use any other places. There is a serious danger that the machine may lose its balance. Always stay clear of
the machine and maintain a safe distance when lifting it.
LIFTING LOCATIONS AND PROCEDURES
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WA380-6
OPERATION
USING WIRE ROPE
When lifting the machine, if the wire rope is not installed correctly on the machine, the machine
may fall and cause serous injury or even death. Raise the machine 100 to 200 mm (3.9 to 7.9 in)
from the ground, check to be sure the machine is horizontal, level and that there is no slack in the
wire rope, then continue to lift the machine.
Before lifting the machine, always stop the engine and lock the brakes. Lock front frame and rear
frame with safety bar.
Lifting operations using a crane must be carried out by a qualified operator.
Never raise the machine with any personnel on it.
Always make sure that the wire rope used for lifting the machine is of ample strength for the
weight of the machine.
When carrying out the lifting operation, please contact your Komatsu distributor.
The lifting procedure applies to machines with standard

specifications.The method of lifting differs according to the
attachments and options actually installed. In such cases, contact
your Komatsu distributor for information.
For details of the weight see MACHINE DIMENSIONS AND
WEIGHTS on page 4-2.
Never use a wire rope which has cut strands (A), reduced diameter
(B), or kinks (C). There is danger that the rope may break during the
lifting process.
PRE LIFTING PROCEDURES

7.
Start the engine and raise the work equipment to the travel
height and roll the bucket back. Be sure the bucket is empty.
WA380-6
2-123
OPERATION
8.
Once at the travel height, lock the controls and cut the engine off.
9.
Place the directional lever in the N (neutral) position and set the
parking brake.
10. Lock the frames with the safety bar.
11. Using the lifting points, carefully lift the machine. Stay clear of
the machine at a safe distance until at this point the machine is
fully resting in place and the cables are slack.
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WA380-6
OPERATION
LIFTING MACHINE
The person using the crane to carry out lifting operations must be a qualified crane operator.
Never carry out lifting operations if any person is on the machine being lifted.
Always use a wire rope that has ample strength for the weight of the machine being lifted.
Keep the machine horizontal when lifting it.
When carrying out lifting operations, do as follows to prevent the machine from moving unexpectedly.
Set the parking brake switch to the ON position.
Set the work equipment lock lever to the LOCK position.
Set the frame lock bar to the LOCK position.
Never enter the area under or around a raised machine.
There is danger of the machine losing its balance.
Use the procedure below to set the machine in the proper posture and use the lifting equipment when lifting the machine.
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor.
For details of the weight, see MACHINE DIMENSIONS AND WEIGHTS on page 4-2.
Lifting position
WA380-6
2-125
OPERATION
TOWING THE MACHINE

If this machine must not be towed except in emergencies. When
towing the machine, take the following precautions.
1.
Align the towing pin (1) with groove (2) in the counterweight,
then insert the pin and turn it 1800.
2.
To prevent the towing pin from turning, fold the handle of the
towing pin and set it in position. Reverse this operation to
remove the pin.
3.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may break during the towing process.
4.
Before releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are not
blocked, the machine may suddenly move.
5.
When towing a machine, tow it at a low speed of less than 2 km h (1.2 MPH), and for a distance of a few meters to a place
where repairs can be carried out. If the machine must be moved long distances, use a transporter.
6.
To protect the operator if the towing rope or bar should break,

install a protector plate to the machine being towed.
7.
If it is impossible to operate the steering and brakes of the

machine being towed, do not let anyone ride on the machine.
8.
Check that the tow rope or bar is of ample strength for the weight
of the machine being towed. If the machine being towed must
travel through mud or up hills, use a tow rope or bar of a strength of
at least 1.5 times the weight of the machine being towed.
9.
Keep the angle of the tow rope as small as possible. Keep the angle
between the center lines of the two machines to
within 30 degrees.
10. If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break. Start
the machine gradually and travel at a constant speed.
11. The towing machine should normally be of the same class as the machine being towed. Check that the towing
machine has ample braking power, weight, and rim pull to allow it to control both machines on slopes or on the tow
road.
12. When towing a machine downhill, use a larger machine for towing to provide ample rim pull and braking power, or
connect another machine to the rear of the machine being towed. This way it is possible to prevent the machine from
losing control and turning over.
13. Towing may be carried out under various differing conditions, so it is impossible to determine beforehand there
requirements for towing. Towing on flat horizontal roads will require the minimum rim pull, while towing on slopes or on
uneven road surfaces will require the maximum rim pull.
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WA380-6
OPERATION
COLD WEATHER OPERATION

If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components. For details of the specified viscosity.
see FUEL, COOLANT AND LUBRICANTS on page 3-11.
COOLANT
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin,
wash it off with large amount of fresh water and see a doctor at once. When changing the coolant contact your Komatsu
distributor. Antifreeze is toxic, so do not dispose of antifreeze in drainage ditches, sewers, on the ground or other areas always
trap and recycle this fluid.
Never use methanol, ethanol or propanol based antifreeze. Never use flammable liquids in the cooling system. Avoid using
any leak-preventing agent, regardless if it is sold separately or in antifreeze. do not mix one antifreeze with a
different brand.
For details on the antifreeze mixture when changing the coolant.
see CLEANING THE COOLING SYSTEM on page 3-22.
Standard requirements for permanent antifreeze:
SAE J1034
FEDERAL STANDARD O-A-548D
PRECAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, always observe the following precautions.
Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent
damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water.
Park the machine on hard, dry ground. If this is impossible, park the machine on wooden boards. The boards help protect
the wheels from being frozen in soil and the machine can start next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see FUEL, COOLANT AND LUBRICANTS on page 3-11.
WA380-6
2-127
OPERATION
BASIC TROUBLESHOOTING
WHEN MACHINE RUNS OUT OF FUEL
When starting the engine again, check carefully that the area around the engine is safe before cranking the engine.
When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.
For details of bleeding the air, see REPLACING PRIMARY FUEL FILTER on page 3-45.
TOWING MACHINE
Serious injury or death could result if there is any mistake in the selection of wire rope or method of towing
a disabled machine.
Always be sure to check carefully that the capacity of the wire rope used for towing is ample for the weight
of the towed machine.
Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that
the rope may break during the towing operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing machine and the machine being towed.
Move the machine slowly and be sure not to apply any sudden load on the wire rope.
If there is a failure in the brake line, the brakes cannot be used, so be extremely careful when towing.
Only tow the machine for a short distances, such as to a place for
inspection or maintenance.
The machine must not be towed for long distances.
For details of the permissible towing load for this machine, see
SPECIFICATIONS on page 4-2.
For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor.
This machine must not be towed except in emergencies. When towing

the machine, take the following precautions.
Before releasing the brakes, put blocks under the wheels to prevent
the machine from moving. If the wheels are not blocked, the machine may suddenly move.
When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance of a few meters to a place
where repairs can be carried out. The machine should be towed only in emergencies. If the machine must be moved long
distances, use a transporter.
If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the machine.
Keep the angle of the towrope as small as possible. Keep the angle between the center lines of the two machines to within
30 degrees.
The towing machine should normally be of the same class as the machine being towed. Check that the towing machine
and towed machine both have ample braking power and that the towing machine has ample rimpull to control both
machines on the slopes or on the tow road.
2-128
WA380-6
OPERATION
When towing a machine downhill, it may be necessary to connect

another machine to the rear of the machine being towed in order to
provide ample rimpull and braking power. This makes it possible to
prevent the machine from losing control.
Towing may be carried out under various differing conditions, so it
is impossible to determine beforehand the requirements for towing.
Towing on flat horizontal roads will require the minimum rimpull,
while towing on slopes or on uneven road surfaces will require the
maximum rim pull.
Connect a wire rope to the part indicated with the arrow in the diagram at right.
WHEN ENGINE CAN BE USED
If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of
mud or to move it for a short distance to the edge of the road.
The operator should sit on the machine being towed and operate the steering in the direction that the machine is towed.
WHEN ENGINE CANNOT BE USED

When towing a machine with the engine stopped, use the following procedure.
1.
2.
3.
The transmission oil does not lubricate the system, so remove the front and rear drive shafts. If necessary, block the tires to
prevent the machine from moving.
The steering cannot be operated, so remove the steering cylinder. Even if the brakes are in good condition, the brakes can
only be used a limited number of times. There is no change in the operating force for the brake pedal, but the braking force
is reduced each time the pedal is depressed.
Connect the towing equipment securely. When carrying out towing operations, use two machines of at least the same class
as the machine being towed. Connect one machine each to the front and rear of the machine being towed, then remove the
blocks from the tires and tow the machine.
Parking brake
The parking brake cannot be turned OFF. To release the parking brake, do as follows.
RELEASING PARKING BRAKE
When releasing the parking brake, stop the machine on level ground and check that the surrounding area
is safe. If it is necessary to release the brake on a slope in an emergency, block the tires before starting the
operation.
If the parking brake is released, the brake cannot be used, so check the safety carefully when moving the
machine.
If the engine will not run for some reason, use the following methods to release the parking brake and tow the
machine.
WA380-6
2-129
OPERATION
METHOD OF RELEASING BRAKE BY USING EMERGENCY PARKING BRAKE CANCEL SWITCH
When the parking brake switch is at the OFF position and the emergency parking brake release valve is
opened, the parking brake is released immediately.
In this condition, even if you feel danger and try to stop the machine, the parking brake will not be applied
immediately even if you close the emergency parking brake release valve.
If the pressure in the brake accumulator is high, do as follows.
1.
Turn the starting switch to the OFF position (A).
2.
Loosen relief valve lock nut (1) by turning it counterclockwise, and

turn grip (2) likewise to relieve the valve.
Remark
The relief valve is located on the left front portion inside the
rear frame and secured to the accumulator mounting bracket.
3.
Turn ignition switch to the ON position (B).
2-130
WA380-6
OPERATION
4.
Move the parking brake switch to the ON (A) position (actuated),

then move it to the OFF (B) position (released).
The parking brake is released.
5.
To restore the function of the parking brake, turn grip (2) of the
release valve clockwise to close the release valve, then turn locknut
(1) clockwise to lock it.
Tightening torque
Grip (2): 20 5 Nm (14.5 3.6 lbft)
Locknut (1): 20 5 Nm (14.5 3.6 lbft)
6.
Move the parking brake switch to the ON (a) position. The parking
brake is applied.
To release the parking brake again, repeat the procedure in Steps 1
to 4.
Remark
If the brake accumulator pressure is low, the parking brake warning lamp may not go out and the alarm buzzer
may sound (a long continuous sound). If this happens, release the brake. For details, see METHOD OF
RELEASING WITH ADJUSTMENT SCREW on page 2-132.
WA380-6
2-131
OPERATION
METHOD OF RELEASING WITH ADJUSTMENT SCREW
If the brake accumulator pressure is low, do as follows.
1.
Loosen bolt (2) and adjustment screw (1) at 3 places (A, B, C) at the
front of the transmission case.
2.
Rotate lock plate (3) to release the lock, then tighten adjustment
screw (1) until it stops.
If this operation is carried out at the same time at A, B, and C, the
parking brake can be released.
3.
EMERGENCY TRAVEL OPERATION

The normal gear shifting operation is carried out by electric signals. If
there should be a failure in the electrical system and the machine does not
move, please contact your Komatsu distributor to have the machine
moved.
Always request your Komatsu distributor to carry out the emergency travel operation.
2-132
WA380-6
OPERATION
IF BATTERY IS DISCHARGED
It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before
charging.
When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.
Battery electrolyte is dilute sulfuric acid, and it will attack your clothes and skin. If it gets on your clothes
or on your skin, immediately wash it off with a large amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
When handling batteries, always wear safety glasses and rubber gloves.
When removing the battery, first disconnect the cable from the ground (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger that it will cause a spark, so be
extremely careful.
If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an
explosion.
When removing or installing the terminals, check which is the positive (+) terminal and which is the negative (-) terminal.
REMOVAL AND INSTALLATION

1.
2.
Before removing battery, remove the ground cable (normally

connected to the negative (-) terminal). If any tool touches between
the positive terminal and the chassis, there is danger of sparks being
generated. Loosen the nuts of the terminal and remove the wires
from the battery.
After installing the battery, fix it with the battery hold down.
Tightening torque: 2 to 2.9 Nm (1.4 to 2.2 lbft)
3.
When installing the battery, connect the ground cable last. Insert the
hole of the terminal on the battery and tighten the nut.
Tightening torque: 5.9 to 9.8 Nm (4.3 to 7.2 lbft)
Remark
The batteries are on both sides at the rear of the machine.
The battery used for the ground is on the left side of the
machine.
WA380-6
2-133
OPERATION
BATTERY
The battery generates flammable gas. 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 a large amount of
water and consult a doctor.
Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
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%. Insulate it against cold temperature to ensure
the machine can be started easily the next morning.
Remark
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte
Temperature oC (oF)
20
(68)
0
(32)
-10
(14)
-20
(-4)
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
Charging
Rare %
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store the battery
in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the day's work
to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS FOR CHARGING BATTERY

When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow
the instructions in BATTERY (PAGE 3-155) and the instruction manual
accompanying the charger, and do as follows.
Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an
explosion.
Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL
line.
Set the voltage of the charger to match the voltage of the battery to be charged. If the correct voltage is not selected, the
charger may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the positive (+) terminal of the battery, then connect the negative () charger clip of the charger to the negative (-) terminal of the battery. Be sure to attach the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set it to less
than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a
danger that this will ignite the battery electrolyte and cause the battery to explode.
2-134
WA380-6
OPERATION
STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:
Never try to start the machine by tampering or shorting the starter
terminals. Accidental movements of the machine could cause injury
or even death.
Always start the machine seated in the operators cab using the
ignition switch.
See ELECTRICAL CIRCUITS on page 2-137
Never use a welder or a machine with a higher voltage system to jump start the machine. Using a
higher voltage to jump-start a machine may damage the machines electrical system or cause an
unexpected explosion or fire. Always jump-start a machine with equal voltages and never allow the
machines to touch each other when jump starting a machine.
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
When connecting the cables, never contact the positive (+) and negative (-) terminals.
When starting the engine with a booster cable, wear safety glasses and
rubber gloves.
Be careful not to let the normal machine and problem machine contact each other. This prevents sparks
from generating near the battery which could ignite the hydrogen gas given off by the battery.
Make sure that there is no mistake in the booster cable connections.
The final connection is to the engine block of the problem machine, but sparks will be generated when this
is done, so connect to a place as far as possible from the battery.
When disconnecting the booster cable, take care not to bring the clips in contact with each other or with
the machine body.
Keep in mind!
The size of the booster cable and clip should be suitable for the battery size.
The battery of the normal machine must be 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.
Check that the work equipment lock levers and parking brake levers of both machines are in the LOCK position.
Check that each lever is in the NEUTRAL position.
WA380-6
2-135
OPERATION
CONNECTING THE BOOSTER CABLE
Keep the starting switch of the normal machine and problem machine in
the OFF position.
1.
2.
3.
4.
5.
Connect the booster cable as follows, in the order of the numbers

marked in the diagram.
Connect the clip of booster cable (A) to the positive (+) terminal of
battery (C) on the problem machine.
Connect the clip at the other end of booster cable (A) to the positive
(+) terminal of battery (D) on the normal machine.
Connect the clip of booster cable (B) to the negative (-) terminal of
battery (D) on the normal machine.
Connect the clip at the other end of booster cable (B) to engine
block (E) on the problem machine.
STARTING ENGINE
Always check that the work equipment lock lever is set to the LOCK position, regardless of whether the machine is working
normally or has failed. Check also that all the control levers are in the HOLD or NEUTRAL position.
1.
2.
3.
4.
Make sure the clips are firmly connected to the battery terminals.
Start engine of the normal machine and run it at high idle speed.
Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, wait for at least 2 minutes before trying again.
DISCONNECTING THE BOOSTER CABLE

After the engine has started, disconnect booster cables in the reverse
order in which they were connected.
1.
2.
3.
4.
Remove the clip of booster cable (B) from engine block (E) on the
problem machine.
Remove the clip of booster cable (B) from the negative (-) terminal
of battery (D) on the normal machine.
Remove the clip of booster cable (A) from the positive (+) terminal
of battery (D) on the normal machine.
Remove the clip of booster cable (A) from the positive (+) terminal
of battery (C) on the problem machine.
2-136
WA380-6
OPERATION
ELECTRICAL CIRCUITS
Trouble
Possible Cause
Remedy
Lights do not work satisfactory even with

the engine running at high RPMs:
Faulty wiring.
Lights come on intermittently with the

engine running:
Poor fan belt tension.
Check and repair terminal

connections.
Adjust fan belt tension.
Alternator charge indicator does not go

out with the engine running and engine
speed is increased:
Faulty alternator.
Faulty wiring.
Serpentine belt worn or damaged.
Replace alternator.
Check and repair wiring.
Replace belt.
Alternator is very noisy:
Defective alternator.
Replace alternator
Starter does not operate when the ignition

key is turned to the START position:
Faulty wiring.
Low battery charge.
Check condition of wiring.

Check battery charge state.
Starter drive chatters:
Low battery charge.

Faulty wiring.
Battery charge insufficient.
Check battery charge state.

Charge the battery.
Starter cranks slowly:
Faulty wiring.

Charge the battery.
Starter cuts out while cranking the

engine:
Faulty wiring.

Charge the battery.
Bad bulb.
Defective heater relay, heater,
controller, temperature sensor.
Faulty wiring
Replace bulb.
Check condition of wiring and
components.
Defective monitor.
Faulty wiring.
Replace or repair.
Preheat pilot lamp does not light up:
Even when engine is stopped, battery

charge circuit caution lamp does not light
up (ignition switch ON):
WA380-6
2-137
OPERATION
CHASSIS
(): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Trouble
Possible Cause
Remedy
Transmission
Engine is running but machine

does not move:
Parking brake is applied

Directional lever is not shifted
properly
Lack of oil in transmission case

Screen is clogged
Too much oil or too little oil in

transmission case
Machine is not traveling in correct
speed range
Torque converter is stalled for long
periods
Engine is overheating
Even when engine is run at full

throttle, machine only move
Release parking brake

Shift lever properly
Add oil to specified level. See
WHEN REQUIRED

WHEN REQUIRED (Disassemble, clean)
Add or drain oil to specified

level.
See WHEN REQUIRED
Place in correct speed range
Reduce stall time
(Check engine)
slowly and lacks power
Oil overheats
Noise generated

WHEN REQUIRED
Add oil to specified level.

See WHEN REQUIRED
Change to specified oil
Replace disc)
EVERY 100 HOURS
Bleed air
Axle
Noise generated
Lack of oil
Improper oil used (for machines
with limited-slip differential)
Brake
Brake is not applied when pedal is

depressed
Brake drags or remains applied
Brakes squeal
2-138
Disc has reached wear limit

Lack of oil in hydraulic tank
Air in brake line
Vent hole of brake valve is clogged
Clean
Disc is worn
Large amount of water in axle oil
Deteriorated axle oil due to overuse of brake
Replace disc
Change axle oil
Change axle oil
WA380-6
OPERATION
Trouble
Possible Cause
Remedy
Steering
Steering wheel is heavy
Steering wheel is loose
Play in steering cylinder pin


EVERY 100 HOURS SERVICE
Grease bearing or replace pin

and bushing where there is play
Parking brake
Braking effect is poor
Disc is worn
Brake drags or remains applied

Screen is clogged
(Replace disc)

WHEN REQUIRED
(Disassemble and clean)
Hydraulic system
Lack of lifting power for bucket

Bucket takes time to rise
Excessive bubbles in oil

Clogged hydraulic tank filter
Low quality oil being used

Air in oil line

causes pump to suck in air
Hydraulic pressure is low
Movement of cylinder is irregular
WA380-6

Replace filter. See EVERY 2000
HOURS SERVICE
Replace with good quality oil
Bleed air. See EVERY 2000
HOURS SERVICE
Then bleed air. See EVERY
2000 HOURS SERVICE
2-139
OPERATION
ENGINE
(): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Trouble
Possible Cause
Remedy
Oil pressure light remains on even with

the engine at high idle:
Oil level too low.

Oil filter plugged.
Incorrect oil for the season.
Top off.
Change oil and filter.
Change oil.
Cooling system overheating:
Coolant low due to leaks.

Fan belt slipping.
Cooling system blocked.
Radiator fins damaged.
Faulty thermostat.
Radiator cap defective.
Top off and repair.

Check belt tension.
Flush cooling system.
Repair or clean.
Replace.
Replace.
Temperature gauge stuck at white

range
Faulty temperature indicator.
Replace.
Engine cranks but will not start:
No fuel.
Air in fuel system.
Low compression.
Refuel.
Bleed system.
Adjust valve clearance.
White or light blue exhaust gasses:
Too much oil in oil pan.

Unstable fuel.
Correct the oil level.

Change to suitable fuel.
Exhaust gasses are black:
Air cleaner clogged.

Faulty injectors or injection pump.
Low compression.
Clean or replace.
Replace.
Adjust valve clearance.
Popping noise heard at exhaust stack:
Faulty injectors.
Replace injectors.
Abnormal engine noise:
Improper fuel Cetane rating.

Overheating.
Damaged exhaust muffler.
Excessive valve clearance.
Change fuels.
See temperature indication.
Replace.
Adjust valves.
2-140
WA380-6
OPERATION
LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than one month), store as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level ground and
cover the machine with a sheet.
Completely fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
Set the lock lever to the LOCK position to prevent the machine from moving.
To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type antifreeze (density between 30% and 68%).
DURING STORAGE
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors
and windows to improve ventilation and prevent gas poisoning.
During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat moving
parts. At the same time, also charge the battery.
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month to lubricate
all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In addition, check the
refrigerant level twice a year.
AFTER STORAGE
Remark
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after starting the engine. If there is water in the oil, change all the oil.
WA380-6
2-141
OPERATION
2-142
WA380-6
MAINTENANCE
WA380-6
3-1
MAINTENANCE
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not
found in this manual.
Due to the high voltage/amps and high pressure fuel avoid

any contact with the engine electrical system (1) and the fuel
injection system (2) when the engine is running. Severe
injury may result.
CHECK SERVICE METER

Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed.
KOMATSU GENUINE REPLACEMENT PARTS

Use Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE OILS

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature.
ALWAYS USE CLEAN WASHER FLUID

Use automobile window washer fluid, and be careful not to let any dirt get into it.
ALWAYS USE CLEAN OIL AND GREASE

Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and grease.
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large
quantities of metal particles or foreign materials are found, always report to the person in charge, and perform suitable action.
FUEL STRAINER
If your machine is equipped with a fuel strainer, do not remove it while fueling.
WELDING INSTRUCTIONS
3-2
Turn off the engine starting switch.

Do not apply more than 200V continuously.
Connect grounding cable within 1 m (3.3 ft.) from the area to be welded. If grounding cable is connected near instruments,
connectors, etc., the instruments may have troubles.
Avoid seals or bearings from being between the area to be welded and the position of grounding point.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
WA380-6
MAINTENANCE
DO NOT DROP THINGS INSIDE THE MACHINE
When opening inspection windows or the oil filler port of the tank to perform an inspection, be careful not to drop nuts,
bolts, or tools inside the machine. If such things are dropped inside the machine, it will cause damage and malfunction of
the machine, and will lead to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
DUSTY WORKSITES
When working at dusty worksites, do as follows:
Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the
oil.
AVOID MIXING OIL

Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with the new
type of oil.
LOCKING INSPECTION COVERS

Lock inspection cover in position securely with a lock bar. If inspection or maintenance is performed with the inspection cover
open and not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause injury to the
worker.
BLEEDING AIR FROM HYDRAULIC CIRCUIT

If the hydraulic oil equipment has been repaired or replaced and if the hydraulic hoses, pipes, etc. have been disconnected, it is
necessary to bleed air in the circuit. See CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT
on page 3-52.
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with
new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist them or bend them into loops with a small radius. This action will cause damage to
the hose and markedly reduce its service life.
CHECKS AFTER INSPECTION AND MAINTENANCE

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to
serious injury or property damage. Always do as follows.
Checks after operation (with engine stopped)

Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been carried out correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside
machine and get caught in the lever linkage mechanism.
Is there any leakage of water or oil? Have all the bolts been tightened?
WA380-6
3-3
MAINTENANCE
HANDLING THE TIRES

1. Side wall
2. Shoulder
3. Tread
4. Breaker or belt (cord layer)
5. Bead
6. Inner liner
7. Carcass
If a tire has reached any of the following service limits, there is danger
that the tire may burst or cause an accident, so to ensure safety, replace it
with a new tire.
SERVICE LIMITS FOR WEAR
When the remaining depth of the grooves on construction equipment tires (at a point approx. 1/4 of the tread width) is 15% of the groove depth on a new tire.
When the tire shows marked uneven wear, stepped wear or other abnormal wear, or when the cord layer is exposed.
Service limits for damage
When there is external damage extending to the cord or when the cord is broken
When the cord is cut or there is dragging
When the tire is peeling (there is separation)
When the bead is damaged
For tubeless tires, when there is air leakage or improper repair
Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due
care.
TIRE PRESSURE
Measure the tire pressure before starting operations, when the tires are
cool.
If the tire inflation pressure is too low, there will be overload; if it is too
high, it will cause tire cuts and shock burst.
To prevent these problems, adjust the tire inflation pressure according to
the table on the next page.
Deflection ratio = H - h / H x 100
As a guideline that can be checked visibly, the deflection ratio of the
front tire (deflection/free height) is as follows.
When carrying normal load (lift arm horizontal): Approx. 15 to 25 %
When digging (rear wheels off ground): Approx. 25 to 35 %
3-4
WA380-6
MAINTENANCE
When checking the tire 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 operating area and maintaining the surface will extend the tire life and give improved
economy.
Tire size
(Pattern)
H
Free height
mm
(in)
Inflation pressure kgf/cm2 (psi)

Soft ground
(sandy soil)
Normal road
When shipped from factory
Stockpile
Stockpile
Digging
0.24 - 0.35
0.26 - 0.35
0.26 - 0.35
(2.4 - 3.6,
(2.6 - 3.6,
(2.6 - 3.6,
34.1 - 51.1)
36.9 - 51.1)
36.9 - 51.1)
23.5-25
(L3: Rock)
(Standard)
23.5-25-20PR
424 [BS]
(17)
(L2: Traction)
Front and Rear tire:
(if equipped)
23.5-25-16PR
0.30 (3.1, 44.0)
(L2: Traction)
(if equipped)
23.5-25-20PR
434 [BS]
(17)
(L3: Rock)
(if equipped)
For operations on normal road surfaces, rock digging operations:

High end of range in air pressure chart
Stockpile operations on soft ground: Average pressure in air
pressure chart
Operations on sand (operations not using much digging force): Low
end of range in air pressure chart
If the deflection of the tire is excessive, raise the inflation pressure
within the limits given in the table to give a suitable deflection (see
deflection ratio).
Stockpile operations mean the loading of sand and other loose materials.
WA380-6
3-5
MAINTENANCE
OUTLINES OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil.
When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil
and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the small amount
of oil remaining in the piping mixes with the new oil.)
Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed in the
table below.
Item
Type
Engine oil
EO15W40-DH (Komatsu genuine parts) API CI-4, JASO DH-1
Transmission oil
Power train oil TO10 (Komatsu genuine parts)
Hydraulic system oil
Power train oil TO10 (Komatsu genuine parts)
Axle oil
AX080 (Komatsu genuine parts)
Engine coolant
Supercoolant AF-NAC (density: 30% or above) (Komatsu genuine parts)
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

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 for use given in the Operation and
Maintenance Manual. Even if the oil is not dirty, always change the oil after the specified interval.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities (water, metal
particles, dirt, etc.) from getting in. The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil. Having too much oil or too little oil are both causes of 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 you have an analysis made of the oil periodically to check the condition of the machine. For those who
wish to use this service, please contact your Komatsu distributor.
FUEL
3-6
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15 C (5 F). It is
necessary to change for the fuel that is suitable for the 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, it is necessary to bleed the air from the circuit.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection system to obtain good
fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good
lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big drop in the durability, so do
not use such fuel.
WA380-6
MAINTENANCE
COOLANT
The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. For details, see CLEANING
THE COOLING SYSTEM on page 3-22.
When diluting the antifreeze coolant, use distilled water or tap water (soft water).
Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium, magnesium,
etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is deposited inside the engine or
radiator, it is extremely difficult to remove. It also causes overheating due to poor heat exchange, so when you dilute the
coolant, we recommend that you use water with an overall hardness of less than 100 PPM.
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
Antifreeze coolant is flammable, so be sure to keep it away from flame.
The ratio of Supercoolant (AF-NAC) to water differs according to the ambient temperature.
For details of the ratio when mixing, see CLEANING THE COOLING SYSTEM on page 3-22.
Supercoolant (AF-NAC) may be supplied already mixed. In such cases, never dilute with water.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering the
coolant.
GREASE
Grease is used to prevent twisting and noise at the joints.

The grease fittings not included in the MAINTENANCE section are grease fittings for overhaul, so they do not need
grease.
If any part becomes stiff or makes noise after being used for long time, apply 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 sticking in the grease would cause wear of
the rotating parts.
WA380-6
3-7
MAINTENANCE
PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS)

KOWA (Komatsu Oil Wear Analysis) is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive
parts and other abnormalities.
Periodic use of KOWA makes the following possible:
It enables the accurate understanding of the machine condition by utilizing our long experience and accumulated data
base.
The report on the result of analysis and recommendation will be delivered to the customer soon at low cost (only the
actual expenses will be charged). Use of this service is strongly recommended.
KOWA ANALYSIS ITEMS
Analysis of metal wear particles.

This uses the latest ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.
Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to measure the
quantity of large iron particles (larger than 5 microns) in the oil,
which enables the early detection of defect.
Others.
Measurements are made of items such as the ratio of water in oil or
fuel in the oil, and the dynamic viscosity.
OIL SAMPLING
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Perform sampling regularly at fixed intervals.
Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
3-8
WA380-6
MAINTENANCE
STORING OIL AND FUEL
Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side.
This action prevents moisture from being sucked in. If the drum cans 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. Filters 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 in severe conditions, replace 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 affixed to the old filter. If any metal particles are found, please
When replacing the engine oil filter, fill the new filter with the specified clean oil, then install it.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.
OUTLINE OF ELECTRIC SYSTEM
It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This situation
will cause an electrical short circuit and may cause the machine to malfunction. Do not wash the inside of the operator's
cab with water. When washing the machine, be careful not to let water get into the electrical components.
Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and check of
battery fluid level.
Never install any electric components other than there specified by Komatsu.
External electrical interference may cause malfunction of the control system controller, so before installing a radio
receiver or other wireless equipment, please contact your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
The optional power source must never be connected to the fuse, starting switch, or battery relay.
WA380-6
3-9
MAINTENANCE
WEAR PARTS LIST

Wear parts such as the filter element, air cleaner element, bucket tooth, etc. are to be replaced at the time of periodic maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
When ordering parts, please check the part number in the parts book.
The parts in parentheses are to be replaced at the same time.

Item
Part Name
Q'ty
Replacement frequency
Engine oil filter
Cartridge
EVERY 500 HOURS
Fuel filter
Cartridge
EVERY 500 HOURS
Fuel strainer
O-ring
Transmission oil filter
Cartridge
EVERY
1000 HOURS
Transmission strainer
O-ring
Hydraulic filter
Element
(O-ring)
1
(1)
EVERY 2000 HOURS
Hydraulic tank breather
Element
EVERY 2000 HOURS
Hydraulic oil strainer
Strainer
Air cleaner
Element assembly
WHEN REQUIRED
PPC accumulator
Accumulator and O-ring
EVERY 4000 HOURS
Fresh
Element
EVERY 2000 HOURS
Recirc
Element
EVERY 2000 HOURS
Standard type
Center edge
Side edge
(Bolt)
(Nut)
(Washer)
1
2
(14)
(14)
(14)
WHEN REQUIRED
Long life type
Center edge
Side edge
(Bolt)
(Nut)
(Washer)
1
2
(14)
(14)
(14)
WHEN REQUIRED
Segmented
type
Edge
(Bolt)
(Nut)
(Washer)
7
(14)
(14)
(14)
WHEN REQUIRED
Air conditioner
air filter
Bolt on
cutting edge
3-10
WA380-6
MAINTENANCE
FUEL, COOLANT AND LUBRICANTS
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

Kind
of
Fluid
Reservoir
Engine oil pan
Ambient Temperature
-4
14
32
50
68
86
104
122 F
-30
-20
-10
10
20
30
40
50 C
Refill
25.5
(6.7)
23
(6.0)
47
(12.4)
38
(10.0)
210
(47.6)
139
(36.4)
40
(10.6)
*40
(10.6)
300
(79.26)
30
(8)
EO10W40-DH
EO30-DH
PT
oil
TO10
PT
oil
TO10
HO46-HM
Hyd.
oil
Hydraulic
system
Specified
EO10W30-DH
Engine
oil API
CI-4
JASO
DH-1
Transmission
case ( 1)
Capacity L/US Gal
-22
EO10W30-DH
Engine
oil
EO10W30-DH
Axle
oil
AX 080 (See 2)
Axle
[EO50-CD] See 3
Engine
oil
ASTM D S15/500 No. 2
Diesel
fuel
Fuel Tank
No.1
Hyper
grease
( 5)
Lithium
EP
grease
Pins
(See 4)
G2-T,G2-TE
G2-L1
Supercoolant AF-NAC (6)
Cooling system
Capacity
Engine oil pan
Transmission case
Hydraulic
system
Axles
(each)
Pins
Fuel tank
Cooling system
Liters
25.5
47
210
40
300
30.5
USgal
6.7
12.4
47.6
10.6
79.3
8.0
Liters
23
38
139
40
USgal
6.0
10.0
36.4
10.0
Reservoirs
Specified
Refill
WA380-6
3-11
MAINTENANCE
Remark
Use only diesel fuel only.
This engine uses an electronically controlled high-pressure fuel injection system to obtain good fuel economy
and low emissions. For this reason, it requires high precision parts and good lubrication. If kerosene or other
fuel with low lubricating ability is used, there will be a big drop in durability.
1: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
2: Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip Differential).If only
AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
3: When the ambient temperature is higher than 45C (113F) and the machine operation hour is longer than 12 hours/day,
then the use of EO50-CD instead of AXO80 is recommended. Squealing of the brakes may occur with EO50-CD, but
there is no problem with the brake performance or durability.
4: Hyper grease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of the grease
in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended.
5: Supercoolant (AF-NAC)
The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AFNAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
For details of the ratio when diluting super coolant with water, see CLEANING THE COOLING SYSTEM on page 3-22.
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant (AF-NAC).
In this case, no adjustment is needed for temperatures down to -10C (14F). (never dilute with water)
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30%
and 68%.
6: Supercoolant (AF-NAC)
Coolant has the important function of anticorrosion as well as antifreeze. Even in the areas where freezing is not an issue, the
use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or
4000 hours. Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
For details of the ratio when diluting super coolant with water, see CLEANING THE COOLING SYSTEM on page 3-22.
Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution. (never dilute with water)
To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and
68%.
RECOMMENDED BRANDS, OTHER THAN KOMATSU GENUINE OIL

When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to
the Komatsu web page or consult your Komatsu distributor.
3-12
WA380-6
MAINTENANCE
STANDARD TIGHTENING TORQUES FOR FASTENERS AND

HOSES
TORQUE LIST
If nuts, bolts, or other parts are not tightened to the specified torque, looseness or
damage to the
tightened parts, which will cause machine failure or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in
the table below.
The tightening torque is determined by the width across the flats of the nut and bolt.
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.
Tightening torque
Thread diameter
a(mm)
Width across flat

b(mm)
Target value
Service limit
Nm
lbft
Nm
lbft
10
13.2
9.8
11.8 - 14.7
8.7 - 10.8
13
31
23.1
27 - 34
20.3 - 25.3
10
17
66
48.5
59 - 74
43.4 - 54.2
12
19
11
83.2
98 - 123
72.3 - 90.4
14
22
177
130.2
157 - 196
115.7 - 144.7
16
24
279
206.1
245 - 309
180.8 - 227.8
18
27
382
282.1
343 - 425
253.2 - 314.6
20
30
549
405.0
490 - 608
361.7 - 448.4
22
32
745
549.7
662 - 829
488.2 - 611.2
24
36
927
683.5
824 - 1030
607.6 - 759.5
27
41
1320
976.5
1180 - 1470
868.0 - 1085.0
30
46
1720
1265.8
1520 - 1910
1121.1 - 1410.4
33
50
2210
1627.4
1960 - 2450
1446.6 - 1808.3
36
55
2750
2025.2
2450 - 3040
1808.3 - 2242.2
39
60
3280
2423.1
2890 - 3630
2133.7 - 2676.2
Use the following table for Hydraulic Hose.
Thread
diameter
a(mm)
Width
across flat
b(mm)
Tightening torque
Target value
Nm
lbft
Service limit
Nm
lbft
14
19
29.4
21.7
27.5 - 39.2
20.3 - 28.9
18
24
78.5
57.3
58.8 - 98.1
43.4 - 72.3
22
27
117.7
86.8
88.3 - 137.3
65.1 - 101.3
24
32
147.1
108.5
117.7 - 176.5
86.8 - 130.2
30
36
215.7
159.1
176.5 - 245.2
130.2 - 180.8
WA380-6
3-13
MAINTENANCE
33
3-14
41
255.0
188.1
215.7 - 284.4
159.1 - 209.8
WA380-6
MAINTENANCE
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always perform periodic
maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next page must also be
replaced at the specified interval. These parts are particularly closely connected to safety and fire prevention, so please contact
your Komatsu distributor to have them replaced.
With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult to judge the
condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced
immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses.
In addition, perform the checks for the hydraulic hoses other than periodic replacement parts. If any abnormality is found,
tighten the clamps or replace the parts.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
WA380-6
3-15
MAINTENANCE
No.
Safety critical parts for periodic replacement
Q'ty
Fuel hose (fuel tank - fuel strainer)
Fuel hose (fuel strainer - supply pump)
Fuel return hose (supply pump - fuel tank)
Fuel hose (supply pump - fuel filter)
Fuel return tube (injector, supply pump, fuel return merge tube from common rail)
Steering hose (pump - merge block)
Steering hose (merge block - steering valve)
Steering hose (steering valve - steering cylinder)
Steering hose (steering valve - drain merge block)
10
Steering hose (drain merge block - hydraulic tank)
11
Steering hose (hydraulic tank - steering pump)
12
Steering hose (hydraulic tank - emergency steering pump)
13
Steering hose (accumulator charge valve - orbital valve)
14
Steering hose (orbital valve - stop valve)
15
Steering hose (stop valve - steering valve)
16
Steering hose (stop valve drain - drain merge block)
17
Steering hose (orbital valve drain - drain merge block)
18
Steering hose (accumulator charge valve - drain merge block)
19
Steering hose (orbital valve drain - drain merge block)
20
Steering hose (steering valve - drain merge block)
21
Steering hose (drain merge block - hydraulic tank)
22
Steering hose (accumulator charge valve - fan pump)
23
Steering hose (fan pump - steering pump)
24
Steering hose (fan pump - work equipment pump)
25
Steering pump LS hose
26
Steering oil pressure check line hose (for emergency steering)
27
Brake hose (pump - accumulator charge valve)
28
Brake hose (accumulator charge valve - brake accumulator)
29
Brake hose (brake accumulator - brake valve)
30
Brake hose (valve drain - hydraulic tank)
31
Brake hose (brake valve - front brake)
32
Brake hose (brake valve - rear brake)
33
Brake hose (brake accumulator - reduction valve for emergency parking brake cancel)
34
Brake hose (reduction valve for emergency parking brake cancel - transmission valve)
35
Turbocharger lubrication hose
36
Accumulator (for PPC)
37
Engine high pressure pip clamp
1 set
38
Fuel splash prevention cap
1 set
39
Seat belt
3-16
Replacement interval
Every 2 years or
every 4000 hours,
whichever
comes first
every 8000 hours

Every 3 years
WA380-6
MAINTENANCE
MAINTENANCE SCHEDULE CHART

This is a schedule outlining the maintenance to be performed on the machine according to the hours accumulated on the
machine. Following these scheduled items will prolong the life of the machine.
Maintenance Interval And Item
Section - Page
GENERAL MAINTENANCE AND INSPECTION

INITIAL 250 HOURS SERVICE
CHANGE TRANSMISSION OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE HYDRAULIC TANK FILTER ELEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-49
3-52
WHEN REQUIRED
CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AXLE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDOW WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING ELECTRICAL INTAKE AIR HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE BOLT ON CUTTING EDGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING SLOW BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION OF TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19
3-19
3-22
3-26
3-27
3-28
3-29
3-29
3-30
3-32
3-33
3-33
3-34
3-35

DRAIN SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-35

LUBRICATE REAR AXLE PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR CONDITIONER FRESH ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-37
3-37
3-38

CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WA380-6
3-39
3-41
3-41
3-41
3-42
3-42
3-51
3-17
MAINTENANCE

CHANGE ENGINE OIL, REPLACING ENGINE OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . .
REPLACING FUEL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-44
3-45
3-45

CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEANING STRAINER . . . . . . . . .
CLEAN THE TRANSMISSION CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING PARTS OF TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-49
3-50
3-51
3-51

CHANGE HYDRAULIC OIL REPLACE HYDRAULIC OIL FILTER ELEMENT. . . . . . . . . . . . . . . .
HYDRAULIC TANK VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGE AXLE OIL (*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK ALTERNATOR, STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK ACCUMULATOR GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used
frequently or the brakes make a sound, change the oil after a shorter interval.
3-52
3-54
3-55
3-55
3-57
3-57
3-36
3-57
3-57
3-56

CHECK WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE INJECTOR NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER . . . . .
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER . . . . .
3-58
3-60
3-60
3-60
3-60
3-61

REPLACE HIGH-PRESSURE PIPING CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE FUEL SPRAY PREVENTION CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18
3-62
3-62
WA380-6
MAINTENANCE
GENERAL MAINTENANCE AND INSPECTION

Perform the following maintenance only after the first 250 hours.
Change transmission oil filter cartridge
Replace hydraulic tank filter element
For details of the method of replacing or maintaining, see the section EVERY 1000 HOURS and 2000 HOURS SERVICE.
Perform the following maintenance only after the first 1000 hours.
Check engine valve clearance
For details of the method of replacing or maintaining, see the section EVERY 2000 HOURS SERVICE
WHEN REQUIRED
CLEANING THE MACHINE
CLEAN TIPS
Never use flammable liquids to clean your machine. Use only
approved non-flammable cleaning solvents to clean parts or the
machine itself. Avoid using high pressure steam cleaners or caustic
soaps to wash the machine if possible. Steam cleaning or using caustic
soaps may damage paint, wiring or sensitive electrical components.
Never use high pressure water or flood the inside of the operators
cab. Doing so may damage sensitive electrical components.
When pressure washing, use high pressure hot water and mild grease
cutting soaps.
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine
and the engine will suffer damage. Always stop the engine before performing these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.
ENGINE AIR FILTER

If air cleaner clogging caution lamp (1) on the machine monitor lights
up, clean the air cleaner element.
Remark
Do not clean the element until the air cleaner clogging
caution lamp lights up. If the element is cleaned frequently
before the air cleaner clogging caution lamp lights up, the air
cleaner will not be able to display its performance fully and
the cleaning efficiency will drop. In addition, the frequency of
dirt stuck to the element falling inside the inner element will
increase.
WA380-6
3-19
MAINTENANCE
CLEANING OR REPLACING OUTER ELEMENT
1.
2.
Open the top cover at the front of the engine side cover on the right
side of the machine.
Remove three clips (1), then remove dust cup (2).
3.
Remove the outer element (4).
4.
Clean the inside of the air cleaner body and dust cup.
5.
Never remove the inner element (5). If it is removed, dust will

enter and cause engine trouble.
The inner element must not be cleaned and used again. When
replacing the outer element, replace the inner element at the
same time.
Direct dry compressed air (less than 0.69 MPa (99.4 psi)) to the
outer element (4) from inside along its folds, then direct it from
outside along its folds and again from inside.
3-20
WA380-6
MAINTENANCE
6.
7.
If small holes or thinner parts are found on the element when it is checked by shining a light
through it after cleaning, replace the element.
Seat the cleaned outer element and install dust cup (3), then secure them with clips (2).
Remark
When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds, gasket or seal are damaged.
Remark
When installing the cover (2), check O-ring (7) and replace it
if there are any scratches or damage.
8.
Set the cleaned outer element in position, then secure cover (3) with
mounting clips (1).
9. Press the dust indicator button to return the yellow piston to its
original position.
10. Close the engine side cover on the right side of the machine.
After cleaning, if the air cleaner clogging caution lamp lights up
immediately or the yellow piston reaches the red line (7.5 kPa),
replace the inner and outer elements.
WA380-6
3-21
MAINTENANCE
CLEANING THE COOLING SYSTEM
Immediately after stopping the engine, the engine coolant is HOT and the pressure inside the radiator is
high. Removing the cap and draining the water under this condition could cause burns. Allow the engine
to cool down, then turn the cap slowly to release the pressure.
Start the engine and flush the system. When standing up or leaving the operator's seat, set the shift lever
to the N position and set the parking brake switch to the PARKING position.
For details of starting the engine, see START-UP PROCEDURES on page 2-85.
When the undercover is removed, there is danger of touching the fan.
Never go to the rear of the machine when the engine is running.
Stop the machine on level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant, and replace the corrosion resistor according to the table below.
Type of coolant
Cleaning inside of cooling

system and changing coolant
Replacing corrosion resistor
Komatsu supercoolant
(AF-NAC)
Every two years or every 4000 hours,

whichever comes first
unnecessary
Permanent type antifreeze

(all season type,* )
Every 6 months (spring, autumn)

(Drain antifreeze in spring,
add antifreeze in autumn).
Every 1, 000 hours and

when cleaning the inside of
the cooling system and
when changing coolant.
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03.

Stop the machine on level ground when cleaning or changing the coolant.
The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30%
and 68%.
When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor.
When no corrosion resistor is used, use the special cover (600-411-9000). Consult your Komatsu distributor about the method
of installing.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table
given below.
It is actually better to estimate and temperature about 10C (18F) lower when deciding the mixing ratio.
The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total
amount of coolant x 100).
The freezing temperature of undiluted antifreeze is -15C (5F). Do not store undiluted antifreeze at a temperature of below 15C (5F)
3-22
WA380-6
MAINTENANCE
.
Min. atmospheric
temperature
-10
-15
-20
-25
-30
14
-4
-13
-22
Liters
10.8
12.6
14.4
16.2
18.0
US gal
2.85
3.33
3.80
4.28
4.76
Liters
25.2
23.4
21.6
19.8
18.0
US gal
6.66
6.18
5.71
5.23
4.75
30
36
41
46
50
Amount of antifreeze
Amount of water
Ratio
Use distilled water for the cooling system water.

We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare the following: Container should hold a minimum of 50 liters (13.21 US gal) capacity to mix the coolant.
1.
Stop the engine and tighten 2 valves (1) of the corrosion resistor.
2.
Turn the radiator cap (2) slowly to release the pressure, then
remove it.
Remark
When mixing coolant with water, do not use tap water, river
water, well water or water from any local source. Use only
distilled or deionized water.
WA380-6
3-23
MAINTENANCE
3.
Set a container in position to catch the drained antifreeze mixture,

then open drain valve (3) under the left side of the fuel tank and
drain the coolant.
4. After draining the coolant, close drain valve (3) and fill with city
water.
5. When the radiator is full of water, start the engine and run the
engine at low idling for about 10 minutes with the water
temperature at 90 or higher.
6. Stop the engine, allow it to cool down then open drain valve (3) and
then tighten them again.
7. After draining the water, clean the cooling system with cleaning
agent. For the cleaning method, see the instructions for the cleaning
agent (FLEETRITE Restore CC261 or restore plus CC2638).
8. Replace the corrosion resistor, (if equipped) the open valves 1 and
Pour the coolant and water mixture into the filler port. See Mixing rate of coolant and water table for the mixing rate of
coolant and water.
9. To remove the air in the cooling system, run the engine for 5 minutes at low idling, and for another 5 minutes at high idle.
When doing this step, leave the radiator cap off.
10. Drain the coolant from sub-tank (4), clean the inside of the subtank, then add water until the coolant level is between the FULL
and LOW marks.
11. Stop the engine, wait for approximately 3 minutes, then add tap
water until the water level is near the water filler port, and tighten
the cap. Check the coolant level and add water, if necessary.
3-24
WA380-6
MAINTENANCE
WATER SEPARATOR
Each part of the engine is still very hot immediately after the engine is stopped. Do not attempt to drain
cooling water or remove the filler element cup.
High pressure is generated inside the engine fuel piping while the engine is running. Wait for more than
30 seconds after the engine stops for it to cool sufficiently, then start with draining coolant or removing
the filter element cup.
Do not bring a flame close to coolant, since antifreeze is flammable.
1. Open the engine side cover on the right side of the chassis.
2. Check the water separator (1) to see that the red ring inside has
risen to the marked line.
3. If red ring (2) has come up to the marked line, perform the
operation
4. Prepare a container to catch the drained fuel and place it under the
water separator.
5. Loosen drain valve (2) at the bottom of the water separator and
drain the water and fuel into the container.
WA380-6
3-25
MAINTENANCE
TRANSMISSION OIL LEVEL
The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the
temperature to go down before starting the work.
Perform this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling water.
1.
2.
3.
Start the engine and run it for at least 5 minutes.

Open the cap of oil filler port (F), remove dipstick (G), and wipe
the oil off with a cloth.
Insert the dipstick (G) again from the top of the oil filler port diagonally as shown in the diagram, then pull it out again. When doing
this, insert the dipstick so that the tip contacts the bottom of the dipstick guide.
4.
The oil level should be between the H and L marks on dipstick (G).
If the oil level is below the L mark, add engine oil through oil filler
(F).
5.
If the oil is above the H mark, drain the excess engine oil from drain
plug (P), and check the oil level again.
If the oil level is correct, insert dipstick (G) into the oil filler pipe,
then tighten the cap.
6.
3-26
WA380-6
MAINTENANCE
AXLE OIL LEVEL
When checking the oil level, apply parking brake and lock the front and rear frames with the safety bar.
After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down
before starting the operation.
Perform this procedure if there is any sign of oil on the axle case. Perform the inspection with the machine on a horizontal road
surface. If the road surface is at an angle, the oil level cannot be checked correctly.
1.
Stop the engine and remove the oil level plug (1).
Remark
Remove the mud and dirt from around plug (1), then remove
the plug.
2.
Wipe off any oil adhering to the oil level gauge attached to plug (1)
with waste cloth.
3.
Set the oil level gauge (G) as shown in the right diagram.
WA380-6
3-27
MAINTENANCE
4.
The oil level is correct when it is between the two lines provided on
the oil level gauge. If the oil level does not reach the lower line, add
axle oil through the filler port (F).
Remark
For axles with ASD (Antislip Differential), the brand of lubricating oil is different, so always use the specified lubricating
oil.
5.
6.
If the oil level is above the upper line, drain off the excess oil
through drain plug (P) and check the oil level again.
If the oil level is correct, install plug (1). Tightening torque: 127 to
177 Nm (94 to 177 lb. ft.).
CHECK AXLE VENT
When cleaning the axle breather, apply the parking brake and lock the front and rear frames with the
safety bar.
Remove all mud and dirt from around the breather with a brush.
After removing the mud or dirt from around the breather, remove the
breather, immerse it in cleaning fluid and clean it.
When cleaning the breather, clean the breathers at two places (front and
rear).
After removing the breather, take steps to prevent dirt or dust from
entering the mount.
3-28
WA380-6
MAINTENANCE
AIR CONDITIONER CONDENSER
Do not wash the condenser using a steam cleaner because the condenser could overheat.
If high-pressure water hits your body directly or high-pressure water sends dirt flying, there is danger of
personal injury. Always wear protective glasses, dust mask, and other protective equipment.
If there is mud or dust on the air conditioner condenser (1), clean it with
water.
If the water pressure is too high, the fins may get deformed. When
washing with a high-pressure washing machine, apply the water from a
reasonable distance.
WINDOW WASHING FLUID LEVEL

Check the washing fluid levels in washer tank (1). When the fluid has
run short, add automotive window washing fluid.
To prevent the nozzles from clogging, be careful not to let dust get into
the fluid.
WA380-6
3-29
MAINTENANCE
CLEAN RADIATOR FINS
Never open the engine side cover when the engine is running. Stop the engine completely before starting
the cleaning operation.
If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to
personal injury. Always wear safety glasses, dust mask, or other protective equipment.
Clean the radiator or cleaner if mud or dirt is stuck to it.
CLEAN FINS BY ROTATING COOLING FAN IN REVERSE
Remark
When rotating the fan in reverse, be careful of flying dust, and
be careful not to let any cloth get caught in the fan. Dust may
rise, so check that there is no one in the surrounding area
when rotating the fan in reverse.
On jobsites where it is easy for dirt to stick to the radiator or cooler, turn
cooling fan reverse rotation switch (1) ON to rotate the fan in reverse.
This will blow off the dirt and dust stuck to the radiator or cooler, and
can extend the cleaning interval.
MANUAL FAN REVERSING FUNCTION
Remark
Never rotate the fan in reverse by hand when carrying out the
operation.
Before operating the fan reverse rotation switch, run the
engine at low idling.
1.
2.
3.
4.
5.
6.
Set the directional lever to the Neutral position.

Set the parking brake switch to the ON position to apply the parking brake.
Run the engine at low idling.
Press position (a) (manual reverse rotation ON) of cooling fan
reverse rotation switch (1).
After the cooling fan reverse rotation pilot lamp on the machine
monitor flashes, check that it lights up. At the same time, COOLING FAN REVERSE ROTATION is displayed on the character
display and the fan is set to rotate in reverse.
Run the engine at high idling.
Select the time for running the engine at high idle as follows
according to the condition of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
3-30
WA380-6
MAINTENANCE
7.
8.
When the cleaning is completed, run the engine at low idling.

Press position (a) (manual reverse rotation ON) of cooling fan
reverse rotation switch (1).
9.
After the cooling fan reverse rotation pilot lamp on the machine
monitor flashes, check that it goes out. The fan is set to rotate in the
normal direction.
10. Run the engine at low idling for approx. 10 seconds.
AUTO REVERSE FUNCTION (IF EQUIPPED)

1.
2.
3.
Run the engine at low idling.

Press position (a) (auto reverse rotation ON) of cooling fan reverse
rotation switch (1).
Check that pilot lamp inside of the switch and the cooling fan
reverse rotation pilot lamp on the machine monitor light up. The fan
automatically rotates in reverse for 2 minutes every 2 hours.
Remark
When the fan direction is switched, the reverse rotation pilot
lamp flashes. When the machine is operating under high load
or in low temperatures, the direction of rotation of the fan may
not change. This is to protect the machine. Run the engine at
low idling and wait for the oil temperature or water temperature to go down before operating the switch.
WA380-6
3-31
MAINTENANCE
CLEAN FINS WITH COMPRESSED AIR
Insert the air nozzle through the gap between the radiator oil cooler after
cooler (1) and the air conditioner condenser (2) to clean the fins.
When cleaning the face behind the radiator, or oil cooler, and after
cooler (1), remove bolt (2) and plate (3), then insert the jet nozzle
through the opening to clean the fins.
Remark
If the steam jet nozzle is brought too close to the radiator fins,
it may damage the fins, so keep the nozzle a suitable distance away from the fins when cleaning.
Work under the following rough conditions.

Injection pressure: Max. 9.8 MPa (100 kgf/cm2, 1420 PSI)
Nozzle diameter: Max. 2 mm (0.1 in)
Distance between nozzle and radiator fins: Min. 100 mm (3.9
in)
Examine the rubber hoses, and if any hose is cracked or deteriorated, replace it. Check also that there are no loose hose clamps.
CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater
checked for dirt or disconnections
AIR CONDITIONING SYSTEM.

Maintenance interval
Inspection
location
Item to check for
Check before
operating
6 months
Replacement
interval
Filter
Clogging or dirt
Condenser
Clogging or dirt
Inspect
Inspect
2 years
Looseness damage or wear
Inspect
Inspect
2 years
Refrigerant gas
Piping
Receiver dryer
Belt
3-32
WA380-6
MAINTENANCE
REPLACE BOLT-ON CUTTING EDGE
It is extremely dangerous if the work equipment moves when performing the turning or replacement operation. Set the work equipment in a stable position, stop the engine, then set the safety lock lever securely
to the LOCK position.
Turn or replace the cutting edge before the wear reaches the edge of the bucket.
1.
2.
3.
4.
5.
6.
7.
Raise the bucket to a suitable height, then put blocks under the
bucket to prevent the bucket from coming down.
Raise the bucket so that the bottom surface of the bucket is
horizontal.
Remove the nuts and bolts (1).
Remove the cutting edge (2).
Clean the mounting surface of the cutting edge (2).
Turn cutting edge (2) and install it to the bucket. When turning the
edge, install it to the opposite side (left edge to right side, right edge
to left side).
If both sides of the cutting edge are worn, replace with a new
part.
If the wear extends to the mounting surface, repair the
mounting surface before installing the cutting edge.
Tighten nuts and bolts (1) uniformly so that there is no gap between the bucket and cutting edge. Tightening the torque for
the mounting bolt: 745 108 Nm (549.7 79.6 lb. ft.)
Tighten the mounting bolts again after operating for several hours.
REPLACE BUCKET TEETH
If the pin is hit with a strong force, there is danger that the pin may fly out. Check that there is no one in the
surrounding area.
There is danger of pieces flying during the replacement operation, so always wear protective clothing,
such as safety glasses and gloves.
Replace the bucket teeth before they wear down as far as the bucket edge.
1.
2.
3.
4.
Raise the bucket to a suitable height, then put blocks under the bucket to
prevent the bucket from coming down. Raise the bucket so that the bottom surface of the bucket is horizontal.
Remove the bolt and nuts (1) and (2), then remove bucket tooth (3).
Clean the installation surface of bucket tooth (3).
Install new teeth to the bucket. When installing new teeth, insert shims
so that there is no clearance between the teeth and the top surface of the
bucket. Continue to add shims until it becomes impossible to add a 0.5
mm (0.02 in.) shim.
If the mounting surface is worn, correct the mounting surface before
installing the teeth.
WA380-6
3-33
MAINTENANCE
5.
To prevent any gap from forming between the teeth and tip of the bucket, tighten bolts and nuts (1) and (2) temporarily,
then hit the tip of the teeth with a hammer.
Tightening torque of mounting bolt (1): 902 39 Nm (665.4 28.9 lb/ ft.)
Tightening torque of mounting bolt (2): 902 39 Nm (665.4 28.9 lb/ ft.)
After operating the machine for a few hours, tighten the mounting bolts again
REPLACING SLOW-BLOW FUSE

Remark
Always turn the power OFF when replacing the slow blow
fuse (turn the starting switch to the OFF position). Always
replace the slow blow fuse with one of the same capacity.
1.
Turn the starting switch to the OFF position.
2.
3.
Remove the slow blow fuse box from the chassis.

Open covers (1), (2), and (3) of the slow blow fuse box. Covers (2)
and (3) can be removed easily by using protrusion (A) on the body
as a fulcrum and levering the catch of the cover with a flat-headed
screwdriver to release it.
Loosen screws (4) and (5), and remove. When screws (4) and (5)
are removed, slow blow fuse (6) will also come off together with
electric wiring (7) and (8).
Using screws (4) and (5), install a new slow blow fuse together with
electric wiring (7) and (8) to the slow blow fuse box, then close
covers (1), (2), and (3).
Install the slow blow fuse box to the chassis.
4.
5.
6.
3-34
WA380-6
MAINTENANCE
INSPECTION OF TIRES
If a tire or a rim is handled wrongly, the tire may burst or

may be damaged and the rim may be broken and scattered,
and that can cause serious injury and death.
Because maintenance, disassembly, repair and assembly of the tires and rims require special equipment and
skill, ask a tire repair shop to perform the work.
Do not heat or weld the rim to which the tire is installed.
Do not make a fire near the tire.
Select the tires according to the conditions of use and attachments on the machine. Use only specified
tires and inflate them to the specified pressure.
Because the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires.
Standard
Maximum load [kg (lb.)]
Tire size
Front
wheel
9,095 (20,054)
23.5-25
Rear
wheel
7,720 (17,023
23.5-25
Remarks
CHECKING TIRE PRESSURE
When inflating a tire, check that no one will enter the working area and use an air chuck which has a clip
and which can be fixed to the air valve.
While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.
If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. To ensure safety,
place a guard around the tire and do not work in front of the rim but work on the tread side of the tire.
Abnormal drop of inflation pressure and abnormal fitting of the rim indicate a trouble in the tire or rim. In
this case, be sure to ask a tire repair shop to perform repairs.
Be sure to observe the specified inflation pressure.
Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-duty work.
WA380-6
3-35
MAINTENANCE
CHECK
Measure the inflation pressure with a tire pressure gauge while the tires
are cool before starting work.
INFLATION OF TIRES
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air
valve of the tire as shown in the figure. Do not work in front of the rim
but work on the tread side of the tire.
The proper inflation pressure is shown below.
Tire size
Inflation pressure
23.5-25
(standard)
Front Tire: 0.30 MPa (44.0 psi)

Rear Tire: 0.30 MPa (44.0 psi)
CHECKING FUNCTION OF ACCUMULATOR

For details of handling the accumulator, see ACCUMULATOR on page 1-34.
ACCUMULATOR FOR TRAVEL DAMPER

When the travel damper switch is ON, the hydraulic spring effect of the accumulator absorbs the up-and-down motion of the
machine during travel and reduces the swaying.
Drive the machine and compare the up-and-down movement of the machine during travel when the travel damper switch is
ON and when it is OFF.
If there is no change in the up-and-down movement of the machine, the gas pressure in the accumulator has probably dropped.
Please contact your Komatsu distributor to have the accumulator inspected.
Remark
Carry out the inspection with the speed range set to 2 - 4, with the machine traveling at a speed of at least 5
km/h. If the speed range is 1st or the machine is traveling at a speed of less than 5 km/h, the E.C.S.S. will not
be actuated even if the E.C.S.S. switch is turned ON.
ACCUMULATOR FOR BRAKE DAMPER

When the brake pedal is depressed, the hydraulic spring effect of the accumulator actuates the brake smoothly.
If any change is felt in the smoothness of the brake operation during daily operations, the gas pressure in the accumulator has
probably dropped.
Please contact your Komatsu distributor to have the accumulator inspected.
Remark
Even if there is any change in the smoothness, there is no drop in the braking force or brake performance.
3-36
WA380-6
MAINTENANCE
EVERY SPECIFIC HOURS OF SERVICE

EVERY 50 HOURS OF SERVICE
DRAIN SEDIMENT FROM FUEL TANK
Open the drain plug (1) on the right side of the fuel tank so that the sediment and water will be drained together.

Maintenance for every 50 hours service should be performed at the
same time.
LUBRICATE THE REAR AXLE PIVOT PIN

(3 points)
1.
2.
Using a grease pump, pump in grease through the grease fittings

marked by the arrow.
After greasing, wipe off any old grease that was pushed out.
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL
The parts and oil are HOT after stopping the engine, and may cause burns. Wait for the temperature to
decrease before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1.
Lower the bucket horizontally to the ground. It is correct if the oil

amount is between H and L marks on the gauge (G) when
measured approximately 5 minutes after the engine stopped.
Remark
Do not add oil if the level is above the H line. If the oil has
been added to above H level, stop the engine and wait for
the hydraulic oil to cool down, then drain the excess oil from
the drain plug. If the oil is above H level, it will damage the
hydraulic circuit or cause the oil to spurt out.
2.
If the oil is below the L mark, open the inspection cover on the step
and add the oil through the filler (F).
WA380-6
3-37
MAINTENANCE
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT
If compressed air is used, there is danger that dirt may fly and cause personal injury.
Always wear safety glasses, dust mask, and other protective equipment.
If the air conditioner has been used, the air filter should be cleaned.
Stop the air conditioner before cleaning the element.
When replacing the air filter element, set the machine facing directly to
the front or articulate it to the right.
1.
Insert the starting key into key slot (1), release the lock, loosen
knob (2), and open cover (3).
2.
3.
Take out element (4) and clean it.

Direct dry compressed air less than 0.69 MPa (99.4 PSI) to the
element from inside along its folds, then direct it from outside along
its folds and again from inside.
4. If the dirt clogging the filter cannot be removed by blowing it with
air, replace the filter with a new part.
5. After cleaning, return filter (4) to its original position and close the
cover. Use the starting switch key to lock the cover. Do not forget to
remove the starting switch key.
Remark
If the filter becomes clogged, the air flow will be reduced, and
there will be an abnormal noise from the air conditioner unit.
3-38
WA380-6
MAINTENANCE

Maintenance for every 50 and 100 hours service should be performed at the same time.
CHECK BATTERY ELECTROLYTE LEVEL

Perform this check before operating the machine.
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This situation will
accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may also cause an explosion.
The battery generates flammable gas and there is danger of explosion, so 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 amount of
water and consult a doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode
other parts.
Remark
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the battery,
check as follows.
1.
2.
Open the cover of the battery box.There are two battery boxes: One
on each side at the rear of the machine.
Use a wet cloth to clean the area around the electrolyte level lines
and check that the electrolyte level is between the UPPER LEVEL
(U.L) and LOWER LEVEL (L.L) lines. If the battery is wiped with
a dry cloth, static electricity may cause a fire or explosion.
WA380-6
3-39
MAINTENANCE
3.
4.
5.
If the electrolyte level is below the midway point between the U.L
and L.L lines, remove cap (1) and add distilled water to the U.L
line.
If distilled water has been added to any cell of cap (1), add distilled
water also to the other cells.
Clean the vents of the battery caps, then close the caps securely.
Keep the top of the battery clean and wipe it with a wet cloth.
Remark
If distilled water is added to above the U.L line, use a pipette
to lower the level to the U.L line. Neutralize the removed fluid
with baking soda (sodium bicarbonate), then flush it away
with a large amount of water or consult your Komatsu distributor or battery maker.
If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on
the side of the battery, check as follows.
1.
Open the cover of the battery box.There are two battery boxes: One on each side at the rear of the machine.
2.
Remove cap (1) at the top of the battery, look through the water filler port,
and check the electrolyte surface. If the electrolyte does not reach the
sleeve, add distilled water so that the level reaches the bottom of the sleeve
(UPPER LEVEL line).
3.
If distilled water has been added to any cell of cap (1), add distilled water
also to the other cells.
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
4.
After adding distilled water, tighten the cap (1) securely.
Remark
If distilled water is added to above the bottom of the sleeve, use a pipette to lower the level to the bottom of the
sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery maker.
3-40
WA380-6
MAINTENANCE
CHECK PARKING BRAKE
1.
2.
Set the machine on a dry downhill slope. Press the parking brake
switch to the ON position. Check if the parking brake holds the
machine in position.
If any abnormality is found, please contact your Komatsu
distributor.
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION

CHECKING
The standard deflection between the air conditioner compressor pulley
and crank pulley when pressed with a thumb (approx. 98 N (10 kgf))
should be approx. 11 to 15 mm (0.4 to 0.6 in).
When a belt tension gauge is used, the standard tension is within a range
of 353 to 530 N (36 to 54 kgf).
CHECK WHEN CHANGING THE V-BELT
The standard deflection between the air conditioner compressor pulley
and fan pulley when pressed with a thumb approx. 98 N (10 kgf should
be approx. 8 to 11.5 mm (0.315 to 0.5 in).
When a belt tension gauge is used, the standard tension is within a range
of 530 to 745 N (54 to 76 kgf).
Remark
When the belt has been replaced with a new part, a high tension is necessary, so the initial tension is in the
value given above.
ADJUSTING
1.
2.
Loosen bolt (1), then loosen the locknut of bolt (2), tighten bolt (2),
and move compressor (3) to adjust.
Tighten bolt (1) and the locknut of bolt (2) to hold the compressor
(3) in position.
Remark
Check each pulley for damage, wear of the V-groove, and
wear of the V-belt. In particular, be sure to check that the
V-belt is not touching the bottom of the V-groove. In case any
of the following occurs, ask the Komatsu distributor in your
territory to replace the belts with new ones.
* The fan belt has elongated, leaving little allowance for
adjustment.
* A cut or crack is found on the belt.
* Slipping or creaking sound is heard coming from the belt.
When the new V-belt is set, readjust it after one hour of operation.
WA380-6
3-41
MAINTENANCE
WHEEL HUB NUTS
If wheel hub nuts (1) are loose, tire wear will be increased and accidents
may be caused.
1.
Check for loose nuts, and tighten if necessary. When checking for
loose nuts, always turn the nuts in the direction of tightening to
check.
Tightening torque: 825 to 1030 Nm (608.5 to 759.7 lbft).
2.
If any stud bolt is broken, replace all the stud bolts for that wheel.
AIR CONDITIONER RECIRCULATION FILTER

1.
Loosen the knob (1), remove the filter inspection cover (2).
2.
3.
Pull the filter (3) out in the direction of the arrow.

Clean with compressed air in the same way as for the fresh air filter.
If the filter is extremely dirty, rinse it in water. After rinsing the filter, dry it completely before installing it again.

For details of handling the accumulator, see ACCUMULATOR on
page 1-34.
BRAKE ACCUMULATOR
If the engine stops when the machine is traveling, the oil pressure in the
accumulator can be used to apply the brake as an emergency measure.
1. Stop the machine on level ground and lower the work equipment completely to the ground.
2. Apply the parking brake.
3. Start the engine, run it at a mid-range speed for 1 minute, then stop the engine.
4. Turn the starting switch key to the ON position and depress the brake pedal repeatedly.
If the brake oil pressure caution lamp does not light up even when the brake is depressed 6 times, the gas pressure in the accumulator is normal.
3-42
WA380-6
MAINTENANCE
LUBRICATING POINTS
1.
Using a grease pump, pump in the grease through the grease fittings marked by the arrows.
2.
Remark
On jobsites where there is a lot of heavy-duty work, or on jobsites where operations are performed
continuously for more than eight hours, grease the machine more frequently than prescribed.
1.
2.
3.
4.
WA380-6
Bucket pin (2 points)

Bucket link pin (2 points)
Dump cylinder pin (2 points)
Lift cylinder pin (4 points)
5.
6.
7.
Lift arm pivot pin (2 points)

Tilt lever pin (1 point)
Steering cylinder pin (4 points)
3-43
MAINTENANCE

Maintenance for every 50, 100 and 250 hours service should be performed at the same time.
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE
Refill capacity: 23 liters (6.08 US gal)

Filter wrench
1.
2.
3.
4.
Open the engine side cover located on the left of machine.

Open the engine oil filler (F).
Loosen the drain plug (P), and drain the oil.
Check the drained oil. If excessive metal particles or foreign
material exist, please contact your Komatsu distributor.
Install drain plug (P).
5.
6.
7.
8.
9.
Using a filter wrench, turn the filter cartridge (1) counterclockwise

to remove it.
If this operation is carried out immediately after stopping the
engine, a large amount of oil will come out. Therefore, wait for 10
minutes before starting the operation.
Clean the filter holder, fill a new filter cartridge with clean engine
oil (or coat thinly with grease), then coat the seal and thread of the
filter cartridge with engine oil. Install the filter.
When installing, bring the seal surface into contact with the filter
holder, and tighten another 3/4 to 1 turn.
10. Run the engine at idle for a while, then stop the engine. Check that
the oil level is between the H and L marks on the dipstick. For
details, see PRE-OPERATIONAL CHECKS on page 2-76.
3-44
WA380-6
MAINTENANCE
REPLACING PRIMARY FUEL FILTER
Immediately after the engine is stopped, all parts are at high temperature, so do not replace the filter immediately.
Wait for the engine to cool down before starting the operation.
The inside of fuel piping system of the engine is under high-pressure when the engine is running. When
replacing the filter, wait for at least 30 seconds after the engine stops to let the internal pressure go down
before replacing the filter.
Do not bring any fire or spark close.
This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so
if dirt gets in, it will cause problems. If there is any dirt stuck to the fuel line, use fuel to wash it off completely.
Always use a Komatsu genuine part for the fuel filter cartridge. If filters other than genuine filters are used,
problems may occur in the injection system, so never use substitute parts.
Be careful when opening the air bleed plug at the fuel filter head and the air bleeder of the supply pump.
The system is still under pressure and fuel may spurt out.
Genuine Komatsu fuel filter cartridges use a special filter that has
highly efficient filtering ability. When replacing the filter cartridge,
always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and
nozzle.
If any part other than a genuine Komatsu filter cartridge is used,
dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system,
pay more attention than normal to the entry of dirt. If dirt is stuck to
any part, use fuel to wash it off completely.
Prepare a filter wrench

1.
2.
3.
4.
Prepare to remove primary (3) fuel filter.
The fuel primary filter (1) forms one unit with the water separator
and is at the rear of the engine.
Set the container to catch the fuel under the filter cartridge.
WA380-6
3-45
MAINTENANCE
5.
6.
Open the drain (2) on the filter to drain all fuel from the pre filter.
Once primary filter (3) is empty use a filter wrench, turn filter
cartridge counterclockwise on remove it.
7.
Take water separator cup (2) installed on the bottom of the cartridge
and turn it to the left to remove it. (This cup is used again. If it is
damaged, replace it with a new part.)
Install cup (2) to the bottom of the new fuel pre-filter cartridge.
8.
When doing this, always replace the seal ring with a new part.
Tightening torque for cup: 10 Nm (88 in/lbs)
Remark
When filling the primary filter cartridge with fuel, carry out the
filling operation with cap (A) fitted.
Cap (A) acts to prevent the entry of dirt or dust into the filter
cartridge.
9.
10.
11.
12.
13.
14.
Fill the primary filter cartridge with clean fuel through the 8 small
holes (B) in the new filter cartridge.
Coat the packing surface of the filter cartridge with oil.
Remove filter cartridge cap (A) and install to the filter holder.
When installing, tighten until the packing surface contacts the seal
surface of the filter holder, then tighten it 3/4 of a turn.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
When carrying out standard replacement of the fuel filter cartridge (every 1000 hours), replace the cartridge and bleed the
air. For details, see REPLACING PRIMARY AND SECONDARY FUEL FILTER on page 3-47.
Start the engine, check that there is no leakage of fuel from the filter seal surface or water separator mounting surface,
then run for approx. 10 minutes at low idling.
3-46
WA380-6
MAINTENANCE

Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.
REPLACING PRIMARY AND SECONDARY FUEL FILTER

Prepare a filter wrench
1.
2.
Prepare to remove primary (3) and secondary (4) fuel filter.
3.
The fuel primary filter (1) forms one unit with the water separator
and is at the rear of the engine.
Set the container to catch the fuel under the filter cartridge.
4.
5.
6.
Open the drain (2) on the filter to drain all fuel from the pre filter.
Once primary filter (3) is empty use a filter wrench, turn filter
cartridge counterclockwise on remove it.
WA380-6
3-47
MAINTENANCE
7.
8.
Take water separator cup (2) installed on the bottom of the cartridge
and turn it to the left to remove it. (This cup is used again. If it is
damaged, replace it with a new part.)
Install cup (2) to the bottom of the new fuel pre-filter cartridge.
When doing this, always replace the seal ring with a new part.
Tightening torque for cup: 10 Nm (88 in/lbs)
Remark
Fill only the primary fuel filter (3), do not pre-fill the secondary
fuel filter (4) carry out the filling operation with cap (A) fitted.
Cap (A) acts to prevent the entry of dirt or dust into the filter
cartridge.
Fill the primary filter cartridge with clean fuel through the 8 small
holes (B) in the new filter cartridge.
When replacing the seal ring, coat the surface with clean fuel before
installing it.
9.
Check that drain plug (3) at the bottom of water separator cup (2) is
tightened securely.
Tightening torque: 0.2 - 0.45 Nm (2 - 4.0 in/lbs)
10. Clean the filter holders and install new primary fuel filter.
11. Remove the secondary filter (4) in the same manor. Remove cap
(A) from new cartridge and install filter dry.
Remark
It is not recommended to pre fill the secondary fuel filter. Due
to the high pressure fuel system the smallest amount of
debris may damage the fuel injection system.
3-48
When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it 3/4 of a turn. If
the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge
is too loose, fuel will also leak from the packing, so always
tighten the correct amount.
WA380-6
MAINTENANCE
PROCEDURE FOR BLEEDING AIR
1.
2.
Fill the fuel tank with fuel.

Loosen the feed pump knob by turning it counter clockwise until it
pops out from its seated position.
The plug on the fuel filter head does not need to be removed.
3.
4.
Pump the knob in and out until the pressure becomes heavy.
After bleeding air, push in and tighten knob clockwise.
After completing the air bleeding, start the engine and check that there
is no leakage of fuel from the filter seal surface. If there is any leakage,
check the tightening condition of the filter cartridge. If there is still fuel
leakage, repeat Steps 1 - 3 to remove the filter cartridge, then check the
packing surface for damage or embedded dirt.
If any damage or embedded dirt is found, replace the cartridge with a
new part and repeat Steps 4 - 8 to install it.
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER
Immediately after stopping the engine, the parts and oil are HOT and may cause burns. Wait for the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure. Remove the cap.

Filter wrench
1.
Set a container to catch the oil under drain plug (P), then remove
drain plug (P) and drain the oil. To prevent the oil from pouring out
suddenly, loosen drain plug (P) and remove it gradually.
After draining the oil, install drain plug (P).
Tightening torque: 68.6 9.8 Nm (50.6 7.2 lb. ft.)
Set a container to catch the oil under the transmission filter.
2.
3.
WA380-6
3-49
MAINTENANCE
4.
5.
6.
7.
Remove the drain plug (1) of the transmission filter, drain the oil,
then tighten the plug again.
Using a filter wrench, turn filter cartridge (2) to the left to remove
it.
Clean the filter holder, coat the seal surface and thread of the new
filter cartridge with engine oil, then install it.
When the seal surface comes into contact with the filter holder,
tighten another 2/5 turns with the filter wrench.
8.
Remove the bolts (3), move the tube (4), and then remove the
strainer (5).
9. Remove any dirt stuck to the strainer (5), then wash it in clean diesel fuel or flushing oil. If the strainer (5) is damaged, replace it with
a new one.
10. Install the strainer (5) in the case. Replace the O-ring of tube (4)
with a new part, then install the tube (4).
11. Pour in the specified amount of engine oil into the oil filler (F).
12. After filling with oil, check that the oil is at the specified level. For
details, see TRANSMISSION OIL LEVEL on page 3-26.
13. Check that there is no oil leakage from the transmission case or oil
filter.
CLEAN THE TRANSMISSION CASE VENT

Loosen bolt (1) and remove cover (2).
Remove all dirt and mud from around the breather, then remove
breather (3), soak it in flushing fluid, and wash it.
After removing the breather, take steps to prevent dirt or dust from
entering the mount.
3-50
WA380-6
MAINTENANCE
LUBRICATING POINTS
1.
2.
3.
Using a grease pump, pump in the grease through the grease fittings
marked by the arrows.
After greasing, wipe off any old grease that was pushed out. Center
hinge pin (2 points).
Drive shaft center support (1 point).
CHECKING PARTS OF TURBOCHARGER

Please contact your Komatsu distributor to have the tightening portions checked.
CHECK PLAY OF TURBOCHARGER ROTOR

Please contact your Komatsu distributor to have the rotor play checked.
CHECK AND REPLACEMENT OF SERPENTINE BELT

Since inspection and replacement of the fan belt requires special tools,
Remark
The machine is equipped with an auto tensioner, so there is
no need to adjust the tension.
If the alternator drive belt is in the following condition, the belt must be
replaced. Please ask your Komatsu distributor to replace the belt.
When horizontal scratch (1) crosses vertical scratch (2)
When there are tears (3) in part of the belt
In case (4) where there are horizontal scratches only, there is no need to
replace the belt.
WA380-6
3-51
MAINTENANCE

Maintenance for every 50, 100, 250, 500 and 1000 hours service should be performed at the same time.
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT
Before removing the oil filter cap for filter or oil change, clean the place around filter cap to avoid any dust
or dirt from entering the hydraulic system which could cause damage to the system.
1.
2.
3.
4.
5.
6.
Lower the bucket horizontally to the ground and apply the parking
brake, then stop the engine.
Remove oil filler cap (F).
Set a container to catch the oil under drain plug (2).

Remove drain plug (2).
Loosen drain valve (3), then gradually pull it out to drain the oil.
After draining the oil, close drain valve (3), install and tighten drain
plug (2).
Tightening torque
Drain plug (2): 68.6 9.8 Nm (50.6 7.2 ft/lbs)
Drain valve (3): 63.7 14.7 Nm (47.0 10.8 ft/lbs)
3-52
WA380-6
MAINTENANCE
7.
Remove mounting bolt (5) of filter cover (4) at the top of the tank,
then remove the cover.
When doing this, the cover may fly off under the force of spring (6),
so keep the cover pressed down when removing the bolts.
8. Remove spring (6) and bypass valve (7), then take out element (8).
9. Check that there is no foreign material inside the tank, then clean it.
10. Install new element (8), then set bypass valve (7), spring (6), and
cover (4) on the tank.
When doing this, check the cover O-ring. If it is damaged or deteriorated, replace it.
11. Remove 6 bolts (10), then remove cover (9).

12. Pull the top of rod (11) from the top and remove strainer (12).
13. Remove any dirt stuck to strainer (12), then wash it in flushing oil.
If strainer (12) is damaged, replace it with a new part.
14. When installing the cover bolts, push down the cover and tighten
the bolts evenly.
15. Add engine oil through oil filler port (F) to the specified level, then
install cap (F).
16. Check that the hydraulic oil is at the standard level. For details,see
CHECKING THE HYDRAULIC TANK OIL LEVEL AND
ADDING OIL on page 3-37.
17. Run the engine at low idle, and extend and retract the steering,
bucket, and lift arm cylinders 4 to 5 times. Be careful not to operate
the cylinder to the end of its stroke (stop approx. 100mm(3.9 in)
before the end of stroke).
Remark
If the engine is run immediately at high speed or the cylinder
is operated to the end of its stroke, the air inside the cylinder
will cause damage to the piston packing.
WA380-6
3-53
MAINTENANCE
18. Next, operate the steering, bucket, and lift arm cylinders fully 3 - 4
times, then stop the engine and loosen air bleed plug (13).
After bleeding the air from the hydraulic tank, tighten plug (13).
Keep the engine running at low idling when bleeding the air.
19. Check that the hydraulic oil is at the standard level. For details, see
CHECKING THE HYDRAULIC TANK OIL LEVEL AND
ADDING OIL on page 3-37.
20. Next, raise the engine speed, repeat the air bleeding procedure in
Step 18, and continue the operation until no more air comes out
from plug (13).
21. After bleeding the air, tighten plug (13).
Tightening torque: 11.3 1.5 Nm (8.3 1.1 ft/lbs)
22. Check that the hydraulic oil is at the standard level. For details, see
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL on page 3-37.
23. Check that there is no leakage of oil from the filter cover mount.
REPLACE HYDRAULIC TANK BREATHER ELEMENT
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Wait for the temperature to go down before starting the work.
1.
2.
3.
4.
5.
Before removing the breather, wipe off all the dirt from around the
breather.
Remove the cap of oil filler (F).
Remove breather (1) built into the cap.
Replace the filter element (2) built into the breather with a new part,
then install breather (1) to the cap.
Tighten the cap of oil filler (F).
3-54
WA380-6
MAINTENANCE
CHANGE THE AXLE OIL
When changing the oil, apply the parking brake and secure the front and rear frames with the safety bar.
Immediately after stopping the engine, the parts and oil are HOT and may cause burns. Wait for the temperature to go down before starting the operation.
When the plug is removed, oil may spurt out. Therefore, turn the plug slowly to release the internal pressure, then remove the plug carefully.
Refill the capacity (front and rear, each): 40 liters (10.57 US gal)
1.
2.
Set a container to catch the oil under drain plug (P).

Remove front and rear oil filler plugs (1), then remove drain plug
(P) to drain the oil.
Remark
Remove the mud and dirt from around the plug (1), then
remove it.
3.
4.
After draining the oil, clean drain plug (P) and install it again.
Add axle oil through plug hole (1) at the specified level.
Remark
For axles with ASD (Antislip Differential), the brand of lubricating oil is different, so always use the specified
lubricating oil.
5.
After adding oil, check that the oil is at the specified level (1). For
details, see CHANGE THE AXLE OIL on page 3-55.
Remark
For frequent brake use, change the axle oil at shorter intervals.
AIR CONDITIONER RECIRCULATION FILTER

Remove both the recirculation air filter and fresh air filter in the same way as when cleaning, and replace them with new ones.
For details of cleaning the recirculation air filter, see AIR CONDITIONER RECIRCULATION FILTER on page 3-55. To
clean the element, see CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT on page 3-38.
WA380-6
3-55
MAINTENANCE
CHECKING BRAKE DISC WEAR
When checking the brake disc for wear, apply the parking brake and secure the front and rear frames with
the safety bar.
Make sure that the brake oil temperature is less than 60 C (140 F) before checking the brake wear.
If the disc is near the wear limit, perform inspection at shorter intervals, regardless of the specified inspection interval.
Check the brake disc for wear at four locations: front axle, rear axle,
left, and right.
1.
Remove the cap nut (1).
2.
Depress the brake pedal, keep it depressed, and push in the rod (2)
of the gauge until contacts the piston.
The wear is the amount that the end face of rod (2) is protruding
from the end face of guide (3). Measure the amount of protrusion.
The point where the rod groove is level with the end face of the
guide is the permissible limit for the disc wear. If the wear has
reached this point, please ask your Komatsu distributor for
inspection and replacement parts. If the disc is near the wear limit,
perform inspection at shorter intervals, regardless of the specified
inspection interval.
Install the cap nut (1).
Tightening torque: 29.4 to 39.2 Nm (21.7 to 28.9 lb. ft.)
3.
4.
Remark
On new machines, the position of the guide is adjusted so
that the end face of the rod (2) comes to the end face of the
guide (3). For this reason, do not loosen the locknut (4),
except when replacing the disc.Perform the operation with
two workers: one worker depresses the brake pedal and the
other worker pushes the rod (2) in.
3-56
WA380-6
MAINTENANCE
For details of handling the accumulator, see ACCUMULATOR on page 1-34.
PPC ACCUMULATOR
If the engine stops with the work equipment raised, and it is impossible to start the engine again, it is possible as an emergency
measure to actuate the valve with the oil pressure stored in the accumulator and lower the work equipment to the ground.
1.
2.
3.
4.
5.
6.
Apply the parking brake.

Raise the work equipment to the maximum height, then operate the
lift arm control lever to HOLD position (b).
Stop the engine.
Leave the work equipment lock lever in the FREE position.
Check that the area around the machine is safe, then operate the lift
arm control lever to FLOAT position (d) and lower the work
equipment to a point 1m above the ground.
When the lift arm comes to the 1m position, return the lift arm
control lever to LOWER position (c), and lower the work
equipment slowly to the ground.
Remark
Carry out the check within 2 minutes after stopping the
engine. If the machine is left with the engine stopped, the
accumulator pressure will drop and it will be impossible to
check the cause of the problem.
If the work equipment stops while it is moving, the gas pressure in the
accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected.
Replace the accumulator every 4000 hours or every 2 years.
CHECK ALTERNATOR, STARTER MOTOR

The brush may be worn or may be no grease on the bearing, so contact your Komatsu distributor for inspection or repair.
If the engine is started frequently, perform an inspection every 1000 hours.
CHECK ENGINE VALVE CLEARANCE

As special tool is required for removing and adjusting the parts, contact your Komatsu distributor for service.
CHECK INJECTOR
See EVERY 8000 HOURS OF SERVICE
CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
WA380-6
3-57
MAINTENANCE

Maintenance for every 50, 100, 250, 500, 1,000 and 2,000 hours service should be performed at the same time.
LUBRICATING POINTS
Perform the greasing once every two years, regardless of whether the 4, 000 hour interval has passed.
1.
2.
3.
4.
Using a grease pump, pump in grease through the grease fittings marked by the arrows.
When greasing set the drive shaft so the grease fitting is positioned as shown by the arrow view in the drawings below.
All views are from the rear of the machine.
Center drive shaft spline (1 point)
View from rear of machine

Front drive shaft (2 points)
3-58
WA380-6
MAINTENANCE
Rear drive shaft (2 points)

Center drive shaft (2 points)
WA380-6
3-59
MAINTENANCE
CHECK WATER PUMP
Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any abnormality
is found, contact your Komatsu distributor for disassembly and repair or replacement.
CHECK AIR CONDITIONER COMPRESSOR

Ask Komatsu distributor.
REPLACE INJECTOR NOZZLE TIP

Ask your Komatsu distributor to perform this work.
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER

Visually check and touch areas by hand to check to be sure there is no hardening of rubber parts or loose bolts for the highpressure piping between the supply pump and the common rail. (2 places) If there are any problems found the parts must be
replaced. Contact your Komatsu distributor for any repairs necessary.
3-60
WA380-6
MAINTENANCE
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
Check for any missing fuel spray prevention caps (12 places) on the fuel injection piping and both ends of the high-pressure
piping act to prevent the fuel from coming into contact with high-temperature parts of the engine and possibly causing a fire.
Visually check and touch by hand for missing or loose caps. If they are damaged, deteriorated, or missing replace them with
new caps. Contact your Komatsu distributor for any repairs.
WA380-6
3-61
MAINTENANCE

Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same time.
REPLACE HIGH-PRESSURE PIPING CLAMP

REPLACE FUEL SPRAY PREVENTION CAP

CHECK, REPLACE INJECTOR

This machine uses an engine that conforms with all exhaust gas regulations.
The exhaust gas regulations differ according to the applicable area. To ensure that the engine conforms with the regulations in
the area of use and can fully display its performance, keep to the following periodic maintenance intervals when check and
replace the injector.
If the periodic maintenance intervals are not observed correctly, the engine may not be able to display its performance fully,
and it may also not conform with the regulations.
When transporting a machine from an A regulation area to a B regulation area, always replace all the injector assemblies
before transporting the machine to the new area.
Check with your Komatsu distributor to confirm if your area of operation is an A regulation area or a B regulation area.
Check injector
Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please ask your Komatsu distributor
to carry out inspection or replacement.
3-62
WA380-6
SPECIFICATIONS
WA380-6
4-1
SPECIFICATIONS
SPECIFICATIONS
MACHINE DIMENSIONS AND WEIGHTS
TIRES
Tire Specifications
mm
(in)
Tread
2160
71
Width over tires
2780
91
Wheel base
3300
1010
Hinge pin height at Max. height
4095
135
Hinge pin height at carry position
520
18
Ground clearance
455
16
Hitch point height
1150
39
Overall height, top of stack
2975
99
Overall height ROPS cab
3390
112
4-2
Measured with 23.5-25-16PR (L3) tires, ROPS/FOPS cab
WA380-6
SPECIFICATIONS
WORK EQUIPMENT
General Purpose
Bolt-on Cutting Edge
Bucket
Excavating Bolt-on
Cutting Edge
Light Material
Bolt-on Cutting Edge
Heaped
3.3m3
4.3yd3
2.9m3
3.8yd3
4.0m3
5.2yd3
Struck
2.9m3
8.3yd3
2.4m3
3.1yd3
3.4m3
4.4yd3
Bucket width
2905mm
96
2905mm
96
2905mm
96
Bucket weight
1620kg
3,570lb
1720mm
3,790lb
1835kg
4,045lb
Dumping clearances
maximum height and 45o dump
angle
2950mm
98
3045mm
100
2855mm
94
Reach at (7) 2130mm 45o dump

angle
1735mm
58
1055mm
36
1240mm
41
Reach at maximum height 45o

dump angle
1150mm
39
1070mm
36
1275mm
41
Reach with arm horizontal

and bucket level
2590mm
86
2450mm
80
2715mm
811
Operating height
Fully raised
5600mm
185
5470mm
1711
5720mm
189
Overall length
Bucket on ground
8140mm
268
8000mm
263
8265mm
271
Loader clearance circle
14440mm
455
14370mm
472
14500mm
477
0o
60mm
2.4
60mm
2.4
60mm
2.4
10o
290mm
114
265mm
10.4
315mm
1.0
158kN
35,490lb
176kN
39,680lb
144kN
32,405lb
17580kg
38760lb
17960kg
39,000lb
17810kg
39,620lb
Bucket
capacity
Digging depth
Breakout force
Operating weight
TRAVEL SPEEDS
1st.
km/h (MPH)
6.6 (4.1)
2nd.
km/h (MPH)
11.5 (7.2)
3rd.
km/h (MPH)
20.2 (21.3)
4th.
km/h (MPH)
34.0 (21.3)
1st.
km/h (MPH)
7.1 (4.4)
2nd.
km/h (MPH)
12.3 (7.7)
3rd.
km/h (MPH)
21.5 (13.4)
4th.
km/h (MPH)
35.5 (22.2)
Forward
Travel speed
Reverse
WA380-6
4-3
SPECIFICATIONS
MACHINE SYSTEMS SPECIFICATIONS
ENGINE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SAA6D107E
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged, and air-to-air after cooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 mm x 124 mm 4.21" x 4.88"
Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69 ltr 408 in3l
Horsepower rating @ 2100 rpm (SAE J1995)
Gross horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 kW 192 HP
Net horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 kW 191 HP
Hydraulic fan at maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 kW 179 HP
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Rail Injection
Lubrication system
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with double radial-sealed elements and dust evacuator, plus dust indicator
4-4
WA380-6
WA380-6
5-1
TORQUE CONVERTER LOCK-UP
When traveling down slopes of a grade of more than 6, never depress the accelerator pedal fully, regardless of whether the torque converter lock-up switch is ON or OFF. It is extremely dangerous to drive fast.
The travel speed shown in this section is the value when the tire size is 23.5-20. The travel speed when the tire size is 20.5-20
is shown in {}. The travel speed is subject to the using condition and road condition.
To prevent overrunning when traveling at high speed in the following cases, do not downshift.
When traveling in F3 at a speed of more than 18 km/h (11.2 mph), do not downshift to F2.
When traveling in F4 at a speed of more than 28 km/h (17.4 mph), do not downshift to F3.
When the actual speed range is 3rd or 4th in either FORWARD or REVERSE, the torque converter lock-up function is actuated according to the travel speed and sets to direct drive. To prevent overrun, the lock-up is automatically canceled to prevent
the travel speed from going above 40 km/h (24.9 mph).
GENERAL LOCATIONS
1.
2.
5-2
Torque converter lock-up switch

Torque converter lock-up pilot lamp
3.
4.
Shift indicator (displays actual speed range)

Character display
WA380-6
TORQUE CONVERTER LOCK-UP SWITCH
This switch (1) is the control switch for the torque converter lock-up
function.
Position (a): ON
The pilot lamp inside the switch lights up and the lock-up is actuated
according to the travel speed. While the lock-up is engaged, the lock-up
pilot lamp on the machine monitor lights up.
Position (b): OFF
The lock-up does not function.
TORQUE CONVERTER LOCK-UP PILOT LAMP

This monitor (2) lights up when the torque converter lock-up is engaged
and the transmission actually enters direct drive.
METHOD OF OPERATION
1.
2.
Press the top (a) of the torque converter lock-up switch to turn it
ON. The pilot lamp inside the switch lights up.
When the actual speed range is 3rd or 4th in either FORWARD or
REVERSE, the torque converter lock-up function is actuated
according to the travel speed and sets to direct drive.
Remark
When 4th is selected in auto-shift mode, the lock-up is not
actuated in 3rd. The lock-up is actuated only in the selected
4th gear.
When the lock-up is actually actuated, the lock-up pilot lamp on the
machine monitor lights up.
3.
To cancel the lock-up, press the bottom (b) of the torque converter
lock-up switch to turn it OFF. The lock-up is canceled.
WA380-6
5-3
The travel speed for actuation and cancellation of the lock-up is as shown below.
Lock-ups
FORWARD travel speed

(km/h (mph))
REVERSE travel speed

(km/h (mph))
Speed range
Actuated
Canceled
Actuated
Canceled
3rd
13 to 15
(8.1 to 9.3)
{12 to 14}
(7.5 to 8.7)
13 to 14
(8.1 to 8.7)
{12 to 13}
(7.5 to 8.1)
14 to16
(8.7 to 9.9)
{13 to 15}
(8.1 to 9.3}
14 to 15
(8.7 to 9.3)
{13 to 14}
(8.1 to 8.7)
4th
22 to 25
(13.7 to 15.5)
{20 to 23}
(12.4 to 14.3)
21
(13.0)
{19}
(11.8)
23 to 27
(14.3 to 16.8)
{21 to 25}
(13.0 to 15.5)
23
(14.3)
{21}
(13.0)
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED

TRAVEL SPEED WARNING FUNCTION
(This functions even when the torque converter lock-up switch is OFF.)
When the travel speed goes above 40.0 km/h (24.9 MPH) {36.5 km/h (22.7 MPH)}, the central warning lamp lights up and the
alarm buzzer sounds.
At the same time, E00 OVERRUN PROTECT is displayed on the character display.
If the alarm buzzer sounds, depress the brake immediately to slow the machine down.
When the travel speed goes below 39.5 km/h (24.5 MPH) {36.0 km/h (22.4)}, the alarm buzzer stops.
TRAVEL SPEED LIMIT FUNCTION

(This functions only when the torque converter lock-up switch is ON.)
To prevent the travel speed from going above 40.0 km/h (24.9 MPH) {36.5 km/h (22.7 MPH)}, the lock-up is automatically
canceled.The lock-up cancel continues until the travel speed goes below 38.0 km/h (23.6 MPH) {35.0 km/h (21.7 MPH)}.
5-4
WA380-6
SELECTING BUCKET AND TIRES

Select the most suitable bucket and tires for the type of work and the ground conditions on the job site.
Type of work
Loading products
Loading and
carrying products
Loading crushed rock
Bucket
Stockpile bucket
(with bolt-on cutting edge)
3.3 m (4.3 cu. yd.)
Stockpile bucket (without teeth)
3.1 m (4.1 cu. yd.)
Light material bucket
(with bolt-on cutting edge)
3.8 m (5.0 cu. yd.)
Excavating bucket
(with segment edge)
2.7 m (3.5 cu. yd.)
Ground Conditions
Tire
General ground
conditions
23.5-25-16PR (L3 Rock)
Leveled ground
23.5-25-16PR (L2 Traction)
Soft ground
23.5-25-16PR (L2 Traction)
General ground
conditions
23.5-25-20PR (L3
Rock)
Soft ground
20.5-25-16PR (L3
Rock)
Ground with many light

23.5-25-16PR (L3
rocks
Rock)
Soft ground with many

23.5-25-16PR (L3
light rocks
Rock)
BOC indicates a bolt-on type cutting edge.

The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your Komatsu
distributor.
WA380-6
5-5
USING MACHINES EQUIPPED WITH KOMTRAX

KOMTRAX is a machine management system that uses wireless communications.
A contract with your Komatsu distributor is necessary before the KOMTRAX system can be used. Any customers desiring to use the KOMTRAX system should consult their Komatsu distributor.
The KOMTRAX equipment is a wireless device using radio waves, so it is necessary to obtain authorization and conform
to the laws of the country or territory where the machine equipped with KOMTRAX is being used. Always contact your
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX.
When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be
necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
If you do not obey the above precautions, neither Komatsu nor your Komatsu distributor can take any responsibility for
any problem that is caused or for any loss that results.
BASIC PRECAUTIONS
Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This
may cause failure or fire on the KOMTRAX equipment or the machine itself. (Your Komatsu distributor
will carry out removal and installation of KOMTRAX.)
Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short
circuits or disconnected wires may cause failure or fire on the KOMTRAX equipment or the machine
itself.
For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm (8.7
in) from the pacemaker.
The radio waves may have an adverse effect on the operation of the pacemaker.
Remark
Even when the key in the starting switch of the KOMTRAX system is at the OFF position, a small amount of
electric power is consumed. When putting the machine into long-term storage, take the action given in
BEFORE STORAGE on page 2-141.
Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
Be careful not to get water on the communications terminal or wiring.
The KOMTRAX system uses wireless communications, so it cannot be used inside tunnels, underground, inside buildings, or
in mountain areas where radio waves cannot be received. Even when the machine is outside, it cannot be used in areas where
the radio signal is weak or in areas outside the wireless communication service area.
There is absolutely no need to inspect or operate the KOMTRAX communications terminal, but if any abnormality is found,
please consult your Komatsu distributor.
5-6
WA380-6
Komatsu America Corp.

DataKom Publications & Training
100 Komatsu Drive
Cartersville, GA 30121 U.S.A
Attn: Service Publications
Fax No. (678) 721-3430
PROPOSER
DATE:
NAME OF COMPANY:
PROPOSAL FOR MANUAL OR CSS REVISION
FOR INTERNAL USE ONLY -- No.PMR

CITY:
STATE OR PROVINCE:
DEPARTMENT:
COUNTRY:
NAME:
FAX:
MANUAL DESCRIPTION:
CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO:
CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE:
CSS BOOK PUBLISHER:
BOOK DESCRIPTION
MACHINE MODEL & S/N:
MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS
PROBLEM:
Attach photos or sketches.

If more space is needed, use another sheet.
FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PROPFREV.FM 100903

O&M WA380-6 A53001 Up CEAM017200

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Operation and Maintenance

Copyright 2006 Komatsu

Storage location for Operation and Maintenance

APPROVED AND NON-APPROVED USES

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

MACHINE SERIAL NUMBER

ENGINE SERIAL NUMBER AND EMISSION LABEL

SERVICE METER LOCATION

SERIAL NUMBERS AND DEALER INFORMATION

SAFETY AND WARNING DECALS

LOCATION OF THE SAFETY DECALS

LOCATION OF SAFETY LABELS

(2) Precautions for safety lock lever (09654-C0481).

Honk horn to alert people nearby.

(4) Precautions for going close to electric cables (09801-C0481).

Keep a safe distance from the electric power lines.

(6) Precautions for safety bar (09161-2300).

(7) Caution when canceling parking brake emergency (423-93-41311)

Allow the radiator or hydraulic tank to cool before removing the

(9) Precautions when handling battery cables (09808-03000).

(10) High-pressure warning (09659-5300).

(11) Do not climb on fender (09805-03000)

Do not stand on this place.

Turn off before inspection and maintenance.

(13) Do not open when the engine is running (09667-03001).

Turn off before inspection and maintenance.

(14) Do not come near the machine (09812-13000).

Keep a safe distance from the vehicle when it is moving.

Keep away when the working device is raised.

(16) Do not modify ROPS (09620-A2000)

(17) Jump start prohibited (09842-A0481)

Allow the hydraulic tank to cool before removing the cap.

(19) Precautions for high temperature exhaust (09817-A0753).

Allow the hydraulic tank to cool before removing the cap.

(20) Caution for common rail high pressure (6217-71-93310)

(22) Escape (425093-51110)

GENERAL SAFETY RULES AND PRECAUTIONS

GENERAL SAFETY AT JOB SITE

WORKING ON LOOSE GROUND

PERSONAL PROTECTIVE EQUIPMENT

FIRE AND EXPLOSION PREVENTION

FIRE CAUSED BY FUEL OR OIL

Do not smoke or use any flame near fuel or oil.

FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL

Tighten any loose connectors or wiring clamps.

FIRE COMING FROM HYDRAULIC LINE

WINDSHIELD WASHER FLUID

Use an automotive type washer fluid in the windshield washer system.

ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows:

FIRE EXTINGUISHER AND FIRST AID KIT

MOUNTING AND DISMOUNTING

INSIDE OPERATORS COMPARTMENT

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

PRECAUTIONS WHEN USING ROPS

EMERGENCY ESCAPE FROM OPERATOR'S CAB

LEAVING OPERATORS COMPARTMENT

Place safety lock lever for loader control in the (LOCKED)

KEEP OPERATOR'S COMPARTMENT CLEAN

DUST HAZARD PRECAUTIONS

ASBESTOS HAZARD ALERT

CRUSH OR PINCH POINT DANGERS