O&m HD1500-8 81001-Up Pen00889-00 PDF

PEN00889-00
DUMP TRUCK HD1500 -8

SERIAL NUMBERS 81001 and up
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 near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
FOREWORD
CALIFORNIA CALIFORNIA
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Battery posts, terminals and
constituents are known to the State related accessories contain lead
and lead compounds, chemicals
of California to cause cancer, birth known to the State of California
defec ts , and other r eproduct iv e to cause cancer, birth defects and
harm. reproductive harm.
Wash hands after handling.
1-1
READ THIS MANUAL FOREWORD
READ THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be observed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
read it at any time.
Keep it in the pocket behind the operator's seat.
If this manual is lost, damaged, or unreadable, contact Komatsu or your Komatsu distributor and tell them about
the machine model name and the serial No. immediately to arrange for its replacement.
For the machine model name and the serial No., see the machine serial No. plate. In order to arrange the prop-
er Operation and Maintenance Manual, you will need to provide the machine model name and the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.
1-2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.
1-3
INTRODUCTION FOREWORD
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.
1-4
FOREWORD INTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT

The visibility of this machine required by visibility standards (ISO 5006) is shown as follows.
Proximity visibility
The figure shows a visibility from the machine at a spot 1 m away from outside the machine and 1.5 m above
the ground.
Shaded area (A) in the figure shows an area whose view is blocked by a part of the machine when the machine
is equipped with the mirrors, rearview camera, and other visibility assistant devices.
Be fully aware that there is an area where the operator cannot see when operating the machine.
Unit: mm
24 m radius visibility
The figure below shows a visibility from the machine for a radius of 24 m.
Shaded area (B) in the figure shows an area whose view is blocked when the machine is equipped with the
mirrors, rearview camera, and other visibility assistant devices.
Be fully aware that there is an area where the operator cannot see when operating the machine.
1-5
PRODUCT INFORMATION FOREWORD
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
It is provided on the front left side of the machine.
The design of the nameplate varies according to the district.
LOCATION OF ENGINE NUMBER PLATE

It is provided on the left front side of the engine.
1-6
FOREWORD PRODUCT INFORMATION
SERVICE METER LOCATION

In the initial state, it is on the left bottom of the machine moni-
tor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.
Engine serial No.
Product identification
number (PIN)
Distributor name
Address
Phone/Fax
Service personnel
1-7
TABLE OF CONTENTS FOREWORD
TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
READ THIS MANUAL ............................................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-3
INTRODUCTION ...................................................................................................................................... 1-4
MAIN USE OF MACHINE .................................................................................................................. 1-4
DIRECTIONS OF MACHINE.............................................................................................................. 1-4
VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-5
PRODUCT INFORMATION....................................................................................................................... 1-6
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........ 1-6
LOCATION OF ENGINE NUMBER PLATE ........................................................................................ 1-6
SERVICE METER LOCATION ........................................................................................................... 1-7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................................................. 1-7
SAFETY........................................................................................................................................................... 2-1
SAFETY LABELS ..................................................................................................................................... 2-2
LOCATION OF SAFETY LABELS...................................................................................................... 2-3
CONTENTS OF SAFETY LABELS .................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-12
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-12
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-12
PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-16
DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-18
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-18
UNAUTHORIZED MODIFICATION .................................................................................................. 2-18
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-18
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ..................................................... 2-19
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-20
PRECAUTIONS FOR JOBSITE ....................................................................................................... 2-20
START ENGINE............................................................................................................................... 2-23
PRECAUTIONS FOR OPERATION ................................................................................................. 2-26
TRANSPORTATION......................................................................................................................... 2-29
TOWING AND BEING TOWED........................................................................................................ 2-30
PRECAUTIONS FOR MAINTENANCE ................................................................................................... 2-31
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-31
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-36
TIRES .............................................................................................................................................. 2-41
OPERATION .................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES ................................................................................................. 3-4
OTHER EQUIPMENT NAME ............................................................................................................. 3-8
EXPLANATION OF COMPONENTS ....................................................................................................... 3-10
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................. 3-10
SWITCHES .................................................................................................................................... 3-104
CONTROL LEVERS AND PEDALS ............................................................................................... 3-120
OTHER EQUIPMENT .................................................................................................................... 3-125
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-150
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-150
METHOD FOR STARTING ENGINE.............................................................................................. 3-192
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-194
METHOD FOR STOPPING ENGINE ............................................................................................. 3-197
METHOD FOR CHECKING AFTER STOPPING ENGINE ............................................................. 3-198
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MA-
CHINE ........................................................................................................................................ 3-199
METHOD FOR SHIFTING GEARS ................................................................................................ 3-205
METHOD FOR TRAVELING DOWNHILL ...................................................................................... 3-207
1-8
FOREWORD TABLE OF CONTENTS
METHOD FOR TURNING MACHINE ............................................................................................ 3-218

HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)..................................................... 3-219
OPERATION OF KTCS.................................................................................................................. 3-219
METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND....................... 3-219
METHOD FOR LOADING .............................................................................................................. 3-220
HANDLING PAYLOAD METER...................................................................................................... 3-221
METHOD FOR DUMPING ............................................................................................................. 3-240
PRECAUTIONS FOR OPERATION ............................................................................................... 3-242
METHOD FOR PARKING MACHINE ............................................................................................. 3-243
METHOD FOR CHECKING AFTER FINISHING WORK ................................................................ 3-244
LOCK ............................................................................................................................................. 3-245
HANDLE TIRE ............................................................................................................................... 3-251
HANDLE AIR CONDITIONER............................................................................................................... 3-254
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-255
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-262
HANDLE RADIO ................................................................................................................................... 3-269
EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-269
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-271
HANDLE KomVision ............................................................................................................................. 3-274
PRECAUTIONS WHEN USING KomVision ................................................................................... 3-274
KomVision CAMERA DISPLAY RANGE ........................................................................................ 3-275
BASIC OPERATION OF KomVision MONITOR ............................................................................. 3-276
EXPLANATION OF KomVision MONITOR SCREEN ..................................................................... 3-279
HANDLE KomVision RADAR ......................................................................................................... 3-287
WARNING WHEN OBSTACLE IS DETECTED .............................................................................. 3-288
HANDLE REAR VIEW MONITOR......................................................................................................... 3-292
SELF-CHECK FUNCTION FOR REAR VIEW MONITOR .............................................................. 3-293
PRECAUTIONS FOR USING REAR VIEW MONITOR .................................................................. 3-294
DETERMINE AND MAINTAIN TRAVEL ROAD ..................................................................................... 3-295
TRANSPORTATION.............................................................................................................................. 3-296
PRECAUTIONS FOR TRANSPORTATION.................................................................................... 3-296
SELECT TRANSPORTATION METHOD........................................................................................ 3-296
METHOD FOR SECURING MACHINE .......................................................................................... 3-296
PRECAUTIONS FOR LIFTING MACHINE..................................................................................... 3-297
COLD WEATHER OPERATION............................................................................................................ 3-300
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-300
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER................................ 3-301
AFTER COLD WEATHER SEASON .............................................................................................. 3-302
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-303
PREPARATION FOR LONG-TERM STORAGE ............................................................................. 3-303
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-303
STARTING MACHINE AFTER LONG-TERM STORAGE ............................................................... 3-304
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE..................................... 3-304
TROUBLES AND ACTIONS ................................................................................................................. 3-305
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-305
ACTIONS IF TRANSMISSION HAS TROUBLE ............................................................................. 3-306
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR .............................................. 3-307
PRECAUTIONS FOR TOWING MACHINE .................................................................................... 3-308
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-313
OTHER TROUBLE......................................................................................................................... 3-319
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE ..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS ................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID ............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
1-9
TABLE OF CONTENTS FOREWORD
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2

PRECAUTIONS FOR WELDING ....................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-3
PRECAUTIONS FOR JACK-UP......................................................................................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS .............................................................. 4-10
MAINTENANCE SCHEDULE.................................................................................................................. 4-13
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-13
MAINTENANCE PROCEDURE .............................................................................................................. 4-15
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-15
WHEN REQUIRED .......................................................................................................................... 4-16
CHECKS BEFORE STARTING........................................................................................................ 4-46
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-47
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-59
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-64
EVERY 15000 HOURS MAINTENANCE ......................................................................................... 4-83
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
SPECIFICATIONS: HD1500-8 ........................................................................................................... 5-2
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
HANDLE SPEED LIMIT FUNCTION ......................................................................................................... 6-2
OPERATION OF SPEED LIMIT FUNCTION ...................................................................................... 6-3
OPERATION IF TROUBLES ON SYSTEM OCCUR .......................................................................... 6-4
HANDLE OVERLOAD SPEED LIMIT FUNCTION .................................................................................... 6-5
OPERATION OF OVERLOAD SPEED LIMIT FUNCTION ................................................................. 6-5
OPERATION IF TROUBLES ON SYSTEM OCCUR .......................................................................... 6-7
REPLACEMENT PARTS.................................................................................................................................. 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2
DEFINED LIFE PARTS LIST.............................................................................................................. 7-2
CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS LIST ............................................................................................................. 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-4
LUBRICATION CHART ...................................................................................................................... 7-5
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-7
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-8
INDEX.............................................................................................................................................................. 8-1
1-10
SAFETY
Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.
2-1
SAFETY LABELS SAFETY
SAFETY LABELS
k WARNING
Be sure that you fully understand the correct position, content and how to avoid a danger shown in the
safety labels.
Handle the warning signs and safety labels used on this machine as follows.
• Always keep the safety labels clean so that you can read it properly. When cleaning the safety labels, do
not use organic solvents or gasoline. These may cause the labels to peel off.
• If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details
of the part numbers for the safety labels, see this manual or the actual label, and place an order to your
Komatsu distributor.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the
same way.
2-2
SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS
2-3
2-4
(1) Caution for modification of ROPS/FOPS (9) Caution before operating, caution when traveling in
(2) Caution against rotating parts reverse, caution for operating hoist control lever
(3) Caution when checking engine room (10) Caution for handling battery cable
(4) Caution when releasing radiator cap (11) Caution for hot exhaust pipe
(5) Caution when opening hydraulic tank cap (12) Caution against falling
(6) Caution for handling suspension (13) Caution for handling battery
(7) Caution for handling accumulator and gas spring (14) Prohibition of start by short-circuiting (This plate is
fixed to the starting motor and starting motor relay.)
(8) Caution for electric cables, caution against falling
when performing inspection and maintenance of (15) Caution for blast site
dump body, caution for performing daily inspection, (16) Caution for high-pressure fuel
caution when leaving operator's seat and when (17) Caution for using seat belt
stopping engine, caution for retarder oil temperature
2-5
CONTENTS OF SAFETY LABELS

Caution for modification of ROPS/FOPS
“09620-A2009”, “09620-A3001” ROPS FOPS CERTIFICATION
This protective structure complies with the standard provided that it is properly equipped on the
machine which mass is less than the specified maximum mass.
• If any modification is applied to the ROPS or FOPS, it may MODEL

SERIAL No.
ROPS: ISO3471: 2008, ISO 13459: 2012, SAE J/ISO 3471 MAY03, FOPS: ISO 3449: 2005, ISO 13459: 2012
MACHINE MODEL
MAX. MASS
FOPS LEVEL No.
kg (Lb)
affect the strength and may not comply with the standard.
Do not drill, cut or weld on the ROPS or FOPS structure.
Any modification is prohibited. 09620-A3001
Komatsu Ltd.
• ROPS or FOPS may provide less protection if it has been
2-3-6 Akasaka, Minato-ku, Tokyo, Japan 09620-A2009
structurally damaged or involved roll-over. Consult Komat-

su Distributor in that case.
• Always wear seat belt when moving.
Caution against rotating parts
“09667-A0880”
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.
Caution when checking engine room

“09667-A0880”
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.
2-6
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.
Caution when opening hydraulic tank cap

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

“09659-A0881”
• There is the hazard of explosion causing injury.
• Do not disassemble the device, make holes in it, weld it,
cut it, hit it, roll it or bring it near flame.
2-7
Caution for handling accumulator and gas spring

“09659-A057B”
• There is the hazard of explosion causing injury.
• Do not disassemble accumulator and gas spring, make
holes in it, weld it, cut it, hit it, roll it or bring it near flame.
Caution for electric cables, caution against falling when performing inspection
and maintenance of dump body, caution for performing daily inspection, cau-
tion when leaving operator's seat and when stopping engine, caution for retard-
er oil temperature
“569–93-82450”
• If the machine comes too close to electric cables, there is danger of electrocution. Always keep a safe dis-
tance from electric cables.
• There is danger that the dump body may come down. Before carrying out inspection or maintenance with
the dump body raised, always read the Operation and Maintenance Manual and take the correct action.
• Always read the Operation and Maintenance Manual before carrying out operation, maintenance, disas-
sembly, assembly, or transportation of machine.
• When leaving operator seat.
1. Lower dump body.
2. Park the machine on level ground.
3. Stop engine and apply parking brake completely.
4. Take out the key.
• If the retarder oil temperature caution lamp light up, stop machine immediately.
Or the brakes will fail, set the shift lever to the N position.
Run the engine under no load at a mid-range speed, and wait for the lamp to go out.
2-8
Caution before operating, caution when traveling in reverse, caution for operat-
ing hoist control lever
“569–93-81720”
• Always read the Operation and Maintenance Manual before carrying out operation maintenance, disassem-
bly, assembly, or translation of the machine.
• There is danger of service injury or death.
Do the following before morning machine or its body.
• Honk horn to alert people nearby.
• Be sure no one is on near machine.
• Use spotter if view is obstructed.
Follow above even if machine equipped with back-up alarm and mirrors.
• Be sure to lower dump body and keep hoist control lever at the float position during travel.
Caution for handling battery cable
“09808-A1681”
• Sign indicates an electric shock hazard from handling the
cable.
• Read manual for safe and proper handling.
Caution for hot exhaust pipe

“09817-K120B”
• Sign indicates a burn hazard from touching heated parts,
exhaust pipe and body during or right after operation.
• Never touch when hot.
.%
2-9
Caution against falling

“09805-C0881”
• There is the hazard of falling.
• Do not step here!
Caution for handling battery

• Never smoke or use any naked flame near the batteries,
ⅆẼཝ⚗࣓࢞ࢿ╔⏝ࡇ࡝ࡶ⚗Ṇ◲㓟ὀពㄝ᫂᭩⇍ㄞ⇿Ⓨὀព
no sparks. ‫ە‬Ỉ⣲࢞ࢫⓎ⏕㸪ྲྀᢅ࠸ࢆㄗࡿ࡜ᘬⅆ⇿Ⓨࡢᜍࢀ࠶ࡾ
࣭ᕤල➼࡛ࢩ࣮ࣙࢺࡸࢫࣃ࣮ࢡࢆࡉࡏ࡞࠸࣭඘㟁ࡣ㢼㏻ࡋࡢࡼ࠸ᡤ࡛⾜࠺
• Always wear protective eyeglasses when working with bat- ༴

࣭ࣈ࣮ࢫࢱ࣮ࢣ࣮ࣈࣝࡢ౑⏝ࡣྲྀᢅㄝ᫂᭩࡟ᚑ࠺
‫ࣜࢸࢵࣂە‬ᾮ◲㓟࡛ኻ᫂ࡸࡸࡅ࡝ࡢᜍࢀ࠶ࡾ
teries. 㝤
ᾮࡀࡘ࠸ࡓࡽࡍࡄ࡟ከ㔞ࡢỈ࡛Ὑ࠸ࠊ┠ࡢሙྜࡣ་ᖌࡢ἞⒪ࢆཷࡅࡿ
‫⇿ە‬Ⓨࡢᜍࢀ࠶ࡾ㸪ᾮ㠃ࡣ/2:(5௨ୗ࡛౑⏝ࡋ࡞࠸
‫ە‬ᾮ₃ࢀࡢᜍࢀ࠶ࡾ㸪833(5௨ୖ࡟⿵Ỉࡋ࡞࠸
• Keep children away from batteries. බ⛠㟁ᅽ
'$1*(5 KEEP SPARKS,FLAME,CIGARETTES AWAY.
ÉLOIGENZ LES ÉTINCELLES,FLAMME,CIGARETTES. 㹔
• Caution battery acid.
• Read the operator's manual before working with batteries.
• Caution - explosive gases.
Prohibition of start by short-circuiting
“09842-A0882”
• Start the engine only after sitting down in the operator's
seat.
• Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.
Caution for blast site

“56D-93-31410”
• Sign indicates an explosion hazard caused by active radio
transmitter at a blast site.
• Keep machine at a safe distance from a blast site and det-
onator.
'
2-10
Caution for high-pressure fuel

“6271-81-2980”
• When the engine is running, high-pressure fuel is generat-
ed in the engine fuel piping. Do not remove or loosen the
fuel system piping when the engine is running.
• When carrying out inspection or maintenance, stop the en-
gine and wait at least 30 seconds to allow internal pressure
to go down.
6271-81-2980
• DO NOT RISK SEVERE INJURY OR DEATH.
Caution for using seat belt

“09848-A0640”
• Always use seat belt when operating the machine to re-
duce risk of injury or death in case of a roll-over.
• Always check for damage or wear of the seat belt, damage
of the connecting brackets, and tightness of bolts.
• Adjust seat position to allow full brake pedal travel with op-
erator's back against seat back.
• After adjusting seat position, get off the seat and tighten
the tether belts located between the floor and seat if equip-
ped.
• Read Operation and Maintenance Manual.
2-11
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
NANCE SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION

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

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

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

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

• Do not wear loose clothes or any accessories. If any of
these catch the control levers or protruding parts, it may
cause the machine to move unexpectedly, it is extremely
dangerous.
• Always wear a hard hat and safety shoes. Wear protective
eyeglasses, mask, gloves, ear plugs, and safety belt when
operating or maintaining the machine.
• Long hair hanging out from the hard hat is dangerous that
it may get caught up in the machine. Tie the hair up and be
careful not to be caught.
• Check that all personal protective items function properly
before using them.
2-12
SAFETY NANCE
KEEP MACHINE CLEAN

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

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

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

If you find any problem in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the per-
son in charge and take the necessary action. Do not operate the machine until the problem has been corrected.
2-13
NANCE SAFETY
PRECAUTIONS TO PREVENT FIRE

ACTIONS IF FIRE OCCURS
• Turn the starting switch to OFF position, and stop the engine.
• Use the handrails and steps to escape from the machine.
• Do not jump off the machine. There is the danger of falling and it may cause personal injury.
• The fume generated by a fire contains harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your
body.
Be sure to wear rubber gloves when handle the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
PREVENT FIRE
Fire caused by fuel, oil, coolant, or window washer fluid
Do not bring any open flame close to flammable substances
such as fuel, oil, coolant, or window washer fluid. There is a
danger that they may catch fire. Always observe the following.
• Do not smoke or use any flame near fuel or other flamma-
ble substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
,&
• Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put the greasy rags and other combustible materials into a
safe container to maintain safety at the workplace.
• When washing the parts with oil, use a non-flammable oil.
Do not use the diesel fuel or gasoline. There is danger that
they may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain combustible liquids. ,&
• Determine the well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
• When performing the machine grinding or welding work, move any flammable materials to a safe place be-
fore starting.
Fire caused by accumulation of combustible material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
or affixed around the engine exhaust manifold, exhaust pipe, battery or dump body (for the machine with
dump body heating specification), or in the undercover.
• To prevent fires from spreading sparks or burning particles from other fires, remove any combustible materi-
als such as dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
around the cooling system (radiator, oil cooler) or inside the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
2-14
SAFETY NANCE
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten the wir-
ing clamps. Repair or replace any damaged wiring.
Fire caused from piping
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage the
hoses and cause the high-pressure oil to spurt out, leading to fire and personal injury.
Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte, or coolant, always use the lighting with anti-explosion specifications.
2-15
NANCE SAFETY
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

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

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

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

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

Never let anyone ride in the dump body. There is a hazard of falling and suffering serious personal injury or
death.
2-16
SAFETY NANCE
WHEN STANDING UP FROM OPERATOR'S SEAT

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

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

The machine equipped with the cab has the doors on its right and left sides. If either door does not open, es-
cape from the other door.
2-17
NANCE SAFETY
DO NOT GET CAUGHT IN WORK EQUIPMENT

The clearance in the area around the dump body changes ac-
cording to the movement of the dump body. If you are caught,
this may lead to serious personal injury or death. Do not allow
anyone near any of the rotating or telescopic parts.
,&
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

The operator's compartment is equipped with a structure (such as ROPS, FOPS) to protect the operator by ab-
sorbing the impact energy.
As for the machine equipped with ROPS, if the machine weight
(mass) exceeds the certified value (shown on ROLL-OVER
PROTECTIVE STRUCTURE (ROPS) CERTIFICATION plate),
ROPS will not be able to fulfill its function. Do not increase ma-
chine weight beyond the certified value by modifying the ma-
chine or by installing attachments to the machine.
Also, if the function of the protective equipment is impeded, the
protective equipment will not be able to protect the operator,
and the operator may suffer injury. Always observe the follow-
ing. ,&
• If the machine is equipped with a protective structure, do

not remove the protective structure and perform operations without it.
• If the protective structure is welded, or holes are drilled in it, or it is modified in any other way, its strength
may drop. Any modification is prohibited.
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be
reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu
distributor.
• Even if the protective structure is installed, always fasten your seat belt properly when operating the ma-
chine. If you do not fasten your seatbelt properly, it cannot display its effect.
Always fasten your seat belt while operating the machine.
UNAUTHORIZED MODIFICATION
• Komatsu will not be responsible for any personal injuries, product failures, physical loss or damage, or influ-
ence on the environment resulting from modifications made without authorization from Komatsu.
• Any modification made without authorization from Komatsu can create hazards. Before making a modifica-
tion, consult your Komatsu distributor.
• Do not try to increase the capacity of the dump body or make any other modifications. Such modifications
will cause a drop in the braking efficiency, the balance of the machine will become poor, and this may lead
to an unexpected accident.
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

• Any personal injuries, product failures, physical loss or damage, or influence on the environment resulting
from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.
• When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential
problems or safety and legal requirements.
• When installing and using optional attachments, always read the instruction manual for the attachment, and
the general information related to attachments in this manual.
2-18
SAFETY NANCE
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

The engine exhaust gas contains substances that may damage
your health or even cause death. Start or operate the engine in
a place where there is good ventilation. If the engine or ma-
chine must be operated inside a building or underground,
where the ventilation is poor, take steps to ensure that the en-
gine exhaust gas is removed and that ample fresh air is
brought in.
,&
2-19
PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS FOR OPERATION

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

• Avoid driving or operating the machine near the edge of cliffs, road edges, and deep ditches. The ground
may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil is weak in these areas, after
heavy rain or blasting or after earthquakes.
• When working on embankments or near excavated ditches, there is a hazard that the weight and vibration
of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the
ground is safe and to prevent the machine from rolling over or falling.
2-20
SAFETY PRECAUTIONS FOR OPERATION
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not drive or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe
the following.
• Before starting work near electric cables, inform the local
power company of the work to be performed, and ask
them to take the necessary action.
• Even going close to high-voltage cables can cause electric
shock. Always maintain a safe distance (see the table) be-
tween the machine and the electric cable. Check with the
local power company about the voltage of cables and safe
operating procedure before starting operations.
Voltage of Cables Safety Distance
100 V, 200 V Min. 2 m {7 ft}
6600 V Min. 2 m {7 ft}
22000 V Min. 3 m {10 ft}
66000 V Min. 4 m {14 ft}
154000 V Min. 5 m {17 ft}
187000 V Min. 6 m {20 ft}
275000 V Min. 7 m {23 ft}
500000 V Min. 11 m {36 ft}
• To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera-
tor's seat, and be careful not to touch the chassis with any exposed part of your body.
• Use a signalman to give warning if the machine approaches too close to the electric cables.
• When performing operations near high voltage cables, prohibit anyone other than related persons to come
close to the machine during operation.
• If the machine should come too close or touch the electric cable, to prevent electric shock, the operator
should not leave the operator's compartment until it has been confirmed that the electricity has been shut
off. Also, prohibit any other persons to come close to the machine.
ENSURE GOOD VISIBILITY

Although this machine is equipped with mirrors and cameras to ensure good visibility, there are places that can-
not be seen from the operator's seat. Be careful when performing operation.
When traveling or performing operations in places with poor visibility, it is dangerous and may cause serious
personal injury or death because it is difficult to check for obstacles and condition of the jobsite. When traveling
or performing operations in places with poor visibility, always observe the following.
• Allocate a signalman for jobsite duty if there are areas where the visibility is poor.
• Only one signalman should give signals.
• When working in dark places, turn on the working lamp and headlamps installed to the machine, and set up
additional lighting equipment in the work area if necessary.
• Stop operations if the visibility is poor because of mist, snow, rain, or dust.
• When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror before
starting the work to ensure good visibility.
• Clean off any dirt from the lens of cameras installed to the machine, and make sure that the camera gives a
clear view.
• The rear view monitor is provided to secure the rear side visibility. If, however, an obstacle is detected on
the monitor, you must confirm it with your eyes.
2-21
CHECK SIGNS AND SIGNALMAN'S SIGNALS

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

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsite
where demolition work is performed or industrial waste is han-
dled. Always observe the following.
• Spray water to keep down the dust.
• Do not use compressed air.
• If there is danger that there may be asbestos dust in the
air, always operate the machine from an upwind position,
and make sure that all workers operate on the upwind ,&
side.
• All workers should use anti-dust masks.
• Prohibit other personnel 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.
2-22
START ENGINE
USE WARNING TAGS
If there is the “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 will be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.
2-23
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

Perform the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If these checks are not performed properly, problems may occur
with the operation of the machine, and there is a danger that may lead to serious personal injury or death.
• Remove all dirt from the surface of the window glass to ensure a good view.
• Perform the walk-around check.
• Remove all dirt from the surface of the lens of the headlamps, working lamps, and combination lamps, and
check that they light up correctly.
• Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
• Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake
pedal, and check that the pedals work properly.
• Adjust the operator's seat to a position where it is easy to perform operations, and check that there is no
damage or wear to the seat belt or mounting clamps.
• Check that the gauges work properly, check the angle of the mirrors, and check that the gear shift lever is at
NEUTRAL position and that the dump control lever is at HOLD position.
• Before starting the engine, check that the lock knob of the dump control lever is at LOCK position.
• Adjust the mirrors so that the rear of the machine can be seen easily from the operator's seat.
• Check that the parking brake switch is at “PARKING” position.
• Adjust the angle of each camera so that the surrounding area can be seen clearly from the operator's seat.
• If snowfalls adhered to a camera, eliminate them with securing your safety by using a stepladder.
• Check that there are no people or obstacles above, below, or in the area around the machine.
PRECAUTIONS WHEN STARTING ENGINE

The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the
following.
• Start the engine only while sitting down in the operator's seat.
• When starting the engine, sound the horn as a warning.
• If another person is allowed on the machine, that person may sit only in the assistant's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious
personal injury or death.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
IN COLD AREAS
• Perform the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the con-
trol levers are operated, the reaction of the machine will be slow, and this may lead to unexpected acci-
dents. Particularly in a cold weather, be sure the warm-up operation is completed.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check
that there is no leakage of electrolyte before starting.
2-24
START ENGINE WITH JUMPER CABLES

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

If any mistake is made in the method of connecting the auxiliary engine starting connector, it may cause the
battery to explode, so always observe the following.
• When connecting a normal machine to a failed machine
with the auxiliary engine starting connector, always use the
normal machine with the same battery voltage as the failed
machine.
• When starting the engine with the auxiliary engine starting
connector, perform the starting operation with 2 workers
(one worker sitting in the operator's seat and the other
working with the battery).
• When starting with the auxiliary engine starting connector,
be careful that the normal machine does not contact with
the failed machine.
• Turn the starting switch of both the failed machine and the normal machine to OFF position when starting
the engine with the auxiliary engine starting connector. If the failed machine has a battery disconnect
switch, turn it to OFF position, and turn it ON again after connecting the cables.
• For the starting procedure with the auxiliary engine starting connector, see OPERATION, “START ENGINE
WITH AUXILIARY ENGINE STARTING CONNECTOR”.
2-25

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

• Always lock all the doors and windows of the operator's compartment in position regardless of whether it is
open or closed.
Always close all the windows and doors on jobsites where there is danger of scattering fragments, and
things which may intrude into operator's cab.
• If another person is allowed on the machine, that person may sit only in the assistant's seat.
• If there are any persons in the area around the machine,
there is danger that they may be hit or caught by the ma-
chine, and this may lead to serious personal injury or
death. Always observe the following before traveling.
• Always operate the machine only when seated on the
operator's seat.
• Before starting to move, check again that there is no
people or obstacle in the surrounding area.
• Before moving, sound the horn to warn people in the
surrounding area.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
• If there is an area in the rear of the machine which cannot be seen, allocate a conductor.
Always be sure to perform the above precautions even when the machine is equipped with mirrors and cam-
eras.
2-26
WHEN TRAVELING
Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact.
Always observe the following.
• Never turn the key in the starting switch to OFF position when the machine is traveling. If the engine stops
when the machine is traveling, the steering wheel becomes heavy to operate, and this will cause a wrong
operation of the steering wheel and may lead to serious personal injury or death. If the engine stops, de-
press the brake pedal immediately to stop the machine.
• When driving the machine or performing operations, always keep a safe distance from people, structures,
or other machines to avoid coming into contact with them.
• Try to avoid traveling over obstacles. If that is unavoidable, let the machine do that at a low speed. The
machine tips over easily to the right or left. Do not drive it over obstacles which make the machine tilt large-
ly to the right or left.
• When traveling on rough ground, drive the machine at low speed and avoid sudden changes in direction to
prevent the machine from turning over.
• Do not load the dump body above the maximum payload. The brakes will lose their effect.
• Lower the dump body, setting the dump lever at “FLOAT” position, then drive the machine.
• When passing over bridges or structures, check first that the structure is strong enough to support the
weight of the machine.
• When operating in tunnels, under bridges, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the machine body or work equipment hit anything.
• If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal
pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces a large
destructive force, and this may cause serious injury or death.
If you are going to drive the machine continuously, consult your Komatsu distributor.
• When traveling, and particularly when traveling downhill, never set the gear shift lever to NEUTRAL position
(N). If the gear shift lever is set to NEUTRAL position (N) while driving the machine at travel speed of above
4 km/h {2.4 MPH} or traveling downhill, the gear speed is not changed to neutral. The centralized warning
lamp flashes and the alarm buzzer sounds. Always set the gear shift lever in D to L position while traveling.
PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side, always observe the following.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly.
• Do not work on a slope covered with the steel plates. Even with slight slopes there is a hazard that the
machine may slip.
• Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that
the machine may slip.
• If the engine should stop on a slope, immediately apply the brakes fully and apply the parking brake also to
stopping the machine.
• When traveling downhill, do not drive the machine with the gear shift lever in NEUTRAL position (N).
If the gear shift lever is set to NEUTRAL position (N) while driving the machine at travel speed of above
4 km/h {2.4 MPH} or traveling downhill, the gear speed is not changed to neutral. The centralized warning
lamp flashes and the alarm buzzer sounds. Always set the gear shift lever in D to L position while traveling.
PRECAUTIONS WHEN OPERATING MACHINE

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

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

• Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma-
chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly
careful when working on slopes.
• Frozen road becomes soft when the temperature rises, and the machine may tip over or be not able to es-
cape. Be particularly careful when working on frozen road.
• When traveling on snow-covered roads, always fit tire chains.
• It is dangerous that the machine enters deep snow. The machine may tip over or become buried in the
snow. Be careful not to go off the road or to get trapped in a drift of snow.
• When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce speed, use the brak-
ing force of the engine, and pump the brakes (depress the brake pedal several times) to stop the machine.
• Do not try to perform dumping operations when the load inside the dump body is frozen. There is danger
that this may cause the machine to tip over.
2-28
WHEN PARKING MACHINE

Unexpected move of the parked machine can cause serious personal injury or death. Always observe the fol-
lowing.
• Place the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, falling rocks, or flooding.
• When leaving the machine, always lower the dump body
completely, lock with dump lever lock knob (1), set the
gear shift lever (2) to NEUTRAL position (N), set the park-
ing brake switch (3) to “PARKING” position, then stop the
engine.
• Close the operator's cab door, and lock all the equipment.
Remove the key in order to prevent any unauthorized per-
son from moving the machine, and keep it in the specified
place.
• If it is necessary to park the machine on a slope, set

blocks under the tires to prevent the machine from moving.
TRANSPORTATION
When the machine is transported on a trailer, serious personal injury or death may result because of the acci-
dent during transportation. Always observe the following.
• Always check the machine dimensions carefully. Depending on the attachments installed, the machine
weight, transportation height, and overall length may differ.
• Check that all bridges and other structures on the transportation route are strong enough to withstand the
combined weight of the transporter and the machine being transported, and determine the transportation
route.
• This machine needs to be divided into components for transportation depending on the regulation. When
transporting the machine, consult your Komatsu distributor.
2-29
TOWING AND BEING TOWED

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

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

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to perform operations safely.
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure your-
self.
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

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

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

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

If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or
high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol-
lowing.
2-31
PRECAUTIONS FOR MAINTENANCE SAFETY
• Stop the engine before performing any inspection and

maintenance.
• Lower the dump body, set the dump lever (1) to “HOLD”
position, lock with dump lever lock knob (2), then stop the
engine.
• Set the gear shift lever (3) to NEUTRAL (N) position, set
the parking brake switch (4) to “PARKING” position to ap-
ply the parking brake, then set chocks in front of and be-
hind the tires to prevent the machine from moving.
2-32
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent an accident, do not perform the maintenance with the engine running. When it is necessary to per-
form the maintenance with the engine running, always observe the following.
• One worker must always sit on the operator's seat and be ready to stop the engine at any time. All workers
must maintain contact with the other workers.
Do not leave the operator's seat during maintenance.
• Rotating parts such as the fan, fan belt are dangerous that
they may easily catch a body part or an object someone
wears. Be careful not to come close to the rotating part.
• Never drop or insert tools or other objects into the fan, fan
belt, or other rotating parts. They may contact the rotating
parts and break, and be scattered. It is dangerous.
,&
• Lower the dump body completely, set dump lever (1) to

“HOLD” position, lock with dump lever lock knob (2) to pre-
vent the dump body from moving.
• Set parking brake switch (3) to “PARKING” position to ap-

ply the parking brake, then put blocks in front of and be-
hind the tires to prevent the machine from moving.
• Do not touch any control levers. When it is necessary to
operate the control levers, always give a signal to your fel-
low workers to evacuate them to a safe place.
2-33
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS

• Appoint a leader before starting removal or installation operations for attachments.
• Place attachments that have been removed from the ma-
chine in a stable condition so that they do not fall. And take
steps to prevent unauthorized persons from entering the
storage area.
,&
PRECAUTIONS FOR WORKING AT HIGH PLACES

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

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

Machine or dump body may fall, and it is dangerous such that
serious personal injury or death may occur. Always observe the
following.
• When performing the check of the machine with the dump
body raised, always set the dump lever to “HOLD” posi-
tion, lock it with the dump lever lock knob, then use the
dump body lock wire for further safety. If the body lock wire
is not installed, the dump body may go down when the
dump control lever is operated, and may catch the person
performing the inspection or cause serious injury or even ,&
death to the person.
• Perform the installation of the dump body lock wire with two persons or more. This operation is performed
with the dump body raised, so if the dump body comes down during the operation, it may lead to serious
injury or even death.
• Make sure the hoists or hydraulic jacks you use are in good repair and strong enough to handle the weight
of the component. Never use hydraulic jacks at places where the machine is damaged, bent, or twisted.
Never use if the strand of wire rope is frayed, twisted or pinched. Never use bent or distorted hooks.
• Never use concrete blocks for supports. Concrete blocks may break under even light loads.
2-34
USE PROPER TOOLS

Use the tools suited to the task and use them correctly. Using
damaged, deformed, or low quality tools, or making improper
use of the tools may cause serious personal injury or death.
,&
2-35
PRECAUTIONS FOR CHECK AND MAINTENANCE

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

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

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire. Always ob-
serve the following.
• When handling the battery, always wear protective eye-
glasses and rubber gloves.
• If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water. After that, get
,&
medical attention immediately.
2-36
• If battery electrolyte gets on your clothes or skin, wash it off immediately with large amounts of water.
Danger of sparks
Sparks may be generated and they can cause a fire. Always observe the following.
• Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools
lying around near the battery.
• When removing the battery terminal, turn the starting switch to OFF position and, after checking that the
system operating lamp goes out, set the battery disconnect switch to OFF position.
When removing the battery terminal, remove the ground cable (negative (-) cable) first. When installing,
connect the positive (+) cable first, then connect the ground.
• Tighten the battery cable terminals securely.
• Secure the battery firmly in the specified position.
WHEN USING HAMMER

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

To prevent burns from boiling water or steam spurting out when
checking or draining the coolant, wait for the coolant to cool
down to a temperature where the radiator cap can be touched
by hand. Then pull up the lever on the cap to release the pres-
sure inside the radiator. Loosen the cap slowly to release the
remaining pressure, and remove it.
PRECAUTIONS FOR HIGH-TEMPERATURE OIL

To prevent burns from hot oil spurting out or from touching
high-temperature parts when checking or draining the oil, wait
for the oil to cool down to a temperature where the cap or plug
can be touched by hand. Then, loosen the cap or plug slowly to
release the internal pressure and remove the cap or plug.
2-37
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS

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

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

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

If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or defective operation. It is dangerous
and may cause serious personal injury or death. If the hose or piping mounts are loose or oil or fuel is found to
be leaking from the mount, stop operations and tighten to the specified torque.
If any damaged or deformed hoses or piping are found, consult your Komatsu distributor.
Replace the hose if any of the following problems are found.
• Damaged hose or deformed hydraulic fitting.
• Frayed or cut covering or exposed reinforcement wire layer.
• Covering swollen in places.
• Twisted or crushed movable portion.
• Foreign material embedded in covering.
2-38
PRECAUTIONS FOR HIGH VOLTAGE

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

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

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

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

If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause
frostbite. Never loosen any parts of the cooling circuit.
2-39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
METHOD FOR SELECTING WINDOW WASHER FLUID

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

• For using the machine safely for a long period, always perform periodic replacement of the defined life parts
that have a particularly close relation to safety, such as hoses and the seat belt.
Replacement of the defined life parts: See “PERIODIC REPLACEMENT OF DEFINED LIFE PARTS”.
• The material of these components naturally changes over time, and repeated use causes deterioration,
wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal
injury or death. It is difficult to judge the remaining life of these components from external inspection or the
feeling when operating, so always replace them at the specified interval.
• Replace or repair the defined life parts if any defect is found, even when they have not reached the speci-
fied replacement time.
2-40
TIRES
HANDLE TIRES
If tires or rims are handled mistakenly, there is danger that the
tire may explode or be damaged, or that the rim may fly off and
cause serious personal injury or death.
To ensure safety, always observe the following.
• Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and spe-
cial technology, so always ask your Komatsu distributor to perform these operations.
• Use only specified tires and inflate them to the specified pressure.
• When pumping up the tires, check that no other person is
standing near the tire, and install an air chuck with a clip
that can be secured to the air valve.
To prevent the tire inflation pressure from becoming too
high, measure the pressure from time to time with an air
gauge while pumping up the tire.
• If the tire inflation pressure goes down abnormally or the
rim parts do not fit the tire, there is a problem with the tire
or rim parts. Always contact your Komatsu distributor for
repairs.
• If the rim parts are not fitted properly when the tire is being
pumped up, there is a danger that the rim parts may fly off, so set up a protective fence around the tire, and
do not stand directly in front of the rim. Stand beside the tread when pumping up the tire.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under heavy
load.
• Never perform welding or light a fire near the tire.
• Always release the inflation pressure from a tire prior to removing rim from tire.
• Before removing the tire from the machine for repairs, remove the valve partially to release the air from the
tire gradually, then remove the tire.
PRECAUTIONS FOR STORING TIRES

Tires for construction equipment are extremely heavy, it may
lead to serious personal injury or death. To maintain safety, al-
ways observe the following.
• As a basic rule, store the tires in a warehouse which unau-
thorized persons cannot enter.
If the tires must be stored outside, always erect a fence
and put up “No Entry” signs.
• Stand the tire at the angle of 60 to 70 ° (A) on a level
ground, and block it securely (1) so that it cannot tip over
or fall over if any person should touch it. Do not lay the tire
on its side. This will deform the tire and cause it to deterio-
rate.
• If the tire should fall over, do not attempt to stop it. Get out of the way quickly.
2-41
OPERATION
Please read and make sure that you understand the SAFETY section before
reading this section.
3-1
GENERAL VIEW OPERATION
GENERAL VIEW
MACHINE EQUIPMENT NAME
(1) Air cleaner (10) Rear wheel

(2) Headlamp (low beam) (11) Dump body
(3) Turn signal lamp and clearance lamp (12) Staircase lighting
(4) Headlamp (high beam) (13) Rear suspension
(5) Front wheel (14) Fuel tank
(6) Steering and hoist oil tank (15) Front suspension
(7) Brake oil tank (16) External display lamp
(8) Side lamp (17) Fog lamp (if equipped)
(9) Hoist cylinder
3-2
OPERATION GENERAL VIEW
(*) Only for machine with radar

(18) Right rear camera (25) Right side front detection radar
(19) Right side rear detection radar (26) Front side right detection radar
(20) Right front camera (27) Front side left detection radar
(21) Front camera (28) Left side front detection radar
(22) Left front camera (29) Rear camera
(23) Left side rear detection radar (30) Rear side right detection radar
(24) Left rear camera (31) Rear side left detection radar
3-3
CONTROLS AND GAUGES NAMES
(1) Wiper and window washer switch (12) Hazard lamp switch
(2) Lamp switch, dimmer switch, turn signal lever (13) Secondary steering switch
(3) Switch panel (14) AISS LOW switch
(4) Monitor brightness selector switch (15) Engine power mode selector switch
(5) Side lamp switch (16) Manual greasing switch
(6) Staircase lighting switch (17) Starting switch
(7) Fog lamp switch (if equipped) (18) Accelerator pedal
(8) Machine monitor (19) Brake pedal
(9) Horn button (20) ARSC speed set lever
(10) Steering wheel (21) Steering tilt lock lever
(11) Retarder control lever (22) Secondary brake pedal
3-4

(23) Gear shift lever (36) Engine shutdown secondary switch
(24) Parking brake switch (37) Power window switch (L.H.)
(25) KomVision monitor brightness adjustment switch (38) Power window switch (R.H.)
(26) Screen mode selector switch (39) Revolving lamp switch (if equipped)
(27) Obstacle warning cancel switch (40) Heated wire mirror switch (if equipped)
(28) Left front camera selector switch (41) Heated wire glass switch (if equipped)
(29) Left rear camera selector switch (42) Dump lever
(30) Front camera selector switch (43) Dump lever lock knob
(31) Rear camera selector switch (44) Room lamp 2 switch
(32) Right front camera selector switch (45) Room lamp 1 switch
(33) Right rear camera selector switch (46) Rearview monitor brightness adjustment switch
(34) Radar check switch (47) KomVision monitor
(35) Cigarette lighter (48) Rearview monitor
3-5
MACHINE MONITOR EQUIPMENT NAME

Machine monitor
(A) LCD unit (C) Meter unit

(B) LED unit
(1) Engine coolant temperature caution lamp (15) Engine tachometer
(2) Engine coolant temperature gauge (16) Speedometer
(3) ECO gauge (17) Fuel level caution lamp
(4) Air conditioner display section (18) Fuel gauge
(5) Clock (19) R.H. meter
(6) Centralized warning lamp (20) L.H. meter
(7) Parking brake pilot lamp (21) Torque converter oil temperature gauge
(8) Turn signal pilot lamp (L.H.) (22) Torque converter oil temperature caution lamp
(9) Headlamp (high beam) pilot lamp (23) Air conditioner switch and numeric keypad
(10) Turn signal pilot lamp (R.H.) (24) Menu switch
(11) Brake oil pressure caution lamp (25) ENTER switch
(12) Clearance lamp pilot lamp (26) RETURN switch
(13) Retarder oil temperature gauge (27) DOWN switch
(14) Retarder oil temperature caution lamp (28) UP switch
3-6
Liquid crystal unit display
(A-1) Standard screen (ARSC setting: ON, payload (C) Maintenance time warning screen
meter: OFF) (D) Warning screen
(A-2) Standard screen (ARSC setting: ON, payload (E) User menu screen
meter: ON)
(B) ECO guidance screen
(28) Message display (35) Torque converter lockup pilot lamp
(29) Retarder pilot lamp (36) Secondary steering pilot lamp
(30) ARSC ready pilot lamp (37) Payload meter display
(30) ARSC off pilot lamp (38) ECO guidance
(31) KTCS pilot lamp (39) Maintenance time caution lamp
(31) KTCS off pilot lamp (40) Guidance icon
(32) ARSC set travel speed indicator (41) Warning display
(33) Shift indicator (42) Seat belt caution lamp
(34) Shift lever position display (43) Action level
At place (28), 2 types of pilot lamp are prepared.
3-7
OTHER EQUIPMENT NAME

Inside of cab
(1) Open knob for cab door (7) AUX

(2) Cab door inner lock (8) Lunch box tray
(3) Magazine box (9) 12 V power supply
(4) Cup holder (2 places) (10) Ashtray
(5) Drink box (11) KomVision system indicator
(6) Fuse
3-8
Outside of cab
(1) Cab door handle (9) Starting motor disconnect switch

(2) Dust indicator (10) Auxiliary engine starting connector
(3) Fuse (11) Rearview camera
(4) Circuit breaker (12) Dump body lock wire
(5) Battery (13) External engine shutdown secondary switch
(6) Fire extinguisher (14) External staircase lighting switch
(7) Battery disconnect switch (15) Engine room lamp switch
(8) System operating lamp
3-9
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of devices necessary to operate the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operat-
ing the equipment, and the meanings of the displays.
EXPLANATION OF MACHINE MONITOR EQUIPMENT
FF: Failure display screen

(A) Warning display (C) Meter display
(B) Pilot display (D) Switch panel
REMARK
One of the characteristics of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit) on the screen. When there are fewer than 10 black or white spots, this is
not a failure or a defect.
3-10
OPERATION EXPLANATION OF COMPONENTS
BASIC OPERATION OF MACHINE MONITOR

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

ENGINE SHUTDOWN SECONDARY SWITCH IS ON
While the engine shutdown secondary switch (1) is turned on
(engine is stopped), when the starting switch key is turned to
ON position, the screen shown in the figure is displayed and
the engine does not start.
If the engine shutdown secondary switch (1) is turned off (nor-
mal), the machine monitor switches to the standard screen,
and the engine can be started with usual starting switch key
operation.
3-12
BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR-

MAL SITUATION
When the starting switch is turned to OFF position, the screen goes out. In the following cases, the end screen
is displayed for 5 seconds, and then screen goes out.
End screen when any message has been received
If there is any message from your Komatsu distributor, it is displayed on the 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.
End screen when there is any “Operational Advice”
If there is any “Operational Advice”, “Operational Advice” is displayed on the end screen EE for 5 seconds, and
then the screen goes out.
3-13
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING SWITCH IS ON

WHILE OPERATOR ID INPUT IS SET
• If inputting the ID number for operator identification function (with SKIP) is set, the opening screen AA
switches to the ID number input screen LL (with SKIP) when the starting switch is turned to ON position.
• If inputting the ID number for operator identification function (without SKIP) is set, the opening screen AA
switches to the ID number input screen MM (without SKIP) when the starting switch is turned to ON posi-
tion.
• On the ID number input screen LL (with SKIP) or MM
(without SKIP), input the already registered ID number,
and press ENTER switch (1). The screen changes to the
check before starting screen BB. If you input an incorrect
ID number, press RETURN switch (2), and clear it one
character at a time.
On the ID number input screen LL (with SKIP), press the
menu switch (3), and the screen changes to the check be-
fore starting screen BB without inputting ID number.
REMARK
• Contact your Komatsu distributor for the method of setting,
changing, or canceling the operator identification function.
• Depending on the set value of ID holding time in set items
of operator identification function, even if inputting the ID
number for operator identification setting is set, the ID
number input screen LL (with SKIP) or MM (without SKIP)
may not be displayed while the starting switch is turned to
ON position.
If the incorrect ID number is inputted for 3 times in a row, you cannot input the ID number in the next 5 minutes.
Wait for more than 5 minutes, and try inputting the ID number again.
As long as the ID number input screen is displayed, the engine cannot be started. If you forget the ID number
and cannot start the engine, ask the person in charge of the machine for it.
3-14
NOTICE
The operator identification function is not for security or protection against theft. Do not use for securi-
ty.
Komatsu cannot take responsibility for any loss or damage from the wrong use of ID or unauthorized
use of ID by a third person.
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB-

NORMAL SITUATION
If there is an abnormality when starting the engine
When the machine monitor is started, if the machine has a trouble, the starting screen AA is displayed for 2
seconds and then it is changed to the failure display screen FF.
When ENTER switch displayed in the guidance icon is press-
ed, “Error List” screen is displayed.
3-15
If there is the maintenance time warning when starting the engine
When the machine monitor is started, if the time to the next maintenance of any item is 30 hours or less, the
starting screen AA is displayed for 2 seconds and then it is changed to the maintenance time warning screen
GG.
When the menu switch displayed in the guidance icon is press-
ed, “Maintenance” menu screen is displayed.
After displaying the maintenance time warning screen GG for
30 seconds, the screen returns to the standard screen BB.
3-16
BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE

OPERATING MACHINE
If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF.
When ENTER switch displayed in the guidance icon is press-
ed, “Error List” screen is displayed.
REMARK
The guidance icon is displayed only while the machine is stop-
ped completely.
Even when ENTER switch is pressed while the machine is not
stopped completely, “Error List” screen is not displayed.
3-17
WARNING DISPLAY
NOTICE
The machine has a trouble if any of the action levels “L01” to “L04” is displayed on the machine moni-
tor.
Take appropriate actions following the list of action level displays and required actions.
• These caution lamps do not guarantee the condition of the machine.
Do not simply rely on the caution lamp when performing check before starting (start-up inspection).
Always get off the machine and check each item directly.
• When the caution lamp is displayed in red, the machine will be seriously affected if it is left without
any action being taken.
Take the action immediately.
• The engine output or engine speed may be limited and the machine operation speed may become
slow, depending on the contents of the warning.
(1) Engine coolant temperature caution lamp (7) Seat belt caution lamp
(2) Warning display (8) Brake oil pressure caution lamp
(3) Warning display (9) Retarder oil temperature caution lamp
(4) Guidance icon (10) Fuel level caution lamp
(5) Centralized warning lamp (11) Torque converter oil temperature caution lamp
(6) Action level display
REMARK
• When 1 type of warning is generated, it is displayed on warning display (2).
• When 2 types of warning are generated, they are displayed on warning displays (2) and (3).
• When more than 3 types of warning are generated, they are displayed on warning displays (2) and (3) alter-
nately at intervals of 2 seconds.
3-18
ACTION LEVEL DISPLAY

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

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

code and ask your Komatsu distributor for inspection
Low and maintenance.
Some functions may be restricted for use, but the ma-
chine can operate.
Does not When you finish the operation, always perform the in-
L01 Not lit Yellow
sound spection and maintenance.
Ask your Komatsu distributor for the inspection and
maintenance as needed.
3-19
REMARK
• When the action level display is “L01”, “L01” is displayed
only for 2 seconds after a failure occurs, and then it disap-
pears.
• If plural failures occur at the same time, the action level
with the highest urgency (the greatest number) is dis-
played.
3-20
ERROR LIST DISPLAY

The monitor provides the information on failures that occurred on the machine and the necessary actions for
action levels that are displayed.
When ENTER switch is pressed while the guidance icon is dis-
played, the screen changes to “Error List” screen.
REMARK
The guidance icon is displayed only while the machine is stop-
ped completely.
Even when ENTER switch is pressed while the machine is not
stopped completely, “Error List” screen is not displayed.
(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 actions according to the displayed message.
3-21
(F) Contact telephone number

The telephone number of your Komatsu distributor is displayed.
If the telephone number of the contact has not been registered, it is not displayed.
Ask your Komatsu distributor for the telephone number registration if necessary.
(G) Guidance icon
On “Error List” screen, the following switches displayed in the guidance icon (G) can be operated.
UP switch
Move to the previous page.
When on the first page, it moves to the last page.
DOWN switch
Move to the next page.
When on the last page, it moves to the first page.
RETURN switch
Returns the screen to the standard screen.
3-22
ENGINE COOLANT TEMPERATURE CAUTION LAMP

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

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

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

The fuel level caution lamp warns about low level of remaining
fuel.
The lamp lights up in red if the fuel level is 313 ℓ or less
{82.7 U.S.Gal or less} .
Add fuel as soon as possible.
3-23
BRAKE OIL PRESSURE CAUTION LAMP

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

The seat belt caution lamp lights up in red when the seat belt is
not fastened.
Always fasten the seat belt while traveling because there may
be a possible danger.
STEERING SYSTEM CAUTION LAMP

The steering system caution lamp warns about abnormality in
the steering system.
The caution lamp lights up in red.
and maintenance.
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for the inspection and maintenance as needed.
3-24
STEERING OIL PRESSURE CAUTION LAMP

The steering oil pressure caution lamp warns the operator that
the steering oil pressure is below the specified value.
When action level “L03” is displayed
If the steering oil pressure drops below the specified value
while the engine is running, the caution lamp lights up in red.
engine, then ask your Komatsu distributor for inspection and
maintenance.
Action level is not displayed and lamp lights up in red
When the engine is started, the caution lamp lights up in red until the steering oil pressure rises above the
specified value.
At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Wait until the caution lamp goes out, and then start the machine.
Action level is not displayed and only lamp lights up in yellow
If the steering oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in
yellow.
STEERING OIL TEMPERATURE CAUTION LAMP

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

The secondary steering system caution lamp warns about ab-
normality in the secondary steering system.
maintenance.
3-25
SECONDARY STEERING MOTOR CAUTION LAMP

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

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

The dump body float caution lamp warns about the condition of
the dump body.
When lamp lights up in red
The gear shift lever is turned to any position other than NEU-
TRAL position (N) while the dump lever is turned to any posi-
tion other than “FLOAT” or the dump body is raised.
When lamp lights up in yellow
The dump lever is turned to any position other than “FLOAT”
position or the dump body is raised.
REMARK
• The dump body float caution lamp lights up if above conditions are satisfied while the engine is running.
• If the engine stops, the dump body is held in HOLD condition, regardless of the position of the dump lever.
3-26
INCLINATION CAUTION LAMP

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

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

The transmission system caution lamp warns about abnormali-
ty in the transmission system.
the alarm buzzer sounds continuously.
Immediately stop the machine and ask your Komatsu distribu-
tor for inspection and maintenance.
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.
3-27
TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP

The transmission oil filter clogging caution lamp warns about
clogging of the transmission oil filter.
If the caution lamp lights up in yellow and the action level “L01”
is displayed, stop the engine and check or replace the trans-
mission oil filter.
See “METHOD FOR REPLACING TRANSMISSION OIL FIL-
TER ELEMENT (4-61)”.
RETARDER SYSTEM CAUTION LAMP

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

The engine system caution lamp warns about abnormality in
the engine system.
The caution lamp lights up in red. At the same time, the central-
ized warning lamp lights up and the alarm buzzer sounds con-
tinuously.
Stop the machine immediately and ask your Komatsu distribu-
tor for the inspection and maintenance.
The caution lamp lights up in red. At the same time, the central-
ized warning lamp lights up and the alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for
the inspection and maintenance.
3-28
PARKING BRAKE SYSTEM CAUTION LAMP

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

The KTCS system caution lamp warns about abnormality in the
KTCS system.
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.
ENGINE OIL PRESSURE CAUTION LAMP

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

The engine overrun caution lamp warns the operator that the
engine speed is higher than the allowable range.
When the caution lamp lights up in red, the centralized warning
lamp lights up and the alarm buzzer sounds intermittently.
If the engine speed increases more, action level “L02” is dis-
played.
Operate the machine with moderate engine speed and travel
speed.
3-29
CHARGE LEVEL CAUTION LAMP

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

Air cleaner clogging caution lamp warns about clogging of the
air cleaner.
displayed, stop the engine, then check and clean the air clean-
er.
See “METHOD FOR CHECKING, CLEANING AND REPLAC-
ING AIR CLEANER (4-16)”.
FAN CONTROL SYSTEM CAUTION LAMP

The fan control system caution lamp warns about abnormality
in the fan control system.
nance as needed.
AIR CONDITIONER SYSTEM CAUTION LAMP

Air conditioner system caution lamp warns about abnormality in
air conditioner system.
nance as needed.
3-30
ARSC SYSTEM CAUTION LAMP

The ARSC system caution lamp warns about abnormality in the
ARSC system.
When an abnormality occurs in ARSC system, the caution
lamp lights up in red, and the action level “L03” is displayed.
and maintenance.
ARSC OVERHEAT NOTICE CAUTION LAMP

k CAUTION
Set the travel speed for ARSC to be the travel speed lower than the maximum permissible speed which
is obtained from the brake performance curve.
If the travel speed is set to the speed higher than the maximum permissible speed, the retarder brake
may get damaged by overheating.
The ARSC overheat notice caution lamp warns about the over-
heating of the retarder oil temperature caused by usage of
ARSC.
The ARSC overheat notice caution lamp lights up in yellow
when the retarder oil temperature increased sharply, and the
overheating is estimated to occur in 5 seconds while ARSC is
being used.
Decrease the travel speed which is set in ARSC.
PAYLOAD METER SYSTEM CAUTION LAMP

The payload meter system caution lamp warns about abnor-
mality in the payload meter system.
If the caution lamp lights up in yellow and the action level “L01”
is displayed, always perform the inspection and maintenance
after the operation is finished.
nance as needed.
3-31
CAMERA SYSTEM CAUTION LAMP

Camera system caution lamp warns about the signal trouble
caused by such as breakage in cables, loose and disconnected
connectors.
When an abnormality is found in the connection of the camera,
this caution lamp lights up in yellow and the action level “L01”
is displayed.
If the caution lamp is lit, the camera image is not displayed on
the machine monitor.
Visually check the safety around the machine always when op-
erating the machine.
Ask your Komatsu distributor for the inspection and maintenance.
RADAR SYSTEM CAUTION LAMP

(Only machine equipped with radar)
The radar system caution lamp warns about abnormality in the
KomVision radar system.
When an abnormality occurs in KomVision radar system, the
caution lamp lights up in red, and the action level “L01” is dis-
played.
Visually check the safety around the machine always when op-
erating the machine.
nance.
MAINTENANCE TIME CAUTION LAMP

Maintenance time caution lamp displays the notices and alarms
concerning maintenance time.
This lamp lights up when the starting switch is turned to ON po-
sition. It goes out after 30 seconds and the screen changes to
the standard screen.
When lamp lights up in red
The maintenance due time is over.
If no action is taken, the machine performance will become
worse and the machine life will be shortened.
Perform necessary maintenance as soon as possible.
When lamp lights up in yellow
The maintenance time is approaching.
Prepare necessary parts for the maintenance.
REMARK
• To check the items that need maintenance, see “Maintenance” menu screen.
• On the standard screen, when the menu switch is pressed while the caution lamp is lit, the screen changes
directly to “Maintenance” menu screen.
• For operations on “Maintenance” menu screen, see “MAINTENANCE SCREEN SETTING (3-75)”.
• By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches
30 hours. However, you can change this setting.
To change the setting, ask your Komatsu distributor.
3-32
CENTRALIZED WARNING LAMP

The centralized warning lamp lights up in red and at the same
time the alarm buzzer sounds intermittently when the machine
is under the following condition.
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 dump body float caution lamp (red) is lit.
When the inclination caution lamp is lit.
When the charge voltage caution lamp is lit.
When the brake oil pressure is below the specified The brake oil pressure caution lamp lights
value while the engine is running. up.
When the steering oil pressure is below the speci- The steering oil pressure caution lamp lights
fied value while the engine is running. up.
When the starting switch is turned to ON position The current gear shift lever position flashes.
while the gear shift lever is in the any position oth-
er than NEUTRAL position (N).
When all the signals from the gear shift lever are
turned OFF.
3-33
Machine conditions under which centralized warn- Monitor display

ing lamp lights up
When the gear shift lever is set to NEUTRAL posi- The current gear shift lever position flashes.
tion (N) during traveling at travel speed 4 km/h or
higher {2.48 MPH or higher} .
When the travel speed is 4 km/h or higher
{2.48 MPH or higher} while the gear shift lever is
in NEUTRAL position (N).
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 the position D and Shift indicator (F1) flashes.
the accelerator pedal is depressed while the brake
is operated. (When the F1 Start at D Position Set-
ting is effective)
3-34
PILOT DISPLAY AND METER DISPLAY
Pilot display
(1) Turn signal pilot lamp (9) Secondary steering pilot lamp
(2) Headlamp (high beam) pilot lamp (10) Shift indicator
(3) Clearance lamp pilot lamp (11) Shift lever position display
(4) Retarder pilot lamp (12) Parking brake pilot lamp
(5) KTCS pilot lamp (13) ARSC pilot lamp
(5) KTCS off pilot lamp (13) ARSC off pilot lamp
(6) Power mode display (14) ARSC set travel speed indicator
(7) Torque converter lockup pilot lamp (15) ECO guidance
(8) Message display
Meter display
(16) Speedometer (21) Fuel gauge
(17) Engine tachometer (22) ECO gauge
(18) Engine coolant temperature gauge (23) R.H. meter
(19) Torque converter oil temperature gauge (24) L.H. meter
(20) Retarder oil temperature gauge (25) Payload display
2 types of pilot lamps are prepared at places (6) and (8).
3-35
PILOT DISPLAY
The pilot display consists of the pilot lamps to check the actuation of each function.
When the starting switch is in ON position, the pilot lamps light up when the display items are functioning.
TURN SIGNAL PILOT LAMP

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

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

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

The retarder pilot lamp lights up when the retarder is actuated.
The retarder operates in the following cases.
• When the retarder control lever is pulled.
• When ARSC is operated.
• When KTCS is operated.
• When the engine overrun prevention function is operated.
3-36
KTCS PILOT LAMP

The KTCS pilot lamp lights up when “TCS Setting” is set to
“ON” and when the system detects slipping of a rear wheel.
KTCS OFF PILOT LAMP

The KTCS off pilot lamp lights up while “TCS Setting” is set to
“OFF”.
POWER MODE DISPLAY

The power mode display indicates the set state of the power mode.
By selecting power mode selector switch, one of the following lamps lights up.
Economy mode
Power mode
3-37
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.
MESSAGE DISPLAY
The message display lights up when there is a message from Komatsu.
To read the message, see “CHECK MESSAGE (3-101)”.
Lights up in green
There is an unread message.
Lights up in blue
There is any read message to which no reply has been made.
Not lit
There is no message.
SECONDARY STEERING SYSTEM PILOT LAMP

The secondary steering pilot lamp lights up while the secon-
dary steering is in operation.
3-38
SHIFT INDICATOR
This indicator shows the transmission shift range (gear shift).
SHIFT LEVER POSITION DISPLAY

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

The parking brake pilot lamp lights up when the parking brake
is applied.
3-39
ARSC PILOT LAMP

The ARSC pilot lamp indicates the ARSC setting state.
Lights up in green
“ARSC Setting” is “ON”, and ARSC is actuated.
Lights up in white
“ARSC Setting” is “ON”, and ARSC is not actuated.
ARSC OFF PILOT LAMP

The ARSC off pilot lamp lights up when “ARSC Setting” is
“OFF”.
ARSC SET TRAVEL SPEED INDICATOR

The ARSC set travel speed indicator indicates the travel speed
which is set with the ARSC travel speed set lever.
When the set travel speed has been reset, “-” is displayed.
When the “ARSC Setting” is “OFF”, the set travel speed goes
out.
3-40
ECO GUIDANCE
ECO guidance is displayed during the operation and supports the fuel saving operation.
The details of the guidance are as follows.
EXCESSIVE IDLING GUIDANCE

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

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

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

Even when the engine speed reaches shift up speed during
traveling, if the upshift disable condition by gear shift lever con-
tinues for 5 seconds or longer, the upshift recommendation
message is displayed on the machine monitor.
This message is as well displayed when the machine travels in
reverse. It is, however, not displayed when the machine travels
downhill with retarder operation.
When traveling on a flat road, reduce the fuel consumption by
shifting up the gear and decreasing the engine speed.
The upshift recommendation message goes out automatically
after 10 seconds.
3-41
GUIDANCE TO AVOID ACCELERATION OPERATION DURING DUMP BODY

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

If the steering oil pressure is relieved for more than 10 sec-
onds, the steering relief restriction message is displayed on the
machine monitor.
Relieving of steering oil pressure occurs when you steer the
wheel fully to the right or left.
Restrict the forcible steering operation to reduce the fuel con-
sumption.
The steering relief restriction message goes out automatically
after 10 seconds.
REMARK
Display/non-display of ECO guidance can be switched.
3-42
METER DISPLAY
SPEEDOMETER
The speedometer indicates the travel speed of the machine.
ENGINE TACHOMETER
The engine tachometer indicates the engine speed.
If the engine speed is higher than the allowable range during
operation, the engine overrun caution lamp lights up in red.
Operate the machine with moderate engine speed and travel
speed.
ENGINE COOLANT TEMPERATURE GAUGE

Engine coolant temperature gauge shows the engine coolant
temperature.
When the indicator is in white range (A) or green range (B) dur-
ing operation, it is normal.
If the engine coolant temperature rises higher than the allowa-
ble range, the engine coolant temperature caution lamp lights
up in red, and action level “L02” is displayed.
NEUTRAL position (N), and run the engine at a medium speed with no load until the engine coolant temperature
caution lamp goes out.
TORQUE CONVERTER OIL TEMPERATURE GAUGE

The torque converter oil temperature gauge indicates the tor-
que converter oil temperature.
When the indicator is in green range (B) during operation, it is
normal.
If the indicator is in red range (C), the torque converter oil tem-
perature caution lamp lights up in red, and action level “L02” is
displayed.
NEUTRAL position (N), and run the engine at a medium speed with no load until the torque converter oil tem-
perature caution lamp goes out.
3-43
RETARDER OIL TEMPERATURE GAUGE

The retarder oil temperature gauge indicates the retarder oil
temperature.
When the indicator is in green range (B) during operation, it is
normal.
If the indicator is in red range (C), the retarder oil temperature
caution lamp lights up in red, and action level “L02” is dis-
played.
with no load until retarder oil temperature caution lamp goes
out.
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 313 ℓ or less {82.7 U.S.Gal or less} . Check the
fuel level, and add fuel.
ECO GAUGE
ECO gauge indicates the instantaneous fuel consumption (fuel
consumption rate at each moment).
The instantaneous fuel consumption varies depending on the
operation ways (accelerator operation, travel speed, gear
speed, etc.) and the given load during travel (load weight,
slope, ground condition, etc.).
As the indication of ECO gauge is higher, the fuel consumption
is higher.
Reduce the indication of gauge to the level where there is no
adverse effect on the operation, it leads to energy saving oper-
ation to reduce the fuel consumption.
REMARK
Even if the indication of ECO gauge is in orange range (A), it is not a machine trouble.
Target fuel consumption (B) displayed by ECO gauge can be changed as necessary.
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L.H. AND R.H. METER DISPLAY

The L.H. meter indicates either of the following which can be selected.
• Service meter
• Odometer
• Clock
The R.H. meter indicates either of the following which can be selected.
• Fuel consumption gauge
• Service meter
• Odometer
• Clock
Service meter display
Indicates the integrated operating hours of the machine.
When the engine has run, the service meter advances even if
the machine is not being operated.
The service meter advances by 0.1 for 6 minutes of engine run-
ning and by 1 for 1 hour of engine running, regardless of the
engine speed.
Odometer display
Indicates the total distance that machine has traveled in unit of
km.
Clock display
Indicates the current time.
12-hour system display
The clock is displayed in 12-hour mode with am or pm.
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24-hour system display

The clock is displayed in 24-hour mode.
REMARK
If the battery is disconnected for a long period for storage etc., the time information may be lost.
Fuel consumption gauge display
Indicates the average fuel consumption of the machine.
One day display
Displays the average fuel consumption of the period (from the
operation starting time until now during 0:00 a.m. of the day
through 0:00 a.m. of the next day).
Split (under measurement) display

Displays the split fuel consumption under measurement.
Split (measurement is stopped) display

Displays the value after the measurement of split fuel con-
sumption is stopped.
REMARK
Display on the fuel consumption gauge can be switched between the average fuel consumption per day and the
average fuel consumption during a selected period (split fuel consumption).
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PAYLOAD METER DISPLAY

Payload meter display is a display of the payload value during
the statistics which is being processed by payload meter func-
tion.
Payload meter display may not be as accurate as that of the
data which is saved as the operated load.
The value displayed on the payload display is provided as a
reference.
3-47
SWITCH PANEL
(1) UP switch (5) RETURN switch

(2) Air conditioner switch and numeric keypad (6) DOWN switch
(3) Menu switch (7) Guidance icon
(4) ENTER switch
These are used for the operation of the machine monitor or air conditioner.
The function of each switch varies depending on the screen of the machine monitor.
REMARK
• The switches available 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.
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MENU SWITCH
When the menu switch is pressed on the standard screen, the
following user menu screen is displayed. However, the user
menu screen is not displayed during traveling.
For the user menu, see “USER MENU (3-51)”.
When normal
“ECO Guidance” menu screen is displayed.
When the maintenance caution lamp lights up
“Maintenance” menu screen is displayed.
When the message display lights up
Message display menu screen is displayed.
When the menu switch is pressed on the user menu screen, the menu screen changes.
ENTER SWITCH
Pressing ENTER switch on the user menu screen decides any
selection and changes, and proceeds to the next screen.
When ENTER switch is pressed on the standard screen with a
warning message displayed, “Error List” screen is displayed.
RETURN SWITCH
Pressing RETURN switch cancels a selection or changes, and
returns the screen to the previous screen or the standard
screen.
UP SWITCH
Pressing UP switch moves the cursor up by one item. When on
the top line, the cursor moves to the bottom line.
On the value input screen, the value is increased by one.
3-49
DOWN SWITCH
Pressing DOWN switch moves the cursor down by one item.
When on the last line, it moves to the first line.
On the value input screen, the value is decreased by one.
AIR CONDITIONER SWITCH AND NUMERIC KEYPAD

The air conditioner switch and numeric keypad consist of 10
types of switches.
Press the air conditioner switch and numeric keypad, and re-
lease them. The confirmation sound is heard when they are re-
leased.
Air conditioner switch

For explanation of each air conditioner switch, see “EXPLANATION OF AIR CONDITIONER EQUIPMENT
(3-255)”.
Numeric keypad function
These switches can be used as a numeric keypad to enter a numeric value such as a password.
Press the air conditioner switch and numeric keypad to enter the numerals 0 to 9, which is indicated at the lower
right of each switch.
3-50
USER MENU
When the menu switch is pressed on the standard screen while
the machine is stopped, the user menu screen is displayed to
enable you to configure and confirm the machine settings.
The user menu consists of the following kinds. The menu

screen can be changed by pressing the menu switch.
(A): “ECO Guidance”
(B): “Machine Setting / Information”
(C): “Maintenance”
(D): “Monitor Setting”
(E): Message display
These menus (A) to (E) are used for setting and confirming the
following items:
(A) “ECO Guidance”
• Check of “Operation Records”
• Check of “ECO Guidance Records”
• Check and resetting of “Average Fuel Consumption Re-
cord”
• “Configurations”
(B) “Machine Setting / Information”

• Display and setting of “Payload Meter”
• “TCS Setting”
• “ARSC Setting”
• Display and resetting of “Dumping Counter” (if equipped)
• Display of “Reverse Travel Odometer”
• Display and resetting of “Trip Meter”
• “F1 Start at D Position Setting”
• “RL/RH Setting”
• “Retarder Lever Release Sound Setting”
3-51
(C) “Maintenance”
• Check and resetting of various maintenance remaining
times
(D) “Monitor Setting”

• “Rear View Monitor Setting”
• “KomVision Setting”
• “Meter Select”
• “Screen Adjustment”
• “Clock Adjustment”
• “Language”
• “Operator ID”
(E) Message display

• Check of message contents and reply to message
On the user menu screen, you can perform the following opera-
tions with the switches.
(1) UP switch
Moves to the item above.
When on the first item, it moves to the last item.
(2) DOWN switch
Moves to the item below.
When on the last item, moves to the first item.
(3) RETURN switch
Cancels a selection or changes, and returns to the previous screen or the standard screen.
(4) ENTER switch
Enters any selection or changes and proceeds to the next screen.
(5) Menu switch
Moves to the right menu screen.
When on the right end menu screen, it moves to the left end menu screen.
3-52
REMARK
• If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the
previous screen or the standard screen.
• The user menu screen is displayed only while the machine is stopped completely.
• If the machine travels while the user menu screen is displayed, the screen automatically returns to the
standard screen.
3-53
ENERGY SAVING GUIDANCE

Each item of “ECO Guidance” menu screen is used for display-
ing and setting the notification relevant to energy saving.
• “Operation Records”
• “ECO Guidance Records”
• “Average Fuel Consumption Logs”
• “Configurations”
CHECK OPERATING RECORD

Select “Operation Records” on “ECO Guidance” menu screen,
then press ENTER switch (4).
On “Operation Records” screen, the following information on a
daily basis or during the split measurement period is displayed.
• “Working Hours (Engine On)”: The time during which the
engine is running
• “Average Fuel Consumption”: Average fuel consumption
while the engine is running
• “Actual Working Hours”: The time spent for traveling, oper-
ation of work equipment and operation of accelerator
• “Ave. Fuel Consumption (Actual Working)”: Average fuel
consumption during actual work
• “Fuel Consumption”: The amount of fuel consumed
• “Idling Hours”: The time during which the machine is stop-
ped, and the work equipment and accelerator are not oper-
ated
• “Economy Mode Ratio”: Percentage of E mode operation
in the engine-running hours
REMARK
The displayed values of fuel consumption and fuel efficiency
may differ from the actual values depending on the machine
operating conditions (fuel, weather or work contents, etc.) at
the customers.
Operations on “Operation Records” screen
When “Average Fuel Consumption Display” is set to “1 Day”.
“1 Day” is displayed on the place shown with arrow in “Opera-
tion Records” screen.
You can perform the following operations with the switches (1)
to (3) on the switch panel.
(1) UP switch
Moves to the previous item (1 line above).
When it is on the first line, it moves to the last line.
(2) DOWN switch
Moves to the next item (1 line below).
When it is on the last line, it moves to the first line.
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(3) RETURN switch

The screen returns to “ECO Guidance” menu screen.
When “Average Fuel Consumption Display” is set to “Split Time”, and the split
time is measured
(A) Display during measurement
(B) Date and time when measurement is started
To stop the split measurement, see the guidance icon, then
press ENTER switch (4).
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
Stops the split measurement.
time is stopped
NOTICE
When the measurement is started, the previous split time measurement results (“Average Fuel Con-
sumption Display”, “Operation Records”, and “ECO Guidance Records”) are reset.
(C) Display while measurement is stopped
(D) Dates and times when the measurement is started and
stopped
To start the split time measurement, see the guidance icon,
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
Starts the split measurement.
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When the confirmation screen is displayed, press ENTER

switch (4) again to start the split measurement, or press RE-
TURN switch (3) to cancel the start.
CHECK ECO GUIDANCE RECORD

Select “ECO Guidance Records” on “ECO Guidance” menu
screen, then press ENTER switch (4).
On “ECO Guidance Records” screen, the frequency of display
of the ECO guidance on a daily basis or during the split meas-
urement period and “Operational Advice” are displayed.
REMARK
• In “Operational Advice” section, the advice is displayed for
the ECO guidance appeared most frequently.
• The ECO guidance count increases when display condi-
tions are satisfied even if the ECO guidance is not dis-
played.
Operations on “ECO Guidance Records” screen

When “Average Fuel Consumption Display” is set to “1 Day”
“1 Day” is displayed on the place shown with arrow in “ECO
Guidance Records” screen.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
3-56
time is measured
(A) Display during measurement
(B) Date and time when measurement is started
To stop the split measurement, see the guidance icon, then
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
Stops the split measurement.
time is stopped
NOTICE
When the measurement is started, the previous split time measurement results (“Average Fuel Con-
sumption Display”, “Operation Records”, and “ECO Guidance Records”) are reset.
(C) Display while measurement is stopped
(D) Dates and times when the measurement is started and
stopped
To start the split time measurement, see the guidance icon,
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
Starts the split measurement.
3-57
When the confirmation screen is displayed, press ENTER

switch (4) again to start the split measurement, or press RE-
TURN switch (3) to cancel the start.
CHECK FUEL CONSUMPTION RECORD

Select “Average Fuel Consumption Logs” on “ECO Guidance”
menu screen, then press ENTER switch (4).
On “Average Fuel Consumption Logs” screen, the graph of
hourly average fuel consumption during “Last 12 hours” or the
graph of daily average fuel consumption during “Last 7 days” is
displayed.
REMARK
The displayed values of fuel consumption and fuel efficiency
may differ from the actual values depending on the machine
operating conditions at the customers (fuel, weather or work
contents, etc.).
Operations on “Average Fuel Consumption Logs” screen

(3) RETURN switch
(4) ENTER switch
Clears the graph data.
(5) Menu switch
Switches the graphical displays of the average fuel consump-
tion.
REMARK
The displayed values of fuel consumption and fuel efficiency may differ from the actual values depending on the
machine operating conditions (fuel, weather or work contents, etc.) at the customers.
Switching of the displayed graph
If you press the menu switch (5) on “Average Fuel Consumption Logs” screen, graph display changes between
the hourly fuel consumption during the last 12 hours and the daily fuel consumption during the last 7 days.
3-58
• Last 12 hours display
• Last 7 days display
REMARK
The graph of “Last 12 hours” is updated every hour of the service meter reading.
The graph of “Last 7 days” is updated every day.
Deletion of “Average Fuel Consumption Logs”
1. When ENTER switch (4) is pressed, the confirmation
screen is displayed.
2. When ENTER switch (4) is pressed, graph data of “Last 12
hours” and “Last 7 days” are both deleted, and the screen
returns to “Average Fuel Consumption Logs” screen.
REMARK
When canceling the data deletion (clear), press RETURN
switch (3).
3-59
CHANGE DISPLAY SETTING

Select “Configurations” on “ECO Guidance” menu screen, then
You can perform the following operations on “Configurations”
menu.
• Setting for “Average Fuel Consumption Display”
• Switching display/non-display of “ECO Gauge”
• Setting for “ECO Gauge Target Value”
• Switching display/non-display of ECO Guidance
• Switching display/non-display of “ECO Guidance at key
off”
Operations on “Configurations” screen

(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
Displays the setting screen for the selected item.
3-60
SET DISPLAY OF FUEL CONSUMPTION GAUGE

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

tions” menu screen, then press ENTER switch (4).
2. Select “1 Day” or “Split Time”, then press ENTER switch

(4).
The default is “1 Day”.
To cancel, press RETURN switch (3).
“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.
It will be reset at 0.00 a.m. of the next day.
“Split Time”
Displays the average fuel consumption on the split measurement period basis (after the measurement is
started until it is finished).
Select “Split Time” to start the split measurement automatically.
You can perform the following operations with the switches (1) to (4) on the switch panel.
(1) UP switch
(2) DOWN switch
3-61

(3) RETURN switch
Cancels the selected change and returns the screen to “Configurations” menu screen.
(4) ENTER switch
Allocates the selected change and returns the screen to “Configurations” menu screen.
REMARK
Setting of “1 Day” or “Split Time” is also applied to the display of “Operation Records” and “ECO Guidance
Records”.
SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE

Display/non-display of ECO gauge can be switched.
1. Select “ECO Gauge” on “Configurations” menu screen,

2. “ECO Gauge” screen is displayed.

Select “ON” or “OFF”, then press ENTER switch (4).
“ON”
Displays the ECO gauge.
“OFF”
Does not display the ECO gauge.
You can perform the following operations with the switches
(1) to (4) on the switch panel.
(1) UP switch
3-62

(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
REMARK
If “OFF” is selected on “ECO Gauge” screen, the items of “ECO
Gauge Target Value” are not displayed.
SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE

ECO gauge display fuel target value (A) (the upper limit value
of the green range) can be changed.
1. Select “ECO Gauge Target Value” on “Configurations”

3-63
2. Use UP switch (1) or DOWN switch (2) to set the value,

(1) UP switch
Increases the target fuel consumption value by 1 ℓ/h.
(2) DOWN switch
Decreases the target fuel consumption value by 1 ℓ/h.
(3) RETURN switch
Cancels the target fuel consumption value setting, and returns the screen to “Configurations” menu screen.
(4) ENTER switch
Allocates the target fuel consumption value setting, and returns the screen to “Configurations” menu
screen.
The default is 232 ℓ/h.
REMARK
If the target fuel value is increased, the fuel consumption indicated when the ECO gauge is at the maximum is
also increased commensurately.
If the target fuel value is decreased, the fuel consumption indicated when the ECO gauge is at the maximum is
also decreased commensurately.
SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE

Display/non-display of ECO guidance displayed on the stand-
ard screen can be switched.
1. Select “ECO Gauge” on “Configurations” menu screen,

3-64
2. “ECO Guidance” screen is displayed.

“ON”
Displays the ECO guidance.
“OFF”
Does not display the ECO guidance.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
The default is “ON”.
REMARK
If “ECO Guidance” is set to “OFF”, the items of “ECO Guidance at key OFF” and “ECO Guidance Records”
are not displayed, but “ECO Guidance Records” is not reset.
SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF

The display/non-display of “Operational Advice” indicated on
the end screen when the key is turned to OFF position can be
switched.
In “Operational Advice” section indicated on the end screen,
the advice to the ECO guidance that appeared most frequently
after turning the starting switch to ON position is displayed.
3-65
1. Select “ECO Guidance at key off” on “Configurations”

2. “ECO Guidance at key OFF” screen is displayed.

“ON”
Displays the operational advice on the end screen.
“OFF”
Does not display the operational advice on the end screen.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
3-66
MACHINE SETTINGS
On each item of “Machine Setting / Information” menu screen, you can perform the settings related to the ma-
chine body.
• Display and setting of “Payload Meter”
• “TCS Setting”
• “ARSC Setting”
• Display and resetting of “Dumping Counter” (if equipped)
• Display of “Reverse Travel Odometer”
• Display and resetting of “Trip Meter”
• “F1 Start at D Position Setting”
• “RL/RH Setting”
• “Retarder Lever Release Sound Setting”
PAYLOAD METER
You can display and set the following items related to the pay-
load meter.
• “Total payload/number of cycles”
• “Load and fuel efficiency record”
• “Machine ID”
• “Open ID”
• “Calibration”
3-67
KTCS SYSTEM SETTING

You can set ON or OFF of the KTCS system.
1. Select “TCS Setting”, then press ENTER switch (4).
2. Select “ON” or “OFF”, then press ENTER switch (4).

“OFF”
KTCS does not operate.
The KTCS off pilot lamp lights up.
“ON”
KTCS operates automatically.
REMARK
This setting is maintained even after turning the starting switch
to OFF position.
3-68
ARSC SETTING
You can set ON or OFF of the ARSC system.
1. Select “ARSC Setting”, then press ENTER switch (4).

“OFF”
The ARSC does not operate.
The ARSC off pilot lamp lights up.
“ON”
The ARSC is ready to operate.
The ARSC pilot lamp lights up.
REMARK
to OFF position.
3-69
DUMPING COUNTER
(if equipped)
The dumping counter is the function that automatically counts and displays the number of loads dumped.
If the dumping counter is not installed on the machine, “Dumping Counter” is not displayed.
The number of times can be reset according to the following procedure.
1. Select “Dumping Counter”, then press ENTER switch (4).
2. Press ENTER switch (4) to reset, or press RETURN switch

(3) to cancel the resetting.
REVERSE TRAVEL ODOMETER

The total reverse travel distance can be checked with “Reverse
Travel Odometer”.
3-70
TRIP METER
The overall travel distance after the previous resetting can be
checked with “Trip Meter”.
Method for resetting “Trip Meter”

1. Select “Trip Meter” on “Machine Setting / Information”
2. The screen changes to “Trip Meter” reset confirmation

screen.
Press ENTER switch (4), and “Trip Meter” is reset. The
screen returns to “Machine Setting / Information” menu
screen.
REMARK
When reset is not necessary, press RETURN switch (3).
3-71
D RANGE F1 START SETTING

Use this setting to change the starting gear speed when the gear shift lever is set to D position.
1. Select “F1 Start at D Position Setting”, then press ENTER
switch (4).
2. Select “F1” or “F2”, then press ENTER switch (4).

“F1”
Machine starts traveling at the 1st speed when the gear
shift lever is set to D position.
“F2”
Machine starts traveling at the 2nd speed when the gear
shift lever is set to D position. (Normal)
NOTICE
Select “F2” usually.
If the machine travels in “F1” while F1 is not necessary,
the service life of the machine may be shortened.
REMARK
This setting is maintained even after turning the starting switch to OFF position.
The default is “F2”.
3-72
RL/RH SETTING
Use this setting for shifting the gear speed of the reverse travel.
1. Select “RL/RH Setting”, then press ENTER switch (4).
2. Select “RL” or “RH”, then press ENTER switch (4).

“RL”
Machine travels in reverse with gear speed at RL.
“RH”
Machine travels in reverse with gear speed at RH.
3. Turn the starting switch to OFF position once when the
setting has been changed.
The setting will be enabled after the starting switch is
turned to OFF position.
REMARK
This setting is maintained even after turning the starting switch to OFF position.
The default is “RH”.
3-73
RETARDER CONTROL LEVER CANCEL SOUND SETTING

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

“ON”
Generates the release sound.
“OFF”
Does not generate the release sound.
REMARK
to OFF position.
3-74
MAINTENANCE SCREEN SETTING

On each item of “Maintenance” menu screen, the notification
related to maintenance can be displayed and set.
The items on "Maintenance" display are as follows.
A B
Air Cleaner Cleaning / Change -
Engine Oil 250
Engine Oil Filter 250
Fuel Pre Filter 500
Fuel Main Filter 500
Transmission Oil Filter 500
Transmission Oil 1000
Brake System Oil Filter 1000
Brake Cooling Oil Filter 1000
Brake Oil 2000
Hydraulic Oil Filter 2000
Hydraulic Oil Tank Breather 2000
Differential Oil 2000
Final Drive Oil 2000
Hydraulic Oil 4000
A: Maintenance item
B: Default maintenance interval settings (h)
C: Time remaining to maintenance (h)
When the time remaining to the next Maintenance for any item is less than the maintenance notice time (initial
setting: 30 hours), the remaining time display (C) is displayed in yellow.
When the time remaining to the maintenance becomes 0 hours, the remaining time display (C) is displayed in
red. The time after the replacement interval is indicated with the negative symbol.
If any item is displayed in red, perform the maintenance for it immediately.
REMARK
The replacement interval in “Air Cleaner Cleaning / Change” is not set initially.
If you want to change the setting for the maintenance interval and the maintenance notice time, consult your
Komatsu distributor.
3-75
METHOD FOR RESETTING REMAINING TIME FOR MAINTENANCE

After performing the maintenance, reset the remaining time for maintenance according to the following proce-
dure.
1. Select an item to reset the remaining time on “Mainte-
nance” menu screen, then hold down ENTER switch (4)
for 1.5 seconds or longer.
REMARK
If ENTER switch (4) is not pressed for enough time, the
switch operating sound can be heard, but the screen does
not switch to “Maintenance Time Reset” screen.
2. When a usage limitation password has been set, the pass-

word input screen is displayed.
Input the usage limitation password by using the numeric
keypad (6), then press ENTER switch (4).
REMARK
For the setting, changing, or canceling the password, ask
your Komatsu distributor.
3. The screen changes to “Maintenance Time Reset” screen.

Press ENTER switch (4) on “Maintenance Time Reset”
screen, and the screen changes to the reconfirmation
screen for “Maintenance Time Reset”.
REMARK
When reset is not necessary, press RETURN switch (3).
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4. Press ENTER switch (4) on the reconfirmation screen for

“Maintenance Time Reset”, the remaining time is reset and
the screen returns to “Maintenance” menu screen.
REMARK
• When reset is not necessary, press RETURN switch
(3).
• If the remaining time and the replacement interval are
equal, the remaining time cannot be reset.
3-77
MONITOR SETTINGS
On each item of “Monitor Setting” menu screen, you can per-
form the settings for the machine monitor.
• “Rear View Monitor Setting”
• “KomVision Setting”
• “Meter Select”
• “Screen Adjustment”
• “Clock Adjustment”
• “Language”
• “Operator ID”
REAR VIEW MONITOR SETTING

This is used to set the rearview monitor.
1. Select “Rear View Monitor Setting” on “Monitor Setting”
2. “Rear View Monitor Setting” menu screen is displayed.

(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the selected item, and returns the screen to “Monitor Setting” menu screen.
(4) ENTER switch
The screen changes to the setting screen for the selected item.
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GUIDE LINE DISPLAY

This is used to change the display or non-display of the reference line on the rearview monitor.
1. Select “Reference Line” on “Rear View Monitor Setting”
2. “Reference Line” screen is displayed.

Select “ON” or “OFF” on “Reference Line” screen, then
“ON”
Displays the reference line.
“OFF”
Hides the reference line.
REMARK
The setting of “Reference Line” is maintained even after turning
the starting switch to OFF position.
The default is “OFF”.
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REAR VIEW MONITOR CONSTANT DISPLAY

The display method of rearview monitor can be changed.
1. Select “Rear View Continuous Display” on “Rear View
Monitor Setting” menu screen, then press ENTER switch
(4).
2. “Rear View Continuous Display” screen is displayed.

Select “ON” or “OFF” on “Rear View Continuous Display”
“OFF”
During the KomVision monitor start-up, the images on the
rearview monitor are displayed when traveling in reverse.
After the KomVision monitor has been started, the rear-
view monitor is not displayed.
“ON”
The images on the rearview monitor are continuously displayed.
REMARK
The setting of “Rear View Continuous Display” is maintained even after turning the starting switch to OFF posi-
tion.
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KomVision SETTING
Perform the setting of the KomVision.
1. Select “KomVision Setting” on “Monitor Setting” menu
2. “KomVision Setting” menu screen is displayed.

(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
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REFERENCE LINE DISPLAY

This is used to change the display or non-display of the reference line on the KomVision monitor.
1. Select “Reference Line Display” on “KomVision Setting”
2. “Reference Line Display” screen is displayed.

Select “ON” or “OFF” on “Reference Line Display” screen,
“ON”
Displays the reference line.
“OFF”
Hides the reference line.
REMARK
The setting of “Reference Line Display” is maintained even af-
ter turning the starting switch to OFF position.
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SWITCH UNDER BODY DISPLAY

The display/non-display of the under body display on the KomVision monitor can be switched.
1. Select “Under Body Display” on “KomVision Setting” menu
2. “Under Body Display” screen is displayed.

Select “ON” or “OFF” on “Under Body Display” screen,
“ON”
The under body display is displayed.
“OFF”
The under body display is not displayed.
REMARK
The setting of “Under Body Display” is maintained even after
turning the starting switch to OFF position.
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SWITCH FORCED DISPLAY

Display/non-display of the KomVision monitor display can be switched while the machine is traveling at high
speed.
1. Select “Forced Display” on “KomVision Setting” menu
2. “Forced Display” screen is displayed.

Select “ON” or “OFF” on “Forced Display” screen, then
“ON”
KomVision monitor image is displayed when the travel
speed is 15 km/h or higher {9.3 MPH or higher} .
“OFF”
KomVision monitor image is not displayed when the travel
speed is 15 km/h or higher {9.3 MPH or higher} .
REMARK
• KomVision monitor image is displayed when 15 km/h or higher {9.3 MPH or higher} with the forced display
“ON”, however, the radar does not detect obstacles.
• The definition of travel speed to switch the display/non display of the KomVision monitor can be changed
according to the situation. If change is required, ask your Komatsu distributor.
• The setting of “Forced Display” is maintained even after turning the starting switch to OFF position.
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METER DISPLAY SELECTION

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

2. “Meter Select” menu screen is displayed.

(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
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SELECT L.H. METER DISPLAY

This is used for the selection of the items to be displayed on the L.H. meter display.
1. Select “Left-meter Select” on “Meter Select” menu screen,
2. “Left-meter Select” screen is displayed.

Select the item to be displayed from the following 3 items
on “Left-meter Select” screen, then press ENTER switch
(4).
“SMR : Service Meter”
Displays the service meter reading.
“ODO : Odometer”
Displays the odometer reading.
“CLK : Clock”
Displays the clock.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the selected item, and returns the screen to “Meter Select” menu screen.
(4) ENTER switch
REMARK
Default setting of L.H. meter is “SMR : Service Meter”.
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SELECT R.H. METER DISPLAY

This is used for the selection of the items to be indicated on the R.H. meter display.
1. Select “Right-meter Select” on “Meter Select” menu
2. “Right-meter Select” screen is displayed.

Select the item to be displayed from the following 4 items
on “Right-meter Select” screen, then press ENTER switch
(4).
“FUEL : Average Fuel Consumption”
Displays the fuel consumption gauge.
“SMR : Service Meter”
Displays the service meter reading.
“ODO : Odometer”
Displays the odometer reading.
“CLK : Clock”
Displays the clock.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the selected item, and returns the screen to “Meter Select” menu screen.
(4) ENTER switch
REMARK
Default setting of R.H. Meter is “FUEL : Average Fuel Consumption”.
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SCREEN ADJUSTMENT
The brightness of the machine monitor can be adjusted.
1. Select “Screen Adjustment” on “Monitor Setting” menu
2. “Screen Adjustment” screen is displayed.

Press UP switch (1) and DOWN switch (2) on “Screen Ad-
justment” screen to adjust the brightness, then press EN-
TER switch (4).
(1) UP switch
Brightness increases. (Moves the indicator to the right by
one division.)
(2) DOWN switch
Brightness decreases. (Moves the indicator to the left by one division.)
(3) RETURN switch
Cancels the change and returns the screen to “Monitor Setting” menu screen.
(4) ENTER switch
Allocates the change and returns the screen to “Monitor Setting” menu screen.
(5) Menu switch
The brightness returns to the initial state.
REMARK
• The brightness in the day and night modes can be adjusted individually.
When the screen is adjusted with the lamp switch in OFF position, the brightness in the day mode can be
adjusted.
When the screen is adjusted with the lamp switch in ON position, and when the monitor brightness selector
switch is set to the night mode, the brightness in the night mode can be adjusted.
• The brightness of night illumination for the switch panel, gear shift lever, and operation switches is adjusted
synchronously with the brightness of the machine monitor.
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CLOCK ADJUSTMENT
You can change the setting of the clock displayed on the standard screen.
1. Select “Clock Adjustment” on “Monitor Setting” menu
2. “Clock Adjustment” menu screen is displayed.

The items related to “Clock Adjustment” are the following 5
items.
• “GPS Synchronization”
• “Calendar”
• “Time”
• “12h/24h Mode”
• “Daylight Saving Time”
(1) UP switch
(2) DOWN switch
(3) RETURN switch
The screen returns to “Monitor Setting” menu screen.
(4) ENTER switch
Displays the setting screen for the selected item.
REMARK
After a long-term storage, the 2 items of “Calendar” and “Time” will be reset. Accordingly, they need to be read-
justed.
When “GPS Synchronization” is “ON”, the 2 items of “Calendar” and “Time” will be readjusted automatically.
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GPS SYNCHRONIZATION SETTING

For the machines equipped with KOMTRAX, you can configure the automatic adjustment of the date and time of
machine monitor in accordance with the clock of GPS on “GPS Synchronization” screen.
1. Select “GPS Synchronization” on “Clock Adjustment”
2. “GPS Synchronization” screen is displayed.

Select “ON” or “OFF” on “GPS Synchronization” screen,
3. “ON”
Date and time on the machine monitor are automatically
adjusted corresponding to the clock of GPS.
“OFF”
Date and time on the machine monitor are not synchron-
ized with the clock of GPS.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the selected setting, and returns the screen to “Clock Adjustment” menu screen.
(4) ENTER switch
Allocates the selected setting, and returns the screen to “Clock Adjustment” menu screen.
REMARK
• When the machine is in the environment where the radio waves from GPS cannot be received, such as
inside of a building, the automatic setting function may not work.
• You cannot select an item in “Calendar” and “Time” when “GPS Synchronization” is “ON”.
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CALENDAR SETTING
The date of the machine monitor can be adjusted on “Calendar” screen.
REMARK
You cannot select “Calendar” while “GPS Synchronization” is “ON”.
1. Select “Calendar” on “Clock Adjustment” menu screen,
2. “Calendar” screen is displayed.

When year display (A) is highlighted in yellow, operate the
following switches to change the year display.
When there is no need to change the year setting, press
ENTER switch (4).
(1) UP switch
Advances the numeral by 1.
(2) DOWN switch
Puts back the numeral by 1.
(3) RETURN switch
Cancels the change and returns the screen to “Clock Adjustment” menu screen.
(4) ENTER switch
Proceeds to setting for month.
3. When month display (B) is highlighted in yellow, operate
the following switches to change the month display.
When there is no need to change the month setting, press
ENTER switch (4).
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the change and returns to setting for year.
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(4) ENTER switch

Proceeds to setting for day.
4. When day display (C) is highlighted in yellow, operate the
following switches to change the day display.
When there is no need to change the day setting, press
ENTER switch (4).
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels change and returns to setting for month.
(4) ENTER switch
Allocates the change and returns the screen to “Clock Adjustment” menu screen.
TIME SETTING
The time of the machine monitor can be adjusted on “Time” screen.
REMARK
You cannot select the items on “Time” when “GPS Synchronization” is ON.
1. Select “Time” on “Clock Adjustment” menu screen, then
2. “Time” screen is displayed.

When time display (D) is highlighted in yellow, operate the
switches as follows to change time display.
When it is not necessary to change the time setting, press
ENTER switch (4).
(1) UP switch
(2) DOWN switch
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(3) RETURN switch

Cancels the change and returns the screen to “Clock Adjustment” menu screen.
(4) ENTER switch
Proceeds to setting for minute.
3. When minute display (E) is highlighted in yellow, operate
the switches as follows to change minute display.
When it is not necessary to change minute display, press
ENTER switch (4).
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the change and returns the screen to the time setting screen.
(4) ENTER switch
Allocates the change and returns the screen to “Clock Adjustment” menu screen.
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12H/24H DISPLAY MODE

“12h/24h Mode” screen is used to set the display mode of the clock.
1. Select “12h/24h Mode” on “Clock Adjustment” menu
2. “12h/24h Mode” screen is displayed.

Select “12H” or “24H”, then press ENTER switch (4).
“12H”
Sets 12-hour display (AM, PM).
“24H”
Select 24-hour display.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
REMARK
The setting of the clock display mode is maintained even after turning the starting switch to OFF position.
The default is “24H”.
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DAYLIGHT SAVING TIME (SUMMER TIME) SETTING

On “Daylight Saving Time” screen, you can set the clock display forward 1 hour.
1. Select “Daylight Saving Time” on “Clock Adjustment” menu
2. “Daylight Saving Time” screen is displayed.

“ON”
The clock is displayed in the daylight saving time.
Displays the time 1 hour forward.
“OFF”
The clock is displayed in normal time.
(1) UP switch
(2) DOWN switch
(3) RETURN switch
(4) ENTER switch
REMARK
• Daylight saving time or summer time means moving the clock forward an hour to take advantage of the fact
that the sun rises early in summer in our daily life.
• The setting of “Daylight Saving Time” is maintained even after turning the starting switch to OFF position.
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LANGUAGE SETTINGS
The language displayed on the machine monitor can be selected.
The languages that can be selected are as follows.
English, Japanese, French, Spanish, German, Italian, Portuguese, Indonesian, Swedish, Dutch, Danish, Norwe-
gian, Finnish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Estonian, Latvian, Lithuanian, Russian,
Bulgarian, Serbian, Arabic, Greek, Turkish, Thai, Romanian, Croatian, Chinese, and Vietnamese
1. Select “Language” on “Monitor Setting” menu screen, then
2. “Language” screen is displayed.

Select the language to be displayed on “Language”
(1) UP switch
(2) DOWN switch
(3) RETURN switch
Cancels the selected setting, and returns the screen to “Monitor Setting” menu screen.
(4) ENTER switch
Allocates the selected setting, and returns the screen to “Monitor Setting” menu screen.
REMARK
The setting of “Language” is maintained even after turning the starting switch to OFF position.
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OPERATOR ID
On “Operator ID” screen, you can check and change “Operator ID” which is under identification.
When the operator identification function is disabled, “Operator ID” screen is not displayed on “Monitor Setting”
menu screen.
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

If the already registered ID is inputted when the starting switch
is turned to ON position, the identified ID is displayed in “Oper-
ator ID” column on “Monitor Setting” menu screen.
If “SKIP” is selected by pressing the menu switch when the

starting switch is turned to ON position, “****” is displayed in
“Operator ID” column on “Monitor Setting” menu screen.
1. Select “Operator ID” on “Monitor Setting” menu screen,

then press ENTER switch (4) for 1 second.
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2. “Operator ID Change” screen is displayed.

REMARK
When the ID change is not necessary, press RETURN
switch (3).
• Input the preregistered ID on “Operator ID Change”

screen by using the numeric keypad (6), and press
ENTER switch (4).
A message is displayed below, the screen returns to
“Monitor Setting” menu screen, and the identified ID is
changed.
The changed ID is displayed at “Operator ID” column
on “Monitor Setting” menu screen.
• When you press the menu switch (5) on “Operator ID

Change” screen, a message is displayed below and
the screen changes to “Monitor Setting” menu screen.
On “Monitor Setting” menu screen, “****” is displayed
in the column of “Operator ID”, and then the operator
ID becomes unidentified.
• On “Operator ID Change” screen, if you press ENTER

switch (4) after inputting the ID which is not registered,
a message is displayed at the bottom and the screen
changes to “Monitor Setting” menu screen and the ID
number is not changed.
• On “Operator ID Change” screen, if no switch is oper-
ated for 30 seconds or longer, the screen changes to
“Monitor Setting” menu screen and the ID number is
not changed.
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WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP

When the operator identification function is available without
skip, the identified ID number is not displayed in “Operator ID”
column on “Monitor Setting” menu screen.
1. Select “Operator ID” on “Monitor Setting” menu screen,
then press ENTER switch (4) for 1 second.
2. “Operator ID Change” screen is displayed.

REMARK
When the ID change is not necessary, press RETURN
switch (3).
• Input the preregistered ID on “Operator ID Change”

screen by using the numeric keypad (6), and press
ENTER switch (4).
A message is displayed below, the screen returns to
“Monitor Setting” menu screen, and the identified ID is
changed.
• On “Operator ID Change” screen, if you press ENTER

switch (4) after inputting the ID which is not registered,
a message is displayed at the bottom and the screen
changes to “Monitor Setting” menu screen and the ID
number is not changed.
• On “Operator ID Change” screen, if no switch is oper-
ated for 30 seconds or longer, the screen changes to
“Monitor Setting” menu screen and the ID number is
not changed.
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MESSAGE DISPLAY
On machines equipped with KOMTRAX, when the message pi-
lot lamp is lit on the standard screen, you can see the messag-
es from your Komatsu distributor on the mail check menu
screen by pressing the menu switch.
Message is distinguished as follows according to the lighting states of the message display.
Lights up in green
There is an unread message.
Lights up in blue
There is any read message to which no reply has been made.
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Not lit
There is no message.
REMARK
• When the message display lights up in blue, it means that no reply has been made yet to any read mes-
sage to your Komatsu distributor. Reply to the message in accordance with the replying method mentioned
below.
• If the starting switch is turned to OFF position when there is any unread message, the message will be dis-
played on the end screen, and when the monitor is started next time, the message will change to a read
message (the message display: lights up in blue).
• The message is deleted when it becomes out of date or when receiving a new message.
CHECK MESSAGE
Select the message confirmation menu screen, and you can
read the received message.
(A) Subject of message
When no message has been received, “No message.” is dis-
played.
(B) Serial No. of message
(C) Validity
(D) Text
(E) Reply field
When there is a message which requests reply, “Numeric Input:
[ ]” is displayed.
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REPLY TO MESSAGE
1. When sending a message in reply, input the selected item
number shown in the text of the message by using the air
conditioner switch and the numeric keypad (6).
(3) RETURN switch
If there is no input value, the screen returns to the stand-
ard screen.
If you input an incorrect number, press RETURN switch
(3), and you can clear an input character at a time.
(4) ENTER switch
Proceeds to the reply confirmation screen.
(6) Air conditioner switch and numeric keypad
The input number is displayed in “Numeric Input: [ ]” of the
reply field.
The air conditioner switch and the numeric keypad (6) cor-
respond to the numeral shown on the lower right of each
switch.
2. After inputting a selected item number, press ENTER
switch (4).
3. When “Proceed?” is displayed, press ENTER switch (4)

again.
The input value is sent out.
REMARK
To cancel sending, press RETURN switch (3).
The input value is cleared.
REMARK
If the message is replied, “Numeric Input Done.” is displayed
for it.
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OTHER FUNCTIONS OF MACHINE MONITOR

Confirming method of the service meter and odometer with the starting switch
in OFF position.
NOTICE
When machine is not under following operation, if the service meter and odometer monitor are dis-
played with the starting switch in OFF position, the machine probably has a failure, so ask your Komat-
su distributor for inspection.
The service meter and odometer can be displayed even if the machine monitor is not turned on.
1. Press UP switch (1) while holding down DOWN switch (3)
with the starting switch in OFF position.
Service meter (A) and odometer (B) are displayed while

both switches are held down.
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SWITCHES
(1) Monitor brightness selector switch (8) AISS LOW switch

(2) Side lamp switch (9) Engine power mode selector switch
(3) Staircase lighting switch (10) Manual greasing switch
(4) Fog lamp switch (if equipped) (11) Starting switch
(5) Horn button (12) Windshield wiper and window washer switch
(6) Hazard lamp switch (13) Lamp switch, dimmer switch, turn signal lever
(7) Secondary steering switch
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(14) Parking brake switch (25) Cigarette lighter
(15) KomVision monitor brightness adjustment switch (26) Engine shutdown secondary switch
(16) Screen mode selector switch (27) Power window switch (L.H.)
(17) Obstacle warning cancel switch (28) Power window switch (R.H.)
(18) Left front camera selector switch (29) Revolving lamp switch (if equipped)
(19) Left rear camera selector switch (30) Heated wire mirror switch (if equipped)
(20) Front camera selector switch (31) Heated wire glass switch (if equipped)
(21) Rear camera selector switch (32) Room lamp 2 switch
(22) Right front camera selector switch (33) Room lamp 1 switch
(23) Right rear camera selector switch (34) Rearview monitor brightness adjustment switch
(24) Radar check switch
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STARTING SWITCH
Starting switch is used to start or stop the engine.
(A) OFF position
The electrical current to the electrical system is cut, and the en-
gine stops.
The key can be inserted into or removed from the starting
switch.
REMARK
Even when the starting switch is at OFF position, the horn, haz-
ard lamp, secondary steering, and room lamp 1 can operate.
(B) ON position
Electric current flows through the charging circuit and lamp circuit.
Keep the starting switch key at ON position (B) while the engine is running.
(C) START position
This is the position to start the engine.
Hold the key at START position (C) while cranking, and release it immediately after the engine starts.
The key will return to ON position (B).
CIGARETTE LIGHTER
The cigarette lighter is used to light the cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after several seconds, then pull it out and use it to
light your cigarette.
If the cigarette lighter is removed, the socket can be used as an
84 W (12 V x 7 A) power supply.
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LAMP SWITCH
The lamp switch is used to turn on and off the headlamp (low beam), clearance lamp, and tail lamp.
(A) OFF position
The lamps go out.
(B) ON position
Clearance lamp and tail lamp light up.
(C) ON (headlamp lighting) position
Clearance lamp, tail lamp and headlamp (low beam) light up.
When the lamp switch is turned on, the clearance pilot lamp
and the night lamp for switches light up.
When the monitor brightness selector switch is set to the night
mode, the machine monitor, KomVision monitor, and rearview monitor are dimmed.
The lamp switch can be switched regardless of the position of the turn signal lever.
DIMMER SWITCH
The dimmer switch is used to turn on or off the headlamps (high beam).
When the lamp switch is turned 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 the original posi-
tion (B).
When the lamp switch is turned off
Only the headlamp (high beam) lights up while the dimmer
switch is operated up to (A).
When the headlamps (high beam) are lit, the headlamp (high
beam) pilot lamp lights up.
TURN SIGNAL LEVER

The turn signal lever is used to flash the turn signal lamps.
(R) Right turn
Push the lever forward
(L) Left turn
Pull the lever backward
When the lever is operated, the turn signal pilot lamp also
flashes.
The lever returns automatically when the steering wheel is
turned back. If the lever does not return, move it by hand.
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WIPER, WINDOW WASHER SWITCH

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

The monitor brightness selector switch is used to select the
brightness (luminosity) of the machine monitor, rearview moni-
tor, and KomVision monitor while lamp switch is turned on.
When operating the machine with the headlamp lit during the
day, if the monitor brightness selector switch is set to the day
position (A), monitor screen does not lose the brightness.
(A) Day position
Sets the machine monitor, rearview monitor, and KomVision
monitor to the day mode.
(B) Night position
Sets the machine monitor, rearview monitor, and KomVision monitor to the night mode.
Monitor screen loses the brightness.
REMARK
When the lamp switch is turned to OFF position, operating this switch does not change the brightness.
SWITCH FOR MIRROR WITH HEATED WIRE

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

Hazard lamp switch is used when it is unavoidable to place the
machine on the road due to any abnormality such as failure,
etc.
Position (A)
The right and left turn signal lamps and right and left turn signal
pilot lamps flash.
Position (B)
The right and left turn signal lamps and right and left turn signal
pilot lamps go out.
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SECONDARY STEERING SWITCH

k WARNING
Do not use the secondary steering more than 90 seconds to avoid damage or fire.
The secondary steering switch is used to operate the secon-

dary steering.
Pressing this switch operates the secondary steering and ena-
bles the operator to steer the machine.
When this switch is turned “ON” or the secondary steering op-
erates automatically, the pilot lamp (red) in the switch and the
secondary steering pilot lamp light up.
When using the secondary steering, limit the travel speed to
5 km/h or lower {3.1 MPH or lower} .
The secondary steering operates automatically in the following
cases.
• When the steering oil pressure drops abnormally
• When the engine stops during operation
When the secondary steering operates, stop the machine immediately and check it.
When the engine stops, if the starting switch is at ON position and the parking brake switch is at “TRAVEL”
position, the secondary steering operates automatically after 1 second. To prevent this, set the parking brake
switch to “PARKING” position.
REARVIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH

The rearview monitor brightness adjustment switch is used to
adjust the brightness of the rearview monitor.
The brightness in the day and night modes can be adjusted in-
dividually.
Position (A)
The rearview monitor becomes brighter.
Position (B)
The rearview monitor becomes darker.
KomVision MONITOR BRIGHTNESS ADJUSTMENT SWITCH

KomVision monitor brightness adjustment switch is used to ad-
just the brightness of KomVision monitor.
The brightness in the day and night modes can be adjusted in-
dividually.
Position (A)
Increases the brightness of KomVision monitor
Position (B)
Decreases the brightness of KomVision monitor
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AISS LOW SWITCH

AISS LOW switch is used to switch the AISS functions.
AISS (Automatic Idling Setting System) adjusts the low idle
speed automatically depending on the operating situations.
(A) AISS LOW switch ON
Use this switch position when fine start control is needed such
as when putting the machine into the garage.
The idle speed is fixed to a lower level.
(B) AISS LOW switch OFF
Use this switch position for the normal operation.
If the parking brake or retarder brake is applied while the AISS LOW switch is in OFF position (B), the idle
speed is automatically set to a lower level. When the parking brake or retarder brake is released, the idle speed
is automatically set to a higher level.
ENGINE POWER MODE SELECTOR SWITCH

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

Greasing is started by pressing the manual greasing switch re-
gardless of the timing which is set by the timer of the auto-
greasing system.
If an abnormality occurs, inside of the manual greasing switch
lights up.
Ask your Komatsu distributor for inspection if it lights up.
3-111
PARKING BRAKE SWITCH

k WARNING
Apply the parking brake when you park the machine.
Depress the brake pedal until the warning lamp comes on.
NOTICE
• Do not use the parking brake switch for braking when traveling except for an emergency. If the park-
ing brake switch is used during traveling, the parking brake may break and a serious accident may
result.
Stop the machine, and then apply the parking brake.
If the parking brake was used as a secondary brake when the machine was traveling, ask your Ko-
matsu distributor for inspection of the parking brake system.
• During the loading operations apply the parking brake.
The parking brake switch is used to apply and release the park-
ing brake.
(A) PARKING position
The parking brake is applied.
When the parking brake switch is set to “PARKING” position
(A), the parking brake pilot lamp lights up on the machine moni-
tor.
When the parking brake switch is set to “PARKING” position
(A), if the gear shift lever is at any position other than NEU-
TRAL position (N), the centralized warning lamp lights up and
(B) TRAVEL position
The parking brake is released.
REMARK
If the engine is stopped while the parking brake switch is kept
in “TRAVEL” position (B), the parking brake is applied automat-
ically.
When starting the engine again, set the parking brake switch to
“PARKING” position (A), and then set it back to “TRAVEL” posi-
tion (B) to release the parking brake.
FOG LAMP SWITCH

(if equipped)
The fog lamp switch is used to turn the fog lamp ON or OFF.
Position (A)
Fog lamp lights up.
Position (B)
Fog lamp goes out.
3-112
POWER WINDOW SWITCH

k CAUTION
When the window is fully opened or fully closed, release the switch immediately.
The power window switch is used to open and close the win-
dow glasses. This switch can only be used when the starting
switch is at ON position.
Position (A)
Glass goes up.
Position (B)
Glass goes down.
When the glass reaches the top or bottom and stops, release
the switch.
SIDE LAMP SWITCH

The side lamp switch is used to turn on and off the side lamp.
Position (A)
Side lamp lights up.
Position (B)
Side lamp goes out.
3-113
ROOM LAMP1 SWITCH

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

Room lamp 2 switch is used to turn on and off the room lamp 2.
Position (A)
Lamp goes out.
Position (B)
Lamp lights up.
3-114
HEATED WIRE GLASS SWITCH

(if equipped)
The heated wire glass switch is used to turn ON or OF the
heater for the rear glass ON or OFF.
Position (A)
Wire heater ON
Position (B)
Wire heater OFF
REMARK
The heated wire glass is not turned OFF automatically.
If unnecessary, turn it OFF by your hand.
REVOLVING LAMP SWITCH

(if equipped)
The revolving lamp switch is used to turn the yellow revolving
lamp ON or OFF.
Position (A)
Yellow revolving lamp lights up.
Position (B)
Yellow revolving lamp goes out.
SCREEN MODE SELECTOR SWITCH

Screen mode selector switch is used for switching the mode of
the KomVision monitor.
Each time the switch is pressed, the screen mode is switched
as follows according to the setting of the Forced Display.
Forced display OFF
2 screens display → 1 screen display → No display → 2
screens display
Forced display ON
2 screens display → 1 screen display → 2 screens display
OBSTACLE WARNING CANCEL SWITCH

Obstacle warning cancel switch is used to cancel the alarm
which is brought when the radar detects an obstacle.
When the switch is pressed, the obstacle alarm is canceled in
order of priority.
Holding down this switch for 1.5 seconds or longer disables the
obstacle alarm buzzer for 30 seconds.
REMARK
If the obstacle warning cancel switch is pressed again during
30 seconds while the obstacle alarm buzzer is being disabled,
the obstacle alarm buzzer returns to be effective.
3-115
LEFT FRONT CAMERA SELECTOR SWITCH

Press the left front camera selector switch, and the KomVision
monitor display is shifted to the machine left front camera im-
age.
LEFT REAR CAMERA SELECTOR SWITCH

Press the left rear camera selector switch, and the KomVision
monitor display is shifted to the machine left rear camera im-
age.
FRONT CAMERA SELECTOR SWITCH

Press the front camera selector switch, and the KomVision
monitor display is shifted to the machine front camera image.
REAR CAMERA SELECTOR SWITCH

Press the rear camera selector switch, and the KomVision
monitor display is shifted to the machine rear camera image.
3-116
RIGHT FRONT CAMERA SELECTOR SWITCH

Press the right front camera selector switch, and the KomVi-
sion monitor display is shifted to the machine right front camera
image.
RIGHT REAR CAMERA SELECTOR SWITCH

Press the right rear camera selector switch, and the KomVision
monitor display is shifted to the machine right rear camera im-
age.
RADAR CHECK SWITCH

Radar check switch is a switch that shifts the display of KomVi-
sion monitor to the radar check mode.
3-117
ENGINE SHUTDOWN SECONDARY SWITCH

NOTICE
The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to
OFF position but the engine does not stop.
• Use the engine shutdown secondary switch only in an emergency.
Ask for repair of the problem part as soon as possible.
• If the engine shutdown secondary switch is set to “STOP ENGINE” position by mistake while the
machine is operating normally, “Engine Shutdown Secondary SW in Operation” is displayed on the
machine monitor.
If “Engine Shutdown Secondary SW in Operation” is displayed on the machine monitor, check that
the cover of engine shutdown secondary switch is closed and the switch is in “NORMAL”position. If
not, set it to “NORMAL” position.
If the engine does not stop even after turning the starting switch to OFF position, operate the engine shutdown
secondary switch according to the following procedure.
1. Raise the cover (1) and open it.
There is a switch under the cover.
2. Raise the engine shutdown secondary switch to upper po-

sition (A) and the engine stops. After 2 seconds from stop-
ping of the engine, “Engine Shutdown Secondary SW in
Operation” is displayed and the alarm buzzer sounds inter-
mittently.
(A) ENGINE STOP
When abnormal (switch is set to upper position)
(B) Normal
When normal (switch is set to lower position)
• When cover (1) is closed, the engine shutdown secondary switch automatically returns to “NORMAL”
position (B).
• When the starting switch is turned to ON position
while the engine shutdown secondary switch is in
“STOP ENGINE” position, “Engine Shutdown Secon-
dary SW in Operation” is displayed on the machine
monitor.
If this screen is displayed, return the engine shutdown
secondary switch to “NORMAL” position (B).
3-118
STAIRCASE LIGHTING SWITCH

The staircase lighting switch is used to turn on and off the staircase lighting.
The staircase lighting switches are at 2 places, one is inside the operator's cab and the other is at the step.
Either one can be used to turn on and off the staircase lighting.
When getting on or off the machine, the staircase lighting can be turned on with the one staircase lighting
switch, and can be turned off with the other staircase lighting switch.
Staircase lighting switch inside the opera-
tor's cab
External staircase lighting switch
REMARK
The staircase lighting lights up even when the starting switch is
at OFF position.
When leaving the machine, be sure to turn off the staircase
lighting to avoid battery draining.
3-119
CONTROL LEVERS AND PEDALS
(1) Retarder control lever (5) Brake pedal

(2) Gear shift lever (6) Secondary brake pedal
(3) ARSC speed set lever (7) Dump lever
(4) Accelerator pedal (8) Dump lever lock knob
BRAKE PEDAL
The brake pedal is used to apply the wheel brakes.
Use it when stopping or decelerating the machine.
REMARK
• The wheel brakes can be operated by depressing the
brake pedal even while ARSC system is in operation.
• If the brake pedal is depressed while the KTCS is in opera-
tion, the KTCS system stops operation.
SECONDARY BRAKE PEDAL

The secondary brake pedal is used to operate the parking
brake.
Use it if the wheel brake does not operate due to damage of
brake pedal.
3-120
ACCELERATOR PEDAL
Use the accelerator pedal to control the engine speed.
It can control the engine speed freely from low idle to full throt-
tle.
REMARK
• When the ARSC Setting is set to ON, the ARSC system
functions only while the accelerator pedal is released.
If the accelerator pedal is depressed while the ARSC is in
operation, the ARSC system stops operation.
• The KTCS system can operate while the accelerator pedal
is depressed and the gear speed is at any of the 1st speed
through 4th speed, or REVERSE.
If the accelerator pedal is released while the KTCS is in
operation, the KTCS system stops operation.
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 the position D is used, the transmission is set automati-
cally between the 2nd or 1st torque converter drive and the 7th
speed according to the travel speed.
The transmission is fixed to the 1st speed and is not changed
while the dump body is raised. Keep the dump body lowered
during travel.
The maximum travel speed in position D is 56.5 km/h {35.1 MPH} .
Positions 6 to L
Use these positions when traveling on soft ground or places where it is difficult to travel at high speed, when
starting on slope with the machine loaded, or when traveling downhill with engine brake.
The transmission is fixed to the 1st speed and is not changed while the dump body is raised. Keep the dump
body lowered during travel.
Position R
This is used when traveling in reverse.
There are two reverse gear speeds of RL and RH from which you can choose on the machine monitor.
For the method of selecting the RL and RH, see “RL/RH SETTING”.
• RL: Use this gear speed when high rim pull is required.
• RH: Use this gear speed when high travel speed is required.
You cannot drive in reverse when the dump body is raised. Lower the dump body, operate the dump lever to
“FLOAT” first, and operate it to “R” position.
REMARK
If driving the machine with the dump body not seated, the gear speed is fixed at the 1st in D to L positions, and
transmission can not be shifted. (This conforms to EU safety standard (EN474-6 5.1.3).
3-121
Automatic gear shift range in each position
Shift indicator Max. speed

Position Gear shift range
display Power mode Economy mode
2nd or 1st speed torque converter to 7th 56.5 km/h 52.7 km/h
D
speed direct {35.1 MPH} {32.7 MPH}
1st speed torque converter to 6th speed di- 38.5 km/h 38.3 km/h
6
rect {23.9 MPH} {23.7 MPH}
5
rect {17.8 MPH} {17.7 MPH}
4 F1 to F7
rect {13.2 MPH} {13.2 MPH}
1st speed torque converter to 3rd speed di- 16.7 km/h 16.7 km/h
3
rect {10.4 MPH} {10.4 MPH}
1st speed torque converter to 2nd speed di- 12.4 km/h 12.4 km/h
2
rect {7.7 MPH} {7.7 MPH}
1st speed torque converter to 1st speed di- 9.5 km/h 9.5 km/h
L
rect {5.9 MPH} {5.9 MPH}
9.2 km/h 9.2 km/h
RL L speed torque converter to L speed direct
{5.7 MPH} {5.7 MPH}
R
12.4 km/h 12.3 km/h
RH H speed torque converter to H speed direct
{7.7 MPH} {7.6 MPH}
The machine moves off at the 2nd speed or 1st speed when the gear shift lever is set to the position D.
Do not set the gear shift lever to NEUTRAL position (N) during the travel.
Before performing the directional selection, stop the machine completely and run the engine at low idle.
When starting the engine, if the gear shift lever is in any position other than NEUTRAL (N), the engine will not
start.
When the starting switch is turned from OFF position to ON position, if the gear shift lever is in any position
other than NEUTRAL (N), the shift lever position display flashes, the centralized warning lamp lights up, and the
alarm buzzer sounds. If the gear shift lever is turned to NEUTRAL position (N), the lamps will go out and the
buzzer will stop sounding.
When the parking brake is applied, if the gear shift lever is in any position other than NEUTRAL (N), the central-
ized warning lamp will light up and the alarm buzzer will sound.
If the gear shift lever is set to any position other than NEUTRAL (N) when the dump lever is at a position other
than “FLOAT” or the dump body is still raised, the centralized warning lamp will light up and the alarm buzzer
will sound.
Always place the gear shift lever securely in position when operating it.
If the gear shift lever is not placed securely in position, the shift lever position pilot lamp on the machine monitor
may start flashing and the centralized warning lamp may light up, and the alarm buzzer may sound.
When shifting the gear shift lever from NEUTRAL position (N)
to D (FORWARD) or R (REVERSE), release the accelerator
pedal, set the engine speed at low idle, then press the lock but-
ton of the gear shift lever to operate.
3-122
RETARDER CONTROL LEVER

k CAUTION
Do not use retarder brake to park the machine.
The retarder control lever is used to operate the retarder when

traveling downhill.
The more the retarder control lever is pulled toward you, the
greater the braking force becomes.
When the retarder operates, the retarder pilot lamp lights up on
the machine monitor.
When leaving the operator's seat, always apply the parking brake.
REMARK
• When the ARSC system is in operation, the retarder control lever has some play at the start of stroke. It
does not mean that the retarder does not work, but that it is the range of the ARSC system operation. Sud-
den operation of the retarder lever will cause sudden braking. Take care.
• If the retarder is operated with retarder control lever while the KTCS is in operation, the KTCS operation
stops.
ARSC TRAVEL SPEED SET LEVER

You can set, finely adjust, and cancel the travel speed of ARSC
with the ARSC travel speed set lever.
(A) Setting of ARSC
Actuates the ARSC.
(B) Decreasing the speed
Decreases the travel speed which is set in ARSC.
(C) Cancel of ARSC
Cancels the ARSC.
(D) Increasing the speed
Increases the travel speed which is set in ARSC.
3-123
DUMP LEVER
k CAUTION
Make sure to lower the dump body and set the dump lever
to “FLOAT” when you travel.
The dump lever is used to operate the dump body.

(A) “RAISE” position
(B) “HOLD” position
The dump body remains in the position where it was stopped.
(C) “FLOAT” position
The dump body moves freely under external force.
(D) “LOWER” position
• Always set it to “FLOAT” position when traveling.
• The machine cannot be driven in reverse when the dump body is raised.
• If the engine stops, the dump body is held in “HOLD” condition, regardless of the position of the dump lever.
Even if the engine is started again with the dump body raised, the dump body is held in “HOLD” condition
and the dump body float caution lamp lights up.
DUMP LEVER LOCK KNOB

k WARNING
When performing the inspection with the dump body
raised, always use the body lock wire to secure the dump
body, and set the dump lever at “HOLD” position.
The dump lever lock knob is a locking device for the dump lev-
er.
To set it to FREE position (F), pull out the lock knob fully, then
turn it to hold it in position.
To set it to LOCK position (L), pull out the lock knob and turn it to remove it from the fixed position.
The knob is pushed into the lock hole in the dump lever by the force of the spring, and the dump lever is locked.
Check that the dump lever is securely locked.
3-124
OTHER EQUIPMENT
CAB DOOR
k CAUTION
• Make sure that the cab door is locked when it is
closed.
• Always place the machine on a level ground when
opening or closing the door.
Avoid opening or closing the door on a slope. The op-
erating effort may suddenly change, and it is danger-
ous.
• Hold the door handle and knob whenever opening or
closing the door.
• Be careful not to get your hands caught in the front
pillar or center pillar.
• When there is anyone inside the cab, always call out a
warning before opening or closing the door.
CAB DOOR HANDLE

Pull the cab door handle while it is not locked, and the door
opens to the full open position.
OPEN KNOB FOR CAB DOOR

Pull the open knob for the cab door, and the cab door opens to
the full open position.
3-125
CAB DOOR INNER LOCK

While the cab door is closed, it can be locked by pressing the
cab door inner lock.
(L) LOCK position
It locks the cab door.
It is used when operating the machine.
(F) FREE position
It unlocks the cab door.
It is used when getting off the machine.
DRINK BOX
The drink box is provided on the rear side of the center console
to store the drinks.
Air according to the setting of the air conditioner blows into the
drink box.
Turn the knob counterclockwise and pull the cover up and open
it.
(L) LOCK position
The cover is locked.
(F) FREE position
The cover is unlocked.
When closing the cover, lock it by turning the knob clockwise while pressing the cover.
LUNCH BOX TRAY

The lunch box tray is located at the rear of the operator's seat.
MAGAZINE BOX
The magazine box is provided on the front right side of opera-
tor's seat for storing an A4-size binder and such.
Do not put in heavy things such as tools.
3-126
CUP HOLDER
The cup holders are located at two places of the center console
and the rear left of the operator's seat.
ASHTRAY
The ashtray is at the front of the center console.
Always extinguish your cigarette before putting it in the ashtray,
and be sure to close the lid.
POWER SUPPLY OUTLET

12V power supply
The outlet for 12 V power is provided in the rear right side of
the operator seat.
Capacity of this power supply is 60 W (12 V x 5 A).
KomVision SYSTEM INDICATOR

KomVision system indicator indicates the operating state of
KomVision system.
Lighting in green
KomVision system is in operation.
Flashing in green
KomVision system is being prepared.
Not lit
KomVision system is not in operation.
3-127
FUSE
NOTICE
Make sure to turn start and battery disconnect switches to
OFF, before you replace a fuse.
• The fuses protect the electrical component and wiring from
burning out.
• If the fuse becomes corroded, or looks white powdery, or
the fuse is loose in the fuse holder, replace the fuse.
• Use a fuse of the same capacity and type always when re-
placing it.
FUSE CAPACITIES AND CIRCUIT NAMES

Fuse box I (BT1)
Capaci-
No. Name of circuit
ty
(1) 10 A Main lamp, clearance lamp
(2) 20 A Headlamp (Hi)
(3) 15 A Headlamp (Lo)
(4) 10 A Stop lamp
(5) 15 A Backup lamp, alarm buzzer
(6) 30 A Heated wire mirror power supply (if equipped)
(7) 10 A Heated wire mirror (upper R.H.) (if equipped)
(8) 10 A Heated wire mirror (L.H.) (if equipped)
(9) 10 A Heated wire mirror (lower R.H.) (if equipped)
(10) 15 A Auto-greasing
(11) 20 A DC converter
(12) 20 A Air suspension seat
(13) 20 A Power window (R.H.)
(14) 20 A Power window (L.H.)
(15) 15 A Fog lamp (if equipped)
3-128
Fuse box II (BT2)
Capaci-
No. Name of circuit
ty
Engine room lamp (if equipped) (continuous pow-
(16) 10 A
er supply)
(17) 15 A Terminal B (continuous power supply)
(18) 5 A Air conditioner (continuous power supply)
(19) 5 A Retarder controller (continuous power supply)
Transmission controller (continuous power sup-
(20) 5 A
ply)
(21) 10 A Monitor panel (continuous power supply)
KomVision controller, rearview monitor, KomVi-
(22) 10 A
sion monitor (continuous power supply)
(23) - -
(24) 10 A KOMTRAX (continuous power supply)
(25) 5 A ID key (if equipped) (continuous power supply)
(26) 10 A KOMTRAX Plus (continuous power supply)
(27) 10 A Download (continuous power supply)
Optional controller (if equipped) (continuous pow-
(28) 5 A
er supply)
(29) 10 A Auto-greasing (continuous power supply)
(30) 20 A Spare (continuous power supply)
Fuse box III (BT3)
Capaci-
No. Name of circuit
ty
(31) 20 A Air conditioner (blower motor)
(32) 10 A Air conditioner (compressor clutch)
(33) 10 A Radio
(34) 20 A Front wiper
(35) 10 A Room lamp 2, door solenoid
(36) 5 A Turn signal lamp
(37) 15 A Side lamp
(38) 10 A Revolving lamp (if equipped)
(39) 20 A Engine controller (continuous power supply)
(41) 10 A Secondary steering (continuous power supply)
(42) 5 A Controller (ACC signal)
(43) 5 A Air conditioner (ACC signal)
(44) 10 A Download, external delivery (ACC signal)
(45) - -
3-129
Fuse box IV (BT4)
Capaci-
No. Name of circuit
ty
(46) 5 A Parking brake
(47) 10 A Retarder controller
(48) 5 A Gear shift lever, starting motor cut-off relay
(49) 5 A Switch panel
(50) 15 A Transmission controller
(51) 10 A Automatic secondary steering
(52) 15 A Optional controller (if equipped)
(53) 10 A Payload meter external pilot lamp
(54) 15 A DC converter (KomVision)
(55) 20 A Spare
(56) 10 A Staircase lighting (continuous power supply)
(57) 5 A Radio (continuous power supply)
(58) 10 A Hazard lamp (continuous power supply)
Room lamp 1, system operating lamp (continuous
(59) 10 A
power supply)
(60) 15 A Horn (continuous power supply)
Fuse box V (BT5)
Capaci-
No. Name of circuit
ty
(61) 15 A Headlamp (Hi)
(62) 15 A Headlamp (Lo)
(63) 10 A Power ladder (if equipped)
(64) 10 A External delivery
(65) 30 A Glass heater (if equipped)
(66) 15 A Additional heater (if equipped)
Power ladder (if equipped) (continuous power
(69) 10 A
supply)
(70) 10 A External delivery (continuous power supply)
(71) - -
(72) 15 A Horn 2 (continuous power supply)
(73) - -
(74) - -
(75) - -
3-130
Fuse box VI (in battery box)
Capaci-
No. Name of circuit
ty
(76) 300 A Power supply for pre-lubrication
(77) 200 A Power supply for battery charge
Fuse box VII (in battery box)

Capaci-
No. Name of circuit
ty
(78) 15 A Power supply for secondary steering
Precautions when changing electrical component

k CAUTION
Do not modify the machine electrical system.
FIRE EXTINGUISHER
The fire extinguisher is installed to the left front of the machine.
3-131
ENGINE ROOM LAMP SWITCH

Engine room lamp switch is used to turn on and off the engine room lamp.
Use this switch when checking the engine.
The engine room lamps are provided at 2 places; at the steps and on the right side of the machine. You can turn
them on or off from both places.
Either one of the engine room lamp switch can turn on and off the engine room lamp.
Engine room lamp switch at the steps
Engine room lamp switch on the right side of the ma-

chine
REMARK
The engine room lamp lights up even when the starting switch
is in OFF position.
When leaving the machine, be sure to turn off the engine room
lamp to avoid battery draining.
3-132
BATTERY DISCONNECT SWITCH

k CAUTION
Do not turn the battery disconnect switch to OFF while engine operates or immediately after engine is
stopped.
This causes damage to the machine system.
NOTICE
• Keep the battery disconnect switch in ON position except the following cases.
• When the machine is stored for a long time (more than a month)
• When repairing the electrical system
• When performing the electric welding
• When handling the battery
• When replacing the fuse, etc.
• Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit.
If the battery disconnect switch is turned to OFF position while the system operating lamp is lit, the
data in the controller may be lost.
• If the battery disconnect switch is turned to OFF position, all the electrical system is cut out and the
functions of KOMTRAX Plus stop.
In addition, the time information of the clock and the radio tuning information may be lost.
If the time information of the clock and the radio tuning information are lost, perform the settings
again by referring to CLOCK ADJUSTMENT (3-89) and HANDLE RADIO (3-269).
Battery disconnect switch (1) is in the box on the front left side
of the machine.
The battery disconnect switch (1) is used to cut out the electric-
ity from the battery.
REMARK
Operate this switch while the system operating lamp (2) is not
lit.
(A) ON position
The current from the battery flows into the circuit.
Before starting the machine, be sure to set the switch to ON
position.
(B) OFF position
The current from the battery is cut off.
3-133
SYSTEM OPERATING LAMP

NOTICE
Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit.
If the battery disconnect switch is turned to OFF position while the system operating lamp is lit, the data
in the controller may be lost.
The system operating lamp indicates that the electric power is
supplied to the controller mounted on the machine.
System operating lamp lights up in green when the controller is
turned on and goes out in 2 to 3 minutes after the power for the
machine is turned off.
Before operating the battery disconnect switch, check that sys-
tem operating lamp is not lit.
REMARK
• Even if the starting switch is in OFF position, the controller
may operate. The system operating lamp lights up at this
time, but it is not a failure.
• After the starting switch has been turned off, the system
operating lamp may stay lit for a long time.
In such case, consult your Komatsu distributor.
HANDLE AUXILIARY ENGINE STARTING CONNECTOR

The SAEJ1283 compliant auxiliary engine starting connector is provided for this machine.
The auxiliary engine starting connector is inside the box on the
left front of the machine.
3-134
STARTING MOTOR DISCONNECT SWITCH

Starting motor disconnect switch is used to shut off the electri-
cal circuit to the starting motor in order to disable the engine to
start.
(A) ON position
Electrical circuit of the starting motor is connected. The engine
is able to be started
Check that the starting motor disconnect switch is in ON posi-
tion before starting the engine.
(B) OFF position
Turning the starting motor disconnect switch counterclockwise
from ON position shuts off the electrical circuit to the starting
motor. The engine is disabled to start.
Turn the starting motor disconnect switch to OFF position al-
ways when performing the works such as replacing oil or grease, maintenance in engine room or pump room.
These works are dangerous if the engine is started.
3-135
EXTERNAL ENGINE SHUTDOWN SECONDARY SWITCH

When pressing the external engine shutdown secondary switch, the engine stops. Use this switch in emergency
only. Use the starting switch normally to stop the engine.
External engine shutdown secondary switch is on the front left
side of the machine.
1. Press the external engine shutdown secondary switch.
The engine will stop.
2. If the engine is going to remain stopped for a long period

of time, turn the starting switch at the operator's seat to
OFF position (A).
If the lamps are kept lit, the battery may run out.
3. Remove the cause which brought the engine to an emer-
gency stop.
4. Turn the external engine shutdown secondary switch in a

direction of arrow (clockwise) until the button moves (re-
turns outside).
The emergency stop is canceled in this way.
5. Start up the engine again with the starting switch at the op-
erator's seat.
3-136
CIRCUIT BREAKER
NOTICE
• Before restoring the circuit breaker, be sure to turn the starting switch to OFF position.
• Do not keep the reset button of the circuit breaker being pressed.
Circuit breakers (1) and (2) may have open circuit if the power
is not supplied by turning the starting switch to ON position.
Open the battery box cover on the right side of the cab, and
check them.
• Circuit breaker (1) may have open circuit if the starting mo-
tor does not operate by turning the starting switch to
START position.
• Circuit breaker (2) may have open circuit if the electric de-
vices do not operate after the fuse has been replaced.
REMARK
A circuit breaker is a circuit protection device to be installed to
a high-voltage current circuit.
Similarly to an ordinary fuse, it protects electrical parts and wir-
ing from burning out caused by abnormal current. It can be op-
erated without replacement after the abnormal part has been
collected.
Capaci-
No. Name of circuit
ty
Continuous power supply and normal power sup-
(1) 60 A
ply
(2) 105 A Electric devices
When the circuit breaker operates

1. Turn the starting switch to OFF position.
2. Push in the reset button after a lapse of 5 to 10 minutes of cutting off.
3. Check the reset button.
Operating effort of the reset button of the open circuit is larger than that of the closed circuit.
If it still requires the large operating effort after the reset button has been pushed in, the electrical circuit
may be open. In such case, ask your Komatsu distributor for repair.
3-137
DUST INDICATOR
This is a device that indicates clogging of the air cleaner.
Red line (1) appears in the transparent portion depending on
the degree of clogging of the element.
If red line (1) indicates 6.23 kPa {0.064 kg/cm2, 0.91 PSI} posi-
tion, immediately clean the element.
After cleaning, press the bottom part (2) of the indicator, and
return the red line (1) to its original position.
3-138
DUMP BODY LOCK WIRE

k WARNING
When performing the inspection with the dump body raised, always use the body lock wire to secure
the dump body, and set the dump lever at “HOLD” position.
Dump body lock wire is a safety device. Use it when performing inspection and maintenance while the dump
body is raised.
How to use the dump body lock wire
1. Raise the dump body to the maximum height in order to
keep the dump body raised.
2. Remove the pin (1) from the storage location, and put it to
the axle housing (2).
3. Fix the ring at the tip of the dump body lock wire (3) with
the pin (1).
Check that the dump body lock wire (3) is taut in order to
check that the dump body is securely fixed.
4. Operate the dump lever slowly to “FLOAT” position until
the dump body starts moving, then release the lever.
The dump body is lowered by its own weight, then the
dump body wire (3) becomes taut.
Inspection and maintenance can be performed when the
dump body wire (3) becomes taut and the dump body is
fixed.
5. Set the dump control lever to “HOLD” position, and lock it
with the dump lever lock knob.
6. When inspection and maintenance are completed, raise
the dump body a little to relax the taut of the dump body
lock wire (3).
Remove the dump body lock wire (3) and pin (1) from the
axle housing (2), and put them in the storage location.
STORE DUMP BODY LOCK WIRE AND PIN

The dump body lock wire (1) and pin (2) are stored in the rear
bottom of the machine.
Hook the dump body lock wire (1) on the hook. Store the pin
(2) by pinning it with the safety pin.
3-139
ESCAPE DOOR
k CAUTION
• Escape door and escape step are provided for emergency when the ladder cannot be used for go-
ing up and down.
Do not use these for going up the machine and down from the machine at normal times.
• Escape door without applying the pin may suddenly open during operation. It is dangerous.
Do not remove the pin at normal times.
• Check the escape door at random times that there is no problem in opening and closing.
• When the machine is disassembled or assembled again, ask your Komatsu distributor to perform
the adjustment of the escape door.
(1) Escape door (2) Escape step
3-140
Pull the knob (3) of the lock pin to unlock it.

The door opens backward.
3-141
SERVICE CENTER
k CAUTION
Immediately after the engine is stopped, oil temperature and pressure are so high that it may cause
burn injury if starting the work soon. Lower the pressure of oil, make sure that the oil temperature is low
enough, then start the work.
Service center is one stop service place to perform refilling oil, draining oil, and oil sampling.
Stop the engine when working with the service center.
REMARK
A pump is necessary for refilling and draining with the service center.
Functions of plugs are as follows.
(1) Refilling engine oil pan with oil, and draining oil (4) Refilling steering and hoist oil tank with oil and
from it draining oil from it
(2) Refilling coolant and draining it (5) Refilling brake oil tank with oil and draining oil from
(3) Refilling transmission with oil, and draining oil from it
it
3-142
VALVE POSITIONS OF REFILLING PIPING AND DISCHARGING PIPING

Check that the valves (1), (2), and (3) are open for when oil or coolant is refilled or drained through the service
center. If those valves are closed, open them before refilling or draining oil or coolant.
Close the valves when the hose is replaced.
(1) Transmission piping valve
Located behind the transmission. (Right side of the machine)
(2) Engine oil pan piping valve

Located behind the engine oil pan. (Right side of the machine)
(3) Radiator piping valve

Located the rear bottom of radiator. (Left side of the machine)
3-143
HANDLE AUTO-GREASING SYSTEM

Greasing can be automatically done by this computer controlled system.
METHOD FOR OPERATING AUTO-GREASING SYSTEM

Turn the starting switch to ON position (B), then greasing auto-
matically starts according to the timer setting.
Greasing is started by pressing the manual greasing switch re-

gardless of the timing of the timer.
If an abnormality occurs, inside of the manual greasing switch
lights up.
Ask your Komatsu distributor for inspection if it lights up.
3-144
METHOD FOR SETTING TIMER

1. Open the upper lid of controller box (1) behind the opera-
tor's seat.
2. Set the DIP switch (2) of “HOURS/MINUTES” in “MODE

SWITCH” to HOURS side or MINUTES side.
Do not operate other DIP switches this time.
3. Operate “OFF TIME SWITCH” (3) in order to set the greas-
ing interval to the desired time.
It is set to 15 minutes at shipment.
Combinations of “MODE SWITCH” and “OFF TIME
SWITCH” are as follows.
OFF TIME SWITCH 0.5 1 2 4 8 15 24 30

MI-
30 sec- 1 mi- 2 mi- 4 mi- 8 mi- 15 mi- 24 mi- 30 mi-
NUTES
onds nute nutes nutes nutes nutes nutes nutes
MODE SWITCH side
HOURS 30 mi- 8 15 24 30
1 hour 2 hours 4 hours
side nutes hours hours hours hours
(Example) When setting to 15 minutes
1. Set the DIP switch of “HOURS/MINUTES” in “MODE SWITCH” to MINUTES side.
2. Set “OFF TIME SWITCH” to “15”.
3-145
METHOD FOR BLEEDING AIR FROM GREASING CIRCUIT

NOTICE
Air must be bled from the greasing circuit. The grease pressure will not be raised to the specified pres-
sure if air remains in the greasing circuit. It may lead to damage to each part of the machine due to in-
sufficient lubrication.
1. Turn the starting switch to ON position (B).
2. Press the manual greasing switch.

Grease pump starts the operation for several tens sec-
onds, then stops. Check that the grease pump has stop-
ped.
3. Repeat the step 2., and check that each point is sufficiently
lubricated as the grease is extruded.
3-146
METHOD FOR ADJUSTING INJECTOR DISCHARGED VOLUME

You can adjust the injector discharged volume in the range of 0.25 to 1.31 cc per one cycle.
1. Remove the injector cap (1).
2. Loosen the locknut (2), and remove the adjustment nut (3).
3. Remove the collar (4).
4. Install the adjustment nut (3), and adjust the discharged
volume.
Turn the adjustment nut (3) clockwise, and tighten it until it
reaches the stopper. The discharged volume can be set to
0.25 cc (minimum).
Loosen the adjustment nut (3) 7 turns counterclockwise
from the stopper position. The discharged volume can be
set to 1.31 cc (maximum).
It is set to the maximum discharged volume (1.31 cc) when
the machine is shipped from factory.
5. After the grease discharged volume is adjusted, tighten the
lock nut (2).
6. Install the injector cap (1).
METHOD FOR CHECKING INJECTOR OPERATION

1. Turn the starting switch to ON position.
2. Check that the indicator (1) of each injector reciprocates
once upward and downward during the lubrication.
Lubrication is not correctly done if the indicator does not
reciprocate.
Bleed air. Contact your Komatsu distributor if it still does
not reciprocate.
3-147
METHOD FOR ADDING GREASE

You can refill the grease grease tank on the R.H. platform from the ground.
REMARK
Grease refilling pump and connecting hose (with quick coupler) are necessary for this refilling method.
(1) Grease tank (5) Remaining grease gauge

(2) Level sensor (6) Refill piping pressure release switch
(3) Shut off valve (7) Refill piping pressure gauge
(4) Grease tank full lamp (8) Lubrication coupler
METHOD FOR OPERATING REFILLING SYSTEM

1. Remove the cap of lubrication coupler (8), then connect the refilling hose to the lubrication coupler (8).
2. Start the refilling pump to refill the grease tank (1) with grease.
After the grease is added, the level sensor (2) detects the grease level, and it displays the grease level with
pointer of the remaining grease gauge (5).
Grease tank full lamp (4) lights up when the grease tank is fully refilled. At this time, the shut-off valve (3)
operates to close the refilling pipe and to prevent the overflow from occurring in the tank.
3. Refilling pump is stopped.
4. Press the refill piping pressure release switch (6) until there is no remaining pressure in the piping while
checking the refill piping pressure gauge (7).
Pressing the refill piping pressure release switch (6) opens the refilling piping which is closed temporarily,
and release the remaining pressure into the grease tank.
5. Remove the refilling hose, and install a cap to the lubrication coupler (8).
3-148
KOMTRAX Plus
k WARNING
• Never disassemble, repair, modify, or move the KOMATRAX Plus, wireless communication terminal,
antenna, or cables. This may cause failure or fire on the wireless equipment or the machine itself.
• Near the blasting jobsite, there may be a danger of unexpected explosion due to use of the wireless
equipment and resulting serious personal injury or death.
If you have to operate the machine within 12 m {within 39 ft 4 in} from the remote-controlled blasting
device, the power supply cable of the wireless communication device must be disconnected in ad-
vance.
The KOMTRAX Plus is a vehicle management system.

If the wireless communication terminal is installed to the machine, it can remotely manage the machines equip-
ped with the KOMTRAX Plus device through satellite communication or portable radio communication.
The machine information such as the machine maintenance, maintenance management, operating situation
management, and machine location management is gathered from the inside network of the machine. It can be
useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma-
chine information for supply of service to the customers, improvement of our products and service, etc.
The type of information which is sent from the machine may vary depending on the machine. For the radio sta-
tion establishment of KOMTRAX Plus, consult your Komatsu distributor.
POWER SUPPLY FOR KOMTRAX Plus

• When a wireless communication terminal is installed to the machine, even if the starting switch key is in
OFF position, KOMTRAX Plus system consumes a small amount of electric power.
It is recommended to start the engine periodically to charge the battery.
• When using the battery disconnect switch, turn the starting switch to OFF position, and after checking that
the system operating lamp is not lit, set the battery disconnect switch to OFF position.
When the battery disconnect switch is turned to OFF position, it prevents the battery power from being con-
sumed, but the functions of KOMTRAX Plus stop at the same time.
• If the power supply cable of KOMTRAX Plus system device has to be disconnected, contact your Komatsu
distributor.
3-149
MACHINE OPERATIONS AND CONTROLS OPERATION
MACHINE OPERATIONS AND CONTROLS

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
METHOD FOR WALK-AROUND CHECK
Walk around the machine and look at the underside of chassis for anything unusual like loose bolts and nuts,
leakage of fuel, oil and coolant before starting the engine. Also check the condition of the work equipment and
the hydraulic system.
Check also for loose wiring, play of wiring, and accumulation of dust in places that get very hot and are exposed
to extremely high temperatures.
k WARNING
• Put the warning tag on the gear shift lever.
• Clean any flammable materials that accumulate around the machine in areas such as exhaust sys-
tem, dump body (equipped with dump body heating specifications), battery, cooling system.
Repair and clean any fuel and oil leaks. If there are any defects, consult your Komatsu distributor.
• The lamps may become hot. Wait until they have cooled down before starting the work.
If the machine is inclining, make it level before checking.

Always perform the following inspections and cleaning every day before starting the engine for the day's work.
1. Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play.
Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and
perform the repairs if any problem is found.
2. Remove dirt and debris from around the engine, battery, radiator, and oil cooler.
Check that there is no dirt or dust accumulated around the engine, radiator or oil cooler. Check also that
there is no combustible material (dry leaves, twigs, etc.) accumulated around the battery, or muffler, turbo-
charger, or other high-temperature parts of the engine or dump body (equipped with dump body heating
specification). Remove any dirt or combustible materials that are found.
3. Check around the engine for coolant and oil leakage.
Check for oil leakage from the engine and coolant leakage from the cooling system. If any problem is found,
repair it.
4. Check the fuel line for leakage.
Check for leakage of fuel or damage to the hoses and tubes. If any problem is found, repair it.
5. Check for oil leakage from the transmission case, differential case, final drive case, steering, hoist oil tank,
brake oil tank, hoses, and joints.
Check for oil leakage. If any problem is found, repair the place where the oil is leaking.
Check for oil leakage from the undercover and oil drop trace on the ground.
6. Check the tires, wheels, and wheel hub bolts and nuts for damage and wear, and check the wheel hub bolts
and nuts for looseness.
Check the tires for cracks or peeling and check the wheels (side ring, rim base, lock ring) for cracks or
wear. If any loose wheel hub bolts or hub nuts are found, retighten them.
If any problem is found, repair or replace the part.
If any valve cap is missing, install a new one.
7. Check the air cleaner mounting bolts for looseness.
Check the mounting bolts for looseness. If any loose bolts are found, retighten them.
8. Check the dump body mount rubbers.
Check for any cracks, caught foreign objects, or loose bolts.
9. Check for damage to the handrail and loose bolts.
3-150
OPERATION MACHINE OPERATIONS AND CONTROLS
If any breakage is found, repair it, and retighten the bolts.

10. Check the lamp, camera, and radar for damage.
If any part is damaged, replace it with new one.
Clean off any dirt on the surface.
11. Check the rearview mirror, side view mirror, and under mirror.
Check that the mirrors are not damaged. If any one is damaged, replace it with a new one.
Clean the surfaces of the mirrors and adjust the angle so that the area at the rear and lower portions can be
seen from the operator's seat.
12. Check the machine monitor, KomVision monitor, and rearview monitor for abnormality.
Check the machine monitor, KomVision monitor, and rearview monitor for abnormality. If any abnormality is
found, replace the failed monitor.
Clean off any dirt on the surface.
13. Check the seat belt and mounting hardware.
k WARNING
Inspect the condition of seat belt and replace any
parts that are damaged. Replace the seat belt three
years from when it was installed or five years from
when it was made. Whichever is the minimum quantity
of time.
REMARK
The date indicated on the seat belt is the manufactured
date. It is the start of the 5-year period.
The manufactured date of the seat belt is printed on the la-
bel indicated by the arrow in the figure.
3-151
Check the seat belt and mounting hardware (1) (2 places)

for abnormality.
If any part is damaged, replace it with a new one.
• Check for looseness of the bolts (1) (2 places) of
mounting hardware which is installed to the machine.
Retighten them if any loose bolts are found.
Tightening torque: 37.3 to 41.2 Nm {3.8 to 4.2 kgm,
27.5 to 30.4 lbft}
• If the seat belt is scratched or frayed, if any fitting is
broken or deformed, replace the seat belt.
14. Check the tires.
k WARNING
If worn or damaged tires are used, they may burst and
cause serious injury or death.
To ensure safety, do not use the following tires.
Wear
• Tires with the tread groove depth of 15 % or less
of that of a new tire
• Tires with the abnormal wear such as uneven wear
or stepped wear
Damage
• Tires with damage that has reached cords (1), or
with cracks in the rubber
• Tires with cut or broken cords (1)
• Tires with peeled (separated) surface
• Tires with damaged bead (2)
• Air leaking tubeless tires or improperly repaired
tires
• Deteriorated, deformed or abnormally damaged
tires, which do not seem usable
15. Check the wheel rims.

Check that the wheel rims and rings are free from deformation, damage caused by corrosion, and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
16. Check the antenna.
Check the satellite communication antenna (1), GPS an-
tenna (2), wireless LAN antenna (3), and cables for dam-
ages. Replace it with a new one if there is any damage.
Clean the antenna if it is dirty.
3-152
METHOD FOR CHECKING BEFORE STARTING

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

1. Open the fuel drain valve cover.
2. Place a container to catch the drained fuel under the drain
valve at the lower part of the fuel tank.
3. Loosen the drain valve to drain all the sediment and water
accumulated at the bottom together with fuel.
4. When only clean fuel flows out, close the drain valve.
METHOD FOR CHECKING LOOSENESS OF WHEEL HUB NUTS

Check the wheel hub nuts (1) for breakage or looseness.
If any wheel hub nut (1) of a wheel is broken, replace all the
wheel hub nus (1) for that wheel.
Retighten the nut if any looseness is found.
Tightening torque: 1000 to 1300 Nm {102 to 133 kgm, 738 to
962 lbft}
Insert a socket wrench into the pipe, then apply a force of
1150 N {117 kg} at point 1 m {3 ft 3 in} from the fulcrum. This
will give a tightening torque of 1150 Nm {117 kgm, 846 lbft}.
METHOD FOR CHECKING OIL LEVEL IN TRANSMISSION CASE, ADDING OIL

NOTICE
• The oil level changes according to the oil temperature, so check the oil level after completing the
warming-up operation.
• Oil level may exceeds the sight gauge (G2) when the engine is running at low idle during operation
or after operation.
• Use the sight gauge (G1) as a reference when checking it with the engine stopped. Use the sight
gauge (G2) when checking it with the engine running at low idle for final check.
• When checking the oil level with the engine stopped, use the sight gauge (G1) to check the oil level
in 20 minutes or more after the engine stopped.
1. Start the engine.
2. Check the oil level with the graduations of the sight gauge
(G2) when engine is running at low idle.
3. If the oil is insufficient, add oil through the oil filler port (F)
or the service center.
3-153
METHOD FOR CHECKING DUST INDICATOR

1. Check that the red line in the transparent portion of dust in-
dicator does not indicate 6.23 kPa {0.064 kg/cm2,
0.91 PSI}.
If 6.23 kPa {0.064 kg/cm2, 0.91 PSI} is indicated, clean or
replace the air cleaner element immediately.
For the cleaning method of the element, see “METHOD
FOR CHECKING, CLEANING AND REPLACING AIR
CLEANER (4-16)”.
2. After cleaning or replacing, press the bottom of dust indi-
cator to return the red line to its original position.
METHOD FOR CHECKING BATTERY DISCONNECT SWITCH AND STARTING

MOTOR DISCONNECT SWITCH
Check that the battery disconnect switch (1) and starting motor
disconnect switch (2) are at ON position (A).
3-154
METHOD FOR CHECKING FUEL STAGE 1 FILTER AND DRAINING MIXED WA-
TER
k WARNING
• Immediately after the engine is stopped, all of parts are still very hot. Avoid draining water or re-
moving the transparent cup.
Wait for all of parts to cool down before starting the work.
• Do not bring any open flame close.
Items to be prepared
Container to catch the drained water
1. Remove the wing bolt (1), and open the fuel STAGE1 filter
cover (2) on the left side of the machine.
2. Check the cup (3) under the filter if water is accumulated.

If water is accumulated in the cup (3), drain water accord-
ing to the following procedure.
1) Place the container to catch water under the water
drain hole (4).
2) Loosen the valve (5), and drain water.
3) Tighten the valve (5) immediately after the fuel starts
draining from the valve (5).
3. Close the fuel STAGE 1 filter cover (2), and tighten the
wing bolt (1).
3-155
METHOD FOR CHECKING OIL LEVEL IN STEERING AND HOIST OIL TANK,
ADDING OIL
k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury.
Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.
1. Check the oil level with the sight gauge (G).

If the oil is seen from the sight gauge (G), the oil level is
correct.
2. If the oil is not seen from the sight gauge (G), add the oil
through the oil filler port (F) or service center.
METHOD FOR CHECKING OIL LEVEL IN BRAKE OIL TANK, ADDING OIL
k WARNING
jury.
NOTICE
• The oil level changes according to the oil temperature, so check the oil level after completing the
warming-up operation.
• Oil level may exceeds the sight gauge (G2) when the engine is running at low idle during operation
or after operation.
• Before checking the brake cooling and brake control oil level, depress the brake pedal several times
to release the pressure in the brake accumulator. Use the sight gauge (G1) as a reference when
checking the oil level with the engine stopped, and use the sight gauge (G2) with the engine running
at low idle for final check.
3-156
The sight gauge (A) on the front of the machine is for brake
cooling. The sight gauge (B) on the rear of the machine is for
brake control.

2. Check the oil level with the graduations of the sight gauge (G2) when engine is running at low idle.
3. If the oil is insufficient, add oil through the oil filler port (F)
or service center.
3-157
METHOD FOR CHECKING OIL LEAKAGE IN BRAKE OIL COLLECTION TANK

1. Check that no oil leaks from the overflow tube at the brake oil collection tank.
Front (right and left)
Rear (right and left)
2. Collect the oil according to the following procedure if it is being leaked.

Front (right and left)
Rear (right and left)
1) Place a container to catch oil just under the drain plug (P).
2) Remove the drain plug (P) and drain the oil.
Collect the oil from the brake oil collection tanks on the right and left sides.
3) Tighten the drain plug (P).
3-158
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT

k WARNING
• Do not open the radiator cap unless necessary.
When checking the coolant level, check it when the engine is cold.
• Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radia-
tor.
You may get burn injury if you remove the cap in this state. Always wait for the temperature to go
down, pull up the lever on the cap slowly to release the pressure, then remove the cap with care.
1. Check that the coolant level in the tank is between the

lines on the gauge (1).
If it is insufficient, add coolant through the filler port or

service center.
When adding coolant through the filler port, pull up the lev-
er on the cap (2) to release the pressure in the radiator,
then remove the cap (2).
Add coolant up to the middle between the lines of the
gauge (1).
If more coolant is added than usual, then check for water
leakage.
2. Check that there is no oil in the engine coolant or any oth-
er problem.
3. After refilling with coolant, tighten the cap (2) securely.
3-159
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL
k WARNING
Allow parts and oils to cool to the touch before you perform maintenance.
1. Pull out the dipstick (G) and wipe the oil off with a cloth.
2. Fully insert the dipstick (G) into the dipstick pipe, then pull it out.
It is correct if the oil level is between marks H and L.
If the oil level is below L mark, add oil through the oil filler
port (F) or the service center.
If the oil level is above H mark, loosen the drain plug (1) to
drain the excessive oil.
3. Check the oil level again.
4. If the oil level is proper, tighten the oil filler cap (F) secure-
ly.
3-160
METHOD FOR CHECKING ELECTRIC WIRING

k CAUTION
• If fuses are frequently blown out or if there are traces of short-circuiting on the electric wiring, im-
mediately ask your Komatsu distributor to locate the cause of it and to perform the repair.
• Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap with water to clear the vent hole.
NOTICE
Perform inspection for the piping of “battery”, “starting motor”, and “alternator” with extreme care.
• Perform inspection to confirm that the fuses have no defect and their capacity is proper.
• Perform inspection to confirm that there is no disconnection or trace of short-circuiting in the electric wiring
and no damage to the coating.
• Perform inspection to confirm that there is no loose terminals, and tighten any loose parts if found.
• Check if there is any accumulation of combustible material around the battery, and remove such combusti-
ble material.
3-161
METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL

k WARNING
• Fuel is highly flammable and dangerous. Do not bring any open flame near fuel.
• Before adding fuel, stop the engine and do not let anyone get on the machine.
Do not allow fuel to spill.
• If any fuel spills, wipe it up completely. If fuel spills over soil or sand, remove that soil or sand.

2. Check the remaining level with the fuel gauge (1) on the
machine monitor.
When the fuel gauge pointer indicates the red range, the
fuel quantity is 313 ℓ or less {82.7 U.S.Gal or less} .
If the fuel level is low, add fuel.
3. After checking, turn the starting switch back to OFF posi-
tion.
4. Open the fuel filler cap (F) of the fuel tank.
5. Add fuel through the fuel filler port.
Fuel tank capacity: 2120 ℓ {560 U.S.Gal}
6. After adding fuel, securely close the fuel filler port cap (F)
of the fuel tank.
After finishing the work, fill the fuel tank.

REMARK
• If the breather hole in the cap is clogged, the pressure inside the tank will go down and this may cause fuel
to stop flowing. To prevent this, clean the breather hole from time to time.
• To prevent air from being sucked into the engine, always pay careful attention to the fuel level in the tank.
METHOD FOR ADDING FUEL BY USING FUEL COUPLER

Pump unit for adding fuel and nozzle for adding fuel (ZZ9A1 manufactured by WIGGINS or equivalent) are nec-
essary when adding fuel from the oil filler port (F).
1. Remove the cap of the fuel coupler for oil filler port (F),
and securely connect the coupler on the pressure pump
side.
2. Refill the fuel with pressure pump.
Fuel tank capacity: 2120 ℓ {560 U.S.Gal}
3. After finishing the refilling of fuel, remove the coupler on
the pressure pump side.
4. Install the cap to the fuel coupler.
3-162
METHOD FOR CHECKING TIRE PRESSURE

Check the tire inflation pressure before starting work while the tires are cold.
1. Measure the tire inflation pressure with an air pressure gauge.
2. Adjust the tire inflation pressure properly.
The proper tire inflation pressure is shown below.
Tire inflation pressure kPa { kg/cm2,
Tire size
PSI}
33.00R51 700 {7.14, 102}
NOTICE
Make sure to keep the tire pressure within 0 to +30 kPa {0 to +0.3 kg/cm2, 0 to +4.27 PSI} of the value
in this table.
3. Check the tires and the rims for wear or damage, and check the hub bolts for looseness.
METHOD FOR CHECKING MACHINE MONITOR

2. Check that all the monitors, gauges and centralized warn-

ing lamp light up for approximately 2 seconds, and check
that the alarm buzzer sounds for approximately 2 seconds.
Check that the pointer of engine tachometer swings.
If the lamps do not light up, there may be a failure or wire
breakage in the machine monitor. Ask your Komatsu dis-
tributor for inspection.
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METHOD FOR CHECKING BRAKE

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

k WARNING
The machine may start moving during the checking of the secondary brake performance. As a result,
serious personal injury or death may occur. Observe the following.
• Select the flat and large area which gives the machine an enough braking distance to stop securely.
• If the machine starts moving during the inspection of the secondary brake performance, immediate-
ly reduce the engine speed, set the gear shift lever to NEUTRAL position (N), set the parking brake
to “PARKING” position, and stop the machine.
• While the dump body float caution lamp is being lit and the shift indicator is displaying “L”, per-
forming the inspection may damage the inside of the transmission.
Before performing the inspection, lower the dump body so that it sits securely. Check that the dump
body float caution lamp is not lit, set the gear shift lever to D position, and check that the shift indi-
cator displays “2”.
REMARK
Secondary brake actuates the parking brake.
1. Park the machine on a flat and large area.
2. Depress the accelerator pedal (1) and increase the engine
speed.
Check that the brake oil pressure caution lamp is not lit on
the machine monitor (2).
If the brake oil pressure caution lamp is lit, the pressure on
the brake accumulator is lowered.
3. Set the parking brake switch (3) to “TRAVEL” position, and
depress the secondary brake pedal (4).
4. Set the gear shift lever (5) to D position.
5. Depress the accelerator pedal (1) to increase the engine
speed gradually until it reaches to 1270 rpm.
There is a trouble in the brake if the machine starts moving
this time.
Ask your Komatsu distributor for repair.
6. Release the accelerator pedal (1) to decrease the engine
speed, set the gear shift lever (5) to NEUTRAL position
(N), and set the parking brake switch (3) to “PARKING” po-
sition.
3-164
METHOD FOR CHECKING SECONDARY STEERING

k WARNING
Do not use the secondary steering pump for longer than 90 seconds.
If it is used continuously for longer than that, the motor of the secondary steering pump may get burnt
or get damaged, or a fire will be caused.
Self-check function for secondary steering

k CAUTION
If the machine is steered during the self-check, it may move.
Do not steer the machine during self-check.
The secondary steering is started automatically when the starting switch is turned to ON position to check the
secondary steering functions.
If a failure of the secondary steering motor is found, ask your Komatsu distributor for repair.
Self-check of the secondary steering is not performed in the following cases.
In this case, perform “Check of automatic secondary steering”.
• When you turn the starting switch to ON position, and turn it to OFF position without starting the engine,
then turn it to ON position again
• When the ambient temperature is low (-10 °C or lower {14 °F or lower} )
REMARK
The battery voltage may drop sharply when the self-check is started due to the low temperature or condition of
the given battery.
METHOD FOR CHECKING MANUAL SECONDARY STEERING

1. Turn the starting switch (1) to ON position.
2. Press the secondary steering switch (2) to make it “ON”.
3. Turn the steering wheel (3) and check that the steering can
be operated.
If the steering cannot be operated when the steering wheel
(3) is turned, ask your Komatsu distributor for repair.
3-165
METHOD FOR CHECKING AUTOMATIC SECONDARY STEERING

1. Turn the starting switch (1) to START position and start the
engine.
2. Check that the brake oil pressure caution lamp is not lit on
the machine monitor (2).
3. Pull the retarder control lever (3) fully.
4. Stop the engine.
6. Set the parking brake switch (4) to “TRAVEL” position, and
check that the secondary steering motor operates in 1 sec-
ond.
While the secondary steering motor is in operation, the
secondary steering pilot lamp (5) lights up.
7. After checking, set the parking brake switch (4) to “PARK-
ING” position.
8. Turn the starting switch (1) back to OFF position.
REMARK
If the secondary steering motor operates 1 minute or longer,
the secondary steering motor long-operation caution lamp (6)
lights up.
Do not operate the secondary steering motor for a long time.
METHOD FOR CHECKING DUMP BODY POSITIONER OPERATION

1. Turn the starting switch to START position and start the
engine.
2. Set the dump lever to “RAISE” position and release it.
3. Check that the dump body stops before the stroke end.
REMARK
If the dump body positioner is not actuated, you can feel
the shock due to the dump body contact when the dump
body reaches to the stroke end. The dump body stops
without shock since the dump body positioner is actuated.
4. Lower the dump body and set the dump lever to “FLOAT”
position.
5. Turn the starting switch to OFF position and stop the engine.
METHOD FOR CHECKING BACKUP ALARM OPERATION

2. Place the gear shift lever in R position and check that the backup alarm sounds.
3. After checking, turn the starting switch back to OFF position.
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METHOD FOR CHECKING HORN OPERATION

2. Check that the horn sounds immediately when the horn
button is pressed.
If the horn does not sound, ask your Komatsu distributor
for repair.
3. After checking, turn the starting switch back to OFF posi-
tion.
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METHOD FOR CHECKING ACTION OF KomVision CAMERA

Camera image area
(A) Front camera (D) Rear camera

(B) Right front camera (E) Left rear camera
(C) Right rear camera (F) Left front camera
KomVision system starts up.
2. Check that all the camera images are correctly displayed

on the KomVision monitor screen (2).
If there is any disturbed image, clean the camera again. If
the condition does not become normal, ask your Komatsu
distributor for repair.
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METHOD FOR CHECKING ACTION OF KomVision RADAR

This is the check to confirm that each KomVision radar is operated normally.
Radar detection range
(A) Front side left detection radar (E) Rear side right detection radar
(B) Front side right detection radar (F) Rear side left detection radar
(C) Right side front detection radar (G) Left side rear detection radar
(D) Right side rear detection radar (H) Left side front detection radar
REMARK
• This figure of radar detection range is only an image. Actually, there is no blind spot between the radars.
• For other area around the machine where is not detected by radar, see “OPERATION AND OBSTRUC-
TION DETECTION AREA OF KomVision RADAR”.
The check does not require a wide space.
KomVision system starts up.
3-169
2. Press the radar check switch (2), and start up the radar
check mode.
Check that it is operated as follows.
• On the KomVision monitor screen (3), the areas (4)

which correspond to 8 radars are filled with yellow.
• The radar check caution lamp (5) is flashing in yellow.
• The obstacle alarm buzzer is sounding intermittently.
If any obstacles are around the machine, the color filling of

the radar detection area where the obstacles are detected
is cleared 3 seconds later, and the condition becomes nor-
mal.
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3. Walk around the machine two times while turning the aper-
ture face (A) of the accompanying corner reflector (6) to-
ward the machine and keeping 2 m {6 ft 7 in} distance (B)
from the machine.
REMARK
Corner reflector (6) is stored in the box (7).
4. Return to the operator's seat, and check the KomVision

monitor.
Check that it is operated as follows.
• On the KomVision monitor screen (3), all the yellow
filling is cleared, and the screen returns to the stand-
ard screen.
• The radar check caution lamp (5) is flashing in green.
• The obstacle alarm buzzer is stopped.
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If there is any trouble in radar, the detection area of that radar remains filled with yellow, and the obstacle alarm
buzzer does not stop.
If a trouble is found, clean the radar and perform the step 3. again. If the condition does not become normal, ask
your Komatsu distributor for repair.
REMARK
• The radar caution lamp (green) goes out when the parking brake is turned to “TRAVEL” position.
• If the parking brake is released during the radar action check, the yellow filling is cleared and the obstacle
alarm buzzer stops, however, the radar check caution lamp (yellow) remains flashing.
3-172
ADJUST BEFORE OPERATION

METHOD FOR ADJUSTING OPERATOR'S SEAT
k WARNING
• When adjusting the operator's seat, stop the machine on a safe place and set the parking brake to
“PARKING” position beforehand.
• Adjust it before starting operation or when operators change shift.
• Adjust the position of the operator's seat so that you can depress the brake pedal fully with your
back against the seat backrest.
METHOD FOR 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 fore-aft adjustment lever.
Adjustment amount: 152.4 mm {6 in}
Number of stages for adjustment: 12 stages
Adjustment amount per 1 stage: 12.7 mm {0.5 in}
If the seat backlash is found, ask your Komatsu distributor for
adjustment.
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METHOD FOR RECLINING SEAT

Pull up the reclining adjustment lever, and move the back cush-
ion forward or backward.
Sit with your back against the backrest when adjusting the re-
clining angle. If your back is not on the backrest, it may sud-
denly return to the original position.
Adjustment amount
Forward tilt: 21 ° (any degree is acceptable if it is 21 ° or more.)
Backward tilt: 15 °
METHOD FOR TILTING SEAT

Operate the tilt adjustment lever upward, move the front of the
seat cushion up and down to adjust it to the desired position,
then release the tilt adjustment lever.
Adjustment amount
Forward tilt: 5 °
Backward tilt: 5 °
3-174
METHOD FOR ADJUSTING SEAT HEIGHT

NOTICE
Avoid using the height adjustment switch continuously for 1 minute or longer since such practice can
damage the air compressor.
Turn the starting switch to ON position when performing adjustments since the air compressor built in the seat is
used for this adjustment.
The seat height is adjusted pneumatically and in stepless.
Press the height adjustment switch, adjust the seat to the de-
sired position, and release the height adjustment switch.
(a) Raise position
Seat rises.
(b) Lower position
Seat lowers.
Adjustment amount: 152 mm {6 in}
REMARK
When the seat is low or when the machine has not been used
for a while, it takes time to raise the seat to the desired height,
since no air is in the suspension.
You can adjust the seat height to the desired position more
quickly by pressing the switch while reducing the load on the
seat.
METHOD FOR ADJUSTING SEAT CUSHION IN FORE-AFTER DIRECTION

Pull up the fore-and-aft adjustment lever, set the seat cushion
to the desired position, then release the fore-and-aft adjust-
ment lever.
Fore-aft adjustment range: 60 mm {2.4 in}
If the seat backlash is found, ask your Komatsu distributor for
adjustment.
3-175
METHOD FOR ADJUSTING HEADREST ANGLE

Move the headrest back and forth to set it to the desired angle.
Adjustment amount: 30 °
METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION

Move the headrest up or down to the desired height.
Adjustment amount: 108 mm {4.3 in}
METHOD FOR ADJUSTING ARMREST ANGLE

Turn the knob to adjust the armrest angle.
Adjustment amount: 35 ° (Forward tilt 12 °, backward tilt 23 °)
REMARK
You can flip up the armrest.
METHOD FOR ADJUSTING AIR LUMBAR SUPPORT

NOTICE
Avoid operating the air lumbar support continuously for 1 minute or longer since such practice can
damage the air compressor.
Operate the air lumbar support adjustment switch to give a
proper tension to the waist part.
(A) Position for air inflation
Air is pumped in the air bag in the backrest and the air bag is
inflated.
(B) Position for air bleeding
Air is bled from the air bag in the backrest and the air bag
shrinks.
3-176
METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS

Adjust the damping force of the suspension damper by operat-
ing the suspension damper hardness adjustment knob.
(A), (B) Low position
The suspension damper becomes softer and its damping force
is reduced.
The shock to the seat is further decreased.
(C) Recommended position
Normally, this position is recommended.
It is preset as the best position for the operator comfort.
(D), (E) High position
The suspension damper becomes harder and its damping force
is increased.
The vertical movement of the suspension is decreased.
Adjustment amount: 5 stages
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METHOD FOR USING SEAT HEATER AND VENTILATION

k CAUTION
• Using the heater for a long time may cause low temperature burn (blister, etc.).
• Do not put heavy luggage on the cushion. Do not stick the cushion with needles, nails, etc.
• Do not put blanket, cushion, or other heat-retaining material on the seat cushion. Doing so may
cause overheat.
• If water or beverage, etc. spills on the seat cushion, immediately wipe it off with soft cloth, etc., and
dry out the seat cushion before using it.
REMARK
• The seat heater and the ventilation cannot be used at the same time.
• The seat heater has no timer function and is not turned off automatically. Be sure to turn off the seat heater
switch immediately after using the heater.
• When using the seat heater
1. Set the seat heater and ventilation selector switch (1)
to the seat heating position (A).
2. Set the air flow control switch (2) to HIGH position (D)
or LOW position (E).
The heater in the seat cushion operates, and the seat
cushion and backrest become warm.
(C) OFF position
The seat heater stops.
(D) HIGH position
The seat heater operates.
(E) LOW position
The seat heater operates.
REMARK
The temperature of the seat does not change even if
the air flow control switch (2) is in either HIGH position
(D) or LOW position (E).
3. Turn the air flow control switch (2) to OFF position (C)
when the temperature of the cushion becomes suitable.
The heater in the seat cushion stops.
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• When using the ventilation

1. Set the seat heater and ventilation selector switch (1)
to the ventilation position (B).
2. Set the air flow control switch (2) to HIGH position (D)
or LOW position (E).
The ventilator operates, and air blows out from the
cushion seat and backrest.
(C) OFF position
The ventilation function stops.
(D) HIGH position
Air flow "high"
(E) LOW position
Air flow "low"
3. When turning the ventilation air flow control switch (2)
to OFF position (C), the ventilation stops.
3-179
METHOD FOR ADJUSTING MIRRORS

k WARNING
Adjust the mirrors for the best visibility before work. Incorrect adjustment may restrict visibility and
may cause serious personal injury or death.
k CAUTION
The following conditions must be met before starting the work to prevent the machine from moving dur-
ing adjustment.
• The machine is placed on a level ground.
• The dump body is seated.
• The engine is stopped.
Loosen mirror mounting bolt (1) and nut (2), then adjust the mirror to the position that assures the best view
from the operator's seat.
• Adjust the position and angle of each mirror so that it re-
flects a sight of 200 mm or more {7.9 in or more} within the
height of 1500 mm {4 ft 11 in} above the ground.
In the adjustment, make sure that a part of the machine al-
so comes into view.
• View range
Mirror (A)
Hatched area (A) must be in view.
Mirror (B)
Hatched area (B), and tire's ground contact point (B') must
be in view.
Mirror (C)
Hatched area (C) must be in view.
Mirror (D)
Hatched area (D), and foot of the ladder (D') must be in
view.
Mirror (E)
Hatched area (E), and foot of the slanted ladder (E') must
be in view.
Mirror (F)
The top of slanted ladder (F) must be in view.
Mirror (G)
Hatched area (G) must be in view.
Mirror (H)
Hatched area (H), and tire's ground contact point (H') must be in view.
3-180
3-181
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE

k WARNING
• When the direction of the camera is changed due to an accident, setting must be done again.
Contact your Komatsu distributor.
• Be sure to adjust the rearview camera before starting work.
If the rearview camera is not adjusted properly, you cannot secure the visibility and will be injured
or may lead to a serious personal injury or death.
• When adjusting the angle of the rearview camera, prepare a scaffold first in order to provide a safe
working platform.
Otherwise serious personal injury or death by such as falling may occur.
• Install only the Komatsu genuine camera.
As shown in the figure, stop the machine on a flat ground, and make the machine unloaded.
When the machine dimensions are changed due to replacement of tires or installation of an optional attachment,
set the reference lines to the non-display mode, 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
the machine width reference line (3) matches with the tire outside width (1) and the distance reference line (4)
matches with the body rear end (2).
3-182
When the reference line is abnormal, change its setting to non-

display and contact your Komatsu distributor.
3-183
ADJUST SEAT BELT

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

Fit the seat belt so that it fits tightly, without being too tight.
1. Sit on the seat and depress the brake pedal fully. Under
this condition, adjust the seat so that your back is fitted to
the backrest.
2. Sit on the seat, pull the right side of the belt, then insert the buckle tongue (1) into buckle (2) until it “clicks”.
Fit the belt along your body without twisting.
When unfastening the belt, press the red button on buckle (2) to free the belt.
REMARK
If the seat belt is not inserted to buckle (2), seat belt cau-
tion lamp (3) is displayed on the machine monitor. Be sure
to fasten the seat belt.
3-184
METHOD FOR CONNECTING SHOULDER BELT AND WAIST BELT

1. Insert the tongue (2) of the shoulder belt into the buckle
tongue (1) of the waist belt.
2. Rotate the tongue (2) of the shoulder belt and make sure
that it is securely fixed to the buckle tongue (1) of the waist
belt.
METHOD FOR RELEASING SEAT BELT RETRACTOR STOPPER

1. Remove the retractor from the seat.
A fitting can be seen from the bolt side through the oblong
hole as shown in the figure.
2. Pull the belt while pushing in the fitting with a ruler or such.
The stopper is released and you can untwist the belt if it is
twisted.
3-185
METHOD FOR ADJUSTING SEAT BELT ANCHOR

Move the seat belt anchor up and down to adjust it to the de-
sired height.
Adjustment amount: 100 mm {3.9 in}
Number of stages for adjustment: 6 stages
Adjustment amount per 1 stage: 20 mm {0.8 in}
METHOD FOR ADJUSTING TILT OF STEERING WHEEL

k WARNING
Stop the machine before adjusting the tilt of the steering wheel.
If this operation (adjustment) is performed while the machine is traveling, it may lead to a serious per-
sonal injury or death.
NOTICE
Do not operate the steering tilt lock lever with excessive force. (Operating effort of steering tilt lock lev-
er: 147 N to 176 N {15 kg to 18 kg})
The steering tilt lock lever may become loosened or the angle of the steering tilt lock lever may be mis-
aligned.
Ask your Komatsu distributor for inspection in such case.
You can adjust the tilt position and height of the steering wheel.
1. Raise the steering tilt lock lever to FREE position (F), and
adjust the steering wheel to a desired position.
Tilt adjustment amount
Forward: 5 °, backward: 10 °
Telescopic adjustment amount
Upward: 20 mm {0.8 in}, downward: 20 mm {0.8 in}
2. Push down the steering tilt lock lever to LOCK position (L),
and fix the steering wheel securely.
3-186
METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE

k WARNING
• Make sure to set the gear shift lever to NEUTRAL (N)
and parking brake switch to “PARKING” before you
start the engine.
• Make sure to set the parking brake switch to “PARK-
ING” before you leave the operator seat to avoid sud-
den machine movement.
1. Check that the battery disconnect switch and starting mo-

tor disconnect switch are at ON position (A).
2. Check that the parking brake switch (1) is in “PARKING”

position.
3. Check that the gear shift lever (2) is in NEUTRAL position

(N).
3-187
4. Check that dump lever (3) is in “HOLD” position.
5. Check that the retarder control lever (5) has been set up-
ward.
6. Check that the cover of the engine shutdown secondary

switch (4) is closed.
7. Insert the key into the starting switch (5) and turn it to ON
position (B).
8. Check that the machine monitor operates in the following

manner.
1) The centralized warning lamp (6) and the pilot display
(7) are lit for 2 seconds and go out for 1 second.
3-188
2) The machine monitor (8) displays the starting screen

for 2 seconds.
3) The pointer of the engine tachometer (9) swings once.
4) The speedometer (10) displays “88” for 2 seconds.
5) The alarm buzzer sounds for 2 seconds, then stops
under the normal condition.
NOTICE
Consult your Komatsu distributor when either the
lamps, buzzers or the machine monitor does not
function.
REMARK
• When the engine is started, the battery voltage may suddenly drop depending on the temperature
and the battery condition.
• Approximately in a second, the rearview monitor
displays the software version for 5 seconds.
6) If a password has been set, the password input screen will be displayed on the monitor screen.
After inputting the password, press ENTER switch.
REMARK
For the password setting, changing or canceling, see
the separate volume “Password Change and Cancel
Procedure”.
7) In 2 seconds, the machine monitor (8) displays the

standard screen.
3-189
• When the starting switch is turned to ON position,

the secondary steering self-check function may
operate.
When the standard screen is displayed while the
self-check is in operation, the secondary steering
pilot lamp (11) lights up.
REMARK
While the secondary steering self-check function is in
operation, the machine monitor may go out temporari-
ly or restart, but it is not a trouble.
If the gear shift lever is in any position other than NEUTRAL position (N) when the starting switch is
turned to ON position, the shift lever position pilot lamp (12) of that position starts flashing, the central-
ized warning lamp lights up, and the alarm buzzer sounds intermittently.
Turning the starting switch to START position in this state does not start the engine.
Turn the gear shift lever to NEUTRAL (N) position, and the centralized warning lamp goes out, the
alarm buzzer stops sounding, and the engine can be started.
9. When the caution lamp stays lit, press ENTER switch, and
“Error List” screen is displayed.
For the contents and check methods for caution lamp, see
“WARNING DISPLAY (3-18)”.
10. When the maintenance time caution lamp lights up in red,

press the menu switch and “Maintenance” menu screen is
displayed.
For the method of checking the maintenance time, see
“MAINTENANCE SCREEN SETTING (3-75)”.
The maintenance time caution lamp is lit for 30 seconds.
11. Check that the KomVision monitor (13) operates as follows after turning the starting switch (5) to ON posi-
tion.
1) “KomVision” logo is displayed after turning the starting
switch (5) to ON position, and the standard screen is
displayed in 30 to 40 seconds.
2) For the machine equipped with radar, the obstacle
alarm buzzer sounds for 2 seconds, then stops under
the normal condition.
3-190
REMARK
• When the starting switch is turned from ON position to OFF position and immediately turned to ON po-
sition again, the start-up of KomVision system may take longer than usual.
• If the standard screen is not displayed or the obstacle alarm buzzer does not sound 2 minutes after the
starting switch is turned to ON position, there may be a problem in the KomVision system. Ask your
Komatsu distributor for repair.
3-191
METHOD FOR STARTING ENGINE

k WARNING
• Start the engine only while sitting on the operator's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit.
Doing so may cause a serious personal injury or death or fire.
• Check that there is no person or obstacle in the area around the machine, then sound the horn and
start the engine.
• Exhaust gas is toxic.
When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
NOTICE
• Do not increase the engine idle speed before the en-
gine becomes warm.
• Do not start the engine for more than 20 seconds inter-
vals.
• Wait 2 minutes between attempts.
• When starting the engine, do not depress the accelera-
tor pedal.
For the machine equipped with ether injection device, if the engine air intake temperature is -4 °C or lower
{24.8 °F or lower} , ether is automatically injected.
1. Turn the key in starting switch (1) to ON position (B).
2. Turn the starting switch (1) key to START position (C).

The lubrication of the engine is automatically started.
When the lubrication of the engine is completed, the start-
ing motor rotates to start the engine.
REMARK
When the ambient temperature is low, the engine may not start even if 20 seconds elapses after the key
in starting switch (1) is kept at START position and the starting motor starts rotating.
In such case, return the key in starting switch (1) to OFF position once, then in approximately 2 minutes,
repeat the operation from the start.
3. After the engine starts, release the key in the starting switch (1).
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The key in starting switch (1) automatically returns to ON

position (B).
REMARK
When starting the engine, battery voltage may drop
abruptly depending on the ambient temperature or battery
condition, and the machine monitor (2) may go out tempo-
rarily or restart, but it is not a trouble.
4. Do not operate the accelerator pedal immediately after
starting the engine. Run the engine for at least 15 seconds
at low idle.
When the engine is started for the first time after the engine oil or engine oil filter is replaced, continue the
low idle run for at least 20 seconds to circulate the engine oil in the engine.
3-193
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE

k WARNING
• If there has been any emergency stop, abnormal actuation, or other trouble, turn the starting switch
key to OFF position.
• If you cannot stop the engine by turning the starting switch key to OFF position, use the engine
shutdown secondary switch to stop the engine.
METHOD FOR CANCELING TO HOLD DUMP BODY

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

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

k CAUTION
• Perform these checks in a safe place, watching out for danger in the area around the machine.
• When the engine performs very badly at low idle and in the acceleration and if that condition contin-
ues, it may damage the engine or confuse the operator's sense of driving or lower the braking effi-
ciency, and as a result lead to an unexpected accident. In that case, ask your Komatsu distributor to
check the engine as soon as possible.
• When stopping the machine during the normal travel operation, check that the engine does not hunt or stop
suddenly.
• When the accelerator pedal is depressed, check that the engine speed rises smoothly.
3-194
METHOD FOR RUNNING-IN THE NEW MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating
the machine under severe conditions at the beginning can adversely affect the performance and short-
en the machine life. Be sure to run in the machine for the initial 100 hours (as indicated by the service
meter).
Make sure that you fully understand the descriptions in this manual, then run in the machine while paying atten-
tion to the following points.
• Perform warm-up operation for 5 minutes after starting it up.
• Avoid operation with heavy loads or at high speeds.
• Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden
stops, and sudden changes in direction of the machine.
METHOD FOR WARM-UP OPERATION

NOTICE
• Do not increase the engine speed sharply during the warm-up operation.
It can shorten the service life of the engine parts.
• Do not continue the low idle or high idle operation for more than 20 minutes.
It does not only adversely affect the environment but also cause oil leakage from the turbocharger.
• When the warming up has not been operated enough, if the parking brake switch is set to “TRAV-
EL” and the dump lever is operated, the secondary steering may be actuated instantaneously.
1. After the engine starts, run it for 5 minutes in the range between low idle and medium speed to warm it up.
2. Check if the indicator of the engine coolant temperature
gauge is over position (A).
When it is over position (A), the warm-up operation is com-
pleted.
If the indicator does not move from position (A), perform
the warm-up operation further
3. After finishing the warm-up operation, check that the ma-
chine monitor is normal.
If any of them is abnormal, ask your Komatsu distributor
for inspection and repair.
4. Check that the steering operation is normal, the lamps light up and go out normally, the horn sounds, and
the exhaust gas color, sound, and vibration are normal.
If any of them is abnormal, ask your Komatsu distributor for inspection and repair.
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FUNCTION OF FILLING ACCUMULATOR

This machine is equipped with the accumulator filling function.
When brake oil pressure is low and the brake oil pressure cau-
tion lamp is displayed at (A) position, the engine low idle speed
will increase to fill the accumulator.
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METHOD FOR STOPPING ENGINE

NOTICE
• Do not stop the engine immediately while loaded. This
can cause the engine to run hot and accelerate wear of
components. Park the machine, engage the park
brake, and run the engine until cool down before shut-
down.
• Always lower the dump body and set the dump lever
to “FLOAT” position, then stop the engine.
1. Set the gear shift lever (1) to NEUTRAL position (N), and
set the parking brake switch (2) to “PARKING” position.
2. Lower the dump body and set the dump lever (3) to
“FLOAT” position.
3. Run the engine at low idle for approximately 5 minutes to
cool it down gradually.
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4. Turn the key in starting switch (4) to OFF position (A), and
stop the engine.
5. Remove the key from the starting switch (4).
METHOD FOR CHECKING AFTER STOPPING ENGINE

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

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

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

Check that the dump body float caution lamp is not lit.
If the dump body float caution lamp is lit, operate the dump
lever (2) to “HOLD” position once, then operate it to
“FLOAT” position to cancel the dump body HOLD condi-
tion.
4. Depress the brake pedal (3) fully.
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5. Then set parking brake switch (4) to “TRAVEL” position to

release the parking brake.
REMARK
If the engine is stopped with the parking brake switch at
“TRAVEL” position, the parking brake will be automatically
applied even though the parking brake switch is at “TRAV-
EL” position. In this case, operate the parking brake switch
to “PARKING” position once, and then move it back to
“TRAVEL” position to release the parking brake.
6. Check that the retarder pilot lamp is not lit on the machine
monitor (1).
7. Set the gear shift lever (5) to a desired position.

NOTICE
• Always place the gear shift lever securely in posi-
tion when operating it. If the gear shift lever is not
placed securely in position, the shift lever position
pilot lamp on the machine monitor may start flash-
ing and the centralized warning lamp may light up,
and the alarm buzzer may sound.
• Always release the accelerator pedal when moving
the gear shift lever from the positions NEUTRAL
(N) to REVERSE (R) or FORWARD (D to L).
8. Depress the accelerator pedal (6) to start the machine.
NOTICE
• If the gear shift lever is shifted to a position other
than NEUTRAL position (N) when the parking
brake has not been released, the centralized warn-
ing lamp will light up and the alarm buzzer will
sound.
• If the gear shift lever is shifted to a position other
than NEUTRAL (N) when the dump lever is in a po-
sition other than “FLOAT” or the dump body is
raised, the centralized warning lamp lights up, the
body float caution lamp lights up in red, and the
alarm buzzer sounds.
• Do not operate the gear shift lever with the accel-
erator pedal depressed.
This will cause a big shock, and will also reduce
the service life of the machine.
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METHOD FOR TRAVELING REVERSE

k WARNING
• When switching the travel direction, confirm the safety
in the direction to select.
There is a blind spot behind the machine, so be ex-
tremely careful when driving the machine in reverse.
• Always stop the machine completely before switching
the travel direction.
NOTICE
• The machine cannot be driven in reverse when the
dump body is raised. Lower the dump body, set the
dump lever to “FLOAT” position, then operate the gear
shift lever to R position.
• When switching between Forward and Reverse, stop
the machine completely and run the engine at low idle
when shifting the direction of travel.
After moving the gear shift lever, do not accelerate un-
til it is detected that the transmission clutch is engag-
ed.
• Do not operate the gear shift lever with the accelerator
pedal depressed.
This will cause a big shock, and will also reduce the
service life of the machine.
1. Set the gear shift lever (1) to R position.
2. Depress the accelerator pedal (2) gradually to move off.
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METHOD FOR STOPPING MACHINE

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

k WARNING
When the machine stops, chock the wheels immediately.
If the machine is not stopped by depressing the brake pedal, perform the following.
1. Pull the retarder control lever (1) fully to apply the retarder.
If operating the retarder control lever (1) does not give

enough braking force, depress the secondary brake pedal
(2).
Secondary brake actuates the parking brake.
REMARK
If the machine is stopped by the secondary brake, the cen-
tralized warning lamp flashes and the alarm buzzer
sounds.
In this case, return the gear shift lever to NEUTRAL posi-
tion (N) to cancel the operation of centralized warning
lamp and alarm buzzer.
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2. After the machine is stopped, set the parking brake switch

(3) to “PARKING” position.
3. When the machine is stopped in emergency, chock the
tires immediately.
Investigate the failure on the front brake and ask your Ko-
matsu distributor for repair.
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METHOD FOR SHIFTING GEARS

k WARNING
• Do not move transmission lever to NEUTRAL (N) when
you travel. Make sure the transmission is in L when
you travel downhill.
• If the gear shift lever is set to NEUTRAL position (N)
while the machine is traveling at the travel speed of
4 km/h or higher {2.5 MPH or higher} or traveling
downhill, the gear speed is not changed to neutral.
The centralized warning lamp flashes and the alarm
buzzer sounds. Always set the gear shift lever in D to
L position while traveling.
• If the gear shift lever is shifted to NEUTRAL position
(N) during traveling or traveling downhill, the engine
brake is disabled and steering operation becomes
heavy. In addition, there will be insufficient cooling oil
for the retarder, and there will be hazard of overheat-
ing or defective operation of the brakes.
• There may also be damage to the transmission or oth-
er parts of the power train, and there is danger of un-
expected accidents.
NOTICE
• When switching the direction (FORWARD or REVERSE), stop the machine completely and run the
engine at low idle, then select the direction of travel.
After moving the gear shift lever, do not accelerate until it is detected that the transmission clutch is
engaged.
• Do not operate the gear shift lever with the accelerator pedal depressed.
This will cause a big shock, and will also reduce the service life of the machine.
Set the 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.
If the dump body is not completely lowered, the gear speed is
fixed at 1st when the gear shift lever position is in D to L. Keep
the dump body lowered when traveling.
• When upshift (acceleration)

Depress the accelerator pedal (2) gradually to accelerate
the machine.
The lockup clutch is engaged and the direct drive starts.
If the machine is accelerated further, the transmission au-
tomatically shifts up.
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• When downshift (deceleration)

Release the accelerator pedal (2).
The machine is decelerated and the transmission automat-
ically shifts down.
Downshift inhibit
If the gear shift lever is operated when the machine is traveling, the travel speed may be faster than the maxi-
mum speed allowed for the new speed range. In this case, do not shift gear immediately. Reduce the travel
speed and then shift down. This will prevent the engine from overrunning.
Downshift when brake pedal is used
When using the brake pedal to reduce the speed, the 4th speed is held for longer than normal to reduce the
shock when shifting gear.
Skip shift
Gear speed is shifted by one step in normal gear shifting.
When the travel speed is suddenly dropped after starting the uphill travel, the gear shifting shock is reduced by
downshifting the gear with skipping the next gear speed.
Engine overrun prevention function
If the engine speed exceeds the allowable range while traveling, the engine overrun caution lamp and the cen-
tralized warning lamp light up and the alarm buzzer sounds intermittently.
If the travel speed and engine speed continue to rise, the brake is automatically applied to prevent the engine
speed from rising too far.
Neutral coast prevention function
If the gear shift lever is set to NEUTRAL position (N) while the machine is traveling at the travel speed of 4 km/h
or higher {2.48 MPH or higher} , the gear shift cannot be changed to neutral. The centralized warning lamp
flashes and the alarm buzzer sounds intermittently.
If the travel speed exceeds 4 km/h {2.48 MPH} while traveling downhill with the gear shift lever in NEUTRAL
position (N), the centralized warning lamp flashes and the alarm buzzer sounds intermittently.
When the travel speed exceeds 15 km/h {9.32 MPH} , the gear speed is automatically shifted to the gear speed
optimum to the current travel speed.
When traveling, and particularly when traveling downhill, never set the gear shift lever to NEUTRAL position (N).
Always set the gear shift lever in D to L position while traveling.
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METHOD FOR TRAVELING DOWNHILL

When traveling downhill, travel at a safe speed which matches the width of the road, the condition of the road
surface, and other conditions of the jobsite.
k WARNING
• When the machine stops, chock the tires immediately.
• For the maximum permissible speed when traveling downhill using the retarder brake, see the
brake performance curve for the downhill distance and grade.
Traveling continuously downhill at a speed greater than the maximum permitted speed on the brake
performance curve is dangerous as the retarder brake may be damaged.
• If the retarder oil temperature caution lamp on the machine monitor lights up when the retarder is
being used, shift down to travel downhill.
(In this case, the centralized warning lamp lights up and alarm buzzer sounds.)
If the retarder oil temperature caution lamp does not go out even when the transmission is shifted
down, stop the machine immediately, set the gear shift lever to NEUTRAL position (N), run the en-
gine at 2000 rpm and wait until the retarder oil temperature caution lamp goes out.
• If the retarder brake loses its effect when it is used for traveling downhill, do as follows.
1. Return the retarder control lever to its original position once completely, then operate the re-
tarder control lever again.
2. If the retarder still has not effect even when the retarder control lever is operated again, return
the retarder control lever completely to “RELEASE” position, and depress the brake pedal to
stop the machine, then contact your Komatsu distributor for repair.
• Operate the retarder control lever gradually.
Sudden braking may cause an accident due to tire slip, and it is dangerous.
• When traveling, and particularly when traveling downhill, never set the gear shift lever to NEUTRAL
position (N).
If the gear shift lever is set to NEUTRAL position (N) while the machine is traveling at the travel
speed of 4 km/h or higher {2.48 MPH or higher} or traveling downhill, the gear speed is not changed
to neutral. The centralized warning lamp flashes and the alarm buzzer sounds. Always set the gear
shift lever in D to L position while traveling.
NOTICE
• If the retarder control lever is operated when traveling downhill, the transmission can be shifted
down sooner than with normal deceleration.
The machine can also travel without shifting up the gear.
• Do not accelerate or shift up the gear when using the retarder.
The engine speed rises and the alarm buzzer may sound and the engine overrun caution lamp and
centralized warning lamp may light up.
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1. Return the accelerator pedal (1) back before entering a

downhill slope.
2. Operate the retarder control lever (2) to decelerate the ma-

chine.
3. Leave the gear shift lever (3) in D position.

It is automatically downshifted to the optimal gear speed
when reducing the travel speed.
Shift the gear shift lever (3) to the position other than D po-
sition (6, 5, 4, 3, 2, L) if the gear speed needs to be fixed
due to the condition of road surface.
4. When traveling downhill, operate the retarder control lever

(2) to set the engine speed to the range of 1800 to
2100 rpm and drive the machine so that the indicator of the
retarder oil temperature gauge comes within the green
range.
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HANDLE Automatic Retarder Speed Control (ARSC)

Pressing the set switch of the ARSC travel speed set lever when the travel speed becomes the desirable speed
on downhill automatically actuates the retarder to keep the travel speed, and the retarder operation becomes
easier.
k WARNING
• ARSC system is enabled when “ARSC Setting” is set to “ON”.
Before entering the slopes, check that the appropriate travel speed is displayed on the ARSC set
travel speed indicator and the ARSC pilot lamp is lit.
• It is dangerous if the travel speed is set to the speed exceeding the maximum permissible speed
which is obtained from the braking performance curve. It may result in overheating and may dam-
age the retarder brake. Set the travel speed so that it does not exceed the maximum permissible
speed.
• The tires may be locked when the dump truck is running on a slippery hauling road and the ARSC
system is enabled. If it happens, refrain from using the ARSC system.
• When the system cannot be properly controlled due to a trouble in the system, the alarm sounds,
and the ARSC is canceled. If necessary, stop the machine at a safe place by controlling the retarder
control lever and brake pedal, and set “ARSC Setting” to “OFF”.
• The ARSC is not actuated with the gear shift lever at NEUTRAL position (N) or REVERSE position
(R). When the gear shift lever is shifted to NEUTRAL position (N) or REVERSE position (R) while
ARSC is actuated, the ARSC off pilot lamp lights up, and the ARSC set travel speed indicator goes
out, and the ARSC is canceled.
METHOD FOR OPERATING ARSC

OPERATION OF ARSC SYSTEM
1. Set “ARSC Setting” to “ON” on the user menu “Machine
Setting / Information” on the machine monitor.
The ARSC pilot lamp (1) lights up in white.
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2. Drive the machine at the desired travel speed to be set as

the set speed in ARSC, and press the setting switch (2) of
the ARSC travel speed set lever.
The travel speed is set as the travel speed for traveling

downhill. It is displayed on the ARSC set travel speed indi-
cator (3).
3. Decrease the travel speed to be lower than the set travel
speed before entering the downhill.
4. Release the accelerator pedal soon after entering the
downhill.
The ARSC pilot lamp (1) lights up in green.
5. Retarder is automatically actuated if the travel speed is ex-
ceeding the set travel speed when the machine travels
downhill.
The retarder pilot lamp (4) lights up while the retarder is actuated.
REMARK
• The set travel speed is displayed on the ARSC set travel speed indicator and saved.
• If the accelerator pedal is depressed when the ARSC is enabled, actuation of the ARSC is stopped and
the machine speed increases.
• If the brake pedal or the retarder control lever are actuated while the ARSC is enabled, the machine
can be slowed down or stopped in the same way as for normal brake operations.
• If the ARSC travel speed is set near the gear shifting point or when the grade of the slope is changed,
the gear speed may be changed (upshift or downshift) even when the ARSC is actuated.
• The time taken for the machine to reach the set travel speed varies with the grade of the downhill
slope.
• Indication of the speedometer and the set travel speed may not always be the same.
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METHOD FOR SETTING TRAVEL SPEED FOR ARSC

k WARNING
It is dangerous if the travel speed is set to the speed exceeding the maximum permissible speed which
is obtained from the braking performance curve. It may result in overheating and may damage the re-
tarder brake. Set the travel speed so that it does not exceed the maximum permissible speed.
If actual travel speed is lower than 10 km/h {6.2 MPH} during performing the setting, it is set to 10 km/h
{6.2 MPH} . If it is higher than 55 km/h {34.1 MPH} , it is set to 55 km/h {34.1 MPH} . The actual travel speed is
set as the set travel speed in other cases than above.
The following is the travel speed which can be set according to the selection of the gear shift lever.
Selection of the gear shift lever Available travel speed
D, 6, 5, 4, 3, 2, L 10 to 55 km/h {6.2 to 34.1 MPH}
N, R Not available
METHOD FOR ADJUSTING ARSC SET TRAVEL SPEED FINE CONTROL

1. Operate the ARSC speed set lever according to the following in order to finely adjust the travel speed that
has been set.
The travel speed can be adjusted by ±5 km/h {±3.1 MPH} of the set travel speed while driving the machine
with the ARSC function (while the foot is off from the accelerator pedal).
• Operate the ARSC speed set lever upward once in order to increase the travel speed by 1 km/h
{0.6 MPH} .
• Operate the ARSC speed set lever downward once in order to decrease the travel speed by 1 km/h
{0.6 MPH} .
Since the ARSC is stopped during depressing the accelerator pedal, you can perform the adjustment in the
range of 10 to 55 km/h {6.2 to 34.1 MPH} .
2. Release your hand from the ARSC speed set lever after finely adjusting the travel speed.
REMARK
• Releasing operation has a priority over the setting operation of the ARSC travel speed if those opera-
tion is performed at the same time.
• Finely adjusting operation has a priority over the setting operation of the ARSC travel speed if those
operation is performed at the same time.
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METHOD FOR CHANGING ARSC SET TRAVEL SPEED TO HIGH SPEED

1. Depress the accelerator pedal to accelerate the machine.
2. When it gets to the desired travel speed, press the set switch of the ARSC travel speed set lever.
The travel speed is changed to the high speed.
METHOD FOR CHANGING ARSC SET TRAVEL SPEED TO LOW SPEED

REMARK
Return the retarder control lever to the original position after deceleration.
Sudden lever operation will cause sudden braking. Take care.
1. Operate the retarder control lever to decelerate the machine.
2. When it gets to the desired travel speed, press the set switch of the ARSC travel speed set lever.
The travel speed is changed to the low speed.
MEMORIZE ARSC SET TRAVEL SPEED

The set travel speed is saved when the starting switch is turned to OFF position, or “ARSC Setting” is set to
“OFF”.
The next time when starting switch is turned to ON position and “ARSC Setting” is set to “ON”, the previous set
travel speed is displayed on the ARSC set travel speed indicator.
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RESTART AT ARSC SET TRAVEL SPEED

If the travel speed is set once, the ARSC is actuated again without setting it for traveling the same slope repeat-
edly.
1. Before traveling the downhill, check that the optimal set travel speed is displayed on the ARSC set travel
speed indicator and the ARSC ready pilot lamp is lit in white.
2. Adjust the travel speed to be lower than the travel speed displayed on the ARSC set travel speed indicator.
3. Release the accelerator pedal soon after entering the downhill.
The ARSC pilot lamp lights up in green, and the ARSC is actuated.
REMARK
If traveling with the travel speed which is higher than the set travel speed displayed on the ARSC set travel
speed indicator, releasing the accelerator pedal does not actuate the ARSC. The ARSC pilot lamp lights up
in white this time.
Adjust the travel speed to be lower than the travel speed displayed on the ARSC set travel speed indicator,
and check that the ARSC pilot lamp is lit in green.
METHOD FOR CANCELING ARSC SET TRAVEL SPEED

You can cancel the set speed by any of the following operation.
• Pull the ARSC travel speed set lever backward for approximately 1 second or longer.
The set travel speed is reset, and “--” is displayed on the ARSC set travel speed indicator.
• Set “ARSC Setting” to “OFF” on the user menu “Machine Setting / Information” of the machine monitor.
The ARSC is stopped.
ARSC setting is canceled, the ARSC set travel speed indicator is not lit, and the ARSC off pilot lamp is lit.
RECOMMENDED ARSC SET TRAVEL SPEED

Set the travel speed so that the engine speed becomes 1800 to 2100 rpm. Drive the machine so that the retard-
er oil temperature gauge is kept within the green range.
If the retarder is likely to become overheated, the retarder oil temperature caution lamp lights up and the set
travel speed automatically drops by 1 km/h {0.6 MPH} in every 3 seconds.
The travel speed displayed on the ARSC set travel speed indicator automatically drops as well.
10 km/h {6.2 MPH} is the lower limit value of the travel speed when it automatically drops.
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BRAKE PERFORMANCE CURVE

How to read the brake performance curve
Example) Downhill distance1500 m {4921 ft}
Traveling resistance–20 % (Grade resistance: –22 %, rolling resistance2 %)
Payload142 t
Obtain the maximum permissible speed and the gear speed range from the graph when traveling downhill under
the above conditions.
1. Use the brake performance curve for downhill distance of 1500 m {4921 ft} .
2. Starting from the point (A) which corresponds to the gross machinery weight, draw a perpendicular line
down.
3. Take the point where it crosses the line for traveling resistance -20 % as (B), and draw a horizontal line.
4. Take the point where it crosses the performance curve as (C), and draw a perpendicular line down. Take
the point where this line crosses the travel speed scale as (D).
5. The following information can be obtained from this procedure.
The maximum permissible speed is “17 km/h {10.6 MPH} ” from the point (D).
The gear speed is “F3” from the point (C).
This maximum permissible speed is a reference obtained from the retarder brake performance. Determine a
safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the
retarder brake oil temperature gauge is always in the green range when traveling.
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Brake performance “Downhill distance: 450 m {1476 ft} ”
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Brake performance “Downhill distance: Continuous”
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METHOD FOR TURNING MACHINE

k WARNING
Do not steer at high speed or on steep slope, you may cause the machine to tilt.
k CAUTION
• If the steering wheel has been turned fully to the right or left, do not continue to apply force to turn
it further.
The oil temperature inside the steering hydraulic circuit will rise and cause overheating.
• When the steering wheel is turned near the right or left end, turn it more slowly.
Turning the steering wheel suddenly to the end of the turn will cause damage to the machine.
When the machine is traveling, turn the steering wheel (1) to

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

k WARNING
• The KTCS is ready to start the control when “TCS Setting” is “ON”.
• When the system cannot be properly controlled due to a trouble in the system, the machine monitor
displays an action level and the system may stop operation depending on the failure condition.
• The machine may not travel safely on an extremely slippery road or on a steep slope even if the
KTCS operates.
• If a wheel is stuck in the ground and the machine cannot escape while the KTCS operates, pull out
the machine with a bulldozer, etc.
KTCS is a system to prevent the drive wheels from slipping caused by excessive torque and improves starting
and traveling ability on the soft or slippery ground.
OPERATION OF KTCS
The KTCS is ready to start the control when “TCS Setting” is
“ON”.
When the KTCS detects the rear wheel slipping, the KTCS
starts the control and the KTCS pilot lamp lights up.
METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN

GROUND
If any wheel is stuck, operate the KTCS.
If it is impossible to get the machine out even when repeating the procedure below, use a bulldozer and such to
tow the machine out.
1. Check that “TCS Setting” is “ON”.
When “TCS Setting” is “ON”, the KTCS operates automatically.
2. Set the gear shift lever to the position 6 and increase the engine speed.
3. Release the accelerator pedal and brake pedal.
4. Set the gear shift lever to the position R and increase the engine speed.
5. Repeat the steps 1 to 4 to move the machine backward and forward until it can escape.
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METHOD FOR LOADING

k WARNING
Do not load while dump body is RAISED.
NOTICE
• When traveling, always set the dump lever to “FLOAT” position, regardless of whether the machine
is loaded or not loaded.
• If the gear shift lever is shifted to a position other than NEUTRAL position (N) when the dump lever
is not at “FLOAT” position, the centralized warning lamp will light up and the alarm buzzer will
sound.
• Apply the parking brake during the loading operations.
If large rocks are loaded directly onto the dump body by using a large-sized loader, etc., the dump body may be
deformed locally.
1. When loading the large rocks, load the soil and sand first as cushion material.
2. After loading the soil and sand, load the rock onto them.
The impacts to the dump body are reduced by this method.
In addition, when loading the rocks that exceed the following conditions, install the optional body reinforcement
plate.
• Rocks with one side 0.5 m or more {19.7 in or more}
• Rocks of hardness more than 4.5 (Mohs scale)
• A rock with weight of 300 kg or more {661.5 lb or more}
• When transporting the steel ingots
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HANDLING PAYLOAD METER

OUTLINE OF SYSTEM
The payload meter performs statistical processing to calculate the payload by the signals received from the sus-
pension pressure sensors and clinometer, etc.
The obtained payload is displayed on the machine monitor and with the external display lamps.
You can download the data saved in the payload meter to a personal computer by using the special software (if
equipped).
Maintain the road surface, smoothly accelerate, and smoothly apply the brake. Otherwise, the roughness of the
road surface, sudden acceleration, and abrupt braking deteriorate the accuracy of the calculation.
Although the following functions are provided, you do not need to change them for the standard operation. If
setting is required, ask your Komatsu distributor.
Setting of Loading End Travel Dist
The payload meter judges that loading is completed when the machine travels continuously 160 m from the
loading pit. If a dumping is performed before the machine travels continuously 160 m, the payload meter cannot
recognize the dumping. In this case, the cycle data may not be recorded correctly. Setting of loading end travel
distance is used to change the setting when the distance between the loading pit and dumping pit is very short.
Display section of payload
While the machine monitor displays the standard screen, the
payload is displayed as shown in the figure.
External display lamp

The external display lamps (2 places) are installed to the rear
left of the cab and right (right side of the machine body).
The external display lamps are installed so that the operator on
the loader can see them. The lamps consist of 3 colors ((1)
green, (2) yellow, and (3) red).
The display of the external display lamps changes according to
the payload.
3-221
Data download connector inside the cab

Communication cable connection port is inside of the cover on
the rear of the operator's seat.
You can download the data saved in the payload meter to a
personal computer through the download connector.
Before downloading the data, remove the cables which have
been connected.
When downloading is completed, be sure to restore the cables
to the original positions. The data cannot be downloaded from
the download box outside the cab if the cables are removed.
Data download connector outside the cab

Connecting port for communication cable outside the cab is in-
side the data download box on the left front side of the ma-
chine.
3-222
PAYLOAD DISPLAY
Payload is displayed on the machine monitor and with the external display lamps.
The state displayed on the machine monitor may be different from that displayed with the external display lamps
depending on the machine condition.
Machine state Machine monitor External display lamp
Engine is stop- When starting switch is in ON po- Clock display All lamps are lit for 30 to 60
ped sition seconds (*5)
Stopped (*3) Clock display Not lit (*6)
Unloaded
Traveling Clock display Not lit
Stopped Payload display (*4) Payload display (*6)(*7)
Loading (*1)
Engine is running
Stopped Payload display (*4) Payload display (*7)
Loaded (*2)
Stopped Payload display (*4) Not lit
Dumping
Traveling Payload display (*4) Not lit
(*1) For the machine to be recognized as "Loading" from "Unloaded", the payload must be approximately 15 %
or more of the rated payload, and the machine must wait for the payload to be stabilized in the stopped state.
(*2) For the machine to be recognized as "Loaded" from "Loading", the machine should have traveled 160 m or
more continuously from the loading point.
(*3) The "Stopped" means the state in which the gear shift lever is in NEUTRAL position (N) or the travel speed
signal is zero.
(*4) Payload is not displayed on the machine monitor immediately after the starting switch is turned to ON posi-
tion. It is displayed when payload meter is ready.
(*5) All the external display lamps are lit until the payload meter is ready.
(*6) All the external display lamps are flashing when the dump lever is set to the position other than “FLOAT”
and the gear shift lever is in NEUTRAL position (N).
(*7) The external display lamps go out when the gear shift lever is in the position other than NEUTRAL position
(N).
The data which is sampled during traveling from the loading pit to the dumping pit is processed statistically, con-
firmed at dumping, and saved as the payload.
The payload which is displayed on the machine monitor is the value before it is processed statistically as descri-
bed above. The accuracy of this value may be lower than that of the payload in the saved data.
Use the value displayed on the machine monitor for reference only.
REMARK
The shifting between cloak display and payload display may be delayed during the period of 2 or 3 minutes after
the starting switch key is turned to ON position. This is due to the data processing, but not a trouble.
Example of payload display
3-223
Example of payload display when an error occurs

• When an error occurs in the suspension pressure sensor, clinometer sensor, etc., “— — — —. —t” is dis-
played, since the payload cannot be calculated. All the external display lamps are flashing this time.
• The payload displayed in the loading pit (just after loading) may be a little different from the value displayed
in the dumping pit.
This is caused by the effect of the frictional force of the suspension, and cannot be eliminated.
A little change of the displayed value between measurement places is not caused by a trouble in the pay-
load meter.
3-224
EXTERNAL DISPLAY LAMP

k CAUTION
Lighting of the red lamp indicates the overloaded state. Do not carry the load with this overloaded state.
The payload should not exceed the limit shown with the lighting of yellow lamp for the safe travel.
The external display lamps display the payload as follows.

Color of lamp HD1500
1 Green 71.0 t
2 Yellow 127.8 t
3 Red 149.1 t
• Lighting of the red lamp (3) indicates the overloaded state.

• If there is difference between the payload and the lighting
of the external display lamp, the model setting may be
wrong.
Display of prediction
Loading state and prediction are indicated by the lamps in different colors and their lighting status (lighting up or
flashing).
When the load changes in steps for each bucket loaded, the payload meter automatically estimates the predict-
ed total payload if one more bucket is loaded, and indicates the predicted payload by flashing of the appropriate
lamp. Flashing of the red lamp (3) indicates that it will be overloading with the next loading.
The predicted load display and actual payload display are shown at the same time.
Predicted number of bucket loads: 4
Payload display and predicted payload when loading of 35 t per one bucket is loaded onto HD1500.
1st time
• The payload is 35 t, and the predicted total payload at the next loading is 70 t.
• All lamps are not lit.
2nd time
• Green lamp (1) flashes, and it indicates that the predicted total payload of the 3rd loading is 71.0 t or more.
3rd time
• Green lamp (1) lights up, and it indicates that the total payload is 71.0 t or more.
Yellow lamp (2) flashes, and it gives a warning that the predicted total payload of the 4th loading is 127.8 t
or more.
4th time
• Yellow lamp (2) lights up, and it warns that the total payload is 127.8 t or more.
Red lamp (3) flashes, and it warns that the predicted total payload of the 5th loading is 149.1 t or more.
Perform the loading carefully so that the red lamp (3) does not light up.
3-225
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER

The payload meter records the data of the dumping cycle (from each dumping to the next dumping).
Cycle data items
Dumping Month/Day Travel time with no load Stopped time for loading Stopped time with load
Time to start dumping Travel distance with no load Travel time with load Dumping time
Machine ID Travel speed with no load Travel distance with load
(maximum)
Open ID Travel speed with no load Travel speed with load
(average) (maximum)
Payload Stopped time with no load Travel speed with load
(average)
• The payload which is a saved data corresponds to the weight carried in each cycle.
• The maximum limit for saving cycle data is 2900 cycles. If the data in memory exceed 2900 cycles, the
newest data are written over the oldest data.
• Download the recorded data through RS232C port to a personal computer installed with special software (if
equipped).
The downloaded data are saved in the text form (CSV type) in a certain place on the personal computer.
For details, see the operation and maintenance manual for the special software.
You can take in and check the downloaded data with the text file read function of the commercially available
spreadsheet software.
3-226
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD

METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD IN
CAB
k WARNING
• When handling the cables, be careful not to damage them or pull them by force.
• Do not leave the connectors disconnected.
• Be careful to prevent dirt from entering the connector portion.
• Do not let any metal objects touch the connector portion.
• Download the data by means of serial communication (RS232C).

For computers without an RS232C port, it may be possible to use a third party USB-RS232 conversion
adapter.
However, this does not guarantee the operation.
The download software supports COM1 and COM2, so check which port it can be connected to.
• Download the recorded data to a personal computer installed with special software (optional).
• When you need to correct the date and time in the downloaded data, consult your Komatsu distributor.
• There is some error in the directory where the data is downloaded by the special software, there may be a
mistake in the setting for the machine.
1. Remove the connected cable.
2. Connect the download cable attached to the special soft-
ware to the download connector.
3. Connect the other end of the download cable to RS232C
port of the personal computer.
5. Start up the personal computer, and use the special soft-
ware to download the data.
6. After finishing downloading, be sure to return the cables.
3-227
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD

OUTSIDE CAB
k WARNING
Check that the starting switch of the machine is in OFF position when you download the data outside
the cab. Also, be careful that the starting switch key is not turned to ON position inside the cab during
performing the downloading.
Pay attention to the safety around the machine during the downloading.
1. Set the gear shift lever to NEUTRAL position (N).
2. Set the parking brake switch to “PARKING” position to ap-

ply the parking brake.

4. Open the cover of the download box.
Use the starting switch key to open or close the cover.
5. Connect the accompanying download cable of the special

software to the connector (1) for downloading.
Connect the other end of the cable to the RS232C port of
the personal computer.
3-228
6. Turn the switch (2) inside the download box to ON posi-

tion.
The display lamp (3) lights up after a while when download
can be performed.
REMARK
If 15 minutes has passed without downloading the data af-
ter turning the switch (2) to ON position, the switch (2) in
the download box is automatically turned off while it re-
mains in ON position. The display lamp (3) goes out this
time.
7. Start up the personal computer and use the special software to download the data.
8. Turn the switch in the download box to OFF position after the downloading is completed.
Close the cover of the download box securely.
3-229
METHOD FOR USING DOWNLOAD SOFTWARE

Start up the personal computer and use the special software to
download the data.
For details of installing the software, see the instruction manual
of the download software.
When the installation is completed, the icon shown in the figure
is created.
1. Double-click the icon.

The download software is started and the screen shown in
the figure is displayed.
2. When the screen “G1000” is displayed, click “PLM”.

The screen “G2000” is displayed.
Do not click “CARD” and “PMC”, since they are not used.
3. Click “Parameter Setting” on the screen “G2000”.

Do not click “PLM Remote Control”, since it is not used.
4. Click “Unit Setting” on the screen “G2200”.

Do not click “User's Comment”, since it is not used.
3-230
On the screen “G2210”, you can select the communication

ports (COM1, COM2), specify the place to save the down-
loaded data, specify the file to create, and select the unit
for the created data.
For details, see the instruction manual of the download
software.
5. Check “Summary Data File” and “Cycle Data File” of “File”.
In this machine, only “Summary Data File” and “Cycle Data
File” are handled.
Once a setting has been made, there is no need to set it again when performing the next download.
6. Click “ENTER” to return to the screen “G2200”.
7. On the screen “G2200”, click “BACK” to return to the

screen “G2000”.
8. Click “Download” on the screen “G2000”.
9. When the screen “G2100” is displayed, click “Start”.

Downloading starts.
When downloading is finished, close the screen.
REMARK
The screen “G2101 < Down load - File ID” is displayed, de-
pending on the software version.
In this case, input the file ID, and click “OK”, then down-
loading starts.
3-231
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES

You can display the accumulated payload and the total number of cycles which are integrated at each dumping.
You can reset those values as well.
1. Press the menu switch (1) to display “Machine Setting / In-
formation” menu, select “Payload Meter”, then press EN-
TER switch (2).
2. Select “Total payload/number of cycles”, then press EN-

TER switch (2).
The accumulated payload and the total number of cycles

are displayed as shown in the figure.
• The date and time of start are those when the data of
“Total payload/number of cycles” have been reset last.
• The date and time of finish are those of the last dump-
ing.
• Accumulated value since they have been last reset is
displayed in “Total payload/number of cycles”.
• The display range is from 0 to 99999999.9t and 0 to
999999 cycles respectively. When they reach the up-
per limits, they are kept at the upper limits until they are reset.
3-232
3. Press ENTER switch (2).

The pop-up window of the data reset is displayed.
Press RETURN switch (3), and the screen returns to “Pay-
load Meter” menu.
4. Press ENTER switch (2) while the pop-up window shown
in the figure is displayed.
“Total payload/number of cycles” are reset, and the pop-up
window closes.
If you press RETURN switch (3), and the pop-up window
closes without doing anything.
3-233
DISPLAY FUEL CONSUMPTION RECORD

You can display the average daily working fuel consumption (ton/l) in the last 1 week.
You can reset that value.
TER switch (2).
2. Select “Load and fuel efficiency record”, then press EN-

TER switch (2).
The average value of the daily working fuel consumption in

the last 1 week is displayed as shown in the figure.
3-234

The pop-up window of the data reset is displayed.
Press RETURN switch (3), and the screen returns to “Pay-
load Meter” menu.
4. Press ENTER switch (2) while the pop-up window shown
in the figure is displayed.
“Load and fuel efficiency record” is reset, and the pop-up
window closes.
If you press RETURN switch (3), and the pop-up window
closes without doing anything.
3-235
SETTING MACHINE ID AND OPEN ID

You can change the setting of the machine ID and open ID which are the items in the cycle data.
You can check the operator and the load of each cycle afterward, by setting the machine No. as the machine ID,
and setting the operator and the load type as the open ID.
TER switch (2).
2. Select “Machine ID”.

The set machine ID is displayed on the right side.

The pop-up window opens and displays the currently set
machine ID. Input the machine ID.
• The settable range is from 0 to 200.
• Each time UP switch (3) is pressed, ID increases by 1.
Each time DOWN switch (4) is pressed, ID decreases
by 1.
• If UP switch (3) is held down, ID increases rapidly. If
DOWN switch (4) is held down, ID decreases rapidly.
• If UP switch (3) is pressed when 200 is displayed as
ID, ID returns to 0. If DOWN switch (4) is pressed when 0 is displayed as ID, it becomes 200.
4. After inputting the machine ID, press ENTER switch (2).
The value at this time is set as ID, and the windows closes.
If you press RETURN switch (5), the window closes without changing the value of ID.
3-236
5. Select “Open ID” on the screen of step 2 for setting the

open ID.
The set open ID is displayed on the right side.
6. The setting procedure for the open ID is the same with the
machine ID.
Set the open ID.
3-237
METHOD FOR PERFORMING CALIBRATION

Perform the calibration in the following cases.
• When the machine or payload meter is delivered
• Once a month
• When the suspension cylinder gas pressure and oil quantity are adjusted (When the suspension is adjust-
ed)
• 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 {220.5 lb
or more} .
NOTICE
• Perform the calibration on a level place.
• Perform the calibration while traveling straight.
A straight road approximately 100 m {328 ft 1 in} long is necessary for the calibration.
• Do not perform the calibration while an error is generated.
• When performing the calibration, seat the dump body and set the dump lever to “FLOAT” position.
You can check that the dump body is seated by checking that the dump body float caution lamp is
not lit.
1. Empty the machine.
Be sure to completely remove all the soil remaining inside the dump body.
2. Run in the machine.
3. While rMETHOD FOR PERFORMING CALIBRATIONunning the engine, set the gear shift lever to NEU-
TRAL position (N), and stop the machine.
4. Prepare for the calibration according to the following procedure.
1) Press the menu switch (1) on the standard screen,
and on “Machine Setting / Information” screen, select
“Payload Meter”, then press ENTER switch (2).
3-238
2) Select “Calibration”, then press ENTER switch (2).

The pop-up window of starting the calibration is dis-
played.
REMARK
If the gear shift lever is in any position other than
NEUTRAL (N), you cannot select the “Calibration”.
3) Press ENTER switch (2) while the pop-up window

shown in the figure is displayed.
If you press RETURN switch (3), the window closes
without starting the calibration.
5. When the display becomes as shown in the figure, drive

the machine at speed of 10 km/h {6.2 MPH} .
REMARK
To cancel at this time, press RETURN switch (3) while the
screen in the figure is displayed.
6. Continue driving the machine at speed of 10 km/h

{6.2 MPH} .
Keep the travel speed at approximately 10 km/h
{6.2 MPH} during the travel.
The display changes as shown in the figure in approxi-
mately 30 seconds, and the calibration is completed.
3-239
METHOD FOR DUMPING

k WARNING
• Always follow the instructions of the signalman when
performing dumping operations.
• When dumping the large rocks, operate the dump
body slowly.
• When performing the inspection or operation with the
dump body raised, always use the body lock wire to
secure the dump body. Also lock the dump control lev-
er at “HOLD” position with the dump lever lock knob.
1. Set the gear shift lever (1) to NEUTRAL position (N), and
set the parking brake switch (2) to “PARKING” position.
When the parking brake has been applied, the parking
brake pilot lamp lights up on the machine monitor.
2. Move the dump lever (3) to “RAISE” position, then depress

the accelerator pedal.
The dump body rises.
If the dump lever is released when it is at “RAISE” position,
it is held at “RAISE” position and the dump body will con-
tinue to rise.
The dumping speed increases in proportion to the engine
speed.
When the dump body rises to the previously set position,
dump lever (3) returns to “HOLD” position.
The dump body is then held at that position.
3-240
3. If it is necessary to raise the dump body further, operate

the dump lever (3) to “RAISE” position.
The dump body rises further.
If dump lever (3) is released, dump lever (3) will return to
“HOLD” position and the dump body will stop at that posi-
tion.
While raising the dump body, when the dump body ap-
proaches the maximum tilt angle, release the accelerator
pedal in order to avoid any impact load on the hydraulic
circuit or hoist cylinder.
4. Set the dump lever (3) to “LOWER” position.
The dump body starts lowering.
5. When the dump body has moved down a certain distance,

move the 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 completely lowered, the gear
speed is fixed at 1st anywhere the gear shift lever position
is in D to L. The reverse travel is not available when the
gear shift lever is in R position and the gear speed is fixed
at NEUTRAL. Keep the dump body lowered when travel-
ing.
3-241

• When traveling on roads in rain or snow, or when traveling on muddy or soft ground, consider the loaded
condition of the machine and be extremely careful not to let the tires slip or the machine spin and sink into
the ground.
• If the engine should stop when the machine is traveling, stop the machine immediately, then move the gear
shift lever to NEUTRAL position (N), and start the engine again.
• If the centralized warning lamp and pilot lamp for any “EMERGENCY” item on the machine monitor should
flash and the buzzer sounds during operation, stop the machine immediately and investigate the cause.
• When loading, be careful to load the dump body uniformly, and be particularly careful to avoid loading too
much at the front.
• When traveling on slippery road surfaces, operate the retarder control lever slowly and shift the transmis-
sion down to prevent the rear wheels from locking.
PERMISSIBLE WATER DEPTH

If it is obliged to drive the machine in water, do not drive it into
the water deeper than the allowable water depth (up to the in-
ner surface of rim (1)).
After completing the operations, wash the machine and lubri-
cate the parts where has entered in water.
When the machine travels in water, water may enter the drain
tank. Remove the plug (P), and drain the water which has en-
tered the tank.
3-242
METHOD FOR PARKING MACHINE

k WARNING
• Avoid a sudden stop. Stop the machine gradually.
• Park the machine on solid level ground.
Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, set the parking brake switch to “PARKING” po-
sition, and chock the wheels to prevent the machine
from moving.
• Set the parking lever securely at the “PARKING” posi-
tion when you leave the operator seat to avoid sudden
and unexpected machine movement.
Sudden and unexpected machine movement can
cause personal injury or death.
• The retarder must not be used as a parking brake.
k CAUTION
To prevent damage to the parking brake, apply the parking
brake only when parking the machine, performing loading
operations, or performing dumping operations.
1. Release the accelerator pedal (1), then depress the brake

pedal (2) to stop the machine.
3-243
2. Place the gear shift lever (3) to NEUTRAL position (N),

then set the parking brake switch (4) to “PARKING” posi-
tion to apply the parking brake.
3. When in the operator's compartment, pull the retarder con-

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

• Check the engine coolant temperature, engine oil pressure, and fuel level with the machine monitor.
• If the engine has overheated, do not stop the engine suddenly. Run it at a mid-range speed to cool it gradu-
ally before stopping.
3-244
LOCK
The following places must always be locked.
(1) Operator's cab door (R.H. and L.H.)
(2) Data download box
(3) Fuel tank filler port cap
(4) Fuel tank quick coupler cover (if equipped)
(5) Transmission case oil filler port cap
(6) Steering and hoist oil tank filler port cap
(7) Brake oil tank filler port cap
(8) Fuel tank drain valve cover
REMARK
The starting switch key is a common key for (1) to (8).
3-245
METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP

PROCEDURES FOR OPENING FUEL FILLER PORT CAP
1. Insert the starting switch key into the key slot.
2. Turn the starting switch key to “OPEN” position (A), and
then align the key slot with the match mark (1) of the cap.
Position (A)
OPEN
Position (B)
LOCK
3. Turn the fuel filler cap slowly to unlock it.
“Click” sound is heard.
4. Open the fuel filler cap.
PROCEDURES FOR LOCKING FUEL FILLER PORT CAP

1. Screw in the fuel filler cap.
3. Turn the starting switch key to “LOCK” position (B), and
Position (A)
OPEN
Position (B)
LOCK
4. Remove the starting switch key.
3-246
METHOD FOR OPENING AND CLOSING TRANSMISSION CASE FILLER CAP

METHOD FOR OPENING TRANSMISSION CASE FILLER CAP
align the key slot with the match mark (1) of the cap.
Position (A)
OPEN
Position (B)
LOCK
3. Turn the oil filler cap slowly to unlock it.
4. Open the oil filler cap.
METHOD FOR LOCKING TRANSMISSION CASE FILLER CAP

1. Screw in the oil filler cap.
Position (A)
OPEN
Position (B)
LOCK
3-247
METHOD FOR OPENING AND CLOSING OIL FILLER CAP OF STEERING AND
HOIST OIL TANK
PROCEDURES FOR OPENING OIL FILLER CAP OF STEERING AND HOIST OIL
TANK
Position (A)
OPEN
Position (B)
LOCK
PROCEDURES FOR LOCKING OIL FILLER CAP OF STEERING AND HOIST OIL
TANK
Position (A)
OPEN
Position (B)
LOCK
3-248
METHOD FOR OPENING AND CLOSING BRAKE OIL TANK FILLER CAPS
METHOD FOR OPENING BRAKE OIL TANK FILLER CAPS
Position (A)
OPEN
Position (B)
LOCK
METHOD FOR LOCKING BRAKE OIL TANK FILLER CAPS

Position (A)
OPEN
Position (B)
LOCK
3-249
METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR

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

1. Insert the starting switch key into the key slot (1).

then remove the starting switch key.
Position (A)
OPEN
Position (B)
LOCK
3. Hold the cab door handle (2) to open the cab door.
When getting on or off the machine, hold the inside handrail.
METHOD FOR LOCKING OPERATOR CAB DOOR

1. Close the cab door.
2. Insert the starting switch key into the key slot (1).
then remove the starting switch key.
Position (A)
OPEN
Position (B)
LOCK
3-250
HANDLE TIRE
PRECAUTIONS WHEN HANDLING TIRES
k WARNING
To ensure safety, the defective tires given below must be replaced with new tires.
• Tires where the bead wire has been cut, broken, or greatly deformed
• Excessively worn tires where more than 1/4 of the circumference of the carcass ply (excluding the
breaker) is exposed
• Tires where damage to the carcass exceeds 1/3 of the tire width
• Tires where ply separation has occurred
• Tires where radial cracks extend to the carcass
• Deteriorated, deformed or abnormally damaged tires, which do not seem usable.
(1) Side wall

(2) Shoulder
(3) Tread
(4) Breaker or belt (cord layer)
(5) Bead
(6) Inner liner
(7) Cord
Contact your Komatsu distributor when replacing the tires. It is
dangerous to jack up the machine without taking due care.
T.Km.P.H (Ton-Km-Hour-Rating)
A tire for the construction machinery has a structure which can tolerate the severe condition, that is incompara-
bly more severe than that of automobiles, buses, general trucks.
Heat is more generated inside the rubber material in OR tires comparing to the general tires during traveling.
The temperature inside the rubber material exceeds the allowable limit if they are used continuously with more
load than their load limit and at higher speed than their speed limit. It may cause the heat separation due to
softening of the rubber.
T.Km.P.H is provided as the standard for the safety travel of the machine in order not to make an incident occur
which is described above.
More tire trouble will occur if the work demanding more T.Km.P.H to the tire is performed (the work T.Km.P.H
value exceeds the T.Km.P.H value particular to the tire).
Observe the following in such case.
• Moderate the work condition so that the work T.Km.P.H value goes down.
• Change the tire to the one whose T.Km.P.H value is higher.
3-251
TIRE T.Km.P.H VALUE AND CONTINUOUS MAX TRAVEL SPEED

How to obtain the work T.Km.P.H value by calculation
The work T.Km.P.H value = Average load per tire x Average travel speed of a day
Average travel speed = The distance of round trip x How many times the round trip is made in a day/Total oper-
ating hours in a day
Average load = (load when unloaded + load when loaded)/2
Total operating hours in a day includes the break time and downtime.
*The T.Km.P.H value in the table varies depending on the manufacturers of tire. Ask your Komatsu distributor
when the work is to be performed with the travel speed near the travel speed shown in the table.
Reference
T.Km.P.H of the tire at each tempera- Travel speed with which the continuous traveling
ture is possible at each temperature ( km/h { MPH} )
16 °C 27 °C 38 °C 49 °C 16 °C 27 °C 38 °C 49 °C
{60.8 °F} {80.6 °F} {100.4 °F} {120.2 °F} {60.8 °F} {80.6 °F} {100.4 °F} {120.2 °F}
33.00R51 When
(Standard) unload-
ed
Structure: CR 30 27 25 23
(Stand- {18.6} {16.8} {15.5} {14.3}
Code: No. E3 ard for
(TRA) the front
839 769 700 631 wheel)
When
loaded
(Stand- 20 18 17
15 {9.3}
ard for {12.4} {11.2} {10.6}
the rear
wheel)
3-252
PRECAUTIONS FOR LONG DISTANCE TRAVEL

If the machine travels continuously at high speed for a long distance, there will be a remarkable increase in the
generation of heat in the tire. This may cause premature damage to the tire, so observe the following.
• Drive the machine only under unloaded condition.
• Check the tire inflation pressure before starting for the day when the tires are cold, and adjust to the follow-
ing inflation pressure.
• Do not reduce the tire inflation pressure when traveling.
Tire size
PSI}
33.00R51 700 {7.14, 102}
NOTICE
Make sure to keep the tire pressure within 0 to +30 kPa {0 to +0.3 kg/cm2, 0 to +4.27 PSI} of the value in
this table.
• The maximum travel speed must be kept to 40 km/h or lower {24.9 MPH or lower} . Stop for at least 1 hour
for every 1 hour of travel to allow the tires and other components to cool down.
• Never drive the machine with “water” or “dry ballast” in the tires.
3-253
HANDLE AIR CONDITIONER OPERATION
HANDLE AIR CONDITIONER

NOTICE
• When running in the air conditioner, always start with the engine running at low speed. Never start
the air conditioner when the engine is running at high speed.
It will cause failure of the air conditioner.
• If water gets into the control panel, it may lead to unexpected failure, take care not to let water get
on them.
In addition, never bring any open flame near them.
• When the air conditioner is not used every day, to prevent loss of the film of oil at various parts, run the air
conditioner with the engine at low speed from time to time and perform cooling or dry heating for several
minutes.
• When the temperature inside the cab is low, the air conditioner may not work. In this case, circulate the
recirculation air to warm the inside of the cab. After that, turn on the air conditioner switch, and the air con-
ditioner will work.
• If any abnormality is detected in any equipment or sensor
used on the air conditioner, the air conditioner system cau-
tion lamp lights up on the monitor screen. If the air condi-
tioner system caution lamp lights up, ask your Komatsu
distributor for the inspection and repair.
Ventilation while cooling

• When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform
ventilation and cooling.
• If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window
and turn the lever to FRESH for a while for ventilation and cooling to drive smoke out.
Temperature control
For reasons of health, it is said that the optimum setting for cooling is the temperature when it is slightly cool (5
to 6 °C {9 to 10.8 °F} lower than the ambient temperature) when you enter the cab.
Be careful to select the appropriate temperature.
3-254
OPERATION HANDLE AIR CONDITIONER
EXPLANATION OF AIR CONDITIONER EQUIPMENT
(1) OFF switch (6) FRESH/RECIRC air selector switch

(2) Fan switch (7) Air conditioner display
(3) Temperature control switch (8) Air conditioner switch
(4) Vent selector switch (9) Defroster switch
(5) Auto switch
Air conditioner display
(A) Air flow bar (E) Vent display
(B) Air conditioner operation symbol (F) Automatic operation symbol
(C) Set temperature display (G) Defroster symbol
(D) FRESH/RECIRC selector symbol
OFF SWITCH
The OFF switch is used for stopping the fan and air conditioner.
REMARK
Even if this OFF switch is pressed, the monitor screen does not
switch to the air conditioner adjustment screen.
3-255
FAN SWITCH
You can adjust the air flow by using the fan switch.
The air flow can be adjusted to 6 levels.
• Press the △ switch to increase the air flow; press the ▽
switch to decrease the air flow.
• During the automatic operation, the air flow is automatical-
ly adjusted.
Air conditioner display and air flow rate

Monitor dis- Air flow rate
play
Air flow "low"
Air flow "medium 1"
Air flow "medium 2"
Air flow "medium 3"
Air flow "medium 4"
Air flow "high"
3-256
TEMPERATURE CONTROL SWITCH

Use the temperature control switch to adjust the temperature
inside the cab. The temperature can be set between 18 to
32 °C {64.4 to 89.6 °F} .
• Press the △ switch to raise the set temperature; press the
▽ switch to lower the set temperature.
The set temperature is indicated on the display monitor.
• Normally, set 25 °C {77 °F} .
• The temperature can be set in stages of 0.5 °C {0.9 °F} .
Air conditioner display and function

Air conditioner display Set temperature
18.0 °C {64.4 °F} Max. cooling
18.5 to 31.5 °C {65.3 to
Adjusts the temperature inside the cab to the set temperature.
88.7 °F}
32.0 °C {89.6 °F} Max. heating
REMARK
If the mode is set to automatic operation and the temperature setting is set to 18 °C {64.4 °F} or 32 °C
{89.6 °F} , the air flow from the fan is always set to “HIGH” and does not change even when the temperature
reaches the set temperature.
3-257
VENT SELECTOR SWITCH

The vent selector switch is used to select the vents.
• When the vent selector switch is pressed, the LC display
on the monitor display switches and air blows out from the
vents displayed.
• During automatic operation, the vents are automatically
selected.
(A): Face vent (4 places)

(B): Foot vent (1 place)
(C): Front window glass vent (3 places)
Liquid crystal dis- Vent

Air vent mode Remarks
play (A) (B) (C)
Face vent -
○
Face vent, foot vent -

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

Defroster vent ○ ○
Air blows out from the vents marked with ○.
3-258
AUTO SWITCH
Auto switch is used to switch the operation to the automatic op-
eration.
It changes the air flow and vents, recirculated air and fresh air
automatically according to the set temperature and the ambient
environment.
This switch is also used as the main switch of the air condition-
er.
• When the auto switch is pressed, the automatic operation

symbol on the air conditioner display lights up to indicate
that the air conditioner is in the automatic mode.
• When each switches is operated, automatic operation
shifts to the manual operation, and the automatic operation
symbol on the air conditioner display goes out.
• When clearing the window mist at low temperature, use
the defroster switch.
REMARK
The automatic operation of the air conditioner is controlled au-
tomatically according to the set temperature and the ambient
environment.
If the environment changed suddenly by leaving cab door open
for a long time, etc., the control of air conditioner may change
temporarily, but this is not a failure.
Even if the control changes, it returns automatically to control
the air according to the set temperature and the ambient envi-
ronment after certain period of time elapses.
FRESH/RECIRC AIR SELECTOR SWITCH

Use the FRESH/RECIRC air selector switch to switch the air
source between recirculation of the air inside the cab and in-
take of fresh air from the outside.
The air source is automatically switched between recirculation
of the air inside the cab and intake of fresh air from the outside
during the automatic operation.
RECIRC
Outside air is shut off and only air inside the cab is circulated.
Use this setting to perform rapid cooling of the cab or when
outside air is dirty.
FRESH
Outside air is taken into the cab.
Use this setting to take in fresh air or to demist the window glass.
REMARK
Intake of external air (FRESH) is automatically selected when the cab door is opened. Selection by use of the
FRESH/RECIRC air selector switch is not available.
When the cab door is closed, the setting returns to the one which has been set before the cab door was
opened.
3-259
AIR CONDITIONER DISPLAY

The air conditioner display displays the state of air flow (A), op-
eration of air conditioner (B), set temperature (C), FRESH/
RECIRC air (D), vents (E), automatic operation (F), and de-
froster (G).
AIR CONDITIONER SWITCH

Use the air conditioner switch to start and stop the cooling,
heating, or drying function.
• Press the air conditioner switch when the fan is operating

(when the air flow level is shown on the display monitor).
The air conditioner is turned on, and starts operating.
Press the switch again to stop the air conditioner.
• Air conditioner cannot be operated while the fan is not op-
erating.
3-260
DEFROSTER SWITCH
The defroster switch is used to set the vents in the defroster
mode.
• Use this mode to clear the front glass mist, etc.
• When the defroster switch is pressed during automatic op-
eration, the automatic operation symbol on the air condi-
tioner display goes out and the defroster mark is dis-
played.
3-261
METHOD FOR OPERATING AIR CONDITIONER

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

1. Press AUTO switch.
The automatic operation symbol on the air conditioner dis-

play lights up.
2. Press switch △ or switch ▽ of the temperature control

switch to set to the desired temperature.
The air flow and combination of the vents are automatically
selected according to the set temperature and environ-
ment, and the air conditioner is operated automatically to
provide the set temperature.
REMARK
• If the air conditioner switch is not turned on when the
ambient temperature is high, air is not cooled and its
temperature may not decrease to the set temperature.
• After automatic operation, the air flow may be set to
“Low” for a certain period to prevent cold air from
blowing out, depending on the ambient temperature.
• Once the desired temperature is set, do not operate
the temperature control switch unnecessarily. It may
take longer time to reach the set temperature.
• To heat or cool the air quickly, set the temperature dis-
play to 18.0 °C {64.4 °F} (max. cooling) or 32.0 °C
{89.6 °F} (max. heating).
• If each switch is operated during automatic operation,
the function of that switch is applied first, the automat-
ic operation symbol on the air conditioner display goes
out, and the manual operation is selected.
3-262
METHOD FOR STOPPING AUTOMATIC OPERATION

Press the air conditioner OFF switch.
The display on the monitor goes out and the operation stops.
METHOD FOR MANUAL OPERATION

1. Press switch △ or switch ▽ of the fan switch and adjust the
air flow.
If switch △ of the fan switch is pressed while the air condi-
tioner power supply is turned off, the air conditioner power
supply is turned on and the air flow is set to “Low”.
2. Press the air conditioner switch.
The air conditioner operation symbol lights up on the air

conditioner display.
3. Press switch △ or switch ▽ of the temperature control

switch to set to the desired temperature.
3-263
REMARK
The air temperature is so adjusted that the temperature in the cab becomes the set temperature when the
set temperature display is 18.5 to 31.5 °C {65.3 to 88.7 °F} even during the manual operation.
To heat or cool the air quickly, set the temperature display to 18.0 °C {64.4 °F} (max. cooling) or 32.0 °C
{89.6 °F} (max. heating).
4. Press vent selector switch and select the desired vents.
The liquid crystal display for the air conditioner display
changes according to the selection.
5. Press the FRESH/RECIRC air selector switch and select

the recirculation of the air inside the cab (RECIRC) or the
intake of fresh air from outside (FRESH).
REMARK
To select the automatic operation during manual operation, press AUTO switch.
METHOD FOR STOPPING MANUAL OPERATION

Press the air conditioner OFF switch.
The display on the monitor goes out and the operation stops.
3-264
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.
1. Press fan switch and adjust the air flow.
When doing this, check that temperature setting (A) and

air flow (B) are displayed on the monitor.
2. Press vent selector switch and set the vent display on the
display monitor to the display shown in the figure.
3. Turn air conditioner switch ON.
3-265
4. Adjust fan switch, temperature control switch and FRESH/

RECIRC air selector switch to the desired positions.
3-266
METHOD FOR OPERATING DEFROSTER

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

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

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

FRESH mode.
3-267
4. Press the temperature control switch and set the tempera-

ture on the display monitor to 32 °C {89.6 °F} of maximum
heating.
5. 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 on the air conditioner switch.
3-268
OPERATION HANDLE RADIO
HANDLE RADIO
• To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera-
tion.
• If water gets into the speaker case or radio, it may lead to failure.
Take care not to let water get on them.
• Do not wipe the display or buttons with solvent such as benzene or thinner.
Wipe with a dry soft cloth.
• When the battery disconnect switch is turned to OFF position or the power for the machine is turned off for
the replacement of the battery, the clock may be initialized. In such a case, set it again.
EXPLANATION OF RADIO EQUIPMENT
(1) Power button (5) Preset button

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

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

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

Use the tuning/time adjustment button to select frequency and step for sound adjustment and to adjust time.
3-269
HANDLE RADIO OPERATION
PRESET BUTTON
If you register the desired stations to the preset button beforehand, you can select each station by touching this
button once.
It is possible to preset 6 stations each for both AM and FM.
DISPLAY SELECTOR BUTTON

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

Press the sound control button, and the sound adjustment is ready.
Each time this button is pressed, BAL (Balance), TRE (Treble) and BAS (Bass) will be selected in this order.
If this button is pressed while BAS is displayed, the sound adjustment will be canceled.
DISPLAY
(A): Band name, “AUX”, frequency, clock and other character/
numeric information are displayed.
(B): Frequencies are displayed at steps of 50 kHz in certain
areas.
(C): Lights up when a stereo broadcasting is heard while a FM
station is selected.
(D): Lights up at the time of balance adjustment in the sound
adjusting condition.
(E): Lights up at the time of treble adjustment in the sound ad-
justing condition.
(F): Lights up at the time of bass adjustment in the sound adjusting condition.
AUX
You can hear the sound through the speaker of the machine when you connect a commercially available porta-
ble audio equipment to the machine.
1. Open the cap (1).
2. Connect a portable audio equipment by using an commer-
cially available audio cable.
3. Press the band/AUX selector button and select AUX.
NOTICE
• A stereo miniature plug can be connected.
Read the instruction manual of the equipment to con-
nect carefully.
• As a power source for the equipment to connect, use
the battery attached to that equipment.
If you use an electric power supply installed to the ma-
chine, the noise may occur.
• The noise may occur if you pull out the input plug
when AUX is selected, or if you push in or pull out the
plugs of the equipment to connect.
3-270
METHOD FOR CONTROLLING RADIO

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

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

2. Press one of 1 to 6 of preset button (2).
The frequency registered in the preset number of the
pressed button is called up and received.
“Example”
While a frequency is displayed, press button 1 of preset
button (2), and the preset number “P-1” is displayed on the
display.
The preset number is shown for 0.5 seconds, and then the
frequency is displayed.
3-271
HANDLE RADIO OPERATION
METHOD FOR REGISTERING PRESET

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

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

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

1. Press sound control button (1) to light up “BAS” on the dis-
play.
You can adjust the sound (bass).
sound (bass).
• Press the △ button, and the bass level increases by 1.
(Maximum +7)
• Press the ▽ button, and the bass level decreases by
1. (Minimum -7)
3-272
METHOD FOR ADJUSTING CLOCK

1. Press display selector button (1) to display the time.
2. Hold down display selector button (1) to flash the “HOUR”
display portion.
You can adjust the hour.
3. Press tuning/time adjustment button (2) to adjust the hour.
• If you press △ button, “HOUR” display increases by 1.
• If you press ▽ button, “HOUR” display decreases by
1.
4. Press display selector button (1) to flash the “MINUTE” dis-
play portion.
You can adjust the minute.
5. Press tuning/time adjustment button (2) to adjust the minute.
• If you press △ button, “MINUTE” display increases by 1.
• If you press ▽ button, “MINUTE” display decreases by 1.
6. Press display selector button (1) to cancel time adjustment.
The screen returns to the clock display.
3-273
HANDLE KomVision OPERATION
HANDLE KomVision
k WARNING
• KomVision is a device to reflect the area around the machine on the KomVision monitor using cam-
eras installed to the machine. It does not mean that it can display everything since it has limitations.
Visually check the surround area of the machine for the safety. Do not rely only on the camera im-
age displayed on the KomVision monitor for the safety.
• Do not perform the modification such as replacing with other cameras or relocating the camera in-
stalling positions. This may cause the blind spots to the image displayed on the KomVision moni-
tor, and it may lead to serious personal injury or death.
KomVision is a device to assist the monitoring around the machine by using cameras and radar (only machine
with radar) to improve safety against possible collision with obstacles around the machine when it moves off.
PRECAUTIONS WHEN USING KomVision

• Adjustment is necessary for the camera and radar (only for machine with radar) in the following cases. Ask
your Komatsu distributor to perform this work.
• Direction in which camera and radar face has been changed by damage or such.
• Camera and radar which are being used need to be removed or replaced.
• Machine dimension has been changed by optional attachment installed or such.
• KomVision monitor image may not be displayed due to darkness at night or in a tunnel, fog, snow, rain,
cloud of dust or such.
• Obstacles above the camera of the machine are not displayed. Be careful enough of the work equipment of
a large machine, tree branches or such in high positions.
• Reference line is displayed with reference to the flat ground. The distance of the reference line is not cor-
rect on slopes and uneven ground.
• The images displayed on the KomVision monitor are converted. So obstacles may look deformed or the dis-
tance shown on the screen may look different from the actual distance.
• The radar installed to the machine is based on the radio law of each country. It has been licensed by the
country of dispatch before shipment. Any modification applied to the radar or use of broken radar will be
punished under a violation of law.
3-274
OPERATION HANDLE KomVision
KomVision CAMERA DISPLAY RANGE

The display range of the KomVision camera is as follows.
(A) Range of front and rear of machine: 10 m {32 ft 10 (L) Distance between front of slanted ladder and rear
in} end of dump body
(B) Range of right and left of machine: 10 m {32 ft 10 (W) Distance between left side of cab and right side of
in} platform
3-275
BASIC OPERATION OF KomVision MONITOR

BASIC OPERATION OF KomVision MONITOR WHEN STARTING ENGINE IN
NORMAL SITUATION
AA: Start screen BB: Standard screen

When the starting switch is turned to ON position, the KomVision monitor starts and operates as follows.
1. KomVision monitor displays the start screen AA, and then changes to the standard screen BB after the
KomVision system has been started.
The outer frame color of the camera switch display (1) on the standard screen BB changes in the order of
No color → Orange → Red → No color.
2. For the machine equipped with radar, the obstacle alarm buzzer sounds for 2 seconds, then stops under
the normal condition.
3. KomVision system indicator (2) flashes.
When KomVision system has been started, KomVision
system indicator (2) lights up.
NOTICE
If the Komvision monitor or obstacle alarm buzzer (only
machine with radar), etc. do not work, the devices may be
failed or the electric wiring may have breakage. In this
case, ask your Komatsu distributor for repair.
3-276
REMARK
• It takes approximately 30 to 40 seconds to complete the start-up of KomVision system. Check that the start-
up of the KomVision system is completed, and start the machine operation.
• When the starting switch is turned from ON position to OFF position and immediately turned to ON position
again, the start-up of KomVision system may take longer than usual.
• If the start-up of KomVision system is not completed 2 minutes after the starting switch is turned to ON po-
sition, ask your Komatsu distributor for repair.
• If the outer frame color of the camera switch display (1) does not change, the KomVision system is stopped
and no image is updated. In this case, turn the starting switch to OFF position once, and turn it to ON posi-
tion again in order to start up the KomVision system again. If the outer frame color of the camera switch
display (1) still does not change, ask your Komatsu distributor for repair.
• When the engine is started, the battery voltage may suddenly drop depending on the temperature and the
battery condition. In such case, the KomVision monitor may go out temporarily or restart.
BASIC OPERATION OF KomVision MONITOR WHEN TROUBLE OCCURS
BB: Standard screen (2-window display mode) DD: Screen when radar has failure
CC: Screen when camera has failure EE: Screen before implementing default setting
(A) Bird's eye view display (D) Radar detection range which includes the failed ra-
(B) Camera image dar
(C) Camera image area of failed camera
3-277
When a trouble occurs in the KomVision system, the following

is shown on the KomVision monitor. The caution lamp (1) and
action level (2) are displayed on the machine monitor.
• Screen when camera has failure (CC)
If a camera has a failure, the area (C) of the failed camera
image is filled with blue. At this time, when displaying the
camera image of the failed camera on the camera display
(B), it will be filled with blue. Ask your Komatsu distributor
for the inspection and repair.
• Screen when radar has failure (DD)
If the radar has a failure, the radar detection range (D)
around is filled with red and flashes even when only one radar has a failure. Ask your Komatsu distributor
for the inspection and repair.
• Screen before implementing default setting (EE)
It will be displayed when the default setting has not been performed.
Ask your Komatsu distributor to perform the setting.
REMARK
KomVision system shows the area which is not shot by camera
in black on the KomVision monitor. The edge of the camera im-
age is displayed in black, however, it is not a trouble.
If a large part is displayed in black and you have difficulty to
check the KomVision monitor, ask your Komatsu distributor for
the inspection and repair.
3-278
EXPLANATION OF KomVision MONITOR SCREEN
AA: 2-window display mode CC: Non-display mode

BB: 1-window display mode
(1) Bird's eye view display (5) Camera switch display
(2) Machine body display (6) Camera image
(3) Guidance display (7) Reference line
(4) Radar pilot lamp
DEFINITION OF TRAVEL SPEED IN KomVision

Travel speed is defined as follows in KomVision system. The screen mode, projection method, and obstacle de-
tection by radar (only machine equipped with radar) change according to the definition of travel speed.
Definition of travel
Travel speed
speed
Stopped 0 km/h {0 MPH}
Less than 15 km/h
Low-speed travel
{Less than 9.3 MPH}
Min. 15 km/h {Min.
High-speed travel
9.3 MPH}
REMARK
Definition of travel speed can be changed according to the situation. If change is required, ask your Komatsu
distributor.
3-279
SWITCH SCREEN MODE

Switching screen mode automatically
KomVision monitor is displayed in 2-window display mode (AA) usually. Setting the gear shift lever to R position
changes the display of KomVision monitor to the 1-window display mode (BB). Rear camera image is displayed
on the camera image screen this time.
When the machine travels at high speed, the display of KomVision monitor changes to the non-display mode
(CC).
REMARK
When “Forced Display” is “ON” on the user menu “KomVision Setting” of the machine monitor, the display of
KomVision monitor does not change to the non-display mode (CC) even if the machine travels at high speed.
Switching screen mode manually
The display of KomVision monitor changes as 2-window dis-
play mode (AA) → 1-window display mode (BB) → non-display
mode (CC) → 2-window display mode (AA) every time when
the screen mode selector switch (1) is pressed.
The screen automatically proceeds to the 2-window display
mode if no switching operation is performed for 10 seconds
while 1-window display mode (BB) or no display mode is se-
lected.
REMARK
When “Forced Display” is “ON” on the user menu “KomVision
Setting” of the machine monitor, the display of KomVision mon-
itor does not change to the non-display mode (CC) even if the
screen mode selector switch (1) is operated.
3-280
BIRD'S EYE VIEW DISPLAY

How the image is projected varies with the travel speed of the machine.
Round corner projection
Round corner projection is displayed when the machine is trav-
eling with low speed or stopped regardless of the setting of the
forced display.
Plain surface projection

Plain surface projection is displayed when the machine is trav-
eling with high speed.
REMARK
When “Forced Display” is “OFF” on “KomVision Setting” of the
user menu on the machine monitor, the plain surface projection
is not displayed because it is not to be displayed when the ma-
chine is traveling at high speed.
MACHINE BODY DISPLAY

Machine body image is displayed in the bird's eye view display.
Machine body image varies with loading state pf the machine and the setting of the camera image.
Loading state display
It is displayed as follows according to the loading state.
(A) When unloaded
(B) When loaded
Under body display

The following is displayed corresponding to the under body dis-
play setting.
(C) Under body display ON: Image of under body is displayed.
(D) Under body display OFF: Image of under body is not dis-
played.
REMARK
Under body display can be set on “Under Body Display” of the
user menu on the machine monitor.
3-281
GUIDANCE DISPLAY
OBSTACLE ALARM BUZZER DEACTIVATE CAUTION LAMP
Obstacle alarm buzzer deactivate caution lamp warns that the
obstacle alarm buzzer is being disabled.
RADAR CHECK CAUTION LAMP

Flashing in yellow
It warns that action of the KomVision radar is being checked.
Lighting in yellow
It warns that the action check of the KomVision radar has not
finished yet if the machine is operated before the completion of
the action check.
Lighting in green
It displays that the action check of the KomVision radar has fin-
ished. It goes out when the machine is operated.
FORCED DISPLAY SETTING PILOT LAMP

Forced display setting pilot lamp is displayed when the Forced
Display setting of the KomVision monitor is set to ON.
RADAR PILOT LAMP

Radar pilot lamp is displayed when the KomVision radar is ef-
fective.
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CAMERA IMAGE SWITCH DISPLAY

On the camera switch display (1), the area displayed in the
camera image (2) is displayed in blue.
The area where an obstacle is detected by radar is displayed in
red.
The border color of the camera switch display (1) changes in
the order of No color → Orange → Red → No color.
REMARK
If the border color of the camera switch display (1) does not
change, the KomVision system is stopped and no image is up-
dated. In this case, turn the starting switch to OFF position
once, and turn it to ON position again in order to start up the
KomVision system again. If the border color of the camera
switch display (1) still does not change, ask your Komatsu dis-
tributor for repair.
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CAMERA IMAGE
The camera images are automatically switched according to
the machine travel speed, forced display setting, and obstacle
detection (only machine equipped with radar).
Obstacle de-
State of machine Forced display setting Camera image
tection
Stopped ON Enabled Camera image of obstacle detected area
Disabled Front camera image
OFF Enabled Camera image of obstacle detected area
FORWARD travel at ON Enabled Camera image of obstacle detected area
low speed
OFF Enabled Camera image of obstacle detected area
FORWARD travel at ON Enabled Front camera image
high speed
OFF Enabled Camera image is not displayed (non display
mode)
Disabled Camera image is not displayed (non display
mode)
Reverse ON Enabled Rear camera image (1-window display mode)
Disabled Rear camera image (1-window display mode)
OFF Enabled Rear camera image (1-window display mode)
Disabled Rear camera image (1-window display mode)
REMARK
• Press the camera selector switch, and the desired camera image can be selected and displayed. The se-
lected camera image is fixed for 10 seconds after switching, and the other camera images cannot be auto-
matically selected.
• Rear view camera image is automatically selected when traveling reverse. Even if the camera selector
switch is pressed during reverse travel, the camera image cannot be switched.
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REFERENCE LINE
Reference line is displayed on the bird's eye view display and
camera image display.
Reference line (1) is displayed in the following color according
to the distance from the machine body.
Distance from the ma-
Color
chine
White 0 m {0 ft}
Red 3 m {9 ft 10 in}
Yellow 5 m {16 ft 5 in}
Black 7 m {23 ft 0 in}
REMARK
• Reference line does not synchronize with the steering angle.
Reference line does not indicate the actual moving direction or travel path.
• Reference line is set for the machine with no load on the flat ground.
When the machine is loaded or the road surface is uneven, the reference line deviates from the actual ma-
chine position.
• The color of the reference line and its distance from the machine cannot be changed.
Front camera image
Reference line (A) is used to check the approximate machine
width.
Front right camera image

Reference line (B) is used to check the approximate front end
position of the machine.
Front left camera image

Reference line (C) is used to check the approximate front end
position of the machine.
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Rear right camera image

Reference line (D) is used to check the approximate machine
longitudinal length.
Rear left camera image

Reference line (E) is used to check the approximate machine
longitudinal length.
Rear camera image

Reference line (F) is used to check the approximate machine
width.
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HANDLE KomVision RADAR

OPERATION AND OBSTACLE DETECTION RANGE OF KomVision RADAR

KomVision radar operates when the machine is stopped or is traveling at low speed (travel speed less than
15 km/h). KomVision radar does not operate when the machine is traveling at high speed (travel speed 15 km/h
or higher).
KomVision system detects the obstacle larger than pickup truck. Humans and small structure may not be de-
tected with radar even if they are in the radar detection range.
Obstacle detection range by radar is shown in the following figure.
(A) Detection range in front and rear of machine: (L) Distance between front of slanted ladder and rear
7.6 m end of dump body
(B) Detection range in right and left of machine: 3.5 m (W) Distance between left side of cab and right side of
(C) Out of detection range in front of machine: 0.5 m platform
(D) Out of detection range in right and left of machine:

0.9 m
To prevent the machine itself from being detected as an obstacle, the area where any obstacle is not detected
are provided around the machine. Be fully aware of the area where no obstacle is detected, and operate the
machine.
If camera and radar get dirt during traveling, park the machine in a safe place, and clean them. After cleaning,
perform the camera and radar action check by referring to “METHOD FOR CHECKING BEFORE STARTING”.
3-287
REMARK
• When “Forced Display” is “ON” on “KomVision Setting” of the user menu on the machine monitor, the Kom-
Vision monitor screen is displayed when the machine is traveling at high speed, however, the radar does
not detect the obstacle and no obstacle warning is given.
• Obstacle detection and warning by the rear side radar are not performed when the machine body is raised,
in order not to wrongly detect the machine body as an obstacle.
• Definition of travel speed can be changed according to the situation. If change is required, ask your Komat-
su distributor.
WARNING WHEN OBSTACLE IS DETECTED

If radar detects the obstacles around the machine, KomVision
monitor automatically changes to the 2-window display mode,
and the camera image of the area where the obstacles are de-
tected.
The warning about the position of the obstacle is given by the
obstacle marker (1).
At the same time, the obstacle alarm buzzer sounds to warn
the operator.
The obstacle marker (1) is displayed in the following color according to the distance from the machine body.
Color Distance from the machine
Red 0 to 3 m {0 to 9 ft 10 in}
Yellow 3 to 5 m {9 ft 10 in to 16 ft 5 in}
Green Min. 5 m {Min. 16 ft 5 in}
REMARK
• When the gear shift lever is in R position, the display of KomVision monitor is displayed in the 1-window
display mode, and it is not automatically switched to the 2-window display mode.
• When the machine is traveling forward at low speed, or high speed, or traveling in reverse, the camera im-
age is not switched automatically even if the obstacles are detected.
• When the machine is traveling at high speed, the alarm is not issued because the KomVision radar does
not operate.
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Obstacle display in 2-window display mode

(A) Bird's eye view display
Obstacle marker (1) is displayed.
The outer frame (2) of the area where the obstacles are detect-
ed is highlighted in red and it flashes.
(B) Camera image
The camera image of the area where the obstacles are detect-
ed.
Obstacle marker is not displayed.
(C) Camera switch display
The area where the obstacles are detected flashes in red.
The area of the currently displayed camera image is displayed in blue.
REMARK
To make it easier to recognize the moving obstacles, the obstacle marker displays the locus marked in the past
as well.
Moving obstacle is displayed with 3 obstacle markers in total per one moving obstacle if it is detected, one for
the current position, one for the position 0.5 seconds before, and one for the position 1 second before.
Obstacle marker is put at newer locus as it is given priority over the older one.
Obstacle display in 1-window display mode
(B) Camera image
Obstacle marker (1) is displayed.
(C) Camera switch display
The area where the obstacles are detected flashes in red.
The area of the currently displayed camera image is displayed
in blue.
REMARK
In 1-window display mode, the locus of obstacle marker is not
displayed.
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AUTOMATIC SWITCHING OF CAMERA IMAGE AND OBSTACLE ALARM BUZ-

ZER WHEN OBSTACLE IS DETECTED
Automatic camera image switching and the obstacle alarm buzzer when an obstacle is detected depend on the
machine condition.
The camera image is automatically switched to the area where an obstacle is detected when the machine is in
the following state.
• When the parking brake switch is in “PARKING” position
• When the parking brake switch is in “TRAVEL” position, and the gear speed is in "NEUTRAL" position (N).
Alarm is performed in order of priority if multiple obstacles are detected.
There are 4 levels (High, Medium, Low, OFF) in the obstacle alarm buzzer. The higher the alarm level is, the
shorter the intervals of buzzer sound become.
The following are the priority of camera image which is selected with automatic switching and the corresponding
level of alarm buzzer.
When the parking brake switch is in “TRAVEL” position, and the gear speed is in "1st" to "7th" speed
position
Priority Area of camera image Level of obstacle alarm buzzer
1 Front camera
2 Right front camera High
3 Left front camera
4 Right rear camera
5 Left rear camera Medium
6 Rear camera
Obstacle alarm buzzer does not sound when the machine is traveling FORWARD at high speed.
When the parking brake switch is in “TRAVEL” position, and the gear speed is in "RL" and "RH" posi-
tion.
1 Rear camera
2 Right rear camera High
3 Left rear camera
4 Right front camera
5 Left front camera Medium
6 Front camera
Obstacle alarm buzzer does not sound when the machine is traveling REVERSE at high speed.
When the parking brake switch is in “TRAVEL” position, and the gear speed is in NEUTRAL position (N).
1 Front camera
Medium
2 Rear camera
4 Left front camera
Low
5 Right rear camera
6 Left rear camera
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When the parking brake switch is in “PARKING” position

1 Front camera
2 Rear camera
Alam buzzer OFF
4 Left front camera
5 Right rear camera
6 Left rear camera
METHOD FOR CANCELING OBSTACLE WARNING

Press the obstacle warning cancel switch, and the obstacle warning can be canceled.
Press the obstacle warning cancel switch when the obstacle
marker is displayed on the KomVision monitor screen.
Obstacle marker is not displayed. At the same time, the obsta-
cle alarm buzzer stops, and the obstacle warning is canceled.
If multiple obstacles are detected, every time when the obsta-
cle warning cancel switch is pressed, the obstacle warning is
canceled in order of priority.
Holding down the obstacle warning cancel switch for 1.5 sec-
onds or longer disables the obstacle alarm buzzer sound for 30
seconds.
REMARK
If the obstacle is no longer in the radar detection range, or the
obstacle is removed from the range, the obstacle warning is
automatically canceled.
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HANDLE REAR VIEW MONITOR OPERATION
HANDLE REAR VIEW MONITOR

k WARNING
• Never perform the switch operation during traveling.
Performing the switch operation during traveling may lead to an erroneous operation of traveling or
fail to ensure the safety of the hauling road ahead. This may lead to serious personal injury or
death.
• The rearview monitor is a device that assists a visual check to ensure safety in rearward and the
area around the machine.
It doesn't mean that it can display everything since it has limitations. Visually check the surround
area of the machine for the safety when traveling reverse.
Never travel reverse as relying only on the image displayed on the rear view monitor.
• Drive the machine slowly in reverse. The distance shown on the rearview monitor may differ from
the actual distance.
• The image reflected on the rearview monitor may be distorted, and it may differ from the actual
state.
The center of the screen is preferable to be used as a guide.
Use the rearview monitor (1) as an auxiliary when performing

the visual check of rear and around the machine until the start-
up of KomVision monitor is completed.
After the KomVision monitor has been started, the rearview
monitor (1) is not displayed.
Reference line (2) on the rearview monitor can be used to

check the approximate width and rear end position of the ma-
chine.
For the other settings of the rearview monitor, see “REAR
VIEW MONITOR SETTING (3-78)”, and for the setting of refer-
ence line, see “METHOD FOR ADJUSTING REAR VIEW
CAMERA ANGLE (3-182)”.
REMARK
• The screen may be hard to see in the dark place at night,
but it is not a trouble.
• Reference line does not synchronize with the steering an-
gle.
Reference line does not indicate the actual moving direc-
tion or travel path.
• Reference line is set for the machine with no load on the
flat ground.
When the machine is loaded or the road surface is un-
even, the reference line deviates from the actual machine
position.
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OPERATION HANDLE REAR VIEW MONITOR
(A) When unloaded (C) When road surface is uneven

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

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

k WARNING
• Do not disassemble or modify the rearview monitor.
There is a danger of electric shock or fire.
• Do not open the back cover of the rearview monitor.
There is a danger of electric shock, as high voltage power is conducted internally.
• Do not use the rearview monitor while it is broken.
There is a danger of electric shock or fire, should it be used in spite of a defect. In that case, ask
your Komatsu distributor for repair or replacement.
• If foreign materials enter into the rearview monitor, or if the rearview monitor gets wet, or if smoke
comes out of it or it gives a bad smell, stop using it immediately.
It poses a big danger to use the monitor when any such abnormality exists. In that case, consult
• When replacing a fuse, be sure to use one with the specified capacity of 10 A.
Should a fuse with a higher- than- specified capacity be used, it can cause fire.
• As a general rule, the rear view monitor should be replaced after a total usage time of approximately 3000
hours (or approximately 3 years), though this may differ according to usage conditions.
• When cleaning the rearview monitor, use dry soft cloth or wet cloth after having well wrung the water out.
If it is very dirty, use neutral detergent.
Do not use thinner or alcohol.
• Sometimes an image on the rearview monitor screen is blurred due to the camera lens being smeared.
In that case, clean the camera lens with dry soft cloth or wet cloth after having well wrung the water out.
3-294
OPERATION DETERMINE AND MAINTAIN TRAVEL ROAD
DETERMINE AND MAINTAIN TRAVEL ROAD

Determining and performing maintenance of the road in the jobsite are the extremely important factors both for
reasons of safety and for reducing the cycle time.
To ensure safety in operations, do as follows.
Determine travel road
• As far as possible, restrict the travel road to one-way travel.
• If it is impossible to keep one-way traffic, make the road with ample width to enable trucks traveling in oppo-
site directions to pass each other.
If it is impossible to provide a sufficient road width, provide passing places at various points along the road.
• Always design the road so that the loaded truck passes on the side closest to the hill face.
• If there are curves with poor visibility along the road, set up mirrors.
• In a place where the road shoulder is weak or likely to collapse, set up a sign at a point 1.5 m or more from
the road shoulder to warn of the danger.
• It is important to set up lighting or reflectors on the road to enable the traveling at night.
• The grade of slope should be kept 10 % (approximately 6 °) as far as possible, and emergency escape
points should be set up on downhill slopes in case of any brake failure.
• Increase the number of places where the road continues in a straight line. If there are curves in high-speed
travel areas, make the radius of the curve as large as possible.
• Small S curves are particularly dangerous, so avoid such curves. The radius of the curve must be a mini-
mum of 15 to 18 m.
• Make the radius of curves as large as possible.
• Make the road wider at curves than it is in straight areas.
• Make the surface of the road slightly higher on the outside of curves.
• Be particularly careful to strengthen the road shoulder on the outside of curves.
• Design the travel road as far as possible so that it does not cross any other travel road.
In particular, when roads cross at an angle on slopes, there is danger that a difference in height will be cre-
ated in the road, and this will make the machine sway strongly when traveling at high speed.
• Cut the slope face to provide a special road for the trucks.
Maintain travel road
Perform the necessary action according to the conditions to insure that the road can always be traveled in safe-
ty.
• Remove any unevenness in the travel surface, sloping to the left or right, or drooping of the road shoulder.
Make the road of ample strength and remove such obstacles as rocks and tree stumps.
• Maintain the road with a bulldozer or motor grader from time to time.
• Spray the road with water at suitable intervals to prevent dust from rising and reducing the visibility.
3-295
TRANSPORTATION OPERATION
TRANSPORTATION
PRECAUTIONS FOR TRANSPORTATION
Always obey the traffic regulations when transporting the machine by road.
k WARNING
This machine may need to be divided into components for transportation depending on the regulation.
When transporting the machine, consult your Komatsu distributor.
SELECT TRANSPORTATION METHOD

As a basic rule, always transport the machine on a trailer.
METHOD FOR SECURING MACHINE

Fix the machine by using the chain or wire rope at the fixing position shown in the following figure.
Put the blocks in front of and behind the tires and secure the
machine with chains or wire rope at the fixing position so that
the machine does not move.
In particular, fix the machine securely to prevent it from slipping
sideways.
3-296
OPERATION TRANSPORTATION
PRECAUTIONS FOR LIFTING MACHINE

When lifting the machine at a port or any other place, always use the following procedure to lift it.
k WARNING
• The person using the crane to perform lifting operations must be a qualified crane operator.
• Do not lift the machine with someone in it.
• Always use a wire rope that has ample strength for the weight of the machine.
• When lifting, keep the machine horizontal.
• Before starting the lifting operation, be sure to stop the engine, and apply the parking brake.
• Never enter the area under or around a lifted machine.
• Never try to lift the machine in any other posture or by using any other lifting equipment than those
given in the following procedures.
There is a danger that the machine loses its balance.
NOTICE
This lifting method applies to the standard specification machine.
The method of lifting differs depending on the attachments and options installed.
For the procedure for machines that are not the standard specification, consult your Komatsu distribu-
tor.
For the weight of the standard specification machine, see “Weight table”.
NOTICE
• Use protectors, etc. so that the wire ropes will not be broken at sharp edges or narrow places.
• When using a spreader beam, select an ample width to prevent contact with the machine.
Consult your Komatsu distributor before performing lifting work.
3-297
TRANSPORTATION OPERATION
Location of lifting position mark
Weight table
Load on front Load on rear Center of gravity
Machine weight
axle axle (from front axle)
107600 kg 55952 kg 51648 kg 2668 mm {8 ft 9
HD1500-8
{237258 lb} {123374 lb} {113884 lb} in}
3-298
OPERATION TRANSPORTATION
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.
2. Set the dump lever to “FLOAT” position and check that the
dump body float caution lamp is not lit.
3. Stop the engine, and set the parking brake switch to

“PARKING” position to apply the parking brake.
4. Select the lifting tools such as wire ropes, slings, or

spreader beams to match the weight of the machine, and
fit them to the lifting hooks (at lifting hook marks) at 4 pla-
ces in total (2 places at front, 2 places at rear) of (1) and
(2) positions.
5. Fit the protector blocks at contact points between the lifting
tool and the dump body to prevent damage to the lifting
tool.
6. When the machine comes off the ground (being lifted 100
to 200 mm {3.9 to 7.9 in} ), stop the lifting operation, check
carefully that the machine is balanced and that the wire
ropes are not loose, then continue the lifting operation slowly.
3-299
COLD WEATHER OPERATION OPERATION
COLD WEATHER OPERATION

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

Change the fuel and oil with ones of low viscosity for all components.
For the specified density, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE”.
COOLANT
k WARNING
• Coolant is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes
or on your skin, wash it off with large amount of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company
to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.
NOTICE
Komatsu recommends the use of the Non-Amine Engine Coolant (AF-NAC) to which DCA4, the additive
agent manufactured by Cummins filtration, is added.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For the coolant change interval and the density of Non-Amine Engine Coolant (AF-NAC), see “METHOD FOR
USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
3-300
OPERATION COLD WEATHER OPERATION
BATTERY
k WARNING
• Do not bring any open flame near the battery. Otherwise, it may explode since the battery generates
the flammable gas.
• Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a
large amount of water and consult a doctor.
• Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
• Do not charge the battery or start the engine with a different power source if the battery electrolyte
is frozen. Battery may explode.
• Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground sur-
face.
When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging
rate as close as possible to 100 %. Insulate it against cold temperature to ensure that the machine can be start-
ed easily in the next morning.
REMARK
Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table.
Electrolyte Temperature 20 °C 0 °C -10 °C -20 °C
Charging Rate ( %) {68 °F} {32 °F} {14 °F} {-4 °F}
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
• When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it
from the machine to place it in the warm place. Restore it again before the operation.
• If the electrolyte level is low, add distilled water in the morning before beginning the work. Do not add water
after the day's work to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER

The machine may get stuck and does not move due to mud and water which become frozen around the under-
carriage of the machine. Observe the following in order to prevent the machine from being frozen.
• Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean
to prevent the seal from being damaged by mud or dirt together with drops of water on the rod which en-
tered inside the seal.
• Place the machine on a firm, dry ground.
If there is no firm and dry ground, park the machine on boards.
This prevents the undercarriage from freezing to the ground surface, and allows the machine to be started
easily the next morning.
• Open the drain valve at the bottom of the fuel tank to drain the water accumulated in the fuel system and
prevent it from freezing.
• The battery function decreases remarkably at low temperature.
Cover it, or remove it from the machine to place it in the warm place. Restore it again before the operation.
• If the electrolyte level is low, add the distilled water in the morning before beginning the work.
Do not add the distilled water after the day's work to prevent the battery electrolyte from freezing during the
night.
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COLD WEATHER OPERATION OPERATION
AFTER COLD WEATHER SEASON

When the season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all equipment with the ones of the specified viscosity by referring to “METHOD FOR
USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
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OPERATION PRECAUTIONS FOR LONG-TERM STORAGE
PRECAUTIONS FOR LONG-TERM STORAGE

PREPARATION FOR LONG-TERM STORAGE
When putting the machine in storage for a long time (more than one month), do as follows.
• Clean and wash all the parts of the machine and store the machine indoors.
If the machine has to be stored outdoors, select a level ground and cover it with waterproof sheet.
• Fill up the fuel tank.
This prevents dew condensation.
• Grease the machine and change the oil before storage.
• Coat the exposed portion of the hydraulic cylinder piston rod with grease.
• Turn the starting switch to OFF position, then turn the battery disconnect switch to OFF position.
When storing the battery, cover it.
• Keep the parking brake applied.
• Set the tire inflation pressure for each tire to within the range of the specified inflation pressure for the type
of tire.
• Push the retarder control lever forward to OFF position.
• Set the gear shift lever to NEUTRAL position (N).
• To prevent rust, fill the cooling circuit with Non-Amine Engine Coolant (AF-NAC) to give a density of 30 % or
more for the engine coolant.
MAINTENANCE DURING LONG-TERM STORAGE

k WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors
and windows to improve ventilation and prevent gas poisoning.
• During storage, operate and move the machine for a short distance once a month so that a new film of oil
will coat moving parts. At the same time, charge the battery as well.
• When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
• If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a
month to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing
this. In addition, check the refrigerant level twice a year.
3-303
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION
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.
Perform the following items when using the machine after long-term storage.
• Wipe off the grease from the hydraulic cylinder piston rods.
• Add oil and grease at all lubrication points.
• When the machine is stored for a long period, moisture in the air will mix with the oil.
Check the oil before and after starting the engine. If there is water in the oil, change all the oil.
• Turn the battery disconnect switch to ON position.
• If the machine is stored for a long period with the battery disconnect switch at OFF position or the battery
terminal disconnected, the time information of the clock and radio tuning information may be lost. In this
case, set the clock and radio again
• When starting the engine, perform the engine warm-up operation thoroughly.
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE

1. Check all the oil and water levels before traveling.
2. When traveling after long-term storage, travel forward at a speed of 10 to 15 km/h (6.2 to 9.3 MPH) for 5
minutes or 1 km (3280 ft) to run the machine in, then change to normal travel.
3-304
OPERATION TROUBLES AND ACTIONS
TROUBLES AND ACTIONS

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

k CAUTION
When starting the engine again, check safety around the engine thoroughly, and then crank the engine.
When fuel is running out, refill the fuel, and start the engine according to the following procedure.
1. Open the valve (1) to the fuel filter which is installed to fuel
tank on the right side of the machine.
2. Remove the cap (2) on the fuel filter, then fill the fuel filter
with fuel.
Fuel to refill: 20 ℓ {5.28 U.S.Gal}
3. Close the valve (1).
4. Refill the hose with fuel through the cap (2) on the fuel fil-
ter, then fill the hose with fuel.
5. Loosen the plug (3).
Check that the fuel feed pump operates and the fuel is
drained.
7. After bleeding air, tighten the plug (3).
Tightening torque: 9.8 to 12.4 Nm {1.0 to 1.3 kgm, 7.23 to 9.4 lbft}
8. Open the valve (1), then start the engine.
3-305
TROUBLES AND ACTIONS OPERATION
ACTIONS IF TRANSMISSION HAS TROUBLE

If the transmission has any trouble, operate the machine according to the following procedure.
1. Use the brake pedal to reduce the travel speed and stop the machine at a safe place.
2. Set the gear shift lever to NEUTRAL position (N) position, and set the parking brake switch to “PARKING”
position.
In some trouble modes, the gear is not shifted even if the shift lever is operated.
In this case, perform the following procedure.
1) Turn the starting switch to ON position or start the engine.
2) Disconnect (pull out) the limp-home connector (1) (No.
A1 (female), A1 (male), white 1-pole connector), and
then connect (insert) it again.
3) Set the parking brake switch to “TRAVEL” position.
4) Operate the gear shift lever to move the machine to a
safe place without depressing the accelerator pedal.
If the gear shift lever is operated with the accelerator pedal depressed, the limp-home function will not work.
In addition, depending on the contents of failure, the limp-home function may not work.
While the limp-home function is actuated, the machine monitor shift indicator displays “E” and the transmission
shift range (gear speed) alternately.
3-306
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR

k WARNING
When lowering the dump body in case of trouble, do not go under the dump body. You may get caught
between the dump body and it is dangerous.
When the dump body needs to be lowered to the seated position while the engine cannot be started for some
trouble, perform the following procedure.
1. Remove the steering and hoist oil tank filler port cap (F),
and release the remaining pressure in the hoist circuit.
2. Loosen the lock nut (2) of the manually lowering valve (1)
on the steering and hoist oil tank at the center of the ma-
chine.
3. Turn the grip (3) of valve (1) counterclockwise.
The oil in the hoist cylinder is returned into the steering
and hoist oil tank, and the dump body lowers.
4. When the dump body is lowered to the desired position,
turn the grip (3) clockwise, and tighten the lock nut (2).
If the dump body cannot be lowered even if the above method is used, consult your Komatsu distributor.
3-307
PRECAUTIONS FOR TOWING MACHINE

k WARNING
Injury or death could result if a disabled machine is towed
incorrectly or if there is a mistake in the selection of the
wire rope or drawbar.
• Always confirm that the wire rope or drawbar used for
towing has ample strength for the weight of the ma-
chine being towed.
• Never use the wire rope which has cut strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
• Wear the leather gloves always when handling the wire
ropes.
• Never tow a machine on a slope.
• During the towing operation, never stand between the
towing machine and the towed machine.
• If the machine moves suddenly, a load is applied sud-
denly to the towing wire or drawbar, and the towing
wire or drawbar may break.
Move the machine gradually to a constant speed.
• Be extremely careful if there is a failure in the engine
or brake system: the brakes will not work.
• If the steering and the brakes on the machine being
towed cannot be operated, do not let anyone ride on
the machine being towed.
NOTICE
• The maximum towing capacity for this machine is 790860 N {80700 kg} . Do not tow any load greater
than this.
• Tow the machine only for a short distance, such as to a place for inspection and maintenance.
Do not tow the machine for a long distance.
• For towing a failed machine, consult your Komatsu distributor.
This machine must not be towed except in emergency. However, if it is unavoidable to tow the machine, pay
attention to the following precautions.
• When towing a machine, tow it at a low speed of 2 km/h or lower {1.2 MPH or lower} , and for a distance of
a few meters to a place where repairs can be performed.
This method is applied only in an emergency. If the machine must be moved a long distance, use a trans-
porter.
• Usually, use a towing machine of the same class as the machine being towed. Check that both towing ma-
chine and towed machine have ample braking power, and rim pull to allow them to control both machines
on slopes or on the tow road.
• Use the specified hook for both the towing machine and the machine being towed.
• To protect the operator if the towing wire or towing bar breaks, install the protective plates on both the tow-
ing machine and the machine being towed.
3-308
• Towing device has hooks for towing on the front bottom of

the frame and holes for towing on the rear bottom of the
axle. Use the shackles (1) (2 pieces) (permitted load: 50 t
or more) of class S which is prescribed in ISO2415 for tow-
ing at rear side.
Use only these hooks when towing. Do not use any other
place.
• When fitting the towing wire, check the condition of the
hook to make sure that there is no problem.
• Keep the angle of the towing wire as small as possible.
Keep the angle between the center lines of 2 machines
within 30 °.
• Towing may be performed under various conditions, so it is
impossible to determine beforehand the requirements for
towing. Towing on flat level roads will require the minimum
rim pull, while towing on slopes or on uneven road surfa-
ces will require the maximum rim pull.
• Always release the parking brake before towing.
• Before releasing the parking brake, always chock the all

wheels.
If the wheels are not chocked, there is a danger that the
machine may move suddenly.
Connect with the towing wire or drawbar, and remove the
blocks from the wheels when the towed machine is in a
condition where it cannot run away.
• When releasing the parking brake, check that the area
around the machine is safe.
• If the parking brake is released, the brakes will not work,
so pay careful attention to safety.
• When towing on a slope, use 2 towing machines. One machine should be uphill side from the towed ma-
chine and should be connected with towing wire or a drawbar to pull back the towed machine in order to
keep it stable. The other machine should tow the towed machine from the foot of a hill.
When engine runs
• If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the
machine out of mud or to move it for a “short distance” to the edge of the road.
• Check the effect of the brakes, and if the brakes do not work properly, take the action given in “When en-
gine does not run”.
• Check if it is possible to steer the machine. If the machine cannot be steered, follow the procedure given in
“When engine does not run”.
3-309
• The operator should get on the machine being towed and operate the steering in the direction that the ma-
chine is towed.
• Always run the engine to allow the steering and brakes to be used.
When engine does not run
• The brakes will not work, so be extremely careful.
• Connect the towing machine securely to the machine being towed.
Use 2 towing machines of the same class or larger than the machine being towed: connect one machine
each to the front and rear of the machine being towed.
• If it is necessary to change the direction of the machine being towed, it is possible to use the secondary
steering, but it can be used for a maximum of only 90 seconds.
• If the secondary steering cannot be used, disconnect 2 hydraulic hoses each on the left and right from the
steering cylinders, then perform the towing operation.
When removing the hoses, block the hoses with plugs and fit oil containers to the mouthpiece of the cylin-
der to prevent oil from draining to the ground.
3-310
METHOD FOR RELEASING PARKING BRAKE

k WARNING
• If any problem occurs in the brake hydraulic system, there is a high probability that the wheel
brakes will not work properly. Always drive slow when towing the machine.
• When releasing the parking brake, check that the area around the machine is safe and always chock
all the wheels before starting the work.
If the wheels are not chocked, there is a danger that the machine may move suddenly.
• Always stop the engine before starting the operation to release the parking brake.
The parking brake is automatically actuated when the pressure in the hydraulic circuit abnormally drops and
when the accumulated pressure in the accumulator drops.
See the following procedure if it is necessary to release the parking brake when towing or moving the machine.
NOTICE
Evenly tighten the bolts for releasing the parking brake. Otherwise, the inside piston will get distorted
and be damaged. Tighten the bolts diagonally and alternately.
• M16 bolt (stem length: 85 to 95 mm {3.3 to 3.7 in} , screw pitch: 2.0 mm {0.079 in} ) x 16 pieces
• M16 bolt (stem length: 100 to 110 mm {3.9 to 4.3 in} , screw pitch: 2.0 mm {0.079 in} ) x 16 pieces
• Washer for M16 bolt x 32 pieces
• Container to catch drained oil
1. Stop the engine.
2. Chock the tires.
3. Place a container to catch the drained oil under the rear
axle brake.
4. Remove the plug (1) of the rear axle brake.

Plugs (1) are installed 8 pieces on the right, 8 pieces on
the left.
5. Attach the washer to the prepared bolt, and put them into
the plug hole.
Use the bolt whose stem length is 100 to 110 mm {3.9 to
4.3 in} for rear axle.
6. Place a container to catch the drained oil under the front
axle brake.
3-311
7. Remove the plug (2) of the front axle brake.

Plugs (2) are installed 8 pieces on the right, 8 pieces on
the left.
8. Attach the washer to the prepared bolt, and put them into
the plug hole.
Use the bolt whose stem length is 85 to 95 mm {3.3 to
3.7 in} for front axle.
9. Tighten the bolts for releasing the brake evenly.
Tighten the bolts on the front and rear, and right and left
sides.
3-312
PRECAUTIONS FOR DISCHARGED BATTERY

k WARNING
• It is dangerous to charge a battery when installed on a
machine. Make sure that it is removed before charg-
ing.
• When checking or handling the battery, stop the en-
gine and turn the starting switch and battery discon-
nect switch to OFF positions.
• The battery generates hydrogen gas, and it is danger-
ous that it may explode. Do not bring open flame such
as lighted cigarettes near the battery, or do nothing
that will cause sparks.
• Battery electrolyte is dilute sulfuric acid, and it will at-
tack your clothes and skin. If it gets on your clothes or
on your skin, immediately wash it off with a large
amount of clean water.
If it gets in your eyes, wash the eyes immediately with
clean water, then consult a doctor for medical treat-
ment.
• When handling batteries, always wear protective eye-
glasses and rubber gloves.
• When removing the battery, first disconnect the cable
from the ground (normally the negative (-) terminal).
When installing, first connect the cable to the positive
(+) terminal.
If a tool touches the positive terminal and the chassis,
it is dangerous that it may cause a spark. Be extremely
careful.
• If the terminals are loose, it is dangerous that the de-
fective contact may generate sparks, and it may cause
an explosion.
Install the cable terminals securely.
• When removing or installing the cable terminals,
check which is the positive (+) terminal and which is
the negative (-) terminal.
3-313
PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY

k CAUTION
• When removing the battery cables, remove the ground cable (normally connected to the negative (-)
terminal) first.
If any tool touches between the positive (+) terminal and the chassis, there is a hazard of sparks
being generated.
• When installing the battery cables, connect the ground cable last.
When replacing the battery, fix the battery body with the battery mounting fixtures.
Securely tighten the terminal to the following tightening torque.
Tightening torque of wiring harness terminal (1): 11.8 to
19.6 Nm {1.2 to 2.0 kgm, 8.68 to 14.5 lbft}
Tightening torque of battery terminal (2): 9.81 to 11.8 Nm {1.0
to 1.2 kgm, 7.23 to 8.68 lbft}
Tightening torque of 1st nut (3) of mounting fixture: 6.96 to
9.02 Nm {0.71 to 0.92 kgm, 5.14 to 6.65 lbft}
Tightening torque of 2nd nut (4) of mounting fixture: 35 to
45 Nm {3.57 to 4.59 kgm, 25.8 to 33.2 lbft}
3-314
PRECAUTIONS FOR CHARGING BATTERY

k WARNING
When charging the battery, if the battery is not handled
correctly, there is a danger that the battery may explode.
Follow the instruction manual accompanying the battery
charger, and observe the following.
• Set the voltage of the charger to match the voltage of
the battery to be charged. If the correct voltage is not
selected, the battery charger may overheat and cause
,&
an explosion.
• Connect the positive (+) charger clip of the battery
charger to the positive (+) terminal of the battery, then
connect the negative (-) charger clip of the battery
charger to the negative (-) terminal of the battery. Be
sure to attach the clips securely.
• Set the charging current to 1/10 or less of the value of
the rated battery capacity. When performing rapid
charging, set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will
leak or the battery cells will dry up, and this may cause
the battery to catch fire and explode.
• Do not charge the battery or start the engine with a dif-
ferent power source if the battery electrolyte is frozen.
This may ignite the battery electrolyte, and battery
may explode.
• Do not use or charge the battery if the battery electro-
lyte level is below LOWER LEVEL line. This may cause
an explosion. Check the battery electrolyte level peri-
odically and add the purified water (such as a commer-
cial battery fluid) to bring the electrolyte level to UP-
PER LEVEL line.
3-315
START ENGINE WITH JUMPER CABLES

k WARNING
• When connecting the cables, never connect the posi-
tive (+) and negative (-) terminals.
• Always wear protective eyeglasses and rubber gloves
when starting the engine by using the jumper cable.
• Do not bring the normal machine into contact with the
failed machine.
The sparks caused near the battery could ignite the
hydrogen gas generated from the battery, so be care-
ful not to let it happen.
• Make sure that there is no mistake in the jumper cable
connections.
When the final connection of the cables is done to the
engine block of the failed machine, sparks will be gen-
erated. So, connect to a place as far as possible from
the battery.
• When disconnecting the jumper cable, take care not to
bring the clips in contact with each other or with the
machine.
NOTICE
• The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped
with a 24 V power supply.
• The sizes of the jumper cables and clips should be suitable for the battery size.
• The battery of the normal machine must be the same capacity as that of the failed machine.
• Check the cables and clips for damage or corrosion.
• Make sure that the cables and clips are firmly connected.
• To prevent damage of the electric devices of the failed machine, before connecting the jumper ca-
bles, turn the starting switch of the failed machine to OFF position first, and then turn the battery
disconnect switch to OFF position.
REMARK
If the battery disconnect switch is turned to OFF position, all the electrical system is cut out and the functions of
KOMTRAX stop.
In addition, the time information of the clock and the radio tuning information may be lost.
In this case, set the clock and radio again
3-316
PROCEDURE FOR CONNECTING JUMPER CABLES

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

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

After the engine has started, disconnect the jumper cables in the reverse of the order in which they were con-
nected.
1. Remove the clip of jumper cable (B) from engine block (E)
on the failed machine.
2. Remove the clip of jumper cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (C) on the failed machine.
3-317
START ENGINE WITH AUXILIARY ENGINE STARTING CONNECTOR

k WARNING
• Do not bring the normal machine into contact with the failed machine.
The sparks caused near the battery could ignite the hydrogen gas generated from the battery, so be
careful not to let it happen.
• Make sure that there is no mistake in the auxiliary engine starting connector.
Connect the final cable to the failed machine.
NOTICE
• The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped
with a 24 V power supply.
• The sizes of the auxiliary engine starting cable should be suitable for the battery size.
• Check that the cables and connectors are free from damage or corrosion.
• Firmly connect the connectors.
• Check that the parking brake switches of both machines are at “PARKING” position.
• Check that each gear shift lever is in NEUTRAL position (N).
• To prevent damage of the electric devices of the failed machine, before connecting the auxiliary en-
gine starting cables, turn the starting switch of the failed machine to OFF position, and then turn the
battery disconnect switch key to OFF position.
Connect the auxiliary engine starting cables
1. Turn the starting switches of both machines to OFF position.
2. Turn the battery disconnect switch keys of both machines to OFF position.
3. Connect the auxiliary engine starting cables to the normal machine.
4. Connect the auxiliary engine starting cables to the failed machine.
Start the engine
1. Check that the connectors are connected firmly.
2. Start the engine of the normal machine, and run it at high idle (max. speed).
3. Turn the starting switch of the failed machine to START position and start the engine.
If the engine does not start, try it again after 2 minutes or longer.
Remove the auxiliary engine starting cables
1. After the engine has been started, remove the auxiliary engine starting cables of the failed machine.
2. Remove the auxiliary engine starting cables of the normal machine.
3-318
OTHER TROUBLE
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM
• Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Lamp does not glow brightly even Defective wiring Check and repair loose terminals,
when the engine runs at high speed. open circuit. (*)
Insufficient battery charge Charge, add distilled water.
Loosening and damage of belt Check alternator belt tension and re-
place.
Lamp flickers while engine is running. Defective wiring Check and repair loose terminals,
open circuit. (*)
Insufficient battery charge Charge, add distilled water.
Loosening and damage of belt Check alternator belt tension and re-
place.
Battery charge level caution lamp Defective alternator Replace. (*)
lights up while engine is running.
Defective wiring Check, repair. (*)
Unusual noise is generated from al- Defective alternator Replace. (*)
ternator.
Loosening and damage of alternator Check alternator belt tension and re-
belt place.
Starting motor does not rotate even Defective wiring Check, repair. (*)
when starting switch is turned to
Defective starting switch Replace switch. (*)
START position.
Insufficient battery charge Charge battery.
Defective battery relay Replace relay. (*)
Battery disconnect switch or starting Turn it to ON position.
motor disconnect switch is at OFF
position
Engine shutdown secondary switch is Set it to “NORMAL” position. Close
at "STOP ENGINE" position. cover.
Starting motor is incapable of crank- Defective wiring Check, repair. (*)
ing engine smoothly.
Starting motor disengages before en- Defective wiring Check, repair. (*)
gine starts. (Rattles)
Rearview monitor displays nothing. Defective wiring Check, repair. (*)
Defective rearview camera Replace. (*)
Improper setting of rearview monitor Set it by referring to “REAR VIEW
MONITOR CONSTANT DISPLAY”.
3-319
PHENOMENA AND ACTIONS FOR CHASSIS

Torque converter oil temperature cau- Leakage of oil or entry of air due to Check, repair. (*)
tion lamp lights up. damage or defective tightening of oil
pipe, pipe joint
Wear, scuffing of gear pump Check, repair. (*)
Lack of oil in transmission case Add oil to the specified level. See
CHECKS BEFORE STARTING.
Clogged oil cooler Clean or replace (*)
Long distance traveled in torque con- Drive in direct range
verter range
Wiring to the sensor is disconnected Repair the wiring, or connect it. (*)
or broken.
Steering wheel is heavy to operate. Insufficient greasing of link Lubricate
Internal leakage inside steering cylin- Replace cylinder seal. (*)
der
Steering wheel is out of control. Tire inflation pressure not uniform on Make tire inflation pressure uniform.
left and right See CHECK BEFORE STARTING.
Dragging, pulling of front brake Check wear of brake disc (*)
Braking effect is poor when brake Disc has reached wear limit. Replace the disc. (*)
pedal is depressed
Insufficient oil pressure Charge to the specified pressure.
Insufficient brake oil Add oil to brake oil tank. See CHECK
BEFORE STARTING.
Air in brake circuit Bleed air. See WHEN REQUIRED.
Brake pulls to one side. Disc has reached wear limit. Replace the disc. (*)
Insufficient oil pressure Charge to the specified pressure.
Insufficient brake oil Add oil to brake oil tank. See CHECK
BEFORE STARTING.
Air in brake circuit Bleed air. See WHEN REQUIRED.
Dump body speed is slow. Defective piston pump Replace piston pump. (*)
Insufficient oil Add oil to the specified level. See
CHECKS BEFORE STARTING.
Suspension is hard. Soil or sand entering through dam- Replace U-packing. (*)
aged dust seal has damaged U-pack-
ing, causing leakage of gas.
Gas leaking from valve core Replace valve core. (*)
3-320

Wheel on one side tends to slip. Air in brake circuit (between slack ad- Bleed air from brakes (R.H. and
juster and brake) L.H.). See WHEN REQUIRED.
Excessive difference in wear between Replace tire. (*)
right and left tires
Excessive difference in division of Make load uniform.
load between left and right wheels
(unbalanced load)
Excessive deformation of disc Overhaul brake. (*)
When accelerator pedal has failed

The accelerator pedal is equipped with a potentiometer that detects the amount that the accelerator pedal is
depressed. In addition, there is a switch that judges if the accelerator pedal is being depressed or if it has been
released.
If it is impossible to detect correctly the amount that the accelerator pedal is depressed because of breakage of
the accelerator pedal or defective wiring, the engine controller controls the engine in accordance with the signal
from this judgment switch.
When the accelerator pedal is being depressed, the engine speed is set to 1500 rpm. When the accelerator
pedal is released, the engine speed is set to low idle speed.
The speed differs according to the load.
Operate the accelerator pedal to move the machine to a safe place, then check the failure code and contact
When operating the accelerator pedal, release the pedal to turn it to OFF position (low idle) or depress it fully to
set it to 1500 rpm.
If the accelerator pedal is depressed half way, it may be impossible to judge if the accelerator pedal is being
operated.
REMARK
If the engine controller cannot correctly receive the signal for the amount that the accelerator pedal is de-
pressed, the centralized warning lamp lights up, the alarm buzzer sounds intermittently, the engine system cau-
tion lamp lights up and action level “L03” is displayed on the machine monitor.
3-321
PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS

Engine oil pressure caution lamp Oil in oil pan is insufficient. Add oil to the specified level.
lights up. See CHECKS BEFORE START-
ING.
Improper oil is used (viscosity is im- Change oil. See METHOD FOR
proper). USING FUEL, COOLANT AND
LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE and
RECOMMENDED FUEL, COOL-
ANT, AND LUBRICANT.
Oil filter cartridge is clogged. Replace cartridge. See EVERY
250 HOURS MAINTENANCE.
Oil leakage due to improper tighten- Check, repair. (*)
ing or breakage of oil pan, pipe joint
Wiring to the sensor is disconnected Repair the wiring, or connect it.
or broken. (*)
Steam spurts out from top of radiator Engine coolant is insufficient, coolant Check, add coolant. See
(pressure valve). leaks. CHECKS BEFORE STARTING.
The coolant level caution lamp lights Dirt or scale accumulated in cooling Change coolant, clean inside of
up and the machine monitor displays system cooling system. See WHEN RE-
low coolant level as L01. QUIRED.
Indicator of engine coolant tempera- Clogged radiator fins or damaged fin Clean or repair by referring to
ture gauge is in red range. (Engine WHEN REQUIRED.
coolant temperature caution lamp
Defective coolant temperature gauge Replace coolant temperature
lights up.)
gauge. (*)
Thermostat has a trouble. Replace thermostat. (*)
Defective thermostat seal Replace thermostat seal. (*)
Loose radiator filler cap Tighten or replace cap.
Wiring to the sensor is disconnected Repair the wiring, or connect it.
or broken. (*)
Indicator of engine coolant tempera- Defective coolant temperature gauge Replace coolant temperature
ture gauge stays at lowest position gauge. (*)
and does not rise.
Thermostat has a trouble. Replace thermostat. (*)
3-322

Starting motor operates but engine Fuel is insufficient. Add fuel. See CHECK BEFORE
does not start. STARTING
Air in fuel system Repair place where air is
sucked. (*)
No fuel in fuel filter Fill filter with fuel by referring to
EVERY 500 HOURS MAINTE-
NANCE.
Starting motor incapable of cranking See PHENOMENA AND AC-
engine smoothly. TIONS FOR ELECTRICAL SYS-
TEM.
Starting motor does not turn. See PHENOMENA AND AC-
TIONS FOR ELECTRICAL SYS-
TEM.
Incorrect valve clearance (defective Adjust valve clearance. (*)
compression)
Gear shift lever is in any position Move gear shift lever to NEU-
other than NEUTRAL position (N). TRAL position (N).
Fuel supply occasionally stops. Clogged fuel tank breather tube Replace breather tube. (*)
Oil consumption is excessive. Oil is leaking. Check, repair. (*)
Exhaust gas color is white or bluish. Excessive oil in oil pan Make the oil level to the speci-
fied level. See CHECKS BE-
FORE STARTING.
Piston, ring, and cylinder liner are Replace. (*)
worn.
Low grade fuel being used Replace with specified fuel.
Turbocharger has a trouble. Check, replace. (*)
Exhaust gas is black. Clogged air cleaner element Clean or replace by referring to
WHEN REQUIRED.
Piston, ring, and cylinder liner are Check, repair. (*)
worn.
Compression is improper. See adjustment of clearance
above.
Turbocharger has a trouble. Check, replace. (*)
Injector has a trouble. Check, replace, repair. (*)
Engine hunts. Air entering suction side of fuel line Repair place where air is
sucked. (*)
Combustion makes breathing sound Defective nozzle Replace nozzle. (*)
from time to time.
There is knocking (combustion or Low grade fuel being used Replace with specified fuel.
mechanical).
Overheating See “Indicator of engine coolant
temperature gauge is in red
range” above.
3-323
IF MACHINE MONITOR SHOWS WARNING DISPLAY
When caution lamp (1) is displayed on the machine monitor, or any of “L04”, “L03”, “L01” is displayed at action
level (2) part of the failure display screen, or action level “L02” is displayed once and an action level is still dis-
played after performing remedies, do as follows.
Apply the parking brake and press ENTER switch (3).
“Error List” is displayed.
Take the actions according to the message shown on the monitor, and check the failure code, and then ask your
Komatsu distributor for repair, as necessary.
Telephone number for the point of contact when an error occurs
When an error screen is displayed on the machine monitor,
press ENTER switch to display “Error List” screen and tele-
phone number for the point of contact is displayed in the mes-
sage column at the bottom of the screen.
REMARK
If no point of contact telephone number is registered, no tele-
phone number is displayed.
Ask your Komatsu distributor for the telephone number regis-
tration if necessary.
3-324
MAINTENANCE
Please read and make sure that you understand the SAFETY section before
reading this section.
4-1
PRECAUTIONS FOR MAINTENANCE MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

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

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

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

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

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

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

At the replacement of the filters when oil is changed, check the old oil and filters for metal particles and foreign
materials. If large quantity of metal particles or foreign materials are found, always report to the person in
charge, and perform suitable action.
PRECAUTIONS FOR REFILLING OIL OR FUEL

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

• When conducting weld repair, turn the starting switch to OFF position and, after confirming that the system
operating lamp is turned off, set the battery disconnect switch to OFF position and pull it out.
• Do not apply a voltage higher than 200 V continuously.
• Connect grounding cable within 1 m {3 ft 3 in} of the area to be welded.
If grounding cable is connected near instruments, connectors, etc., the instruments may malfunction.
• Prevent seals, bearings or bushings from entering the space between the weld zone and grounding point.
Seals and the like can cause damage to the nearby parts by catching fire from sparks.
• Do not connect the grounding cable around a pin or to a hydraulic cylinder.
Sparks generated there can damage the plated portion.
DO NOT DROP THINGS INSIDE MACHINE

• When opening the inspection windows or the oil filler port of the tank to perform inspection, be careful not to
drop nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine,
and will lead to failure. If anything drops, be sure to take it out.
• Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
MAINTENANCE PRECAUTIONS FOR MAINTENANCE
DUSTY JOBSITES
When working at dusty jobsites, observe the following.
• Check the dust indicator frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
• Clean the radiator fins, oil cooler fins, air conditioner condenser fins, and other parts of the heat exchange
equipment at a shorter interval than specified, and take care not to let them become clogged.
• Replace the fuel filter at a shorter interval than specified.
• Clean the electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
• When checking and replacing the oil or filters, move the machine to a place where there is no dust and take
care to prevent dust from entering the system.
AVOID MIXING OIL

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

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

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit.
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES

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

Unexpected problems may occur if you do not perform the necessary inspection and maintenance. Always ob-
serve the following, otherwise it may lead to personal injury.
Checks after operation (with engine stopped)
• Have any inspection and maintenance points not been forgotten?
• Have all inspection and maintenance items been performed correctly?
• Have any tools or parts not dropped inside the machine? It is particularly dangerous if the parts drop inside
the machine and get caught in the lever linkage mechanism.
• Isn't there any leakage of coolant or oil? Have all nuts and bolts been tightened?
Checks while the engine is running
• Isn't there any fuel leakage or oil leakage when the engine speed is increased?
• Check if the inspected and serviced area is normally operated.
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE

It is necessary to select fuel or lubricant according to the ambient temperature.
4-3
PRECAUTIONS FOR MAINTENANCE MAINTENANCE
PRECAUTIONS FOR JACK-UP

• Stop the machine on a level ground, set the parking brake switch to “PARKING”, and chock the tires.
• Stop the engine.
• The machine should be empty when you jack-up.
• Use the hydraulic jack of 50 t.
Front
(The machine is jacked up on the left side as shown in the illus-
tration.)
• When you jack up the front axle to replace the front tire or
such, insert the plate such as an iron plate (3) between the
holder portion (1) of the bottom of the kingpin and the jack
(2), and apply the jack.
Be careful that the bolt (4) does not touch the iron plate (3)
this time.
• When you lift only one side of tire off the ground, set the
support stand (5) under the frame to make the machine
stable.
• Do not jack up by applying the jack to the A-frame (6). Oth-
erwise the A-frame will become deformed or damaged by
the load of the jack.
Rear
(The machine is jacked up on the left side as shown in the illus-
tration.)
• When you jack up the rear axle to replace the rear tire or
such, insert the plate such as an iron plate (3) between the
bottom of rear axle (7) and the jack (2), and apply the jack.
• When you lift only one side of tire off the ground, set the
support stand (5) under the frame to make the machine
stable.
4-4
MAINTENANCE OUTLINE OF MAINTENANCE
OUTLINE OF MAINTENANCE
• Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil.
• When changing the oil or adding oil, do not mix the different types of oil. When changing the type of oil,
drain all the old oil and fill completely with the new oil. Replace the filter at the same time. (There is no
problem if the small amount of oil remaining in the piping mixes with the new oil.)
• Unless otherwise specified, when the machine is shipped from the plant, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40-DH (Komatsu genuine)
Transmission case Power train oil TO30 (Komatsu genuine)
Steering and hoist oil tank Power train oil TO10 (Komatsu genuine)
Brake oil tank Power train oil TO10 (Komatsu genuine)
Front suspension
Hydraulic oil HO-MVK (Komatsu genuine)
Rear suspension
Differential case
Power train oil TO30 (Komatsu genuine)
Final drive case
Non-Amine Engine Coolant (AF-NAC) (Komatsu genuine)
Radiator (Density 30 % or more) (Additive agent DCA4 of Cummins Filteration has
been added)
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
• Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature,
high pressure), and deteriorates with use.
Always use the oil that matches the grade and maximum/minimum ambient temperatures recommended in
Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil at the specified interval.
• Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of failures with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
• Never mix oils of different grades or brands.
• Always add the specified amount of oil.
Having too much oil and too little oil are both causes of failures.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. Consult
• When changing the oil, always replace the related filters at the same time.
• We recommend that you have an oil analysis periodically to check the condition of the machine. For those
who wish to use this service, consult your Komatsu distributor.
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom-
mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail.
4-5
OUTLINE OF MAINTENANCE MAINTENANCE
FUEL
• To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank with fuel after completing the day's work.
• The fuel pump is a precision equipment, and if fuel containing water or dirt is used, it cannot work properly.
• Be extremely careful not to let impurities get in when storing or adding fuel.
• Always use the fuel specified for the temperature that is described in Operation and Maintenance Manual.
• If the fuel is used at the temperatures lower than the operating temperature (particularly at tempera-
tures below -15 °C {5 °F} ), the fuel will solidify.
• If the fuel is used at temperatures higher than the operating temperature, the viscosity will drop, and it
may result in troubles such as a drop of output.
• Before starting the engine, or after 10 minutes of adding fuel, drain the sediment and water from the fuel
tank.
• If the engine runs out of fuel, or if the filters are replaced, it is necessary to bleed the air from the circuit.
• If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
Always use the diesel fuel. Never use any other fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device. Since the high-
pressure fuel injection device requires high precision parts and lubrication, if low viscosity fuel with low
lubricating ability is used, its durability may drop considerably. Also, using fuel with high sulfur content
may deteriorate the engine parts, inducing failures, decrease of the life and degradation in performance.
The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel
may contain 7 % or less of it. Use the fuel which is filled into the storage tank or the fuel tank of the
machine as soon as possible.
When the diesel fuel is changed to the one mixed with the bio-fuel, replace the fuel filter cartridge with a
new one.
COOLANT AND WATER FOR DILUTION

• The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant
(AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for
2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may
cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
• When using antifreeze, always observe the precautions given in Operation and Maintenance Manual.
• Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
• The coolant density needs to be changed in accordance with the ambient temperature.
Even in areas where it is not considered necessary to prevent freezing, always use Non-Amine Engine
Coolant (AF-NAC) with a density of 30 % or more in order to prevent corrosion of the cooling system.
Non-Amine Engine Coolant (AF-NAC) is diluted with distilled water that does not contain any ions or water-
hardening substances. Never dilute it with water.
• If the engine overheats, wait for the engine to cool down before adding coolant.
• If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air
entering the coolant.
4-6
GREASE
• Grease is used to prevent seizure and noises at the joints.
• This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom-
mended grease and follow the replacement intervals and recommended ambient temperatures given in this
Operation and Maintenance Manual.
• Grease fittings not included in the periodic maintenance section are the grease fittings for overhaul, so they
do not need grease.
If any part becomes stiff after being used for long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.
4-7
OUTLINE OF MAINTENANCE MAINTENANCE
PERFORM KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other problems.
Thanks to long term experience and ample data accumulated, we can grasp condition of your machine accu-
rately and provide proper recommendation.
We strongly recommend you to use this service. The oil analysis is performed at actual cost, so the cost is low,
and results of the analysis and recommendations are reported promptly.
KOWA analysis items
Measurement of metallic powder concentration
An ICP (Inductively Coupled Plasma) analyzer is used for
measuring the concentration of iron, copper, and other metal
powder in the oil.
Measurement of quantity of iron particles

A PQI (Particle Quantifier Index) measuring instrument is used
for measuring the quantity of iron particles of 5 μm or more, en-
abling early detection of failures.
Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity, if
necessary, to enable a highly precise diagnosis of the machine and the components' condition.
Oil sampling interval
500 hours
Precautions when sampling
• Make sure that the oil is well mixed before sampling.
• Perform sampling at regular fixed intervals.
• Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
STORE OIL AND FUEL

• Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
• When keeping drum cans for a long period, lay the drums so that the filler ports of the drums are located in
the lower part of the side to prevent moisture from being sucked in. If drums have to be stored outside, cov-
er them with a waterproof sheet or take other measures to protect them.
• To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out
(use the oldest oil or fuel first).
4-8
FILTER
• Filters are extremely important safety parts. They prevent impurities in the oil, fuel, and air circuits from en-
tering important equipment and causing problems. Replace all filters periodically. For details, see Operation
and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and
fuel (sulfur content) being used.
• Never try to clean and use again the filters (cartridge type). Always replace them with new filters.
• When replacing oil filters, check if any metal particles are attached to the old filters.
If any metal particles are found, consult your Komatsu distributor.
• Do not open packages of spare filters until just before they are to be used.
• Komatsu recommends using Komatsu genuine filters.
HANDLE ELECTRICAL COMPONENTS

k WARNING
• It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is
damaged. This will cause an electrical leakage and may lead to malfunction of the machine.
Do not wash the inside of the operator's cab with water.
When washing the machine, be careful not to let water get into the electrical components.
• Wipe off the water drops stuck around connectors before removing the connectors and do not let water
drops get into the connectors when removing the connectors of electrical components after washing the
machine or in the rain.
• Checking and maintenance items are the checking fan belt tension, the checking damage of the fan belt,
and the checking battery fluid level.
• Komatsu recommends installing electric components specified by Komatsu.
• External electro-magnetic interference may cause malfunction of the control system controller. Accordingly,
consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma-
chine.
• When working at the seashore, keep the electrical component clean to prevent corrosion.
• When installing electrical component, connect it to the specified power supply connector.
Do not connect the optional power supply to the fuse or starting switch or battery relay, etc.
4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUE FOR BOLTS AND

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

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

Width
diame-
across Target value Allowable range
ter of
flats “b”
bolt “a”
(mm) Nm kgm lbft Nm kgm lbft
(mm)
6 10 13.3 1.35 9.8 11.8 to 14.7 1.2 to 1.5 8.7 to 10.8
8 13 31 3.2 22.8 27 to 34 2.8 to 3.5 20.3 to 25.3
10 17 67 6.8 48.8 59 to 74 6 to 7.5 43.4 to 54.2
12 19 111 11.3 81.4 98 to 123 10 to 12.5 72.3 to 90.4
14 22 172 17.5 127 153 to 190 15.5 to 19.5 112 to 141
16 24 260 26.5 192 235 to 285 23.5 to 29.5 170 to 213
18 27 360 37 268 320 to 400 33 to 41 239 to 297
20 30 510 52.3 378 455 to 565 46.5 to 58 336 to 420
22 32 688 70.3 508 610 to 765 62.5 to 78 452 to 564
24 36 883 90 651 785 to 980 80 to 100 579 to 753
27 41 1295 133 957 1150 to 1440 118 to 147 853 to 1060
30 46 1715 175 1265 1520 to 1910 155 to 195 1120 to 1410
33 50 2205 225 1630 1960 to 2450 200 to 250 1450 to 1810
36 55 2745 280 2025 2450 to 3040 250 to 310 1810 to 2240
39 60 3260 333 2405 2890 to 3630 295 to 370 2130 to 2680
Tighten the hoses to the torque shown in the table.
4-10
MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
Taper seal
Width Tightening torque

Outside diameter across
Target value Allowable range
of hose “a” (mm) flats “b”
(mm) Nm kgm lbft Nm kgm lbft
14 19 44 4.5 32.5 34 to 63 3.5 to 6.5 25.3 to 47.0
18 24 78 8.0 57.9 59 to 98 6.0 to 10.0 43.4 to 72.3
22 27 103 10.5 75.9 84 to 132 8.5 to 13.5 61.5 to 97.6
24 32 157 16.0 116 128 to 186 13.0 to 19.0 94 to 137
30 36 216 22.0 159 177 to 245 18.0 to 25.0 130 to 181
33 41 216 22.0 159 177 to 245 18.0 to 25.0 130 to 181
36 46 245 25.0 181 197 to 294 20.0 to 30.0 145 to 217
42 55 294 30.0 217 246 to 343 25.0 to 35.0 181 to 253
Face seal
Width Tightening torque

across
Nominal - No. of Target value Allowable range
flats
threads “a”
"b" Nm kgm lbft Nm kgm lbft
(mm)
9/ -18UN 19 44 4.5 32.5 34 to 54 3.5 to 5.5 25.3 to 39.8
16
11/ -16UN 22 74 7.5 54.2 54 to 93 5.5 to 9.5 39.8 to 68.7

16
13/ -16UN 27 103 10.5 75.9 84 to 132 8.5 to 13.5 61.5 to 97.6
16
1-14UNS 32 157 16.0 116 128 to 186 13.0 to 19.0 94.0 to 137
13/16 -12UN 36 216 22.0 159 177 to 245 18.0 to 25.0 130 to 181
4-11
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE
Unless otherwise specified, tighten the bolts of the unified thread to the torque shown in the table below.
Unified coarse thread

Tightening torque
Nominal -
No. of Target value Allowable range
threads
Nm kgm lbft Nm kgm lbft
1/ -20UNC 12.7 1.3 9.4 9.8 to 14.7 1 to 1.5 7.2 to 10.8
4
5/ -18UNC 29.4 3 21.7 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3

16
3/ -16UNC 52.0 5.3 38.3 44.1 to 58.8 4.5 to 6 32.5 to 43.4

8
7/ -14UNC 86.3 8.8 63.7 73.5 to 98.1 7.5 to 10 54.2 to 72.3

16
1/ -13UNC 127 13 94 108 to 147 11 to 15 79.6 to 108

2
9/ -12UNC 186 19 137 157 to 216 16 to 22 116 to 159

16
5/ -11UNC 265 27 195 226 to 294 23 to 30 166 to 217

8
3/ -10UNC 461 47 340 392 to 530 40 to 54 289 to 391

4
7/ -9UNC 745 76 550 637 to 853 65 to 87 470 to 629

8
1 -8UNC 1040 106 767 883 to 1196 90 to 122 651 to 882
1 1/8 -7UNC 1393 142 1030 1187 to 1608 121 to 164 875 to 1190
1 1/4 -7UNC 1873 191 1380 1598 to 2157 163 to 220 1180 to 1590
1 1/2 -6UNC 2765 282 2040 2354 to 3177 240 to 324 1740 to 2340
Unified fine thread

Tightening torque
Nominal -
No. of Target value Allowable range
threads
Nm kgm lbft Nm kgm lbft
1/ -28UNF 17.7 1.8 13 14.7 to 19.6 1.5 to 2 10.8 to 14.5
4
5/ -24UNF 34.3 3.5 25.3 34.3 to 39.2 3.5 to 4 25.3 to 28.9

16
3/ -24UNF 61.8 6.3 45.6 53.9 to 68.6 5.5 to 7 39.8 to 50.6

8
7/ -20UNF 96.1 9.8 70.9 83.4 to 108 8.5 to 11 61.5 to 79.6

16
1/ -20UNF 147 15 108 127 to 167 13 to 17 94 to 123

2
9/ -18UNF 216 22 159 186 to 245 19 to 25 137 to 181

16
5/ -18UNF 294 30 217 255 to 343 26 to 35 188 to 253

8
3/ -16UNF 520 53 383 441 to 598 45 to 61 325 to 441

4
7/ -14UNF 843 86 622 716 to 961 73 to 98 528 to 709

8
1 -14UNF 1196 122 882 1020 to 1373 104 to 140 752 to 1010
1 1/8 -12UN 1598 163 1180 1353 to 1844 138 to 188 998 to 1360
1 1/4 -12UN 2118 216 1560 1804 to 2432 184 to 248 1330 to 1790
1 1/2 -12UN 3177 324 2340 2707 to 3658 276 to 373 2000 to 2700
4-12
MAINTENANCE MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Ask 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) .......................................... 4-15
WHEN REQUIRED ........................................................................................................................................ 4-16
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER .......................................... 4-16
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ................................................................. 4-22
METHOD FOR CLEANING RADIATOR FINS AND OIL COOLER FINS ................................................. 4-25
METHOD FOR CLEANING HYDRAULIC TANK STRAINER .................................................................. 4-25
METHOD FOR REPLACING ETHER CARTRIDGE................................................................................ 4-26
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID ................................. 4-26
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER................................................. 4-27
METHOD FOR CHECKING DUMP BODY.............................................................................................. 4-28
METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER .................................................... 4-29
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT....................................................................... 4-31
METHOD FOR BLEEDING AIR FROM STEERING AND HOIST CIRCUIT ............................................ 4-35
METHOD FOR BLEEDING AIR FROM PISTON PUMP.......................................................................... 4-35
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER ............................................................. 4-37
METHOD FOR BLEEDING AIR FROM HOIST CYLINDER .................................................................... 4-38
METHOD FOR BLEEDING AIR FROM BRAKE COOLING CIRCUIT ..................................................... 4-40
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT................................ 4-41
SELECT AND CHECK TIRES................................................................................................................. 4-42
METHOD FOR CLEANING LAMPS, CAMERAS AND RADAR DEVICE................................................. 4-44
CHECKS BEFORE STARTING...................................................................................................................... 4-46
EVERY 250 HOURS MAINTENANCE ........................................................................................................... 4-47
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE .....
............................................................................................................................................................ 4-47
METHOD FOR CHECKING AND ADDING OIL IN DIFFERENTIAL CASE ............................................. 4-48
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL ..................................... 4-49
METHOD FOR CHECKING DRIVE SHAFT ............................................................................................ 4-49
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL ............................................................. 4-50
METHOD FOR CHECKING AND ADJUSTING CONCENTRATION OF COOLANT ADDITIVE AGENT . 4-53
METHOD FOR CHECKING FRAME ....................................................................................................... 4-54
METHOD FOR CHECKING FOOT BRAKE PERFORMANCE ................................................................ 4-54
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE....................................................... 4-55
METHOD FOR CHECKING PARKING BRAKE PERFORMANCE .......................................................... 4-56
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR ............................................................... 4-57
EVERY 500 HOURS MAINTENANCE ........................................................................................................... 4-59
METHOD FOR REPLACING FUEL FILTER CARTRIDGE ...................................................................... 4-59
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT ................................................. 4-61
METHOD FOR CHECKING AND REPLACING AIR CONDITIONER COMPRESSOR BELT.................. 4-62
EVERY 1000 HOURS MAINTENANCE ......................................................................................................... 4-64
METHOD FOR CHANGING OIL IN TRANSMISSION CASE AND CLEANING STRAINER .................... 4-64
METHOD FOR REPLACING BRAKE COOLING OIL FILTER ELEMENT ............................................... 4-65
METHOD FOR REPLACING BRAKE CONTROL OIL FILTER ELEMENT .............................................. 4-66
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT......................................................... 4-67
METHOD FOR LUBRICATING ............................................................................................................... 4-67
METHOD FOR CHECKING FRONT BRAKE DISC WEAR AMOUNT ..................................................... 4-68
METHOD FOR CHECKING REAR BRAKE DISC WEAR AMOUNT ....................................................... 4-69
METHOD FOR COLLECTING LEAKED OIL FROM FLOATING SEAL ................................................... 4-70
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP ............................. 4-71
METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT ...................................... 4-72
METHOD FOR CHANGING OIL IN BRAKE OIL TANK ........................................................................... 4-73
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ....................................................................... 4-75
METHOD FOR CHANGING OIL IN DIFFERENTIAL CASE .................................................................... 4-75
METHOD FOR CLEANING DIFFERENTIAL CASE BREATHER ............................................................ 4-76
4-13
MAINTENANCE SCHEDULE MAINTENANCE
METHOD FOR CHECKING FRONT WHEEL BEARING......................................................................... 4-76

METHOD FOR CHECKING REAR WHEEL BEARING ........................................................................... 4-76
METHOD FOR CLEANING TRANSMISSION CASE BREATHER .......................................................... 4-77
METHOD FOR REPLACING STEERING AND HOIST OIL TANK BREATHER ELEMENT..................... 4-78
METHOD FOR CLEANING BRAKE OIL TANK BREATHER ................................................................... 4-78
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE ........................................................... 4-78
METHOD FOR CLEANING FINAL DRIVE MAGNET .............................................................................. 4-78
REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-79
METHOD FOR CHANGING OIL IN STEERING AND HOIST OIL TANK................................................. 4-80
METHOD FOR CHECKING VIBRATION DAMPER ................................................................................ 4-80
METHOD FOR CHECKING ACCUMULATOR ........................................................................................ 4-81
METHOD FOR LUBRICATING DRIVE SHAFT ....................................................................................... 4-82
EVERY 15000 HOURS MAINTENANCE ....................................................................................................... 4-83
METHOD FOR CHECKING AND REPLACING STEERING-A ARM MOUNTING BOLT ......................... 4-83
4-14
MAINTENANCE MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250
HOURS)
Perform the following maintenance after the first 250 hours only for the new machine.
• Change oil in engine oil pan, replace engine oil filter cartridge
• Replace element in the transmission oil filter
• Change oil in transmission case and clean strainer
• Replace brake cooling oil filter element
• Replace brake control oil filter element
• Replace steering and hoist oil filter element
• Change oil in brake oil tank, clean strainer
• Change oil in final drive case
• Change oil in differential case
• Clean final drive magnet
• Change oil in steering and hoist oil tank
For the maintenance method, see EVERY 250 HOURS MAINTENANCE, EVERY 500 HOURS MAINTENANCE,
EVERY 1000 HOURS MAINTENANCE, EVERY 2000 HOURS MAINTENANCE, and EVERY 4000 HOURS
MAINTENANCE.
4-15
MAINTENANCE PROCEDURE MAINTENANCE
WHEN REQUIRED
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER
k WARNING
• When using compressed air, there is a danger that dirt may scatter and cause personal injury.
Always wear the protective eyeglasses, dust mask, or other protective equipment.
• When removing the outer element from the air cleaner body, it is dangerous to pull it out by force.
When working in high places or where the foothold is poor, be careful not to fall because of the re-
action when pulling out the outer element.
NOTICE
• Do not clean the element before the air cleaner clogging caution lamp on the machine monitor
lights up, or the yellow piston of the dust indicator laps over the peripheral red zone (6.23 kPa
{0.064 kg/cm2, 0.91 PSI}).
If the element is cleaned frequently before the air cleaner clogging caution lamp on the machine
monitor lights up or the yellow piston of the dust indicator laps over the peripheral red zone
(6.23 kPa {0.064 kg/cm2, 0.91 PSI}), the air cleaner will not be able to display its performance fully,
and the cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner
element.
• If any dirt enters the engine, it can damage the engine. Be sure to stop the engine before checking,
cleaning, or servicing the air cleaner. Do not check, clean, or service the air cleaner in strong winds,
or in a dusty place.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner
element.
• Replace the outer element if it is cleaned 6 times or used throughout a year. Replace the inner ele-
ment as well at the same time.
4-16
METHOD FOR CHECKING AIR CLEANER

NOTICE
The electric air cleaner clogging sensor and dust indicator are used to indicate the clogging on the air
cleaner. The electric air cleaner clogging sensor indicates the cleaning timing of the air cleaner element
and the dust indicator indicates the level of clogging.
Check the dust indicator before operating the machine so that cleaning of the air cleaner element is not
required during operation.
Clean the element when the yellow piston shown in the dust in-
dicator (1) display entered the red (6.23 kPa {0.064 kg/cm2,
0.91 PSI}) position.
After the cleaning, press the dust indicator button to reset it.
If the yellow piston enters the red (6.23 kPa {0.064 kg/cm2,
0.91 PSI}) position soon after the cleaning, the element must
be replaced.
Electric air cleaner clogging sensor

Clean the air cleaner element when the yellow piston of dust in-
dicator (1) display enters the red (6.23 kPa {0.064 kg/cm2,
0.91 PSI}) position or the air cleaner clogging caution lamp (2)
of the machine monitor lights up.
4-17
METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT

NOTICE
• Never remove the inner element. Dusts may enter causing the engine failure.
• Do not use damaged element.
• Do not use the removed inner element more than once.
• Make sure to replace the inner element when you replace the outer element.
• Keep new elements dry.
1. Stop the engine.
2. Remove the clips (1) (4 places each of right and left) and
remove the cover (2).
3. Hold the outer element (3), rock it lightly up and down and
to the right and left, and pull out the outer element (3)
while turning it to the right or left.
4. Hold inner element (4) so that it does not come out, and
clean the inside of the air cleaner body with a dry cloth.
5. Unhook the dust cap (5), and remove the dust cap.
6. Use a dry cloth or compressed air (0.2 MPa {2.1 kg/cm2,
29.9 PSI} or less) to clean off the dirt stuck to the dust cup
(5) and vacuator valve (6).
7. Check that the lip of vacuator valve (6) has no crack.
If there is any crack, replace it with a new one.
8. When the outer element has been cleaned 6 times or used for 1 year, replace it.
• When the element needs to be replaced
Replace both inner and outer elements with new ones.
• When the element does not need to be replaced
Clean the outer element. Continue the cleaning procedure.
4-18
9. If the machine is being operated in dusty atmosphere,

check the tube (7) for clogging.
10. If the tube (7) is clogged, clean it with a brush.
Never use the compressed air or steam for cleaning.
11. Blow dry compressed air (0.21 MPa {2.1 kg/cm2, 29.9 PSI}

or less) from the inside of the outer element along the
pleats.
12. Blow along the pleats from the outside, then blow again
from the inside.
13. After cleaning the outer element, illuminate the inside of

the element with an electric bulb to check.
If any hole or thin place is found, replace the outer ele-
ment.
14. Check the seal of the cleaned or new element for sticking
of dusts and oil and wipe them off, if any.
15. Push the outer element (3) straight into the air cleaner
body with your hand.
Hold the outer element (3), and rock the outer element (3)
lightly up and down and to the right and left while pushing
it in, and you can insert it easily.
4-19
16. Fit the hook (1) of cover (2) to the protruding portion of the
air cleaner body and install it.
17. Fit the hook of the dust cup (5) to the air cleaner body and
install it.
18. Press the bottom of the dust indicator and return the yel-
low piston.
If the air cleaner clogging caution lamp lights up or the yel-
low piston reaches the red line (6.23 kPa {0.064 kg/cm2,
0.91 PSI}) immediately after the cleaning of the outer ele-
ment, replace both inner and outer elements with new
ones.
METHOD FOR REPLACING AIR CLEANER ELEMENT

1. Stop the engine.
2. Remove the clips (1) (4 places each of right and left) and
remove the cover (2).
3. Hold the outer element (3), rock it lightly up and down and
to the right and left, and pull out the outer element (3)
while turning it to the right or left.
Do not remove the inner element (4) at this time.
4. Hold the inner element (4) so that it does not come out,
and clean the inside of the air cleaner body with a dry
cloth.
5. Unhook the dust cap (5), and remove the dust cap.
6. Use a dry cloth or compressed air (0.2 MPa {2.1 kg/cm2,
29.9 PSI} or less) to clean off the dirt stuck to the dust cup
(5) and vacuator valve (6).
7. Check that the lip of vacuator valve (6) has no crack.
If there is any crack, replace it with a new one.
8. Remove the inner element (4), and then quickly install the new inner element.
Install the inner element securely so that it does not move.
4-20
9. Push new outer element (3) in straight with your hand into
the air cleaner body.
Hold the outer element (3), and rock the outer element (3)
lightly up and down and to the right and left while pushing
it in, and you can insert it easily.
10. Fit the hook (1) of cover (2) to the protruding portion of the
air cleaner body and install it.
11. Fit the hook of the dust cup (5) to the air cleaner body and
install it.
12. Press the bottom of the dust indicator and return the yel-
low piston.
4-21
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM

k WARNING
• Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in
the radiator. If the cap is removed under this condition and the coolant is drained, it may cause
burn. Always wait for the temperature to go down, pull up the lever on the cap slowly to release the
pressure, then remove the cap with care.
• Start the engine and clean the inside of the cooling system. Make sure to set the gear shift lever to
NEUTRAL and set parking brake switch to “PARKING” before you leave the operator seat to avoid
sudden machine movement.
• When the undercover is removed, there is a danger of touching the fan. Never enter the rear of the
machine when the engine is running.
Place the machine on a level ground when cleaning or changing the coolant.
For cleaning the inside of the cooling system and changing the coolant, see the following table.
Interval for cleaning inside of cooling system
Coolant Type of coolant additive agent
and changing coolant
Non-Amine Engine Coolant Every 2 years or every 4000 hours whichever
Cummins DCA4
(AF-NAC) comes sooner
The coolant has the important function of preventing corrosion as well as preventing freezing.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC).
Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be
used continuously for 2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC).
If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts
of the cooling system.
To maintain the anti-corrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of
Non-Amine Engine Coolant between 30 % and 64 %.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water. When using coolant, investigate the
lowest temperature in the past and decide the density for the coolant from the coolant density table below.
When deciding the density for the coolant, set it for a temperature 10 below the actual lowest temperature in the
working area.
The coolant density varies according to the ambient temperature, but it must be 30 % or more at least.
Coolant density table and mixing volume of additive agent

-10 or
°C -15 -20 -25 -30 -35 -40 -45 -50
Min. atmospheric tem- more
perature 14 or
°F 5 -4 -13 -22 -31 -40 -49 -58
more
Density ( %) 30 36 41 46 50 54 58 61 64
Volume of additive agent (DCA4)
19 {5.02}
( ℓ { U.S.Gal} )
REMARK
The volume of additive agent (DCA4) is not affected by the minimum atmospheric temperature.
4-22
k WARNING
• Coolant is toxic. When opening the drain plug, be careful not to get coolant on you. If it gets in your
eyes, flush your eyes with large amount of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company
to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
Check the density with a coolant tester.
A container whose capacity is enough to receive the coolant of specified capacity
1. Stop the engine.
2. Pull up the lever on top of the radiator cap (1) to release
the pressure, and remove the cap.
4-23
3. Place the containers to catch the coolant under 3 places in

total; the drain plug (2) at rear L.H. of radiator, the drain
plug (3) in front of the engine R.H. pump, and the drain
plug (4) at the lower part of oil cooler.
4. Open each drain plug and drain the coolant.
5. After draining the coolant, close the drain plugs (2), (3),
and (4), and fill with tap water.
6. After the radiator is filled with tap water, start the engine.
Run the engine at low idle for 5 minutes to remove the air
from the coolant, then raise the coolant temperature to
90 °Cor higher {194 °For higher} , and continue to run the
engine for approximately 10 minutes.
7. Stop the engine and open the drain plugs (2), (3), and (4)
to drain the tap water. After draining, close the drain plugs.
8. See “Coolant density table and mixing volume of additive
agent” and pour the coolant and coolant additive agent into
a mixing container and mix them throughly.
9. Add the coolant which has been mixed in the step 8.
through the filler port (5) up to the mouth of the port.
10. Run the engine at low idle for 5 minutes to remove the air
from the coolant, then run at high idle for a further 5 mi-
nutes.
When doing this, leave the filler cap removed.
11. Add coolant up to the middle between the lines of the

gauge (5) through filler port or service center.
4-24
METHOD FOR CLEANING RADIATOR FINS AND OIL COOLER FINS

k WARNING
• If the compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by
use of it, there is a danger of personal injury. Wear the protective equipment such as the protective
eyeglasses and dust mask.
• If you need to rotate the fan, always install the fan net and close the radiator grille to prevent the
contact with fan.
NOTICE
Do not cause damage to the coolers (radiator, oil cooler, aftercooler, fuel cooler, air conditioner con-
denser) when you clean with high-pressure water.
Perform this procedure if there is any mud or dirt stuck to the radiator.
1. Blow off mud, dirt, leaves, etc. in the radiator fins with compressed air.
Steam or water may be used instead of compressed air.
2. Check the rubber hoses. If any hose is cracked or becomes brittle, replace it with a new one. Also check all
the hose clamps for looseness.
METHOD FOR CLEANING HYDRAULIC TANK STRAINER

k WARNING
jury. Wait for the temperature to go down, and then start the work.
• If there is remaining pressure inside the case, the oil or plug may jump out. Turn the plug slowly to
release the pressure, then remove it carefully.
If any abnormality is found in hydraulic components such as pumps in the steering and hoist line, remove the
dirt from the line filter as follows.
1. Remove the bolts (1) (4 pieces) and remove the flange (2).
Set 2 bolts of the removed ones into the cover (3) tempo-
rarily.
Set the bolt (1) diagonally.
2. Fit the wrench to the bolt at an angle, remove the cover
(3), and clean the filter (4).
When cleaning the filter, remove the dust stuck to the side
of the case.
3. Replace the O-ring (5) and backup ring (6).
4. Install the cover (3).
5. Install the flange (2) and tighten it with the bolt (1).
Tightening torque: 98 to 123 Nm {10.0 to 12.5 kgm, 72.3 to
90.4 lbft}
4-25
METHOD FOR REPLACING ETHER CARTRIDGE

(Only machine equipped with ether injection device)
Replace the ether cartridge when it is empty.
If the ether cartridge becomes empty, the engine system cau-

tion lamp and the action level “L01” are displayed on the ma-
chine monitor.
For the replacement procedure of the ether cartridge, see the
Operation and Maintenance Manual of the engine or ask your
Komatsu distributor for replacement.
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID

1. Open the cover (1) on the right side of the cab.
2. Check the fluid level in the window washer tank (2).
1) If the window washer fluid is insufficient, open the cap
of window washer tank (2), add the window washer
fluid for automobiles.
Be careful not to let dirt or dust get in when adding it.
2) Close the cap of window washer tank (2).
3. After checking the fluid level, close the cover (1).
4-26
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER

METHOD FOR CHECKING REFRIGERANT LEVEL FOR AIR CONDITIONER (GAS)
k WARNING
Do not touch the refrigerant, loosen any part of the refrigerant circuit, or bring any open flame near re-
frigerant gas. If you get the refrigerant in your eyes or on your hand, it may cause injury.
If the level of the refrigerant (gas) is low, the cooling effect will be reduced. Check the refrigerant level with the
engine speed at approximately 1500 rpm while the cooler is running in high speed.
Check the condition of the refrigerant gas (Hydrofluorocarbons
HFC-134a) that circulates the refrigerant circuit, through the
sight glass (1) (inspection window) at the refrigerant hose fit-
ting.
(A) No bubbles in refrigerant flow: Suitable

(B) Some bubbles in refrigerant flow: Insufficient (bubbles pass
continuously)
(C) Colorless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant (gas) level is low, so ask your Komatsu distributor to add refrigerant. If
the air conditioner continues to run with low refrigerant (gas) level, it will cause damage to the compressor.
4-27
METHOD FOR CLEANING AIR CONDITIONER AIR FILTERS

If the air filter at the suction port of the air conditioner unit or the air filter at the fresh air intake port become
clogged, the cooling or heating capacity will drop, so clean the filters.
1. Open the cover (1) on the side of the cab.
2. Pull out the air filter (fresh air filter).
3. Clean the air filter (fresh air filter) with compressed air.
4. Open the cover (2) at the rear left of the operator's seat.
5. Pull out the air filter (recirculation air filter).
6. Remove the dust sticking to the air filter (recirculation air
filter) with low compressed air or a soft brush.
METHOD FOR CHECKING DUMP BODY

Check that there are no cracks in the dump body.
1. Clean the dump body so that you can check it easily.
2. Check each portion of the dump body for damage.
If any cracks or abnormal wear are found, perform repairs.
Contact your Komatsu distributor for details of the repair procedure.
4-28
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 length of the suspension cylinder.
Check the front suspension (1) and the rear suspension (2)
with the machine unloaded.
METHOD FOR CHECKING LENGTH OF FRONT SUSPENSION CYLINDER

1. Check on a level ground that the bottom end of the front
suspension cylinder cover is within the range (A) shown by
arrow in the label (1).
2. Remove the bolts (2) (4 pieces), and remove the cover (3)
of the front suspension cylinder.
4-29
3. Measure the dimension (B) from the shoulder at the rod

head of the front suspension cylinder to the top surface of
the flange.
Dimension (B)
277 to 297 mm {10.9 to 11.7 in}
Reference (C)
438 to 458 mm {17.2 to 18 in}
Ask your Komatsu distributor for inspection if there is any
problem found when checking the front suspension.
4. Install the cover (3) with bolts (2) (4 pieces).
METHOD FOR CHECKING LENGTH OF REAR SUSPENSION CYLINDER

Measure the distance (D) from the shoulder at the rod head of
the rear suspension cylinder to the top surface of the flange.
Dimension (D)
230 to 250 mm {9.1 to 9.8 in}
Ask your Komatsu distributor for inspection if there is any prob-
lem found when checking the rear suspension.
4-30
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT

k WARNING
• Stop the machine on a flat ground, turn the parking brake switch to “PARKING” position, chock the
tires, and then bleed air.
• When air bleeding is performed, the brake will be released and the machine may start moving. It
may lead to serious personal injury or death.
Stop the machine on a level ground and chock the wheels before bleeding the air.
When any brake circuit device is repaired or replaced, or the hydraulic piping is disconnected, bleed air from the
brake circuit.
Warm the oil up to a temperature of 40 °C or higher {104 °F or higher} before bleeding air to improve the air
bleeding performance.
Bleed air from the front brake circuit and rear brake circuit in the same way both on the right and left sides.
• Vinyl hose
• Container with oil in it
METHOD FOR BLEEDING AIR FROM REAR BRAKE

2. Check with the sight gauge that the oil level in the brake oil tank is at the specified level.
3. Check that the brake oil pressure caution lamp is not lit.
4. Bleed air from the slack adjuster.
1) Remove the cap of bleeder screw (1) of the slack ad-
juster.
2) Insert a vinyl hose to the bleeder screw (1).
Use a commercially available vinyl hose.
3) Place a container with oil in it.
4) Put the other end of the hose in the oil in the container
approximately 50 mm {approximately 2 in} .
5) Depress the brake pedal and keep it depressed.
6) Loosen the bleeder screw (1) approximately 3/4 turns.
7) Keep depressing the brake pedal until no bubble comes out through the vinyl hose.
8) Tighten the bleeder screw (1) securely.
9) Pull the retarder control lever and hold it.
11) Keep pulling the retarder control lever until no bubble comes out through the vinyl hose.
13) Install the cap to the bleeder screw (1).
5. Bleed air from the parking brake.
4-31
1) Remove the cap of bleeder screw (2) of the parking

brake.
5) Pull the retarder control lever, and set the parking
brake switch to “TRAVEL” position.
7) Keep draining the oil until no bubble comes out through the vinyl hose.
6. Bleed air from the foot brake and retarder brake.
1) Remove the cap of the bleeder screw (3) of the foot
brake and retarder brake.
7. Make the oil level in the brake oil tank to the specified level.
4-32
METHOD FOR BLEEDING AIR FROM FRONT BRAKE

2. Check with the sight gauge that the oil level in the brake oil tank is at the specified level.
3. Check that the brake oil pressure caution lamp is not lit.
4. Bleed air from the slack adjuster.
1) Remove the cap of bleeder screw (1) of the slack ad-
juster.
11) Keep pulling the retarder control lever until no bubble comes out through the vinyl hose.
5. Bleed air from the parking brake.
1) Remove the cap of bleeder screw (2) of the parking
brake.
5) Pull the retarder control lever, and set the parking
brake switch to “TRAVEL” position.
6. Bleed air from the foot brake and retarder brake.
1) Remove the cap of the bleeder screw (3) of the foot
brake and retarder brake.
4-33
7. Make the oil level in the brake oil tank to the specified level.
4-34
METHOD FOR BLEEDING AIR FROM STEERING AND HOIST CIRCUIT

k WARNING
• Stop the machine on a flat ground, turn the parking brake switch to “PARKING” position, chock the
tires, and then bleed air.
• When performing the inspection with the dump body raised, always use the body lock wire to se-
cure the dump body, and set the dump lever at “HOLD” position.
When removing the devices of the steering and hoist circuit, bleed air from the steering and hoist circuit.
Before removing and installing the devices of the steering and hoist circuit, raise the dump body and fix it by
using dump body lock wire.
• Vinyl hose
• Container to catch the oil
METHOD FOR BLEEDING AIR FROM PISTON PUMP

1. Check with the sight gauge that the oil level in the steering and hoist oil tank is at the specified level.
2. Bleed air from the steering and hoist cylinder.
2) Place a container to catch oil under another end of the
vinyl hose.
3) Tighten the bleeder screw (1).
4) When the oil in which no air is mixed flows out, tighten
the bleeder screw (1) securely.
4-35
3. Bleed air from the hoist and front brake cooling motor drive
pump.
vinyl hose.
4. Bleed air from the rear brake cooling motor drive pump.
vinyl hose.
5. Add oil to the specified level by referring to “METHOD
FOR CHECKING OIL LEVEL IN STEERING AND HOIST
OIL TANK, ADDING OIL”.
6. While checking the sight gauge (G), crank the engine but
not start it.
7. Stop the cranking before the oil level cannot be seen
through the sight gauge (G), and add oil.
8. Repeat the steps 6. to 7. until the oil level does not de-
crease any more.
9. While checking the sight gauge (G), run the engine at low
idle.
10. Stop the engine before the oil level cannot be seen
through the sight gauge (G), and add oil.
11. Repeat the steps 9. to 10. until the oil level does not decrease any more.
12. Check that the oil level is in the range of the sight gauge (G).
13. Bleed air from the return filter case.
vinyl hose.
14. Start the engine and run it at high idle at least 2 minutes.
2) Place a container to catch oil under another end of the vinyl hose.
4) When the oil in which no air is mixed flows out, tighten the bleeder screw (4) securely.
4-36
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER

k WARNING
Do not use the secondary steering pump for longer than 90 seconds.
If it is used continuously for longer than that, the motor of the secondary steering pump may get burnt
or get damaged, or a fire will be caused.
1. Run the engine at low idle and turn the steering wheel to the right and left slowly until the steering cylinder
starts moving.
2. When the cylinder starts moving, run the engine at low idle and turn the steering wheel once fully from the
end of one side to the end of another side.
Never make the oil relieved.
vinyl hose.
4. Press the secondary steering switch to actuate the secon-
dary steering pump.
5. Run the engine at low idle and turn the steering wheel to
the right and left slowly until the steering cylinder starts
moving.
6. Press the secondary steering switch to stop the secondary steering pump.
7. Run the engine at high idle and turn the steering wheel once fully from the end of one side to the end of
another side.
9. Run the engine at low idle and turn the steering wheel once fully from the end of one side to the end of
another side.
Operate the steering cylinder to the stroke end to make the oil relieved.
11. Run the engine at high idle and turn the steering wheel once fully from the end of one side to the end of
another side.
Operate the steering cylinder to the stroke end to make the oil relieved.
4-37
METHOD FOR BLEEDING AIR FROM HOIST CYLINDER

1. Run the engine at low idle for 5 seconds or longer while
the dump body is seated and the dump lever is at FLOAT
position.
2. Add oil up to the mouth of the filler port of the steering and
hoist oil tank
3. Run the engine at low idle and raise the dump body to the
position just before the stroke end (position where the
body stops automatically) from the seated position, then
make the dump body seated.
dump body stops automatically) from the seated position,
then lower the dump body to the position at approximately
20 °. (Do not make the dump body seated.)
dump body stops automatically) from the position where
the dump body is at an approximate angle of 20 ° again,
then lower the dump body to the position at approximately
20 °. (Do not make the dump body seated.)

vinyl hose.
3) Loosen the bleeder screw (1).
4-38
body stops automatically) from the position where the
dump body is at angle approximately 20 °, then operate
the dump lever further to RAISE position to make the oil
relieved.
Perform 2 seconds of the raise relief for 3 times.
9. Run the engine at low idle and lower the dump body to the
position at approximately 20 °.
body stops automatically) from the position where the
dump body is at angle approximately 20 ° again, then op-
erate the dump lever further to RAISE position to make the
oil relieved.
Perform 2 seconds of the raise relief for 3 times.
11. Run the engine at low idle and lower the dump body to the
position at approximately 20 °.
12. Run the engine at low idle and make the dump body seat-
ed from the position where the dump body is at angle ap-
proximately 20 °.
13. Run the engine at high idle and operate the dump lever to
LOWER position while the dump body is being seated to
make the oil relieved.
Perform 5 seconds of the lower relief for 3 times.
14. Run the engine at high idle and raise the dump body to the
body stops automatically), then operate the dump lever
further to RAISE position to make the oil relieved.
Perform 10 seconds of the raise relief for 1 time.
15. Run the engine at high idle and make the dump body seat-
ed.
16. Repeat the steps 13. to 15. for 10 times.
4-39
METHOD FOR BLEEDING AIR FROM BRAKE COOLING CIRCUIT

When removing and installing the devices of the brake cooling circuit, bleed air from the brake cooling circuit.
1. Add oil to the brake cooling oil tank.
2. Add oil to the brake cooling motor through the case ports (1) and (2).
Be sure to add oil just before the oil overflows through the case ports (1) and (2).
Front
Rear
4-40
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT

k WARNING
To correctly park the machine, set the parking brake, stop the engine and chock the wheels.
If any unusual noise occurs around the output shaft (1) or front drive shaft (2), the rubber inside the output shaft
may be deteriorated or damaged, so check the play of coupling (3) as follows.
1. Install the wire (4) as shown in the figure.
2. By using the tip of the wire as a benchmark, measure the
amount of movement (L) of the coupling.
3. Rotate the coupling at a force of 49 N {5 kg} to the circum-
ferential direction by using bar (5), etc.
4. Mark the position of the wire.
5. Check that the engine crankshaft is not rotating.
REMARK
If excessive force is applied in rotating the coupling, the
engine rotates at idle and it becomes impossible to judge
accurately.
6. Rotate the coupling in the reverse direction from the step

3.
7. Mark the position of the wire similarly to the step 3.
8. Measure the amount of movement (L) of the coupling by
using the marks made in the steps 4 and 7.
If amount of movement (L) exceeds 15 mm {0.6 in} , the
rubber inside the output shaft may be deteriorated or dam-
aged, so ask your Komatsu distributor for disassembly and
inspection of the internal parts of the output shaft.
4-41
SELECT AND CHECK TIRES

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

the tires and rims require special equipment and skill, be
sure to ask a tire repair shop to do the work.
• Never perform welding or light a fire near the tire.
TIRE SELECTION
k WARNING
Use tires that meet recommended specification, tire pressure and speed limitations to include the at-
tachments.
Select the tires according to the conditions of use and the weight of the attachments of the machine.
Use the tires in the following table.
The speed display varies with the tire size.
Consult your Komatsu distributor when using the optional tires.
Maximum load [ kg { lb} ] Size Remarks
Front wheel and rear wheel 38750 {85443.8} 33.00R51 For construction machinery, type 1
4-42
METHOD FOR CHECKING AND INFLATING TIRE

k WARNING
• When inflating the tire, check that no one can enter the area around the tire, and always use an air
chuck with a clip that can be fixed to the air valve.
• To prevent the tire inflation pressure from becoming too high, measure the pressure from time to
time with an air gauge while pumping up the tire.
• If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. Accordingly,
place a guard around the tire and do not work in front of the rim but work on the tread side of the
tire.
• Abnormal drop of tire inflation pressure and abnormal fitting of the rim will cause a failure in the tire
or rim. In this case, be sure to ask a tire repair shop for repair.
• Be sure to observe the specified tire inflation pressure.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under
heavy load.
Check the tire inflation pressure before starting work while the tires are cold.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure.
Do not work in front of the rim but work on the tread side of the
tire.
1. Measure the tire inflation pressure with a tire inflation pressure gauge.
2. Adjust the tire inflation pressure properly.
The proper tire inflation pressure is shown below.
Tire size
PSI}
33.00R51 700 {7.14, 102}
NOTICE
If the tires are used when the tire inflation pressure is less than the value given in the table above,
the rim may be damaged.
Maintain the tire inflation pressure within 0 to +30 kPa {0 to +0.3 kg/cm2, 0 to +4.27 PSI} of the above
value.
4-43
METHOD FOR CLEANING LAMPS, CAMERAS AND RADAR DEVICE

Check that the lamps (1), cameras (2), and radar devices (3) are not dirty.
If they are dirty with mud or dirt, use a stepladder and clean them with a soft cloth.
4-44
4-45
CHECKS BEFORE STARTING

For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING (3-153)”.
• Drain water and sediment from fuel tank
• Check wheel hub nuts
• Check oil level in transmission case, add oil
• Check dust indicator
• Check battery disconnect switch and starting motor disconnect switch
• Check fuel STAGE 1 filter and drain mixed water
• Check oil level in steering and hoist oil tank, add oil
• Check oil level in brake oil tank, add oil
• Check oil leakage in brake oil collection tank
• Check coolant level, add coolant
• Check oil level in engine oil pan, add oil
• Check electric wiring
• Check fuel level, add fuel
• Check tire pressure
• Check machine monitor
• Check brake
• Check braking performance of secondary brake
• Check automatic secondary steering
• Check manual secondary steering
• Check automatic secondary steering
• Check dump body positioner operation
• Check backup alarm operation
• Check horn operation
• Check action of KomVision camera
• Check action of KomVision radar
4-46
EVERY 250 HOURS MAINTENANCE

METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL
FILTER CARTRIDGE
k WARNING
• Allow parts and oils to cool then remove the cap slowly to relieve pressure.
Refill capacity: 215 ℓ {56.8 U.S.Gal}

• Container to catch the drained oil
• Filter wrench
1. Place the oil container just under the drain plug (1) to
catch the drained oil.
2. Loosen the drain plug (1) to drain oil. Do it slowly so that
you do not get splashed with the drained oil.
3. Check the drained oil.
If there are excessive metal powder or foreign material,
contact your Komatsu distributor.
4. Tighten the drain plug (1).
Tightening torque: 117.6 to 161.7 Nm {12 to 16.5 kgm, 86.8
to 119 lbft}
5. Place a container just under the drain plug (2) to catch the
drained oil.
6. Loosen the drain plug (2) to drain oil. Do it slowly so that
you do not get splashed with the drained oil.
7. Turn the filter cartridges (3) (4 pieces) counterclockwise by
using the filter wrench, and remove it.
When doing this, to prevent get splashed with drained oil,
do not perform this operation right under the cartridge.
In particular, if this work is performed immediately after
stopping the engine, a large amount of oil will come out, so
wait for approximately 10 minutes before starting the work.
8. Clean the filter head.
9. Fill the new filter cartridge with clean oil.
10. Apply oil (or thinly apply grease) to the packing surfaces and thread portion.
11. Install the filter cartridge.
When doing this, be careful not to damage the outside cylinder of the cartridge.
When installing the filter cartridge, tighten until the packing face is in contact with the filter head, then tight-
en a further 3/4 to 1 turn.
4-47
12. Add the specified amount of oil through the oil filler port (F)
or service center.
When adding oil through the service center, see “SERVICE
CENTER”.
13. Run the engine at low idle for a while.
14. Check that the engine oil level is in the specified range.
METHOD FOR CHECKING AND ADDING OIL IN DIFFERENTIAL CASE

k WARNING
jury.
• When removing the plug, oil may spurt out, so turn it slowly to release the internal pressure, then
remove it carefully.
1. Remove the plug (G).

2. Check that the oil level is close to the lower edge of the
plug hole.
If the oil level is too low, add oil until the oil level comes
close to the lower edge of the hole of the plug (G).
3. Install the plug (G).
4-48
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL
k WARNING
Allow parts and oils to cool then remove the cap slowly to relieve pressure.
1. Stop the machine so that “TOP” embossed mark is at the

top and the drain plug (P) is at the bottom.
2. Remove the plug (G).
If the oil level is too low, add oil until the oil level comes
close to the lower edge of the hole of the plug (G).
3. Install the plug (G).
METHOD FOR CHECKING DRIVE SHAFT

Check that there is no problem 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.
4-49
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL

Perform this procedure before operating the machine.
Inspect the battery electrolyte level according to the standard at least once a month.
k WARNING
Do not use the battery if the battery electrolyte level is below LOWER LEVEL line.
If you do so, it will reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is a danger of explosion. Do not bring any open flame
near the battery.
Battery electrolyte is dangerous object.
If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static electrici-
ty.
NOTICE
Do not add the electrolyte to the battery exceeding UPPER LEVEL line.
If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other
parts.
If there is a fear that the battery water may freeze after refilling with purified water (such as a commer-
cial battery fluid), do the replenishment before the day's work on the next day.
4-50
METHOD FOR CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the battery, check as follows.
The battery box is on the front of the machine.
1. Open the cover (1) of the battery box.
Open the cover (1) of the battery box fully, and it is se-
cured by rod (2).
2. Clean around the electrolyte level line with a cloth wet with
water.
3. Check that the electrolyte level is between UPPER LEVEL

line and LOWER LEVEL line.
4. If the electrolyte level is below the middle between UPPER
LEVEL and LOWER LEVEL lines, immediately remove the
cap (3) and add the purified water (such as a commercial
battery fluid) to UPPER LEVEL line.
5. When you add the battery fluid to the cell of cap (3), add it
to other cells as well.
6. Clean the vent hole of the battery cap, then tighten the cap
securely.
Keep the battery top surface clean and wipe off dirt on it by using a wet cloth.
REMARK
If the battery refilling liquid exceeds the maximum level line (UPPER LEVEL), use a syringe to lower the
level to the maximum level line (UPPER LEVEL). 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.
7. Release the lock of battery box cover (1), and close the cover.
4-51
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 the level according to the following procedure.
The battery box is on the front of the machine.
1. Open the cover (1) of the battery box.
Open the cover (1) of the battery box fully, and it is se-
cured by rod (2).
2. Remove the cap (3) at the top of the battery and check the
electrolyte level through electrolyte filler port (4).
3. If the electrolyte does not reach the sleeve (5), always add
the purified water (such as a commercial battery fluid) so
that the level reaches the bottom of the sleeve (UPPER
LEVEL line).
• (A) Correct level: Electrolyte level is up to bottom of
sleeve, so surface tension causes electrolyte surface
to bulge and pole plate appears to be warped.
• (B) Low level: Electrolyte level does not reach the bot-
tom of sleeve, so pole plate appears straight and not
to be warped.
4. When you add the battery fluid to the cell of cap (3), add it to other cells as well.
5. After adding, tighten the cap (3) securely.
REMARK
If the battery fluid is added to the level above the bottom of the sleeve, use a syringe to remove it until the
level becomes under the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicar-
bonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a
battery manufacturer.
6. Release the lock of battery box cover (1), and close the cover.
METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
4-52
METHOD FOR CHECKING AND ADJUSTING CONCENTRATION OF COOLANT

ADDITIVE AGENT
k WARNING
Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in the
radiator.
You may get burn injury if you remove the cap in this state. Always wait for the temperature to go down,
pull up the lever on the cap slowly to release the pressure, then remove the cap with care.
NOTICE
If the concentration of the coolant additive agent is low, pitting of the liner or corrosion of the system
will be caused. If the concentration is excessively high, leakage from the water pump seal will be
caused.
Concentration test kit (1) for the coolant additive agent (DCA4)
A test kit has an expiration date. Prepare the appropriate test
kit from the following according to the frequency of usage.
Cummins part number
• CC2602 (50 pieces)
• CC2602A (4 pieces)
• CC2602B (1 piece)
1. Pull up the lever on top of the radiator cap (2) to release

the pressure, and remove the cap.
2. Take out a small amount of coolant from the radiator, and
measure the concentration of the additive agent with the
test kit (1).
For the measuring procedure, see the explanation attach-
ed to the concentration test kit (1).
3. Follow the measurement result, and determine how to ad-
just the concentration of the additive agent.
• When the concentration is less than 1.2 (unit/gallon)
Replace the corrosion resistor and replace the coolant with the one which includes the specified con-
centration of additive agent.
For the replacement procedure of the corrosion resistor, see the Operation and Maintenance Manual of
the engine or ask your Komatsu distributor for replacement.
• When the concentration is 1.2 to 3 (unit/gallon)
Replace only the corrosion resistor
For the replacement procedure of the corrosion resistor, see the Operation and Maintenance Manual of
the engine or ask your Komatsu distributor for replacement.
• When the concentration is more than 3 (unit/gallon)
Do not replace the corrosion resistor.
If the concentration is 3 (unit/gallon) or less in the next checking or after, replace the corrosion resistor.
4-53
METHOD FOR CHECKING FRAME

k WARNING
When performing the inspection with the dump body raised, always use the body lock wire to secure
the dump body, and set the dump lever at “HOLD” position.
1. Clean the frame so that you can check them easily.

2. Check that there is no damage to the frame.
In particular, check the shaded area in the figure. If any
cracks or other damage are found, perform the repairs.
Contact your Komatsu distributor for the repair procedure.
METHOD FOR CHECKING FOOT BRAKE PERFORMANCE

k WARNING
If the machine moves when the braking capacity is being checked, it may lead to serious personal injury
or death.
If the machine moves, lower the engine speed immediately, set the gear shift lever to NEUTRAL position
(N) and set the parking brake switch to “PARKING” position.
NOTICE
When checking, be sure to select “F2” in “F1 Start at D Position Setting”, and then set the gear shift
lever to position D. Neglecting this can damage the inside of the transmission.
1. Check that “F2” is selected on “F1 Start at D Position Set-
ting” of user menu of the machine monitor.
2. Place the machine on a flat ground and depress the foot

brake (1).
3. Set the gear shift lever (2) in the position D and increase
the engine speed gradually.
If the machine does not move when the engine speed is
increased to 1390 rpm, it is normal.
If any problem is found, ask your Komatsu distributor for
repair.
4. Decrease the engine speed and set the gear shift lever to
NEUTRAL position (N).
5. Set the parking brake switch to “PARKING” position to apply the parking brake.
4-54
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE

k WARNING
If the machine moves when the braking capacity is being checked, it may lead to serious personal injury
or death.
If the machine moves, lower the engine speed immediately, return the gear shift lever to NEUTRAL posi-
tion (N), and depress the foot brake.
NOTICE
2. Stop the machine on a flat ground and pull the retarder

control lever (1) fully.
repair.
4-55
METHOD FOR CHECKING PARKING BRAKE PERFORMANCE

k WARNING
If the machine starts to move during the test, reduce the engine speed, set the gear shift lever to NEU-
TRAL (N) and engage the parking brake.
Consult your Komatsu distributor for inspection and repair. Make sure to repair the brake before opera-
tion.
NOTICE
2. Set the parking brake switch (1) to “PARKING” position on

a flat ground.
repair.
4-56
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR

If the engine stops during travel, the brake can be operated with the oil pressure in the accumulator temporarily.
1. Stop the machine on a flat ground.
2. Set the parking brake switch to “PARKING” position.
3. Turn the starting switch to START position (C) and start the
engine.
4. Run the engine at medium speed for 1 minute, turn the

starting switch to OFF position (A), and then stop the en-
gine.
4-57
6. Depress the brake pedal several times.

After the brake pedal is depressed some times, the brake
oil pressure caution lamp (1) lights up.
• If the brake oil pressure caution lamp lights up when
the brake pedal is depressed 4 times or less, the gas
pressure in the accumulator may be low. Ask your Ko-
matsu distributor for inspection.
• If the brake oil pressure caution lamp does not light up
when the brake pedal is depressed 5 times, the gas
pressure in the accumulator is normal.
REMARK
Check the function within 5 minutes after stopping the en-
gine.
If the engine is kept stopped, the gas pressure in the accu-
mulator lowers and cannot be checked.
7. After checking, turn the starting switch to OFF position (A).
4-58

Maintenance for every 250 hours service should be performed out at the same time.
METHOD FOR REPLACING FUEL FILTER CARTRIDGE

k WARNING
• After the engine stops, all parts are still very hot, so do not replace the filter immediately. Wait for all
of parts to cool down before starting the work.
• Do not bring any open flame close.
• Container to catch the fuel
• Filter wrench
1. Open the fuel filter covers (1) and (2), place the containers
under the fuel filter cartridges to catch the fuel.
2. Close the fuel valve (3) of the fuel tank.
STAGE1 filter
3. Close the valve (4) on the fuel outlet side.
4. Loosen the valve (5) on the lower part of the filter housing,
and drain the fuel from the STAGE1 filter.
5. Remove the transparent cover (6) by using the filter
wrench and remove the filter element.
6. Install the new filter element.
7. Install the transparent cover (6) as in the original position.
Perform the installation by hand. Do not use the filter
wrench.
8. Remove the cap (7) on top of of the transparent cover (6)
and fill it with fuel up to the line (A).
9. Install the cap (7) to its original position.
Perform the installation by hand. Do not use the filter wrench.
10. Open the valve (4) on the fuel outlet side.
4-59
STAGE2 filter
11. Loosen the drain plug (8) to drain the fuel. Do it slowly so
that you do not get splashed with the drained fuel.
12. Remove the STAGE2 filter cartridges (9) (3 pieces).
13. Clean the seal surface of the filter head.
14. Thinly apply oil to the seal ring surface, and install the new
filter cartridge to the filter head.
NOTICE
Install the STAGE2 filter cartridge without filling with
fuel so that the fuel flows through the STAGE1 filter in-
to the pump.
15. Tighten the drain plug (8).
16. When installing the cartridge, tighten it until the packing surface contacts the sealing surface of the filter
head, then tighten it 1/2 to 3/4 turns.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If
the filter cartridge is tightened too loose, fuel will also leak from the packing, so always tighten to the speci-
fied angle.
17. Close the fuel valve (3) which has been closed in the step 2.
18. After replacing the filter cartridge, turn the starting switch to ON position.
The fuel feed pump which is provided with the STAGE1 filter operates.
The fuel feed pump stops automatically 2 minutes after it has been started.
19. After the fuel feed pump is stopped, turn the starting switch to OFF position.
20. Repeat the steps 18. to 19. for 3 times.
21. Loosen the plug (10) at the outlet piping of the STAGE1 fil-
ter, turn the starting switch to ON position again, and
check that the fuel flows out from the plug
23. After draining the oil, tighten the plug (10).
24. Turn the starting switch to START position in this state.
If the engine does not start, repeat the steps 17 and 22,
and try starting the engine again.
25. If the engine has been started, check that there is no leak-
age of fuel from the filter seal surface.
If there is any leakage of fuel, check the tightening condition of the filter cartridge.
If the fuel still leaks, remove the fuel filter cartridge according to the steps 10. to 11. If the seal surface has
damage or foreign material on it, replace the cartridge with a new one, and repeat the steps 12. to 22.
4-60
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT

k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Container to catch the drained oil
1. Place a container to catch the drained oil under the trans-
mission oil filter (1).
2. Remove the plug (2) of the transmission oil filter (1), and
drain the oil.
3. After draining the oil, tighten the plug (2).
Tightening torque of drain plug: 49 to 58.8 Nm {5 to 6 kgm,
36.2 to 43.4 lbft}
4. Loosen the hexagonal portion (4) of the filter case (3), and
remove the filter case (3).
5. Take out the element, and clean the inside of the case.
6. Replace the O-ring of the transmission oil filter with a new
one.
Thinly apply clean oil to the O-ring, and install it.
7. Install a new element to the filter case (3).
Tightening torque of filter case: 58.8 to 78.5 Nm {6 to
8 kgm, 43.4 to 57.9 lbft}
Run the engine at low idle for a while.
9. Check that the oil level in the transmission case, and that it reaches the specified level.
Replace the element immediately if the transmission oil filter clogging caution lamp lights up when the engine is
running at high idle and the oil is warmed.
4-61
METHOD FOR CHECKING AND REPLACING AIR CONDITIONER COMPRESSOR

BELT
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT
k WARNING
Do not open the cover while the engine is running. Stop the engine always before performing the in-
spection.
1. Remove the nuts (1) (3 pieces) and bolts (2) (2 pieces)

and remove the cover (3).
2. Check the belt.

If the belt shows the following state, it must be replaced.
• There is a vertical flaw (5) that crosses horizontal flaw
(4).
• There is a tear (6) on the belt.
Replacement is not required when only horizontal flaw (7)
is found on it.
3. Install the cover (3) with bolts (2) (2 pieces) and nuts (1) (3
pieces).
METHOD FOR REPLACING AIR CONDITIONER COMPRESSOR BELT

k WARNING
Do not open the cover while the engine is running. Stop the engine always before performing the in-
spection.
1. Remove the nuts (1) (3 pieces) and bolts (2) (2 pieces)

and remove the cover (3).
4-62
2. Remove the tension pulley (4) from the belt (5).

3. Replace the belt (5).
4. Bring the tension pulley (4) into contact with the belt.
5. Install the cover (3) with bolts (2) (2 pieces) and nuts (1) (3
pieces).
4-63

Maintenance for every 250 and 500 hours services should be performed out at the same time.
METHOD FOR CHANGING OIL IN TRANSMISSION CASE AND CLEANING

STRAINER
k WARNING
jury.
NOTICE
If the engine is started when the transmission oil pan is empty, the pump will be broken. Do not start the
engine if the oil level cannot be seen through the sight gauge.
• Container with oil in it
1. Stop the engine.
2. Drain the oil in the transmission case.
1) Place a container to catch the oil just under the drain
plug (1).
2) Remove the drain plug (1), and install the drain hose.
3) Loosen the drain valve (2) and drain the oil.
4) After draining the oil, tighten the drain valve (2).
5) Remove the drain hose and install the drain plug (1).
3. Wash the strainers (3 places).

1) Remove the bolts (3), and remove the cover (4).
2) Take out the strainer (5).
3) Remove all dirt from strainer (5), then wash it in clean
diesel fuel or flushing oil.
4) Check the strainer (5).
If the strainer is damaged, replace it.
5) Install the new O-ring, and install the strainer (5).
6) Install the cover (4) with bolt (3).
4-64
4. Add 170 ℓ {44.9 U.S.Gal} of oil through the oil filler port (F)

or service center without starting the engine.
Add oil so that the oil level is at the sight gauge (G1).
When adding oil through the service center, see “SERVICE
CENTER”.
5. While checking the sight gauge, crank the engine but not
start it.
through the sight gauge (G2), and add oil up to the sight
gauge (G1) through the oil filler port (F) or service center.
7. Repeat the steps 5. to 6. until the oil level does not decrease any more.
8. After the warm-up operation is finished, check the oil level in the transmission case.
For the method of checking the oil level, see “METHOD FOR CHECKING OIL LEVEL IN TRANSMISSION
CASE, ADDING OIL (3-153)”.
METHOD FOR REPLACING BRAKE COOLING OIL FILTER ELEMENT

k WARNING
jury.
1. Stop the engine.

2. Turn the cap of oil filler port (F) to release the internal pres-
sure before removing the cap.
3. Remove the bolt (1) (4 pieces) and remove the cover (2).
4. Remove the O-ring (3), spring (4), valve (5), strainer (6),
and element (7).
5. Wash the inside of the case, valve (5), and strainer (6).
6. Prepare a new element. Install the element, strainer, valve,
and spring to the case.
7. Replace the O-ring with a new one, apply thin film of oil to
it, and install it.
8. Install the cover (2) with bolt (1).
9. Install the cap of oil filler port (F).
4-65
METHOD FOR REPLACING BRAKE CONTROL OIL FILTER ELEMENT

k WARNING
jury.
• Filter wrench
• Wrench
1. Stop the engine.
2. Depress the brake pedal 20 times or more to reduce the pressure inside the brake control accumulator to 0.
REMARK
When the pressure in accumulator is released, the depressing effort of the brake pedal decreases, and no
hydraulic sound is made.
3. Place a container to catch oil just under the brake oil filter.
4. Rotate the hexagonal portion on the bottom of the filter
case (1) by using a wrench, and remove the filter case (1).
5. Remove the element (2).

6. Clean the inside of the filter case
7. Replace the O-ring (3) of the filter case and backup ring
(4) with new ones, and thinly apply the clean oil to them.
8. Thinly apply the clean oil to the O-ring of the new element.
9. Put the element (2) into the filter case (1).
10. Install the filter case (1).
Tightening torque: 78.4 to 98.0 Nm {8 to 10 kgm, 57.9 to
72.3 lbft}
4-66
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT

1. Remove the cap (with element) (2) of the breather (1).
2. Install the cap (2).
METHOD FOR LUBRICATING

1. Stop the engine.
2. By using a grease pump, pump in grease through the grease fitting shown by arrow.
3. Check visually that the greasing has been performed properly.
4. After greasing, wipe off any old grease that is pushed out.
Engine front trunnion (1 place)
4-67
METHOD FOR CHECKING FRONT BRAKE DISC WEAR AMOUNT

k WARNING
jury.
• If the disc wear approaches the wear limit, check the condition frequently, regardless of the mainte-
nance interval. In addition, check the retarder capacity carefully.
• Be sure to stop the engine before starting the work.

Check this time that other brakes are not applied.
3. Remove the cap nut (1).
4. Push in the rod (2) of the gauge until it touches the piston.
Do not depress the brake pedal this time.
If the slit (3) of rod (2) enters beyond the guide end face
(4), it means that the disc has reached the wear limit.
Ask your Komatsu distributor for inspection and mainte-
nance in such case.
5. Install the cap nut (1) which is removed in the step 3.
137 lbft}
REMARK
• The position of the guide has been adjusted so that the slit (5) matches the end face of guide (4) for a new
machine. Therefore, do not loosen the lock nut (6) except when replacing the disc.
• If the rod is pushed in when the engine is running, the rod will be pushed back by the brake cooling oil pres-
sure, so the engine should be stopped when pushing the rod.
4-68
METHOD FOR CHECKING REAR BRAKE DISC WEAR AMOUNT

k WARNING
jury.
• If the disc wear approaches the wear limit, check the condition frequently, regardless of the mainte-
nance interval. In addition, check the retarder capacity carefully.
• Be sure to stop the engine before starting the work.

Check this time that other brakes are not applied.
3. Remove the cap nut (1).
4. Push in the rod (2) of the gauge until it touches the piston.
Do not depress the brake pedal this time.
If the slit (3) of rod (2) enters beyond the guide end face
(4), it means that the disc has reached the wear limit.
Ask your Komatsu distributor for inspection and mainte-
nance in such case.
5. Install the cap nut (1) which is removed in the step 3.
137 lbft}
REMARK
• The position of the guide has been adjusted so that the slit (5) matches the end face of guide (4) for a new
machine. Therefore, do not loosen the lock nut (6) except when replacing the disc.
• If the rod is pushed in when the engine is running, the rod will be pushed back by the brake cooling oil pres-
sure, so the engine should be stopped when pushing the rod.
4-69
METHOD FOR COLLECTING LEAKED OIL FROM FLOATING SEAL

k WARNING
jury.
• If there is remaining pressure inside the case, the oil or plug may jump out.
Turn the plug slowly to release the pressure, then remove it carefully.
REMARK
• Collect the oil from 4 wheels in the same way.
• Whenever oil flows out of the overflow hose, collect the oil.
1. Place the oil container to catch the oil just under the drain plug (P).
2. Remove the drain plug (P) and drain the oil.
Collect the oil from the brake oil collection tanks on the right and left sides.
3. After draining the oil, tighten the drain plug (P).
Front
Rear
4-70
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP

1. Check for looseness in the air intake piping clamps between the air cleaner, turbocharger, oil cooler, and
engine.
2. If clamp is loose, retighten it.
Tightening torque of clamps (1) and (2): 8.8±0.5 Nm {0.90±0.05 kgm, 6.51±0.36 lbft}
When retightening the clamp (1), remove the cover (3).
4-71

Maintenance for every 250, 500, and 1000 hours services should be performed out at the same time.
METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT

k WARNING
jury.
1. Stop the engine.

2. Turn the cap of oil filler port (F) to release the internal pres-
sure before removing the cap.
3. Remove the bolts (1) (4 pieces) and remove the cover (2).
4. Remove the O-ring (3), spring (4), valve (5), strainer (6),
and element (7).
5. Wash the inside of the case, valve (5), and strainer (6).
6. Prepare a new element. Install the element, strainer, valve,
and spring to the case.
7. Replace the O-ring with a new one, apply thin film of oil to
it, and install it.
8. Install the cover (2) with bolt (1).
4-72
METHOD FOR CHANGING OIL IN BRAKE OIL TANK

k WARNING
• Stop the machine on a flat ground, turn the parking brake switch to “PARKING” position, and chock
the tires.
jury.
NOTICE
If the engine is started when the tank is empty, the pump will be broken. Do not start the engine if the oil
level cannot be seen through the sight gauge.
Refill capacity: 429 ℓ {113 U.S.Gal} in total (brake control oil 87 ℓ {23 U.S.Gal} , brake cooling oil 342 ℓ
{90 U.S.Gal} )
The sight gauge (A) on the front of the machine is for brake
cooling. The sight gauge (B) on the rear of the machine is for
brake control.
1. Stop the engine.

2. Place a container just under the drain plug of brake oil tank to catch the oil.
(2 places of brake control and brake cooling)
3. Remove the drain plugs (1) and (2), and install the drain hoses.
4-73
4. Loosen the drain valves (3) and (4), drain the oil, and tight-
en the drain valves.
5. Remove the drain hoses.
6. Install the drain plugs (1) and (2).
7. Place the containers just under the drain plugs (5) and (6)
of the cooling circuit inside of the final drive to catch the
drained oil.
8. Remove the drain plugs (5) and (6), and drain the oil.
Perform the oil draining at 4 places in total (front wheels,
rear wheels, R.H. wheels, and L.H. wheels).
9. After draining the oil, install the drain plugs (5) and (6).
10. Add oil through the oil filler port (F) up to the upper limit of
the sight gauges (7) and (8).
11. While checking the sight gauges (7) and (8), crank the en-
gine but not start it.
through the sight gauge (7) or (8), and add oil up to the up-
per limit of the sight gauge.
13. Repeat the steps 11. to 12. until the oil level does not de-
crease any more.
14. In order to release the pressure in the accumulator, de-
press the brake pedal several times until the oil pressure sound cannot be heard.
15. Start the engine and wait 5 minutes until the accumulator is charged with oil pressure.
16. Check that the oil levels in the sight gauge (7) of brake control and the sight gauge (8) of brake cooling are
in the range (G2).
17. If the oil level is not in the range (G2), add oil through the oil filler port (F) or service center.
When adding oil through the service center, see “SERVICE CENTER”.
18. If the oil level is above the range (G2), remove the drain plug (1) or (2), loosen the drain valve (3) or (4) to
drain the excessive oil, and check the oil level again.
19. Bleed air from the brake circuit.
For bleeding air, see “METHOD FOR BLEEDING AIR FROM REAR BRAKE” and “METHOD FOR BLEED-
ING AIR FROM FRONT BRAKE”. Add oil after bleeding air.
4-74
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE

k WARNING
Refill capacity: (each of right and left) 107 ℓ {28.3 U.S.Gal}

1. Stop the machine so that “TOP” embossed mark is at the
top and the drain plug (P) is at the bottom.
3. After draining oil, tighten the drain plug.
4. Add the specified amount of oil through the hole of plug
(G).
5. After adding oil, check that the oil level is in the specified
range.
METHOD FOR CHANGING OIL IN DIFFERENTIAL CASE

k WARNING
Refill capacity: 439 ℓ {116 U.S.Gal}

2. After draining oil, tighten the drain plug.
3. Add the specified amount of oil through the hole of plug
(G).
4. After adding oil, check that the oil level is in the specified
range.
4-75
METHOD FOR CLEANING DIFFERENTIAL CASE BREATHER

k WARNING
jury.
• When using compressed air, there is a danger that dirt may scatter and cause personal injury.
Always wear the protective eyeglasses, dust mask, or other protective equipment.
1. Stop the engine.

2. Remove mud and dirt around the breather.
3. Remove the breather.
Take care to prevent entry of dusts through the mounting
section of the breather.
4. Rinse the breather (5) in clean diesel fuel or flushing oil,
and remove dirt from inside.
5. Blow the breather with compressed air to dry.
6. Install the breather.
METHOD FOR CHECKING FRONT WHEEL BEARING

k WARNING
• If the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then re-
move it carefully.
1. Take the oil from the plug of front wheel hub cover, and perform the oil clinic.
2. If there is any symptom of damage on wheel bearing, ask your Komatsu distributor for inspection and ad-
justment.
Perform the check every 4000 hours from then.
METHOD FOR CHECKING REAR WHEEL BEARING

k WARNING
• If the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then re-
move it carefully.
1. Collect the oil from near the oil filler port not from near the drain plug of the final drive, and perform the oil
clinic.
2. If there is any symptom of damage on wheel bearing, ask your Komatsu distributor for inspection and ad-
justment.
Perform the check every 4000 hours from then.
4-76
METHOD FOR CLEANING TRANSMISSION CASE BREATHER

k WARNING
1. Raise the dump body.

2. Fix the dump body with the dump body lock wire.
3. Remove mud and dirt around the breathers (1) and (2).
4. Remove the breathers (1) and (2).
6. Install the breathers (1) and (2).
7. Remove the dump body lock wire.
8. Lower the dump body.
4-77
METHOD FOR REPLACING STEERING AND HOIST OIL TANK BREATHER ELE-
MENT
k WARNING
1. Remove the nut (2) of breather assembly (1).

2. Remove the cover (3).
3. Replace the breather element (4) with a new one.
4. Install the cover (3) and nut (2).
METHOD FOR CLEANING BRAKE OIL TANK BREATHER

k WARNING
1. Remove mud and dirt around the breather.

2. Remove the breather.
4. Install the breather.
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE

Contact your Komatsu distributor to have the gas pressure checked when making periodically replacement of
safety parts or performing the legally required 2000 hour or every year service.
METHOD FOR CLEANING FINAL DRIVE MAGNET

For cleaning the final drive magnet, ask your Komatsu distributor.
4-78

Maintenance for every 250, 500, 1000, and 2000 hours services should be performed out at the same time.
REPLACE DEFINED LIFE PARTS

Material quality of these parts can change as time passes and they are likely to wear out or deteriorate.
Replace them every 2 years or every 4000 hours, whichever comes sooner.
DEFINED LIFE PARTS LIST

No. Periodical replacement parts
1 Fuel system Fuel hose
Spill hose
2 Engine lubrication system Engine oil filter hose
3 Steering system High pressure circuit hose
4 Brake system Brake oil pressure hose
Retarder control valve rubber parts
5 Torque converter, transmis- Ask your Komatsu distributor
Transmission circuit hose for replacement.
sion system
6 Work equipment hydraulic Main pump delivery hose
system
Main pump delivery hose other than descri-
bed above
Main pump LS hose
External work equipment hose
• Hoist circuit hose
4-79
METHOD FOR CHANGING OIL IN STEERING AND HOIST OIL TANK

k WARNING
jury.
NOTICE
If the engine is started when the tank is empty, the pump will be broken. Do not start the engine if the oil
level cannot be seen through the sight gauge.
1. Stop the engine.
2. Place a container to catch the oil just under the drain plug
(1).
3. Remove the drain plug (1), and install the drain hose.
4. Loosen the drain valve (2), drain the oil, and tighten the
drain valve.
5. Remove the drain hose, and install the drain plug (1).
6. Add oil up to the upper limit of the sight gauge (G).

7. Add oil up to the upper limit of the oil filler port again by
considering that the piping is filled with oil immediately af-
ter the engine is started.
8. Bleed air from the piston pump.
For air bleeding method, see “METHOD FOR BLEEDING
AIR FROM PISTON PUMP”.
Bleed air according to the step 13 of “METHOD FOR
BLEEDING AIR FROM PISTON PUMP”.
10. Bleed air from the steering cylinder and hoist cylinder.
For bleeding air, see “METHOD FOR BLEEDING AIR FROM STEERING CYLINDER” and “METHOD FOR
BLEEDING AIR FROM HOIST CYLINDER”.
11. If the oil level is not in the range of the sight gauge (G), add oil through the oil filler port (F) or service cen-
ter.
When adding oil through the service center, see “SERVICE CENTER”.
12. If the oil level is above the range of the sight gauge (G), remove the drain plug (1), loosen the drain valve
(2) to drain the excessive oil, and check the oil level again.
METHOD FOR CHECKING VIBRATION DAMPER

Ask your Komatsu distributor for inspection of the vibration damper.
4-80
METHOD FOR CHECKING ACCUMULATOR

Replace the parts of accumulator every 4000 hours or every 2 years, whichever comes sooner. Ask your Ko-
matsu distributor for replacement.
4-81

Maintenance for every 250, 500 and 1000 hours service should be performed at the same time.
METHOD FOR LUBRICATING DRIVE SHAFT

Use the special grease for drive shaft, and perform greasing every 5000 hours or every 2 years.
Part No. of special grease for drive shaft: 56B-20-19910
1. Stop the engine.
2. By using a grease pump, apply grease to the grease fit-
tings marked by arrows (4 places).
• Grease the spider part until grease comes out from
the cap seal.
• Grease the spline part until grease comes out from the
vent.
3. Check visually that the greasing has been performed prop-
erly.
4. After greasing, wipe off any old grease that is pushed out.
4-82

Maintenance for every 250, 500, 1000 and 5000 hours should be performed at the same time.
METHOD FOR CHECKING AND REPLACING STEERING-A ARM MOUNTING

BOLT
Ask your Komatsu distributor for checking and replacing the A-arm mounting bolt, washer, and holder.
(1) A-arm
(2) Front suspension
(3) Washer
(4) Bolt
(5) Holder
4-83
SPECIFICATIONS
5-1
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: HD1500-8
HD1500-8
Item Unit
Power mode Economy mode
Overall weight (unloaded weight + maximum
kg { lb} 249575 {550313}
payload + 1 operator (75 kg {165.4 lb} ))
Unloaded weight kg { lb} 107600 {237258}
Unloaded weight (without dump body) kg { lb} 89000 {196245}
Maximum payload kg { lb} 141900 {312890}
Standard Struck m3 { cu.yd} 65 {85.02}

specifica- Heaped
tion m3 { cu.yd} 94 {122.95}
(2:1)
Dump body capacity
Quarry Struck m3 { cu.yd} 50 {65.40}
use speci- Heaped
fication m3 { cu.yd} 78 {102.02}
(2:1)
Dumping speed (1900 rpm) (raised) Second 13.5
Engine model - SDA16V159–3
Engine rated horsepower
1175 {1580}/ 1900 1074 {1440}/ 1900
• SAE J1995 (gross)
{1900} {1900}
kW { HP} / 1175 {1580}/ 1900
• ISO14396 -
min-1 { rpm} {1900}
1103 {1479}/ 1900 1000 {1340}/ 1900
• ISO 9249 /SAE J1349 (net)
{1900} {1900}
Nm { kgm,
Engine maximum torque 7382 {753, 5450}/ 1300
lbft} / rpm
A Overall length mm {ft in} 12935 {42' 5"}
B Overall height mm {ft in} 6180 {20' 3"}
C Overall height when dumping mm {ft in} 11415 {37' 5"}
D Overall width mm {ft in} 7550 {24' 9"}
Minimum ground clearance (bottom surface
E mm {ft in} 880 {2' 11"}
of differential case)
Minimum turning radius (center of outside
mm {ft in} 11200 {36' 9"}
tire)
5-2
SPECIFICATIONS SPECIFICATIONS
HD1500-8
Item Unit
Power mode Economy mode
1st km/h { MPH} 9.5 {5.9} 9.5 {5.9}
2nd km/h { MPH} 12.4 {7.7} 12.4 {7.7}
3rd km/h { MPH} 16.7 {10.4} 16.7 {10.4}
Forward 4th km/h { MPH} 21.3 {13.2} 21.3 {13.2}
Travel speed 5th km/h { MPH} 28.6 {17.8} 28.5 {17.7}
6th km/h { MPH} 38.5 {23.9} 38.3 {23.7}
7th km/h { MPH} 56.5 {35.1} 52.7 {32.7}
RL km/h { MPH} 9.2 {5.7} 9.2 {5.7}
Reverse
RH km/h { MPH} 12.4 {7.7} 12.3 {7.6}
Operating temperature range °C { °F} -20 to 45 {-4 to 113}
5-3
ATTACHMENTS AND OP-
TIONS
Before reading this chapter, read and understand the SAFETY.
6-1
HANDLE SPEED LIMIT FUNCTION ATTACHMENTS AND OPTIONS
HANDLE SPEED LIMIT FUNCTION

k WARNING
If the alarm buzzer sounds due to a failure while the speed limit function is enabled, stop the machine
on a level ground with the brake pedal or retarder control lever.
If the speed limit function cannot be controlled due to a trouble in the system, it may lead to serious
injury or death.
The speed limit function can control the travel speed automatically to the speed that has been set beforehand,
regardless of the grade of the road or the loaded condition of the machine.
Explanation of components
(1) Overspeed caution lamp (3) Retarder pilot lamp

(2) Speed limit function pilot lamp
Overspeed caution lamp
The overspeed caution lamp warns about the overspeed of the travel speed while the speed limit function is
actuated.
Speed limit function pilot lamp
The speed limit function pilot lamp lights up while the travel speed of the machine is limited by speed limit func-
tion.
Retarder pilot lamp
The retarder pilot lamp lights up while the retarder is being actuated by the speed limit function.
6-2
ATTACHMENTS AND OPTIONS HANDLE SPEED LIMIT FUNCTION
OPERATION OF SPEED LIMIT FUNCTION

k WARNING
Change the speed limit when the fuel consumption becomes worse or any phenomena such as gear
shift hunting occur while the speed limit function is enabled.
The speed limit function automatically controls the engine and retarder so that the travel speed does not exceed
the speed limit which has been set when the travel speed is reaching the speed limit.
REMARK
• Ask your Komatsu distributor to set the speed limit.
The speed limit can be set respectively for the loaded state and the empty state.
• If the brake pedal or retarder control lever are actuated while the speed limit function is enabled, you can
slow down the machine or stop it in the same way as that of the normal brake operations.
• The ARSC travel speed can be set only to the speed which is lower than the speed limit for the loaded
state.
The operation method of ARSC is not different from usual.
• The travel speed may exceed the limit speed temporarily when entering the downhill while the accelerator
pedal is kept depressed.
In such case, the overspeed caution lamp lights up on the machine monitor. Release the accelerator pedal.
The retarder control is started, and the display will disappear when the travel speed is decreased.
6-3
HANDLE SPEED LIMIT FUNCTION ATTACHMENTS AND OPTIONS
OPERATION IF TROUBLES ON SYSTEM OCCUR

The machine has a trouble if any of the action levels “L01” to
“L04” is displayed on the machine monitor.
Take appropriate actions following the list of action level dis-
plays and required actions.
See what the failure code is active for. Notify your Komatsu dis-
tributor of the failure code and ask for repair.
Whether the systems continue or discon-

tinue the control
Failure code Failure name (●: Continue, x: Discontinue)
Engine control Retarder control
CA1358 Accelerator Pedal Sensor Potentiometer Voltage High x x
Error
Accelerator Pedal Sensor Potentiometer Voltage Low x x
CA1359
Error
CA1888
CB1888 Multiplexed Accelerator Pedal x x
CC1888
DLT3KA Disconnection of Output Speed Sens. (Main) x ●
DLT3LC Failure of T/M Output Speed Sensor ● x
DHP6KA
Out of Range of Sus. Press. Sensor (RR) ● x
DHP6KX
DHP7KA
Out of Range of Sus. Press. Sensor (RL) ● x
DHP7KX
DX30KA Disconnection of Retarder EPC Sol. (FL) ● x
DX30KB Ground Fault of Retarder EPC Sol. (FL) ● x
DX30KY Hot Short of Retarder EPC Sol. (FL) ● x
DX33KA Disconnection of Retarder EPC Sol. (FR) ● x
DX33KB Ground Fault of Retarder EPC Sol. (FR) ● x
DX33KY Hot Short of Retarder EPC Sol. (FR) ● x
DX37KA Disconnection of Retarder EPC Sol. (RR) ● x
DX37KB Ground Fault of Retarder EPC Sol. (RR) ● x
DX37KY Hot Short of Retarder EPC Sol. (RR) ● x
DX38KA Disconnection of Retarder EPC Sol. (RL) ● x
DX38KB Ground Fault of Retarder EPC Sol. (RL) ● x
DX38KY Hot Short of Retarder EPC Sol. (RL) ● x
6-4
ATTACHMENTS AND OPTIONS HANDLE OVERLOAD SPEED LIMIT FUNCTION
HANDLE OVERLOAD SPEED LIMIT FUNCTION

k WARNING
If the alarm buzzer sounds due to a failure while the overload speed limit function is enabled, stop the
machine on a level ground with the brake pedal or the retarder control lever.
If the speed limit function cannot be controlled due to a trouble in the system, it may lead to serious
injury or death.
The overload speed limit function is used to control the travel speed automatically so that it does not exceed the
set speed when the payload becomes overload.
Explanation of components
(1) Overload caution lamp (3) Retarder pilot lamp

(2) Overspeed caution lamp
Overload caution lamp
The overload caution lamp warns about the overload when the overload speed limit function is actuated.
Overspeed caution lamp
The overspeed caution lamp warns about the overspeed of the travel speed while the overload speed limit func-
tion is actuated.
Retarder pilot lamp
The retarder pilot lamp lights up while the retarder is being actuated by the speed limit function.
OPERATION OF OVERLOAD SPEED LIMIT FUNCTION

The overload speed limit function judges the load if it is overloaded after the machine starts traveling when the
loading has been completed.
The overload speed limit function judges the load as overloaded this time, the alarm buzzer sounds, the over-
load pilot lamp lights up, and the overload speed limit function is actuated.
The overload speed limit function automatically controls the engine and the retarder so that the travel speed
does not exceed 14 km/h {8.7 MPH} .
The alarm buzzer, message, and the control of the overload speed limit function will not be canceled until the
load is dumped.
6-5
HANDLE OVERLOAD SPEED LIMIT FUNCTION ATTACHMENTS AND OPTIONS
REMARK
• The speed limit cannot be changed.
• If the brake pedal or retarder control lever are actuated while the overload speed limit function is enabled,
the machine can be slowed down or stopped in the same way as for normal brake operations.
• Setting the ARSC to 15 km/h or higher {9.3 MPH or higher} does not actuate the ARSC during the opera-
tion of the overload speed limit function.
Setting the ARSC to 14 km/h or lower {8.7 MPH or lower} actuates the ARSC as usual.
The operation method of ARSC is not different from usual.
• The travel speed may exceed the limit speed temporarily when entering the downhill while the accelerator
pedal is kept depressed.
In such case, the overspeed caution lamp lights up on the machine monitor. Release the accelerator pedal.
The retarder control is started, and the display will disappear when the travel speed is decreased.
6-6
ATTACHMENTS AND OPTIONS HANDLE OVERLOAD SPEED LIMIT FUNCTION
OPERATION IF TROUBLES ON SYSTEM OCCUR

The machine has a trouble if any of the action levels “L01” to
“L04” is displayed on the machine monitor.
Take appropriate actions following the list of action level dis-
plays and required actions.
See what the failure code is active for. Notify your Komatsu dis-
tributor of the failure code and ask for repair.

tinue the control
CA1358 Accelerator Pedal Sensor Potentiometer Voltage High x x
Error
Accelerator Pedal Sensor Potentiometer Voltage Low x x
CA1359
Error
CA1888
CB1888 Multiplexed Accelerator Pedal x x
CC1888
DLT3KA Disconnection of Output Speed Sens. (Main) x ●
DLT3LC Failure of T/M Output Speed Sensor ● x
DHP4KY Hot Short of Suspension Press. S. (FR) x x
DHP4KZ Failure of Suspension Press. S. (FR) x x
DHP5KY Hot Short of Suspension Press. S. (FL) x x
DHP5KZ Failure of Suspension Press. S. (FL) x x
DHP6KA
Out of Range of Sus. Press. Sensor (RR) x x
DHP6KX
DHP7KA
Out of Range of Sus. Press. Sensor (RL) x x
DHP7KX
DKH1KX Out of Range of Long. Inclination Angle S. x x
DK54KX Out of Range of Body Potentio. x x
DX30KA Disconnection of Retarder EPC Sol. (FL) ● x
DX30KB Ground Fault of Retarder EPC Sol. (FL) ● x
DX30KY Hot Short of Retarder EPC Sol. (FL) ● x
DX33KA Disconnection of Retarder EPC Sol. (FR) ● x
DX33KB Ground Fault of Retarder EPC Sol. (FR) ● x
DX33KY Hot Short of Retarder EPC Sol. (FR) ● x
DX37KA Disconnection of Retarder EPC Sol. (RR) ● x
DX37KB Ground Fault of Retarder EPC Sol. (RR) ● x
DX37KY Hot Short of Retarder EPC Sol. (RR) ● x
DX38KA Disconnection of Retarder EPC Sol. (RL) ● x
6-7
HANDLE OVERLOAD SPEED LIMIT FUNCTION ATTACHMENTS AND OPTIONS

tinue the control
DX38KB Ground Fault of Retarder EPC Sol. (RL) ● x
DX38KY Hot Short of Retarder EPC Sol. (RL) ● x
6-8
REPLACEMENT PARTS
7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS REPLACEMENT PARTS
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts listed in the table of the defined life parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. Howev-
er, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is im-
portant to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time
as the hoses.
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all
loose hoses and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the defined life parts.
DEFINED LIFE PARTS LIST

N
Periodical replacement parts Replacement interval
o.
1 Fuel system Fuel hose
Spill hose
2 Engine lubrication
Engine oil filter hose
system
3 Steering system High pressure circuit hose
4 Brake system Brake oil pressure hose
Retarder control valve rubber parts Every 2 years or 4000
5 Torque converter, hours, whichever
transmission sys- Transmission circuit hose comes sooner
tem
6 Work equipment Main pump delivery hose
hydraulic system
Main pump delivery hose other than described above
Main pump LS hose
External work equipment hose
• Hoist circuit hose
7 Others Every 3 years from
start of usage or 5
years after manufac-
Seat belt
turing of seat belt,
whichever comes
sooner
7-2
REPLACEMENT PARTS CONSUMABLE PARTS
CONSUMABLE PARTS
Replace consumable parts such as the filter element or air cleaner element at the time of periodic maintenance
or before they reach the wear limit. The consumable parts should be replaced correctly in order to ensure more
economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko-
matsu distributor of the machine serial number and check the latest part number when ordering parts.
CONSUMABLE PARTS LIST

The parts in parentheses are to be replaced at the same time.
Replacement in-
Item Part No. Part name Q'ty
terval
562-01-3A810
Engine oil filter (Cummins part Cartridge 4 Every 250 hours
number 4920071)
562-01-3A820
STAGE1 (Cummins part Element 1
number 4328041)
Fuel filter
562-01-3A830
Every 500 hours
STAGE2 (Cummins part Cartridge 3
number 2881455)
569-16-81160 Element 5
Transmission oil filter
(07000-12125) (O-ring) (5)
569-43-83920 Element 1
Brake control oil filter 07000-12065 (O-ring) (1)
07001-02065 (Back-up ring) (1) Every 1000
426-60-65230 Element 2 hours
Brake cooling oil filter
(07000-F5195) (O-ring) (2)
Transmission case strainer 07000-72105 O-ring (3)
426-60-65230 Element 1
Steering and hoist oil filter Every 2000
(07000-F5195) (O-ring) (1)
hours
Steering and hoist oil tank breather 421-60-35170 Element (3)
562-02-3A610
Air cleaner Element assembly 2 -
562-02-3A620
7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS
RECOMMENDED FUEL, COOLANT, AND LUBRICANT

NOTICE
• Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construc-
tion equipment and components.
In order to keep your machine in the best condition for long period of time, it is essential to follow
the instructions in this Operation and Maintenance Manual.
• Failure to follow these recommendations may result in shortened life or excessive wear of the en-
gine, power train, cooling system, and/or other components.
• Commercially available lubricant additives may be good or bad for the machine. Komatsu does not
recommend any commercially available lubricant additive.
• Use the fuels, oils, and lubricants according to the ambient temperature.
• If the machine is operated at a temperature of -20 °C or lower {-4 °F or lower} , separate devices are
needed, so consult your Komatsu distributor.
NOTICE
Always use diesel fuel. Never use any other fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device. Since the high-
pressure fuel injection device requires high precision parts and lubrication, if low viscosity fuel with low
lubricating ability is used, its durability may drop considerably. Also, using fuel with high sulfur content
may deteriorate the engine parts, inducing failures, decrease of the life and degradation in performance.
The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel
may contain 7 % or less of it. Use the fuel which is filled into the storage tank or the fuel tank of the
machine as soon as possible.
When the diesel fuel is changed to the one mixed with the bio-fuel, replace the fuel filter cartridge with a
new one.
7-4
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
LUBRICATION CHART
• The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication
interval.
Keep this chart in the magazine box inside the cab so that the people concerned can refer it any time dur-
ing lubrication.
• Even if the same symbol is used in the lubrication chart, the recommended genuine oil may differ according
to the lubrication points and the ambient temperature.
• The symbols used in the lubrication chart are explained as follows.

Symbol Meaning of the symbol Symbol Meaning of the symbol
Read Operation and Maintenance Manual Supply grease
7-5
Symbol Meaning of the symbol Symbol Meaning of the symbol
Change engine oil Check oil level in engine oil pan
Change hydraulic oil Check hydraulic oil level
Change power train oil Check power train oil level
Replace engine oil filter Replace hydraulic oil filter
Replace breather element in hydraulic tank Replace fuel filter
Change axle oil Check axle oil level
Change power train oil filter Replace breather element in fuel tank
Change brake fluid/oil Change brake oil filter
Check brake fluid/oil level Drain
7-6
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE
Ambient temperature
Recommended Komat-
Reservoir Fluid type °C °F
su Fluids
Min Max Min Max
EO10W30-DH
-20 40 -4 104
(KES Diesel Engine Oil)
EOS5W40
-25 40 -13 104
Engine oil pan Engine Oil
EOS0W30
-30 35 -22 95
EO15W40-DH
-15 50 5 122
TO10 (KES) -30 10 -22 86
Transmission Case Power train oil (Note.1)
TO30 (KES) 0 50 32 122
Power train oil TO10 (KES) -30 50 -22 122
Steering hoist oil tank HO46-HM (KES) -20 50 -4 122
Hydraulic Oil
HO-MVK (KES) -30 50 -22 122
Brake oil tank Power train oil TO10 (KES) -30 50 -22 122
Front suspension
Hydraulic Oil HO-MVK (KES) -30 50 -22 122
Rear suspension
Differential case
Power train oil TO30 (KES) -30 50 -22 122
Final drive case
G2-T (KES)
Hyper grease (Note.2) -20 50 -4 122
G2-TE (KES)
Grease fitting Lithium EP grease G2-LI (KES) -10 50 14 122
G2-LI-S (KES) -30 50 -22 122
Lithium grease
GLT2-LI (KES) -30 30 -22 86
Non-Amine Engine Coolant
Cooling system AF-NAC (KES) -30 50 -22 122
(AF-NAC) (Note.3)
EN 590 Class 2 -30 20 -22 68
Fuel tank Diesel fuel
EN 590 Grade D -10 50 14 122
Specified capacity Refill capacity

ℓ U.S.Gal ℓ U.S.Gal
Engine oil pan 238 62.9 215 56.8
Transmission case 232 61.3 129 34.1
Steering and hoist oil tank 459 121 316 83.5
Brake control 94 24.8 87 23
Brake cooling 652 172 342 90
Front suspension (each of right and left) 66.2 17.5 66.2 17.5
7-7
Specified capacity Refill capacity

ℓ U.S.Gal ℓ U.S.Gal
Rear suspension (each of right and left) 32.7 8.64 32.7 8.64
Differential case 439 116 439 116
Final drive case (each of right and left) 107 28.3 107 28.3
Fuel tank 2120 560 - -
Cooling system 520 137 460 122
REMARK
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity
means the amount of oil needed to refill the system during checking and maintenance.
Note 1: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 2: Hyper grease (G2-TE) has high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-T or G2-TE is recommended.
Note 3: Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing.
Komatsu machines are supplied with KES 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.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2. The concentration of Non-Amine Engine Coolant (AF-NAC) is as shown in the following table.
Coolant density table

-10 or
°C -15 -20 -25 -30 -35 -40 -45 -50
Min. atmospheric tem- more
perature 14 or
°F 5 -4 -13 -22 -31 -40 -49 -58
more
Density ( %) 30 36 41 46 50 54 58 61 64
The supplied Non-Amine Engine Coolant (AF-NAC) is already diluted.

In this case, fill up the tank with pre-diluted fluid. (Never dilute the Non-Amine Engine Coolant with ordinary
water.)
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU

GENUINE OILS
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
7-8
INDEX
INDEX
Symbols Auto-greasing system - Operate......................... 3-144
Automatic Retarder Speed Control (ARSC) - Handle..
12/24 display mode...............................................3-94 .....................................................................3-209
2 workers for maintenance when engine is running..... Automatic secondary steering - Check............... 3-166
.......................................................................2-33 AUX.....................................................................3-270
Auxiliary engine starting connector - Handle...... 3-134
A Average fuel consumption record - Display........ 3-234
Avoid mixing oil....................................................... 4-3
Accelerator pedal................................................ 3-121
Accumulator - Check.............................................4-81
Accumulator - Check function............................... 4-57
B
Accumulator - Filling function..............................3-196 Backup alarm operation - Check.........................3-166
Accumulator gas pressure - Check.......................4-78 Band/AUX selector button...................................3-269
Action level display............................................... 3-19 Basic operation of machine monitor......................3-11
Actions if fire occurs..............................................2-14 Battery.................................................................3-301
Actions when running out of fuel.........................3-305 Battery - Check electrolyte level from side............4-51
After cold weather season.................................. 3-302 Battery - Check electrolyte level when impossible
After finishing work - Check................................ 3-244 checking from side.........................................4-52
Air cleaner - Check............................................... 4-17 Battery - Handle.................................................... 2-36
Air cleaner - Check / Clean / Replace...................4-16 Battery disconnect switch................................... 3-133
Air cleaner clogging caution lamp......................... 3-30 Battery disconnect switch and starting motor discon-
Air cleaner element - Replace...............................4-20 nect switch - Check......................................3-154
Air cleaner outer element - Clean......................... 4-18 Battery electrolyte level - Check........................... 4-50
Air conditioner - Check / Maintenance.................. 4-27 Before operation - Adjust.................................... 3-173
Air conditioner - Handle...................................... 3-254 Beware of asbestos dust.......................................2-22
Air conditioner - Operate.....................................3-262 Bird's eye view display........................................ 3-281
Air conditioner - Start automatic operation..........3-262 Brake circuit - Bleed air.........................................4-31
Air conditioner - Stop automatic operation..........3-263 Brake control oil filter element - Replace.............. 4-66
Air conditioner - Stop manual operation..............3-264 Brake cooling circuit - Bleed air............................ 4-40
Air conditioner air filter - Clean..............................4-28 Brake dragging prevention guidance.................... 3-41
Air conditioner compressor belt - Check............... 4-62 Brake oil collection tank - Check oil leakage.......3-158
Air conditioner compressor belt - Check / Replace...... Brake oil pressure caution lamp............................3-24
.......................................................................4-62 Brake oil tank - Change oil....................................4-73
Air conditioner compressor belt - Replace............ 4-62 Brake oil tank - Check oil level / Add oil..............3-156
Air conditioner display.........................................3-260 Brake oil tank breather - Clean............................. 4-78
Air conditioner switch.......................................... 3-260 Brake oil tank filler caps - Lock........................... 3-249
Air conditioner switch and numeric keypad...........3-50 Brake oil tank filler caps - Open.......................... 3-249
Air conditioner system caution lamp..................... 3-30 Brake oil tank filler caps - Open / Close..............3-249
Air lumbar support - Adjust................................. 3-176 Brake pedal.........................................................3-120
AISS LOW switch................................................ 3-111 Brake pedal - Test............................................... 3-164
Allowable water depth.........................................3-242 Brake performance curve....................................3-214
Always use clean washer fluid................................ 4-2
Appoint leader when working with others............. 2-31 C
Armrest angle - Adjust........................................ 3-176
ARSC - Operate..................................................3-209 Cab door............................................................. 3-125
ARSC off pilot lamp...............................................3-40 Cab door handle................................................. 3-125
ARSC overheat notice caution lamp..................... 3-31 Cab door inner lock.............................................3-126
ARSC pilot lamp....................................................3-40 Calendar - Set.......................................................3-91
ARSC set travel speed indicator........................... 3-40 Calibration - Perform...........................................3-238
ARSC setting........................................................ 3-69 Camera image.................................................... 3-284
ARSC system caution lamp.................................. 3-31 Camera image and obstacle alarm buzzer- Automatic
ARSC travel speed set lever...............................3-123 switching when obstacle is detected............3-290
Ashtray................................................................3-127 Camera switch display........................................ 3-283
Attachments and options........................................ 6-1 Camera system caution lamp............................... 3-32
Auto switch..........................................................3-259 Centralized warning lamp..................................... 3-33
Auto-greasing system - Handle...........................3-144 Charge level caution lamp.................................... 3-30
8-1
INDEX
Chassis - Phenomena and actions..................... 3-320 Do not go close to high-voltage cables................. 2-21
Check drained oil and used filter.............................4-2 Down switch..........................................................3-50
Check service meter reading.................................. 4-2 Download software - Use....................................3-230
Check signs and signalman's signals................... 2-22 Drink box.............................................................3-126
Checks after inspection and maintenance.............. 4-3 Drive shaft - Check............................................... 4-49
Checks and adjustment before starting engine............ Drive shaft - Lubricate...........................................4-82
.............................................................2-24,3-150 Dump body - Check.............................................. 4-28
Checks before starting..................................2-26,4-46 Dump body - Load................................................ 2-28
Cigarette lighter...................................................3-106 Dump body - Lower if troubles occur.................. 3-307
Circuit breaker.....................................................3-137 Dump body float caution lamp.............................. 3-26
Clearance lamp pilot lamp.................................... 3-36 Dump body hold condition - Cancel.................... 3-194
Clock - Adjust......................................................3-273 Dump body lock wire...........................................3-139
Clock adjustment.................................................. 3-89 Dump body lock wire and pin - Store.................. 3-139
Cold weather operation.......................................3-300 Dump body positioner - Check operation............3-166
Cold weather operation information.................... 3-300 Dump lever..........................................................3-124
Consumable parts...................................................7-3 Dump lever lock knob......................................... 3-124
Consumable parts list............................................. 7-3 Dumping counter...................................................3-70
Contents of safety labels.........................................2-6 Dust indicator...................................................... 3-138
Control levers and pedals................................... 3-120 Dust indicator - Check.........................................3-154
Controls and gauges names................................... 3-4 Dusty jobsite........................................................... 4-3
Coolant................................................................3-300
Coolant - Check level / Add................................ 3-159 E
Coolant additive agent - Check / Adjust concentration
.......................................................................4-53 ECO gauge........................................................... 3-44
Coolant and water for dilution................................. 4-6 ECO gauge - Set target fuel consumption value...3-63
Cooling system - Clean inside.............................. 4-22 ECO guidance.......................................................3-41
Cup holder.......................................................... 3-127 ECO guidance record - Check.............................. 3-56
Electric wiring - Check........................................ 3-161
Electrical system - Phenomena and actions....... 3-319
D Emergency exit from operator's cab..................... 2-17
D range F1 start setting........................................ 3-72 Energy saving guidance........................................3-54
Data - Download from connector for download in cab. Engine - Check low-speed run and acceleration 3-194
.....................................................................3-227 Engine - Check starting condition and unusual noise..
Data - Download from connector for download out- .....................................................................3-194
side cab....................................................... 3-228 Engine - Operate / Check after starting.............. 3-194
Daylight saving time - Set..................................... 3-95 Engine - Operate / Check before starting........... 3-187
Defined life parts list....................................... 4-79,7-2 Engine - Start............................................3-192,3-317
Definition of travel speed in KomVision.............. 3-279 Engine - Start by auxiliary engine starting connector...
Defroster - Operate............................................. 3-267 .......................................................................2-25
Defroster switch.................................................. 3-261 Engine - Start with auxiliary engine starting connector
Details of data stored in memory of payload meter...... .....................................................................3-318
.....................................................................3-226 Engine - Start with jumper cables....................... 3-316
Differential case - Change oil................................4-75 Engine - Stop...................................................... 3-197
Differential case - Check oil level / Add oil............4-48 Engine coolant temperature caution lamp............ 3-23
Differential case breather - Clean......................... 4-76 Engine coolant temperature gauge.......................3-43
Dimmer switch.................................................... 3-107 Engine intake pipe clamps - Check for looseness 4-71
Directions of machine............................................. 1-4 Engine oil pan - Change oil / Engine oil filter cartridge
Display................................................................ 3-270 - Replace....................................................... 4-47
Display selector button........................................3-270 Engine oil pan - Check oil level / Add oil.............3-160
Display setting - Change.......................................3-60 Engine oil pressure caution lamp..........................3-29
Display warning tag during inspection and mainte- Engine overrun caution lamp................................ 3-29
nance............................................................. 2-31 Engine power mode selector switch.................... 3-111
Display/non-display of ECO gauge - Switch......... 3-62 Engine room lamp switch....................................3-132
Display/non-display of ECO guidance - Switch.....3-64 Engine shutdown secondary switch.................... 3-118
Display/non-display of guidance when key is OFF - Engine system caution lamp................................. 3-28
Switch............................................................ 3-65 Engine tachometer................................................3-43
Do not drop things inside machine..........................4-2 Ensure good visibility............................................ 2-21
Do not get caught in work equipment................... 2-18 Ensuring safe operation........................................ 2-12
8-2
INDEX
Enter switch.......................................................... 3-49 Fuel tank - Open / Close fuel filler port cap.........3-246
Error list display.................................................... 3-21 Fuel tank breather element - Replace...................4-67
Escape door........................................................3-140 Fuel, coolant and lubricants according to ambient
Ether cartridge - Replace...................................... 4-26 temperature - Use............................................7-7
Every 1000 hours maintenance............................ 4-64 Fuse.................................................................... 3-128
Every 15000 hours maintenance.......................... 4-83 Fuse capacities and circuit names......................3-128
Every 2000 hours maintenance............................ 4-72
Every 250 hours maintenance.............................. 4-47 G
Every 4000 hours maintenance............................ 4-79
Every 500 hours maintenance.............................. 4-59 Gear shift lever....................................................3-121
Every 5000 hours maintenance............................ 4-82 General precautions common to operation and main-
Excessive idling guidance.....................................3-41 tenance.......................................................... 2-12
Explanation of air conditioner equipment............3-255 General view........................................................... 3-2
Explanation of components...................................3-10 GPS synchronization - Set....................................3-90
Explanation of machine monitor equipment..........3-10 Grease.................................................................... 4-7
Explanation of radio equipment.......................... 3-269 Grease - Add.......................................................3-148
External display lamp..........................................3-225 Greasing circuit - Bleed air..................................3-146
External engine shutdown secondary switch...... 3-136 Guidance display................................................ 3-282
Guidance to avoid acceleration operation during
dump body lowering.......................................3-42
F Guidance to avoid hoist relief................................3-41
Fan control system caution lamp.......................... 3-30 Guidance to avoid steering relief.......................... 3-42
Fan switch...........................................................3-256 Guidance to recommend shifting up..................... 3-41
Filter........................................................................ 4-9 Guide line display..................................................3-79
Final drive case - Change oil................................ 4-75
Final drive case - Check oil level / Add oil............ 4-49 H
Final drive magnet - Clean....................................4-78
Fire extinguisher................................................. 3-131 Handle electrical components.................................4-9
Floating seal - Collect leaked oil........................... 4-70 Handle oil, fuel, coolant, and performing oil clinic...4-5
Fog lamp switch.................................................. 3-112 Hazard lamp switch.............................................3-109
Foot brake performance - Check.......................... 4-54 Headlamp high beam pilot lamp........................... 3-36
Forced display - Switch.........................................3-84 Headrest - Adjust angle...................................... 3-176
Forced display setting pilot lamp.........................3-282 Headrest - Adjust in vertical direction................. 3-176
Frame - Check...................................................... 4-54 Heated mirror switch........................................... 3-109
Frequency - Adjust..............................................3-271 Heated wire glass switch.....................................3-115
Frequency - Auto preset..................................... 3-271 High-pressure hoses and pipings - Handle...........2-38
Fresh and clean lubricants......................................4-2 Hoist control system caution lamp........................ 3-26
FRESH/RECIRC air selector switch................... 3-259 Hoist cylinder - Bleed air....................................... 4-38
Front brake - Bleed air.......................................... 4-33 Horn - Check operation.......................................3-167
Front brake disc - Check wear amount................. 4-68 Horn button......................................................... 3-108
Front camera selector switch.............................. 3-116 Hydraulic circuit - Bleed air..................................... 4-3
Front suspension cylinder - Check length.............4-29 Hydraulic tank strainer - Clean..............................4-25
Front wheel bearing - Check.................................4-76
Fuel......................................................................... 4-6 I
Fuel - Add by using fuel coupler......................... 3-162
Fuel - Check level / Add......................................3-162 If any problem is found..........................................2-13
Fuel and lubricants..............................................3-300 If machine monitor shows warning display......... 3-324
Fuel and lubricants to match the ambient temperature Inclination caution lamp........................................ 3-27
.........................................................................4-3 Indicator - Check electrolyte level......................... 4-52
Fuel circuit - Bleed air......................................... 3-305 Initial 250 hours maintenance (only after the first 250
Fuel consumption gauge - Set display..................3-61 hours).............................................................4-15
Fuel consumption record - Check......................... 3-58 Injector discharged volume - Adjust....................3-147
Fuel filler port cap - Open................................... 3-246 Injector operation - Check...................................3-147
Fuel filter cartridge - Replace................................4-59 Inside operator's compartment............................. 2-13
Fuel gauge............................................................ 3-44 Inspecting machine............................................... 2-12
Fuel level caution lamp......................................... 3-23 Introduction............................................................. 1-4
Fuel stage 1 filter - Check / Drain mixed water... 3-155 Investigate and confirm jobsite conditions............ 2-20
Fuel tank - Drain water and sediment................. 3-153
8-3
INDEX
J Machine - Lubricate.............................................. 4-67

Machine - Move off............................................. 3-199
Jumper cable - Connect......................................3-317 Machine - Operate if troubles occur on system 6-4,6-7
Jumper cable - Disconnect................................. 3-317 Machine - Operate when tires are stuck in ground......
.....................................................................3-219
K Machine - Park....................................................3-243
Machine - Running-in the new machine..............3-195
Keep machine clean............................................. 2-13 Machine - Secure................................................3-296
Komatsu genuine lubricants....................................4-2 Machine - Shift gear............................................3-205
Komatsu genuine replacement parts...................... 4-2 Machine - Start (Travel forward and reverse) / Stop....
Komatsu Traction Control System (KTCS) - Handle.... .....................................................................3-199
.....................................................................3-219 Machine - Steer...................................................3-218
KOMTRAX Plus.................................................. 3-149 Machine - Stop....................................................3-202
KomVision - Handle............................................ 3-274 Machine - Stop in emergency............................. 3-203
KomVision camera - Check action......................3-168 Machine - Travel downhill................................... 3-207
KomVision camera display range....................... 3-275 Machine - Travel reverse.................................... 3-201
KomVision monitor - Basic operation..................3-276 Machine - Warm up.............................................3-195
KomVision monitor - Basic operation when starting Machine body display......................................... 3-281
engine in normal situation............................3-276 Machine equipment name.......................................3-2
KomVision monitor - Basic operation when trouble Machine ID and Open ID - Set............................3-236
occurs.......................................................... 3-277 Machine monitor - Basic operation when starting en-
KomVision monitor brightness adjustment switch........ gine in abnormal situation..............................3-15
..................................................................... 3-110 Machine monitor - Basic operation when starting en-
KomVision monitor screen.................................. 3-279 gine in normal situation.................................. 3-11
KomVision radar - Check action......................... 3-169 Machine monitor - Basic operation when starting en-
KomVision radar - Handle...................................3-287 gine while engine shutdown secondary switch is
KomVision radar - Operation and obstacle detection ON................................................................. 3-12
range............................................................3-287 Machine monitor - Basic operation when starting
KomVision setting................................................. 3-81 switch is ON while operator ID input is set.... 3-14
KomVision system indicator................................3-127 Machine monitor - Basic operation when stopping en-
KTCS off pilot lamp............................................... 3-37 gine in normal situation..................................3-13
KTCS pilot lamp.................................................... 3-37 Machine monitor - Basic operation when trouble oc-
KTCS settings....................................................... 3-68 curs while operating machine........................ 3-17
KTCS system caution lamp...................................3-29 Machine monitor - Check.................................... 3-163
Machine monitor - Operate when operator identifica-
L tion function is available with skip..................3-97
Machine monitor - Operate when operator identifica-
L.H. and R.H. meter display..................................3-45
tion function is available without skip.............3-99
L.H. meter display - Select....................................3-86
Machine monitor equipment name..........................3-6
Lamp switch........................................................ 3-107
Machine operations and controls........................ 3-150
Lamps, cameras and radar device - Clean........... 4-44
Machine settings................................................... 3-67
Language settings.................................................3-96
Magazine box......................................................3-126
Left front camera selector switch........................ 3-116
Main use of machine...............................................1-4
Left rear camera selector switch......................... 3-116
Maintenance during long-term storage............... 3-303
Location of engine number plate.............................1-6
Maintenance of air conditioner..............................2-39
Location of product identification number (PIN)/
Maintenance procedure........................................ 4-15
machine serial No. plate.................................. 1-6
Maintenance schedule.......................................... 4-13
Lock.................................................................... 3-245
Maintenance schedule table................................. 4-13
Lock inspection cover............................................. 4-3
Maintenance screen - Set..................................... 3-75
Lubrication chart..................................................... 7-5
Maintenance time caution lamp............................ 3-32
Lunch box tray.................................................... 3-126
Manual greasing switch....................................... 3-111
Manual operation................................................ 3-263
M Manual secondary steering - Check................... 3-165
Machine - Check after stopping engine.............. 3-198 Menu switch.......................................................... 3-49
Machine - Check walk-around............................ 3-150 Message - Check................................................ 3-101
Machine - Dump..................................................3-240 Message - Reply................................................. 3-102
Machine - Lift...................................................... 3-299 Message display......................................... 3-38,3-100
Machine - Loading work......................................3-220 Meter display.........................................................3-43
8-4
INDEX
Meter display selection......................................... 3-85 Pilot display and meter display............................. 3-35
Method for checking before starting....................3-153 Piston pump - Bleed air.........................................4-35
Mirrors - Adjust....................................................3-180 Play in output shaft output coupling - Check.........4-41
Monitor brightness selector switch......................3-109 Power button.......................................................3-269
Monitor settings.....................................................3-78 Power mode display..............................................3-37
Power supply for KOMTRAX Plus...................... 3-149
N Power supply outlet.............................................3-127
Power window switch.......................................... 3-113
No jumping on or off machine............................... 2-16 Precautions after daily work completion in cold
weather........................................................ 3-301
O Precautions before starting inspection and mainte-
nance............................................................. 2-31
Obstacle alarm buzzer deactivate caution lamp. 3-282 Precautions before starting operation................... 2-12
Obstacle warning - Cancel..................................3-291 Precautions before traveling after long-term storage...
Obstacle warning cancel switch.......................... 3-115 .....................................................................3-304
OFF switch..........................................................3-255 Precautions for charging battery......................... 3-315
Oil............................................................................4-5 Precautions for check and maintenance...............2-36
Oil filler cap of steering and hoist oil tank - Open / Precautions for cold weather................................ 2-24
Close............................................................3-248 Precautions for compressed air............................ 2-39
Only authorized personnel.................................... 2-31 Precautions for discharged battery..................... 3-313
Open knob for cab door...................................... 3-125 Precautions for disposing of waste materials........2-40
Operating record - Check......................................3-54 Precautions for getting on or off machine............. 2-16
Operation of ARSC system.................................3-209 Precautions for handling tires............................. 3-251
Operation of KTCS system................................. 3-219 Precautions for high voltage................................. 2-39
Operation of overload speed limit function..............6-5 Precautions for high-pressure fuel........................ 2-38
Operation of speed limit function............................ 6-3 Precautions for high-pressure oil.......................... 2-38
Operation with cold air to face and warm air to feet - Precautions for high-temperature coolant.............2-37
Start............................................................. 3-265 Precautions for high-temperature oil.....................2-37
Operator cab door - Lock.................................... 3-250 Precautions for high-temperature parts................ 2-38
Operator cab door - Open / Close.......................3-250 Precautions for installing, removing, or storing attach-
Operator ID........................................................... 3-97 ments............................................................. 2-34
Operator's cab door - Open................................ 3-250 Precautions for jack-up........................................... 4-4
Operator's seat - Adjust...................................... 3-173 Precautions for jobsite.......................................... 2-20
Other equipment................................................. 3-125 Precautions for lifting machine............................3-297
Other equipment name........................................... 3-8 Precautions for long distance travel....................3-253
Other functions of machine monitor.................... 3-103 Precautions for long-term storage.......................3-303
Other trouble....................................................... 3-319 Precautions for maintenance.......................... 2-31,4-2
Outline of maintenance........................................... 4-5 Precautions for noise............................................ 2-39
Outline of system................................................ 3-221 Precautions for operation................... 2-20,2-26,3-242
Overload speed limit function - Handle................... 6-5 Precautions for refilling oil or fuel............................4-2
Precautions for removing and installing battery.. 3-314
P Precautions for storing tires.................................. 2-41
Precautions for towing and being towed............... 2-30
Parking brake - Release......................................3-311
Precautions for towing machine..........................3-308
Parking brake performance - Check..................... 4-56
Precautions for transportation.....................2-29,3-296
Parking brake pilot lamp....................................... 3-39
Precautions for welding.................................. 2-36,4-2
Parking brake switch........................................... 3-112
Precautions for working at high places................. 2-34
Parking brake system caution lamp...................... 3-29
Precautions for working under machine or work
Payload display...................................................3-223
equipment...................................................... 2-34
Payload meter.......................................................3-67
Precautions related to attachments and options...2-18
Payload meter - Handle...................................... 3-221
Precautions related to protective structure........... 2-18
Payload meter display...........................................3-47
Precautions to prevent fire.................................... 2-14
Payload meter system caution lamp..................... 3-31
Precautions when dumping...................................2-28
People on dump body........................................... 2-16
Precautions when installing hydraulic hoses.......... 4-3
Perform KOWA (Komatsu Oil Wear Analysis)........ 4-8
Precautions when leaving machine...................... 2-17
Periodic replacement of defined life parts.............2-40
Precautions when operating machine...................2-27
Phenomena and actions for engine related parts........
Precautions when parking machine...................... 2-29
.....................................................................3-322
Precautions when running engine inside building.2-19
Pilot display...........................................................3-36
8-5
INDEX
Precautions when standing up from operator's seat.... Retarder oil temperature gauge............................ 3-44
.......................................................................2-17 Retarder pilot lamp................................................3-36
Precautions when starting engine.........................2-24 Retarder system caution lamp.............................. 3-28
Precautions when traveling...................................2-27 Return switch........................................................ 3-49
Precautions when traveling in forward or reverse.2-26 Reverse travel odometer.......................................3-70
Precautions when traveling on slopes.................. 2-27 Revolving lamp switch.........................................3-115
Precautions when using hammer..........................2-37 Right front camera selector switch...................... 3-117
Precautions when using KomVision....................3-274 Right rear camera selector switch.......................3-117
Precautions when working on loose ground......... 2-20 RL/RH setting........................................................3-73
Precautions when working on machine................ 2-34 Room lamp 1 switch............................................3-114
Preparation for long-term storage....................... 3-303 Room lamp 2 switch............................................3-114
Preparations for safe operation.............................2-12
Preset - Call up................................................... 3-271 S
Preset - Register................................................. 3-272
Preset button.......................................................3-270 Safety information................................................... 1-3
Prevent fire............................................................2-14 Safety labels........................................................... 2-2
Product information.................................................1-6 Safety labels - Location...........................................2-3
Provide fire extinguisher and first aid kit............... 2-13 Safety-related equipment......................................2-12
Screen adjustment................................................ 3-88
Screen mode - Switch.........................................3-280
R Screen mode selector switch.............................. 3-115
R.H. meter display - Select................................... 3-87 Seat - Adjust tilt...................................................3-174
Radar check caution lamp.................................. 3-282 Seat - Recline..................................................... 3-174
Radar check switch............................................. 3-117 Seat belt - Adjust.................................................3-184
Radar pilot lamp..................................................3-282 Seat belt - Fasten and unfasten..........................3-184
Radar system caution lamp.................................. 3-32 Seat belt anchor - Adjust.....................................3-186
Radiator fin and oil cooler fin - Clean....................4-25 Seat belt caution lamp.......................................... 3-24
Radio - Control....................................................3-271 Seat belt retractor stopper - Release.................. 3-185
Radio - Handle.................................................... 3-269 Seat cushion - Adjust in fore-after direction........ 3-175
Read this manual.................................................... 1-2 Seat heater and ventilation - Use........................3-178
Rear brake - Bleed air...........................................4-31 Seat height - Adjust.............................................3-175
Rear brake disc - Check wear...............................4-69 Seat unit - Adjust in fore-and-aft direction...........3-173
Rear camera selector switch...............................3-116 Secondary brake pedal....................................... 3-120
Rear suspension cylinder - Check length............. 4-30 Secondary brake performance - Check.............. 3-164
Rear view monitor constant display...................... 3-80 Secondary steering - Check................................3-165
Rear wheel bearing - Check................................. 4-76 Secondary steering motor caution lamp............... 3-26
Rearview camera - Adjust angle......................... 3-182 Secondary steering switch.................................. 3-110
Rearview monitor - Handle................................. 3-292 Secondary steering system caution lamp............. 3-25
Rearview monitor - Perform self check............... 3-293 Secondary steering system pilot lamp.................. 3-38
Rearview monitor - Precautions for using........... 3-294 Select suitable place for inspection and maintenance.
Rearview monitor - Set......................................... 3-78 .......................................................................2-31
Rearview monitor brightness adjustment switch. 3-110 Service center..................................................... 3-142
Recommended ARSC set travel speed.............. 3-213 Service meter location............................................ 1-7
Recommended brands and qualities other than ko- Set travel speed - Adjust fine control.................. 3-211
matsu genuine oils...........................................7-8 Set travel speed - Cancel....................................3-213
Recommended fuel, coolant, and lubricant.............7-4 Set travel speed - Change to high speed............3-212
Reference line.....................................................3-285 Set travel speed - Change to low speed............. 3-212
Reference line display...........................................3-82 Set travel speed - Memorize............................... 3-212
Refilling piping and discharging piping - Valve posi- Set travel speed - Restart................................... 3-213
tions............................................................. 3-143 Shift indicator........................................................ 3-39
Refilling system - Operate...................................3-148 Shift lever position display.................................... 3-39
Refrigerant (gas) - Check level............................. 4-27 Shoulder belt and waist belt - Connect............... 3-185
Remaining time for maintenance - Reset..............3-76 Side lamp switch................................................. 3-113
Replace defined life parts..................................... 4-79 Sound (balance) - Adjust.................................... 3-272
Retarder brake performance - Check................... 4-55 Sound (bass) - Adjust......................................... 3-272
Retarder control lever......................................... 3-123 Sound (treble) - Adjust........................................ 3-272
Retarder control lever cancel sound - Set.............3-74 Sound control button...........................................3-270
Retarder oil temperature caution lamp..................3-23 Specifications..........................................................5-2
8-6
INDEX
Specifications - HD1500-8...................................... 5-2 Transmission and rear brake cooling oil filter element
Speed limit function - Handle.................................. 6-2 - Replace....................................................... 4-65
Speedometer........................................................ 3-43 Transmission case - Change oil / Clean strainer.. 4-64
Staircase lighting switch......................................3-119 Transmission case - Check oil level / Add oil......3-153
Standard tightening torque for bolts and nuts....... 4-10 Transmission case breather - Clean..................... 4-77
Start engine...........................................................2-23 Transmission case filler cap - Lock..................... 3-247
Start engine with jumper cables............................2-25 Transmission case filler cap - Open....................3-247
Start the machine after long-term storage.......... 3-304 Transmission case filler cap - Open / Close........3-247
Starting motor disconnect switch........................ 3-135 Transmission oil filter clogging caution lamp.........3-28
Starting switch.....................................................3-106 Transmission oil filter element - Replace.............. 4-61
Steering A-arm mounting bolt - Check / Replace..4-83 Transmission system caution lamp....................... 3-27
Steering and hoist circuit - Bleed air..................... 4-35 Transportation..................................................... 3-296
Steering and hoist oil filter element - Replace...... 4-72 Transportation method - Select...........................3-296
Steering and hoist oil tank - Change oil................ 4-80 Travel road - Determine / Maintain......................3-295
Steering and hoist oil tank - Check oil level / Add oil... Travel speed - Set............................................... 3-211
.....................................................................3-156 Trip meter..............................................................3-71
Steering and hoist oil tank - Lock oil filler cap.....3-248 Troubles and actions...........................................3-305
Steering and hoist oil tank - Open oil filler cap....3-248 Tuning/time adjustment button............................3-269
Steering and hoist oil tank breather element - Re- Turn battery disconnect switch to off position....... 2-36
place.............................................................. 4-78 Turn signal lever..................................................3-107
Steering cylinder - Bleed air..................................4-37 Turn signal pilot lamp............................................ 3-36
Steering oil pressure caution lamp........................3-25
Steering oil temperature caution lamp.................. 3-25 U
Steering system caution lamp...............................3-24
Steering wheel - Adjust tilt.................................. 3-186 Unauthorized modification.................................... 2-18
Stop engine before performing inspection and main- Under body display - Switch................................. 3-83
tenance.......................................................... 2-31 Understanding the machine.................................. 2-12
Store oil and fuel..................................................... 4-8 Up switch.............................................................. 3-49
Suspension cylinder - Check length......................4-29 Use handrails and steps when getting on or off ma-
Suspension cylinder / Accumulator / Gas spring - chine.............................................................. 2-16
Handle........................................................... 2-39 Use proper tools....................................................2-35
Suspension damper hardness - Adjust............... 3-177 Use warning tags.................................................. 2-23
Switch panel..........................................................3-48 User menu............................................................ 3-51
Switches..............................................................3-104
System caution lamp.............................................3-27 V
System operating lamp....................................... 3-134
Vent selector switch - Select............................... 3-258
Vibration damper - Check..................................... 4-80
T Visibility from operator's seat.................................. 1-5
T.Km.P.H (Ton-Km-Hour-Rating).........................3-251 Volume control button......................................... 3-269
Temperature control switch................................. 3-257
Time - Set..............................................................3-92 W
Timer - Set.......................................................... 3-145
Tire - Handle............................................... 2-41,3-251 Warning display.....................................................3-18
Tire - Select / Check..............................................4-42 Warning when obstacle is detected.................... 3-288
Tire inflation pressure - Check............................ 3-163 Wear well-fitting clothes and protective equipment......
Tire inflation pressure - Check / Inflate................. 4-43 .......................................................................2-12
Tire T.Km.P.H value and continuous max. travel Wheel hub nuts - Check......................................3-153
speed........................................................... 3-252 When operating on snow or frozen ground...........2-28
Tires...................................................................... 2-41 When required...................................................... 4-16
Tires - Select......................................................... 4-42 Window washer fluid - Check level / Add..............4-26
Torque converter lockup pilot lamp....................... 3-38 Window washer fluid - select................................ 2-40
Torque converter oil temperature caution lamp.....3-23 Wiper and window washer switch....................... 3-108
Torque converter oil temperature gauge............... 3-43 Work place - Clean / Tidy......................................2-31
Total payload and number of cycles - Display.....3-232
Towing and being towed....................................... 2-30 Y
Transmission - Act against trouble......................3-306
Your machine serial numbers and distributor..........1-7
8-7
HD1500-8 DUMP TRUCK
Form No. PEN00889-00
©2017 KOMATSU
All Rights Reserved
Printed in Japan 04-2017

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PEN00889-00

DUMP TRUCK HD1500 -8

READ THIS MANUAL

(A) Front (D) Right

VISIBILITY FROM OPERATOR'S SEAT

LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

LOCATION OF ENGINE NUMBER PLATE

SERVICE METER LOCATION

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

METHOD FOR TURNING MACHINE ............................................................................................ 3-218

PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2

LOCATION OF SAFETY LABELS

CONTENTS OF SAFETY LABELS

• If any modification is applied to the ROPS or FOPS, it may MODEL

structurally damaged or involved roll-over. Consult Komat-

Caution when checking engine room

Caution when releasing radiator cap

Caution when opening hydraulic tank cap

Caution for handling suspension

Caution for handling accumulator and gas spring

Caution for hot exhaust pipe

Caution against falling

Caution for handling battery

• Always wear protective eyeglasses when working with bat- ༴

Caution for blast site

Caution for high-pressure fuel

Caution for using seat belt

GENERAL PRECAUTIONS COMMON TO OPERATION

PRECAUTIONS BEFORE STARTING OPERATION

UNDERSTAND THE MACHINE

PREPARATIONS FOR SAFE OPERATION

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

KEEP MACHINE CLEAN

PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

IF ANY PROBLEM IS FOUND

PRECAUTIONS TO PREVENT FIRE

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

• The handrails and steps marked by arrows B are for es-

• Always face the machine and maintain at least three-point

NO JUMPING ON OR OFF MACHINE

PEOPLE ON DUMP BODY

WHEN STANDING UP FROM OPERATOR'S SEAT

PRECAUTIONS WHEN LEAVING MACHINE

EMERGENCY EXIT FROM OPERATOR'S CAB

DO NOT GET CAUGHT IN WORK EQUIPMENT

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

• If the machine is equipped with a protective structure, do

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN WORKING ON LOOSE GROUND

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

ENSURE GOOD VISIBILITY

CHECK SIGNS AND SIGNALMAN'S SIGNALS

BEWARE OF ASBESTOS DUST

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

PRECAUTIONS WHEN STARTING ENGINE

START ENGINE WITH JUMPER CABLES

START ENGINE WITH AUXILIARY ENGINE STARTING CONNECTOR

PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

PRECAUTIONS WHEN TRAVELING ON SLOPES