Page 1 1 - 1...
Page 2 Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
Page 3 FOREWORD FOREWORD 1 - 3...
Page 4 FOREWORD FOREWORD 1 - 4...
Page 5 FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 6 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 7 FOREWORD INTENDED USE INTENDED USE DIRECTIONS OF MACHINE 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 - 7...
Page 8 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the rear left of the cab.
Page 9 FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SERVICE METER POSITION It is at the center bottom of the machine monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel...
Page 10: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS...
Page 11: Foreword
FOREWORD CONTENTS TRAVELING DOWNHILL 3- 92 STEERING THE MACHINE 3-100 OPERATION USING DIFFERENTIAL LOCK 3-100 LOADING OPERATIONS 3-102 DUMP OPERATIONS 3-103 CAB TILT OPERATION 3-105 PRECAUTIONS FOR OPERATION 3-106 PARKING MACHINE 3-107 CHECKS AFTER COMPLETION OF WORK 3-108 LOCKING 3-108 HANDLING TIRES 3-109 DETERMINING AND MAINTAINING TRAVEL ROAD...
Page 12 FOREWORD CONTENTS WHEN REQUIRED 4- 20 CHECK BEFORE STARTING 4- 34 EVERY 50 HOURS SERVICE 4- 35 EVERY 250 HOURS SERVICE 4- 36 EVERY 500 HOURS SERVICE 4- 49 EVERY 1000 HOURS SERVICE 4- 56 EVERY 2000 HOURS SERVICE 4- 63 EVERY 4000 HOURS SERVICE 4- 71 EVERY 6000 HOURS SERVICE...
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Page 14: Safety Information
SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTION 2- 11 SAFETY RULES 2- 11 IF ABNORMALITIES ARE FOUND 2- 11 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11 FIRE EXTINGUISHER AND FIRST AID KIT 2- 11 SAFETY FEATURES 2- 12...
Page 15: Safety
SAFETY SAFETY INFORMATION PRECAUTIONS DURING OPERATION 2- 19 STARTING ENGINE 2- 19 CHECKS BEFORE STARTING ENGINE, ADJUST 2- 19 PRECAUTIONS WHEN STARTING 2- 19 PRECAUTIONS IN COLD AREAS 2- 20 OPERATION 2- 21 CHECKS BEFORE STARTING OPERATION 2- 21 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 21 PRECAUTIONS WHEN TRAVELING 2- 22...
Page 16: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. POSITION FOR ATTACHING SAFETY LABELS...
Page 17: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Roll-over protective structure(ROPS) (09620-30202) (2) Cautions for checking engine room (09667-A0880) (3) Precaution when releasing radiator cap (09653-A0641) 2 - 5...
Page 18 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Precaution when releasing hydraulic tank cap (09653-A0641) (5) Precaution when handling suspension (09659-A0641) (6) Precautions for handling accumulator (09659-A057B) 2 - 6...
Page 19 SAFETY SAFETY LABELS (7) Warnings for electric wire Warnings for crush hazard when inspection and maintenance Warnings for inspection of emergency steering system, brake system Warning for leaving operator's seat, stopping engine Warning for retarder oil temperature (56B-93-12180) (8) Cautions before starting Cautions when traveling in reverse Cautions for operating hoist control lever (569-93-61720)
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (9) Precaution when handling battery cable (09808-A1681) (10) Exhaust pipe is hot! (09817-A1103) (11) Prohibited to enter (09162-C0881) 2 - 8...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Precaution for safety bar (09161-C0881) (13) Precautions for high voltage (7872-10-1600) (14) Precaution when handling battery (This plate is fixed in position by the battery maker) 2 - 9...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (15) Precaution for parking brake (This plate is fixed in position by the chamber maker) (16) Prohibited to jump start (09842-A0481) (This plate is fixed to the starting motor) 2 - 10...
Page 23: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 24: Safety Features
SAFETY GENERAL PRECAUTIONS SAFETY FEATURES Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition. KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation.
Page 25: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the parts marked by arrows in the diagram when getting on or off the machine. A: For getting on or off machine using left door B: For getting on or off machine using right door To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and...
Page 26: Prevention Of Burns
SAFETY GENERAL PRECAUTIONS PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 27: Action If Fire Occurs
SAFETY GENERAL PRECAUTIONS Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers. Fire coming from electric wiring Short circuits in the electrical system can cause fire.
Page 28: Precautions When Using Rops (Roll Over Protective Structure)
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 29: Working On Loose Ground
SAFETY GENERAL PRECAUTIONS WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.
Page 30: Precautions Related To Ventilation Of Exhaust Gas
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 18...
Page 31: Precautions During Operation
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS DURING OPERATION STARTING ENGINE If there is a warning tag hanging from the shift lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE, ADJUST Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 32: Precautions In Cold Areas
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the gearshift lever or dump lever are operated, the reaction of the machine will be slow or may change suddenly, and this may cause an accident.
Page 33: Operation
SAFETY PRECAUTIONS DURING OPERATION OPERATION CHECKS BEFORE STARTING OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of the steering, travel, and brake systems.
Page 34: Precautions When Traveling
The explosion of the tire is very destructive, and it can lead to serious injury or death. Contact with your Komatsu distributor before doing long continuous traveling. PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows.
Page 35: Precautions For Accumulated Snow, Ice
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS FOR ACCUMULATED SNOW, ICE Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 36: Transportation
PRECAUTIONS DURING OPERATION TRANSPORTATION This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. SHIPPING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 37: Battery
SAFETY PRECAUTIONS DURING OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 38: Starting With Booster Cables
SAFETY PRECAUTIONS DURING OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 39: Towing
SAFETY PRECAUTIONS DURING OPERATION TOWING WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-120)". Always wear leather gloves when handling wire rope.
Page 40: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Attach the DO NOT OPERATE warning tag to shift lever in the operator's cab during the inspection and maintenance. Attach additional warning tags around the machine if necessary. Warning tag Part No. 09963-03001 Keep the warning tag in the tool box when it is not used.
Page 41: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the dump body, set dump lever (1) to the HOLD position, lock with safety lock knob (2), then stop the engine.
Page 42: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Lock with articulation lock (4) so that the machine that does not articulate. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running.
Page 43: Proper Tools
Do not make holes in it, weld it, or use a cutting torch. Do not bear any shock by hammering, rolling, etc.. Ask for your Komatsu distributor when sealing gas into the cylinder or releasing gas from it. PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
Page 44: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, and bearings are hit with a hammer, there is danger that small pieces will fly off;...
Page 45: Handling High-Pressure Hoses, Piping
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 46: Periodic Replacement Of Safety-Critical Parts
SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Page 47: Precautions With Tires
To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations. Use only the specified tires and inflate them to the specified pressure.
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Page 50: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Hydraulic tank Turn signal lamp Dump body Head lamp Rear wheel Air cleaner Hoist cylinder Fuel tank Front wheel 3 - 2...
Page 51: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Dump lever Shift lever Lamp switch, Turn signal lever, Dimmer switch Parking brake switch Steering wheel Accelerator pedal Machine monitor (10) Brake pedal Retarder control lever (11) Left and right differential lock pedal Cigarette lighter (12) Safety lock knob...
Page 52 OPERATION GENERAL VIEW Enlargement of Machine monitor Machine monitor mode selector switch 2 Night lighting dimmer switch Machine monitor mode selector switch 1 (10) Hazard lamp switch Fog lamp switch (if equipped) (11) Emergency steering switch Yellow rotating lamp switch (if equipped) (12) Power mode selector switch Side lamp switch (if equipped)
Page 53: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand the methods of operating equipment and meanings of the displays. MACHINE MONITOR Character display Meter display portion...
Page 54 After a 3-second system check, the meter starts to function. The character display shows KOMATSU SYSTEM CHECK for 3 seconds. If the lamps do not work, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection.
Page 55 OPERATION EXPLANATION OF COMPONENTS CHARACTER DISPLAY Service meter Action code display Odometer Filter, oil replacement time display Reverse travel odometer Normally, the service meter/odometer is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action.
Page 56 ( ) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection. ODOMETER This meter (2) indicates the total distance traveled in kilometers.
Page 57 ACTION CODE DISPLAY CAUTION If action code E03 is displayed, stop the machine immediately. Then see "ACTION CODE (PAGE 3-130)" and contact your Komatsu distributor for repairs. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed on this panel (4) to recommend suitable action.
Page 58 If "MAINTENANCE" is displayed together with E01, check the failure code and contact your Komatsu distributor for repairs. REMARK The top line of the character display displays "E01" and the bottom line displays "MAINTENANCE"...
Page 59 OPERATION EXPLANATION OF COMPONENTS Items for display of filter, oil replacement time Replacement Item Character display ID number interval Fuel filter FUEL FILT Engine oil filter ENG FILT Engine oil ENG OIL Corrosion resistor 1000 CORR RES Transmission oil 1000 TM OIL Transmission oil filter 1000...
Page 60 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the monitor lights up during travel, inspect the location of the problem quickly and take the necessary action. Seat belt caution lamp Emergency steering pilot lamp Parking brake pilot lamp Fuel level caution lamp Dump body pilot lamp Maintenance caution lamp SEAT BELT CAUTION LAMP...
Page 61 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE PILOT LAMP This monitor (2) lights up when the parking brake is applied. DUMP BODY PILOT LAMP This monitor (3) lights up when the dump body is raised or the dump body lever is at any position other than "FLOAT". After the engine has been started, the dump body is held in position regardless of the position of the dump lever and this monitor lights up, so turn the lamp off (see Section "CANCELING DUMP BODY...
Page 62 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This monitor (6) lights up if any of the the following are applicable. When it lights up, action code "E01" and the location needing maintenance are displayed on the character display at the same time, so carry out inspection, filling, or replacement.
Page 63 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEM CAUTION If the monitor lights up, stop operations immediately, then check the corresponding area and carry out the action. If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor for the location of the abnormality and the central warning lamp will light up.
Page 64 OPERATION EXPLANATION OF COMPONENTS TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP This monitor (2) warns the operator that the torque converter oil temperature has risen. When it lights up, "E02 TC OVERHEAT" is displayed on the character display at the same time, so stop the machine in a safe place, set the shift lever to the N position, and run the engine under no load at a mid-range speed until the lamp goes out.
Page 65 OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE CAUTION LAMP This monitor (6) lights up to warn the operator that the engine lubricating oil pressure has dropped. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display, and the engine output is automatically limited. Stop the machine immediately at a safe place, then stop the engine and carry out inspection.
Page 66 OPERATION EXPLANATION OF COMPONENTS ENGINE SYSTEM CAUTION LAMP This monitor (10) lights up when an abnormality has been detected in the system controlled by the engine controller. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.
Page 67 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION PILOT DISPLAY PORTION When ignition switch is ON, the pilot display lights up when display items are functioning. Preheating pilot lamp Head lamp high beam pilot lamp Exhaust brake pilot lamp (if equipped) Turn signal pilot lamp Retarder pilot lamp Shift indicator...
Page 68 OPERATION EXPLANATION OF COMPONENTS EXHAUST BRAKE PILOT LAMP (If equipped) This monitor (2) lights up when the exhaust brake is actuated. RETARDER PILOT LAMP This monitor (3) lights up when the retarder control lever is pulled and the retarder is actuated. INTER-AXLE DIFFERENTIAL LOCK PILOT LAMP This monitor (4) lights up when the inter-axle differential lock is actuated.
Page 69 OPERATION EXPLANATION OF COMPONENTS SHIFT HOLD PILOT LAMP This monitor (6) lights up when the shift hold switch is actuated. HEAD LAMP HIGH BEAM PILOT LAMP This monitor (7) lights up when the head lamps are set to high beam. TURN SIGNAL PILOT LAMP This monitor (8) flashes at the same time as the turn signal lamp flashes.
Page 70 OPERATION EXPLANATION OF COMPONENTS SHIFT LEVER POSITION PILOT LAMP This monitor (10) displays the position of the shift lever. The letter or number for the speed range selected by the shift lever lights up. POWER MODE PILOT LAMP This monitor (11) displays the power mode. When the mode is selected with the power mode selector switch, either High Power (P) or Economy (E) lights up.
Page 71 OPERATION EXPLANATION OF COMPONENTS METERS Speedometer Engine water temperature gauge Engine tachometer Torque converter oil temperature gauge Fuel gauge Retarder oil temperature gauge SPEEDOMETER This meter (1) indicates the travel speed of the machine. 3 - 23...
Page 72 OPERATION EXPLANATION OF COMPONENTS ENGINE TACHOMETER This meter (2) shows the engine speed. If the gauge indicator the red range during operations, the alarm buzzer will sound and the central warning lamp will light up at the same time, so reduce the engine speed and the machine travel speed.
Page 73 OPERATION EXPLANATION OF COMPONENTS RETARDER OIL TEMPERATURE GAUGE This meter (6) indicates the retarder oil temperature. It should be in the white range during operation. If it is in the red range during operation, the alarm buzzer will sound and the central warning lamp will light up at the same time. "E02 BRAKE OVERHEAT"...
Page 74: Other Functions Of Machine Monitor
OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF MACHINE MONITOR DISPLAY METHOD FOR REVERSE TRAVEL ODOMETER Use this when checking the total travel distance in reverse. 1. Check that the character display is showing the service meter/odometer, or the action code. If it is giving any other display, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display to be given.
Page 75 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 5. Press the ( ) of machine monitor mode selector switch 1. It will change to the display in the diagram on the right. The top line shows [Reset] and [Item to be reset] in turn. 6.
Page 76 OPERATION EXPLANATION OF COMPONENTS METHOD FOR SELECTING LANGUAGE Use this when switching the language displayed on the character display. 1. Press the ( ) of machine monitor mode selector switch 1 and display the reverse travel odometer. 2. Press (>) or (<) of machine monitor mode selector switch 2 and display "LANGUAGE".
Page 77: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch (13) Left and right differential lock switch Lamp switch (14) Fog lamp switch (if equipped) Turn signal lever (15) Side lamp switch (if equipped) Dimmer switch (16) Working lamp (front) switch Machine monitor bulb check switch (17) Working lamp (rear) switch (if equipped) Exhaust brake switch (if equipped)
Page 78 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position : At this position, the starting switch key can be inserted or removed. When the key is turned to this position, all the electric circuits are switched off and the engine stops.
Page 79 OPERATION EXPLANATION OF COMPONENTS TURN SIGNAL LEVER This switch (2) is used to operate the turn signal lamp. (a) Right turn: Push the lever forward (b) Left turn: Pull the lever back When the lever is operated, the pilot lamp turn signal pilot lamp also flashes.
Page 80 OPERATION EXPLANATION OF COMPONENTS EXHAUST BRAKE SWITCH (If equipped) This switch (4) is used to switch the operating condition of the exhaust brake. (a): When the accelerator pedal is released and the torque converter is in the lock-up condition, the exhaust brake is actuated and the exhaust brake pilot lamp lights up.
Page 81 OPERATION EXPLANATION OF COMPONENTS POWER MODE SELECTOR SWITCH This switch (7) is used to switch the power mode. This makes it possible to travel economically in a way suited to the operating conditions. If portion (a) of the switch is pressed, high-power mode pilot lamp (P) lights up and the system is switched to the high-power mode.
Page 82 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE SWITCH WARNING When parking or leaving the machine, always apply the parking brake. NOTICE During loading operations, do not apply the parking brake. Apply the retarder brake. This switch (10) is used to actuate and release the parking brake valve.
Page 83 OPERATION EXPLANATION OF COMPONENTS INTER-AXLE DIFFERENTIAL LOCK SWITCH This switch (12) can be used to switch the actuating conditions for the inter-axle differential lock. When this switch is pressed, the system is switched to MANUAL. When the switch is not pressed or is pressed to return it, the system is switched to AUTO.
Page 84 OPERATION EXPLANATION OF COMPONENTS FOG LAMP SWITCH (If equipped) This switch (14) is use to switch the fog lamp on and off. (a): Fog lamp goes out (b): Fog lamp lights up When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.
Page 85 OPERATION EXPLANATION OF COMPONENTS YELLOW ROTATING LAMP SWITCH (If equipped) This switch (18) is used to switch the yellow rotating lamp on and off. When the lamp is switched on, it lights up and rotates. (a): Yellow rotating lamp goes out (b): Yellow rotating lamp lights up When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.
Page 86 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER This switch (22) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, then pull it out and use it to light your cigarette.
Page 87 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH The switch (25) is used to turn the room lamp ON and OFF. Position (a): OFF Position (b): Lights up when the door opens Position (c): Lights up REMARK The room lamp lights up even when the main switch is OFF, so when leaving the operator's seat, set the switch to position (a) or (b).
Page 88: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Brake pedal Retarder control lever Accelerator pedal Left and right differential lock pedal Shift lever Safety lock knob Dump lever BRAKE PEDAL This pedal (1) is used to apply the wheel brakes. 3 - 40...
Page 89 OPERATION EXPLANATION OF COMPONENTS ACCELERATOR PEDAL This pedal (2) is used to adjust the engine speed. It can be operated freely between the engine low idle position and the full throttle position. SHIFT LEVER The gear range can be selected with this lever (3) to match the travel conditions.
Page 90 OPERATION EXPLANATION OF COMPONENTS The speed ranges for each position are as follows. Position Speed range Max. speed [km/h (MPH)] 1st torque converter - 5th direct 39.4 (24.5) 1st torque converter - 4th direct 25.8 (16.0) 1st torque converter - 3rd direct 16.9 (10.5) 1st torque converter - 2nd direct 11.0 (6.8)
Page 91 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Activating the shift hold function will restrict the automatic shifting of the transmission to gear speeds below the gearshift lever gear shifting. The shift hold function can be canceled by [1] moving the gearshift lever or [2] activating the shift hold switch located on the gearshift lever.
Page 92 OPERATION EXPLANATION OF COMPONENTS LEFT AND RIGHT DIFFERENTIAL LOCK PEDAL This pedal (6) is used to actuate the left and right differential lock. When the pedal is depressed, the left and right differential lock is actuated according to the position of the left and right differential lock switch.
Page 93: Mechatronics Equipment Controller
OPERATION EXPLANATION OF COMPONENTS MECHATRONICS EQUIPMENT CONTROLLER Transmission controller Retarder controller Engine controller TRANSMISSION CONTROLLER A 2-digit failure code is displayed in the inspection window of this controller (1) to show the location of the abnormality. When the condition is normal, "0.0", "0.L", "0.-", or "0.C" is displayed. ENGINE CONTROLLER A 2-digit failure code is displayed in the inspection window of this controller (2) to show the location of the abnormality.
Page 94: Safety Pin
OPERATION EXPLANATION OF COMPONENTS SAFETY PIN WARNING When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the safety lock knob, then use the safety pin. This is a safety device for the dump body, and is used when carrying out inspection or maintenance with the dump body raised.
Page 95: Dust Indicator
OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This device indicates clogging of the air cleaner. Depending on the degree of clogging of the element, red line (1) appears in the transparent portion. If red line (1) indicates 0.0075 MPa (30 INCHES H O) (0.076 kgf/cm , 1.1 PSI), clean the element immediately.
Page 96 OPERATION EXPLANATION OF COMPONENTS Fuse box II No. Capacity Name of circuit (11) Machine monitor panel (12) Engine controller (13) Rear view monitor (if equipped) (14) Power window (left) (15) Power window (right) Electric mirror (left) (if equipped), (16) Mirror heater (left) (if equipped) Electric mirror (right) (if equipped), (17) Mirror heater (right) (if equipped)
Page 97 If the electrical equipment system is changed, abnormalities may occur in the machine control. Do not make any changes to the electrical system. If you want to make any change to the electrical system, please contact your Komatsu distributor. 3 - 49...
Page 98: Car Radio
OPERATION EXPLANATION OF COMPONENTS CAR RADIO (If equipped) EXPLANATION OF COMPONENTS Power switch/Volume Preset switch Tone control knob Seek Display Band selector switch Clock button/Displaying frequency Tuning switch POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on.
Page 99 OPERATION EXPLANATION OF COMPONENTS TONE CONTROL KNOB If this knob (2) is turned to the right, the high tone is emphasized; if it is turned to the left, the high tone is reduced. DISPLAY This display (3) shows the radio reception frequency and the operating mode.
Page 100 OPERATION EXPLANATION OF COMPONENTS PRESET SWITCH With this switch (6), each button can be set to one station each for FM and MW (AM). (For details of the method of resetting, see "METHOD OF PRESET (PAGE 3-54)".) SEEK When this switch (7) ("SEEK") is pressed, it automatically searches for stations that can be received, and when it receives a station, it stops.
Page 101 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION LISTENING TO RADIO 1. This switches on power (1) for the radio. 2. "BAND" switch (2) is used to select MW (AM) or FM. 3. Use the preset switch or tuning switch (3) to select the station. 4.
Page 102 OPERATION EXPLANATION OF COMPONENTS METHOD OF PRESET 1. Select the desired preset station. Use the "BAND" button to select MW (AM) or FM, and use the "TUNE" button to select the frequency of the broadcasting station. 2. Decide the number of the button to be preset, and keep it pressed for 2 seconds.
Page 103 OPERATION EXPLANATION OF COMPONENTS ADJUSTING TIME 1. Turn the radio power ON. If the display shows the frequency, set the CLOCK button to the time display. 2. To set the time, keep the CLOCK button pressed and Press the button to change the minutes Press the button to change the hours PRECAUTIONS FOR USE...
Page 104: Car Stereo
OPERATION EXPLANATION OF COMPONENTS CAR STEREO (If equipped) EXPLANATION OF COMPONENTS Power switch/volume Cassette door Auto-store/preset scan button Fast forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/radio display selector button (13) Seek tuning buttons...
Page 105 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions.
Page 106 OPERATION EXPLANATION OF COMPONENTS TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized LOUDNESS BUTTON This button (5) is used when playing at low volume.
Page 107 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).
Page 108 OPERATION EXPLANATION OF COMPONENTS METAL TAPE BUTTON (used also for preset button No.5) This button (11) is used when playing a metal or chrome tape. This button is used also for preset button No.5. When it is pressed, "MTL" appears on the display. MANUAL TUNING BUTTONS These buttons (12) are used for manual tuning.
Page 109 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
Page 110 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set band selector button (2) to AM or FM. 3. Select the station with the preset buttons or manual tuning button (3).
Page 111 OPERATION EXPLANATION OF COMPONENTS REVERSING TAPE When listening to the tape, press both FAST FORWARD, REWIND buttons (A) and (B) at the same time lightly. When this is done, the tape direction display will be reversed. PRECAUTIONS FOR USE Stow the antenna when traveling in places with low overhead clearance. To ensure safety during operations, keep the volume at a level where it is possible to hear other machines.
Page 112: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER (If equipped) By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS ON CONTROL PANEL Fan switch External/Internal air changeover switch...
Page 113 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 114 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) steplessly from low temperature to high temperature. The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the green lamps light up, the lower the temperature is.
Page 115 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION Switch External/Internal Air conditioner Temperature Mode selector Fan switch air changeover switch control switch switch switch Condition of use Rapid All green RECIRC FACE Cooling More than half Normal HI - LO FRESH FACE are green Dehumidifying,...
Page 116 4-26)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-26)". To enable the air conditioner to perform to the full and to maintain a pleasant working environment, always contact your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks. 3 - 68...
Page 117: Operation
Leakage of oil or fuel, or accumulation of flammable material around the battery or high temperature parts of the engine, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Always carry out the following items before starting the engine each day.
Page 118 OPERATION OPERATION 8. Check for damage to gauges, lamps on instrument panel and loose bolts. Check for damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any dirt on the surface. Tighten any loose bolts. 9.
Page 119 OPERATION OPERATION CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 120 OPERATION OPERATION CHECK DUST INDICATOR 1. Check that the red line in the transparent portion of dust indicator (1) does not indicate 0.0075 MPa (30 INCHES H (0.076 kgf/cm , 1.1 PSI). 2. If the red line indicates 0.0075 MPa (30 INCHES H O) (0.076 kgf/cm , 1.1 PSI), clean or replace the air cleaner element...
Page 121 OPERATION OPERATION REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine. The dipstick has the oil level marked on both sides: ENGINE STOPPED for measuring when the engine is stopped, and ENGINE IDLING for measuring when the engine is idling.
Page 122 OPERATION OPERATION DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve (1) at the bottom of the fuel tank, and drain the water and sediment collected at the bottom of the tank together with the fuel. CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow.
Page 123 Komatsu distributor for inspection. CHECK BRAKING EFFECT Check that the parking brake, foot brake, and retarder brake work properly. If there is any abnormality, please contact your Komatsu distributor for repair. CHECK EMERGENCY STEERING 1. Turn ignition switch key to the ON position.
Page 124 Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of any abnormalities found. CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Page 125 OPERATION OPERATION ADJUSTMENT BEFORE OPERATION ADJUSTING OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat before starting operations or when changing operators. Adjust the position of the operator's seat so that you can depress the brake pedal fully with your back against the seat backrest. (A) Fore-and-aft adjustment Move lever (1) up, move the seat to the desired position, then release the lever.
Page 126 OPERATION OPERATION (E) Seat height adjustment Move lever (2) up or down to move the seat up or down as desired. Lever (2) is also used for adjusting the seat angle, so set the seat to the desired height while adjusting the angle. Adjustment range: 60 mm (2.4 in) (F) Adjusting headrest height Move the headrest up or down to the desired height.
Page 127 OPERATION OPERATION ADJUST STEERING WHEEL TILT WARNING Always stop the machine before adjusting the tilt of the steering wheel. The tilt of the steering wheel can be adjusted to the front and rear, and up and down. Pull lever up and set the steering wheel to the desired position, then push lever down to lock the steering wheel securely in position.
Page 128 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING WARNING When starting the engine, check that the shift lever is set in the N (neutral) position and that the parking brake switch is at PARKING position. Before standing up from the operator's seat, place the shift lever at N (neutral) position, and set the parking brake switch to the PARKING position.
Page 129: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING 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 serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 130 OPERATION OPERATION STARTING IN COLD WEATHER WARNING 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. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 131 OPERATION OPERATION OPERATION OPERATION 5. When the engine starts, release the key in starting switch (1). The key will return automatically to the ON position. REMARK If the engine does not start, turn the key in starting switch (1) to the OFF position, then turn it back to the ON position.
Page 132: Operations, Checks After Starting Engine
BREAKING-IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 133: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is suddenly stopped without allowing it to cool down, there is danger that the life of the engine parts will be shortened, so never stop the engine suddenly except in emergency. Allow the engine to cool down gradually before stopping it. After the engine is stopped, the dump body is held at the same position, regardless of the position of the dump lever.
Page 134: Moving Machine Off (Forward, Reverse), Stopping
OPERATION OPERATION MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING MOVING MACHINE FORWARD WARNING When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people to get near the machine. Clear the machine's travel path of any obstacle.
Page 135 OPERATION OPERATION OPERATION OPERATION 5. Check that retarder pilot lamp (3) is not lighted up, then set shift lever (4) to the desired position. NOTICE When operating the shift lever, be sure to set it in position securely. If the lever is not placed in position properly, the shift position display on the panel may go out and the transmission warning monitor lamp may light up.
Page 136 OPERATION OPERATION MOVING MACHINE REVERSE WARNING When switching between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so use extreme caution when reversing the machine. Always stop the machine completely before shifting between FORWARD and REVERSE.
Page 137 Immediately after making an emergency stop, the parking brake disc will be at high temperature, so wait for it to cool down before carrying out repair or adjustment. Ask your Komatsu distributor for repair and adjustment. 1. Pull retarder control lever (1) fully to apply the retarder.
Page 138 3. If an emergency stop has been made, put blocks under the tires immediately, then try to find the cause, and repair it on site. If the parking brake has been used to make an emergency stop, it is necessary to re-adjust the parking brake. Contact your Komatsu distributor for adjustment. 3 - 90...
Page 139: Shifting Gear
OPERATION OPERATION SHIFTING GEAR When shifting gear, do as follows. This machine has an automatic transmission, so set shift lever (1) to the desired position, and the transmission will automatically shift to a position to match the travel speed. When the dump body is raised, if the shift lever is at the D position, the transmission is fixed in 2nd, and if it is at positions 1 - 5, the transmission is fixed in 1st.
Page 140: Traveling Downhill
2. If the retarder still has no effect even when the retarder control lever is operated again, return the retarder control lever completely to the released position, then depress the brake pedal to stop the machine, and contact your Komatsu distributor for repairs.
Page 141 OPERATION OPERATION OPERATION OPERATION 1. Before starting to travel downhill, release accelerator pedal (1) and operate retarder control lever (2) to slow the machine down. 2. Move the shift lever to a position (5, 4, 3, 2) that matches the maximum permissible speed retarder brake...
Page 142 OPERATION OPERATION BRAKE PERFORMANCE CURVE Method of using graph Example: Machine equipped with exhaust brake Downhill distance: 1500 m (4921 ft) Travel resistance: -11% [grade resistance: -13%, rolling resistance: 2%] Load: 36 tons Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
Page 143 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1476 ft)] Brake performance [Downhill distance: 450 m (1476 ft)] (with exhaust brake) 3 - 95...
Page 144 OPERATION OPERATION Brake performance [Downhill distance: 600 m (1968 ft)] Brake performance [Downhill distance: 600 m (1968 ft)] (with exhaust brake) 3 - 96...
Page 145 OPERATION OPERATION Brake performance [Downhill distance: 900 m (2952 ft)] Brake performance [Downhill distance: 900 m (2952 ft)] (with exhaust brake) 3 - 97...
Page 146 OPERATION OPERATION Brake performance [Downhill distance: 1500 m (4921 ft)] Brake performance [Downhill distance: 1500 m (4921 ft)] (with exhaust brake) 3 - 98...
Page 147 OPERATION OPERATION Brake performance [Downhill distance: Continuous] Brake performance [Downhill distance: Continuous] (with exhaust brake) 3 - 99...
Page 148: Steering The Machine
OPERATION OPERATION STEERING THE MACHINE WARNING If the machine is turned at high speed or on a steep slope, there is danger that it will turn over, so do not operate the steering in such conditions. CAUTION Do not continue to turn the steering wheel when it has been turned fully to the left or right.
Page 149 OPERATION OPERATION COMBINATION OF DIFFERENTIAL LOCK (A): Manual actuation of inter-axle lock Use this when operating on soft ground or in places where the tires may slip. Cancel the differential lock when operating on harder ground. REMARK If the tires slip or there is a difference in the rotating speed of the tires when the inter-axle differential lock switch is at AUTO, the inter-axle differential lock is automatically actuated to set to condition (A).
Page 150: Loading Operations
OPERATION OPERATION (C): Manual actuation of inter-axle differential lock, and actuation of front, center, rear axle left and right differential lock Use this when the maximum rim pull is needed. REMARK If the tires slip or there is a difference in the rotating speed of the tires when the inter-axle differential lock switch is at AUTO, the inter-axle differential lock is automatically actuated to set to condition (C).
Page 151: Dump Operations
OPERATION OPERATION DUMP OPERATIONS WARNING When dumping a load, always carry out the dumping operation in accordance with the signals from the flagman. When dumping large rocks, operate the dump body slowly. Do not load the dump body while it is still raised. When carrying out inspection with the dump body raised, always use the safety pins, and set the dump lever to the HOLD position.
Page 152 OPERATION OPERATION OPERATION OPERATION 4. When dump lever (3) is moved to the LOWER position, the dump body will start to move down. 5. When the dump body has moved down a certain distance, move dump lever (3) to the FLOAT position. (When the lever is released, it will return to the FLOAT position.) The dump body will then move down under its own weight.
Page 153: Cab Tilt Operation
OPERATION OPERATION CAB TILT OPERATION CAUTION Carry out the tilt operation on flat ground. When the cab is tilted up, hold it in position securely in with the lock bar. When lowering the cab using the tilt cylinder, do not lower the oil pressure suddenly. Adjust the lowering speed to lower the cab.
Page 154: Precautions For Operation
OPERATION OPERATION WHEN USING TILT CYLINDER 1. Remove pin (1) in the mount at the rear of the cab, and insert it in hole (3). 2. Apply hydraulic pressure 20.6 to 34.3 MPa (210 to 350 kgf/cm , 2980 to 4970 PSI) to hose (4) behind the front right wheel and raise the cab.
Page 155: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Park the machine on firm, horizontal ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, put blocks under the tires to prevent the machine from moving.
Page 156: Checks After Completion Of Work
OPERATION OPERATION OPERATION OPERATION 3. When in the operator's compartment, pull retarder control lever (5) fully to apply the retarder. NOTICE The retarder must not be used as a parking brake. Do not use the retarder for long-term parking, regardless of the engine speed.
Page 157: Handling Tires
Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use. Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. PRECAUTIONS FOR LONG DISTANCE TRAVEL If the machine travels continuously at high speed for a long distance, there will be a marked increase in the generation of heat in the tire.
Page 158: Determining And Maintaining Travel Road
OPERATION DETERMINING AND MAINTAINING TRAVEL ROAD DETERMINING AND MAINTAINING TRAVEL ROAD Determining and traveling the road in the jobsite is an extremely important factor both for reasons of safety and for reducing the cycle time.To ensure safety in operations, do as follows. DETERMINING TRAVEL ROAD As far as possible, restrict the travel road to one-way travel.
Page 159: Transportation
TRANSPORTATION TRANSPORTATION PRECAUTIONS WHEN TRANSPORTING WARNING This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. STEPS FOR TRANSPORTATION As a basic rule, always transport the machine on a trailer. When selecting the trailer, see the weights and dimensions given in Section SPECIFICATIONS (PAGE 5-2).
Page 160: Method Of Lifting Machine
CAUTION When the machine is raised, check that there is no oil leakage from the hydraulic circuits. When carrying out the lifting operation, please contact your Komatsu distributor. For details of the weight, see "SPECIFICATIONS (PAGE 5-2)". 3 - 112...
Page 161 Center wheel Rear wheel Center of gravity weight load load load (from front axle) 30,350 kg 16,810 kg 6,770 kg 6,770 kg 2,380 mm HM400-1 (66,922 lb) (37,066 lb) (14,928 lb) (14,928 lb) (7 ft 10 in) 3 - 113...
Page 162 OPERATION TRANSPORTATION LIFTING PROCEDURE Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the machine in a horizontal place and do as follows. 1. Start the engine, set the machine facing directly to the front, place the dump lever at the FLOAT position, and check that the dump body pilot lamp goes out.
Page 163: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 164: Precautions After Completion Of Work
OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 165: After Cold Weather
OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER When season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".
Page 166: Long-Term Storage
AFTER STORAGE NOTICE If the machine has been stored without the monthly rust prevention operation, consult your Komatsu distributor for service. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods.
Page 167: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting. PROCEDURE FOR BLEEDING AIR CAUTION This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will cause problems.
Page 168: Towing The Machine
Do not tow the machine for long distances. If the machine has to be towed, please consult your Komatsu distributor. This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
Page 169 If the pressure in the hydraulic circuit has dropped abnormally because of leakage of oil, the parking brake will be applied automatically. If it is necessary to release the parking brake in order to tow the machine, please ask your Komatsu distributor to carry out the operation.
Page 170: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 171 OPERATION TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow the instructions in "IF BATTERY IS DISCHARGED (PAGE 3-122)" and the instruction manual accompanying the charger, and do as follows.
Page 172 OPERATION TROUBLESHOOTING NOTICE The size of the booster cable and clip should be suitable for the battery size. The battery of the normal machine must be the same capacity as that of the problem machine. Check the cables and clips for damage or corrosion. Make sure that the cables and clips are firmly connected.
Page 173: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even...
Page 174 OPERATION TROUBLESHOOTING CHASSIS ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Torque converter oil temperature Leakage of oil or entry of air due...
Page 175 After using the accelerator pedal to move the machine to a safe place, check the service code and contact your Komatsu distributor. There are two methods when operating the accelerator pedal: either release the pedal (check switch is OFF, low idling), or depress the pedal fully (1500 rpm).
Page 176 OPERATION TROUBLESHOOTING ENGINE ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights Insufficient oil in oil pan Add oil to specified level.
Page 177 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Excessive oil consumption Oil leakage ( Check, repair) Excessive oil in oil pan Add oil to specified level. See CHECK BEFORE STARTING Worn piston, ring, cylinder liner ( Replace) Exhaust gas is white or bluish Improper fuel Replace with specified fuel Defective turbocharger...
Page 178 If more than one failure has occurred, the next failure code is displayed. 3. Check the failure code, then contact your Komatsu distributor for repairs. REMARK The 6-digit code displayed on the left of the line at the top of the character display is the failure code.
Page 179 4 - 1...
Page 180: Maintenance
KOMATSU GENUINE REPLACEMENT PARTS: Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 181 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently.
Page 182: Outline Of Service
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original antifreeze in the coolant when the machine is shipped. This antifreeze is effective in preventing corrosion of the cooling system.
Page 183 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. CARRYING OUT 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.
Page 184: Outline Of Electric System
Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor. When working at the seashore, carefully clean the electric system to prevent corrosion.
Page 185: Wear Parts
The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.
Page 186: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE *1: Use only diesel fuel. *2: Use the oil in the table below. Maker Brand SHELL DONAX TD MOBIL MOBILFLUID 424 NOTICE Use only diesel fuel.
Page 187 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 188 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
Page 189 MAINTENANCE MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40...
Page 190: Standard Tightening Torques For Bolts And Nuts
The tightening torque is determined by the width across the flats (b) of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 191 MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS Face seal Width Tightening torque Nominal - across No. of Target value Permissible range flats (b) threads (a) · · · · lbft lbft (mm) m kgf 9/16 -18UNF 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0 11/16 -16UN...
Page 192: Periodic Replacement Of Safety Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 193: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Change oil in engine oil pan, replace engine oil filter cartridge 4- 49 Replace fuel filter cartridge 4- 50 Replace transmission filter element (valve side, brake cooling side) 4- 57 Change oil in transmission case 4- 58...
Page 194 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE Change oil in engine oil pan, replace engine oil filter cartridge 4- 49 Replace fuel filter cartridge 4- 50 Clean fuel tank strainer 4- 51 Lubrication 4- 52 Check oil level in final drive case, add oil 4- 52 Check oil level in differential case, add oil 4- 53...
Page 195 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 8000 HOURS SERVICE Replace injector nozzle tip (all areas except EPA exhaust gas regulation areas) 4- 73 Replace high-pressure piping clamp 4- 73 Replace fuel spray prevention cap 4- 73 4 - 17...
Page 196: Adjust Injector
When transporting a machine from an A regulation area to a B regulation area, always replace all the injector assemblies before transporting the machine to the new area. Check with your Komatsu distributor to confirm if your area of operation is an A regulation area or a B regulation area. A REGULATION AREA...
Page 197: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance only after the first 250 hours. Change oil in engine oil pan, replace engine oil filter cartridge Replace fuel filter cartridge Replace transmission filter element (valve side, brake cooling side) Change oil in transmission case Change oil in brake oil tank, replace brake oil filter element...
Page 198: When Required
MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN OR REPLACE AIR CLEANER WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 199 MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT 1. Release lock (2) of cover (3), then remove the cover. 2. Remove outer element (5). 3. Clean the air cleaner body interior and the cover. 4. Direct dry compressed air (less then 0.69 MPa (7 kgf/cm , 99.4 PSI)) along the folds of the element from the inside.
Page 200 MAINTENANCE SERVICE PROCEDURE REPLACING INNER ELEMENT 1. First remove the cover and the outer element, and then remove the inner element. 2. Cover the air connector side (outlet side) with a clean cloth or tape. 3. Clean the air cleaner body interior, then remove the cover installed in Step 2. 4.
Page 201: Clean Inside Of Cooling System
MAINTENANCE SERVICE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING Immediately after the engine is stopped, the engine coolant is hot and the pressure inside the radiator is high. Removing the cap and draining the water under this condition could cause burns. Allow the engine to cool down, then turn the cap slowly to release the pressure.
Page 202 Komatsu genuine "Super Coolant" is recommended for anti-freeze. Use city water for the coolant. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 203: Check Level Of Window Washer Fluid, Add Fluid
MAINTENANCE SERVICE PROCEDURE 12. To remove the air contained in the coolant, run the engine at low idle for 5 minutes, then run for a another 5 minutes at high idle. (When doing this, leave the water filler cap OFF.) 13.
Page 204: Clean Air Conditioner Air Filter
REMARK Run the engine at idling, and if bubbles appear in the sight glass when the air conditioner is set to cooling, the refrigerant level is low, so please contact your Komatsu distributor to have it refilled. 4 - 26...
Page 205: Check Dump Body
Contact your Komatsu distributor for details of the repair procedure. CHECK ELECTRIC INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater checked for dirt or disconnections.
Page 206: Bleed Air From Front Brake
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM FRONT BRAKE WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air. 1.
Page 207: Bleed Air From Center Brake
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM CENTER BRAKE WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air. 1.
Page 208: Bleed Air From Rear Brake
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM REAR BRAKE WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air. 1.
Page 209: Check Play Of Output Coupling Of Output Shaft
If the result of the measurement shows that it is greater than the standard value, please contact your Komatsu distributor for disassembly and inspection. 4 - 31...
Page 210: Selection And Inspection Of Tires
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the following table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
Page 211 MAINTENANCE SERVICE PROCEDURE Check Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work. Inflation of tires Adjust the inflation pressure properly. When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not work in front of the rim but work on the tread side of the tire.
Page 212: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For the following items, see "CHECK BEFORE STARTING (PAGE 3-71)". Check coolant level, add coolant Check dust indicator Check oil level in engine oil pan, add oil Check oil level in transmission case, add oil Check oil level in hydraulic tank, add oil Drain water, sediment from fuel tank Check fuel level, add fuel...
Page 213: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE LUBRICATION 1. Stop the engine. 2. Use the grease pump to pump in grease through the grease fitting marked by the arrow. 3. Check visually that the greasing has been carried out properly. 4.
Page 214: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATION 1. Stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 215 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (4) Body hinge pin (2 places) (5) Hitch bearing (1 place) LUBRICATE DRIVE SHAFT When using lithium-based grease, or after changing to lithium-based grease, carry out greasing every 250 hours. Special drive shaft grease is used when the machine is shipped from the factory, so it is unnecessary to carry out greasing for the first 6000 hours or 2 years.
Page 216: Check Drive Shaft
SERVICE PROCEDURE CHECK DRIVE SHAFT If there is any abnormality, such as looseness of the drive shaft connection, play in the spline or bearing portion, or runout of the shaft, please contact your Komatsu distributor for repair. 4 - 38...
Page 217: Clean Breather
MAINTENANCE SERVICE PROCEDURE CLEAN BREATHERS WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation. Remove the mud and dirt from around the breather, then remove the breather, and use clean diesel oil or flushing oil to rinse off the dirt stuck to the filter inside the breather.
Page 218 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Differential case breather (rear) Brake drain breather (rear) 4 - 40...
Page 219: Clean Brake Drain Tube
MAINTENANCE SERVICE PROCEDURE CLEAN BRAKE DRAIN TUBE WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. A brake drain tube is installed to each wheel. Clean the tubes of all the wheels. 1.
Page 220: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 42...
Page 221 If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 222: Check Alternator Belt Tension, Adjust
V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
Page 223: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING The belt should normally deflect by 10 mm (0.4 in) when pressed with the thumb (with a force of approx. 58.8 N (6 kgf)) at a point midway between the air compressor pulley and drive pulley. ADJUSTING 1.
Page 224: Check Frame, A-Arm
2. Check all parts of the frame and A-frame for damage. In particular, check the hatched portions in the diagram, and if any cracks or damage are found, repair the damage. Please contact your Komatsu distributor for details of the repair procedure. 4 - 46...
Page 225: Check Braking Capacity Of Foot Brake
1510 rpm, it is normal. 3. Lower the engine speed, set shifting lever at N position, and then set parking brake at PARKING position. If any abnormality is found, ask your Komatsu distributor for repair. NOTICE There is danger of damage inside the transmission, so always do this with the shift lever at the "D" position. Do not use any other position.
Page 226: Check Braking Capacity Of Parking Brake
1400 rpm, it is normal. 3. Lower the engine speed, set shift lever at N position. If any abnormality is found, ask your Komatsu distributor for repair. NOTICE There is danger of damage inside the transmission, so always do this with the shift lever at the "D" position. Do not use any other position.
Page 227: Every 500 Hours Service
3. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 4. Tighten drain valve (2) and drain plug (1).
Page 228: Replace Fuel Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 229: Clean Fuel Tank Strainer
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 9. Loosen the knob of priming pump (3), then pump the knob and check that fuel comes out from air bleed plug (2). 10. Tighten air bleed plug (2). Tightening torque: 7.8 to 9.8 N·m (0.8 to 1 kgf·m, 5.9 to 7.2 lbft) 11.
Page 230: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. Carry out the greasing operation every day when operating in places where the grease flows out easily, such as when traveling through mud or water.
Page 231: Check Oil Level In Differential Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. When removing plug, oil may spout out.
Page 232: Clean, Check Radiator Fins And After Cooler Fins
MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. If the radiator fins become clogged or bent, this may cause overheating of the engine, so always clean or carry out inspection and take the necessary actions.
Page 233: Check Fan Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK FAN BELT TENSION, ADJUST TESTING The deflection should be approx. 17 to 19 mm (0.67 to 0.75 in) when a point midway between the fan pulley and tension pulley is pressed with the thumb with a force of 98 N (10 kgf). ADJUSTING 1.
Page 234: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 250 and 500 hours should be carried out at the same time. REPLACE CORROSION RESISTOR CARTRIDGE WARNING All the engine parts are at high temperature after the engine has been operated, so never replace the cartridge immediately after finishing operations.
Page 235: Replace Transmission Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. VALVE SIDE Prepare a filter wrench 1.
Page 236: Change Oil In Transmission Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. Refill capacity: 115 liters (30.38 US gal) (including brake oil tank) To drain all the oil, carry out the procedure for Item "CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT (PAGE 4-60)"...
Page 237 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Remove the cap installed to bleeder screw (1), then insert a vinyl hose. Prepare a container with oil in it and insert the other end of the hose approx. 50 mm (2.0 in) below the surface of the oil.
Page 238: Change Oil In Brake Oil Tank, Replace Brake Oil Filter Element
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 239 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 6. Refill the specified quantity of engine oil through oil filler (F). 7. After adding oil, check that the oil is at the specified level. See "CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL (PAGE 3-73)".
Page 240 There are marks on the rod at three places (A, B, C), but on this machine, use the mark at position A. CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 4 - 62...
Page 241: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 242: Change Oil In Differential Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DIFFERENTIAL CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 243: Replace Hydraulic Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 244: Clean Hydraulic Tank Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 245: Clean Transmission Case Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN TRANSMISSION CASE STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 246 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Line strainer for center, rear differential lock This is on the left side at the front of the rear frame. Suction strainer for center differential lock This is at the rear of the center differential case. Suction strainer for rear differential lock This is on the left side of the rear differential case.
Page 247: Clean Breather
MAINTENANCE SERVICE PROCEDURE CLEAN BREATHER WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation. Remove the mud and dirt from around the breather, then remove the breather, and use clean diesel oil or flushing oil to rinse off the dirt stuck to the filter inside the breather.
Page 248: Check Alternator, Starting Motor
CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 249: Every 4000 Hours Service
CHECK AIR COMPRESSOR Ask your Komatsu distributor to carry out this work. CHECK FAN PULLEY AND TENSION PULLEY Check for play of the pulley and leakage of grease. If any abnormality is found, please contact your Komatsu distributor. CHECK VIBRATION DAMPER There is the possibility of drop in the level of the damper fluid and runout of the concave surface.
Page 250: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber
Check clamps (1) to (15) for loose bolts and hardening of the rubber parts. If there are any loose bolts or hardened rubber, please contact your Komatsu distributor for replacement. CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER Check for any missing fuel spray prevention caps (1) to (11) or fuel spray prevention cover (12), and check also for any hardened rubber portions.
Page 251: Every 6000 Hours Service
REPLACE INJECTOR NOZZLE TIP See Section "B REGULATION AREA (PAGE 4-18)". REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to carry out this work. REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to carry out this work. 4 - 73...
Page 253 5 - 1...
Page 254: Specifications
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Item Unit HM400-1 Overall weight kg (lb) 67425 (148672) (unladen weight + max. payload + 1 operator (75kg (165 lb))) Unladen weight kg (lb) 30350 (66922) Max. payload kg (lb) 37000 (81585) Struck (cu.yd) 16.5 (21.6) Dump body capacity Heaped (2 : 1) (cu.yd)
Page 255: Index
INDEX INDEX <A> <I> AIR CONDITIONER 3- 64 INTENDED USE ARTICULATE LOCK 3- 46 DIRECTIONS OF MACHINE <C> <L> CAB TILT OPERATION 3-105 LOADING OPERATIONS 3-102 CAR RADIO 3- 50 LOCATION OF PLATES, TABLE TO CAR STEREO 3- 56 ENTER SERIAL NO. AND CHECK BEFORE STARTING ENGINE 3- 69 DISTRIBUTOR...
Page 256 INDEX <P> PRECAUTIONS WHEN PARKING MACHINE 3-107 TRANSPORTING 3-111 PERIODIC REPLACEMENT OF SAFETY STEPS FOR TRANSPORTATION 3-111 CRITICAL PARTS 4- 14 TRAVELING DOWNHILL 3- 92 PRECAUTIONS DURING OPERATION 2- 19 TROUBLESHOOTING 3-119 BATTERY 2- 25 AFTER RUNNING OUT OF FUEL 3-119 OPERATION 2- 21...

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