HM400 5 Operation Manual

Operation & EENAM03380
Maintenance Manual
HM400-5
ARTICULATED DUMP TRUCK
SERIAL NUMBERS
HM400-5 - 10001 and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read ORIGINAL INSTRUCTIONS
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).
1-1
BEFORE READING THIS MANUAL FOREWORD
BEFORE READING THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
read it at any time.
Keep the Operation and Maintenance Manual inside of the left
door.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.
1-2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
k
This signal word indicates an imminently hazardous situation which, if not avoided,
DANGER will result in death or serious injury.
k
This signal word indicates a potentially hazardous situation which, if not avoided,
WARNING could result in death or serious injury.
k
This signal word indicates a potentially hazardous situation which, if not avoided,
CAUTION may result in minor or moderate injury. It may also be used to alert against unsafe
practices that may cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
NOTICE If precautions described are not observed, the machine may be damaged or the service life may
be reduced.
REMARK This word is used for information that is useful to know.
1-3
NOISE FOREWORD
NOISE
Two labels indicating the machine noise level are affixed on the machine.
• Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator’s position is 2.5dB, in accordance with
ISO 11201
• Sound power level emitted by the machine, measured ac-

cording to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 4.0 dB.
1-4
FOREWORD VIBRATION LEVELS
VIBRATION LEVELS
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper-
ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with
ISO 7096.
FOR HM400-5 WITH STANDARD TIRES :
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.58 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.16
m/s2 according to EN12096:1997.
FOR HM400-5 WITH WIDE TIRES :
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.59 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.24
m/s2 according to EN12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
VIBRATION - OPERATING CONDITION

(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading and
travelling without load)
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE

The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
• Tire pressures (for wheeled machines), tension of crawler (for crawler machines)
• Brake and steering systems
• Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling in good condition
• Remove any large rocks or obstacles
• Fill any ditches and holes
• Site manager should provide machine operators with machine and schedule time to maintain terrain
conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
• Adjust the seat and suspension for the weight and size of the operator
• Wear seat belt
• Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
• When pushing with bucket or blade, avoid sudden loading; load gradually
• Drive around obstacles and rough terrain conditions
• Slow down when it is necessary to go over rough terrain
• Make the curve radius of travelling path as large as possible
• Travel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance travelling
1-5
VIBRATION LEVELS FOREWORD
• Reduce speed to prevent bounce

• Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
• Operate the machine only when you are in good health
• Provide breaks to reduce long periods of sitting in the same posture
• Do not jump down from the cab or machine
• Do not repeatedly handle and lift loads
1-6
FOREWORD INTRODUCTION
INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Traveling with a load
DIRECTIONS OF MACHINE
(A) Front (D) Right

(B) Rear (E) Operator's seat
(C) Left
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from
the operator's seat in the direction of travel (front) of the machine.
VISIBILITY FROM OPERATOR'S SEAT

This machine complies with the visibility standard (ISO 5006).
This machine maintains a proximity visibility of a height of 1.5 m at a point 1 m away from the outside surface of
the machine, and a visibility for a circumference of 12 m.
1-7
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION FOREWORD
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS

EMISSION
About Engine Technology

This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
1-8
FOREWORD PRODUCT INFORMATION
PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

AL NO. PLATE
This is on the rear left side of the operator's cab.
The design of the nameplate differs according to the district.
LOCATION OF ENGINE NUMBER PLATE

The is on the engine cylinder head.
1-9
PRODUCT INFORMATION FOREWORD
SERVICE METER LOCATION

In the initial state, it is on the left bottom of the machine moni-
tor.
See “METER DISPLAY SELECTION (3-78)” if the screen is
not displayed.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.
Engine serial No.
Product identification number
(PIN)
Manufacturers name: KOMATSU LTD.
Address: 2-3-6 Akasaka
Minato-ku, Tokyo 107-8414
Japan
Authorised representative: KOMATSU EUROPE INT.
Address: Mechelsesteenweg 586
B-1800 Vilvoorde
Belgium
Distributor name
Address
Service personnel
Phone/Fax
1-10
FOREWORD SERIAL PLATE
SERIAL PLATE
B C
D E
F
EI000001
A MACHINE DESIGNATION/TYPE E ENGINE POWER
B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
D OPERATING MASS H AUTHORISED REPRESENTATIVE
1-11
DECLARATION OF CONFORMITY FOREWORD
DECLARATION OF CONFORMITY
The manufacturer/Authorised representative
The manufacturer Authorised representative
KOMATSU LTD. KOMATSU EUROPE INT.
2-3-6 Akasaka Mechelsesteenweg 586
Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde
Japan Belgium
Declares that this machine:

HM400-5
Fulfils all the relevant provisions of following EC Directives:
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Outdoor Noise Directive 2001/14/EC amended by 2005/88/EC
1-12
FOREWORD TABLE OF CONTENTS
TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
BEFORE READING THIS MANUAL ......................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-3
NOISE....................................................................................................................................................... 1-4
VIBRATION LEVELS ................................................................................................................................ 1-5
VIBRATION - OPERATING CONDITION ........................................................................................... 1-5
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ................................................................ 1-5
INTRODUCTION ...................................................................................................................................... 1-7
MAIN USE OF MACHINE .................................................................................................................. 1-7
DIRECTIONS OF MACHINE.............................................................................................................. 1-7
VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-7
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION ..................................................... 1-8
PRODUCT INFORMATION....................................................................................................................... 1-9
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........ 1-9
LOCATION OF ENGINE NUMBER PLATE ........................................................................................ 1-9
SERVICE METER LOCATION ......................................................................................................... 1-10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................................ 1-10
SERIAL PLATE ........................................................................................................................................1-11
DECLARATION OF CONFORMITY ........................................................................................................ 1-12
SAFETY........................................................................................................................................................... 2-1
SAFETY.................................................................................................................................................... 2-2
SAFETY LABELS ..................................................................................................................................... 2-4
LOCATION OF SAFETY LABELS...................................................................................................... 2-5
CONTENTS OF SAFETY LABELS .................................................................................................... 2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-15
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-15
PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-18
DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-20
UNAUTHORIZED MODIFICATION .................................................................................................. 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ..................................................... 2-21
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-22
PRECAUTIONS FOR JOBSITE ....................................................................................................... 2-22
START ENGINE............................................................................................................................... 2-24
PRECAUTIONS FOR OPERATION ................................................................................................. 2-26
TRANSPORTATION......................................................................................................................... 2-29
TOWING AND BEING TOWED........................................................................................................ 2-30
PRECAUTIONS FOR MAINTENANCE ................................................................................................... 2-31
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-31
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-35
TIRES .............................................................................................................................................. 2-39
PRECAUTIONS FOR DEF...................................................................................................................... 2-41
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING .................................................. 2-41
PRECAUTIONS FOR ADDING ........................................................................................................ 2-41
PRECAUTIONS FOR STORING...................................................................................................... 2-41
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE .................................................................... 2-41
OTHER PRECAUTIONS.................................................................................................................. 2-41
OPERATION .................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES ................................................................................................. 3-3
OTHER EQUIPMENT NAME ............................................................................................................. 3-7
EXPLANATION OF COMPONENTS ....................................................................................................... 3-10
1-13
TABLE OF CONTENTS FOREWORD
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................. 3-10

SWITCHES ...................................................................................................................................... 3-93
CONTROL LEVERS AND PEDALS ............................................................................................... 3-104
OTHER EQUIPMENT .................................................................................................................... 3-107
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-150
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-150
METHOD FOR STARTING ENGINE.............................................................................................. 3-177
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-181
METHOD FOR STOPPING ENGINE ............................................................................................. 3-183
METHOD FOR CHECKING AFTER STOPPING ENGINE ............................................................. 3-183
START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MACHINE........................ 3-184
METHOD FOR SHIFTING GEARS ................................................................................................ 3-188
METHOD FOR TRAVELING DOWNHILL ...................................................................................... 3-190
METHOD FOR TURNING MACHINE ............................................................................................ 3-195
OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK ................................................................. 3-196
HANDLE AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC) ................................... 3-197
OPERATION OF ARAC SYSTEM.................................................................................................. 3-198
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)..................................................... 3-199
OPERATION OF KTCS SYSTEM .................................................................................................. 3-200
OPERATION IF TROUBLES ON SYSTEM OCCUR ...................................................................... 3-200
OPERATION IF TIRES ARE STUCK IN GROUND ........................................................................ 3-201
METHOD FOR LOADING .............................................................................................................. 3-201
METHOD FOR DUMPING ............................................................................................................. 3-202
METHOD FOR OPERATING CAB TILT ......................................................................................... 3-204
PRECAUTIONS FOR OPERATION ............................................................................................... 3-207
METHOD FOR PARKING MACHINE ............................................................................................. 3-208
METHOD FOR CHECKING AFTER FINISHING WORK ................................................................ 3-209
LOCK ............................................................................................................................................. 3-209
HANDLE TIRE ............................................................................................................................... 3-218
HANDLE AIR CONDITIONER............................................................................................................... 3-219
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-220
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-225
HANDLE RADIO ................................................................................................................................... 3-232
EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-232
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-234
DUMP BODY HEATING SPECIFICATIONS.......................................................................................... 3-237
DETERMINE AND MAINTAIN TRAVEL ROAD ..................................................................................... 3-238
TRANSPORTATION.............................................................................................................................. 3-239
PRECAUTIONS FOR TRANSPORTATION.................................................................................... 3-239
PRECAUTIONS FOR TRANSPORTING MACHINE ...................................................................... 3-239
SELECT TRANSPORTATION METHOD........................................................................................ 3-239
METHOD FOR SECURING MACHINE .......................................................................................... 3-239
PRECAUTIONS FOR LIFTING MACHINE..................................................................................... 3-240
COLD WEATHER OPERATION............................................................................................................ 3-244
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-244
PRECAUTIONS AFTER DAILY WORK COMPLETION ................................................................. 3-245
AFTER COLD WEATHER SEASON .............................................................................................. 3-245
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-246
PREPARATION FOR LONG-TERM STORAGE ............................................................................. 3-246
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-246
STARTING MACHINE AFTER LONG-TERM STORAGE ............................................................... 3-246
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE..................................... 3-247
TROUBLES AND ACTIONS ................................................................................................................. 3-248
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-248
ACTIONS IF TRANSMISSION HAS TROUBLE ............................................................................. 3-248
METHOD FOR LOWERING DUMP BODY IN EMERGENCY ........................................................ 3-249
PRECAUTIONS FOR TOWING MACHINE .................................................................................... 3-250
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-253
1-14
FOREWORD TABLE OF CONTENTS
OTHER TROUBLE......................................................................................................................... 3-256

MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE ..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS ................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID ............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR ADDING DEF ................................................................................................. 4-2
PRECAUTIONS FOR WELDING ....................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-2
PRECAUTIONS FOR SCR ASSEMBLY ............................................................................................ 4-3
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS .............................................................. 4-10
MAINTENANCE SCHEDULE.................................................................................................................. 4-12
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-12
MAINTENANCE PROCEDURE .............................................................................................................. 4-14
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-14
WHEN REQUIRED .......................................................................................................................... 4-14
CHECKS BEFORE STARTING........................................................................................................ 4-35
EVERY 50 HOURS MAINTENANCE ............................................................................................... 4-36
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-37
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-48
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-56
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
HANDLE CAB POWER TILT..................................................................................................................... 6-2
HANDLING PAYLOAD METER................................................................................................................. 6-6
OUTLINE OF SYSTEM...................................................................................................................... 6-6
NORMAL OPERATION DISPLAY ...................................................................................................... 6-7
EXTERNAL DISPLAY LAMP.............................................................................................................. 6-8
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER ................................................... 6-9
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD............................ 6-9
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES ............................................................... 6-12
DISPLAY FUEL CONSUMPTION RECORD .................................................................................... 6-13
SETTING MACHINE ID AND OPEN ID............................................................................................ 6-14
METHOD FOR PERFORMING CALIBRATION................................................................................ 6-15
REPLACEMENT PARTS.................................................................................................................................. 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2
1-15
TABLE OF CONTENTS FOREWORD
DEFINED LIFE PARTS LIST.............................................................................................................. 7-2

CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS LIST ............................................................................................................. 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-4
LUBRICATION CHART ...................................................................................................................... 7-4
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-6
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-8
INDEX.............................................................................................................................................................. 8-1
1-16
SAFETY
Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.
2-1
SAFETY SAFETY
SAFETY
SAFETY LABELS ............................................................................................................................................ 2-4
LOCATION OF SAFETY LABELS............................................................................................................. 2-5
CONTENTS OF SAFETY LABELS ........................................................................................................... 2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-15
ENSURE SAFE OPERATION .......................................................................................................... 2-15
UNDERSTAND THE MACHINE ....................................................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION ............................................................................................ 2-15
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ................................................................. 2-15
INSPECT MACHINE ........................................................................................................................ 2-15
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ............................................. 2-15
KEEP MACHINE CLEAN ................................................................................................................. 2-15
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT ...................................................... 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ................................................................... 2-16
IF ANY PROBLEM IS FOUND ......................................................................................................... 2-16
PRECAUTIONS TO PREVENT FIRE...................................................................................................... 2-16
ACTIONS IF FIRE OCCURS ........................................................................................................... 2-16
PREVENT FIRE............................................................................................................................... 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.................................................................... 2-18
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE ..................................... 2-18
NO JUMPING ON OR OFF MACHINE............................................................................................. 2-19
PEOPLE ON DUMP BODY.............................................................................................................. 2-19
WHEN STANDING UP FROM OPERATOR'S SEAT ........................................................................ 2-19
PRECAUTIONS WHEN LEAVING MACHINE .................................................................................. 2-19
EMERGENCY EXIT FROM OPERATOR'S CAB .............................................................................. 2-20
DO NOT GET CAUGHT IN WORK EQUIPMENT ................................................................................... 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-20
UNAUTHORIZED MODIFICATION ......................................................................................................... 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ........................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................................................ 2-21
PRECAUTIONS FOR OPERATION ............................................................................................................... 2-22
PRECAUTIONS FOR JOBSITE .............................................................................................................. 2-22
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS................................................................. 2-22
PRECAUTIONS WHEN WORKING ON LOOSE GROUND ............................................................. 2-22
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................................ 2-22
ENSURE GOOD VISIBILITY............................................................................................................ 2-23
CHECK SIGNS AND SIGNALMAN'S SIGNALS............................................................................... 2-23
BEWARE OF ASBESTOS DUST ..................................................................................................... 2-23
START ENGINE...................................................................................................................................... 2-24
USE WARNING TAGS ..................................................................................................................... 2-24
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ........................................................ 2-24
WHEN STARTING ENGINE............................................................................................................. 2-25
IN COLD AREAS ............................................................................................................................. 2-25
START ENGINE WITH JUMPER CABLES ...................................................................................... 2-25
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-26
CHECKS BEFORE OPERATION..................................................................................................... 2-26
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE ............................................... 2-26
WHEN TRAVELING ......................................................................................................................... 2-27
WHEN TRAVELING ON SLOPES.................................................................................................... 2-27
PRECAUTIONS WHEN OPERATING MACHINE............................................................................. 2-27
WHEN LOADING ON DUMP BODY ................................................................................................ 2-28
WHEN DUMPING ............................................................................................................................ 2-28
WHEN OPERATING ON SNOW OR FROZEN SURFACES ............................................................ 2-28
WHEN PARKING MACHINE ............................................................................................................ 2-28
TRANSPORTATION................................................................................................................................ 2-29
PRECAUTIONS WHEN LOADING AND UNLOADING .................................................................... 2-29
2-2
SAFETY SAFETY
TOWING AND BEING TOWED............................................................................................................... 2-30

PRECAUTIONS FOR TOWING AND BEING TOWED..................................................................... 2-30
PRECAUTIONS FOR MAINTENANCE .......................................................................................................... 2-31
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-31
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ....................................... 2-31
KEEP WORK PLACE CLEAN AND TIDY ........................................................................................ 2-31
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE .......................................... 2-31
ONLY AUTHORIZED PERSONNEL................................................................................................. 2-31
APPOINT LEADER WHEN WORKING WITH OTHERS .................................................................. 2-31
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ........................... 2-31
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING .......................................... 2-33
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS...................... 2-33
PRECAUTIONS FOR WORKING AT HIGH PLACES ...................................................................... 2-34
PRECAUTIONS WHEN WORKING ON MACHINE.......................................................................... 2-34
PRECAUTIONS WHEN WORKING UNDER MACHINE .................................................................. 2-34
USE PROPER TOOLS .................................................................................................................... 2-35
PRECAUTIONS FOR CHECK AND MAINTENANCE ............................................................................. 2-35
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION ....................................................... 2-35
PRECAUTIONS FOR WELDING ..................................................................................................... 2-35
HANDLE BATTERY ......................................................................................................................... 2-35
WHEN USING HAMMER ................................................................................................................. 2-36
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT ............................................................... 2-36
PRECAUTIONS FOR HIGH-TEMPERATURE OIL........................................................................... 2-37
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS..................................................................... 2-37
PRECAUTIONS FOR HIGH-PRESSURE OIL.................................................................................. 2-37
PRECAUTIONS FOR HIGH-PRESSURE FUEL .............................................................................. 2-37
HANDLE HIGH-PRESSURE HOSES AND PIPING ......................................................................... 2-37
PRECAUTIONS FOR HIGH VOLTAGE............................................................................................ 2-38
PRECAUTIONS FOR NOISE........................................................................................................... 2-38
HANDLE SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGS .............................. 2-38
PRECAUTIONS FOR COMPRESSED AIR...................................................................................... 2-38
MAINTENANCE OF AIR CONDITIONER ........................................................................................ 2-38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS .......................................................... 2-38
METHOD FOR SELECTING WINDOW WASHER FLUID................................................................ 2-39
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS................................................................. 2-39
TIRES ..................................................................................................................................................... 2-39
HANDLE TIRES............................................................................................................................... 2-39
PRECAUTIONS FOR STORING TIRES .......................................................................................... 2-40
PRECAUTIONS FOR DEF............................................................................................................................. 2-41
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING ......................................................... 2-41
PRECAUTIONS FOR ADDING ............................................................................................................... 2-41
PRECAUTIONS FOR STORING............................................................................................................. 2-41
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE ........................................................................... 2-41
OTHER PRECAUTIONS......................................................................................................................... 2-41
2-3
SAFETY LABELS SAFETY
SAFETY LABELS
k WARNING
Be sure that you fully understand the correct position, content and how to avoid a danger shown in the
safety labels.
Handle the warning signs and safety labels used on this machine as follows.
• Always keep the safety labels clean so that you can read it properly. When cleaning the safety labels, do
not use organic solvents or gasoline. These may cause the labels to peel off.
• If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details
of the part numbers for the safety labels, see this manual or the actual label, and place an order to your
Komatsu distributor.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the
same way.
2-4
SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS
2-5
2-6
(1) Caution for modification of ROPS/FOPS (11) Caution for hot exhaust pipe
(2) Caution for rotating parts (12) Prohibition of trespassing
(3) Caution when checking engine room (13) Caution for articulation lock
(4) Caution when releasing radiator cap (14) Caution against falling
(5) Caution when opening hydraulic tank cap (15) Caution for handling battery
(6) Caution for handling suspension (16) Caution for parking brake
(7) Caution for handling accumulator (17) Prohibition of start by short-circuiting (This plate is
(8) Caution for electric cables, caution against falling fixed to the starting motor.)
when performing inspection and maintenance of (18) Caution for blast site (only when equipped with
dump body, caution for performing daily inspection, KOMTRAX)
caution when leaving operator's seat and when (19) Caution for high temperature (only for the ma-
stopping engine, caution for retarder oil temperature chine with dump body heating specifications)
(9) Caution before operating, caution when traveling in (20) Caution for handling DEF
reverse, caution for operating hoist control lever
(21) Caution for handling gas spring
(10) Caution for handling battery cable
2-7
CONTENTS OF SAFETY LABELS

(1) Caution for modification of ROPS/FOPS ROPS FOPS CERTIFICATION
This protective structure complies with the standard provided that it is properly equipped on the
machine which mass is less than the specified maximum mass.
ROPS: ISO3471: 2008, ISO 13459: 2012, SAE J/ISO 3471 MAY03, FOPS: ISO 3449: 2005, ISO 13459: 2012
“09620-A2009”“09620–A3001” MODEL
SERIAL No.
MACHINE MODEL
MAX. MASS
FOPS LEVEL No.
kg (Lb)
ROPS/FOPS CERTIFCATION
This protective structure complies with the standard provided 09620-A3001
that it is properly equipped on the machine which mass is less Komatsu Ltd. 2-3-6 Akasaka, Minato-ku, Tokyo, Japan 09620-A2009
࣭If any modification is applied to the ROPS or FOPS,

than the specified maximum mass. it may afect the strength and may not comply with the
standard. Do not drill, cut or weld on the ROPS or FOPS
• If some modification is applied to the ROPS or FOPS, it structure. Any modification is prohibited.
may effect the strength and may not comply with the ࣭ROPS or FOPS may provide less protection if it has been
structurally damaged or involved roll-over. Consult
standard. Do not drill, cut or weld on the ROPS or FOPS Komatsu Distributor in that case.
structure. Consult Komatsu Distributor before altering. ࣭Always wear seat belt when moving.
• ROPS or FOPS may provide less protection if it has been

structurally damaged or involved roll-over. Consult Komatsu Distributor in that case.
• Always wear seat belt when moving.
(2) Caution for rotating parts
“09667-A0880”
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.
(3) Caution when checking engine room

“09667-A0641”
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.
2-8
(4) Caution when releasing radiator cap

“09653–A0641”
• Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic tank is uncapped while hot.
• Allow radiator or hydraulic tank to cool before removing
cap.
(5) Caution when opening hydraulic tank cap

“09653-A0641”
• Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic tank is uncapped while hot.
• Allow radiator or hydraulic tank to cool before removing
cap.
(6) Caution for handling suspension

“09659-A0641”
• 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 flame.
2-9
(7) Caution for handling accumulator

“09659-A057B”
weld it, cut it, hit it,roll it or bring it near flame.
(8) Caution for electric cables, caution against falling when performing inspec-
tion and maintenance of dump body, caution for performing daily inspection,
caution when leaving operator's seat and when stopping engine, caution for re-
tarder oil temperature
“561–93-82410”
• If the machines comes too close to electric cables, there is danger of electrocution. Always keep a safe dis-
tance from electric cables.
• There is danger that the dump body may come down.
Before carrying out inspection or maintenance with the dump body raised, always reed the Operation and
Maintenance Manual and take the correct action.
• Always read the Operation and Maintenance Manual before carrying out operation, maintenance, dissas-
sembly or transportation of machine.
• When leaving operator seat.
1. Lower dump body.
2. Park the machine on level ground
3. Stop engine and apply parking brake completely.
4. Take out the key.
• If the retarder oil temperature caution lamp light up, stop machine immediately. Or the brakes will fail. set
the shift lever to the N position.
Run the engine under no load at at mid-range speed, and wait for the lamp to go out.
2-10
(9) Caution before operating, caution when traveling in reverse, caution for op-
erating hoist control lever
“561–93-82380”
• Always read the Operation and Maintenance Manual before carrying out operation maintenance disassem-
bly , assembly or transportation of the machine.
• There is danger of service inury or death.
Do the following before moving machine or its body :
. Honk horn to alert people nearby
.Be sure no one in on or near the machine
.Use spotter if view is obstructed
• Follow above even if machine equipped with back-up alarm and mirrors.
• BE SURE TO LOWER DUMP BODY AND KEEP HOIST CONTROL LEVER AT THE FLOAT POSITION
DURING TRAVEL .
(10) Caution for handling battery cable
“09808-A1681”
• Sign indicates an electric hazard from handling the cable.
• Read manual for safe and proper handling.
(11) Caution for hot exhaust pipe

“09817-A1103”
• Sign indicates a burn hazard from touching heated parts,
such as engine, motor, or muffler during or right after oper-
ation.
• Never touch when hot.
2-11
(12) Prohibition of trespassing

“09162-C0881”
• Sign indicates a crush hazard between the articulating
parts of vehicle.
• Keep away from the vehicle when it is moving.
(13) Caution for articulation lock

“09161-C0881”
• Sign indicates a crush hazard between the articulating
parts of vehicle.
• Lock vehicle with lock bar to avoid movement of the vehi-
cle during maintenance, transportation and travelling.
(14) Caution against falling

“09805-C0481”
• There is the hazard of falling.
• Do not step here !
(15) Caution for handling battery

(This plate is fixed in position by the battery maker)
a) Never smoke or use any naked flame near the batteries, no
sparks
b) Always wear safety glasses when working with batteries.
2-12
c) Keep children away from batteries.

d) Caution - battery acid.
e) Read the operator's manual before working with batteries.
f) Caution explosice gases.
(16) Caution for parking brake
“566–93–82320”
• Do not attempt to remove spring(s), saw, torch or modify
this chamber , serious injury or death may result
566-93-82320
(17) Prohibition of start by short-circuiting

“09842-A0481”
• Start the engine only after sitting down in the operator's
seat.
• Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury of fire.
(18) Caution for blast site

“56D–93–31410”
• Sign indicates an explosion hazard caused by active radio
transmitter at a blast zone.
• Keep machine at a safe distance from a blast zone and
detonator.
2-13
(19) Caution for high temperature

“09817–A1103”
• Sign indicates a burn hazard from touching heated parts,
such as engine, motor , or muffler during or right after oper-
ation.
• Never touch when hot.
(20) Caution for handling DEF

“09632-61480”
• DEF only.To avoid engine damage or fire, fill with DEF only.
• Never use diesel fuel.
(21) Caution for handling gas spring

“09659-A057B”
weld it, cut it, hit it, roll it or bring it near flame.
2-14
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
SAFETY NANCE
GENERAL PRECAUTIONS COMMON TO OPERATION

AND MAINTENANCE
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per-
forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine
carefully and obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION

ENSURE SAFE OPERATION
• Only trained and authorized personnel can operate and maintain the machine.
• Follow all safety, precautions, and instructions in this manual when operating or performing inspection or
maintenance on the machine.
• If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely
operate or repair your machine may be severely impaired, putting yourself and everyone else on your job
site in danger.
• When working with another operator or with the person on the worksite traffic duty, discuss the content of
the operation beforehand and use the determined signals when performing the operation.
UNDERSTAND THE MACHINE

Before operating the machine, read this manual thoroughly. If there is any place in this manual that you do not
understand, ask the person in charge of safety for explanation.
PREPARATIONS FOR SAFE OPERATION

PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT
• Be sure that all guards, covers, cameras, and mirrors are in their proper position. Repair them immediately
if they are damaged.
• Understand the using method of the safety related devices and use them properly.
• Never remove any safety related devices. Always keep them in good operating condition.
INSPECT MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until re-
pairs of the problem location have been completed.
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

• Do not wear loose clothes or any accessories. If any of
these catch the control levers or protruding parts, it may
cause the machine to move unexpectedly, it is extremely
dangerous.
• Always wear a hard hat and safety shoes. Wear protective
eyeglasses, mask, gloves, ear plugs, and safety belt de-
pending on the work.
• Long hair hanging out from the hard hat is dangerous that
it may get caught up in the machine. Tie the hair up and be
careful not to be caught.
• Check that all personal protective items function properly
before using them.
KEEP MACHINE CLEAN

• If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you
may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine
clean.
2-15
NANCE SAFETY
• If water gets into the electrical system, electric devices will

cause malfunctions, and the machine will cause error. If
the machine cause error, it may move unexpectedly and
cause serious personal injury or death. When washing the
machine with water or steam, do not allow the water or
steam to come into direct contact with electrical compo-
nents.
• If high-pressure water is sprayed directly onto camera, it
may cause failure. Defective camera cannot monitor sur-
rounding area. When cleaning, do not allow the high-pres-
sure water to get into camera directly, and wipe off any dirt
with soft cloth.
• When cleaning camera, if you stand on an unstable place, or take an unstable posture, you may fall and be
injured. Put proper stepladder or step on the level and firm ground, and clean the camera in secure posture.
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT

• 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 affixed to your shoes, your foot may slip and this may cause a seri-
ous accident.
• Do not leave tools or machine parts lying around inside the operator's compartment. If tools or parts get into
the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
• Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
• Do not use a cellular phone when driving or operating the machine. This may lead to mistakes in operation,
and may cause serious personal injury or death.
• Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Observe the following precautions to prepare for action if any
serious personal injury or death or fire should occur.
• Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them
for the possibility of fires.
• Perform periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
• Provide a first aid kit in the storage point. Perform periodic
checks and add to the contents if necessary. ,&
IF ANY PROBLEM IS FOUND

If you find any problem in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the per-
son in charge and take the necessary action. Do not operate the machine until the problem has been corrected.
PRECAUTIONS TO PREVENT FIRE

ACTIONS IF FIRE OCCURS
• Turn the starting switch to OFF position, and stop the engine.
• Use the handrails and steps to escape from the machine.
• Do not jump off the machine. There is the danger of falling and it may cause personal injury.
• The fume generated by a fire contains harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
2-16
SAFETY NANCE
• After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your
body.
Be sure to wear rubber gloves when handle the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
PREVENT FIRE
Fire caused by fuel, oil, coolant, or window washer fluid
Do not bring any open flame close to flammable substances
such as fuel, oil, coolant, or window washer fluid. There is a
danger that they may catch fire. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
,&
• Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other combustible materials into a
safe container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel fuel or gasoline. There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain combustible liquids. ,&
• Determine well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation of combustible material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
or affixed around the engine exhaust manifold, muffler, battery or dump body (for the machine with dump
body heating specification).
• To prevent fires from spreading sparks or burning particles from other fires, remove any combustible materi-
als such as dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
around the cooling system (radiator, oil cooler) or inside the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused from piping
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 and personal injury.
2-17
NANCE SAFETY
Fire around the machine due to highly heated exhaust gas

This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF).
KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi-
cation process (regeneration). Do not bring any combustible material close to the outlet of the exhaust pipe.
When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regener-
ation disable to prevent fire hazards due to highly heated exhaust gas during the aftertreatment devices regen-
eration. For setting, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-121)”.
If the following materials are loaded to the machine equipped with the dump body heating specification, fire may
occur because the dump body becomes highly heated during the aftertreatment devices regeneration.
• Objects which contains many combustible industrial wastes
• Objects which mainly contains combustible materials such as dry leaves, chips, pieces of paper, and coal
dusts
Take appropriate actions to prevent fire.
For details of remedies, see “DUMP BODY HEATING SPECIFICATIONS (3-237)”.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
• When taking the electrical power for the lighting equipment from the machine, see “POWER SUPPLY OUT-
LET (3-109)”.
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE
To prevent personal injury caused by slipping or falling off the machine, always observe the following.
• Use the handrails and steps indicated by arrow A in the
figure when getting on or off the machine.
• The handrails and steps marked by arrows B are for es-

caping in emergencies.
Use these only when escaping from the machine in a fire
or other emergencies. Do not use them in normal situa-
tions.
2-18
SAFETY NANCE
• Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one
foot) with the handrails and steps to ensure that you sup-
port yourself.
• Before getting on and off the machine, check the handrails
and steps if there is any oil, grease, or mud on them. Wipe
it off immediately not to slip if any. In addition, tighten any
loose bolt of the handrails and steps.
If the handrails and steps are damaged or deformed, they
need to be repaired immediately. Ask your Komatsu dis- ,&
tributor to perform this work.
• Do not grip the control levers when getting on or off the machine.
• Never climb on the engine hood or covers where there are no non-slip pads.
• Do not get on or off the machine with tools in your hand.
NO JUMPING ON OR OFF MACHINE

Getting on or off the moving machine can cause serious personal injury or death. Always observe the following.
• Never jump on or off the machine. Never get on or off a moving machine.
• If the machine starts to move when there is no operator on the machine, do not jump on to the machine and
try to stop it.
PEOPLE ON DUMP BODY

Never let anyone ride in the dump body. There is a hazard of falling and suffering serious personal injury or
death.
WHEN STANDING UP FROM OPERATOR'S SEAT

Before standing up from the operator's seat to adjust the opera-
tor's seat, always lower the dump body completely, lock with
dump lever lock knob (1), set gear shift lever (2) to NEUTRAL
position (N), set parking brake switch (3) to “PARKING” posi-
tion, then stop the engine.
If the control levers are touched by mistake, there is danger
that the machine may suddenly move and cause serious per-
sonal injury or death.
PRECAUTIONS WHEN LEAVING MACHINE

If the proper procedures are not taken when parking the machine, the machine may suddenly move off by itself,
and this may lead to serious personal injury or death. Always observe the following.
2-19
NANCE SAFETY
When leaving the machine, always lower the dump body com-
pletely, lock with dump lever lock knob (1), set gear shift lever
(2) to NEUTRAL position (N), set parking brake switch (3) to
“PARKING” position, then stop the engine.
In addition, lock all places and always take the key with you
and keep it in the specified location.
EMERGENCY EXIT FROM OPERATOR'S CAB

• If it should be impossible to open the door of the cab, break the window glass with the hammer supplied
and use the window as an emergency escape.
For details, see “EMERGENCY ESCAPE HAMMER (3-107)” in this manual.
• When escaping, remove all the pieces of glass from the window frame first and be careful not to cut your-
self on the glass.
Be careful also not to slip on the broken pieces of glass on the ground.
DO NOT GET CAUGHT IN WORK EQUIPMENT

• If the clearance at the articulating portion changes and you
get caught in it, you will suffer serious personal injury or
death. Do not allow anyone to come inside the articulation
range.
• The clearance in the area around the dump body changes
according to the movement of the dump body. If you are
caught, this may lead to serious personal injury or death.
Do not allow anyone near any of the rotating or telescopic
parts.
,&
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

The operator's compartment is equipped with a structure (such as ROPS, FOPS) to protect the operator by ab-
sorbing the impact energy.
As for the machine equipped with ROPS, if the machine weight
(mass) exceeds the certified value (shown on ROLL-OVER
PROTECTIVE STRUCTURE (ROPS) CERTIFICATION plate),
ROPS will not be able to fulfill its function. Do not increase ma-
chine weight beyond the certified value by modifying the ma-
chine or by installing attachments to the machine.
Also, if the function of the protective equipment is impeded, the
protective equipment will not be able to protect the operator,
and the operator may suffer injury. Always observe the follow-
ing. ,&
2-20
SAFETY NANCE
• If the machine is equipped with a protective structure, do not remove the protective structure and perform
operations without it.
• If the protective structure is welded, or holes are drilled in it, or it is modified in any other way, its strength
may drop. Any modification is prohibited.
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be
reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu
distributor.
• Even if the protective structure is installed, always fasten your seat belt properly when operating the ma-
chine. If you do not fasten your seatbelt properly, it cannot display its effect.
Always fasten your seat belt while operating the machine.
UNAUTHORIZED MODIFICATION
• Komatsu will not be responsible for any personal injuries, product failures, physical loss or damage, or influ-
ence on the environment resulting from modifications made without authorization from Komatsu.
• Any modification made without authorization from Komatsu can create hazards. Before making a modifica-
tion, consult your Komatsu distributor.
• Do not try to increase the capacity of the dump body or make any other modifications. Such modifications
will cause a drop in the braking efficiency, the balance of the machine will become poor, and this may lead
to an unexpected accident.
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

• Any personal injuries, product failures, physical loss or damage, or influence on the environment resulting
from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.
• When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential
problems or safety and legal requirements.
• When installing and using optional attachments, always read the instruction manual for the attachment, and
the general information related to attachments in this manual.
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

The engine exhaust gas contains substances that may damage
your health or even cause death. Start or operate the engine in
a place where there is good ventilation. If the engine or ma-
chine must be operated inside a building or underground,
where the ventilation is poor, take steps to ensure that the en-
gine exhaust gas is removed and that ample fresh air is
brought in.
,&
2-21
PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR JOBSITE
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start-
ing operations, always check the following to confirm that there is no danger on the jobsite.
• Check the terrain and condition of the ground at the jobsite, and determine the safest method of operation.
Do not operate in a dangerous area where landslides or rockfall may occur.
• Take necessary measures to prohibit the unauthorized person from coming close to the machine during op-
eration.
• When traveling or operating in shallow water or on soft ground, check the water depth, speed of the current,
condition of bedrock, and shape of the ground beforehand. Always avoid any place that will obstruct travel.
• Maintain the travel path on the jobsite so that there is no obstruction to travel operations.
PRECAUTIONS WHEN WORKING ON LOOSE GROUND

• Avoid driving or operating the machine near the edge of cliffs, road edges, 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 weak in these areas, 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.
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not drive or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe
the following.
• Before starting work near electric cables, inform the local
power company of the work to be performed, and ask
them to take the necessary action.
• Even going close to high-voltage cables can cause electric
shock. Always maintain a safe distance (see the table) be-
tween the machine and the electric cable. Check with the
local power company about the voltage of cables and safe
operating procedure before starting operations.
Voltage of cables Safety distance
100 V, 200 V Min. 2 m
6600 V Min. 2 m
22000 V Min. 3 m
66000 V Min. 4 m
154000 V Min. 5 m
187000 V Min. 6 m
275000 V Min. 7 m
500000 V Min. 11 m
• To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera-
tor's seat, and be careful not to touch the chassis with any exposed part of your body.
• Use a signalman to give warning if the machine approaches too close to the electric cables.
• When performing operations near high voltage cables, prohibit anyone other than related persons to come
close to the machine during operation.
2-22
SAFETY PRECAUTIONS FOR OPERATION
• If the machine should come too close or touch the electric cable, to prevent electric shock, the operator
should not leave the operator's compartment until it has been confirmed that the electricity has been shut
off. Also, prohibit any other persons to come close to the machine.
ENSURE GOOD VISIBILITY

Although this machine is equipped with mirrors and cameras to ensure good visibility, there are places that can-
not be seen from the operator's seat. Be careful when performing operation.
When traveling or performing operations in places with poor visibility, it is dangerous and may cause serious
personal injury or death because it is difficult to check for obstacles and condition of the jobsite. When traveling
or performing operations in places with poor visibility, always observe the following.
• Allocate a signalman for jobsite duty if there are areas where the visibility is poor.
• Only one signalman should give signals.
• When working in dark places, turn on the working lamp and headlamps installed to the machine, and set up
additional lighting equipment in the work area if necessary.
• Stop operations if the visibility is poor because of mist, snow, rain, or dust.
• When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror before
starting the work to ensure good visibility.
• Clean off any dirt from the lens of cameras installed to the machine, and make sure that the camera gives a
clear view.
• The rear view monitor is provided to secure the rear side visibility. If, however, an obstacle is detected on
the monitor, you must confirm it with your eyes.
CHECK SIGNS AND SIGNALMAN'S SIGNALS

If signals and labels are not clear, serious personal injury can result from downward slip, overturn or accidental
contact with nearby people or obstacles. Always observe the following.
• Set up labels to inform of road edges and soft ground. If the visibility is not good, position a conductor if
necessary. Operator should pay careful attention to the labels and follow the instructions from the conduc-
tor.
• Only one signalman should give signals.
• Make sure that all workers understand the meaning of all signals, signs, and labels before starting work.
BEWARE OF ASBESTOS DUST

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsite
where demolition work is performed or industrial waste is han-
dled. Always observe the following.
• Spray water to keep down the dust.
• Do not use compressed air.
• If there is danger that there may be asbestos dust in the
air, always operate the machine from an upwind position,
and make sure that all workers operate on the upwind ,&
side.
• All workers should use anti-dust masks.
• Prohibit anyone other than the operator from coming close to the machine during operation.
• Always observe the regulations for jobsite and environmental standards.
This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing
asbestos. Always use Komatsu genuine parts.
2-23
START ENGINE
USE WARNING TAGS
If there is a "DANGER! Do NOT operate!" warning tag dis-
played, it means that someone is performing inspection and
maintenance of the machine. If the warning tag is ignored and
the machine is operated, the person performing inspection or
maintenance may be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

Perform the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If these checks are not performed properly, problems may occur
with the operation of the machine, and there is a danger that may lead to serious personal injury or death.
• Remove all dirt from the surface of the window glass to ensure a good view.
• Perform the walk-around check securely according to “METHOD FOR WALK-AROUND CHECK (3-150)”.
• Remove all dirt from the surface of the lens of the headlamps, working lamps, and combination lamps, and
check that they light up correctly.
• Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
• Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake
pedal, and check that the pedals work properly.
• Adjust the operator's seat to a position where it is easy to perform operations, and check that there is no
damage or wear to the seat belt or mounting clamps.
• Check that the gauges work properly, check the angle of the mirrors, and check that the gear shift lever is at
NEUTRAL position and that the dump control lever is at HOLD position.
• Before starting the engine, check that the lock knob of the dump control lever is at LOCK position.
• Adjust the mirrors so that the rear of the machine can be seen easily from the operator's seat.
For the adjustment, see “METHOD FOR ADJUSTING MIRRORS (3-168)”.
• Check that the parking brake switch is at “PARKING” position.
2-24
• Check that the articulation lock is fixed securely at FREE

position (F).
• Adjust the angle of each camera so that the surrounding
area can be seen clearly from the operator's seat. For de-
tails of the adjustment, see “METHOD FOR ADJUSTING
REAR VIEW CAMERA ANGLE (3-169)”.
• If snowfalls adhered to a camera, eliminate them with se-
curing your safety by using a stepladder.
• Check that there are no people or obstacles above, below,
or in the area around the machine.
WHEN STARTING ENGINE

The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the
following.
• Start the engine only while sitting down in the operator's seat.
• When starting the engine, sound the horn as a warning.
• If another person is allowed on the machine, that person may sit only in the assistant's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious
personal injury or death.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
IN COLD AREAS
• Perform the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the con-
trol levers are operated, the reaction of the machine will be slow, and this may lead to unexpected acci-
dents. Particularly in a cold weather, be sure the warm-up operation is completed.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check
that there is no leakage of electrolyte before starting.
START ENGINE WITH JUMPER CABLES

If any mistake is made in the method of connecting the jumper cables, it may cause the battery to explode, so
always observe the following.
• Always wear protective eyeglasses and rubber gloves
when starting the engine by using the jumper cables.
• When connecting a normal machine to a failed machine
with the jumper cables, always use the normal machine
with the same battery voltage as the failed machine.
• When starting the engine with the jumper cables, perform
the starting operation with 2 workers (one worker sitting in
the operator's seat and the other working with the battery).
• When starting from another machine, be careful that the
normal machine does not contact with the failed machine.
• When connecting the jumper cables, turn the starting
switch to OFF position for both the failed machine and the normal machine. If the failed machine has a bat-
tery disconnect switch, turn it to OFF position, and turn it ON again after connecting the cables.
For details of operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-115)”.
It is dangerous that the machine may move when the power is connected.
• Be sure to connect the positive (+) cable first when installing the jumper cables. Disconnect the negative (-)
cable (ground side) first when removing them.
• When disconnecting the jumper cables, take care not to bring the clips in contact with each other or with the
machine.
2-25
• For the starting procedure with the jumper cables, see OPERATION, “START ENGINE WITH JUMPER CA-
BLES (3-255)”.

CHECKS BEFORE OPERATION
If the checks before starting are not performed properly, the machine will be unable to display its full perform-
ance. It is dangerous and may cause serious personal injury or death.
When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention
to the surroundings. Prohibit anyone other than the operator from coming close to the machine during checks.
• Fasten the seat belt. When the brakes are applied sudden-
ly, the operator may be thrown out of the operator's seat. It
is dangerous and may cause personal injury.
• Check the operation of travel, steering and brake systems,
and dump body control system.
• Check for any problem in the sound, vibration, heat and
smell of the machine, or abnormalities of instruments. Also
check that there is no leakage of oil or fuel.
• If any problem is found, repair it immediately.
• Before starting to drive the machine or perform operations,

check that articulation lock (1) is fixed securely at FREE
position.
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

• Always lock all the doors and windows of the operator's compartment in position regardless of whether it is
open or closed.
Always close all the windows and doors on jobsites where there is danger of scattering fragments, and
things which may intrude into operator's cab.
• If another person is allowed on the machine, that person may sit only in the assistant's seat.
• If there are any persons in the area around the machine,
there is danger that they may be hit or caught by the ma-
chine, and this may lead to serious personal injury or
death. Always observe the following before traveling.
• Always operate the machine only when seated on the
operator's seat.
• Before starting to move, check again that there is no
people or obstacle in the surrounding area.
• Before moving, sound the horn to warn people in the
surrounding area.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
• If there is an area in the rear of the machine which cannot be seen, allocate a conductor.
Always be sure to perform the above precautions even when the machine is equipped with mirrors and cam-
eras.
2-26
WHEN TRAVELING
Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact.
Always observe the following.
• Never turn the key in the starting switch to OFF position when the machine is traveling. If the engine stops
when the machine is traveling, the steering wheel becomes heavy to operate, and this will cause a wrong
operation of the steering wheel and may lead to serious personal injury or death. If the engine stops, de-
press the brake pedal immediately to stop the machine.
• When driving the machine or performing operations, always keep a safe distance from people, structures,
or other machines to avoid coming into contact with them.
• Try to avoid traveling over obstacles. If that is unavoidable, let the machine do that at a low speed. The
machine tips over easily to the right or left. Do not drive it over obstacles which make the machine tilt large-
ly to the right or left.
• When traveling on rough ground, drive the machine at low speed and avoid sudden changes in direction to
prevent the machine from turning over.
• Do not load the dump body above the maximum payload. The brakes will lose their effect.
• Lower the dump body, setting the dump lever at “FLOAT” position, then drive the machine.
• When passing over bridges or structures, check first that the structure is strong enough to support the
weight of the machine.
• When operating in tunnels, under bridges, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the machine body or work equipment hit anything.
• If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal
pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces a large
destructive force, and this may cause serious injury or death.
If you are going to drive the machine continuously, consult your Komatsu distributor.
• When traveling, and particularly when traveling downhill, never set the gear shift lever to NEUTRAL position
(N). If the gear shift lever is set to NEUTRAL position (N) while driving the machine at travel speed of above
4 km/h or traveling downhill, the gear speed is not changed to neutral. The centralized warning lamp flashes
and the alarm buzzer sounds. Always set the gear shift lever in D to 1 position while traveling.
WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side, always observe the following.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly.
• Do not work on a slope covered with the steel plates. Even with slight slopes there is a hazard that the
machine may slip.
• Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that
the machine may slip.
• If the engine should stop on a slope, immediately apply the brakes fully and apply the parking brake also to
stopping the machine.
• When traveling downhill, do not drive the machine with the gear shift lever in NEUTRAL position (N).
If the gear shift lever is set to NEUTRAL position (N) while driving the machine at travel speed of above
4 km/h or traveling downhill, the gear speed is not changed to neutral. The centralized warning lamp flashes
and the alarm buzzer sounds. Always set the gear shift lever in D to 1 position while traveling.
PRECAUTIONS WHEN OPERATING MACHINE

• When using the machine, to prevent serious personal injury or death caused by the work equipment or by
the machine tipping over due to overloading, do not use the machine beyond the permitted performance of
the machine such as the maximum permitted load for the structure of the machine.
• When operating in tunnels, or under bridges or under electric wires, or in other places where the height is
limited, operate slowly and be extremely careful not to let the dump body contact anything.
• To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe
for operation, particularly in confined spaces, indoors, and in places where there are other machines.
2-27
WHEN LOADING ON DUMP BODY

• Do not load the dump body so that the load is on one side. Always perform loading that the load is spread
uniformly.
• Do not leave or return to the operator's seat while the dump body is being loaded.
WHEN DUMPING
• Before starting the dumping operation, check to be sure there is no people or object behind the machine.
• Stop the machine in a right position, and check again that there is no people or object behind the machine.
Give the determined signal, then slowly operate the dump body. If necessary, use chocks for the wheels or
allocate a conductor.
• Do not perform dumping operations on slopes. The machine stability will become poor and it may tip over.
• Do not drive the machine with the dump body raised.
• When performing dumping operations, drive the machine in a straight line. If dumping operations are per-
formed with the machine articulated, the machine stability will become poor and the machine may tip over.
• When the dump body is raised, the center of gravity of the machine varies continuously. If the ground is
soft, this will affect the stability of the machine.
• Take extreme care when dumping sticky material (wet clay, frozen material, etc.) on a soft ground. The sta-
bility of the machine becomes worse and it may tip over.
WHEN OPERATING ON SNOW OR FROZEN SURFACES

• Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma-
chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly
careful when working on slopes.
• Frozen road becomes soft when the temperature rises, and the machine may tip over or be not able to es-
cape. Be particularly careful when working on frozen road.
• When traveling on snow-covered roads, always fit tire chains.
• It is dangerous that the machine enters deep snow. The machine may tip over or become buried in the
snow. Be careful not to go off the road or to get trapped in a drift of snow.
• When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce speed, use the brak-
ing force of the engine, and pump the brakes (depress the brake pedal several times) to stop the machine.
• Do not try to perform dumping operations when the load inside the dump body is frozen. There is danger
that this may cause the machine to tip over.
WHEN PARKING MACHINE

Unexpected move of the parked machine can cause serious personal injury or death. Always observe the fol-
lowing.
• Park the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, falling rocks, or flooding.
2-28
• When leaving the machine, always lower the dump body

completely, lock with dump lever lock knob (1), set gear
shift lever (2) to NEUTRAL position (N), set parking brake
switch (3) to “PARKING” position, then stop the engine.
• Always close the operator's cab door, and use the key to
lock all the equipment in order to prevent any unauthorized
person from operating the machine. Always remove the
key, take it with you, and keep it in the specified place.
• If it is necessary to park the machine on a slope, set

blocks under the tires to prevent the machine from moving.
TRANSPORTATION
When the machine is transported on a trailer, serious personal injury or death may result because of the acci-
dent during transportation. Always observe the following.
• Always check the machine dimensions carefully. Depending on the attachments installed, the machine
weight, transportation height, and overall length may differ.
• Check beforehand that all bridges and other structures on the transportation route are strong enough to
withstand the combined weight of the transporter and the machine being transported.
• This machine needs to be divided into components for transportation depending on the regulation. When
transporting the machine, consult your Komatsu distributor.
• Lock the articulation lock to prevent the machine from articulating.
• For details of the transportation procedure, see “TRANSPORTATION (3-239)”.
PRECAUTIONS WHEN LOADING AND UNLOADING

If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or
fall. It requires particular attention. Always observe the following.
• Perform loading and unloading on a firm, level ground only. Avoid road edge or place near the cliff.
2-29
• Always use ramps of adequate strength. Be sure that the

ramps are wide, long, and thick enough to provide a safe
loading slope. Take suitable steps to prevent the ramps
from moving out of position or coming off.
(1) Chocks
(2) Ramp
(3) Width of ramps: Same width as tires
(4) Angle of ramp: Max. 15°
(5) Block
• Be sure the ramp surface and the platform of trailer are
clean and free of grease, oil, ice, water and other loose
materials. If any, remove them. Remove dirt around the undercarriage of the machine. On a rainy day, in
particular, be extremely careful since the ramp surface is slippery.
• Run the engine at low idle and drive the machine slowly at low speed.
• Never correct your steering on the ramps. If necessary, drive off the ramps onto the ground, correct the di-
rection, then enter the ramps again.
• When unloading to an embankment or platform, make sure that it has suitable width, strength, and grade.
• For machines equipped with a cab, always lock the door after loading the machine. To prevent the door
from opening during transportation.
For detail, see “TRANSPORTATION (3-239)”.
• When it is necessary to remove handrails and steps, take care not to lose removed handrails and steps.
Install the removed handrails and steps securely.
TOWING AND BEING TOWED

PRECAUTIONS FOR TOWING AND BEING TOWED
Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or
drawbar or the method of towing a failed machine and being towed may lead to serious personal injury or death.
For towing, see “PRECAUTIONS FOR TOWING MACHINE (3-250)”.
• Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the ma-
chine being towed.
• Never use the wire rope which has breaks in strands (A),
reduced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
• Always wear leather gloves when handling the wire rope.
• Never tow a machine on a slope.
• During the towing operation, never stand between the tow-
ing machine and the machine being towed.
2-30
SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE
During inspection and maintenance, always display the "DAN-
GER! Do NOT operate!" warning tag.
If there is a "DANGER! Do NOT operate!" warning tag dis-
played, it means that someone is performing inspection and
maintenance of the machine. If the warning tag is ignored and
the machine is operated, the person performing inspection or
maintenance may be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.
If necessary, put up signs around the machine as well.
Warning tag part No. 09963-A1640
When not using this warning tag, keep it in the toolbox. If there
is no toolbox, keep it in the pocket for Operation and Mainte-
nance Manual.
KEEP WORK PLACE CLEAN AND TIDY

• Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean the tidy to enable you to perform oper-
ations safely. If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall
over and injure yourself.
• When cleaning the ceiling window which is made of organic glass (polycarbonate), use tap water and avoid
use of organic solvents for cleaning. An organic solvent like benzene, toluene or methanol can invite a
chemical reaction like dissolution and decomposition on the window glass, deteriorating polycarbonate in
use.
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

• Stop the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, falling rocks, or flooding.
ONLY AUTHORIZED PERSONNEL

As long as maintenance of the machine is continued, do not allow unauthorized person to come near the work-
place. They might get unexpected personal injury from, for instance, touching machine. Do not allow anyone
except the workers concerned to enter the workplace. If necessary, employ a guard.
APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his/hers instructions during the operation in order to prevent personal injuries caused by being caught or
pinched.
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or
high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol-
lowing.
2-31
PRECAUTIONS FOR MAINTENANCE SAFETY
• Lower the work equipment to the ground and stop the en-
gine before performing any inspection and maintenance.
• Lower the dump body, set dump lever (1) to “HOLD” posi-
tion, lock with dump lever lock knob (2), then stop the en-
gine.
• Set parking brake switch (3) to “PARKING” position to ap-

ply the parking brake, then put blocks in front of and be-
hind the tires to prevent the machine from moving.
• Lock the front and rear frames with articulation lock (4).
2-32
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the
maintenance with the engine running, always observe the following.
• One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers
must maintain contact with the other workers.
Do not leave the operator's seat during maintenance.
• Rotating parts such as the fan, fan belt are dangerous that
they may easily catch a body part or an object someone
wears. Be careful not to come close to the rotating part.
• Never drop or insert tools or other objects into the fan, fan
belt, or other rotating parts. They may contact the rotating
parts and break, and be scattered. It is dangerous.
• If the automatic active regeneration of KDPF starts during
maintenance work, surroundings of KDPF become high
temperature. ,&
When performing maintenance work, perform regeneration
disable of KDPF according to “HANDLE Komatsu Diesel
Particulate Filter (KDPF) (3-121)”.
• Lower the dump body completely, set dump lever (1) to
“HOLD” position, lock with dump lever lock knob (2) to pre-
vent the dump body from moving.
• Set parking brake switch (3) to “PARKING” position to ap-

ply the parking brake, then put blocks in front of and be-
hind the tires to prevent the machine from moving.
• Do not touch any control levers. If any control lever must
be operated, give a signal to the other workers to warn
them to move to a safe place.
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS

• Appoint a leader before starting removal or installation operations for attachments.
2-33
• Place attachments that have been removed from the ma-

chine in a stable condition so that they do not fall. And take
steps to prevent unauthorized persons from entering the
storage area.
,&
PRECAUTIONS FOR WORKING AT HIGH PLACES

When working at high places, use a step ladder or other stand to ensure that the work can be performed safely.
There is a danger falling from high place that can lead to serious personal injury or death.
PRECAUTIONS WHEN WORKING ON MACHINE

• When performing maintenance work on the machine,
maintain the foothold clean and orderly to prevent falling.
Always observe the followings.
• Avoid spilling of oil and grease.
• Do not litter the tools.
• Watch your step when walking around on the ma-
chine.
• Remove mud and greases stuck to the shoe sole.
• Never jump down from the machine. When getting on and
off the machine, always face the machine and maintain at least three-point contact (both feet and one hand,
or both hands and one foot) with the handrails and steps to ensure that you support yourself.
• You must walk along the access aisle for checking being paved with non-slip pads. Never climb on the en-
gine hood and cover to prevent personal injuries from falling or failing over due to losing your footing.
PRECAUTIONS WHEN WORKING UNDER MACHINE

Machine or dump body may fall, and it is dangerous that seri-
ous personal injury or death may occur. Always observe the fol-
lowing.
• When performing inspection with the dump body raised, al-
ways set the dump control lever to “HOLD” position, set
the lock knob to LOCK position, then insert the body pivot
pin. If the body pivot pin is not inserted, the dump body
may go down when the dump control lever is operated,
and catch or cause serious injury or even death to the per-
son performing the inspection. ,&
• Always perform the operation to remove or insert the body

pivot pin with at least 2 workers. This operation is performed with the dump body raised, so if the dump
body comes down during the operation, it may lead to serious injury or even death.
For detail, see “BODY PIVOT PINS (3-117)”.
• Make sure the hoists or hydraulic jacks you use are in good repair and strong enough to handle the weight
of the component. Never use hydraulic jacks at places where the machine is damaged, bent, or twisted.
Never use if the strand of wire rope is frayed, twisted or pinched. Never use bent or distorted hooks.
• Never use concrete blocks for supports. Concrete blocks may break under even light loads.
2-34
USE PROPER TOOLS

Use the tools suited to the task and use them correctly. Using
damaged, deformed, or low quality tools, or making improper
use of the tools may cause serious personal injury or death.
,&
PRECAUTIONS FOR CHECK AND MAINTENANCE

TURN BATTERY DISCONNECT SWITCH TO OFF POSITION
In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Then set the battery disconnect switch to OFF position and remove the switch key.
If you check and handle battery without turning battery disconnect switch to OFF position, serious personal in-
jury or death by such as an electric shock may occur.
• When storing the machine for a long time (more than 1 month)
• When repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
PRECAUTIONS FOR WELDING

Welding operations must always be performed by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electric shock when performing welding, so never allow any unqualified
person to perform welding.
HANDLE BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the
system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key.
Danger of battery exploding
When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the bat-
tery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explo-
sion, or fire, so always observe the following.
• Do not use or charge the battery if the battery electrolyte is below LOWER LEVEL mark. This may cause
an explosion. Always perform periodic inspection of the battery electrolyte level, and add purified water
(such as a commercial battery fluid) to UPPER LEVEL mark.
• Do not smoke or bring any open flame close to the battery.
• Hydrogen gas is generated when the battery is being
charged, so remove the battery from the machine, take it
to a well-ventilated place, remove the battery caps, then
perform the charging.
• After charging, tighten the battery caps securely.
2-35
Danger from dilute sulphuric acid

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire. Always ob-
serve the following.
• When handling the battery, always wear protective eye-
glasses and rubber gloves.
• If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water. After that, get
,&
medical attention immediately.
• If battery electrolyte gets on your clothes or skin, wash it
off immediately with large amounts of water.
Danger of sparks
Sparks may be generated and they can cause a fire. Always observe the following.
• Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools
lying around near the battery.
• When removing the battery cables, turn the starting switch to OFF position and, after checking that the sys-
tem operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing, con-
nect the positive (+) cable first, then connect the ground.
• Tighten the battery cable terminals securely.
• Secure the battery firmly in the specified position.
WHEN USING HAMMER

When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause
serious personal injury or death. Always observe the following.
• When hitting pins, etc., broken pieces may be scattered, and it may cause personal injury to the people in
the surrounding area. Always check that there is no one in the surrounding area.
• When hard metal parts such as pins or bearings are hit
with a hammer, pieces may be scattered. It may cause se-
rious personal injury or death. Always wear protective
equipment such as protective eyeglasses and gloves.
• If the pin is hit with strong force, it may come out, and in-
jure people in the surrounding area. Do not allow anyone
to enter the surrounding area.
,&
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT

To prevent burns from boiling water or steam spurting out when
checking or draining the coolant, wait for the coolant to cool
down to a temperature where the radiator cap can be touched
by hand. Then loosen the cap slowly to release the pressure in-
side the radiator, and remove the cap.
2-36
PRECAUTIONS FOR HIGH-TEMPERATURE OIL

To prevent burns from hot oil spurting out or from touching
high-temperature parts when checking or draining the oil, wait
for the oil to cool down to a temperature where the cap or plug
can be touched by hand. Then, loosen the cap or plug slowly to
release the internal pressure and remove the cap or plug.
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS

To prevent burns from touching high-temperature parts, when checking or performing maintenance after stop-
ping engine, check the parts have been cooled down to touch with bare hand before checking or maintenance.
PRECAUTIONS FOR HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pres-
sure when the engine is running and immediately after the engine is stopped. When performing inspection or
replacement of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not
done, serious personal injury or death may occur. Always observe the following.
• Do not perform inspection or replacement work with the circuit 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 performing inspection, wear protective equipment such as protective eyeglasses and leather gloves.
• High-pressure oil leaking from small holes is dangerous
that may penetrate your skin and cause loss of sight if it
contacts your skin or eyes directly. If a jet of high-pressure
oil hit your skin or eyes, and suffer injury, wash the place
with clean water, and consult a doctor immediately for
medical attention.
PRECAUTIONS FOR HIGH-PRESSURE FUEL

While the engine is running, high-pressure is generated in the engine fuel piping. If you try to disassemble the
piping before the internal pressure is released, serious personal injury or death can result. When performing in-
spection or maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the
internal pressure to go down before starting the work.
HANDLE HIGH-PRESSURE HOSES AND PIPING

If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or defective operation. It is dangerous
and may cause serious personal injury or death. If the hose or piping mounts are loose or oil or fuel is found to
be leaking from the mount, stop operations and tighten to the specified torque.
If any damaged or deformed hoses or piping are found, consult your Komatsu distributor.
Replace the hose if any of the following problems are found.
• Damaged hose or deformed hydraulic fitting.
• Frayed or cut covering or exposed reinforcement wire layer.
• Covering swollen in places.
• Twisted or crushed movable portion.
2-37
• Foreign material embedded in covering.
PRECAUTIONS FOR HIGH VOLTAGE

When the engine is running and immediately after it is stopped,
high voltage is generated inside the engine controller and the
engine injector, and there is danger of electric shock. Never
touch the inside of the engine controller or the injector part of
the engine. If it is necessary to touch the inside of the engine
controller or the injector part of the engine, consult your Komat-
su distributor.
PRECAUTIONS FOR NOISE

When performing maintenance of the engine and you are exposed to noise for long periods of time, wear ear
covers or ear plugs while working.
If the noise is too loud, it may cause temporary or permanent hearing problems.
HANDLE SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGS

The suspension cylinders, accumulator, and gas springs are charged with high-pressure nitrogen gas. If any
mistake is made in handling, there is danger that it may cause an explosion or serious personal injury or death.
Always observe the following.
• Do not disassemble it.
• Do not bring it near open flame or dispose of it in fire.
• Do not make holes in it, weld it, nor use a cutting torch.
• Do not hit or roll it, or subject it to any impact.
• Ask your Komatsu distributor when sealing gas into the
cylinder or replacing gas from it.
• When disposing of the accumulator, the gas must be re-
leased. Ask your Komatsu distributor to perform this work.
PRECAUTIONS FOR COMPRESSED AIR

• When performing cleaning with compressed air, there is a hazard of serious personal injury or death
caused by flying dust or particles.
• When using compressed air to clean the filter element or radiator, wear protective eyeglasses, anti-dust
mask, gloves, and other protective equipment.
MAINTENANCE OF AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause
frostbite. Never loosen any parts of the cooling circuit.
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
2-38
• Always drain the oil from your machine in containers. Nev-

er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
METHOD FOR SELECTING WINDOW WASHER FLUID

Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

• For using the machine safely for a long period, always perform periodic replacement of the defined life parts
that have a particularly close relation to safety, such as hoses and the seat belt.
Replacement of the defined life parts: See “PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
(7-2)”.
• The material of these components naturally changes over time, and repeated use causes deterioration,
wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal
injury or death. It is difficult to judge the remaining life of these components from external inspection or the
feeling when operating, so always replace them at the specified interval.
• Replace or repair the defined life parts if any defect is found, even when they have not reached the speci-
fied replacement time.
TIRES
HANDLE TIRES
If tires or rims are handled mistakenly, there is danger that the
tire may explode or be damaged, or that the rim may fly off and
cause serious personal injury or death.
To ensure safety, always observe the following.
• Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and spe-
cial technology, so always ask your Komatsu distributor to perform these operations.
• Use only specified tires and inflate them to the specified pressure.
Appropriate inflation pressure: See “HANDLE TIRE (3-218)”.
2-39
• When pumping up the tires, check that no other person is

standing near the tire, and install an air chuck with a clip
that can be secured to the air valve.
To prevent the tire inflation pressure from becoming too
high, measure the pressure from time to time with an air
gauge while pumping up the tire.
• If the tire inflation pressure goes down abnormally or the
rim parts do not fit the tire, there is a problem with the tire
or rim parts. Always contact your Komatsu distributor for
repairs.
• If the rim parts are not fitted properly when the tire is being
pumped up, there is a danger that the rim parts may fly off, so set up a protective fence around the tire, and
do not stand directly in front of the rim. Stand beside the tread when pumping up the tire.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under heavy
load.
• Never perform welding or light a fire near the tire.
• Always release the inflation pressure from a tire prior to removing rim from tire.
• Before removing the tire from the machine for repairs, remove the valve partially to release the air from the
tire gradually, then remove the tire.
PRECAUTIONS FOR STORING TIRES

Tires for construction equipment are extremely heavy, it may
lead to serious personal injury or death. To maintain safety, al-
ways observe the following.
• As a basic rule, store the tires in a warehouse which unau-
thorized persons cannot enter.
If the tires must be stored outside, always erect a fence
and put up “No Entry” signs.
• Stand the tire at the angle of 60 to 70 ° (A) on a level
ground, and block it securely (1) so that it cannot tip over
or fall over if any person should touch it. Do not lay the tire
on its side. This will deform the tire and cause it to deterio-
rate.
• If the tire should fall over, do not attempt to stop it. Get out of the way quickly.
2-40
SAFETY PRECAUTIONS FOR DEF
PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.
PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from
the filler port during opening or refilling.
PRECAUTIONS FOR STORING

If the temperature of DEF becomes high, a harmful ammonia gas may be emitted. Completely seal up its con-
tainer for storage. Only open containers in a well-ventilated area. For the method of storing, see “STORE DEF
(4-8)”.
When storing DEF, avoid direct sunlight. Always use the original container it came in. Do not exchange the con-
tainer of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a
chemical reaction may corrode the container.
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Follow the instructions
and precautions according to “ACTIONS IF FIRE OCCURS (2-16)”.
If DEF is spilled, immediately wash and clean the area with water. If spilled DEF is left unattended and the area
is not washed and cleaned, it can cause corrosion to the contaminated area and emit toxic gas.
OTHER PRECAUTIONS
When disposing of DEF, treat it as an industrial waste. For treatment of the waste, see “PRECAUTIONS FOR
DISPOSING OF WASTE MATERIALS (2-38)”. The container for DEF is an industrial waste as well. It should be
treated in the same way.
Never use an iron or aluminum container when disposing DEF, because toxic gas may develop and a chemical
reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the
fluid waste of DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas aftertreatment devices. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws. For detail, see “UNAUTHORIZED MODI-
FICATION (2-21)”.
2-41
OPERATION
Please read and make sure that you understand the SAFETY section before
reading this section.
3-1
GENERAL VIEW OPERATION
GENERAL VIEW
MACHINE EQUIPMENT NAME
(1) Headlamp (high beam) (9) Center wheel

(2) Headlamp (low beam) (10) Rear wheel
(3) Fog lamp (if equipped) (11) Hydraulic tank
(4) Turn signal lamp and clearance lamp (12) Fuel tank
(5) Working lamp (13) Hoist cylinder
(6) Yellow revolving lamp (if equipped) (14) Dump body
(7) Side lamp (15) Air Cleaner
(8) Front wheel
3-2
OPERATION GENERAL VIEW
CONTROLS AND GAUGES NAMES
(1) Starting switch (11) Cigarette lighter

(2) Lamp switch, dimmer switch, turn signal lever (12) Fog lamp switch (if equipped)
(3) Wiper, window washer switch (13) Revolving lamp switch (if equipped)
(4) Steering wheel (14) Power window switch
(5) Horn button (15) Side lamp switch
(6) Machine monitor (16) Dump lever
(7) Retarder control lever (17) Dump lever lock knob
(8) Parking brake switch (18) Accelerator pedal
(9) Gear shift lever (19) Brake pedal
(10) Engine shutdown secondary switch
3-3
Enlargement of machine monitor
(1) Heated wire mirror switch (if equipped) (7) Rear view monitor brightness adjustment switch
(2) Working lamp switch (8) Engine power mode selector switch
(3) Monitor brightness selector switch (9) AISS LOW switch
(4) Switch panel (10) Automatic retarder, accelerator linked control
(5) Hazard lamp switch switch (if equipped)
(6) Secondary steering switch (11) Inter-axle differential lock switch
3-4
MACHINE MONITOR EQUIPMENT NAME

Machine monitor
(1) Speedometer (15) Retarder oil temperature caution lamp

(2) Engine tachometer (16) Fuel gauge
(3) Centralized warning lamp (17) Fuel level caution lamp
(4) Parking brake pilot lamp (18) ECO gauge
(5) Turn signal lamp pilot lamp (L.H.) (19) DEF level gauge
(6) Headlamp (high beam) pilot lamp (20) Air conditioner display section
(7) Turn signal lamp pilot lamp (R.H.) (21) Clock
(8) Brake oil pressure caution lamp (22) L.H. meter
(9) Clearance lamp pilot lamp (23) R.H. meter
(10) Engine coolant temperature gauge (24) Enter switch
(11) Engine coolant temperature caution lamp (25) Up switch
(12) Torque converter oil temperature gauge (26) Down switch
(13) Torque converter oil temperature caution lamp (27) Return switch
(14) Retarder oil temperature gauge (28) Air conditioner switches / Numeric keypad
3-5
Display of liquid crystal unit
(A) Standard screen (D) Warning screen

(B) ECO guidance screen (E) User menu screen
(C) Maintenance time warning screen
(29) Shift indicator (39) Torque converter lockup pilot lamp
(30) Shift lever position display (40) Fan reverse pilot lamp
(31) Message display (41) Preheating pilot lamp
(32) Retarder pilot lamp (42) ECO guidance
(33) Inter-axle differential lock pilot lamp (43) Maintenance time caution lamp
(34) KTCS display (44) Guidance icon
(35) Aftertreatment devices regeneration display (45) Seat belt caution lamp
(36) Secondary steering pilot lamp (46) Warning display
(37) Power mode display (47) Action level display
(38) Shift hold pilot lamp
3-6
OTHER EQUIPMENT NAME

Inside of cab
(1) Ashtray (7) 12 V power supply

(2) Drink box (8) Fuse
(3) Cup holder (9) Cab handle
(4) Handy tray (10) Open knob for cab door
(5) Magazine box (11) Cab door inner lock
(6) Emergency escape hammer (12) Rear view monitor
3-7
Outside of cab
(1) Fire extinguisher (6) Articulation lock pin

(2) Fuse (7) Toolbox
(3) Battery disconnect switch (8) Body pivot pin
(4) System operating lamp (9) Komatsu Closed Crankcase Ventilation (hereafter
(5) Circuit breaker KCCV) ventilator
3-8
(10) Dust indicator (14) DEF pump

(11) KDPF (15) DEF injector
(12) SCR assembly (16) DEF filter
(13) DEF tank
3-9
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of devices necessary to operate the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operat-
ing the equipment, and the meanings of the displays.
EXPLANATION OF MACHINE MONITOR EQUIPMENT
FF: Failure display screen

(A) Warning display (C) Meter display
(B) Pilot display (D) Switch panel
REMARK
• For the user menu used for setting various items of the machine on the machine monitor, see “USER
MENU (3-48)”.
• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit) on the screen. When there are fewer than 10 black or white spots, this
is not a failure or a defect.
3-10
OPERATION EXPLANATION OF COMPONENTS
BASIC OPERATION OF MACHINE MONITOR

BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR-
MAL SITUATION
When the starting switch is turned to ON position, the machine monitor starts and operates as follows.
1. Centralized warning lamp (A) and pilot lamp (B) light up for 2 seconds and go out for 1 second.
2. Liquid crystal display (C) displays starting screen AA for 2 seconds, and then changes to standard screen
BB.
3. The pointer of engine tachometer (D) moves one cycle.
4. Speedometer (E) displays “88” for 2 seconds.
5. The alarm buzzer sounds for 2 seconds, then stops under the normal condition.
NOTICE
If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring
may have breakage. In this case, ask your Komatsu distributor for repair.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat-
tery condition.
In such case, the machine monitor may go out temporarily or restart, but it is not a trouble.
3-11
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE

ENGINE SHUTDOWN SECONDARY SWITCH IS ON
While engine shutdown secondary switch (1) is ON (engine is
stopped), when the starting switch is turned to ON position, the
screen shown in the figure is displayed and engine does not
start.
If engine shutdown secondary switch (1) is turned OFF (nor-
mal), the machine monitor switches to the standard screen,
and the engine can be started with usual starting switch key
operation.
For the function and operating method of engine shutdown sec-
ondary switch (1), see “ENGINE SHUTDOWN SECONDARY
SWITCH (3-103)”.
BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR-

MAL SITUATION
When starting switch is turned to OFF position, the screen goes out. In the following case, the end screen is
displayed for 5 seconds, and then screen goes out.
3-12
End screen with message

If there is any message from your Komatsu distributor, it is displayed on end screen DD for 5 seconds, and then
the screen goes out.
In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting
response, send back your reply.
For the method of displaying and replying the messages, see “MESSAGE DISPLAY (3-90)”.
End screen with “Operational Advice”
If there is any “Operational Advice”, “Operational Advice” is displayed on end screen EE for 5 seconds, and then
the screen goes out.
For the “Operational Advice” when ending, see “SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY
IS OFF (3-60)”.
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING SWITCH IS ON

WHILE OPERATOR ID INPUT IS SET
• If inputting ID number for operator identification function (with SKIP) is set, the opening screen AA switches
to ID number input screen LL (with SKIP) when the starting switch is turned to ON position.
• If inputting ID number for operator identification function (without SKIP) is set, the opening screen AA
switches to ID number input screen MM (without SKIP) when the starting switch is turned to ON position.
• On the ID number input screen LL (with SKIP) or MM
(without SKIP), input the already registered ID number,
and press enter switch (1). The screen changes to the
Check Before Starting screen BB. If you input an incorrect
ID number, press return switch (2), and clear an input
character at a time.
On the ID number input screen LL (with SKIP), press
menu switch (3), and the screen changes to the Check Be-
fore Starting screen BB without inputting ID number.
3-13
REMARK
• Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator
identification function.
• Depending on the set value of ID holding time, even if inputting ID number for operator identification func-
tion is set, the ID number input screen LL (with SKIP) or MM (without SKIP) may not be displayed while the
starting switch is turned to ON position.
If inputting incorrect ID number for 3 times continuously, you cannot input ID number for 5 minutes. Wait for
more than 5 minutes, try inputting ID number again.
As long as ID number input screen is displayed, the engine cannot be started. If you forget the ID number and
cannot start the engine, confirm the person in charge of the machine.
NOTICE
Since the purpose of the operator identification function is neither security enhancement nor a protec-
tion against theft, it has no antitheft effect. Be careful not to use it for the purpose of security enhance-
ment.
Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or
unauthorized use of ID by a third person.
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB-

NORMAL SITUATION
When machine has abnormality

Starting screen AA is displayed for 2 seconds, and then failure display screen FF is displayed.
3-14
When the enter switch is pressed while guidance icon (1) is

displayed, the “Current Abnormality” screen is displayed.
For the “Current Abnormality” screen and the remedies, see
“WARNING DISPLAY (3-16)”.
When time remaining to maintenance for any item is less than 30 hours
Starting screen AA is displayed for 2 seconds, and then Maintenance time warning screen GG is displayed.
When the menu switch displayed in guidance icon (2) is press-
ed, the “Maintenance” menu screen is displayed.
For the “Maintenance” menu screen and the remedies, see
“MAINTENANCE SCREEN SETTING (3-73)”.
After displaying the maintenance time warning screen GG for
30 seconds, the screen returns to the standard screen BB.
BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE

OPERATING MACHINE
If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF.
3-15
When the enter switch is pressed while guidance icon (1) is

displayed, the “Current Abnormality” screen is displayed.
For the “Current Abnormality” screen and the remedies, see
“WARNING DISPLAY (3-16)”.
REMARK
Guidance icon (1) is displayed only while the machine is stop-
ped completely.
Even when the enter switch is pressed while the machine is not
stopped completely, the “Current Abnormality” screen is not
displayed.
WARNING DISPLAY
NOTICE
Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab-
normality the machine.
Take appropriate remedies according to “ACTION LEVEL DISPLAY (3-17)”.
• These caution lamps do not guarantee the condition of the machine.
Do not simply rely on the caution lamp when performing checks before starting (start-up inspec-
tion). Always get off the machine and check each item directly.
• When the caution lamp is displayed in red, if no action is taken, the machine can be seriously affect-
ed.
Take the action immediately.
• The engine output or engine speed is limited and the machine operation speed may become slow,
depending on the contents of the warning.
(1) Action level display (7) Brake oil pressure caution lamp
(2) Guidance icon (8) DEF level caution lamp
(3) Engine coolant temperature caution lamp (9) Seat belt caution lamp
(4) Torque converter oil temperature caution lamp (10) Warning display
(5) Retarder oil temperature caution lamp (11) Warning display
(6) Fuel level caution lamp (12) Centralized warning lamp
3-16
ACTION LEVEL DISPLAY

Action level display indicates the degree of urgency of the ab-
normality currently generated on the machine by “L01” to “L04”.
The larger the number in the table is, the more serious effects
the abnormality may have on the machine if it is left with no ac-
tion.
When the machine monitor displays an action level, take ap-
propriate actions according to “List of action level displays and
required actions”.
List of action level displays and required actions

Degree Color of
Action Centralized
of ur- Alarm buzzer caution Required action
level warning lamp
gency lamp
Sounds con- Stop the machine immediately and ask your Komatsu
L04 Lights up Red
tinuously distributor for inspection and maintenance.
Stop the operation and move the machine to a safe
Sounds inter-
L03 Lights up Red place, then ask your Komatsu distributor for inspec-
mittently
tion and maintenance.
If there is an overrun related display, reduce the en-
High gine speed and machine travel speed while continu-
ing operations.
↑
If there is an overheat related display, stop the ma-
│ chine at a safe place, and run the engine at medium
│ Sounds inter- speed with no load.
L02 Lights up Red
mittently
│ If there is an secondary steering related display,
│ avoid a long time usage of the secondary steering.
↓ If the condition is not improved, check the failure

code and ask your Komatsu distributor for inspection
Low and maintenance.
Some functions may be restricted for use, but the ma-
chine can operate.
Does not When you finish the operation, always have the in-
L01 OFF Yellow
sound spection and maintenance performed.
As needed, ask your Komatsu distributor for inspec-
tion and maintenance.
3-17
REMARK
• When the action level display is “L01”, “L01” is displayed
only for 2 seconds, and then it is turned OFF.
• If plural failures occur at the same time, the action level
with the highest urgency (the greatest number) is dis-
played.
OCCURRED FAILURE CODE DISPLAY

The monitor provides information on failures that occurred on the machine and necessary remedies for action
levels that are displayed.
When the enter switch is pressed while the guidance icon is
displayed, the screen changes to the “Current Abnormality”
screen.
REMARK
The guidance icon is displayed only while the machine is stop-
ped completely.
Even when the enter switch is pressed while the machine is not
stopped completely, the “Current Abnormality” screen is not
displayed.
3-18
(A) Caution lamp

(B) Action level
(C) Failure code
Code to indicate the content of the failure. Notify it when calling your Komatsu distributor.
(D) Failure name
(E) Message
Take appropriate remedies according to the displayed message.
(F) Contact telephone number
The telephone number of your Komatsu distributor is displayed.
If the telephone number of the contact has not been registered, it is not displayed.
Ask your Komatsu distributor for the telephone number registration if necessary.
(G) Guidance icon
On the “Current Abnormality” list screen, the following switches displayed in guidance icon (G) can be operated.
UP switch
Move to the previous page.
When on the first page, move to the last page.
3-19
DOWN switch
Move to the next page.
When on the last page, move to the first page.
RETURN switch
Return to the standard screen.
ENGINE COOLANT TEMPERATURE CAUTION LAMP

Engine coolant temperature caution lamp warns about over-
heating of the engine coolant.
If the engine coolant temperature is abnormally high, the cau-
tion lamp lights up in red and action level “L02” is displayed.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Place the machine in a safe place, set the gear shift lever to
NEUTRAL position (N), and run the engine at a medium speed
under no load until the caution lamp goes out.
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP

The torque converter oil temperature caution lamp warns about
overheating of the torque converter oil.
If the torque converter oil temperature is abnormally high, the
caution lamp lights up in red and action level “L02” is displayed.
3-20
RETARDER OIL TEMPERATURE CAUTION LAMP

The retarder oil temperature caution lamp warns about over-
heating of the retarder oil.
If the retarder oil temperature increases abnormally high, the
FUEL LEVEL CAUTION LAMP

The fuel level caution lamp warns about low remaining fuel lev-
el.
The lamp lights up in red if the fuel level is 106 ℓ or below.
Add fuel as soon as possible.
BRAKE OIL PRESSURE CAUTION LAMP

The brake oil pressure caution lamp warns that the brake oil
pressure is below the specified value.
When action level “L03” is displayed
If the brake oil pressure drops below the specified value while
the engine is running, the caution lamp lights up in red.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for inspection and
maintenance.
Action level is not displayed and lamp lights up in red
If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in
red.
When the engine is started, the caution lamp lights up in red until the brake oil pressure rises above the speci-
fied value.
At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Wait until the caution lamp goes out, and then start the machine.
3-21
DEF LEVEL CAUTION LAMP

DEF level caution lamp alerts when DEF tanlk level becomes
low.
Whenever the caution lamp lights up in red, immediately add
DEF.
Fault conditions that result in activation of the Inducement strat-
egy for engine derates to prompt to maintain or repair the emis-
sion control system.
When Lightning in red,
With Action level “L04”, DEF tank level is too low. Inducement
status is “Severe Inducement”. Engine power is under heavy
deration.
With Action level “L03”, DEF tank level is low. Inducement status is “Low level Inducement”. Engine power is
under deration.
With No Action level display. DEF tank level is lower. Inducement status is “Continuous Warning”. Need to add
DEF immediately to avoid advancing to the next Inducement status.
With No Action level display. DEF tank level is becomes low. Warning starts. Inducement status is “Warning”.
Need to add DEF immediately.
When Lightning in white
When fluctuation of DEF tank level is large, frozen, or not limited to, tank level sensing is not performed correct-
ly.
When DEF is added after engine starting switch turn to OFF.
When DEF tank level sensor is defective.
REMARK
For more information about the Inducement strategy, and Inducement status concerning engine power deration,
see “HANDLE UREA SCR SYSTEM WARNING (3-132)”.
SEATBELT CAUTION LAMP

The seat belt caution lamp lights up in red when the seat belt is
not fastened.
Always fasten the seat belt while traveling because there may
be a possible danger.
WARNING DISPLAY
The caution lamps displayed on the warning display section are
as follows.
Take appropriate remedies as specified.
3-22
REMARK
• When 1 type of alarm is generated, it is displayed on caution lamp (A).
• When 2 types of alarm are generated, they are displayed on caution lamps (A) and (B).
• When 3 types of alarm are generated, they are displayed on caution lamps (A) and (B) alternately at inter-
vals of 2 seconds.
STEERING SYSTEM CAUTION LAMP

The steering system caution lamp warns about abnormality in
the steering system.
If the caution lamp lights up in yellow and action level “L01” is
displayed, always perform inspection and maintenance after
the operation is finished.
Ask your Komatsu distributor for the inspection and mainte-
nance as needed.
STEERING OIL PRESSURE CAUTION LAMP

The steering oil pressure caution lamp warns the operator that
the steering oil pressure is below the specified value.
If the steering oil pressure drops below the specified value
while the engine is running, the caution lamp lights up in red.
maintenance.
Action level is not displayed and lamp lights up in red
When the engine is started, the caution lamp lights up in red until the steering oil pressure rises above the
specified value.
Wait until the caution lamp goes out, and then start the machine.
Action level is not displayed and only lamp lights up in yellow
If the steering oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in
yellow.
STEERING OIL TEMPERATURE CAUTION LAMP

The steering oil temperature caution lamp warns about over-
heating of the steering oil.
If the steering oil temperature increases abnormally high, the
3-23
SECONDARY STEERING SYSTEM CAUTION LAMP

The secondary steering system caution lamp warns about ab-
normality in the secondary steering system.
The caution lamp lights up in red.
maintenance.
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for the inspection and maintenance as needed.
SECONDARY STEERING MOTOR CAUTION LAMP

The secondary steering motor caution lamp warns that the sec-
ondary steering motor has been operating for a long period.
The caution lamp lights up in red and action level “L02” is dis-
played.
Do not use the secondary steering for more than 90 seconds.
HOIST CONTROL SYSTEM CAUTION LAMP

The hoist control system caution lamp warns about abnormality
in the hoist control system.
maintenance.
3-24
BODY FLOAT CAUTION LAMP

The dump body float caution lamp warns about the condition of
the dump body.
When lamp lights up in red
The gear shift lever is turned to any position other than NEU-
TRAL position (N) while the dump lever is turned to any posi-
tion other than “FLOAT” or the dump body is raised.
When lamp lights up in yellow
The dump lever is turned to any position other than “FLOAT”
position or the dump body is raised.
REMARK
If the engine stops, the dump body is held in HOLD condition, regardless of the position of the dump lever.
Although this body float caution lamp does not light up while the starting switch is turned to ON position, it lights
up when the engine is stared.
Cancel the body HOLD condition. For details, see “METHOD FOR CANCELING TO HOLD DUMP BODY
(3-181)”.
INCLINATION CAUTION LAMP

The inclination caution lamp warns about danger of tipping
caused by inclination of the machine.
When the dump lever is in “RAISE” position, if the rear part of
the machine is inclined more than the lateral stable range, the
caution lamp lights up in red.
Lower the dump body and move the machine to a safe and lev-
el place.
SYSTEM CAUTION LAMP

The system caution lamp warns about abnormality in the ma-
chine system, including the sensors.
maintenance.
3-25
KDPF SYSTEM CAUTION LAMP

The KDPF system caution lamp warns about abnormality in the
KDPF system.
the alarm buzzer sounds continuously.
Stop the machine immediately and ask your Komatsu distribu-
tor for inspection and maintenance.
Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for
inspection and maintenance.
REMARK
For details of KDPF, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-121)”.
KDPF SOOT ACCUMULATION CAUTION LAMP

The KDPF soot accumulation caution lamp warns that soot is
accumulated in KDPF or the filtering function of KDPF has low-
ered abnormally.
The caution lamp lights up in red if much soot is accumulated
in KDPF or a system trouble such as lowering of the filtering
function of KDPF occurs.
Stop the operation, move the machine to a safe place, and per-
form the manual stationary regeneration.
The manual stationary regeneration may start automatically to protect the KDPF system.
The caution lamp lights up in yellow if much soot is accumulated in KDPF.
After the operation is finished, move the machine to a safe place and perform manual stationary regeneration.
REMARK
For details of the manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF)
(3-121)”.
3-26
DEF SYSTEM CAUTION LAMP

DEF system caution lamp alerts when abnormality in the sys-
tem are detected.
Whenever the caution lamp lights up in yellow or in red, take
necessary actions by instructions.
Fault conditions that result in activation of the Inducement strat-
egy for engine derates to prompt to maintain or repair the emis-
sion control system.
Lighting in red
With Action level “L04”, Inducement status is “Severe Induce-
ment”. Engine power is under heavy deration.
With Action level “L03”, Inducement status is “Low level Inducement”. Engine power is under deration.
Lighting in yellow
With Action level “L01”, Inducement status is “Warning” or “Continuous Warning”.
When “Continuous Warning”, If no maintenance, advancing to the next Inducement status. Engine power will be
derated.
REMARK
For more information about the Inducement strategy, and Inducement status concerning engine power deration,
see “HANDLE UREA SCR SYSTEM WARNING (3-132)”.
DEF SYSTEM HIGH TEMPERATURE STOP CAUTION LAMP

DEF system Temperature stop caution lamp alerts when the
times of engine is shut down under the condition of high degree
temperature of DEF system exceeds the defined number of
times.
Whenever the caution lamp lights up in yellow, it is necessary
to ask your Komatsu distributor to go off this caution lamp.
When stopping the engine, stop it after running it at low idle for
approximately 5 minutes. For details, see “METHOD FOR
STOPPING ENGINE (3-183)”.
When stopping the engine during the aftertreatment devices re-
generation, stop the regeneration first according to “PROCE-
DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-128)”, then stop the en-
gine after running it at low idle for approximately 5 minutes.
TRANSMISSION SYSTEM CAUTION LAMP

The transmission system caution lamp warns about abnormali-
ty in the transmission system.
the alarm buzzer sounds continuously.
Immediately stop the machine and ask your Komatsu distribu-
3-27

TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP

The transmission oil filter clogging caution lamp wans about
clogging of the transmission oil filter.
displayed, stop the engine and check or replace the transmis-
sion oil filter.
See “METHOD FOR REPLACING TRANSMISSION OIL FIL-
TER ELEMENT (4-60)”.
INTER-AXLE DIFFERENTIAL LOCK SYSTEM CAUTION LAMP

The inter-axle differential lock system caution lamp warns
about abnormality in the inter-axle differential lock system.
maintenance.
RETARDER SYSTEM CAUTION LAMP

The retarder system caution lamp warns about abnormality in
the retarder system.
maintenance.
3-28
ENGINE SYSTEM CAUTION LAMP

k WARNING
If the operation is continued while the caution lamp is lit in red, accumulation and combustion of the
soot in KDPF are accelerated, and consequently the temperature of KDPF and exhaust gas can increase
high. Stop the engine immediately.
The engine system caution lamp warns about abnormality in

the engine system.
The caution lamp lights up in red. At the same time, the central-
ized warning lamp lights up and the alarm buzzer sounds con-
tinuously.
Immediately stop the machine and ask your Komatsu distribu-
ized warning lamp lights up and alarm buzzer sounds intermittently.
PARKING BRAKE SYSTEM CAUTION LAMP

The parking brake system caution lamp warns about abnormal-
ity in the parking brake system.
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds intermittently.
maintenance.
The lamp lights up in yellow.
KTCS SYSTEM CAUTION LAMP

The KTCS system caution lamp warns about abnormality in the
KTCS system.
nance as needed.
3-29
ENGINE OIL PRESSURE CAUTION LAMP

Engine oil pressure caution lamp warns about low engine lubri-
cating oil pressure.
If the engine oil pressure drops below the specified value while
the engine is running, the caution lamp lights up in red and ac-
tion level “L03” is displayed.
maintenance.
ENGINE OIL LEVEL CAUTION LAMP

Engine oil level caution lamp warns about drop of engine lubri-
cating oil level.
It displays only while the engine is stopped.
displayed, check the oil level in the oil pan and add oil.
See “METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL
PAN, ADDING OIL (3-156)”.
If the oil level drops again in a short time, the engine oil may be
leaking. Ask your Komatsu distributor for inspection and repair.
ENGINE OVERRUN CAUTION LAMP

The engine overrun caution lamp warns the operator that the
engine speed is higher than the allowable range.
When the caution lamp lights up in red, the centralized warning
lamp lights up and the alarm buzzer sounds intermittently.
If the engine speed increases more, action level “L02” is dis-
played.
Operate the machine with moderate engine speed and travel
speed.
RADIATOR COOLANT LEVEL CAUTION LAMP

Radiator coolant level caution lamp warns about drop of radia-
tor coolant level.
displayed, check the coolant level in the reservoir tank and add
coolant.
See “METHOD FOR CHECKING COOLANT LEVEL, ADDING
COOLANT (3-155)”.
If it occurs again in a short time, the coolant may be leaking
from the radiator. Ask your Komatsu distributor for inspection
and maintenance.
3-30
CHARGE LEVEL CAUTION LAMP

Charge level caution lamp warns about abnormality in the
charging system while the engine is running.
If the battery is not charged properly while the engine is run-
ning, the caution lamp lights up in red.
When action level “L03” is displayed at the same time, the cen-
tralized warning lamp lights up and the alarm buzzer sounds in-
termittently.
Stop the engine and check the alternator belt for damage, then
ask your Komatsu distributor for inspection and maintenance.
See “OTHER TROUBLE (3-256)”.
AIR CLEANER CLOGGING CAUTION LAMP

Air cleaner clogging caution lamp warns about clogging of the
air cleaner.
displayed, stop the engine, then check and clean the air clean-
er.
See “METHOD FOR CHECKING, CLEANING AND REPLAC-
ING AIR CLEANER (4-14)”.
FAN CONTROL SYSTEM CAUTION LAMP

The fan control system caution lamp warns about abnormality
in the fan control system.
ized warning lamp lights up and alarm buzzer sounds intermit-
tently.
maintenance.
FAN-REVERSE OPERATION CAUTION LAMP

The wrong operation in fan reverse mode caution lamp warns
about misoperation while the fan is rotating in reverse.
If the gear shift lever is set to any position other than NEU-
TRAL position (N) or the dump body is not seated while the fan
(radiator or after cooler) is rotating in reverse, the lamp lights
up in red.
Keep the gear shift lever in NEUTRAL position (N) and keep
the dump body seated while the fan is rotating in reverse.
3-31
AIR CONDITIONER SYSTEM CAUTION LAMP

Air conditioner system caution lamp warns about abnormality in
air conditioner system.
nance as needed.
MAINTENANCE TIME CAUTION LAMP

Maintenance time caution lamp displays notices and alarms
concerning maintenance time.
This lamp lights up when the starting switch is turned to ON po-
sition. It goes out after 30 seconds and the display changes to
the standard screen.
When lamp lights up in red
The maintenance due time is over.
If no action is taken, the machine performance will become
worse and the machine life will be shortened.
Perform necessary maintenance as soon as possible.
When lamp lights up in yellow
The maintenance due time is approaching.
Prepare necessary parts for the maintenance.
REMARK
• To check the items that need maintenance, see the “Maintenance” menu screen.
• On the standard screen, when the menu switch is pressed while the caution lamp is lit, the screen changes
directly to the “Maintenance” menu screen.
• For operations on the “Maintenance” menu screen, see “MAINTENANCE SCREEN SETTING (3-73)”.
• By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches
30 hours. However, you can change this setting.
To change the setting, ask your Komatsu distributor.
CENTRALIZED WARNING LAMP

The centralized warning lamp lights up in red and at the same
time the alarm buzzer sounds intermittently when the machine
is in any of the following conditions.
3-32
Machine conditions under which centralized warn- Monitor display

ing lamp lights up
Action level
When L02, L03, or L04 is displayed.
When the engine overrun caution lamp is lit.
When the wrong operation in fan reverse mode

caution lamp is lit.
When the dump body float caution lamp (red) is lit.
When the inclination caution lamp is lit.
When the charge voltage caution lamp is lit.
When the brake oil pressure is below the specified The brake oil pressure caution lamp lights
value while the engine is running. up.
When the steering oil pressure is below the speci- The steering oil pressure caution lamp lights
fied value while the engine is running. up.
When the starting switch is turned to ON position The current gear shift lever position flashes.
while the gear shift lever is in the any position oth-
er than NEUTRAL position (N).
When all the signals from the gear shift lever are
turned OFF.
When the gear shift lever is set to NEUTRAL posi- The current gear shift lever position flashes.
tion (N) during traveling at travel speed above
4 km/h.
When the travel speed exceeds 4 km/h while the
gear shift lever is in NEUTRAL position (N).
3-33
Machine conditions under which centralized warn- Monitor display

ing lamp lights up
When the gear shift lever is not in NEUTRAL posi- The parking brake pilot lamp is lit.
tion (N) while the parking brake is applied.
When the gear shift lever is in position D and the Shift indicator (F1) flashes.
accelerator pedal is depressed while the brake is
operated. (When F1 Start at D Position Setting is
effective)
PILOT DISPLAY AND METER DISPLAY
Pilot display
(1) Turn signal lamp pilot lamp (11) Preheating pilot lamp
(2) Headlamp (high beam) pilot lamp (12) Message display
(3) Clearance lamp pilot lamp (13) Aftertreatment devices regeneration display
(4) Retarder pilot lamp (14) Secondary steering pilot lamp
(5) Inter-axle differential lock pilot lamp (15) Shift indicator
(6) KTCS display (16) Shift lever position display
(7) Power mode display (17) Parking brake pilot lamp
(8) Shift hold pilot lamp (18) ECO guidance
(9) Torque converter lockup pilot lamp (19) DEF low level guidance
(10) Fan reverse pilot lamp
Meter display
(20) Speedometer (21) Engine tachometer
3-34
(22) Engine coolant temperature gauge (26) ECO gauge

(23) Torque converter oil temperature gauge (27) L.H. meter
(24) Retarder oil temperature gauge (28) R.H. meter
(25) Fuel gauge (29) DEF level gauge
PILOT DISPLAY
The pilot display consists of the pilot lamps to check the actuation of each function.
When the starting switch is in ON position, the pilot lamps light up when the display items are functioning.
TURN SIGNAL PILOT LAMP

The turn signal pilot lamp flashes synchronously with the turn
signal lamp, when it is turned on.
HEADLAMP (HIGH BEAM) PILOT LAMP

The headlamp (high beam) pilot lamp lights up when the head-
lamps are set to high beam.
CLEARANCE LAMP PILOT LAMP

The clearance lamp pilot lamp lights up when the clearance
lamps are turned on.
3-35
RETARDER PILOT LAMP

The retarder pilot lamp lights up when the retarder is in opera-
tion.
The retarder operates in the following cases.
• When the retarder control lever is pulled.
• When the automatic retarder, accelerator linked control
system (ARAC) is in operation.
INTER-AXLE DIFFERENTIAL LOCK PILOT LAMP

The inter-axle differential lock pilot lamp lights up when the in-
ter-axle differential lock is in operation.
KTCS DISPLAY
KTCS display indicates the operating state of KTCS.
(A): Lights up when KTCS is in operation.
(B): Lights up when setting of KTCS is turned OFF.
For setting of KTCS, see “KTCS SYSTEM SETTING (3-65)”.
POWER MODE DISPLAY

The power mode display indicates the set state of the output
mode.
By selecting engine power mode selector switch, one of the fol-
lowing lamps lights up.
(A): Power mode
(B): Economy mode
3-36
SHIFT HOLD PILOT LAMP

The shift hold pilot lamp lights up when the shift hold function
works.
TORQUE CONVERTER LOCKUP PILOT LAMP

The torque converter lockup pilot lamp lights up when the tor-
que converter lockup is actuated and the transmission is shift-
ed to the direct drive.
FAN REVERSE ROTATION PILOT LAMP

The fan reverse rotation pilot lamp lights up when the radiator
fan or aftercooler fan is set in fan reverse mode.
For details of the method of setting the fan reverse mode, see
“RADIATOR FAN REVERSE MODE (3-61)” and “AFTER
COOLER FAN REVERSE MODE (3-63)”.
PREHEATING PILOT LAMP

The preheating pilot lamp lights up when the automatic pre-
heating function of the engine is actuated, and goes out when
preheating is completed.
This lamp also lights up during manual preheating.
The electrical heater for engine preheating is actuated while
this lamp is lit.
For details of engine preheating, see “METHOD FOR START-
ING ENGINE (3-177)”.
3-37
MESSAGE DISPLAY
The message display lights up when your Komatsu distributor
sends out any information.
(A): There is unread message.
(B): There is any read message to which no reply is made.
To read the message, see “MESSAGE DISPLAY (3-90)”.
AFTERTREATMENT DEVICES REGENERATION PILOT LAMP

k CAUTION
• Exhaust gas temperature may increase higher than the previous models during the aftertreatment
devices regeneration.
Stay away from the exhaust pipe outlet to prevent yourself from getting burnt.
Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire.
• When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to
the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after-
treatment devices regeneration.
For details of the setting method, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-121)”.
Aftertreatment devices regeneration display indicates the re-

generation state of the exhaust gas aftertreatment devices.
(A): Lights up during regeneration of the exhaust gas aftertreat-
ment devices. It goes out when the regeneration is complet-
ed.
(B): Lights up when the exhaust gas aftertreatment devices are
set to “Regeneration Disable”.
REMARK
• The lighting cycle becomes shorter when the ambient tem-
perature is lower or working load is smaller.
• Even if the aftertreatment devices regeneration is disabled,
when the manual stationary regeneration is necessary,
KDPF soot accumulation caution lamp lights up.
If KDPF soot accumulation caution lamp lights up, cancel
the regeneration disable setting and perform manual sta-
tionary regeneration.
For the procedures of cancellation of regeneration disable
setting, and setting of manual stationary regeneration, see
“HANDLE Komatsu Diesel Particulate Filter (KDPF)
(3-121)”.
3-38
SECONDARY STEERING SYSTEM PILOT LAMP

The secondary steering pilot lamp lights up while the secon-
dary steering is in operation.
SHIFT INDICATOR
This indicator shows the transmission shift range (speed
range).
SHIFT LEVER POSITION DISPLAY

The gear shift lever position display indicates the gear shift lev-
er position.
The character for the selected gear shift lever position is en-
larged.
PARKING BRAKE PILOT LAMP

The parking brake pilot lamp lights up when the parking brake
is applied.
ECO GUIDANCE
ECO guidance is displayed during the operation that lowers the fuel efficiency, and support energy saving oper-
ation for reducing the fuel consumption.
The details of the guidance are as follows.
3-39
EXCESSIVE IDLING GUIDANCE

If the engine continues running idle for more than 5 minutes,
the excessive idling message is displayed on the machine
monitor.
When waiting for loading or stopping operation for a short peri-
od, stop the engine to reduce unnecessary fuel consumption.
When the accelerator pedal is depressed or the machine starts
traveling, the excessive idling message goes out.
GUIDANCE TO AVOID HOIST RELIEF

When relief of the hoist oil pressure is continued for more than
5 seconds while the accelerator pedal is depressed, the hoist
pressure relief deterrence message is displayed on the ma-
chine monitor.
Relief of the host oil pressure occurs if you set the dump lever
to “RAISE” position while the dump body is raised to the maxi-
mum height or to “LOWER” position while the dump body is
seated.
Return the dump lever to “HOLD” or “FLOAT” position to pre-
vent unnecessary relief.
The hoist pressure relief deterrence message goes out auto-
matically in 10 seconds.
BRAKE DRAGGING PREVENTION GUIDANCE

If the accelerator pedal is depressed for more than 5 seconds
while applying the brake during traveling, the brake dragging
prevention message is displayed on the machine monitor.
If the accelerator is operated while the brake is used, fuel con-
sumption is increased.
The brake dragging prevention message goes out automatical-
ly after 10 seconds.
GUIDANCE TO RECOMMEND SHIFTING UP

Even when the engine speed reaches shift up speed during
traveling, if the upshift disable condition continues more than 5
seconds, by gear shift lever or shift hold switch, the upshift rec-
ommendation message is displayed on the machine monitor.
This message is displayed in the reverse travel, as well. It is,
however, not displayed in the downhill travel with retarder oper-
ation.
When traveling on a flat road, reduce the fuel consumption by
shifting the gear up and decreasing the engine speed.
The upshift recommendation message goes out automatically
after 10 seconds.
3-40
GUIDANCE TO AVOID ACCELERATION OPERATION DURING DUMP BODY

LOWERING
If you depress the accelerator pedal for more than 5 seconds
while the dump body is lowering, the message to restrict the
accelerator operation during the dump body lowering operation
is displayed on the machine monitor.
When the dump body is lowering, restrict the accelerator oper-
ation in order to reduce the fuel consumption.
The message to restrict the accelerator operation during dump
body lowering operation goes out automatically after 10 sec-
onds.
GUIDANCE TO AVOID STEERING RELIEF

If the steering oil pressure is relieved for more than 5 seconds,
the steering relief restriction message is displayed on the ma-
chine monitor.
Relieving of steering oil pressure occurs when you steer the
wheel fully to the right or left.
Restrict forcible steering operation to reduce the fuel consump-
tion.
The steering relief restriction message goes out automatically
after 10 seconds.
REMARK
Display/Non-display of ECO guidance can be switched.
For the method of switching the display, see “SWITCH DIS-
PLAY/NON-DISPLAY OF ECO GUIDANCE (3-59)”.
DEF LOW LEVEL GUIDANCE

If the operable time estimated from the current DEF level and
the latest average DEF consumption is shorter than 8 hours,
the low DEF level message is displayed.
The low DEF level message goes out more than 10 seconds
after or when the enter switch is pressed.
METER DISPLAY
SPEEDOMETER
The speedometer indicates the travel speed of the machine.
3-41
ENGINE TACHOMETER
The engine tachometer indicates the engine speed.
If the engine speed is higher than the allowable range during
operation, the engine overrun caution lamp lights up in red.
Operate the machine with moderate engine speed and travel
speed.
ENGINE COOLANT TEMPERATURE GAUGE

Engine coolant temperature gauge shows the engine coolant
temperature.
When the indicator is in white range (A) or green range (B) dur-
ing operation, it is normal.
If the indicator is in red range (C), the engine coolant tempera-
ture caution lamp lights up in red, and action level “L02” is dis-
played.
The engine output is then limited automatically.
Place the machine in a safe place, set the gear shift lever to NEUTRAL position (N), and run the engine at a
medium speed with no load until the engine coolant temperature caution lamp goes out.
TORQUE CONVERTER OIL TEMPERATURE GAUGE

The torque converter oil temperature gauge indicates the tor-
que converter oil temperature.
When the indicator is in green range (B) during operation, it is
normal.
If the indicator is in red range (C), the torque converter oil tem-
perature caution lamp lights up in red, and action level “L02” is
displayed.
NEUTRAL position (N), and run the engine at a medium speed with no load until the torque converter oil tem-
perature caution lamp goes out.
RETARDER OIL TEMPERATURE GAUGE

The retarder oil temperature gauge indicates the retarder oil
temperature.
When the indicator is in green range (B) during operation, it is
normal.
If the indicator is in red range (C), the retarder oil temperature
caution lamp lights up in red, and action level “L02” is dis-
played.
with no load until retarder oil temperature caution lamp goes
out.
3-42
FUEL GAUGE
Fuel gauge shows the amount of fuel in the fuel tank.
If the indicator is in red range (C), the fuel level caution lamp
lights up in red.
The fuel level is below 106 ℓ. Check the fuel level, and add fuel.
ECO GAUGE
ECO gauge indicates the instantaneous fuel consumption (fuel
consumption rate at each moment).
The instantaneous fuel consumption varies depending on the
operation ways (accelerator operation, travel speed, gear
speed, etc.) and the given load during travel (load weight,
slope, ground condition, etc.).
As the gauge is higher, the fuel consumption is higher.
Reduce the gauge to a point where there is no adverse effect
on the operation, leading to energy saving operation to reduce
the fuel consumption.
REMARK
Even if the gauge is in orange range (A), it is not a machine trouble.
Target fuel consumption (B) displayed by ECO gauge can be changed as necessary.
For the method of changing the target value, see.“SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN
ECO GAUGE (3-58)”
L.H. AND R.H. METER DISPLAY

The L.H. meter indicates either of the following which can be selected.
• Service meter
• Odometer
• Clock
For the method of selecting the display, see “SELECT L.H. METER DISPLAY (3-78)”.
R.H. meter indicates either of the following which can be selected.
• Fuel Consumption gauge
• Service meter
• Odometer
• Clock
For the method of selecting the display, see “SELECT R.H. METER DISPLAY (3-79)”.
3-43
Service meter display

Indicates the integrated operating hours of the machine.
When the engine is running, the service meter advances even
if the machine is not being operated.
The service meter advances by 0.1 for 6 engine running mi-
nutes and by 1 for 1 engine running hour, regardless of the en-
gine speed.
Odometer display
Indicates the total distance that machine has traveled in kilo-
meters.
Clock display
Indicates the current time.
(A): 12-hour display
(B): 24-hour display
REMARK
If the battery is disconnected for a long period for storage etc.,
the time information may be lost.
For the method of setting and correcting the time and changing
the display of the clock, see “CLOCK ADJUSTMENT (3-81)”.
3-44
Fuel consumption gauge display

Indicates the average fuel consumption of the machine.
(C): Average fuel consumption in a day
(D): Split fuel consumption (under measuring)
(E): Split fuel consumption (when measuring is stopped)
REMARK
Display on the fuel consumption gauge can be switched be-
tween the average fuel consumption per day (from 0:00 am of
the day to 0:00 am of the next day) and the average fuel con-
sumption during an selected period (split fuel consumption).
For details of the fuel consumption gauge and the method of
switching the display, see “SET DISPLAY OF FUEL CON-
SUMPTION GAUGE (3-56)”.
DEF LEVEL GAUGE

DEF level gauge indicates the remaining level of DEF.
If the indicator is in green range during operations, it is normal.
If the indicator comes close to (A) of red range during opera-
tion, check and add DEF.
(A) to (B): Red range
(A) to (C): Green range
When the indicator is in red range from (A) to (B), DEF level
caution lamp (1) lights up in red.
If DEF level further decreases after the lamp lights up in red,
the engine output power and engine speed are limited. For de-
tail, see “HANDLE UREA SCR SYSTEM WARNING (3-132)”.
When remaining level of DEF cannot be detected, DEF level caution lamp (1) lights up in white.
REMARK
• Immediately after turning the starting switch to ON position and during the engine is running, DEF level cau-
tion lamp (1) lights up in white. However, this does not indicate abnormality.
• In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi-
mately 1 hour. However, this does not indicate abnormality.
• Even if DEF level caution lamp (1) is not lit in white, it may take a long time for DEF level gauge to display
the correct position.
Note that the following cases are not abnormal:
• When DEF is added while the starting switch is kept at ON position.
• When the starting switch is turned to ON position immediately after adding DEF (within approximately
30 seconds).
Before adding DEF, turn the starting switch to OFF position. Wait for a while after adding, then turn the
starting switch to ON position.
MONITOR SWITCHES
This is used for the operation of the machine monitor or air conditioner.
3-45
The function of each switch varies depending on the screen of the machine monitor being displayed when the
switch is pressed.
(1) Menu switch (5) Down switch

(2) Enter switch (6) Air conditioner switches / Numeric keypad
(3) Return switch (7) Guidance icon
(4) Up switch
MENU SWITCH
When this switch is pressed on the standard screen, the follow-
ing user menu screen is displayed. However, the user menu
screen is not displayed during traveling.
For details of the user menu, see “USER MENU (3-48)”.
When normal
Displays the “Energy Saving Guidance” menu screen.
When KDPF soot accumulation caution lamp lights up
Displays the “Aftertreatment Devices Regeneration” menu
screen.
When maintenance caution lamp lights up
Displays the “Maintenance” menu screen.
When fan automatic reverse display lights up
Displays the “Machine Setting and Information” menu screen.
When message pilot lamp lights up
Displays the Message display menu screen.
When menu switch is pressed on the user menu screen, the menu screen changes.
3-46
ENTER SWITCH
Pressing the enter switch on the user menu screen decides
any selection and changes, and proceeds to the next screen.
When the enter switch is pressed on the standard screen with
a warning message displayed, the “Current Abnormality”
screen is displayed.
For the “Current Abnormality” screen, see “OCCURRED FAIL-
URE CODE DISPLAY (3-18)”.
RETURN SWITCH
Pressing the return switch cancels a selection or changes, and
returns the screen to the previous screen or the standard
screen.
UP SWITCH
Pressing the up switch moves the cursor up by one item. When
on the top line, the cursor moves to the bottom line.
On the value input screen, the value is increased by one.
DOWN SWITCH
Pressing the down switch moves the cursor down by one item.
When on the bottom line, it moves to the top line.
On the value input screen, the value is decreased by one.
3-47
REMARK
• The switches effective on each screen can be checked
with the guidance icon.
• This function is not available when you press a switch not
marked by the guidance icon or you press the guidance
icon itself.
AIR CONDITIONER SWITCH / NUMERIC KEYPAD

The air conditioner switch, which is used for the operation of
the air conditioner, consists of 10 switches.
For explanation of each switch, see “HANDLE AIR CONDI-
TIONER (3-219)”.
These switches can be used as a numeric keypad to enter a
numeric value such as a password.
Press a desired switch to enter a numeric value “0” to “9”,
which is indicated at the lower right of each switch.
REMARK
• For details of other switch functions, see the explanation
for each screen in “USER MENU (3-48)”.
• The confirmation sound is heard when the switch is press-
ed, but a reaction is taken (the switch function is operated)
when the switch is released.
USER MENU
When menu switch (1) is pressed on the standard screen while
the machine is stopped, the user menu screen is displayed to
enable you to configure and confirm machine settings.
3-48
The user menu consists of the following kinds. The menu

screen can be changed by pressing the menu switch (1).
(A): “Energy Saving Guidance”
(B): “Machine Setting and Information”
(C): “Aftertreatment Devices Regeneration”
(D): “SCR Information”
(E): “Maintenance”
(F): “Monitor Setting”
(G): Message Display
These menus (A) to (G) are for setting and confirming the following items:
(A) “Energy Saving Guidance”
• Check of “Operation Records”
• Check of “ECO Guidance Records”
• Check and reset of “Average Fuel Consumption Record”
• “Configurations”
(B) “Machine Setting and Information”

• Setting of “Radiator Fan Reverse Mode”
• Setting of “Aftercooler Fan Reverse Mode”
• Display and setting of “Payload Meter”(if equipped)
• “KTCS setting”
• Display and resetting of “Dumping Counter”(if equipped)
• Display of “Reverse Travel Odometer”
• Display and resetting of “Trip Meter”
• “F1 Start at D Position Setting”
• “A/C ECO Mode Setting”
• “Retarder Lever Release Sound Setting”
• “Auto Idle Stop Timer Setting”
(C) “Aftertreatment Devices Regeneration”
• Setting “Regeneration Disable”
• Operation of “Manual Stationary Regeneration”
3-49
(D) “SCR Information”

• Check of DEF level
• Information on DEF system
(E) “Maintenance”
• Check and reset of various maintenance remaining times
(F) “Monitor Setting”

• “Rear View Monitor Setting”
• “Meter Display Selection”
• “Screen Adjustment”
• “Clock Adjustment”
• “Language Setting”
• “Operator ID”
(G) Message Display

• Check of message contents and reply to message
On the user menu screen, it is possible to perform the following

operations with the switches.
(1) Up switch
Moves to the item above.
When on the first item, moves to the last item.
(2) Down switch
Moves to the item below.
When on the last item, moves to the first item.
(3) Enter switch
Enters any selection or changes and proceeds to the next screen.
3-50
(4) Return switch

Cancels a selection or changes, and returns to the previous screen or the standard screen.
REMARK
• If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the
previous screen or the standard screen.
• The user menu screen is displayed only while the machine is stopped completely.
• If the machine travels while the user menu screen is displayed, the screen automatically returns to the
standard screen.
ENERGY SAVING GUIDANCE

Each item of “Energy Saving Guidance” menu (A) is used for
displaying and setting the notification relevant to energy saving.
• “Operating Records”
• “Eco Guidance Records”
• “Average Fuel Consumption Records”
• “Configurations”
OPERATING RECORD
The “Operation Records” screen displays the following informa-
tion on a daily basis or during the split measurement period.
• “Working Hours (Engine On)”
• “Average Fuel Consumption”
• “Actual Working Hours”
• “Ave. Fuel Consumption (Actual Working)”
• “Fuel Consumption”
• “Idling Hours”
• “Economy Mode Ratio”
Select “Operation Records” from the “Energy Saving Guidance”
screen, then press enter switch (1).
REMARK
For the definition and display change method of the “1 Day”
and “Split Time”, see “SET DISPLAY OF FUEL CONSUMP-
TION GAUGE (3-56)”.
3-51
When the “Average Fuel Consumption Display” is set to “1 Day”
When “Average Fuel Consumption Display” is set to “Split Time” and split time
is measured
(A) Display during measurement
(B) Date and time when the measurement is started
To stop the split measurement, see the guidance icon and
press enter switch (1).
When “Average Fuel Consumption Display” is set to “Split Time” and split time
measurement is stopped
(C) Display while measurement is stopped
(D) Dates and times when measurement is started and stopped
To start the split measurement, see the guidance icon and
When the measurement is started, the previous split measure-
ment results (“Average Fuel Consumption Display”, “Operation
Records”, and “ECO Guidance Records”) are reset.
When the confirmation screen is displayed, press enter switch

(1) again to start the split measurement, or press return switch
(2) to cancel the start.
NOTICE
The displayed value of fuel consumption may differ from
the actual value due to the operating conditions of the cus-
tomers (fuel, weather or work contents, etc.).
3-52
ECO GUIDANCE RECORD

From the “ECO Guidance Records” screen, the frequency of
display of the ECO guidance on a daily basis or during the split
measurement period and “Operational Advice” are displayed.
Select “ECO Guidance Records” from the “Energy Saving

Guidance” menu screen, then press enter switch (1).
REMARK
For the definition and display change method of the “1 Day”
and “Split Time” measurements, see “SET DISPLAY OF FUEL
CONSUMPTION GAUGE (3-56)”.
For the ECO guidance, see “ECO GUIDANCE (3-39)”.
In the one-point advice section, the advice to the ECO guid-
ance that appeared most frequently is displayed.
The ECO guidance count increases when display conditions
are satisfied even if the ECO guidance is not displayed.
When “Average Fuel Consumption Display” is set to “1 Day”
When “Average Fuel Consumption Display” is set to “Split Time”, and split time
is mesured
(A) Display during measurement
(B) Date and time when measurement is started
To stop the split measurement, see the guidance icon and
3-53
When display of “Average Fuel Consumption Display” is set to “Split Time”,

and split time measurement is stopped
(C) Display while measurement is stopped
(D) Dates and times when the measurement is started and
stopped
To start the split measurement, see the guidance icon and
When the measurement is started, the previous split measure-
ment results (“Average Fuel Consumption Display”, “Operation
Records”, and “ECO Guidance Records”) are reset.
When the confirmation screen is displayed, press enter switch

(1) again to start the split measurement, or press return switch
(2) to cancel the start.
FUEL CONSUMPTION RECORD

The “Average Fuel Consumption Record” screen alternately
displays the following graphs.
• Average fuel consumption for the “Last 12 hours”
• Average fuel consumption for the “Last 7 days”.
Select “Average Fuel Consumption Record” from the “Energy
Saving Guidance” menu screen, then press ENTER switch (1).
To change a graph, see the guidance icon and press menu
switch (2).
3-54
• When display of the “Last 12 hours” is selected
• When display of the “Last 7 days” is selected
REMARK
The graph of the “Last 12 hours” is updated every hour of the service meter reading.
The graph of the “Last 7 days” is updated every day.
To clear a graph, see the guidance icon and press ENTER
switch (1).
When the confirmation screen is displayed, press ENTER
switch (1) again to clear or press RETURN switch (3) to cancel
clearing.
REMARK
If clearing is performed while the graph of the “Last 12 hours” is
displayed, only the graph of the “Last 12 hours” is cleared.
If clearing is performed while the graph of the “Last 7 days” is
displayed, both graphs of the “Last 12 hours” and “Last 7 days”
are cleared.
3-55
DISPLAY SETTING
On the “Configurations” menu, it is possible to perform follow-
ing settings.
• Setting “Average Fuel Consumption Display”
• Switching ON/OFF of “ECO Gauge Display”
• Setting “ECO Gauge Display Fuel Target Value”
• Switching ON/OFF of ECO guidance
• Switching ON/OFF of “ECO Guidance Display at Key OFF”
Select “Configurations” from “Energy Saving Guidance” menu
screen, then press ENTER switch (1).
SET DISPLAY OF FUEL CONSUMPTION GAUGE

The display of the fuel consumption gauge can be set to the
value on daily basis or during split measurement period.
1. Select “Average Fuel Consumption Display” from “Configu-

rations” menu, then press enter switch (1).
3-56
2. Select “1 Day” or “Split Time”, then press enter switch (1).

The default is “1 Day”.
To cancel, press return switch (2).
“1 Day”
Displays the average fuel consumption in 1 day from 0:00 a.m.
of the day to 0:00 a.m. of the next day.
Reset at 0.00 a.m. of the next day.
“Split Time”
Displays the average fuel consumption during the split meas-
urement period (after the measurement is started until it is finished).
Select “Split Time” to start the split measurement automatically.
REMARK
For the display of the Average Fuel Consumption Display, see “L.H. AND R.H. METER DISPLAY (3-43)”.
Setting of “1 Day” or “Split Time” is also applied to the display of the “Operation Records” and “ECO Guidance
Records”.
When stopping the split measurement, see “OPERATING RECORD (3-51)” or “ECO GUIDANCE RECORD
(3-53)”.
SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE

The is used to change ON/OFF of the ECO gauge.
1. Select “ECO Gauge Display” from the “Configurations”

menu, then press enter switch (1).
3-57
2. Select “ON” or “OFF”, then press enter switch (1).

“ON”
Displays the ECO gauge.
“OFF”
Does not display the ECO gauge.
To cancel sending, press return switch (2).
The default is “ON”.
REMARK
For the ECO gauge, see “ECO GAUGE (3-43)”.
If the “ECO Gauge Display” is set to “OFF”, the items of “ECO
Gauge Display Fuel Target Value” is not indicated.
SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE

ECO Gauge Target Value (A) (the upper limit value of the green
range) can be changed.
1. Select “ECO Gauge Display Fuel Target Value” from the

“Configurations” menu, then press enter switch (1).
3-58
2. Using UP switch (2) or DOWN switch (3) to set the value,

and press enter switch (1).
(2) Up switch
Increases the target fuel consumption value by 1 ℓ/h.
(3) Down switch
Decreases the target fuel consumption value by 1 ℓ/h.
To cancel sending, press return switch (4).
The default is 74 ℓ/h.
REMARK
For the ECO gauge, see “ECO GAUGE (3-43)”.
SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE

Display/non-display of ECO guidance indicated on the standard
screen can be switched.
1. Select “ECO Guidance Display ” from the “Configurations”

3-59

“ON”
Displays the ECO guidance.
“OFF”
Does not display the ECO guidance.
REMARK
For the ECO guidance, see “ECO GUIDANCE (3-39)”.
If the “ECO Guidance Display” is turned “OFF”, display of “ECO
Guidance Display at Key OFF” and “ECO Guidance Record” do
not appear when the starting key is turned “OFF”. The “ECO
Guidance Record”, however, is not reset.
SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF

Display/non-display of the “Operational Advice” indicated on
the end screen when the key is turned to OFF position can be
switched.
1. Select “ECO Guidance Display at Key OFF” from the “Con-

figurations” menu, then press enter switch (1).
3-60

“ON”
Displays the one-point advice on the exit screen.
“OFF”
Does not display the one-point advice on the exit screen.
REMARK
In the “Operational Advice” section indicated on the end
screen, the advice to the ECO guidance that was displayed
most frequently after the starting switch is turned to ON posi-
tion is indicated. Accordingly, the operational advice indicated
on the end screen may be different from the “Operational Ad-
vice” indicated on “ECO GUIDANCE RECORD (3-53)”.
MACHINE SETTING AND INFORMATION

In each item of “Machine Setting and Information” menu (B),
setting and information of the machine are checked or
changed.
RADIATOR FAN REVERSE MODE

k CAUTION
When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc.
will not be wound in the fan.
Since dust may blown up, check that there is no person around while the fan is rotating in reverse.
When cleaning the dirt or dusts stuck to the radiator, you can rotate the fan in the reverse direction.
1. Seat the dump body, stop the engine, and open the engine hood.
3-61
2. Turn the starting switch to ON position, select “Radiator

Fan Reverse Mode” in the “Machine Setting and Informa-
tion” menu, and press enter key (1).
3. Press enter switch (1) to rotate the fan in the reverse direc-
tion, or press return switch (2) to cancel.
If the dump body is not seated or the engine is running, the

screen as shown in the figure appears, and the fan rotation
cannot be switched.
In this case, press return switch (2), and then repeat the
procedure from the first.
4. Fan automatic reverse display (3) lights up.

Start the engine. The fan rotates in reverse.
3-62
If you start the machine travel or operate the dump body

while the fan rotates in reverse, wrong operation in fan re-
verse mode caution lamp (4) lights up.
At the same time, the centralized warning lamp lights up
and alarm buzzer sounds intermittently.
5. After finishing cleaning, stop the engine.
A certain time after the starting switch key is turned to OFF
position, the fan is returned to the normal rotation mode
automatically.
Check that fan automatic reverse display (3) is OFF when
the starting switch is turned ON.
Use the following procedure when restoring the normal rotation manually.
1. Turn the starting switch to ON position again, select “Radi-
ator Fan Reverse Mode” in the “Machine Setting and Infor-
mation” menu, and press enter switch (1).
2. When the screen shown in the figure appears, press enter

switch (1) to return the radiator fan to the normal rotation
mode.
REMARK
When the aftercooler fan is set in the reverse mode, the radia-
tor fan is returned to the normal rotation mode automatically.
If the engine compartment is heated high due to the reverse
mode-based reverse rotation of the fan, the controller may stop
the air conditioner to protect itself from being damaged.
AFTER COOLER FAN REVERSE MODE

k CAUTION
When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc.
When cleaning the dirt or dusts stuck to the aftercooler, you can rotate the fan in the reverse direction.
1. Seat the dump body and stop the engine.
3-63
2. Turn the starting switch to ON position, select “Aftercooler

Fan Reverse Mode” in the “Machine Setting and Informa-
tion” menu, and press enter key (1).
3. Press enter switch (1) to rotate the fan in the reverse direc-
tion, or press return switch (2) to cancel.
If the dump body is not seated or the engine is running, the

screen as shown in the figure appears, and the fan rotation
cannot be switched.
In this case, press return switch (2), and then repeat the
procedure from the first.
4. Fan automatic reverse display (3) lights up.

Start the engine. The fan rotates in reverse.
3-64
If you start the machine travel or operate the dump body

while the fan rotates in reverse, Wrong operation in fan re-
verse mode caution lamp (4) lights up.
At the same time, the centralized warning lamp lights up
and alarm buzzer sounds intermittently.
A certain time after the starting switch key is turned to OFF
position, the fan is returned to the normal rotation mode
automatically.
Check that fan automatic reverse display (3) is OFF when
the starting switch is turned ON.
Use the following procedure when restoring the normal rotation manually.
1. Turn the starting switch to ON position again, select “After-
cooler Fan Reverse Mode” in the “Machine Setting and In-
formation” menu, and press enter key (1).
2. When the screen shown in the figure appears, press enter

switch (1) to return the aftercooler fan to the normal rota-
tion mode.
REMARK
If the radiator fan is set in the reverse mode, the aftercooler fan
is returned to the normal rotation automatically.
PAYLOAD METER
(if equipped)
You can display and set the following items related to the pay-
load meter.
“Accumulated Payload and Total Cycles”
“Average Fuel Consumption Record”
“Machine ID Setting”
“Open ID Setting”
“Calibration”
For detail, see “HANDLING PAYLOAD METER (6-6)”.
KTCS SYSTEM SETTING

Allows setting ON or OFF of the KTCS system.
3-65
1. Select “KTCS Setting”, then press enter switch (1).

“ON”
KTCS operates automatically.
“OFF”
KTCS does not operate.
Display (2) of KTCS out of operation lights up.
REMARK
For function of KTCS, see “HANDLE KOMATSU TRACTION
CONTROL SYSTEM (KTCS) (3-199)”.
This setting is held even after the starting switch key is turned
to OFF position.
DUMPING COUNTER
(if equipped)
The dumping counter is the function that automatically counts and displays the number of loads dumped.
If the dumping counter is not installed on the machine, the “Dumping Counter” is not displayed.
The number of times can be reset according to the following procedure.
3-66
1. Select “Dumping Counter”, then press enter switch (1).
2. Press enter switch (1) to reset or press return switch (2) to

cancel resetting.
REVERSE TRAVEL ODOMETER

The total reverse travel distance can be checked with the “Re-
verse Travel Odometer”.
3-67
TRIP METER
The overall travel distance after the previous resetting can be
checked by using the “Trip Meter”.
You can reset it according to the following procedure.
1. Select “Trip Meter”, then press enter switch (1).
2. Press enter switch (1) to reset or press return switch (2) to

cancel resetting.
D RANGE F1 START SETTING

Use this setting to change the starting gear speed when the gear shift lever is set to D position.
3-68
1. Select “F 1 Start at D Position Setting”, then press enter

switch (1).
2. Select “F 1” or “F 2”, then press enter switch (1).

“F 1”
Starts the machine travel at 1st speed when the gear shift
lever is set to D position.
“F 2”
Starts the machine travel at 2nd speed when the gear shift
lever is set to D position. (Normal)
NOTICE
Select “F 2” usually.
If the machine travels in “F 1” while F1 is not necessary,
the service life of the machine may be shortened.
REMARK
If the machine travels in “F 1” while the dump body is not seated, the gear speed is fixed to the 1st even if the
gear shift lever is in D position.
This setting is held even if the starting switch is turned to OFF position.
The default is “F 2”.
AIR CONDITIONER ECO MODE SETTING

Turns ON or OFF the air conditioner mode that improves the fuel consumption by reducing efficacy of the air
conditioner.
3-69
1. Select “A/C ECO Mode Setting”, then press enter switch

(1).

“ON”
Sets the air conditioner to the ECO mode operation.
“OFF”
Turns on the normal air conditioner operation.
REMARK
If the ambient temperature is above 30 °C or the set tempera-
ture of the air conditioner is 18 °C (maximum cooling), air con-
ditioner may not be operated in the ECO mode, even if the
“A/C ECO Mode Setting” is turned “ON”.
This setting is held even if the starting switch is turned to OFF
position.
The default is “OFF”.
RETARDER CONTROL LEVER CANCEL SOUND SETTING

This is used for selecting ON or OFF of the cancel sound of the retarder control lever.
3-70
1. Select “Retarder Lever Release Sound Setting”, then


“ON”
Generates the cancel sound.
“OFF”
Does not generate the cancel sound.
REMARK
position.
AUTO IDLE STOP TIMER SETTING

Stops the engine automatically when the idle state continued for a predetermined time.
The auto idle stop works only when all of the following conditions are met.
• The accelerator pedal is not depressed.
• Gear shift lever is in NEUTRAL position (N).
• The dump lever is placed in “FLOAT” position and dump body is seated.
(When the dump body float caution lamp is not lit)
• The machine is stopped.
• KDPF regeneration is not performed.
• There is no possibility of overheat.
• The indicator of the engine coolant temperature gauge is
over position (A), and the warm-up operation is finished.
3-71
1. Select “Auto Idle Stop Timer Setting” on “Machine Setting

and Information” menu, and press enter switch (1).
2. Select the operating time of the auto idle stop, and press
enter switch (1).
REMARK
Selecting “OFF” disables operation of the auto idle stop.
3. If the idle state is continued up to 30 seconds before the

current auto idle stop timer setting , the countdown screen
appears on the standard screen.
If you increase the engine speed or set the gear shift lever
to any position other than NEUTRAL position (N) at this
point, the countdown is stopped and the screen returns to
4. If the idle state is further continued and the countdown

reaches 0 second, the engine stops.
At the same time the parking brake is applied.
Turn unnecessary switches to OFF position to prevent the
battery to run out.
REMARK
When the auto idle stop operates while the parking brake is in
“TRAVEL” position, set the parking brake switch to “PARKING”
position and then to “TRAVEL” position again, and the parking
brake is released.
When restarting the engine, turn the starting switch as usual.
3-72
AFTERTREATMENT DEVICES REGENERATION

Each item of “Aftertreatment Devices Regeneration” menu (C)
is for settings and operations of the aftertreatment devices re-
generation.
For details of aftertreatment devices regeneration, see “HAN-
DLE Komatsu Diesel Particulate Filter (KDPF) (3-121)”.
The operation methods and the contents of the display of
KDPF regeneration and urea SCR regeneration are common.
SCR INFORMATION
Each item in “SCR Information” menu (D) is for displaying the
information related to SCR and DEF.
For details of “SCR Information”, see “HANDLE UREA SCR
SYSTEM WARNING (3-132)”.
MAINTENANCE SCREEN SETTING

Each item on “Maintenance” menu screen (E) is used for dis-
playing and setting the notification relevant to maintenance.
On the “Maintenance” menu screen, the maintenance items in
the table, their replacement intervals, and remaining time to the
next replacement are displayed.
Replacement interval (h)

Maintenance item
(Default)
Air Cleaner Cleaning or Change -
Engine Oil Change 500
Engine Oil Filter Change 500
Fuel Prefilter Change 500
T/M Oil and Brake Oil Change 1000
T/M Oil Filter Change 1000
Brake System Oil Filter Change 1000
Brake Cooling Oil Filter Change 1000
Fuel Main Filter Change 1000
Hydraulic Oil Filter Change 1000
DEF Tank Breather 1000
Hyd Oil Tank Breather Change 2000
3-73
Replacement interval (h)

Maintenance item
(Default)
Differential Oil Change 2000
Final Drive Oil Change 2000
KCCV Filter Change 2000
DEF Filter 2000
Hydraulic Oil Change 4000
KDPF Filter Cleaning 4500
Fuel Doser Cleaning 4500
DEF Tank Cleaning 4500
When the time remaining to the next maintenance for any item
is less than the maintenance notice time (initial setting: 30
hours), the “Remain” (1) is highlighted in yellow.
When the time remaining to the maintenance becomes 0
hours, the “Remain” (1) is highlighted in red. The time after the
replacement interval is indicated with the negative symbol.
If any item is displayed in red, perform the maintenance for it
immediately.
REMARK
The replacement interval in “Air Cleaner Cleaning or Change”
is not set initially.
If you want to change the setting for the maintenance interval
and the maintenance notice time, consult your Komatsu distrib-
utor.
When the maintenance time caution (2) is lit on the standard
screen, press the menu switch, and the screen automatically
displays the “Maintenance” menu screen (E).
RESET REMAINING TIME FOR MAINTENANCE

After performing maintenance, reset the remaining time for maintenance according to the following procedure.
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1. On the “Maintenance” menu screen, select an item to reset

the remaining time, then keep pressing enter switch (1) for
more than 1.5 seconds.
REMARK
If enter switch (1) is not pressed for enough time, the
switch operating sound can be heard, but the screen does
not switch to the screen for resetting the remaining time for
maintenance.
When a password for restriction of use has been set, the

password input screen is displayed.
Input the password for restriction of use by using the nu-
meric keypad, then press enter key (1).
REMARK
For the setting, changing, or canceling the password, ask
your Komatsu distributor.
2. The screen changes to “Maintenance Due Time Reset”

screen.
When enter switch (1) is pressed, the following reconfirma-
tion screen is displayed.
3. On the re-confirmation screen shown in the figure, when

enter switch (1) is pressed again, the remaining time is re-
set and the screen returns to the “Maintenance” menu
screen.
REMARK
If the remaining time and the replacement interval are the
same, the remaining time cannot be reset.
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MONITOR SETTINGS
Each item of “Monitor Setting” menu (F) is to make settings for
the machine monitor.
REAR VIEW MONITOR SETTING

This is used to set the rearview monitor.
Select “Rearview Monitor Setting” on the “Monitor Setting”
menu screen, and press enter switch (1).
Reference line display

The is used to change ON/OFF of the reference line on the rearview monitor.
1. Select “Guide Line Display Mode” from the “Rearview
Monitor Setting” menu, and press enter switch (1).
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“ON”
Displays the reference line.
“OFF”
Hides the reference line.
REMARK
For the rearview monitor and the reference line, see “HANDLE
REAR VIEW MONITOR (3-118)” and “METHOD FOR AD-
JUSTING REAR VIEW CAMERA ANGLE (3-169)”.
This setting is held even if the starting switch is turned to OFF position.
REVERSE-INTERLOCK ENABLED MODE

In this mode, display method of rear view monitor can be changed by switching ON/OFF.
1. Select “Reverse-interlock Selection mode” on the “Rear-
view Monitor Setting” menu, then press ENTER switch (1).
2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays images on the rear view monitor only when trav-
eling in reverse.
“OFF”
Always displays images on the rear view monitor.
REMARK
position.
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METER DISPLAY SELECTION

This is used for the selection of the items to be displayed on
L.H. meter display (A) or R.H. meter display (B).
“Meter Display Selection” on the “Monitor Setting” menu

SELECT L.H. METER DISPLAY

This is used for the selection of the items to be displayed on the L.H. meter display.
3-78
1. Select “LH Meter Display Selection” on the “Meter Display

Selection” menu, then press enter switch (1).
2. Select the items to be displayed, then press enter switch

(1).
The following 3 items can be selected.
• “SMR: Service Meter”
• “ODO: Odometer”(Odometer)
• “CLK: Clock”
REMARK
For details of each item, see “L.H. AND R.H. METER DISPLAY
(3-43)”.
The default of L.H. meter is “SMR: Service Meter”.
SELECT R.H. METER DISPLAY

This is used for the selection of the items to be indicated on the R.H. meter display.
3-79
1. Select “RH Meter Display Selection” on the “Meter Display

Selection” menu, then press enter switch (1).
2. Select the items to be displayed, then press enter switch

(1).
The following 4 items can be selected.
• “FUEL: Average Fuel Consumption”
• “SMR : Service Meter”
• “ODO : Odometer”(Odometer)
• “CLK: Clock”
REMARK
For details of each item, see “L.H. AND R.H. METER DISPLAY
(3-43)”.
The default of R.H. meter is “FUEL: Average Fuel Consump-
tion”
SCREEN ADJUSTMENT
This function is used for the adjustment of brightness of the machine monitor.
1. Select “Screen Adjustment” on the “Monitor Setting”
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2. Adjust the brightness by using the switch panel.

The brightness can be adjusted individually in the day and
night modes.
(1) Menu switch
Brightness is set to default.
(2) Up switch
Brightness increases. (Moves the indicator to the right by
one division.)
(3) Down switch
Brightness decreases. (Moves the indicator to the left by
one division.)
(4) Return switch
Cancels the change and returns to “Monitor Setting” menu.
(5) Enter switch
Accepts the change and then returns to “Monitor Setting”
menu.
REMARK
When the screen is adjusted while the lamp switch is turned
OFF, the brightness in the day mode can be adjusted.
Turn the lamp switch ON, then adjust the screen when the the
monitor brightness selector switch is set to the night mode, the
brightness in the night mode can be adjusted.
The brightness of night illumination for the switch panel, gear
shift lever, and operation switches is adjusted synchronously
with the brightness of the machine monitor.
CLOCK ADJUSTMENT
On the clock adjustment menu, you can change the setting of
the clock displayed on the standard screen.
The following items can be changed.
“GPS Synchronization”
“Calendar”
“Time”
“12hour or 24hour Mode”
“Daylight Saving Time”
Select “Clock Adjustment” on the “Monitor Setting” menu
REMARK
After a long-term storage of the machine, Calendar and Time
are reset, so you must readjust them.
When the “GPS Synchronization” is set to “ON”, the above are
automatically readjusted.
GPS SYNCHRONIZATION
On the machines equipped with KOMTRAX, you can configure automatic setting of the machine monitor's date
and time in accordance with the GPS's clock.
3-81
1. Select “GPS Synchronization” from the “Clock Adjustment”


“ON”
Sets the date and time automatically.
“OFF”
Does not set the date and time automatically. (Can be set
manually.)
REMARK
position.
When the machine is in the environment where the radio
waves from GPS cannot be received, the automatic setting
function might be disable.
Turning the “GPS Synchronization” “ON” disables selecting the
“Calendar” and “Time”.
CALENDAR SETTING
Adjust the date of the machine monitor.
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1. Select “Calendar” from the “Clock Adjustment” menu, then

REMARK
As long as “ON” is selected for the “GPS Synchronization”,
“Calendar” is not selectable.
2. The “Calendar” screen is displayed.

When year display (A) is highlighted in yellow, operate the
switches as follows to change year display.
When it is not necessary to change the year setting, press
enter switch (4).
(1) Up switch
Advances calendar one year.
(2) Down switch
Put Calendar back one year.
(3) Return switch
Cancels the change and returns the screen to “Clock Adjustment” menu.
(4) Enter switch
Proceeds to setting for month.
3. When month display (B) is highlighted in yellow, operate
the switches as follows to change month display.
When it is not necessary to change the month setting,
(1) Up switch
Advances calendar one month.
(2) Down switch
Put calendar back one month.
(3) Return switch
Cancels change and returns to setting for year.
(4) Enter switch
Proceeds to setting for day.
3-83
4. When day display (C) is highlighted in yellow, operate the

switches as follows to change day display.
When it is not necessary to change the day setting, press
enter switch (4).
(1) Up switch
Advances calendar one day.
(2) Down switch
Put calendar back one day.
(3) Return switch
Cancels change and returns to setting for month.
(4) Enter switch
Accepts change and returns the screen to the “Clock Adjustment” screen.
TIME SETTING
Adjust the time of the machine monitor clock.
1. Select “Time” from the “Clock Adjustment” menu, and
REMARK
If “ON” is selected for the setting of “GPS Synchroniza-
tion”, you cannot select the “Time”.
2. The “Time” screen is displayed.

When time display (D) is highlighted in yellow, operate the
switches as follows to change time display.
When it is not necessary to change the time setting, press
enter switch (4).
(1) Up switch
Advances time one hour.
(2) Down switch
Puts time back one hour.
(3) Return switch
Cancels change and returns screen to “Clock Adjustment” menu.
(4) Enter switch
Proceeds to setting for minute.
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3. When minute display (E) is highlighted in yellow, operate

the switches as follows to change minute display.
When it is not necessary to change the minute setting,
(1) Up switch
Advances time 1 minute.
(2) Down switch
Puts time back 1 minute.
(3) Return switch
Cancels change and returns to the time setting screen.
(4) Enter switch
Accepts change and returns the screen to the “Clock Adjustment” screen.
12-HOUR AND 24-HOUR DISPLAY MODE

Choose either a 12-hour display (am/pm) or a 24-hour display.
1. Select “12hour or 24hour Mode” from the “Clock Adjust-
ment” menu, then press enter switch (1).
2. Select “12hour” or “24hour”, then press enter switch (1).

“12hour”
Select 12H display (AM, PM).
“24hour”
Select 24H display.
REMARK
position.
The default is “24hour”.
DAYLIGHT SAVING TIME (SUMMER TIME)

Set the clock display based on the Daylight Saving Time.
3-85
1. Select “Daylight Saving Time” from the “Clock Adjustment”


“ON”
Displays the time 1 hour earlier.
“OFF”
Returns the time to the original.
REMARK
Daylight saving time (summer time) means setting the clock
ahead 1 hour to make the better use of daytime for everyday
life.
position.
LANGUAGE SETTINGS
The language displayed on the machine monitor can be selected.
The languages that can be selected are as follows.
English, Japanese, French, Spanish, Portuguese, Italian, German, Swedish, Dutch, Danish, Norwegian, Fin-
nish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Romanian, Croatian, Estonian, Latvian, Lithuanian,
Bulgarian, Greek, Serbian, Turkish
3-86
1. Select “Language Setting” on the “Monitor Setting” menu

2. Select the language to be displayed, then press ENTER

switch (1).
REMARK
position.
OPERATOR ID
You can check and change the “Operator ID” which is under identification on the “Operator ID” menu.
The “Operator ID” menu is not displayed when the operator identification function is disabled.
REMARK
Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi-
fication function.
WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP

When the starting switch is ON and ID is inputted, the identified
ID is displayed in the column of “Operator ID” on the “Monitor
Setting” menu screen.
3-87
When the starting switch is ON and “SKIP” is selected, “****” is

displayed in the column of “Operator ID” on the “Monitor Set-
ting” menu screen.
1. Select “Operator ID” on the “Monitor Setting” menu screen,

then ENTER switch (1) for 1 second.
2. The “Operator ID Change” screen is displayed.
• Input the already registered ID on the “Operator ID

Change” screen and press ENTER switch (1). Then,
the identified ID can be changed.
A message is displayed below and the screen returns
to the “Monitor Setting” menu screen.
On the “Monitor Setting” menu screen, the inputted ID
is displayed in the column of “Operator ID”.
3-88
• When you press menu switch (2) on the “Operator ID

Change” screen, a message is displayed below and
the screen returns to the “Monitor Setting” menu
screen.
On the “Monitor Setting” menu screen, as the same
way when the starting switch is ON and “SKIP” is se-
lected, “****” is displayed in the column of “Operator
ID”.
In this case, the operator ID is not identified.
• When you press ENTER switch (1) after inputting the

ID which is not registered to the “Operator ID Change”
screen, a message is displayed below and the screen
returns to the “Monitor Setting” menu screen.
In this case, the identified ID is not changed.
• On the “Operator ID” screen, if no switch is operated
for more than 30 seconds, the screen automatically
changes to the “Monitor Setting” menu screen.
WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP

When the operator identification function is available without
SKIP, the identified ID number is not displayed in the “Operator
ID” column of “Monitor Setting” screen.
1. Select “Operator ID” on the “Monitor Setting” menu screen,

then ENTER switch (1) for 1 second.
2. The “Operator ID Change” screen is displayed.
3-89
• Input the already registered ID on the “Operator ID

Change” screen and press ENTER switch (1). Then,
the identified ID can be changed.
A message is displayed below and the screen returns
to the “Monitor Setting” menu screen.
• When you press ENTER switch (1) after inputting the

ID which is not registered to the “Operator ID Change”
screen, a message is displayed below and the screen
returns to the “Monitor Setting” menu screen.
• On the “Operator ID” screen, if no switch is operated
for more than 30 seconds, the screen automatically
changes to the “Monitor Setting” menu screen.
MESSAGE DISPLAY
On machines equipped with KOMTRAX, you can see the mes-
sages from your Komatsu distributor on this User Message
menu (G).
When there is any message, message display (1) of the stand-

ard screen lights up.
(A): There is unread message.

(B): There is any read message to which no reply is made.
Reply to the message in accordance with the replying method
mentioned later.
3-90
REMARK
• While message display (1) is lit on the standard screen,
when menu switch (2) is pressed, message display menu
screen (G) appears automatically.
• When the starting switch is turned OFF while there is any
unread message, the message is displayed on the end
screen, and when the monitor is started next time, the
message changes to a read message.
• The message is deleted when it becomes out of date or
when a new message reaches.
CHECK MESSAGE
Select message display menu screen (G), and you can read
the arrived message.
(A) Subject of message
When no message has been received, “No message.” is dis-
played.
(B) Serial No. of message
(C) Validity
(D) Text
(E) Reply field
In case of a message requesting for reply, the “Numeric Input: [ ]” is displayed. Make any reply to the message.
REPLY TO MESSAGE
1. When replying to a message, input the selected item num-
ber shown in the text of the message by using the switch
panel.
• Each switch of the switch panel corresponds to the
number shown on the lower right of the switch.
• The input number is displayed in “Numeric Input: [ ]”of
the reply field.
• If you input an incorrect number, press RETURN
switch (1), and you can clear an input character at a
time.
• If RETURN switch (1) is pressed while no number is entered, the display returns to the standard
screen.
2. After inputting a selected item number, press ENTER
switch (2).
3-91
3. “Do you send Numeric Input?” When this message is dis-

played, press ENTER switch (2) again.
The input value will be sent out.
To cancel, press RETURN switch (1).
The input number is cleared.
REMARK
If the message is replied, “Numeric Input (Done)” is displayed
for it.
OTHER FUNCTIONS OF MACHINE MONITOR

Confirm the service meter or odometer when the starting switch key is set to
OFF position
The service meter and odometer can be displayed even if the machine monitor is not turned ON.
1. Press UP switch (2) while holding down DOWN switch (1)
when the starting switch is in OFF position.
Service meter (A) and odometer (B) are displayed while

both switches are held down.
NOTICE
If the monitor screen is displayed during other operations
while the starting switch is at OFF position, there is proba-
bly a failure in the equipment, so ask your Komatsu dis-
tributor for inspection.
3-92
SWITCHES
(1) Starting switch (14) AISS LOW switch

(2) Cigarette lighter (15) Engine power mode selector switch
(3) Lamp switch, dimmer switch, turn signal lever (16) Parking brake switch
(4) Windshield wiper and window washer switch (17) Shift hold switch
(5) Horn button (18) Fog lamp switch (if equipped)
(6) Monitor brightness selector switch (19) Power window switch
(7) Working lamp switch (20) Side lamp switch
(8) Mirror heater switch (if equipped) (21) Revolving lamp switch (if equipped)
(9) Hazard lamp switch (22) Engine shutdown secondary switch
(10) Secondary steering switch (23) Room lamp 1 switch
(11) Brightness adjustment switch of rear view monitor (24) Room lamp 2 switch
(12) Inter-axle differential lock switch
(13) Automatic retarder and accelerator linked control
switch (if equipped)
STARTING SWITCH
Starting switch is used to start or stop the engine.
(A) OFF position
The key can be removed from the starting switch, the electrical
current to the electrical system is cut, and the engine stops.
REMARK
Even when the starting switch is at OFF position, the horn, haz-
ard lamp, secondary steering, and room lamp 1 operate.
(B) ON position
The electrical current flows to the electrical system.
Keep the starting switch key at ON position while the engine is
running.
3-93
Controller may detect a failure if the starting switch is held at a position between ON and OFF when turning the
starting switch to ON or OFF position.
In such case, return the starting switch to OFF position, then turn it to ON position again.
In cold weather, when the key is turned to ON position, engine preheating starts automatically and the preheat-
ing pilot lamp lights up.
When preheating is completed, the preheating pilot lamp goes out.
(C) START position
This is the position to start the engine.
Hold the key at this position while cranking, and release it immediately after the engine starts.
The key will return to ON position when released.
(D) PREHEAT position
While the key is at PREHEAT position, the engine is preheated manually.
The preheating pilot lamp lights up while the engine is preheated.
When preheating manually, see “METHOD FOR MANUAL PREHEATING WHEN STARTING ENGINE (3-179)”.
CIGARETTE LIGHTER
The cigarette lighter is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after several seconds, then pull it out and use it to
light your cigarette.
If the cigarette lighter is removed, the socket can be used as an
84 W (12 V x 7 A) power supply.
LAMP SWITCH
The lamp switch is used to turn ON and OFF the headlamp (low beam), clearance lamp, and tail lamp.
(A): OFF position
The lamps go out.
(B): ON position
Clearance lamp and tail lamp light up.
(C): ON (headlamp lighting) position
Clearance lamp, tail lamp and headlamp (low beam) light up.
When the lamp switch is turned ON, the clearance pilot lamp
and the night lamp for switches light up.
When the monitor brightness selector switch is set to the night
mode, the machine monitor and rear view monitor are dimmed.
The lamp switch can be switched regardless of the position of the turn signal lever.
3-94
DIMMER SWITCH
The dimmer switch is used to turn the headlamps (high beam) ON or OFF.
When the lamp switch is ON
Each time the dimmer switch is operated up to (A), the head-
lamp (high beam) is turned ON or OFF alternately. When the
switch is released, it automatically returns to original position
(B).
When the lamp switch is OFF
Only the headlamp (high beam) lights up while the dimmer
switch is operated up to (A).
When the headlamps (high beam) are lit, the headlamp (high
beam) pilot lamp lights up.
TURN SIGNAL LEVER

The turn signal lever is used to flash the turn signal lamps.
(A) Turn to right
Push the lever forward
(B) Turn to left
Pull the lever back to this side
When the lever is operated, the turn signal pilot lamp also
flashes.
The lever returns automatically when the steering wheel is
turned back. If the lever does not return, move it by hand.
WIPER, WINDOW WASHER SWITCH

The windshield wiper and window washer switch is used to operate the wiper for the front glass and rear glass.
NOTICE
Using the wiper when the glass is dry will scratch the glass. Spray with window washer fluid before ac-
tuating the wiper.
Front wiper
Turn lever (E), and the front wiper operates.
Position (A) (OFF)
Stop
Position (B) (INT)
The wiper operates at intervals of 4 to 7 seconds.
Position (C) (LOW)
The wiper operates at low speed.
Position (D) (HI)
The wiper operates at high speed.
When button (F) at the tip of the switch is pressed, washer fluid is sprayed out.
Do not keep pressing the window washer switch for more than 10 seconds.
3-95
Rear wiper
Turn lever (E), and the rear wiper operates.
Position (A)
Washer fluid is sprayed out.
Position (B) (OFF)
Stop
Position (C)
The windshield wiper operates.
Position (D)
Wiper operates and washer fluid is sprayed out simultaneously.
HORN BUTTON
When the horn button at the center of the steering wheel is
pressed, the horn sounds.
NOTICE
If the horn is sounded continuously (the horn button is
kept pressed), its service life is shortened.
Avoid continuous use except in an emergency.
MONITOR BRIGHTNESS SELECTOR SWITCH

The monitor brightness selector switch is used to select the
brightness (luminosity) of the machine monitor and rear view
monitor while lamp switch is turned ON.
When operating the machine with the headlamp lighting up dur-
ing the day, if this switch is set to Day mode, monitor screen
does not loose the brightness.
(A) Day position
The monitor screen is set to the day mode.
(B) Night position
The monitor screen is set to the night mode.
REMARK
When the lamp switch is turned to OFF position, operating this switch does not change the brightness.
For the fine adjustment method of brightness of the machine monitor, see “SCREEN ADJUSTMENT (3-80)”.
For the fine adjustment method of brightness of the rear view monitor, see “BRIGHTNESS ADJUSTMENT
SWITCH OF REAR VIEW MONITOR (3-98)”.
3-96
WORKING LAMP SWITCH

The working lamp switch is used to turn the working lamp ON
or OFF.
Position (A)
Working lamp lights up.
Position (B)
Working lamp goes out.
SWITCH FOR MIRROR WITH HEATED WIRE

(if equipped)
Heated mirror switch is used to turn the heater for side view
mirrors ON or OFF.
Position (A)
Wire heater ON
Position (B)
Wire heater OFF
REMARK
The wire heater does not automatically turn OFF when it be-
comes hot, so when it is not needed, turn the switch manually
to OFF position.
HAZARD LAMP SWITCH

The hazard lamp switch is used to flash the R.H. and L.H. turn
signal lamps.
Position (A)
The turn signal lamps and the turn signal pilot lamp flash.
Position (B)
The turn signal lamps and the turn signal pilot lamp go out.
SECONDARY STEERING SWITCH

k WARNING
Do not use the secondary steering pump for more than 90 seconds.
If it is used continuously for more than that, motor may get burn out or get damaged, or that it may
cause a fire.
3-97
The secondary steering switch is used to operate the secon-

dary steering.
When this switch is pressed, the secondary steering operates
and the operator can steer the machine.
When this switch is turned ON or the secondary steering oper-
ates automatically, the pilot lamp (red) in the switch and the
secondary steering pilot lamp light up.
When using the secondary steering, limit the travel speed to
5 km/h.
The secondary steering operates automatically in the following
cases.
• When the steering oil pressure drops abnormally
• When the engine stops during operation
When the secondary steering operates, stop the machine immediately and check it.
When the engine stops, if the starting switch is at ON position and the parking brake switch is at “TRAVEL”
position, the secondary steering operates automatically after 1 second. To prevent this, set the parking brake
switch to “PARKING” position.
BRIGHTNESS ADJUSTMENT SWITCH OF REAR VIEW MONITOR

The brightness adjustment switch of rear view monitor is used
to adjust the brightness of the rearview monitor.
The brightness in the day and night modes can be adjusted in-
dividually.
Position (A)
The rearview monitor becomes brighter.
Position (B)
The rearview monitor becomes darker.
INTER-AXLE DIFFERENTIAL LOCK SWITCH

The inter-axle differential lock switch is used to select the differential mode of the inter-axle differential lock.
Set it to AUTO when traveling on a normal ground.
(A) MANUAL
The inter-axle differential lock is actuated while the shift range
(gear speed) is at F3, F2, F1, R1, or R2, and the machine is
not turning.
During traveling on dry sandy ground, etc., tires may slip and
machine may be vibrated up and down. In this case, set it to
MANUAL in advance.
(B) AUTO
Ability to travel through or escape from soft ground is improved
when KTCS operates. The inter-axle differential lock operates automatically to stabilize the machine when the
brake is applied or the gear is shifted.
REMARK
Regardless of the position of the switch, when the inter-axle differential lock operates, the inter-axle differential
lock pilot lamp lights up.
For operating inter-axle differential lock, see “OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK (3-196)”.
AUTOMATIC RETARDER, ACCELERATOR LINKED CONTROL SWITCH

(if equipped)
3-98
The automatic retarder and accelerator linked switch is used to

turn ON or OFF the ARAC (Automatic Retarder Accelerator
Control).
Position (A)
The automatic retarder, accelerator linked control system oper-
ates and the retarder pilot lamp lights up.
Position (B)
The automatic retarder, accelerator linked control system does
not operate.
AISS LOW SWITCH

NOTICE
During aftertreatment devices regeneration, the idle speed is set to rather high regardless of ON or OFF
of AISS LOW switch.
AISS LOW switch is used to switch the AISS functions.
AISS (Automatic Idling Setting System) adjusts the low idle
speed automatically depending on the engine coolant tempera-
ture and operating situations.
(A) AISS LOW switch ON
Use this switch position when fine start control is needed such
as when putting the machine into the garage.
The low idle speed is fixed to a rather low level.
REMARK
When the automatic warm-up is turned on, this switch position
stops it, and set a low idle speed to a rather low level.
(B) AISS LOW switch OFF
Use this switch position for the normal operation.
AISS function is actuated to produce the states described below.
• When the engine coolant temperature is low, this switch position automatically sets the idle speed to a high-
er level. (Automatic warm-up function)
• When the parking brake or retarder brake is applied, the idle speed is automatically set to a rather low level
in order to reduce fuel consumption when the machine is stopped.
REMARK
While the automatic warm-up is turned on, the idle speed is not set to low even if the parking brake or retarder
brake is applied.
For the automatic warm-up, see “AUTOMATIC WARM-UP FUNCTION (3-182)”.
3-99
ENGINE POWER MODE SELECTOR SWITCH

The engine power mode selector switch is used to shift the op-
timum power mode for economical operation depending on the
operation condition..
(A): Economy mode (operations on a flat ground)
Use this mode for the operation with emphasis on fuel con-
sumption, such as operation on flat ground where the maxi-
mum power is not needed.
The economy mode pilot lamp lights up on the machine moni-
tor.
(B): Power mode (general operations)
Use this mode for the normal standard operation.
The power mode pilot lamp lights up on the machine monitor.
PARKING BRAKE SWITCH

k WARNING
When parking or leaving the machine, always apply the parking brake.
The parking brake switch is used to actuate and release the

parking brake.
(A) Parking
The parking brake is applied.
When this switch is set to PARKING position, the parking brake
pilot lamp lights up on the machine monitor.
When the switch is set to PARKING position, if the gear shift
lever is at any position other than NEUTRAL position (N), the
centralized warning lamp flashes and the alarm buzzer sounds
intermittently.
(B) Travel
The parking brake is released.
REMARK
If the engine is stopped when the parking brake switch is set to
TRAVEL, the parking brake is applied automatically.
When starting the engine again, set the parking brake switch to
PARKING, and then set it back to TRAVEL to release the park-
ing brake.
NOTICE
During loading operations, do not apply the parking brake.
Apply the retarder brake.
3-100
SHIFT HOLD SWITCH

The shift hold switch is used to actuate the shift hold function.
When the shift hold switch is pressed once, the shift hold pilot
lamp lights up and the shift hold function is actuated.
When the shift hold function is actuated, the gear speed is not
shifted up from the current level.
The shift hold function can be canceled by setting the gear shift
lever to another position or pressing the shift hold switch once
more.
If the travel speed drops excessively when the shift hold func-
tion is being actuated, the transmission shifts down, but when
the travel speed increases, the transmission is held at the original speed range
When the travel hunts (it is shifted up and down repeatedly at short intervals), depending on the road condition,
uphill grade, or loading condition, fix the transmission to a lower gear speed to improve the operator comfort and
protect the transmission.
FOG LAMP SWITCH

(if equipped)
The fog lamp switch is used to turn the fog lamp ON or OFF.
Position (A)
Fog lamp lights up.
Position (B)
Fog lamp goes out.
POWER WINDOW SWITCH

k WARNING
When closing the window glass, be careful not to catch anyone's hands or head in the window.
There is a danger of serious injury if anyone is caught in the window glass.
k CAUTION
After fully opening or fully closing the window glass, do not keep operating the switch.
If the switch is kept operated, it may cause failure of the power window.
The power window switch is used to open and close L.H. win-
dow glass. This switch can only be used when the starting
switch is at ON position.
Position (A)
Glass goes up.
Position (B)
Glass goes down.
When the glass reaches the top or bottom and stops, release
the switch.
3-101
SIDE LAMP SWITCH

The side lamp switch is used to turn the side lamp ON or OFF.
Position (A)
Side lamp lights up.
Position (B)
Side lamp goes out.
ROOM LAMP1 SWITCH

Room lamp 1 switch is used to turn room lamp 1 ON or OFF.
Position (A)
OFF
Position (B)
Lights up when the cab door opens.
Position (C)
Lights up
REMARK
• The room lamp lights up even when the starting switch is
at OFF position, so when leaving the operator's compart-
ment, set the switch to position (A) or (B).
• When performing operations with the door fully opened,
set the switch to position (A).
ROOM LAMP2 SWITCH

Room lamp 2 switch is used to turn room lamp 2 ON or OFF.
Position (A)
Lamp goes out.
Position (B)
Lamp lights up.
REVOLVING LAMP SWITCH

(if equipped)
The revolving lamp switch is used to turn the yellow revolving
lamp ON or OFF.
Position (A)
Yellow revolving lamp lights up.
Position (B)
Yellow revolving lamp goes out.
3-102
ENGINE SHUTDOWN SECONDARY SWITCH

NOTICE
The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to
OFF position but the engine does not stop.
Do not use it except for emergency. Contact your Komatsu distributor for repair immediately when there
is any abnormality on this switch.
1. Raise cover (1) and open it.
2. When the engine shutdown secondary switch is set to the

STOP ENGINE position, the engine stops, and after 3 sec-
onds, “Engine Shutdown Secondary SW in Operation” is
displayed on the machine monitor, and the alarm buzzer
sounds intermittently.
(A): STOP ENGINE (when abnormal)
(B): Normal
REMARK
• When cover (1) is closed, the engine shutdown secondary
switch automatically returns to NORMAL position (B).
• While engine shutdown secondary switch is at the STOP
ENGINE position, if the starting switch is turned ON, “En-
gine Shutdown Secondary SW in Operation” is displayed,
and the alarm buzzer sounds intermittently.
If this message is displayed when the machine is normal,
check that the switch cover is closed and the engine shut-
down secondary switch is in NORMAL position. If not, set
it to NORMAL position.
3-103
CONTROL LEVERS AND PEDALS
(1) Brake pedal (4) Retarder control lever

(2) Accelerator pedal (5) Dump lever
(3) Gear shift lever (6) Dump lever lock knob
BRAKE PEDAL
The brake pedal is used to apply the wheel brakes.
ACCELERATOR PEDAL
Use the accelerator pedal to control the engine speed.
It can be operated freely from low idle to full throttle.
3-104
GEAR SHIFT LEVER

Select the gear shift range with the gear shift lever according to
the travel conditions.
.
Position D
This is used for the normal travel.
When position D is used, the transmission is set automatically
between 2nd or 1st torque converter drive and 6th gear accord-
ing to the travel speed.
Transmission is fixed to 2nd or 1st speed and is not changed
while the dump body is raised. Keep the dump body lowered
during the travel.
The maximum travel speed in position D is 55.9 km/h.
Positions 5 to 1
Use these positions when traveling on soft ground or places where it is difficult to travel at high speed, when
starting uphill with the machine loaded, or when traveling downhill with engine brake.
Transmission is fixed to the 1st speed and is not changed while the dump body is raised.
Keep the dump body lowered during the travel.
Position R1
This is used when traveling in reverse.
Transmission is fixed in reverse 1st and the travel is performed in torque converter drive or direct drive accord-
ing to the travel speed while position R1 is used.
The maximum travel speed in position R1 is 6.8 km/h.
Position R2
This is used when traveling in reverse.
Transmission is fixed in reverse 2nd and the travel is performed in torque converter drive or direct drive accord-
ing to the travel speed while position R2 is used.
The maximum travel speed in position R2 is 16.0 km/h.
The machine cannot travel in reverse while the dump body is raised.
Lower the dump body, set the dump lever to “FLOAT”, then operate the gear shift lever to R1 or R2.
REMARK
If driving the machine with the dump body not seated, the speed range is fixed at 2nd or 1st in D position, and
transmission can not be shifted. In position 5 to 1, the speed range is fixed at 1st position, and transmission can
not be shifted. (This conforms to EU safety standard (EN474-6 5.1.3).
Automatic gear shifting range in each position

Position Speed range Max. speed
R2 R2 torque converter to direct 16.0 km/h
R1 R1 torque converter to direct 6.8 km/h
D 2nd or 1st torque converter to 6th direct 55.9 km/h
5 1st torque converter to 5th direct 36.5 km/h
4 1st torque converter to 4th direct 23.7 km/h
3 1st torque converter to 3rd direct 15.5 km/h
2 1st torque converter to 2nd direct 10.1 km/h
1 1st torque converter to 1st direct 6.6 km/h
3-105
For selection of start in 2nd or 1st gear speed in position D, see “D RANGE F1 START SETTING (3-68)”.
Do not set the gear shift lever to NEUTRAL position (N) position during the travel.
When performing directional selection, stop the machine completely and run the engine at low idle.
When starting the engine, if the gear shift lever is in any position other than NEUTRAL (N), the engine will not
start.
When the starting switch is turned from OFF position to ON position, if the gear shift lever is in any position
other than NEUTRAL (N), the shift lever position pilot lamp flashes, the centralized warning lamp lights up, and
the alarm buzzer sounds. If the gear shift lever is turned to NEUTRAL position (N), the lamps will go out and the
buzzer will stop.
When the parking brake is applied, if the gear shift lever is in any position other than NEUTRAL (N), the central-
ized warning lamp will light up and the alarm buzzer will sound.
If the gear shift lever is set to any position other than NEUTRAL (N) when the dump lever is at a position other
than “FLOAT” or the dump body is still raised, the centralized warning lamp will light up and the alarm buzzer
will sound.
Always place the gear shift lever securely in position when operating it.
If the gear shift lever is not placed securely in position, the shift lever position pilot lamp on the machine monitor
may start flashing and the centralized warning lamp may light up, and the alarm buzzer may sound.
When shifting the gear shift lever from NEUTRAL position (N)
to D (FORWARD) or R1 (REVERSE), release the accelerator
pedal, set the engine speed at low idle, then press the lock but-
ton of gear shift lever to operate.
Pressing the shift hold switch actuates the shift hold function.
For details of the shift hold function, see “SHIFT HOLD
SWITCH (3-101)”.
RETARDER CONTROL LEVER

k CAUTION
The retarder must not be used as a parking brake.
The retarder control lever is used to operate the retarder when

traveling downhill.
The more the retarder control lever is pulled toward you, the
greater the braking force becomes.
When the retarder operates, the retarder pilot lamp lights up on
the machine monitor.
When leaving the operator's seat, always apply the parking brake.
3-106
REMARK
While the ARAC (Automatic Retarder Accelerator Control) is in operation, a certain play is induced at start when
the retarder control lever is pulled. Such play is not because the retarder is out of action. It is within the range
employed in the ARAC (Automatic Retarder Accelerator Control).
DUMP LEVER
k CAUTION
To prevent damage to the dump body caused by vibration
from the road, always lower the dump body when traveling
and set the dump lever to “FLOAT” position.
The dump lever used for operating the dump body.

(A) RAISE
(B) HOLD: The dump body remains in the position where it was
stopped.
(C) FLOAT: The dump body moves freely under external force.
(D) LOWER
Always set it to “FLOAT” position when traveling.
The machine cannot be driven in reverse when the dump body is raised.
If the engine stops, the dump body is held in “HOLD” condition, regardless of the position of the dump lever.
When the engine is started again, the dump body is held in HOLD condition and the dump body float caution
lamp lights up.
For method to cancel “HOLD” condition, see “METHOD FOR CANCELING TO HOLD DUMP BODY (3-181)”.
DUMP LEVER LOCK KNOB

k WARNING
When performing inspection with the dump body raised,
always set the dump lever to HOLD position, lock it with
the dump lever lock knob, and use the body pivot pin.
The dump lever lock knob is a locking device for the dump lev-
er.
To set it to FREE position (F), pull the lock knob out fully, then
turn it to hold it in position.
To set it to LOCK position (L), pull the lock knob out and turn it to remove it from the fixed position.
The knob is pushed into the lock hole in the dump lever by the force of the spring, and the dump lever is locked.
Check that the dump lever is securely locked.
OTHER EQUIPMENT
EMERGENCY ESCAPE HAMMER
k CAUTION
• If it is necessary to break the window glass with the hammer, be extremely careful not to get injured
with scattered pieces of broken glass.
• To prevent injury, remove the broken pieces of glass remaining in the frame before escaping
through the window. Be careful also not to slip on the broken pieces of glass on the ground.
3-107
If it should become impossible to open the cab door for any

reason, and it is necessary to make an emergency escape
from the operator's compartment, use hammer (1) to escape.
To escape from the operator's cab, use hammer (1) to break

the glass and escape through the window.
DRINK BOX
The drink box is provided on the right side of the operator's
seat to store drinks.
Hot or cold air blows into the box according to the setting of the
air conditioner.
Turn the knob counterclockwise and pull the cover up and open
it.
Position (A)
Close (Lock)
Position (B)
Open (Unlock)
When closing the cover, lock it by turning the knob clockwise while pressing the cover.
MAGAZINE BOX
The magazine box is provided on the front left side of opera-
tor's seat for storing an A4-size binder and such.
Do not put in heavy things such as tools.
3-108
HANDY TRAY
The handy tray is provided in the rear right of the operator seat.
CUP HOLDER
The cup holder (2 pieces) are provided on the rear side of the
drink box.
ASHTRAY
The ashtray is provided on the top of the console box on the
right side of the operator seat.
Always put out your cigarette before putting it in the ashtray
and be sure to close the lid.
POWER SUPPLY OUTLET

12V POWER SOURCE
The outlet for 12 V power is provided in the rear right side of
the operator seat.
Capacity of this power supply is 60 W (12 V x 5 A).
3-109
FUSE
NOTICE
Before replacing a fuse, be sure to turn the starting switch
to OFF position, then turn the battery disconnect switch to
OFF position.
• The fuses protect the electrical component and wiring from
burning out.
• If a fuse is corroded and coated with white powder, or
there is any play between the fuse and fuse holder, re-
place the fuse.
• When replacing the fuse, always use a fuse of the same
capacity and type.
FUSE CAPACITIES AND CIRCUIT NAMES

Fuse box I (BT1)
No. Capacity Name of circuit

(1) 15 A Retarder controller
Automatic secondary steer-
(2) 10 A
ing
(3) - -
(4) 5 A Switch panel
Shift lever, personal lock re-
(5) 5 A
lay
(6) 10 A Preheat relay
Air conditioner (blower mo-
(7) 20 A
tor)
Air conditioner (compressor
(8) 10 A
clutch)
Heated wire mirror (right) (if
(9) 10 A
equipped)
Heated wire mirror (left) (if
(10) 10 A
equipped)
DEF heater (continuous
(11) 20 A
power supply)
DEF pump (continuous pow-
(12) 10 A
er supply)
Smart sensor 1 (continuous
(13) 10 A
power supply)
3-110
Smart sensor 2 (continuous

(14) 20 A
power supply)
(15) - -
Fuse box II (BT2)

Air conditioner (continuous
(16) 5 A
power supply)
(17) 15 A Terminal B
(18) 15 A Transmission controller
Retarder controller (continu-
(19) 5 A
ous power supply)
Machine monitor controller
(20) 10 A
(continuous power supply)
(21) 10 A KOMTRAX
(22) 10 A Payload meter (if equipped)
Download (continuous pow-
(23) 10 A
er supply)
Radio (continuous power
(24) 5 A
supply)
(25) 10 A Hazard
(26) 5 A Room lamp 1
(27) 15 A Horn
(28) 5 A -
(29) 5 A Rearview monitor
Spare (continuous power
(30) 20 A
supply)
3-111
Fuse box III (BT3)

(31) 15 A Headlamp (high beam)
(32) 15 A Headlamp (low beam)
(33) 10 A Clearance lamp
(34) 10 A Stop lamp
(35) 15 A Fog lamp (if equipped)
(36) 10 A Radio
(37) 10 A Turn signal lamp
(38) 20 A Air suspension seat
Backup lamp, backup buz-
(39) 15 A
zer
(40) 10 A Room lamp 2, door solenoid
(41) 15 A Working lamp
(42) 15 A Side lamp
(43) 20 A Rear glass heater
Heated wire mirror power
(44) 30 A
supply (if equipped)
(45) 20 A Spare
Fuse box IV (BT4)

(46) 20 A Power window
(47) 20 A Front wiper
(48) 10 A Rear wiper
(49) 20 A DC converter
(50) 10 A Revolving lamp
Payload meter external pilot
(51) 10 A
lamp
Heated wire mirror switch (if
(52) 5 A
equipped)
(53) 5 A Controller (ACC signal)
(54) 5 A Air conditioner (ACC signal)
(55) 10 A Download (ACC signal)
(56) 10 A Parking brake
(57) 30 A Engine controller
(58) 10 A Manual secondary steering
(59) 5 A System operating lamp
(60) 10 A Cab power tilt (if equipped)
3-112
Fuse box V (inside battery case)

Power supply for engine
120 A
heater
(61)
Power supply for charging
120 A
battery
Fuse box VI (in battery case)

Power supply for secondary
(62) 15 A
steering
Power supply for fuel feed
(63) 15 A pump (continuous power
supply)
Power supply for urea SCR
(64) 65 A
system
Cab power tilt main power
(65) 200 A supply (continuous power
supply, if equipped)
Precautions when changing electrical component

k CAUTION
If the electrical equipment system is changed, problems may occur in the machine control. Do not make
any changes to the electrical system.
If you want to make any change to the electrical system, contact your Komatsu distributor.
OPEN AND CLOSE CAB DOOR

k CAUTION
• Make sure that the cab door is locked.
• Always place the machine on a level ground when
opening or closing the door.
• Avoid opening or closing the door on a slope, since
there is a danger that the operating effort may sudden-
ly change.
• Hold the door handle and knob whenever opening or
closing the door.
• Be careful not to get your hands caught between the
front pillar or center pillar.
• When there is anyone inside the cab, always call out a
warning before opening or closing the door.
3-113
CAB DOOR HANDLE

While the cab door handle is not locked with the key, pull door
handle, and the door opens to the full open position.
OPEN KNOB FOR CAB DOOR

Pull the open knob for the cab door, and the door opens to the
full open position.
CAB DOOR INNER LOCK

When the cab door inner lock is pressed, the door is locked.
Position (A):
Lock
Position (B):
Canceled
TOOL BOX
The toolbox is stored in the front side of the hydraulic tank on
the left side of the machine.
3-114
FIRE EXTINGUISHER
The fire extinguisher is installed to the left front of the machine.
BATTERY DISCONNECT SWITCH

k CAUTION
• Do not operate the battery disconnect switch while the engine is running.
The large current generated by the alternator may burn the electric parts and cause a fire.
When operating the battery disconnect switch, always stop the engine.
• If the battery disconnect switch is turned to OFF position, always remove the switch key.
If someone turns the key to ON position carelessly, this is extremely dangerous.
NOTICE
• Keep battery disconnect switch in ON position except the following cases.
• When the machine is stored for a long time (more than a month)
• When repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• Do not turn battery disconnect switch to OFF position while the system operating lamp is lit.
If the battery disconnect switch is turned OFF while this lamp is lit, the data in the controller may be
lost.
• If this switch is turned to OFF position, all the electrical system is cut out and the functions of KOM-
TRAX stop.
In addition, the time information of the clock and the radio tuning information may be lost.
In this case, set again. For detail, see “CLOCK ADJUSTMENT (3-81)” and “HANDLE RADIO (3-232)”.
Battery disconnect switch (1) is in the battery box on the left
side of the machine.
Battery disconnect switch (1) is used to cut out the electricity
from the battery.
REMARK
Operate this switch while system operating lamp (2) is OFF.
3-115
(O) OFF position

Switch key (3) can be pulled out (and inserted) and the current
from the battery is cut out.
(I) ON position
The current from the battery flows into the circuit.
Before starting the machine, be sure to set the switch to ON
position.
SYSTEM OPERATING LAMP

System operating lamp (1) indicates that the controller mount-
ed on the machine is turned ON.
System operating lamp (1) lights up in green when the control-
ler is turned ON and goes out in 1 to 2 minutes after the power
for the machine is turned OFF.
Before operating the battery disconnect switch, check that sys-
tem operating lamp (1) is turned OFF.
NOTICE
If the battery disconnect switch is turned OFF while the
system operating lamp is lit, the data in the controller may
be lost.
REMARK
• Even if the starting switch is in OFF position, the controller may operate. The system operating lamp lights
up at this time, but it is not a failure.
• After the starting switch has been turned OFF, the system operating lamp may stay lit for a long time.
In such case, consult your Komatsu distributor.
CIRCUIT BREAKER
When the circuit breaker operates, it can be reset by pushing in
the reset button.
If the reset button pops up soon after it is pushed in, there may
be a short circuit in the electric circuit. In such case, ask your
Komatsu distributor for repair.
(1) For primary power supply (40 A)
(2) For primary power supply (direct) and engine controller
(30 A)
(3) For secondary power supply (accessory power) (80 A)
(105 A for the machine equipped with large capacity alternator
(if equipped))
3-116
DUST INDICATOR
This device indicates clogging of the air cleaner.
Depending on the degree of clogging of the element, red line
(1) appears in the transparent portion.
If red line (1) indicates 7.5 kPa(30 INCHES H2O)
{0.076 kg/cm2, 1.08 PSI}, clean the element immediately.
After cleaning, press the top part (2) of the indicator, and the
red line (1) returns to its original position.
ARTICULATION LOCK
k WARNING
If the machine is transported or lifted without applying the articulation lock, the machine may suddenly
bend.
This may cause serious personal injury or death in the surrounding area.
• When transporting or raising the machine, always apply the articulation lock.
• Apply the articulation lock if necessary when performing maintenance.
The articulation lock is a device to lock the front frame and rear
frame to prevent the machine from articulating.
LOCK position (L)
Always set the lock to this position before starting transporta-
tion or lifting operation. Set the lock to this position if necessary
when performing maintenance.
FREE position (F)
Always set the lock to this position when traveling.
BODY PIVOT PINS

k WARNING
When performing inspection of the machine with the dump body raised, always set the dump lever to
HOLD position, lock with the dump lever lock knob, then use the body pivot pin.
3-117
The body pivot pin is a safety device for the dump body. Use it
when performing inspection and maintenance with the dump
body raised.
Raise the dump body fully, insert body pivot pins (1).
Always insert the body pivot pin on both sides.
STORAGE FOR BODY PIVOT PIN

The body pivot pin is stowed under the rear portion of the body.
Insert body pivot pin (1), then insert lock pin (2) to stow the
body pivot pin.
HANDLE REAR VIEW MONITOR

k WARNING
• Never perform the switch operation while traveling.
If you do so, there is the fear that you may make an error in the truck operation, or neglect to watch
the hauling road ahead for safety, and this may lead to serious personal injury or death.
• The rear view monitor is an supporting aid for checking obstacles in the rear or surroundings.
An image displayed on the monitor is limited. So when traveling in reverse, do not rely solely on the
monitor, but be sure to make a visual check for safety.
Never rely solely on the rearview monitor when traveling in reverse.
• An image on the rear view monitor does not show an actual distance, so drive the machine slowly,
when backing it up.
• The distortion different from the actual state appears on an image on the rear view monitor.
So, look at the center of the screen as a reference.
3-118
Starting up rearview monitor (1) when traveling in reverse, then

it assists at checking backward. Reference line (2) on the rear-
view monitor is used to check the side and rear of the machine
roughly.
The luminance of the rear view monitor can be adjusted with
rear view monitor brightness adjustment switch (3). For the ad-
justment method, see “BRIGHTNESS ADJUSTMENT SWITCH
OF REAR VIEW MONITOR (3-98) ”.
For the other settings of the rear view monitor, see “REAR
VIEW MONITOR SETTING (3-76)”, and for the setting of refer-
ence line, see “METHOD FOR ADJUSTING REAR VIEW
CAMERA ANGLE (3-169)”.
REMARK
The screen may be hard to see in the dark place at night, but it
is not a trouble.
k WARNING
• The reference line dose not synchronize with steering
angle.
The reference line does not indicate the actual moving
direction or travel path.
• The guide line is set for the machine with no load on
the flat ground.
When the machine is loaded or the road surface is un-
even, the guide line deviates from the actual machine
position.
3-119
(A) When unloaded (C) When road surface is uneven

(B) When loaded (D) Display on rearview monitor
SELF-CHECK FUNCTION FOR REAR VIEW MONITOR

When the starting switch is turned to ON position, the rearview
monitor starts and the camera image is displayed for 5 sec-
onds, regardless of the display mode (reverse travel interlock,
constant display) of the rearview monitor or the position of the
gear shift lever.
During this period, the version No. of the rearview monitor is
displayed at the top right of the rearview monitor.
After the camera image is displayed on the rearview monitor for
5 seconds, the rearview monitor displays the camera image ac-
cording to the display mode (reverse travel interlock, constant
display) and the gear shift lever position.
If the rearview monitor or the camera does not work, ask your Komatsu distributor for repair since it has a failure
or open circuit in electric wiring.
3-120
PRECAUTIONS FOR USING REAR VIEW MONITOR

k WARNING
• Do not disassemble or modify the rearview monitor.
There is a danger of electric shock or fire.
• Do not open the back cover of the rearview monitor.
There is a danger of electric shock, as high voltage power is conducted internally.
• Do not use the rearview monitor while it is broken.
There is a danger of electric shock or fire, should it be used in spite of a defect. In that case, ask
your Komatsu distributor for repair or replacement.
• If foreign materials enter into the rearview monitor, or if the rearview monitor gets wet, or if smoke
comes out of it or it gives a bad smell, stop using it immediately.
It poses a big danger to use the monitor when any such abnormality exists. In that case, consult
• When replacing a fuse, be sure to use one with the specified capacity of 5 A.
Should a fuse with a higher- than- specified capacity be used, it can cause fire.
• As a general rule, the rear view monitor should be replaced after a total usage time of approximately 3000
hours (or approximately 3 years), though this may differ according to usage conditions.
• When cleaning the rearview monitor, use dry soft cloth or wet cloth after having well wrung the water out.
If it is very dirty, use neutral detergent.
Do not use thinner or alcohol.
• Sometimes an image on the rearview monitor display is blurred due to the camera lens being smeared.
In that case, clean the camera lens with dry soft cloth or wet cloth after having well wrung the water out.
HANDLE Komatsu Diesel Particulate Filter (KDPF)

k CAUTION
• Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high
temperature may last after the completion of regeneration.
Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being
burnt.
Also, keep combustible materials away from the exhaust pipe outlet and around the aftertreatment
devices to prevent a fire.
• When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to
the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after-
treatment devices regeneration.
For the setting procedure, see “PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION
DISABLE SETTING (3-128)”.
• For the machines equipped with dump body heating specification, the dump body becomes highly
heated during the aftertreatment devices regeneration. Stay away from the dump body to prevent
yourself from getting burnt.
If the following objects are loaded, fire may occur.
• Objects which mainly contains combustible materials such as dry leaves, chips, pieces of pa-
per, and coal dusts
For details of remedies, see “DUMP BODY HEATING SPECIFICATIONS (3-237)”.
• Do not leave the operator's seat during the aftertreatment devices regeneration.
3-121
KDPF is a device to capture soot in the exhaust gas to purify

the exhaust gas.
If soot is accumulated to a certain level in the filter, a purifica-
tion process to burn the soot is performed automatically to
keep the filtering performance of KDPF high.
This purification process is called the “regeneration”.
If operations which lower the purification function of KDPF con-
tinues for long hours, the regeneration is performed to protect
the KDPF system, regardless of the quantity of the accumulat-
ed soot.
NOTICE
During the aftertreatment devices regeneration, aftertreatment devices regeneration display (1) lights up
on the machine monitor and the idle speed is set to rather high regardless of ON or OFF of AISS LOW
switch.
After the automatic regeneration is finished, aftertreatment devices regeneration display (1) goes out
and the idle speed is returned to the level corresponding to the AISS LOW switch.
REMARK
• Even if aftertreatment devices regeneration pilot lamp (1)
lights up, the machine does not need to be stopped and
the work can be continued, unless when the KDPF soot
accumulation caution lamp (2) lights up.
• Accumulation amount of soot can be checked by soot ac-
cumulation level (3) on the “Aftertreatment Devices Regen-
eration” screen.
Operate the menu switch on the standard screen to dis-
play the “Aftertreatment Devices Regeneration” screen.
• Automatic regeneration against accumulation of soot starts
when the soot accumulation level increases “3” or above,
and stops a while after the soot accumulation level de-
creases to “0”.
The KDPF regeneration is performed automatically. However,
the accumulated soot may not be burnt sufficiently and the fil-
tering function may not be improved under certain operating
conditions.
In that case, KDPF soot accumulation caution lamp (2) lights
up. If this lamp lights up, stop the machine in a safe place and
perform the manual stationary regeneration.
For details of the procedure, see “PROCEDURE FOR MAN-
UAL STATIONARY REGENERATION (3-125)”.
Two types of monitor display require the manual stationary re-
generation, depending on the level of urgency.
When the gear shift lever is turned to NEUTRAL position (N)
and the parking brake switch is turned to the “PARKING” posi-
tion, the manual stationary regeneration may start automatical-
ly to protect the KDPF.
NOTICE
Do not stop engine when the aftertreatment devices regeneration is activated.
3-122
If KDPF soot accumulation caution lamp (2) is displayed, be sure to perform the manual stationary re-
generation.
When stopping the engine, stop the aftertreatment devices regeneration first according to “PROCE-
DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-128)”, then keep en-
gine running at low idle for approximately 5 minutes, and stop engine.
When the Action level “L03” lights up in red, and the KDPF soot accumulation caution lamp (2) lights up
in red, engine power deration is activated. To restore engine power, it is necessary to perform “PROCE-
DURE FOR MANUAL STATIONARY REGENERATION”.
If soot accumulated in the KDPF exceed the defined level
without performing “PROCEDURE FOR MANUAL STA-
TIONARY REGENERATION”, the Action level “L04” lights
up in red. Stop the machine immediately and ask your Ko-
matsu distributor.
REMARK
• If KDPF soot accumulation caution lamp (2) lights up in
red, engine power is derated to protect the engine and
KDPF system.
• Soot accumulation level (3) can be checked with the “Af-
tertreatment Devices Regeneration” screen. Press the
menu switch on the standard screen to display the “After-
treatment Devices Regeneration” screen of the user menu.
• Since the soot in the filter of KDPF can be burnt by the
high-performance catalyst and high-temperature exhaust
heat, the soot accumulation quantity may decrease even if
the regeneration is not performed, depending on the oper-
ating condition.
• Even when the soot accumulation level is low, the automatic regeneration may be performed and the man-
ual stationary regeneration may be requested to protect the system.
In particular, if engine is kept running with no load, the regeneration frequency may increase, but this is not
a failure.
• Even just after the regeneration is completed, the soot accumulation level may not be “0”. This is caused by
the accumulated noncombustible material in the exhaust gas and is not a failure.
• Since noncombustible matter which cannot be burnt by the regeneration is accumulated in the filter of
KDPF, the filter needs to be cleaned or replaced at regular intervals. For details, see “METHOD FOR
CLEANING KDPF (4-84)”.
• The engine speed or engine sound may change during or after the regeneration. This is caused by the con-
trol for better regeneration and this is not a failure.
• The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas filtering function.
• White smoke may be discharged for a short time just after the engine is started or during the regeneration
in the cold season, but this is not a failure.
• Komatsu recommends using Komatsu genuine engine oil for KDPF.
If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF
filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may
cause failure.
In addition, the regeneration interval may be shortened and the fuel consumption may increase.
For details of the genuine oil, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”.
3-123
When the degree of emergency is low

yellow (action level (4): “L01”), screen (A) is displayed first.
• The action level goes out 2 seconds after and the screen
changes to standard screen (B).
• If the machine is completely stopped, the display switches
to “Aftertreatment Devices Regeneration” screen (C) after
3 seconds only the first time. If, however, the manual sta-
tionary regeneration is not performed, the display returns
to standard screen (B) after 30 seconds.
Then, if the accumulated soot does not decrease, the “Af-
tertreatment Devices Regeneration” screen (C) is dis-
played for 30 seconds every 2 hours.
yellow, stop the machine in a safe place and perform the
manual stationary regeneration.
When the degree of emergency is high

• KDPF soot accumulation caution lamp (2) lights up in red
and the action level “L03” lights up in red (4).
• If the machine is stopped completely, the screen changes
to the “Aftertreatment Devices Regeneration” screen (E)
after 3 seconds.
Then, the “Aftertreatment Devices Regeneration” screen
(E) and standard screen (D) are automatically displayed
alternately in accordance with machine stop, until the man-
ual stationary regeneration is performed.
red, immediately stop the machine in a safe place and per-
form the manual stationary regeneration.
3-124
PROCEDURE FOR MANUAL STATIONARY REGENERATION

k CAUTION
• Exhaust gas temperature may increase higher than the previous models during the aftertreatment
devices regeneration.
Stay away from the exhaust pipe outlet to prevent yourself from getting burnt.
Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire.
• For the machines equipped with dump body heating specification, the dump body becomes highly
heated during the aftertreatment devices regeneration.
Stay away from the dump body to prevent yourself from getting burnt.
• Do not leave the operator's seat during the aftertreatment devices regeneration.
The manual stationary regeneration can be performed while

KDPF soot accumulation caution lamp (1) is lit.
REMARK
• On this machine, the manual stationary regeneration can
be performed when soot accumulation level is “1” or
above.
• If there is a failure of which action level is “L02” or above,
or the fuel level caution lamp is lit, the manual stationary
regeneration cannot be performed.
1. Move the machine to a safe place and stop it with engine
running.
2. Check that there is no person or combustible matter around the machine (particularly in the direction of the
exhaust gas flow).
3. Release the accelerator pedal.
4. Place gear shift lever to NEUTRAL position (N).
3-125
5. Set the parking brake switch to “PARKING” position to ap-

ply the parking brake.
6. Press the menu switch to display the “Aftertreatment Devi-

ces Regeneration” screen.
7. Select the “Manual Stationary Regeneration”, check again safety of the surrounding area and make sure
the area is free from irrelevant people or combustible matter, then press the enter switch.
If the machine needs to be moved again to secure safety, move it to a safe place and repeat the procedure
from step 1.
REMARK
When performing the manual stationary regeneration, lower the dump body and set the fan rotation in the
normal direction.
If the dump body is operated during the manual stationary regeneration, the regeneration may stop.
REMARK
After the enter switch is pressed in step 7, the screen
shown in the figure may be displayed. This indicates that
the operations in steps 1 to 5 were not performed correctly
or there is trouble other than KDPF soot accumulation ab-
normality. After making sure that the engine is running nor-
mally, the accelerator pedal is not depressed, and the gear
shift lever is turned to NEUTRAL position (N) and the park-
ing brake switch is turned to PARKING position, repeat the
procedure from step 7.
If the manual stationary regeneration still cannot be per-
formed, return to the standard screen, press the enter
switch to check the contents of other occurring troubles,
stop the work and perform inspection and maintenance.
3-126
REMARK
The explanation of the manual stationary regeneration is
displayed in 3 parts on the machine monitor panel. When
the enter switch is pressed, the regeneration can be start-
ed immediately, regardless of which part is displayed.
When the return switch is pressed, the display returns to
If no machine monitor switch is operated for 30 seconds,
the explanation of the manual stationary regeneration dis-
appears and the screen returns to the standard screen.
At this time, to display the explanation of the manual sta-
tionary regeneration again, press the menu switch on the
standard screen to display the “Aftertreatment Devices Re-
generation” screen.
8. This screen is displayed during the manual stationary re-

generation.
It may take more than 40 minutes to complete the manual
stationary regeneration. Do not touch any switch on the
screen or accelerator pedal until the regeneration is com-
pleted and the standard screen appears again.
3-127
REMARK
During the manual stationary regeneration, idle speed is
set rather high.
• The progress of the manual stationary regeneration
performed when soot is accumulated can be checked
by the number of lighting lamps of soot accumulation
level (2).
The manual stationary regeneration starts at soot ac-
cumulation level "4" or higher and finishes when all
the level lamps go out.
• The time required for the manual stationary regenera-
tion depends on the soot deposition level or the ambi-
ent temperature when it is started. If the regeneration
starts at soot accumulation level "6" or higher, it may
take approximately 2 hours to finish.
• The manual stationary regeneration for protection of
the system may start even when the soot accumula-
tion level is “0” to “3”.
In this case, the soot accumulation level may not de-
crease, but this is not trouble.
The progress is not displayed on the machine monitor
during this regeneration. It is completed in approxi-
mately 10 minutes.
• If the accelerator pedal, gear shift lever, or parking
brake switch is operated during the manual stationary
regeneration, the regeneration is stopped automatical-
ly.
Release the accelerator pedal, return the gear shift
lever to NEUTRAL position (N), return the parking
brake to PARKING position, and then repeat the pro-
cedure from step 7.
• If the machine needs to be moved during the manual
stationary regeneration, stop the regeneration tempo-
rarily and move the machine, referring to the after-
treatment devices regeneration disable and cancel
procedures described below.
When restarting the manual stationary regeneration,
secure the safety of the machine and around it, then
cancel the regeneration disable.
9. After the manual stationary regeneration is completed, the screen automatically returns to the standard
screen.
PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE

SETTING
If there is combustible material around the machine and the active regeneration that increases the exhaust tem-
perature must not be performed, the automatic active aftertreatment devices regeneration can be disabled.
Also, the regeneration in progress can be stopped.
3-128
NOTICE
Even if the regeneration is disabled, KDPF soot accumula-
tion caution lamp (1) lights up if soot is accumulated and
the manual stationary regeneration is required.
If KDPF soot accumulation caution lamp lights up, move
the machine to a safe place and perform manual stationary
regeneration.
If the operation is continued without performing the man-
ual stationary regeneration, it may cause the failure of
KDPF or the engine.
WHILE REGENERATION IS NOT BEING PERFORMED: SETTING PROCEDURE

FOR REGENERATION DISABLE
(When the aftertreatment devices regeneration display is not lit on the standard screen)
1. Press the menu switch on the standard screen.
2. Operate the menu switch to select “Aftertreatment Devices

Regeneration” menu (C) and display the “Aftertreatment
Devices Regeneration” screen.
3. Select “Regeneration Disable” and press the enter switch.

The regeneration function is disabled and the regeneration
is not performed.
3-129
REMARK
• When the regeneration is disabled, aftertreatment devices
regeneration disable pilot lamp (1) is displayed with hatch
on the standard screen.
• The setting of Regeneration Disable is canceled by turning
starting switch to OFF position. When the automatic regen-
eration needs to be kept disabled, perform the above pro-
cedure each time you start the engine.
• During the regeneration to protect the system, even if the
regeneration disable is set, aftertreatment devices regen-
eration display (2) may light up, but this does not indicate
abnormality. Also, during the regeneration to protect the
system, the Regeneration Disable cannot be operated.
• When the regeneration is performed to protect the system,
the exhaust temperature is lower than that of when the re-
generation is performed to burn soot, and is almost the
same level as the normal exhaust gas temperature.
WHILE REGENERATION IS BEING PERFORMED: STOPPING PROCEDURE FOR

REGENERATION
(When the aftertreatment devices regeneration display is lit on the standard screen)
1. When the menu switch is pressed on the standard screen,
the “Aftertreatment Devices Regeneration” screen is dis-
played.
3-130
2. Press the enter switch after selecting “Regeneration Disa-

ble”, and the regeneration stops.
REMARK
The regeneration performed to protect the system may not be
stopped, but this is not a failure.
PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION

DISABLE SETTING
k CAUTION
When canceling the Regeneration Disable, move the machine to a safe place and check that there is no
person or combustible matter around the machine, and start the cancel operation.
1. When the menu switch is pressed on the standard screen,

the “Aftertreatment Devices Regeneration” screen is dis-
played.
(If the “Aftertreatment Devices Regeneration” screen is not
displayed, display it by pressing the menu switch several
times.)
2. Select “Cancel of Regeneration Disable” and press the en-

ter switch, and the regeneration disable is canceled.
If soot accumulation level (1) lights up 3 or more, the re-
generation may be started automatically.
REMARK
• When canceling the regeneration disable, release the ac-
celerator pedal, set the gear shift lever in NEUTRAL posi-
tion (N), set the parking brake switch to “PARKING” posi-
tion, then cancel the regeneration disable.
• The regeneration disable setting is also canceled by turn-
ing the starting switch to OFF position to stop the engine.
3-131
Komatsu Closed Crankcase Ventilation (KCCV)

KCCV is a device to clean the gas discharged from the engine
crankcase with the filter element and return it to the engine air
intake system.
NOTICE
• The KCCV filter element needs to be replaced every
2000 hours.
For the replacement procedure, see “METHOD FOR
REPLACING KCCV FILTER ELEMENT (4-75)”.
• If the engine is operated without KCCV filter element
or if a filter element other than the Komatsu genuine
element is used, the engine sucks oil and foreign ma-
terial which can cause a failure.
Always install Komatsu genuine KCCV filter element.
• The filter element cannot be flushed.
Never reuse the filter element. Even if it is cleaned, its
filtering performance may decrease and it can cause
an engine failure.
HANDLE UREA SCR SYSTEM WARNING

Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless nitro-
gen and water. By spraying DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3)
and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
The Komatsu Urea SCR System continuously monitors its operation conditions and stores information on inap-
propriate operations including malfunctions. The information is used for system diagnostics and also for Induce-
ment required by the authorities on engine systems that use Urea SCR systems. Inducement is intended for the
operator to take prompt actions to maintain and correct inappropriate behaviors of Urea SCR systems by utiliz-
ing visible and audible alerts , and engine power derate in addition. Alerts in Inducement of the Komatsu Urea
SCR System progresses step by step starting from visual indications on the machine monitor and audible
sounds to engine power derate to avoid getting into unsafe conditions.
The Komatsu Urea System also monitors recurrences of abnormalities of the system. Inducement in the recur-
rences is activated when another abnormality occurs within 40 hours after the first abnormality is fixed.
The Komatsu’s Urea is composed of two major systems, which are the DEF system and the SCR catalyst Ass’y.
DEF is supplied from DEF system into the exhaust system.
DEF system consist of DEF tank (1), DEF hose (2), DEF pump
(3), and DEF injector (4). SCR Ass’y is indicated by (5).
In the event that indications of potential degradation of nitrogen
oxides conversion efficiency are detected, the active regenera-
tion is triggered to rejuvenate Urea SCR system even if the
amount of soot accumulated in the KDPF has not reached to
the regeneration thresholds.
For details of Aftertreatment Devices Regeneration, see “HAN-
DLE Komatsu Diesel Particulate Filter (KDPF) (3-121)”.
k WARNING
Fill ONLY DEF into DEF tank. Foreign material in the DEF
system or urea deposits caused by evaporation may hin-
der operation of the devices.
3-132
NOTICE
• Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder
operation of the devices.
• Do not disassemble any devices of the DEF System other than the filter for change. Do not modify
any devices of the DEF System.
• Paint may cause deterioration of the devices. When painting the surrounding areas, take care not to
get any paint on the injector and the supply pump.
• Always use DEF that conforms to the quality standard. If any additional additive agents or water is
mixed in DEF and that mixture is used, the devices will not function properly, and conformance to
the exhaust gas regulations will be lost. In addition, it may cause failures in the engine system. If
DEF out of the standard is filled or used by mistake, contact your Komatsu distributor.
About the operation of Urea SCR system
The Urea SCR System automatically starts operating as soon as the engine is started.
Even after the engine starting switch is turned to the OFF position, the devices will still be in operation for sever-
al minutes to purge any DEF in the lines, the injector and the supply pump back to the DEF tank. It does not
indicate any abnormality. When DEF has been returned to the tank, the devices stop.
Do not turn OFF the battery disconnect switch while the devices are still in operation. When the devices com-
plete their shutdown process, the system operating lamp will go out, and the battery disconnect switch may be
disconnected.
About the operation in cold weather
DEF freezes at –11 °C.
Urea SCR system is equipped with a heating system to thaw frozen DEF once it is frozen, for example, during
parking and to prevent DEF from freezing during operation.
In case DEF freezes during parking, once the engine starts running the heating system automatically starts pro-
viding heat to thaw frozen DEF. The pump and the injector start working only after a proper amount of DEF is
thawed. This may be noticed as a delay in the start of functioning of the pump and the injector.
The heating system is also activated automatically during operation to prevent DEF from freezing whenever the
ambient temperature drops below a certain threshold where DEF in the system may freeze. In the event that the
ambient temperature drops further than a temperature where the heating system is capable of maintaining fluidi-
ty of DEF, the DEF system automatically starts purging the remaining DEF back to the tank and stops pumping
and injection while heating continues. Once the ambient temperature rises above a temperature where DEF
system becomes functional, it resumes operation automatically.
Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in
cold weather, but this is not malfunction.
Inducement strategy when the DEF tank Level becomes low
When the amount of DEF in the tank goes low, the Inducement strategy will be activated.
If Inducement starts, add DEF to the DEF tank immediately.
The DEF level caution lamp (1) on the monitor lights up, the audible alert starts, and the Action level is dis-
played, and Inducement strategy is activated. Inducement strategy includes engine output deration, speed limi-
tation, or other warning actions intend to prompt the operator to maintain or repair SCR system.
The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low level Inducement and
Severe Inducement.
3-133
The DEF level caution lamp (1) on the machine monitor will
light up, audible alert will start, then Action level will be dis-
played on the machine monitor, and engine power will be derat-
ed in steps.
In Action Level “L03 (Low level Inducement)” and “L04 (Severe
Inducement)” engine power will be derated. When Action Level
“03” or “04” is displayed, move the machine to a safe place and
add DEF.
The content of the warning can be checked on the “SCR Infor-
mation” screen of the user menu.
Perform the following procedure.
Press the menu switch on the standard screen to display the
“SCR Information” screen of the user menu.
After a lapse of 3 seconds to stop the machine, “SCR Informa-
tion” screen is displayed.
“SCR Information” screen displays the DEF level caution lamp

(1), the DEF level gauge (2), information on the Urea SCR Sys-
tem condition (3), and the current status of Inducement (4).
If Inducement starts, stop the machine in a safe place and add
DEF.
• Warning:
2 gradations of the DEF level gauge light up in the red
range.
The DEF level caution lamp (1) lights up in red.
No audible alert.
No Action level is displayed.
Press the menu switch to display the “SCR Information”
screen.
Inducement status (4): “1 DEF low level warning appears.”

Add DEF to the DEF tank immediately.
3-134
• Continuous Warning:
The audible alert sounds in repetition of “three beeps and
a pause”.
2 gradations of the DEF level gauge light up in the red
range.
DEF level caution lamp (1) lights up in red.
No Action level is displayed.
screen.
Inducement status (4): “2 Without treatment, engine power

will be derated.”
• Low level Inducement:

The audible alert sounds in short and sharp beeps.
1 gradation of the DEF level gauge light up in red.
Action Level “L03” is displayed in red (5).
screen.
Inducement status (4): “3 Engine power is under deration.”

• Severe Inducement:
The audible alert sounds in continuous beep.
No gradation of the DEF level gauge lights up .
The Action level “L04” is displayed in red (5).
screen.
3-135
Inducement status (4): “4 Engine power is under heavy de-

ration.”
Engine power can be restored temporarily from power derate. This engine power restoration works only
when the Inducement status is “Severe Inducement”and relieves back temporarily to the power deration of
the “Low level Inducement”. The operator can restore engine power through the machine monitor. For the
engine power restoration procedure, refer to the section of “Temporary Restoration from Inducement” in this
manual. Once in “Severe Inducement” and it becomes necessary to restore engine power, use the engine
power restoration function to move the machine to a safe place and add DEF.
Inducement strategy when abnormalities are detected in the Urea SCR System
devices (Except abnormalities in the KDPF and the EGR system)
If any abnormality is detected in the DEF quality or in the Urea SCR system, the Inducement strategy is activa-
ted.
The inducement strategy progresses in 4 levels, “Warning”,
“Continuous Warning”, “Low level Inducement” and “Severe In-
ducement”. The Inducement strategy includes visual alert by
the DEF caution lamp, the KDPF system caution lamp or the
Engine system caution lamp (1), and Action Level displayed on
the machine monitor (2), and the audible alert by a buzzer and
stepwise engine power deration that advances to speed limita-
tion to low idle. Engine power deration starts with Action Level
“L03 (Low level Inducement)” and advances to further deration
when “L04 (Severe Inducement)” is displayed. If “L03” is dis-
played, move the machine to a safe place and contact your Ko-
matsu distributor.
The content of the warning can be checked on the “SCR Information” screen of the user menu.
“SCR Information” screen displays remaining time to the next

Inducement status in the column (5), and information on the
Urea SCR System condition (3), and the current status of In-
ducement (4).
3-136
• Warning:
No audible alert.
The DEF system caution lamp (1) lights up in yellow.
Note: Action Level “L01” once shows up in yellow on the
machine monitor (2) for two seconds and goes out.
screen.
“SCR Information” screen message (4): “1 Please inspect

and maintain SCR system.”
Move the machine to the safe place and contact your Ko-
matsu Distributor.
If operation continues for 5 hour after “Warning” started
without taking any actions instructed by the Action Level
table, Inducement advances to “Continuous Warning”.
a pause”.
screen.
“SCR Information” screen message (4): “2 Without treat-

ment, engine power will be derated.”
matsu Distributor.
The duration of “Continuous Warning” is 5 hours. The re-
maining time (Hours and Minutes) to “Low level Induce-
ment” is displayed in the column (5) of the “SCR Informa-
tion” screen.
In “Low level Inducement”, engine performance will be de-
rated.

The DEF system caution lamp (1) lights up in red.
Action level “L03” lights up in red at action level display (2)
and stays on.
screen.
3-137
“SCR Information” screen message (4): “3 Engine power is

under deration.”
Due to the engine power deration, capability of the ma-
chine will be limited.
matsu Distributor.
The duration of “Low level Inducement” is 10 hours. The
remaining time (Hours and Minutes) to “Severe Induce-
ment” is displayed in the column (5) of the “SCR Informa-
tion” screen.
In “Severe Inducement”, engine power will be derated fur-
ther.
The DEF system caution lamp (1) lights up in red.
Action level “L04” lights up in red (2).
screen.

under heavy deration.”
Due to the further deration of engine power, capability the
machine will be limited further.
“Severe Inducement” is the final status of Inducement.
Unless all the “SCR system” abnormalities are corrected,
engine performance will be kept derated.
Engine power can be restored temporarily from power derate. If Inducement advances to “Severe Induce-
ment” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor. This engine power restoration
works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power
deration of “Low level Inducement”. The operator can restore engine power through the machine monitor.
For the engine power restoration procedure, refer to the section of “Temporary Restoration from Induce-
ment” in this manual.
Inducement strategy when abnormality is found in the KDPF System by the
Urea SCR system
If any abnormality is detected in the KDPF System through the Urea SCR system, the Inducement strategy is
activated.
“Continuous Warning”, “Low level Inducement”, and “Severe In-
the KDPF System caution lamp (1), DEF system caution lamp
(2), and Action Level displayed on the machine monitor (3), au-
dible alert by a buzzer and stepwise engine power deration that
advances to speed limitation to low idle. Engine power deration
starts with Action Level “L03 (Warning, Continuous Warning
and Low level Inducement)” and advances to further deration
when “L04 (Severe Inducement)” is displayed. Once the
3-138
system advances to “Severe Inducement”, the engine power will be further derated. If “L03” is displayed, move
the machine to a safe place and contact your Komatsu distributor.

ducement (5).
• Warning:
The KDPF system caution lamp (1) lights up in red.
The action level “L03” lights up in red at action level dis-
play (3).
screen.

Engine power is derated.
matsu Distributor.
3-139
a pause”.
play (3).
screen.

matsu Distributor.
The duration time of “Continuous Warning” is 5 hour. The
remaining time (Minutes) till the next Inducement status of
“Low level Inducement” is displayed in the column (6) of
“SCR Information” screen.
In “Low level Inducement”, engine power will be derated.

DEF system caution lamp (2) lights up in red.
play (3).
screen.

under deration.”
Due to the reduction of engine power, the machine normal
operation will be limited.
The duration time of “Low level Inducement” is 10 hour.
The remaining time (Minutes) to “Severe Inducement” is
displayed in the column (6) of “SCR Information” screen.
ther.
matsu Distributor.
Action level “L04” lights up in red at action level display (3).
screen.
3-140

If the restoration of the KDPF system abnormality is not
performed, engine performance will kept be derated.
when the Inducement status is “Severe Inducement” and Engine power can be restored temporarily from
power derate. This engine power restoration works only when the Inducement status is “Severe Induce-
ment” and relieves back temporarily to the power deration of “Low level Inducement”. The operator can re-
store engine power through the machine monitor. For the engine power restoration procedure, refer to the
section of “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In-
ducement” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor.
Inducement strategy when abnormality is found in the EGR Valve System by the
Urea SCR system
If any abnormality is detected in the EGR Valve System through the Urea SCR system, the Inducement strategy
is activated.
“Continuous Warning”, “Low level Inducement”, and “Severe In-
the Engine system caution lamp (1), DEF system caution lamp
(2), and Action Level displayed on the machine monitor (3), au-
dible alert by a buzzer and stepwise engine power deration that
advances to speed limitation to low idle. Engine power deration
starts with Action Level “L03 (Warning, Continuous Warning
and Low level Inducement)” and advances to further deration
when “L04 (Severe Inducement)” is displayed. Once the sys-
tem advances to “Severe Inducement”, the engine power will
be further derated. If “L03” is displayed, move the machine to a
safe place and contact your Komatsu distributor.
screen.
3-141

ducement (5).
• Warning:
The Engine system caution lamp (1) lights up in red.
play (3).
screen.

Engine power is derated.
matsu Distributor.
a pause”.
play (3).
screen.

matsu Distributor.
The duration time of “Continuous Warning” is 5 hour. The
remaining time (Minutes) till the next Inducement status of
“Low level Inducement” is displayed in the column (6) of
“SCR Information” screen.
In “Low level Inducement”, engine power will be derated.
3-142

play (3).
screen.

under deration.”
Due to the reduction of engine power, the machine normal
operation will be limited.
The duration time of “Low level Inducement” is 10 hour.
The remaining time (Minutes) to “Severe Inducement” is
displayed in the column (6) of “SCR Information” screen.
ther.
matsu Distributor.
Action level “L04” lights up in red at action level display (3).
screen.

If the restoration of the KDPF system abnormality is not
performed, engine performance will kept be derated.
when the Inducement status is “Severe Inducement” and Engine power can be restored temporarily from
power derate. This engine power restoration works only when the Inducement status is “Severe Induce-
ment” and relieves back temporarily to the power deration of “Low level Inducement”. The operator can re-
store engine power through the machine monitor. For the engine power restoration procedure, refer to the
section of “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In-
ducement” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor.
Temporary Restoration from Inducement
Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea
SCR systems.
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In case the Urea SCR system advances to “Severe Inducement”, engine power is derated heavily. This may
cause difficulties of moving the machine to a safe place for adding DEF or troubleshooting and correcting abnor-
malities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine
power for a short time to the deration of “Low level Inducement” through the machine monitor. Note that “Tempo-
rary Restoration from Inducement” does not regain full engine power.
“Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe In-
ducement”. The maximum duration is limited to 30 minutes in each restoration operation, and only 3 operations
are allowed unless all the abnormalities of the Urea SCR system are corrected.
If the system advances to “Severe Inducement”, utilize “Temporary Restoration from Inducement” immediately.
Procedure to activate “Temporary Restoration from Inducement”.
1. Press the menu switch (1) to display the “SCR Information”
screen when the Standard screen is on, only when the
Urea SCR system is in “Severe Inducement”.
2. Press the enter switch (2) to display the menu windows

popping up in the bottom half of the “SCR Information”.
The menu windows popping up in the bottom half of the
“SCR Information” screen alternate every 15 seconds as
shown in the graphics A and B.
3-144
3. Press the enter switch (2) while the pop-up menu screen B
is displayed.
The “Engine power Recovery” window pops up.
If the enter switch (2) is not pressed for 30 seconds,
“Standard Screen” will be displayed, and start again by
pressing the menu switch (1).
The remaining number of operations of Temporary Resto-
ration from inducement is displayed in the column (3) of
the pop-up menu window B.
4. Press the enter switch (2) while the “Engine power Recov-
ery” window is displayed.
Temporary Restoration from Inducement is activated and
engine power deration is relieved to the deration of “Low
level Inducement” for the maximum of 30 minutes.
The remaining time (minutes/seconds) of “Temporary Re-

storation from Inducement” is displayed in the column (4)
on the “SCR Information” screen.
If it is decided NOT to activate “Temporary Restoration from Inducement” after having progressed to the “Engine
Power Recovery” window, follow the steps explained in this section.
To deactivate “Temporary Restoration from Inducement” function.
3-145
1. Press the return switch (5) while the “Engine Power Re-
covery” window is displayed.
This procedure is split from procedure 4 in “Temporary Re-
storation from Inducement”.
“SCR Information” screen is displayed.
2. Move the machine to display the to display “Standard

Screen”.
“Temporary Restoration from Inducement” is deactivated.
Inducement Strategy for abnormalities recurrences within 40 hours

The Urea SCR system continuously monitors its operation conditions and stores information on inappropriate
operations including malfunctions. The stored information is utilized to monitor recurrences of abnormalities,
“Abnormality Recurrence Counter”. “Abnormality Recurrence Counter” is required by the authorities. The recur-
rence monitoring spans 40 hours and it monitors the abnormalities that trigger Inducement other than the
amount of DEF in the tank.
If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected,
regardless of the level of the previous Inducement and whether the new abnormality/abnormalities is the same
as the previous ones or not, it is judged as a recurrence.
If a recurrence occurs, “Severe Inducement” will be activated.
Inducement in the recurrence resumes counting time at the time when the previous abnormalities were correc-
ted if the previous Inducement is in “ Warning” or “Continuous Warning” or “Low level Inducement”. The alerts
resume the previous Inducement.
If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and
contact your Komatsu distributor.
The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
To activate “Temporary Restoration from Inducement”, refer to the “Temporary Restoration from Inducement”
section in this manual.
3-146
DEF FILTER
DEF filter is an filter element to clean DEF sucked from the
DEF tank by DEF pump, and to supply it to DEF injector.
NOTICE
• The DEF filter element needs to be replaced every
2000 hours. For details of the replacement procedure,
see “METHOD FOR REPLACING DEF FILTER (4-78)”.
• If the machine is operated without DEF filter attached,
or with the filter other than Komatsu genuine parts,
foreign materials may enter into DEF pump and DEF
injector which will cause failure of the machine. Never
operate the machine without DEF filter attached, nor
use the filter other than Komatsu genuine parts.
• DEF filter cannot be flushed. Flushing or regenerating
of it will degrade the performance of DEF filter, and will
contaminate DEF pump and DEF injector which will
cause the failure of the machine. Never reuse the DEF
filter.
KOMTRAX
KOMTRAX equipment may not be mounted on machines for some countries or regions.
OUTLINE OF KOMTRAX
KOMTRAX is a system that remote-controls machines equipped with the KOMTRAX device by using satellite
communication or portable radio communication.
Each customer can check the machine information of various types (machine position information, etc.) in the
web screen of a personal computer
The machine information you can check with KOMTRAX includes the following; “Machine position”, “service me-
ter”, “working hours”, “fuel consumption”.
Your Komatsu distributor uses the above machine information for supply of service to the customers, improve-
ment of our products and service, etc.
If you want to use KOMTRAX, you are required to register to your Komatsu distributor.
3-147
k WARNING
• 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 distribu-
tor will perform removal and installation of KOMTRAX.)
• For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm
from the pacemaker. The radio waves may have an adverse effect on the operation of the pacemak-
er.
• Near the blasting jobsite, there may be a danger of unexpected explosion due to use of interactive
wireless communication device of KOMTRAX and resulting serious personal injury or death. Make
sure to operate the machine away from the blasting jobsite.
If you have to operate the machine within 12 m from the blasting jobsite or the remote-controlled
blasting device, the power supply cable of KOMTRAX must be disconnected in advance. If you want
to do this, ask your Komatsu distributor for disconnecting power supply cable of KOMTRAX.
Also, if there are any requirements or regulations of the territory or country where the machine
equipped with this device is used, such requirements or regulations have a priority than this warn-
ing.
When checking for compliance with regulations, refer to the following KOMTRAX equipment satel-
lite communication specifications.
Rated transmit power: 5 to 10 W
Transmit frequency:148 to 150 MHz
PRECAUTIONS FOR USING KOMTRAX

• Even when the key in the starting switch of the KOMTRAX system is at OFF position, a small amount of
electric power is consumed.
It is recommended to run the engine periodically to charge the battery. When storing the machine for a long
period, see “PRECAUTIONS FOR LONG-TERM STORAGE (3-246)”.
• When using the battery disconnect switch, turn the starting switch to OFF position and turn the battery dis-
connect switch key to OFF position. Then, remove the key.
When the battery disconnect switch is turned to OFF position, it is possible to prevent power consumption
of the battery, but the functions of KOMTRAX stop at the same time.
For operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-115)”.
REMARK
The KOMTRAX device 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.
OBSERVANCE OF THE APPLICABLE LAWS AND REGULATIONS, EXEMPTION

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. Ob-
serve the applicable laws and regulations of the country or region in which the machine is used.
Always contact your Komatsu distributor before exporting this machine equipped with KOMTRAX or using it in a
foreign country.
The KOMTRAX may already have been registered and used if the machine is purchased as second-hand. For
the registration and usage records of KOMTRAX, consult your Komatsu distributor.
If the machine has been lent out by the customer, the borrower or another third party may have been using the
KOMTRAX. Confirm with the lessor about using condition of KOMTRAX.
Komatsu may suspend KOMTRAX communication in the following cases.
• When Komatsu judges that KOMTRAX is used by an unregistered customer.
• When Komatsu judges that KOMTRAX is used in a country or region where its use is not authorized.
3-148
• In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com-
munication.
If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any
resulting impacts or damages.
3-149
MACHINE OPERATIONS AND CONTROLS OPERATION
MACHINE OPERATIONS AND CONTROLS

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
METHOD FOR WALK-AROUND CHECK
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual
like loose bolts and nuts, leakage of fuel, oil and coolant. Also check the condition of the work equipment and
the hydraulic system.
Check also for loose wiring, play, and accumulation of dust in places that get very hot and are exposed to ex-
tremely high temperatures.
k WARNING
• Always hang the warning tag from the gear shift lever.
• Any combustible materials accumulated around the exhaust pipe, aftertreatment devices, turbo-
charger, or other high temperature engine parts or dump body (equipped with dump body heating
specifications) or the battery, and leakage of fuel or oil will cause the machine to catch fire.
Check carefully, and if any problem is found, repair and clean it or contact your Komatsu distribu-
tor.
• The lamps may become hot. Wait until they have cooled down before starting any work.
If the machine is inclining, make it level before checking.

Always perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play.
Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and
perform repairs if any problem is found.
2. Remove dirt and debris from around the engine, battery, radiator, and aftercooler.
Check that there is no dirt or dust accumulated around the engine, radiator or aftercooler. Check also that
there is no combustible material (dry leaves, twigs, etc.) accumulated around the battery, or muffler, turbo-
charger, or other high temperature parts of the engine or dump body (equipped with dump body heating
specification). Remove any dirt or combustible materials that are found.
For the method to remove dirt from the radiator and aftercooler, see “METHOD FOR CHECKING AND
CLEANING RADIATOR FINS, AFTERCOOLER FINS, AND AIR CONDITIONER CONDENSER FINS
(4-53)”.
3. Check around the engine for coolant and oil leakage.
Check for oil leakage from the engine and coolant leakage from the cooling system. If any problem is found,
repair it.
4. Check the fuel line for leakage.
Check for leakage of fuel or damage to the hoses and tubes. If any problem is found, repair it.
5. Remove dirt and check DEF line for leakage.
Check for dirt accumulated around the DEF tank and clean blue DEF tank filler cap and surrounding area.
Check DEF tank, pump, injector, and hoses and their connections for leakage. If any problem is found, ask
your Komatsu distributor for repair.
6. Removal dirt from around the aftertreatment devices.
Check for dirt and combustible materials (dry leaves, twigs, etc.) accumulated around the aftertreatment de-
vices. If any dirt or combustible materials are found, remove them.
7. Check around the aftertreatment devices for exhaust gas leakage.
Check the pipe connecting the turbocharger to the aftertreatment devices and also KDPF connections for
leakage of exhaust gas (and deposition of soot).
If any problem is found, ask your Komatsu distributor for repair.
3-150
OPERATION MACHINE OPERATIONS AND CONTROLS
8. Check the hose to KCCV and oil drain hose.

Check the hose to the KCCV and the oil drain hose for breakage and leakage.
If there is breakage or leakage, the emission standards are not satisfied. Ask your Komatsu distributor for
repair.
9. Check around SCR for exhaust gas leakage.
Check the pipe between the KDPF and SCR and also the SCR connections for leakage of exhaust gas
(and urea deposit). If any problem is found, ask your Komatsu distributor for repair.
10. Check for oil leakage from the transmission case, differential case, final drive case, hydraulic tank, brake
control oil tank, hoses, and joints.
Check for oil leakage. If any problem is found, repair the place where the oil is leaking.
Check for oil leakage from the undercover and oil drop trace on the ground.
11. Check the tires, wheels, and wheel hub bolts and nuts for damaged and wear, and check the wheel hub
bolts and nuts for looseness.
Check for cracks or peeling of the tires and for cracks or wear to the wheels (side ring, rim base, lock ring).
Tighten any loose wheel hub bolts or nuts.
If any problem is found, repair or replace the part.
If any valve cap is missing, install a new one.
12. Check the air cleaner mounting bolts for looseness.
Check for the loose bolts. If loose, tighten them.
13. Check the dump body mount rubbers.
Check for any cracks, caught foreign objects, or loose bolts.
14. Check for damage to the handrail and loose bolts.
If any breakage is found, repair it, and retighten the bolts.
15. Check for damage to the lamp and rear view camera.
If any part is damaged, replace it with new one.
Clean off any dirt on the surface.
16. Check the side mirror and under view mirror.
Check that the mirrors are not damaged. If any one is damaged, replace it with a new one.
Clean the surfaces of the mirrors and adjust the angle so that the area at the rear and lower portions can be
seen from the operator's seat.
17. Check the machine monitor and rear view monitor for abnormality.
Check the machine monitor and rear view monitor for abnormality. If any abnormality is found, replace the
failed monitor.
Clean off any dirt on the surface.
18. Check the seat belt and mounting hardware.
Check the seat belt and mounting hardware for abnormality.
If any part is damaged, replace it with a new one.
• Check for any loose bolts of the clamps mounting the equipment to the machine. Tighten any loose
bolts.
• If the seat belt is scratched or frayed, if any fittings are broken or deformed, replace the seat belt imme-
diately.
19. Check the tires.
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k WARNING
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 cords (1), or
with cracks in the rubber
• Tires with cut or broken cords (1)
• Tires with peeling (separation)
• Tires with damaged bead (2)
• Leaking or improperly repaired tubeless tires
• Deteriorated, deformed or abnormally damaged
tires, which do not seem usable.
20. Check the wheel rims.

Check that the wheel rims and rings are free from deformation, damage caused by corrosion, and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
METHOD FOR CHECKING BEFORE STARTING

Always check the items in this section before starting the engine each day.
METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK

1. Open fuel drain valve cover (1).
2. Place a container to receive drained oil under drain valve
(2) at the bottom of the fuel tank.
3. Loosen drain valve (2) to drain all the sediment and water
accumulated at the bottom together with fuel.
4. When clean fuel flows out, close drain valve (2).
METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS, RETIGHTEN-

ING BOLTS
Check wheel hub bolts (1) for breakage or looseness.
If any wheel hub bolt (1) of a wheel is broken, replace all the
wheel hub bolts (1) for that wheel.
If any bolt is loose, retighten it.
Tightening torque: 824 to 1030 Nm {84 to 105 kgm}
Insert a socket wrench in a pipe, then apply a force of 932 N
{95 kg} at point 1 m from the fulcrum. This will give a tightening
torque of 932 Nm {95 kgm}.
When the hub bolts are tightened after the tires are replaced,
travel for 5 to 6 km, then check for loose hub bolts.
3-152
METHOD FOR CHECKING OIL LEVEL IN TRANSMISSION CASE, ADDING OIL

1. Start the engine.
2. Run the engine at low idle and check the oil level using the
“Low temperature” scale on sight gauge (G).
If the oil level is low, add oil through oil filler port (F).
NOTICE
• The oil level changes according to the oil tempera-
ture, so check the oil level after completing the
warming-up operation.
• During operations or when idling the engine after
operations, check the oil level using the “High
temperature” scale.
METHOD FOR CHECKING DUST INDICATOR

1. Check that the red line in the transparent portion of dust in-
dicator (1) does not indicate 7.5 kPa (30 INCHES H2O)
{0.076 kg/cm2, 1.08 PSI}.
If the red line indicates 7.5 kPa (30 INCHES H2O)
{0.076 kg/cm2, 1.08 PSI}, clean or replace the air cleaner
element immediately.
For the cleaning method of the element, see “METHOD
FOR CHECKING, CLEANING AND REPLACING AIR
CLEANER (4-14)”.
2. After cleaning or replacing, press the top of dust indicator
(1) to return the red line to its original position.
METHOD FOR CHECKING BATTERY DISCONNECT SWITCH

Check that battery disconnect switch (S) is in ON position (I).
METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI-

MENT
The water separator forms one unit with fuel prefilter (1).
1. Check for water and sediment.

The water level and sediment are seen through transparent cup (2).
3-153
2. Put a container to receive the water under drain hose (4).

3. Loosen drain valve (3) and drain the water.
4. When fuel starts draining from drain hose (4), tighten valve (3) immediately.
REMARK
• If transparent cup (2) is dirty or it is difficult to see the inside, clean transparent cup (2) when replacing fuel
prefilter cartridge (1).
• When the drain valve (3) has been removed during the cleaning operation, coat O-ring with grease and
tighten until it contacts the bottom.
METHOD FOR ADJUSTING DRAIN VALVE

1. Place a container under the fuel prefilter cartridge to receive the fuel.
2. Loosen drain valve (1) and drain water and sediments
from transparent cup (2), and also drain all the fuel from fil-
ter cartridge (3).
3. Check that nothing more comes out from drain hose (4),
then remove drain valve (1).
4. Apply a suitable amount of grease to O-ring (5).

When doing this, be careful not to allow the grease to ad-
here to water drain port (6) and threaded portion (7) of the
drain valve.
5. Tighten drain valve (1) by hand until it contacts the bottom
of transparent cup (2).
6. Remove the fuel container.
7. Fill the fuel tank with fuel.
8. Bleed air from the fuel system.
For the air bleeding procedure of the fuel circuit, see
“PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT (3-248)”.
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury.
Accordingly, wait until they have cooled down before starting the work.
• When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
3-154
1. Check with sight gauge (G1).

If the oil level does not reach the window of gauge (G1),
add oil through oil filler port (F).
2. When checking the oil level after adding oil, check with
dipstick (G2).
The oil should be between H and L marks on dipstick (G2).
If the oil level is below L mark, add oil again through oil fill-
er port (F).
METHOD FOR CHECKING CAB MOUNTING BOLTS AND PINS

When getting on or off the machine with carrying a tool etc.,
place it once in part (A) to ensure your safety.
1. Check cab mount bolts (1) (4 pieces each on right and left)
for looseness.
If any bolt is loose, retighten it.
Tightening torque: 245 to 309 Nm {25 to 31.5 kgm}
2. Check that there are no loose or broken cab mount pins

(2) (right and left: 1 place each).
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT

k WARNING
• Do not open the sub-tank cap unless necessary.
When checking the coolant level, check the reservoir tank when the engine is cold.
• Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radia-
tor.
If the cap is removed in this condition, it is dangerous that you may get burn injury.
Always wait for the temperature to go down, turn the cap slowly to release the pressure, then re-
move the cap with care.
3-155
1. Open the engine hood.

2. Check that the coolant level in reservoir tank (1) is be-
tween FULL and LOW marks.
If the level is below LOW, remove cap (2) and add the
coolant up to FULL mark.
If no coolant is left in reservoir tank, add coolant through

water filler port (3) on the top of the sub-tank and also to
the reservoir tank.
If more coolant is added than normal, then check for water
leakage.
3. Check that there is no oil in the engine coolant or any oth-
er problem.
4. After refilling with coolant, tighten cap (2) securely.
5. Close the engine hood.
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
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 inclining, make it level before checking.
• When the ambient temperature is low, water or emulsified matter may stick to the dipstick, fuel filler cap,
etc. or the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant
level is normal, it is not a problem.
3-156
When getting on or off the machine with carrying oil, place it

once in part (A) to ensure your safety.

2. Pull out dipstick (G) and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into the dipstick pipe, then remove
it.
4. Check if the oil is sticking up to between marks H and L on

dipstick (G).
It is appropriate if the oil level is between marks H and L.
If the oil level is below L mark, add oil through oil filler port
(F).
If the oil level is higher than H, decrease it to a proper level

according to the following procedure.
1) Remove the bolts, and remove cover (1).
2) Place the oil container right under the drain plug to re-
ceive the drained oil.
3) Remove drain plug (2).

4) Install the drain hose on the back of the hydraulic tank
cover.
5) Loosen drain valve (3) gradually with care not to get
splashed with drained oil, and drain the excess oil.
6) Check the oil level again.
If the oil level is correct, tighten the oil filler cap se-
curely.
3-157
METHOD FOR CHECKING ELECTRIC WIRING

k CAUTION
• If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring,
promptly ask your Komatsu distributor to locate the cause of it and to make the repair.
• Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clog-
ged with dirt or dust, wash the battery cap to clear the breather hole.
NOTICE
Perform inspection for the piping of “battery”, “starting motor”, and “alternator” with particular care.
• Perform inspection to confirm that the fuses have no defect and their capacity is proper.
• Perform inspection to confirm that there is no disconnection or trace of short-circuiting in the electric wiring
and no damage to the coating.
• Perform inspection to confirm that there is no loose terminals, and tighten any loose parts if found.
• Check if there is any accumulation of combustible material around the battery, and remove such combusti-
ble material.
METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL

k WARNING
• When adding fuel, be careful not to let the fuel overflow.
This may cause fire.
Always wipe up all the spilled fuel.
• If fuel spills onto dirt and sand sticking to the machine, remove it and dirt and sand together.
• Fuel is highly flammable and dangerous. Do not bring any open flame near fuel.
1. Turn the starting switch to ON position.

2. When the fuel level caution lamp lights up in red, check the
fuel level with fuel level gauge (1) on the machine monitor.
When the fuel gauge pointer reads the red range, the fuel
quantity is 106 ℓ or less.
The fuel level is low. Add fuel.
3. After checking, return the starting switch to OFF position.
4. Open fuel filler cap (F) of the fuel tank.

5. Add fuel through the fuel filler port.
Fuel tank capacity: 525 ℓ
6. After adding fuel, close fuel filler cap (F) of the fuel tank.
After finishing the work, fill the fuel tank.
3-158
REMARK
• If the breather hole in the cap is clogged, the pressure inside the tank will go down and this may cause the
fuel to stop flowing. To prevent this, clean the breather hole from time to time.
• To prevent air from being sucked into the engine, always pay careful attention to the fuel level in the tank.
METHOD FOR CHECKING DEF LEVEL, ADDING DEF

k WARNING
• Do not put fluid other than DEF into DEF tank.
• When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face
away from the filler port.
• Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder
operation of the devices. Before removing the filler cap, wipe off the dirt from around the filler port.
Before inserting the filler nozzle into the filler port, wipe off dirt from it.
• If DEF is spilled, immediately wipe and wash the area with water. If spilled DEF is left unattended
and the area is not washed and cleaned, it can cause corrosion to the contaminated area and emit
toxic gas.
NOTICE
• Do not add DEF more than line F of sight gauge (4). DEF may leak through the breather. When the
ambient temperature is low and DEF may freeze, do not add it more than line (8) of sight gauge (4).
Be careful of the DEF line to be added when performing operations on a slope or traveling on a
rough ground. When the remaining DEF level is low, it may become the warning level if DEF pump
sucks air or if DEF level suddenly drops.
• If DEF is stored in unspecified container, foreign material may mix in it and toxic gas or corrosive
substance may be produced by chemical reactions. When adding DEF, do not transfer it to another
container.
• Do not use a funnel when to add DEF. The strainer may be broken.
• When using a portable DEF refill container, use up DEF each time. If any of DEF is left, remove for-
eign material, if there is any.
• Do not wash the adding nozzle in city water. Minerals may clog the devices.
• Do not dilute DEF with water.
• If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution
lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu
distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may
need to be replaced.
1. Turn the starting switch to ON position (B).
3-159
2. Check the DEF level gauge (1) on the machine monitor.

When adding DEF, perform actions written in “DEF LEVEL
CAUTION LAMP (3-22)”.
3. After checking, turn the starting switch back to OFF posi-

tion (A).
4. Open up cover (2) at the right side of the machine, clean

blue DEF tank filler cap (3) and surrounding area.
Turn the cap (3) counterclockwise.
The caps of DEF tanks are blue, as required by emission
regulations.
5. By sight gauge (4), add DEF through the filler port until
float (5) reaches line F (6).
Refill capacity of DEF tank: 33 ℓ
Line (7) in the sight gauge indicates approximately 5 ℓ be-
low line F, and line (8) indicates approximately 10 ℓ.
Line (8) is the max adding line when DEF may freeze in
cold weather.
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6. After adding, align claw (9) of the cap with groove (10) of
the filler port and close the cap securely by turning it clock-
wise by 90 °.
REMARK
• It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto
stop function to add DEF. When the specified nozzle is used, the magnet installed inside the filler port of the
tank cancels the wrong fluid addition prevention device, and you can add DEF. This mechanism prevents
addition of DEF into the fuel tank, addition of fuel into DEF tank, and spill of DEF from the filler port.
• When using a nozzle which is not conformed to ISO 22241-4, hold it in your hand and add DEF carefully
while checking the sight gauge.
• Add only DEF in clearly marked DEF tanks that have the blue cap.
METHOD FOR CHECKING TIRE PRESSURE

Check the tire inflation pressure before starting work while the tires are cold.
1. Measure the air pressure with an air pressure gauge.
2. Adjust the inflation pressure properly.
The proper inflation pressure is shown below.
Inflation pressure kPa {kg/cm2}

Tire size
Front wheel Center wheel Rear wheel
29.5-R25 (standard) 375 {3.8} 390 {4.0} 390 {4.0}
875/65R29 (option) 440 {4.5} 440 {4.5} 440 {4.5}
NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the
rim may be damaged.
Always keep the tire inflation pressure within 0 to +30 kPa {0 to +0.3 kg/cm2} of the value in the table
above.
3. Check the tires and the rims for wear or damage, and check the hub bolts for loosening.
METHOD FOR CHECKING CENTRALIZED WARNING LAMP, ALARM BUZZER, PI-

LOT LAMPS, AND METERS
1. Before starting the engine, turn the starting switch to ON position.
3-161
2. Check that the machine monitor operates as shown in “BASIC OPERATION OF MACHINE MONITOR
(3-11)”.
If the machine monitor does not work, there is probably a failure in the machine monitor system, so ask
your Komatsu distributor to perform inspection.
METHOD FOR CHECKING BRAKE

Check that the parking brake, foot brake, and retarder brake work sufficiently.
If any abnormality is found, ask Komatsu distributor to repair.
METHOD FOR CHECKING SECONDARY STEERING

k WARNING
Do not use the secondary steering motor for more than 90 seconds.
cause a fire.
Self-check function for secondary steering

The secondary steering is started automatically when the starting switch is turned to ON position to check the
secondary steering functions.
If defective operation of the secondary steering motor is found, ask your Komatsu distributor for repair.
k CAUTION
If the machine is steered during self-check, it may move.
Do not steer the machine during self-check.
Self-check of the secondary steering is not performed in the following cases.

In this case, perform “Check of automatic secondary steering”.
• After the starting switch is turned ON, without starting the engine, turned the starting switch OFF and then
turned it ON again
• When the engine preheating is operated.
• When ambient temperature is low (-10 °C or below)
REMARK
The battery voltage may drop sharply when the self-check is started due to the low temperature or condition of
the given battery.
METHOD FOR CHECKING MANUAL SECONDARY STEERING

k WARNING
cause a fire.
1. Turn the starting switch key to ON position.
3-162
2. Turn secondary steering switch (1) ON.

3. Turn the steering wheel and check that the steering is op-
erated.
If the steering is not operated when the steering wheel is
turned, ask your Komatsu distributor for repair.
METHOD FOR CHECKING AUTOMATIC SECONDARY STEERING

k WARNING
cause a fire.
1. Turn the starting switch to START position and start the engine.
2. Check that the brake oil pressure caution lamp is turned OFF.
3. Pull retarder control lever (2) fully.
4. Stop the engine.
5. Turn the starting switch key to ON position.
6. Set parking brake switch (3) to “TRAVEL” position, and
check that the secondary steering motor operates in 1 sec-
ond.
7. After checking set parking brake switch (3) to “PARKING”
position.
8. Turn the starting switch to OFF position.
REMARK
While the secondary steering motor is in operation, secondary
steering pilot lamp (4) lights up.
If the secondary steering motor operates 1 minute or longer,
secondary steering motor long-operation caution lamp (5) lights
up.
Do not operate the secondary steering motor for a long time.
METHOD FOR CHECKING BACKUP ALARM OPERATION

2. Place the gear shift lever in R position and check that the backup alarm sounds.
METHOD FOR CHECKING HORN OPERATION

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2. Check that the horn sounds immediately when the horn

button is pressed.
If the horn does not sound, ask your Komatsu distributor
for repair.
ADJUST BEFORE OPERATION

METHOD FOR ADJUSTING OPERATOR'S SEAT
k WARNING
• When adjusting the operator's seat, stop the machine on a safe place and set the parking brake to
“PARKING” position beforehand.
• Adjust it before starting operation or when operators change shift.
• Adjust the position of the operator's seat so that you can depress the brake pedal fully with your
back against the seat backrest.
METHOD FOR RECLINING SEAT

Pull the reclining adjustment lever upward, and move the back
cushion forward or backward.
Sit with your back against the backrest when adjusting the re-
clining angle. If your back is not on the backrest, it may sud-
denly return to the original position.
Adjustment amount
Forward tilt: 10 °(any degree is acceptable if it is greater than
10 °.)
Backward tilt: 18 °.
METHOD FOR TILTING SEAT

Operate the tilt adjustment lever upward, set the front of the
seat cushion to the desired height, then release the lever.
Adjustment amount
Forward tilt: 3 °
Backward tilt: 11 °
METHOD FOR ADJUSTING SEAT HEIGHT

Turn the engine starting switch to ON position when performing adjustments since the air compressor built in the
seat is used for this adjustment.
NOTICE
Avoid using the seat cushion height adjustment lever continuously for 1 minute or longer since such
practice can damage the air compressor.
The seat height is adjusted pneumatically and in stepless.
3-164
Pull up the height adjustment lever until it clicks or push it down

fully, and release it at a desired position.
If the height adjustment lever is pulled up and held, the seat
stops at the maximum height.
If the seat is raised to the maximum height, the suspension
lowers a little automatically to secure some stroke.
If you rise from the seat or try to change the load to the seat
during adjustment, the air in the suspension may be released.
Adjustment amount: 80 mm
REMARK
If you further pull up the height adjustment lever after the seat
reaches the highest position, the seat may not move up al-
though operating sounds of the air compressor are heard.
However, it is not a trouble.
In such case, the air compressor stops automatically in approx-
imately 8 seconds. You can also stop its operation by pushing
down the height adjustment lever.
METHOD FOR ADJUSTING WEIGHT ON SEAT

Turn the engine starting switch to ON position when performing adjustments since the air compressor built in the
seat is used for this adjustment.
NOTICE
Avoid using the seat cushion adjustment lever continuously for 1 minute or longer since such practice
can damage the air compressor.
The suspension should be adjusted in proportion to the operator's weight to protect the operator.
1. Press down the seat cushion adjustment lever and lower
the seat to the lowest position.
2. Pull up the seat cushion adjustment lever fully (until it
clicks), and then release it.
The seat cushion is adjusted automatically.
Operate the lever in the normal operating posture to en-
sure the correct weight-based adjustment at this time.
If you stand up from the seat or try to change the load ap-
plied to the seat during adjustment, the air in the suspen-
sion may be released.
When the operator is replaced with another person, push down the seat cushion adjustment lever and
move the seat to the lowest position, then fully pull up the seat cushion adjustment lever (until it clicks) and
release it. The seat cushion is adjusted automatically.
The seat-cushion adjustment starts as soon as the seat cushion adjustment lever is pulled lightly. Pull it up
fully (until it clicks), and then release it.
3-165
REMARK
• When doing the seat-cushion adjustment for the initial adjustment or for another operator, reduce the
damping force of the suspension damper before starting the adjustment. For details, see “METHOD
FOR ADJUSTING SUSPENSION DAMPER HARDNESS (3-167)”. If the damping force of the suspen-
sion damper is not reduced before starting adjustment of the seat height, the seat may slide down. If
the seat slides down, try the seat-cushion adjustment again after reducing the damping force of the
suspension damper. After the seat-cushion and height adjustment are completed, adjust the damping
force of the suspension damper to the desired level.
• The suspension should be adjusted in proportion to the operator's weight to protect the operator. Al-
ways perform this adjustment before starting the operation.
• If you stand up from the seat or try to change the load applied to the seat during adjustment, the air in
the suspension may be released.
METHOD FOR ADJUSTING SEAT CUSHION IN FORE-AFTER DIRECTION

Operate the fore-aft adjustment lever upward, set the seat
cushion to the desired position, then release the lever.
Fore-aft adjustment: 60 mm
METHOD FOR ADJUSTING HEADREST ANGLE

Turn the headrest back and forth and set it to a desired angle.
Adjustment amount: 38 °
METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION

Move the headrest up or down to the desired height.
Adjustment amount: 100 mm
3-166
METHOD FOR ADJUSTING ARMREST HEIGHT

1. Remove cap and loosen the nut.
2. After adjusting to the desired height, tighten the nut and at-
tach the cap.
Adjustment amount
Upward: 16 mm
Downward: 24 mm
You can flip up the armrest.
METHOD FOR ADJUSTING ARMREST ANGLE

Turn the angle adjustment knob to adjust the armrest angle.
Amount of adjustment: 40 ° (Forward tilt 30 °, backward tilt
10 °)
METHOD FOR ADJUSTING LUMBER SUPPORT

Turn the lumber support adjustment knob to the right or left,
and give proper tension to the waist part.
METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS

Adjust the damping force of the suspension damper by operating the suspension damper hardness adjustment
knob.
• To increase the damping force, direct knob toward outside
(A) of the seat.
• To decrease the damping force, direct knob toward inside
(B) of the seat.
Amount of adjustment: 5 steps
3-167
METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION

Operate the fore-aft adjustment lever upward, set the seat to
the desired position, then release the lever.
Fore-and-aft adjustment: 210 mm (10 mm x 21 stages)
METHOD FOR ADJUSTING MIRRORS

k WARNING
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 lead to a serious personal injury or death.

Loosen mirror mounting bolt (1) and nut (2), then adjust the
mirror to the position that assures the best view from the opera-
tor's seat.
• Adjust the position and angle of each mirror so that it re-
flects a sight 200 mm above the ground and up to
1500 mm.
In the adjustment, make sure that a part of the machine al-
so comes into view.
• View range
Mirror A
Machine's front side must be in view.
Mirror B
Hatched area (B), tire's ground contact point (B') and ground (B'') must be in view.
Mirror C
Machine's left side must be in view.
Mirror D
Hatched area (D), tire's ground contact point (D') and ground (D'') must be in view.
Mirror E
Hatched area (E) must be in view.
Mirror F
Hatched area (F) must be in view.
3-168
Rearview monitor
Hatched area (G) must be in view.
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE

k WARNING
• When the direction of the camera is changed due to an accident, setting must be done again.
Contact your Komatsu distributor.
• Install only the Komatsu genuine camera.
As shown in the figure, park the unloaded machine on a flat ground directing it straight forward.
3-169
When the machine dimensions are changed due to replacement of tires or installation of an optional attachment,
set the reference lines to the non-display mode according to the procedure in “REAR VIEW MONITOR SET-
TING (3-76)”, and then contact your Komatsu distributor.
Make sure that the images on the rear view monitor are normal as shown in the illustration. Then, confirm that
machine width guide line (3) matches with tire outside width (1) and distance guide line (4) matches with body
rear end (2).
When the reference line is abnormal, change its setting to Non-
display and contact your Komatsu distributor.
HANDLE SEAT BELT

k CAUTION
The three-point seat belt is installed to this machine. For the safety, always wear the shoulder belt even
if it can be removed from the waist belt.
If the shoulder belt is necessary to be removed from the waist belt, use the seat belt in the following
procedure.
3-170
1. After removing shoulder belt tongue (1) from the waist belt
buckle tongue, retract belt (2) slowly while putting a hand
on it.
If it is rewound suddenly, the winding device may be
locked on impact, and shoulder belt (1) may not be pulled
out.
Detail (A): When shoulder belt tongue (1) is removed from

waist belt buckle tongue (3)
Detail (A): When shoulder belt tongue (1) is inserted into

waist belt buckle tongue (3)
2. When the winding device is locked, tilt the back cushion

(5) backward by operating lever (4).
The shoulder belt becomes loose and the winding lock is
canceled.
If the lock cannot be canceled (shoulder belt tongue (1)

cannot be pulled out) after performing above operation,
3-171
ADJUST SEAT BELT

k WARNING
• Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt.
If it is worn or damaged, replace it.
• Even if no problem can be seen in the belt, replace it in accordance with the following schedule:
5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage,
whichever date comes sooner.
• Adjust and fasten the seat belt before starting to travel.
• Always fasten the seat belt when traveling.
• Make sure that the seatbelt is not twisted.
REMARK
The date indicated on the seat belt is the manufactured date.
It is the start of the 5-year period.
It is not the start of the 3-year period of actual usage.
METHOD FOR FASTENING AND UNFASTENING SEAT BELT

Fit the seat belt so that it fits tightly, without being too tight.
1. Sit in the seat and depress the brake pedal fully. Under this
condition, adjust the seat so that your back is fitted to the
backrest.
2. Sit in the seat, pull the right side of the belt, then insert buckle tongue (1) into buckle (2) until it “clicks”.
Fit the belt along your body without twisting.
When unfastening the belt, press the red button on buckle (2) to free the belt.
REMARK
If the seat belt is not inserted to buckle (2), seat belt cau-
tion lamp (3) is displayed on the machine monitor. Be sure
to fasten the seat belt.
3-172
METHOD FOR CONNECTING SHOULDER BELT AND WAIST BELT

1. Insert tongue (2) of the shoulder belt into buckle (1) of the
waist belt.
2. Rotate tongue (2) of the shoulder belt and make sure that
it is securely fixed to buckle (1) of the waist belt.
METHOD FOR ADJUSTING TILT OF STEERING WHEEL

k WARNING
Stop the machine before adjusting the tilt of the steering wheel.
If this operation (adjustment) is performed while the machine is traveling, it may lead to a serious per-
sonal injury or death.
You can adjust the lengthwise position and height of the steering wheel.
1. Raise the lever to FREE position (F) and adjust the steer-
ing wheel to a desired position.
2. Push down the lever to LOCK position (L) and fix the
steering wheel securely.
Tilting amount
Forward: 5 °, backward: 10 °
Telescopic adjustment amount
Upward: 20 mm, downward: 20 mm
NOTICE
Do not operate the lever with and excessive force. (Op-
erating effort of lever: 147 N to 176 N {15 kg to
17.9 kg})
The lever can be loosened or its angle can be dis-
placed.
In such case, ask your Komatsu distributor for the in-
spection.
3-173
METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE

k WARNING
• When starting the engine, check that the gear shift lev-
er is set to NEUTRAL position (N) and that the parking
brake switch is in “PARKING” position.
• Before standing up from the operator's seat, be sure
to set the parking brake switch to “PARKING” posi-
tion.
1. Check that battery disconnect switch (1) is in ON position

(I).
2. Check that parking brake switch (2) is in “PARKING” posi-

tion.
3-174
3. Check that gear shift lever (3) is in NEUTRAL position (N).
4. Check that dump lever (4) is in “HOLD” position.
5. Check that engine shutdown secondary switch (5) is in

“NORMAL” position (the cover is closed).
6. Insert the key into starting switch (6) and turn it to ON posi-
tion (B).
7. Check that the machine monitor operates as follows.

1) Centralized warning lamp (7) and pilot lamp (8) light
up for 2 seconds and go out for 1 second.
3-175
2) Machine monitor (9) displays start screen AA for 2

seconds, and then changes to standard screen BB.
3) The pointer of engine tachometer (10) swings once.
4) Speedometer (11) displays “88” for 2 seconds.
5) The alarm buzzer sounds for 2 seconds, then stops
under the normal condition.
NOTICE
If the lamps, alarm buzzer, etc. do not work, the
machine monitor may be defective or the electric
wiring may have breakage. In this case, ask your
Komatsu distributor for repair.
REMARK
• When the engine is started, the battery voltage
may suddenly drop depending on the temperature
and the battery condition.
In such case, the machine monitor may go out
temporarily or restart, but it is not a trouble.
• In approximately a second, the rear view monitor
displays soft version (12) for 5 seconds.
6) In 2 seconds, machine monitor (9) displays the stand-

ard screen.
If a password has been set, the password input
screen will be displayed on the monitor screen.
After inputting the password, press the enter switch.
REMARK
For details of the password setting, changing or can-
celing, see the separate “Password Change and Can-
cel Procedure”.
3-176
• When the starting switch is turned ON, the secon-

dary steering self-check function may operate.
When the standard screen is displayed while the
self-check is in operation, the secondary steering
pilot lamp (13) lights up.
REMARK
While the secondary steering self-check function is in
operation, the machine monitor may go out temporari-
ly or restart, but it is not a trouble.
For the secondary steering self-check function , see
“METHOD FOR CHECKING SECONDARY STEER-
ING (3-162)”.
If the gear shift lever is in any position other than NEUTRAL position (N) when the starting switch is
turned to ON position, the shift lever position display (14) of that position starts flashing, the centralized
warning lamp lights up, and the alarm buzzer sounds intermittently.
Even though the starting switch is turned to START position in this state, the engine is not started.
Turn the gear shift lever to NEUTRAL position (N), and the centralized warning lamp goes out, the
alarm buzzer stops sounding, and the engine can be started.
8. If caution lamp (15) stays lit, press the enter switch to iden-
tify the item lit in red, and check it immediately.
For details of contents and check methods for caution
lamp, see “WARNING DISPLAY (3-16)”.
9. If the maintenance due time of that item has been passed,

maintenance time caution lamp (16) lights up in red for 30
seconds. Press the menu switch, check that item, and then
perform maintenance immediately.
For details of the method of checking the maintenance in-
terval, see “MAINTENANCE SCREEN SETTING (3-73)”
METHOD FOR STARTING ENGINE

k WARNING
• Start the engine only while sitting down in the operator's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit.
Doing so may cause a fire or serious personal injury or death.
• Check that there are no persons or obstacles in the surrounding area, then sound the horn and start
the engine.
• Never use starting aid fluids as they may cause explosions.
• Exhaust gas is toxic.
When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
3-177
NOTICE
• Do not accelerate the engine abruptly until it is warmed up.
• Do not turn the starting motor continuously for more than 20 seconds.
• If the engine does not start, wait for 2 minutes or so, and then try to start the engine again.
• When starting the engine, do not depress the accelerator pedal.
Even if the accelerator pedal is depressed just after the engine is started, the engine speed is limi-
ted by the turbo protect function. After the turbo protect time, however, the engine speed rises
sharply and the turbocharger may be damaged.
This machine is equipped with an engine automatic preheating device that functions to start the engine preheat-
ing automatically.
When the engine coolant temperature is low, preheating pilot lamp (2) lights up when the key in starting switch
(1) is turned to 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 engine coolant temperature is low, preheating pilot

lamp (2) lights up and the automatic preheating starts.
2. Keep the key in starting switch (1) at ON position (B) until
preheating is completed and the preheating pilot lamp
goes out.
The following shows the rough preheating time.
Engine coolant temperature Preheating time
Min. –5 °C -
–5 to –20 °C 20 to 40 seconds
Max. –20 °C 40 seconds
REMARK
If the engine coolant temperature is –5 °C or above, when the starting switch is turned to ON position (B),
preheating of the engine is not performed.
In this case, it is possible to start the engine immediately.
3-178
3. If the preheating pilot lamp 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
START position (C).
The engine starts.
REMARK
If the ambient temperature is low, the engine may not start even when the key in starting switch (1) is
kept at START position for 20 seconds.
In such case, return the key in starting switch (1) to OFF position once, then in approximately 2 minutes,
repeat the operation from the start.
If the starting switch is not returned to OFF position, the automatic preheating does not start.
4. After the engine starts, release the key in the starting switch (1).
The key returns to ON position (B) automatically.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and
the battery condition.
5. Do not operate the accelerator pedal immediately after starting the engine. Run the engine for at least 15
seconds at low idle.
When the engine is started for the first time after the engine oil or engine oil filter is replaced, continue the
low idle run for at least 20 seconds to circulate the engine oil in the engine.
METHOD FOR MANUAL PREHEATING WHEN STARTING ENGINE

Manual preheating of the engine is available regardless of the ambient temperature.
3-179
1. Turn starting switch (1) from OFF position (A) to PREHEAT

position (D).
Preheating pilot lamp (2) lights up and the preheating of
the engine starts. (Preheating continues while the key in
starting switch (1) is held counterclockwise.)
While preheating is being performed, preheating pilot lamp
(2) lights up to show that preheating is being performed.
For the preheat time, see the table in “METHOD FOR
STARTING ENGINE (3-177)”.
2. After the preheating time passes, turn starting switch key

(1) to START position.
The engine starts.
If the engine cannot be started with the above procedure,
wait for at least 2 minutes, then repeat the procedure
again from step 1.
REMARK
When the key in starting switch (1) proceeds through OFF posi-
tion, the indicator of tachometer (3) may swing once and "88"
may be displayed on speedometer (4). It is, however, not a
trouble.
3-180
REMARK
If a password is set, the password enter screen is displayed on
the monitor screen, but the preheating pilot lamp lights up as
on the standard screen.
TURBOCHARGER PROTECTION FUNCTION

Since the turbocharger is a device that rotates at a very high speed, seizure results if it is not lubricated well.
In order to protect above trouble, the turbo protect function restricts increase of the engine speed immediately
after the engine is started until its oil pressure reaches an appropriate level.
• While the turbo protect function is operating, increase of the engine speed is restricted even if the accelera-
tor pedal is depressed.
• The turbo protect function operates as long as 20 seconds.
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE

METHOD FOR CANCELING TO HOLD DUMP BODY
k WARNING
If HOLD is canceled when the dump body is raised, the body will go down under its own weight. This is
very dangerous.
Always lower the dump body before stopping the engine.
If the engine is stopped, the body will stay in “HOLD” condition, regardless of the position of the dump lever.
If the engine is started in this condition, the dump body float caution lamp will light up.
Return the dump control lever to “HOLD” position, then move it to “FLOAT” position to cancel the dump body
“HOLD” condition.
When the dump body is set to “FLOAT” condition, the body float caution lamp will go out.
METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF

ENGINE
• When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and
smoothly.
• Check that there is no abnormal noise when the engine is idling or when the engine speed rises slightly.
When there is an abnormal noise at the engine startup and if that condition continues, the engine may be dam-
aged. In that case, ask your Komatsu distributor to check the engine as soon as possible.
METHOD FOR CHECKING LOW-SPEED RUN AND ACCELERATION OF ENGINE

k CAUTION
• Perform these checks in a safe place, watching out for danger in the surroundings.
• When the engine performs very badly at low idle and in the acceleration and if that condition contin-
ues, it may damage the engine or confuse the operator's sense of driving or lower the braking effi-
ciency, and as a result lead to an unexpected accident. In that case, ask your Komatsu distributor to
check the engine as soon as possible.
3-181
• When stopping the machine during the normal traveling operation, check that the engine does not hunt or
stop suddenly.
• When the accelerator pedal is depressed, check that the engine speed rises smoothly.
REMARK
• The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas filtering function.
• White smoke may be discharged for a short time immediately after the engine is started or during the after-
treatment devices regeneration in the cold season, but this is not a failure.
METHOD FOR RUNNING-IN THE NEW MACHINE

NOTICE
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 short-
en the machine life. Be sure to run in the machine for the initial 100 hours (as indicated by the service
meter).
Make sure that you fully understand the descriptions in this manual, then run in the machine while paying atten-
tion to the following points.
• Perform warm-up operation for 5 minutes after starting it up.
• Avoid operation with heavy loads or at high speeds.
• Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden
stops, and sudden changes in direction of the machine.
AUTOMATIC WARM-UP FUNCTION

This machine is equipped with the automatic warm-up function.
While the AISS LOW switch is in OFF position or when the engine coolant temperature is low, the low idle
speed is automatically increased to cut down the warm-up time.
REMARK
Turning AISS LOW switch to ON position stop the automatic warm up and decreases the idle speed.
If the engine coolant temperature is low and AISS LOW switch is returned to OFF position within a specific time
after engine is started, the automatic warm-up is resumed.
For AISS LOW switch, see “AISS LOW SWITCH (3-99)”.
NOTICE
When you are forced to urgently cancel the automatic warm-up operation, run the engine at full speed
for 3 seconds, then automatic warm-up operation is canceled.
During KDPF regeneration, the idle speed is set to rather high regardless of the engine coolant tempera-
ture.
METHOD FOR WARM-UP OPERATION

NOTICE
• Do not accelerate the engine sharply during the warm-up operation.
It can shorten the service life of the engine parts.
• Do not continue the low idle or high idle operation for more than 20 minutes.
It does not only adversely affect environment but also cause oil leakage from the turbocharger.
1. After the engine starts, run it for 5 minutes in the range between low idle and medium speed to warm it up.
3-182
2. Check if the indicator of the engine coolant temperature

gauge is over position (A).
When it is over position (A), the warm-up operation is com-
pleted.
If the indicator does not move from position (A), perform
the warm-up operation further
3. After finishing the warm-up operation, check that the ma-
chine monitor is normal.
If any of them is abnormal, ask your Komatsu distributor
for inspection and repair.
4. Check that the steering operation is normal, the lamps light up and go out normally, the horn sounds, and
the exhaust gas color, sound, and vibration are normal.
If any of them is abnormal, ask your Komatsu distributor for inspection and repair.
METHOD FOR STOPPING ENGINE

NOTICE
• If the engine is suddenly stopped without allowing it to cool down, there is danger that the life of the
engine parts will be shortened, so never stop the engine suddenly except in emergency. Allow the
engine to cool down gradually before stopping it.
• Always lower the dump body and set the dump lever to “FLOAT” position, then stop the engine.
1. Set the gear shift lever to NEUTRAL position (N), and set the parking brake switch to “PARKING” position.
2. Lower the dump body and set the dump lever to “FLOAT” position.
3. Run the engine at low idle for approximately 5 minutes to cool it down gradually.
4. Turn the key in starting switch (1) to OFF position (A).
The engine will stop.
5. Remove the key from starting switch (1).
METHOD FOR CHECKING AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check
for any leakage of oil or coolant. If any problems are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.
3-183
START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MA-

CHINE
METHOD FOR MOVING MACHINE
k WARNING
• When moving the machine off, check that the area around the machine is safe, then sound the horn
before starting.
• Keep people away from the machine.
• Clear any obstacles from the travel path.
• There is a blind spot behind the machine, so be extremely careful when driving the machine in re-
verse.
1. Check that there is no warning display on the machine

monitor.
2. Fasten the seat belt.
3. Set dump lever (1) to FLOAT position.

Check that the dump body float caution lamp is OFF.
If the dump body float caution lamp is lit, operate the dump
lever to “HOLD” position, then operate it to “FLOAT” posi-
tion to cancel the dump body HOLD condition.
4. Depress the brake pedal fully.
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5. Then set parking brake switch (2) to “TRAVEL” position to

release the parking brake.
REMARK
If the engine is stopped with the parking brake switch at
“TRAVEL”, the parking brake will be automatically applied
even though the parking brake switch is at “TRAVEL”. In
this case, operate the switch to “PARKING”, and then
move it back to “TRAVEL” to release the parking brake.
6. Check that retarder pilot lamp (3) is not lit.
7. Set gear shift lever (4) to a desired position.

NOTICE
• Always place the gear shift lever securely in posi-
tion when operating it. If the gear shift lever is not
placed securely in position, the shift lever position
pilot lamp on the machine monitor may start flash-
ing and the centralized warning lamp may light up,
and the alarm buzzer may sound.
• Always release the accelerator pedal when moving
the gear shift lever from positions NEUTRAL (N) to
REVERSE (R) or FORWARD (D or F).
8. Depress accelerator pedal (5) to start the machine.
NOTICE
• If the gear shift lever is shifted to a position other
than NEUTRAL position (N) when the parking
brake has not been released, the centralized warn-
ing lamp will light up and the alarm buzzer will
sound.
• If the gear shift lever is shifted to a position other
than NEUTRAL (N) when the dump lever is in a po-
sition other than “FLOAT” or the dump body is
raised, the centralized warning lamp lights up, the
body float caution lamp lights up in red, and the
alarm buzzer sounds.
• Do not operate the gear shift lever with the accel-
erator pedal depressed.
This will cause a big shock, and will also reduce
the service life of the machine.
3-185
METHOD FOR TRAVELING REVERSE

k WARNING
• When switching the travel direction, confirm the safety
in the direction to select.
There is a blind spot behind the machine, so be ex-
tremely careful when driving the machine in reverse.
• Always stop the machine completely before switching
the travel direction.
1. Set gear shift lever (1) to “R1” or “R2” position.
2. Depress accelerator pedal (2) gradually to start the ma-

chine.
NOTICE
• The machine cannot be driven in reverse when the
dump body is raised. Lower the dump body, set
the dump lever to “FLOAT” position, then operate
the gear shift lever to “R1” or “R2”.
• When switching between Forward and Reverse,
stop the machine completely and run the engine at
low idle when shifting the direction of travel.
After moving the gear shift lever, do not accelerate
until it is detected that the transmission clutch is
engaged.
• Do not operate the gear shift lever with the accel-
erator pedal depressed.
This will cause a big shock, and will also reduce
the service life of the machine.
METHOD FOR STOPPING MACHINE

k WARNING
• Avoid a sudden stop. Stop the machine gradually.
• If the foot brake is used repeatedly or is kept depressed for a long time, the brake may overheat and
its life will be shortened.
• If the parking brake is used to stop the machine, the parking brake will be damaged.
Do not use the parking brake except when stopping in emergency or when parking the machine af-
ter stopping it.
3-186
Release accelerator pedal (1), then depress brake pedal (2) to

stop the machine.
METHOD FOR STOPPING MACHINE IN EMERGENCY

If the machine is not stopped by depressing the brake pedal, perform the following.
k WARNING
• When the machine stops, chock the wheels immediately.
• If the parking brake is used to make an emergency stop, the performance of the parking brake may
drop below the standard value, so it is necessary to repair and adjust the parking brake.
Ask your Komatsu distributor to perform this work.
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1. Pull retarder control lever (1) fully to apply the retarder.

If operating retarder control lever (1) does not give enough
braking force, set parking brake switch (2) to “PARKING”
position to apply the parking brake.
2. When the machine stops in emergency, chock the tires im-
mediately.
Find out the cause and repair on the spot, when possible.
METHOD FOR SHIFTING GEARS

k WARNING
When traveling, and particularly when traveling downhill,
never set the gear shift lever to NEUTRAL position (N).
If the gear shift lever is set to NEUTRAL position (N) while
driving a machine at travel speed of above 4 km/h or trav-
eling downhill, the gear speed is not changed to neutral.
The centralized warning lamp flashes and the alarm buzzer
sounds. Always set the gear shift lever in D to 1 position
while traveling.
Shift gear as follows.
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Set gear shift lever (1) to a desired position.

This machine is equipped with automatic transmission, so the
transmission will shift automatically to match the travel speed.
When the dump body is raised, if the gear shift lever is at D po-
sition, the transmission is fixed in 2nd or 1st speed, and if it is
at positions 1 to 5, the transmission is fixed in 1st speed. Keep
the dump body lowered when traveling.
NOTICE
• When switching direction (FORWARD or REVERSE),
stop the machine completely and run the engine at low
idle, then select the direction of travel.
After moving the gear shift lever, do not accelerate un-
til it is detected that the transmission clutch is engag-
ed.
• Do not operate the gear shift lever with the accelerator
pedal depressed.
This will cause a big shock, and will also reduce the
service life of the machine.
Upshift (acceleration)
Depress accelerator pedal (2) gradually to accelerate the ma-
chine.
The lockup clutch is engaged and the direct drive starts.
If the machine is accelerated further, the transmission will auto-
matically shift up.
Downshift (deceleration)
Release decelerator pedal (2).
The machine is decelerated and the transmission automatically
shifts down.
Downshift inhibit
If the gear shift lever is operated when the machine is traveling, the travel speed may be faster than the maxi-
mum speed allowed for the new speed range. In this case, do not shift gear immediately. Reduce the travel
speed and then shift down. This will prevent the engine from overrunning.
Downshift when brake pedal is used
When using the brake pedal to reduce speed, the 3rd speed is held for longer than normal to reduce the shock
when shifting gear.
Engine overrun prevention function
If the engine speed exceeds the allowable range while traveling, the engine overrun caution lamp and the cen-
tralized warning lamp light up and the alarm buzzer sounds intermittently.
3-189
If the travel speed and engine speed continue to rise, the brake is automatically applied to prevent the engine
speed from rising too far.
Neutral coast prevention function
If the gear shift lever is set to NEUTRAL position (N) while driving a machine at travel speed of above 4 km/h,
the gear shift cannot be changed to neutral. The centralized warning lamp flashes and the alarm buzzer sounds
intermittently.
If a travel speed exceeds 4 km/h while going downhill with the gear shift lever in NEUTRAL position (N), the
centralized warning lamp flashes and the alarm buzzer sounds intermittently.
When the travel speed exceeds 23 km/h, the gear speed is automatically shifted to the gear speed optimum to
the current travel speed.
When traveling, and particularly when traveling downhill, never set the gear shift lever to NEUTRAL position (N).
Always set the gear shift lever in D to 1 position while traveling.
METHOD FOR TRAVELING DOWNHILL

When traveling downhill, travel at a safe speed which matches the width of the road, the condition of the road
surface, and other conditions of the jobsite.
k WARNING
• When the machine stops, chock the tires immediately.
• For the maximum permissible speed when traveling downhill using the retarder brake, see the
brake performance curve for the downhill distance and grade.
Traveling continuously downhill at a speed greater than the maximum permitted speed on the brake
performance curve is dangerous as the retarder brake may be damaged.
• If the retarder oil temperature caution lamp on the machine monitor lights up when the retarder is
being used, shift down to travel downhill.
(In this case, the centralized warning lamp lights up and alarm buzzer sounds.)
It the retarder oil temperature caution lamp does not go out even when the transmission is shifted
down, stop the machine immediately, set the gear shift lever to NEUTRAL position (N), run the en-
gine at 1800 rpm and wait the retarder oil temperature caution lamp goes out.
• If the retarder brake loses its effect when it is used for traveling downhill, do as follows.
1. Return the retarder control lever to its original position once completely, then operate the re-
tarder control lever again.
2. If the retarder still has not effect even when the retarder control lever is operated again, return
the retarder control lever completely to the “RELEASE” position, then depress the brake pedal
to stop the machine, then contact your Komatsu distributor for repair.
• Operate the retarder control lever gradually.
Sudden braking might cause an accident due to tire slip.
• When traveling, and particularly when traveling downhill, do not set the gear shift lever to NEUTRAL
position (N).
If the gear shift lever is set to NEUTRAL position while driving the machine at 4 km/h or traveling
downhill, the gear range is not changed to NEUTRAL. The centralized warning lamp flashes and the
alarm buzzer sounds. Always set the gear shift lever in D to 1 position while traveling.
NOTICE
• If the retarder control lever is operated when traveling downhill, the transmission can be shifted
down sooner than with normal deceleration.
It is also possible to travel without shifting up.
• Do not accelerate or shift up when using the retarder.
The engine speed rises and the alarm buzzer may sound and the engine overrun caution lamp and
centralized warning lamp may light up.
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1. Return accelerator pedal (1) before entering a downhill

slope.
2. Operate retarder control lever (2) to decelerate the ma-
chine.
3. Move the gear shift lever to the position (5, 4, 3, 2) that

matches the maximum permitted speed on the brake per-
formance curve.
4. When traveling downhill, operate retarder control lever (2)

to set the engine speed to above 1800 rpm and drive the
machine so that the indicator of the retarder oil tempera-
ture gauge comes within the white range.
BRAKE PERFORMANCE CURVE

How to read the graph
Example) Downhill distance: 1500 m
Traveling resistance: –11 % (Grade resistance: –13 %, rolling resistance: 2 %)
Payload: 40 t
Obtain the maximum permissible speed and the gear speed range from the graph when traveling downhill under
the above conditions.
1. Use the brake performance curve for downhill distance of 1500 m.
2. Starting from point (A) which corresponds to the gross machinery weight, draw a perpendicular line down.
3. Take the point where it crosses the line for travel resistance 1500 m as (B) and draw a horizontal line.
3-191
4. Take the point where it crosses the performance curve as (C), and draw a perpendicular line down. Take
the point where this line crosses the travel speed scale as (D).
5. The following information can be obtained from this procedure.
From point (D): Maximum permissible speed = “24 km/h”
From point (C): Gear speed = “F4”
This maximum permissible speed is one guideline determined from the retarder brake performance, so on an
actual jobsite, determine a safe travel speed below the maximum permissible speed to match the conditions of
the jobsite so that the retarder brake oil temperature gauge is always in the white range when traveling.
Terminology of the graphs

Gross vehicle weight (tons) Gross vehicle weight (tons)
Empty Empty
Load Load
Total resistance (grade + rolling) (%) Total resistance (grade + rolling) (%)
Vehicle speed (km/h) Vehicle speed (km/h)
3-192
Brake performance “Downhill distance: 450 m”
3-193
3-194
Brake performance “Downhill distance: Continuous”
PAY ATTENTION TO DEF LEVEL

Before working on a slope or traveling on a rough ground, check DEF tank and add sufficient amount of DEF as
necessary. If the remaining DEF level becomes low, sudden drop of its level or abnormality in urea SCR system
may be detected. If DEF level caution lamp or DEF system caution lamp lights up in red, move the machine to a
level place immediately and add DEF.
METHOD FOR TURNING MACHINE

k WARNING
If the machine is turned at high speed or on a steep slope, there is danger that it will tip over, so do not
operate the steering in such conditions.
k CAUTION
• If the steering wheel has been turned fully to the right or left, do not continue to apply force to turn
it further.
The oil temperature inside the steering hydraulic circuit will rise and cause overheating.
• When the steering nears the end of the turn on the left or right, turn the steering wheel more slowly.
Turning the steering wheel suddenly to the end of the turn will cause damage to the machine.
3-195
When the machine is traveling, turn steering wheel (1) in the

desired direction.
The machine turns.
On roads where there are curves, let the accelerator pedal
back before coming to the curve, shift down to the lowest
speed range possible then depress the accelerator pedal again
to continue driving.
Do not coast at high speed on a curved road.
REMARK
• The angle of the steering wheel may change (the position
of the spoke may change slightly) when the machine is
traveling, but this is not a failure.
• If force is applied to the steering wheel when the tires have
been turned fully to the right or left, the steering wheel will
turn a little at a time, but this is not a failure.
OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK

During traveling on dry sandy ground, etc., tire may slip and the machine may be vibrated up and down. In this
case, use the inter-axle differential lock switch before driving the machine.
NOTICE
Do not use inter-axle differential lock.
If inter-axle differential lock is used,
• it will be more difficult to operate the steering wheel.
• It will become more difficult to turn than it should be when the inter-axle differential lock is not
used, and in some cases, it may not be possible to steer around curves which were previously pos-
sible.
How to use inter-axle differential lock
Inter-axle differential lock switch
MANUAL AUTO
Inter-axle differential lock
§Actuated §Cancel
Terminology
Inter-axle differential lock switch Inter-axle differential lock switch
Manual Manual
3-196
Auto Auto
Inter-axle differential lock Inter-axle differential lock
Actuated Actuated
Cancel Cancel
Set the inter-axle differential lock switch to MANUAL before entering the dry sandy ground and actuate the inter-
axle differential lock.
Set it to AUTO when traveling on a normal ground.
HANDLE AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)

This is a system to automatically activate the retarder when an operator wants to use it on a downslope or slow
down on a flat hauling road.
It enables the retarder to automatically function according to the present selected gear speed and engine revo-
lution, thus making it easier for an operator to use the retarder.
k WARNING
• The ARAC system begins to function when the automatic retarder, accelerator control switch is in
ON position.
Check that automatic retarder, accelerator linked control switch is turned ON before running down
on a slope.
• The ARAC system may not assure thorough braking force to slow down, depending on a slope incli-
nation, load weight and selected gear speed.
In that case, use the retarder control lever and brake pedal to slow down to a safe speed.
• The tires may be locked when the dump truck is running on a slippery hauling road and the ARAC
system is in service.
If that happens, stop using the ARAC system.
• If some abnormalities occur in the ARAC system and the machine cannot be controlled securely,
the alarm buzzer sounds and the system is turned OFF to release ARAC. In that case, keep control
of the machine by using the retarder control lever and brake pedal, stop it in a safe place, and turn
the automatic retarder, accelerator linked control switch to OFF position.
• ARAC system does operate when the gear shift lever is in NEUTRAL position (N).
When ARAC operates, if the gear shift lever is set to NEUTRAL position (N), the retarder pilot lamp
goes out, and ARAC is released.
3-197
Explanation of components
(1) Automatic retarder, accelerator linked control (4) Brake pedal

switch (5) Retarder pilot lamp
(2) Retarder control lever
(3) Accelerator pedal
Automatic retarder, accelerator linked control switch
Automatic retarder, accelerator linked control switch is used to turn ON or OFF the ARAC system.
Retarder control lever
The retarder can be operated with the retarder control lever even while ARAC system is in operation.
REMARK
When the ARAC system is in operation, the retarder control lever has some play at the start of stroke.
It does not mean that the retarder brake does not work, but that it is the range of ARAC system operation.
Accelerator pedal
ARAC system functions only while the accelerator pedal is released.
Brake pedal
The wheel brakes can be operated with the brake pedal even while ARAC system is in operation.
Retarder pilot lamp
The retarder pilot lamp lights up when ARAC system operates and when the retarder is operated with the re-
tarder control lever.
(If the engine speed is low, even when ARAC system is actuated, the retarder pilot lamp may not light up.)
OPERATION OF ARAC SYSTEM

The ARAC system is actuated when the automatic retarder, accelerator linked control switch is turned to ON
position.
When the automatic retarder, accelerator linked control switch is turned to ON position, the retarder is automati-
cally actuated according to the travel speed and engine speed at that point.
If the accelerator pedal is depressed when the ARAC system is being actuated, actuation of the ARAC stops
and the machine speed increases.
3-198
If the brake pedal or retarder control lever are actuated while the ARAC is being actuated, the machine can be
slowed down or stopped in the same way as for normal brake operations.
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)

KTCS is a system to prevent slipping of the drive wheels caused by excessive torque and improve starting and
traveling ability on soft or slippery ground.
k WARNING
• KTCS system is enabled when the “KTCS Setting” is turned ON.
• If the system has trouble and cannot be controlled securely, the machine monitor displays an action
level and the system may stop operation depending on the failure condition.
• The machine may not travel safely on an extremely slippery road or a steep slope even if the KTCS
operates.
• If a wheel is stuck in the ground and the machine cannot escape while the KTCS operates, pull out
the machine with a bulldozer, etc.
Explanation of components
(1) KTCS setting (5) Accelerator pedal

(2) KTCS display (6) Brake pedal
(3) Inter-axle differential lock pilot lamp (7) Inter-axle differential lock switch
(4) Retarder control lever (8) KTCS system caution lamp
3-199
KTCS system setting

KTCS system can be set ON or OFF with “KTCS Setting”.
“OFF”
KTCS system does not operate.
“ON”
KTCS system operates.
REMARK
For operation method of KTCS setting, see “KTCS SYSTEM
SETTING (3-65)”.
KTCS display/ Inter-axle differential lock pilot lamp

KTCS display/ inter-axle differential lock pilot lamp lights up when the system detects slipping of a front or a
center wheel while the KTCS setting is ON and the KTCS operates.
Retarder control lever
If the retarder is operated with retarder control lever while the KTCS is in operation, the KTCS system stops
operation.
Accelerator pedal
The KTCS system can operate while accelerator pedal is depressed and the gear speed is any of F1, F2, F3,
R1, and R2.
If the accelerator pedal is released while the KTCS is in operation, the KTCS system stops operation.
Brake pedal
If the brake pedal is depressed while the KTCS is in operation, the KTCS system stops operation.
KTCS system caution lamp
If the KTCS system has a trouble, caution lamp is displayed on the machine monitor.
OPERATION OF KTCS SYSTEM

The KTCS system is enabled when the “KTCS Setting” is turned “ON”.
When KTCS system senses slip of the front wheel or center wheel, KTCS operates. At this time, KTCS display
or inter-axle differential lock pilot lamp lights up.
OPERATION IF TROUBLES ON SYSTEM OCCUR

When failure code DBIRKR, CA131, CA132, or DK30KX occurs, operate KTCS according to the following pro-
cedure.
For check of the failure codes, see “IF MACHINE MONITOR
SHOWS WARNING DISPLAY (3-261)”.
1. Use the brake pedal to reduce the travel speed and stop the machine at a safe place.
2. Set the gear shift lever to NEUTRAL position (N) position, and set the parking brake switch to “PARKING”
position.
3. Turn the starting switch to ON position or start the engine.
3-200
4. Disconnect (pull out) the secondary KTCS operation connectors (1) (No. TC1 (male), TC2 (female)), and
then connect (insert) them again.
Then, KTCS can operate.
5. Set the parking brake switch to TRAVEL position and move the machine to a safe place.
OPERATION IF TIRES ARE STUCK IN GROUND

If any wheel is stuck, operate the KTCS.
If it is impossible to get the machine out even when repeating the procedure below, use a bulldozer to tow the
machine out.
1. Check that the “KTCS Setting” is “ON”.
When the “KTCS Setting” is “ON”, the KTCS operates automatically. For KTCS Setting, see “HANDLE KO-
MATSU TRACTION CONTROL SYSTEM (KTCS) (3-199)”.
2. Set the gear shift lever to position “5” and increase the engine speed.
3. Release the accelerator pedal and brake pedal.
4. Set the gear shift lever to position “R1” and increase the engine speed.
5. Repeat steps 1 to 4 to move the machine backwards and forwards until it can escape.
METHOD FOR LOADING

k WARNING
Do not load the truck while its dump body is raised.
NOTICE
• When traveling, always set the dump lever to “FLOAT” position, regardless of whether the machine
is loaded or not loaded.
• If the gear shift lever is shifted to a position other than NEUTRAL position (N) when the dump lever
is not at “FLOAT” position, the centralized warning lamp will light up and the alarm buzzer will
sound.
• During loading operations, do not apply the parking brake. Apply the retarder brake.
• To maintain the operation of the retarder brake, do not stop the engine during loading work.
If large rocks are loaded directly onto the dump body by using a large-sized loader, etc., the dump body may be
deformed locally.
1. When loading large rocks, load soil and sand first as cushion material.
2. After loading the soil and sand, load the rock onto them.
The impacts to the dump body are reduced by this method.
In addition, when loading rocks that exceed the following conditions, install the optional body reinforcement
plate.
• Rocks with one side of more than 0.3 m
• Rocks of hardness more than 4.5 (Mohs scale)
• Rocks with weight of more than 150 kg
• When transporting steel ingots
HANDLE TAILGATE
(if equipped)
k WARNING
When hauling rocks or sticky materials, always remove the tailgate.
3-201
k CAUTION
Soil and sand accumulated on tail gate top (1) may fall. When approaching for testing or maintenance,
check that no soil or sand is accumulated.
NOTICE
Do not use a tailgate if the dump body is loaded with rocks, gravel, or sticky material such as clay.
There is a danger that the tailgate may be damaged, the operator's cab may be pushed up by the loaded
material caught in the tailgate during dumping operations.
Install a tailgate when hauling fluid materials such as finely
crushed soil.
When removing or installing the tailgate, consult your Komatsu
distributor.
METHOD FOR DUMPING

k WARNING
• Always follow the instructions of the signalman when
performing dumping operations.
• When dumping large rocks, operate the dump body
slowly.
• When performing inspection or maintenance with the
dump body raised, always use the body pivot pin and
lock the dump lever at “HOLD” position.
For detail, see “BODY PIVOT PINS (3-117)”.
Operate the dump body as follows.

1. Set gear shift lever (1) to NEUTRAL position (N), and set
parking brake switch (2) to “PARKING” position.
3-202
2. Move dump lever (3) to “RAISE” position, then depress the

accelerator pedal.
The dump body rises.
If the dump lever is released when it is at “RAISE” position,
it is held at “RAISE” position and the dump body will con-
tinue to rise.
The dumping speed increases in proportion to the engine
speed.
When the dump body rises to the previously set position,
dump lever (3) returns to “HOLD” position.
The dump body is then held at that position.
3. If it is necessary to raise the dump body further, operate
dump lever (3) to “RAISE” position.
The dump body rises further.
If dump lever (3) is released, dump lever (3) will return to
“HOLD” position and the dump body will stop at that posi-
tion.
While raising the dump body, when the dump body ap-
proaches the maximum tilt angle, release the accelerator
pedal in order to avoid any impact load on the hydraulic
circuit or hoist cylinder.
REMARK
• When the dump body is not seated, the engine speed is limited to 1800 rpm or below to protect the
work equipment pump.
And if the dump body is not lowered when the steering oil temperature is low (25 °C or below), the en-
gine speed is limited to 1500 rpm or below.
• During the dump body “RAISE” operation, if you set the dump lever to any position other than “RAISE”
once and set it to “RAISE” again, the dump body RAISE operation is delayed.
• To raise the dump body fastest, depress the accelerator pedal fully while the dump body is seated and
then set the lever to “RAISE” position.
(Above cuts the time shorter than depressing down on the accelerator after setting the dump lever to
RAISE position.)
4. Set dump lever (3) to “LOWER” position.
The dump body starts lowering.
3-203
5. When the dump body has moved down a certain distance,

move dump lever (3) to “FLOAT” position.
(When you release the lever, it returns to “FLOAT” posi-
tion.)
The dump body will then move down under its own weight.
REMARK
If the dump body is not seated, when the gear shift lever is
at “D” position, the transmission is fixed in 2nd or 1st
speed, and when it is at positions 1 to 5, the transmission
is fixed in 1st speed. Keep the dump body lowered when
traveling.
METHOD FOR OPERATING CAB TILT

k WARNING
To prevent serious injury or death if the cab comes down, always observe the following strictly when
tilting the cab.
Precautions before starting cab tilt operation
• Perform the cab tilt operation on a flat place.
• When performing the cab tilt operation, set the machine facing directly to the front to prevent con-
tact between the cab and dump body, and secure the front and rear frames with the articulation
lock.
• Set the parking brake switch to “PARKING” position to apply the parking brake.
• Lock the dump control lever with the dump lever lock knob.
• Chock the tires to prevent the machine from moving.
• Always remove the pin from rear mounting position and insert it in the position for tilting, before
removing the cab mount.
• Do not perform the cab tilt operation in the strong wind.
Precautions for cab tilt operation
• Do not perform the cab tilt operation when the machine is loaded.
• Do not stand under the cab during the cab tilt operation.
• When the cab is tilted up, lock it securely in position with the lock bar.
• When installing the lock bar, do not enter under the cab but install it from the side of the cab.
• While the cab is tilted up, do not get on or off it.
• While the cab is tilted up, do not operate the gear shift lever nor dump lever.
• While the cab is tilted up, do not start the engine.
If it is necessary to start the engine when performing inspection, check first that there is no one un-
der the cab.
• While the cab is tilted up, do not give a large impact to the machine.
• When using the cab power tilt function to lower the cab, do not open the valve quickly but open it
gradually while adjusting the lowering speed.
• The lock bar is set on the left inside of the engine hood. After using it, be sure to restore it.
3-204

1. Tilt guard (1) at the rear of the cab and fix it according to
the following procedure.
1) Remove mounting bolts (3) of R.H. bracket (2).
2) Turn bracket (2) counterclockwise 90 ° and fix it with

the bolts.
3) Remove mounting bolts (5) of L.H. bracket (4).
4) Flip up guard (1).

5) Turn bracket (4) 180 ° and hitch it on rear guard (6).
6) Fix bracket (4) with the bolts.
3-205
7) Turn R.H. bracket (2) counterclockwise 90 ° and fix it

with the bolts.
2. Remove pin (7) in the mount at the rear of the cab, and in-
sert pin (8) instead. (each of the right and left)
A: For traveling
B: For tilting
3. Remove cab mounting bolts (9) (8 pieces).

5. Install the sling to hooks (10) installed to the front of the

cab (on both right and left sides).
6. Sling the cab.
7. After tilting up the cab, fix it in position with lock bar (11).
Make sure that lock bar (11) is installed in the correct di-
rection and lock it securely with lock (12).
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8. After returning the cab to its original position, remove pin

(8) and insert pin (7) instead.
9. Install mounting bolts (9) (8 pieces).
11. Return guard (1) at the rear of the cab according to the fol-
lowing procedure.
1) Remove the bolts of R.H. bracket (2).
2) Turn bracket (2) clockwise 90 ° and fix it with the bolts.
3) Remove the bolts of L.H. bracket (4) and remove it

from the rear guard.
4) Lower guard (1).
5) Turn bracket (4) 180 ° and fix it with mounting bolts
(5).

7) Turn bracket (2) clockwise 90 ° and fix it with mounting
bolts (3).

• When traveling on roads in rain or snow, or when traveling on muddy or soft ground, consider the loaded
condition of the machine and be extremely careful not to let the tires slip or the machine spin and sink into
the ground.
• If the engine should stop when the machine is traveling, stop the machine immediately, then move the gear
shift lever to NEUTRAL position (N), and start the engine again.
• If the centralized warning lamp and pilot lamp for any “EMERGENCY” item on the machine monitor should
flash and the buzzer sounds during operation, stop the machine immediately and investigate the cause.
(See “TROUBLES AND ACTIONS (3-248)”)
• When loading, be careful to load the dump body uniformly, and be particularly careful to avoid loading too
much at the front.
• When traveling on a slippery road, use the accelerator pedal as long as possible since KTCS operates.
3-207
PERMISSIBLE WATER DEPTH

Do not go into water or swampy ground where the water is
deeper than the permissible water depth (up to the bottom sur-
face of differential case (1)).
After completing operations, wash the machine and lubricate
the parts where water has entered.
METHOD FOR PARKING MACHINE

k WARNING
• Avoid a sudden stop. Stop the machine gradually.
• Place the machine on a firm, level ground.
Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, set the parking brake switch to “PARKING” po-
sition, and chock the wheels to prevent the machine
from moving.
• If the gear shift lever is touched by mistake, the ma-
chine may move suddenly, and this may lead to a seri-
ous injury or death.
Before standing up from the operator's seat, always
set the parking brake switch securely to “PARKING”
position.
• The retarder must not be used as a parking brake.
k CAUTION
To prevent damage to the parking brake, apply the parking
brake only when parking the machine or performing dump-
ing operations.
1. Release accelerator pedal (1), then depress brake pedal

(2) to stop the machine.
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2. Place gear shift lever (3) to NEUTRAL position (N), then

set parking brake switch (4) to PARKING position to apply
the parking brake.
3. When in the operator's compartment, pull retarder control

lever (5) fully to apply the retarder.
METHOD FOR CHECKING AFTER FINISHING WORK

• Check the engine coolant temperature, engine oil pressure, and fuel level with the machine monitor.
• If the engine has overheated, do not stop the engine suddenly. Run it at a mid-range speed to cool it gradu-
ally before stopping.
LOCK
Always lock the following places.
(1) Fuel tank filler cap
(2) Engine hood
(3) Battery box
(4) DEF filler port cover
(5) Tool box
(6) Fuel drain valve cover
(7) Cab door
REMARK
Use the starting switch key to lock and unlock all these places.
METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP

PROCEDURES FOR OPENING FUEL FILLER PORT CAP
1. Insert the key into the key slot.
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2. Turn the key clockwise to unlock.

Position (A): OPEN
Position (B): CLOSE (LOCK)
3. Turn the cap clockwise and remove it.
PROCEDURES FOR CLOSING FUEL FILLER PORT CAP

1. Screw in the cap until it becomes tight, then insert the key into the key slot.
2. Turn the key counterclockwise and remove it.
Position (A): OPEN
METHOD FOR OPENING AND CLOSING ENGINE HOOD

k CAUTION
• When opening or closing the engine hood, place the machine on a level ground, and stop the en-
gine.
• When opening the engine hood, do not release the handle until the lock plate is set in LOCK posi-
tion securely.
• When closing the engine hood, hold the handle securely since the engine hood may moves down
because of its own weight.
If the engine hood is not locked, it may close suddenly because of wind, etc.
• Immediately after the engine is stopped, the engine hood and the aftertreatment devices are still
hot. Accordingly wait until they have cooled down before opening or closing the engine hood.
METHOD FOR OPENING ENGINE HOOD

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Position (A): OPEN
3. Pull grip (1) toward you and unlock it.

4. Keep lever (2) depressed, hold handle (3) of the hood, and
pull it up to open.
Open the hood until it is fixed securely.
METHOD FOR LOCKING ENGINE HOOD

1. Hold hood knob (1), operate lever (2), and unlock.
2. Lower the hood.
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4. Turn the key clockwise and remove it.

(A): OPEN
(B): CLOSE (LOCK)
METHOD FOR OPENING AND CLOSING BATTERY INSPECTION COVER

METHOD FOR OPENING BATTERY INSPECTION COVER
Position (A): OPEN
3. Push in the key groove and open up the cover.
METHOD FOR LOCKING BATTERY INSPECTION COVER

1. Close the cover and insert the key into the key slot.
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Position (A): OPEN
METHOD FOR OPENING AND CLOSING DEF TANK FILLER CAP COVER
k CAUTION
• When opening or closing the DEF tank filler cap cover, place the machine on a level place, lower the
work equipment to the ground, stop the engine, then perform the operation.
• When opening it, do not release the handle until the stay is set in the lock position securely.
• When closing it, hold the handle securely since the DEF tank filler cap cover may move down be-
cause of its own weight.
If it is not locked, it may close suddenly because of wind, etc.
METHOD FOR OPENING DEF TANK FILLER PORT COVER

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2. Turn the key counterclockwise and open the cover by pull-

ing it.
Position (A): OPEN
METHOD FOR LOCKING DEF TANK FILLER PORT COVER

Position (A): OPEN
METHOD FOR OPENING AND CLOSING TOOL BOX COVER

PROCEDURES FOR OPENING TOOL BOX COVER
3-214

Position (A): OPEN
3. Turn the handle counterclockwise, and then open the cov-
er.
PROCEDURES FOR LOCKING TOOL BOX COVER

1. Close the cover and turn the handle clockwise.
Position (A): OPEN
METHOD FOR OPENING AND CLOSING FUEL TANK DRAIN VALVE COVER
PROCEDURES FOR OPENING FUEL TANK DRAIN VALVE COVER
1. Open the key cover.
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3. Turn the key counterclockwise and open the cover by pull-

ing it.
Position (A): OPEN
PROCEDURES FOR LOCKING FUEL TANK DRAIN VALVE COVER

Position (A): OPEN
3. Close the key cover.
METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR LOCK

When opening the door (locked door)
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2. Turn the key counterclockwise, and the door is unlocked.

Position (A): OPEN
The key returns to position C automatically.
3. Pull the door handle, and the door opens.
When locking
1. Close the door and insert the key into the key slot.
2. Turn the key clockwise, and the door is locked.
Position (A): OPEN
The key returns to position C automatically.
3. After locking, pull out the key.
3-217
HANDLE TIRE
PRECAUTIONS WHEN HANDLING TIRES
k WARNING
To ensure safety, the defective tires given below must be replaced with new tires.
• Tires where the bead wire has been cut, broken, or greatly deformed
• Excessively worn tires where more than 1/4 of the circumference of the carcass ply (excluding the
breaker) is exposed
• Tires where damage to the carcass exceeds 1/3 of the tire width
• Tires where ply separation has occurred
• Tires where radial cracks extend to the carcass
• Deteriorated, deformed or abnormally damaged tires, which do not seem usable.
(1) Side wall

(2) Shoulder
(3) Tread
(4) Breaker or belt (cord layer)
(5) Bead
(6) Inner liner
(7) Cord
Contact your Komatsu distributor when replacing the tires. It is
dangerous to jack up the machine without taking due care.
PRECAUTIONS FOR LONG DISTANCE TRAVEL

If the machine travels continuously at high speed for a long distance, there will be a remarkable increase in the
generation of heat in the tire. This may cause premature damage to the tire, so observe the following.
• Travel only unloaded.
• Check the tire inflation pressure before starting for the day when the tires are cold, and adjust to the follow-
ing inflation pressure.
• Do not reduce the tire inflation pressure when traveling.

Tire size
29.5-R25 (standard) 375 {3.8} 390 {4.0} 390 {4.0}
875/65R29 (option) 440 {4.5} 440 {4.5} 440 {4.5}
NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim
may be damaged.
Always keep the tire inflation pressure within 0 to +30 kPa {0 to +0.3 kg/cm2} of the value in the table
above.
• The maximum travel speed must be kept to less than 40 km/h km/h. Stop for at least 1 hour for every 1
hour of travel to allow the tires and other components to cool down.
• Never drive the machine with “water” or “dry ballast” in the tires.
3-218
OPERATION HANDLE AIR CONDITIONER
HANDLE AIR CONDITIONER

NOTICE
• When running in the air conditioner, always start with the engine running at low speed. Never start
the air conditioner when the engine is running at high speed.
It will cause failure of the air conditioner.
• If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, take care
not to let water get on these parts.
In addition, never bring any open flame near them.
• For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean
and do not leave anything around the sunlight sensor that may interfere with its sensor function.
• When performing inspection and maintenance of the ma-
chine equipped with the air conditioner, refer to the tables
in “METHOD FOR CLEANING AIR CONDITIONER AIR
FILTERS (4-23)” and “METHOD FOR CHECKING RE-
FRIGERANT LEVEL FOR AIR CONDITIONER (GAS)
(4-22)”.
• When the air conditioner is not used every day, to prevent
loss of the film of oil at various parts, run the air condition-
er with the engine at low speed from time to time and per-
form cooling or dry heating for several minutes.
• When the temperature inside the cab is low, the air condi-
tioner may not work. In this case, circulate recirculation air to warm the inside of the cab. After that, turn the
air conditioner switch ON, the air conditioner will work.
• If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner
system caution lamp lights up on the monitor screen. If the air conditioner system caution lamp lights up,
ask your Komatsu distributor for inspection and repair.
Ventilation
• When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform
ventilation and cooling.
• If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window
and turn the lever to FRESH for a while for ventilation and cooling to drive smoke out.
Temperature control
For reasons of health, the optimum setting for cooling is considered to be when it feels slightly cool (5 to 6 °C)
lower than the ambient temperature) when you enter the cab.
Be careful to select the appropriate temperature.
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HANDLE AIR CONDITIONER OPERATION
EXPLANATION OF AIR CONDITIONER EQUIPMENT
(1) OFF switch (6) FRESH/RECIRC air selector switch

(2) Fan switch (7) Display monitor
(3) Temperature control switch (8) Air conditioner switch
(4) Vent selector switch (9) Defroster switch
(5) Auto switch
OFF SWITCH
The OFF switch is used for stopping the fan and air conditioner.
REMARK
Even if this OFF switch is pressed, the monitor screen does not
switch to the air conditioner adjustment screen.
3-220
FAN SWITCH
You can adjust the air flow by using the fan switch.
The air flow can be adjusted to 6 levels.
• Press the △ switch to increase the air flow; press the ▽
switch to decrease the air flow.
• During auto operation, the air flow is automatically adjust-
ed.
Monitor display and air flow

Monitor dis- Air flow rate
play
Air flow "low"
Air flow "medium 1"
Air flow "medium 2"
Air flow "medium 3"
Air flow "medium 4"
Air flow "high"
TEMPERATURE CONTROL SWITCH

Use the temperature control switch to adjust the temperature
inside the cab. The temperature can be set between 18 to
32 °C.
• Press the △ switch to raise the set temperature; press the
▽ switch to lower the set temperature.
The set temperature is indicated on the display monitor.
• The temperature is generally set at 25 °C.
• The temperature can be set in stages of 0.5 °C.
Monitor display and function

Monitor display Set temperature
18 °C Max. cooling
18.5 to 31.5 °C Adjusts temperature inside cab to set temperature
32 °C Max. heating
3-221
REMARK
If the mode is set to auto mode and the temperature setting is set to 18 °C or 32 °C, the air flow from the fan is
always set to “HIGH” and does not change even when the temperature reaches the set temperature.
VENT SELECTOR SWITCH

The vent selector switch is used to select the vents.
• When vent selector switch is pressed, the LC display on
the monitor display switches and air blows out from the
vents displayed.
• During automatic operation, the vents are automatically
selected.
(A): Rear window glass vent (2 places)

(B): Face vent (4 places)
(C): Foot vent (1 place)
(D): Front window glass vent (2 places)
Vent
LCD display Air vent mode Remarks
(A) (B) (C) (D)
Face vent -
○
Face vent, foot vent -

○ ○
Foot vent -
○
Foot vent Not selected in auto mode

Defroster vent ○ ○ ○
Air blows out from the vents marked with ○.
3-222
AUTO SWITCH
Use the auto switch for automatic selection of the air flow,
vents, and air source (FRESH/RECIRC) according to the set
temperature.
• Press the auto switch, then use temperature control switch
(1) to set the temperature, and run the air conditioner un-
der automatic control.
• When switching from automatic operation to manual oper-
ation, it is possible to use the switches to select the vents
and air source (FRESH/RECIRC).
REMARK
When Auto Mode is selected, if the set temperature is set to
18 °C or 32 °C, the air flow is always set to “High”, but this is
not a problem.
FRESH/RECIRC AIR SELECTOR SWITCH

Use FRESH/RECIRC air selector switch to switch the air
source between recirculation of the air inside the cab and in-
take of fresh air from the outside.
During automatic operation, the selection of inside air (RE-
CIRC) and outside air (FRESH) is performed automatically.
RECIRC
Outside air is shut off and only air inside the cab is circulated.
Use this setting to perform rapid cooling of the cab or when
outside air is dirty.
FRESH
Outside air is taken into the cab.
Use this setting to take in fresh air or to demist the window glass.
REMARK
Intake of external air (FRESH) is automatically selected when the door is opened. Selection by use of the switch
is not available.
The setting mode is restored after the door is closed.
DISPLAY MONITOR
This monitor display displays the status of temperature setting
(A), air flow (B), and vents (C).
3-223
When OFF switch (1) is pressed, the display of temperature

setting (A) and air flow (B) goes out, and operation stops.
AIR CONDITIONER SWITCH

Use the air conditioner switch for turning the air conditioner
(cooling, dry heating) ON or OFF.
• Press air conditioner switch when the fan is operating

(when air flow level is shown on the display monitor). The
air conditioner is switched ON and starts to work. Press
the switch again to stop the air conditioner.
• Air conditioner cannot be operated while the fan is stop-
ped.
DEFROSTER SWITCH
This defroster switch is used to select the defroster mode.
3-224
When this switch is pressed, the display on the display monitor

changes to (F).
When the defroster switch is pressed, the defroster mode is se-
lected, from any mode of FACE, FACE/FOOT, and FOOT.
When the defroster switch is pressed again, the mode before
the defroster mode is selected.
REMARK
Air also blows out from the FOOT vent even in the defroster
mode.
METHOD FOR OPERATING AIR CONDITIONER

The air conditioner can be operated automatically or manually. Select the method of operation as desired.
METHOD FOR AUTOMATIC OPERATION

1. Turn the auto switch ON.
Set temperature (A) and air flow (B) are displayed.
2. Use temperature control switch to set to the desired tem-

perature.
The air flow, combination of vents, and selection of fresh or
recirculated air is automatically selected according to the
set temperature, and the air conditioner is operated auto-
matically to provide the set temperature.
3-225
REMARK
When vent display monitor (C) displays (D) or (E), and engine
coolant temperature is low, the air flow is automatically limited
to prevent cold air from blowing out.
METHOD FOR STOPPING AUTOMATIC OPERATION

Press OFF switch.
The air conditioner stops.
METHOD FOR MANUAL OPERATION

1. Press fan switch and adjust the air flow.
When doing this, check that temperature setting (A) and

air flow (B) are displayed.
3-226
2. Turn air conditioner switch ON.
3. Use temperature control switch to set to the desired tem-

perature.
4. Press vent selector switch and select the desired vents.
When this is done, the display for vent (C) of the monitor
changes according to the selection.
5. Press FRESH/RECIRC air selector switch and select recir-

culation of the air inside the cab (RECIRC) or intake of
fresh air from outside (FRESH).
3-227
METHOD FOR STOPPING MANUAL OPERATION

Press OFF switch.
The air conditioner stops.
METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET
To operate with cold air blowing to the face and warm air blowing to the feet, set as follows.

air flow (B) are displayed on the monitor.
2. Press vent selector switch and set the vent display on the
display monitor to the display shown in the figure.
3-228
3. Turn air conditioner switch ON.
4. Adjust fan switch, temperature control switch and FRESH/

RECIRC air selector switch to the desired positions.
METHOD FOR OPERATING DEFROSTER

3-229

air flow (B) are displayed on the monitor.
2. Press the vent selector switch or defroster switch and set

vent display on the display monitor to (F) or (G) as shown
in the figure.
3. Press FRESH/RECIRC air selector switch and set it to

FRESH mode.
4. Press temperature control switch and set temperature on

the display monitor to 32 °C of maximum heating.
5. Adjust vents (A) so that the air blows onto the window glass.
3-230
(Vent (D) is fixed.)
6. When operating in the rainy season or when it is desired to

remove the mist from the window glass or to dehumidify
the air, turn air conditioner switch ON.
3-231
HANDLE RADIO OPERATION
HANDLE RADIO
• To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera-
tion.
• If water gets into the speaker case or radio, it may lead to failure.
Take care not to let water get on them.
• Do not wipe the display or buttons with solvent such as benzene or thinner.
Wipe with a dry soft cloth.
• When the battery disconnect switch is turned to OFF position or the power for the machine is turned off for
the replacement of the battery, the clock may be initialized. In such a case, set it again.
For handling of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-115)”.
EXPLANATION OF RADIO EQUIPMENT
(1) Power button (5) Preset button

(2) Band/AUX selector button (6) Display selector button
(3) Volume control button (7) Sound control button
(4) Tuning/time adjustment button (8) Display
POWER BUTTON
Press the power button to supply the power to the radio and the frequency is shown on display. As long as AUX
is selected, display indicates AUX on it. Press the button again to turn the power off.
BAND/AUX SELECTOR BUTTON

Press band/AUX selector button to select the desired band or AUX.
Each time the button is pressed, the band changes FM → AM → AUX → FM...
VOLUME CONTROL BUTTON

Use the volume control button to control the volume.
Press the △ button, and the volume increases. Press the ▽ button, and the volume decreases. The range for
the volume is 0 to 32.
Hold down this button, and you can change the volume continuously.
TUNING/TIME ADJUSTMENT BUTTON

Use the tuning/time adjustment button to select frequency and step for sound adjustment and to adjust time.
For the adjusting method, see “METHOD FOR CONTROLLING RADIO (3-234)”.
3-232
OPERATION HANDLE RADIO
PRESET BUTTON
If you register desired stations to the preset button beforehand, you can select each station by touching this but-
ton once.
It is possible to preset 6 stations each for both AM and FM.
For the presetting method, see “METHOD FOR CONTROLLING RADIO (3-234)”.
DISPLAY SELECTOR BUTTON

Use the display selector button to change frequency and clock shown on the display.
Each time you press this button, frequency, clock and band are shown on the display in this order.
If 1.5 seconds passes while a band is shown, a frequency will be displayed.
As long as AUX is selected, this button alternately switches the display between AUX and the clock.
SOUND CONTROL BUTTON

Press the sound control button, and the sound adjustment is ready.
Each time this button is pressed, BAL (Balance), TRE (Treble) and BAS (Bass) will be selected in this order.
If this button is pressed while BAS is displayed, the sound adjustment will be canceled.
For the sound adjusting method, see “METHOD FOR CONTROLLING RADIO (3-234)”.
DISPLAY
(A): Band name, “AUX”, frequency, clock and other character/
numeric information are displayed.
(B): Frequencies are displayed at steps of 50 kHz in certain
areas.
(C): Lights up when a stereo broadcasting is heard while a FM
station is selected.
(D): Lights up at the time of balance adjustment in the sound
adjusting condition.
(E): Lights up at the time of treble adjustment in the sound ad-
justing condition.
(F): Lights up at the time of bass adjustment in the sound adjusting condition.
AUX
You can hear the sound through the speaker of the machine when you connect a commercially available porta-
ble audio equipment to the machine.
3-233
1. Open cap (1).

2. Connect a portable audio equipment by using an commer-
cially available audio cable.
3. Press the band/AUX selector button and select AUX.
NOTICE
• A stereo miniature plug can be connected.
Read the instruction manual of the equipment to con-
nect carefully.
• As a power source for the equipment to connect, use
the battery attached to that equipment.
If you use an electric power supply installed to the ma-
chine, the noise may occur.
• The noise may occur if you pull out the input plug
when AUX is selected, or if you push in or pull out the
plugs of the equipment to connect.
METHOD FOR CONTROLLING RADIO

METHOD FOR ADJUSTING FREQUENCY
1. Press band/AUX selector button (1) and select FM or AM.
2. Press tuning/time adjustment button (2) to adjust the fre-
quency.
• Press the △ button, and the frequency increases;
press the ▽ button, and the frequency decreases.
• Hold down the △ button, and the frequency increases
continuously; hold down the ▽ button, and the fre-
quency decreases continuously.
• Hold down the △ button and release it, then the fre-
quency increases continuously. Hold down the ▽ but-
ton and release it, then the frequency decreases continuously as an auto seek.
When a proper frequency is picked up, the tuning automatically stops.
METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING)

2. Hold down sound control button (2).
When a proper frequency is picked up, it is automatically
registered to preset memories 1 to 6.
3-234
OPERATION HANDLE RADIO
METHOD FOR CALLING PRESET

2. Press one of 1 to 6 of preset button (2).
The frequency registered in the preset number of the
pressed button is called up and received.
“Example”
While a frequency is displayed, press button 1 of preset
button (2), and the preset number “P-1” is displayed on the
display.
The preset number is shown for 0.5 seconds, and then the
frequency is displayed.
METHOD FOR REGISTERING PRESET

Hold down one of 1 to 6 of preset button (1) while listening to
the radio.
The currently received frequency is registered to the preset
number corresponding to the pressed button.
“Example”
While a frequency is displayed, keep pressing button 1 of pre-
set button (1), and the preset number “P-1” is displayed.
After the preset number flashes 3 times, the frequency is dis-
played and then registered to preset number “P-1”.
METHOD FOR ADJUSTING SOUND BALANCE

1. Press sound control button (1) to light up “BAL” on the dis-
play.
You can adjust the sound (balance).
2. Press tuning/time adjustment button (2) to adjust the
sound (balance).
• Press the △ button, and the speaker output on the R
side increases by 1. (R1 to R7)
• Press the ▽ button, and the speaker output on the L
side increases by 1. (L1 to L7)
METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE)

1. Press sound control button (1) to light up “TRE” on the dis-
play.
You can adjust the sound (treble).
sound (treble).
• Press the △ button, and the treble level increases by
1. (Maximum +7)
• Press the ▽ button, and the treble level decreases by
1. (Minimum -7)
3-235
METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS)

1. Press sound control button (1) to light up “BAS” on the dis-
play.
You can adjust the sound (bass).
sound (bass).
• Press the △ button, and the bass level increases by 1.
(Maximum +7)
• Press the ▽ button, and the bass level decreases by
1. (Minimum -7)
METHOD FOR ADJUSTING CLOCK

1. Press display selector button (1) to display the time.
2. Hold down display selector button (1) to flash the “HOUR”
display portion.
You can adjust the hour.
3. Press tuning/time adjustment button (2) to adjust the hour.
• If you press △ button, “HOUR” display increases by 1.
• If you press ▽ button, “HOUR” display decreases by
1.
4. Press display selector button (1) to flash the “MINUTE” dis-
play portion.
You can adjust the minute.
5. Press tuning/time adjustment button (2) to adjust the minute.
• If you press △ button, “MINUTE” display increases by 1.
• If you press ▽ button, “MINUTE” display decreases by 1.
6. Press display selector button (1) to cancel time adjustment.
The screen returns to the clock display.
3-236
OPERATION DUMP BODY HEATING SPECIFICATIONS
DUMP BODY HEATING SPECIFICATIONS

The dump body heating is a function to improve the removal of soil from the dump body by heating the dump
body with the exhaust gas.
If the dump body heating specification is employed, the machine can obtain outstanding easiness of dumping
when the operation is performed in the freezing area.
After the aftertreatment devices regeneration, the temperature of dump body may rise 250 °C or higher because
of the exhaust gas.
k CAUTION
For the machines equipped with dump body heating specification, the dump body becomes highly heat-
ed during the aftertreatment devices regeneration.
Stay away from the dump body to prevent burn injury.
If the following objects are loaded, fire may occur.
• Objects which mainly contains combustible materials such as dry leaves, chips, pieces of paper,
and coal dusts
The temperature around the dump body becomes high as shown in the figure.
Remedy to prevent fire

When loading the combustible materials, change the machine specification to the specification without dump
body heating.
Contact your Komatsu distributor for changing the machine specification to the specification without dump body
heating.
In case the combustible materials are loaded, momentarily avoid a fire in the following procedure.
1. Avoid the automatic regeneration by performing regeneration disable operation after the engine is started.
2. After finishing the work, perform the manual stationary regeneration while the machine is unloaded.
For the methods of the manual stationary regeneration and regeneration disable operation, see “HANDLE Ko-
matsu Diesel Particulate Filter (KDPF) (3-121)”.
REMARK
Mixing a large amount of soil into the combustible materials helps to decrease the fire.
3-237
DETERMINE AND MAINTAIN TRAVEL ROAD OPERATION
DETERMINE AND MAINTAIN TRAVEL ROAD

Determining and performing maintenance of the road in the jobsite are the extremely important factors both for
reasons of safety and for reducing the cycle time.
To ensure safety in operations, do as follows.
Determine travel road
• As far as possible, restrict the travel road to one-way travel.
• If it is impossible to keep one-way traffic, make the road with ample width to enable trucks traveling in oppo-
site directions to pass each other.
If it is impossible to provide a sufficient road width, provide passing places at various points along the road.
• Always design the road so that the loaded truck passes on the side closest to the hill face.
• If there are curves with poor visibility along the road, set up mirrors.
• In a place where the road shoulder is weak or likely to collapse, set up a sign at a point at least 1.5 m from
the road shoulder to warn of the danger.
• It is important to set up lighting or reflectors on the road to enable the traveling at night.
• The grade of slope should be kept within 10 % (approximately 6 °) as far as possible, and emergency es-
cape points should be set up on downhill slopes in case of any brake failure.
• Increase the number of places where the road continues in a straight line. If there are curves in high-speed
travel areas, make the radius of the curve as large as possible.
• Small S curves are particularly dangerous, so avoid such curves. The radius of the curve must be a mini-
mum of 12 m to 15 m.
• Make the radius of curves as large as possible.
• Make the road wider at curves than it is in straight areas.
• Make the surface of the road slightly higher on the outside of curves.
• Be particularly careful to strengthen the road shoulder on the outside of curves.
• Design the travel road as far as possible so that it does not cross any other travel road.
In particular, when roads cross at an angle on slopes, there is danger that a difference in height will be cre-
ated in the road, and this will make the machine sway strongly when traveling at high speed.
• Cut the slope face to provide a special road for the trucks.
Maintain travel road
Perform the necessary action according to the conditions to insure that the road can always be traveled in safe-
ty.
• Remove any unevenness in the travel surface, sloping to the left or right, or drooping of the road shoulder.
Make the road of ample strength and remove such obstacles as rocks and tree stumps.
• Maintain the road with a bulldozer or motor grader from time to time.
• Spray the road with water at suitable intervals to prevent dust from rising and reducing the visibility.
3-238
OPERATION TRANSPORTATION
TRANSPORTATION
PRECAUTIONS FOR TRANSPORTATION
Always obey the traffic regulations when transporting the machine by road.
k WARNING
This machine may need to be divided into components for transportation depending on the regulation.
When transporting the machine, consult your Komatsu distributor.
PRECAUTIONS FOR TRANSPORTING MACHINE

SELECT TRANSPORTATION METHOD
As a basic rule, always transport the machine on a trailer.
When selecting the trailer, refer to the weight and dimensions shown in “SPECIFICATIONS (5-2)”.
Note that the “SPECIFICATIONS” for the weights and dimensions for transportation differ according to the type
of tires and type of dump body.
METHOD FOR SECURING MACHINE

After loading the machine in the specified position, secure it in place as follows.
1. Set the parking brake switch to “PARKING” position to ap-
ply the parking brake.
2. Turn the starting switch key to OFF position, and stop the
engine.
3. Remove the key from the starting switch.
4. Set the articulation lock to LOCK position (L) to lock the

front and rear frames.
3-239
TRANSPORTATION OPERATION
5. Put blocks in front of and behind the tires and secure the
machine with chains or wire rope of a suitable strength to
prevent the machine from moving during transportation.
In particular, fix the machine securely to prevent it from
slipping sideways.
NOTICE
Always retract the antenna.
Reassemble the mirrors so that they are within the
width of the machine.
PRECAUTIONS FOR LIFTING MACHINE

When lifting the machine at a port or any other place, always use the following procedure to lift it.
k WARNING
• The person using the crane to perform lifting operations must be a qualified crane operator.
• Do not lift the machine with someone in it.
• Always use a wire rope that has ample strength for the weight of the machine being lifted.
• When lifting, keep the machine horizontal.
• Before starting the lifting operation, always stop the engine, apply the parking brake, and use the
articulation lock to prevent the front frame from articulating.
• Never enter the area under or around a lifted machine.
Never try to lift the machine in any other posture or by using any other lifting equipment than those given in the
following procedures.
There is a danger that the machine loses its balance.
NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs depending on the attachments and options installed.
For details of the procedure for machines that are not the standard specification, consult your Komatsu
distributor.
For the weight of standard specification machine, see “Weight table”.
NOTICE
• Use protectors, etc. so that the wire ropes will not be broken at sharp edges or narrow places.
• When using a spreader beam, select an ample width to prevent contact with the machine.
Consult your Komatsu distributor before performing lifting work.
3-240
Location of lifting position mark
Weight table
Machine Load on Load on Load on rear Center of gravity
weight front axle center axle axle (from front axle)
HM400-5 35055 kg 20035 kg 7690 kg 7340 kg 2287 mm
PROCEDURE FOR LIFTING MACHINE

Lifting work is allowed for only machines having lifting marks.
When performing the lifting operation, place the machine on a firm, level ground, and do as follows.
1. Start the engine set the machine in the straight travel posture.
3-241
TRANSPORTATION OPERATION
2. Set the dump lever to “FLOAT” position and check that the
dump body float caution lamp is not lit.
3. Stop the engine and apply the parking brake.
4. Check the safety around the operator's compartment, set

the articulation lock to LOCK position (L) to prevent the
front frame and rear frame from articulating.
5. Select wire ropes, slings, spreader beams and other lifting

tool to match the weight of the machine, and fit the wire
ropes to the lifting hooks (at lifting hook marks) at the front
of the front frame and the rear of the rear frame.
3-242
For the front portion of the front frame, install the sling,
passing it through center bumper (1) as shown in the fig-
ure.
If the sling is passed through side bumper (2), the bumper
may be damaged.
6. Fit protector blocks at contact points (3) between the lifting

tool and the dump body to prevent damage to the lifting
tool.
7. When the machine comes off the ground (raised 100 to
200 mm), stop the lifting operation once, check carefully
that the machine is balanced and that the wire ropes are
not loose, then continue the lifting operation slowly.
3-243
COLD WEATHER OPERATION OPERATION
COLD WEATHER OPERATION

COLD WEATHER OPERATION INFORMATION
If the ambient temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze.
Follow the instructions described as follows.
FUEL AND LUBRICANTS

Change fuel and oil with ones of low viscosity for all components.
For the details of specified viscosity, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”.
COOLANT
k WARNING
• Coolant 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 immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to
perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.
NOTICE
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC) for the coolant.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For details on the coolant change interval and the concentration of Non-Amine Engine Coolant (AF-NAC), see
“METHOD FOR CLEANING INSIDE OF COOLING SYSTEM (4-19)”.
DEF
NOTICE
• DEF freezes at –11 °C.
If DEF in DEF tank freezes, it may expand to break the devices in the tank. The parts inside the tank
may be affected. Add DEF to the specified amount for cold weather (below the level of when DEF
may freeze).
For the specified amount of DEF, see “METHOD FOR CHECKING DEF LEVEL, ADDING DEF (3-159)”.
• If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is
lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF,
and keep it in the condition free from freezing.
BATTERY
k WARNING
• Battery generates flammable gas. Never bring any open flame near fuel.
• Battery electrolyte is dangerous object. 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 pow-
er 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 sur-
face.
3-244
OPERATION COLD WEATHER OPERATION
When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging
rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be
started easily in the next morning.
REMARK
Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table.
Electrolyte Temper-
ature 20 °C 0 °C –10 °C –20 °C
Charging Rate (%)
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
• When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it
from the machine to place it in the warm place. Restore it again before the operation.
• If the electrolyte level is low, add distilled water in the morning before beginning the work. Do not add water
after the day's work to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS AFTER DAILY WORK COMPLETION

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
• Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean
to prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
• Place the machine on a firm, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to move the next morn-
ing.
• Open the drain valve at the bottom of the fuel tank to drain the water accumulated in the fuel system and
prevent it from freezing.
• In cold weather condition, add DEF to the defined level strictly. If adding more than the defined level, it may
expand to break the devices in the tank when it freeze.
If DEF tank level is lower than the defined level for the cold weather, DEF may freeze easily to damage the
parts in DEF system. If the filler cap freeze, de freeze and open.
• The battery function decreases remarkably at low temperature.
Cover it, or remove it from the machine to place it in the warm place. Restore it again before the operation.
• If the electrolyte level is low, add distilled water in the morning before beginning the work.
Do not add water after the day's work to prevent diluted electrolyte in the battery from freezing during the
night.
AFTER COLD WEATHER SEASON

When the season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM-
MENDED FUEL, COOLANT, AND LUBRICANT (7-4)”.
If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated
freeze, ask your Komatsu distributor to inspect.
3-245
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION
PRECAUTIONS FOR LONG-TERM STORAGE

PREPARATION FOR LONG-TERM STORAGE
When putting the machine in storage for a long time (more than one month), do as follows.
• Clean and wash all parts of the machine and store it indoors.
If the machine has to be stored outdoors, select a level ground and cover the machine with waterproof
sheet.
• Fill up the fuel tank.
This prevents dew condensation.
• Fill up DEF tank (Except cold weather condition).
If the inside dries up, urea is deposited and it may cause failures in component operation.
• Grease the machine and change the oil before storage.
• Coat the exposed portion of the hydraulic cylinder piston rod with grease.
• Turn the starting switch to OFF position, then turn the battery disconnect switch key to OFF position, and
remove it.
When storing the battery, cover it.
For the operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-115)”.
• Apply the parking brake.
• Set the tire inflation pressure for each tire to within the range of the specified inflation pressure for the type
of tire.
• Push the retarder control lever forward to OFF position.
• Set the gear shift lever to NEUTRAL position (N).
• To prevent rust, fill the cooling circuit with Non-Amine Engine Coolant (AF-NAC) to give a density of at least
30 % for the engine coolant.
MAINTENANCE DURING LONG-TERM STORAGE

k WARNING
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, charge the battery as well.
• 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.
STARTING MACHINE AFTER LONG-TERM STORAGE

NOTICE
If the machine has been stored without performing the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine after long-term storage, perform the following items 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.
• Insert the battery disconnect switch key and turn it to ON position.
For the operation method, see “BATTERY DISCONNECT SWITCH (3-115)”.
3-246
OPERATION PRECAUTIONS FOR LONG-TERM STORAGE
• If the machine is stored for a long period with the battery disconnect switch OFF or the battery terminal dis-
connected, the clock information and radio tuning information may be lost. In this case, set the information
again. For detail, see “CLOCK ADJUSTMENT (3-81)” and “HANDLE RADIO (3-232)”.
• When starting the engine, warm it up sufficiently according to the procedure in “METHOD FOR WARM-UP
OPERATION (3-182)”.
If the machine has been stored for more than 2 months, perform the following procedure.
• Before starting the engine, replace DEF filter and fill up DEF tank according to the procedure in “METHOD
FOR REPLACING DEF FILTER (4-78)”.
• Start the engine and check correctly.
If SCR system has any abnormality, warning is displayed on the monitor screen and the audible alert
sounds. If SCR system has any abnormality, stop the engine, and then start it again.
If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor.
• If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement.
Dispose of drained DEF according to the local regulations and rules.
Aged DEF may have smell of ammonia. Replace DEF in a well-ventilated place and take care not to inhale
its vapor.
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE

1. Check all the oil and water levels before traveling.
2. When traveling after long-term storage, travel forward at a speed of 10 to 15 km/h for 5 minutes or 1 km to
run the machine in, then change to normal travel.
3-247
TROUBLES AND ACTIONS OPERATION
TROUBLES AND ACTIONS

ACTIONS WHEN RUNNING OUT OF FUEL
When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system
before starting the engine.
Always check the fuel level to prevent running out of fuel.
If the engine has stopped due to run out of fuel, all air must be sufficiently bled from the fuel circuit.
PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT

k CAUTION
When using the fuel feed pump, do not loosen the air bleeding plug of the fuel circuit.
The fuel circuit is pressurized while the fuel feed pump is operated. If the air bleeding plug is loosened
at this time, fuel may spout out and it is dangerous.
1. Turn the starting switch key to OFF position (A) and stop
the engine.
2. Tilt switch for the fuel feed pump (1) to ON position.

Lamp (2) flashes and the fuel feed pump operates.
After the specified time (approximately 7 minutes), lamp
(2) goes out automatically and the fuel feed pump stops.
3. If the engine stopped because of running out of fuel or if
the supply pump is replaced after servicing of the fuel ho-
ses and tubes, the fuel circuit is empty. In such a case, set
fuel feed pump switch (1) to ON position again after the
fuel feed pump stops (the lamp goes out) automatically.
When the lamp goes out, air bleeding is completed.
If the engine does not start, air may not be bled completely. In this case, repeat the operations of steps 1 to
4.
ACTIONS IF TRANSMISSION HAS TROUBLE

If the transmission has any trouble, operate the machine according to the following procedure.
1. Use the brake pedal to reduce the travel speed and stop the machine at a safe place.
2. Set the gear shift lever to NEUTRAL position (N) position, and set the parking brake switch to “PARKING”
position.
In some trouble modes, the gear is not shifted even if the shift lever is operated.
In this case, perform the following procedure.
1) Turn the starting switch to ON position or start the engine.
3-248
OPERATION TROUBLES AND ACTIONS
2) Disconnect (pullout) emergency escape connector (1)

(No. A1 (female), A1 (male), white 1-pole connector),
and then connect (insert) it again.
3) Set the parking brake switch to the “TRAVEL” position.
4) Operate the gear shift lever to move the machine to a
safe place without depressing the accelerator pedal.
If the gear shift lever is operated with the accelerator pedal depressed, the emergency escape function will not
work.
In addition, the emergency escape function may not work for some failure codes.
While the emergency escape function is actuated, the machine monitor shift indicator displays “E” and the trans-
mission shift range in turn.
METHOD FOR LOWERING DUMP BODY IN EMERGENCY

When the dump body needs to be lowered to the seat while the engine cannot be started for some trouble, per-
form the following procedure.
1. Remove cover (2) from the rear of hydraulic tank (1).
2. Loosen locknut (4) of manual lower valve (3).
3. Turn grip (5) of valve (3) counterclockwise.
The oil in the hoist cylinder is drained into the hydraulic
tank and the dump body lowers.
4. Tighten grip (5) and lock nut (4).
5. Install cover (2).
If the dump body does not go down even when the above
method is used, consult your Komatsu distributor.
3-249
PRECAUTIONS FOR TOWING MACHINE

k WARNING
Injury or death could result if a disabled machine is towed
incorrectly or if there is a mistake in the selection of the
wire rope or drawbar.
• Always confirm that the wire rope or drawbar used for
towing has ample strength for the weight of the ma-
chine being towed.
• Never use the wire rope which has cut strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
• Always wear leather gloves when handling the wire
rope.
• Never tow a machine on a slope.
• During the towing operation, never stand between the
towing machine and the towed machine.
• If the machine moves suddenly, a load is applied sud-
denly to the towing wire or drawbar, and the towing
wire or drawbar may break.
Move the machine gradually to a constant speed.
• Be extremely careful if there is a failure in the engine
or brake system: the brakes will not work.
• If the steering and the brakes on the disabled machine
cannot be operated, do not let anyone ride on the disa-
bled machine.
NOTICE
• The maximum towing capacity for this machine is 247569 N{25245 kg}. Do not tow any load greater
than this.
• Towing is only permitted in order to move a disabled machine to a place where it is possible to per-
form inspection and maintenance.
Do not tow it a long distance.
• Consult your Komatsu distributor for information about towing a disabled machine.
This machine must not be towed except in emergencies. However, if it is avoidable to tow the machine, take the
following precautions.
• When towing a machine, tow it at a low speed of less than 2 km/h, and for a distance of a few meters to a
place where repairs can be performed. This method is applied only in emergencies. If the machine must be
moved long distances, use a transporter.
• Use a towing machine 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 ma-
chines on slopes or on the tow road.
• When towing, set the articulation lock of the towed machine to LOCK position.
However, when towing in places where it is needed to steer, set the articulation lock to FREE position. Use
2 towing machines of the same class or larger than the machine being towed: connect one machine each to
the front and rear of the machine being towed.
• Use the specified hook for both the towing machine and the machine being towed.
• To protect the operator if the towing wire or towing bar breaks, install protective plates on both the towing
machine and the machine being towed.
3-250
• There are towing hooks under the front frame and at the
rear of the rear frame.
Use only these hooks when towing. Do not use any other
place for towing.
• When fitting the towing wire, check the condition of the
hook to make sure that there is no problem.
• Keep the angle of the towing wire as small as possible.
Keep the angle between the center lines of 2 machines to
within 30 °.
• Towing may be performed under various differing condi-
tions, so it is impossible to determine beforehand the re-
quirements for towing.
Towing on flat level roads will require the minimum rim pull,
while towing on slopes or on uneven road surfaces will re-
quire the maximum rim pull.
• Always release the parking brake before towing.
For the releasing method, see “METHOD FOR RELEAS-
ING PARKING BRAKE (3-252)”.
• Before releasing the parking brake, always chock the all

wheels.
If the wheels are not chocked, there is a danger that the
machine may move suddenly.
Connect with the towing wire or drawbar, and remove the
blocks from the wheels when the towed machine is in a
condition where it cannot run away.
• When releasing the parking brake, check that the sur-
rounding area is safe.
• If the parking brake is released, the brakes will not work,
so pay careful attention to safety.
• When towing down a slope, use 2 towing machines. One machine should be uphill from the disabled ma-
chine and should be connected with towing wire or a drawbar to pull the disabled machine back and keep it
stable. The other machine should tow the disabled machine downhill.
When engine runs
• 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.
• Check the effect of the brakes, and if the brakes do not work properly, take the action given in “When en-
gine does not run”.
• Check if it is possible to steer the machine. If the machine cannot be steered, follow the procedure given in
“When engine does not run”.
• The operator should sit on the machine being towed and operate the steering in the direction that the ma-
chine is towed.
• Always run the engine to allow the steering and brakes to be used.
When engine does not run
• The brakes will not work, so be extremely careful.
• Connect the towing machine securely to the towed machine.
Use 2 towing machines of the same class or larger than the machine being towed: connect one machine
each to the front and rear of the machine being towed.
3-251
• If it is necessary to change the direction of the machine being towed, it is possible to use the secondary
steering, but it can be used for a maximum of only 90 seconds.
• If the secondary steering cannot be used, disconnect 2 hydraulic hoses each on the left and right from the
steering cylinders, then perform the towing operation.
When removing the hoses, block the hoses with plugs and fit oil containers to the mouthpiece of the cylin-
der to prevent oil from draining to the ground.
METHOD FOR RELEASING PARKING BRAKE

See the following procedure if it is necessary to release the parking brake when towing or moving the machine.
Ask your Komatsu distributor if it is necessary to release the parking brake.
k WARNING
• If any problem occurs in the brake hydraulic system, there is a high probability that the wheel
brakes will not work properly. Always drive slow when towing the machine.
• When releasing the parking brake, check that the surrounding area is safe and always chock the all
wheels before starting the work.
If the wheels are not chocked, there is a danger that the machine may move suddenly.
• Always stop the engine before starting the operation to release the parking brake.
1. Stop the engine.

2. Chock the wheels.
3. Turn adjustment screw (1) of parking brake counterclock-

wise.
4. Check that there is a clearance between the parking brake
pad and brake disc.
5. When the parking brake is released, tow the machine im-
mediately to a safe place.
For towing, see “PRECAUTIONS FOR TOWING MA-
CHINE (3-250)”.
3-252
PRECAUTIONS FOR DISCHARGED BATTERY

k WARNING
• It is dangerous to charge a battery when installed on a
machine. Make sure that it is removed before charg-
ing.
• When checking or handling the battery, stop the en-
gine and turn the starting switch and battery discon-
nect switch keys to OFF positions.
• The battery generates hydrogen gas, and it is danger-
ous that it may explode. Do not bring open flame such
as lighted cigarettes near the battery, or do nothing
that will cause sparks.
• Battery electrolyte is dilute sulfuric acid, and it will at-
tack your clothes and skin. If it gets on your clothes or
on your skin, immediately wash it off with a large
amount of clean water.
If it gets in your eyes, wash the eyes immediately with
clean water, then consult a doctor for medical treat-
ment.
• When handling batteries, always wear protective eye-
glasses and rubber gloves.
• When removing the battery, first disconnect the cable
from the ground (normally the negative (-) terminal).
When installing, first connect the cable to the positive
(+) terminal.
If a tool touches the positive terminal and the chassis,
it is dangerous that it may cause a spark. Be extremely
careful.
• If the terminals are loose, it is dangerous that the de-
fective contact may generate sparks, and it may cause
an explosion.
Install the cable terminals securely.
• When removing or installing the cable terminals,
check which is the positive (+) terminal and which is
the negative (-) terminal.
PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY

k CAUTION
• Before removing the battery, remove the ground cable (normally connected to the negative (-) termi-
nal).
If any tool touches between the positive (+) terminal and the chassis, there is a hazard of sparks
being generated.
• When installing the battery, connect the ground cable last.
When replacing the battery, fix the battery body with the battery mounting fixtures.
Securely tighten the terminal to the following tightening torque.
3-253
Tightening torque of wiring harness terminal (1): 11.8 to

19.6 Nm {1.2 to 2.0 kgm}
Tightening torque of battery terminal (2): 9.81 to 11.8 Nm {1.0
to 1.2 kgm}
Tightening torque of 1st nut (3) of mounting fixture: 6.96 to
9.02 Nm {0.71 to 0.92 kgm}
Tightening torque of 2nd nut (4) of mounting fixture: 35 to
45 Nm {3.57 to 4.59 kgm}
PRECAUTIONS FOR CHARGING BATTERY

k WARNING
When charging the battery, if the battery is not handled
correctly, it is dangerous that the battery may explode. Al-
ways follow the instructions in “PRECAUTIONS FOR DIS-
CHARGED BATTERY (3-253)” and the instruction manual
accompanying the charger, and observe the following.
• 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 ex-
plosion.
• 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 nega-
tive (-) terminal of the battery. Be sure to attach the
clips securely.
• Set the charging current to 1/10 of the value of the rat-
ed battery capacity; when performing rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will
leak or the battery cells will 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. It is dangerous that this may ignite the battery
electrolyte and cause the battery to explode.
• Do not use or charge the battery if the battery electro-
lyte level is below LOWER LEVEL line. This may cause
an explosion. Check the battery electrolyte level peri-
odically and add distilled water to bring the electrolyte
level to UPPER LEVEL line.
3-254
START ENGINE WITH JUMPER CABLES

k WARNING
• When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.
• Always wear protective eyeglasses and rubber gloves
when starting the engine by using the jumper cable.
• Be careful not to let the normal machine and failed ma-
chine contact each other.
The sparks caused near the battery could ignite the
hydrogen gas generated from the battery, so be care-
ful not to let it happen.
• Make sure that there is no mistake in the jumper cable
connections.
When the final connection of the cables is done to the
engine block of the failed machine, sparks will be gen-
erated. So, connect to a place as far as possible from
the battery.
• When disconnecting the jumper cable, take care not to
bring the clips in contact with each other or with the
machine.
NOTICE
• The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped
with a 24 V battery.
• The sizes of the jumper cables and clips should be suitable for the battery size.
• The battery of the normal machine must be the same capacity as that of the failed machine.
• Check the cables and clips for damage or corrosion.
• Make sure that the cables and clips are firmly connected.
• To prevent damage of the electric devices of the failed machine, turn the starting switch of the failed
machine to OFF position, and then turn the battery disconnect switch key to OFF position before
connecting the jumper cables. For the operating method of the battery disconnect switch, see “BAT-
TERY DISCONNECT SWITCH (3-115)”.
REMARK
If the battery disconnect switch is turned to OFF position, all the electrical system is cut out and the functions of
KOMTRAX stop.
In addition, the time information of the clock and the radio tuning information may be lost.
In this case, set again. For detail, see “CLOCK ADJUSTMENT (3-81)” and “HANDLE RADIO (3-232)”.
PROCEDURE FOR CONNECTING JUMPER CABLES

Turn the starting switch and battery disconnect switch of the failed machine, and the starting switch of the nor-
mal machine to OFF position.
3-255
1. Connect the clip of jumper cable (A) to the positive (+) ter-
minal of battery (C) on the failed machine.
2. Connect the clip at the other end of jumper cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of jumper cable (B) to the negative (-) ter-
minal of battery (D) on the normal machine.
4. Turn the battery disconnect switch (S) of the failed ma-
chine to ON position.
5. Connect the clip at the other end of jumper cable (B) to en-
gine block (E) of the failed machine.
METHOD FOR STARTING ENGINE

1. Check that the parking brake switches of both normal machine and failed machine are set to “PARKING”
position
In addition, check that the gear shift levers are in NEUTRAL position (N).
2. Make sure the clips are firmly connected to the battery terminals.
3. Start the engine of the normal machine and run it at full speed (Max. speed).
4. Turn the starting switch of the failed machine to START position and start the engine.
If the engine does not start, try again after at least 2 minutes.
PROCEDURE FOR DISCONNECTING JUMPER CABLES

After the engine has started, disconnect the jumper cables in the reverse of the order in which they were con-
nected.
1. Remove the clip of jumper cable (B) from engine block (E)
on the failed machine.
2. Remove the clip of jumper cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (C) on the failed machine.
OTHER TROUBLE
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM
• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Lamp does not glow brightly even Defective wiring Check and repair loose terminals,
when the engine runs at high speeds. open circuit. (*)
Insufficient battery charge Charge, add distilled water.
Loosening and damage of belt Check alternator belt tension and re-
place.
Lamp flickers while engine is running. Defective wiring Check and repair loose terminals,
open circuit. (*)
Insufficient battery charge Charge, add distilled water.
Loosening and damage of belt Check alternator belt tension and re-
place.
3-256

Battery charge level caution lamp Defective alternator Replace. (*)
lights up while engine is running.
Defective wiring Check, repair. (*)
Unusual noise is generated from al- Defective alternator Replace. (*)
ternator
Loosening and damage of alternator Check alternator belt tension and re-
belt place.
Starting motor does not rotate even Defective wiring Check, repair. (*)
when starting switch is turned to
Defective starting switch Replace switch (*)
START position.
Insufficient battery charge Charge battery.
Defective battery relay Replace relay. (*)
Battery disconnect switch is turned Turn ON.
OFF
Engine shutdown secondary switch is Set it to “NORMAL” position. Close
at "STOP ENGINE" position. the cover.
Starting motor incapable of cranking Defective wiring Check, repair. (*)
engine smoothly.
Starting motor disengages before en- Defective wiring Check, repair. (*)
gine starts. (Rattles)
When startability at low temperature Defective wiring Check, repair. (*)
is poor, if you touch the outside of the
Wire breakage in electrical intake air Replace. (*)
electric heater by hand after preheat-
heater
ing, it is not felt warm.
Defective operation of heater relay Replace. (*)
Blown fuse of heater Replace. (*)
PHENOMENA AND ACTIONS FOR CHASSIS

Torque converter oil temperature cau- Leakage of oil or entry of air due to Check, repair. (*)
tion lamp flashes. damage or defective tightening of oil
pipe, pipe joint
Wear, scuffing of gear pump Check, repair. (*)
Lack of oil in transmission case Add oil to specified level. See
CHECK BEFORE STARTING.
Clogged oil cooler Clean or replace (*)
Long distance traveled in torque con- Drive in direct range
verter range
Disconnected, broken wiring to sen- Repair, connect wiring (*)
sor
Steering wheel is heavy Insufficient greasing of link Lubricate.
Internal leakage inside steering cylin- Replace cylinder seal. (*)
der
3-257

Steering wheel is out of control. Tire inflation pressure not uniform on Make tire inflation pressure uniform.
left and right See CHECK BEFORE STARTING.
Dragging, pulling of front brake Check wear of brake disc (*)
Braking effect is poor when brake Disc has reached wear limit. Replace disc. (*)
pedal is depressed
Insufficient oil pressure Charge to specified pressure.
Insufficient brake oil Add oil to the transmission case. See
Air in brake circuit Bleed air. See WHEN REQUIRED.
Brake pulls to one side. Disc has reached wear limit. Replace disc. (*)
Insufficient oil pressure Charge to specified pressure.
Insufficient brake oil Add oil to the transmission case. See
Air in brake circuit Bleed air. See WHEN REQUIRED.
Dump body speed is slow. Defective piston pump Replace piston pump. (*)
Insufficient oil Add oil to specified level. See
Suspension is hard. Soil or sand entering through dam- Replace U-packing. (*)
aged dust seal has damaged U-pack-
ing, causing leakage of gas.
Gas leaking from valve core Replace valve core. (*)
Wheel on one side tends to slip. Air in brake circuit (between slack ad- Bleed air from brakes (R.H. and
juster and brake) L.H.). See WHEN REQUIRED.
Excessive difference in wear between Replace tire. (*)
right and left tires
Excessive difference in division of Make load uniform.
load between left and right wheels
(unbalanced load)
Excessive deformation of disc Overhaul brake. (*)
When accelerator pedal has failed

The accelerator pedal is equipped with a potentiometer that detects the amount that the accelerator pedal is
depressed. In addition, there is a switch that judges if the accelerator pedal is being depressed or if it has been
released.
If it is impossible to detect correctly the amount that the accelerator pedal is depressed because of breakage of
the accelerator pedal or defective wiring, the engine controller controls the engine in accordance with the signal
from this judgment switch.
When the accelerator pedal is being depressed, the engine speed is set to 1500 rpm; when the accelerator ped-
al is released, the engine speed is set to low idle speed.
The speed differs according to the load.
Operate the accelerator pedal to move the machine to a safe place, then check the failure code and contact
When operating the accelerator pedal, release the pedal to turn it to OFF position (low idle) or depress it fully to
set it to 1500 rpm.
If the accelerator pedal is depressed half way, it may be impossible to judge if the accelerator pedal is being
operated.
3-258
REMARK
If the engine controller cannot correctly receive the signal for the amount that the accelerator pedal is de-
pressed, the centralized warning lamp lights up, the alarm buzzer sounds intermittently, the engine system cau-
tion lamp lights up and action level “L03” is displayed on the machine monitor.
PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS

Engine oil pressure caution lamp Insufficient oil in oil pan Add oil to specified level. See
lights up. CHECKS BEFORE STARTING.
Improper oil is used (viscosity is im- Replace oil. See METHOD FOR
proper) USING FUEL, COOLANT AND
LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE and
RECOMMENDED FUEL, COOL-
ANT, AND LUBRICANT.
Clogged oil filter cartridge Replace cartridge. See EVERY
500 HOURS MAINTENANCE.
Oil leakage due to improper tighten- Check, repair. (*)
ing or breakage of oil pan, pipe joint.
Disconnected, broken wiring to sen- Repair, connect wiring. (*)
sor
Steam spurts out from the radiator Lowered coolant level, leakage of Check, add coolant. See
sub-tank (pressure valve). coolant CHECKS BEFORE STARTING.
The coolant level caution lamp lights Dirt or scale accumulated in cooling Change coolant, clean inside of
up and the machine monitor displays system cooling system. See WHEN RE-
low coolant level as L01. QUIRED.
Indicator of engine coolant tempera- Clogged radiator fins or damaged fin Clean or repair. See EVERY 500
ture gauge is in red range. (Engine HOURS MAINTENANCE.
coolant temperature caution lamp
Defective coolant temperature gauge Replace coolant temperature
lights up.)
gauge. (*)
Defective thermostat Replace thermostat. (*)
Defective sealing of thermostat Replace thermostat seal. (*)
Loose radiator filler cap Tighten or replace cap.
Disconnected, broken wiring to sen- Repair, connect wiring. (*)
sor
Indicator of engine coolant tempera- Defective coolant temperature gauge Replace coolant temperature
ture gauge stays at lowest position gauge. (*)
and does not rise.
Defective thermostat Replace thermostat. (*)
3-259

Starting motor turns but engine does Lack of fuel Add fuel. See CHECKS BE-
not start. FORE STARTING.
Air in fuel system Repair place where air is
sucked. (*)
No fuel in fuel filter Fill filter with fuel. See EVERY
500 HOURS MAINTENANCE.
Starting motor turns engine sluggish- See PHENOMENA AND AC-
ly. TIONS FOR ELECTRICAL SYS-
TEM.
Starting motor does not turn. See PHENOMENA AND AC-
TIONS FOR ELECTRICAL SYS-
TEM.
Defective valve clearance (defective Adjust valve clearance. (*)
compression)
Gear shift lever is in any position Place gear shift lever to NEU-
other than NEUTRAL position (N). TRAL position (N).
Fuel supply occasionally stops. Clogged fuel tank breather tube Replace breather tube. (*)
Oil consumption is excessive. Oil leakage Check, repair. (*)
Exhaust gas color is white or bluish. Excessive oil in oil pan Set oil to specified level. See
CHECKS BEFORE STARTING.
Worn piston, ring, cylinder liner Replace. (*)
Low grade fuel being used Replace with specified fuel.
Defective turbocharger Check, replace. (*)
Water entry in the aftertreatment de- Check, repair. (*)
vices
Breakage of the aftertreatment devi- Replace the aftertreatment devi-
ces ces. (*)
Exhaust gas is black. Clogged air cleaner element Clean or replace. See WHEN
REQUIRED.
Worn piston, ring, cylinder liner Check, repair. (*)
Defective compression See adjustment of clearance
above.
Defective turbocharger Check, replace. (*)
Breakage of the aftertreatment devi- Replace the aftertreatment devi-
ces ces. (*)
Defective injector Check, replace, repair. (*)
Engine hunts. Air entering suction side of fuel line Repair place where air is
sucked. (*)
Combustion makes breathing sound Defective nozzle Replace nozzle. (*)
from time to time.
There is knocking (combustion or Low grade fuel being used Replace with specified fuel.
mechanical).
Overheating See “Indicator of engine coolant
temperature gauge is in red
range” above.
Breakage of inside of the aftertreat- Replace the aftertreatment devi-
ment devices ces. (*)
3-260

DEF level caution lamp lights up. Lowering of DEF level Add DEF.
IF MACHINE MONITOR SHOWS WARNING DISPLAY
When caution lamp (1) is displayed on the machine monitor, or any of “L04”, “L03”, “L01” is displayed at action
level (2) part of the failure display screen, or action level “L02” is displayed once and an action level is still dis-
played after performing remedies, do as follows.
Apply the parking brake and press enter switch (3).
“Current Abnormality” screen is displayed.
Take actions according to the message shown on the monitor, and check the failure code, and then ask your
Komatsu distributor for repair, as necessary.
For the caution lamps and action levels, see “WARNING DISPLAY (3-16)”.
For the operation methods and failure codes shown on “Current Abnormality” screen, see “OCCURRED FAIL-
URE CODE DISPLAY (3-18)”.
Telephone number for the point of contact if an error occurs
When the guidance icon is displayed on the monitor, press the
enter switch, and the “Current Abnormality” screen is displayed
and the telephone number for the point of contact is shown in
the message column at the bottom of the screen.
REMARK
If no point of contact telephone number is registered, no tele-
phone number is displayed.
Ask your Komatsu distributor for the telephone number regis-
tration if necessary.
3-261
MAINTENANCE
Please read and make sure that you understand the SAFETY section before
reading this section.
4-1
PRECAUTIONS FOR MAINTENANCE MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

Do not perform any inspection and maintenance operation that are not found in this manual.
CHECK SERVICE METER READING

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

Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts.
KOMATSU GENUINE LUBRICANTS

For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of
the specified viscosity according to the ambient temperature.
ALWAYS USE CLEAN WASHER FLUID

Use automobile window washer fluid, and be careful not to let any dirt get into it.
FRESH AND CLEAN LUBRICANTS

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away
from oil and grease.
CHECK DRAINED OIL AND USED FILTER

When replacing filters after oil is changed, check the old oil and filters for metal particles and foreign materials. If
large quantity of metal particles or foreign materials are found, always report to the person in charge, and per-
form suitable action.
PRECAUTIONS FOR REFILLING OIL OR FUEL

If your machine is equipped with a strainer, do not remove it while filling oil or fuel.
PRECAUTIONS FOR ADDING DEF

Do not remove the strainer while adding DEF.
PRECAUTIONS FOR WELDING

• When conducting weld repair, turn the starting switch to OFF position and, after confirming that the system
operating lamp is turned off, set the battery disconnect switch key to OFF position and pull it out.
• Do not apply a voltage higher than 200 V continuously.
• Connect grounding cable within 1 m of the area to be welded.
If grounding cable is connected near instruments, connectors, etc., the instruments may malfunction.
• Prevent seals, bearings or bushings from entering the space between the weld zone and grounding point.
Seals and the like can cause damage to the nearby parts by catching fire from sparks.
• Do not connect the grounding cable around a pin or to a hydraulic cylinder.
Sparks generated there can damage the plated portion.
DO NOT DROP THINGS INSIDE MACHINE

• When opening the inspection windows or the oil filler port of the tank to perform inspection, be careful not to
drop nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine,
and will lead to failure. If anything drops, be sure to take it out.
• Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
PRECAUTIONS FOR KDPF

When performing inspection and maintenance during or just after regeneration, take care of the high tempera-
ture parts.
Even after the engine stops the parts around KDPF may be at high temperature.
4-2
MAINTENANCE PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR SCR ASSEMBLY

Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine
stops the parts around SCR device may be at high temperature.
DUSTY JOBSITES
When working at dusty jobsites, observe the following.
• Inspect the dust indicator frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
• Clean the radiator fins, aftercooler fins, air conditioner condenser fins, and other parts of the heat exchange
equipment more frequently, and take care not to let the fins become clogged.
• Replace the fuel filter more frequently.
• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
• When checking and replacing the oil or filters, move the machine to a place where there is no dust and take
care to prevent dust from entering the system.
AVOID MIXING OIL

Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and
replace all the oil with the new brand or grade of oil.
LOCK INSPECTION COVERS

Lock inspection cover securely into position with the lock bar, etc. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly shut by the wind and cause
personal injury.
BLEED AIR FROM HYDRAULIC CIRCUIT

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit.
For the procedure to bleed air, see “WHEN REQUIRED (4-14)”.
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES

• When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace them with new parts.
When doing this, be careful not to forget to assemble O-rings and gaskets.
• When installing the hoses, do not twist them or bend them sharply.
If they are installed so, their service life will be extremely shortened and they may be damaged.
CHECKS AFTER INSPECTION AND MAINTENANCE

If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to
personal injury. Always observe the following.
Checks after operation (with engine stopped)
• Have any inspection and maintenance points been forgotten?
• Have all inspection and maintenance items been performed correctly?
• Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
• Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
Checks while the engine is running
• For details of the checks when the engine is running, see SAFETY, “TWO WORKERS FOR MAINTE-
NANCE WHEN ENGINE IS RUNNING (2-33)” and pay attention to safety.
• Increase the engine speed to check for the leakage of fuel or oil.
• Check if the inspected and serviced area is normally operated.
4-3
PRECAUTIONS FOR MAINTENANCE MAINTENANCE
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE

It is necessary to select fuel or lubricant according to the ambient temperature.
For detail, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”.
4-4
MAINTENANCE OUTLINE OF MAINTENANCE
OUTLINE OF MAINTENANCE
• Komatsu recommends using 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 prob-
lem 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 plant, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40-LA (Komatsu genuine)
Transmission case
Power train oil TO10 (Komatsu genuine)
(Incl. brake oil tank)
Hydraulic tank Power train oil TO10 (Komatsu genuine)
Front suspension
Hydraulic oil HO-MVK (Komatsu genuine)
Rear suspension
Front differential
Center differential case
Rear differential case
Axle oil AXO80 (Komatsu genuine parts)
Front final drive case
Center final drive case
Rear final drive case
Non-Amine Engine Coolant (AF-NAC) (Komatsu genuine)
Radiator
(density: 30% or above)
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
• Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature,
high pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in
Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil at the specified interval.
• Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of failures with the 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 failures.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such
cases, consult your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend that you have an oil analysis periodically to check the condition of the machine. For those
who wish to use this service, consult your Komatsu distributor.
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom-
mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail.
4-5
OUTLINE OF MAINTENANCE MAINTENANCE
NOTICE
Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu
genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the en-
gine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of
the machine life, lowering of performance and increase of fuel consumption.
FUEL
• To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank with fuel after completing the day's work.
• The fuel pump is a precision equipment, 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 for the temperature that is described in Operation and Maintenance Manual.
• If the fuel is used at the temperatures lower than the specified temperature (particularly at tempera-
tures below -15 °C), the fuel will solidify.
• If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and it
may result in troubles such as a drop of output.
• Before starting the engine, or after 10 minutes of adding fuel, drain the sediment and water from the fuel
tank.
• If the engine runs out of fuel, or if the filters are replaced, it is necessary to bleed the air from the circuit.
• If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
The fuel used must be ultra low-sulfur diesel fuel. (≤10 ppm)
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device and emission gas
control system (KDPF). Since the high-pressure fuel injection device requires high precision parts and
lubrication, if low viscosity fuel with low lubricating ability is used, its durability may drop considerably.
And using fuel with high sulfur content can deteriorate the engine parts and KDPF catalyzer, inducing
failures, decrease of the life and degradation in performance.
COOLANT AND WATER FOR DILUTION

• 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 coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC).
Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and
can be used continuously for 2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC).
If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum
parts of the cooling system.
• When using antifreeze, always observe the precautions given in Operation and Maintenance Manual.
• Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
• The coolant density needs to be changed according to the ambient temperature.
For details of the coolant density, see “METHOD FOR CLEANING INSIDE OF COOLING SYSTEM
(4-19)”.
Even in areas where it is not considered necessary to prevent freezing, always use Non-Amine Engine
Coolant (AF-NAC) with a density of over 30 % in order to prevent corrosion of the cooling system.
Non-Amine Engine Coolant (AF-NAC) is diluted with distilled water that does not contain any ions or water-
hardening substances. Never dilute the Non-Amine Engine Coolant (AF-NAC) with ordinary water.
• If the engine overheats, wait for the engine to cool down 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.
4-6
DEF
• If DEF gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes
off and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated
or begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.
• When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away
from the filler port.
• Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause
a fire. Some fluids or agents added can create and emit a toxic gas.
• DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Follow the instruc-
tions and precautions according to “ACTIONS IF FIRE OCCURS (2-16)”.
• If DEF is spilled, immediately wash and clean the area with water. If spilled DEF is left unattended and the
area is not washed and cleaned, it can cause corrosion to the contaminated area and emit toxic gas.
• When disposing of DEF, treat it as an industrial waste. For treatment of the waste, see “PRECAUTIONS
FOR DISPOSING OF WASTE MATERIALS (2-38)”. The container for DEF is an industrial waste as well. It
should be treated in the same way.
• Never use an iron or aluminum container when disposing DEF, because toxic gas may develop and a
chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel
when handling the fluid waste of DEF.
NOTICE
If you add any additional additive agents or water to DEF, the devices in the Urea SCR system may be
detective, and conformance to the exhaust gas regulations will be lost.
GREASE
• Grease is used to prevent seizure and noises at the joints.
• This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom-
mended grease and follow the replacement intervals and recommended ambient temperatures given in this
Operation and Maintenance Manual.
• Grease fittings not included in the MAINTENANCE section are the grease fittings for overhaul, so they do
not need grease.
If any part becomes stiff after being used for long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.
PERFORM KOWA (Komatsu Oil Wear Analysis)

KOWA 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 problems.
Thanks to long term experience and ample data accumulated, we can grasp condition of your machine accu-
rately and provide proper recommendation.
We strongly recommend you to use this service. The oil analysis is performed at actual cost, so the cost is low,
and results of the analysis and recommendations are reported promptly.
4-7
OUTLINE OF MAINTENANCE MAINTENANCE
KOWA analysis items

Measurement of metallic powder concentration
An ICP (Inductively Coupled Plasma) analyzer is used for
measuring the concentration of iron, copper, and other metal
powder in the oil.
Measurement of quantity of iron particles

A PQI (Particle Quantifier Index) measuring instrument is used
for measuring the quantity of iron particles of 5 μm or more, en-
abling early detection of failures.
Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity, if
necessary, to enable a highly precise diagnosis of the machine and the components' condition.
Oil sampling interval
500 hours
Precautions when sampling
• Make sure that the oil is well mixed before sampling.
• Perform sampling at regular 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, contact your Komatsu distributor.
STORE OIL AND FUEL

• Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
• When keeping drum cans for a long period, lay the drums so that the filler ports of the drums are located in
the lower part of the side to prevent moisture from being sucked in. If drums have to be stored outside, cov-
er 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).
STORE DEF
• Completely seal up its container for storage. Only open containers in a well-ventilated area.
• When storing DEF, avoid direct sunlight. Always use the original container. Make sure that transfer equip-
ment and tank must meet DEF compatible material specification. If DEF is stored in an iron or aluminum
container, toxic gas may develop and a chemical reaction may corrode the container.
• The relationship between the upper limit of storage temperature and the storage period of DEF is shown in
the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
4-8
Temperature of storage area Storage period

*: Do not store DEF in the temperature of 35 °C or above.

For the storage in cold weather, see the section about DEF in “COLD WEATHER OPERATION (3-244)”.
FILTER
• Filters are extremely important safety parts. They prevent impurities in the oil, fuel, and air circuits from en-
tering important equipment and causing problems. Replace all filters periodically. For details, see 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 and use again the filters (cartridge type). Always replace them with new filters.
• When replacing oil filters, check if any metal particles are attached to the old filters.
If any metal particles are found, consult your Komatsu distributor.
• Do not open packages of spare filters until just before they are to be used.
• Komatsu recommends using Komatsu genuine filters.
HANDLE ELECTRICAL COMPONENTS

k WARNING
• When the battery disconnect switch key is turned to OFF position for the maintenance work, always
pull out the key and keep it with you. If the key is left in the switch, someone may turn ON the power
by mistake. It is dangerous that causes an electric shock.
For the operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-115)”.
• It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is
damaged. This will cause an electrical leakage and may lead to malfunction of the machine.
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.
• When removing the connectors of electrical components after washing the machine or in the rain, wipe off
the water drop stuck around connectors before removing the connectors and keep the water drop away
from inside of the connectors.
• Checking and maintenance items are checking fan belt tension, checking damage of the fan belt and
checking battery fluid level.
• Never install any electrical components other than those specified by Komatsu.
• External electro-magnetic interference may cause malfunction of the control system controller. Accordingly,
consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma-
chine.
• When working at the seashore, keep the electrical component clean to prevent corrosion.
• When installing electrical component, connect it to the special power supply connector.
Do not connect the optional power supply to the fuse or starting switch or battery relay, etc.
4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUE FOR BOLTS AND

NUTS
Tightening torque list
k CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage
to the tightened parts, and this will cause failure of the machine or problems with operation.
Always be careful when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to

the torque shown in the table below.
If it is necessary to replace any nut or bolt, Komatsu recom-
mends using Komatsu genuine part of the same size as the
part that is removed.
Thread di- Width Tightening torque

ameter of across
Target value Allowable range
bolt “a” flats “b”
(mm) (mm) Nm kgm Nm kgm
6 10 13.2 1.35 11.8 to 14.7 1.2 to 1.5
8 13 31 3.2 27 to 34 2.8 to 3.5
10 17 66 6.7 59 to 74 6.0 to 7.5
12 19 113 11.5 98 to 123 10.0 to 12.5
14 22 177 18.0 157 to 196 16 to 20
16 24 279 28.5 245 to 309 25 to 31.5
18 27 382 39.0 343 to 427 35 to 43.5
20 30 549 56.0 490 to 608 50 to 62
22 32 745 76.0 662 to 829 67.5 to 84.5
24 36 927 94.5 824 to 1030 84 to 105
27 41 1320 135 1180 to 1470 120 to 150
30 46 1720 175 1520 to 1910 155 to 195
33 50 2210 225 1960 to 2450 200 to 250
36 55 2750 280 2450 to 3040 250 to 310
39 60 3280 335 2890 to 3630 295 to 370
Tighten the hoses to the torque shown in the table.
4-10
MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
Taper seal
Width Tightening torque

Outside di-
acros
ameter of Target value Allowable range
s flats
hose “a”
“b”
(mm) Nm kgm Nm kgm
(mm)
14 19 44 4.5 34 to 63 3.5 to 6.5
18 24 78 8.0 59 to 98 6.0 to 10.0
22 27 103 10.5 84 to 132 8.5 to 13.5
24 32 157 16.0 128 to 186 13.0 to 19.0
30 36 216 22.0 177 to 245 18.0 to 25.0
33 41 216 22.0 177 to 245 18.0 to 25.0
36 46 245 25.0 197 to 294 20.0 to 30.0
42 55 294 30.0 246 to 343 25.0 to 35.0
Face seal
Width Tightening torque

across
Nominal - No. of Target value Allowable range
flats
threads “a”
"b" Nm kgm Nm kgm
(mm)
9/ -18UN 19 44 4.5 34 to 54 3.5 to 5.5
16
11/ -16UN 22 74 7.5 54 to 93 5.5 to 9.5

16
13/ -16UN 27 103 10.5 84 to 132 8.5 to 13.5

16
1-14UNS 32 157 16.0 128 to 186 13.0 to 19.0
13/16 -12UN 36 216 22.0 177 to 245 18.0 to 25.0
4-11
MAINTENANCE SCHEDULE MAINTENANCE
MAINTENANCE SCHEDULE
• When using the engine oil for cold district, the maintenance intervals of the engine oil and filter cartridge are
changed to for every 250 hours. For details, see the oil part number and note in “RECOMMENDED FUEL,
COOLANT, AND LUBRICANT (7-4)”.
• Contact your Komatsu distributor for changing the maintenance interval of the machine monitor.
MAINTENANCE SCHEDULE TABLE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .......................................... 4-14
WHEN REQUIRED ........................................................................................................................................ 4-14
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER .......................................... 4-14
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ................................................................. 4-19
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID ................................. 4-22
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER................................................. 4-22
METHOD FOR REPLACING SLOW-BLOW FUSE ................................................................................. 4-24
METHOD FOR CHECKING DUMP BODY.............................................................................................. 4-25
METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER .................................................... 4-25
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT....................................................................... 4-26
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT .............................................................. 4-30
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT................................ 4-30
SELECT AND CHECK TIRES................................................................................................................. 4-31
METHOD FOR ADJUSTING PARKING BRAKE ..................................................................................... 4-33
COLLECT LEAKED OIL FROM FLOATING SEAL .................................................................................. 4-34
METHOD FOR CHECKING AND ADJUSTING BODY MOUNT .............................................................. 4-35
CHECKS BEFORE STARTING...................................................................................................................... 4-35
EVERY 50 HOURS MAINTENANCE ............................................................................................................. 4-36
METHOD FOR LUBRICATING ............................................................................................................... 4-36
EVERY 250 HOURS MAINTENANCE ........................................................................................................... 4-37
METHOD FOR CHECKING DRIVE SHAFT ............................................................................................ 4-38
METHOD FOR CLEANING BREATHER................................................................................................. 4-39
METHOD FOR CLEANING OVERFLOW HOSE..................................................................................... 4-41
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL ............................................................. 4-41
METHOD FOR CHECKING FRAME AND A-ARM .................................................................................. 4-44
METHOD FOR CHECKING FOOT BRAKE PERFORMANCE ................................................................ 4-44
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE....................................................... 4-45
METHOD FOR CHECKING PARKING BRAKE PERFORMANCE .......................................................... 4-45
METHOD FOR CHECKING WEAR OF PARKING BRAKE PADS ........................................................... 4-46
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR ............................................................... 4-46
EVERY 500 HOURS MAINTENANCE ........................................................................................................... 4-48
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE .....
............................................................................................................................................................ 4-48
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................... 4-49
METHOD FOR LUBRICATING CAB MOUNTING PINS.......................................................................... 4-51
METHOD FOR CHECKING AND ADDING OIL IN DEFERENTIAL CASE .............................................. 4-52
METHOD FOR CHECKING AND CLEANING RADIATOR FINS, AFTERCOOLER FINS, AND AIR CONDI-
TIONER CONDENSER FINS .............................................................................................................. 4-53
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL ..................................... 4-56
EVERY 1000 HOURS MAINTENANCE ......................................................................................................... 4-56
METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT ........................................................ 4-57
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ............................................................ 4-57
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT......................................................... 4-59
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT ................................................. 4-60
METHOD FOR CHANGING OIL IN TRANSMISSION CASE .................................................................. 4-61
METHOD FOR CHANGING OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT ...... 4-61
METHOD FOR LUBRICATING PARKING BRAKE.................................................................................. 4-63
METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT .................................................................. 4-65
4-12
MAINTENANCE MAINTENANCE SCHEDULE TABLE
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP ............................. 4-66
METHOD FOR APPLYING LUBRICANT ON EXHAUST PIPE SPHERICAL SURFACE JOINT PORTION.....
............................................................................................................................................................ 4-67
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT........................................................... 4-68
METHOD FOR CHECKING DRIVE BELT TENSION PULLEY ASSEMBLY OF COMPRESSOR FOR AL-
TERNATOR AND AIR CONDITIONER ................................................................................................ 4-69
METHOD FOR LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF COMPRESSOR FOR AL-
TERNATOR AND AIR CONDITIONER ................................................................................................ 4-70
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ....................................................................... 4-70
METHOD FOR CHANGING OIL IN DEFERENTIAL CASE..................................................................... 4-71
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ............................................. 4-72
METHOD FOR CLEANING TRANSMISSION CASE STRAINER............................................................ 4-73
METHOD FOR CLEANING BREATHER................................................................................................. 4-74
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE ........................................................... 4-75
METHOD FOR CHECKING ALTERNATOR ............................................................................................ 4-75
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE ...................................... 4-75
METHOD FOR REPLACING KCCV FILTER ELEMENT ......................................................................... 4-75
METHOD FOR REPLACING DEF FILTER.............................................................................................. 4-78
REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-80
METHOD FOR CHANGING OIL IN HYDRAULIC TANK ......................................................................... 4-81
METHOD FOR CHECKING WATER PUMP............................................................................................ 4-82
METHOD FOR CHECKING STARTING MOTOR.................................................................................... 4-82
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIPING CLAMP, HARD-
ENING OF RUBBER ........................................................................................................................... 4-83
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.
............................................................................................................................................................ 4-83
METHOD FOR CHECKING EXHAUST PIPE FIRE PREVENTION COVER ........................................... 4-84
METHOD FOR CLEANING KDPF .......................................................................................................... 4-84
METHOD FOR CLEANING DEF TANK................................................................................................... 4-84
METHOD FOR CLEANING FUEL DOSER ............................................................................................. 4-84
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING,
HARDENING OF RUBBER ................................................................................................................. 4-84
METHOD FOR LUBRICATING DRIVE SHAFT ....................................................................................... 4-85
METHOD FOR REPLACING ENGINE HIGH-PRESSURE PIPING CLAMP ........................................... 4-86
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP............................................................ 4-86
METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR ............................................ 4-86
METHOD FOR REPLACING DEF HOSE ............................................................................................... 4-86
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING ................. 4-86
4-13
MAINTENANCE PROCEDURE MAINTENANCE
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250
HOURS)
Perform the following maintenance only after the first 250 hours.
• Replace transmission filter element (valve side, brake cooling side)
• Change oil in transmission case
• Change oil in brake oil tank, replace brake oil filter element
• Change oil in final drive case
• Change oil in differential case
For details of the method of replacement or maintenance. See EVERY 1000 HOURS MAINTENANCE and EV-
ERY 2000 HOURS MAINTENANCE.
WHEN REQUIRED
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER
After the outer element has been cleaned 6 times, or if the air cleaner element has been used for 1 year, re-
place the outer element, inner element, and O-ring.
For the replacement procedure, see “METHOD FOR REPLACING AIR CLEANER ELEMENT (4-17)”.
If the air cleaner clogging caution lamp flashes and the machine monitor displays action level “L01” during oper-
ation immediately after the outer element is cleaned, replace the element even if the outer element has not been
cleaned 6 times or the air cleaner element has not been used more than 1 year.
METHOD FOR CHECKING AIR CLEANER

NOTICE
Do not clean the outer element until the red line of the dust indicator is at 7.5 kPa {0.076 kg/cm2}.
If the element is cleaned frequently, the filtering efficiency of the air cleaner will drop and this will re-
duce the service life of the engine.
Check if the red line of dust indicator (1) is at 7.5 kPa
{0.076 kg/cm2}.
If it is at 7.5 kPa {0.076 kg/cm2}, clean the outer element.
REMARK
Air cleaner clogging caution lamp (2) is on the machine moni-
tor.
If the air cleaner clogging caution lamp lights up and the ma-
chine monitor displays “L01” during operation, the air cleaner is
clogged. Clean the outer element in this case, as well.
4-14
MAINTENANCE MAINTENANCE PROCEDURE
METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT

k WARNING
• Dirt will fly if compressed air is used for cleaning.
If dirt gets into your eyes it may cause blindness, and if you breathe in the dust it may damage your
lungs.
To prevent these problems, always wear protective eyeglasses, dust mask, and other protective
equipment.
• When pulling out the outer element from the air cleaner body, make sure that you are standing on a
firm place.
If your footing is not secure when you perform the operation, there is danger of falling and suffering
injury.
NOTICE
• Never remove the inner element.
If it is removed, dirt will enter and can cause an engine trouble.
• Do not use a screwdriver or other tool.
• When cleaning the element, do not hit it or hit anything with the element.
• Before and after cleaning the element, do not leave or keep it under direct sunlight.
1. Stop the engine.
2. Undo hooks (1) (6 places) and remove cover (2).
3. Hold the outer element (3), rock it lightly up and down and
to the right and left, and pull it out while turning it to the
right or left.
4. When outer element (3) is removed, check that inner ele-
ment (4) does not come off or incline.
If it is at an angle, push it straight to the bottom with your
hand.
5. After removing outer element (3), cover the inner element
(4) with a clean cloth or tape to prevent dirt or dust from
entering.
6. Clean dusts in inside and on cover (2) of air cleaner body (5) by using a clean cloth or brush.
7. If any dust is attached to vacuator valve (6) installed to cover (2), remove it.
Check that the lip of vacuator valve (6) has no crack.
If there is any crack, replace it with a new one.
NOTICE
• If a damaged element is used, air will pass the air cleaner filter and will be sucked into the en-
gine. Do not damage the element, when cleaning it. If the element is damaged, replace it with a
new element.
• When cleaning the element, do not tap it or hit it against something.
• Do not use the element with damaged pleats or a damaged gasket or seal.
4-15
8. When the outer element has been cleaned 6 times or used for 1 year, replace it.
• When the element needs to be replaced
Replace the inner and outer elements with new ones. For details, see “METHOD FOR REPLACING
AIR CLEANER ELEMENT (4-17)”.
• When the element does not need to be replaced
Clean the outer element. Continue the cleaning procedure.
9. Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm2}) from
the inside of outer element (3) along the pleats.
10. Blow along the pleats from the outside, then blow again
from the inside.
11. After cleaning, illuminate the inside of outer element (3)

with an electric bulb to check.
If any hole or thin place is found, replace the outer ele-
ment.
12. Remove the cover of cloth or tape attached to inner ele-
ment (4).
13. Check the seal of the cleaned or new element for sticking
of dusts and oil and wipe them off, if any.
14. Push outer element (3) straight into air cleaner body (5)
with your hand.
Hold outer element (3), and rock it lightly up and down and
to the right and left while pushing it in, and you can insert it
easily.
15. Install cover (2) as follows.
1) Check that O-ring (7) is fitted to cover (2).

2) Align cover (2) with the element.
Insert cover (2) with vacuator valve (6) right at the bot-
tom into air cleaner body (5).
4-16
3) Lock the tips of hooks (1) (6 places) on the protrusion

of the air cleaner body (5).
Lock hooks (1) diagonally, (top and bottom, right and
left) in the same way as when tightening bolts.
4) When cover (2) is installed, check that the clearance
between air cleaner body (5) and cover (2) is not too
large.
If the clearance is too large, remove cover (2), and
then install it again.
16. Push the head of dust indicator (8) to return the red line to
its original position.
METHOD FOR REPLACING AIR CLEANER ELEMENT

k WARNING
When pulling out the outer element from the air cleaner body, make sure that you are standing on a firm
place.
If your footing is not secure when you perform the operation, there is danger of falling and suffering
injury.
1. Stop the engine.

2. Undo hooks (1) (6 places) and remove cover (2).
4-17
3. Hold the outer element (3), rock it lightly up and down and
to the right and left, and pull it out while turning it to the
right or left.
4. When outer element (3) is removed, check that inner ele-
ment (4) does not come off or incline.
If it is at an angle, push it straight to the bottom with your
hand.
5. After removing outer element (3), cover the inner element
(4) with a clean cloth or tape to prevent dirt or dust from
entering.
6. Clean dusts in inside and on cover (2) of air cleaner body (5) by using a clean cloth or brush.
7. If any dust is attached to vacuator valve (6) installed to cover (2), remove it.
Check that the lip of vacuator valve (6) has no crack.
If there is any crack, replace it with a new one.
8. Remove inner element (4), then quickly install the new inner element.
Install the inner element securely so that it does not move.
9. Push new outer element (3) in straight with your hand into
the air cleaner body.
Hold the element, and rock it lightly up and down and to
the right and left while pushing it in, the element can be in-
serted easily.
10. Install cover (2) as follows.
1) Replace O-ring (7) with a new one.

2) Align cover (2) with the element.
Insert cover (2) with vacuator valve (6) right at the bot-
tom into air cleaner body (5).
3) Lock the tips of hooks (1) (6 places) on the protrusion

of the air cleaner body (5).
Lock hooks (1) diagonally, (top and bottom, right and
left) in the same way as when tightening bolts.
4) When cover (2) is installed, check that the clearance
between air cleaner body (5) and cover (2) is not too
large.
If the clearance is too large, remove cover (2), and
then install it again.
4-18
11. Push the head of dust indicator (8) to return the red line to
its original position.
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM

k WARNING
• Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in
the radiator.
If the radiator cap is removed in this condition and the coolant is drained, it may cause burns.
Always wait for the temperature to go down, turn the cap slowly to release the pressure.
• Start the engine and clean the inside of the cooling system.
When standing up or leaving the operator's seat, set the gear shift lever to NEUTRAL position (N)
and set the parking brake switch to “PARKING” position.
• For details of starting the engine, see OPERATION, “METHOD FOR OPERATIONS AND CHECKS BE-
FORE STARTING ENGINE (3-174)” and “METHOD FOR STARTING ENGINE (3-177)”.
• When the undercover is removed, there is a danger of touching the fan.
Never enter in the rear part of the machine when the engine is running.
Place the machine on a level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant according to the table below.
Interval for cleaning inside of cooling sys-
Coolant
tem and changing coolant
Every 2 years or 4000 hours, whichever
Non-Amine Engine Coolant (AF-NAC)
comes sooner
The coolant has the important function of preventing corrosion as well as preventing freezing.
Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be
used continuously for 2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC).
If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts
of the cooling system.
4-19
To maintain the anti-corrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of
Non-Amine Engine Coolant between 30 % and 64 %.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water. When using coolant, investigate the
lowest temperature in the past and decide the density for the coolant from the coolant density table below.
When deciding the density for the coolant, set it for a temperature 10 °C below the actual lowest temperature in
the working area.
The coolant density varies according to the ambient temperature, but it must be over 30 % at least.
Coolant density table

Min. atmospheric tem-
°C Min. -10 -15 -20 -25 -30 -35 -40 -45 -50
perature
Density (%) 30 36 41 46 50 54 58 61 64
k WARNING
• Coolant is toxic.
When opening the drain valve, be careful not to get coolant on you.
If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor immediate-
ly.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to
perform the operation.
Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For dilution, see “COOLANT AND WATER FOR DILUTION (4-6)”.
Check the density with a coolant tester.
k CAUTION
• If the air in the engine cooling system has not been completely bled, it may cause damage of EGR
cooler and it may lead to serious failure such as seizure inside of the engine. Therefore, be sure to
check the coolant level or add coolant immediately after changing the coolant, and bleed air thor-
oughly according to the following procedure.
Before starting the work, be sure to perform METHOD FOR CHECKING COOLANT LEVEL, ADDING
COOLANT (3-155).
• After changing the coolant, as time passes, the coolant level of reservoir tank may drop largely. Op-
eration with low coolant level may cause damage of EGR cooler in the worst case, and it may lead
to serious failure such as seizure inside of the engine.
If an alarm (failure code B@BCZK) is generated due to the drop of the coolant level of the reservoir
tank, or before starting the engine at the next day of the coolant change, be sure to perform METH-
OD FOR CHECKING COOLANT LEVEL, ADDING COOLANT (3-155).
Refill amount of coolant 114 ℓ

Items to be prepared
• A container whose capacity is enough to receive the specified capacity of coolant
• A hose to add coolant
4-20
When getting on or off the machine with carrying coolant, place

it once in part (A) to ensure your safety.
1. Stop the machine on a level place.

2. Stop the engine.
3. Remove cover (1) from under the radiator, and pull out
coolant drain hose (1 piece).
4. Check that the sub-tank cap is cooled enough to touch by

bare hands and turn sub-tank cap (2) a little to release the
pressure, and then turn it slowly to remove it.
5. Place the container to receive the coolant.
6. Open drain valve (3) to drain the coolant.

7. After draining the coolant, close drain valve (3), and fill
with city water through filler port of the sub-tank.
Add water until it fills the radiator, sub-tank, and reservoir
tank.
Run the engine at low idle for 10 minutes.
9. Stop the engine and open drain valve (3) to drain the wa-
ter.
10. After draining the water, close drain valve (3).
11. Fill with coolant through the coolant filler port of the sub-tank up to the mouth of the port.
For the concentration of Non-Amine Engine Coolant (AF-NAC) , see “Coolant density table”.
12. Run the engine at low idle for 5 minutes to remove the air from the coolant, then run at high idle for a further
5 minutes.
At this time, remove sub-tank cap (2).
13. Stop the engine.
14. Approximately 3 minutes after stopping the engine, add coolant to near the mouth of the water filler port.
15. After adding the coolant, tighten sub-tank cap (2).
4-21
16. Drain the coolant in reservoir tank (4).

17. Clean the inside of reservoir tank (4).
18. Add coolant up to the middle between FULL and LOW.
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID

Perform this check if there is air in the window washer fluid.
When getting on or off the machine with carrying window wash-
er fluid, place it once in part (A) to ensure your safety.
Check the fluid level in window washer tank (1).

If the level is low, add window washer fluid for automobile.
Be careful not to let dirt or dust get in when adding fluid.
When operating at below freezing point, use fluid with anti-
freeze.
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER

METHOD FOR CHECKING REFRIGERANT LEVEL FOR AIR CONDITIONER (GAS)
k WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of
sight or frostbite.
Never touch the refrigerant.
Do not loosen any part of the refrigerant circuit.
Do not bring any open flame close to any point where the refrigerant gas is leaking.
If the cooling effect is poor, there is probably lack of refrigerant (gas).

1. When checking the refrigerant (gas) level, set the machine under the following condition.
1) Start the engine and run it at approximately 1500 rpm.
2) Press the fan switch and set the air flow of the air conditioner to the maximum.
3) Turn air conditioner switch ON.
4) Press the temperature control switch and set the temperature to the lowest level.
5) Press FRESH/RECIRC air selector switch and set it to FRESH mode.
4-22
6) Fully close the doors and windows.

2. Check sight glass (2) of receiver drier (1) on the left side of
the engine.
If the condition of sight glass (2) is “correct” as shown in
the figure below, the condition is normal.
If the condition of sight glass (2) is “overfilling” or “insuffi-
cient” as shown in the figure below, ask your Komatsu dis-
tributor for service.
Quantity of refrigerant Condition

Only few bubbles are contained. Bubbles disappear and the
refrigerant becomes transparent when the engine speed is
Correct
increased gradually from idle to 1500 rpm.
No bubble is contained. In this case, both high and low

pressures are high and cooling efficiency is low.
Overfilling
Bubbles pass continuously.

Insufficient
METHOD FOR CLEANING AIR CONDITIONER AIR FILTERS

If the air filter at the suction port of the air conditioner unit or the air filter at the fresh air intake port become
clogged, the cooling or heating capacity will drop, so clean the filters.
When getting on or off the machine with carrying a nozzle and
a brush, place it once in part (A) to ensure your safety.
1. Open cover (1) on the side of the cab.

2. Pull out the air filter (fresh air filter).
3. Clean the air filter (fresh air filter) with compressed air.
4-23
4. Open cover (2) at the rear left of the operator's seat.

5. Pull out the air filter (recirculation air filter).
6. Remove the dust sticking to the air filter (recirculation air
filter) with low compressed air or a soft brush.
METHOD FOR REPLACING SLOW-BLOW FUSE

NOTICE
• Before replacing the slow blow fuse, be sure to turn the starting switch to OFF position (A) and turn
the battery disconnect switch to OFF position.
• Replace the slow blow fuse with the one of the same capacity.
Should the slow-blow fuse is blown, investigate the cause and take necessary actions.
1. Turn the starting switch to OFF position (A).
2. Check that the system operating lamp goes out.
3. Turn the battery disconnect switch to OFF position.
4. Remove the slow-blow fuse box from the machine body.
5. Open covers (1), (2) and (3) of the slow-blow fuse box.
4-24
You can remove the box easily by removing the covers (2)
and (3) with a flat-head screwdriver using projection (A) as
a fulcrum.
6. Loosen and remove screws (4) and (5).
When you remove screws (4) and (5), slow-blow fuse (6)
comes off along with electric wiring (7) and (8).
7. Install a new slow-blow fuse to the slow-blow fuse box
along with electric wiring (7) and (8) with screws (4) and
(5).
8. Close covers (1), (2), and (3).
9. Install the slow-blow fuse box to the machine.
METHOD FOR CHECKING DUMP BODY

Check that there are no cracks in the dump body.
1. Clean the dump body so that you can check it easily.
2. Check each portion of the dump body for damage.
If any cracks or abnormal wear are found, perform repairs.
Contact your Komatsu distributor for details of the repair procedure.
METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER

If the machine reacts to the rough ground conditions when traveling, such as making high bounds or the cylinder
retracting and hitting the stopper, check the following.
Check front suspension (1) and the rear suspension (2) with
the machine unloaded.
4-25
1. Remove cover (3) of the suspension.

2. Measure distance (A) from the shoulder at the head end of
the suspension cylinder rod to the top surface of the
flange.
Front suspension dimension (A): 166 to 186 mm
Rear suspension dimension (A): 101 to 111 mm
If any abnormality is found when checking the front and
rear suspension, ask your Komatsu distributor for inspec-
tion.
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT

k WARNING
Stop the machine on a flat place, turn the parking brake switch to “PARKING” position, chock the tires,
and then bleed air.
When any brake circuit device is repaired or replaced, or the hydraulic piping is disconnected, bleed air from the
brake circuit.
Always bleed air from the brake circuit in the order of the slack adjuster and wheel brake.
Warm the oil up to a temperature of at least 40 °C before bleeding the air to make it easier to bleed the air.
Bleed the air from the slack adjuster, front brakes, and center brakes in the same way both on the right and left
sides.
• Vinyl hose
• Container with oil in it
2. Check that the oil level in the transmission case is at the
specified level with sight gauge (G).
If the oil level is low, add oil through oil filler port (F).
3. Check if the brake oil pressure caution lamp is not lit.
4-26
• If the brake oil pressure caution lamp is not lit, bleed

air from the slack adjuster.
• If the brake oil pressure caution lamp is lit, check the
oil level in the brake oil tank with sight gauge (G). If
the caution lamp is lit while the oil level is at the speci-
fied level, contact your Komatsu distributor.
METHOD FOR BLEEDING AIR FROM SLACK ADJUSTER

1. Remove the cap of bleeder screw (1) of slack adjuster.
Front
Center
2. Connect a vinyl hose to either of the right and left bleeder

screws (1).
Use a commercially available vinyl hose.
3. Place a container with oil in it.
4. Put the other end of the hose in the oil in the container ap-
proximately 50 mm.
5. Depress the brake pedal and keep it.
6. Loosen bleeder screw (1) approximately 3/4 turns.
Oil containing air is discharged.
• If the brake oil pressure caution lamp lights up while air is being bled from the front slack adjuster, per-
1) Tighten bleeder screw (1).
2) Depress the brake pedal 8 to 10 times.
Increase the oil pressure in the accumulator.
4-27
3) Use sight gauge (G) to check if there is oil re-

maining in the brake oil tank.
If there is no oil in the tank, stop the engine.
When the engine is stopped, the oil level rises
and oil is automatically supplied to the brake oil
tank.
• If the brake oil pressure caution lamp lights up while
air is being bled from the center slack adjuster, per-
2) Use sight gauge (G) to check if there is oil remaining in the brake oil tank.
When the engine is stopped, the oil level rises and oil is automatically supplied to the brake oil
tank.
7. Keep depressing the brake pedal and check that no bubble comes out through the vinyl hose.
8. Next, pull the retarder control lever and hold it.
Keep pulling the retarder control lever. When no bubble is
discharged through the vinyl hose, all air is bled.
10. Tighten bleeder screw (1) securely.
11. Install the cap to bleeder screw (1).
12. Bleed air from bleeder screw (1) on the opposite side ac-
cording to steps 1. to 11.
Next, bleed air from the wheel brake.
METHOD FOR BLEEDING AIR FROM WHEEL BRAKE

1. Remove the cap of bleeder screw (2).
Front
Center
4-28
2. Connect a vinyl hose to bleeder screw (2).

Use a commercially available vinyl hose.
3. Place a container with oil in it.
4. Put the other end of the hose in the oil in the container ap-
proximately 50 mm.
• If the brake oil pressure caution lamp lights up while air is being bled from the front brake, perform the
following procedure.
2) Depress the brake pedal 8 to 10 times.
Increase the oil pressure in the accumulator.
3) Use sight gauge (G) to check if there is oil re-
maining in the brake oil tank.
When the engine is stopped, the oil level rises
and oil is automatically supplied to the brake oil
tank.
• If the brake oil pressure caution lamp lights up while
air is being bled from the center brake, perform the fol-
lowing procedure.
2) Use sight gauge (G) to check if there is oil remaining in the brake oil tank.
When the engine is stopped, the oil level rises and oil is automatically supplied to the brake oil
tank.
7. Keep depressing the brake pedal and check that no bubble comes out through the vinyl hose.
8. Tighten bleeder screw (2) securely.
9. Install the cap to bleeder screw (2).
10. Bleed air from bleeder screw (2) on the opposite side according to steps 1. to 9.
After bleeding air, check the oil level in the transmission.
ACTIONS AFTER BLEEDING AIR

Adjust the oil level in the transmission case to the specified level.
1. Stop the engine for 2 to 3 minutes.
When the engine is stopped, the oil level will rise and oil will be automatically supplied to the brake oil tank.
2. Check the oil level in the brake oil tank with sight gauge
(G).
3. Check the oil level in the transmission case.
For detail, see “METHOD FOR CHECKING OIL LEVEL IN
TRANSMISSION CASE, ADDING OIL (3-153)”.
4. Adjust the oil level to the specified level.
4-29
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit.
NOTICE
If the air is not bled, it stays in the suction piping and can
damage the pump.
When filling the tank with oil after draining the hydraulic
oil with the pump suction piping disconnected, be sure to
bleed air.
(1) Pump
(2) Air stays in intake piping
(3) Hydraulic tank
1. Raise the front section of the cab. For details, see “METH-
OD FOR OPERATING CAB TILT (3-204)”.
2. Bleed air through bleeder (4).
3. After bleeding air, lower the cab. For details, see “METH-
OD FOR OPERATING CAB TILT (3-204)”.
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT

k WARNING
To prevent the machine from moving, set the parking brake switch to “PARKING”, stop the engine, then
chock the wheels.
If any unusual noise occurs around the output shaft (1) or front drive shaft (2), the rubber inside the output shaft
may be deteriorated or damaged, so check the play of coupling (3) as follows.
When getting on or off the machine with carrying a wire, a tool,
etc., place it once in part (A) to ensure your safety.
4-30
1. Install wire (4) as shown in the figure.

2. By using the tip of the wire as a benchmark, measure the
amount of movement (L) of the coupling.
3. Rotate the coupling at a force of approximately 49 N {5 kg}
to the circumferential direction with bar (5), etc.
4. Mark the position of the wire.
5. Check that the engine crankshaft is not rotating.
REMARK
If excessive force is applied in rotating the coupling, the
engine rotates at idle and it becomes impossible to judge
accurately.
6. Rotate the coupling in the reverse direction from step 3.

7. Mark the position of the wire similarly to Step 3.
8. Measure the amount of movement (L) of the coupling by
using the marks made in steps 4 and 7.
If amount of movement (L) is more than 12 mm, the rubber
inside the output shaft may be deteriorated or damaged,
so ask your Komatsu distributor for disassembly and in-
spection of the internal parts of the output shaft.
SELECT AND CHECK TIRES

k WARNING
If a tire or a rim is handled improperly, the tire may burst or
may be damaged and the rim may be broken and scat-
tered, and that can cause serious injury or death.
• Since maintenance, disassembly, repair and assembly of

the tires and rims require special equipment and skill, be
sure to ask a tire repair shop to do the work.
• Never perform welding or light a fire near the tire.
4-31
TIRE SELECTION
k WARNING
Select the tires according to the conditions of use and the weight of the attachments on the machine.
Use only specified tires and inflate them to the specified pressure.
Select the tires according to the conditions of use and the weight of the attachments of the machine.
Use the following table.
The speed display varies with the tire size.
Consult your Komatsu distributor when using optional tires.
Maximum load Size (standard) Remarks
(kg)
Front wheel 14000 29.5–R25
For construction machinery,
Center wheel 14000 29.5–R25
type 1
Rear wheel 14000 29.5–R25
METHOD FOR CHECKING AND INFLATING TIRE

k WARNING
• When inflating the tire, check that no one can enter the area around the tire, and always use an air
chuck with a clip that can be fixed to the air valve.
• To prevent the tire inflation pressure from becoming too high, measure the pressure from time to
time with an air gauge while pumping up the tire.
• If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. Accordingly,
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 for repair.
• Be sure to observe the specified inflation pressure.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under
heavy load.
Check the tire inflation pressure before starting work while the tires are cold.
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.
1. Measure the inflation pressure with a tire inflation pressure gauge.

2. Adjust the inflation pressure properly.
The proper inflation pressure is shown below.
4-32

Tire size
29.5–R25
375 {3.8} 390 {4.0} 390 {4.0}
(Standard)
875/65R29
440 {4.5} 440 {4.5} 440 {4.5}
(Option)
NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the
rim may be damaged.
Always keep the tire inflation pressure within 0 to +30 kPa {0 to +0.3 kg/cm2 of the value in the table
above.
PRECAUTIONS FOR REPLACING TIRES

After tightening hub bolts (1) when replacing the tire, travel for
5 to 6 km, tighten the bolts again to settle all the contacting
parts.
In particular, there are more contacting parts on the rear
wheels than on the front wheels, so it will take time for the parts
to settle. For this reason, repeat the tightening process during
the first 50 hours after installation.
METHOD FOR ADJUSTING PARKING BRAKE

k WARNING
• To prevent the parking brake from being automatically applied during the adjustment operation,
raise the brake oil pressure to a sufficiently high level. To prevent any other person from operating
the parking brake switch, hang a warning tag so that it can be seen clearly.
• Never put any oil or grease on the surface of the brake pad or disc.
If the parking brake effect is poor, adjust as follows.

2. Chock the tires to prevent the machine from moving.
4. Check that the brake oil pressure caution lamp is off (the brake accumulator pressure is sufficiently high).
5. Release the parking brake by operating the parking brake switch.
6. Loosen bolt (2) (4 pieces) for bracket (1) to be loose.
4-33
7. Repeat actuating and releasing of parking brake by operat-

ing the parking brake switch.
Repeat this operation until screw (3) does not move.
8. Check that the total of both clearances (a) and (b) between
disc (4) and pad (5) is within 1.02 to 1.52 mm.
9. Tighten bolts (2) (4 pieces) for bracket (1) not to be loose.
Make sure to position bracket (1) correctly when tightening
bolts (2).
10. Check that both clearances (a) and (b) between disc (4)
and pad (5) is 0.05 mm or more on one side.
Adjust the position of bracket (1) by displacing if the clearance is 0.05 mm or less.
11. After adjustment, check the parking brake performance.
For the performance check method for the parking brake, see “METHOD FOR CHECKING PARKING
BRAKE PERFORMANCE (4-45)”.
If the machine moves, ask your Komatsu distributor for inspection.
COLLECT LEAKED OIL FROM FLOATING SEAL

REMARK
Whenever oil flow out of the overflow hose, collect the oil.
1. Place the oil container to receive oil right under the drain plug.
2. Remove the drain plug and drain the oil.
There are drain plugs (4 places).
Collect oil through all the drain holes.
Front axle (right and left)
Center axle (right and left)
3. After draining the oil, tighten the drain plug.
4-34
METHOD FOR CHECKING AND ADJUSTING BODY MOUNT

k WARNING
When performing inspection of the machine with the dump body raised, always set the dump lever to
HOLD position, lock with the dump lever lock knob, then use the body pivot pin.
If the dump body mounting is not adjusted correctly, the frame may be damaged. Check and adjust it correctly.
1. Clean the dump body and frame to make them easier to check.
2. Check that bottom face (1) of the bottom mounting of
dump body is set evenly on top face (2) of the frame.
Check 6 places in total at (A), (B), and (C) on right and left.
If there is clearance (D) between bottom face (1) of the

bottom mounting and top face (2) of the frame, ask your
Komatsu distributor for adjustment.
3. Lower the dump body and check that all 6 places of the
bottom face of the bottom mounting are set evenly on top
face (2) of the frame.
CHECKS BEFORE STARTING

For the following items, see OPERATION, METHOD FOR CHECKING BEFORE STARTING (3-152).
• Drain water and sediment from fuel tank
• Check looseness of wheel hub bolts, and retighten bolts
• Check oil level in transmission case, add oil
• Check dust indicator
• Check battery disconnect switch
• Check water separator, drain water and sediment
• Check oil level in hydraulic tank, add oil
• Check cab mounting bolts and pins
• Check coolant level, add coolant
4-35
• Check oil level in engine oil pan, add oil

• Check electric wiring
• Check fuel level, add fuel
• Check DEF level, add DEF
• Check tire pressure
• Check centralized warning lamp, alarm buzzer, pilot lamps, and meters
• Check brake
• Check secondary steering
• Check manual secondary steering
• Check automatic secondary steering
• Check backup alarm operation
• Check horn operation
EVERY 50 HOURS MAINTENANCE

METHOD FOR LUBRICATING
1. Stop the engine.
2. By using a grease pump, pump in grease through the grease fittings.
3. Check visually that the greasing has been performed properly.
4. After greasing, wipe off any old grease that is pushed out.
Perform the greasing work every day when operating in places where the grease flows out easily, such as when
traveling through mud or water.
Front suspension (left) (2 places)
Front suspension (right) (2 places)
4-36
Rear suspension (right and left) (2 places each)

Maintenance for every 50 hours service should be performed at the same time.

1. Operate the dump body to be seated on a level ground.
2. Stop the engine.
3. By using a grease pump, pump in grease through the grease fittings.
Perform the greasing work every day when operating in places where the grease flows out easily, such as when
Steering cylinder (left) (2 places)
Steering cylinder (right) (2 places)
4-37
Hoist cylinder (right and left) (2 places each)
Dump body hinge pin (2 places)
Hitch bearing (2 places)
METHOD FOR CHECKING DRIVE SHAFT
4-38
Check for abnormality such as loose connection of the drive

shaft, play in the splines and bearings, runout of the shaft, etc.
If any problem is found, ask your Komatsu distributor for repair.
METHOD FOR CLEANING BREATHER

k WARNING
jury.
• When using compressed air, there is a danger that dirt may scatter and cause personal injury.
Always wear protective equipment such as protective eyeglasses and dust mask.
When getting on or off the machine with carrying breather, a

tool, etc., place it once in part (A) to ensure your safety.
1. Remove mud and dirt around the breather.

2. Remove the breather.
3. Rinse the breather in clean diesel fuel or cleaning oil, and remove dirt from inside.
4-39
Front differential
Rear differential case
Front final drive case (left)

It is located inside of the hydraulic tank.
Front final drive case (right)

It is located rear inside of the right front wheel.
Center differential
4-40
Center final drive case
METHOD FOR CLEANING OVERFLOW HOSE

k WARNING
When using compressed air, there is a danger that dirt may scatter and cause personal injury.
The overflow hoses are installed to the front and center wheels.
Remove and clean all of the 4 hoses.
1. Disconnect overflow hose (1).
Front
Center
2. Remove the soil and sand from inside of the disconnected hose with compressed air, etc.
3. Install overflow hose (1).
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL

Perform this procedure before operating the machine.
Inspect the battery electrolyte level according to the standard at least once a month.
4-41
k WARNING
Do not use the battery if the battery electrolyte level is below LOWER LEVEL line.
If you do so, it will reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is a danger of explosion. Do not bring any open flame
near the battery.
Battery electrolyte is dangerous object.
If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
NOTICE
Do not add the electrolyte to the battery exceeding UPPER LEVEL line.
If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other
parts.
If there is a fear that the battery water may freeze after refilling with purified water (such as a commer-
cial battery fluid), do the replenishment before the day's work on the next day.
METHOD FOR 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.
k WARNING
If the battery is wiped with a dry cloth, static electricity may cause a fire or explosion.
1. Open the battery box cover (1).
2. Use a wet cloth to clean the area around the electrolyte

level lines and check that the electrolyte level is between
UPPER LEVEL and LOWER LEVEL lines.
3. If the electrolyte level is below the middle between UPPER

LEVEL and LOWER LEVEL lines, immediately remove
cap (2) and add purified water (e.g. commercially available
replenishment water for a battery) to UPPER LEVEL line.
4. After adding the purified water, tighten cap (2) securely.
5. Close the battery box cover (1).
4-42
REMARK
If the purified water is added to above UPPER LEVEL line, remove the fluid by using a syringe to lower the level
to UPPER LEVEL line.
Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of
water.
If necessary, consult your Komatsu distributor or a battery manufacturer.
METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO

CHECK FROM SIDE OF BATTERY
If it is impossible to check the electrolyte level from the side of the battery, or there is no UPPER LEVEL line on
the side of the battery, check as follows.
1. Open the battery box cover (1).
2. Remove cap (2) at the top of the battery and check the
electrolyte level through electrolyte filler port (3).
3. If the electrolyte does not reach the sleeve (4), always add
the purified water (e.g. commercially available replenish-
ment water for a battery) so that the level reaches the bot-
tom of the sleeve (UPPER LEVEL line).
(A) Correct level: Electrolyte level is up to bottom of
sleeve, so surface tension causes electrolyte surface to
bulge and pole plate appears to be warped.
(B) Low level: Electrolyte level does not reach the bottom
of sleeve, so pole plate appears straight and not to be
warped.
4. After adding the purified water, tighten cap (2) securely.
5. Close the battery box cover (1).
REMARK
If purified water is added to above the bottom tip of the sleeve, use a syringe to remove electrolyte.
Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of
water.
If necessary, consult your Komatsu distributor or your battery manufacturer.
METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
4-43
METHOD FOR CHECKING FRAME AND A-ARM

k WARNING
When performing inspection with the dump body raised, always set the dump lever to “HOLD” position,
lock it with the dump lever lock knob, and use the dump body pivot pin.
1. Clean the frame and A-arm so that you can check them
easily.
2. Check that there is no damage to the frame or A-arm.
In particular, check the hatched area in the figure. If any
cracks or other damage are found, perform repairs.
Contact your Komatsu distributor for details of the repair
procedure.
METHOD FOR CHECKING FOOT BRAKE PERFORMANCE

k WARNING
If the machine moves when the braking capacity is being checked, it may lead to serious personal injury
or death.
If the machine moves, lower the engine speed immediately, set the gear shift lever to NEUTRAL position
(N) and set the parking brake switch to “PARKING” position.
NOTICE
When checking, be sure to select “F2” in “F1 Start at D Position Setting”, and then set the gear shift
lever to position “D”. Neglecting this can damage the inside of the transmission.
Check the braking capacity of the foot brake as follows.
4-44
1. Select “F2” in “D RANGE F1 START SETTING (3-68)” in

the user menu of the machine monitor.
2. Place the machine on flat ground and depress foot brake
(1).
3. Set gear shift lever (2) in position “D” and increase the en-
gine speed gradually.
If the machine does not move when the engine speed is
increased to 1100 rpm, it is normal.
If any problem is found, ask your Komatsu distributor for
repair.
4. Decrease the engine speed and set the gear shift lever to NEUTRAL position (N).
5. Set the parking brake switch to “PARKING” position to apply the parking brake.
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE

k WARNING
or death.
If the machine moves, lower the engine speed immediately, return the gear shift lever to NEUTRAL posi-
tion (N) and depress the foot brake.
NOTICE
Check the braking capacity of the retarder brake as follows.
2. Stop the machine on flat ground and pull retarder control
lever (1) fully.
repair.
METHOD FOR CHECKING PARKING BRAKE PERFORMANCE

k WARNING
or death.
If the machine moves, lower the engine speed immediately, return the gear shift lever to NEUTRAL posi-
tion (N) and depress the foot brake.
NOTICE
Check the braking capacity of the parking brake as follows.
4-45

2. Set parking brake switch (1) to “PARKING” position on a
flat ground.
repair.
METHOD FOR CHECKING WEAR OF PARKING BRAKE PADS

k WARNING
Never put any oil or grease on the surface of the pad or disc.
Measure the thickness of pad (1).

If thickness (A) is 1.5 mm or less, contact your Komatsu distrib-
utor.
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR

For handling of the accumulator, see “HANDLE SUSPENSION CYLINDERS, ACCUMULATOR AND GAS
SPRINGS (2-38)”.
If the engine stops during travel, the brake can be operated with the oil pressure in the accumulator temporarily.
1. Stop the machine on a flat ground.
2. Set parking brake switch (1) to “PARKING” position.
4-46
4. Run the engine at a medium speed for 1 minutes, and then

stop it.
6. Depress the brake pedal several times.

After the brake pedal is depressed some times, the brake
oil pressure caution lamp (1) lights up.
• If the brake oil pressure caution lamp lights up when
the brake pedal is depressed 4 times or less, the gas
pressure in the accumulator may be low. Ask your Ko-
matsu distributor for inspection.
• If the brake oil pressure caution lamp does not light up
when the brake pedal is depressed 5 times, the gas
pressure in the accumulator is normal.
REMARK
Check the function within 5 minutes after stopping the en-
gine.
If the engine is kept stopped, the gas pressure in the accu-
mulator lowers and cannot be checked.
4-47
7. After checking, turn the starting switch to OFF position.

Maintenance for every 50 and 250 hours should be performed at the same time.
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL
FILTER CARTRIDGE
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Refill capacity of engine oil pan: 50 ℓ

• Container to receive drained oil
• Filter wrench
When getting on or off the machine with carrying a filter, oil
container, a tool, etc., place it once in part (A) to ensure your
safety.
1. Remove the bolts, and remove cover (1).

2. Place the oil container right under the drain plug to receive
the drained oil.
4-48
3. Remove drain plug (2).

4. Install the drain hose on the back of the hydraulic tank cov-
er.
5. When draining the oil, loosen drain valve (3) slowly so that
you will not get oil on yourself.
Be careful not to loosen drain valve (3) too far and deform
the stopper pin inside the valve.
6. Inspect the drained oil.
If there are excessive metal particles or foreign material,
7. Tighten drain valve (3) and drain plug (2).
Tightening torque: 68.6±9.8 Nm {7±1 kgm}
8. Turn filter cartridge (4) counterclockwise by using the filter
wrench, and remove it.
When doing this, to prevent get splashed with drained oil,
do not perform this operation right under the cartridge.
In particular, if this work is performed immediately after
stopping the engine, a large amount of oil will come out, so
wait for 10 minutes before starting the work.
9. Clean the filter head.
10. Fill the new filter cartridge with clean oil.
11. Apply oil (or thinly apply grease) to the packing surfaces
and thread portion.
12. Install the filter cartridge.
When doing this, be careful not to damage the outside cylinder of the cartridge.
When installing the filter cartridge, tighten until the packing face is in contact with the filter head, then tight-
en a further 3/4 to 1 turn.
13. Add the specified amount of oil through oil filler port (F).
14. Run the engine at low idle for a while.
15. Check that the engine oil level is in the specified range.
For the method to check the engine oil level, see “METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL
PAN, ADDING OIL (3-156)”.
REMARK
When the ambient temperature is low, water or emulsified matter may stick to the dipstick, oil filler cap, etc. or
the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant level is
normal, it is not a problem.
There is no problem even if the emulsified matter cannot be removed completely after changing oil.
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE

k WARNING
• Just after the engine stops, all parts are still very hot, so do not replace the filter immediately.
Wait until all of parts cool down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.
4-49
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing parts, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles.
If any cartridge other than a Komatsu genuine filter cartridge is used, dust or dirt may get in and
cause problems with the injection system.
Never use a substitute.
• When performing the inspection or maintenance of the fuel system, pay more attention than normal
to the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
• Container to receive drained fuel
• Filter wrench
When replacing the fuel main filter cartridge (every 1000 hours), replace the fuel prefilter cartridge first.
When getting on or off the machine with carrying a filter, a tool,

2. Place a container under the fuel prefilter cartridge to receive the fuel.
3. Loosen drain valve (1) and drain water and sediments
from transparent cup (2), and also drain all the fuel from fil-
ter cartridge (3).
4. Remove drain hose (4).
6. Make sure that drain valve (1), which is provided in the
lower part of the transparent cup of the new filter cartridge,
is firmly tightened.
Tightening torque: 2.5 to 3.4 Nm {0.25 to 0.35 kgm}
4-50
8. Fill the new filter cartridge with clean fuel.

NOTICE
• When filling the filter cartridge with fuel, do not re-
move cap (B) at the center. Always fill with fuel
from small holes (C) (8 places) on the dirty side.
• After filling with fuel, remove cap (B) and install
the fuel filter.
• Always fill with clean fuel. Be careful not to let any
dirt or dust get into the fuel.
In particular, center portion is the clean side, so
do not remove cap (B) when filling with fuel. Be
careful not to let dirt or dust get into the center
portion on the clean side.
9. Thinly apply oil to the packing surfaces.
10. Remove filter cartridge cap (B) and install it to the filter
head.
When installing the cartridge, tighten it until the packing
surface contacts the sealing surface of the filter head, then
tighten it 1/2 to 3/4 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 tightened too loose, fuel will also leak
from the packing, so always tighten to the specified angle.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter cartridge.
11. Install drain hose (4).
12. After replacing the filter cartridge, start the engine and run it at low idle for 10 minutes.
13. Check the filter seal surface and the mounting face of the transparent cup for fuel leakage.
14. If there is any leakage of fuel, check the fastening condition of the filter cartridge.
If there is fuel leakage, repeat steps 1. to 5. to remove the filter cartridge, and if any damage or pinched
foreign material on the packing surface is found, replace it with a new cartridge and repeat steps 6. to 11. to
install it.
METHOD FOR LUBRICATING CAB MOUNTING PINS

(1 place each on right and left sides)
1. Stop the engine.
2. By using a grease pump, pump in grease through the
grease fittings.
3. Check visually that the greasing has been performed prop-
erly.
Perform the greasing work every day when operating in
places where the grease flows out easily, such as when
4-51
METHOD FOR CHECKING AND ADDING OIL IN DEFERENTIAL CASE

k WARNING
jury.
• If the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then re-
move it carefully.
When getting on or off the machine with carrying oil, a tool,

1. Remove plug (G).

2. Check that the oil level is near the lower edge of the plug
hole.
1) If the oil level in the front differential case is low, add

oil through oil filler port (F).
Add oil until it overflows from the plug hole.
2) If the oil level in the center or rear differential case is low, add oil through the plug hole.
Add oil until it overflows from the plug hole.
Center
4-52
Rear
METHOD FOR CHECKING AND CLEANING RADIATOR FINS, AFTERCOOLER

FINS, AND AIR CONDITIONER CONDENSER FINS
Perform this procedure if there is any mud or dirt stuck to the fins of the radiator, aftercooler, or air conditioner
condenser.
REMARK
Check the rubber hoses. If they are cracked or fragile, replace them. Check the hose clamps for looseness as
well.
METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE

k CAUTION
When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth etc.
You can blow off dirt sticking to the radiator or cooler by rotating the cooling fan in reverse.
1. Seat the dump body and stop the engine.
3. Turn the starting switch to ON position (A).
4. On the user menu, set Fan Reverse Mode.

The fan automatic reverse display lights up.
For setting of Radiator Fan Reverse Mode, see “RADIA-
TOR FAN REVERSE MODE (3-61)”.
4-53
For setting of Aftercooler Fan Reverse Mode, see “AFTER

COOLER FAN REVERSE MODE (3-63)”.
REMARK
When the dump body is not seated or when the engine is
running, even if the fan reverse mode is set, the direction
of rotation of the fan does not change.
The screen in the figure is displayed to inform the operator
that the direction of rotation of the fan has not been
changed.
Stop the engine, and then follow steps 3 and 4 above.

The cooling fan rotates in reverse.
A certain time after the starting switch key is turned to OFF position, the fan is returned to the normal rota-
tion mode automatically.
REMARK
• Blow off the dirt stuck in the radiator fins.
• In a cold circumstance, perform the cleaning by cooling fan reverse rotation within less than 5 minutes.
If the fan reverse rotation is performed for a long time, DEF hose may freeze.
METHOD FOR CLEANING FIN WITH COMPRESSED AIR

k WARNING
• If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the
compressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear
protective equipment such as protective eyeglasses and dust mask.
• When performing cleaning, always stop the engine and check that the fan is not rotating. If you
touch the fan when it is rotating, it will cause serious personal injury or death.
4-54
NOTICE
• When using compressed air for cleaning, blow it keep-
ing some distance to avoid damaging fins (1). Damage
on the fins can cause water leakage and overheating.
In a dusty job site, check the fins every day, regardless
of the maintenance interval.
• When using compressed air or steam, keep the nozzle
at a right angle (90 °) to the radiator, aftercooler, or air
conditioner condenser.
METHOD FOR CLEANING RADIATOR FIN AND AIR CONDITIONER CONDENSER

FIN
1. Remove mounting bolts (2) of radiator grille (1).
2. Remove radiator grille (1).
3. Blow off mud, dirt, leaves, etc. in radiator fins (3) and air
conditioner condenser fins (4) with compressed air.
Steam or water may be used instead of compressed air.
However, when performing powerful steam cleaning (high-
pressure machine washing) of the heat exchanger (radia-
tor), maintain sufficient distance from the machine.
If steam cleaning (high-pressure machine wash) is per-
formed at close distance, there is a danger that the internal
fins of the heat exchange equipment may be deformed,
and this will cause early clogging and breakage of the
equipment.
4. Perform the following check.
• Check the rubber hoses. If they are cracked or fragile,
replace them.
• Check the hose clamps for looseness.
METHOD FOR CLEANING AFTERCOOLER FIN

4-55
2. Remove mounting bolts (2) of cover (1) on the right side of

the machine.
3. Remove cover (1).
4. Blow off mud, dirt, leaves, etc. in aftercooler fins (3) with
compressed air.
Steam or water may be used instead of the compressed
air.
However, when performing powerful steam cleaning (high-
pressure machine washing) of the heat exchanger (radia-
tor), maintain sufficient distance from the machine.
If steam cleaning (high-pressure machine wash) is per-
formed at close distance, there is a danger that the internal
fins of the heat exchange equipment may be deformed,
and this will cause early clogging and breakage of the
equipment.
5. Perform the following check.
• Check the rubber hoses. If they are cracked or fragile,
replace them.
• Check the hose clamps for looseness.
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL
k WARNING
jury.
• If there is remaining pressure inside the case, the oil or plug may jump out.
Turn the plug slowly to release the pressure, then remove it carefully.
Check the oil level and add oil to all the final drive cases (front, center, rear).
1. Stop the machine so that the TOP embossed mark is at
the top and drain plug (P) is at the bottom.
2. Remove plug (G).
3. Check that the oil level is near the lower edge of the plug
hole.
If the oil level is too low, add oil through the plug hole until
the it overflows.

Maintenance for every 50, 250 and 500 hours should be performed at the same time.
4-56
METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT

k WARNING
jury.
1. Remove bolts (1), and remove cover (2).

2. Turn the cap of oil filler port (F) to release the internal pres-
sure before removing the cap.
4. Remove the element.
5. Clean the inside of the case and removed parts.
6. Install the new element.
7. Install cover (4) with bolt (3).
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE

k WARNING
• After the engine stops, all parts are still very hot, so do not replace the filter immediately.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.
• When using the fuel feed pump, do not loosen the air bleeding plug of the fuel circuit.
The fuel circuit is pressurized while the fuel feed pump is operated. If the air bleeding plug is loos-
ened at this time, fuel may spout out and it is dangerous.
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing parts, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles.
If any cartridge other than a Komatsu genuine filter cartridge is used, dust or dirt may get in and
cause problems with the injection system. Never use a substitute.
• When performing the inspection or maintenance of the fuel system, pay more attention than normal
to the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
4-57
• Container to receive drained fuel
• Filter wrench
After replacing the fuel prefilter cartridge, replace the fuel main filter cartridge.
When getting on or off the machine with carrying a filter, a tool,

2. Place a container under the filter cartridge to receive fuel.
5. Coat the packing surface of the new filter cartridge with oil.
6. Install the new filter cartridge to the filter head.

NOTICE
• Do not fill the new filter cartridge with fuel.
• Remove cap (B) at center and install the filter car-
tridge.
When installing the cartridge, tighten it until the packing
surface contacts the sealing surface of the filter head, then
tighten it 1/2 to 3/4 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.
7. Fill the fuel tank with fuel.
8. Tilt switch for the fuel feed pump (2) to ON position.
Lamp (3) flashes and the fuel feed pump operates.
After the specified time (approximately 7 minutes), lamp
(3) goes out automatically and the fuel feed pump stops.
When the lamp goes out, air bleeding is complete.
If the engine does not start, air may not be bled complete-
ly. In this case, repeat the operations of steps 8 to 9.
10. After replacing the filter cartridge, start the engine and
check that there is no leakage of fuel from the filter seal
surface.
4-58
If there is any leakage of fuel, check the tightening condition of the filter cartridge.
If there is still leakage of fuel, follow steps 2 and 3 to remove the filter cartridge, then check the packing
surface for damage or foreign material. If any problem is found, replace the cartridge with a new part, then
repeat steps 4 to 9 to install the filter cartridge.
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT

k WARNING
Wait for the temperature to go down, and then start the work.
When getting on or off the machine with carrying an element, a

1. Remove mounting bolts (2) of hydraulic tank top cover (1).
2. Remove nut (4) of breather assembly (3).

4. Replace breather element (6) with a new one.
5. Install cover (5) and nut (4).
6. Install cover (1) with bolts (2).
4-59
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT

k WARNING
jury.
• When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
VALVE SIDE
• Filter wrench
1. Remove bolts (1) (4 pieces), and open cover (2).
2. Place a container under the filter case to receive drained
oil.
3. Remove drain plug (3) of the filter head and drain the oil.
4. After draining the oil, tighten drain plug (3).
7. Apply clean oil to the sealing surface of the new filter car-
tridge.
8. Install the new filter cartridge.
Tightening torque: 54 to 64 Nm {5.5 to 6.5 kgm}
9. Add oil.
For the method to add oil to the transmission case, see “METHOD FOR CHECKING OIL LEVEL IN
10. Fix cover (2) with bolts (1).
BRAKE COOLING SIDE

1. Remove bolts (1) (4 pieces), and open cover (2).
4-60

3. Place the oil container right under the drain plug to receive
the drained oil.
4. Remove drain plug (P) and drain the oil.
5. After draining the oil, tighten drain plug (P).
7. Wash the inside of the filter case, strainer at the bottom of
the filter case, and removed parts.
8. Install the new element.
10. Add oil.
For the method to add oil to the transmission case, see “METHOD FOR CHECKING OIL LEVEL IN
11. Remove the cap of bleeder screw (5).
12. Insert a vinyl hose to bleeder screw (5).
13. Prepare a container with oil in it, and put the other end of the hose approximately 50 mm into the oil.
(Use a commercially available vinyl hose.)
15. Loosen bleeder screw (5) approximately 3/4 turns and run the engine at low idle until fewer bubbles come
out from the vinyl hose.
16. Tighten bleeder screw (5) securely, then install the cap.
17. Check that the oil level in the transmission case reaches the specified level.
If the oil level is low, add oil.
REMARK
When the air is bled from inside the case, the transmission oil level becomes stable.
18. Fix cover (2) with bolts (1).
METHOD FOR CHANGING OIL IN TRANSMISSION CASE

METHOD FOR CHANGING OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FIL-
TER ELEMENT
k WARNING
jury.
• Refill capacity of transmission case 125 ℓ including brake oil tank, and filter cases.)
Perform the following items at the same time in order to drain oil completely.
• METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT (4-60)
• METHOD FOR CHANGING OIL IN TRANSMISSION CASE (4-61)
• METHOD FOR CHANGING OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT (4-61)
• Filter wrench
4-61
1. Depress the brake pedal at least 20 times to reduce the pressure inside the brake control accumulator to 0.
2. Place the oil container right under drain plug (P) to receive
the drained oil.
4. After draining the oil, tighten drain plug (P).
5. Place the oil container right under filter case (1) to receive
the drained oil.
6. Remove filter case (1).

8. Clean the inside of the filter case
Replace O-ring (2) and backup ring (3) on the filter case
with new parts, apply thin film of clean oil to them, then in-
stall them to filter case.
9. Install the new element to the filter case.
10. When installing the element, thinly apply clean oil to its O-
ring.
Tightening torque: 78.4 to 98 Nm {8 to 10 kgm}
4-62
11. Before starting the engine, add 125 ℓ of oil through oil filler
port (F).
When oil is added, the level will temporarily go above the
oil level on sight gauge (G2), but this does not indicate any
abnormality.
12. Start the engine, and run it at low idle.
NOTICE
Do not start the engine before filling with oil.
If the engine is started when there is no oil in the sys-
tem, it will cause damage to the transmission and hy-
draulic pump.
13. Add oil through oil filler port (F) until the oil level is between H and L marks on sight gauge (G2).
When running the engine at idle, be careful not to let the oil level in the brake oil tank go below sight gauge
(G1).
If the oil level goes below sight gauge (G1), stop the engine to raise the oil level in the brake oil tank.
14. Remove the cap from bleeder screw (4) and insert a vinyl
hose.
(Use a commercially available vinyl hose.)
15. Prepare a container with oil in it, and put the other end of
the vinyl hose approximately 50 mm into oil.
17. Run the engine at low idle until no bubble comes out
through the vinyl hose.
18. When fewer bubbles come out, tighten bleeder screw (4)
securely, remove the vinyl hose, then install the cap.
19. Perform the warm-up operation of the engine until the torque converter oil temperature gauge goes to 40 °C
or above.
20. When the torque converter oil temperature gauge rises to 40 °C, bleed the air from the brakes.
For the procedure to bleed air from the brake, see “METHOD FOR BLEEDING AIR FROM BRAKE CIR-
CUIT (4-26)”.
NOTICE
• Do not re-use the oil drained when bleeding the air.
It will cause damage to the equipment.
• Be careful not to let the oil level in the brake oil tank go below sight gauge (G1) during the air
bleed operation.
This will cause damage to the pump.
21. After completely bleeding the air from the brakes, stop the engine for approximately 2 to 3 minutes.
22. After stopping the engine for approximately 2 to 3 minutes, check the oil level in the transmission case, and
adjust it to the specified level.
For the method to check the oil level in the transmission case and add oil, see “METHOD FOR CHECKING
OIL LEVEL IN TRANSMISSION CASE, ADDING OIL (3-153)”.
METHOD FOR LUBRICATING PARKING BRAKE

k WARNING
• When performing maintenance, raise the brake oil pressure sufficiently to prevent the parking brake
from being automatically applied. In addition, hang a warning tag that can be seen clearly to prevent
any other person from operating the parking brake switch.
• Never put any oil or grease on the surface of the brake disc or pad.
4-63

2. Chock the wheels.
3. Raise the dump body.
4. Fix the dump body with the dump body pivot pin.
5. Before starting operations, raise the brake oil pressure sufficiently to prevent the parking brake from being
automatically applied, and check that the brake oil pressure caution lamp is not lit.
6. Release the parking brake.
7. Stop the engine.
8. By using a grease pump, apply grease to the grease fit-
tings (1) and (2) (2 places) attached to the parking brake
body.
Apply grease until the grease come out from breather (3).
NOTICE
Do not use air pressure or oil pressure to perform high
pressure greasing.
10. Operate parking brake by repeating actuation and releas-
ing more than 5 times.
Excessive grease will come out by this operation.
11. Stop the engine.
12. Wipe off the grease come out.
13. Check the parking brake performance.
For the performance check method for the parking brake,
see “METHOD FOR CHECKING PARKING BRAKE PER-
FORMANCE (4-45)”.
If the machine moves during performance check, adjust
the parking brake.
For the method to adjust the parking brake, see “METHOD
FOR ADJUSTING PARKING BRAKE (4-33)”.

1. Stop the engine.
2. Pump in grease through the grease fittings shown by arrows by using a grease pump.
Perform the greasing work every day when operating in places where the grease flows out easily, such as
when traveling through mud or water.
4-64
Transmission front trunnion (1 place)
Transmission rear trunnion (1 place)
Center hinge pin (2 places)
METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT

k WARNING
• Perform this check when the brake oil temperature is 60 °C or below.
• If the disc wear approaches the wear limit, check the condition frequently, regardless of the mainte-
nance interval.
In addition, check the retarder capacity carefully.
1. Stop the machine on a flat place.

2. Set parking brake switch to “PARKING” position.
3. Chock the tires to prevent the machine from moving.
4. Check that nothing is actuated other than parking brake.
5. Turn the starting switch to ON position and check that the brake oil pressure caution lamp is not lit.
If the brake oil pressure caution lamp is lit, start the engine, and run it at 2000 rpm. When the lamp goes
out, turn the starting switch to OFF position.
4-65
6. Remove cap nut (1).

8. Push in shaft (2) of gauge until it contacts piston (3).

Portion (a): Shows the default value of thickness of brake
disc.
Portion (b): Shows the wear limit of thickness of brake
disc.
If it has reached the wear limit, ask your Komatsu distribu-
9. Install cap nut (1) removed in step 6.
Tightening torque: 29.4 to 39.2 Nm {3.0 to 4.0 kgm}
REMARK
• With new machines, the positions are adjusted so that
groove underline (a) of shaft (2) matches to upper sur-
face (c) of the guide. So do not loosen locknut (5) ex-
cept when replacing the disc.
• Perform the operation with 2 workers. One worker de-
presses the brake pedal and the other pushes in the
rod.
• If shaft (2) is pushed in when the engine is running,
shaft (2) will be pushed back by the brake cooling oil
pressure. So always perform this operation with the
engine stopped.
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP

1. Check for looseness in the air intake piping clamps between the air cleaner, turbocharger, aftercooler, and
engine.
2. Retighten any loose clamps.
Tightening torque of clamp (1): 8.8±0.5 Nm {0.9±0.05 kgm}
Tightening torque of clamp (2): 9.8±0.5 Nm {1.0±0.05 kgm}
4-66
METHOD FOR APPLYING LUBRICANT ON EXHAUST PIPE SPHERICAL SUR-

FACE JOINT PORTION
k WARNING
Immediately after the engine is stopped, the parts around the exhaust pipe are still very hot, and may
cause burn injury.
4-67
Apply lubricant to the spherical sliding portion of the exhaust pipe of the dump body heating unit (if equipped).
There are 2 spherical sliding portions, (1) and (2). Apply lubri-
cant to both of them.
1. Clean hatched portion (3) thoroughly.

2. Apply dry film lubricant until the base metal is invisible.
3. Dry for 1 hour.
4. When tightening bolts (4) (6 pieces), apply seizure preven-
tion and rust prevention lubricant to the underhead of the
bolts.
5. Install bolts (4) (6 pieces).
6. Slide the spherical parts to spread the lubricant thoroughly.
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT

k WARNING
Do not replace the element immediately after engine is stopped.
NOTICE
• Komatsu recommends using Komatsu genuine parts for replacement parts.
• If the machine is operated without DEF tank breather element attached, or with the element other
than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which
will cause failure of the machine. Never operate the machine without DEF tank breather element at-
tached, nor use the element other than Komatsu genuine parts.
• Do not flush DEF tank breather element. Flushing or regenerating of it will degrade the performance
of element, and will cause the breakage of DEF tank. Never reuse the DEF element.
• Always stop the engine and clean around DEF tank before replacing.
• After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF
pump and return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or
deposition of urea.
After the engine is stopped, the devices are operated for a few minutes. Replace the element after
DEF system devices stop.
• Improper assembly of DEF tank breather element may cause leakage of DEF. Replace the element in
the correct procedure.
4-68
2. Remove nut (4) of breather assembly (3) at the top of DEF

tank, then remove cover (5).
3. Replace breather (6) with a new one.
METHOD FOR CHECKING DRIVE BELT TENSION PULLEY ASSEMBLY OF COM-

PRESSOR FOR ALTERNATOR AND AIR CONDITIONER
Check the pulley for play and grease leakage.
If any abnormality is found, ask your Komatsu distributor for re-
pair or replacement.
4-69
METHOD FOR LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF

COMPRESSOR FOR ALTERNATOR AND AIR CONDITIONER
grease fittings shown by arrows.

Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time.
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE

k WARNING
jury.
• Front final drive case (each of right and left) refill capacity 5.5 ℓ
• Center final drive case (each of right and left) refill capacity 4.5 ℓ
• Rear final drive case (each of right and left) refill capacity 5.5 ℓ
Container to receive drained oil
Change the oil of all the final drive cases (front, center, rear).
Change the oil according to the following procedure.
1. Stop the machine so that the TOP embossed mark is at
the top and drain plug (P) is at the bottom.
4. Add the specified amount of oil through the hole of plug
(G).
5. After adding oil, check that the oil level is in the specified
range.
For the method to check the oil level in the final drive case,
see “METHOD FOR CHECKING OIL LEVEL IN FINAL
DRIVE CASE, ADDING OIL (4-56)”.
4-70
METHOD FOR CHANGING OIL IN DEFERENTIAL CASE

k WARNING
jury.
• Refill capacity of front differential case: 25.0 ℓ

• Refill capacity of center differential case: 43.0 ℓ
• Refill capacity of rear differential case: 38.0 ℓ
When getting on or off the machine with carrying oil, a tool,
Change the oil in all the differential cases (front, center, rear).
Change the oil according to the following procedure.
3. Refill with oil to the specified level through the hole for plug (G) or oil filler port (F).
4. After adding oil, check that the oil level is in the specified range.
For the method to check the oil level in the differential case, see “METHOD FOR CHECKING AND ADD-
ING OIL IN DEFERENTIAL CASE (4-52)”.
4-71
Front
Center
Rear
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT

k WARNING
1. Remove mounting bolts (2) of hydraulic tank top cover (1).

4-72
3. Remove nut (4) of breather assembly (3).

5. Replace breather element (6) with a new one.
7. Install cover (1) with mounting bolts (3).
METHOD FOR CLEANING TRANSMISSION CASE STRAINER

k WARNING
jury.
1. Drain the oil in the transmission case.
For the method to drain the oil from the transmission case, see “METHOD FOR CHANGING OIL IN
TRANSMISSION CASE (4-61)”.
2. Place the oil container right under drain plug (P) to receive the drained oil.
4-73

5. Take out the strainer.
6. Remove all dirt from the strainer, then wash it in clean die-
sel fuel or flushing oil.
If the strainer is damaged, replace it.
7. Install the drain plug and strainer in their original positions.
METHOD FOR CLEANING BREATHER

k WARNING
jury.
• When using compressed air, there is a danger that dirt may scatter and cause personal injury.
When getting on or off the machine with carrying breather, a

1. Remove mud and dirt around the breather.

2. Remove the breather.
4-74
3. Rinse the breather in clean diesel fuel or cleaning oil, and remove dirt from inside.
Transmission
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE

Contact your Komatsu distributor to have the gas pressure checked when making periodically replacement of
safety parts or performing the legally required 2000 hour or every year service.
METHOD FOR CHECKING ALTERNATOR

The brush may be worn and the grease in the bearings may have dried out.
Ask your Komatsu distributor for inspection and repair.
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE

Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work.
METHOD FOR REPLACING KCCV FILTER ELEMENT

k WARNING
After the engine has been operated, all of parts are still very hot. Do not replace the filter element imme-
diately.
NOTICE
• If the engine is operated without the filter element, the turbocharger and aftercooler become dirty
and their performance will lower and that can cause engine problems such as overrun caused by
suction of oil. Therefore, do not start the engine without the filter element.
• The filter element cannot be flushed.
Flushing or regenerating of the filter element will degrade performance of the filter. As a result, the
turbocharger and aftercooler become dirty and the performance lowers or the crankcase pressure
increases.
Never reuse the filter element since it can cause an engine failure.
• After the filter element is replaced, if KCCV is not assembled correctly, oil or blowby gas may leak.
Replace the filter element in the correct procedure.
• Special wrench for KCCV
4-75
The KCCV ventilator is located in the positions shown in the

figure.
For the use of the special KCCV wrench, see the figure.
1. By using the special KCCV wrench, loosen ring (3) of

KCCV ventilator (1).
2. After ring (3) comes off, remove case (4) from body (2) and
remove element (5).
Oil may be accumulated in or sticking to the case and ele-
ment. When replacing the element, take care that the oil
will not spill out.
REMARK
When the ambient temperature is low, water or emulsified
matter may stick to the inside of KCCV because of con-
densation of water vapor in the blowby gas. However, as
far as the coolant level is normal, it is not a problem.
3. Remove used O-ring (6) sticking to case (4) and install a
new O-ring contained in the service kit.
4-76
4. While matching ◇ marks (7) of the new element with ◇

mark (8) of the body label, insert the element thoroughly
into the end of the body.
The element can be installed only when its claws (9) are
correctly inserted in grooves (10) of the filter body.
Bases (11) and (12) are oval. Take extreme care so that
those bases are matched with each other.
5. Align the position of ◇ mark (13) on the case with that of ◇

mark (8) of the filter body label, then install the case to the
filter body.
The case can be installed only when its claws (14) are cor-
rectly inserted in grooves (10) of the filter body.
When inserting, take extreme care so that protrusion (15)
in the case is joined together with rubber lip (16) of the ele-
ment.
6. Fit ring (3) to the threaded part of the body and tighten it
with the hand firmly until it stops.
4-77
7. By using the special KCCV wrench, further tighten the ring

1/15 to 2/15 turns (1 to 2 ridges of the ring).
If the engine is operated with the ring tightened insufficient-
ly, oil and blowby gas may leak.
Check the KCCV hose for leakage, crack, and loose clamp, and replace it if necessary.
METHOD FOR REPLACING DEF FILTER

k WARNING
Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immediately.
NOTICE
• Komatsu recommends using Komatsu genuine parts for replacement parts.
• If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine
parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the
machine. Never operate the machine without DEF filter attached, nor use the filter other than Komat-
su genuine parts.
• DEF filter cannot be flushed. Flushing or regenerating of it will degrade the performance of filter,
and will cause the breakage of DEF tank. Never reuse the element.
• Improper assembly of DEF filter may cause leakage of DEF. Replace the DEF filter in the correct pro-
cedure.
• DEF freezes at –11 °C. If it is frozen, replacement of the filter becomes difficult. Replace the filter
when the temperature around DEF pump is higher than -11 °C, and in the condition that DEF is not
frozen.
After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF pump and
return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or deposition of urea.
After the engine is stopped, the devices are operated for a few minutes. Before replacing the filter, clean around
the DEF pump first after DEF system devices stop.
• DEF filter removal tool
• Torque wrench
The DEF filter is located at the positions shown in the figure.
4-78
1. Remove filter cap (1) at the bottom of DEF pump, and re-
move element (2).
2. Turn cap (4) of filter removal tool (3) and remove it.
3. Check the installation of spacer (5).
4. Insert filter removal tool (3) into the bottom of the DEF
pump and thrust in with hand.
5. Check that filter removal tool (3) is fully inserted to the end.
Insert the filter removal tool (3) to the end where you can-
not thrust it in any further.
6. Turn filter removal tool (3) in reverse, and remove filter (6).
Filter (6) is removed and you can take it out together with
filter removal tool (3).
If filter (6) cannot be removed from DEF pump, grip filter
removal tool (3), pull it down, then it will be removed.
4-79
7. Slide filter (6) down, and remove spacer (5) from filter re-
moval tool (3).
8. Pull filter (6) up while pushing in the tip of filter removal

tool (3), and remove it.
9. Return the removed spacer (5) to filter removal tool (3),
and keep them.
10. Insert a new filter and a new element into the bottom of
DEF pump, and lightly tighten them with hand.
11. Tighten filter cap (1).

Tightening torque: 20 to 25 Nm {2.0 to 2.5 kgm}

Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be performed at the same time.
REPLACE DEFINED LIFE PARTS

These parts change in material, wear, and deteriorate as they are aged.
Replace them every 2 years or every 4000 hours, whichever comes sooner.
4-80
DEFINED LIFE PARTS LIST

No. Periodical replacement parts Replacement interval
1 Fuel system Fuel hose
Spill hose
2 Engine lubrication system Turbocharger lubrication hose
Engine oil filter hose
3 Steering system High pressure circuit hose
4 Brake system Brake oil pressure hose
5 Torque converter, trans-
Transmission circuit hose
mission system
3 Work equipment hydraulic Main pump delivery hose Every 2 years or 4000 hours,
system whichever comes sooner
Main pump delivery hose other than described
above
Pump branch hose
Main pump LS hose
Hose for hydraulic drive fan
External work equipment hose
• Hoist circuit hose
4 Others PPC accumulator
METHOD FOR CHANGING OIL IN HYDRAULIC TANK

k WARNING
jury.
NOTICE
When filling the tank with oil after draining the hydraulic oil with the pump suction piping disconnected,
be sure to bleed air through the bleeder.
If the air is not bled, it stays in the suction piping and can damage the pump.
Hydraulic tank refill capacity 167 ℓ
1. Lower the dump body and stop the engine.
4-81
2. Turn the cap of oil filler port (F) gradually to release the in-
ternal pressure, and removing the cap.
3. Remove hydraulic tank cover (1) to take oil drain hose (2)
out from inside.
4. Remove drain plug (P) to install oil drain hose (2).
5. Place the container to receive the drained oil.
6. Loosen drain valve (3) and drain the oil.
7. After draining the oil, tighten drain valve (3).
8. Remove oil drain hose (2) and install drain plug (P).
9. Stow oil drain hose (2) and install hydraulic tank cover (1).
10. Add the specified amount of oil through oil filler port (F).
11. After adding oil, check that the hydraulic oil is at the speci-
fied level.
For the method to check the oil level in the hydraulic tank,
see “METHOD FOR CHECKING OIL LEVEL IN HY-
DRAULIC TANK, ADDING OIL (3-154)”.
12. Bleed air from the hydraulic circuit.
For the air bleeding procedure of hydraulic circuit, see
“METHOD FOR BLEEDING AIR FROM HYDRAULIC CIR-
CUIT (4-30)”.
METHOD FOR CHECKING WATER PUMP

Check around the water pump for water leakage.
If any part is leaking, ask your Komatsu distributor for inspection/repair.
METHOD FOR CHECKING STARTING MOTOR

The brush may be worn and the grease in the bearings may have dried out.
Ask your Komatsu distributor for inspection and repair.

If the engine is started frequently, have this inspection performed every 1000 hours.
4-82
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIP-

ING CLAMP, HARDENING OF RUBBER
Check clamps (1) to (14) visually and with your fingers that there are no loose bolts or hardening of the rubber.
If there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement.
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,

HARDENING OF RUBBER
Check for any missing fuel spray prevention caps (1) to (10) or fuel spray prevention cover (11), and check also
for any hardened rubber portions.
If there are any missing caps or cover or the rubber is hardened, ask your Komatsu distributor for installation or
replacement.
4-83
METHOD FOR CHECKING EXHAUST PIPE FIRE PREVENTION COVER

k WARNING
Immediately after the engine is stopped, all the parts are still very hot, and may cause burn injury.
Exhaust pipe fire prevention covers (3) and (4) may suffer material deterioration or damage depending on the
conditions of use and the operating environment of the machine.
2. Remove covers (1) and (2).
3. Check exhaust pipe fire prevention covers (3) and (4).

If any part is deteriorated or damaged, ask your Komatsu
distributor for replacement.
4. Install covers (1) and (2).

Maintenance for every 50, 250 and 500 hours should be performed at the same time.
METHOD FOR CLEANING KDPF

Contact your Komatsu distributor for cleaning of the KDPF.
METHOD FOR CLEANING DEF TANK

Ask your Komatsu distributor for cleaning of the DEF tank.
METHOD FOR CLEANING FUEL DOSER

For cleaning the fuel doser, ask your Komatsu distributor.
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON

FUEL DOSER PIPING, HARDENING OF RUBBER
The fuel spray prevention cap acts to prevent the fuel from coming into contact with high-temperature parts of
the engine and causing a fire if the fuel should leak or spray out.
Check visually and touch by hand to check that there are no missing caps, loose bolts or hardening of the rub-
ber.
If there are any problems, the parts must be replaced. Ask your Komatsu distributor for replacement.

Perform the periodic maintenance work of every 50, 250, 500, 1000 and 2000 hours of operation at the same
time.
4-84
METHOD FOR LUBRICATING DRIVE SHAFT

When greasing, use lithium grease (G2-LI), and perform the greasing every 6000 hours or every 2 years.
When getting on or off the machine with carrying grease, a tool
1. Stop the engine.

grease fittings shown by arrows.
3. Grease the spider portion until grease comes out from the
cap seal.
4. Check visually that the greasing has been performed prop-
erly.
METHOD FOR CHECKING LOCATION OF FRONT DRIVE SHAFT GREASE FIT-

TING
k WARNING
When checking the positions of the grease holes and grease fittings, ensure that the machine is stop-
ped.
It is very dangerous to check the positions of the grease holes and grease fittings while the machine is
running.
Check that grease hole (1) of the A-arm (at the rear of the machine) is matched with grease fitting (2) of the
spider.
If grease hole (1) is not matched with grease fitting (2) of the spider, match them according to the following pro-
cedure.
4-85
1) Move the machine backward or forward.

Do not go under the machine at this time.
2) Stop the engine.
3) Chock the wheels.
4) Check that grease hole (1) is matched with grease fitting
(2).
If grease hole (1) is not matched with grease fitting (2),
match them by repeating steps 1) to 3).

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

Special techniques and tools are required for this work.
Ask your Komatsu distributor for replacement of the engine high-pressure piping.
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP

Ask your Komatsu distributor for replacement of the fuel spray prevention caps.
METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR

Ask your Komatsu distributor to perform this work.

Maintenance for every 50, 250, 500, 1000 and 4500 hours service should be performed at the same time.
METHOD FOR REPLACING DEF HOSE

Ask your Komatsu distributor for replacement of the DEF hose.
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER

PIPING
Special techniques and tools are required for this work.
Ask your Komatsu distributor for replacement of the fuel spray prevention cap on fuel doser.
4-86
SPECIFICATIONS
5-1
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit HM400-5
Overall weight (unloaded weight + max. payload + 1 operator
kg 75135
(80 kg))
Unloaded weight kg 35055
Max. payload kg 40000
Struck m3 18.2
Dump body capacity
Heaped (2 : 1) m3 24.0
Dumping speed (2000 rpm) (raised) sec 12.0
Komatsu SAA6D140E-7 die-
Engine model -
sel engine
Engine rated horsepower
• SAE J1995 (gross) 353 / 2000
• ISO14396 kW /min-1 353 / 2000
• ISO9249 / SAE J1349 (net) 348 / 2000
Engine max. torque Nm {kgm}/ rpm 2280 {232} / 1400
A Overall length mm 11105
B Overall height mm 3735
C Overall height when dumping mm 7171
D Overall width mm 3450
E Min. ground clearance (bottom of center axle) mm 615
Min. turning radius mm 8885
1st km/h 6.6
2nd km/h 10.1
3rd km/h 15.5
Forward
4th km/h 23.7
Travel speed
5th km/h 36.5
6th km/h 55.9
1st km/h 6.8
Reverse
2nd km/h 16.0
Operating temperature range °C -20 to 40
5-2
SPECIFICATIONS SPECIFICATIONS
5-3
ATTACHMENTS AND OP-
TIONS
Before reading this chapter, read and understand the SAFETY.
6-1
HANDLE CAB POWER TILT ATTACHMENTS AND OPTIONS
HANDLE CAB POWER TILT

k WARNING
To prevent serious injury or death if the cab comes down, always observe the following strictly when
tilting the cab.
Precautions before starting cab tilt operation
• Perform the cab tilt operation on a flat place.
• When performing the cab tilt operation, set the machine facing directly to the front to prevent con-
tact between the cab and dump body, and secure the front and rear frames with the articulation
lock.
• Set the parking brake switch to “PARKING” position to apply the parking brake.
• Lock the dump control lever with the dump lever lock knob.
• Chock the tires to prevent the machine from moving.
• Always remove the pin from rear mounting position and insert it in the position for tilting, before
removing the cab mount.
• Do not perform the cab tilt operation in the strong wind.
Precautions for cab tilt operation
• Do not perform the cab tilt operation when the machine is loaded.
• Do not stand under the cab during the cab tilt operation.
• When the cab is tilted up, lock it securely in position with the lock bar.
• When installing the lock bar, do not enter under the cab but install it from the side of the cab.
• While the cab is tilted up, do not get on or off it.
• While the cab is tilted up, do not operate the gear shift lever nor dump lever.
• While the cab is tilted up, do not start the engine.
If it is necessary to start the engine when performing inspection, check first that there is no one un-
der the cab.
• While the cab is tilted up, do not give a large impact to the machine.
• When using the cab power tilt function to lower the cab, do not open the valve quickly but open it
gradually while adjusting the lowering speed.
• The lock bar is set on the left inside of the engine hood. After using it, be sure to restore it.

6-2
ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT
1. Tilt guard (1) at the rear of the cab and fix it according to
the following procedure.
1) Remove mounting bolts (3) of R.H. bracket (2).
2) Turn bracket (2) counterclockwise 90 ° and fix it with

the bolts.
3) Remove mounting bolts (5) of L.H. bracket (4).
4) Flip up guard (1).

5) Turn bracket (4) 180 ° and hitch it on rear guard (6).
6) Fix bracket (4) with the bolts.
7) Turn R.H. bracket (2) counterclockwise 90 ° and fix it

with the bolts.
6-3
HANDLE CAB POWER TILT ATTACHMENTS AND OPTIONS
2. Remove pin (7) in the mount at the rear of the cab, and in-
sert pin (8) instead. (each of the right and left)
A: For traveling
B: For tilting
3. Remove cab mounting bolts (9) (8 pieces).
4. Open the cab power tilt unit on the L.H. fender.

5. Turn valve (10) clockwise and close it fully.
6. Set switch (11) to ON position to raise the cab.
7. After tilting up the cab, fix it in position with lock bar (12).
Make sure that lock bar (12) is installed in the correct di-
rection and lock it securely with lock (13).
8. When lowering the cab, remove lock bar (12).

9. Turn valve (10) counterclockwise and open it gradually.
The cab lowers slowly.
10. After returning the cab to its original position, remove pin
(8) and insert pin (7) instead.
11. Install mounting bolts (9) (8 pieces).
6-4
ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT
12. Return guard (1) at the rear of the cab according to the fol-
lowing procedure.
2) Turn bracket (2) clockwise 90 ° and fix it with the bolts.
3) Remove the bolts of L.H. bracket (4) and remove it

from the rear guard.
4) Lower guard (1).
5) Turn bracket (4) 180 ° and fix it with mounting bolts
(5).

7) Turn bracket (2) clockwise 90 ° and fix it with mounting
bolts (3).
6-5
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS
HANDLING PAYLOAD METER

OUTLINE OF SYSTEM
The payload meter detects the signals from the pressure sensors, clinometer, body float detection, neutral de-
tection, and travel speed detection, and calculates the payload by using the microcomputer built in the control-
ler.
Also, it displays the calculated payload on the machine monitor and indicates the loading state with the external
display lamps.
You can download the data saved in the payload meter to a personal computer by using the special software (if
equipped). The measurement is performed by statistically processing the signals from the pressure sensors,
etc.
The road surface roughness, sudden acceleration, and sharp braking can decrease the accuracy.
For higher accuracy, maintain the road surface and smoothly accelerate and decelerate.
Although the following functions are installed, you do not need to change them for the standard operation. If set-
ting is required, ask your Komatsu distributor.
Setting of Loading End Travel Dist
The payload meter judges that loading is completed when the machine travels continuously 160 m from the
loading pit. If the machine dumps within 160 m, the controller does not judge that dumping is performed, thus
the cycle data is not completed at this time. This is used to change Loading End Travel Dist when the distance
between the loading pit and dumping pit is very short.
Display section of payload
While the machine monitor is displaying the standard screen,
the payload is displayed as shown in the figure.
External display lamp

The external display lamps are on top of the cab.
To make them visible for the digging operator or wheel loader,
there are 2 sets of external display lamps: Each set consists of
3 lamps ((1) green, (2) yellow, (3) red).
The display of the external display lamps changes according to
the payload.
6-6
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER
Download connector
The communication cable connection port is on the side of the
engine shutdown secondary switch.
When not using the communication cable connection port, fit
the download connector cap.
You can download the data saved in the payload meter to a
personal computer through the download connector.
NORMAL OPERATION DISPLAY

The normal operation is displayed by 2 methods of the machine monitor display which notifies the machine con-
dition and the external display lamps.
The machine motor and external display lamps indicate the machine states of unloaded, during loading, loaded,
and during dumping, each of which is classified into the stopped and traveling states.
Machine state Display on machine monitor External display lamp
When starting switch is in ON position - Lights up for 30 seconds
Stopped (*1) Clock display OFF
When unloaded
Traveling Clock display OFF
Stopped Payload display (*2) Payload display
During loading
Stopped Payload display Payload display
When loaded
Stopped Payload display Payload display
During dumping
Traveling Payload display OFF
(*1) The "Stopped" means state in which the gear shift lever is in NEUTRAL position (N) or the travel speed
signal is zero.
(*2) To change the state from "Unloaded" to "Loaded", the payload must be approximately 15 % of the rated
payload or more and the machine must wait for the payload to be stabilized in the stopped state.
The payload is checked and saved by statistically processing the data sampled during travel from the loading pit
to the dumping pit.
The payload displayed on the machine monitor is the value before the above statistic processing. The accuracy
of this value may be lower than that of the payload in the saved data.
Use the value displayed on the machine monitor for reference only.
Example of payload display
6-7
Example of payload display when an error occurs

• When an error occurs in the suspension pressure sensor, clinometer sensor, etc., “-----” is displayed, since
the payload cannot be calculated.
• The payload displayed in the loading pit (just after loading) may be a little different from the value displayed
in the dumping pit.
This is caused by the effect of the frictional force of the suspension, and cannot be eliminated.
A little change of the displayed value between measurement places is not caused by a trouble in the pay-
load meter.
EXTERNAL DISPLAY LAMP

The external lamps display the payload as follows.
Color of lamp HM400

1 Green 20.0 t and up
2 Yellow 36.0 t and up
3 Red 42.0 t and up
If there is difference between the payload and the lighting of

the external display lamp, the model setting may be wrong.
Display of prediction
When the load changes in steps for each bucket loaded, the system estimates the total load weight if one more
bucket is loaded, and flashes the appropriate lamp to prevent overloading.
The predicted load display and actual load weight display are shown at the same time.
Expected number of bucket loads: 4
1st bucket: 9.5 t
2nd bucket: 9.5 t (total: 19.0 t)
3rd bucket: 9.5 t (total: 28.5 t)
4th bucket: 9.5 t (total: 38.0 t)
When the machine is loaded in this way, the external display lamps light up as shown in the following chart.
Number of buck- External display lamp Remarks
et loads
• Since the actual payload is 9.5 t, no lamp lights up.

1st time
• Since the predicted payload is 19.0 t, no lamp lights up.
• Since the actual payload is 19.0 t, no lamp lights up.

2nd time • Since the predicted load weight is 28.5 t, the green lamp
flashes.
• Since the actual payload is 28.5 t, the green lamp lights

up.
3rd time
• Since the predicted payload is 38.0 t, the yellow lamp
flashes.
• Since the actual payload is 38.0 t, the green and yellow

4th time lamps light up.
• Since the predicted payload is 47.5 t, the red lamp flashes.
6-8
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER

The payload meter records the data of the dumping cycle (from each dumping to the next dumping).
Cycle data items
Dumping Month/Day Travel time with no load Stopped time for loading Stopped time with load
Time to start dumping Travel time with no load Travel time with load Dumping time
Machine ID Travel speed with no load Travel distance with load Limited travel speed
(Max.)
Open ID Travel speed with no load Travel speed with load Warning items for each cy-
(Average) (Max.) cle
Payload Stopped time with no load Travel speed with load
(Average)
• The payload which is a saved data corresponds to the weight carried in each cycle.
• The maximum limit for saving cycle data is 2900 cycles. If the data in memory exceed 2900 cycles, the
newest data are written over the oldest data.
• Download the recorded data through RS232C port to a personal computer installed with special software (if
equipped).
The downloaded data are saved in the text form (CSV type) in a certain place on the personal computer.
For details, see the operation and maintenance manual for the special software.
You can take in and check the downloaded data with the text file read function of the commercially available
spreadsheet software.
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWN-

LOAD
k WARNING
• When handling the cables, be careful not to damage them or pull them by force.
• Do not leave the connectors disconnected.
• Be careful to prevent dirt from entering the connector portion.
• Do not let any metal objects touch the connector portion.
• Download the data by means of serial communication (RS232C).

For computers without an RS232C port, it may be possible to use a third party USB-RS232C conversion
adapter.
However, this does not guarantee the operation.
The download software supports COM1 and COM2, so check which port it can be connected to.
• Download the recorded data to a personal computer installed with special software (optional).
• When you need to correct the date and time in the downloaded data, consult your Komatsu distributor.
• There is some error in the directory where the data is downloaded by the special software, there may be a
mistake in the setting for the machine.
6-9
1. Remove cap (1).

2. Connect the download cable attached to the special soft-
ware to the download connector.
3. Connect the other end of the download cable to RS232C
port of the personal computer.
5. Start up the personal computer and use the special soft-

ware to download the data.
You can use the card type payload meter download soft-
ware for HM400 as it is.
For details of installing the software, see the instruction
manual provided with the download software.
When the installation is completed, the icon shown in the
figure is created.
1) Double-click the icon.

The download software is started and the screen
shown in the figure is displayed.
2) When screen “G1000” is displayed, click “PLM”.

Screen “G2000” is displayed.
Do not click “CARD” and “PMC”, since they are not
used.
3) Click “Parameter Setting” on screen “G2000”.

Do not click “PLM Remote Control”, since it is not
used.
6-10
4) Click “Unit Setting” on screen “G2200”.

Do not click “User’s Comment”, since it is not used.
On screen “G2210”, you can select communication

ports (COM1, COM2), specify the place to save the
downloaded data, specify the file to be made, and se-
lect the unit for the made data.
For details, see the instruction manual provided for the
download software.
5) Check “Summary Data File” and “Cycle Data File” of
“File”.
In HM400, only “Summary Data File” and “Cycle Data
File” are handled.
Once a setting has been made, there is no need to set it again when performing the next download.
6) Click “ENTER” to return to screen “G2200”.
7) On screen “G2200”, click “BACK” to return to screen

“G2000”.
8) Click “Download” on screen “G2000”.
9) When screen “G2100” is displayed, click “Start”.

Downloading starts.
When downloading is finished, close the screen.
REMARK
Screen “G2101 < Down load - File ID” is displayed,
depending on the software version.
In this case, input the file ID, then click “OK”, and
downloading starts.
6. After finishing downloading, be sure to return the cable.
6-11
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES

You can display the accumulated payload and the total number of cycles which are integrated at each dumping.
You can reset those values as well.
1. Press menu switch (1) on the standard screen and display
“Machine Setting and Information” menu. Select “Payload
Meter” and press enter switch (2).
2. Select “Accumulated Payload and Total Cycles” and press

enter switch (2).
The accumulated payload and the total number of cycles

are displayed as shown in the figure.
• The data and time of start are those when “Accumulat-
ed Payload and Total Cycles” were reset last time.
• The date and time of finish are those of the last dump-
ing.
• “Accumulated Payload and Total Cycles” are the inte-
grated values after the previous resetting.
• The display range is from 0 to 99999999.9t and 0 to
999999 cycles respectively. When they reach the up-
per limits, they are kept at the upper limits until they are reset.
6-12
3. Press enter switch (2).

The pop-up window of the data reset is displayed.
Press return switch (3), and the screen returns to “Payload
Meter” menu.
4. Press enter switch (2) while the pop-up window shown in
the figure is displayed.
“Accumulated Payload and Total Cycles” are reset and the
pop-up window closes.
If you press return switch (3), nothing is done and the pop-
up window closes.
DISPLAY FUEL CONSUMPTION RECORD

You can display the average daily working fuel consumption (ton/l) in the last 1 week.
You can reset that value.
2. Select “Average Fuel Consumption Record” and press en-

ter switch (2).
6-13
The average value of the daily working fuel consumption in

the last 1 week is displayed as shown in the figure.

The pop-up window of the data reset is displayed.
Press return switch (3), and the screen returns to “Payload
Meter” menu.
4. Press enter switch (2) while the pop-up window shown in
the figure is displayed.
“Average Fuel Consumption Record” is reset and the pop-
up window closes.
If you press return switch (3), nothing is done and the pop-
up window closes.
SETTING MACHINE ID AND OPEN ID

You can change the setting of the machine ID and open ID which are items in the cycle data.
You can check the operator and load of each cycle by setting the machine No. as the machine ID and setting
the operator and the load type as the open ID.
6-14
2. Select “Machine ID Setting”.

The set machine ID is displayed on the right side.

The pop-up window opens and displays the currently set
machine ID. Input the machine ID.
• The settable range is from 0 to 200.
• Each time Up switch (3) is pressed, ID increases by 1.
Each time Down switch (4) is pressed, ID decreases
by 1.
• If Up switch (3) is held down, ID increases rapidly. If
Down switch (4) is held down, ID decreases rapidly.
• If UP switch (3) is pressed when 200 is displayed as
ID, ID returns to 0. If Down switch (4) is pressed when 0 is displayed as ID, it becomes 200.
4. After inputting the machine ID, press enter switch (2).
The value at this time is set as ID, and the windows closes.
If you press return switch (5), the window closes without changing the value of ID.
5. When setting an open ID, select “Open ID Setting” on the
screen of step 2.
The set open ID is displayed on the right side.
6. The setting procedure for the open ID is the same with the
machine ID.
Set the open ID.
METHOD FOR PERFORMING CALIBRATION

Perform calibration in the following cases.
• When the machine or payload meter is delivered
• Once a month
• When the suspension cylinder gas pressure and oil quantity are adjusted (When the suspension is adjus-
ted)
6-15
• When the suspension pressure sensor is replaced

• When the machine is modified and the empty weight of the machine changes by 100 kg or more.
NOTICE
• Perform calibration on a level place.
• Perform calibration while traveling straight.
A straight road approximately 100 m long is necessary for calibration.
• Do not perform calibration while an error is generated.
• When performing calibration, seat the dump body and set the dump lever to “FLOAT” position.
You can check that the dump body is seated by checking that the dump body float caution lamp is
turned OFF.
1. Empty the machine.
Be sure to completely remove all the soil remaining inside the dump body.
2. Run in the machine.
3. While running the engine, set the gear shift lever to NEUTRAL position (N), and stop the machine.
4. Prepare for calibration according to the following procedure.
1) Press menu switch (1) on the standard screen and
display “Machine Setting and Information” menu. Se-
lect “Payload Meter” and press enter switch (2).
2) Select “Calibration” and press enter switch (2).

The pop-up window of starting calibration is displayed.
6-16
3) Press enter switch (2) while the pop-up window shown

in the figure is displayed.
If you press return switch (3), the window closes with-
out starting calibration.
5. When the display becomes as shown in the figure, drive

the machine at speed of 10 km/h.
REMARK
To cancel at this time, press return switch (3) while the
screen in the figure is displayed.
6. Continue driving the machine at speed of 10 km/h.

Keep the travel speed at 10 km/h during the travel.
The display changes as shown in the figure in approxi-
mately 30 seconds, and the calibration is completed.
6-17
REPLACEMENT PARTS
7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS REPLACEMENT PARTS
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts listed in the table of the defined life parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. Howev-
er, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is im-
portant to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time
as the hoses.
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all
loose hoses and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the defined life parts.
DEFINED LIFE PARTS LIST

No. Parts for periodic replacement Replacement interval
1 Fuel system Fuel hose
Spill hose
2 Engine lubrication system Turbocharger lubrication hose
Engine oil filter hose
3 Steering system High pressure circuit hose
4 Brake system Brake oil pressure hose
5 Torque converter, trans-
Transmission circuit hose
mission system
3 Work equipment hydraulic Main pump delivery hose Every 2 years or 4000 hours,
system whichever comes sooner
Main pump delivery hose other than described
above
Pump branch hose
Main pump LS hose
Hose for hydraulic drive fan
External work equipment hose
• Hoist circuit hose
4 Others PPC accumulator
Every 3 years from start of us-
age or 5 years after manufac-
Seat belt
turing of seat belt, whichever
comes sooner.
7-2
REPLACEMENT PARTS CONSUMABLE PARTS
CONSUMABLE PARTS
Replace consumable parts such as the filter element or air cleaner element at the time of periodic maintenance
or before they reach the wear limit. The consumable parts should be replaced correctly in order to ensure more
economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko-
matsu distributor of the machine serial number and check the latest part number when ordering parts.
CONSUMABLE PARTS LIST

The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No. Part name Q'ty
interval
Engine oil filter 600-211-1340 Cartridge 2
500 hours
Fuel prefilter 600-319-4800 Cartridge 1
Fuel main filter 600-319-3841 Cartridge 1
Transmission oil filter
714-07-28713 Cartridge 2
(valve side)
Transmission oil filter 208-60-71124 Element 1
(brake cooling side) (07000-F5210) (O-ring) (1)
569-43-83920 Element 1
1000 hours
Brake oil filter (07000-12065) (O-ring) (1)
(07001-02065) (Back-up ring) (1)
Fuel tank breather 421-60-35170 Element 1
207-60-71183 Element 1
Hydraulic oil filter
(07000-F5200) (O-ring) (1)
DEF tank breather 421-60-35170 Element 1
KCCV filter 600-331-1900 Element 1
419-60-15250 Element 1
Hydraulic tank breather 2000 hours
(419-60-15270) (O-ring) (1)
DEF filter 6540-71-2320 Filter kit 1
Air cleaner 600-185-6100 Element assembly 1 -
7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS
RECOMMENDED FUEL, COOLANT, AND LUBRICANT

NOTICE
• Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construc-
tion equipment and components.
In order to keep your machine in the best condition for long period of time, it is essential to follow
the instructions in this Operation and Maintenance Manual.
• Failure to follow these recommendations may result in shortened life or excessive wear of the en-
gine, power train, cooling system, and/or other components.
• Commercially available lubricant additives may be good or bad for the machine. Komatsu does not
recommend any commercially available lubricant additive.
• Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komat-
su genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect
the engine such as deteriorated oil may reduce lubricating function, and it may cause failure, short-
ening of the machine life, lowering of performance and increase of fuel consumption.
• Use the fuel, the oil and the lubricant according to the ambient temperature as recommended.
• If the machine is operated at a temperature of -20 °C and below, separate devices are needed, so
consult your Komatsu distributor.
NOTICE
The fuel used must be ultra low-sulfur diesel fuel.
(≤10 ppm)
To ensure good fuel consumption characteristics and ex-
haust gas characteristics, the engine mounted on this ma-
chine uses an electronically controlled high-pressure fuel
injection device and emission gas control system (KDPF).
Since the high-pressure fuel injection device requires high
precision parts and lubrication, if low viscosity fuel with
low lubricating ability is used, its durability may drop con-
siderably. And using fuel with high sulfur content can dete-
riorate the engine parts and KDPF catalyzer, inducing fail-
ures, decrease of the life and degradation in performance.
NOTICE
Use DEF as the aqueous urea solution for SCR system.
DEF is a colorless transparent 32.5 % aqueous urea solu-
tion.
The quality of DEF is prescribed in ISO22241-1. Always use
DEF that conforms to this quality standard.
LUBRICATION CHART
• The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication
interval.
Keep this chart in the magazine box inside the cab so that the people concerned can refer it any time dur-
ing lubrication.
• Even if the same symbol is used in the lubrication chart, the recommended genuine oil may differ according
to the lubrication points and the ambient temperature. For details, see “RECOMMENDED FUEL, COOL-
ANT, AND LUBRICANT (7-4)”.
7-4
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
• For details of lubrication, see “MAINTENANCE SCHEDULE (4-12)”.
• The symbols used in the lubrication chart are explained as follows.

Symbol Meaning of the symbol Symbol Meaning of the symbol
Read the Operation and Maintenance
Greasing of the grease
Manual.
Change of the engine oil Check oil level in engine oil pan
Change hydraulic oil Change hydraulic oil
7-5
Symbol Meaning of the symbol Symbol Meaning of the symbol
Change power train oil Change power train oil
Change engine oil filter Change hydraulic oil filter
Change breather element in hydraulic tank Change fuel filter
Change KCCV filter breather element Change axle oil
Check axle oil level Power train oil filter
Change breather element in fuel tank Change brake fluid/oil
Change oil filter Change DEF tank breather element
Change DEF filter
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE
Ambient Temperature, degrees Celsius Recommended Komatsu
Reservoir Fluid Type
Min Max Fluids
Engine oil for EOS5W30-LA

KDPF used in -25 °C 35 °C (KES Diesel Engine Oil)
cold terrain (Oil (Note 1)
Change interval
EOS5W40-LA
250 hours)
-25 °C 40 °C (KES Diesel Engine Oil)
Engine oil pan (Note 1)
Engine oil for EO10W30-LA

-20 °C 40 °C
KDPF (Oil (KES Diesel Engine Oil)
Change interval EO15W40-LA
500 hours) -15 °C 50 °C
(KES Diesel Engine Oil)
Transmission Case Power train oil TO10
-30 °C 50 °C
(incl. brake oil tank (Note.2) (KES) (Note 2)
TO10
Power train oil -30 °C 50 °C
(KES)
HO46-HM
Hydraulic tank -20 °C 50 °C
(KES)
Hydraulic oil
HO-MVK
-30 °C 50 °C
(KES)
Front suspension HO-MVK
Hydraulic oil -30 °C 50 °C
Rear suspension (KES)
7-6
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
Front differential
case
Center differential
case
Rear differential
case AXO80
Axle oil -30 °C 50 °C
Front final drive (KES)
case
Center final drive
case
Rear final drive
case
G2-TE
Hyper grease -20 °C 50 °C
(KES) (Note 3)
Lithium EP G2-LI
-20 °C 50 °C
grease (KES)
Grease fitting
G2-LI-S
Lithium grease -30 °C 40 °C
(KES)
GLT2-LI
Lithium grease -30 °C 30 °C
(KES)
Spherical joint Air-curing dry lu- MOLYKOTE D321R
-30 °C 50 °C
(Body heating) bricant (56B-98-21370)
Lubricant for
Stainless bolt LC-G
burning and rust- -30 °C 50 °C
(Body heating) (KES)
ing prevention
Non-Amine En-
AF-NAC
Cooling system gine Coolant -30 °C 50 °C
(KES) (Note 4)
(AF-NAC)
-30 °C 20 °C EN 590 Class 2
Fuel tank Diesel fuel
-10 °C 50 °C EN 590 Grade D
DEF tank DEF -30 °C 50 °C DEF (Note 5)
Front sus- Rear sus- Front final

Transmis-
pension pension drive case
Engine oil sion case Hydraulic Front differ-
pan tank (each of (each of ential (each of
(Incl. brake
right and right and right and
oil tank)
left) left) left)
Specified
ℓ 58.0 295.0 245.0 8.3 2.4 25.0 6.0
capacity
Refill ca-
ℓ 50.0 156.0 167.0 8.3 2.4 25.0 5.5
pacity
Center final Rear final

Center dif- drive case drive case
Rear differ- Cooling
ferential (each of (each of Fuel tank DEF tank
ential case system
case right and right and
left) left)
Specified
ℓ 43.0 5.0 38.0 6.0 525 120 33
capacity
Refill ca-
ℓ 43.0 4.5 38.0 5.5 - 114 -
pacity
7-7
REMARK
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity
means the amount of oil needed to refill the system during checking and maintenance.
Note 1: KDPF engine oil for cold district is deteriorated easily than that for normal area (replace every 500
hours), so replace oil and filter cartridge every 250 hours. For changing maintenance time of machine monitor,
ask your Komatsu distributor to perform the work.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-TE) has 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.
Note 4: Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing.
Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and
can be used continuously for 2 years or 4000 hours.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2. For details of the density of Non-Amine Engine Coolant (AF-NAC), see “METHOD FOR CLEANING INSIDE
OF COOLING SYSTEM (4-19)”.
Non-Amine Engine Coolant (AF-NAC) is supplied already diluted.
In this case, fill up the tank with pre-diluted fluid. (Never dilute the Non-Amine Engine Coolant with ordinary
water.)
Note 5: DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after
the engine is started.
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU

GENUINE OILS
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
7-8
INDEX
INDEX
Symbols AUX.....................................................................3-233
Average fuel consumption display - Set................3-56
12hour or 24hour Mode........................................ 3-85 Average fuel consumption record......................... 3-54
12V power supply............................................... 3-109 Average fuel consumption record - Display.......... 6-13
Avoid mixing oil....................................................... 4-3
A
A/C ECO mode setting..........................................3-69
B
Accelerator pedal................................................ 3-104 Backup alarm operation - Check.........................3-163
Accumulator gas pressure - Check.......................4-75 Band/AUX selector button...................................3-232
Action level display............................................... 3-17 Basic operation of machine monitor......................3-11
Actions after bleeding air...................................... 4-29 Battery.................................................................3-244
Actions against transmission trouble.................. 3-248 Battery - Check electrolyte level from side............4-42
Actions if fire occurs..............................................2-16 Battery - Check electrolyte level impossible from side.
Actions when running out of fuel.........................3-248 .......................................................................4-43
After cold weather season.................................. 3-245 Battery - Handle.................................................... 2-35
After finishing work - Check................................ 3-209 Battery - Remove / Install....................................3-253
Aftercooler fan reverse mode................................3-63 Battery disconnect switch....................................3-115
Aftercooler fin - Clean........................................... 4-55 Battery disconnect switch - Check...................... 3-153
Aftertreatment devices regeneration.....................3-73 Battery electrolyte level - Check........................... 4-41
Aftertreatment devices regeneration disable - Cancel. Battery inspection cover - Lock...........................3-212
.....................................................................3-131 Battery inspection cover - Open..........................3-212
Aftertreatment devices regeneration disable - Set....... Battery inspection cover - Open / Close............. 3-212
.....................................................................3-128 Before operation - Adjust.................................... 3-164
Aftertreatment devices regeneration display.........3-38 Before reading this manual..................................... 1-2
Air cleaner - Check............................................... 4-14 Beware of asbestos dust.......................................2-23
Air cleaner - Check / Clean / Replace...................4-14 Body pivot pin......................................................3-117
Air cleaner clogging caution lamp......................... 3-31 Body pivot pin - Stow.......................................... 3-118
Air cleaner element - Replace...............................4-17 Brake circuit - Bleed air.........................................4-26
Air cleaner outer element - Clean......................... 4-15 Brake cooling side.................................................4-60
Air conditioner - Check / Maintain......................... 4-22 Brake disc - Check wear....................................... 4-65
Air conditioner - Handle...................................... 3-219 Brake dragging prevention guidance.................... 3-40
Air conditioner - Operate.....................................3-225 Brake oil pressure caution lamp............................3-21
Air conditioner air filter - Clean..............................4-23 Brake oil tank - Replace oil / Brake oil filter element -
Air conditioner switch..................................3-48,3-224 Replace..........................................................4-61
Air conditioner system caution lamp..................... 3-32 Brake pedal.........................................................3-104
AISS LOW switch..................................................3-99 Brake pedal - Test............................................... 3-162
Alternator - Check................................................. 4-75 Brake performance curve....................................3-191
Always use clean washer fluid................................ 4-2 Braking capacity of parking brake - Check........... 4-45
Appoint leader when working with others............. 2-31 Breather - Clean........................................... 4-39,4-74
ARAC system - Operate..................................... 3-198 Brightness adjustment switch of rear view monitor......
Armrest angle - Adjust........................................ 3-167 .......................................................................3-98
Armrest height - Adjust....................................... 3-167
Articulate lock......................................................3-117 C
Ashtray................................................................3-109
Attachments and options........................................ 6-1 Cab door - Lock / Unlock.................................... 3-216
Auto idle stop timer - Set.......................................3-71 Cab door - Open and close................................. 3-113
Auto switch..........................................................3-223 Cab door handle..................................................3-114
Automatic operation - Start................................. 3-225 Cab door inner lock............................................. 3-114
Automatic operation - Stop................................. 3-226 Cab mount bolts and pins - Check......................3-155
Automatic retarder and accelerator linked control Cab mount pin - Lubricate.....................................4-51
switch.............................................................3-98 Cab power tilt unit - Handle.....................................6-2
Automatic retarder, accelerator control (ARAC) - Han- Cab tilt function - Operate................................... 3-204
dle................................................................ 3-197 Calendar - Set.......................................................3-82
Automatic secondary steering - Check............... 3-163 Calibration - Perform.............................................6-15
Automatic warm-up function............................... 3-182 Centralized warning lamp..................................... 3-32
8-1
INDEX
Centralized warning lamp, alarm buzzer, monitor Dimmer switch...................................................... 3-95

lamp, and meter - Check............................. 3-161 Directions of machine............................................. 1-7
Charge level caution lamp.................................... 3-31 Display................................................................ 3-233
Chassis - Act for phenomena..............................3-257 Display monitor................................................... 3-223
Check drained oil and used filter.............................4-2 Display selector button........................................3-233
Check service meter reading.................................. 4-2 Display warning tag during inspection and mainte-
Check signs and signalman's signals................... 2-23 nance............................................................. 2-31
Checks and adjustment before starting engine............ Display/non-display of ECO guidance - Switch.....3-59
.............................................................2-24,3-150 Display/non-display of guidance when key is OFF -
Checks before starting..................................2-26,4-35 Switch............................................................ 3-60
Cigarette lighter.....................................................3-94 Do not drop things inside machine..........................4-2
Circuit breaker.....................................................3-116 Do not get caught in work equipment................... 2-20
Clearance lamp pilot lamp.................................... 3-35 Do not go close to high-voltage cables................. 2-22
Clock - Adjust..............................................3-81,3-236 Down switch..........................................................3-47
Cold weather operation.......................................3-244 Drain valve - Adjust.............................................3-154
Cold weather operation information.................... 3-244 Drink box.............................................................3-108
Configurations.......................................................3-56 Drive belt tension pulley assembly of compressor for
Consumable parts...................................................7-3 alternator and air conditioner - Check............4-69
Consumable parts list............................................. 7-3 Drive belt tension pulley assembly of compressor for
Contents of safety labels.........................................2-8 alternator and air conditioner - Lubricate....... 4-70
Control levers and pedals................................... 3-104 Drive shaft - Check............................................... 4-38
Controls and gauges names................................... 3-3 Drive shaft - Lubricate...........................................4-85
Coolant................................................................3-244 Dump body - Check.............................................. 4-25
Coolant - Check level / Add................................ 3-155 Dump body - Load................................................ 2-28
Coolant and water for dilution................................. 4-6 Dump body - Lower in emergency...................... 3-249
Cooling system - Clean inside.............................. 4-19 Dump body float caution lamp.............................. 3-25
Cup holder.......................................................... 3-109 Dump body heating specifications...................... 3-237
Current abnormality screen...................................3-18 Dump body hold condition - Cancel.................... 3-181
Dump body mount - Check / Adjust...................... 4-35
D Dump lever..........................................................3-107
Dump lever lock knob......................................... 3-107
D range F1 start - Set........................................... 3-68 Dumping counter...................................................3-66
Data - Download from download connector............6-9 Dust indicator...................................................... 3-117
Daylight saving time..............................................3-85 Dust indicator - Check.........................................3-153
Declaration of conformity...................................... 1-12 Dusty jobsite........................................................... 4-3
DEF...............................................................3-244,4-7
DEF - Check level / Add......................................3-159
DEF - Store............................................................. 4-8
E
DEF filter............................................................. 3-147 ECO gauge........................................................... 3-43
DEF filter - Replace...............................................4-78 ECO gauge display fuel target value - Set............3-58
DEF hose - Replace..............................................4-86 ECO guidance.......................................................3-39
DEF level - Check............................................... 3-195 ECO guidance records..........................................3-53
DEF level caution lamp......................................... 3-22 Electric wiring - Check........................................ 3-158
DEF level gauge................................................... 3-45 Electrical components - Handle.............................. 4-9
DEF low level guidance........................................ 3-41 Electrical system - Act for phenomena............... 3-256
DEF system caution lamp..................................... 3-27 Emergency escape hammer............................... 3-107
DEF system high-temperature stop caution lamp.3-27 Emergency exit from operator's cab..................... 2-20
DEF tank - Clean.................................................. 4-84 Energy saving guidance........................................3-51
DEF tank breather element - Replace.................. 4-68 Engine - Check low-speed run and acceleration 3-181
DEF tank filler cap cover - Open / Close.............3-213 Engine - Check starting condition and unusual noise..
DEF tank filler port cover - Lock..........................3-214 .....................................................................3-181
DEF tank filler port cover - Open........................ 3-213 Engine - Operate / Check after starting.............. 3-181
Defined life parts list....................................... 4-81,7-2 Engine - Operate / check before starting............ 3-174
Defroster - Operate............................................. 3-229 Engine - Preheat manually..................................3-179
Defroster Switch..................................................3-224 Engine - Start............................................3-177,3-256
Details of data stored in memory of payload meter 6-9 Engine - Start with jumper cables....................... 3-255
Differential case - Change oil................................4-71 Engine - Stop...................................................... 3-183
Differential case - Check oil level / Add oil............4-52 Engine coolant temperature caution lamp............ 3-20
8-2
INDEX
Engine coolant temperature gauge.......................3-42 Fresh and clean lubricants......................................4-2

Engine high-pressure piping - Replace.................4-86 Freshrecirc air changeover switch...................... 3-223
Engine high-pressure piping clamp - Check for loose- Front drive shaft - Check location of grease fitting4-85
ness and hardening of rubber........................4-83 Fuel......................................................................... 4-6
Engine hood - Lock............................................. 3-211 Fuel - Check level / Add......................................3-158
Engine hood - Lock / Unlock............................... 3-210 Fuel and lubricants..............................................3-244
Engine hood - Open............................................3-210 Fuel and lubricants to match ambient temperature.4-4
Engine intake pipe clamps - Check for looseness 4-66 Fuel circuit - Bleed air......................................... 3-248
Engine oil level caution lamp................................ 3-30 Fuel doser - Clean................................................ 4-84
Engine oil pan - Check oil level / Add oil.............3-156 Fuel filler port cap - Close................................... 3-210
Engine oil pan - Replace oil / Engine oil filter cartridge Fuel filler port cap - Open................................... 3-209
- Replace....................................................... 4-48 Fuel gauge............................................................ 3-43
Engine oil pressure caution lamp..........................3-30 Fuel level caution lamp......................................... 3-21
Engine overrun caution lamp................................ 3-30 Fuel main filter cartridge - Replace....................... 4-57
Engine power mode selector switch................... 3-100 Fuel prefilter cartridge - Replace...........................4-49
Engine shutdown secondary switch....................3-103 Fuel spray prevention cap - Check for missing and
Engine system caution lamp................................. 3-29 hardening of rubber....................................... 4-83
Engine tachometer................................................3-42 Fuel spray prevention cap - Replace.................... 4-86
Engine technology to conform exhaust gas emission . Fuel spray prevention cap on fuel doser piping -
.........................................................................1-8 Check for missing and hardening of rubber...4-84
Engine valve clearance - Check / Adjust.............. 4-75 Fuel spray prevention cap on fuel doser piping - Re-
Ensure good visibility............................................ 2-23 place.............................................................. 4-86
Ensuring safe operation........................................ 2-15 Fuel tank - Drain water and sediment................. 3-152
Enter switch.......................................................... 3-47 Fuel tank - Open / Close fuel filler port cap.........3-209
Every 1000 hours maintenance............................ 4-56 Fuel tank breather element - Replace...................4-59
Every 2000 hours maintenance............................ 4-70 Fuel tank drain valve cover - Lock...................... 3-216
Every 250 hours maintenance.............................. 4-37 Fuel tank drain valve cover - Open..................... 3-215
Every 4000 hours maintenance............................ 4-80 Fuel tank drain valve cover - Open and close.....3-215
Every 4500 hours maintenance............................ 4-84 Fuel, coolant and lubricants according to ambient
Every 50 hours maintenance................................ 4-36 temperature - Use............................................7-6
Every 500 hours maintenance.............................. 4-48 Function of accumulator - Check.......................... 4-46
Every 6000 hours maintenance............................ 4-84 Fuse.................................................................... 3-110
Every 8000 hours maintenance............................ 4-86 Fuse capacity and circuit name...........................3-110
Every 9000 hours maintenance............................ 4-86
Excessive idling guidance.....................................3-40 G
Exhaust pipe fire prevention cover - Check.......... 4-84
Explanation of air conditioner equipment............3-220 Gear shift lever....................................................3-105
Explanation of components...................................3-10 Gear shift lever position display............................ 3-39
Explanation of machine monitor equipment..........3-10 General character and precautions for handling...2-41
Explanation of radio equipment.......................... 3-232 General precautions common to operation and main-
External display lamp..............................................6-8 tenance.......................................................... 2-15
General view........................................................... 3-2
GPS synchronization............................................ 3-81
F Grease.................................................................... 4-7
Fan control system caution lamp.......................... 3-31 Guidance to avoid acceleration operation during
Fan reverse rotation pilot lamp............................. 3-37 dump body lowering.......................................3-41
Fan switch...........................................................3-221 Guidance to avoid hoist relief................................3-40
Fan-reverse operation caution lamp..................... 3-31 Guidance to avoid steering relief.......................... 3-41
Filter........................................................................ 4-9 Guidance to recommend shifting up..................... 3-40
Fin - Clean by rotating cooling fan in reverse....... 4-53 Guide to reduce vibration levels on machine.......... 1-5
Final drive case - Change oil................................ 4-70
Final drive case - Check oil level / Add oil............ 4-56 H
Fire extinguisher..................................................3-115
Fog lamp switch.................................................. 3-101 Handle oil, fuel, coolant, and performing oil clinic...4-5
Foot brake - Check braking capacity.................... 4-44 Handy tray...........................................................3-109
Frame and A-arm - Check.................................... 4-44 Hazard lamp switch...............................................3-97
Frequency - Adjust..............................................3-234 Headlamp high beam pilot lamp........................... 3-35
Frequency - Auto preset..................................... 3-234 Headrest - Adjust angle...................................... 3-166
8-3
INDEX
Headrest - Adjust in vertical direction................. 3-166 Leaked oil from floating seal - Collect................... 4-34
Heated mirror switch............................................. 3-97 LH meter display selection....................................3-78
High-pressure hoses and pipings - Handle...........2-37 Location of engine number plate.............................1-9
Hoist control system caution lamp........................ 3-24 Location of product identification number (PIN)/
Horn - Check operation.......................................3-163 machine serial No. plate.................................. 1-9
Horn button........................................................... 3-96 Location of safety labels......................................... 2-5
Hydraulic circuit - Bleed air............................. 4-3,4-30 Lock.................................................................... 3-209
Hydraulic oil filter element - Replace.................... 4-57 Lock inspection cover............................................. 4-3
Hydraulic tank - Change oil...................................4-81 Lubrication chart..................................................... 7-4
Hydraulic tank - Check oil level / Add oil.............3-154 Lumber support - Adjust......................................3-167
Hydraulic tank breather element - Replace...........4-72
M
I Machine - Check after stopping engine.............. 3-183
If any problem is found..........................................2-16 Machine - Check walk-around............................ 3-150
If machine monitor shows warning display......... 3-261 Machine - Checks after inspection and maintenance..
Inclination caution lamp........................................ 3-25 .........................................................................4-3
Indicator - Check electrolyte level......................... 4-43 Machine - Clean with compressed air...................4-54
Initial 250 hours maintenance (only 1st maintenance Machine - Dump..................................................3-202
of new machine)............................................ 4-14 Machine - Lift...................................................... 3-241
Inside operator's compartment............................. 2-16 Machine - Loading work......................................3-201
Inspecting machine............................................... 2-15 Machine - Lubricate.............................. 4-36,4-37,4-64
Inter-axle differential lock - Operate....................3-196 Machine - Operate if troubles occur on system.. 3-200
Inter-axle differential lock pilot lamp......................3-36 Machine - Park....................................................3-208
Inter-axle differential lock switch........................... 3-98 Machine - Running-in the new machine..............3-182
Inter-axle differential lock system caution lamp.... 3-28 Machine - Secure................................................3-239
Introduction............................................................. 1-7 Machine - Shift gear............................................3-188
Investigate and confirm jobsite conditions............ 2-22 Machine - Start....................................................3-184
Machine - Start (Travel forward and reverse) / Stop....
J .....................................................................3-184
Machine - Start after long-term storage.............. 3-246
Jumper cable - Connect......................................3-255 Machine - Stop....................................................3-186
Jumper cable - Disconnect................................. 3-256 Machine - Stop in emergency............................. 3-187
Machine - Travel downhill................................... 3-190
K Machine - Travel reverse.................................... 3-186
Machine - Turn.................................................... 3-195
KCCV filter element - Replace.............................. 4-75 Machine - Warm up.............................................3-182
KDPF - Clean........................................................4-84 Machine equipment name.......................................3-2
KDPF soot accumulation caution lamp................. 3-26 Machine ID and Open ID - Set..............................6-14
KDPF system caution lamp...................................3-26 Machine monitor - Operate when operator identifica-
Keep machine clean............................................. 2-15 tion function is available with skip..................3-87
Keep work place clean and tidy............................ 2-31 Machine monitor - Operate when operator identifica-
Komatsu Closed Crankcase Ventilation (KCCV) 3-132 tion function is available without skip.............3-89
Komatsu Diesel Particulate Filter (KDPF) - Handle..... Machine monitor - Operate when starting engine in
.....................................................................3-121 abnormal situation......................................... 3-14
Komatsu genuine lubricants....................................4-2 Machine monitor - Operate when starting engine in
Komatsu genuine replacement parts...................... 4-2 normal situation..............................................3-11
Komatsu traction control system (KTCS) - Handle...... Machine monitor - Operate when starting engine
.....................................................................3-199 while engine shutdown secondary switch is ON...
KOMTRAX.......................................................... 3-147 .......................................................................3-12
KTCS display........................................................ 3-36 Machine monitor - Operate when starting switch is
KTCS settings....................................................... 3-65 ON while operator ID input is set................... 3-13
KTCS system - Operate......................................3-200 Machine monitor - Operate when stopping engine in
KTCS system caution lamp...................................3-29 normal situation............................................. 3-12
Machine monitor - Operate when trouble occurs while
L operating machine......................................... 3-15
Machine monitor equipment name..........................3-5
Lamp switch.......................................................... 3-94
Machine operations and controls........................ 3-150
Language settings.................................................3-86
8-4
INDEX
Machine setting and information........................... 3-61 Parking brake - Lubricate......................................4-63

Magazine box......................................................3-108 Parking brake - Release..................................... 3-252
Main use of machine...............................................1-7 Parking brake pad - Check for wear..................... 4-46
Maintenance during long-term storage............... 3-246 Parking brake pilot lamp....................................... 3-39
Maintenance of air conditioner..............................2-38 Parking brake switch...........................................3-100
Maintenance procedure........................................ 4-14 Parking brake system caution lamp...................... 3-29
Maintenance schedule.......................................... 4-12 Payload meter.......................................................3-65
Maintenance schedule table................................. 4-12 Payload meter - Handle.......................................... 6-6
Maintenance screen - Set..................................... 3-73 People on dump body........................................... 2-19
Maintenance time caution lamp............................ 3-32 Perform KOWA (Komatsu Oil Wear Analysis)........ 4-7
Manual operation - Start..................................... 3-226 Periodic replacement of defined life parts.............2-39
Manual operation - Stop......................................3-228 Permissible water depth......................................3-208
Manual secondary steering - Check................... 3-162 Phenomena and actions for engine related parts........
Manual stationary regeneration - Operate.......... 3-125 .....................................................................3-259
Menu switch.......................................................... 3-46 Pilot display...........................................................3-35
Message - Check.................................................. 3-91 Pilot display and meter display............................. 3-34
Message - Reply................................................... 3-91 Play in output shaft output coupling - Check.........4-30
Message display........................................... 3-38,3-90 Power button.......................................................3-232
Meter display.........................................................3-41 Power mode display..............................................3-36
Meter display selection......................................... 3-78 Power supply outlet.............................................3-109
Method for checking before starting....................3-152 Power window switch..........................................3-101
Mirrors - Adjust....................................................3-168 Precautions after finishing cold weather operation......
Monitor brightness selector switch........................3-96 .....................................................................3-245
Monitor settings.....................................................3-76 Precautions before starting inspection and mainte-
Monitor switches................................................... 3-45 nance............................................................. 2-31
Precautions before starting operation................... 2-15
N Precautions before traveling after long-term storage...
.....................................................................3-247
No jumping on or off machine............................... 2-19 Precautions for adding.......................................... 2-41
Noise.......................................................................1-4 Precautions for adding DEF....................................4-2
Normal operation display........................................ 6-7 Precautions for charging battery......................... 3-254
Precautions for check and maintenance...............2-35
O Precautions for cold weather................................ 2-25
Precautions for compressed air............................ 2-38
Observance of the applicable laws and regulations, Precautions for DEF..............................................2-41
exemption.................................................... 3-148 Precautions for discharged battery..................... 3-253
OFF switch..........................................................3-220 Precautions for disposing of waste materials........2-38
Oil............................................................................4-5 Precautions for fire hazard and leakage............... 2-41
ON/OFF of ECO gauge display - Switch...............3-57 Precautions for getting on or off machine............. 2-18
Only authorized personnel.................................... 2-31 Precautions for handling tires............................. 3-218
Open knob for cab door...................................... 3-114 Precautions for high voltage................................. 2-38
Operating records................................................. 3-51 Precautions for high-pressure fuel........................ 2-37
Operation with cold air to face and warm air to feet - Precautions for high-pressure oil.......................... 2-37
Start............................................................. 3-228 Precautions for high-temperature coolant.............2-36
Operator ID........................................................... 3-87 Precautions for high-temperature oil.....................2-37
Operator's seat - Adjust...................................... 3-164 Precautions for high-temperature parts................ 2-37
Other equipment................................................. 3-107 Precautions for installing, removing, or storing attach-
Other equipment name........................................... 3-7 ments............................................................. 2-33
Other functions of machine monitor...................... 3-92 Precautions for jobsite.......................................... 2-22
Other precautions................................................. 2-41 Precautions for KDPF............................................. 4-2
Other trouble....................................................... 3-256 Precautions for lifting machine............................3-240
Outline of KOMTRAX..........................................3-147 Precautions for long distance travel....................3-218
Outline of maintenance........................................... 4-5 Precautions for long-term storage.......................3-246
Outline of system.................................................... 6-6 Precautions for maintenance.......................... 2-31,4-2
Overflow hose - Clean.......................................... 4-41 Precautions for noise............................................ 2-38
Precautions for operation................... 2-22,2-26,3-207
P Precautions for refilling oil or fuel............................4-2
Precautions for replacing tire................................ 4-33
Parking brake - Adjust...........................................4-33
8-5
INDEX
Precautions for SCR assembly............................... 4-3 Remaining time for maintenance - Reset..............3-74
Precautions for storing.......................................... 2-41 Replace defined life parts..................................... 4-80
Precautions for storing tires.................................. 2-40 Retarder brake performance - Check................... 4-45
Precautions for towing and being towed............... 2-30 Retarder control lever......................................... 3-106
Precautions for towing machine..........................3-250 Retarder lever release sound setting.................... 3-70
Precautions for transportation.....................2-29,3-239 Retarder oil temperature caution lamp..................3-21
Precautions for transporting machine................. 3-239 Retarder oil temperature gauge............................ 3-42
Precautions for using KOMTRAX....................... 3-148 Retarder pilot lamp................................................3-36
Precautions for welding.................................. 2-35,4-2 Retarder system caution lamp.............................. 3-28
Precautions for working at high places................. 2-34 Return switch........................................................ 3-47
Precautions for working under machine or work Reverse Travel Odometer.....................................3-67
equipment...................................................... 2-34 Reverse-interlock selection mode.........................3-77
Precautions related to attachments and options...2-21 Revolving lamp switch........................................ 3-102
Precautions related to protective structure........... 2-20 RH meter display selection................................... 3-79
Precautions to prevent fire.................................... 2-16 Room lamp 1 switch............................................3-102
Precautions when installing hydraulic hoses.......... 4-3 Room lamp 2 switch............................................3-102
Precautions when leaving machine...................... 2-19
Precautions when loading and unloading............. 2-29 S
Precautions when operating machine...................2-27
Precautions when parking machine...................... 2-28 Safety......................................................................2-2
Precautions when running engine inside building.2-21 Safety information................................................... 1-3
Precautions when standing up from operator's seat.... Safety labels........................................................... 2-4
.......................................................................2-19 Safety-related equipment......................................2-15
Precautions when traveling...................................2-27 SCR information....................................................3-73
Precautions when traveling in forward or reverse.2-26 Screen adjustment................................................ 3-80
Precautions when using hammer..........................2-36 Seat - Adjust tilt...................................................3-164
Precautions when working on loose ground......... 2-22 Seat - Recline..................................................... 3-164
Precautions when working on machine................ 2-34 Seat belt - Adjust.................................................3-172
Preheating pilot lamp............................................ 3-37 Seat belt - Fasten and unfasten..........................3-172
Preparation for long-term storage....................... 3-246 Seat belt - Handle............................................... 3-170
Preparations for safe operation.............................2-15 Seat belt caution lamp.......................................... 3-22
Preset - Call up................................................... 3-235 Seat cushion - Adjust in fore-after direction........ 3-166
Preset - Register................................................. 3-235 Seat height - Adjust.............................................3-164
Preset button.......................................................3-233 Seat unit - Adjust fore-and-aft direction.............. 3-168
Prevent fire............................................................2-17 Secondary steering - Check................................3-162
Product information.................................................1-9 Secondary steering motor caution lamp............... 3-24
Provide fire extinguisher and first aid kit............... 2-16 Secondary steering switch.................................... 3-97
Secondary steering system caution lamp............. 3-24
Secondary steering system pilot lamp.................. 3-39
R Select suitable place for inspection and maintenance.
R.H. meter and L.H. meter....................................3-43 .......................................................................2-31
Radiator coolant level caution lamp...................... 3-30 Serial plate............................................................ 1-11
Radiator fan reverse mode................................... 3-61 Service meter location.......................................... 1-10
Radiator fin and air conditioner condenser fin - Clean. Shift hold pilot lamp...............................................3-37
.......................................................................4-55 Shift hold switch.................................................. 3-101
Radiator fin, aftercooler fin, and air conditioner con- Shift indicator........................................................ 3-39
denser fin - Clean / Check............................. 4-53 Shoulder belt and waist belt - Connect............... 3-173
Radio - Control....................................................3-234 Side lamp switch................................................. 3-102
Radio - Handle.................................................... 3-232 Slack adjuster - Bleed air...................................... 4-27
Rearview camera - Adjust angle......................... 3-169 Slow-blow fuse - Replace..................................... 4-24
Rearview monitor - Handle..................................3-118 Sound (balance) - Adjust.................................... 3-235
Rearview monitor - Perform self check............... 3-120 Sound (bass) - Adjust......................................... 3-236
Rearview monitor - Precautions for using........... 3-121 Sound (treble) - Adjust........................................ 3-235
Rearview monitor - Set......................................... 3-76 Sound control button...........................................3-233
Recommended brands and qualities other than ko- Specifications..........................................................5-2
matsu genuine oils...........................................7-8 Speedometer........................................................ 3-41
Recommended fuel, coolant, and lubricant.............7-4 Spherical joint of exhaust pipe - Apply lubricant... 4-67
Refrigerant (gas) - Check level............................. 4-22 Standard tightening torque for bolts and nuts....... 4-10
8-6
INDEX
Start engine...........................................................2-24 U
Start engine with jumper cables............................2-25
Starting motor - Check.......................................... 4-82 Unauthorized modification.................................... 2-21
Starting motor and alternator - Overhaul.............. 4-86 Understanding the machine.................................. 2-15
Starting switch.......................................................3-93 Up switch.............................................................. 3-47
Steering oil pressure caution lamp........................3-23 Urea SCR system warning - Handle................... 3-132
Steering oil temperature caution lamp.................. 3-23 Use handrails and steps when getting on or off ma-
Steering system caution lamp...............................3-23 chine.............................................................. 2-18
Steering wheel - Adjust tilt.................................. 3-173 Use proper tools....................................................2-35
Stop engine before performing inspection and main- Use warning tags.................................................. 2-24
tenance.......................................................... 2-31 User menu............................................................ 3-48
Store oil and fuel..................................................... 4-8
Suspension cylinder - Check length......................4-25 V
Suspension cylinder / Accumulator / Gas spring -
Handle........................................................... 2-38 Valve side..............................................................4-60
Suspension damper hardness - Adjust............... 3-167 Vent selector switch - Select............................... 3-222
Switches................................................................3-93 Vibration levels........................................................1-5
System caution lamp.............................................3-25 Visibility from operator's seat.................................. 1-7
System operating lamp....................................... 3-116 Volume control button......................................... 3-232
T W
Tailgate - Handle................................................. 3-201 Warning display............................................ 3-16,3-22
Temperature control switch................................. 3-221 Water pump - Check............................................. 4-82
Time - Set..............................................................3-84 Water separator - Check / Drain water and sediment..
Tire - Handle............................................... 2-39,3-218 .....................................................................3-153
Tire - Select / Check..............................................4-31 Wear well-fitting clothes and protective equipment......
Tire inflation pressure - Check............................ 3-161 .......................................................................2-15
Tire inflation pressure - Check and inflate.............4-32 Weight on seat - Adjust.......................................3-165
Tires...................................................................... 2-39 Wheel - Operate when stuck in ground...............3-201
Tires - Select......................................................... 4-32 Wheel brake - Bleed air........................................ 4-28
Tool box cover - Lock.......................................... 3-215 Wheel hub bolts - Check / Retighten.................. 3-152
Tool box cover - Open.........................................3-214 When dumping......................................................2-28
Tool box cover - Open / Close.............................3-214 When operating on snow or frozen ground...........2-28
Toolbox................................................................3-114 When regeneration is not performed: Regeneration
Torque converter lockup pilot lamp....................... 3-37 disable - Set.................................................3-129
Torque converter oil temperature caution lamp.....3-20 When required...................................................... 4-14
Torque converter oil temperature gauge............... 3-42 When starting engine............................................ 2-25
Total payload and number of cycles - Display.......6-12 When traveling on slopes......................................2-27
Towing and being towed....................................... 2-30 While regeneration is performed - Stop regeneration..
Transmission case - Check oil level - Add oil......3-153 .....................................................................3-130
Transmission case - Replace oil........................... 4-61 Window washer fluid - Check level / Add..............4-22
Transmission case strainer - Clean.......................4-73 Window washer fluid - select................................ 2-39
Transmission oil filter clogging caution lamp.........3-28 Windshield wiper and window washer switch....... 3-95
Transmission oil filter element - Replace.............. 4-60 Working lamp switch............................................. 3-97
Transmission system caution lamp....................... 3-27
Transportation..................................................... 3-239 Y
Transportation method - Select...........................3-239
Your machine serial numbers and distributor........1-10
Travel road - Determine / Maintain......................3-238
Trip meter..............................................................3-68
Troubles and actions...........................................3-248
Tuningtime adjustment button.............................3-232
Turbocharger protection function........................ 3-181
Turn battery disconnect switch to off position....... 2-35
Turn signal lever....................................................3-95
Turn signal pilot lamp............................................ 3-35
Two workers for maintenance when engine is running
.......................................................................2-33
8-7
HM400-5 ARTICULATED DUMP TRUCK
Form No. EENAM03380
©2015 KOMATSU
All Rights Reserved
Printed in Belgium 09-2015

HM400 5 Operation Manual

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Operation & EENAM03380

BEFORE READING THIS MANUAL

REMARK This word is used for information that is useful to know.

• Sound power level emitted by the machine, measured ac-

VIBRATION - OPERATING CONDITION

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE

• Reduce speed to prevent bounce

(A) Front (D) Right

VISIBILITY FROM OPERATOR'S SEAT

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS

About Engine Technology

LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

LOCATION OF ENGINE NUMBER PLATE

SERVICE METER LOCATION

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Declares that this machine:

EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................. 3-10

OTHER TROUBLE......................................................................................................................... 3-256

DEFINED LIFE PARTS LIST.............................................................................................................. 7-2

TOWING AND BEING TOWED............................................................................................................... 2-30

LOCATION OF SAFETY LABELS

CONTENTS OF SAFETY LABELS

࣭If any modification is applied to the ROPS or FOPS,

• ROPS or FOPS may provide less protection if it has been

(3) Caution when checking engine room

(4) Caution when releasing radiator cap

(5) Caution when opening hydraulic tank cap

(6) Caution for handling suspension

(7) Caution for handling accumulator

(11) Caution for hot exhaust pipe

(12) Prohibition of trespassing

(13) Caution for articulation lock

(14) Caution against falling

(15) Caution for handling battery

c) Keep children away from batteries.

(17) Prohibition of start by short-circuiting

(18) Caution for blast site

(19) Caution for high temperature

(20) Caution for handling DEF

(21) Caution for handling gas spring

GENERAL PRECAUTIONS COMMON TO OPERATION

PRECAUTIONS BEFORE STARTING OPERATION

UNDERSTAND THE MACHINE

PREPARATIONS FOR SAFE OPERATION

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

KEEP MACHINE CLEAN

• If water gets into the electrical system, electric devices will

PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

IF ANY PROBLEM IS FOUND

PRECAUTIONS TO PREVENT FIRE

Fire around the machine due to highly heated exhaust gas

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

• The handrails and steps marked by arrows B are for es-

• Always face the machine and maintain at least three-point

NO JUMPING ON OR OFF MACHINE

PEOPLE ON DUMP BODY

WHEN STANDING UP FROM OPERATOR'S SEAT

PRECAUTIONS WHEN LEAVING MACHINE

EMERGENCY EXIT FROM OPERATOR'S CAB