Komatsu HM400-5 Operation & Maintenance Manual
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Komatsu HM400-5 Operation & Maintenance Manual

Articulated dump truck
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Table of Contents

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Operation &
Maintenance Manual
HM400-5
ARTICULATED DUMP TRUCK
SERIAL NUMBERS
HM400-5
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
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.
- 10001
and up
ORIGINAL INSTRUCTIONS
EENAM03380

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Do you have a question about the HM400-5 and is the answer not in the manual?

Questions and answers

Brett wilkes
February 21, 2025

Where do I add oil to engine when it gets low? I have checked over the engine and I have checked over the manual and I'm seeing where it's located

0
1 comments:
Mr. Anderson
February 21, 2025

The oil fill location for the Komatsu HM400-5 engine is through the oil filler port (F).

This answer is automatically generated

0
dandy balisong
April 7, 2025

how to adjust the brake

0
1 comments:
Mr. Anderson
April 7, 2025

To adjust the brakes on a Komatsu HM400-5, follow these steps:

1. Park the machine on a level surface.
2. Chock the tires to prevent movement.
3. Turn the starting switch to the ON position.
4. Ensure the brake oil pressure caution lamp is off (brake accumulator pressure is sufficient).
5. Release the parking brake using the parking brake switch.
6. Loosen the four bolts (2) holding bracket (1) so the bracket is loose.
7. Repeatedly operate the parking brake switch to actuate and release the brake until screw (3) no longer moves.
8. Measure the total clearance (a + b) between disc (4) and pad (5). It should be between 1.02 mm and 1.52 mm.
9. Tighten the four bolts (2) on bracket (1), ensuring the bracket is correctly positioned.
10. Verify that the clearances are still within the specified range.

This answer is automatically generated

0
Александр
April 11, 2025

Доброго времени! Ребят подскажите, такая проблема: при начале движения загорает ндикатор красным кузов и непрерывно звучки сигнал! Как отрегулировать и избавиться от этого звука?

0
1 comments:
Mr. Anderson
April 11, 2025

To adjust and eliminate the continuous sound from the red body indicator (engine system caution lamp) on a Komatsu HM400-5 when starting to move, follow these steps:

1. Check SCR Information Screen: Press the menu switch to display the “SCR Information” screen and read the message (e.g., “Please inspect and maintain SCR system”).

2. Understand the Warning Level: If the action level “L03” is lit in red and the engine system caution lamp is red, the machine is in a warning or continuous warning state. The DEF system caution lamp may also be yellow.

3. Derated Engine Power: Engine power is already reduced (derated) as part of the warning.

4. Move to a Safe Location: Stop operating the machine and move it to a safe place.

5. Contact Komatsu Distributor: You must contact your Komatsu distributor to inspect and service the SCR system.

The continuous sound and warnings will not stop until the cause is diagnosed and corrected by authorized service.

This answer is automatically generated

0

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Summary of Contents for Komatsu HM400-5

  • Page 1 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 ORIGINAL INSTRUCTIONS death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
  • Page 3 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).
  • Page 4 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.

  • Page 5: Safety Information

    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.

  • Page 6: Noise

    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...

  • Page 7: Vibration Levels

    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/s , the uncertainty for this value is 0.58  m/s...
  • Page 8 VIBRATION LEVELS FOREWORD • Reduce speed to prevent bounce • Transport machines long distances between worksites The following guidelines can be effective to minimize risks of low back pain • Operate the machine only when you are in good health •...

  • Page 9: Introduction

    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.

  • Page 10: Engine Technology To Conform Exhaust Gas Emission

    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.

  • Page 11: Product Information

    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.

  • Page 12: Service Meter Location

    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...

  • Page 13: Serial Plate

    FOREWORD SERIAL PLATE SERIAL PLATE EI000001 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER OPERATING MASS AUTHORISED REPRESENTATIVE 1-11...

  • Page 14: Declaration Of Conformity

    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:...

  • Page 15: Table Of Contents

    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 ............................
  • Page 16 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 ................
  • Page 17 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..................
  • Page 18 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...

  • Page 19: Safety

    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.
  • Page 20 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 ....................
  • Page 21 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 ..........

  • Page 22: Safety Labels

    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. •...

  • Page 23: Location Of Safety Labels

    SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
  • Page 24 SAFETY LABELS SAFETY...
  • Page 25 SAFETY SAFETY LABELS (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...

  • Page 26: Contents Of Safety Labels

    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”...
  • Page 27 SAFETY SAFETY LABELS (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.
  • Page 28 SAFETY LABELS SAFETY (7) Caution for handling accumulator “09659-A057B” • 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. (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-...
  • Page 29 SAFETY SAFETY LABELS (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. •...
  • Page 30 SAFETY LABELS SAFETY (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.
  • Page 31 SAFETY SAFETY LABELS 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...
  • Page 32 SAFETY LABELS SAFETY (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”...

  • Page 33: General Precautions Common To Operation And Maintenance

    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.

  • Page 34: Precautions To Prevent Fire

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- 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.

  • Page 35: Prevent Fire

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- 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).

  • Page 36: Precautions When Getting On Or Off Machine

    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).

  • Page 37: No Jumping On Or Off Machine

    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. •...

  • Page 38: Do Not Get Caught In Work Equipment

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- 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”...

  • Page 39: Unauthorized Modification

    • 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.

  • Page 40: Precautions For Operation

    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. •...

  • Page 41: Ensure Good Visibility

    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...

  • Page 42: Start Engine

    PRECAUTIONS FOR OPERATION SAFETY 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.

  • Page 43: When Starting Engine

    SAFETY PRECAUTIONS FOR OPERATION • 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)”.

  • Page 44: Precautions For Operation

    PRECAUTIONS FOR OPERATION SAFETY • For the starting procedure with the jumper cables, see OPERATION, “START ENGINE WITH JUMPER CA- BLES (3-255)”. PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance.

  • Page 45: When Traveling

    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. •...

  • Page 46: When Loading On Dump Body

    PRECAUTIONS FOR OPERATION SAFETY 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 •...

  • Page 47: Transportation

    • 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.

  • Page 48: Towing And Being Towed

    PRECAUTIONS FOR OPERATION SAFETY • 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...

  • Page 49: Precautions For Maintenance

    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.
  • Page 50 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.

  • Page 51: Two Workers For Maintenance When Engine Is Running

    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”...

  • Page 52: Precautions For Working At High Places

    PRECAUTIONS FOR MAINTENANCE SAFETY • 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.

  • Page 53: Precautions For Check And Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE 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.

  • Page 54: When Using Hammer

    PRECAUTIONS FOR MAINTENANCE SAFETY 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.

  • Page 55: Precautions For High-Temperature Oil

    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.

  • Page 56: Precautions For High Voltage

    • 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.

  • Page 57: Tires

    • 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.

  • Page 58: Precautions For Storing Tires

    • 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.

  • Page 59: Precautions For Def

    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: •...

  • Page 61: Operation

    OPERATION Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 62: General View

    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)

  • Page 63: Controls And Gauges Names

    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...
  • Page 64 GENERAL VIEW OPERATION 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 switch (if equipped)
  • Page 65 OPERATION GENERAL VIEW 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...
  • Page 66 GENERAL VIEW OPERATION 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...

  • Page 67: Other Equipment Name

    OPERATION GENERAL VIEW 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...
  • Page 68 GENERAL VIEW OPERATION 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 KCCV) ventilator (5) Circuit breaker...
  • Page 69 OPERATION GENERAL VIEW (10) Dust indicator (14) DEF pump (11) KDPF (15) DEF injector (12) SCR assembly (16) DEF filter (13) DEF tank...

  • Page 70: Explanation Of Components

    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...
  • Page 71 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.
  • Page 72 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 73 EXPLANATION OF COMPONENTS 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.
  • Page 74 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.
  • Page 75 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 76 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 77 Required action level warning lamp gency lamp Sounds con- Stop the machine immediately and ask your Komatsu Lights up tinuously distributor for inspection and maintenance. Stop the operation and move the machine to a safe Sounds inter- Lights up...
  • Page 78 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 79 EXPLANATION OF COMPONENTS (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.
  • Page 80 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 81 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. 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.
  • Page 82 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 83 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.
  • Page 84 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.
  • Page 85 Komatsu distributor for inspection and maintenance. When action level “L01” is displayed 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. 3-25...
  • Page 86 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
  • Page 87 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
  • Page 88 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. TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP The transmission oil filter clogging caution lamp wans about clogging of the transmission oil filter.
  • Page 89 The caution lamp lights up in red. At the same time, the central- ized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
  • Page 90 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. ENGINE OIL LEVEL CAUTION LAMP Engine oil level caution lamp warns about drop of engine lubri- cating oil level.
  • Page 91 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. FAN-REVERSE OPERATION CAUTION LAMP The wrong operation in fan reverse mode caution lamp warns about misoperation while the fan is rotating in reverse.
  • Page 92 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. MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displays notices and alarms concerning maintenance time.
  • Page 93 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 94 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 95 OPERATION EXPLANATION OF COMPONENTS (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.
  • Page 96 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 97 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 98 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.
  • Page 99 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 100 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 101 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 102 EXPLANATION OF COMPONENTS OPERATION 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. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
  • Page 103 OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 104 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 105 OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 106 EXPLANATION OF COMPONENTS OPERATION 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...
  • Page 107 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 108 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 109 OPERATION EXPLANATION OF COMPONENTS 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”...
  • Page 110 EXPLANATION OF COMPONENTS OPERATION (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” •...
  • Page 111 OPERATION EXPLANATION OF COMPONENTS (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.
  • Page 112 EXPLANATION OF COMPONENTS OPERATION 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).
  • Page 113 OPERATION EXPLANATION OF COMPONENTS 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”...
  • Page 114 EXPLANATION OF COMPONENTS OPERATION 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 press enter switch (1).
  • Page 115 OPERATION EXPLANATION OF COMPONENTS • 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”...
  • Page 116 EXPLANATION OF COMPONENTS OPERATION 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 •...
  • Page 117 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 118 EXPLANATION OF COMPONENTS OPERATION 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”...
  • Page 119 OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 120 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press enter switch (1). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. To cancel, press return switch (2). The default is “ON”. REMARK For the ECO guidance, see “ECO GUIDANCE (3-39)”. If the “ECO Guidance Display”...
  • Page 121 OPERATION EXPLANATION OF COMPONENTS Select “ON” or “OFF”, then press enter switch (1). “ON” Displays the one-point advice on the exit screen. “OFF” Does not display the one-point advice on the exit screen. To cancel, press return switch (2). The default is “ON”. REMARK In the “Operational Advice”...
  • Page 122 EXPLANATION OF COMPONENTS OPERATION 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). Press enter switch (1) to rotate the fan in the reverse direc- tion, or press return switch (2) to cancel.
  • Page 123 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 124 EXPLANATION OF COMPONENTS OPERATION 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). Press enter switch (1) to rotate the fan in the reverse direc- tion, or press return switch (2) to cancel.
  • Page 125 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 126 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.
  • Page 127 OPERATION EXPLANATION OF COMPONENTS Select “Dumping Counter”, then press enter switch (1). 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”.
  • Page 128 EXPLANATION OF COMPONENTS OPERATION 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. Select “Trip Meter”, then press enter switch (1). Press enter switch (1) to reset or press return switch (2) to cancel resetting.
  • Page 129 OPERATION EXPLANATION OF COMPONENTS Select “F 1 Start at D Position Setting”, then press enter switch (1). 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.
  • Page 130 EXPLANATION OF COMPONENTS OPERATION Select “A/C ECO Mode Setting”, then press enter switch (1). Select “ON” or “OFF”, 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-...
  • Page 131 OPERATION EXPLANATION OF COMPONENTS Select “Retarder Lever Release Sound Setting”, then press enter switch (1). Select “ON” or “OFF”, then press enter switch (1). “ON” Generates the cancel sound. “OFF” Does not generate the cancel sound. REMARK This setting is held even if the starting switch is turned to OFF position.
  • Page 132 EXPLANATION OF COMPONENTS OPERATION Select “Auto Idle Stop Timer Setting” on “Machine Setting and Information” menu, and press enter switch (1). Select the operating time of the auto idle stop, and press enter switch (1). REMARK Selecting “OFF” disables operation of the auto idle stop. 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.
  • Page 133 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.
  • Page 134 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”...
  • Page 135 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. The screen changes to “Maintenance Due Time Reset” screen. When enter switch (1) is pressed, the following reconfirma- tion screen is displayed.
  • Page 136 EXPLANATION OF COMPONENTS OPERATION 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).
  • Page 137 OPERATION EXPLANATION OF COMPONENTS Select “ON” or “OFF”, then press enter switch (1). “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)”.
  • Page 138 EXPLANATION OF COMPONENTS OPERATION 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 screen, then press enter switch (1). SELECT L.H.
  • Page 139 OPERATION EXPLANATION OF COMPONENTS Select “LH Meter Display Selection” on the “Meter Display Selection” menu, then press enter switch (1). Select the items to be displayed, then press enter switch (1). The following 3 items can be selected. • “SMR: Service Meter” •...
  • Page 140 EXPLANATION OF COMPONENTS OPERATION Select “RH Meter Display Selection” on the “Meter Display Selection” menu, then press enter switch (1). Select the items to be displayed, then press enter switch (1). The following 4 items can be selected. • “FUEL: Average Fuel Consumption” •...
  • Page 141 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 142 EXPLANATION OF COMPONENTS OPERATION Select “GPS Synchronization” from the “Clock Adjustment” menu, then press enter switch (1). Select “ON” or “OFF”, then press enter switch (1). “ON” Sets the date and time automatically. “OFF” Does not set the date and time automatically. (Can be set manually.) REMARK This setting is held even if the starting switch is turned to OFF...
  • Page 143 OPERATION EXPLANATION OF COMPONENTS Select “Calendar” from the “Clock Adjustment” menu, then press enter switch (4). REMARK As long as “ON” is selected for the “GPS Synchronization”, “Calendar” is not selectable. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display.
  • Page 144 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 145 OPERATION EXPLANATION OF COMPONENTS 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, press enter switch (4). (1) Up switch Advances time 1 minute. (2) Down switch Puts time back 1 minute.
  • Page 146 EXPLANATION OF COMPONENTS OPERATION Select “Daylight Saving Time” from the “Clock Adjustment” menu, then press enter switch (1). Select “ON” or “OFF”, then press enter switch (1). “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...
  • Page 147 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”...
  • Page 148 EXPLANATION OF COMPONENTS OPERATION 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. Select “Operator ID” on the “Monitor Setting” menu screen, then ENTER switch (1) for 1 second. The “Operator ID Change”...
  • Page 149 OPERATION EXPLANATION OF COMPONENTS • 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”...
  • Page 150 In this case, the identified ID is not changed. 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.
  • Page 151 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 152 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...

  • Page 153: Switches

    OPERATION EXPLANATION OF COMPONENTS 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)
  • Page 154 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 155 OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 156 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 157 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 158 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 159 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 160 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 161 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 162 EXPLANATION OF COMPONENTS OPERATION 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) Position (B) Lights up when the cab door opens.
  • Page 163 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.

  • Page 164: Control Levers And Pedals

    EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 165 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 166 EXPLANATION OF COMPONENTS OPERATION 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.

  • Page 167: Other Equipment

    OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 168 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 169 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 170 EXPLANATION OF COMPONENTS OPERATION 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. •...
  • Page 171 OPERATION EXPLANATION OF COMPONENTS Smart sensor 2 (continuous (14) 20 A power supply) (15) Fuse box II (BT2) Capacity Name of circuit 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...
  • Page 172 EXPLANATION OF COMPONENTS OPERATION Fuse box III (BT3) Capacity Name of circuit (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)
  • Page 173 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 CAUTION •...
  • Page 174 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 175 OPERATION EXPLANATION OF COMPONENTS FIRE EXTINGUISHER The fire extinguisher is installed to the left front of the machine. BATTERY DISCONNECT SWITCH 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.
  • Page 176 • 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.
  • Page 177 OPERATION EXPLANATION OF COMPONENTS 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. line indicates 7.5 kPa(30 INCHES {0.076 kg/cm , 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.
  • Page 178 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 179 OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 180 (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.
  • Page 181 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. •...
  • Page 182 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 183 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.
  • Page 184 EXPLANATION OF COMPONENTS OPERATION When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in 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).
  • Page 185 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION 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. •...
  • Page 186 EXPLANATION OF COMPONENTS OPERATION Set the parking brake switch to “PARKING” position to ap- ply the parking brake. Press the menu switch to display the “Aftertreatment Devi- ces Regeneration” screen. 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.
  • Page 187 OPERATION EXPLANATION OF COMPONENTS 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 the standard screen.
  • Page 188 EXPLANATION OF COMPONENTS OPERATION 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).
  • Page 189 OPERATION EXPLANATION OF COMPONENTS 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.
  • Page 190 EXPLANATION OF COMPONENTS OPERATION 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.
  • Page 191 OPERATION EXPLANATION OF COMPONENTS 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 CAUTION When canceling the Regeneration Disable, move the machine to a safe place and check that there is no...
  • Page 192 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.
  • Page 193 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.
  • Page 194 EXPLANATION OF COMPONENTS OPERATION 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)”...
  • Page 195 OPERATION EXPLANATION OF COMPONENTS • 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.
  • Page 196 EXPLANATION OF COMPONENTS OPERATION 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”.
  • Page 197 OPERATION EXPLANATION OF COMPONENTS • 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. Press the menu switch to display the “SCR Information” screen.
  • Page 198 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”.
  • Page 199 “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. The content of the warning can be checked on the “SCR Information” screen of the user menu.
  • Page 200 EXPLANATION OF COMPONENTS OPERATION • Continuous Warning: The audible alert sounds in repetition of “three beeps and a pause”. The KDPF system caution lamp (1) lights up in red. The DEF system caution lamp (2) lights up in yellow. The action level “L03” lights up in red at action level dis- play (3).
  • Page 201 Komatsu distributor. Inducement strategy when abnormality is found in the EGR Valve System by the...
  • Page 202 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen displays remaining time to the next Inducement status in the column (6), and information on the Urea SCR System condition (4), and the current status of In- ducement (5). • Warning: The audible alert sounds in short and sharp beeps. The Engine system caution lamp (1) lights up in red.
  • Page 203 “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.
  • Page 204 EXPLANATION OF COMPONENTS OPERATION 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”...
  • Page 205 OPERATION EXPLANATION OF COMPONENTS 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).
  • Page 206 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.
  • Page 207 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.
  • Page 208 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...
  • Page 209 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.

  • Page 210: Machine Operations And Controls

    (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.
  • Page 211 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.
  • Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION 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 •...
  • Page 213 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN TRANSMISSION CASE, ADDING OIL Start the engine. 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 •...
  • Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION Put a container to receive the water under drain hose (4). Loosen drain valve (3) and drain the water. 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).
  • Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS Check with sight gauge (G1). If the oil level does not reach the window of gauge (G1), add oil through oil filler port (F). When checking the oil level after adding oil, check with dipstick (G2). The oil should be between H and L marks on dipstick (G2).
  • Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION Open the engine hood. 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.
  • Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS When getting on or off the machine with carrying oil, place it once in part (A) to ensure your safety. Open the engine hood. Pull out dipstick (G) and wipe the oil off with a cloth. Fully insert dipstick (G) into the dipstick pipe, then remove Check if the oil is sticking up to between marks H and L on dipstick (G).
  • Page 218 • 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.
  • Page 219 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.
  • Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION Check the DEF level gauge (1) on the machine monitor. When adding DEF, perform actions written in “DEF LEVEL CAUTION LAMP (3-22)”. After checking, turn the starting switch back to OFF posi- tion (A). Open up cover (2) at the right side of the machine, clean blue DEF tank filler cap (3) and surrounding area.
  • Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS 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.
  • Page 222 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. CAUTION If the machine is steered during self-check, it may move.
  • Page 223 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 WARNING Do not use the secondary steering motor for more than 90 seconds.
  • Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Check that the horn sounds immediately when the horn button is pressed. If the horn does not sound, ask your Komatsu distributor for repair. After checking, return the starting switch to OFF position. ADJUST BEFORE OPERATION...
  • Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS 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.
  • Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION 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.
  • Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING ARMREST HEIGHT Remove cap and loosen the nut. 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.
  • Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION 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 WARNING Be sure to adjust the mirrors before starting work.
  • Page 229 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...
  • Page 230 “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).
  • Page 231 (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, contact your Komatsu distributor. 3-171...
  • Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION ADJUST SEAT BELT 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.
  • Page 233 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...
  • Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE 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. •...
  • Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Check that gear shift lever (3) is in NEUTRAL position (N). Check that dump lever (4) is in “HOLD” position. Check that engine shutdown secondary switch (5) is in “NORMAL” position (the cover is closed). Insert the key into starting switch (6) and turn it to ON posi- tion (B).
  • Page 236 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.

  • Page 237: Method For Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS • 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-...
  • Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION 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. •...
  • Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS 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.
  • Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION 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.

  • Page 241: Method For Operations And Checks After Starting Engine

    In that case, ask your Komatsu distributor to check the engine as soon as possible.
  • Page 242 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).

  • Page 243: Method For Stopping Engine

    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 •...

  • Page 244: Start Machine (Travel Forward And Reverse) And Stop Machine

    MACHINE OPERATIONS AND CONTROLS OPERATION START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MA- CHINE METHOD FOR MOVING MACHINE WARNING • When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. •...
  • Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS 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”...
  • Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR TRAVELING REVERSE 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. •...
  • Page 247 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. 3-187...

  • Page 248: Method For Shifting Gears

    MACHINE OPERATIONS AND CONTROLS OPERATION 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. When the machine stops in emergency, chock the tires im- mediately.
  • Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS 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.

  • Page 250: Method For Traveling Downhill

    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. •...
  • Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Return accelerator pedal (1) before entering a downhill slope. Operate retarder control lever (2) to decelerate the ma- chine. Move the gear shift lever to the position (5, 4, 3, 2) that matches the maximum permitted speed on the brake per- formance curve.
  • Page 252 MACHINE OPERATIONS AND CONTROLS OPERATION 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). The following information can be obtained from this procedure. From point (D): Maximum permissible speed = “24 km/h”...
  • Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 450 m” Brake performance “Downhill distance: 600 m” 3-193...
  • Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 900 m” Brake performance “Downhill distance: 1500 m” 3-194...

  • Page 255: Method For Turning Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS 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.

  • Page 256: Operate With Inter-Axle Differential Lock

    MACHINE OPERATIONS AND CONTROLS OPERATION 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.

  • Page 257: Handle Automatic Retarder, Accelerator Control (Arac)

    OPERATION MACHINE OPERATIONS AND CONTROLS 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.

  • Page 258: Operation Of Arac System

    MACHINE OPERATIONS AND CONTROLS OPERATION 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.

  • Page 259: Handle Komatsu Traction Control System (Ktcs)

    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.

  • Page 260: Operation Of Ktcs System

    MACHINE OPERATIONS AND CONTROLS OPERATION 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.

  • Page 261: Operation If Tires Are Stuck In Ground

    OPERATION MACHINE OPERATIONS AND CONTROLS Disconnect (pull out) the secondary KTCS operation connectors (1) (No. TC1 (male), TC2 (female)), and then connect (insert) them again. Then, KTCS can operate. 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.

  • Page 262: Method For Dumping

    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 WARNING •...
  • Page 263 OPERATION MACHINE OPERATIONS AND CONTROLS 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.

  • Page 264: Method For Operating Cab Tilt

    MACHINE OPERATIONS AND CONTROLS OPERATION 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”...
  • Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS When getting on or off the machine with carrying a tool etc., place it once in part (A) to ensure your safety. Tilt guard (1) at the rear of the cab and fix it according to the following procedure.
  • Page 266 MACHINE OPERATIONS AND CONTROLS OPERATION Turn R.H. bracket (2) counterclockwise 90 ° and fix it with the bolts. 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 Remove cab mounting bolts (9) (8 pieces).

  • Page 267: Precautions For Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS After returning the cab to its original position, remove pin (8) and insert pin (7) instead. Install mounting bolts (9) (8 pieces). 10. Close the engine hood. 11. Return guard (1) at the rear of the cab according to the fol- lowing procedure.

  • Page 268: Method For Parking Machine

    MACHINE OPERATIONS AND CONTROLS OPERATION 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.

  • Page 269: Method For Checking After Finishing Work

    OPERATION MACHINE OPERATIONS AND CONTROLS Place gear shift lever (3) to NEUTRAL position (N), then set parking brake switch (4) to PARKING position to apply the parking brake. When in the operator's compartment, pull retarder control lever (5) fully to apply the retarder. METHOD FOR CHECKING AFTER FINISHING WORK •...
  • Page 270 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key clockwise to unlock. Position (A): OPEN Position (B): CLOSE (LOCK) Turn the cap clockwise and remove it. PROCEDURES FOR CLOSING FUEL FILLER PORT CAP Screw in the cap until it becomes tight, then insert the key into the key slot. Turn the key counterclockwise and remove it.
  • Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key counterclockwise and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) Pull grip (1) toward you and unlock it. Keep lever (2) depressed, hold handle (3) of the hood, and pull it up to open. Open the hood until it is fixed securely.
  • Page 272 MACHINE OPERATIONS AND CONTROLS OPERATION 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 Insert the key into the key slot. Turn the key clockwise to unlock. Position (A): OPEN Position (B): CLOSE (LOCK) Push in the key groove and open up the cover.
  • Page 273 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key counterclockwise and remove it. Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR OPENING AND CLOSING DEF TANK FILLER CAP COVER 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.
  • Page 274 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key counterclockwise and open the cover by pull- ing it. Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR LOCKING DEF TANK FILLER PORT COVER Close the cover and insert the key into the key slot. Turn the key clockwise and remove it.
  • Page 275 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key clockwise to unlock. Position (A): OPEN Position (B): CLOSE (LOCK) Turn the handle counterclockwise, and then open the cov- PROCEDURES FOR LOCKING TOOL BOX COVER Close the cover and turn the handle clockwise. Insert the key into the key slot.
  • Page 276 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key counterclockwise and open the cover by pull- ing it. Position (A): OPEN Position (B): CLOSE (LOCK) PROCEDURES FOR LOCKING FUEL TANK DRAIN VALVE COVER Close the cover and insert the key into the key slot. Turn the key clockwise and remove it.
  • Page 277 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key counterclockwise, and the door is unlocked. Position (A): OPEN Position (B): CLOSE (LOCK) The key returns to position C automatically. Pull the door handle, and the door opens. When locking Close the door and insert the key into the key slot. Turn the key clockwise, and the door is locked.

  • Page 278: Handle Tire

    (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.

  • Page 279: Handle Air Conditioner

    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 •...

  • Page 280: Explanation Of Air Conditioner Equipment

    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.
  • Page 281 OPERATION HANDLE AIR CONDITIONER 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. •...
  • Page 282 HANDLE AIR CONDITIONER OPERATION 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.
  • Page 283 OPERATION HANDLE AIR CONDITIONER 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.
  • Page 284 HANDLE AIR CONDITIONER OPERATION 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. •...

  • Page 285: Method For Operating Air Conditioner

    OPERATION HANDLE AIR CONDITIONER 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.
  • Page 286 HANDLE AIR CONDITIONER OPERATION 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.
  • Page 287 OPERATION HANDLE AIR CONDITIONER Turn air conditioner switch ON. Use temperature control switch to set to the desired tem- perature. 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.
  • Page 288 HANDLE AIR CONDITIONER OPERATION 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. Press fan switch and adjust the air flow.
  • Page 289 OPERATION HANDLE AIR CONDITIONER Turn air conditioner switch ON. Adjust fan switch, temperature control switch and FRESH/ RECIRC air selector switch to the desired positions. METHOD FOR OPERATING DEFROSTER Press fan switch and adjust the air flow. 3-229...
  • Page 290 HANDLE AIR CONDITIONER OPERATION When doing this, check that temperature setting (A) and air flow (B) are displayed on the monitor. 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.
  • Page 291 OPERATION HANDLE AIR CONDITIONER (Vent (D) is fixed.) 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...

  • Page 292: Handle Radio

    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.
  • Page 293 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.

  • Page 294: Method For Controlling Radio

    HANDLE RADIO OPERATION Open cap (1). Connect a portable audio equipment by using an commer- cially available audio cable. 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.
  • Page 295 OPERATION HANDLE RADIO METHOD FOR CALLING PRESET Press band/AUX selector button (1) and select FM or AM. 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”...
  • Page 296 HANDLE RADIO OPERATION METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS) Press sound control button (1) to light up “BAS” on the dis- play. You can adjust the sound (bass). Press tuning/time adjustment button (2) to adjust the sound (bass). Press the △ button, and the bass level increases by 1. •...

  • Page 297: Dump Body Heating Specifications

    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.

  • Page 298: Determine And Maintain Travel Road

    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 •...

  • Page 299: Transportation

    Always obey the traffic regulations when transporting the machine by road. 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.

  • Page 300: Precautions For Lifting Machine

    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”.
  • Page 301 Load on Load on Load on rear 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.
  • Page 302 TRANSPORTATION OPERATION Set the dump lever to “FLOAT” position and check that the dump body float caution lamp is not lit. Stop the engine and apply the parking brake. 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.
  • Page 303 OPERATION TRANSPORTATION 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. Fit protector blocks at contact points (3) between the lifting tool and the dump body to prevent damage to the lifting tool.

  • Page 304: Cold Weather Operation

    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.

  • Page 305: Precautions After Daily Work Completion

    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...

  • Page 306: Precautions For Long-Term Storage

    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. •...

  • Page 307: Preparation Before Traveling After Long-Term Storage

    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.

  • Page 308: Troubles And Actions

    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.

  • Page 309: Method For Lowering Dump Body In Emergency

    The oil in the hoist cylinder is drained into the hydraulic tank and the dump body lowers. Tighten grip (5) and lock nut (4). Install cover (2). If the dump body does not go down even when the above method is used, consult your Komatsu distributor. 3-249...

  • Page 310: Precautions For Towing Machine

    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.
  • Page 311 OPERATION TROUBLES AND ACTIONS • 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.
  • Page 312 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. WARNING •...

  • Page 313: Precautions For Discharged Battery

    OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY 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.
  • Page 314 TROUBLES AND ACTIONS OPERATION 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}...
  • Page 315 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES 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. •...

  • Page 316: 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...
  • Page 317 PHENOMENA AND ACTIONS FOR CHASSIS • 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...
  • Page 318 Operate the accelerator pedal to move the machine to a safe place, then check the failure code and contact your Komatsu distributor. 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.
  • Page 319 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • 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...
  • Page 320 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy 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.
  • Page 321 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...

  • Page 323: Maintenance

    MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 324: Precautions For Maintenance

    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.

  • Page 325: Precautions For Scr Assembly

    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. •...

  • Page 326: Fuel And Lubricants To Match The Ambient Temperature

    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)”.

  • Page 327: Outline Of Maintenance

    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.
  • Page 328 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.
  • Page 329 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.
  • Page 330 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.

  • Page 331: Handle Electrical Components

    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. •...

  • Page 332: Standard Tightening Torque For Bolts And Nuts

    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.
  • Page 333 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) (mm) 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132 8.5 to 13.5...

  • Page 334: Maintenance Schedule

    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 ............................
  • Page 335 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 ....................

  • Page 336: Maintenance Procedure

    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 •...
  • Page 337 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT 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.
  • Page 338 MAINTENANCE PROCEDURE MAINTENANCE 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)”.
  • Page 339 MAINTENANCE MAINTENANCE PROCEDURE 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. When cover (2) is installed, check that the clearance between air cleaner body (5) and cover (2) is not too large.
  • Page 340 MAINTENANCE PROCEDURE MAINTENANCE 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. When outer element (3) is removed, check that inner ele- ment (4) does not come off or incline.

  • Page 341: Method For Cleaning Inside Of Cooling System

    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.
  • Page 342 • 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.
  • Page 343 MAINTENANCE MAINTENANCE PROCEDURE When getting on or off the machine with carrying coolant, place it once in part (A) to ensure your safety. Stop the machine on a level place. Stop the engine. Remove cover (1) from under the radiator, and pull out coolant drain hose (1 piece).

  • Page 344: Method For Checking Window Washer Fluid Level, Adding Fluid

    MAINTENANCE PROCEDURE MAINTENANCE 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.
  • Page 345 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.

  • Page 346: Method For Replacing Slow-Blow Fuse

    MAINTENANCE PROCEDURE MAINTENANCE Open cover (2) at the rear left of the operator's seat. Pull out the air filter (recirculation air filter). 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 •...

  • Page 347: Method For Checking Dump Body

    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.

  • Page 348: Method For Bleeding Air From Brake Circuit

    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 WARNING Stop the machine on a flat place, turn the parking brake switch to “PARKING”...
  • Page 349 (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 Remove the cap of bleeder screw (1) of slack adjuster.
  • Page 350 MAINTENANCE PROCEDURE MAINTENANCE 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.
  • Page 351 MAINTENANCE MAINTENANCE PROCEDURE Connect a vinyl hose to bleeder screw (2). Use a commercially available vinyl hose. Place a container with oil in it. Put the other end of the hose in the oil in the container ap- proximately 50 mm. Depress the brake pedal and keep it.

  • Page 352: Method For Bleeding Air From Hydraulic Circuit

    MAINTENANCE PROCEDURE MAINTENANCE 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.

  • Page 353: Select And Check Tires

    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...
  • Page 354 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)

  • Page 355: Method For Adjusting Parking Brake

    MAINTENANCE MAINTENANCE PROCEDURE Inflation pressure kPa {kg/cm Tire size Front wheel Center wheel Rear wheel 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.

  • Page 356: Collect Leaked Oil From Floating Seal

    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.

  • Page 357: Checks Before Starting

    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. 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.

  • Page 358: Every 50 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE • 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 •...

  • Page 359: Every 250 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE Rear suspension (right and left) (2 places each) EVERY 250 HOURS MAINTENANCE Maintenance for every 50 hours service should be performed at the same time. METHOD FOR LUBRICATING Operate the dump body to be seated on a level ground. Stop the engine.

  • Page 360: Method For Checking Drive Shaft

    MAINTENANCE PROCEDURE MAINTENANCE 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...

  • Page 361: Method For Cleaning Breather

    MAINTENANCE PROCEDURE 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 WARNING •...
  • Page 362 MAINTENANCE PROCEDURE MAINTENANCE 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...

  • Page 363: Method For Cleaning Overflow Hose

    MAINTENANCE MAINTENANCE PROCEDURE Center final drive case METHOD FOR CLEANING OVERFLOW HOSE WARNING 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. The overflow hoses are installed to the front and center wheels.
  • Page 364 MAINTENANCE PROCEDURE MAINTENANCE 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.
  • Page 365 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.

  • Page 366: Method For Checking Frame And A-Arm

    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...

  • Page 367: Method For Checking Retarder Brake Performance

    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. Decrease the engine speed and set the gear shift lever to NEUTRAL position (N).

  • Page 368: Method For Checking Wear Of Parking Brake Pads

    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)”.
  • Page 369 MAINTENANCE MAINTENANCE PROCEDURE Start the engine. Run the engine at a medium speed for 1 minutes, and then stop it. Turn the starting switch to ON position. Depress the brake pedal several times. After the brake pedal is depressed some times, the brake oil pressure caution lamp (1) lights up.

  • Page 370: Every 500 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE After checking, turn the starting switch to OFF position. EVERY 500 HOURS MAINTENANCE 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 WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.

  • Page 371: Method For Replacing Fuel Prefilter Cartridge

    Inspect the drained oil. If there are excessive metal particles or foreign material, contact your Komatsu distributor. Tighten drain valve (3) and drain plug (2). Tightening torque: 68.6±9.8 Nm {7±1 kgm} Turn filter cartridge (4) counterclockwise by using the filter wrench, and remove it.
  • Page 372 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.

  • Page 373: Method For Lubricating Cab Mounting Pins

    MAINTENANCE MAINTENANCE PROCEDURE 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. •...

  • Page 374: Method For Checking And Adding Oil In Deferential Case

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING AND ADDING OIL IN DEFERENTIAL CASE 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. •...

  • Page 375: Method For Checking And Cleaning Radiator Fins, Aftercooler Fins, And Air Conditioner Condenser Fins

    MAINTENANCE MAINTENANCE PROCEDURE 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.
  • Page 376 MAINTENANCE PROCEDURE MAINTENANCE 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.
  • Page 377 MAINTENANCE MAINTENANCE PROCEDURE 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.

  • Page 378: Every 1000 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE Remove mounting bolts (2) of cover (1) on the right side of the machine. Remove cover (1). Blow off mud, dirt, leaves, etc. in aftercooler fins (3) with compressed air. Steam or water may be used instead of the compressed air.

  • Page 379: Method For Replacing Hydraulic Oil Filter Element

    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.
  • Page 380 MAINTENANCE PROCEDURE MAINTENANCE Items to be prepared • 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, etc., place it once in part (A) to ensure your safety.

  • Page 381: Method For Replacing Fuel Tank Breather Element

    MAINTENANCE MAINTENANCE PROCEDURE 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.

  • Page 382: Method For Replacing Transmission Oil Filter Element

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT 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. •...

  • Page 383: Method For Changing Oil In Transmission Case

    MAINTENANCE MAINTENANCE PROCEDURE Remove bolts (3), and remove cover (4). Place the oil container right under the drain plug to receive the drained oil. Remove drain plug (P) and drain the oil. After draining the oil, tighten drain plug (P). Remove the element.
  • Page 384 MAINTENANCE PROCEDURE MAINTENANCE Depress the brake pedal at least 20 times to reduce the pressure inside the brake control accumulator to 0. Place the oil container right under drain plug (P) to receive the drained oil. Remove drain plug (P) and drain the oil. After draining the oil, tighten drain plug (P).

  • Page 385: Method For Lubricating Parking Brake

    MAINTENANCE MAINTENANCE PROCEDURE 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.

  • Page 386: Method For Lubricating

    MAINTENANCE PROCEDURE MAINTENANCE Stop the machine on a level place. Chock the wheels. Raise the dump body. Fix the dump body with the dump body pivot pin. 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.

  • Page 387: Method For Checking Brake Disc Wear Amount

    MAINTENANCE MAINTENANCE PROCEDURE Transmission front trunnion (1 place) Transmission rear trunnion (1 place) Center hinge pin (2 places) METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT 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.

  • Page 388: Method For Checking For Looseness Of Engine Intake Pipe Clamp

    Portion (b): Shows the wear limit of thickness of brake disc. If it has reached the wear limit, ask your Komatsu distribu- tor for inspection and maintenance. Install cap nut (1) removed in step 6. Tightening torque: 29.4 to 39.2 Nm {3.0 to 4.0 kgm} REMARK •...
  • Page 389 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR APPLYING LUBRICANT ON EXHAUST PIPE SPHERICAL SUR- FACE JOINT PORTION WARNING Immediately after the engine is stopped, the parts around the exhaust pipe are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. 4-67...

  • Page 390: Method For Replacing Def Tank Breather Element

    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.

  • Page 391: Method For Checking Drive Belt Tension Pulley Assembly Of Compressor For Al- Ternator And Air Conditioner

    Install cover (2) with bolt (1). 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...

  • Page 392: Every 2000 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF COMPRESSOR FOR ALTERNATOR AND AIR CONDITIONER By using a grease pump, pump in grease through the grease fittings shown by arrows. After greasing, wipe off any old grease that is pushed out. EVERY 2000 HOURS MAINTENANCE Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time.

  • Page 393: Method For Changing Oil In Deferential Case

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN DEFERENTIAL CASE 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. •...

  • Page 394: Method For Replacing Hydraulic Tank Breather Element

    MAINTENANCE PROCEDURE MAINTENANCE Front Center Rear METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. Remove mounting bolts (2) of hydraulic tank top cover (1).

  • Page 395: Method For Cleaning Transmission Case Strainer

    MAINTENANCE MAINTENANCE PROCEDURE Remove nut (4) of breather assembly (3). Remove cover (5). Replace breather element (6) with a new one. Install cover (5) and nut (4). Install cover (1) with mounting bolts (3). METHOD FOR CLEANING TRANSMISSION CASE STRAINER WARNING •...

  • Page 396: Method For Cleaning Breather

    MAINTENANCE PROCEDURE MAINTENANCE Remove drain plug (P) and drain the oil. Remove bolts (1), and remove cover (2). Take out the strainer. Remove all dirt from the strainer, then wash it in clean die- sel fuel or flushing oil. If the strainer is damaged, replace it. Install the drain plug and strainer in their original positions.

  • Page 397: Method For Checking Accumulator Gas Pressure

    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 WARNING After the engine has been operated, all of parts are still very hot.
  • Page 398 MAINTENANCE PROCEDURE MAINTENANCE The KCCV ventilator is located in the positions shown in the figure. For the use of the special KCCV wrench, see the figure. By using the special KCCV wrench, loosen ring (3) of KCCV ventilator (1). After ring (3) comes off, remove case (4) from body (2) and remove element (5).
  • Page 399 MAINTENANCE MAINTENANCE PROCEDURE 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.

  • Page 400: Method For Replacing Def Filter

    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.
  • Page 401 MAINTENANCE MAINTENANCE PROCEDURE Remove filter cap (1) at the bottom of DEF pump, and re- move element (2). Turn cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5). Insert filter removal tool (3) into the bottom of the DEF pump and thrust in with hand.

  • Page 402: Every 4000 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE Slide filter (6) down, and remove spacer (5) from filter re- moval tool (3). Pull filter (6) up while pushing in the tip of filter removal tool (3), and remove it. Return the removed spacer (5) to filter removal tool (3), and keep them.

  • Page 403: Method For Changing Oil In Hydraulic Tank

    MAINTENANCE MAINTENANCE PROCEDURE DEFINED LIFE PARTS LIST Periodical replacement parts Replacement interval Fuel system Fuel hose Spill hose Engine lubrication system Turbocharger lubrication hose Engine oil filter hose Steering system High pressure circuit hose Brake system Brake oil pressure hose Torque converter, trans- Transmission circuit hose mission system...

  • Page 404: Method For Checking Water Pump

    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.

  • Page 405: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening 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.

  • Page 406: Every 4500 Hours Maintenance

    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. EVERY 6000 HOURS MAINTENANCE Perform the periodic maintenance work of every 50, 250, 500, 1000 and 2000 hours of operation at the same time.

  • Page 407: Method For Lubricating Drive Shaft

    MAINTENANCE MAINTENANCE PROCEDURE 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 etc., place it once in part (A) to ensure your safety. Stop the engine.

  • Page 408: Every 8000 Hours Maintenance

    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...

  • Page 409: Specifications

    SPECIFICATIONS...
  • Page 410 Max. payload 40000 Struck 18.2 Dump body capacity Heaped (2 : 1) 24.0 Dumping speed (2000 rpm) (raised) 12.0 Komatsu SAA6D140E-7 die- Engine model sel engine Engine rated horsepower SAE J1995 (gross) 353 / 2000 • ISO14396 • 353 / 2000 kW /min •...
  • Page 411 SPECIFICATIONS SPECIFICATIONS...

  • Page 413: Attachments And Options

    ATTACHMENTS AND OP- TIONS Before reading this chapter, read and understand the SAFETY.

  • Page 414: Handle Cab Power Tilt

    HANDLE CAB POWER TILT ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT 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. •...
  • Page 415 ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT Tilt guard (1) at the rear of the cab and fix it according to the following procedure. Remove mounting bolts (3) of R.H. bracket (2). Turn bracket (2) counterclockwise 90 ° and fix it with the bolts.
  • Page 416 HANDLE CAB POWER TILT ATTACHMENTS AND OPTIONS 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 Remove cab mounting bolts (9) (8 pieces). Open the cab power tilt unit on the L.H.
  • Page 417 ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT 12. Return guard (1) at the rear of the cab according to the fol- lowing procedure. Remove the bolts of R.H. bracket (2). Turn bracket (2) clockwise 90 ° and fix it with the bolts. Remove the bolts of L.H.

  • Page 418: Handling Payload Meter

    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...

  • Page 419: Normal Operation Display

    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.

  • Page 420: External Display Lamp

    If there is difference between the payload and the lighting of the external display lamp, the model setting may be wrong. In such case, consult your Komatsu distributor. 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.

  • Page 421: Details Of Data Stored In Memory Of Payload Meter

    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.
  • Page 422 HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS Remove cap (1). Connect the download cable attached to the special soft- ware to the download connector. Connect the other end of the download cable to RS232C port of the personal computer. Turn the starting switch to ON position. Start up the personal computer and use the special soft- ware to download the data.
  • Page 423 ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER Click “Unit Setting” on screen “G2200”. Screen “G2210” is displayed. 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.

  • Page 424: Display Total Payload And Number Of Cycles

    HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS 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. Press menu switch (1) on the standard screen and display “Machine Setting and Information”...

  • Page 425: Display Fuel Consumption Record

    ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER 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. Press enter switch (2) while the pop-up window shown in the figure is displayed.

  • Page 426: Setting Machine Id And Open Id

    HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS The average value of the daily working fuel consumption in the last 1 week is displayed as shown in the figure. 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”...

  • Page 427: Method For Performing Calibration

    ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER Select “Machine ID Setting”. The set machine ID is displayed on the right side. Press enter switch (2). The pop-up window opens and displays the currently set machine ID. Input the machine ID. • The settable range is from 0 to 200.
  • Page 428 HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS • 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. •...
  • Page 429 ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER 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. When the display becomes as shown in the figure, drive the machine at speed of 10 km/h.

  • Page 431: Replacement Parts

    REPLACEMENT PARTS...

  • Page 432: Periodic Replacement Of Defined Life Parts

    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 Parts for periodic replacement...

  • Page 433: Consumable Parts

    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.

  • Page 434: Recommended Fuel, Coolant, And Lubricant

    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. •...
  • Page 435 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.

  • Page 436: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature

    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 Fluids Engine oil for EOS5W30-LA KDPF used in -25 °C...
  • Page 437 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...

  • Page 438: Recommended Brands And Qualities Other Than Komatsu Genuine Oils

    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.

  • Page 439: Index

    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/C ECO mode setting..........3-69 Accelerator pedal..........3-104 Backup alarm operation - Check......3-163 Accumulator gas pressure - Check.......4-75 Band/AUX selector button........3-232...
  • Page 440 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........
  • Page 441 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.................
  • Page 442 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...
  • Page 443 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...
  • Page 444 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....
  • Page 445 INDEX Start engine............2-24 Start engine with jumper cables......2-25 Unauthorized modification........2-21 Starting motor - Check.......... 4-82 Understanding the machine........2-15 Starting motor and alternator - Overhaul....4-86 Up switch.............. 3-47 Starting switch............3-93 Urea SCR system warning - Handle....3-132 Steering oil pressure caution lamp......3-23 Use handrails and steps when getting on or off ma- Steering oil temperature caution lamp....
  • Page 446 HM400-5 ARTICULATED DUMP TRUCK Form No. EENAM03380 ©2015 KOMATSU All Rights Reserved Printed in Belgium 09-2015...

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