PEN00635-23

ARTICULATED HM400 -3R

DUMP TRUCK SERIAL NUMBERS 8001 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.
1 FOREWORD

FOREWORD

1-1
BEFORE READING THIS MANUAL FOREWORD

BEFORE READING THIS MANUAL (HM-0110-010-A-00-A)

This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
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
precautions.
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. Improper operation and maintenance
of the machine can be hazardous and could result in 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 loca-

tion shown on the right so that all relevant personnel can read it at
any time.
Storage location for the Operation and Maintenance Manual:
On inside of left door

If this manual is lost or damaged, contact and tell your distributor about the machine model name and the serial
No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to ar-
range the proper Operation and Maintenance Manual, you will need to provide the machine model name and the
serial No. to your Komatsu distributor.
This manual uses the international 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 addi-
tional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
• The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: ① as (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 speci-
fications 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 Komatsu or your Komatsu distributor before
operating the machine.

Some of Komatsu machines have the software based on the Open Source Software (OSS).
By the license of the OSS, Komatsu publishes the license information of the software to be used in the website
that follows.
[Link]

1-2
FOREWORD SAFETY INFORMATION

SAFETY INFORMATION (ALL-1110-010-A-00-A)

To enable you to use the machine safely, and to prevent injury or death to operators, service personnel or bystand-
ers, the precautions and warnings included in this manual and the safety signs attached to the machine must al-
ways 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 message.

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 exists which, if not avoided,
may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.

This precaution is given where the machine may be damaged or the service life reduced
if the precaution is not followed.
This word is used for information that is useful to know.

1-3
INTRODUCTION FOREWORD

INTRODUCTION (PC-0000-001-K-00-A)

USE OF MACHINE (HM-0000-04H-K-00-A)

This Komatsu machine is designed to be used mainly for the following work.
• Traveling with a load

DIRECTIONS OF MACHINE (HM-0000-04B-K-00-A)

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.
(A) FRONT (D) RIGHT
(B) REAR (E) OPERATOR'S SEAT
(C) LEFT

1-4
FOREWORD INTRODUCTION

VISIBILITY FROM OPERATOR’S SEAT (HM400-0000-031-K-02-A)

The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.

PROXIMITY VISIBILITY (HM400-0000-031-K-00-A)

The operator's visibility on a rectangular 1 m {3 ft 3 in} (2.5m {8 ft 2 in} forward)/ 1.5 {4 ft 11 in} m height boundary
close around the machine and on a 12 m {39 ft 4 in} radius visibility test circle is shown in the diagram below. The
hatched areas (A) show the areas where the view is blocked by a part of the machine when mirrors or other aids
for visibility are installed as standard. Please be fully aware that there are places that cannot be seen when operat-
ing the machine.

12 m CIRCUMFERENCE VISIBILITY
visibility
The figure at a shows
below radius of 12 m {39from
a visibility ft 4 the
in} from the machine
machine is as shownofin12
for a circumference themdiagram below.
{39 ft 4 in}. The hatched
Shaded area (B) areas
in the
(B) show
figure showsthe an
areas
areawhere
whose theview
viewis isblocked
blockedwhenwhenthemirrors or other
machine aids to with
is equipped visibility are installed
the mirrors as standard.
and other visibility
Please bedevices.
assistant fully aware that there
Operate are places
the machine, that
fully cannot
aware thatbe seen
the when has
machine operating thethat
a portion machine.
an operator cannot see.

When the machine is equipped with the rearview camera and monitor, it conforms to visibility standard (ISO 5006).
Please install as necessary.
This machine maintains a close visibility of a height of 1.5 {4 ft 11 in} m at a point 1 {3 ft 3 in} m away from the out-
side face of the machine (2.5 {8 ft 2 in} m from the front face), and a visibility for a circumference of 12 m {39 ft 4 in}.

1-5
PRODUCT INFORMATION FOREWORD

PRODUCT INFORMATION (ALL-0000-20E-K-00-A)

When requesting service or ordering replacement parts, contact your Komatsu distributor of the following items.

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO.

PLATE (HM400-0000-20R-K-00-A)
This is at the rear left of the cab.
The design of the nameplate differs according to the territory.

ENGINE NUMBER PLATE (HM400-0000-20S-K-02-A)

It is on the left side of the engine cylinder block.

1-6
FOREWORD PRODUCT INFORMATION

SERVICE METER LOCATION (HM400-0000-20T-K-00-A)

In the initial state, this is in the left bottom of the machine monitor.
If it is not displayed, display it. For details, see "METER DISPLAY
SELECTION（PAGE 3-66）".

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR (ALL-0000-20E-K-01-A)

Machine serial No.

Engine serial No.

Product identification
number (PIN)

Distributor name
Address
Phone/Fax
Service personnel

1-7
CONTENTS FOREWORD

CONTENTS (PC-0310-001-A-00-A)

FOREWORD .............................................................................................................................................1-1
BEFORE READING THIS MANUAL .....................................................................................................1-2
SAFETY INFORMATION .....................................................................................................................1-3
INTRODUCTION.................................................................................................................................1-4
USE OF MACHINE .......................................................................................................................1-4
DIRECTIONS OF MACHINE .........................................................................................................1-4
VISIBILITY FROM OPERATOR’S SEAT.........................................................................................1-5
PROXIMITY VISIBILITY................................................................................................................1-5
12 m CIRCUMFERENCE VISIBILITY.............................................................................................1-5
PRODUCT INFORMATION..................................................................................................................1-6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE .................................1-6
ENGINE NUMBER PLATE ............................................................................................................1-6
SERVICE METER LOCATION.......................................................................................................1-7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ............................................................1-7
CONTENTS........................................................................................................................................1-8
SAFETY....................................................................................................................................................2-1
SAFETY .............................................................................................................................................2-2
SAFETY LABELS................................................................................................................................2-4
LOCATION OF SAFETY LABELS ..................................................................................................2-5
SAFETY LABELS .........................................................................................................................2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION ..................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION .................................................................................. 2-16
FIRE PREVENTION ................................................................................................................... 2-18
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ........................................................... 2-20
DO NOT GET CAUGHT IN WORK EQUIPMENT .......................................................................... 2-23
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ...................................................... 2-23
UNAUTHORIZED MODIFICATION .............................................................................................. 2-23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ................................................... 2-23
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING .................................................... 2-24
PRECAUTIONS FOR OPERATION .................................................................................................... 2-25
PRECAUTIONS FOR JOBSITE................................................................................................... 2-25
STARTING ENGINE ................................................................................................................... 2-27
OPERATION .............................................................................................................................. 2-30
TRANSPORTATION ................................................................................................................... 2-34
TOWING.................................................................................................................................... 2-35
PRECAUTIONS FOR MAINTENANCE ............................................................................................... 2-36
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-36
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ........................................................... 2-42
TIRES ....................................................................................................................................... 2-47
OPERATION .............................................................................................................................................3-1
GENERAL VIEW .................................................................................................................................3-2
GENERAL VIEW OF MACHINE.....................................................................................................3-2
GENERAL VIEW OF CONTROLS AND GAUGES...........................................................................3-3
EXPLANATION OF COMPONENTS.....................................................................................................3-7
MACHINE MONITOR....................................................................................................................3-7
SWITCHES................................................................................................................................ 3-76
CONTROL LEVERS AND PEDALS ............................................................................................. 3-86
CIGARETTE LIGHTER ............................................................................................................... 3-90
ASHTRAY.................................................................................................................................. 3-90
DRINK BOX ............................................................................................................................... 3-90
CUP HOLDER............................................................................................................................ 3-91
HANDY TRAY ............................................................................................................................ 3-91
MAGAZINE BOX ........................................................................................................................ 3-91
EMERGENCY ESCAPE HAMMER .............................................................................................. 3-92
HANDLING AIR CONDITIONER.................................................................................................. 3-93
HANDLING RADIO................................................................................................................... 3-106

1-8
FOREWORD CONTENTS

AUXILIARY ELECTRIC POWER ............................................................................................... 3-112

FUSE ...................................................................................................................................... 3-113
OPEN AND CLOSE CAB DOOR ............................................................................................... 3-117
STORAGE FOR TOOLS ........................................................................................................... 3-118
STORAGE FOR FIRE EXTINGUISHER ..................................................................................... 3-118
BATTERY DISCONNECT SWITCH ........................................................................................... 3-119
CIRCUIT BREAKER ................................................................................................................. 3-121
DUST INDICATOR ................................................................................................................... 3-121
ARTICULATION LOCK ............................................................................................................. 3-122
BODY PIVOT PINS .................................................................................................................. 3-123
HANDLING REAR VIEW MONITOR .............................................................................................3-123-1
HANDLING MACHINES EQUIPPED WITH KOMTRAX ............................................................... 3-124
MACHINE OPERATIONS AND CONTROLS ..................................................................................... 3-126
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ..................................................... 3-126
STARTING ENGINE ................................................................................................................. 3-150
OPERATIONS AND CHECKS AFTER STARTING ENGINE......................................................... 3-155
STOPPING ENGINE................................................................................................................. 3-158
CHECKS AFTER STOPPING ENGINE ...................................................................................... 3-158
MACHINE OPERATION............................................................................................................ 3-159
SHIFTING GEARS ................................................................................................................... 3-164
TRAVELING DOWNHILL .......................................................................................................... 3-166
STEERING MACHINE .............................................................................................................. 3-172
OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK ................................................................... 3-172-1
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC) ............................... 3-173
HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS) ................................................ 3-175
LOADING WORK ..................................................................................................................... 3-177
DUMPING................................................................................................................................ 3-178
CAB TILT OPERATION ............................................................................................................. 3-180
OPERATION ............................................................................................................................ 3-186
PARKING MACHINE ................................................................................................................ 3-187
AFTER DAILY WORK COMPLETION ........................................................................................ 3-188
LOCKING ................................................................................................................................ 3-188
HANDLING TIRES ................................................................................................................... 3-189
DETERMINE AND MAINTAIN TRAVEL ROAD .................................................................................. 3-190
DETERMINE TRAVEL ROAD.................................................................................................... 3-190
MAINTAIN TRAVEL ROAD........................................................................................................ 3-190
TRANSPORTATION........................................................................................................................ 3-191
TRANSPORTATION ................................................................................................................. 3-191
SECURING MACHINE.............................................................................................................. 3-192
LIFTING MACHINE .................................................................................................................. 3-193
COLD WEATHER OPERATION ....................................................................................................... 3-197
COLD WEATHER OPERATION INFORMATION ......................................................................... 3-197
AFTER DAILY WORK COMPLETION ........................................................................................ 3-198
LONG-TERM STORAGE ................................................................................................................. 3-199
BEFORE STORAGE................................................................................................................. 3-199
TROUBLES AND ACTIONS............................................................................................................. 3-200
RUNNING OUT OF FUEL ......................................................................................................... 3-200
IF TRANSMISSION HAS TROUBLE .......................................................................................... 3-201
LOWERING DUMP BODY IN EMERGENCY .............................................................................. 3-201
TOWING MACHINE.................................................................................................................. 3-202
DISCHARGED BATTERY ......................................................................................................... 3-205
OTHER TROUBLE ................................................................................................................... 3-209
MAINTENANCE ........................................................................................................................................4-1
RULES FOR MAINTENANCE ..............................................................................................................4-2
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
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CONTENTS FOREWORD

CAUTION FOR REFILLING OIL OR FUEL .....................................................................................4-2

WELDING INSTRUCTIONS ..........................................................................................................4-2
DO NOT DROP THINGS INSIDE MACHINE...................................................................................4-2
DUSTY JOBSITES .......................................................................................................................4-2
AVOID MIXING OIL ......................................................................................................................4-3
LOCKING 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
OUTLINE OF MAINTENANCE .............................................................................................................4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ..............................................4-4
HANDLING ELECTRICAL COMPONENTS ....................................................................................4-8
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...............................................................4-9
TIGHTENING TORQUE LIST ........................................................................................................4-9
MAINTENANCE SCHEDULE............................................................................................................. 4-11
MAINTENANCE SCHEDULE TABLE ........................................................................................... 4-11
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED..................... 4-13
MAINTENANCE PROCEDURE.......................................................................................................... 4-14
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).............................. 4-14
WHEN REQUIRED..................................................................................................................... 4-15
CHECKS BEFORE STARTING.................................................................................................... 4-39
EVERY 50 HOURS MAINTENANCE............................................................................................ 4-40
EVERY 250 HOURS MAINTENANCE.......................................................................................... 4-41
EVERY 500 HOURS MAINTENANCE.......................................................................................... 4-56
EVERY 1000 HOURS MAINTENANCE ........................................................................................ 4-63
EVERY 2000 HOURS MAINTENANCE ........................................................................................ 4-76
EVERY 4000 HOURS MAINTENANCE ........................................................................................ 4-82
EVERY 6000 HOURS MAINTENANCE ........................................................................................ 4-85
EVERY 8000 HOURS MAINTENANCE ........................................................................................ 4-87
SPECIFICATIONS .....................................................................................................................................5-1
SPECIFICATIONS ..............................................................................................................................5-2
ATTACHMENTS AND OPTIONS.................................................................................................................6-1
CAB POWER TILT ..............................................................................................................................6-2
HANDLING PAYLOAD METER ............................................................................................................6-4
OUTLINE OF SYSTEM .................................................................................................................6-4
DISPLAY DURING NORMAL OPERATION ....................................................................................6-5
EXTERNAL DISPLAY LAMP .........................................................................................................6-6
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER...................................................6-7
PROCEDURE WHEN DOWNLOADING.........................................................................................6-8
DISPLAY TOTAL PAYLOAD / NUMBER OF CYCLES.................................................................... 6-11
DISPLAY LOAD AND FUEL EFFICIENCY RECORD..................................................................... 6-12
SETTING MACHINE ID AND OPEN ID ........................................................................................ 6-13
PERFORMING CALIBRATION .................................................................................................... 6-15
PAYLOAD OF CYCLE DATA ....................................................................................................... 6-17
SERVICE FUNCTION................................................................................................................. 6-17
THE OTHER INFORMATION ...................................................................................................... 6-17
HANDLING CENTRALIZED BREATHERS .......................................................................................... 6-18
EVERY 250 HOURS MAINTENANCE.......................................................................................... 6-18
CLEAN BREATHER ................................................................................................................... 6-18
EVERY 2000 HOURS MAINTENANCE ........................................................................................ 6-20
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK............................................................. 6-20
EVERY 4000 HOURS MAINTENANCE ........................................................................................ 6-21
REPLACE AIR CLEANER ELEMENT .......................................................................................... 6-21
CONSUMABLE PARTS LIST ...................................................................................................... 6-23
HANDLING FUEL QUICK CHARGE SYSTEM..................................................................................... 6-24
PROCEDURE FOR REFUELING ................................................................................................ 6-24
CHECK AND MAINTENANCE..................................................................................................... 6-25

1-10
FOREWORD CONTENTS

ROLLOVER AVOIDANCE SYSTEM .............................................................................................................6-26

OPERATION IF TROUBLES ON SYSTEM OCCUR.............................................................................6-27
REPLACEMENT PARTS ............................................................................................................................7-1
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 .................................................................................................................7-4
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURE .............................................................................................................7-7
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE
OIL.................................................................................................................................7-9
INDEX ......................................................................................................................................................8-1

1-11
CONTENTS FOREWORD

1-12
2 SAFETY

SAFETY

2-1
SAFETY SAFETY

SAFETY (PC220-1210-002-A-00-A)

SAFETY....................................................................................................................................................2-2
SAFETY LABELS ......................................................................................................................................2-4
LOCATION OF SAFETY LABELS.........................................................................................................2-5
SAFETY LABELS................................................................................................................................2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION ............................................................................ 2-15
ENSURING SAFE OPERATION .................................................................................................. 2-15
UNDERSTANDING THE MACHINE ............................................................................................. 2-15
PREPARATIONS FOR SAFE OPERATION ......................................................................................... 2-16
SAFETY-RELATED EQUIPMENT ................................................................................................ 2-16
INSPECTING MACHINE ............................................................................................................. 2-16
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ............................................ 2-16
KEEP MACHINE CLEAN ............................................................................................................ 2-16
INSIDE OPERATOR'S COMPARTMENT...................................................................................... 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT.................................................................. 2-17
IF ANY PROBLEM IS FOUND ..................................................................................................... 2-17
FIRE PREVENTION .......................................................................................................................... 2-18
ACTIONS IF FIRE OCCURS ....................................................................................................... 2-18
PREVENT FIRE ......................................................................................................................... 2-18
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE .................................................................. 2-20
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE ..................................... 2-20
NO JUMPING ON OR OFF MACHINE ......................................................................................... 2-20
NO PEOPLE ON DUMP BODY ................................................................................................... 2-20
WHEN STANDING UP FROM OPERATOR'S SEAT ...................................................................... 2-21
WHEN LEAVING MACHINE ........................................................................................................ 2-21
EMERGENCY EXIT FROM OPERATOR'S CAB ........................................................................... 2-22
DO NOT GET CAUGHT IN WORK EQUIPMENT................................................................................. 2-23
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ............................................................. 2-23
UNAUTHORIZED MODIFICATION ..................................................................................................... 2-23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.......................................................... 2-23
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING........................................................... 2-24
PRECAUTIONS FOR OPERATION........................................................................................................... 2-25
PRECAUTIONS FOR JOBSITE ......................................................................................................... 2-25
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS ............................................................... 2-25
WORK ON LOOSE GROUND ..................................................................................................... 2-25
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................................... 2-25
ENSURE GOOD VISIBILITY ....................................................................................................... 2-26
CHECK SIGNS AND SIGNALMAN'S SIGNALS ............................................................................ 2-26
BEWARE OF ASBESTOS DUST ................................................................................................. 2-26
STARTING ENGINE .......................................................................................................................... 2-27
USE WARNING TAGS ................................................................................................................ 2-27
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ....................................................... 2-27
WHEN STARTING ENGINE ........................................................................................................ 2-28
IN COLD AREAS........................................................................................................................ 2-28
START ENGINE WITH JUMPER CABLES ................................................................................... 2-29
OPERATION..................................................................................................................................... 2-30
CHECKS BEFORE OPERATION................................................................................................. 2-30
WHEN TRAVELING IN FORWARD OR REVERSE ....................................................................... 2-30
WHEN TRAVELING.................................................................................................................... 2-31
WHEN TRAVELING ON SLOPES................................................................................................ 2-31
WHEN OPERATING ................................................................................................................... 2-32
WHEN LOADING ON DUMP BODY............................................................................................. 2-32
WHEN DUMPING....................................................................................................................... 2-32
WHEN OPERATING ON SNOW OR FROZEN SURFACES ........................................................... 2-32
WHEN PARKING MACHINE ....................................................................................................... 2-33
TRANSPORTATION.......................................................................................................................... 2-34
SAFETY RULES FOR LOADING AND UNLOADING .................................................................... 2-34

2-2
SAFETY SAFETY

TOWING .......................................................................................................................................... 2-35

SAFETY RULES FOR TOWING .................................................................................................. 2-35
PRECAUTIONS FOR MAINTENANCE...................................................................................................... 2-36
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-36
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ....................................... 2-36
KEEP WORKPLACE CLEAN AND TIDY ...................................................................................... 2-37
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE .......................................... 2-37
ONLY AUTHORIZED PERSONNEL ............................................................................................. 2-37
APPOINT LEADER WHEN WORKING WITH OTHERS................................................................. 2-37
STOP ENGINE BEFORE PERFORMING INSPECTION AND MAINTENANCE ............................... 2-38
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING .......................................... 2-40
INSTALLING, REMOVING, OR STORING ATTACHMENTS .......................................................... 2-41
WORK AT HIGH PLACES ........................................................................................................... 2-41
WORK UNDER MACHINE .......................................................................................................... 2-41
PROPER TOOLS ....................................................................................................................... 2-41
PRECAUTIONS FOR INSPECTION AND MAINTENANCE .................................................................. 2-42
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION ...................................................... 2-42
WELDING INSTRUCTIONS ........................................................................................................ 2-42
BATTERY .................................................................................................................................. 2-42
WHEN USING HAMMER ............................................................................................................ 2-43
HIGH-TEMPERATURE COOLANT .............................................................................................. 2-43
HIGH-TEMPERATURE OIL ......................................................................................................... 2-43
HIGH-TEMPERATURE PARTS ................................................................................................... 2-43
HIGH-PRESSURE OIL ............................................................................................................... 2-44
HIGH-PRESSURE FUEL ............................................................................................................ 2-44
HIGH-PRESSURE HOSES AND PIPING ..................................................................................... 2-44
NOISE ....................................................................................................................................... 2-44
HANDLING SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGS ........................... 2-45
COMPRESSED AIR ................................................................................................................... 2-45
MAINTENANCE OF AIR CONDITIONER ..................................................................................... 2-45
DISPOSE OF WASTE MATERIALS ............................................................................................. 2-45
SELECT WINDOW WASHER FLUID ........................................................................................... 2-45
PERIODIC INSPECTION OF DEFINED LIFE PARTS ......................................................................... 2-46
TIRES .............................................................................................................................................. 2-47
HANDLING TIRES ..................................................................................................................... 2-47
STORING TIRES........................................................................................................................ 2-47

2-3
SAFETY LABELS SAFETY

SAFETY LABELS (ALL-Q5L0-043-K-00-A)

The following warning signs and safety labels are used on this machine.
• Be sure that you fully understand the correct position and content of labels.
• To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels
to peel off.
• 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.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.

2-4
SAFETY SAFETY LABELS

LOCATION OF SAFETY LABELS

2-5
SAFETY LABELS SAFETY

2-6
SAFETY SAFETY LABELS

Machine with dump body heating specifications

Machine with anchor point for tie-off

2-7
SAFETY LABELS SAFETY

SAFETY LABELS
(1) Caution for modification of ROPS/FOPS (09620-A2001,
09620-A3001)

(2) Caution for rotating parts (09667-A0880)

(3) Caution when checking engine room (09667-A0641)

2-8
SAFETY SAFETY LABELS

(4) Caution when releasing radiator cap (09653-A0641)

(5) Caution for opening hydraulic tank cap (09653-A0641)

(6) Caution for handling suspension (09659-A0641)

(7) Caution for handling accumulator (09659-A057B)

2-9
SAFETY LABELS SAFETY

(8) Warning for electric wire

Warning for crush hazard when performing inspection and maintenance
Warning for daily inspection
Warning for leaving operator's seat, stopping engine
Warning for retarder oil temperature
(561–93-82410)

2-10
SAFETY SAFETY LABELS

(9) Caution before operating

Caution before traveling in reverse
Caution for operating hoist control lever (561-93-82380)

(10) Caution for handling battery cable (09808-A1681)

2-11
SAFETY LABELS SAFETY

(11) Caution for hot exhaust pipe (09817-A1103)

(12) Prohibited to enter (09162-C0881)

(13) Caution for articulation lock (09161-C0881)

2-12
SAFETY SAFETY LABELS

(14) Caution against falling (09805-C0481)

(15) Caution for handling battery

(This plate is fixed in position by the battery maker)

(a) Never smoke or use any naked flame near the batteries, no
sparks.

(b) Always wear protective eyeglasses when working with batter-

ies.

(c) Keep children away from batteries.

2-13
SAFETY LABELS SAFETY

(d) Caution battery acid.

(e) Read the operator's manual before working with batteries.

(f) Caution - explosive gases.

(16) Caution for parking brake

(This plate is fixed in position by the chamber manufacturer)

(17) Prohibited to start by short-circuiting (09842-A0481)

(This plate is fixed to the starting motor)

2-14
SAFETY SAFETY LABELS

(18) Caution for blast site (56D–93–31410)

(only when equipped with KOMTRAX)

(19) Caution for hot exhaust pipe (09817-A1103)

(only for the machine with dump body heating specifications)

(20) Prohibition of lifting operation (09951-00281)

(21) Anchor point for tie-off (09850-00641)

Anchor point for personal fall-arrest equipment

2-14-1
SAFETY LABELS SAFETY

2-14-2
 GENERAL PRECAUTIONS COMMON TO OPERA-
SAFETY TION AND MAINTENANCE

GENERAL PRECAUTIONS COMMON TO OPERATION AND

MAINTENANCE (ALL-1130-010-A-00-A)
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before performing
operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and
obey the warnings.

PRECAUTIONS BEFORE STARTING OPERATION (ALL-0000-001-K-07-A)

ENSURING SAFE OPERATION (ALL-0000-177-K-00-A)

• 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 oper-
ate 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.

UNDERSTANDING THE MACHINE (ALL-0000-178-K-00-A)

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.

2-15
GENERAL PRECAUTIONS COMMON TO OPERA-
TION AND MAINTENANCE SAFETY

PREPARATIONS FOR SAFE OPERATION (ALL-0000-001-K-08-A)

SAFETY-RELATED EQUIPMENT
• Be sure that all guards, covers, mirrors and cameras (if equipped) are installed in their proper position. Have
them repaired immediately if they are damaged.
• Understand the method of use of safety features and use them properly.
• Never remove any safety devices. Always keep them in good operating condition.

INSPECTING MACHINE (ALL-0000-128-K-00-A)

Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

• Do not wear loose clothes or any accessories. If these catch
on the control levers or protruding parts, there is danger that it
may cause the machine to move unexpectedly.
• Always wear a hard hat and safety shoes. If the nature of the
work requires it, wear protective eyeglasses, mask, gloves,
ear plugs, and personal fall-arrest equipment as appropriate
for the work function.
• If you have long hair and it hangs out from your hard hat, there
is a hazard that it may get caught up in the machine, so tie
your hair up and be careful not to let it get caught.
• Check that all protective equipment functions properly before
using it.

KEEP MACHINE CLEAN

• If you get on or off the machine or perform inspection and maintenance when the machine is dirty with mud or
oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the ma-
chine clean.
• If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. If there is any misop-
eration, there is a danger that the machine may move unex-
pectedly 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
components.
• When washing the machine with high-pressure water, direct
spray onto camera (if equipped) may cause trouble. Defective
camera cannot monitor surrounding area. When cleaning
camera, do not allow the high-pressure water to get into
camera directly, and wipe off any dirt with soft cloth.
• When cleaning camera (if equipped), 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.

INSIDE OPERATOR'S COMPARTMENT (ALL-0000-12B-K-00-A)

• 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 serious
accident.
• Do not leave tools or a 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 seri-
ous 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,
which could cause serious personal injury or death.
• Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

2-16
 GENERAL PRECAUTIONS COMMON TO OPERA-
SAFETY TION AND MAINTENANCE

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT (ALL-Q5G5-012-K-00-A)

Always follow the precautions below to prepare for action if any injury 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 in
emergencies.
• 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 (ALL-0000-12C-K-00-A)

If you find any problems 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 person in
charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

2-17
GENERAL PRECAUTIONS COMMON TO OPERA-
TION AND MAINTENANCE SAFETY

FIRE PREVENTION (ALL-0000-001-K-09-A)

ACTIONS IF FIRE OCCURS (ALL-0000-17A-K-00-A)

• Turn the starting switch OFF to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. There is the danger of falling and suffering serious injury.
• When the machine is involved with a fire, fumes include harmful materials.
Don’t breathe the fumes.
• After a fire, there might be harmful material left. Don’t touch them directly, because they might be harmful to
person.
Anyone conducting clean-up must wear rubber groves.
Rubber gloves should be polychloroprene (Neoprene) or polyvinyl chloride (in the case of low temperature).
When wearing cotton-work-gloves, wear rubber gloves under them.

PREVENT FIRE (HM400-0000-17B-K-02-A)

• 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. Observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a
safe container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil.
Do not use diesel oil 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 flammable liquids.
• Determine well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the ma-
chine, move any flammable materials to a safe place be-
fore starting.
• Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engine exhaust manifold, muffler, battery, or dump body (body heating specification) or in-
side the undercovers.
• Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
• Fire caused by 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. There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal in-
jury or death.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion
specifications.

2-18
 GENERAL PRECAUTIONS COMMON TO OPERA-
SAFETY TION AND MAINTENANCE

• When taking the electrical power for the lighting from the machine body, see"AUXILIARY ELECTRIC
POWER（PAGE 3-112）" in the OPERATION section.

2-19
GENERAL PRECAUTIONS COMMON TO OPERA-
TION AND MAINTENANCE SAFETY

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE (ALL-0000-001-K-10-A)

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE (HM400-0000-17D-K-

00-A)
To prevent personal injury caused by slipping or falling off the machine, always observe the following.

• Use the handrails and steps marked by arrows (A) in the fig-
ure on the right when getting on or off the machine.

• The handrails and steps marked by arrows (B) are for escap-
ing in emergencies.
Use these when escaping from the machine in a fire or other
emergencies. Do not use them in normal situations.

• Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one foot)
with the handrail and steps to ensure that you support
yourself.

9 J D 0 1 7 2 2

• Before getting on and off the machine, check the handrails and steps if there is any oil, grease, or mud on
them. Wipe it off immediately not to slip if any. In addition, tighten any loose bolt of the handrails and steps.
If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu
distributor 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 while holding tools in your hand.

NO JUMPING ON OR OFF MACHINE (ALL-0000-17E-K-00-A)

Getting on or off the moving machine can cause serious personal injury. 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.

NO PEOPLE ON DUMP BODY (HM-0000-17F-K-00-A)

Never let anyone ride in the dump body. There is danger of falling and suffering serious personal injury.

2-20
 GENERAL PRECAUTIONS COMMON TO OPERA-
SAFETY TION AND MAINTENANCE

WHEN STANDING UP FROM OPERATOR'S SEAT (HM-0000-17G-K-01-A)

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 N position, set park-
ing brake switch (3) to PARKING position, then stop the engine.
If this is not done and the control levers are touched by mistake,
there is a danger that the machine may suddenly move and cause
serious personal injury or death.

WHEN LEAVING MACHINE (HM-0000-17H-K-01-A)

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. Observe the following.

• When leaving the machine, always lower the dump body

completely, lock with dump lever lock knob (1), set gear shift
lever (2) to N (NEUTRAL) position, set parking brake switch
(3) to PARKING position, then stop the engine.
In addition, lock all places and always take the key with you
and leave it in the specified location.

2-21
GENERAL PRECAUTIONS COMMON TO OPERA-
TION AND MAINTENANCE SAFETY

EMERGENCY EXIT FROM OPERATOR'S CAB (HM-0000-17J-K-00-A)

• If it should be impossible to open the door of the cab, break the window glass with the hammer supplied and
use the window as an emergency escape.
For details, see "EMERGENCY ESCAPE HAMMER（PAGE 3-92）" in this volume.
• When escaping, remove all the pieces of glass from the window frame first and be careful not to cut yourself
on the glass.
Be careful also not to slip on the broken pieces of glass on the ground.

2-22
 GENERAL PRECAUTIONS COMMON TO OPERA-
SAFETY TION AND MAINTENANCE

DO NOT GET CAUGHT IN WORK EQUIPMENT (HM-0000-17K-K-00-A)

• If the clearance at the articulating portion changes and you
get caught in it, you will suffer serious personal injury or
death. Do not allow anyone to come inside the articulation
range.
• The clearance in the area around the dump body changes ac-
cording to the movement of the dump body. If you are caught,
there is danger that you will suffer serious injury or death. Do
not allow anyone near any of the rotating or telescopic parts.

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES (HM-K200-170-K-00-A)

The operator's compartment is equipped with a structure (such as
ROPS, FOPS) to protect the operator by absorbing the impact
energy.
As for the machine equipped with ROPS, if the machine weight
(mass) exceeds the certified value (shown on the 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 machine
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 or death. To prevent accidents, al-
ways do as follows.
• If the machine is equipped with a protective structure, do not remove the protective structure and perform op-
erations 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. Consult your Komatsu distributor before performing any modifications.
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be re-
duced and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu distribu-
tor for advice on the method of repair.
• Even if the protective structure is installed, if you do not fasten your seatbelt properly, it cannot display its ef-
fect. Always fasten your seat belt properly when operating the machine.

UNAUTHORIZED MODIFICATION (HM-0000-17M-K-00-A)

• Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result-
ing from modifications made without authorization from Komatsu.
• Any modification made without authorization from Komatsu can create hazards. Before making a modification,
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 (HM-RA17-170-K-03-A)

• Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized at-
tachments or parts will not be the responsibility of Komatsu.
• When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-
fore contact your Komatsu distributor for advice.
• When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.

2-23
GENERAL PRECAUTIONS COMMON TO OPERA-
TION AND MAINTENANCE SAFETY

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING (ALL-0000-17N-K-00-A)

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 machine
must be operated inside a building or under ground, where the
ventilation is poor, take steps to ensure that the engine exhaust
gas is removed and that ample fresh air is brought in.

2-24
SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR OPERATION (ALL-1140-001-A-00-A)

PRECAUTIONS FOR JOBSITE (PC-0000-001-K-08-A)

INVESTIGATE AND CONFIRM JOBSITE CONDITIONS (HM-0000-17R-K-00-A)

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm that there is no danger on the jobsite.
• Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not operate where there is a hazard of landslides or falling rocks.
• Take necessary measures to prevent any unauthorized person from entering the operating area.
• When traveling or operating in water or on soft ground, check the water depth, speed of the current, bedrock,
and shape of the ground beforehand and avoid any place that will obstruct travel.
• Maintain the travel path on the jobsite so that there is no obstruction to travel operations.

WORK ON LOOSE GROUND (ALL-0000-17S-K-00-A)

• 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 ma-
chine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blast-
ing or after earthquakes is weak in these areas.
• When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES (HM-0000-17T-K-00-A)

Do not travel or operate the machine near electric cables. There is
a hazard of electric shock, which may cause serious personal in-
jury or death. On jobsites where the machine may go close to
electric cables, always do as follows.
• 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, which may cause serious burns or even death. Always Voltage of Cables Safety Distance
maintain a safe distance (see the table on the right) between 100 V, 200 V Over 2 m (7 ft)
the machine and the electric cable. 6,600 V Over 2 m (7 ft)
Check with the local power company about safe operating 22,000 V Over 3 m (10 ft)
procedure before starting operations. 66,000 V Over 4 m (14 ft)
• To prepare for any possible emergencies, wear rubber shoes 154,000 V Over 5 m (17 ft)
and gloves. Lay a rubber sheet on top of the seat, and be 187,000 V Over 6 m (20 ft)
careful not to touch the chassis with any exposed part of your Over 7 m (23 ft)
275,000 V
body.
500,000 V Over 11 m (36 ft)
• Use a signalman to give warning if the machine approaches
too close to the electric cables.
• When performing operations near high voltage cables, do not let anyone near the machine.
• 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,
do not let anyone near the machine.

2-25
PRECAUTIONS FOR OPERATION SAFETY

ENSURE GOOD VISIBILITY

This machine is equipped with mirrors and cameras (optional) to ensure good visibility, but even then there are
places that cannot be seen from the operator's seat, so be careful when operating.
When traveling or performing operations in places with poor visibility, it is impossible to check for obstacles in the
area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury
or death. When traveling or performing operations in places with poor visibility, always observe the following.
• Position a signalman if there are areas where the visibility is not good.
• Only 1 signalman should give signals.
• When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
• Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
• When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to en-
sure good visibility.
• If the machine is equipped with cameras, clean off any dirt from the lens and make sure that the camera
gives a clear view.

CHECK SIGNS AND SIGNALMAN'S SIGNALS (ALL-0000-17V-K-00-A)

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 signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operator should pay careful attention to the signs and follow the instructions from the signalman.
• Only 1 signalman should give signals.
• Make sure that all workers understand the meaning of all signals and signs before starting work.

BEWARE OF ASBESTOS DUST (ALL-0000-17W-K-00-A)

Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working
on jobsites handling demolition work or work handling industrial waste. 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.
• 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
improper part may contain asbestos, so always use genuine Ko-
matsu parts.

2-26
SAFETY PRECAUTIONS FOR OPERATION

STARTING ENGINE (ALL-0000-001-K-05-A)

USE WARNING TAGS (HM-0000-17Y-K-03-A)

If there is any "DANGER! Do NOT operate!" warning tag dis-
played, it means that someone is performing inspection and main-
tenance of the machine. If the warning sign is ignored and the
machine is operated, there is a danger that the person performing
inspection or maintenance may be caught in the rotating parts or
moving parts and suffer serious personal injury or death. Do not
start the engine or touch the levers.

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE (HM400-0000-17Z-K-02-A)

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 this may lead to serious personal injury or death.
• Remove all dirt from the surface of the window glass to ensure a good view.
• Always perform the "WALK-AROUND CHECKS（PAGE 3-126）"
• Remove all stain from the surface of the lens of the headlamps, working lamps, and rear combination lamp,
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 dam-
age 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. Perform the ad-
justment. For details, see "ADJUST MIRROR（PAGE 3-145）".
• Check that there are no persons or obstacles above, below, or in the area around the machine.
• Check that the parking brake switch is at PARKING position.
• Check that the articulation lock is fixed securely at FREE
position.

2-27
PRECAUTIONS FOR OPERATION SAFETY

WHEN STARTING ENGINE (HM-0000-181-K-00-A)

• Start the engine only after 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 (HM-0000-182-K-00-A)

• Perform the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
• 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.

2-28
SAFETY PRECAUTIONS FOR OPERATION

START ENGINE WITH JUMPER CABLES (HM400-AW10-14J-K-01-A)

If any mistake is made in the method of connecting the jumper ca-
bles, it may cause the battery to explode, so always observe the
following.
• Always wear protective eyeglasses and rubber gloves when
starting the engine with jumper cable.
• When connecting a normal machine to a failed machine with
jumper cables, always use the normal machine with the same
battery voltage as the failed machine.
• When starting with a jumper cable, perform the starting oper-
ation with 2 workers (1 worker sitting in the operator's seat
and the other working with the battery).
• When starting from another machine, do not allow the 2 ma-
chines to touch.
• 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 battery disconnect switch
(S), turn the switch to OFF position, and turn it ON again after
connecting the cables.
For detail, see "BATTERY DISCONNECT SWITCH（PAGE
3-119）".
There is a danger that the machine will 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.
• For details of the starting procedure when using jumper ca-
bles, see "START ENGINE WITH JUMPER CABLES（PAGE
3-207）" in the OPERATION section.

2-29
PRECAUTIONS FOR OPERATION SAFETY

OPERATION (ALL-0000-001-K-11-A)

CHECKS BEFORE OPERATION (HM400-0000-184-K-01-A)

If the checks before starting are not performed properly, the machine will be unable to achieve its full performance,
and there is also a danger that it may lead to serious personal injury or death.
When performing the checks, move the machine to a wide area where there are no obstructions, and pay careful
attention to the surrounding area. Do not allow anyone near the machine.

• Always fasten the seatbelt. There is a danger that you may

be thrown out of the operator's seat and suffer serious injury
when the brakes are applied suddenly.
• Check the operation of travel, steering and brake systems,
and dump body control system.
• Check for any problem in the sound of the machine, vibration,
heat, smell, or gauges; check also that there is no leakage of
oil or fuel.
• If any problem is found, perform repairs immediately.

• Before starting to travel or perform operations, check that ar-

ticulation lock (1) is fixed securely at FREE position.

WHEN TRAVELING IN FORWARD OR REVERSE

• Always lock all the doors and windows of the operator's compartment in position (open or closed).
• If another person is allowed on the machine, that person must sit only in the assistant's seat.
• If there are any persons in the area around the machine,
there is a 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.
• Before moving off, check again that there is no person or
obstruction in the surrounding area.
• Before moving, sound the horn to warn people in the sur-
rounding area.
• Check that the backup alarm (alarm buzzer when ma-
chine travels in reverse) works properly.
• If there is an area to the rear of the machine which can-
not be seen, position a signalman.
Always be sure to perform the above precautions even when the
machine is equipped with mirrors and cameras (optional).

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SAFETY PRECAUTIONS FOR OPERATION

WHEN TRAVELING (HM-0000-186-K-00-A)

Serious personal injury can result from tipping over of the traveling machine or its accidental contact. To prevent
accidents, always do as follows.
• Never turn the key in the starting switch to OFF position. It is dangerous if the engine stops when the machine
is traveling, because the steering wheel becomes heavy. There is danger that this will cause misoperation of
the steering and may lead to serious personal injury or death. If the engine stops, depress the brake pedal im-
mediately to stop the machine.
• When traveling or performing operations, always keep a safe distance from people, structures, or other ma-
chines to avoid coming into contact with them.
• Try to avoid having the machine climb over obstacles. If that is unavoidable, let the machine do that at a low
speed. Nonetheless avoid a big obstacle that greatly tilts the machine to the right or left, because in such a
case the machine can easily overturn sideways.
• When traveling on rough ground, travel 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 travel.
• 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, op-
erate 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 de-
structive force, and this may cause serious injury or death.
If you are going to travel continuously, consult your Komatsu distributor.
• When travelling, and particularly when travelling downhill, never set the gear shift lever to the Neutral position.
Always keep it in a speed range when travelling.
• If the gear shift lever is at Neutral, it will be impossible to use the braking force of the engine and the
steering wheel will become heavier. In addition, there will be insufficient cooling oil for the retarder, and
this will lead to overheating or defective operation of the brakes and dangerous.
• The transmission and other parts of the power train may be damaged, and there is danger that this will
lead to serious injury or death.

WHEN TRAVELING ON SLOPES (HM-0000-187-K-00-A)

To prevent the machine from tipping over or slipping to the side, always do as follows.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly.
• Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that
the machine may slip.
• If the engine should stop on a slope, apply the brakes fully and apply the parking brake also to stop the
machine.
• Do not shift gear while traveling downhill or travel downhill with the transmission in neutral.
It is dangerous if the engine has no braking effect. Always set the transmission to a lower gear before starting
to travel downhill.

2-31
PRECAUTIONS FOR OPERATION SAFETY

WHEN OPERATING (HM-0000-170-K-00-A)

• When using the machine, to prevent personal injury caused by damage to the work equipment or by the ma-
chine overturning due to overloading, do not exceed the permitted performance of the machine or the maxi-
mum permitted load for the structure of the machine.
• When operating in tunnels, or under bridges or electric wires, or in other places where the height is limited, op-
erate 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, particular in confined spaces, indoors, and in places where there are other machines.

WHEN LOADING ON DUMP BODY (HM-0000-170-K-01-A)

• 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 (HM-0000-170-K-02-A)

• Before starting the dumping operation, check to be sure there is no person or object behind the machine.
• Stop the machine in the correct position, and check again that there is no person or object behind the ma-
chine. Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels
or position a flagman.
• Not perform dumping operations on slopes. The machine stability will become poor and there is danger that it
may tip over.
• Do not travel with the body raised.
• When performing dumping operations, set the machine in a straight line. If dumping operations are performed
with the machine articulated, the machine stability will become poor there is danger that it may tip over.
• Be careful when raising the dump body. When the dump body is raised, the center of gravity of the machine
changes continuously. If the ground is soft, this will affect the stability of the machine.
• Take care particularly when dumping sticky material (wet clay, frozen material, etc.) on a soft ground. The
stability of the machine is reduced and there is danger that it may tip over.

WHEN OPERATING ON SNOW OR FROZEN SURFACES (HM-0000-18A-K-00-A)

• Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma-
chine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be par-
ticularly careful when working on slopes.
• With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over or make it impossible for the machine to escape.
• When traveling on snow-covered roads, always fit tire chains.
• If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
• Do not apply the brakes suddenly on snow-covered slopes. Reduce speed, use the braking force of the en-
gine, 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.

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SAFETY PRECAUTIONS FOR OPERATION

WHEN PARKING MACHINE (HM-0000-161-K-01-A)

Unexpected move of the parked machine can cause serious personal injury. Observe the following.
• Park 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 gear shift
lever (2) to N (NEUTRAL) position, set parking brake switch
(3) to PARKING position, then stop the engine.
• Always close the operator's cab door, and use the key to lock
all the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave 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.

2-33
PRECAUTIONS FOR OPERATION SAFETY

TRANSPORTATION (HM-0000-81A-K-00-A)
When the machine is transported on a trailer, there is danger of serious personal injury or death during transporta-
tion. To prevent accidents, always do as follows.
• Always check the machine dimensions carefully. Depending on the attachments installed, the machine
weight, transportation height, and overall length may differ.
• Check beforehand that all bridges and other structures on the transportation route are strong enough to with-
stand the combined weight of the transporter and the machine being transported.
• This machine needs to be divided into components for transportation depending on the regulation. When
transporting the machine, consult your Komatsu distributor.
• Lock the articulation lock to prevent the machine from articulating.
• For the procedure when transporting, see "TRANSPORTATION（PAGE 3-191）" in the Operation section.

SAFETY RULES FOR LOADING AND UNLOADING (HM-0000-84A-K-00-A)

When loading or unloading the machine, mistaken operation may
bring the hazard of the machine tipping over or falling, so particu-
lar care is necessary. To prevent accidents, always do as follows.
• Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
• Always use ramps of adequate strength. Be sure that the
ramps are wide, long, and thick enough to provide a safe
loading slope. Take suitable steps to prevent the ramps from
moving out of position or coming off.
• Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials. Remove dirt from the tire of the machine.
On a rainy day, in particular, be extremely careful since the
ramp surface is slippery. (1) Chocks
• Run the engine at low idle and drive the machine slowly at (2) Ramp
low speed. (3) Width of ramps: Same width as tires
• Never correct your steering on the ramps. If necessary, drive (4) Angle of ramps: Max. 15 deg.
off the ramps, correct the direction, then enter the ramps (5) Block
again.
• When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
• For machines equipped with a cab, always lock the door after loading the machine. If this is not done, the door
may open during transportation.
See "TRANSPORTATION（PAGE 3-191）".
• When it is necessary to remove handrails and steps, take care not to lose removed handrails and steps.
Install the removed handrails and steps securely.

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SAFETY PRECAUTIONS FOR OPERATION

TOWING (ALL-0000-001-K-15-A)

SAFETY RULES FOR TOWING (HM400-0000-147-K-00-A)

Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or tow-
ing bar or in the method of towing a failed machine may lead to serious personal injury or death.
For towing, see "TOWING MACHINE（PAGE 3-202）".
• Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine
being towed.
• Never use the wire rope which has cut 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 towing
machine and the machine being towed.

2-35
PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS FOR MAINTENANCE (ALL-1150-001-A-00-A)

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE (ALL-

0000-001-K-12-A)

DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE (HM400-0000-2A6-K-00-

A)
Always display the "DANGER! Do NOT operate" warning tag dur-
ing the inspection and maintenance.
If there is any "DANGER! Do NOT operate!" warning tag dis-
played, it means that someone is performing inspection and main-
tenance of the machine. If the warning sign is ignored and the
machine is operated, there is a danger that the person performing
inspection or maintenance may be caught in the rotating parts or
moving parts and suffer serious personal injury or death. Do not
start the engine or touch the levers.
• If necessary, put up signs around the machine also.
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 the Operation and
Maintenance Manual.

2-36
SAFETY PRECAUTIONS FOR MAINTENANCE

KEEP WORKPLACE CLEAN AND TIDY (PC-0000-2A7-K-00-A)

• Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substan-
ces that will cause you to slip. Always keep the work place clean and 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 in-
jure yourself.
• When cleaning the ceiling window which is made of organic glass (polycarbonate), use tap water and avoid
use of organic solvents for cleaning. An organic solvent like benzene, toluene or methanol can invite a chemi-
cal reaction like dissolution and decomposition on the window glass, deteriorating polycarbonate in use.

SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE (ALL-0000-2A8-K-00-A)

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

ONLY AUTHORIZED PERSONNEL (ALL-0000-2A9-K-00-A)

As long as maintenance of the machine is continued, do not allow unauthorized person comes near the workplace.
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 (ALL-0000-2AA-K-00-A)

• When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his instructions during the operation in order to prevent personal injuries caused by being caught or pinched.

2-37
PRECAUTIONS FOR MAINTENANCE SAFETY

STOP ENGINE BEFORE PERFORMING INSPECTION AND MAINTENANCE (HM400-

0000-2AB-K-01-A)
Serious personal injury can result if you are caught or pinched be-
tween the work equipment in operation, or exposed to high-tem-
perature or high-pressure liquids. Always observe the following.
• Always stop the engine before performing any inspection and
maintenance.

• Lower the dump body completely, set dump lever (1) to HOLD
position, lock with dump lever lock knob (2), then stop the
engine.

• Set parking brake switch (3) to PARKING position to apply

the parking brake, then put blocks in front of and behind the
tires to prevent the machine from moving.

2-38
SAFETY PRECAUTIONS FOR MAINTENANCE

• Lock the front and rear frames with articulation lock (4).

2-39
PRECAUTIONS FOR MAINTENANCE SAFETY

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (HM400-0000-2AC-K-02-A)

To prevent personal injury, do not perform maintenance with the engine running. If the maintenance must be per-
formed with the engine running, observe the following.

• 1 worker must always sit in the operator's seat and be ready

to stop the engine at any time. All workers must maintain con-
tact with the other workers.
• When performing works near the fan, fan belt, or other rotat-
ing parts, there is a hazard of being caught in the parts, so be
careful not to come close.
• Never drop or insert tools or other objects into the fan, fan
belt, or other rotating parts. There is a danger that they may
contact the rotating parts and break or be sent flying.

• Lower the dump body completely, set dump lever (1) to HOLD
position, lock with dump lever lock knob (2), and take steps to
prevent the dump body from moving.

• Set parking brake switch (3) to PARKING position to apply

the parking brake, then put blocks in front of and behind the
tires to prevent the machine from moving.
• Do not touch any control levers. If any control lever must be
operated, give a signal to the other workers to warn them to
move to a safe place.

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SAFETY PRECAUTIONS FOR MAINTENANCE

INSTALLING, REMOVING, OR STORING ATTACHMENTS (ALL-0000-2AD-K-00-A)

• Appoint a leader before starting removal or installation opera-
tions for attachments.
• Place attachments that have been removed from the machine
in a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.

WORK 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.
• To prevent personal injury caused by slipping or falling off the machine, be sure to set the hook of the personal
fall-arrest equipment on the anchor point for tie-off.
• The anchor points for tie-off are set to the positions that follow.
• Cab (4 places)

• Dump body (2 places)

• Do not set other ones than the hook of the personal fall-arrest
equipment to the anchor point for tie-off. The anchor points
installed to the cab are also used as the cab lifting points. When
you lift the cab, consult your Komatsu distributor.

2-41
PRECAUTIONS FOR MAINTENANCE SAFETY

･ The safety label as shown in the figure is attached on the

anchor point for tie-off.



PRECAUTIONS WHEN WORKING ON MACHINE 1

･ 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 machine.
･ 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 sup-
port yourself.
･ You must walk along the access aisle for checking being paved
with non-slip pads. Never climb on the engine hood and cover
to prevent personal injuries from falling or failing over due to
losing your footing.

WORK UNDER MACHINE (HM400-0000-2AF-K-00-A)

Fall of the machine may cause serious personal injuries or death.
To prevent accidents, always do as follows.
• When performing inspection with the dump body raised, al-
ways set the dump control lever to HOLD position, set the
lock knob to LOCK position, then insert the body pivot pin. If
the body pivot pin is not inserted, the dump body may go
down when the dump control lever is operated, and catch or
cause serious injury or even death to the person performing
the inspection.
• Always perform the operation to remove or insert the body
pivot pin with at least 2 workers. This operation is performed
with the dump body raised, so if the dump body comes down
during the operation, it may lead to serious injury or even
death.
See "BODY PIVOT PINS（PAGE 3-123）".
• Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight of the com-
ponent. Never use jacks at places where the machine is damaged, bent, or twisted. Never use frayed, twisted
or pinched wire rope. Never use bent or distorted hooks.
• Never use concrete blocks for supports. They can collapse under even light loads.

2-41-1
SAFETY PRECAUTIONS FOR MAINTENANCE

PROPER TOOLS (ALL-0000-2AG-K-00-A)

Use only tools suited to the task and be sure to use the tools cor-
rectly. By using damaged, deformed, or low quality tools, or mak-
ing improper use of the tools may cause serious personal injury.

2-41-2
PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE (ALL-0000-001-K-06-A)

TURN BATTERY DISCONNECT SWITCH TO OFF POSITION (ALL-AW1P-012-K-00-A)

In the following cases, turn the starting switch to OFF position and check that the system operating lamp is OFF.
Then set the battery disconnect switch to OFF position, and remove the switch key.
Performing the inspection of the battery or handling the battery without having set the battery disconnect switch to
OFF position may cause serious personal injury or death by electric shock.
• When the machine is stored for a long time (more than a month)
• When the electrical system is repaired
• When an electrical welding is performed
• When the battery is handled
• When replacing the fuse

WELDING INSTRUCTIONS (ALL-0000-629-K-00-A)

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 electrocution when performing welding, so never allow any unqualified per-
sonnel to perform welding.

BATTERY
In case of performing inspection of the battery and handling of the battery, turn the starting switch to OFF position,
and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position, and re-
move the switch key.
DANGER OF BATTERY EXPLODING
When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte in-
cludes dilute sulfuric acid. Any mistake in handling may cause
serious personal injury, explosion, or fire, so always observe the
following.
• Do not use or charge the battery if the battery electrolyte is
below the LOWER LEVEL mark. This may cause explosion.
Be sure to do the periodic inspection of the battery electrolyte
level.
• In the case of a liquid stopper type, add purified water (such
as a commercial battery fluid) to UPPER LEVEL line. For the
Komatsu maintenance-free battery (if equipped), check the
indicator display and follow the instructions. See "CHECK
KOMATSU MAINTENANCE-FREE BATTERY INDICATOR
(PAGE 4-22-1)" for how to read the indicator.
• Do not use a direct air blow or dry cloth to clean the battery.
A wet cloth 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 SULFURIC ACID

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
in-cludes dilute sulfuric acid. Any mistake in handling may cause
serious personal injury, explosion, or fire, so always observe the
following.
• When handling the battery, always wear protective eye-
glasses and rubber gloves.
• If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water. After that, get
medical attention immediately.
• If battery electrolyte gets on your clothes or skin, wash it off
immediately with large amounts of water.
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SAFETY PRECAUTIONS FOR MAINTENANCE

DANGER OF SPARKS
There is hazard that sparks will be generated, so always observe the following.
• Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying
around near the battery.
• When removing the battery cables, turn the starting switch to OFF position and, after checking that the system
operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing, con-
nect the positive (+) cable first, then connect the ground.
• Tighten the battery cable terminals securely.
• Secure the battery firmly in the specified position.

WHEN USING HAMMER (HM-0000-2AK-K-00-A)

When using a hammer, pins may fly out or metal particles may be
scattered. This may lead to serious personal injury or death. To
prevent accidents, always do as follows.
• If pins are hit with a hammer, there is a hazard that the metal
particles may fly out and injure people in the surrounding
area. Always make sure that no-one is in the surrounding
area before using the hammer.
• If hard metal parts such as pins, or bearings are hit with a
hammer, there is a hazard that pieces might be scattered and
cause serious personal injury or death. Always wear protec-
tive equipment such as protective eyeglasses and gloves.
• If the pin is hit with strong force, there is a hazard that it may
fly out and injure people in the surrounding area. Do not allow
anyone to enter the surrounding area.

HIGH-TEMPERATURE COOLANT (ALL-B210-012-K-00-A)

To prevent burns from boiling water or steam spurting out when
checking or draining the coolant, wait for the coolant to cool down
to a temperature where the radiator cap can be touched by hand.
Then loosen the cap slowly to release the pressure inside the radi-
ator, and remove the cap.

HIGH-TEMPERATURE OIL (ALL-0000-2AL-K-00-A)

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.

HIGH-TEMPERATURE PARTS (PC220-0000-2AH-K-00-A)

To prevent burns from touching high-temperature parts, when checking or performing maintenance after stopping
engine, check the parts have been cooled down to touch with bare hand before checking or maintenance.

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PRECAUTIONS FOR MAINTENANCE SAFETY

HIGH-PRESSURE OIL (HM-0000-2AM-K-00-A)

The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pressure
when the engine is running and immediately after the engine is stopped. When performing inspection or replace-
ment of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not done, it
may lead to serious personal injury or death. Always do as follows.
• 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 perform inspection, wear protective equipment such as protective eyeglasses and leather gloves.
• There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause loss of sight if it con-
tacts your skin or eyes directly. If you are hit by a jet of high-
pressure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately for
medical attention.

HIGH-PRESSURE FUEL (ALL-AD02-2AH-K-00-A)

When the engine is running, high-pressure is generated in the engine fuel piping. If you try to disassemble the pip-
ing before the internal pressure is released, serious personal injury can result. When performing inspection or
maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal pres-
sure to go down before starting the operation.

HIGH-PRESSURE HOSES AND PIPING (ALL-0000-2AN-K-00-A)

• If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or misoperation, and lead to 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.

NOISE (ALL-0000-2AQ-K-00-A)
When performing maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

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SAFETY PRECAUTIONS FOR MAINTENANCE

HANDLING SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGS (HM-

0000-2AS-K-00-A)
The suspension cylinders, accumulator, and gas springs are charged with high-pressure nitrogen gas. If any mis-
take is made in handling, there is danger that it may cause an explosion or serious personal injury. To prevent acci-
dents, always do as follows.

• Do not remove or disassemble unless necessary.

• Do not bring it near open flame or dispose of it in fire.
• Do not make holes in it, weld it, or use a cutting torch.
• Do not hit or roll the accumulator, or subject it to any impact.
• Ask your Komatsu distributor when sealing gas into the cylin-
der or replacing gas from it.
• When disposing of the accumulator, the gas must be re-
leased. Ask your Komatsu distributor to perform this work.

COMPRESSED AIR (ALL-0000-2AT-K-00-A)

• When performing cleaning with compressed air, there is a hazard of serious personal injury 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 (ALL-K500-2AH-K-00-A)

• 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.

DISPOSE OF WASTE MATERIALS (ALL-0000-99A-K-00-A)

To prevent pollution, pay careful attention to the method of disposing of waste materials.

• Always put oil drained from your machine in containers.

Never drain oil directly onto the ground or dump into the sew-
age system, rivers, the sea, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
Some kinds of rubber, plastics might produce poisonous gas
harmful to person, when they are burned.
• When disposing of rubber, plastics, or parts (hoses, cables,
and harness) made of those materials, these must be treated
by industrial waste disposer in accordance with local
regulations.

SELECT WINDOW WASHER FLUID (ALL-K7B3-171-K-00-A)

Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

2-45
PRECAUTIONS FOR MAINTENANCE SAFETY

PERIODIC INSPECTION OF DEFINED LIFE PARTS

• To use the machine safely for a long period, be sure to periodically inspect the defined life parts that have an
especially close relation to safety, such as hoses and the seat belt. If an abnormality is found, replace it
immediately.
• 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 can fail and cause serious personal
injury or death. It is not easy to judge the remaining life of these components but inspect them as much as
possible before work and at the regular maintenance.
• Replace or repair the defined life parts if a defect is found by the check.

2-46
SAFETY PRECAUTIONS FOR MAINTENANCE

TIRES (WA-DW60-001-K-00-A)

HANDLING TIRES (HM-DW60-100-K-00-A)

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 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 perform these
operations.
• Use only specified tires and inflate them to the specified
pressure.
Specified inflation pressure: See "HANDLING TIRES（PAGE
3-189）".
• 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 pressure goes down abnormally or the rim parts do
not fit the tire, there is a problem with the tire or rim parts. Al-
ways contact your Komatsu distributor for repairs.
• If the rim parts are not fitted properly when the tire is being
pumped up, there is danger that the rim parts may fly off, so
set up a protective fence around the tire, and do not stand di-
rectly in front of the rim. Stand beside the tread when pump-
ing up the tire.
• Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-load work.
• Never perform welding or light a fire near the tire.
• Always release all pressure from a single tire or from both tires of a dual assembly prior to removing any rim
components.
• Before removing the tire from the machine for repairs, remove the valve partially to release the air from the
tire, then remove the tire.

STORING TIRES (HM-DW60-876-K-00-A)

Tires for construction equipment are extremely heavy, it may lead
to serious personal injury or death. To maintain safety, always do
as follows.
• 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 on level ground at angle (A) of 60 to 70 deg.
and fit blocks (1) securely so that the cannot roll 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 deteriorate.
• If the tire should fall over, do not attempt to stop it. Get out of
the way quickly.

2-47
PRECAUTIONS FOR MAINTENANCE SAFETY

2-48
3 OPERATION

OPERATION

3-1
GENERAL VIEW OPERATION

GENERAL VIEW (PC-0000-001-K-01-A)

GENERAL VIEW OF MACHINE (HM400-0000-04D-K-02-A)

(1) Headlamp (high beam) (9) Hydraulic tank

(2) Headlamp (low beam) (10) Hoist cylinder
(3) Fog lamp (if equipped) (11) Dump body
(4) Turn signal lamp and clearance lamp (12) Rear wheel
(5) Working lamp (13) Side lamp (if equipped)
(6) Yellow revolving warning lamp (if equipped) (14) Muffler
(7) Fire extinguisher (15) Fuel tank
(8) Front wheel (16) Air cleaner

3-2
OPERATION GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES

(1) Starting switch (10) Engine shutdown secondary switch

(2) Lamp switch, dimmer switch, turn signal lever (11) Fog lamp switch (if equipped)
(3) Wiper, window washer switch (12) Yellow revolving warning lamp switch
(4) Steering wheel (if equipped)
(5) Horn button (13) Power window switch
(6) Machine monitor (14) Side lamp switch (if equipped)
(7) Retarder control lever (15) Dump lever
(8) Parking brake switch (16) Dump lever lock knob
(9) Gear shift lever (17) Accelerator pedal
(18) Brake pedal

3-3
GENERAL VIEW OPERATION

Enlarged view of machine monitor

(1) Working lamp switch (7) Power mode selector switch

(2) Monitor brightness selector switch (8) AISS LOW switch
(3) Switch panel (9) Automatic retarder, accelerator linked control
(4) Hazard lamp switch switch (if equipped)
(5) Emergency steering switch (10) Inter-axle differential lock switch
(6) Rear view monitor brightness adjustment switch

3-4
OPERATION GENERAL VIEW

Machine monitor

(1) Speedometer (14) Retarder oil temperature gauge

(2) Engine tachometer (15) Retarder oil temperature caution lamp
(3) Centralized warning lamp (16) Fuel gauge
(4) Parking brake pilot lamp (17) Fuel level caution lamp
(5) Turn signal pilot lamp (L.H.) (18) Eco gauge
(6) Headlamp high beam pilot lamp (19) Air conditioner display
(7) Turn signal pilot lamp (R.H.) (20) Clock
(8) Brake oil pressure caution lamp (21) L.H. meter
(9) Clearance lamp pilot lamp (22) R.H. meter
(10) Engine coolant temperature gauge (23) Enter switch
(11) Engine coolant temperature caution lamp (24) Up switch
(12) Torque converter oil temperature gauge (25) Down switch
(13) Torque converter oil temperature caution lamp (26) Return switch
(27) Air conditioner switches/ Numeric keypad

3-5
GENERAL VIEW OPERATION

Liquid crystal unit display

(A) Standard screen (D) Warning screen

(B) ECO guidance screen (E) User menu screen
(C) Maintenance time warning screen
(28) Shift indicator (37) Torque converter lockup pilot lamp
(29) Shift lever position pilot lamp (38) Fan reverse pilot lamp
(30) Message pilot lamp (39) Engine preheating pilot lamp
(31) Retarder pilot lamp (40) ECO guidance
(32) Inter-axle differential lock pilot lamp (41) Maintenance time caution lamp
(33) KTCS pilot lamp (42) Guidance icon
(34) Emergency steering pilot lamp (43) Seat belt caution lamp
(35) Power mode pilot lamp (44) Caution display
(36) Shift hold pilot lamp (45) Action level

3-6
OPERATION EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS (ALL-0000-043-K-00-A)

The following is an explanation of devices needed for operating the machine.

To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.

MACHINE MONITOR (HM400-Q180-04D-K-01-A)

FF: Failure display screen

(A) Warning display (C) Meter display
(B) Pilot display (D) Switch panel

3-7
EXPLANATION OF COMPONENTS OPERATION

BASIC OPERATION OF MACHINE MONITOR (ALL-Q180-001-K-00-A)

STARTING ENGINE WHEN SITUATION IS NORMAL (HM400-Q180-044-K-03-A)

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) are lit for 2 seconds and go out for 1 second.
2. Liquid crystal display (C) displays starting screen AA for 2 seconds, and then changes to standard screen BB.
3. The pointer of engine tachometer (D) moves 1 cycle.
4. Speedometer (E) displays "88" for 2 seconds.
5. The alarm buzzer sounds for 2 seconds, then stops under the normal condition.
NOTICE
If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring may
have breakage. In this case, ask your Komatsu distributor for repair.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery
condition.
In such case, the machine monitor may go out temporarily or restart, but it is not a trouble.

3-8
OPERATION EXPLANATION OF COMPONENTS

START ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON (HM400-Q180-044-K-04-

A)
While engine shutdown secondary switch (1) is ON (stops en-
gine), even if the starting switch is turned to ON position, the
screen shown at right is displayed and the engine does not start.
When 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 operation.
For the function and operating method of engine shutdown secon-
dary switch (1), see "ENGINE SHUTDOWN SECONDARY
SWITCH（PAGE 3-84）".

STOPPING ENGINE WHEN SITUATION IS NORMAL (HM400-Q180-044-K-05-A)

When starting switch is turned to OFF position, the screen goes out. In the following case, the end screen is dis-
played for 5 seconds, and then screen goes out.
End screen with message
If there is any message from your Komatsu distributor, it is displayed on end screen DD for 5 seconds, and then
the screen goes out.
In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting re-
sponse, send back your reply.
For the method of display and reply for messages, see "MESSAGE DISPLAY（PAGE 3-74）".

3-9
EXPLANATION OF COMPONENTS OPERATION

End screen with 1-point advice

If there is any 1-point advice, it is displayed on end screen EE for 5 seconds, and then the screen goes out.
For the 1-point advice at the ending, see "SWITCHING DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS
OFF（PAGE 3-54）".
IF PROBLEM WAS FOUND WHEN STARTING MACHINE (HM400-Q180-044-K-06-A)

When the machine monitor is started, if the machine has trouble,

starting screen AA is displayed for 2 seconds and then it is
changed to the failure display screen FF.
When the enter switch is pressed while guidance icon (1) is dis-
played, the occurred error list screen is displayed.
For the occurred error list screen and the remedies, see "WARN-
ING DISPLAY（PAGE 3-12）".

When the machine monitor is started, if the time to the next main-
tenance of any item is 30 hours or less, starting screen AA is dis-
played for 2 seconds and then it is changed to maintenance time
warning screen GG.
When the menu switch displayed in guidance icon (2) is pressed,
the maintenance menu screen is displayed.
For the maintenance menu screen and the remedies, see "MAIN-
TENANCE（PAGE 3-63）".
After displaying the maintenance time warning screen GG for 30
seconds, the screen returns to the standard screen BB.

3-10
OPERATION EXPLANATION OF COMPONENTS

IF TROUBLE OCCURS WHILE OPERATING MACHINE (HM400-Q180-044-K-07-A)

If any trouble occurs during operation, the standard screen BB

changes to the failure display screen FF.
When the enter switch is pressed while guidance icon (1) is dis-
played, the occurred error list screen is displayed.
For the occurred error list screen and the remedies, see "WARN-
ING DISPLAY（PAGE 3-12）".
REMARK
Guidance icon (1) is displayed only while the machine is stopped
completely.
Even when the enter switch is pressed while the machine is not
stopped completely, the occurred error list screen is not displayed.

3-11
EXPLANATION OF COMPONENTS OPERATION

WARNING DISPLAY (HM400-Q1FB-043-K-00-A)

NOTICE
Appearance of any of action levels "L01" to "L04" on the machine monitor indicates presence of an trouble
on the machine.
Take appropriate remedies according to "ACTION LEVEL（PAGE 3-12）".
• These cautions do not guarantee the condition of the machine.
Do not simply rely on the monitor when performing checks before starting (start-up inspection). Al-
ways get off the machine and check each item directly.
• When the caution is displayed in red, if no action is taken, the machine can be seriously affected. Ac-
cordingly, take proper remedies immediately.
• The engine output or engine speed is limited and the machine operation speed may become slow, de-
pending on the contents of the alarm.

(1) Action level (7) Brake oil pressure caution lamp

(2) Guidance icon (8) Seat belt caution lamp
(3) Engine coolant temperature caution lamp (9) Caution display
(4) Torque converter oil temperature caution lamp (10) Caution display
(5) Retarder oil temperature caution lamp (11) Centralized warning lamp
(6) Fuel level caution lamp

ACTION LEVEL (HM400-Q1FC-043-K-00-A)

This action level (1) indicates the degree of urgency for occurring
trouble on the the machine by "L01" to "L04".
The larger number in the table is, the more serious effects the
trouble has on the machine if it is left with no remedy.
When the machine monitor displays an action level, take appropri-
ate remedies according to "List of action levels and remedies".

3-12
OPERATION EXPLANATION OF COMPONENTS

List of action levels and remedies

Centralized
Urgen- Color of
Action level warning Alarm buzzer Remedy
cy caution
lamp
Stop the machine immediately, and per-
form the inspection and maintenance.
Sounds
L04 ON Red Check the failure code and ask your Ko-
continuously
matsu distributor for inspection and
maintenance.
Stop the operation, move the machine to
a safe place, stop the machine, and per-
Sounds form the inspection and maintenance.
L03 ON Red
intermittently Check the failure code and ask your Ko-
matsu distributor for inspection and
maintenance.
High If there is an overrun related display, re-
↑ duce the engine speed and machine trav-
│ el speed while continuing operations.
│ If there is an overheat related display,
│ park the machine at a safe place, and run
│ the engine at medium speed with no
Sounds
↓ L02 ON Red load.
intermittently
Low If there is an emergency steering related
display, avoid a long time usage of the
emergency steering.
If the condition is not improved, check the
failure code and ask your Komatsu dis-
tributor for inspection and maintenance.
Some functions may be restricted for use,
but the machine can operate. When you
finish the operation, always perform the
L01 OFF － Yellow
inspection and maintenance.
Ask your Komatsu distributor for inspec-
tion and maintenance as needed.

REMARK
• When action level (1) is "L01", "L01" is displayed only for 2
seconds, and then disappears.
• If plural failures occur at the same time, the action level with
the highest urgency (the greatest number) is displayed.

3-13
EXPLANATION OF COMPONENTS OPERATION

OCCURRED FAILURE CODE DISPLAY (HM400-Q1FC-043-K-01-A)

The monitor provides information on failures that occurred on the
machine and necessary remedies for action levels that are
displayed.
When the enter switch is pressed while guidance icon (2) is dis-
played, the screen changes to the occurred error list screen.
REMARK
Guidance icon (2) is displayed only while the machine is stopped
completely.
Even when the enter switch is pressed while the machine is not
stopped completely, the occurred 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 remedies according to the displayed message.
(F): Contact telephone number
The telephone number of your Komatsu distributor is displayed.
If the telephone number of the contact has not been registered, it is not displayed.
When it is necessary to register the telephone number, ask your Komatsu distributor to perform the registration.
(G): Guidance icon

3-14
OPERATION EXPLANATION OF COMPONENTS

On the occurred error list screen, the following switches displayed

in guidance icon (G) can be operated.
Up switch: Moves selection to the previous page. When on the
first page, moves selection to the last page.

Down switch: Moves selection to the next page. When on the last
page, moves selection to the first page.

Return switch: Returns the display to the standard screen.

ENGINE COOLANT TEMPERATURE CAUTION LAMP (HM-BA8D-043-K-00-A)

This lamp (3) warns the operator that the engine coolant is
overheated.
If the engine coolant temperature increases abnormally high, the
lamp lights up in red and action level "L02" appears. At the same
time, the centralized warning lamp lights up and the alarm buzzer
sounds intermittently.
Stop the machine in a safe place, set the gear shift lever to N
(NEUTRAL) position, and run the engine at medium speed with
no load until the lamp goes out.

3-15
EXPLANATION OF COMPONENTS OPERATION

TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP (HM-CDK6-043-K-00-A)

This lamp (4) warns the operator that the torque converter oil is
overheated.
If the torque converter oil temperature increases abnormally high,
the lamp lights up in red and action level "L02" appears. At the
same time, the centralized warning lamp lights up and the alarm
buzzer sounds intermittently.
Stop the machine in a safe place, set the gear shift lever to N
(NEUTRAL) position, and run the engine at medium speed with
no load until the lamp goes out.

RETARDER OIL TEMPERATURE CAUTION LAMP (HM-GTB2-043-K-00-A)

This lamp (5) warns the operator that the retarder oil temperature
is overheated.
If the retarder oil temperature increases abnormally high, the lamp
lights up in red and action level "L02" appears. At the same time,
the centralized warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the machine in a safe place, set the gear shift lever to N
(NEUTRAL) position, and run the engine at medium speed with
no load until the lamp goes out.

FUEL LEVEL CAUTION LAMP (HM400-AD45-043-K-00-A)

This lamp (6) lights up to warn the operator that the fuel level has
dropped.
The lamp lights up in red if the fuel level is 102 liters (26.95 US
gal) or below.
Add fuel as soon as possible.

3-16
OPERATION EXPLANATION OF COMPONENTS

BRAKE OIL PRESSURE CAUTION LAMP (HM-G423-043-K-00-A)

This lamp (7) warns the operator that the brake oil pressure is be-
low the specified value.
• When action level "L03" is displayed
If the brake oil pressure drops below the specified value while
the engine is running, the lamp lights up in red. At the same
time, the centralized warning lamp lights up and alarm buzzer
sounds intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• Action level is not displayed and only lamp lights up in red
If the brake oil pressure is below the specified value while the
engine is stopped, the lamp lights up in red.
When the engine is started, the lamp lights up in red until the
brake oil pressure increases above the specified value. At the
same time, the centralized warning lamp lights up and alarm
buzzer sounds intermittently.
Wait until the lamp goes out, and then move the machine.

SEAT BELT CAUTION LAMP (HM-K2S5-043-K-00-A)

This lamp (8) lights up in red if the seat belt is not fastened.
There is a danger when traveling, so always fasten your seat belt.

CAUTION DISPLAY (HM400-Q180-043-K-00-A)

The following caution lamps are displayed in caution display areas
(9) and (10). Take appropriate remedies as specified.
REMARK
• If 1 caution is currently issued, its caution lamp is displayed
on caution display area (9).
• If 2 cautions are currently issued, their caution lamps are dis-
played on caution display areas (9) and (10).
• If 3 cautions are currently issued, their caution lamps are dis-
played on caution display areas (9) and (10) alternately on a
2 seconds basis.

3-17
EXPLANATION OF COMPONENTS OPERATION

ENGINE SYSTEM CAUTION LAMP (HM400-A9HC-043-K-00-A)

This lamp warns the operator that the engine system has a
trouble.
• When action level "L04" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and the alarm buzzer sounds
continuously.
Stop the machine immediately and ask your Komatsu distrib-
utor for inspection and maintenance.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
When you finish the operation, always perform the inspection
and maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

ENGINE OIL PRESSURE CAUTION LAMP (HM-ABL0-043-K-00-A)

This lamp warns the operator that the engine lubricating oil pres-
sure is low.
If the engine oil pressure drops below the specified value while
the engine is running, the lamp lights up in red and action level
L03 appears. 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 en-
gine, then ask your Komatsu distributor for inspection and
maintenance.

ENGINE OIL LEVEL CAUTION LAMP (HM400-AB4A-043-K-02-A)

This lamp warns the operator that the engine lubricating oil level is
low. It displays only while the engine is stopped.
If the lamp lights up in yellow and action level "L01" is displayed,
inspect the oil level in the oil pan and add oil.
"CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL（PAGE 3-
136）"See .
If the oil level drops again in a short time, the engine oil may be
leaking. Ask your Komatsu distributor for inspection and repair.

3-18
OPERATION EXPLANATION OF COMPONENTS

ENGINE OVERRUN CAUTION LAMP (HM-APE7-043-K-00-A)

This lamp warns the operator that the engine speed is higher than
the allowable range.
When the 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 displayed.
Operate the machine with moderate engine speed and travel
speed.

RADIATOR COOLANT LEVEL CAUTION LAMP (HM400-B255-043-K-01-A)

This lamp warns the operator that the radiator coolant level is low.
If the lamp lights up in yellow and action level "L01" is displayed,
inspect the coolant level in the reservoir tank and add coolant.
See "CHECK COOLANT LEVEL, ADD COOLANT（PAGE 3-
137）".
If the coolant level drops again in a short time, the coolant may be
leaking from the radiator. Ask your Komatsu distributor for inspec-
tion and maintenance.

AIR CLEANER CLOGGING CAUTION LAMP (HM400-A96F-043-K-00-A)

This lamp warns the operator about clogging of the air cleaner.
If the lamp lights up in yellow and action level "L01" is displayed,
stop the engine, then inspect and clean the air cleaner.
See "CHECK, CLEAN, AND REPLACE AIR CLEANER（PAGE
4-15）".

FAN CONTROL SYSTEM CAUTION LAMP (HM-B443-043-K-00-A)

This lamp warns the operator about trouble in the fan control
system.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

3-19
EXPLANATION OF COMPONENTS OPERATION

FAN-REVERSE OPERATION CAUTION LAMP (HM-B7B2-043-K-00-A)

This lamp warns the operator about malfunction during the fan-re-
verse operation.
If the gear shift lever is turned to any position other than N (NEU-
TRAL) or the dump body is not seated while the fan (radiator or
after cooler) is rotating in reverse, the lamp lights up in red. At the
same time, the centralized warning lamp lights up and alarm buz-
zer sounds intermittently.
Keep the gear shift lever in N (NEUTRAL) position and keep the
dump body seated while the fan is rotating in reverse.

TRANSMISSION SYSTEM CAUTION LAMP (HM-CZTH-043-K-00-A)

This lamp warns the operator about trouble in the transmission
system.
• When action level "L04" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
continuously.
Stop the machine immediately and ask your Komatsu distrib-
utor for inspection and maintenance.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP (HM-CH61-043-K-00-A)

This lamp warns the operator about clogging of the transmission
oil filter.
If the lamp lights up in yellow and action level "L01" is displayed,
stop the engine, then inspect or replace the transmission oil filter.
See "REPLACE TRANSMISSION OIL FILTER ELEMENT
（PAGE 4-66）".

3-20
OPERATION EXPLANATION OF COMPONENTS

INTER-AXLE DIFFERENTIAL LOCK SYSTEM CAUTION LAMP (HM-DDU6-043-K-00-A)

This lamp warns the operator about trouble in the inter-axle differ-
ential lock system.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

RETARDER SYSTEM CAUTION LAMP (HM-GT85-043-K-00-A)

This lamp warns the operator about trouble in the retarder system.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

PARKING BRAKE SYSTEM CAUTION LAMP (HM-GP31-043-K-00-A)

This lamp warns the operator about trouble in the parking brake
system.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

3-21
EXPLANATION OF COMPONENTS OPERATION

KTCS SYSTEM CAUTION LAMP (HM-C7K7-043-K-00-A)

This lamp warns the operator about trouble in the KTCS system.
If the 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 inspection and maintenance as
needed.

STEERING SYSTEM CAUTION LAMP (HM-FV91-043-K-00-A)

This lamp warns the operator about trouble in the steering system.
If the 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 inspection and maintenance as
needed.

STEERING OIL PRESSURE CAUTION LAMP (HM-F7C4-043-K-00-A)

This lamp warns the operator that the steering oil pressure is be-
low 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 lamp lights up in red. At the
same time, the centralized warning lamp lights up and alarm
buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• Action level is not displayed and only lamp lights up in red
When the engine is started, the 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 lamp goes out, and then move 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 lamp lights up in yellow.

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OPERATION EXPLANATION OF COMPONENTS

STEERING OIL TEMPERATURE CAUTION LAMP (HM-F7D4-043-K-00-A)

This lamp warns the operator about overheat of the steering oil.
If the steering oil temperature increases abnormally high, the 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.
Stop the machine in a safe place, set the gear shift lever to N
(NEUTRAL) position, and run the engine at medium speed with
no load until the lamp goes out.

EMERGENCY STEERING SYSTEM CAUTION LAMP (HM-F9S8-043-K-00-A)

This lamp warns the operator that the emergency steering system
has a trouble.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

EMERGENCY STEERING MOTOR CAUTION LAMP (HM-F9R2-043-K-00-A)

This lamp warns the operator that the emergency steering motor
has been operating for a long time.
The lamp lights up in yellow and action level "L02" is displayed. At
the same time, the centralized warning lamp lights up and alarm
buzzer sounds intermittently.
Do not continue to use the emergency steering for more than 90
seconds.

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EXPLANATION OF COMPONENTS OPERATION

HOIST CONTROL SYSTEM CAUTION LAMP (HM-M6KH-043-K-00-A)

This lamp warns the operator about trouble in the hoist control
system.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

BODY FLOAT CAUTION LAMP (HM-M6KK-043-K-00-A)

This lamp warns the operator about condition of the dump body.
• When lamp lights up in red
The dump lever is turned to any position other than FLOAT or
the gear shift lever is turned to any position other than N
(NEUTRAL) while the dump body is raised. At the same time,
the centralized warning lamp lights up and alarm buzzer
sounds intermittently.
• When lamp lights up in yellow
The dump lever is turned to any position other than FLOAT
position or the dump body is raised.
REMARK
If the engine stops, the dump body is held in the HOLD condition,
regardless of the position of the dump lever. Although this lamp
does not lights up in while the starting switch is turned to ON posi-
tion, it lights up when the engine is stared.
Cancel the HOLD condition of the dump body. For details, see
"CANCEL TO HOLD DUMP BODY（PAGE 3-155）".

INCLINATION CAUTION LAMP (HM-M5D4-043-K-00-A)

This lamp warns the operator about danger of turning over caused
by inclination.
When the dump lever is in RAISE position, if the rear part of the
machine is inclined more than the lateral stable range, the lamp
lights up in red. At the same time, the centralized warning lamp
lights up and alarm buzzer sounds intermittently.
Lower the dump body and move the machine to a safe level
ground.

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OPERATION EXPLANATION OF COMPONENTS

SYSTEM CAUTION LAMP (HM-Q1FD-043-K-00-A)

This lamp warns the operator that the system has a trouble.
• When action level "L03" is displayed
The lamp lights up in red. At the same time, the centralized
warning lamp lights up and alarm buzzer sounds
intermittently.
Stop the operation, move the machine to a safe place, stop
the engine, then ask your Komatsu distributor for inspection
and maintenance.
• When action level "L01" is displayed
The lamp lights up in yellow.
Whenever finished the work, perform the inspection and
maintenance.
Ask your Komatsu distributor for inspection and maintenance
as needed.

CHARGING SYSTEM CAUTION LAMP (HM-AKV5-043-K-00-A)

This lamp warns the operator about trouble in the charging system
while the engine is running.
If the battery is not charged properly while the engine is running,
the lamp lights up in red. When 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.
See "OTHER TROUBLE（PAGE 3-209）".

AIR CONDITIONER SYSTEM CAUTION LAMP (HM-K5V3-043-K-00-A)

This lamp warns the operator about trouble in the air conditioner
system.
If the 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 inspection and maintenance as
needed.

MAINTENANCE TIME CAUTION LAMP (HM400-Q1D3-043-K-01-A)

This lamp displays notices and alarms concerning maintenance
due time.
This monitor lights up when the starting switch is turned to ON po-
sition. It goes out after 30 seconds and the display changes to the
standard screen.
• When lamp lights up in red
The maintenance due time is over.
If no action is taken, the machine performance will become
worse and the machine life will be shortened. Perform neces-
sary maintenance as soon as possible.
• When lamp lights up in yellow
The maintenance due time is approaching.
Prepare necessary parts for the maintenance.

3-25
EXPLANATION OF COMPONENTS OPERATION

REMARK
• To check the items that need maintenance, see the maintenance menu screen.
• On the standard screen, when the menu switch is pressed while the lamp is lit, the screen changes directly to
the maintenance menu screen.
• For operations on the maintenance menu screen, see "MAINTENANCE（PAGE 3-63）".
• 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. However, you can change this setting. To change the initial set-
ting, ask your Komatsu distributor for change.
CENTRALIZED WARNING LAMP (HM-Q1G4-043-K-00-A)
This lamp (11) lights up in red, and at the same time the alarm
buzzer sounds intermittently when the machine is in any of the fol-
lowing conditions.

Machine conditions under which centralized Monitor display

warning lamp lights up
When action level "L02", "L03", or "L04" is
displayed.

When the engine overrun caution lamp is lit.

When the misoperation caution lamp in fan re-

verse mode is lit.

When the dump body float caution (red) is lit.

When the inclination caution lamp is lit.

When the charge voltage caution lamp is lit.

3-26
OPERATION EXPLANATION OF COMPONENTS

Machine conditions under which centralized Monitor display

warning lamp lights up
When the brake oil pressure is below the speci- The brake oil pressure caution lamp lights
fied value while the engine is running. up.

When the steering oil pressure is below the The steering oil pressure caution lamp
specified value while the engine is running. lights up.

When the starting switch is turned to ON position The current gear shift lever position pilot
while the gear shift lever is in the position other lamp flashes.
than N (NEUTRAL).
When all the signals from the gear shift lever are
turned OFF.

If the parking brake is applied, but the gear shift The parking brake pilot lamp is lit.
lever is not at N (NEUTRAL) position.

When the gear shift lever is in position D and the Shift indicator (F1) flashes.
accelerator pedal is depressed while the brake
is operated. (When D range F1 start setting is
effective)

3-27
EXPLANATION OF COMPONENTS OPERATION

PILOT DISPLAY (HM400-Q15A-043-K-00-A)

The pilot display consists of the pilot lamps to check the actuation of each function.
While the starting switch is in ON position, the pilot lamp lights up when the display items are functioning.

(1) Parking brake pilot lamp (10) Shift hold pilot lamp
(2) Turn signal lamp pilot lamp (11) Torque converter lockup pilot lamp
(3) Headlamp high beam pilot lamp (12) Fan reverse pilot lamp
(4) Clearance lamp pilot lamp (13) Engine preheating pilot lamp
(5) Retarder pilot lamp (14) Message pilot lamp
(6) Inter-axle differential lock pilot lamp (15) Shift indicator
(7) KTCS pilot lamp (16) Shift lever position pilot lamp
(8) Emergency steering pilot lamp (17) ECO guidance
(9) Power mode pilot lamp

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OPERATION EXPLANATION OF COMPONENTS

PARKING BRAKE PILOT LAMP (HM-GP31-043-K-01-A)

This lamp (1) lights up when the parking brake is applied.

TURN SIGNAL PILOT LAMP (HM-Q6DM-043-K-00-A)

This lamp (2) flashes synchronously with the turn signal lamp,
when it is turned on.

HEADLAMP HIGH BEAM PILOT LAMP (HM-Q646-043-K-00-A)

This lamp (3) lights up when the headlamps are set to high beam.

CLEARANCE LAMP PILOT LAMP (HM-Q1C9-110-K-00-A)

This lamp (4) lights up when the clearance lamps are turned on.

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EXPLANATION OF COMPONENTS OPERATION

RETARDER PILOT LAMP (HM-GT84-043-K-00-A)

This lamp (5) lights up when the retarder is in operation.
The retarder operates in the following cases.
• When the retarder control lever is pulled.
• When the auto retarder, accelerator control system (ARAC) is
in operation.

INTER-AXLE DIFFERENTIAL LOCK PILOT LAMP (HM-DDU8-043-K-00-A)

This lamp (6) lights up when the inter-axle differential lock is
actuated.

KTCS PILOT LAMP (HM400-GX01-043-K-01-A)

This lamp (7) indicates the operating state of KTCS.
(A): Lights up when KTCS is in operation.
(B): Lights up when KTSC is turned OFF.
For details of KTCS setting, see "KTCS SYSTEM SETTING
（PAGE 3-59）".

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OPERATION EXPLANATION OF COMPONENTS

EMERGENCY STEERING PILOT LAMP (HM400-F9S9-043-K-00-A)

This lamp (8) lights up when the emergency steering is actuated.

POWER MODE PILOT LAMP (HM400-AP19-043-K-00-A)

This lamp (9) displays the output mode setting state.
By selecting power mode selector switch, one of the following
lamps lights up.
(A): Power mode
(B): Economy mode

SHIFT HOLD PILOT LAMP (HM400-CP2C-043-K-00-A)

This lamp (10) lights up when the shift hold function is turned on.

TORQUE CONVERTER LOCKUP PILOT LAMP (HM400-CDU6-043-K-00-A)

This lamp (11) lights up when the torque converter lockup is en-
gaged and the transmission is shifted to direct drive.

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EXPLANATION OF COMPONENTS OPERATION

FAN REVERSE PILOT LAMP (HM400-B736-043-K-01-A)

This lamp (12) lights up when the radiator fan or CAC fan is set in
fan reverse mode.
For details of the method to set the fan reverse mode, see "RADI-
ATOR FAN REVERSE MODE（PAGE 3-55）" or "CAC FAN RE-
VERSE MODE（PAGE 3-57）".
REMARK
"CAC" denotes the after cooler.

ENGINE PREHEATING PILOT LAMP (HM400-AM4A-043-K-01-A)

This lamp (13) lights up when the automatic preheating function of
the engine is actuated, and goes out when preheating is
completed.
This lamp also lights up during manual preheating. The electrical
heater for engine preheating is activated while this lamp is lit.
For details of engine preheating, see "STARTING ENGINE
（PAGE 3-150）".

MESSAGE PILOT LAMP (HM400-Q235-043-K-01-A)

This lamp (14) lights up when your Komatsu distributor sends out
any information.
(A):There is unread message(s).
(B):There is any read message to which no reply is made.
To read the message, see "MESSAGE DISPLAY（PAGE 3-74）".

SHIFT INDICATOR (HM400-CZ35-043-K-00-A)

This indicator (15) shows the transmission shift range (speed
range).

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OPERATION EXPLANATION OF COMPONENTS

SHIFT LEVER POSITION PILOT LAMP (HM400-CZ34-043-K-00-A)

This lamp (16) displays the position of the gear shift lever.
The character for the selected gear shift lever position is enlarged.

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EXPLANATION OF COMPONENTS OPERATION

ECO GUIDANCE (HM400-Q1L3-043-K-01-A)

This guidance (17) is displayed during the operation that lowers the fuel efficiency, and support energy saving op-
eration for reducing the fuel consumption.
The details of the guidance are as follows:
EXCESSIVE IDLING GUIDANCE (HM-Q1L3-043-K-01-A)
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 periods,
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.
NOTICE
During loading work, do not stop the engine to maintain the
operation of the retarder brake.

GUIDANCE TO AVOID HOIST RELIEF (HM-Q1L3-043-K-02-A)

When relief of oil pressure of the hoist is continued for more than
5 seconds while the accelerator pedal is depressed, the hoist-re-
lief restriction message is displayed on the machine monitor.
Relief of the host oil pressure occurs if you turn the hoist lever to
RAISE position when the dump body is raised to the maximum
height or when the hoist lever is turned to LOWER position when
the dump body is seated.
Return the hoist lever to HOLD or FLOAT position to restrict un-
necessary relief.
• The hoist-release restriction message goes out automatically
in 10 seconds.

BRAKE DRAGGING PREVENTION GUIDANCE (HM-Q1L3-043-K-03-A)

If the accelerator pedal is depressed for more than 5 seconds
while applying the brake during traveling, the brake dragging re-
striction message is displayed on the machine monitor.
If the accelerator is operated while the brake is applied, fuel con-
sumption is increased.
• The brake dragging restriction message goes out automati-
cally after 10 seconds.

GUIDANCE TO RECOMMEND SHIFTING UP (HM-Q1L3-043-K-04-A)

Even when the engine speed reaches shift up speed during travel-
ing, if the upshift disable condition continues more than 5 sec-
onds, by gear shift lever or shift hold switch, the upshift
recommendation message is displayed on the machine monitor.
This message appears in the reverse travel, as well. It is, however,
not displayed in the downhill travel with retarder operation.
When traveling on a flat road, reduce the fuel consumption by
shifting the gear up and decreasing the engine speed.
• The upshift recommendation message goes out automatically
after 10 seconds.

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OPERATION EXPLANATION OF COMPONENTS

GUIDANCE TO AVOID ACCELERATION OPERATION DURING DUMP BODY LOWERING (HM-Q1L3-

043-K-05-A)
If you depress the accelerator pedal for more than 5 seconds
while the dump body is lowering, the message to restrict the accel-
erator operation during the dump body lowering operation is dis-
played on the machine monitor.
When the dump body is lowering, restrict the accelerator operation
in order to reduce the fuel consumption.
• The message to restrict the accelerator operation during
dump body lowering operation goes out automatically after
10 seconds.

GUIDANCE TO AVOID STEERING RELIEF (HM400-Q1L3-043-K-02-A)

If the steering oil pressure is relieved for more than 5 seconds, 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 forcible steering operation to reduce the fuel
consumption.
• The steering relief restriction message goes out automatically
after 10 seconds.

REMARK
Display/Non-display of ECO guidance can be switched.
For the method of switching the display, see "SWITCHING DISPLAY/NON-DISPLAY OF ECO GUIDANCE
（PAGE 3-53）".

3-35
EXPLANATION OF COMPONENTS OPERATION

METER DISPLAY (HM400-Q1LB-04D-K-00-A)

(1) Speedometer (6) Fuel gauge

(2) Engine tachometer (7) ECO gauge
(3) Engine coolant temperature gauge (8) L.H. meter
(4) Torque converter oil temperature gauge (9) R.H. meter
(5) Retarder oil temperature gauge

SPEEDOMETER (HM-Q1LH-043-K-00-A)
This meter (1) indicates the travel speed of the machine.

ENGINE TACHOMETER (HM-Q1LJ-043-K-00-A)

This meter (2) indicates the engine speed.
If the engine speed is higher than the allowable range during oper-
ation, the engine overrun caution lamp lights up in red. At the
same time, the centralized warning lamp lights up and alarm buz-
zer sounds intermittently.
Operate the machine with moderate engine speed and travel
speed.

3-36
OPERATION EXPLANATION OF COMPONENTS

ENGINE COOLANT TEMPERATURE GAUGE (HM-BA80-043-K-00-A)

This meter (3) indicates the engine coolant temperature.
When the indicator is in the white range (A) or green range (B)
during operation, engine coolant temperature is normal.
If the indicator is in the red range (C), the engine coolant tempera-
ture caution lamp lights up in red, and action level "L02" appears.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
The engine output is then limited automatically.
Stop the machine in a safe place, set the gear shift lever to N
(NEUTRAL) position, 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 (HM-CDK0-043-K-00-A)

This meter (4) indicates the torque converter oil temperature.
When the indicator is in the green range (B) during operation, tor-
que converter oil temperature is normal.
If the indicator is in the red range (C), the torque converter oil tem-
perature caution lamp lights up in red, and action level "L02" ap-
pears. At the same time, the centralized warning lamp lights up
and alarm buzzer sounds intermittently.
Stop the machine in a safe place, set the shift lever to N (NEU-
TRAL) position, and run the engine at a medium speed with no
load until the torque converter oil temperature caution lamp goes
out.

RETARDER OIL TEMPERATURE GAUGE (HM-GTB0-043-K-00-A)

This meter (5) indicates the retarder oil temperature.
When the indicator is in the green range (B) during operation, the
retarder oil temperature is normal.
If the indicator is in the red range (C), the retarder oil temperature
caution lamp lights up in red, and action level "L02" appears.
Stop the machine in a safe place, set the shift lever to N (NEU-
TRAL) position, and run the engine at a medium speed with no
load until the retarder oil temperature caution lamp goes out.

FUEL GAUGE
This meter (6) indicates the amount of fuel remaining in the fuel
tank.
If the indicator is in red range (C), the fuel level caution lamp lights
up in red. The fuel level is below 102 liters (26.9 US gal). Check
fuel level, and add fuel.
The fuel in the fuel tank shakes when traveling on the slopes or
curves. For this reason, the display of the fuel gauge may go up
and down, but it is not a trouble.

3-37
EXPLANATION OF COMPONENTS OPERATION

ECO GAUGE (HM-Q1LC-043-K-00-A)

This gauge (7) indicates the instantaneous fuel consumption (fuel
consumption rate at each moment).
The instantaneous fuel consumption varies depending on the op-
eration ways (accelerator operation, travel speed, gear speed,
etc.) and the given load during travel (load weight, slope, ground
condition, etc.).
As the gauge is higher, the fuel consumption is [Link] the
gauge to a point where there is no adverse effect on the operation,
leading to energy saving operation to reduce the fuel
consumption.
REMARK
Even if the gauge is in orange range (A), it is not a machine
trouble.
Target fuel consumption (B) displayed by the ECO gauge can be
changed as necessary.
For the method of changing the target value, see "SETTING THE
TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO
GAUGE（PAGE 3-52）".

L.H. AND R.H. METER DISPLAY (HM400-Q196-043-K-01-A)

L.H. meter (8) indicates either of the following which can be selected.
• Service meter
• Odometer
• Clock
For the method of selecting the display, see "SELECT L.H. METER DISPLAY（PAGE 3-67）".
R.H. meter (9) indicates either of the following which can be selected.
• Fuel consumption gauge
• Service meter
• Odometer
• Clock
For the method of selecting the display, see "SELECT R.H. METER DISPLAY（PAGE 3-67）".
Service meter display
Indicates the integrated operating hours of the machine.
When the engine is running, the service meter advances even if
the machine is not being operated.
The service meter advances by 0.1 for 6 engine running minutes
and by 1 for 1 engine running hour, regardless of the engine
speed.

Odometer display
Indicates the total distance that machine has traveled in
kilometers.

3-38
OPERATION EXPLANATION OF COMPONENTS

Clock display
Indicates the current time.
(A): 12-hour display
(B): 24-hour display

REMARK
If the battery is disconnected for a long period for storage etc., the time information may be lost.
For the method of setting and correcting the time and changing the display of the clock, see "CLOCK ADJUST-
MENT（PAGE 3-69）".
Fuel consumption gauge display
Indicates the average fuel consumption of the machine.
(C): Average fuel consumption in a day
(D): Split fuel consumption (under measuring)
(E): Split fuel consumption (when measuring is stopped)
REMARK
Display on the fuel consumption gauge can be switched between
the average fuel consumption per day (from 0:00 am of the day to
0:00 am of the next day) and the average fuel consumption during
an selected period (split fuel consumption).
For the method of switching the display, see "SETTING DISPLAY
OF FUEL CONSUMPTION GAUGE（PAGE 3-49）".

3-39
EXPLANATION OF COMPONENTS OPERATION

SWITCH PANEL (HM400-Q1C0-04D-K-00-A)

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 being displayed when the
switch is pressed.

(1) Menu switch (5) Down switch

(2) Enter switch (6) Air conditioner switches/ Numeric keypad
(3) Return switch (7) Guidance icon
(4) Up switch

MENU SWITCH (HM400-Q1C1-04D-K-02-A)

When this switch (1) is pressed on the standard screen, the follow-
ing user menu screen is displayed. However, the user menu
screen is not displayed during traveling.
For details of the user menu, see "USER MENU（PAGE 3-43）".
Normal: Displays the ECO guidance menu screen.
When maintenance caution lights up: Displays the Maintenance
menu screen.
When fan reverse pilot lamp lights up: Displays the Machine Set-
ting/Information menu screen.
When message pilot lamp lights up: Displays the Message display
menu screen.
When this switch (1) is pressed on the user menu screen, the
menu screen changes.

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OPERATION EXPLANATION OF COMPONENTS

ENTER SWITCH (HM400-Q1C1-04D-K-03-A)

Pressing this switch (2) on the user menu screen decides any se-
lection and changes, and proceeds to the next screen.
When this switch is pressed on the standard screen with a warn-
ing message displayed, the occurred error list screen is displayed.
For the occurred error list screen, see "OCCURRED FAILURE
CODE DISPLAY（PAGE 3-14）".

RETURN SWITCH (HM-Q1C1-04D-K-03-A)

Pressing this switch (3) cancels a selection or changes, and re-
turns to the previous screen or the standard screen.

UP SWITCH (HM-Q1C1-04D-K-04-A)
Pressing this switch (4) moves up by 1 item. When on the top, it
moves to the last on the previous page.
On the value input screen, the value is increased by one.

DOWN SWITCH (HM400-Q1C1-04D-K-04-A)

Pressing this switch (5) moves selection down by one item. When
on the last, it moves selection to the top on the next page.
On the value input screen, the value is decreased by one.

3-41
EXPLANATION OF COMPONENTS OPERATION

REMARK
• The switches effective on each screen can be checked with
guidance icon (7).
This function is not available when you press a switch not
marked by guidance icon (7) or you press guidance icon (7)
itself.

AIR CONDITIONER SWITCH / NUMERAL KEY PAD (HM400-K5FK-043-K-01-A)

This switch (6), which is used for the operation of the air condi-
tioner, consists of 10 switches.
For explanation of each switch, see "HANDLING AIR CONDI-
TIONER（PAGE 3-93）".
These switches can be used as a numeric keypad to enter a nu-
meric value such as a password.
Press a desired switch to enter a numeric value 0 to 9, which is in-
dicated at the lower right of each switch.

REMARK
• For details of other switch functions, see the explanation for each screen in "USER MENU（PAGE 3-43）".
• The confirmation sound is heard when the switch is pressed, but a reaction is taken (the switch function is op-
erated) when the switch is released.

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OPERATION EXPLANATION OF COMPONENTS

USER MENU
When menu switch (1) is pressed on the standard screen while
the machine is stopped, the user menu screen is displayed to ena-
ble you to configure and confirm machine settings.

The user menu consists of the following kinds. The menu screen can be changed by pressing menu switch (1).

(A): ECO guidance

(B): Machine setting/ Information
(C): Maintenance
(D): Monitor setting
(E): Message display

These menus (A) to (E) are for setting and confirming the following items:

(A): ECO guidance

(D): Monitor setting
• Check of operating record
• Rear view monitor setting (if equipped)
• Check of ECO guidance record
• Meter display selection
• Check and reset of fuel consumption record
• Screen adjustment
• Configurations
• Clock adjustment
(B): Machine setting/ Information
• Language selection
• Setting of radiator fan reverse mode
(E): Message display
• Setting of CAC fan reverse mode
• Check of message contents and reply to
• Setting of KTCS
message
• Display and reset of dumping counter
• Display of reverse travel odometer
• Display and reset of trip meter
• F1 Start at D Position Setting
• Air-conditioner ECO Mode Setting
• Retarder Lever Release Sound Setting
(C): Maintenance
• Check and reset of various maintenance remaining times

REMARK
"CAC" denotes the after cooler.

3-43
EXPLANATION OF COMPONENTS OPERATION

On the user menu screen, it is possible to perform the following

operations with the switches.
(1) Up switch: Moves to item above. When on the first item, moves
to the last item.
(2) Down switch: Moves to item below. When on the last item,
moves to the first item.
(3) Enter switch: Enters any selection or changes and to proceed
to the next screen.
(4) Return switch: Cancels a selection or changes, and returns to
the previous screen or the standard screen.

REMARK
• If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the pre-
vious 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 stand-
ard screen.
ECO GUIDANCE (HM400-Q1L3-100-K-00-A)
Each item of this menu (A) is used for displaying and setting the
notification relevant to energy saving.

OPERATING RECORD (HM400-Q1L3-110-K-06-A)

The operating record screen displays the following information on
a daily basis or during the split measurement period.
• Working Hours (Engine On)
• Average Fuel Consumption
• Actual Working Hours
• Ave. Fuel Consumption (Actual Working)
• Fuel Consumption
• Idling Hours
• E mode Time Ratio
Select Operating Record (1) from the ECO guidance menu
screen, then press enter switch.
REMARK
For details of the definition and display change method of the daily
and split measurements, see "SETTING DISPLAY OF FUEL
CONSUMPTION GAUGE（PAGE 3-49）".

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OPERATION EXPLANATION OF COMPONENTS

When display of the fuel consumption gauge is set to "1 Day"

When display of the fuel consumption gauge is set to "Split Time", and performing split time
measurement
(2): Display during measurement
(3): Date and time when the measurement is started
To stop the split measurement, see guidance icon (4) and press
the enter switch.

When display of the fuel consumption gauge is set to "Split Time", and split time measurement is
stopped
(5): Display while measurement is stopped
(6): Dates and times when the measurement is started and
stopped
To start the split measurement, see guidance icon (7) and press
the enter switch.
When the split measurement is started, the previous split meas-
urement results (fuel consumption gauge display, operation re-
cord, and ECO guidance record) are reset.

When the confirmation screen is displayed, press the enter switch

again to start the split measurement, or press the return switch to
cancel the start.

NOTICE
The displayed value of Fuel Consumption and Ave. Fuel Consumption may differ from the actual value due
to the operating conditions of the customers (fuel, weather or work contents, etc.).

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EXPLANATION OF COMPONENTS OPERATION

ECO GUIDANCE RECORD (HM400-Q1L3-110-K-07-A)

From the ECO guidance record screen, the frequency of display
of the ECO guidance on a daily basis or during the split measure-
ment period and the one-point advice are displayed.
Select ECO Guidance Records (1) from the ECO guidance menu
screen, then press the enter switch.
REMARK
For details of the definition and display change method of the daily
and split measurements, see "SETTING DISPLAY OF FUEL
CONSUMPTION GAUGE（PAGE 3-49）".
For details of the ECO guidance, see "ECO GUIDANCE（PAGE
3-34）".
In the one-point advice section, the advice to the ECO guidance
that appeared most frequently is displayed.
The ECO guidance count increases when display conditions are
satisfied even if the ECO guidance is not displayed.

When the fuel consumption gauge is set to "1 Day":

When display of the fuel consumption gauge is set to "Split Time", and performing split time
measurement
(2): Display during measurement
(3): Date and time when the measurement is started
To stop the split measurement, see guidance icon (4) and press
the enter switch.

When display of the fuel consumption gauge is set to "Split Time", and split time measurement is
stopped
(5): Display while measurement is stopped
(6): Dates and times when the measurement is started and
stopped
To start the split measurement, see guidance icon (7) and press
the enter switch.
When the split measurement is started, the previous split meas-
urement results (fuel consumption gauge display, operation re-
cord, and ECO guidance record) are reset.

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OPERATION EXPLANATION OF COMPONENTS

When the confirmation screen is displayed, press the enter switch

again to start the split measurement, or press the return switch to
cancel the start.

FUEL CONSUMPTION RECORD (HM400-Q1L3-110-K-08-A)

The fuel consumption record screen alternately displays the fol-
lowing graphs.
• Average fuel consumption for the last 12 hours
• Average fuel consumption for the last 1 week
Select Average Fuel Consumptions Logs (1) from the ECO guid-
ance menu screen, then press the enter switch.
To change a graph, see guidance icon (2) and press the menu
switch.

• When display of the last 12 hours is selected

• When display of the last 1 week is selected

REMARK
The graph of the last 12 hours is updated every hour of the service
meter reading.
The graph of the last 1 week is updated every day.
To clear a graph, see guidance icon (3) and press the enter
switch.

When the confirmation screen is displayed, press the enter switch

again to clear or press the return switch to cancel clearing.

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EXPLANATION OF COMPONENTS OPERATION

REMARK
If a graph for the last 12 hours is selected to be cleared, only this graph is cleared.
If a graph for the last 1 week is selected to be cleared, both the graphs for the last 12 hours and last 1 week are
cleared.

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OPERATION EXPLANATION OF COMPONENTS

CONFIGURATIONS (HM400-Q1L3-110-K-09-A)
On the display setting menu, it is possible to perform following
settings.
• Setting of fuel consumption gauge display
• Switching Display/Non-display of ECO gauge
• Setting the target fuel consumption value displayed in ECO
gauge
• Switching DisplayNon-display of ECO guidance
• Switching Display/Non-display of guidance at key-off
Select Cinfigurations (1) from ECO guidance menu screen, then
press the enter switch.

SETTING DISPLAY OF FUEL CONSUMPTION GAUGE (HM400-Q1L3-110-K-10-A)

The display of fuel consumption gauge (2) can be set to the value
on daily basis or during split measurement period.

1. Select fuel consumption gauge display (3) from the display

setting menu, then press the enter switch.

2. Select 1 Day or Split Time, then press the enter switch.

Initially, the 1 Day is selected.
To cancel selection, press the return switch.

1 Day
Displays the average fuel consumption in 1 day from 0:00 a.m. of the day to 0:00 a.m. of the next day.
Reset at 0:00 a.m. of the next day.
Split Time
Displays the average fuel consumption during the split measurement period (after the measurement is started until
it is finished).

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EXPLANATION OF COMPONENTS OPERATION

Select Split Time to start the split measurement automatically.

REMARK
For the display of the fuel consumption gauge, see "L.H. AND R.H. METER DISPLAY（PAGE 3-38）".
Setting 1 Day or Split Time is also applied to the display of the operation record and ECO guidance record.
When stopping the split measurement, see "OPERATING RECORD（PAGE 3-44）" or "ECO GUIDANCE RE-
CORD（PAGE 3-46）".

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OPERATION EXPLANATION OF COMPONENTS

SWITCHING DISPLAY/NON-DISPLAY OF ECO GAUGE (HM400-Q1L3-110-K-11-A)

Display/non-display of ECO gauge (1) can be switched.

1. Select ECO gauge display (2) from the display setting menu,
then press the enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Displays the ECO gauge.
OFF: Does not display the ECO gauge.
To cancel selection, press the return switch.
Initially, ON is selected.

REMARK
For the ECO gauge, see "ECO GAUGE（PAGE 3-38）".
If the ECO Gauge display is set to OFF, the items of ECO Gauge Target Value (3) are not indicated.

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EXPLANATION OF COMPONENTS OPERATION

SETTING THE TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE (HM-Q1L3-110-K-07-A)
ECO Gauge Target Value (A) (the upper limit value of the green
range) can be changed.

1. Select ECO Gauge Target Value (1) displayed in the ECO

gauge from the display setting menu, then press enter switch.

2. Use the UP switch or DOWN switch to set the value, and

press the enter switch.
UP switch: Increases the target fuel consumption value by 1
liter/h.
DOWN switch: Decreases the target fuel consumption value
by 1 liter/h.
To cancel sending, press the return switch.
Initially, this value is set to 53 liter/h.

REMARK
For the ECO gauge, see "ECO GAUGE（PAGE 3-38）".

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OPERATION EXPLANATION OF COMPONENTS

SWITCHING DISPLAY/NON-DISPLAY OF ECO GUIDANCE (HM400-Q1L3-110-K-13-A)

Display/non-display of ECO guidance (1) indicated on the stand-
ard screen can be switched.

1. Select ECO Guidance display (2) from the display setting

menu, then press enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Displays the ECO guidance.
OFF: Does not display the ECO guidance.
To cancel selection, press the return switch.
Initially, ON is selected.

REMARK
For details of the ECO guidance, see "ECO GUIDANCE（PAGE
3-34）".
If the ECO Guidance display is turned OFF, display of ECO Guid-
ance (3) and ECO Guidance Record (4) do not appear when the
starting key is turned off. The ECO guidance records, however,
are not reset.

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EXPLANATION OF COMPONENTS OPERATION

SWITCHING DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF (HM400-Q1L3-110-K-14-A)

Display/ non-display of the one-point advice indicated on the end
screen when the key is turned to OFF position can be switched.

1. Select "ECO Guidance at key off" (1) from the display setting
menu, then press the enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Displays the one-point advice on the end screen.
OFF: Does not display the one-point advice on the end
screen.
To cancel selection, press the return switch.
Initially, ON is selected.

REMARK
In the one-point advice section indicated on the end screen, the advice to the ECO guidance that was displayed
most frequently after the starting switch is turned to ON position is indicated. Accordingly, the one-point advice indi-
cated on the end screen may be different from the one-point advice indicated on "ECO GUIDANCE RECORD
（PAGE 3-46）".

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OPERATION EXPLANATION OF COMPONENTS

MACHINE SETTING / INFORMATION (HM400-Q647-043-K-00-A)

In each item of this menu (B), setting and information of the ma-
chine are checked or changed.

RADIATOR FAN REVERSE MODE (HM400-Q1C9-110-K-02-A)

CAUTION
• When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth etc.
will not be wound in the fan.
Since dust may blown up, check that there is no person around while the fan is rotating in reverse.

When cleaning the dirt or dusts stuck to the radiator, you can ro-
tate the fan in the reverse direction.
1. Seat the dump body, stop the engine, and open the engine
hood.
2. Turn the starting switch to ON position, select Manual fan re-
verse mode (1) in the Machine setting/Information menu, and
press the enter key.

3. Press the enter switch to rotate the fan in the reverse direc-
tion, or press the return switch to cancel the setting.

If the dump body is not seated or the engine is running, the screen
as shown in the figure to the right appears, and the fan rotation
cannot be switched.
In this case, press the return switch, and then repeat the proce-
dure from the first.

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EXPLANATION OF COMPONENTS OPERATION

4. Fan reverse pilot lamp (2) lights up.

Start the engine. The fan rotates in reverse.

If you start the machine travel or operate the dump body while the
fan rotates in reverse, misoperation caution in fan reverse mode
(3) appears. At the same time, the centralized warning lamp lights
up and alarm buzzer sounds intermittently.
5. After finishing cleaning, stop the engine.
A certain time after the starting switch key is turned to OFF
position, the fan is returned to the normal rotation mode
automatically.
Check that fan reverse pilot lamp (2) is OFF when the starting
switch is turned ON.

Use the following procedure when restoring the normal rotation

manually.
1) Turn the starting switch to ON position again, select Radia-
tor fan reverse mode (1) in the Machine Setting/ Informa-
tion menu, and press the enter key.
2) When the screen shown to the right appears, press the en-
ter switch to return the fan to the normal rotation mode.
REMARK
• When the CAC fan is set in the reverse mode, the radiator fan
is returned to the normal rotation mode automatically.
• "CAC" denotes the after cooler.
• If the engine compartment is heated high due to the reverse
mode-based reverse rotation of the fan, the controller may
stop the air conditioner to protect itself from being damaged.

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OPERATION EXPLANATION OF COMPONENTS

CAC FAN REVERSE MODE (HM400-Q1C9-100-K-00-A)

CAUTION
• When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth etc.
will not be wound in the fan.
Since dust may blown up, check that there is no person around while the fan is rotating in reverse.

When cleaning the dirt and dusts stuck to the CAC, you can rotate
the fan in the reverse direction.
1. Seat the dump body and stop the engine.
REMARK
• "CAC" denotes the after cooler.
2. Turn the starting switch to ON position, select CAC Fan Re-
verse Mode (1) in the Machine Setting/Information menu, and
press the enter key.

3. Press the enter switch to rotate the fan in the reverse direc-
tion, or press the return switch to cancel setting.

If the dump body is not seated or the engine is running, the screen
as shown in the figure to the right appears, and the fan rotation
cannot be switched.
In this case, press the return switch, and then repeat the proce-
dure from the first.

4. Fan reverse pilot lamp (2) lights up.

Start the engine. The fan rotates in reverse.

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EXPLANATION OF COMPONENTS OPERATION

If you start the machine travel or operate the dump body while the
fan rotates in reverse, misoperation caution in fan reverse mode
(3) appears. At the same time, the centralized warning lamp lights
up and alarm buzzer sounds intermittently.
5. After finishing cleaning, stop the engine.
A certain time after the starting switch key is turned to OFF
position, the fan is returned to the normal rotation mode
automatically.
Check that fan reverse pilot lamp (2) is OFF when the starting
switch is turned ON.

Use the following procedure when restoring the normal rotation

manually.
1) Turn the starting switch to ON position again, select Radia-
tor fan reverse mode (1) in the Machine Setting/Informa-
tion menu, and press the enter key.
2) When the screen shown to the right appears, press the en-
ter switch to return the fan to the normal rotation mode.
REMARK
• If the radiator fan is set in the reverse mode, the after cooler
fan is returned to the normal rotation automatically.

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OPERATION EXPLANATION OF COMPONENTS

KTCS SYSTEM SETTING (HM400-Q1C9-110-K-03-A)

Allows setting ON or OFF of the KTCS system.
1. Select KTCS setting (1), then press the enter switch.

2. Select ON or OFF, then press the enter switch.

ON: KTCS operates automatically.
OFF: KTCS does not operate. KTCS pilot lamp (2) lights up
to indicate operation is stopped.

REMARK
For details of KTCS function, see "HANDLING KOMATSU TRAC-
TION CONTROL SYSTEM (KTCS)（PAGE 3-175）".
This setting is held even after the starting switch key is turned to
OFF position.
The default is ON.

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EXPLANATION OF COMPONENTS OPERATION

DUMPING COUNTER (HM400-Q1C9-110-K-04-A)

(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 (1) is not displayed.
The number of times can be reset according to the following procedure.

1. Select dumping counter (1), then press the enter switch.

2. Press the enter switch to reset or press the return switch to

cancel resetting.

REVERSE TRAVEL ODOMETER (HM400-Q1C9-110-K-05-A)

The total reverse travel distance can be checked with reverse
travel odometer (1).

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OPERATION EXPLANATION OF COMPONENTS

TRIP METER (HM400-Q1C9-110-K-06-A)

The overall travel distance after the previous resetting can be
checked by using trip meter (1).
The trip meter can be reset according to the following procedure.
1. Select Trip Meter (1), then press the enter switch.

2. Press the enter switch to reset or press the return switch to

cancel resetting.

D RANGE F1 START SETTING (HM400-Q1C9-110-K-07-A)

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 (1), then press the enter
switch.

2. Select F1 or F2, then press the enter switch.

F1: Starts the machine travel at 1st speed when the shift lever
is set to D position.
F2: Starts the machine travel at 2nd speed when the shift lev-
er is set to D position. (Normal)

NOTICE
Select F2 usually.
If the machine travels in F1 unnecessarily, the service life of the machine may be shortened.
REMARK
If the machine travels in F1 while the dump body is not seated, the gear speed is fixed to the 1st even if the gear
shift lever is in D position.
This setting is held even if the starting switch is turned to OFF position.
The default is F2.

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EXPLANATION OF COMPONENTS OPERATION

AIR CONDITIONER ECO MODE SETTING (HM400-Q1C9-110-K-08-A)

Turns ON or OFF the air conditioner mode that improves the fuel
consumption by reducing efficacy of the air conditioner.
1. Select air conditioner ECO mode setting (1), then press the
enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Sets the air conditioner to ECO mode operation.
OFF: Turns on the normal air conditioner operation.

REMARK
If the ambient temperature is above 30°C or the set temperature of the air conditioner is 18°C (maximum cooling),
air conditioner may not be operated in ECO mode, even if the air conditioner ECO mode is turned ON.
This setting is held even if the starting switch is turned to OFF position.
The default is OFF.
RETARDER CONTROL LEVER CANCEL SOUND SETTING (HM400-Q1C9-110-K-09-A)
This is used for selecting ON or OFF of the cancel sound of the re-
tarder control lever.
1. Select retarder control lever cancel sound setting (1), then
press the enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Generates the cancel sound.
OFF: Does not generate the cancel sound.

REMARK
• This setting is held even if the starting switch is turned to OFF position.
• The default is ON.

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OPERATION EXPLANATION OF COMPONENTS

MAINTENANCE (HM400-Q1C2-110-K-00-A)
Each item of this menu (C) is used for displaying and setting the
notification relevant to maintenance.
On the maintenance menu screen, the following maintenance
items, their replacement intervals, and remaining time to the next
replacement are displayed.

Replacement interval (h)

Maintenance item
(Default)
Air Cleaner Cleaning / Change -
Engine oil 500
Engine oil filter 500
Fuel prefilter 500
Transmission oil and brake oil 1000
Transmission oil filter 1000
Brake system oil filter 1000
Brake cooling oil filter 1000
Fuel main filter 1000
Hydraulic oil filter 1000
Hydraulic tank breather 2000
Differential oil 2000
Final drive oil 2000
Hydraulic oil 4000

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EXPLANATION OF COMPONENTS OPERATION

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 (1) is highlighted in yellow.
When the time remaining to the maintenance becomes 0 hours,
the remaining time display (1) is highlighted in red. The time ex-
ceeded 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.
When maintenance time caution lamp (2) is lit on the standard
screen, press the menu switch, and the screen automatically dis-
plays maintenance menu screen (C).

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OPERATION EXPLANATION OF COMPONENTS

RESET REMAINING TIME FOR MAINTENANCE (HM400-Q1C2-110-K-01-A)

After performing maintenance, reset the remaining time for maintenance according to the following procedure.
1. On the maintenance menu screen, select an item to reset the
remaining time, then keep pressing the enter switch for 1.5
seconds or longer.
REMARK
If the enter switch is not pressed for enough time, the switch oper-
ating sound can be heard, but the screen does not switch to the
screen for resetting the remaining time for maintenance.

When a password for restriction of use has been set, the pass-
word input screen is displayed.
Input the password for restriction of use by using the numeric key-
pad, then press the enter key.
REMARK
For the setting, changing, or canceling the password, ask your Ko-
matsu distributor.

2. The screen changes to the maintenance time reset screen.

When the enter switch is pressed, the following reconfirma-
tion screen is displayed.
To cancel it, press the return switch.

3. On the re-confirmation screen shown right, when the enter

switch is pressed again, the remaining time is reset and the
screen returns to the maintenance menu screen.
To cancel it, press the return switch.
REMARK
If the remaining time and the replacement interval are the same,
the remaining time cannot be reset.

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OPERATION EXPLANATION OF COMPONENTS

MONITOR SETTING (HM400-Q193-110-K-04-A)

Each item of this menu (D) is to make settings for the machine
monitor.

REAR VIEW MONITOR SETTING (HM400-Q193-110-K-08-A)

This is used to set the rearview monitor.
Select rearview monitor setting (1) on the monitor setting menu
screen, and press the enter switch.

Reference line display

The is used to change ON/OFF of the reference line on the rear-
view monitor.
1. Select reference line display (2) from the rearview monitor
setting menu, and press the enter switch.

2. Select ON or OFF, then press the enter switch.

ON:Displays the reference line.
OFF:Hides the reference line.

REMARK
For the rearview monitor and the reference line, see "HANDLING
REAR VIEW MONITOR（PAGE 3-123-1）" and "ADJUST
REAR VIEW MONITOR（PAGE 3-145-1）".
This setting is held even if the starting switch is turned to OFF
position.
The default is ON.

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EXPLANATION OF COMPONENTS OPERATION

REVERSE-INTERLOCK ENABLED MODE (HM-Q193-110-K-02-A)

This mode is used for changing the method of the rear view moni-
tor display that is indicated only when traveling in reverse.
1. Select reverse-interlock enabled mode (3) on the rear view
monitor setting menu, then press the enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Displays images on the rear view monitor only when trav-
eling in reverse.
OFF: Always displays images on the rear view monitor.

REMARK
This setting is held even if the starting switch is turned to OFF position.
The default is ON.

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EXPLANATION OF COMPONENTS OPERATION

METER DISPLAY SELECTION (HM400-Q193-110-K-05-A)

This is used for the selection of the items to be displayed on L.H.
meter display (1) or R.H. meter display (2).
Select meter display selection (3) on the monitor setting menu
screen, then press the enter switch.

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OPERATION EXPLANATION OF COMPONENTS

SELECT L.H. METER DISPLAY (HM400-Q193-110-K-06-A)

This is used for the selection of the items to be displayed on L.H.
meter display (1).
1. Select Left-meter Select (4) on the meter display selection
menu, then press the enter switch.

2. Select the items to be displayed, then press the enter switch.

The following 3 items can be selected.
• SMR: Service Meter
• ODO: Odometer
• CLK: Clock

REMARK
For details of each item, see "L.H. AND R.H. METER DISPLAY（PAGE 3-38）".
The default of L.H. meter is a service meter.
SELECT R.H. METER DISPLAY (HM400-Q193-110-K-07-A)
This is used for the selection of the items to be indicated on R.H.
meter display (2).
1. Select Right-meter Select (5) on the Meter Select menu, then
press the enter switch.

2. Select the items to be displayed, then press the enter switch.

The following 4 items can be selected.
• FUEL: Fuel consumption gauge
• SMR: Service meter
• ODO: Odometer
• CLK: Clock

REMARK
For details of each item, see "L.H. AND R.H. METER DISPLAY（PAGE 3-38）".
The default of R.H. meter is a fuel consumption gauge.

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EXPLANATION OF COMPONENTS OPERATION

SCREEN ADJUSTMENT (HM400-Q19C-110-K-00-A)

This function is used for the adjustment of brightness of the ma-
chine monitor.
1. Select Screen Adjustment on the Monitor Setting screen, then
press the enter switch.

2. Adjust the brightness by using the switch panel.

The brightness can be adjusted individually in the day and
night modes.
Menu switch: Sets brightness to the initial state.
UP switch: Increases the brightness. (Moves the indicator to
the right by 1 division.)
DOWN switch: Decreases the brightness. (Moves the indica-
tor to the left by 1 division.)
RETURN switch: Cancels the change and returns the display
to the Monitor Setting menu.
ENTER switch: Accepts change and returns the display to
the Monitor Setting menu.

REMARK
• When the screen is adjusted while the lamp switch is turned OFF, the brightness in the day mode can be
adjusted.
• Turn the lamp switch ON, then adjust the screen when the 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, shift lever, and operation switches is adjusted syn-
chronously with the brightness of the machine monitor.

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OPERATION EXPLANATION OF COMPONENTS

CLOCK ADJUSTMENT (HM400-Q1MC-110-K-00-A)

On the clock adjustment menu, you can change the setting of the
clock displayed on the standard screen.
The following items can be changed.
• GPS Synchronization
• Calender
• Time
• 12h/24h Mode
• Daylight Saving Time
Select Clock Adjustment (1) on the Monitor Setting menu screen,
then press the enter switch.

REMARK
• After a long-term storage of the machine, Calendar and Time are reset, so you must readjust them.
• When the GPS Synchronization is set to ON, the above are automatically readjusted.
GPS SYNCHRONIZATION (HM-Q1MC-110-K-01-A)
On the machines equipped with KOMTRAX, you can configure
automatic setting of the machine monitor's date and time in ac-
cordance with the GPS's clock.
1. Select GPS Synchronization (2) from the Clock Adjustment
menu, then press enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Sets the date and time automatically.
OFF: Does not set the date and time automatically. (Can be
set manually.)

REMARK
This setting is held even if the starting switch is turned to OFF position.
The default is OFF.
When the machine is in the environment where the radio waves from GPS cannot be received, the automatic set-
ting function might be disable.
Turning the GPS Synchronization ON disables selecting the Calendar and Time.

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EXPLANATION OF COMPONENTS OPERATION

CALENDAR SETTING (HM-Q1MC-110-K-02-A)

Adjust the date of the machine monitor.
1. Select Calendar (3) from the Clock Adjustment menu, then
press enter switch.
REMARK
As long as the GPS Synchronization menu is turned ON, Calendar
(3) is not selectable.

2. The calendar setting screen is displayed.

When year display (A) is highlighted in yellow, operate the
switches as follows to change year display.
When it is not necessary to change the year setting, press
the enter switch.
UP switch: Sets calendar forward 1 year.
DOWN switch: Sets calendar back 1 year.
RETURN switch: Cancels a change and restores the clock
adjustment screen.
ENTER switch: Proceeds to setting for month

3. When month display (B) is highlighted in yellow, operate the

switches as follows to change month display.
When it is not necessary to change the month setting, press
the enter switch.
UP switch: Sets calendar forward 1 month.
DOWN switch: Sets calendar back 1 month.
RETURN switch: Cancels a change and restores the clock
adjustment screen.
ENTER switch: Proceeds to setting for date.

4. When day display (C) is highlighted in yellow, operate the

switches as follows to change day display.
When it is not necessary to change the date setting, press
the enter switch.
UP switch: Sets calendar forward 1 day.
DOWN switch: Sets calendar back 1 day.
RETURN switch: Cancels change and returns to setting for
month.
ENTER switch: Accepts change and returns to the clock ad-
justment menu.

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OPERATION EXPLANATION OF COMPONENTS

TIME SETTING (HM-Q1MC-110-K-03-A)

Adjust the time of the machine monitor clock.
1. Select Time (4) from the Clock Adjustment menu, then press
enter switch.
REMARK
As long as the GPS Synchronization is turned ON, Time (4) is not
selectable.

2. The time setting 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 the
enter switch.
UP switch: Sets time forward 1 hour.
DOWN switch: Sets time back 1 hour.
RETURN switch: Cancels the change and returns to the
Clock Adjustment menu.
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 the minute setting, press
the enter switch.
UP switch: Sets time forward 1 minute.
DOWN switch: Sets time back 1 minute.
RETURN switch: Cancels the change and returns to the year
setting screen.
ENTER switch: Accepts change and returns to the clock ad-
justment menu.

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EXPLANATION OF COMPONENTS OPERATION

12H/24H DISPLAY MODE (HM-Q1MC-110-K-04-A)

This mode is used for switching the clock display between the 12-
hour display (am/pm) and the 24-hour display.
1. Select 12h/24h Mode (5) on the Clock Adjustment menu, then
press enter switch.

2. Select 12H or 24H, then press the enter switch.

12H: Sets 12-hour display (am/pm).
24H: Sets 24-hour display.

REMARK
This setting is held even if the starting switch is turned to OFF position.
The default is 24H.
DAYLIGHT SAVING TIME (SUMMER TIME) (HM-Q1MC-110-K-05-A)
Set the clock display based on the Daylight Saving Time.
1. Select Daylight Saving Time (6) on the Clock Adjustment
menu, then press enter switch.

2. Select ON or OFF, then press the enter switch.

ON: Displays the time 1 hour earlier.
OFF: Returns the time to the original.

REMARK
Daylight saving time (summer time) means setting the clock ahead 1 hour to make the better use of daytime for
everyday life.
This setting is held even if the starting switch is turned to OFF position.
The default is OFF.

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OPERATION EXPLANATION OF COMPONENTS

LANGUAGE SELECTION (HM400-Q19B-110-K-00-A)

The language displayed on the machine monitor can be selected.
The languages that can be selected are as follows.
English, Japanese, French, Spanish, Portuguese, Italian, German, Indonesian, Russian, Arabic, Turkish, Thai,
Chinese, Vietnamese
1. Select Language (1) on the Monitor Setting menu screen,
then press the enter switch.

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

switch.

REMARK
This setting is held even if the starting switch is turned to OFF position.

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EXPLANATION OF COMPONENTS OPERATION

MESSAGE DISPLAY (HM400-Q235-110-K-00-A)

On machines equipped with KOMTRAX, you can see the mes-
sages from your Komatsu distributor on this menu (E).
When there is any massage, message pilot lamp (1) of the stand-
ard screen lights up.
(A): There is unread message(s).
(B): There is any read message to which no reply is made.
Reply to the message in accordance with the replying method
mentioned later.
REMARK
• While message pilot lamp (1) is lit on the standard screen,
when the menu switch is pressed, message display menu
screen (E) appears automatically.
• When the starting switch is turned OFF while there is any un-
read message, the message is displayed on the end screen,
and when the monitor is started next time, the message
changes to a read message.
• The message is deleted when it expires or when a new mes-
sage reaches.

CONFIRMATION METHOD OF A MESSAGE (HM400-Q235-110-K-01-A)

Select message display menu screen (E), and you can read the
arrived message.
(A): Subject of message
When no message has been received, "No message." is
displayed.
(B): Serial No. of message
(C): Validity of message
(D): Text
(E): Reply field
In case of a message requesting for reply, the column of "Numeric
Input: [ ]" is displayed. Make any reply to the message.

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OPERATION EXPLANATION OF COMPONENTS

REPLYING METHOD TO A MESSAGE (HM400-Q235-110-K-02-A)

1. When replying to a message, input the selected item number
shown in text (D) of the message by using the switch panel.
• Each switch of the switch panel corresponds to the num-
ber shown on the lower right of the switch.
• The input number is displayed in "Numeric Input: [ ]" of
the reply field (E).
• If you input an incorrect number, press the return switch,
and you can clear an input character at a time.
• If the return switch is pressed while no number is en-
tered, the display returns to the standard screen.

2. After inputting a selected item number, press the enter

switch.
3. "Proceed?" When message (2) is displayed, press the enter
switch again.
The input value will be sent out.
To cancel sending, press the return switch.
The input number is cleared.

REMARK
If the message is replied, "Replied" (3) is displayed for it.

OTHER FUNCTIONS OF MACHINE MONITOR (HM-Q170-110-K-00-A)

CONFIRM THE SERVICE METER OR ODOMETER WHEN THE STARTING SWITCH KEY IS SET TO OFF
POSITION
The service meter and odometer can be displayed even if the ma-
chine monitor is not turned ON.
1. Press UP switch while holding down DOWN switch when the
starting switch key is set to OFF position.
2. Service meter (1) and odometer (2) are displayed while both
switches are held down.
NOTICE
If the monitor screen is displayed during other operations
while the starting switch is at OFF position, there is probably
a failure in the equipment, so ask your Komatsu distributor
for inspection.

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EXPLANATION OF COMPONENTS OPERATION

SWITCHES

(1) Starting switch (11) Automatic retarder, accelerator linked contro switch
(2) Lamp switch (if equipped)
Dimmer switch (12) AISS LOW switch
Turn signal lever (13) Power mode selector switch
(3) Wiper and window washer switch (14) Parking brake switch
(4) Horn button (15) Fog lamp switch (if equipped)
(5) Monitor brightness selector switch (16) Shift hold switch
(6) Working lamp switch (17) Yellow revolving warning lamp switch (if equipped)
(7) Hazard lamp switch (18) Power window switch
(8) Emergency steering switch (19) Side lamp switch (if equipped)
(9) Brightness adjustment switch of rearview moni- (20) Engine shutdown secondary switch
tor (if equipped) (21) Room lamp 1 switch
(10) Inter-axle differential lock switch (22) Room lamp 2 switch

STARTING SWITCH (HM400-AKB0-043-K-01-A)

This switch (1) is used to start or stop the engine.
(A): OFF position
The key can be removed from the starting switch, the electrical
current to the electrical system is cut, and the engine stops.
REMARK
Even when the starting switch is set to OFF position, the horn,
hazard lamp, emergency steering and room lamp 1 can be
operated.
(B): ON position
Flows current to the electrical system. Keep the starting switch
key at ON position while the engine is running.
When turning the starting switch ON or OFF, if the starting switch
is held at a position between ON and OFF, the controller may de-
tect this as a problem. If this happens, return the starting switch to
OFF position, then operate it as usual to ON position.
In cold weather, when the key is turned ON, engine preheating starts automatically and the preheating pilot lamp
lights up. When preheating is completed, the preheating pilot lamp goes out.

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OPERATION EXPLANATION OF COMPONENTS

(C): START position

This is the position to start the engine. Hold the key at this position while cranking. and release the key immediately
after the engine has been started. The key will automatically return to ON position (B).
Position (D)
Perform preheating of the engine manually while the key is at this position. The preheating pilot lamp lights up dur-
ing preheating.
For manual preheating, see "MANUAL PREHEATING FUNCTION（PAGE 3-153）".

LAMP SWITCH
This switch (2) is used for switching 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 (headlamps lighting) position
Clearance lamp, tail lamp and headlamp (low beam) light up.
When turning the lamp switch 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 are and rear view monitor dimmed.
The lamp switch can be switched regardless of the position of the
turn signal lever.

DIMMER SWITCH (HM-Q688-043-K-00-A)

This switch (2) is used to switch on and off the head lamps (high
beam).
When the lamp switch is turned to ON position, each time switch
(2) is moved up in direction (A), the head lamps (high beam)
changes between on and off. When the switch is released, it auto-
matically returns to original position (B).
When the lamp switch is OFF, if the switch is operated in direction
(A), the head lamps (high beam) alone light up.
When the head lamps (high beam) is lit, the head lamp (high
beam) pilot lamp is lit.

TURN SIGNAL LEVER (HM-Q6D6-043-K-00-A)

This lever (2) operates the turn signal lamp.
(A)Right turn: Push the lever forward
(B)Left turn: Push the lever back
When the lever is operated, the turn signal pilot lamp also flashes.
The lever is automatically returned when the steering wheel is
turned back. If the lever does not return, move it by hand.

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EXPLANATION OF COMPONENTS OPERATION

WIPER, WINDOW WASHER SWITCH (HM-K751-043-K-00-A)

This switch (3) is used for operating the wiper for the front glass and rear glass.
Using the wiper when the glass is dry will scratch the glass. Spray with window washer fluid before actuating the
wiper.

Front wiper
Turn lever (E), then front wiper operates.
Position (A) (OFF): Wiper is stopped
Position (B) (INT): Wiper moves intermittently once every 4 to 7
seconds
Position (C) (LOW): Wiper moves at low speed
Position (D) (Hi): Wiper moves at high speed
When the button (F) at the tip of the switch is pressed, washer fluid
is sprayed out.
Do not keep the button pressed for more than 10 seconds.

Rear wiper
Turn lever (E), then rear wiper operates.
Position (A): Washer fluid is sprayed out
Position (B) (OFF): Wiper is stopped
Position (C): Wiper is actuated
Position (D): Wiper is actuated and washer fluid is sprayed out

HORN BUTTON (HM-Q543-043-K-00-A)

When the horn button (4) in the center of the steering wheel is
pressed, the horn sounds.
NOTICE
To sound the horn continuously (keep pressing the horn but-
ton) makes its service life shortened, and it may cause failure
on early stage.
Avoid the continuous usage of the horn except in an
emergency.

MONITOR BRIGHTNESS SELECTOR SWITCH

This switch (5) is used for switching the brightness (luminosity) of
the machine monitor and rear view monitor while lamp switch is
turned to ON position.
When operating the machine with the headlamp stayed lit during
the day, if this switch is set to Day mode, monitor screen does not
loose the brightness.
(A): Day mode
(B): Night mode
REMARK
When the lamp switch is turned to OFF position, operating this
switch does not change the brightness.
For the fine adjustment method of brightness of the machine moni-
tor, see "SCREEN ADJUSTMENT（PAGE 3-68）".
For the fine adjustment method of brightness of the rearview monitor,
see "BRIGHTNESS ADJUSTMENT SWITCH OF REAR VIEW
MONITOR（PAGE 3-80）".
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OPERATION EXPLANATION OF COMPONENTS

WORKING LAMP SWITCH (HM-Q6B8-043-K-00-A)

This switch (6) is used for turning the working lamp ON or OFF.
(A): Working lamp lights up.
(B): Working lamp goes out.

HAZARD LAMP SWITCH (HM400-Q6D7-043-K-00-A)

This switch (7) is used for making the left and right turn signal
lamp flash.
(A): Turn signal lamp and its pilot lamp flash
(B): Light off

EMERGENCY STEERING SWITCH (HM400-F9S4-043-K-00-A)

WARNING
Do not continue to use the emergency steering pump for more than 90 seconds. If the emergency steering
is used continuously for more than 90 seconds, there is danger that the pump may burn out or be dam-
aged, or that it may cause a fire.

This switch (8) is used for actuating the emergency steering pump.
When the switch is pressed, the emergency pump is actuated to
make it possible to operate the steering.
When the switch is turned ON or the emergency steering is auto-
matically activated, the pilot lamp (red) in the switch and emer-
gency steering pilot lamp light up.
When using the emergency steering pump, maintain the travel
speed at 5 km/h (3.1 MPH) or below.

The emergency steering is actuated automatically in the following cases.

• When the steering hydraulic pump has failed.
• When the engine has stopped during operation.
When the emergency steering is actuated, stop the machine immediately and perform inspection.
If the starting switch is at ON position and the parking brake switch is at TRAVEL position when the engine is
stopped, the emergency steering is actuated automatically after 1 second, so set the parking brake switch to
PARKING position.

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EXPLANATION OF COMPONENTS OPERATION

BRIGHTNESS ADJUSTMENT SWITCH OF REAR VIEW MONITOR (HM400-Q16E-043-K-00-A)

This switch (9) is used for adjusting the brightness (luminance) of
the rearview monitor.
The brightness can be adjusted individually in the day and night
modes.
(A): Brightness increases.
(B): Brightness decreases.

INTER-AXLE DIFFERENTIAL LOCK SWITCH

The inter-axle differential lock switch (10) is used to select the
operation mode of the inter-axle differential lock.
Set it to AUTO when traveling on a normal ground.
(A): MANUAL
The inter-axle differential lock is actuated while the shift range
(gear speed) is at F3, F2, F1, R1, or R2, and the machine is not
turning.
On dry sandy ground, etc., if the tires slip and the machine
bounces up and down, or on muddy ground, etc., if the travel
speed lowers largely because the tires slip and sink into mud.
Before these cases, set it to the MANUAL.
Operation mode is shifted to AUTO mode when the steering
angle becomes more than the specified angle during turning.
(B): AUTO
Ability to travel through or escape from soft ground is improved
when KTCS operates. The inter-axle differential lock operates
automatically to stabilize the machine when the brake is applied
or the gear is shifted.
REMARK
Regardless of the position of the switch, when the inter-axle
differential lock operates, the inter-axle differential lock pilot lamp
lights up.

AUTOMATIC RETARDER, ACCELERATOR LINKED CONTROL SWITCH

(if equipped)
This switch (11) is used for turning ON or OFF the automatic re-
tarder, accelerator linked control system (ARAC).
(A): The automatic retarder, accelerator linked control system
operates.
(B): The automatic retarder, accelerator linked control system
does not operate.

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OPERATION EXPLANATION OF COMPONENTS

AISS LOW SWITCH

This switch (12) is used for switching the AISS functions.
AISS (Automatic Idling Setting System) adjusts the low idle speed
automatically depending on the engine coolant temperature and
operating situations.
(A): AISS LOW switch ON
Use this switch position when fine start control is needed such as
when putting the machine into the garage.
The low idle speed is fixed to a rather low level.
REMARK
When the automatic warm-up is turned on, this switch position
stops it, and set a low idle speed to a rather low level.
(B): AISS LOW switch OFF
Use this switch position for the normal operation.
AISS function is actuated to produce the states described below.
• When the engine coolant temperature is low, this switch posi-
tion automatically sets the idle speed to a higher level. (Auto-
matic warm-up function)
• When the parking brake or retarder brake is applied, the idle
speed is automatically set to a rather low level in order to re-
duce fuel consumption when the machine is stopped.
REMARK
While the automatic warm-up is turned on, the idle speed is not
set to low even if the parking brake or retarder brake is applied.
For details of automatic warm-up, see "AUTOMATIC WARM-UP
FUNCTION（PAGE 3-156）".

POWER MODE SELECTOR SWITCH

By changing the output mode by using this switch (13), you can
select economical travel suited to the given operating conditions.
(A): Economy mode (operations on a flat ground)
Use this mode for the operation with emphasis on fuel consump-
tion, such as operation on flat ground where the maximum power
is not needed.
Economy mode pilot lamp (E) lights up.
(B): Power mode (general operations)
Use this mode for the normal standard operation.
Power mode pilot lamp (P) lights up.

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EXPLANATION OF COMPONENTS OPERATION

PARKING BRAKE SWITCH

WARNING
When parking or leaving the machine, always apply the parking brake.

This switch (14) is used for actuating and releasing the parking
brake.
(A): Parking
The parking brake is applied.
(B): Travel
The parking brake is released.
When the switch is set to PARKING position, the parking brake pi-
lot lamp lights up.
When the switch is set to PARKING position, if the gear shift lever
is at any position other than N (NEUTRAL), the centralized warn-
ing lamp lights up and the alarm buzzer sounds intermittently.

REMARK
If the engine is stopped when the parking brake switch is set to TRAVEL, the parking brake is applied automati-
cally. When starting the engine again, set the parking brake switch to PARKING, and then set it back to TRAVEL
to release the parking brake.
NOTICE
During loading operations, do not apply the parking brake. Apply the retarder brake.

SHIFT HOLD SWITCH

Use this switch (15) to actuate the shift hold function.
When this switch is pressed once, the shift hold pilot lamp lights
up and the shift hold function is actuated.
When the shift hold function is actuated, the gear speed is not
shifted up from the current level.
If the travel speed drops excessively when the shift hold function
is being actuated, the transmission shifts down, but when the trav-
el speed increases, the transmission is held at the original speed
range
The shift hold function can be canceled by performing the follow-
ing operations.
1) When the gear shift lever is set to another position.
2) When the shift hold switch is pressed again.
There may be hunting of the transmission (shifting up or down is repeated in short intervals) depending on the road
condition, uphill grade and load weight. If this happens, to improve the operator comfort and to protect the trans-
mission, travel with the transmission fixed in a low speed range.

FOG LAMP SWITCH

(if equipped)
This switch (16) is used for turning fog lamp ON or OFF.
(A): Fog lamp lights up.
(B): Fog lamp goes out.

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OPERATION EXPLANATION OF COMPONENTS

YELLOW REVOLVING WARNING LAMP SWITCH

(if equipped)
This switch (17) is used for turning the yellow revolving warning
lamp ON or OFF.
When the lamp is ON, it lights up while rotating.
(A): Yellow revolving warning lamp lights up.
(B): Yellow revolving warning lamp goes out.

POWER WINDOW SWITCH

WARNING
When closing the window glass, be careful not to get anyone's hands or head caught.
There is a danger of serious injury if anyone is caught in the window glass.

NOTICE
After fully opening or fully closing the window glass, release the switch immediately.
If the switch is kept operated, it may cause failure of the power window.
This switch (18) is used for opening and closing the L.H. window
glass. This switch can only be used when the starting switch is at
ON position.
(A): Glass goes up.
(B): Glass goes down.
When the glass reaches the top or bottom and stops, release the
switch.

SIDE LAMP SWITCH

(if equipped)
This switch (19) is used for turning the side lamp ON or OFF.
(A): Side lamp lights up.
(B): Side lamp goes out.

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EXPLANATION OF COMPONENTS OPERATION

ENGINESHUTDOWNSECONDARYSWITCH
NOTICE
Thisswitch()isusedforstoppingtheenginewhenthestartingswitchisturnedtoOFFpositionbutthe
engine does not stop. Do not use it except in emergencies. Ask for repair of the problem as soon as
possible.
1. Raise cover (A) to open it.

2. Whenswitch()issettoSTOPENGINEposition,theen-
gine stops, and after 3 seconds, "Engine Shutdown Secon-
dary Switch is ON" is displayed on the machine monitor, and
the alarm buzzer sounds intermittently.
(B): STOP ENGINE (when abnormal)
(C): NORMAL
REMARK
• When cover (A) is closed, switch () is automatically re-
turnedtoNORMALposition(C).
• Whileswitch()isatSTOPENGINEposition,ifthestarting
switchisturnedON,"EngineShutdownSecondarySwitchis
ON"isdisplayed,andthealarmbuzzersoundsintermittently.
If this message is displayed when the machine is normal,
check that the switch cover is closed and the switch is in
NORMALposition.Ifnot,setittoNORMALposition.

ROOMLAMP1SWITCH
Thisswitch()isusedforturningroomlamp1ONorOFF.
Position(A):OFF
Position(B):Lightsupwhenthecabdooropens
Position(C):ON
REMARK
• The room lamp lights up even when the starting switch is at
OFF position, so when leaving the operator's compartment,
set the switch to position (A) or (B).
• When performing operations with the door fully opened, set
the switch to position (A).

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OPERATION EXPLANATION OF COMPONENTS

ROOM LAMP 2 SWITCH

This switch (22) is used for turning room lamp 2 ON or OFF.
Position (A): OFF
Position (B): ON

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EXPLANATION OF COMPONENTS OPERATION

CONTROL LEVERS AND PEDALS (HM400-K191-04D-K-00-A)

(1) Brake pedal (4) Retarder control lever

(2) Accelerator pedal (5) Dump lever
(3) Gear shift lever (6) Dump lever lock knob

BRAKE PEDAL (HM-G4A1-043-K-00-A)

This pedal (1) is used to apply the wheel brakes.

ACCELERATOR PEDAL (HM-AEX1-043-K-00-A)

Use this pedal (2) to control the engine speed.
It can be operated freely from low idle to full throttle.

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OPERATION EXPLANATION OF COMPONENTS

GEAR SHIFT LEVER

NOTICE
When you clean the indicator on the side of the gear shift lever, use a cloth wet with water or warm water.
Do not use a cloth with alcohol. The indicator can have damage.
The gear shift range can be selected with this lever (3) to match
the travel conditions.
Position D:
Used for the normal travel. When this position is used, the trans-
mission is set automatically between the 2nd or 1st torque con-
verter drive and 6th gear according to the travel speed.
While the dump body is raised, however, the transmission is fixed
to the 2nd or 1st speed and is not changed. Keep the dump body
lowered during travel.
The maximum travel speed in this position is 55.9 km/h (34.7
MPH).
Positions 5 to 1:
Use these positions when traveling on soft ground or places
where it is difficult to travel at high speed, when starting uphill with
the machine loaded, or when traveling downhill with engine brake.
While the dump body is raised, the transmission is fixed to the 1st
speed and is not changed. Keep the dump body lowered during
travel.
Position R1:
This is used when traveling in reverse. When this position is used, the transmission is fixed in R1 and the travel is
performed in torque converter drive or direct drive according to the travel speed. The maximum travel speed in this
position is 6.8 km/h (4.2 MPH).
Position R2:
This is used when traveling in reverse. When this position is used, the transmission is fixed in R2 and the travel is
performed in torque converter drive or direct drive according to the travel speed. The maximum travel speed in this
position is 16.0 km/h (9.9 MPH).
The machine cannot be driven in reverse when the dump body is raised. Lower the dump body, set the dump lever
to FLOAT, then operate the gear shift lever to R1 or R2.
REMARK
If the machine is driven when the dump body is not seated, the speed range is fixed at 2nd or 1st in D position,
and transmission can not be shifted. In position 5 to 1, the speed range is fixed at 1st position, and transmission
can not be shifted. (This conforms to EU safety standard (EN474-6 5.1.3).
• The automatic gear shift range for each position is as shown below.
Position Speed range Max. speed
R2 R2nd torque converter - direct 16.0 km/h (9.9 MPH)
R1 R1st torque converter - direct 6.8 km/h (4.2 MPH)
D 2nd or 1st torque converter - 6th direct 56.0 km/h (34.7 MPH)
5 1st torque converter - 5th direct 36.5 km/h (22.7 MPH)
4 1st torque converter - 4th direct 23.8 km/h (14.7 MPH)
3 1st torque converter - 3rd direct 15.5 km/h (9.6 MPH)
2 1st torque converter - 2nd direct 10.1 km/h (6.3 MPH)
1 1st torque converter - 1st direct 6.6 km/h (4.1 MPH)

The gear shift lever must not be returned to N (NEUTRAL) position while traveling.
When switching between FORWARD and REVERSE, 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 N (NEUTRAL), the engine will not
start.

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EXPLANATION OF COMPONENTS OPERATION

When the parking brake is applied, if the gear shift lever is in any position other than N (NEUTRAL), the centralized
warning lamp will light up and the alarm buzzer will sound.
If the gear shift lever is set to any position other than N (NEUTRAL) when the dump lever is at a position other than
FLOATor 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 N (NEUTRAL) to D (FOR-

WARD) or R1 (REVERSE), release the accelerator pedal, set the
engine speed at low idle, then press the lock button of gear shift
lever to operate.

When the shift hold switch is pressed, the shift hold function
actuates.
For details of the shift hold function, see "SHIFT HOLD SWITCH
（PAGE 3-82）".

RETARDER CONTROL LEVER (HM-GT48-043-K-00-A)

CAUTION
The retarder must not be used as a parking brake.

This lever (4) is used for operating the retarder when traveling
downhill.
The more the lever is pulled towards you, the greater the braking
force becomes.
When the retarder is operated, the retarder pilot lamp lights up.

When leaving the operator's seat, always apply the parking brake.
REMARK
While the auto retarder, accelerator linked control system (ARAC) is turned on, a certain play is induced when you
start to pull the lever.
Such play is not because the retarder is out of action. It is within the range admitted by the auto retarder, accelera-
tor linked control system (ARAC).

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OPERATION EXPLANATION OF COMPONENTS

DUMP LEVER (HM-M6K1-043-K-00-A)

CAUTION
To prevent damage to the dump body caused by vibration
from the road, always lower the dump body when traveling
and set the dump lever to FLOAT position.

This lever (5) is used for operating the dump body.

(A) RAISE
(B) HOLD: The dump body remains in the position where it was
stopped.
(C) FLOAT: The dump body moves freely under external force.
(D) LOWER
Always set 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. Wven if
the engine is started again, the dump body is held in HOLD condition and the dump body float caution lamp lights
up. For releasing HOLD state, see "CANCEL TO HOLD DUMP BODY（PAGE 3-155）".

DUMP LEVER LOCK KNOB (HM-M6B7-043-K-00-A)

WARNING
When performing inspection with the dump body raised, al-
ways set the dump lever to HOLD position, lock it with the
dump lever lock knob, and use the body pivot pin.

This device (6) is used for locking the dump lever.

To set it to FREE (F) position, pull the lock knob out fully, then turn
it to hold it in position.
To set it to LOCK (L) position, pull the lock knob out and turn it to
remove it from the fixed position. The knob is pushed into the lock
hole in the dump lever by the force of the spring, and the dump
lever is locked. Check that the dump lever is securely locked.

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EXPLANATION OF COMPONENTS OPERATION

CIGARETTE LIGHTER (HM-K850-043-K-00-A)

It is used for lighting a cigarette.
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.
If the cigarette lighter is removed, the socket can be used as an
84 W (12V x 7A) power source.

ASHTRAY (HM300-K851-043-K-00-A)
It is provided on the top of the console box that situates on the
right side of the operator seat.
Always put out your cigarette before putting it in the ashtray and
be sure to close the lid.

DRINK BOX (HM-K821-043-K-00-A)

It is provided on the right side of the operator's seat to store
drinks.
Hot or cold air blows into the box according to the setting of the air
conditioner.
Turn the knob counterclockwise and pull the cover up to open it.
Position (A): CLOSE (lock)
Position (B): OPEN (release)
When closing the cover, lock it by turning the knob clockwise while
pressing the cover.

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OPERATION EXPLANATION OF COMPONENTS

CUP HOLDER (HM-K822-043-K-00-A)

Two are provided on the rear side of the drink box.

HANDY TRAY (HM300-K851-043-K-01-A)

It is provided in the rear right of the operator seat

MAGAZINE BOX (HM-K820-043-K-00-A)

It is provided on the front left side of operator's seat for storing an
A4-size binder and such.
Do not put heavy goods such as tools in the box.

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EXPLANATION OF COMPONENTS OPERATION

EMERGENCY ESCAPE HAMMER (HM300-Q5K1-043-K-00-A)

CAUTION
• If it is necessary to break the window glass with the hammer, be extremely careful not to injure your-
self on the flying pieces of broken glass.
• To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through
the window. Be careful also not to slip on the broken pieces of glass on the ground.

If it should become impossible to open the cab door for any rea-
son, and it is necessary to make an emergency escape from the
operator's compartment, use hammer (A) to escape.

To escape from the operator's cab, use hammer (A) to break the
glass and escape through the window.

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OPERATION EXPLANATION OF COMPONENTS

HANDLING AIR CONDITIONER (ALL-K500-001-K-00-A)

AIR CONDITIONER CONTROL PANEL (HM400-K5V0-04D-K-00-A)

(1) OFF switch (6) FRESH/RECIRC air selector switch

(2) Fan switch (7) Display monitor
(3) Temperature control switch (8) Air conditioner switch
(4) Vent selector switch (9) DEF switch
(5) Auto switch

OFF SWITCH (HM-K5V4-043-K-00-A)

Switch (1) is used to stop the fan and air conditioner.
REMARK
Even if this switch (1) is pressed, the monitor screen does not
switch to the air conditioner adjustment screen.

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EXPLANATION OF COMPONENTS OPERATION

FAN SWITCH (HM-K5V5-043-K-00-A)

This switch (2) is used for adjusting the air flow.
The air flow can be adjusted to 6 levels.
• Press the E switch to increase the air flow; press the R
switch to decrease the air flow.
• During auto operation, the air flow is automatically adjusted.

Monitor display and air flow

A: Monitor display
B: Air flow
a: Air flow "low"
b: Air flow "medium 1"
c: Air flow "medium 2"
d: Air flow "medium 3"
e: Air flow "medium 4"
f: Air flow "high"

TEMPERATURE CONTROL SWITCH (HM-K5V6-043-K-00-A)

This switch (3) is used for controlling temperature inside the cab.
The temperature can be set between 18°C (64.4°F) and 32°C
(89.6°F).
• Press the E switch to raise the set temperature; press the R
switch to lower the set temperature.
• The temperature is generally set at 25°C (77°F).
• The temperature can be set in stages of 0.5°C (0.9°F).

Monitor display and the function

Monitor display (°C) (°F) Set temperature
18.0 (64.4) Max. cooling
18.5 (65.3) to 31.5 (88.7) Adjusts temperature inside cab to set temperature
32.0 (89.6) Max. heating

REMARK
If the temperature setting is set to 18.0°C (64.4°F) or 32.0°C (89.6°F) in the auto mode, the air flow from the fan is
always set to "high" and does not change even when the set temperature is reached.

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OPERATION EXPLANATION OF COMPONENTS

VENT SELECTOR SWITCH (HM-K5V7-043-K-00-A)

This switch (4) is used for selecting the vents.
• When switch (4) is pressed, the display on monitor display (7)
switches and air blows out from the vents displayed.
• During automatic operation, the vents are automatically
selected.

(A): Rear window glass vent (2 places)

(B): Face vent (4 places)
(C): Foot vent (1 place)
(D): Front window glass vent (2 places)

AUTO SWITCH (HM-K5V8-043-K-00-A)

With switch (5), the air flow, vents, and air source (FRESH/RE-
CIRC) are automatically selected according to the set
temperature.
• Press switch (5), then use temperature control switch (3) to
set the temperature, and run the air conditioner under auto-
matic control.
• When switching from automatic operation to manual opera-
tion, it is possible to use the switches to select the vents and
air source (FRESH/RECIRC).
REMARK
When Auto Mode is selected, if the set temperature is set to 18.0°
C (64.4°F) or 32.0°C (89.6°F), the air flow is always set to High,
but this is not a problem.

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EXPLANATION OF COMPONENTS OPERATION

FRESH/RECIRC SELECTOR SWITCH (HM-K5V9-043-K-00-A)

This switch (6) is used for switching the air source between recir-
culation of the air inside the cab and intake of fresh air from the
outside.
• During automatic operation, the selection of inside air (RE-
CIRC) and outside air (FRESH) is performed automatically.

Outside air is shut off and only air inside the cab is circulated.
RECIRC
Use this setting to perform rapid cooling of the cab or when outside air is dirty.
Outside air is taken into the cab.
FRESH
Use this setting to take in fresh air or to demist the window glass.

REMARK
Intake of external air (FRESH) is automatically selected when the door is opened. Selection by use of the switch is
not available.
The setting mode is restored after the door is closed.
DISPLAY MONITOR (HM-K5VA-043-K-00-A)
This monitor display (7) indicates the state of temperature setting
(A), air flow (B), and vents (C).
• When OFF switch (1) is pressed, the display of temperature
setting (A) and air flow (B) goes out, and operation stops.

AIR CONDITIONER SWITCH (HM-K5FK-043-K-01-A)

This switch (8) is used for turning the air conditioner (cooling, dry
heating) ON or OFF.

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OPERATION EXPLANATION OF COMPONENTS

• Press air conditioner switch (8) when the fan is operating

(when display monitor is shown on the screen). The air condi-
tioner is switched ON and starts to work. Press the switch
again to stop the air conditioner.
• Air conditioner cannot be operated while the fan is stopped.

DEF SWITCH (HM-K5VB-043-K-00-A)

Use this switch (9) to change the vents to the DEF mode.

If this switch is pressed, display monitor (C) changes to (F).

When the DEF switch is pressed in any of the FACE, FACE/
FOOT, or FOOT modes, the system changes to the DEF mode. In
addition, when the DEF mode selector switch is pressed, the sys-
tem will return to the mode being used before switching to the
DEF mode.
REMARK
Air also blows out from the foot vent in DEF mode.

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EXPLANATION OF COMPONENTS OPERATION

OPERATION METHOD (D65-K500-100-K-03-A)

The air conditioner can be operated automatically or manually. Select the method of operation as desired.
AUTOMATIC OPERATION (HM-K500-100-K-01-A)
1. Turn the auto switch ON.
• The monitors for the set temperature (A) and air flow (B) are
also displayed.

2. Use the temperature control switch to set to the desired tem-

perature. The air flow, combination of vents, and selection of
fresh or recirculated air is automatically selected according to
the set temperature, and the air conditioner is operated auto-
matically to provide the set temperature.

REMARK
When vent display monitor (C) displays (D) or (E), and engine
coolant temperature is low, the air flow is automatically limited to
prevent cold air from blowing out.

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OPERATION EXPLANATION OF COMPONENTS

STOP AUTOMATIC OPERATION (HM-K500-100-K-02-A)

Press OFF switch. Operation stops.

MANUAL OPERATION (HM-K500-100-K-03-A)

1. Press the fan switch and adjust the air flow. When doing this,
check that temperature setting (A) and air flow (B) are dis-
played on the monitor.

2. Turn the air conditioner switch ON.

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EXPLANATION OF COMPONENTS OPERATION

3. Press the temperature control switch to adjust temperature in-

side the cab.

4. Press the vent selector switch and select the desired vents.
When doing this, the display of vent (C) of the display monitor
changes according to the selection.

5. Press the FRESH/RECIRC selector switch and select recircu-

lation of the air inside the cab (RECIRC) or intake of fresh air
from outside (FRESH).

STOP MANUAL OPERATION (HM-K500-100-K-04-A)

Press the OFF switch. Operation stops.

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OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET (HM-K500-100-K-05-A)
To operate with cold air blowing to the face and warm air blowing
to the feet, set as follows.
1. Press the fan switch and adjust the air flow. When doing this,
check that temperature setting (A) and air flow (B) are dis-
played on the monitor.

2. Press the vent selector switch and set the vent display on the
display monitor to the display shown in the figure on the right.

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EXPLANATION OF COMPONENTS OPERATION

3. Turn the air conditioner switch ON.

4. Adjust the fan switch, temperature control switch and

FRESH/RECIRC selector switch to the desired positions.

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OPERATION EXPLANATION OF COMPONENTS

USE DEFROSTER (HM-K500-100-K-06-A)

1. Press the fan switch and adjust the air flow. When doing this,
check that temperature setting (A) and air flow (B) are dis-
played on the monitor.

2. Press the vent selector switch or DEF switch and set vent dis-
play on the display monitor to (G) or (F) as shown in the figure
on the right.

3. Press the FRESH/RECIRC selector switch and set it to

FRESH mode.

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EXPLANATION OF COMPONENTS OPERATION

4. Press the temperature control switch and set temperature on

the display monitor to 32.0°C (89.6°F) of maximum heating.

5. Adjust vents (A) so that the air blows onto the window glass.
(Vents (D) is fixed and cannot be adjusted.)

When operating in the rainy season or when it is desired to re-

move the mist from the window glass or to dehumidify the air, turn
the air conditioner switch ON.

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OPERATION EXPLANATION OF COMPONENTS

RULES FOR USING AIR CONDITIONER (ALL-K500-170-K-00-A)

NOTICE
• When running the air conditioner, always start with the engine running at low speed. Never start the
air conditioner when the engine is running at high speed. It will cause failure of the air conditioner.
• If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, be careful not
to let water get on these parts. In addition, never bring any open flame near these parts.
• For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean
and do not leave anything around the sunlight sensor that may interfere with its sensor function.
VENTILATION (ALL-K500-170-K-01-A)
• 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 start to hurt your eyes, so open the window and
turn the lever to FRESH for a while to remove the smoke while continuing the cooling.
TEMPERATURE CONTROL (HM-K500-170-K-00-A)
When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 or 6°C (9 or 10.8°
F) lower than the outside temperature). This temperature difference is considered to be the most suitable for your
health.
Be extremely careful to select the appropriate temperature.

CHECK AND MAINTENANCE OF AIR CONDITIONER EQUIPPED MACHINE (HM400-

K500-280-K-01-A)
• When performing inspection and maintenance of the machine equipped with the air conditioner, observe the
instructions in the tables in "CLEAN AIR CONDITIONER AIR FILTERS（PAGE 4-23）" and "CHECK LEVEL
OF REFRIGERANT (GAS)（PAGE 4-25）".
• When the air conditioner is not being used every day, to pre-
vent loss of the film of oil at various parts, run the air condi-
tioner 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 condi-
tioner may not work. In this case, circulate recirculation air to
warm the inside of the cab. After that, turn the air conditioner
switch ON, the air conditioner will work.
• If any abnormality is detected in any equipment or sensor
used on the air conditioner, the air conditioner system operat-
ing monitor lights up on the monitor screen. If the air condi-
tioner system state monitor lights up, ask your Komatsu
distributor for inspection and repair.

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EXPLANATION OF COMPONENTS OPERATION

HANDLING RADIO (PC-K860-001-K-01-A)

(If equipped)

EXPLANATION OF COMPONENTS (HM-K860-043-K-00-A)

(1) Power button (5) Preset buttons

(2) Band/AUX selector button (6) Display selection button
(3) Volume control button (7) Sound control button
(4) Tuning/time adjustment button (8) Display

POWER BUTTON (HM-K860-043-K-01-A)

Press this power button (1) to supply the power to the radio and the frequency is shown on the display (8). As long
as AUX is selected, display (8) indicates AUX on it. Press the button again to turn the power off.
BAND/AUX SELECTOR BUTTON (HM-K860-043-K-09-A)
Press this button (2) to select the desired band
Each time the button is pressed, the band changes FM -> AM -> AUX -> FM - - - -.
Even if AUX is selected, it does not operate.
VOLUME CONTROL BUTTON (HM-K860-043-K-03-A)
Use this button (3) to control volume.
Press the E button, and the volume increases. Press the R button, and the volume decreases. The range for the
volume is 0 to 32.
Hold down this button, and you can change the volume in stepless.
TUNING/TIME ADJUSTMENT BUTTON (HM-K860-043-K-04-A)
Use the button (4) to select frequency and step for sound adjustment and to adjust time.
For details of the adjusting method, see "OPERATION METHOD（PAGE 3-108）".
PRESET BUTTON (HM-K860-043-K-05-A)
If you register desired stations to this button (5) beforehand, you can select the station by touching this button
once.
It is possible to preset 6 stations each for both AM and FM.
For details of the presetting method, see "OPERATION METHOD（PAGE 3-108）".
DISPLAY SELECTOR BUTTON (HM-K860-043-K-06-A)
Use this button (6) to change frequency and time shown on the display.
Each time you press this button, frequency, time and band are shown on the display in this order.
1.5 seconds elapse when a band is shown, a frequency will be displayed again.
As long as AUX is selected, this button alternately switches the display between AUX and the time.

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OPERATION EXPLANATION OF COMPONENTS

SOUND CONTROL BUTTON (HM-K860-043-K-07-A)

Press this button (7), 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 (7) is pressed while BAS is displayed, the sound adjustment will be cancelled.
For details of the sound adjusting method, see "OPERATION METHOD（PAGE 3-108）".
DISPLAY (HM-K860-043-K-08-A)
(A): Band name, "AUX", frequency, time and other character/nu-
meric information are displayed.
(B): Frequencies are displayed in step of 50 kHz in certain areas.
(C): Lights up when a stereo broadcasting is heard while a FM sta-
tion is selected.
(D): Lights up at the time of balance adjustment in the sound ad-
justing condition.
(E): Lights up at the time of treble adjustment in the sound adjust-
ing condition.
(F): Lights up at the time of bass adjustment in the sound adjusting
condition.

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EXPLANATION OF COMPONENTS OPERATION

OPERATION METHOD (HM-K860-001-K-01-A)

FREQUENCY ADJUSTMENT (HM-K860-100-K-00-A)

1. Press band/AUX selector button (2) and select FM or AM.
2. In this condition, press the E button of the tuning/time adjust-
ment button (4), and the frequency becomes higher.
Also, press the R button, and the frequency becomes lower.
3. Keep pressing the E button of tuning/time adjustment button
(4), and the frequency becomes higher continuously.
4. Keep pressing the R button of tuning/time adjustment button
(4), and the frequency becomes lower continuously.
5. Keep pressing the E button and release it, and the frequency
becomes higher continuously. Keep pressing the R button
and release it, and the frequency becomes lower continu-
ously as an auto seek.
When a proper frequency is picked up, the tuning automati-
cally stops.

AUTO PRESETTING (HM-K860-100-K-01-A)

1. Press band/AUX selector button (2) and select FM or AM.
2. In this condition, keep pressing sound control button (7), and
the auto presetting starts, i.e., a well-receiving frequency is
detected and is automatically registered in the preset memory
1 to 6.

PRESET CALL (HM-K860-100-K-07-A)

1. Press band/AUX selector button (2) and select FM or AM.
2. In this condition, press any of buttons 1 to 6 of preset button
(5), and the frequency registered to the preset number is
called to start receiving.
Example:
While a frequency is displayed, press button 1 of preset button
(5), and the preset number "P-1" appears on the display.
The preset number is shown for 0.5 seconds, and then the fre-
quency is displayed.

PRESET MEMORY (HM-K860-100-K-02-A)

While the radio is receiving a station, keep pressing any of buttons
1 to 6 of preset button (5), and the frequency being received now
is memorized to the corresponding preset number.
Example:
While a frequency is displayed, keep pressing button 1 of preset
button (5), and the preset number "P-1" is displayed.
After the preset number flashes 3 times, the frequency is dis-
played and then memorized to the preset number "P-1".

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OPERATION EXPLANATION OF COMPONENTS

SOUND CONTROL (BALANCE) (HM-K860-100-K-03-A)

1. Press the sound control button (7) to turn on BAL on the dis-
play for starting sound adjustment (balance).
2. In this condition, press the E button of the tuning/time adjust-
ment button (4), and the speaker output increases by 1 to-
wards R output. (R1 to R7)
3. Also, press the R button of the tuning/time adjustment button
(4), and the speaker output increases by 1 towards L output.
(L1 to L7)

SOUND CONTROL (TREBLE) (HM-K860-100-K-04-A)

1. Press the sound control button (7) to turn on TRE on the dis-
play for starting sound adjustment (treble).
2. In this condition, press the E button of the tuning/time adjust-
ment button (4), and the treble level increases by 1. (Maxi-
mum + 7)
3. Also, press the R button of the tuning/time adjustment button
(4), and the treble level decreases by 1. (Minimum - 7)

SOUND CONTROL (BASS) (HM-K860-100-K-05-A)

1. Press the sound control button (7) to turn on BAS on the dis-
play for starting sound adjustment (bass).
2. In this condition, press the E button of the tuning/time adjust-
ment button (4), and the bass level increases by 1. (Maximum
+ 7)
3. Also, press the R button of the tuning/time adjustment button
(4), and the bass level decreases by 1. (Minimum - 7)

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EXPLANATION OF COMPONENTS OPERATION

TIME ADJUSTMENT BUTTON (HM-K860-100-K-06-A)

1. Press display selector button (6) to display the time.
2. In this condition, keep pressing display selector button (6) for
starting time adjustment.
3. For the time adjustment, press display selector button (6),
and the adjustment target changes from "Hour" to "Minute".
At this time, the adjustment target flashes.
4. Flash the item to be adjusted, and press the tuning/time ad-
justment button (4) and start the adjustment.
5. If display selector button (6) is pressed during the minute ad-
justment, the time adjustment will be released and the time
display will resume.

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OPERATION EXPLANATION OF COMPONENTS

PRECAUTIONS (HM400-K860-170-K-01-A)
• To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during
operation.
• If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
• 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 off at the re-
placement of the battery, the clock may be initialized. In such a case, set it again.
For details of the operating method of the battery disconnect switch, see "BATTERY DISCONNECT SWITCH
（PAGE 3-119）".

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EXPLANATION OF COMPONENTS OPERATION

AUXILIARY ELECTRIC POWER (ALL-K890-001-K-00-A)

12V POWER SOURCE (HM-K892-043-K-00-A)

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

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OPERATION EXPLANATION OF COMPONENTS

FUSE (HM400-Q6G0-043-K-00-A)
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
NOTICE
Before replacing a fuse, be sure to turn the starting switch to
OFF position.
When replacing the fuse, always use a fuse of the same ca-
pacity and type.

FUSE CAPACITIES AND CIRCUIT NAMES

Fuse box I (BT1)
ca-
No. pacity Name of circuit
(1) 15 A Retarder controller
(2) 10 A Auto-emergency steering
(3) – –
(4) 5A Switch panel
(5) 5A Shift lever, personal code relay
(6) 10 A Preheat relay
(7) 20 A Air conditioner (blower motor)
(8) 10 A Air conditioner (compressor clutch)
(9) 10 A –
(10) 10 A –

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EXPLANATION OF COMPONENTS OPERATION

Fuse box II (BT2)

Ca-
No. Name of circuit
pacity
(11) 5A Air conditioner (continuous power supply)
(12) 15 A Terminal B
(13) 15 A Transmission controller
(14) 5A Retarder controller (continuous power supply)
(15) 10 A Monitor controller (continuous power supply)
(16) 10 A KOMTRAX
(17) 10 A Payload meter (if equipped)
(18) 10 A Download (continuous power supply)
(19) 5A Radio (continuous power supply)
(20) 10 A Hazard lamp
(21) 5A Room lamp 1
(22) 15 A Horn
(23) 5A –
(24) 5A Rear view monitor (if equipped)
(25) 20 A Continuous power supply (spare)

Fuse box III (BT3)

ca-
No. pacity Name of circuit
(26) 15 A Headlamp (high beam)
(27) 15 A Headlamp (low beam)
(28) 10 A Clearance lamp
(29) 10 A Stop lamp
(30) 15 A Fog lamp (if equipped)
(31) 10 A Radio
(32) 10 A Turn signal lamp
(33) 20 A Air suspension seat
(34) 15 A Backup lamp, backup buzzer
(35) 10 A Room lamp 2, door solenoid
(36) 15 A Working lamp
(37) 15 A Side lamp (if equipped)
(38) 20 A –
(39) 30 A –
(40) 20 A Spare

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OPERATION EXPLANATION OF COMPONENTS

Fuse box IV (BT4)

Ca-
No. Name of circuit
pacity
(41) 20 A Power window
(42) 20 A Front wiper
(43) 10 A Rear wiper
(44) 20 A 12 V power supply, cigarette lighter
(45) 10 A Yellow revolving warning lamp (if equipped)
Payload meter external indicator lamp (if
(46) 10 A
equipped)
(47) 5A –
(48) 5A Controller (ACC signal)
(49) 5A Air conditioner (ACC signal)
(50) 10 A Download (ACC signal)
(51) 10 A Parking brake
(52) 30 A Engine controller
(53) 10 A Manual emergency steering
(54) 5A System operating lamp
(55) 10 A Cab power tilt (if equipped)

Fuse box V (inside battery case)

ca-
No. pacity Name of circuit
120 A Power supply for engine heater
(56)
120 A Power supply for battery charging

Fuse box VI (inside battery case)

ca-
No. pacity Name of circuit
(57) 15 A Power supply for emergency steering
(58) 15 A –

Fuse box VII (inside battery case)

ca-
No. pacity Name of circuit
Cab power tilt main power supply (continuous
(59) 200 A
power supply, if equipped)

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EXPLANATION OF COMPONENTS OPERATION

Precautions when changing electrical component

CAUTION
If the electrical equipment system is changed, problems may occur in the machine control. Do not make
any changes to the electrical system.

If you want to make any change to the electrical system, contact your Komatsu distributor.

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OPERATION EXPLANATION OF COMPONENTS

OPEN AND CLOSE CAB DOOR (HM-K160-012-K-00-A)

CAUTION
• Make sure that the cab door is locked.
• Always stop the machine on level ground when opening
or closing the door.
If the door is opened or closed on a slope, there is danger
that the operating effort will suddenly change. Do not
open or close the door on slopes.
• Hold the door handle and knob whenever opening or
closing the door.
• Be careful not to get your hands caught between the front
pillar or center pillar.
• If there is anyone inside the cab, call out to that person
before opening or closing the door.

CAB DOOR HANDLE (HM-K161-043-K-00-A)

If the door handle is pulled while it is not locked with the key, it
opens to the open position.

OPEN KNOB FOR CAB DOOR (HM-K161-043-K-01-A)

If the open knob is pulled, the door opens to the open position

CAB DOOR INNER LOCK (HM-K164-043-K-00-A)

If the cab door inner lock is pressed, the door is locked.
Position (a): Locked
Position (b): Released

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STORAGE FOR TOOLS (HM400-Q8G1-043-K-00-A)

The attached tool (1) is stored in the front side of the hydraulic
tank, which situates on the left side of the machine.

STORAGE FOR FIRE EXTINGUISHER (HM400-Q5G1-043-K-00-A)

Fire extinguisher (1) is installed to the left front of the machine.

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BATTERY DISCONNECT SWITCH (HM400-AW1P-043-K-02-A)

CAUTION
• Do not operate the battery disconnect switch while the engine is running.
The large current generated by the alternator may burn the electric parts and cause a fire.
When operating the battery disconnect switch, always stop the engine.
• If the battery disconnect switch is turned to OFF position, always remove the switch key.
If someone turns the key to ON position carelessly, this is extremely dangerous.

NOTICE
• Keep this switch in ON position, except the following cases.
• When the machine is stored for a long time (more than 1 month)
• When the electrical system is repaired
• When an electrical welding is conducted
• When the battery is handled
• When the fuse is replaced
• Do not turn battery disconnect switch to OFF position while the system operating lamp is lit.
• If the battery disconnect switch is turned OFF while this lamp is lit, the data in the controller may be
lost.
• If this switch is turned to OFF position, all the electrical system is cut out and the functions of KOM-
TRAX stop. In addition, the time information of the clock and the radio station select information may
be lost. In this case, set the information again. For detail, see "CLOCK ADJUSTMENT（PAGE 3-69）"
and "HANDLING RADIO（PAGE 3-106）".
Use switch (1) to cut out the electricity from the battery.
This is installed in the battery box on the left side of the machine.
REMARK
Operate this switch while system operating lamp (2) is OFF.

(O): OFF position

Switch key (1) can be pulled out (and inserted) and the current
from the battery is cut out.
(I): ON position
The current from the battery flows into the circuit.
Before starting the machine, be sure to set the switch to this
position.

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EXPLANATION OF COMPONENTS OPERATION

SYSTEM OPERATING LAMP

This lamp (1) indicates that the controller mounted on the machine
is turned ON.
Lamp (1) lights up in green when the controller is turned ON and
normally goes out in 1 to 2 minutes after the power for the ma-
chine is turned OFF.
Before operating the battery disconnect switch, check that lamp
(1) is turned OFF.

NOTICE
• If the battery disconnect switch is turned OFF while this lamp is lit, the data in the controller may be
lost.
REMARK
• Even if the starting switch is in OFF position, the controller is sometimes activated. The lamp lights up at this
time, but it is not trouble.
• Even if the starting switch is turned to OFF position, system operating lamp may be kept lit for a long time. In
such case, consult to your Komatsu distributor.
• The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute
leakage of current and not an abnormal phenomenon.

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CIRCUIT BREAKER (HM400-AW1R-043-K-00-A)

When the circuit breaker operates, it can be reset by pushing in
the reset button.
If the reset button pops up soon after it is pushed in, there may be
a short circuit in the electric circuit. In such case, ask your Komat-
su distributor for repair.
(1) For primary power supply (40 A)
(2) For primary power supply (Direct) and engine controller (30 A)
(3) For secondary power supply (accessory power) (80 A)
(105 A for the machine equipped with circuit breaker for large ca-
pacity alternator (optional))

DUST INDICATOR (HM400-A960-043-K-00-A)

This device indicates clogging of the air cleaner.
Depending on the degree of clogging of the element, red line (1)
appears in the transparent portion. If red line (1) indicates 7.5 kPa
(30 INCHES H2O) (0.076 kg/cm2), clean the element immediately.
After cleaning, press top portion (2) of the indicator to return red
line (1) to its original position.

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ARTICULATION LOCK (HM400-FW10-043-K-00-A)

WARNING
If the machine is transported or lifted without applying the articulation lock, the machine may suddenly
articulate.
This may cause serious injury to persons in the surrounding area.
• When transporting or lifting the machine, always apply the articulation lock.
• Apply the articulation lock if necessary when performing maintenance.

The articulation lock is a device to lock the front frame and rear
frame to prevent the machine from articulating.
LOCK position (L): Always set to this position when transporting or
lifting the machine.
Set to LOCK position if necessary when performing maintenance.
FREE position (F): Always set to this position when traveling

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BODY PIVOT PINS (HM400-M570-043-K-00-A)

WARNING
When performing inspection of the machine with the dump body raised, always set the dump lever to
HOLD position, lock with the dump lever lock knob, then use the body pivot pin.

This is a safety device for the dump body. Use it when performing
inspection and maintenance with the dump body raised.
Raise the dump body fully, insert body pivot pins (1).
Always insert the body pivot pin on both sides.

STORAGE FOR BODY PIVOT PIN (HM400-M570-043-K-01-A)

Store the body pivot pin under the rear of the dump body.
Insert body pivot pin (1), then insert lock pin (2) to stow the body
pivot pin.

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HANDLING REAR VIEW MONITOR

(if equipped)

WARNING
• Never operate any of the switches while traveling. If you operate a switch while traveling, you may
make a mistake in travel operation, or in checking safety of travel path, this may cause serious per-
sonal injury or death.
• The rearview monitor is an supporting aid for checking obstacles in the rear or surroundings. An im-
age appearing on the monitor is limited. So when backing up the machine, be sure to make a visual
check, not relying solely on the monitor.
Never rely solely on the rearview monitor when backing up the machine.
• An image on the rearview monitor does not show an actual distance, so drive the machine slowly,
when backing it up.
• The aberration appears on an image on the rear view monitor which is different from the actual state.
So, look at the center of the screen as a reference.

When the machine is backed up and rear view monitor (1) is set in
operation, a monitor screen enables the operator to check the rear
for safety. Refference line (2) on the monitor is used for checking
the side and rear of the machine roughly.
The luminance of the rear view monitor can be adjusted with rear
view monitor brightness adjustment switch (3). For the details of
adjusting method,
See "BRIGHTNESS ADJUSTMENT SWITCH OF REAR VIEW
MONITOR（PAGE 3-80）".
For other settings of the rearview monitor, see "REAR VIEW
MONITOR SETTING（PAGE 3-65-1）", and for the setting of the
reference line, see "ADJUST REAR VIEW MONITOR（PAGE
3-145-1）".
REMARK
The screen may be hard to see in the dark place at night, but it is
not a trouble.

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WARNING
• The reference line dose not synchronize with steering angle. The reference line dose not indicate the
actual moving direction or travel path.
• The 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
machine position.

(A) When unloaded (C) When road surface is uneven

(B) When loaded (D) Display on monitor

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RULES FOR USING REAR VIEW MONITOR (HM400-Q16D-170-K-00-A)

WARNING
• Do not attempt to disassemble or modify the monitor. There is a danger of electric shock or fire.
• Do not attempt to open the monitor backside cover. There is a danger of electric shock, as high volt-
age power is conducted internally.
• Do not use the monitor if it is suspected of defect. 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.
• In case a foreign material has got into the monitor or it gets wet, or if a smoke comes out of the moni-
tor or it gives a bad smell, stop the use immediately. It poses a big danger to use the monitor when
any such abnormality exists. In that case, consult your Komatsu distributor.
• When replacing a fuse, be sure to use one with the specified capacity of 5 A. Should a fuse with a high-
er- 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 3,000
hours (or approximately 3 years), though this may differ according to usage conditions.
• When cleaning the 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 monitor display is blurred due to the camera lens being dirty. In that case, clean
the camera lens with dry soft cloth or wet cloth after having well wrung the water out.

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EXPLANATION OF COMPONENTS OPERATION

HANDLING MACHINES EQUIPPED WITH KOMTRAX (ALL-Q210-043-K-01-A)

KOMTRAX equipment may not be mounted on machines for some countries or regions.

OUTLINE OF KOMTRAX (ALL-Q210-042-K-00-A)

KOMTRAX is a system used for remote management of machines mounted with KOMTRAX equipment by using
satellite communication or cellular wireless communication.
The customer can obtain various machine information (including machine position) by viewing the web screen on
a personal computer.
Machine information that can be viewed with KOMTRAX includes the following.
• Machine position, service meter, operating hours, and fuel consumption
Komatsu and associated companies, Komatsu distributors will use these machine information to provide better
service to customers and improve products and services, etc.
If you are interested in using KOMTRAX, consult your Komatsu distributor for registration of using KOMTRAX.

WARNING
• Never disassemble, repair, modify, or move the communication terminal, antenna, or cables. This may
cause failure or fire on the KOMTRAX equipment or the machine itself. (Your Komatsu distributor will
perform removal and installation of KOMTRAX.)
• Near the blasting jobsite, there may be a danger of unexpected explosion due to use of interactive
wireless communication device of KOMTRAX and resulting serious personal injury. Make sure to op-
erate the machine away from the blasting jobsite.
If you have to operate the machine within 12 m from the blasting jobsite or the remote-controlled blast-
ing device, the power supply cable of KOMTRAX must be disconnected in advance. If you want to do
this, ask your Komatsu distributor for disconnecting power supply cable of KOMTRAX.
Also, if there are requirements or regulations concerning the operation of this machine in your area or
country, be sure to observe them in priority to this warning.

PRECAUTIONS (HM400-Q210-10A-K-02-A)
• Even when the key in the starting switch of the KOMTRAX system is at OFF position, a small amount of elec-
tric power is consumed.
It is recommended to run the engine periodically to charge the battery. When putting the machine into long-
term storage, take the action given in "LONG-TERM STORAGE（PAGE 3-199）".
• When using the battery disconnect switch, turn the starting switch to OFF position and turn the battery discon-
nect switch key to OFF position. Then, remove the key.
When the battery disconnect switch is turned to OFF position, it is possible to prevent power consumption of
the battery, but the functions of KOMTRAX stop at the same time.
For details of the operation of the battery disconnect device, see "BATTERY DISCONNECT SWITCH（PAGE
3-119）".
• Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
REMARK
The KOMTRAX device uses wireless communications, so it cannot be used inside tunnels, underground, inside
buildings, or in mountain areas where radio waves cannot be received. Even when the machine is outside, it can-
not be used in areas where the radio signal is weak or in areas outside the wireless communication service area.

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OBSERVANCE OF THE APPLICABLE LAWS AND REGULATIONS,

EXEMPTION (ALL-Q210-18B-K-00-A)
The KOMTRAX equipment is a wireless device using radio waves, so it is necessary to obtain authorization and
conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used. Observe
the applicable laws and regulations of the country or region in which the machine is used.
Always contact your Komatsu distributor before exporting this machine equipped with KOMTRAX or using it in a
foreign country.
The KOMTRAX may already have been registered and used if the machine is purchased as second-hand. For the
registration and usage records of KOMTRAX, consult your Komatsu distributor.
If the machine has been lent out by the customer, the borrower or another third party may have been using the
KOMTRAX. Ask the borrower about the usage of KOMTRAX.
Komatsu may suspend KOMTRAX communication in the following cases.
• When Komatsu judges that KOMTRAX is used by an unregistered user.
• When Komatsu judges that KOMTRAX is used in a country or region not allowing the use of KOMTRAX.
• In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX
communication.
If you do not obey the above precautions, neither Komatsu nor your Komatsu distributor can take any responsibility
for any problem that is caused or for any loss that results.

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MACHINE OPERATIONS AND CONTROLS (ALL-0000-001-K-13-A)

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE (ALL-3310-001-A-00-A)

WALK-AROUND CHECKS
Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or
leakage of oil, fuel, or coolant, and check the condition of the hydraulic system.
Check also for loose wiring, play, and accumulation of dust in places that get very hot and are exposed to ex-
tremely high temperatures.

WARNING
• Always hang the warning tag from the gear shift lever.
• Accumulation of flammable material and leakage of fuel or oil around the battery or high temperature
engine parts such as muffler, turbocharger, or dump body (equipped with dump body heating specifi-
cation), may cause the machine fire. Check carefully, and if any problem is found, repair and clean it
or contact your Komatsu distributor.
• The lamps may become hot. Wait until they have cooled down before starting any work.

Always perform the following inspections and cleaning every day before starting engine for the day's work.

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1. Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play. Check
the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and perform
repairs if any problem is found.
For the details of check method of dump body, see "CHECK DUMP BODY (PAGE 4-27)".
2. Remove dirt from around engine, battery, radiator, and aftercooler.
Check that there is no dirt or dust accumulated around the engine, radiator or aftercooler. Check also that
there is no flammable material (dry leaves, twigs, etc.) accumulated around the battery, or muffler,
turbocharg-er, or other high temperature parts of the engine or dump body (equipped with dump body heating
specifica-tion). Remove any dirt or flammable materials that are found.
For details of removal of dirt from radiator and aftercooler, see "CHECK RADIATOR FIN, AFTERCOOLER
FIN, AND AIR CONDITIONER CONDENSER FIN, CLEAN（PAGE 4-62）".
3. Check for leakage of coolant or oil around engine
Check for oil leakage from the engine and coolant leakage from the cooling system. If any problem is found,
repair it.
For the anchor point if you do the check when the engine hood is opened, see "CHECK FOR LOOSENESS
OF ENGINE INTAKE PIPE CLAMP (PAGE 4-74)".
4. Check of 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 transmission case, differential case, final drive case, hydraulic tank, brake control
oil tank, hoses, and joints
Check for oil leakage. If any problem is found, repair the place where the oil is leaking.
Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.
6. Check of tires, wheels, and wheel hub bolts and nuts for damaged and wear, and check of wheel hub bolts
and nuts for looseness
Check for cracks or peeling of the tires and for cracks or wear to the wheels (side ring, rim base, lock ring).
Tighten any loose wheel hub bolts or nuts.
If any problem is found, repair or replace the part.
If any valve cap is missing, install one.
7. Check of air cleaner mounting bolts for looseness
Check for the loose bolts. If loose, tighten them.
8. Check dump body mount rubber
Check for any cracks, embedded foreign objects, or loose bolts.
To check the dump body mount rubber, see "CHECK DUMP BODY (PAGE 4-27)".
9. Check for damage to handrail, loose bolts
If any problem is found, repair it. Tighten any loose bolts.
10. Check for damage to lamp and rear view camera (if equipped)
If damaged, replace it with a new one.
Clean off any dirt on the surface.
If any problem is found in headlamps, ask your Komatsu distributor for repair.
11. Check of side view mirror and under view mirror
Check that the mirrors are not damaged. If damaged, replace it with a new one. Clean the surface of the mir-
rors and adjust the angle so that the operator can see the area to the rear and under the machine from the op-
erator's seat.
For the details of adjustment method of mirrors, see "ADJUST MIRROR (PAGE 3-145)".
12. Check of machine monitor and rear view monitor (if equipped) for abnormality
Check the machine monitor and rear view monitor (if equipped) for abnormality. If any abnormality is found,
replace the failed monitor. Clean off any dirt on the surface.
13. Check of seat belt and mounting hardware
Check for damage to seat belt and mounting clamps. If damages are found, replace with the new one.
• Check for any loose bolts of the clamps mounting the equipment to the machine. Tighten any loose bolts.
• If the seat belt is scratched or frayed, if any fittings are broken or deformed, replace the seat belt
immediately.

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14. Check of tires.

WARNING
If worn or damaged tires are used, they may burst and cause
serious injury or death.
To ensure safety, do not use the following tires.
Wear:
• Tires with a tread grooves of less than 15% of that of a
new tire
• Tires with extreme uneven wear or with stepped-type
wear
Damage:
• Tires with damage that has reached cords (1), or with
cracks in the rubber
• Tires with cut or broken cords (1)
• Tires with peeling (separation)
• Tires with damaged bead (2)
• Leaking or improperly repaired tubeless tires
• Deteriorated, deformed or abnormally damaged tires,
which do not seem usable.

15. Check of rims.

WARNING
Check that the rims (wheels) and rings are free from deformation, damage caused by corrosion and
cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.

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CHECKS BEFORE STARTING (HM-3340-015-A-00-A)

Perform the contents of this section before starting the work of each day.
CHECK LOOSENESS OF WHEEL HUB BOLTS, RETIGHTEN (HM400-DA51-71A-K-00-A)
Check for loose wheel hub bolts. If any are found, tighten them.
Tightening torque: 824 to 1,030 Nm {84 to 105 kgm, 608 to 759
lbft}
Insert a socket wrench in a pipe, then apply a force of 932 N {95
kg} at a point 1 meter from the fulcrum. This will give a tightening
torque of 932 Nm {95 kgm, 687 lbft}.
When the hub bolts were tightened again after replacement of the
tires, travel for 5 to 6 km, then check the tightening torque to en-
sure that there are no loose bolts.
If any wheel hub bolt is broken, replace all the wheel hub bolts for
that wheel.

CHECK TIRE PRESSURE (HM400-DW60-360-K-00-A)

Use a tire pressure gauge to measure the tire inflation pressure before starting operations when the tires are cool.
Check the tires and the rims for wear or damage, check the hub bolt for loosening.
The proper inflation pressure is shown in table below.

Inflation pressure kPa {kg/cm2, PSI}

Tire size
Front tire Center tire Rear tire
29.5–R25 (standard) 375 {3.8, 54.0} 390 {4.0, 56.8} 390 {4.0, 56.8}
875/65R29
440 {4.5, 63.9} 440 {4.5, 63.9} 440 {4.5, 63.9}
(if equipped)

NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim may
be damaged.
Always keep the tire inflation pressure within +0 to +29 kPa {0.3 kg/cm 2, 4.3 PSI} of the value in the table
above.
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL (HM400-CH13-212-K-00-A)
After starting the engine, run it at low idle and check the oil level
by using the "LOW TEMPERATURE" scale on sight gauge (G).
If the oil level is low, add oil through oil filler port (F).
NOTICE
• The oil level changes according to the oil temperature, so
check the oil level after completing the warming-up
operation.
• During operations or when running the engine at low idle
after operations, check the oil level by using the "HIGH
TEMPERATURE" scale.

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CHECK DUST INDICATOR (HM400-A960-280-K-00-A)

1. Check that the red line in the transparent portion of dust indi-
cator (1) does not indicate 7.5 kPa (30 INCHES H2O) {0.076
kg/cm2}.
2. If the red line indicates 7.5 kPa (30 INCHES H2O) {0.076 kg/
cm2}, clean or replace the air cleaner element immediately.
For the cleaning method of the element, see "CHECK,
CLEAN, AND REPLACE AIR CLEANER（PAGE 4-15）".
3. After cleaning or replacing, press the top of dust indicator (1)
to return the red line to its original position.

CHECK BATTERY DISCONNECT SWITCH (HM-AW1P-111-K-00-A)

Check that battery disconnect switch (S) is at ON position (I).

DRAIN WATER AND SEDIMENT FROM FUEL TANK (HM300-AD10-220-K-00-A)

1. Prepare a container to receive drained oil under drain valve
(1) at the bottom of the fuel tank.
2. Loosen drain valve (1) to drain sediments at the bottom and
mixed water together with the fuel.
3. When clean fuel alone started to flow out, close drain valve
(1).

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CHECK FUEL LEVEL, ADD FUEL (HM400-AD10-211-K-01-A)

WARNING
• When adding fuel, be careful not to let the fuel overflow. It may cause fire. Always wipe up all the
spilled fuel.
• If fuel spills onto dirt and sand sticking to the machine, remove it and dirt and sand together.
• Since fuel is flammable and dangerous, do not bring any open flame near fuel.

1. Turn the starting switch to ON position and check the fuel lev-
el with fuel gauge (1) on the machine monitor.
2. After completing operations, add fuel through fuel filler port
(F) to fill the tank.
Fuel tank capacity: 525 liters (138.71 US gal)
3. After adding fuel, tighten the cap securely.

REMARK
• If the breather hole in the cap is clogged, the pressure inside the tank will go down and this may cause the fuel
to stop flowing. To prevent this, clean the breather hole from time to time.
• To prevent air from being sucked into the engine, always pay careful attention to the fuel level in the tank.
DRAIN WATER IN FUEL PREFILTER (HM400-AEA0-220-K-00-A)
The water separator and fuel prefilter (1) are integrated and com-
posed of (2) to (4) in the lower section.
1. It is possible to judge the amount of water or sediment
through transparent cap (2). If water or sediment has accu-
mulated, place a container under drain hose (4) to catch the
drained water.
2. Loosen drain valve (3) to drain the water.
3. When fuel starts flowing out through drain hose (4), close
valve (3) immediately.

NOTICE
• If the water inside transparent cap (2) freezes, check that the frozen water has melted completely, then
use the procedure above to drain the water.
REMARK
• If transparent cap (2) is dirty or it is difficult to see the inside, clean transparent cap (2) when replacing fuel pre-
filter cartridge (1).
• When the drain valve (3) has been removed during the cleaning operation, apply the grease to the O-ring and
tighten the valve until it contacts the bottom.

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ADJUST DRAIN VALVE (HM400-AEB4-270-K-01-A)

1. Place the container to catch the fuel under the prefilter
cartridge.
2. Loosen drain valve (3) to drain water and sediments from
transparent cap (2), and also drain all the fuel from filter car-
tridge (1).
3. Check that nothing more comes out from drain hose (4), then
remove drain valve (3).
4. Apply a suitable amount of grease to O-ring part (5).
When doing this, be careful not to allow the grease to adhere
to water drain port (6) and threaded part (7) of the drain valve.
5. Finger-tighten drain valve (3) until it contacts the bottom of
transparent cap (2).
6. Remove the fuel container.
7. Fill the fuel tank fully with fuel, then bleed the air.
For the air bleeding procedure of fuel circuit, see "PROCE-
DURE FOR BLEEDING AIR（PAGE 3-200）".

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CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT (HM400-AEB0-220-K-02-A)

WARNING
• Do not bring any open fire or open flame close.

The water separator serves to separate moisture mixed in the fuel.

• Prepare a container to catch the water.
NOTICE
If float (1) goes above level line (2), there is danger that the
separated water may be sucked into the engine. Always drain
the water before float (1) reaches level line (2).
1. Open engine hood.
2. Check the position of float (1).
If float (1) is about to reach level line (2), drain the water as
follows.

3. Set a container under the water separator drain hose to catch

the drained water.

4. Close supply valve (3) of the fuel tank.

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MACHINE OPERATIONS AND CONTROLS OPERATION

5. Drain plug (4) and drain the water.

6. If the water cannot be drained, remove air intake plug (5).
(Width across flats: 14 mm (0.6 in)) The water will drain from
plug (4).
7. When fuel starts to come out, tighten drain plug (4)
immediately.
Tightening torque: 2.0 to 3.0 Nm {0.20 to 0.30 kgm, 1.5 to 2.2
lbft}
8. If the inside of filter case (6) is dirty with the sediment, wash it.
For details, see "CHECK WATER SEPARATOR, CLEAN FIL-
TER CASE（PAGE 4-29）".

9. Tighten air intake plug (5).

Tightening torque: 8.0 to 12.0 Nm (0.8 to 1.2 kgm, 5.8 to 8.7 lbft)
10. Open supply valve (3).
11. After completing the water drain operation, bleed the air. Use the same procedure as when replacing the fuel
filter cartridge.
For details of the method for bleeding the air, see "PROCEDURE FOR BLEEDING AIR（PAGE 3-200）".

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (HM400-PM30-212-K-00-A)

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Ac-
cordingly, wait until they have cooled down before starting the work.
If the oil filler cap is removed without releasing the internal pressure, oil will spurt out, so turn the oil filler
cap slowly to release the internal pressure, then remove it carefully.

1. Check with sight gauge (G1).

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

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CHECK CAB MOUNTING BOLTS AND PINS (HM400-K132-92B-K-00-A)

Check that there are no loose cab mounting bolts (1) (4 pieces
each of right and left). Tighten any loose bolts.
Tightening torque: 245 to 309 Nm {25 to 31.5 kgm, 181 to 228 lbft}

When getting on or off the machine with carrying a tool etc., place
it once in portion (A) to ensure your safety.

Check that there are no loose or broken cab mount pins (2) (1
pieces each of right and left).

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CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (HM400-AB20-212-K-01-A)

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Ac-
cordingly, wait until they have cooled down before starting the work.

1. Open the engine hood cover and check the oil level with dip-
stick (G).
2. Pull out dipstick (G) and wipe off the oil with cloth.
3. Fully insert dipstick (G) into the dipstick pipe, then pull out it.
4. The oil level should be between the H and L marks on dipstick
(G).
If the oil level is below the L mark, add oil through oil filler port
(F).

When getting on or off the machine with carrying oil, place it once
in part (A) to ensure your safety.

5. If the oil level is above the H mark, open the underguard of

the engine, remove drain plug (1), and loosen drain valve (2)
to drain the excess oil, and then check the oil level again.
6. If the oil level is correct, tighten the handle of the oil filler cap
securely.
REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
If the machine is inclining, make it level before checking.

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CHECK COOLANT LEVEL, ADD COOLANT (HM400-B000-216-K-01-A)

WARNING
• Do not open the sub-tank cap unless necessary. When checking the coolant level, check the reservoir
tank when the engine is cold.
• Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radia-
tor. If the cap is removed in this condition, there is a hazard of burns. Always wait for the temperature
to go down, turn the cap slowly to release the pressure, then remove the cap with care.

1. Open the engine hood and check that the coolant in reservoir
tank (1) is between FULL and LOW marks.
2. If the level is below LOW, remove cap (2) and add the coolant
up to FULL mark.

3. If no coolant is left in reservoir tank, add coolant to the sub-

tank through water filler port (3) on the top of the sub-tank
and add coolant to the reservoir tank as well.
4. Check that there is no oil in the engine coolant or any other
problem.
5. After adding coolant, tighten the cap securely.
6. If more coolant is added than normal, then check for water
leakage.

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CHECK ELECTRIC WIRING

CAUTION
• If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly
ask your Komatsu distributor to locate the cause and make 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, wash the battery cap with water to clear the vent hole.

Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no discon-
nection or trace of short-circuiting in the electric wiring and no damage to the coating. Check also that there is no
loosened terminals. If any, tighten them.
Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and
alternator.
Be sure to check that there is no inflammable material accumulated around the battery. If any is found, remove
immediately.
CHECK CENTRALIZED WARNING LAMP, WARNING BUZZER, MONITOR LAMP AND
METER DISPLAY (HM-Q180-383-K-00-A)
Before starting the engine, turn the starting switch to ON position and check that the machine monitor operates as
shown in "BASIC OPERATION OF MACHINE MONITOR（PAGE 3-8）".
If the machine monitor does not work, there is probably a failure in the machine monitor system, so ask your Ko-
matsu distributor to perform inspection.
CHECK BRAKE (HM-G4A1-360-K-00-A)
Check if the braking capacity of the parking brake, foot brake, and retarder brake.
If any abnormality is found, ask Komatsu distributor to repair.

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CHECK EMERGENCY STEERING (HM-F900-012-K-00-A)

WARNING
Do not continue to use the emergency steering motor for more than 90 seconds. If the using time is not ob-
served, there is danger that the motor may burn out or be damaged, or that it may cause a fire.

SELF-CHECK FUNCTION FOR EMERGENCY STEERING (HM-F900-043-K-00-A)

The emergency steering is started automatically when the starting switch is turned to ON position to check the
emergency steering functions.
If defective operation of the emergency steering motor is found, ask your Komatsu distributor for repair.

CAUTION
Operating the steering during self-check can start move of the machine.
Do not try to operate the steering as long as the self-check is continued.

Checkup of the emergency steering becomes unavailable in the following cases. In such case, you must turn on
AUTOMATIC EMERGENCY STEERING CHECKUP.
• After the starting switch is turned ON, without starting the engine, turned the starting switch OFF and then
turned it ON again
• When the engine preheating is turned on
• When ambient temperature is low (-10°C (14°F) or below)
REMARK
The battery voltage may drop sharply when the self-check is started due to the low temperature or condition of the
given battery.
In such case, the machine monitor may go out temporarily or restart, but it is not a trouble.
CHECK MANUAL EMERGENCY STEERING (HM400-F900-280-K-00-A)
1. Turn starting switch key to ON position.
2. Turn emergency steering switch (1) ON, turn the steering
wheel, and check that the steering can be operated.
If the steering is not operated when the steering wheel is
turned, ask your Komatsu distributor for repair.

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CHECK AUTO-EMERGENCY STEERING (HM400-F900-280-K-01-A)

1. Turn the starting switch key to START position and start the
engine.
2. Check that the brake oil pressure caution lamp is OFF, then
pull retarder control lever (1) fully and stop the engine.
3. Turn the starting switch key to ON position.
4. Set parking brake switch (2) to "TRAVEL", and check that the
emergency steering motor is actuated in 1 second.

REMARK
The emergency steering pilot lamp (3) stays lit as long as the
emergency steering motor is run.
If the emergency steering motor is run 1 minute or longer, emer-
gency steering motor prolonged-operation caution (4) is lit up.
Do not try to run the emergency steering motor a prolonged time.

TESTING BODY POSITIONER OPERATION (HM300-M5D0-280-K-01-A)

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.

CHECK BACKUP ALARM (HM-Q51A-383-K-00-A)

1. Turn the engine starting switch to ON position.
2. Place the gear shift lever in the R position and check that the backup alarm is working.
CHECK FUNCTION OF HORN (HM400-Q544-280-K-00-A)
1. Turn the starting switch to ON position.
2. Check that the horn sounds immediately when the horn but-
ton is pressed.
If the horn does not sound, ask your Komatsu distributor for
repair.

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ADJUST BEFORE OPERATION (HM-0000-184-K-01-A)

SEAT ADJUSTMENT (HM400-K2Q0-270-K-00-A)

WARNING
• Place the machine in a safe place and stop the engine when performing adjustment of the operator's
seat.
• Always adjust the operator's seat before starting each day's work 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.

(A) Fore-and-aft adjustment of seat

Pull lever (1) up, set the seat to the desired position, then release
the lever.
Fore-and-aft adjustment range: 180 mm (7 in) (10 mm (0.4 in) x 18
stages)
(B) Seat angle adjustment
Pull rear lever (2) up to increase the load on the rear of the seat.
The seat will tilt to the rear.
Push lever (2) down to increase the load on the front of the seat.
The seat will tilt to the front.
Adjustment range: 13 deg. (Front tilt, rear tilt: 4 stages each)

(C) Setting seat for operator's weight

Sit on the seat and adjust the strength of the suspension with
valve (3).
Adjustment range (target): 50 to 120 kg {110.25 to 264.6 lb}
(J) Pushing: Suspension is strengthened.
(K) Pulling: Suspension is weakened.

(D) Adjusting backrest angle

Pull lever (4) up, move the backrest forward or backward.
Sit with your back against the backrest when adjusting the reclining angle. If your back is not touching the back-
rest, it may suddenly return to the original position.
Adjustment range: Forward tilt 66 deg. (3 deg. x 22 stages)
: Rear tilt 30 deg. (3 deg. x 10 stages)
NOTICE
If the seat back is reclined too far, the headrest may hit the rear glass, so move it to a position where it
does not contact the glass.
(E) Seat height adjustment
Operate lever (2) up or down to raise or lower the seat. This also acts to adjust the seat angle, so adjust the seat
angle while setting the seat to the desired position.

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MACHINE OPERATIONS AND CONTROLS OPERATION

Adjustment range: 60 mm
(F) Adjusting headrest height
Move the headrest up or down to the desired height.
Adjustment range: 50 mm
(G) Adjusting headrest angle
Rotate the headrest to the front or rear.
(H) Lumbar support
Turn grip (5) to adjust the tension applied to the lower back.

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ADJUST SEAT BELT (HM400-K2Q3-100-K-00-A)

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, which-
ever date comes sooner.
• Adjust and fasten the seat belt before starting to travel.
• Always fasten the seat belt when traveling.
• Do not use the seat belt with either half of the belt 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.
FASTEN AND UNFASTEN SEAT BELT (HM400-K2Q3-100-K-01-A)
Fit the seat belt so that it fits tightly, without being too tight.
1. Sit on the seat, depress the brake pedal fully, and adjust the
seat so that your back is pressed against the backrest.
2. Sit in the seat, pull the right side of the belt, then insert tongue
(1) into buckle (2) until a click is heard.
Fit the belt along your body without twisting.
3. 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 caution (3) is
displayed on the machine monitor. Be sure to fasten the seat belt.

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MACHINE OPERATIONS AND CONTROLS OPERATION

ADJUST TILT OF STEERING WHEEL (HM-F172-043-K-00-A)

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 accident or personal injury.

Amount of adjustment
The steering wheel can be adjusted fore-and-aft and up-and-down
direction. Pull the lever up to FREE position (F) and set the steer-
ing wheel to the desired position, then push the lever down to
LOCK position (L) to fix the steering wheel securely in position.
Tilt amount: Front 5 deg., rear 10 deg.
Telescopic amount: Up 20 mm, down 20 mm

NOTICE
Do not apply an excessive force to the lever when operating it. (Operating effort of lever: 147 N to 176 N
{15 kg to 18 kg})
The lever can be loosened or its angle can be displaced. In such case, ask your Komatsu distributor for
the inspection.

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ADJUSTMIRROR
WARNING
Be sure to adjust the mirrors before starting operation. If they are not adjusted properly, you cannot secure
the visibility and may be injured or may injure someone seriously.

When getting on or off the machine with carrying a tool etc., place
it once in part (A) to ensure your safety.

1. Install the personal fall-arrest equipment to the anchor point for

tie-off (1). The anchor point for tie-off (1) is on the right and left
sides (2 places) of the cab.

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MACHINE OPERATIONS AND CONTROLS OPERATION

2. Loosen mirror mounting bolt (2) and nut (3), then adjust the
mirror to the position that assures the best view from the
operator's seat.
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OPERATION MACHINE OPERATIONS AND CONTROLS

ADJUST REAR VIEW MONITOR (HM400-Q162-270-K-02-A)

(if equipped)

WARNING
• When the direction of the camera is changed due to a damage etc., setting must be done again. Con-
tact your Komatsu distributor.
• Install only the Komatsu genuine camera.

As shown in the figure, park the unloaded machine in a flat ground directing it straight forward (no articulation).
When the machine dimensions are changed due to replacement of tires or installation of an optional attachment,
set the reference lines as non-display according to "REAR VIEW MONITOR SETTING（PAGE 3-65-1）" and
con-tact your Komatsu distributor.

Make sure that the images on the rearview monitor are normal as
shown in the illustration. Then, confirm that machine width refer-
ence line (3) matches with tire outside width (1) and distance refer-
ence line (4) matches with dump body rear end (2).
When the reference line is abnormal, change its setting to Non-
display and contact your Komatsu distributor.

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MACHINE OPERATIONS AND CONTROLS OPERATION

OPERATIONS AND CHECKS BEFORE STARTING ENGINE

WARNING
• When starting the engine, check that the gear shift lever
is set to N (NEUTRAL) position and that the parking brake
switch is in PARKING position.
• Before standing up from the operator's seat, be sure to
set the parking brake switch to PARKING position.

1. Check that battery disconnect switch (1) is in ON position (I).

2. Check that parking brake switch (2) is in PARKING position.

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

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OPERATION MACHINE OPERATIONS AND CONTROLS

4. Check that dump lever (4) is in HOLD position.

5. Check that engine shutdown secondary switch (5) is in NOR-

MAL position (cover is closed).

6. Insert the key in starting switch (6), turn the key to ON posi-
tion (B), then check whether the following actions are turned
on.

1) When the starting switch is turned to ON position, the ma-

chine monitor starts and operates as follows.
1] Centralized warning lamp (7) and pilot lamp (8) are lit
for 2 seconds and go out for 1 second.

2] Machine monitor (9) displays start screen AA for 2

seconds, and then changes to standard screen BB.
3] The pointer of engine tachometer (10) swings once.
4] Speedometer (11) displays "88" for 2 seconds.

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MACHINE OPERATIONS AND CONTROLS OPERATION

5] The alarm buzzer sounds for 2 seconds, then stops

under the normal condition.
NOTICE
If the lamps, alarm buzzer, etc. do not work, the machine mon-
itor may be defective or the electric wiring may have break-
age. In this case, ask your Komatsu distributor for repair.
REMARK
• When the engine is started, the battery voltage may suddenly
drop depending on the temperature and the battery condition.
In such case, the machine monitor may go out temporarily or
restart, but it is not a trouble.
• In approximately 1 second, the rear view monitor (if equipped)
displays soft version (12) for 5 seconds.

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OPERATION MACHINE OPERATIONS AND CONTROLS

2) In 2 seconds, machine monitor (9) displays the standard

screen.
• If a user password has been set, the password input screen
will be displayed on the monitor screen.
After inputting the password, press the enter switch.
REMARK
For details of the password setting, changing or canceling,
see the separate "Password Change and Cancel Procedure"
• When the starting switch is turned to ON position, the emer-
gency steering self-check function may operate.
When the standard screen is displayed while the self-check is
turned on, emergency steering pilot lamp (13) lights up.
REMARK
While the emergency steering self-check function is turned on, the
machine monitor may go out temporarily or restart, but it is not a
trouble.
For details of the emergency steering self-check function, see
"SELF-CHECK FUNCTION FOR EMERGENCY STEERING
（PAGE 3-139）".
• If the gear shift lever is in any position other than N (NEU-
TRAL) when the starting switch is turned to ON position, the
shift lever pilot lamp (14) of that position starts flashing, the
centralized warning lamp lights up and the alarm buzzer
sounds intermittently.
Even the starting switch is turned to START position in this
state, the engine does not start.
Turn the gear shift lever to N (NEUTRAL), and the centralized
warning lamp goes out, the alarm buzzer stops sounding, and
the engine can be started.

3) If alarm caution (15) remains displayed, press the enter

switch to identify the items lit in red. Then proceed to
checkup of such items immediately.
For details of contents and check methods for alarm cau-
tion, see "WARNING DISPLAY（PAGE 3-12）".

4) If the maintenance time has expired for certain items, the

corresponding maintenance time caution (16) appears in
red for 30 seconds to indicate such items.
Press the menu switch to identify such items and perform
maintenance immediately.
For details of the method of checking the maintenance
time, see "MAINTENANCE（PAGE 3-63）".

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MACHINE OPERATIONS AND CONTROLS OPERATION

STARTING ENGINE (HM400-0000-132-K-00-A)

WARNING
• Start the engine only while sitting down in the operator's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a
serious personal injury or fire.
• Check that there are no persons or obstacles in the surrounding area, then sound the horn and start
the engine.
• Never use starting aid fluids as they may cause explosions.
• Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.

NOTICE
• Do not accelerate the engine abruptly until it is warmed up.
• Do not operate the starting motor continuously for more than 20 seconds.
• If the engine does not start, wait for 2 minutes or so, and then try to start the engine again.
• When starting the engine, do not depress the accelerator pedal. Even if the accelerator pedal is de-
pressed just after the engine is started, the engine speed is limited by the turbo protect function. After
the turbo protect time, however, the engine speed rises sharply and the turbocharger may be
damaged.
This machine is equipped with the function for automatically starting preheating of the engine (automatic engine-
preheating mechanism).
When the engine coolant temperature is low, set the key of starting switch (1) to ON position. Preheating pilot lamp
(2) lights up and notice that the automatic preheating has been started.

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OPERATION MACHINE OPERATIONS AND CONTROLS

1. Turn the key in starting switch (1) to ON position (B).

If the engine coolant temperature is low, preheating pilot lamp
(2) lights up and the automatic preheating starts.
Keep the key in starting switch (1) at ON position (B) until the
preheating is completed and the preheating pilot lamp goes
out.
The following shows the rough preheating time.
ENG coolant temperature Preheating time
Min. -5°C (23°F) —
-5 to -20°C (23 to -4°F) 20 to 40 sec
Max. -20°C (-4°F) 40 sec

REMARK
If the engine coolant temperature is -5°C (23°F) or above, when
the starting switch is turned to ON position (B), preheating of the
engine is not performed. In this case, it is possible to start the en-
gine immediately.

2. If the preheating pilot lamp does not light up, or lights up once
but goes out, stopping the engine preheating, turn the key in
starting switch (1) to START position (C) and start the engine.
REMARK
If the ambient temperature is low, the engine may not start even
when the key in starting switch (1) is kept at START position for 20
seconds.
In such case, return the starting switch (1) to OFF position once,
then, in approximately 2 minutes, repeat the operation from the
start.
If the starting switch is not returned to OFF position, the automatic
preheating does not start.

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MACHINE OPERATIONS AND CONTROLS OPERATION

3. After the engine starts, release your hand from the key in
starting switch (1).
The key returns to ON position (B) automatically.
REMARK
When the engine is started, the battery voltage may suddenly drop
depending on the ambient temperature and the battery condition.
In such case, the machine monitor may go out temporarily or re-
start, but it is not a trouble.

4. Do not operate the accelerator pedal immediately after start-

ing 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.

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OPERATION MACHINE OPERATIONS AND CONTROLS

MANUAL PREHEATING FUNCTION (HM400-AM40-100-K-01-A)

Manual preheating of the engine is made available regardless of
the ambient temperature.
1. Turn the key in starting switch (1) leftward from OFF position
(A) to (D) position, and preheating pilot lamp (2) lights up and
engine preheating starts. (Preheating continues as long as
the key in starting switch (1) is held in the left position.)
While preheating is performed, preheating pilot lamp (2) lights
up indicating that preheating is continued.
For the details of the preheating time, see the table in "STARTING
ENGINE（PAGE 3-150）".

2. After the preheating time has elapsed, turn the key of starting
switch (1) to START position to start the engine.
If the engine cannot be started with the above procedure, wait
for at least 2 minutes, then repeat the procedure again from
step 1.

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MACHINE OPERATIONS AND CONTROLS OPERATION

REMARK
When the key in starting switch (1) proceeds through OFF posi-
tion, the indicator of tachometer (3) may swing once and "88" may
be displayed on speedometer (4). It is, however, not a trouble.

REMARK
If a user password is set, the password enter screen is displayed
on the monitor screen, but the preheating pilot lamp lights up as
on the standard screen.

TURBOCHARGER PROTECTION FUNCTION (HM-AA90-043-K-00-A)

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

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OPERATION MACHINE OPERATIONS AND CONTROLS

OPERATIONS AND CHECKS AFTER STARTING ENGINE (HM300-0000-133-K-00-A)

CANCEL TO HOLD DUMP BODY (HM-MD01-13U-K-00-A)

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.

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MACHINE OPERATIONS AND CONTROLS OPERATION

WARM-UP OPERATION (HM-0000-138-K-01-A)

NOTICE
• Do not accelerate the engine sharply during the warm-up operation. It can shorten the service life of
the engine parts.
• Do not continue the low idle or high idle operation for more than 20 minutes. It does not only adversely
affect environment but also cause oil leakage from the turbocharger.
1. After the engine starts, run it for 5 minutes in the range be-
tween 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
completed.
When it is below position (A), continue the warm-up
operation.
After finishing the warm-up operation, check that the machine
monitor is normal.
If any of them is abnormal, ask your Komatsu distributor for
inspection and repair.
3. 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.

AUTOMATIC WARM-UP FUNCTION (HM400-AM40-043-K-01-A)

This machine is equipped with the automatic warm-up function.
While the AISS LOW switch is in OFF position or when the engine coolant temperature is low, the low idle speed is
automatically increased to cut down the warm-up time.
REMARK
Turning AISS LOW switch to ON position stops the automatic warm-up and decreases the idle speed.
If the engine coolant temperature is low and AISS LOW switch is returned to OFF position within a specific time
after engine is started, the automatic warm-up is resumed.
For details of AISS LOW switch, see "AISS LOW SWITCH（PAGE 3-81）".
NOTICE
When you are forced to urgently cancel the automatic warm-up operation, run the engine at full speed for
3 seconds, then automatic warm-up operation is canceled.

CHECK STARTING CONDITION AND UNUSUAL NOISE OF ENGINE (HM400-0000-134-K-00-A)

When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and
smoothly.
Check also that there is no abnormal noise when the engine is running at low idle 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
damaged. In that case, ask your Komatsu distributor to check the engine as soon as possible.

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OPERATION MACHINE OPERATIONS AND CONTROLS

BREAK-IN THE NEW MACHINE (HM-0000-138-K-00-A)

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).

Make sure that you fully understand the descriptions in this manual, then break-in the machine while paying atten-
tion to the following points.
• Idle the engine 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.

CHECK ENGINE ACCELERATION AND DECELERATION (HM-0000-137-K-00-A)

When stopping the machine during the normal traveling operation, check that the engine does not hunt or stop
suddenly.
When the accelerator pedal is depressed, check that the engine speed rises smoothly.
• Perform these checks in a safe place, watching out for danger in the surroundings.
• When the engine performs very badly at low idle and in the acceleration and if that condition continues, it may
damage the engine or confuse the operator's sense of driving or lower the braking efficiency, and as a result
lead to an unexpected accident. In that case, ask your Komatsu distributor to check the engine as soon as
possible.

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STOPPING ENGINE (HM400-0000-13G-K-00-A)

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 ex-
cept in emergency.
Allow the engine to cool down gradually before stopping
it.
• Always lower the dump body and set the dump lever to
FLOAT position, then stop the engine.
1. Set the gear shift lever to N (NEUTRAL) position, then set the
parking brake switch to PARKING position.
2. Lower the dump body and set the dump lever to FLOAT
position.
3. Run the engine at low idle for approximately 5 minutes to cool
down gradually.
4. Turn the key of starting switch (1) to OFF position (A) to stop
the engine.
5. Remove the key from starting switch (1).

CHECKS AFTER STOPPING ENGINE (HM-0000-28A-K-00-A)

1. Walk around the machine and check the work equipment, bodywork, and undercarriage, and check also for
oil and water leakage.
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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MACHINE OPERATION (HM-0000-13H-K-00-A)

MOVE OFF THE MACHINE (HM400-0000-13H-K-05-A)

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 any obstacles from the travel path.
• There is a blind spot behind the machine, so be ex-
tremely careful when driving the machine in reverse.

1. Check that there is no warning display on the machine

monitor.

2. Fasten the seat belt.

3. Set dump lever (1) to FLOAT position and check that the
dump body float caution lamp is OFF.
If the dump body float caution lamp is lit, set the dump lever
to HOLD position, then set it to FLOAT position to cancel the
holding condition of dump body.

4. Depress the brake pedal fully. Then set parking brake switch
(2) to TRAVEL position to release the parking brake.
REMARK
If the engine is stopped with the parking brake switch at TRAVEL,
the parking brake will be automatically applied even though the
switch is at TRAVEL. In this case, operate the switch to PARKING,
and then move it back to TRAVEL to release the parking brake.

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5. Check that retarder pilot lamp (3) is OFF, then set gear shift
lever (4) to the desired position.
NOTICE
• Always place the gear shift lever securely in position
when operating it. If the gear shift lever is not placed se-
curely in position, the shift lever position pilot lamp on
the machine monitor may start flashing and the central-
ized warning lamp may light up, and the alarm buzzer
may sound.
• Always release the accelerator pedal when moving the
gear shift lever from N (NEUTRAL) to R (REVERSE) or F
(FORWARD).

6. Depress accelerator pedal (5) to move the machine off.

NOTICE
• If the gear shift lever is shifted to a position other than N
(NEUTRAL) when the parking brake has not been re-
leased, the centralized warning lamp will light up and the
alarm buzzer will sound.
• If the gear shift lever is shifted to a position other than N
(NEUTRAL) when the dump lever is at a position other
than FLOAT or the dump body is raised, the centralized
warning lamp will light up, the dump body float caution
lamp will light up in red, and the alarm buzzer will sound.
• Do not operate the gear shift lever with the accelerator
pedal depressed.
This will cause a big shock, and will also reduce the serv-
ice life of the machine.

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REVERSE (HM400-0000-13H-K-01-A)

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 be ex-
tremely careful when driving the machine in reverse.
• Always stop the machine completely before shifting be-
tween FORWARD and REVERSE.

Operate gear shift lever (1) to R1 or R2 position, then gradually

depress accelerator panel (2) to move the machine off.
NOTICE
• The machine cannot be driven in reverse when the dump
body is raised. Lower the dump body, set the dump lever
to FLOAT, then operate the gear shift lever to R1 or R2.
• When switching between Forward and Reverse, stop the
machine completely and run the engine at low idle when
shifting the direction of travel.
After moving the gear shift lever, do not accelerate until it
is detected that the transmission clutch is engaged.
• Do not operate the gear shift lever with the accelerator
pedal depressed.
This will cause a big shock, and will also reduce the serv-
ice life of the machine.

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STOP THE MACHINE (HM400-0000-13H-K-02-A)

WARNING
• Avoid a sudden stop. Stop the machine gradually.
• If the foot brake is used repeatedly or is kept depressed
for a long time, the brake may overheat and its life will be
shortened.
• If the parking brake is used to stop the machine, the park-
ing brake will be damaged. Do not use the parking brake
except when stopping in emergencies or when parking
the machine after stopping it.

NORMAL STOP (HM-0000-13H-K-04-A)

Release accelerator pedal (1), then depress brake pedal (2) to
stop the machine.

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EMERGENCY STOP (HM400-0000-13H-K-03-A)

If there should be a failure in the foot brake, stop the machine as
follows.

WARNING
• When the machine stops, chock the wheels immediately.
• If the parking brake is used to make an emergency stop,
the performance of the parking brake may drop below the
standard value, so it is necessary to repair and adjust the
parking brake. Ask your Komatsu distributor to perform
this work.

1. Pull retarder control lever (1) fully to apply the retarder.

2. If operating retarder control lever (1) does not give enough

braking force, set parking brake switch (2) to PARKING to ap-
ply the parking brake.

3. If an emergency stop has been made, chock the wheels im-

mediately, then try to find the cause, and repair it on site.

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SHIFTING GEARS (HM400-0000-135-K-00-A)

WARNING
Do not operate the gear shift lever to N (NEUTRAL) position when traveling or when going downhill. Al-
ways travel with the gear shift lever in a speed range position.
• The braking force of the engine cannot be used and the steering will become heavy. In addition, there
will be insufficient cooling oil for the retarder, and this will lead to overheating or defective operation
of the brakes and dangerous.
• There may also be damage to the transmission or other parts of the power train, and there is danger
of unexpected accidents.

Shift gear as follows.

This machine is equipped with automatic transmission, so if gear
shift lever (1) is set at the desired position, the transmission will
shift automatically to match the travel speed.
When the dump body is raised, if the gear shift lever is at the D po-
sition, the transmission is fixed in 2nd or 1st speed, and if it is at
positions 1 to 5, the transmission is fixed in 1st speed. Keep the
dump body lowered when traveling.
NOTICE
• When switching direction (FORWARD or REVERSE), stop
the machine completely and run the engine at low idle,
then select the direction of travel.
After moving the gear shift lever, do not accelerate 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 serv-
ice life of the machine.

UPSHIFT (ACCELERATION) (HM-0000-130-K-00-A)

1. When accelerator pedal (2) is depressed to accelerate the
machine, the lockup clutch is engaged to shift the transmis-
sion to direct drive.
2. If the machine is accelerated further, the transmission will au-
tomatically shift up.

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DOWNSHIFT (DECELERATION) (HM-0000-130-K-01-A)

If accelerator pedal (2) is released, the machine speed will be re-
duced, and the transmission will automatically shift down.

DOWNSHIFT INHIBIT (HM-0000-130-K-02-A)

If the gear shift lever is operated when the machine is traveling, the travel speed may be faster than the maximum
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.

USE FOOT BRAKE TO REDUCE SPEED (HM-0000-130-K-03-A)

When using the foot brake to reduce speed, 3rd speed is held for longer than normal to reduce the shock when
shifting gear.

ENGINE OVERRUN PREVENTION FUNCTION (HM-0000-130-K-04-A)

If the engine speed exceeds the allowable range while traveling, the engine overrun caution lamp and the central-
ized warning lamp light up and the alarm buzzer sounds [Link] the travel speed and engine speed contin-
ue to rise, the brake is automatically applied to prevent the engine speed from rising too far.

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TRAVELING DOWNHILL (HM400-0000-130-K-00-A)

When traveling downhill, travel at a safe speed which matches the width of the road, the condition of the road sur-
face, and other conditions of the jobsite.

WARNING
• When the machine stops, put chocks under the tires immediately.
• For the maximum permissible speed when traveling downhill using the retarder, see the brake per-
formance 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 caution lamp does not go out even when the transmission is shifted down, stop the machine im-
mediately, set the gear shift lever to N (NEUTRAL), run the engine at 1,800 rpm and wait until the cau-
tion lamp goes out.
• It the retarder loses its effect when it is used for traveling downhill, do as follows.
Return the retarder control lever to its original position once completely, then operate the retarder
control lever again.
If the retarder still has not effect even when the retarder control lever is operated again, return the re-
tarder control lever completely to the release position, then depress the brake pedal to stop the ma-
chine, then contact your Komatsu distributor for repair.
• Operate the retarder control lever gradually. Sudden braking might cause an accident due to tire slip.
• Do not operate the gear shift lever to N (NEUTRAL) position when traveling or when going downhill.
Always travel with the gear shift lever in a speed range position.
• The braking force of the engine cannot be used and the steering will become heavy. In addition, there
will be insufficient cooling oil for the retarder, and this will lead to overheating or defective operation
of the brakes and dangerous.
• There may also be damage to the transmission or other parts of the power train, and there is danger
of unexpected accidents.

NOTICE
• If the retarder control lever is operated when traveling downhill, the transmission can be shifted down
sooner than with normal deceleration. It is also possible to travel without shifting up.
• Do not accelerate or shift up when using the retarder.
The engine speed rises and the alarm buzzer may sound and the engine overrun caution lamp and
centralized warning lamp may light up.

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1. Let accelerator pedal (1) back before starting to travel down-

hill and operate retarder control lever (2) to reduce speed.

2. Move the gear shift lever to the position (5, 4, 3, 2) that

matches the maximum permitted speed on the brake per-
formance curve.

3. When traveling downhill, operate retarder control lever (2) to

set the engine speed to 1,800 rpm or above, and travel so
that the indicator of the retarder oil temperature gauge comes
within the green range.

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BRAKE PERFORMANCE CURVE (HM400-G100-34E-K-00-A)

• How to read the graph
Example: Downhill distance 1,500 m (4,921 ft)
Travel resistance -11%
(Grade resistance -13%, rolling resistance 2%)
Payload 40 tons
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 1,500 m (4,921 ft)
2. Starting from point (A) which corresponds to the overall weight of the machine, draw a perpendicular line
down.
3. Take the point where it crosses the line for travel resistance -11% 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.
From point (D): Maximum permissible speed = 24 km/h (14.9 MPH)
From point (C): Gear speed range = F4
This maximum permissible speed is 1 guideline determined from the retarder brake performance, so on an ac-
tual jobsite, determine a safe travel speed below the maximum permissible speed to match the conditions of
the jobs so that the retarder brake oil temperature gauge is always in the white range when traveling.

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• Brake performance [Downhill distance: 450 m (1,476 ft)]

• Brake performance [Downhill distance: 600 m (1,968 ft)]

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• Brake performance [Downhill distance: 900 m (2,952 ft)]

• Brake performance [Downhill distance: 1,500 m (4,921 ft)]

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• Brake performance [Downhill distance: Continuous]

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STEERING MACHINE (HM400-0000-13T-K-00-A)

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
• If the steering wheel has been turned fully to the left or
right, do not continue to apply force to turn it further. The
oil temperature inside the steering hydraulic circuit will
rise and cause overheating.
• When the steering nears the end of the turn on the left or
right, turn the steering wheel more slowly. Turning the
steering wheel suddenly to the end of the turn will cause
damage to the machine.

To turn the machine when traveling, turn steering wheel (1) in the direction of the turn.
On roads where there are curves, let the accelerator pedal back before coming to the curve, shift down to the low-
est speed range possible then depress the accelerator pedal again to continue driving. Do not enter the curve at
high speed.
REMARK
• The angle of the steering wheel may change (the position of the spoke may change slightly) when the ma-
chine 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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OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK

On dry sandy ground, etc., if the tires slip and the machine bounces up and down, or on muddy ground, etc., if
the travel speed lowers largely because the tires slip and sink into mud. In these cases, use the inter-axle
differential lock function when you drive the machine.
NOTICE
Do not use inter-axle differential lock.
If inter-axle differential lock is used,
• It will be more difficult to operate the steering wheel.
• It will become more difficult to turn than it should be when the inter-axle differential lock is not
used, and in some cases, it may not be possible to steer around curves which were previously pos-
sible.
How to use inter-axle differential lock
Set the inter-axle differential lock switch to the MANUAL before you go into the dry sandy ground or the muddy
ground, and activate the inter-axle differential lock.
Set it to AUTO when traveling on a normal ground.
(A) MANUAL
The inter-axle differential lock (1) is actuated while the shift
range (gear speed) is at F3, F2, F1, R1, or R2, and the ma-
chine is not turning.
On dry sandy ground, etc., if the tires slip and the machine
bounces up and down, or on muddy ground, etc., if the travel
speed lowers largely because the tires slip and sink into mud.
Before these cases, set it to the MANUAL.
Operation mode is shifted to AUTO mode when the steering
angle becomes more than the specified angle during turning.
(B) AUTO
Ability to travel through or escape from soft ground is improved
when KTCS operates. The inter-axle differential lock (1) oper-
ates automatically to stabilize the machine when the brake is
applied or the gear is shifted.

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HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL

(ARAC) (HM400-GT81-10A-K-00-A)
(if equipped)
This is a system to automatically activate the retarder when an operator wants to use it on a downslope or slow
down on a flat hauling road. It enables the retarder to automatically function according to the present selected gear
speed and engine revolution, thus making it easier for an operator to use the retarder.

WARNING
• The ARAC system begins to function when the automatic retarder, accelerator control switch is in ON
position. Check that automatic retarder, accelerator linked control switch is turned on before running
down on a slope.
• The ARAC system may not assure thorough braking force to slow down, depending on a slope inclina-
tion, load weight and selected gear speed. In that case, use the retarder control lever and brake pedal
to slow down to a safety speed.
• The tires may be locked when the dump truck is running on a slippery hauling road and the ARAC sys-
tem is in service. If that happens, stop using the ARAC system.
• Should some abnormality happen on the ARAC system and disable an operator from secure control
of the machine, the system is turned OFF and ARAC is released, while the alarm buzzer sounds. In
that case, keep control of the machine, by using the retarder control lever and brake pedal, bring the
machine to a halt in a safe place and turn off the automatic retarder, accelerator linked control switch.

EXPLANATION OF COMPONENTS (HM400-C7K0-04D-K-00-A)

(1) Automatic retarder, accelerator linked control (4) Brake pedal

switch (5) Retarder pilot lamp
(2) Retarder control lever
(3) Accelerator pedal

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AUTOMATIC RETARDER, ACCELERATOR LINKED CONTROL SWITCH (HM-GT82-043-K-01-A)

This switch (1) is used to turn on and off the ARAC system.
RETARDER CONTROL LEVER (HM-GT48-043-K-02-A)
This lever (2) activates the retarder even while the ARAC system is in operation.
REMARK
When the ARAC system is in operation, the lever has some play at the start of stroke. It does not mean that the re-
tarder does not work, but that it is the range of the ARAC system operation.
ACCELERATOR PEDAL (HM-AEX1-043-K-02-A)
The ARAC system functions only while accelerator pedal (3) is released.
BRAKE PEDAL (HM-G4A1-043-K-02-A)
This pedal (4) can activate the wheel brakes even while the ARAC system is in service.
RETARDER PILOT LAMP (HM-GT84-043-K-01-A)
This lamp (5) lights on when the ARAC system begins to function and when the retarder is operated with the re-
tarder control lever. (If the engine speed is low, even when the ARAC system is actuated, the retarder pilot lamp
may not light up.)
ACTUATION OF ARAC SYSTEM (HM-GT81-044-K-00-A)
The ARAC system is actuated when the auto retarder, accelerator control switch is turned ON.
When the auto retarder, accelerator control switch is turned ON, the retarder is automatically actuated according
to the travel speed and engine speed at that point.
If the accelerator pedal is depressed when the ARAC system is being actuated, actuation of the ARAC stops and
the machine speed increases.
If the brake pedal or retarder control lever are actuated while the ARAC is being actuated, the machine can be
slowed down or stopped in the same way as for normal brake operations.

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HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS) (HM-C7K0-043-K-00-A)

KTCS is a system to prevent slipping of the drive wheels caused by excessive torque and improve starting and
traveling ability on soft or slippery ground.

WARNING
• The KTCS system is enabled when the KTCS setting is turned ON.
• If the system has trouble and cannot control securely, the multi monitor displays an action level and
the system may stops operation, depending on the trouble condition.
• The machine may not travel safely on an extremely slippery road or a steep slope, even if the KTCS
operates.
• If a wheel is stuck in the ground and the machine cannot escape while the KTCS operates, pull out the
machine with a bulldozer etc.

EXPLANATION OF COMPONENTS (HM400-GT81-04D-K-00-A)

(1) KTCS setting (5) Accelerator pedal

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

KTCS SYSTEM SETTING (HM400-C7K0-100-K-01-A)

Use this KTCS setting (1) to switch ON or OFF of KTCS system.
OFF: KTCS system does not operate.
ON: KTCS system operates.
REMARK
For operating method of KTCS setting, see "KTCS SYSTEM SET-
TING（PAGE 3-59）".

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MACHINE OPERATIONS AND CONTROLS OPERATION

KTCS PILOT LAMP/ INTER-AXLE DIFFERENTIAL LOCK PILOT LAMP (HM-C7K6-043-K-00-A)

This KTCS pilot lamp (2)/ inter-axle differential lock pilot lamp (3) lights up when the system detects slipping of a
front or a center wheel while the KTCS setting is ON and the KTCS operates.
RETARDER CONTROL LEVER (HM-GT48-043-K-01-A)
If the retarder is operated with retarder control lever (4) while the KTCS is in operation, the KTCS system stops
operation.
ACCELERATOR PEDAL (HM-AEX1-043-K-01-A)
The KTCS system can operate while accelerator pedal (5) is depressed and the gear speed is any of F1, F2, F3,
R1, and R2.
If the accelerator pedal is released while the KTCS is in operation, the KTCS system stops operation.
BRAKE PEDAL (HM-G4A1-043-K-01-A)
If brake pedal (6) is depressed while the KTCS is in operation, the KTCS stops operation.
KTCS SYSTEM CAUTION LAMP (HM-C7K7-043-K-01-A)
If the KTCS system has a trouble, KTCS system caution lamp (8) is displayed on the machine monitor.

ACTUATION OF KTCS (HM-C7K0-044-K-00-A)

To enable the KTCS system, turn the KTCS setting ON.
If the KTCS system detects slipping of the front wheels or both front and rear wheels, the KTCS operates. At this
time, the KTCS pilot lamp or inter-axle pilot lamp lights up.

IF TROUBLES ON SYSTEM OCCUR (HM400-C7K0-100-K-02-A)

When failure code DBIRKR, CA131, CA132, or DK30KX occurs,
operate KTCS according to the following procedure.
For details of the failure code check, see "ACTION LEVELS
（PAGE 3-214）".
1. Use the foot brake to reduce the travel speed and stop the
machine at a safe place.
2. Set the gear shift lever to N (NEUTRAL) position, then set the
parking brake switch to PARKING position.
3. When the starting switch is at ON position or the engine is
started, disconnect (pull out) KTCS secondary connector (1)
(No. TC1 (male), TC2 (female)), then connect (insert) again.
4. Then, KTCS can operate.
5. Set the parking brake switch to TRAVEL position and move
the machine to a safe place.

WHEN TIRES ARE STUCK IN GROUND (HM400-C7K0-14C-K-01-A)

If any wheel is stuck, operate the KTCS.
If it is impossible to get the machine out even when repeating the procedure below, use a bulldozer to tow the ma-
chine out.
1. Check that the KTCS setting is ON. When the KTCS setting is ON, the KTCS operates automatically. For de-
tail of KTCS setting, see "KTCS SYSTEM SETTING（PAGE 3-175）".
2. Set the gear shift lever to position "5" and raise the engine speed.
3. Release the accelerator pedal and brake pedal.
4. Set the gear shift lever to position R1 and raise the engine speed.
5. Repeat steps 1 to 4 to move the machine backwards and forwards until it can escape.

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LOADING WORK (HM-M510-13Z-K-00-A)

WARNING
Do not load the dump body when the dump body is raised.

When loading large rocks or when using a large-sized loader, if the load is dumped directly into the dump body, it
may result in deformation of parts of the dump body. To prevent this, when loading large rocks, first load with soil to
act as a cushion, then load the large rocks on top of the cushion. This will reduce the impact shock on the dump
body.
In addition, when loading rocks that exceed the following conditions, install the optional body reinforcement plate.
• Rocks with one side over 0.3 m (12 in)
• Rocks of hardness more than 4.5 (Mohs scale)
• Rocks with a weight of more than 150 kg (331 lb)
• When transporting steel ingots
NOTICE
• When traveling, always set the dump lever to FLOAT position, regardless of whether the machine is
loaded or not loaded.
• If the dump lever is not at FLOAT position and the gear shift lever is not at N (NEUTRAL) position, the
centralized warning lamp will light up and the alarm buzzer will sound.
• During loading operations, do not apply the parking brake. Apply the retarder brake.

HANDLING TAILGATE (HM400-M730-170-K-00-A)

(If equipped)

WARNING
When hauling rocks or sticky materials, always remove the tailgate.

CAUTION
Soil and sand accumulated on tail gate top (1) may fall. When approaching for testing or maintenance,
check that no soil or sand is accumulated.

When removing or installing the tailgate, consult your Komatsu

distributor.
NOTICE
• Install a tailgate when hauling fluid materials such as
finely crushed soil.
• Do not use a tailgate if the dump body is loaded with
rocks, gravel, or sticky material such as clay. There is a
danger that the tailgate may be damaged, the operator's
cab may be pushed up by the loaded material caught in
the tailgate during dumping operations.

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DUMPING (HM400-M510-13U-K-02-A)

WARNING
• Always follow the instructions of the signalman when
performing dumping operations.
• When dumping large rocks, operate the dump body
slowly.
• When performing inspection or maintenance with the
dump body raised, always use the body pivot pin and
lock the dump lever at HOLD position.
For detail, see "BODY PIVOT PINS（PAGE 3-123）".

Operate the dump body as follows.

1. Place gear shift lever (1) at N (NEUTRAL) position, and set
parking brake switch (2) to PARKING position.

2. Move dump lever (3) to RAISE position, then depress the ac-
celerator pedal to raise the dump body.
If the dump lever is released when it is at RAISE position, it is
held at RAISE position and the dump body will continue to
rise.
The dumping speed increases in proportion to the engine
speed.

3. 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.
If it is necessary to raise the dump body further, operate dump
lever (3) to RAISE position and the dump body will rise. If
dump lever (3) is released, dump lever (3) will return to HOLD
position and the dump body will stop at that position.
When raising the dump body, to prevent any impact load on
the hydraulic circuit or hoist cylinder, let the accelerator pedal

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back when the dump body approaches the maximum tilt

angle.
REMARK
• When the dump body is not seated, the engine speed is lim-
ited to 1,800 rpm or below to protect the work equipment
pump.
And if the dump body is not lowered when the steering oil
temperature is low (25°C or below), the engine speed is lim-
ited to 1,500 rpm or below.
• During the dump body RAISE operation, if you set the dump
lever to any position other than RAISE once and set it to
RAISE again, the dump body RAISE operation is delayed.
• To raise the dump body fastest, depress the accelerator pedal
fully while the dump body is seated and then set the lever to
RAISE position. (Above cuts the time shorter than depressing
down on the accelerator after setting the dump lever to
RAISE position.)
4. When dump lever (3) is moved to 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 FLOAT position. (When the lever is
released, it will return to FLOAT position.) The dump body will
then move down under its own weight.
REMARK
If the dump body is not seated, when the gear shift lever is at D
position, the transmission is fixed in 2nd or 1st speed, and when it
is at positions 1 to 5, the transmission is fixed in 1st speed. Keep
the dump body lowered when traveling.

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MACHINE OPERATIONS AND CONTROLS OPERATION

CAB TILT OPERATION (HM-K000-100-K-00-A)

WARNING
To prevent serious injury or death if the cab comes down, always observe the following strictly when tilting
the cab.
Precautions before performing cab tilt operation
• Perform the cab tilt operation on a flat place.
• When operating the cab tilt, to prevent contact between the cab and dump body, set the machine fac-
ing directly to the front and secure the front and rear frames with the articulation lock.
• Set the parking brake switch to PARKING position to apply the parking brake.
• Lock the dump control lever with the dump lever lock knob.
• Chock the wheels to prevent the machine from moving.
• Always remove the pin from rear mounting position and insert it in the position for tilting, before re-
moving the cab mount.
• Do not perform the cab tilt operation in the strong wind.
Precautions when performing cab tilt operation
• Do not operate the cab tilt when the machine is loaded.
• Do not stand under the cab during the cab tilt operation.
• When the cab is tilted up, lock it securely in position with the lock bar.
• When installing the lock bar, do not enter under the cab but install it from the side of the cab.
• While the cab is tilted up, do not get on or off it.
• While the cab is tilted up, do not operate the gear shift lever or dump lever.
• While the cab is tilted up, do not start the engine . If it is necessary to start the engine when performing
inspection, check first that there is no one under the cab.
• While the cab is tilted up, do not subject to the machine to any large impact force .
• When using the cab power tilt function to lower the cab, do not open the valve quickly but open it grad-
ually while adjusting the lowering speed.
• The lock bar is set on the left inside of the engine hood. After using it, be sure to return it.

WHEN USING CRANE (HM400-K000-100-K-00-A)

1. Remove the lock bolt (2) from the guard (1) at the rear of the
cab, then lock the guard (1) in position with rod (3).

When getting on or off the machine with carrying a tool etc., place
it once in the part (A) to ensure your safety.

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OPERATION MACHINE OPERATIONS AND CONTROLS

2. Remove the pin (4) in the mount at the rear of the cab, and in-
sert the pin (5) instead. (each of the right and left)
A: For traveling
B: For tilting

1) Remove the lock bolt (7) of tilt pin (6), washer (8), and col-
lar (9).
2) Remove the bolt (10) and washers (11).
3) Install the bolt (7) to the tap hole (C).
4) After the tip of bolt (7) touches the stopper bracket (12),
turn it further and pull out the tilt pin (6).
REMARK
• When using the bar (D), pull out the tilt pin (6) by using the
bar (D) until the tilt pin lock plate (14) comes off from the
stepped boss (13).
• Use the stopper bracket (12) as a fulcrum and pull out the tilt
pin (6) by using the bar (D).

5) Turn the tilt pin (6) from the plate position at traveling (H) to
the plate position at cab tilting (J).

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MACHINE OPERATIONS AND CONTROLS OPERATION

6) Insert the tilt pin (6) until the tilt pin lock plate (14) touches
the stepped boss (15).

7) Install the bolt (10), washer (8), and collar (9), and fix the tilt
pin (6).
8) Install the bolt (7) and washers (11).

3. Remove the cab mounting bolts (16) (8 pieces).

4. Open the engine hood and set the slings to the hooks (17) in-
stalled to the front of the cab (on both right and left sides) and
lift up the cab.

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OPERATION MACHINE OPERATIONS AND CONTROLS

5. After tilting up the cab, fix it in position with the lock bar (18).
6. Make sure that the lock bar (18) is installed in the correct di-
rection and lock it securely with lock (19).
7. Perform the inspection and maintenance under the cab.
8. After restoring the cab to the original position, install the
mounting bolts (16) (8 pieces).

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MACHINE OPERATIONS AND CONTROLS OPERATION

9. Remove the pin (5) and insert the pin (4) instead.
1) Remove the lock bolt (10) of tilt pin (6), washer (8), and col-
lar (9).
2) Remove the bolt (7) and washers (11).
3) Install the bolt (7) to the tap hole (C).
4) After the tip of bolt (7) touches the stopper bracket (12),
turn it further and pull out the tilt pin (6).
REMARK
• When using the bar (D), insert it to the gap between the tilt
pin (6) and stopper bracket (12), and pull out the tilt pin
• Change the inserting position of bar (D), and pull out the tilt
pin (6).

5) Turn the tilt pin (6) from the plate position at cab tilting (J)
to the plate position at traveling (H).

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OPERATION MACHINE OPERATIONS AND CONTROLS

6) Insert the tilt pin until the tilt pin lock plate (14) touches the
stepped boss (13).

7) Install the bolt (7), washer (8), and collar (9), and fix the tilt
pin (6).
8) Install the bolt (10) and washers (11).

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MACHINE OPERATIONS AND CONTROLS OPERATION

OPERATION (HM-0000-170-K-03-A)
• When traveling on roads in rain or snow, or when traveling on muddy or soft ground, consider the loaded con-
dition 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 the N (NEUTRAL) position, 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.
(For details, see "TROUBLES AND ACTIONS（PAGE 3-200）".)
• When loading, be careful to load the dump body uniformly, and be particularly careful to avoid loading too
much at the front.
• When traveling on a slippery road, use the accelerator pedal as long as possible since KTCS operates.

PERMISSIBLE WATER DEPTH (HM-0000-170-K-04-A)

Do not go into water or swampy ground where the water is deeper
than the permissible water depth (up to the bottom surface of dif-
ferential case (1)).
After completing operations, wash the machine and lubricate the
parts where water has entered.

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OPERATION MACHINE OPERATIONS AND CONTROLS

PARKING MACHINE (HM400-0000-160-K-00-A)

WARNING
• Avoid a sudden stop. Stop the machine gradually.
• Place the machine on a firm, level ground.
Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, set the parking brake switch to PARKING, and
chock the wheels to prevent the machine from moving.
• If the gear shift lever is touched by mistake, the machine
may move suddenly, and this may lead to a serious injury
or death. Before standing up from the operator's seat, al-
ways set the parking brake switch securely to PARKING
position.
• The retarder must not be used as a parking brake.

CAUTION
To prevent damage to the parking brake, apply the parking
brake only when parking the machine or performing dumping
operations.

1. Release accelerator pedal (1), then depress brake pedal (2)

to stop the machine.

2. Place gear shift lever (3) to N (NEUTRAL) position, then set

parking brake switch (4) to PARKING position to apply the
parking brake.

3. When in the operator's compartment, pull retarder control lev-

er (5) fully to apply the retarder.

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MACHINE OPERATIONS AND CONTROLS OPERATION

AFTER DAILY WORK COMPLETION (HM-3330-200-A-00-A)

Use the machine monitor to check the engine coolant temperature, engine oil pressure, and fuel level.
If the engine has overheated, do not stop the engine suddenly. Run it at a mid-range speed to cool it gradually be-
fore stopping.

LOCKING (HM400-Q8E0-100-K-00-A)
Always lock the following places.
(1) Fuel filler cap of fuel tank
(2) Cab door
(3) Engine hood
(4) Tool box
(5) Battery box
REMARK
The starting switch key is used for locking places (1), (2), (3), (4)
and (5).

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OPERATION MACHINE OPERATIONS AND CONTROLS

HANDLING TIRES (WA-DW60-001-K-01-A)

PRECAUTIONS WHEN HANDLING TIRES (HM-DW60-04F-K-00-A)

WARNING
To ensure safety, the defective tires given below must be re-
placed 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 cir-
cumference 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 (1) Side wall
• Tires where radial cracks extend to the carcass (2) Shoulder
• Tires where there is abnormal deterioration, deformation, (3) Tread
and damage, and the tire cannot withstand use. (4) Breaker or belt (cord layer)
(5) Bead
(6) Inner liner
Contact your Komatsu distributor when replacing the tires. It is (7) Carcass
dangerous to jack up the machine without taking due care.

PRECAUTIONS FOR LONG DISTANCE TRAVEL (HM400-DW60-04F-K-00-A)

If the machine travels continuously at high speed for a long distance, there will be a remarkable increase in the
generation of heat in the tire. This may cause premature damage to the tire, so observe the following.
• Travel only unloaded.
• Check the tire inflation pressure before starting for the day when the tires are cold, and adjust to the following
inflation pressure.
• Do not reduce the tire inflation pressure when traveling.
Inflation pressure kPa {kg/cm2, PSI}
Tire size
Front tire Center tire Rear tire
29.5–R25 (standard) 375 {3.8, 54.0} 390 {4.0, 56.8} 390 {4.0, 56.8}
875/65R29
440 {4.5, 63.9} 440 {4.5, 63.9} 440 {4.5, 63.9}
(if equipped)

NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim may
be damaged.
Always keep the tire inflation pressure within +0 to +29 kPa {0.3 kg/cm 2, 4.3 PSI} of the value in the table
above.
• The maximum travel speed must be kept to less than 40 km/h. Stop for at least 1 hour for every 1 hour of trav-
el to allow the tires and other components to cool down.
• Never travel with water or dry ballast in the tires.

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DETERMINE AND MAINTAIN TRAVEL ROAD OPERATION

DETERMINE AND MAINTAIN TRAVEL ROAD (HM-0000-17Q-K-00-A)

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.

DETERMINE TRAVEL ROAD (HM-0000-17Q-K-01-A)

• As far as possible, restrict the travel road to one-way travel.
• If it is impossible to keep to 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 places where the road should is weak or likely to collapse, set up a sign at a point at least 1.5 m (4 ft 11 in)
from the road shoulder to warn of the danger.
• It is important to set up lighting or reflectors on the road to enable the traveling at night.
• The grade of slope should be kept within 10% (approximately 6 deg.) as far as possible, and emergency es-
cape points should be set up on downhill slopes in case of any brake failure.
• Increase the number of places where the road continues in a straight line. If there are curves in high-speed
travel areas, make the radius of the curve as large as possible.
• Small S curves are particularly dangerous, so avoid such curves. The radius of the curve must be a minimum
of 12 to 15 m (39 ft 4 in to 49 ft 3 in).
• 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 created 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 (HM-0000-17Q-K-02-A)

Perform the necessary action according to the conditions to insure that the road can always be traveled in safety.
• 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 ocasionally with a bulldozer or motor grader.
• Spray the road with water at suitable intervals to prevent dust from rising and reducing the visibility.

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OPERATION TRANSPORTATION

TRANSPORTATION (HM-0000-810-K-00-A)

TRANSPORTATION (HM-0000-81A-K-01-A)
Always obey the traffic regulations when transporting the machine by road.

WARNING
This machine must be disassembled for transportation. When transporting the machine, consult your Ko-
matsu distributor.

TRANSPORTATION PROCEDURE (HM400-0000-813-K-02-A)

As a basic rule, always transport the machine on a trailer.
Choose the trailer in reference to the weight and dimensions shown in "SPECIFICATIONS（PAGE 5-2）".
Note that the specifications for the weights and dimensions for transportation differ according to the type of tires
and type of dump body.

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TRANSPORTATION OPERATION

SECURING MACHINE (HM400-0000-821-K-02-A)

After loading the machine in the specified position, secure it in place as follows.

1. Set the parking brake switch to PARKING position to apply

the parking brake.
2. Turn the starting switch key to OFF position to stop the
engine.
3. Remove the key from the starting switch.

4. Set the articulation lock to LOCK position (L) to lock the front
and rear frames.

5. Put blocks in front of and behind the tires and secure the ma-
chine with chains or wire rope of a suitable strength to prevent
the machine from moving during transportation.
In particular, fix the machine securely to prevent it from slip-
ping sideways.
NOTICE
Always retract the antenna. Reassemble the mirrors so that
they are within the width of the machine.

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OPERATION TRANSPORTATION

LIFTING MACHINE (HM400-0000-815-K-09-A)

When lifting the machine at a port or any other place, always use the following procedure to lift it.

WARNING
• The operator performing the lifting operation using a crane must be a properly qualified crane
operator.
• Never raise the machine with any worker on it.
• Always make sure that the wire rope is of ample strength for the weight of this machine.
• When lifting, keep the machine horizontal.
• Before starting the lifting operation, always stop the engine, apply the parking brake, and use the artic-
ulation lock to prevent the front frame from articulating.
• Never enter the area around or under the machine when it is raised.

Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting
equipment other than in the procedure below. There is a hazard that the machine may lose its balance.
NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs according to the attachments and options installed.
For details of the procedure for machines that are not the standard specification, consult your Komatsu
distributor.
For the weight of the standard specification machine, see "WEIGHT TABLE（PAGE 3-194）".
NOTICE
• Use protectors to prevent the wire rope from being cut on sharp corners and to prevent the wire rope
from cutting into the machine bodywork.
• When using a spreader bar, select an ample width to prevent contact with the machine.
Consult your Komatsu distributor before performing lifting work.

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TRANSPORTATION OPERATION

LOCATION OF LIFTING POSITION MARK (HM400-0000-815-K-00-A)

WEIGHT TABLE (HM400-0000-815-K-08-A)

Machine Load on Load on Load on rear Center of gravity
weight front axle center axle axle (from front axle)
33,925 kg 19,205 kg 7,880 kg 6,840 kg 2,310 mm
HM400-3R
(74,805 lb) (42,347 lb) (17,375 lb) (15,082 lb) (7 ft 7 in)

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OPERATION TRANSPORTATION

PROCEDURE FOR LIFTING MACHINE (HM400-0000-815-K-07-A)

Lifting work of only machines having lifting marks is allowed.
When performing the lifting operation, place the machine on a firm, level ground, and do as follows.

1. Start the engine, make the machine straight (no articulation),

place the dump lever to FLOAT position, and check that the
dump body float caution pilot lamp is OFF.

2. Stop the engine, check safety around the operator's compart-

ment, set the articulation lock to LOCK position (L) to prevent
the front frame and rear frame from articulating.

3. Select wire ropes, slings, spreader bars and other lifting tool
to match the weight of the machine, and fit the wire ropes to
the lifting hooks (at lifting hook marks) at the front of the front
frame and the rear of the rear frame.

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TRANSPORTATION OPERATION

For the front of the front frame, apply the lifting tool so that it
passes through center bumper (1) as shown in the figure.
If passing through side bumper (2), the bumper may be damaged.

4. Fit protector blocks at contact points (3) between the lifting

tool and the dump body to prevent damage to the lifting tool.
5. When the machine comes off the ground (raised 10 to 20 cm
(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.

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OPERATION COLD WEATHER OPERATION

COLD WEATHER OPERATION (ALL-0000-265-K-00-A)

COLD WEATHER OPERATION INFORMATION (ALL-0000-265-K-01-A)

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

FUEL AND LUBRICANTS (HM400-RA19-265-K-02-A)

Change fuel and oil with ones of low viscosity for all components.
For the details of specified viscosity, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT（PAGE 7-4）".

COOLANT (HM400-B210-265-K-02-A)

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 amounts of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the cool-
ant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform
the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground
surface.

NOTICE
Komatsu recommends using Komatsu genuine Non-Amine Engine Coolant (AF-NAC) for the coolant.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For details of the coolant exchange interval and the density of Non-Amine Engine Coolant (AF-NAC), see"CLEAN
INSIDE OF COOLING SYSTEM（PAGE 4-20）".

BATTERY
WARNING
• The battery generates flammable hydrogen gas. Do not bring 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.
• Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.
• Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.

When the ambient temperature drops, the capacity of the battery will also drop. If the battery charging rate is low,
the battery electrolyte may freeze. Maintain the battery charging rate as close as possible to 100%. Insulate it
against cold temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table.
For the Komatsu maintenance-free battery (if equipped), check the indicator display and follow the instructions.
See "CHECK KOMATSU MAINTENANCE-FREE BATTERY INDICATOR (PAGE 4-22-1)" for how to read the
indicator.

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

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COLD WEATHER OPERATION OPERATION

• As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine,
store the battery in a warm place, and install it again the next morning.
• If the electrolyte level is low, add distilled water (such as a commercial battery fluid) in the morning before be-
ginning work. Do not add water after the day's work to prevent diluted electrolyte in the battery from freezing
during the night.
For the Komatsu maintenance-free battery (if equipped), check the indicator display and follow the
instructions. See "CHECK KOMATSU MAINTENANCE-FREE BATTERY INDICATOR (PAGE 4-22-1)" for
how to read the indicator.

AFTER DAILY WORK COMPLETION (HM-0000-15A-K-00-A)

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
• Mud and water on the machine body should be completely removed.
This is to prevent damage to the seal caused by water in mud or dirt getting inside the seal and freezing.
• Park the machine on a firm, dry surface.
If such a place is not available, put steel sheets of the ground and park the machine on top of the steel sheets.
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 pre-
vent it from freezing.
• The performance of the battery drops in low temperatures, so cover it or remove it from the machine and keep
it in a warm place, and then install it again the next morning.
• If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after
the day's work to prevent diluted electrolyte in the battery from freezing during the night.

AFTER COLD WEATHER SEASON (HM400-0000-266-K-02-A)

When the season changes and the weather becomes warmer, do as follows.
• Replace the fuel and oil for all devices with the ones of the viscosity specified. For details, see "RECOM-
MENDED FUEL, COOLANT, AND LUBRICANT（PAGE 7-4）".

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OPERATION LONG-TERM STORAGE

LONG-TERM STORAGE (ALL-0000-870-K-00-A)

BEFORE STORAGE (HM400-0000-870-K-05-A)

When keeping in long-term storage (more than 1 month), store as follows.
• Clean and wash all parts and store the machine indoors. If the machine must be stored outdoors, select a flat
area and cover the machine with a sheet.
• Completely fill the fuel tank. This prevents moisture from collecting.
• Lubricate and change the oil before storage.
• Apply grease to the exposed portion of the hydraulic cylinder piston rod.
• Turn OFF the starting switch, turn the battery disconnect switch key to OFF position and pull it out, then store
the battery after placing a cover on it.
For the operation of the battery disconnect switch, see ."BATTERY DISCONNECT SWITCH（PAGE 3-
119）"
• Apply the parking brake.
• Set the tire inflation pressure for each tire to within the range of the specified inflation pressure for the type of
tire.
• Push the retarder control lever forward to OFF position.
• Place the gear shift lever to N (NEUTRAL) position.
• To prevent rust, fill the cooling circuit with Non-Amine Engine Coolant (AF-NAC) to give a density of at least
30% for the engine coolant.

DURING STORAGE (ALL-0000-870-K-02-A)

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, also charge the battery.
• When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
• If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month
to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In
addition, check the refrigerant level twice a year.

AFTER STORAGE (HM400-0000-870-K-03-A)

NOTICE
If the machine has been stored without performing the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine for the first time after a long-term storage, do as follows before using it.
• Wipe off the grease from the hydraulic cylinder rods.
• Add oil and grease at all lubrication points.
• When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and
after starting the engine. If there is water in the oil, change all the oil.
• Insert the battery disconnect switch key and turn it to ON position.
For the operation method, see "BATTERY DISCONNECT SWITCH（PAGE 3-119）"
• If the machine is stored for a long period with the battery disconnect switch OFF or the battery terminal discon-
nected, the clock information and radio tuning information may be lost. In this case, set the information again.
For detail, see "CLOCK ADJUSTMENT（PAGE 3-69）" and "HANDLING RADIO（PAGE 3-106）".

PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE

1. Check all the oil and water levels before traveling.
2. Do not accelerate suddenly. Before the machine starts normal travel, operate the machine in the forward
direction at a speed of 10 to 15 km/h (6.2 to 9.3 MPH) for 5 minutes, and then operate the machine in the
forward direction at a speed of 30 km/h (18.6 MPH) or below for approximately 30 minutes.

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TROUBLES AND ACTIONS OPERATION

TROUBLES AND ACTIONS (ALL-0000-001-K-14-A)

RUNNING OUT OF FUEL (HM-0000-14G-K-00-A)

If the engine runs out of fuel, add fuel to the fuel tank, then bleed the air from the fuel system before starting the
engine.

PROCEDURE FOR BLEEDING AIR (HM400-0000-14G-K-01-A)

CAUTION
• The fuel injection pump and nozzle of this engine consist of more precise parts than the conventional
ones. If foreign matter enters them, it can cause a trouble. Accordingly, if dust sticks to the fuel sys-
tem, wash it off with clean fuel.
• Be careful when opening the air bleed plug in the fuel filter head. There may be remaining pressure
and fuel may spout out.

1. Fill the fuel tank with fuel.

2. Loosen air bleeding plug (1) at the fuel main filter head.
Do not loosen the plug in the filter head of the fuel prefilter. It
will become impossible to bleed the air.
3. Loosen wing nut (3) holding lever (4) of priming pump (2).
Pump lever (4) up and down to perform priming. Continue un-
til bubbles stop coming out with the fuel from the hole for air
bleeding plug (1).
4. Tighten air bleeding plug (1) and then tighten wing nut (3) of
priming pump (2) securely to lock lever (4).
• Tightening torque for air bleeding plug
7.8 to 9. 8Nm {0.8 to 1.0 kgm, 5.8 to 7.2 lbft}
• Tightening torque for wing nut
6.9 to 12.7 Nm {0.7 to 1.3 kgm, 5.1 to 9.4 lbft}
5. Turn the key of the starting switch to START position to start
the engine.
When doing this, do not crank the starting motor continuously
for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes before
trying again. Perform this operation a maximum of 4 times.
6. If the engine does not start, repeat the procedure from step 2.

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OPERATION TROUBLES AND ACTIONS

IF TRANSMISSION HAS TROUBLE (HM-0000-14A-K-00-A)

If the transmission has any trouble, operate the machine accord-
ing to the following procedure.
1. Use the foot brake to reduce the speed and stop the machine
at a safe place.
2. Set the gear shift lever to N (NEUTRAL) position, then set the
parking brake switch to PARKING position.
3. In some trouble modes, the gear is not shifted even if the shift
lever is operated.
In this case, perform the following procedure.
1) When the starting switch is at ON position or the engine
is started, disconnect (pull out) emergency connector (1)
(No. A1 (female), A1 (male), white 1-pin connector), then
connect (insert) again.
2) Set the parking brake switch to TRAVEL position.
3) Operate the gear shift lever to move the machine to a
safe place without depressing the accelerator pedal.
If the gear shift lever is operated with the accelerator pedal depressed, the emergency escape function will not
work. In addition, the emergency escape function may not work for some failure codes.
While the emergency escape function is actuated, the machine monitor shift indicator displays "E" and the trans-
mission shift range in turn.

LOWERING DUMP BODY IN EMERGENCY (HM400-0000-14A-K-00-A)

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

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TROUBLES AND ACTIONS OPERATION

TOWING MACHINE

WARNING
Injury or death could result if a disabled machine is towed in-
correctly 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 machine
being towed.
• Never use a wire rope which has cut 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.
• Never go between the towing machine and the towed ma-
chine during the towing operation.
• If the machine is towed abruptly, 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 towed machine can-
not be operated, do not let anyone ride on the towed
machine.

NOTICE
• The allowable traction force of one towing device is 247569 N (25245 kgf). Do not tow any load
greater than this.
• Towing is only permitted in order to move a disabled machine to a place where it is possible to per-
form inspection and maintenance.
Do not tow the machine for long distances.
• Consult your Komatsu distributor for information about towing a disabled machine.
This machine must not be towed except in emergencies. However, if it is avoidable to tow the machine, take the
following precautions.
• For the failed machine, make the dump body seated in the unloaded state.
• When towing a machine, tow it at a low speed of less than 2 km/h, and for a distance of a few meters to a
place where repairs can be performed. This method is applied only in emergencies. If the machine must be
moved long distances, use a transporter.
• Use a towing machine of the same class or larger than the machine being towed.
Check that the towing machine has ample braking power, weight, and rimpull to allow it to control both ma-
chines on slopes or on the tow road.
• When towing, set the articulate lock of the towed machine to LOCK position. However, when towing in places
where it is needed to steer, set the articulate lock to FREE position. Use 2 towing machines of the same class
or larger than the machine being towed: connect 1 machine each to the front and rear of the machine being
towed.
• Use the specified hook for both the towing machine and the machine being towed.
• To protect the operator if the towing wire or towing bar breaks, install protective plates on both the towing ma-
chine and the machine being towed.

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OPERATION TROUBLES AND ACTIONS

• There are towing hooks under the front frame and at the rear
of the rear frame. Use only these hooks when towing. Do not
use any other place for towing.
• When fitting the towing wire, check the condition of the hook
to make sure that there is no problem.
• Keep the angle between the towing wire and machine 20 deg.
or below, and make it small as possible.
• Towing may be performed under various differing 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 surfaces will re-
quire the maximum rim pull.
• Always release the parking brake before towing.
For the method of releasing, see "RELEASING PARKING
BRAKE（PAGE 3-204）".

• 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 condi-
tion where it cannot run away.
• When releasing the parking brake, check that the surrounding
area is safe.
• If the parking brake is released, the brakes will not work, so
pay careful attention to safety.
• When towing down a slope, use 2 towing machines. 1 ma-
chine should be uphill from the disabled machine and should
be connected with towing wire or a drawbar to pull the dis-
abled machine back and keep it stable. The other machine
should tow the disabled machine downhill.

WHEN ENGINE RUNS (HM-0000-146-K-01-A)

• If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the ma-
chine 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 engine
does not run".
• Check if it is possible to steer the machine. If the machine cannot be steered, follow the procedure given in
"WHEN ENGINE DOES NOT RUN".
• The operator should sit on the machine being towed and operate the steering in the direction that the machine
is towed.
• Always run the engine to allow the steering and brakes to be used.

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TROUBLES AND ACTIONS OPERATION

IF ENGINE DOES NOT START (HM-0000-146-K-02-A)

• The brakes will not work, so be extremely careful.
• Connect the towing machine securely to the towed machine. Use 2 towing machines of the same class or
larger than the machine being towed: connect 1 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 emergency steer-
ing, but it can be used for a maximum of only 90 seconds.
• If the emergency steering cannot be used, disconnect 2 hydraulic hoses each of right and left from the steer-
ing cylinders, then perform the towing operation. When removing the hoses, block the hoses with plugs and fit
oil containers to the mouthpiece of the cylinder to prevent oil from draining to the ground.

RELEASING PARKING BRAKE (HM400-GJ00-100-K-00-A)

When it is necessary to tow or move the machine, the parking brake must be released. Release the parking brake
as follows.
Ask your Komatsu distributor to release the parking brake.

WARNING
• If any problem occurs in the brake hydraulic system, there is a high probability that the wheel brakes
will not work properly, so when towing, always travel at low speed.
• When releasing the parking brake, check that the surrounding area is safe and always chock the all
wheels before starting the [Link] the wheels are not chocked, there is a danger that the machine may
move suddenly.
• Always stop the engine before starting the operation to release the parking brake.

1. Stop the engine.

2. Chock the wheels.

3. Push down the lock portion of parking brake adjustment

screw (1), then turn adjustment screw (1) clockwise.
4. Check that there is a clearance between the parking brake
pad and brake disc.
5. When the parking brake is released, tow the machine immedi-
ately to a safe place.
For towing, see "TOWING MACHINE（PAGE 3-202）".

3-204
OPERATION TROUBLES AND ACTIONS

DISCHARGED BATTERY (PC-AW10-2A1-K-00-A)

WARNING
• It is dangerous to charge a battery installed on a ma-
chine. Make sure that it is removed before charging.
• When checking or handling the battery, stop the engine
and turn the starting switch and battery disconnect
switch keys to OFF positions.
• The battery generates hydrogen gas, so there is a hazard
of explosion. Do not bring lighted cigarettes near the bat-
tery, or do nothing that will cause sparks.
• Battery electrolyte is dilute sulfuric acid, and it will attack
your clothes and skin. If it gets on your clothes or on
your skin, immediately wash it off with a large amount of
water.
If it gets into your eyes, wash them immediately with
fresh water, then consult a doctor for treatment.
• 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,
there is a danger that it will cause a spark, so be ex-
tremely careful.
• If the terminals are loose, there is a danger that the defec-
tive contact may generate sparks that will 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 nega-
tive (-) terminal.

REMOVE AND INSTALL BATTERY (HM-AW10-924-K-00-A)

• Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal).
If a tool touches the positive (+) terminal and the chassis, there is danger that it will cause a spark.
• When installing the battery, connect the ground cable last.
• When replacing the battery, fix the battery body with the bat-
tery mounting fixtures. Securely tighten the terminal to the fol-
lowing tightening torque.
Tightening torque of wiring harness terminal (1): 11.8 to 19.6
Nm {1.2 to 2.0 kgm}
Tightening torque of battery terminal (2): 9.8 to 11.8 Nm {1.0
to 1.2 kgm}
Tightening torque of 1st nut (3) of mounting fixture: 7 to 9 Nm
{0.71 to 0.92 kgm}
Tightening torque of 2nd nut (4) of mounting fixture: 35 to 45
Nm {3.57 to 4.59 kgm}

3-205
TROUBLES AND ACTIONS OPERATION

BATTERY CHARGES

WARNING
When charging the battery, if the battery is not handled cor-
rectly, there is a hazard that the battery may explode. Always
follow the instructions of "DISCHARGED BATTERY（PAGE 3-
205）" and the instruction manual accompanying the charg-
er, and do as follows.
• Set the voltage of the charger to match the voltage of the
battery to be charged. If the correct voltage is not se-
9 J D 0 1 7 3 5
lected, the charger may overheat and cause an
explosion.
• Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the neg-
ative (-) charger clip of the charger to the negative (-) ter-
minal of the battery. Be sure to attach the clips securely.
• In the case of a liquid stopper type, set the charge
current to 1/10 or less of the value of the rated battery
capacity.
When you do the fast charging, set it to less than the
rated battery capacity.
For the Komatsu maintenance-free battery (if equipped),
the charging current is less than 1/10 of the rated
capacity of the battery. Do not do the fast charging.
If the charger current is too large, the electrolyte will leak
or dry up, and this may cause the battery to catch fire
and explode.
• If the battery electrolyte is frozen, do not charge the bat-
tery or start the engine with a different power source.
There is a danger that this will ignite the battery electro-
lyte and cause the battery to explode.
• Do not use or charge the battery if the battery electrolyte
level is below the LOWER LEVEL line. It can cause
explosion. Be sure to do the periodic inspection of the
battery electrolyte level. In the case of a liquid stopper
type, add purified water (such as a commercial battery
fluid) to UPPER LEVEL line.
For the Komatsu maintenance-free battery (if equipped),
check the indicator display and follow the instructions.
See "CHECK KOMATSU MAINTENANCE-FREE BATTERY
INDICATOR (PAGE 4-22-1)" for how to read the indicator.

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OPERATION TROUBLES AND ACTIONS

START ENGINE WITH JUMPER CABLES (ALL-AW10-14B-K-00-A)

When starting the engine with a jumper cable, do as follows.
CONNECT AND DISCONNECT JUMPER CABLES (HM400-AW10-14B-K-02-A)

WARNING
• When installing the cables, take extreme care not to con-
nect positive (+) and negative (-) terminals of batteries
with each other.
• When starting the engine with jumper cables, wear pro-
tective eyeglasses and rubber gloves.
• Be careful not to let the normal machine and failed ma-
chine contact each other.
The sparks caused near the battery could ignite the hy-
drogen gas generated from the battery, so be careful.
• Connect the jumper cables correctly. When the final con-
nection of the cables is done to the engine block of the
failed machine, sparks will be generated. So, connect to
a place as far as possible from the battery.
• When disconnecting the jumper cables, take care not to
bring the clips in contact with each other or with the ma-
chine body.

NOTICE
• The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped
with a 24 V battery.
• The sizes of the jumper cables and clips should be suitable for the battery size.
• The battery of the normal machine must be the same capacity as that of the failed machine.
• Check the cables and clips for damage or corrosion.
• Make sure that the cables and clips are firmly connected.
• To prevent damage of the electric devices of the failed machine, turn the starting switch of the failed
machine to OFF position, and then turn the battery disconnect switch key to OFF position before con-
necting the jumper cable.
For the operating method of the battery disconnect switch, see "BATTERY DISCONNECT SWITCH
（PAGE 3-119）".
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 information again. For detail, see "CLOCK ADJUSTMENT（PAGE 3-69）" and "HANDLING RADIO
（PAGE 3-106）".

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TROUBLES AND ACTIONS OPERATION

CONNECT JUMPER CABLES (HM-AW10-14B-K-01-A)

Set the starting switch and the battery disconnect switch of the failed machine, and the starting switch of the nor-
mal machine to OFF positions, and connect the jumper cables as follows in the order of the numbers marked in
the figure.

1. Connect the clip of jumper cable (A) to the positive (+) termi-
nal of battery (C) on the problem 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 (-) termi-
nal of battery (D) on the normal machine.
4. Turn the battery disconnect switch (S) of the problem ma-
chine to ON position.
5. Connect the other clip of jumper cable (B) to the engine block
of the problem machine.

STARTING ENGINE (HM-AW10-14B-K-02-A)

CAUTION
Make sure that the parking brake switch is at PARKING position and the gear shift lever is at N (NEUTRAL)
position for both normal machine and the problem machine.

1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle speed.
3. Turn the starting switch of the problem machine to START position and start the engine.
If the engine doesn't start at first, try again after 2 minutes or so.
DISCONNECT JUMPER CABLES (HM-AW10-14B-K-03-A)
After the engine has started, disconnect the jumper cables in the reverse of the order in which they were
connected.

1. Remove 1 clip of jumper cable (B) from the engine block of

the problem machine.
2. Remove the clip of jumper cable (B) from the negative (-) ter-
minal of battery (D) on the normal machine.
3. Remove the clip of jumper cable (A) from the positive (+) ter-
minal of battery (D) on the normal machine.
4. Remove the clip of jumper cable (A) from the positive (+) ter-
minal of battery (C) on the problem machine.

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OPERATION TROUBLES AND ACTIONS

OTHER TROUBLE (ALL-5110-001-A-00-A)

ELECTRICAL SYSTEM (HM300-AK50-400-K-00-A)

• As for the corrective actions indicated with (*) in the remedy column, be sure to contact your Komatsu
distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Lamp does not glow brightly even Defective wiring Check and repair loose terminals,
when the engine runs at high speed open circuit (*)
Insufficient battery charge Charge, add distilled water
Loosening and damage of belt Check alternator belt tension,
replace
Lamp flickers while engine is Defective wiring Check and repair loose terminals,
running open circuit (*)
Insufficient battery charge Charge, add distilled water
Loosening and damage of belt Check alternator belt tension,
replace
Battery charge caution lamp lights Defective alternator Replace (*)
up while engine is running Defective wiring Check, repair (*)
Unusual noise is generated from Defective alternator Replace (*)
alternator Loosening and damage of alternator Check alternator belt tension,
belt replace
Starting motor does not rotate even Defective wiring Check, repair (*)
when starting switch is turned ON Defective starting switch Replace switch (*)
Insufficient battery charge Charge
Defective battery relay Replace relay (*)
Battery disconnect switch is turned Turn it to ON position
OFF
Engine shutdown secondary switch Set to NORMAL position Close the
is set to STOP ENGINE position cover.
Starting motor turns engine Defective wiring Check, repair (*)
sluggishly. Insufficient battery charge Charge
Starting motor disengages before Defective wiring Check, repair (*)
engine starts Insufficient battery charge Charge
When startability at a low tempera- Defective wiring Check, repair (*)
ture is bad, outside of the electric Wire breakage in electrical intake air Replace (*)
heater after pre-heating is not felt heater
warn when touched by hand. Defective operation of heater relay Replace (*)
Fuse of the heater is blown Replace (*)

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TROUBLES AND ACTIONS OPERATION

CHASSIS (HM300-RA15-400-K-00-A)
• As for the corrective actions indicated with (*) in the remedy column, be sure to contact your Komatsu
distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Torque converter oil temperature Leakage of oil or entry of air due to Check, repair (*)
caution lamp flashes damage or defective tightening of oil
pipe, pipe joint
Wear, scuffing of gear pump Check, repair (*)
Insufficient oil in transmission case Add oil to specified level. See
CHECK BEFORE STARTING.
Clogged oil cooler Clean or replace (*)
Long distance traveled in torque Drive in direct range
converter range
Disconnected, broken wiring to Repair, connect wiring (*)
sensor
Operating effort of steering wheel is Insufficient greasing of link Lubricating
high Internal leakage inside steering Replace cylinder seal (*)
cylinder
Steering wheel is pulled Tire inflation pressure not uniform on Make tire inflation pressure uniform.
left and right See CHECK BEFORE STARTING.
Dragging, pulling of front brake Check wear of brake disc (*)
Braking effect is poor when brake Disc has reached wear limit Replace disc (*).
pedal is depressed Insufficient oil pressure Charge to specified pressure
Insufficient brake oil Add oil to the transmission case.
See CHECK BEFORE STARTING.
Air in brake circuit Bleed air. See WHEN REQUIRED.
Brake pulls to one side Disc has reached wear limit Replace disc (*).
Insufficient oil pressure Charge to specified pressure
Insufficient brake oil Add oil to the transmission case.
See 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 specified level. See
CHECK BEFORE STARTING.
Suspension is hard Soil or sand entering through dam- Replace U-packing (*)
aged dust seal has damaged U-
packing, causing leakage of gas
Gas leaking from valve core Replace valve core (*)
Wheel on one side tends to slip Air in brake circuit (between slack Bleed air from brakes (left, right).
adjuster and brake) See WHEN REQUIRED.
Excessive difference in wear be- Replace tire (*)
tween 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 (*)

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OPERATION TROUBLES AND ACTIONS

IF ACCELERATOR PEDAL HAS FAILED (HM-0000-14A-K-03-A)

The accelerator pedal is equipped with a potentiometer that detects the amount that the accelerator pedal is de-
pressed. 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 1,500 rpm;
when the accelerator pedal is released, the engine speed is set to low idle. 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 your
Komatsu distributor.
When operating the accelerator pedal, release the pedal to turn it to OFF position (low idle) or depress it fully to set
to 1,500 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 depressed,
the centralized warning lamp lights up, the alarm buzzer sounds intermittently, and Engine System Error and action
level "L03" is displayed on the machine monitor.

3-211
TROUBLES AND ACTIONS OPERATION

ENGINE (HM400-A000-400-K-01-A)
• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Engine oil pressure caution lamp Insufficient oil in oil pan Add oil to specified level. See Check
lights up before starting.
Improper oil is used (viscosity is Replace oil. See section of How to
improper) use lubricants according to ambient
temperature and Komatsu genuine
oil.
Clogged oil filter cartridge Replace cartridge. See EVERY 500
HOURS MAINTENANCE.
Oil leakage due to improper tighten- Check and repair. (*)
ing or breakage of oil pan, pipe joint.
Disconnected, broken wiring to Repair, connect wiring (*)
sensor
Steam spurts out from radiator sub- Lowered coolant level, leakage of Check, add coolant. See CHECK
tank (pressure valve). coolant BEFORE STARTING.
Dirt or scale accumulated in cooling Change coolant, clean inside of
system cooling system. See WHEN
REQUIRED.
Clogged radiator fins or damaged fin Clean or repair. See EVERY 500
HOURS MAINTENANCE.
Defective coolant temperature Replace coolant temperature gauge
gauge (*)
Defective thermostat Replace thermostat (*)
Defective sealing of thermostat Replace thermostat seal (*)
Disconnected, broken wiring to Repair, connect wiring (*)
sensor
The coolant level caution lamp lights Lowered coolant level, leakage of Check, add coolant. See CHECK
up and the machine monitor displays coolant BEFORE STARTING.
low coolant level as "L01". Dirt or scale accumulated in cooling Change coolant, clean inside of
system cooling system. See WHEN
REQUIRED.
Clogged radiator fins or damaged fin Clean or repair. See EVERY 500
HOURS MAINTENANCE.
Defective coolant temperature Replace coolant temperature gauge
gauge (*)
Defective thermostat Replace thermostat (*)
Defective sealing of thermostat Replace thermostat seal (*)
Disconnected, broken wiring to Repair, connect wiring (*)
sensor
Indicator of engine coolant tempera- Lowered coolant level, leakage of Check, add coolant. See CHECK
ture gauge is in red range. (Engine coolant BEFORE STARTING.
coolant temperature caution lamp Dirt or scale accumulated in cooling Change coolant, clean inside of
lights up.) system cooling system. See WHEN
REQUIRED.
Clogged radiator fins or damaged fin Clean or repair. See EVERY 500
HOURS MAINTENANCE.
Defective coolant temperature Replace coolant temperature gauge
gauge (*)
Defective thermostat Replace thermostat (*)
Defective sealing of thermostat Replace thermostat seal (*)
Disconnected, broken wiring to Repair, connect wiring (*)
sensor

3-212
OPERATION TROUBLES AND ACTIONS

Problem Main causes Remedy

Indicator of engine coolant tempera- Defective coolant temperature Replace coolant temperature gauge
ture gauge stays at lowest position gauge (*)
and does not rise. Defective thermostat Replace thermostat (*)
Starting motor turns but engine does Lack of fuel Add fuel. See Check before starting.
not start Air in fuel system Repair place where air is sucked (*)
No fuel in fuel filter Fill filter with fuel. See EVERY 500
HOURS MAINTENANCE.
Starting motor incapable of cranking See Electrical system.
engine smoothly.
Starting motor incapable of turning See Electrical system.
Defective valve clearance Adjust valve clearance (*)
(defective compression)
Gear shift lever is in any position oth- Place gear shift lever to N (NEU-
er than N (NEUTRAL) TRAL) position
Fuel supply occasionally stops. Clogged fuel tank breather tube Replace breather tube (*)
Excessive oil consumption Oil leakage Check and repair. (*)
Excessive oil in oil pan Set oil to specified level. See
CHECK BEFORE STARTING.
Worn piston, ring, cylinder liner Replace. (*)
Low grade fuel being used Replace with specified fuel.
Defective turbocharger Check, replace (*)
Exhaust gas color is white or bluish Oil leakage Check and repair. (*)
Excessive oil in oil pan Set oil to specified level. See
CHECK BEFORE STARTING.
Worn piston, ring, cylinder liner Replace. (*)
Low grade fuel being used Replace with specified fuel.
Defective turbocharger Check, replace (*)
Exhaust gas is black. Clogged air cleaner element Clean or replace. See "When
required"
Worn piston, ring, cylinder liner Check and repair. (*)
Defective compression See adjustment of clearance above.
Defective turbocharger Check, replace (*)
Defective injector Check, replace, repair (*)
Engine hunts. Air entering suction side of fuel line Repair place where air is sucked (*)
Combustion noise makes breathing Defective nozzle Replace nozzle (*)
sound from time to time.
There is knocking. Low grade fuel being used Replace with specified fuel.
(combustion or mechanical) Overheating See "Indicator of engine coolant
temperature gauge is in red range"
above

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TROUBLES AND ACTIONS OPERATION

ACTION LEVELS (HM400-0000-14A-K-02-A)

If "L04", "L03", or "L01" is displayed as alarm caution (1) or action level (2) in the failure display screen FF of the
machine monitor, or if action level "L02" is displayed and the action level still remains after taking the remedy, do
as followings.
Apply the parking brake and press enter switch (3). Occurred error list screen is displayed.
Take remedy according to the message displayed in the monitor, check the failure code, and then ask your Komat-
su distributor for repairs as needed.
For the alarm caution and action level, see "OCCURRED FAILURE CODE DISPLAY（PAGE 3-14）".
For the operation method of the occurred error list screen and the failure code, see "OCCURRED FAILURE CODE
DISPLAY（PAGE 3-14）".

3-214
4 MAINTENANCE

MAINTENANCE

4-1
RULES FOR MAINTENANCE MAINTENANCE

RULES FOR MAINTENANCE (ALL-0000-2A4-K-00-A)

Do not perform any inspection and maintenance operation that are not found in this manual.

SERVICE METER READING (ALL-Q1M0-280-K-00-A)

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

KOMATSU GENUINE REPLACEMENT PARTS (ALL-0000-203-K-00-A)

Komatsu recommends using Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE LUBRICANTS (ALL-0000-201-K-00-A)

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

ALWAYS USE CLEAN WASHER FLUID (ALL-K7B3-200-K-00-A)

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

FRESH AND CLEAN LUBRICANTS (ALL-RA1A-2A4-K-00-A)

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 (HM-C940-2A4-P-00-A)

After changing the oil or replacing the filter, check the drained oil and filter for metal particles and foreign materials.
If large quantities of metal particles or foreign materials are found, always report to the person in charge and per-
form suitable action. In addition, when replacing the engine oil filter, fill the new filter with the specified clean oil,
then install it.

CAUTION FOR REFILLING OIL OR FUEL (ALL-0000-21E-K-00-A)

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

WELDING INSTRUCTIONS (HM-0000-628-K-00-A)

• When performing weld repair, turn the starting switch to OFF position and, after checking that the system op-
erating lamp is turned off, set the battery disconnect switch to OFF position and pull it out.
• Do not apply more than 200 V continuously.
• Connect grounding the cable within 1 m (3.28 ft) from the area to be welded. Connecting grounding cable near
meters and connectors will lead to the failure of meters.
• If a seal or bearing bushing happens to come between the part being welded and grounding point, change the
grounding point to avoid such parts.
Sparks will cause damage to the seals.
• Do not use the area around the pins or the hydraulic cylinders as the grounding point.
Sparks will cause damage to the plated portion.

DO NOT DROP THINGS INSIDE MACHINE (ALL-0000-20G-K-00-A)

• 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 you drop anything inside the machine, always remove it immediately.
• Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

DUSTY JOBSITES (HM-0000-20H-K-00-A)

When working at dusty worksites, observe the following:
• Inspect the dust indicator frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
• Clean the radiator fins, aftercooler fins, air conditioner condenser fins, and other parts of the heat exchange
equipment more frequently, and take care not to let the fins become clogged.

4-2
MAINTENANCE RULES FOR MAINTENANCE

• Clean and replace the fuel filter frequently.

• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
• When checking and replacing the oil or filters, move the machine to a place where there is no dust and take
care to prevent dust from entering the system.

AVOID MIXING OIL (ALL-C940-2A4-P-02-A)

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 re-
place all the oil with the new brand or grade of oil.

LOCKING INSPECTION COVERS (ALL-M190-2AH-P-00-A)

Lock inspection cover securely into position with the lock bar etc. If inspection or maintenance is performed with in-
spection cover not locked in position, there is a danger that it may be suddenly shut by the wind and cause injury
to the worker.

BLEED AIR FROM HYDRAULIC CIRCUIT (HM400-C000-231-P-02-A)

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit. "WHEN REQUIRED（PAGE 4-11）"See .

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES (ALL-CE00-72B-P-00-A)

• 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 the 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 shortened extremely and they may be damaged.

CHECKS AFTER INSPECTION AND MAINTENANCE (HM400-0000-20J-K-02-A)

If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to
serious injury or property damage. Always observe the following:
• Checks after operation (with engine stopped)
• Have any inspection and maintenance points been forgotten?
• Have all inspection and maintenance items been performed correctly?
• Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are
dropped inside the machine and get caught in the lever linkage mechanism.
• Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
• Checks when the engine is running
• For details of the checks when the engine is running, see Safety, "TWO WORKERS FOR MAINTE-
NANCE WHEN ENGINE IS RUNNING（PAGE 2-40）" and pay attention to safety.
• Check if the inspected and serviced area is normally operated.
• Increase the engine speed to check for the leak of fuel and oil.

FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE (HM400-

RA19-05A-K-03-A)
It is necessary to select fuel or lubricant according to the ambient temperature.
For detail, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT（PAGE 7-4）".

4-3
OUTLINE OF MAINTENANCE MAINTENANCE

OUTLINE OF MAINTENANCE (HM400-RA1B-2A4-K-00-A)

• Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil.
• When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all
the old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem
if the small amount of oil remaining in the piping mixes with the new oil.)
• Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40–DH (Komatsu genuine)
Transmission case
Power train oil TO10 (Komatsu genuine)
(incl. brake oil tank)
Hydraulic oil tank Power train oil TO10 (Komatsu genuine)
Front suspension
Hydraulic oil HO-MVK (Komatsu genuine)
Rear suspension
Front differential case
Center differential case
Rear differential case
Axle oil AXO80 (Komatsu genuine)
Front final drive case
Center final drive case
Rear final drive case
Non-Amine Engine Coolant (AF-NAC) (Komatsu genuine) (Density: 30% or
Radiator
above)

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC (PC-RA1B-001-K-

00-A)

OIL (HM400-C940-2A4-P-00-A)
• Since the engine and hydraulic component are used under extremely severe conditions (high temperature,
high pressure), and the oil deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in
the Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil at the specified interval.
• Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of failures with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
• Never mix oils of different grades or brands.
• Always add the specified amount of oil.
Having too much oil or too little oil are both causes of failures.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
consult your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend that you have an oil analysis periodically to check the condition of the machine. For those
who wish to use this service, consult your Komatsu distributor.
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend
that you use the Komatsu oil clinic to check the characteristics of the oil in detail.

4-4
MAINTENANCE OUTLINE OF MAINTENANCE

FUEL (HM400-AD02-2A4-K-00-A)
• 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 instrument, and if fuel containing water or dirt is used, it cannot work properly.
• Be extremely careful not to let impurities get in when storing or adding fuel.
• Always use the fuel specified for the temperature that is described in the Operation and Maintenance Manual.
• If the fuel is used at the temperatures lower than the specified temperature (particularly at temperatures
below -15 °C ( 5 °F)), the fuel will solidify.
• If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and it
may result in troubles such as a drop of output.
• Before starting the engine, or after 10 minutes of adding fuel, drain the sediment and water from the fuel tank.
• If the engine runs out of fuel, or if the filters are replaced, it is necessary to bleed the air from the circuit.
• If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
Always use diesel oil for the 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. This device requires
high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durabil-
ity may drop remarkably.

BIO-FUEL
The biofuel is a fuel that is formed in a transesterification reaction of vegetable oil, animal fat, and edible oil.
The ASTM D975 diesel fuel can contain 5 % or less of biofuel.
Use the biofuel conforming to ASTM D7467 if its mixing ratio is between 6% to 20%.
The EN590 diesel fuel can contain 7 % or less of biofuel.
When you use 100% biofuel for mixing, it needs to conform to ASTM D6751 or EN14214.
In the United States, purchase the biofuel from the dealer certified by BQ-9000.
In the EU, purchase the biofuel from the member companies of European Biodiesel Board (EBB).
In other countries or regions, purchase the biofuel from the dealer that guarantees the same quality as BQ-9000
or EBB.
NOTICE
When you use biofuel other than the preceding diesel fuel and its mixing ratio is up to 20%, obey the
precautions that follow.
• It is necessary to consult with the local regulatory authorities of engine exhaust gas regulation
whether the biofuel can be used or not.
• The fuel can possibly leak because of the deterioration of rubber material of the fuel hose. Replace it
with the fuel hose applicable for biofuel. Consult your Komatsu distributor for replacement
of the fuel hose.
• Biofuel can not be stored for a long time because it is easy to deteriorate and change in quality. Use
the fuel in the storage tank or the fuel tank of the machine within 6 months.
If the deteriorated and altered biofuel is used, it can cause adverse effects on the engine parts.
When you store the machine which uses the diesel fuel mixed with the biofuel for more than 3
months, do the procedure that follows.
• Replace it with pure diesel fuel or the new diesel fuel mixed with the biofuel at the lowest possi-
ble mixing ratio.
• After you change the fuel, run the engine for a minimum of 30 minutes before you store the ma-
chine.

4-5
OUTLINE OF MAINTENANCE MAINTENANCE

• Because the biofuel dissolves the materials sticking to the fuel tank and fuel line, the fuel filter
can be clogged with them.
When you change the diesel fuel to the biofuel, replace the fuel main filter cartridge and fuel prefilter
cartridge with new ones. When you replace the fuel main filter cartridge and fuel prefilter cartridge,
make the replacement interval half the normal time until the second replacement after you
change the diesel fuel to the biofuel.
• Because the biofuel absorbs moisture easily, it can possibly cause a growth of microorganism.
When the microorganism grows in the biofuel, it can cause corrosion of the fuel system
and the clogging of the fuel filter.
Drain the water from the fuel tank before you start the operation.
When you complete the operation, fill the fuel tank to reduce the air layer.
• If the biofuel is used under conditions of the specific operation, the fuel can possibly get mixed
into the engine oil.
The fuel level in the engine oil must not exceed 5%. Deteriorated engine oil can cause
adverse effects on the engine parts such as a reduction of lubricating function. It is
recommended to take a sample of the oil on a periodic basis.
• The characteristics of the biofuel change when outside air temperature is low. The fuel filter can
be clogged and the fuel inside the fuel tank can be solidified. Store the biofuel in the warm
building or in the storage tank.
The energy density of the biofuel becomes lower by 7 to 10% with that of the diesel fuel. Fuel consumption and
output can possibly be lowered when the mixing ratio is high.
Fuel hose quality can change as time passes due to the influence of material of bio when using BDF that mixing
ratio is over 20% and they are likely to wear out or deteriorate.
Strongly recommend to replace Fuel hose every 2 years or every 4000 hours, whichever comes sooner.

PARAFFIN-BASED FUEL
The paraffin-based fuel is generated by natural gas, coal, vegetable oil, and animal and plant fat, and its
main constituent is paraffin.
The paraffin-based fuel has almost the same characteristics as the diesel fuel.
Vegetable oil and fat-derived fuel are called renewable diesel (RD) and hydrogenated vegetable oil (HVO).
The fuel synthesized from natural gas is called gas-to-liquid (GTL).
NOTICE
Use the paraffin-based fuel which agrees with EN15940:2016 and ASTM D975.
As long as the fuel agrees with EN15940:2016 and ASTM D975, its mixing ratio can be up to 100%.
The energy density of the paraffin-based fuel becomes lower up to 10% with that of the diesel fuel. Thus,
fuel consumption and output can possibly be lowered.

4-5-1
MAINTENANCE OUTLINE OF MAINTENANCE

COOLANT AND WATER FOR DILUTION (HM400-B210-2A4-K-02-A)

• 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 4,000 hours.
Basically, Komatsu does not recommend the use of coolant other than 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 the Operation and Maintenance Manual.
• Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
• The coolant density needs to be changed according to the ambient temperature.
For details of the coolant density, see "CLEAN INSIDE OF COOLING SYSTEM（PAGE 4-20）".
Even in areas where it is not considered necessary to prevent freezing, always use Non-Amine Engine Cool-
ant (AF-NAC) with a density of over 30% in order to prevent corrosion of the cooling system.
Non-Amine Engine Coolant (AF-NAC) is diluted with distilled water that does not contain any ions or water-
hardening substances. Never dilute the Non-Amine Engine Coolant (AF-NAC) with ordinary water.
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air en-
tering the coolant.

GREASE (ALL-Q811-2A4-K-00-A)
• 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 change intervals and recommended ambient temperatures given in this Opera-
tion and Maintenance Manual.
• Grease fittings not included in the maintenance section are the grease fittings for overhaul, so they do not
need grease.
If any part becomes stiff after being used for long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.

4-5-2
OUTLINE OF MAINTENANCE MAINTENANCE

PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS) (ALL-0000-371-K-00-A)

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 accurately
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 (ALL-0000-371-K-01-A)
• Measurement of metallic powder density
An ICP (Inductively Coupled Plasma) analyzer is used for
measuring the density of iron, copper, and other metal pow-
der 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 5μm or
more, enabling 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 (ALL-0000-371-K-02-A)
• 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.

STORING OIL AND FUEL (ALL-RA19-876-K-00-A)

• 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, cover them
with a waterproof sheet or take other measures to protect them.
• To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).

FILTERS (HM-C950-2A4-P-00-A)
• Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems. Replace all filters periodically. For details, see Operation and
Maintenance Manual.

4-6
MAINTENANCE OUTLINE OF MAINTENANCE

However, when working in severe conditions, or depending on the oil and fuel (sulfur content) being used, re-
place the filters at shorter intervals.
• 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.
• When replacing the engine oil filter, fill the new filter with the specified clean oil, then install it.
• Do not open packs of spare filters until just before they are to be used.
• Komatsu recommends using Komatsu genuine filters.

4-7
OUTLINE OF MAINTENANCE MAINTENANCE

HANDLING ELECTRICAL COMPONENTS (HM400-AK50-2A4-K-02-A)

WARNING
• When the battery disconnect switch key is turned to OFF position for the maintenance work, always
pull out the key and keep it with you. If the key is left in the switch, someone may turn ON the power
by mistake. It is dangerous that causes an electric shock.
For the operation of the battery disconnect switch, see "BATTERY DISCONNECT SWITCH（PAGE 3-
119）".
• It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is
damaged. This will cause an electrical leakage and may lead to malfunction of the machine. Do not
wash the inside of the operator's cab with water. When washing the machine, be careful not to let
water get into the electrical components.

• When removing the connectors of electrical components after washing the machine or in the rain, wipe off the
water drop stuck around connectors before removing the connectors and keep the water drop away from in-
side of the connectors.
• Checking and maintenance items are checking fan belt tension, checking damage of the fan belt and check-
ing battery fluid level.
• Komatsu recommends installing electrical 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 device or other wireless equipment to the machine.
• When working at the seashore, carefully clean the electric system to prevent corrosion.
• When installing electrical component, connect it to the special power supply connector.
Do not connect the optional power supply to the fuse or starting switch or battery relay, etc.

4-8
 STANDARD TIGHTENING TORQUE FOR BOLTS AND
MAINTENANCE NUTS

STANDARD TIGHTENING TORQUE FOR BOLTS AND

NUTS (ALL-M140-03B-P-00-A)
TIGHTENING TORQUE LIST (HM-M140-03B-P-02-A)

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. Pay enough at-
tention when you tighten up.

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, always use a Komatsu genuine part of the same size as the part that
was replaced.

Thread Width Tightening torque

diameter across Target value Allowable range
of bolt (a) flat (b)
Nm kgm lbft Nm kgm lbft
(mm) (mm)
6 10 13.2 1.35 9.8 11.8 to 14.7 1.2 to 1.5 8.7 to 10.8
8 13 31 3.2 23.1 27 to 34 2.8 to 3.5 20.3 to 25.3
10 17 66 6.7 48.5 59 to 74 6.0 to 7.5 43.4 to 54.2
12 19 113 11.5 83.2 98 to 123 10.0 to 12.5 72.3 to 90.4
14 22 177 18 130.2 157 to 196 16.0 to 20.0 115.7 to 144.7
16 24 279 28.5 206.1 245 to 309 25.0 to 31.5 180.8 to 227.8
18 27 382 39 282.1 343 to 425 35.0 to 43.5 253.2 to 314.6
20 30 549 56 405.0 490 to 608 50.0 to 62.0 361.7 to 448.4
22 32 745 76 549.7 662 to 829 67.5 to 84.5 488.2 to 611.2
824 to
24 36 927 94.5 683.5 84.0 to 105.0 607.6 to 759.5
1030
1180 to 868.0 to
27 41 1320 135.0 976.5 120.0 to 150.0
1470 1085.0
1520 to 1121.1 to
30 46 1720 175.0 1265.8 155.0 to 195.0
1910 1410.4
1960 to 1446.6 to
33 50 2210 225.0 1627.4 200.0 to 25.0
2450 1808.3
2450 to 1808.3 to
36 55 2750 280.0 2025.2 250.0 to 310.0
3040 2242.2
2890 to 2133.7 to
39 60 3280 335.0 2423.1 295.0 to 370.0
3630 2676.2

Apply the following table for Hydraulic hose.

• Taper seal

Thread Width Tightening torque

diameter across Target value Allowable range
of bolt (a) flat (b)
Nm kgm lbft Nm kgm lbft
(mm) (mm)
10 14 14.7 1.5 10.8 12.7 to 16.7 1.3 to 1.7 9.4 to 12.3
14 19 29.4 3.0 21.7 27.5 to 39.2 2.8 to 4.0 20.3 to 28.9
18 24 78.5 8.0 57.3 58.8 to 98.1 6.0 to 10.0 43.4 to 72.3
22 27 117.7 12.0 86.8 88.3 to 137.3 9.0 to 14.0 65.1 to 101.3
117.7 to 12.0 to
24 32 147.1 15.0 108.5 86.8 to 130.2
176.5 18.0
176.5 to 18.0 to
30 36 215.7 22.0 159.1 130.2 to 180.8
245.2 25.0
215.7 to 22.0 to
33 41 255.0 26.0 188.1 159.1 to 209.8
284.4 29.0

4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND
NUTS MAINTENANCE

• Face seal

Width Tightening torque (Nm {kgm})

Nominal -
across
Threads per Target
flats Allowable range
inch (a) value
(b) (mm)
9/16 to 18 UNF 19 44 {4.5} 35 to 63 {3.5 to 6.5}
11/16 to 16 UN 22 74 {7.5} 54 to 93 {5.5 to 9.5}
13/16 to 16 UN 27 103 {10.5} 84 to 132 {8.5 to 13.5}
128 to 186 {13.0 to
1 to 14 UNS 32 157 {16.0}
19.0}
1･3/16 to 12 177 to 245 {18.0 to
36 216 {22.0}
UN 25.0}

4-10
MAINTENANCE MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE TABLE (ALL-3130-001-A-00-A)

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) (HM400-
3350-002-A-01-A)
REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................................................................... 4-66
CHANGE OIL IN TRANSMISSION CASE ........................................................................................................... 4-67
CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.............................................. 4-67
CHANGE OIL IN FINAL DRIVE CASE................................................................................................................. 4-77
CHANGE OIL IN DIFFERENTIAL CASE ............................................................................................................. 4-78

WHEN REQUIRED
CHECK, CLEAN, AND REPLACE AIR CLEANER .............................................................................................. 4-15
CLEAN INSIDE OF COOLING SYSTEM............................................................................................................. 4-20
CHECK KOMATSU MAINTENANCE-FREE BATTERY (IF EQUIPPED) INDICATOR ................................. 4-22-1
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .................................................................................. 4-23
CLEAN AIR CONDITIONER AIR FILTERS ......................................................................................................... 4-23
CHECK LEVEL OF REFRIGERANT (GAS)......................................................................................................... 4-25
REPLACE SLOW-BLOW FUSE .......................................................................................................................... 4-26
CHECK DUMP BODY .......................................................................................................................................... 4-27
CHECK LENGTH OF SUSPENSION CYLINDER ............................................................................................... 4-28
CHECK WATER SEPARATOR, CLEAN FILTER CASE ...................................................................................... 4-29
BLEEDING AIR OF FRONT BRAKE.................................................................................................................... 4-31
BLEEDING AIR OF CENTER BRAKE ................................................................................................................. 4-32
BLEED AIR FROM HYDRAULIC CIRCUIT ......................................................................................................... 4-33
CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT .......................................................................... 4-33
SELECTION AND INSPECTION OF TIRES........................................................................................................ 4-35
ADJUST PARKING BRAKE ................................................................................................................................. 4-37
TESTING AND ADJUSTING BODY MOUNT ...................................................................................................... 4-38

CHECKS BEFORE STARTING (HM400-3340-208-A-00-A)

EVERY 50 HOURS MAINTENANCE (HM400-3390-002-A-00-A)
LUBRICATE.......................................................................................................................................................... 4-40

EVERY 250 HOURS MAINTENANCE (HM400-33B0-002-A-02-A)

LUBRICATE.......................................................................................................................................................... 4-40
CHECK DRIVE SHAFT ........................................................................................................................................ 4-42
CLEAN BREATHER ............................................................................................................................................. 4-43
CLEAN OVERFLOW HOSE................................................................................................................................. 4-44
COLLECT LEAKED OIL FROM FLOATING SEAL .............................................................................................. 4-45
CHECK LEVEL OF BATTERY ELECTROLYTE .................................................................................................. 4-46
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST................................................................................. 4-48
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................................................... 4-49
CHECK FRAME AND A-ARM .............................................................................................................................. 4-50
CHECK FOOT BRAKE PERFORMANCE ........................................................................................................... 4-51
CHECK RETARDER BRAKE PERFORMANCE ................................................................................................. 4-51
CHECK PARKING BRAKE PERFORMANCE ..................................................................................................... 4-52
CHECK WEAR OF PARKING BRAKE PADS ...................................................................................................... 4-52
CHECK FUNCTION OF ACCUMULATOR........................................................................................................... 4-53

EVERY 500 HOURS MAINTENANCE (HM400-33C0-002-A-02-A)

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........................................ 4-56
REPLACE FUEL PREFILTER CARTRIDGE ....................................................................................................... 4-58
LUBRICATE CAB MOUNT PINS ......................................................................................................................... 4-60

4-11
MAINTENANCE SCHEDULE MAINTENANCE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....................................................................................... 4-60

CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL ................................................................................... 4-60
CHECK RADIATOR FIN, AFTERCOOLER FIN, AND AIR CONDITIONER CONDENSER FIN, CLEAN.......... 4-62

EVERY 1000 HOURS MAINTENANCE (HM400-33D0-002-A-02-A)

REPLACE FUEL MAIN FILTER CARTRIDGE..................................................................................................... 4-63
REPLACE BREATHER ELEMENT IN FUEL TANK............................................................................................. 4-65
REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................................................................... 4-66
CHANGE OIL IN TRANSMISSION CASE ........................................................................................................... 4-67
CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.............................................. 4-67
REPLACE HYDRAULIC OIL FILTER ELEMENT ................................................................................................ 4-70
LUBRICATE.......................................................................................................................................................... 4-71
LUBRICATE PARKING BRAKE ........................................................................................................................... 4-72
CHECK BRAKE DISC WEAR AMOUNT ............................................................................................................. 4-73
CHECK FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP ....................................................................... 4-74
DO NOT APPLY LUBRICANT ON EXHAUST PIPE SPHERICAL SURFACE JOINT PORTION....................... 4-75

EVERY 2000 HOURS MAINTENANCE (HM400-33E0-002-A-01-A)

REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................................................. 4-76
CHANGE OIL IN FINAL DRIVE CASE................................................................................................................. 4-77
CHANGE OIL IN DIFFERENTIAL CASE ............................................................................................................. 4-78
CLEAN TRANSMISSION CASE STRAINER....................................................................................................... 4-80
CLEAN BREATHER ............................................................................................................................................. 4-81
CHECK ACCUMULATOR GAS PRESSURE ...................................................................................................... 4-81
CHECK ENGINE VALVE CLEARANCE, ADJUST .............................................................................................. 4-81

EVERY 4000 HOURS MAINTENANCE

CHANGE OIL IN HYDRAULIC TANK .................................................................................................................. 4-82
CHECK ALTERNATOR AND STARTING MOTOR.............................................................................................. 4-82
CHECK WATER PUMP........................................................................................................................................ 4-82
CHECK AIR CONDITIONER COMPRESSOR .................................................................................................... 4-82
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER................... 4-83
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.................................. 4-83
CHECK EXHAUST PIPE FIRE PREVENTION COVER...................................................................................... 4-84
REPLACE COOLANT FILTER CARTRIDGE ...................................................................................................... 4-84

EVERY 6000 HOURS MAINTENANCE (HM400-33G0-002-A-00-A)

LUBRICATE DRIVE SHAFT................................................................................................................................. 4-85

EVERY 8000 HOURS MAINTENANCE (HM300-33H0-002-A-00-A)

REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS ................................................................................. 4-87
REPLACE FUEL SPRAY PREVENTION CAP ON ENGINE............................................................................... 4-87
OVERHAUL STARTING MOTOR AND ALTERNATOR ...................................................................................... 4-87

4-12
MAINTENANCE MAINTENANCE SCHEDULE

4-13
MAINTENANCE PROCEDURE MAINTENANCE

MAINTENANCE PROCEDURE (ALL-3510-001-A-00-A)

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250

HOURS) (HM300-3350-208-A-00-A)
Perform the following maintenance only after the first 250 hours.
• Replace transmission filter element (valve side, brake cooling side)
• Change oil in transmission case
• Change oil in brake oil tank, replace brake oil filter element
• Change oil in final drive case
• Change oil in differential case
For details of the method of replacement or maintenance, see EVERY 500 HOURS MAINTENANCE and EVERY
1,000 HOURS MAINTENANCE and EVERY 2,000 HOURS MAINTENANCE.

4-14
MAINTENANCE MAINTENANCE PROCEDURE

WHEN REQUIRED (ALL-3370-001-A-00-A)

CHECK, CLEAN, AND REPLACE AIR CLEANER (HM400-A910-929-K-00-A)

After the outer element has been cleaned 6 times, or if the air cleaner element has been used for 1 year, replace
the outer element, inner element, and O-ring. For details of the procedure for replacement, see "REPLACE ELE-
MENT（PAGE 4-18）".
If the air cleaner clogging caution lamp flashes and the machine monitor displays action level "L01" during opera-
tion immediately after the outer element is cleaned, replace the element even if the outer element has not been
cleaned 6 times or the air cleaner element has not been used more than 1 year.
CHECK (HM400-A910-280-K-00-A)
NOTICE
Do not clean the outer element until the red line of the dust indicator is at 7.5 kPa. If the element is cleaned
frequently, the filtering efficiency of the air cleaner will drop and this will reduce the service life of the
engine.
1. Check if the red line of dust indicator (1) is at 7.5 kPa. If it is at
7.5 kPa, clean the outer element.

REMARK
There is air cleaner clogging caution lamp (2) on the machine
monitor.
If the air cleaner clogging caution lamp lights up and the machine
monitor displays "L01" during operation, the air cleaner is clogged.
Clean the outer element in this case, as well.

CLEAN OUTER ELEMENT (HM400-A92G-250-K-00-A)

WARNING
• Dirt will fly if compressed air is used for cleaning. If dirt gets into your eyes it may cause blindness,
and if you breathe in the dust it may damage your lungs. To prevent these problems, always wear pro-
tective eyeglasses, dust mask, and other protective equipment.
• When pulling out the air cleaner element, make sure that you are standing on a firm place. If your foot-
ing is not secure when you perform the operation, there is a danger of falling and suffering injury.

NOTICE
Clean only the outer element. Do not remove the inner element. If the inner element is removed while the
outer element is being cleaned, dirt may enter the engine and cause damage to the engine.

4-15
MAINTENANCE PROCEDURE MAINTENANCE

1. Stop the engine.

2. Remove 6 hooks (4) from dust cap (3), then remove the dust
cap.

3. Hold outer element (5) with both hands, and move it up and
down and to the right and left while pulling it out.
4. Hold inner element (6) so that it does not come out, and clean
the inside of the air cleaner body with a dry cloth.
5. Use a dry cloth or compressed air to clean off the dirt stuck to
dust cup (3) and vacuator valve (7).
6. Check that there are no cracks in the lip of the vacuator valve
(7). If any cracks are found, replace with a new part.

NOTICE
• If a damaged element is used, air will pass the air cleaner
filter and will be sucked into the engine. Never use any
cleaning method that will damage the element. If the ele-
ment is damaged, replace it with a new element.
• Never tap the element or hit it against any other object
when cleaning it.
• Do not use an element of which pleats or gasket or seal
are damaged.
7. Blow dry compressed air (max. 0.2 MPa {2.1 kg/cm2, 30.0
PSI}) from the inside of outer element (5) along the pleats.
Next, blow along the pleats from the outside, then blow again
from the inside.

8. After cleaning, shine a light bulb from inside outer element (5)
to check. If any holes or thin places are found, replace the
outer element.

4-16
MAINTENANCE MAINTENANCE PROCEDURE

9. Install outer element (5) in the air cleaner body.

10. Check that O-ring (8) is fitted to dust cup (3).

Next, set so that vacuator valve (7) of dust cup (3) is at the
bottom, and insert it into the air cleaner body.

11. Fit 6 hooks (4) of dust cap (3) to the protruding portion of the
air cleaner body to lock in position.

12. Push the head of dust indicator (1) to return the red line to its
original position.

4-17
MAINTENANCE PROCEDURE MAINTENANCE

REPLACE ELEMENT (HM400-A921-923-K-00-A)

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

1. Stop the engine.

2. Remove 6 hooks (4) from dust cap (3), then remove the dust
cap.

3. Hold outer element (5) with both hands, and move it up and
down and to the right and left while pulling it out.
4. Hold inner element (6) so that it does not come out, and clean
the inside of the air cleaner body with a dry cloth.
5. Use a dry cloth or compressed air to clean off the dirt stuck to
dust cup (3) and vacuator valve (7).
6. Check that there are no cracks in the lip of the vacuator valve
(7). If any cracks are found, replace with a new part.
7. Pull out inner element (6) and install a new inner element.

8. Install outer element (5) in the air cleaner body.

9. Replace O-ring (8) with a new one.

Next, set so that vacuator valve (7) of dust cup (3) is at the
bottom, and insert it into the air cleaner body.

4-18
MAINTENANCE MAINTENANCE PROCEDURE

10. Fit 6 hooks (4) of dust cap (3) to the protruding portion of the
air cleaner body to lock in position.

11. Push the head of dust indicator (1) to return the red line to its
original position.

4-19
MAINTENANCE PROCEDURE MAINTENANCE

CLEAN INSIDE OF COOLING SYSTEM (HM400-B000-255-K-02-A)

WARNING
• Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in the
radiator. If the radiator cap is removed in this condition and the coolant is drained, it may cause burns.
Accordingly, wait until the coolant temperature drops, then turn the cap slowly to release the
pressure.
• Start the engine and clean the inside of the cooling system. When standing up or leaving the opera-
tor's seat, set the gear shift lever to the N position and set the parking brake switch to PARKING
position.
• For details of starting the engine, see "OPERATIONS AND CHECKS BEFORE STARTING ENGINE
（PAGE 3-146）" and "STARTING ENGINE（PAGE 3-150）" in the OPERATION section.
• When the undercover is removed, there is a danger of touching the fan.
Never go to the front of the machine when the engine is running.

Place the machine on a level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant according to the table below.
Interval for cleaning inside of cooling
Coolant
system and changing coolant
Non-Amine Engine Coolant Every 2 years or every 4000 hours
(AF-NAC) whichever comes sooner

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 anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or
4000 hours.
Basically, Komatsu does not recommend the use of coolant other than 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 anticorrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of the
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 actually deciding the density for the coolant, set a temperature that is approximately 10°C (18°F) lower than
the lowest temperature.
The coolant density varies according to the ambient temperature, but it must be over 30% at least.
Coolant density table
Min. atmospheric °C Min. -10 -15 -20 -25 -30 -35 -40 -45 -50
temperature °F Min. 14 5 -4 -13 -22 -31 -40 -49 -58
Density (%) 30 36 41 46 50 54 58 61 64

WARNING
• Coolant is toxic. When open the drain valve, be careful not to get coolant on you. If it gets in your eyes,
flush your eyes with large amount of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the cool-
ant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform
the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground
surface.

Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable. For detail of di-
lution, see "COOLANT AND WATER FOR DILUTION（PAGE 4-5）". Check the density with a coolant tester.
Prepare a container that is a larger than the specified amount of coolant, then drain the coolant into it.
Prepare a hose to use when filling with coolant.

4-20
MAINTENANCE MAINTENANCE PROCEDURE

When getting on or off the machine with carrying coolant, place it

once in portion (A) to ensure your safety.
1. Stop the engine.

2. Remove cover (1) at the bottom of radiator, and pull out the
coolant drain hose (1piece).

3. Loosen sub-tank cap (2) a bit to release the pressure, then

slowly turn it to remove.

4-21
MAINTENANCE PROCEDURE MAINTENANCE

4. Open drain valve (3) on the oil cooler and drain the coolant.
5. After draining the coolant, close drain valve (3) and fill with
city water.
6. When the radiator, sub-tank, and reservoir tank are full of
water, start the engine and run it at low idle for 10 minutes.
7. Stop the engine, open drain valve (3), and drain the water.
After draining the water, close it.
8. Fill with Non-Amine Engine Coolant through the water filler
port up to the mouth of the port.
For the density of Non-Amine Engine Coolant, see "Coolant
density table".
9. Run the engine at low idle for 5 minutes to remove the air
from the coolant, then run at high idle for a further 5 minutes.
When doing this, leave the sub-tank cap (2) removed.
10. Stop the engine. Approximately 3 minutes later, add the Non-
Amine Engine Coolant up to the water filler port, then close
the sub-tank cap (2).
11. Drain the coolant from reservoir tank (4), clean the inside of
the reservoir tank, then refill with Non-Amine Engine Coolant
until the coolant level is between the FULL and LOW marks.

4-22
MAINTENANCE MAINTENANCE PROCEDURE

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MAINTENANCE PROCEDURE MAINTENANCE

4-22-2
MAINTENANCE MAINTENANCE PROCEDURE

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (HM400-K7B0-217-K-01-A)

Perform this check if there is air in the window washer fluid.

Check the level of the fluid in window washer tank (1), and if it is
insufficient, add the window washer fluid for automobiles.
Be careful not to let dirt or dust get in when adding fluid.
When operating at below freezing point, use fluid with antifreeze.

When getting on or off the machine with carrying window washer

fluid, place it once in portion (A) to ensure your safety.

CLEAN 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 cover (1) on the side of the cab.

When getting on or off the machine with carrying a nozzle, place it

once in portion (A) to ensure your safety.

4-23
MAINTENANCE PROCEDURE MAINTENANCE

2. Pull up the left end part of the air filter (FRESH filter) (2). Pull it
out at an angle.
3. Blow compressed air from the inside of the air filter (FRESH fil-
ter) (2) along the pleats.

4. Open cover (3) at the rear left of the operator's seat.

5. Pull out the air filter (RECIRC filter).
6. Blow compressed air from the inside of the air filter (RECIRC
filter) along the pleats.

When getting on or off the machine with carrying a nozzle and a

brush, place it once in portion (A) to ensure your safety.

4-24
MAINTENANCE MAINTENANCE PROCEDURE

CHECK LEVEL OF REFRIGERANT (GAS) (HM400-K512-21D-K-01-A)

WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight
or frostbite. Never touch the refrigerant. Do not loosen any part of the refrigerant circuit.
Do not bring any open flame close to any point where the refrigerant gas is leaking.

If the cooling effect is poor, there is probably lack of refrigerant

gas (Hydrofluorocarbons HFC-134a).
In this case, check sight glass (2) of receiver drier (1) on the left
side of the engine.
Before performing inspection, set to the following conditions.
• Start the engine and run it at approximately 1,500 rpm.
• Turn the air conditioner ON/OFF switch to ON position.
• Set the air flow to the maximum position.
• Set the temperature to the lowest position.
• Open the doors and windows fully.
• Turn the air conditioner switch ON.
• Set the air conditioner in FRESH mode.
If the condition of sight glass (2) is "correct" as shown in the figure below, the condition is normal.
If the condition of sight glass (2) is "overfilling" or "insufficient" as shown in the figure below, ask your Komatsu dis-
tributor for service.
Quantity of
Condition
refrigerant

Only few bubbles are contained. Bubbles disappear and the refrigerant becomes
Correct
transparent when the engine speed is increased gradually from idle to 1,500 rpm.

No bubble is contained. In this case, both high and low pressures are high and
Overfilling
cooling efficiency is low.

Insufficient Bubbles pass continuously.

4-25
MAINTENANCE PROCEDURE MAINTENANCE

REPLACE SLOW-BLOW FUSE (HM400-Q6G1-923-K-00-A)

NOTICE
• Before replacing the slow blow fuse, be sure to turn the starting switch to OFF position (A) and turn
the battery disconnect switch key to OFF position.
• Replace the slow blow fuse with a new one of the same capacity.
Should the slow blow fuse is blown, investigate the cause and take necessary actions.
1. Turn the starting switch to OFF position (A).
2. Turn the battery disconnect switch key to OFF position and
make sure the system operation lamp is turned off.

3. Remove the slow blow fuse box from the machine.

4. Open covers (1), (2) and (3) of the slow blow fuse box.
You can remove the box easily by removing the covers (2)
and (3) with a flat-head screwdriver by using projection (A) as
a fulcrum.
5. Loosen and remove screws (4) and (5).
If you remove screws (4) and (5), slow blow fuse (6) comes
off along with electric wiring (7) and (8).
6. By using screws (4) and (5), install a new slow blow fuse to
the slow blow fuse box along with electric wiring (7) and (8),
then close covers (1), (2) and (3).
7. Install the slow blow fuse box to the machine.

4-26
MAINTENANCE MAINTENANCE PROCEDURE

CHECKDUMPBODY
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1. Install the personal fall-arrest equipment to the anchor point

for tie-off (1). The anchor point for tie-off (1) is on the dump
body side (2 places).
2. Clean the dump body to make easier to check.
3. Check all parts 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 pro-
cedure.

4-27
MAINTENANCE PROCEDURE MAINTENANCE

CHECK LENGTH OF SUSPENSION CYLINDER (HM-E000-360-K-00-A)

If the machine reacts to the rough ground conditions when traveling, such as making high bounds or the cylinder
retracting and hitting the stopper, check the following.
CHECK LENGTH OF CYLINDER (HM400-E000-360-K-00-A)
Check front suspension (1) and the rear suspension (2) with the
machine unloaded.

1. Remove cover (3).

2. Measure distance (A) from the shoulder at the head end of
the suspension cylinder rod to the top surface of the flange.
Front suspension dimension (A): 166 to 186 mm {6.5 to 7.3
in}
Rear suspension dimension (A): 101 to 111 mm {4.0 to 4.4 in}
3. If any abnormality is found when checking the front and rear
suspension, ask your Komatsu distributor for inspection.

4-28
MAINTENANCE MAINTENANCE PROCEDURE

CHECK WATER SEPARATOR, CLEAN FILTER CASE (HM400-AEB0-220-K-03-A)

WARNING
• Do not bring any fire or open flame close.

NOTICE
• When performing inspection and maintenance of the fuel system, the particularly careful not to let any
dirt or dust get in. If there is any dirt of dust around the fuel system, clean it off thoroughly with fuel be-
fore starting the operation.
• To prevent dirt or dust from getting into the fuel circuit, remove all dirt and dust from the surrounding
area before starting the operation.
• Prepare a container to catch the fuel.
1. Open engine hood.
2. Set a container under the water separator drain hose to catch
the drained water.

3. Close supply valve (1) of the fuel tank.

4. Loosen plug (2) and drain the fuel from inside the case.
5. If the fuel cannot be drained, remove air intake plug (3).
(Width across flats: 14 mm (0.6in))
The fuel will drain from plug (2).

4-29
MAINTENANCE PROCEDURE MAINTENANCE

6. Loosen the ring nut (4), then remove case (5).

7. Pull screen (6) down to remove it from the water separator
holder.
8. Wash screen (6) in clean fuel.
Check screen (6) and replace it if it is damaged.
9. Wash the inside of case (5) with clean fuel. Check case (5). If
it is scratched or damaged, or so dirty that the position of float
(7) cannot be checked, replace case (5).
10. Install screen (6) to the water separator holder.
11. Replace O-ring (8),gasket(9) with a new part.
12. Tighten plug (2), insert case (5) so that float (7) is not at an
angle, then fill case (5) carefully with clean fuel.
Tightening torque: 2.0 to 3.0 Nm (0.20 to 0.30 kgm, 1.5 to 2.2
lbft)
13. Install case (5) to the water separator holder, then tighten ring
nut (4).
Tightening torque: 16 to 20 Nm (1.6 to 2.0 kgm, 11.6 to 14.5
lbft)
14. Tighten air intake plug (3).
Tightening torque: 8.0 to 12.0 Nm (0.8 to 1.2 kgm, 5.8 to 8.7
lbft)
15. Open supply valve (1).
16. After completing the inspection and maintenance, bleed the
air. Use the same procedure as when replacing the fuel filter
cartridge.
For details of the method for bleeding the air, "PROCEDURE
FOR BLEEDING AIR（PAGE 3-200）"see
REMARK
• If the dirt is accumulated in the water separator case, clean the inside of the case, remove the drain plug and
clean the thread part.
• The dirt may be accumulated in the fuel tank as well, accordingly drain the fuel from the tank to remove the
dirt.

4-30
MAINTENANCE MAINTENANCE PROCEDURE

BLEEDING AIR OF FRONT BRAKE (HM400-GA10-231-K-00-A)

WARNING
Stop the machine on level ground and chock 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.
Bleed the air from the slack adjuster and front brakes in the same way on both the left and right sides.

1. Start the engine, check that the oil in the transmission case is
the specified level, and the brake oil pressure caution lamp is
OFF.
2. Remove the cap installed to bleeder screw (1) of the slack ad-
juster, then insert a vinyl hose.
Prepare a container with oil in it and insert the other end of
the hose approximately 50 mm (2.0 in) below the surface of
the oil.
(Use a commercially available vinyl hose.)
3. Depress the brake pedal and loosen bleeder screw (1) ap-
proximately 3/4 turns. Keep the pedal depressed until no
more bubbles come out from the vinyl hose.
4. Pull the retarder control lever and loosen bleeder screw (1)
approximately 3/4 turns. Keep the retarder control lever
pulled until no more bubbles come out from the vinyl hose.
5. After bleeding the air, tighten bleeder screw (1) securely and
fit the cap.
6. The procedure for bleeder screw (2) of the front brake is the
same as for the slack adjuster (with step 4 excluded).

NOTICE
The brake oil pressure caution lamp may light up during the
air bleed work. If this happens, tighten the bleeder screw and
depress the brake pedal 8 to 10 times to charge the accumu-
lator with oil pressure.
Use sight gauge (H) to check if there is oil remaining in the
brake oil tank. If there is no oil, stop the engine. (When the en-
gine is stopped, the oil level will rise and oil will be automati-
cally supplied to the brake oil tank.)
7. After completely bleeding the air from the brakes, stop the en-
gine for approximately 2 to 3 minutes. After that, check the oil
level in the transmission case and add oil to bring it to the
specified level. For details, see "CHECK OIL LEVEL IN
TRANSMISSION CASE, ADD OIL（PAGE 3-129）".

4-31
MAINTENANCE PROCEDURE MAINTENANCE

BLEEDING AIR OF CENTER BRAKE (HM400-GD10-231-K-00-A)

WARNING
Stop the machine on level ground and chock 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.
Bleed the air from the slack adjuster and center brakes in the same way on both the left and right sides.

1. Start the engine, check that the oil in the transmission case is
the specified level, and the brake oil pressure caution lamp is
OFF.
2. Remove the cap installed to bleeder screw (1) of the slack ad-
juster, then insert a vinyl hose.
Prepare a container with oil in it and insert the other end of
the hose approximately 50 mm (2.0 in) below the surface of
the oil.
(Use a commercially available vinyl hose.)
3. Depress the brake pedal and loosen bleeder screw (1) ap-
proximately 3/4 turns. Keep the pedal depressed until no
more bubbles come out from the vinyl hose.
4. Pull the retarder control lever and loosen bleeder screw (1)
approximately 3/4 turns. Keep the retarder control lever
pulled until no more bubbles come out from the vinyl hose.
5. After bleeding the air, tighten bleeder screw (1) securely and
fit the cap.
6. The procedure for bleeder screw (2) of the center brake is the
same as for the slack adjuster (with step 4 excluded).

NOTICE
The brake oil pressure caution lamp may light up during the
air bleed work. If this happens, tighten the bleeder screw and
use sight gauge (H) to check if there is oil remaining in the
brake oil tank. If there is no oil, stop the engine. (When the en-
gine is stopped, the oil level will rise and oil will be automati-
cally supplied to the brake oil tank.)
7. After completely bleeding the air from the brakes, stop the en-
gine for approximately 2 to 3 minutes. After that, check the oil
level in the transmission case and add oil to bring it to the
specified level. For details, see "CHECK OIL LEVEL IN
TRANSMISSION CASE, ADD OIL（PAGE 3-129）".

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MAINTENANCE MAINTENANCE PROCEDURE

BLEED AIR FROM HYDRAULIC CIRCUIT (HM400-C000-231-P-05-A)

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit.

NOTICE
When filling the tank with oil after draining the hydraulic oil
with the pump suction piping disconnected, be sure to bleed
air through bleeder (1).
If the air is not bled, it stays in the suction piping and can
damage the pump.

CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT (HM400-CB34-360-K-00-A)

WARNING
To prevent the machine from moving, set the parking brake switch to PARKING, stop the engine, then
chock the wheels.

If any unusual noise occurs around the output shaft (1) or front drive shaft (2), the rubber inside the output shaft
may be deteriorated or damaged, so check the play of coupling (3) as follows.

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MAINTENANCE PROCEDURE MAINTENANCE

1. Set wire (4) as shown in the figure.

By using the tip of the wire as a benchmark, measure the
amount of movement (L) of the coupling.
When getting on or off the machine with carrying a wire, a
tool, etc., place it once in portion (A) to ensure your safety.
2. Rotate the coupling at a force of approximately 49 N {5 kg} to
the circumferential direction with bar (5), etc.
When doing this, mark the position of the wire.
3. Check that the engine crankshaft is not rotating.
REMARK
If excessive force is applied in rotating the coupling, the engine ro-
tates freely and it becomes impossible to judge accurately.

4. Rotate the coupling in the reverse direction from step 2.

When doing this, mark the position of the wire in the same
way as in step 2.
5. Measure the amount of movement (L) of the coupling by us-
ing the marks made in steps 2 and 4.
If amount of movement (L) is more than 12 mm (0.5 in), the
rubber inside the output shaft may be deteriorated or dam-
aged, so ask your Komatsu distributor for disassembly and in-
spection of the internal parts of the output shaft.

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MAINTENANCE MAINTENANCE PROCEDURE

SELECTION AND INSPECTION OF TIRES (HM-DW60-2AH-K-00-A)

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 scattered,
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 (HM400-DW60-05A-K-00-A)

WARNING
Select the tires according to the conditions of use and the weight of the attachments on the machine. Use
only specified tires and inflate them to the specified pressure.

Select the tires according to the weight of the attachments on the machine. Use the following table. The travel
speed displayed varies with the tire size.
Consult your Komatsu distributor when using optional tires.

Maximum load (kg (lb)) Size (standard) Remarks

14,000
Front tire 29.5–R25
(30,870)
Type 1 for con-
14,000
Center tire 29.5–R25 struction
(30,870)
equipment
14,000
Rear tire 29.5–R25
(30,870)

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MAINTENANCE PROCEDURE MAINTENANCE

CHECK INFLATION PRESSURE OF TIRES, INFLATE (HM-DW60-2AH-K-01-A)

WARNING
• When inflating the tires, check that no other person is
standing near the tire, and install an air chuck with a clip
that can be fixed to the air valve.
• while inflating the tire, check the inflation pressure occa-
sionally so that it will not rise too much.
• If the rim is not fitted normally, it may be broken and scat-
tered while the tire is inflated. Accordingly, place a guard
around the tire and do not work in front of the rim but
work on the tread side of the tire.
• Abnormal drop of inflation pressure and abnormal fitting
of the rim indicate a trouble in the tire or rim. In this case,
be sure to ask a tire repair shop for repair.
• Be sure to observe the specified inflation pressure.
• Do not adjust the inflation pressure of the tires just after
high-speed travel or heavy-load work.

CHECK (HM-DW60-2AH-K-02-A)
Use a tire pressure gauge to measure the tire inflation pressure before starting operations when the tires are cool.
INFLATION OF TIRES (HM400-DW60-2AH-K-00-A)
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not
work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown in table below.

Inflation pressure kPa {kg/cm2, PSI}

Tire size
Front tire Center tire Rear tire
29.5–R25 (standard) 375 {3.8, 54.0} 390 {4.0, 56.8} 390 {4.0, 56.8}
875/65R29
440 {4.5, 63.9} 440 {4.5, 63.9} 440 {4.5, 63.9}
(if equipped)

NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim may
be damaged.
Always keep the tire inflation pressure within +0 to +29 kPa {0.3 kg/cm 2, 4.3 PSI} of the value in the table
above.
PRECAUTIONS WHEN REPLACING TIRES (HM-DW60-71A-K-00-A)
After tightening hub bolts (1) when replacing the tire, travel for 5 to
6 km, tighten the bolts again to settle all the contacting parts.
In particular, there are more contacting parts on the rear wheels
than on the front wheels, so it will take time for the parts to settle.
For this reason, repeat the tightening process during the first 50
hours after installation.

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MAINTENANCE MAINTENANCE PROCEDURE

ADJUST PARKING BRAKE (HM400-GJ00-270-K-00-A)

WARNING
• To prevent the parking brake from being automatically applied during the adjustment operation, raise
the brake oil pressure to a sufficiently high level and hang a warning notice that can be seen clearly to
prevent any other person from operating the parking brake switch.
• Never put any oil or grease on the surface of the brake pad or disc.

If the parking brake effect is poor, adjust as follows.

1. Check that the brake oil pressure caution lamp is turned OFF
(the brake accumulator pressure is sufficiently high), and then
release the parking brake.
2. Push down the lock part of adjustment screw (1) and turn it
counterclockwise to bring the pad into tight contact with the
disc.
3. Push down the lock part of adjustment screw (1) and turn it
back clockwise by 240 ± 15 deg. (2/3 turns).

Measure the thickness of pad (2), and if thickness (A) is 1.5 mm

(0.059 in) or below, contact your Komatsu distributor to have it
replaced.
When performing the first adjustment after replacing the pad, push
down the lock part of adjustment screw (1) and turn it back clock-
wise by 360 ± 15 deg. (1 turn).
After adjustment, check the parking brake performance. For detail,
see "CHECK PARKING BRAKE PERFORMANCE（PAGE 4-
52）". If the machine moves, ask your Komatsu distributor to per-
form inspection.

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MAINTENANCE PROCEDURE MAINTENANCE

TESTING AND ADJUSTING BODY MOUNT (HM300-H000-921-K-00-A)

WARNING
When performing inspection of the machine with the dump body raised, always place the dump lever in
HOLD position, lock with the dump lever lock knob, and then use the body pivot pin.

If the dump body mounting is not adjusted correctly, the frame may be damaged. Check and adjust it correctly.
CHECK (HM400-H000-280-K-01-A)
1. Clean the dump body and frame to make them easier to
check.
2. Check that bottom face (1) of the bottom mounting of dump
body is set evenly on top face (2) of the frame.
Check 6 places in total at (A), (B) and (C) on right and left.

ADJUST (HM400-H000-270-K-01-A)
1. If there is clearance (D) between bottom face (1) of the bot-
tom mounting and top face (2) of the frame, adjust bottom
mounting with shims.
For the adjustment, ask your Komatsu distributor.
2. Lower the dump body and check that bottom face (4) of the
bottom mounting of dump body is set evenly on top face (2)
of the frame.

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MAINTENANCE MAINTENANCE PROCEDURE

CHECKS BEFORE STARTING (HM400-3340-015-A-01-A)

For details of the following items, see "CHECKS BEFORE STARTING（PAGE 3-129）" in the Operation section.
• Check looseness of wheel hub bolts, and retightening
• Check inflation pressure of tires
• Check oil level in transmission case, add oil
• Check dust indicator
• Check battery disconnect switch
• Drain water , sediment from fuel tank
• Check fuel level, add fuel
• Drain water in fuel pre-filter
• Check water separator, clean filter
• Check oil level in hydraulic tank, oil
• Check cab mounting bolts, pins
• Check oil level in engine oil pan, add oil
• Check coolant level, add coolant
• Check electric wiring
• Check centralized warning lamp, alarm buzzer, monitor lamps and meters
• Check braking effect
• Self-check function of emergency steering
• Check manual emergency steering
• Check auto-emergency steering
• Check dump body positioner operation
• Check backup alarm
• Check function of horn

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MAINTENANCE PROCEDURE MAINTENANCE

EVERY 50 HOURS MAINTENANCE (ALL-3390-001-A-00-A)

LUBRICATE
1. Stop the engine.
2. By using a grease pump, pump in grease through grease fittings marked by arrows.
3. Check visually that the greasing has been performed properly.
4. After greasing, wipe off any old grease that was pushed out.
Perform the greasing work every day when operating in places where the grease flows out easily, such as when
traveling through mud or water.

(1) Front suspension (left) (2 places)

(2) Front suspension (right) (2 places)

(3) Rear suspension (2 places each of right and left)

(4) Tail gate hinge pin (1 place each of right and left) (if equipped)

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MAINTENANCE MAINTENANCE PROCEDURE

EVERY 250 HOURS MAINTENANCE (ALL-33B0-015-A-00-A)

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

LUBRICATE (HM400-RA1H-242-K-00-A)
1. Stop the engine.
2. By using a grease pump, pump in grease through the grease fittings shown by arrows.
3. Check visually that the greasing has been performed properly.
4. After greasing, wipe off any old grease that was pushed out.
5. When pumping in grease through the grease fittings, place the machine on a flat ground, and pump in with the
dump body seated.
Perform the greasing work every day when operating in places where the grease flows out easily, such as when
traveling through mud or water.

(1) Steering cylinder (left) (2 places)

(2) Steering cylinder (right) (2 places)

(3) Hoist cylinder (2 places each of right and left)

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MAINTENANCE PROCEDURE MAINTENANCE

(4) Body hinge pin (2 places)

(5) Hitch bearing (2 places)

CHECK DRIVE SHAFT (HM300-D510-280-K-00-A)

If there is any problem, such as looseness of the drive shaft con-
nection, play in the spline or bearing portion, or runout of the shaft,
ask your Komatsu distributor for repair.

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MAINTENANCE MAINTENANCE PROCEDURE

CLEAN BREATHER (HM400-RA1L-255-K-02-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When using compressed air, there is a danger that dirt may be blown up and cause personal injury.
Always wear protective equipment such as protective eyeglasses and dust mask.

Remove any mud or dirt from around the breather, then remove the breather and use clean diesel fuel or flushing
oil to flush out the dirt inside.

When getting on or off the machine with carrying breather, a tool,

etc., place it once in part (A) to ensure your safety.

• Differential case (front)

• Final drive case (front, left)

It is located inside of the hydraulic tank.

• Final drive case (front, right)

It is located rear inside of front right wheel.

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MAINTENANCE PROCEDURE MAINTENANCE

• Differential case (center)

Final drive case (center)

• Differential case (rear)

CLEAN OVERFLOW HOSE (HM400-DF11-250-K-00-A)

WARNING
When using compressed air, there is a danger of dirt flying and causing personal injury. Always wear pro-
tective equipment such as protective eyeglasses and dust mask.

The overflow hoses are installed to the front and center wheels. Remove and clean all of the 4 hoses.
1. Remove overflow hose (1).
2. After removing the hose, use compressed air to blow out the soil and dirt from the hose.
3. Install overflow hose (1).
Front

Center

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MAINTENANCE MAINTENANCE PROCEDURE

COLLECT LEAKED OIL FROM FLOATING SEAL (HM400-DA46-220-K-00-A)

There are 4 drain plugs. Loosen each drain plug and collect oil through all the drain holes.
REMARK
Whenever oil flow out of the overflow hose, collect the oil.
1. Place a container directly under the drain plug to catch the oil.
2. Remove the drain plug, drain the oil, then tighten the plug again.
Front axle (left) and (right)

Center axle (left) and (right)

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MAINTENANCE PROCEDURE MAINTENANCE

CHECK LEVEL OF BATTERY ELECTROLYTE

Perform this procedure before operating the machine.

WARNING
• Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler-
ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may cause an explosion.
• The battery generates flammable gas and there is danger of explosion, 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.
• When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.
• Do not use a direct air blow or dry cloth to clean the battery. A wet cloth will prevent fire or explosion
from static electricity.

NOTICE
If there is a fear that the battery water may freeze after refilling with purified water (e.g. commercially avail-
able replenishment water for a battery), do the replenishment before the day's work in the morning on the
next day.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY (HM400-AW10-217-K-00-A)
If it is possible to check the electrolyte level from the side of the battery, check as follows.

1. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the
UPPER LEVEL and LOWER LEVEL lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.

2. If the electrolyte level is below the midway point between the

UPPER LEVEL and LOWER LEVEL lines, remove cap (1)
and add purified water (e.g. commercially available replenish-
ment water for a battery) to the UPPER LEVEL line.
3. After adding purified water, tighten cap (1) securely.
REMARK
If purified water is added to above the UPPER LEVEL line, use a
syringe to lower the level to the UPPER LEVEL line. Neutralize
the removed fluid with baking soda (sodium bicarbonate), then
flush it away with a large amount of water. If necessary, consult
your Komatsu distributor or battery manufacturer.

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MAINTENANCE MAINTENANCE PROCEDURE

WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF

BATTERY (HM400-AW10-217-K-01-A)
If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.

1. Remove cap (1) at the top of the battery, look through water
filler port (2), and check the electrolyte surface. If the electro-
lyte does not reach the sleeve (3), always add purified water
(e.g. commercially available replenishment water for a bat-
tery) 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 bottom
of sleeve, so pole plate appears straight and not to be
warped.
2. After adding purified water, tighten cap (1) securely.
REMARK
If purified water is added to above the bottom tip of the sleeve,
use a syringe to remove electrolyte. Neutralize the removed fluid
with baking soda (sodium bicarbonate), then flush it away with a
large amount of water. If necessary, consult your Komatsu distrib-
utor or your battery manufacturer.

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
In the case of the Komatsu maintenance-free battery (if equipped), indicators that show the charging state and
battery electrolyte level are installed to the top of the battery. See "CHECK KOMATSU MAINTENANCE-FREE
BATTERY INDICATOR (PAGE 4-22-1)" for how to read the indicator.

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MAINTENANCE PROCEDURE MAINTENANCE

CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST (HM400-AKM4-92C-K-00-A)

CHECK (HM400-AKM4-285-K-00-A)
Press the midway point between drive pulley (1) and alternator
pulley (2) with a finger pressure (approximately 98.1 N {10 kg}).
When deflection (A) is 13 to 16 mm (0.5 to 0.6 in), the belt tension
is normal.

ADJUST (HM400-AKM4-27C-K-00-A)
1. Loosen cover mounting bolts (6) (2 places) to remove the
cover.
2. Loosen bolts and nuts (1), (2), and (5), and then turn nut (4)
to adjust the tension of the belt.
3. After adjusting, tighten bolts and nuts (1), (2), and (5) to fix al-
ternator (3).
4. Install the cover that was removed in step 1.
Check that the covers do not touch the rotation area of the
alternator.

REMARK
• Check each pulley for breakage and wear of the V-groove. In particular, check that the V-belt does not touch
the bottom of the 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.
• When adjusting the V-belt, do not push the alternator directly by using the bar, etc. Inset a piece of wood in be-
tween and the push it by using the bar.
• If the V-belt has been replaced with a new part, there will be initial elongation, so inspect and adjust it again
after one-hour of operation.

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MAINTENANCE MAINTENANCE PROCEDURE

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (HM400-K5A0-92C-K-

00-A)

CHECK (HM400-K5A0-285-K-00-A)
Press the midway point between air conditioner compressor pulley
(1) and drive pulley (2) with a finger pressure (approximately 58.8
N {6 kg}).
When deflection (A) is 10 mm (0.4 in), the belt tension is normal.

ADJUST (HM400-K5A0-27C-K-00-A)
1. Loosen bolt (1).
2. Press the belt at a point midway between the air conditioner
compressor pulley and drive pulley with a finger pressure of
(approximately 58.8 N {6 kg}) and turn nut (2) to adjust so that
the deflection is approximately 10 (0.4 in) mm.
3. Tighten bolt (1) and nut (2) to secure the compressor in
position.
4. Check each pulley for damage, wear of the V-groove, and
wear of the V-belt. In particular, be sure to check that the V-
belt is not touching the bottom of the V-groove.
5. If the V-belt is so lengthened that it cannot be adjusted any
more or if it has any cuts or cracks, replace it.
6. If the V-belt has been replaced with a new part, there will be
initial elongation, so adjust the belt again after operating for 2
to 3 days.

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MAINTENANCE PROCEDURE MAINTENANCE

CHECK FRAME AND A-ARM (HM400-H000-280-K-00-A)

WARNING
When performing inspection with the dump body raised, always set the dump lever to HOLD position, lock
it with the dump lever lock knob, and use the body pivot pin.

1. Wash the frame and A-arm to make it easier to check.

2. Check that there is no damage to the frame or A-arm.
In particular, check the hatched area in the figure. If any
cracks or other damage are found, perform repairs.
Contact your Komatsu distributor for details of the repair
procedure.

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MAINTENANCE MAINTENANCE PROCEDURE

CHECK FOOT BRAKE PERFORMANCE (HM400-G100-360-K-01-A)

WARNING
If the machine moves when the braking capacity is being checked, it may lead to serious personal injury. If
the machine moves, lower the engine speed immediately, return the gear shift lever to N (NEUTRAL) posi-
tion and set the parking brake switch to PARKING position.

Check the braking capacity of the foot brake as follows.

1. Select "F2" in "D RANGE F1 START SETTING（PAGE 3-

61）" of the user menu in the machine monitor.
2. Place the machine on flat ground and depress brake (1).
3. Set gear shift lever (2) to the D position, gradually raise the
engine speed. If the machine does not move even when the
engine speed reaches 1,100 rpm, it is normal.
4. Lower the engine speed, set gear shift lever to N (NEUTRAL)
position, and then apply parking brake.
If any problem is found, ask your Komatsu distributor for
repair.

NOTICE
When checking, be sure to select "F2" in "F1 Start at D Position Setting", and then set the gear shift lever
to position "D". Neglecting this can damage the inside of the transmission.

CHECK RETARDER BRAKE PERFORMANCE (HM400-GT30-360-K-01-A)

WARNING
If the machine moves when the braking capacity is being checked, it may lead to serious personal injury. If
the machine moves, lower the engine speed immediately, return the gear shift lever to the N (NEUTRAL)
position and depress the foot brake.

Check the braking capacity of the retarder brake as follows.

1. Select "F2" in "D RANGE F1 START SETTING（PAGE 3-
61）" of the user menu in the machine monitor.
2. Stop the machine on flat ground and pull retarder control lever
(1) fully.
3. Set gear shift lever (2) to the D position, gradually raise the
engine speed. If the machine does not move even when the
engine speed reaches 1,090 rpm, it is normal.
4. Lower the engine speed, set gear shift lever at N position. If
any problem is found, ask your Komatsu distributor for repair.

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.

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MAINTENANCE PROCEDURE MAINTENANCE

CHECK PARKING BRAKE PERFORMANCE (HM400-GJ00-360-K-01-A)

WARNING
If the machine moves when the braking capacity is being checked, it may lead to serious personal injury. If
the machine moves, lower the engine speed immediately, return the gear shift lever to N (NEUTRAL) posi-
tion and depress the foot brake.

Check the braking capacity of the parking brake as follows.

1. Select "F2" in "D RANGE F1 START SETTING（PAGE 3-
61）" of the user menu in the machine monitor.
2. Stop the machine on flat ground and set parking brake switch
(1) to PARKING.
3. Set gear shift lever (2) to D position, gradually raise the en-
gine speed. If the machine does not move even when the en-
gine speed reaches 1,100 rpm, it is normal.
4. Lower the engine speed, set gear shift lever (2) at N position.
If any problem is found, ask your Komatsu distributor for
repair.

NOTICE
When checking, be sure to select "F2" in "F1 Start at D Position Setting", and then set the gear shift lever
to position "D". Neglecting this can damage the inside of the transmission.

CHECK WEAR OF PARKING BRAKE PADS (HM400-GJ34-360-K-00-A)

WARNING
Never put any oil or grease on the surface of the pad or disc.

Measure the thickness of pad (1), and if thickness (A) is 1.5 mm

(0.06 in) or less, contact your Komatsu distributor.

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MAINTENANCE MAINTENANCE PROCEDURE

CHECK FUNCTION OF ACCUMULATOR (HM-G2G0-360-K-00-A)

For handling of the accumulator, see "HANDLING SUSPENSION CYLINDERS, ACCUMULATOR AND GAS
SPRINGS（PAGE 2-45）".
If the engine stops during travel, the brake can be operated with the oil pressure in the accumulator temporarily.

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MAINTENANCE PROCEDURE MAINTENANCE

CHECK FUNCTIONS (HM-PL40-360-K-01-A)

1. Stop the machine on a flat place and set the parking brake
switch to PARKING position.

2. Start the engine and run it at medium speed for 1 minute, and
then stop it.

3. Turn the starting switch to ON position and depress the brake

pedal several times. After the brake pedal is depressed sev-
eral times, 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 Komatsu 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 engine. If
the engine is kept stopped, the gas pressure in the accumulator
lowers and cannot be checked.

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MAINTENANCE MAINTENANCE PROCEDURE

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MAINTENANCE PROCEDURE MAINTENANCE

EVERY 500 HOURS MAINTENANCE (ALL-33C0-015-A-03-A)

Maintenance for every 50 and 250 hours should be performed at the same time.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER

CARTRIDGE (HM400-AB02-923-K-02-A)
WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Ac-
cordingly, wait until they have cooled down before starting the work.

• Refill capacity: 50 liters (13.2 US gal)

• Prepare a filter wrench and a container to catch the oil.
1. Remove the bolts and cover (1).
2. Place the oil container directly under the drain valve.

3. Remove drain plug (2) and install the drain hose to the back
of the hydraulic tank cover. When draining the oil, loosen
drain valve (3) slowly so that you will not get oil on yourself.
Be careful not to loosen the drain valve too far and deform the
stopper pin inside the valve.
4. Check the drained oil, and if there are excessive metal par-
ticles or foreign material, contact your Komatsu distributor.
5. Tighten drain valve (3) and drain plug (2).
Tighten both of drain plug (2) and drain valve (3) to 68.6 ± 9.8
Nm {7 ± 1 kgm, 50.6 ± 7.2 lbft}.

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MAINTENANCE MAINTENANCE PROCEDURE

6. By using a filter wrench, turn filter cartridge (4) counterclock-

wise to remove it. When doing this, to prevent get splashed
with drained oil, do not perform this operation from directly
under the cartridge. In particular, if this work is performed im-
mediately after stopping the engine, a large amount of oil will
come out, so wait for 10 minutes before starting the work.
When getting on or off the machine with carrying a filter, a
tool, etc., place it once in portion (A) to ensure your safety.
7. Clean the filter head, fill the new filter cartridge with oil, coat
the packing face and thread with oil (or coat thinly with
grease), then install the filter cartridge.
8. 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 tighten a further 3/4
to 1 turn.
9. Fill the tank with oil to the specified level from oil filler port (F).
When getting on or off the machine with carrying oil, place it
once in part (A) to ensure your safety.

10. Run the engine at low idle for a short time, then check that the oil level is at the specified level. For details,
see "CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL（PAGE 3-136）".

4-57
MAINTENANCE PROCEDURE MAINTENANCE

REPLACE FUEL PREFILTER CARTRIDGE (HM400-AEA0-923-K-01-A)

WARNING
• Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immedi-
ately. Wait until all of parts have cooled down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pres-
sure go down before replacing the filter.
• Do not bring any open flame close.

NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability. When
replacing fuel filter cartridges, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle. If any cartridge other than a Komatsu genuine fuel filter car-
tridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid us-
ing substitute parts.
• When performing the inspection or maintenance of the fuel system, pay more attention than normal to
the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
• Prepare a filter wrench and a container to catch the fuel.
When replacing the fuel main filter cartridge (every 1000 hours), replace the fuel prefilter cartridge first.

4-58
MAINTENANCE MAINTENANCE PROCEDURE

1. Place a container under the fuel prefilter cartridge to catch the

fuel.
2. Loosen drain valve (1) to drain water and sediments from
transparent cap (2), and also drain all the fuel from filter car-
tridge (3).
3. Remove the drain hose.
4. By using a filter wrench, turn filter cartridge (3) counterclock-
wise to remove it.
When getting on or off the machine with carrying a filter, a
tool, etc., place it once in part (A) to ensure your safety.
5. Make sure that drain plug (1), which is provided in the lower
part of transparent plug (2) of the new filter cartridge, is firmly
tightened.
Tightening torque: 2.5 to 3.4 Nm {0.25 to 0.35 kgm}

6. Clean the filter holder, fill the new filter cartridge with clean
fuel, apply thin film of oil to the packing surface, then install
the filter cartridge to the filter holder.
NOTICE
• When filling the filter cartridge with fuel, do not remove
center cap (B). Always fill with fuel from 8 small holes (A)
on the dirty side.
• After filling with fuel, remove center cap (B) and install
the fuel filter.
• Always fill with clean fuel. Be careful not to let any dirt or
dust get into the fuel. In particular, center portion is the
clean side, so do not remove cap (B) when filling with
fuel. Be careful not to let dirt or dust get into the center
portion on the clean side.

7. When installing, tighten it until the packing surface contacts the seal surface of the filter holder, then tighten it
further 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 specified
angle.
• When tightening with a filter wrench, be extremely careful not to dent or damage the filter cartridge.
8. Install the drain hose.
9. After replacing the filter cartridge, start the engine and run it at low idle for 10 minutes.
Check for leakage of fuel from the filter seal surface and transparent cap mounting face. If there is any leak-
age of fuel, check the tightening condition of the filter cartridge. If there is still oil leakage, repeat steps 1 to 4
to remove the filter cartridge, and if any damage or embedded foreign material on the packing surface is
found, replace it with a new cartridge and repeat steps 5 to 9 to install it.

4-59
MAINTENANCE PROCEDURE MAINTENANCE

LUBRICATE CAB MOUNT PINS (HM400-K139-242-K-00-A)

(1 place each on right and left)
1. Stop the engine.
2. By 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.
Perform the greasing work every day when operating in pla-
ces where the grease flows out easily, such as when traveling
through mud or water.

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL (HM300-DF30-212-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• If there is still pressure remaining inside the case, the oil or plug may fly out. Turn the plug slowly to
release the pressure, then remove it carefully.

1. Stop the machine so that the TOP casting mark is at the top
and drain plug (P) is at the bottom.
2. Remove plug (G) and check that the oil is near the bottom
edge of the plug hole.
3. If the oil level is too low, add oil through the plug hole until the
oil overflows.
4. Repeat the procedure in steps 1 to 3 and check the oil level
and refill oil to all the final drive cases (front, center, rear) with
oil.

CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL (HM400-DC10-212-K-01-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• If the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove
it carefully.

1. Remove plug (G) and check that the oil is near the bottom
edge of the plug hole.
2. If the oil level in the front differential case is low, add oil
through oil filler port (F).
Add oil until it overflows from the plug hole.
When getting on or off the machine with carrying oil, a tool,
etc., place it once in part (A) to ensure your safety.
3. If the oil level in the center or rear differential case is low, add
oil through the plug hole.
Add oil until it overflows from the plug hole.

4-60
MAINTENANCE MAINTENANCE PROCEDURE

Front

Center

Rear

4-61
MAINTENANCE PROCEDURE MAINTENANCE

CHECK RADIATOR FIN, AFTERCOOLER FIN, AND AIR CONDITIONER

CONDENSER FIN, CLEAN (HM400-RA16-92D-K-01-A)
WARNING
When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear
protective equipment such as protective eyeglasses and dust mask.

If the radiator fins or aftercooler fins become clogged or bent, this

will cause overheat of the engine.
Inspect fin (1). If any fins are clogged, clean the fins.
If any fins (1) are bent, ask your Komatsu distributor for repair.
• The fan reverse mode can be applied to both radiator and
aftercooler.
while engine is stopped, select fan reverse mode and start
the engine. For details, see "RADIATOR FAN REVERSE
MODE（PAGE 3-55）" and "CAC FAN REVERSE MODE
（PAGE 3-57）".
• Cleaning can be performed by using jets of air, steam, or
water, but be careful not to let the nozzle contact the fin.
• When using compressed air or steam, keep the nozzle per-
pendicularly to radiator (2), aftercooler (3), or air conditioner
condenser (4).
• Check the rubber hose, and if any cracks or brittle places are
found, replace the hose. In addition, check also for loose
hose clamps.

Steam or water may be used instead of compressed air. However, when performing powerful steam cleaning
(high-pressure machine wash) of the heat exchange equipment (radiator, aftercooler,), maintain sufficient distance
from the machine when performing the operation. If steam cleaning (high-pressure machine wash) is performed at
close range, there is a danger that the internal fins of the heat exchange equipment may be deformed, and this will
cause early clogging and breakage of the equipment.

4-62
MAINTENANCE MAINTENANCE PROCEDURE

EVERY 1000 HOURS MAINTENANCE (ALL-33D0-015-A-02-A)

Maintenance for every 50, 250 and 500 hours should be performed at the same time.

REPLACE FUEL MAIN FILTER CARTRIDGE (HM400-AED0-923-K-01-A)

WARNING
• Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immedi-
ately. Wait until all of parts have cooled down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pres-
sure go down before replacing the filter.
• Do not bring any open flame close.

NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability. When
replacing fuel filter cartridges, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle. If any cartridge other than a Komatsu genuine fuel filter car-
tridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid us-
ing substitute parts.
• When performing the inspection or maintenance of the fuel system, pay more attention than normal to
the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
• Prepare a filter wrench and a container to catch the fuel.
After replacing the fuel prefilter cartridge, replace the fuel main filter cartridge.

4-63
MAINTENANCE PROCEDURE MAINTENANCE

1. Place a container under the filter cartridge to catch the fuel.

2. By using the filter wrench, turn filter cartridge (1) counter-
clockwise to remove it.
When getting on or off the machine with carrying a filter, a
tool, etc., place it once in part (A) to ensure your safety.
3. Clean the filter head, apply thin film of oil to the packing sur-
face of the new filter cartridge, then install the filter cartridge
to the filter head.
NOTICE
Do not fill the new filter cartridge with fuel.

4. When installing, tighten until the packing surface contacts the seal surface of the filter head, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
5. After replacing filter cartridge (1), loosen air bleed plug (2).
Do not loosen the plug in the filter head of the fuel prefilter. It will become impossible to bleed the air.
6. Fill the fuel tank until fully (to FULL mark on the fuel gauge) with fuel.
7. Loosen wing bolt (4) holding lever (5) of priming pump (3).
Pump lever (5) up and down to perform priming. Continue un-
til bubbles stop coming out with the fuel from the hole for air
bleeding plug (2).
8. Tighten air bleeding plug (2) and then tighten wing bolt (4) of
priming pump (3) securely to lock lever (5).
Tightening torque of air bleeding plug: 7.8 to 9.8 Nm {0.8 to 1
kgm, 5.8 to 7.2 lbft}
Tightening torque of wing bolt: 6.9 to 12.7 Nm {0.7 to 1.3
kgm, 5.1 to 9.4 lbft}
9. After replacing the filter cartridge, start the engine and check
that there is no leakage of fuel from the filter seal surface.
If there is any leakage of fuel, check the tightening condition
of the filter cartridge. If there is still leakage of fuel, follow
steps 1 and 2 to remove the filter cartridge, then check the
packing surface for damage or foreign material. If any dam-
age or foreign material is found in the packing, replace the
cartridge with a new one, then repeat steps 3 to 9 to install
the filter cartridge.

4-64
MAINTENANCE MAINTENANCE PROCEDURE

REPLACE BREATHER ELEMENT IN FUEL TANK (HM400-AD1D-92D-K-01-A)

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Ac-
cordingly, wait until they have cooled down before starting the work.

1. Remove nut (2) of breather assembly (1) at the top surface of

the fuel tank, then remove cover (3).
When getting on or off the machine with carrying an element,
a tool, etc., place it once in portion (A) to ensure your safety.
2. Replace breather element (4) with a new one.
3. Install cover (3) and nut (2).

4-65
MAINTENANCE PROCEDURE MAINTENANCE

REPLACE TRANSMISSION OIL FILTER ELEMENT (HM300-CH12-92D-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

VALVE SIDE (HM400-CH12-92D-K-00-A)

• Prepare a filter wrench and a container to catch the oil.
1. Place a container under the filter case to catch the oil.
2. Remove drain plug (1) at the filter head, drain the oil, then
tighten the plug again.
3. By using the filter wrench, turn filter cartridge (2) counter-
clockwise to remove it.
4. Clean the filter head, apply thin film of clean oil to the seal sur-
face of the new filter cartridge, then install it.
Tightening torque: 49 to 59 Nm {4.9 to 6.1 kgm, 35.4 to 43.4
lbft}

5. Add oil. For details, see "CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL（PAGE 3-129）".

BRAKE COOLING SIDE (HM400-CH12-92D-K-01-A)

1. Remove bolts (1), then remove cover (2).
2. Place a container directly under the drain plug to catch the oil.
Remove drain plug (P), drain the oil, then tighten the plug
again.
3. Remove the element, then wash the inside of the filter case,
the strainer at the bottom of the filter case, and the parts that
were removed.
4. Install the new element, then install cover (2) with bolts (1).
5. Add oil. For details, see "CHECK OIL LEVEL IN TRANSMIS-
SION CASE, ADD OIL（PAGE 3-129）".
6. Remove the cap installed to bleeder screw (3), then insert a
vinyl hose. Prepare a container with oil in it and insert the oth-
er end of the hose approximately 50 mm (2.0 in) below the
surface of the oil. (Use a commercially available vinyl hose.)
7. Start the engine, loosen bleeder screw (3) approximately 3/4
turns, and keep the engine running at low idle until fewer bub-
bles come out from the vinyl hose.
8. Tighten bleeder screw (3) securely, then install the cap.
9. Check that the oil level in the transmission case is up to the
specified level.
10. If the oil level is low, add oil.

REMARK
When the air is bled from inside the case, the transmission oil level becomes stable.

4-66
MAINTENANCE MAINTENANCE PROCEDURE

CHANGE OIL IN TRANSMISSION CASE (HM300-CF10-292-K-00-A)

CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER
ELEMENT (HM400-G240-292-K-00-A)
WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pressure,
then remove it with care.

• Refill capacity: 125 liters (33.03 US gal) (including transmission case, brake oil tank, and filter cases.)
Perform the following items at the same time in order to drain oil completely.
• REPLACE TRANSMISSION OIL FILTER ELEMENT（PAGE 4-66）
• CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT（PAGE 4-67）
• Prepare a filter wrench and a container to catch the oil.
1. Depress the brake pedal at least 20 times to reduce the pressure inside the brake control accumulator to 0.
2. Place a container directly under drain plug (P) to catch the oil.
3. Remove drain plug (P), drain the oil, then tighten the plug
again.

4-67
MAINTENANCE PROCEDURE MAINTENANCE

4. Place a container directly under filter case (1) to catch the oil,
then remove filter case (1).

5. Take out the element and wash the inside of the filter case.
Replace O-ring (2) and backup ring (3) on the filter case with
new parts, apply thin film of clean oil to them, then install them
to filter case.
6. Assemble a new element in the filter case, apply thin film of
clean oil to the O-ring of the element, then install to the
machine.
Tightening torque: 78.4 to 98 Nm {8 to 10 kgm, 57.9 to 72.3
lbft}

7. Before starting the engine, add 90 liters (23.78 US gal) of oil

through oil filler port (F).
When oil is added, the level will temporarily exceed the oil lev-
el on sight gauge (G2), but this does not indicate any
abnormality.
8. Start the engine and run it at low idle.
NOTICE
Do not start the engine before filling with oil. If the engine is
started when there is no oil in the system, it will cause dam-
age to the transmission and hydraulic pump.

9. Add oil through oil filler port (F) until the oil level is between the H and L marks on sight gauge (G2).
The amount of oil to add is more or less 35 liters (9.25 US gal). Add oil so that the oil level is between H and L
of sight gauge (G2).
When running the engine at idle, be careful not to let the oil level in the brake oil tank go below sight gauge
(G1). If the oil level goes below sight gauge (G1), stop the engine to raise the oil level in the brake oil tank.

4-68
MAINTENANCE MAINTENANCE PROCEDURE

10. Remove the cap from bleeder screw (1) and insert a vinyl
hose.
(Use a commercially available vinyl hose.)
11. Prepare a container with oil in it, put the other end of the vinyl
hose approximately 50 mm (2 in) into oil.
12. Loosen bleeder screw (1) approximately 3/4 turns and run the
engine at low idle until fewer bubbles come out from the vinyl
hose.
13. When fewer bubbles come out, tighten bleeder screw (1) se-
curely, remove the vinyl hose, then install the cap.

14. Perform the warm-up operation of the engine until the torque converter oil temperature gauge goes above 40°
C (104°F).
15. When the torque converter oil temperature gauge rises to 40°C (104°F), bleed the air from the brakes.
Front brake: See "BLEEDING AIR OF FRONT BRAKE（PAGE 4-31）".
Center brake: See "BLEEDING AIR OF CENTER BRAKE（PAGE 4-32）".
NOTICE
• Do not re-use the oil drained when bleeding the air. It will cause damage to the equipment.
• Be careful not to let the oil level in the brake oil tank go below sight gauge (H) during the air bleed
work. This will cause damage to the pump.
16. After completely bleeding the air from the brakes, stop the engine for approximately 2 to 3 minutes. After that,
check the oil level in the transmission case and add oil to bring it to the specified level. For details, see
"CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL（PAGE 3-129）".

4-69
MAINTENANCE PROCEDURE MAINTENANCE

REPLACE HYDRAULIC OIL FILTER ELEMENT (HM400-PM35-923-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pressure,
then remove it with care.

1. Remove bolts (1), then remove cover (2).

2. Turn the cap of oil filler (F) slowly to release the internal pres-
sure, then remove the cap.
3. Remove bolts (3), then remove cover (4).
4. Take out the element, then wash the inside of the case and
the removed parts.
5. Install the new element, then install cover (4) with bolts (3).
6. Install cover (2) with bolts (1).

4-70
MAINTENANCE MAINTENANCE PROCEDURE

LUBRICATE (HM400-H340-242-K-00-A)
1. By using a grease pump, pump in grease through grease fittings marked by arrows.
2. After greasing, wipe off any old grease that was pushed out.
Perform the greasing work every day when operating in places where the grease flows out easily, such as when
traveling through mud or water.

(1) Transmission front mount (1 place)

(2) Transmission rear mount (1 place)

(3) Center hinge pin (2 places)

4-71
MAINTENANCE PROCEDURE MAINTENANCE

LUBRICATE PARKING BRAKE (HM400-GJ00-242-K-01-A)

WARNING
• When performing maintenance, raise the brake oil pressure sufficiently to prevent the parking brake
from being automatically applied. In addition, hang a warning tag that can be seen clearly to prevent
any other person from operating the parking brake switch.
• Do not get any oil or grease on the brake disc or pad surface.

1. Stop the machine in a flat place and put the blocks under the tires to prevent the machine from moving.
2. Raise the dump body and secure it in position with the body pivot pin.
3. Before starting operations, raise the brake oil pressure sufficiently to prevent the parking brake from being au-
tomatically applied, and check that the brake pressure caution lamp is not lit.
4. Release the parking brake and stop the engine.
5. By using a grease pump, pump in grease through fittings (1)
and (2) (2 places) in the parking brake body and fitting (3) (1
place) in the slack adjuster.
NOTICE
Do not use air pressure or oil pressure to perform high-pres-
sure greasing.
6. After completing the greasing operation, remove fitting (1).
If grease comes out, wipe off all the grease that comes out.
REMARK
Removing fitting (1) makes it possible to release the abnormal in-
ternal pressure created by excessive greasing.
7. If no grease comes out, install fitting (1).

8. Check the parking brake performance. For detail, see "CHECK PARKING BRAKE PERFORMANCE（PAGE
4-52）".
9. If machine moves after performance check, adjust the parking brake. For details, see "ADJUST PARKING
BRAKE（PAGE 4-37）".

4-72
MAINTENANCE MAINTENANCE PROCEDURE

0(7+2')25&+(&.,1*%5$.(',6&:($5$02817
WARNING
• Do
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5. Push the brake pedal, keep it pushed, and push in shaft (3)
of the gauge until it contacts the piston (4). 6
6. If the position “C” of shaft (3) goes into the end face of guide
(5), it means that the disc has reached the wear limit.
If the disc has reached the wear limit, consult your Komatsu
distributor for inspection and maintenance.
7. Install the cap nut (2) which is removed in the step 4.
Tightening torque: 29.4 to 39.2 Nm {3.0 to 4.0 kgm, 21.7 to
28.9 lbft}
-'
8. Install the cover (1) which is removed in the step 3.
Tightening torque: 59 to 74 Nm {6.0 to 7.5 kgm, 43.4 to 54.2
lbft}

-'

REMARK
• 2QDQHZPDFKLQHWKHHQGIDFHVRIJXLGH  DUHDGMXVWHGWROHWWKHJURRYHXQGHUOLQHV % DQG $ RIVKDIW
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4-73
MAINTENANCE PROCEDURE MAINTENANCE

CHECKFORLOOSENESSOFENGINEINTAKEPIPECLAMP
:KHQJHWWLQJRQRURIIWKHPDFKLQHZLWKFDUU\LQJDWRROHWFSODFH
LWRQFHLQSRUWLRQ $ WRHQVXUH\RXUVDIHW\

1. Install the personal fall-arrest equipment to the anchor point

for tie-off (1).
The anchor point for tie-off (1) is on the left side of the cab.

2. Check for looseness in the air intake piping clamps between the air cleaner, turbocharger, aftercooler, and
engine.
Tigthen any loose clamps.
Tigthening torque of clamp (2): 8.3 to 9.3 Nm {0.85 to 0.95 kgfm, 6.2 to 6.9 lbft}
Tigthening torque of clamp (3): 10.0 to 11.0 Nm {1.02 to 1.12 kgfm, 7.4 to 8.1 lbft}

4-74
MAINTENANCE MAINTENANCE PROCEDURE

DO NOT APPLY LUBRICANT ON EXHAUST PIPE SPHERICAL SURFACE JOINT

PORTION (HM400-M56B-242-K-00-A)
CAUTION
Immediately after the engine is stopped, the parts around the exhaust pipe are still very hot, and may
cause burn injury. Accordingly, wait until they have cooled down before starting the work.

Apply lubricant to the spherical sliding portion of the exhaust pipe of the dump body heating unit (if equipped).
1. There are 2 spherical sliding portions, (1) and (2). Apply lubri-
cant to both of them.

2. Clean hatched area (3) thoroughly and apply dry film lubricant
until the base surface is not seen any more.
Lubricant: 56B-98-21370 (spray)
3. Dry for 1 hour.
4. When tightening 6 bolts (4), apply seizure prevention and rust
prevention lubricant to the underhead of the bolts.
5. Slide the spherical portions to spread the lubricant
thoroughly.

4-75
MAINTENANCE PROCEDURE MAINTENANCE

EVERY 2000 HOURS MAINTENANCE (ALL-33E0-015-A-02-A)

Maintenance for every 50, 250, 500 and 1000 hours should be performed at the same time.

REPLACE BREATHER ELEMENT IN HYDRAULIC TANK (HM400-PM39-923-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.

1. Remove nut (2) of breather assembly (1) at the top of the hy-
draulic tank, then remove cover (3).
2. Replace breather element (4) with a new one.
3. Install cover (3) and nut (2).

4-76
MAINTENANCE MAINTENANCE PROCEDURE

CHANGE OIL IN FINAL DRIVE CASE (HM400-DF30-292-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• If there is remaining pressure inside the case, the oil or plug may jump out. Turn the plug slowly to re-
lease the pressure, then remove it carefully.

• Refill capacity
Rear right, left 5.5 liters (1.45 US gal) each
Center right, left 4.5 liters (1.19 US gal) each
Rear right, left 5.5 liters (1.45 US gal) each
1. Stop the machine so that the "TOP" casting mark is at the top
and drain plug (P) is at the bottom.
2. Remove drain plug (P), drain the oil, then tighten the plug
again.
3. Refill with oil through the hole for plug (G) to the specified
level.
4. Check that the oil is at the specified level. For details, see
"CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
（PAGE 4-60）".
5. Repeat the procedure in steps 1 to 4 and change the oil to all
the final drive cases (front, center, rear).

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MAINTENANCE PROCEDURE MAINTENANCE

CHANGE OIL IN DIFFERENTIAL CASE (HM400-DC70-292-K-01-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• If there is remaining pressure inside the case, the oil or plug may jump out. Turn the plug slowly to re-
lease the pressure, then remove it carefully.

• Refill capacity
Front 26.0 liters (6.87 US gal)
Center 43.0 liters (11.36 US gal)
Rear 39.0 liters (10.30 US gal)
When getting on or off the machine with carrying oil, a tool, etc.,
place it once in portion (A) to ensure your safety.

1. Remove drain plug (P), drain the oil, then tighten the plug again.
2. Refill with oil to the specified level through the hole for plug (G) or oil filler port (F).
3. After refilling, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN DIFFEREN-
TIAL CASE, ADD OIL（PAGE 4-60）".
4. Repeat the procedure in steps 1 to 3 and change the oil to all the differential cases (front, center, rear).
Front

4-78
MAINTENANCE MAINTENANCE PROCEDURE

Center

Rear

4-79
MAINTENANCE PROCEDURE MAINTENANCE

CLEAN TRANSMISSION CASE STRAINER (HM400-CH31-255-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pressure,
then remove it with care.

Drain the oil from the transmission case before starting the work. For details, see Section "CHANGE OIL IN
TRANSMISSION CASE（PAGE 4-67）".

1. Place a container immediately under drain plug (P) to catch

the oil.
Remove drain plug (P) to drain the oil.
2. Remove bolt (1), then remove cover (2) and take out the
strainer.
3. Remove any dirt stuck to the strainer, then wash it in clean
diesel oil or flushing oil. If the strainer is damaged, replace it.
4. Install the drain plug and strainers in their original positions.

4-80
MAINTENANCE MAINTENANCE PROCEDURE

CLEAN BREATHER (HM400-RA1L-255-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When using compressed air, there is a danger of dirt flying and causing personal injury.
Always wear protective equipment such as protective eyeglasses and dust mask.

Remove any mud or dirt from around the breather, then remove the breather and use clean diesel fuel or flushing
oil to flush out the dirt inside.

When getting on or off the machine with carrying a breather, a tool,

etc., place it once in portion (A) to ensure your safety.

CHECK ACCUMULATOR GAS PRESSURE (HM-G2G0-280-K-01-A)

Ask your Komatsu distributor to check the gas pressure when making periodical replacement of safety parts at
every 2000 hours or every year.

CHECK ENGINE VALVE CLEARANCE, ADJUST (ALL-A700-27D-K-00-A)

Special tools are needed for inspection and maintenance. Ask your Komatsu distributor.

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MAINTENANCE PROCEDURE MAINTENANCE

EVERY 4000 HOURS MAINTENANCE (ALL-33F0-015-A-05-A)

Every 50, 250, 500, 1000 and 2000 hours maintenance should be performed at the same time.

CHANGE OIL IN HYDRAULIC TANK (HM400-PM30-292-K-00-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pressure,
then remove it with care.

• Refill capacity: 167 liters (44.12 US gal)

1. Lower the dump body and stop the engine.
2. Turn the cap of oil filler port (F) to release the internal pres-
sure before removing the cap.
3. Remove hydraulic oil tank cover (1) to take oil drain hose (2)
out from inside.
4. Remove drain plug (P) to install oil drain hose (2).
5. Drain oil with care not to get splashed with oil. After draining
the oil, install drain plug (P), oil drain hose (2) and hydraulic
oil tank cover (1) in their original positions.
6. Fill the tank with oil to the specified level from oil filler port (F).
7. Check that the hydraulic oil is at the specified level. For de-
tails, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD
OIL（PAGE 3-134）".

CHECK ALTERNATOR AND STARTING MOTOR (HM400-AK50-360-K-00-A)

The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspec-
tion and repairs.
If the engine is started frequently, have this inspection performed every 1000 hours.

CHECK WATER PUMP (HM-BA10-280-K-00-A)

Check around the water pump for water leakage. If any part is leaking, ask your Komatsu distributor for inspection
and repair.

CHECK AIR CONDITIONER COMPRESSOR (HM400-K590-280-K-00-A)

Ask your Komatsu distributor to perform this work.

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MAINTENANCE MAINTENANCE PROCEDURE

CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF

RUBBER (HM400-AEF2-287-K-01-A)

Check clamps (1) to (18) visually and with your fingers that there are no loose bolts or hardening of the rubber. If
there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement.

CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF

RUBBER (HM400-AEFU-288-K-01-A)

Check fuel spray prevention caps (1) to (12) to see if any of them has slipped off, or the rubber part is hardened. If
there are any missing caps or cover or the rubber is hardened, ask your Komatsu distributor for installation or
replacement.

4-83
MAINTENANCE PROCEDURE MAINTENANCE

CHECK EXHAUST PIPE FIRE PREVENTION COVER (HM400-A9D7-280-K-01-A)

WARNING
Immediately after the engine is stopped, all the parts are still very hot, and may cause burn injury. Accord-
ingly, wait until they have cooled down before starting the work.

Exhaust pipe fire prevention cover (1) may suffer material deterio-
ration or damage depending on the conditions of use and the op-
erating environment of the machine.
Open the engine hood and check exhaust pipe fire prevention
cover (1). If any deterioration or damage to the material is found,
ask your Komatsu distributor to replace it.

REPLACE COOLANT FILTER CARTRIDGE

WARNING
Immediately after the engine is stopped, the cooling system is very hot and can cause burn injury. Wait for the temperature to go
down, and then start the work.

Replace the coolant filter in 4000 hours or 2 years whichever comes first. (Replace this at the same time as the
coolant change)
1. Close the valve (1) on the upper part of the coolant filter.
2. By using the filter wrench, turn the cartridge (2)
counterclockwise to remove it.
3. Coat the seal surface of the new filter cartridge with engine oil,
then install it.
When installing it, tighten it until the packing surface contacts
the seal surface of the filter head, then tighten it approximately
2/3 of a turn.
Komatsu recommends using Komatsu genuine cartridge.
4. Open valve (1).
5. Start the engine.
Make sure that no water leaks from the seal surface.
6. Stop the engine.

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MAINTENANCE MAINTENANCE PROCEDURE

EVERY 6000 HOURS MAINTENANCE (ALL-33P0-015-A-01-A)

Every 50, 250, 500, 1000 and 2000 hours maintenance should be performed at the same time.

LUBRICATE DRIVE SHAFT (HM400-D510-242-K-00-A)

When greasing, use lithium grease (G2-LI), and perform the
greasing every 6000 hours or every 2 years.
When getting on or off the machine with carrying grease, a tool
etc., place it once in portion (A) to ensure your safety.

1. By using a grease pump, pump in grease through the grease

fittings marked by the arrows.
2. Grease the spider portion until grease comes out from the
cap seal.
3. After greasing, wipe off any old grease that was pushed out.

4-85
MAINTENANCE PROCEDURE MAINTENANCE

LUBRICATE FRONT DRIVE SHAFT (HM300-D510-242-K-01-A)

WARNING
When checking the positions of the grease holes and grease fittings, ensure that the machine is stopped.
It is very dangerous to check the positions of the grease holes and grease fittings while the machine is
running.

Check that grease hole (1) of the A-arm (at the rear of the machine) is matched with grease fitting (2) of the spider.
If grease hole (1) is not matched with grease fitting (2) of the spider, match them according to the following
procedure.

1. Move the machine backward and forward.

Do not go under the machine at this time.
2. Stop the engine and chock the wheels to secure the machine.
3. Check that grease hole (1) is matched with grease fitting (2).
4. If grease hole (1) is not matched with grease fitting (2), match
them by repeating steps 1 and 2.

4-86
MAINTENANCE MAINTENANCE PROCEDURE

EVERY 8000 HOURS MAINTENANCE (ALL-33H0-015-A-01-A)

Perform the periodic maintenance work at every 50, 250, 500, 1000, 2000 and 4000 hours of operation at the
same time.

REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS (HM-AEF2-923-K-00-A)

Ask your Komatsu distributor to replaced the engine high-pressure clamps.

REPLACE FUEL SPRAY PREVENTION CAP ON ENGINE (HM-AEFU-923-K-00-A)

Ask your Komatsu distributor to replace of the fuel spray prevention cap.

OVERHAUL STARTING MOTOR AND ALTERNATOR (HM-AK70-663-K-00-A)

Ask your Komatsu distributor to perform this work.

4-87
MAINTENANCE PROCEDURE MAINTENANCE

4-88
5 SPECIFICATIONS

SPECIFICATIONS

5-1
SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS (HM400-2110-930-A-02-A)

Item Unit HM400-3R

Overall weight (unloaded weight + max. payload + 1 opera-
kg (lb) 74,000 (163,170)
tor (75 kg (165 lb)))
Unloaded weight kg (lb) 33,925 (74,805)
Max. payload kg (lb) 40,000 (88,200)

Struck m3 ([Link]) 18.2 (23.8)

Dump body capacity

Heaped (2 : 1) m3 ([Link]) 24.0 (31.4)

Dumping speed (at 1,800 rpm) (raised) sec 12.0
Komatsu SAA6D140E-5 die-
Engine model －
sel engine
Engine rated horsepower
• SAE J1995 (gross) 338 {453} /2,000 {2,000}
kW {HP} /min-1
• ISO 14396 338 {453} /2,000 {2,000}
{rpm}
• ISO 9249 / SAE J1349 (net) 334 {448} /2,000 {2,000}
Engine max. torque Nm {kgm, lbft} /rpm 2,089 {213, 1,530.4} /1,400
A Overall length mm (ft in) 11,105 (36' 5")
B Overall height mm (ft in) 3,735 (12' 3")
C Overall height when dumping mm (ft in) 7,171 (23' 6")
D Overall width mm (ft in) 3,450 (11' 4")
E Min. ground clearance (bottom of rear axle) mm (ft in) 615 (2' 0")
Min. turning radius mm (ft in) 8,800 (28' 10")
1st km/h (MPH) 6.6 (4.1)
2nd km/h (MPH) 10.1 (6.3)
3rd km/h (MPH) 15.5 (9.6)
Forward
4th km/h (MPH) 23.8 (14.8)
Travel speed
5th km/h (MPH) 36.5 (22.7)
6th km/h (MPH) 56.0 (34.8)
1st km/h (MPH) 6.8 (4.2)
Reverse
2nd km/h (MPH) 16.0 (9.9)
Operating temperature range ºC (ºF) -20 to 40 (-4 to 104)

5-2
6 ATTACHMENTS AND OPTIONS

ATTACHMENTS AND
OPTIONS

6-1
CAB POWER TILT ATTACHMENTS AND OPTIONS

CAB POWER TILT (HM400-K261-100-K-00-A)

WARNING
To prevent serious injury or death if the cab comes down, always observe the following strictly when tilting
the cab.
Precautions before starting cab-tilting operation
• Perform the cab-tilting operation on a flat place.
• When operating the cab tilt, to prevent contact between the cab and dump body, set the machine fac-
ing directly to the front and secure the front and rear frames with the articulation lock.
• Set the parking brake switch to PARKING position to apply the parking brake.
• Lock the dump control lever with the dump lever lock knob.
• Chock the wheels to prevent the machine from moving.
• Always remove the pin from rear mounting position and insert it in the position for tilting, before re-
moving the cab mount.
• Do not perform the cab tilt operation in the strong wind.
Precautions for cab-tilting operation
• Do not perform the cab-tilting operation when the dump body is loaded.
• Do not stand under the cab during the cab-tilting operation.
• When the cab is tilted up, lock it securely in position with the lock bar.
• When installing the lock bar, do not enter under the cab but install it from the side of the cab.
• While the cab is tilted up, do not get on or off it.
• While the cab is tilted up, do not operate the gear shift lever or dump lever.
• While the cab is tilted up, do not start the engine . If it is necessary to start the engine when performing
inspection, check first that there is no one under the cab.
• While the cab is tilted up, do not give a large impact to the machine.
• When using the cab power tilt function to lower the cab, do not open the valve quickly but open it grad-
ually while adjusting the lowering speed.
• The lock bar is set on the left inside of the engine hood. After using it, be sure to return it.

1. Remove lock bolt (2) from guard (1) at the rear of the cab,
then lock guard (1) in position with rod (3).

When getting on or off the machine with carrying a tool etc., place
it once in part (A) to ensure your safety.

6-2
ATTACHMENTS AND OPTIONS CAB POWER TILT

2. Remove pin (4) in the mount at the rear of the cab, and insert
pin (5) instead. (each of right and left)
A: For traveling
B: For tilting

3. Remove cab mounting bolts (6) (8 pieces).

4. Open the cover of the cab power tilt unit on the left fender,
and turn valve (7) clockwise fully to close it.
5. Set switch (8) to ON position to raise the cab.

6. After tilting up the cab, fix it in position with lock bar (9).

7. Make sure that lock bar (9) is installed in the correct direction
and lock it securely with lock (10).
8. When lowering the cab, open valve (7) gradually by turning it
counterclockwise. The cab lowers slowly.
9. After returning the cab to its original position, remove pin (5)
and insert pin (4) instead. Install mounting bolts (6) (8
pieces).

6-3
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

HANDLING PAYLOAD METER (HM-M710-001-K-00-A)

OUTLINE OF SYSTEM (HM400-M710-043-K-00-A)

The payload meter detects the signals including the pressure sensor, clinometer, body float detection, neutral de-
tection, and travel speed detection, and uses the microcomputer built-in controller to calculate the payload. The
meter also displays the calculated payload on the liquid crystal unit of the machine monitor. In addition, it displays
the loading state by the external display lamp.
The data recorded by the payload meter can be downloaded to a personal computer by using the special software
(separated option).
For measurement, statistics of the signals such as a pressure sensor are processed during loaded travel.
Road surface roughness, sudden acceleration, and sudden braking deteriorates the accuracy. To use the meter
accurately, maintain the road surface and accelerate/ deaccelerate smoothly with care.
Payload display
Loaded weight is displayed in the standard screen on the machine
monitor as shown in the figure on the right.

External display lamp

External display lamps are located on the cab. There are 2 exter-
nal display lamps so that the worker of digging and operator of
wheel loader can see the lamps. Each of these 2 lamps consists
of 3 lamps ((1): Green, (2): Yellow, (3): Red). Depending on the
loaded weight, indication of the external display lamp changes.

Download connector
The communication cable connection port is next to the engine
shutdown secondary switch. When not using the communication
cable connection port, fit the connector cap. Through this connec-
tor for download, stored data in payload meter can be downloaded
to a personal computer.

6-4
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

DISPLAY DURING NORMAL OPERATION (HM400-M710-043-K-01-A)

Normal operation display has 2 methods; Machine monitor display which informs machine condition, and External
display lamp. Machine condition has 4 states; Empty, In loading, Loaded, In dumping. Machine monitor display
and indication of external display lamp differs for each state, and it also differs depending on whether machine is
stopped or traveling.

Machine condition Machine monitor display External display lamp

When starting switch in ON － ON for 30 seconds
Stopping the machine (*1) Clock display OFF
When unloaded
Traveling Clock display OFF
Stopping the machine Payload display (*2) Payload display
During loading
Traveling Clock display OFF
Stopping the machine Payload display Payload display
When loaded
Traveling Clock display OFF
Stopping the machine Payload display Payload display
When dumping
Traveling Payload display OFF

(*1) Stopping the machine is the case where the gear shift lever is in N (NEUTRAL) position or the travel speed
signal is zero.
(*2) To change the conditions from unloaded machine to loading, the load must be approximately 15% or more of
the rated payload and the variation of the payload during the machine stop must be stabilized.
Example of payload display

Example of payload display when an error occurs

Since the payload cannot be calculated if an error of the suspension pressure sensor or clinometer sensor occurs,
"- - - - -" is displayed.
The payload (right after loading) at the loading site may differ from the displayed value at the dumping site. This dif-
ference is caused by the frictional force of the suspension and cannot be resolved. If the display value slightly
varies depending on the measuring site, this variation is not caused by the malfunction of the payload meter.

6-5
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

EXTERNAL DISPLAY LAMP (HM400-M713-043-K-00-A)

• The external lamps display the payload as follows.

Color of lamp HM400

1 Green 20.0 tons and up

2 Yellow 36.0 tons and up

3 Red 42.0 tons and up

Prediction display
• When the load changes in steps for each bucket loaded, the system estimates the total payload if one more
bucket is loaded, and flashes the appropriate lamp to prevent overloading.
• The predicted load display and actual payload display are shown at the same time.
Expected number of 4 bucket loads

1st 9.5 tons

bucket
2nd 9.5 tons (total: 19 tons)
bucket
3rd 9.5 tons (total: 28.5 tons)
bucket
4th 9.5 tons (total: 38 tons)
bucket

When the machine is loaded in this way, the external display lamps light up as shown in the chart below.

6-6
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER (HM400-M710-043-K-02-

A)
• The payload meter records data between dumping and the next dumping as 1 cycle.
• Cycle data items

Day/Month of dumping Unloaded travel hours Stop hours for loading Loaded stop hours
Dumping time Unloaded travel hours Loaded travel hours Dumping hours
Machine ID Unloaded travel speed Loaded travel distance Travel speed limit
(Max.)
Open ID Unloaded travel speed Loaded travel speed Warning items for each
(Ave.) (Max.) cycle
Payload Unloaded stop hours Loaded travel speed
(Ave.)

• The maximum limit for saving cycle data is 2,900 cycles. If exceeding 2,900 cycles, the newest data are writ-
ten over the oldest.
• Download the recorded data through RS232C port to a personal computer with the special software (sepa-
rated option) installed.
Save the downloaded data as a text file (CSV format) to the specified location of the computer. For details,
see the instruction manual provided with the special software.
To check the downloaded data, it can be imported by the text file reading function of the commercially-avail-
able spreadsheet software.

6-7
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

PROCEDURE WHEN DOWNLOADING (HM400-M710-100-K-01-A)

CAUTION
• When handling the cables, be careful not to damage them or pull them by force.
• Do not leave the connectors disconnected.
• Take steps to prevent dirt from entering the connector part.
• Do not let any metal objects touch the connector part.

Download the recorded data to a personal computer which has the separately sold special software installed.
Downloading from download connector
1. Remove cap (1) and connect the download cable supplied
with the special software. Connect the other end of the cable
to the RS232C port of the personal computer.
2. Turn the starting switch to ON position.

3. Start up the personal computer and use the special software to download the data.
The download software of the card-type payload meter for HM400 can be used directly as the special
software.
4. After completion of download, be sure to restore the cable.

6-8
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

Download software
For details of installing the software, see the instruction manual provided with the download software.
1. When the installation is completed, the icon shown in the dia-
gram on the right is created.

2. Double click the icon. The download software is started and

the screen shown in the diagram on the right is displayed.
After that, screen "G1000" is displayed, so click "PLM".
"CARD" and "PMC" are not used, so do not click them.

3. Click "Parameter Setting" on screen "G2200".

"PLM Remote Control" is not used, so do not click them.

4. Click "Unit Setting" on screen "G2200". Screen "G2210" is

displayed.
"User's Comment" is not used, so do not click them.

6-9
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

5. With screen "G2210", it is possible to select the communica-

tions port (com1, com2), specify the destination for saving the
download data, specify the file name, and select the unit to
use for the data. For details, see the instruction manual pro-
vided with the download software.
The files to be handled in HM400 are Summary and Cycle on-
ly. Check "Summary Data File" and "Cycle Data File" of "File".
Once a setting has been made, there is no need to set it
again when performing next download.
Click "ENTER" to return to screen "G2200".
6. On screen "G2200", click "BACK" to return to screen
"G2000".
7. Click "Download" on screen "G2200". Screen "G2100" is dis-
played, so click "START" to download.
After completing the download operation, close the screen.
REMARK
The "G2101 < Down load - File ID" screen appears depending on
the software version. Input the file ID, then click "OK" to start the
download operation.

6-10
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

DISPLAY TOTAL PAYLOAD / NUMBER OF CYCLES (HM400-M710-110-K-01-A)

"Total payload/ number of cycles" that added every time the load is dumped can be displayed.
Furthermore, it is possible to clear this figure and return the total to 0 at any time.

1. Press the menu switch on the standard screen to display

"Machine Setting / Information" and select "Payload Meter".

2. Select "Total payload/ number of cycles".

3. "Total payload/ number of cycles" is displayed as shown in

the right figure.
• Start date indicates the time when the last "Total payload/
number of cycles" data was reset.
• Finish date indicates the last time of dumping.
• "Total payload/ number of cycles" indicates the accumulated
value from the last reset.
• The display range is 0 to 99999999.9 t. If reaching the upper
limit with 0 to 999999 (cycle), the value is kept at the upper
limit until the data is reset.

4. Press the enter switch. The pop up window to reset data

appears.
When the return switch is pressed, the display returns to the
payload meter menu.
5. When the pop up window as shown in the right figure ap-
pears, press the enter switch. "Total payload/ number of
cycles" will be reset and the pop up window is closed.
When pressing the return switch, the pop up window is closed
without resetting.

6-11
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

DISPLAY LOAD AND FUEL EFFICIENCY RECORD (HM400-M710-110-K-02-A)

The daily average value of the load and fuel efficiency (ton/liters) for the last 1 week can be displayed.
Furthermore, it is possible to clear this figure and return the total to 0 at any time.

1. Press the menu switch on the standard screen to display

"Machine Setting / Information" and select "Payload Meter".

2. Select "Load and fuel efficiency record".

3. The daily average value of the load and fuel efficiency for the
last 1 week can be displayed as shown in the right figure.
4. Press the enter switch. The pop up window to reset data
appears.
When the return switch is pressed, the display returns to the
payload meter menu.

5. When the pop up window as shown in the right figure ap-

pears, press the enter switch. "Load and fuel efficiency re-
cord" will be reset and the pop up window is closed.
When pressing the return switch, the pop up window is closed
without resetting.

6-12
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

SETTING MACHINE ID AND OPEN ID (HM400-M710-110-K-00-A)

The settings of "Machine ID" and "Open ID" in the cycle data items can be changed. By setting the machine num-
ber to "Machine ID" and setting the value determined by the customer in advance when changing the operator and
load type to "Open ID", these IDs can be used in order to check the operator and load of the related cycle later.

1. Press the menu switch on the standard screen to display

"Machine setting / Information" and select "Payload Meter".

2. Select "Machine ID".

The preset ID is displayed on the right side.

3. When the pop up window opens, "Machine ID" set at this time
appears. Enter "Machine ID".
• Available range for setting is between 0 and 200
• An ID is added every time pressing E switch.
• The ID is added at high speed by keeping E switch pressed.
• The ID returns to 0 by pressing E switch when ID200 is
displayed.
• An ID is reduced every time pressing R switch.
• The ID is reduced at high speed by keeping R switch
pressed.
• 200 is displayed by pressing R switch when 0 is displayed.
4. After entering "Machine ID", press the enter switch. The value at this time is set as ID. The window is closed.
When pressing the return switch, the window is closed without changing ID value.

6-13
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

5. When setting "Open ID", select "Open ID" in step 2.

The preset ID is displayed on the right side.

6. The setting procedure of "Open ID" is the same as that of

"Machine ID". "Set Open ID".

6-14
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

PERFORMING CALIBRATION (HM400-M710-100-K-00-A)

Perform calibration in the following cases.
• When a machine or payload meter is delivered
• Once for every month
• When the suspension cylinder gas pressure and oil has been adjusted (When the suspension has been
adjusted)
• When the suspension pressure sensor has been replaced
• When the machine has been modified and the unloaded weight of the machine has changed more than 981 N
{100 kg}.
Performing calibration
1. Perform the checks with the machine unloaded. Be sure to completely remove all the soil remaining inside the
dump body.
2. Perform the running in operation.
3. Place gear shift lever to N (NEUTRAL) position and stop the machine with the engine running.
4. Prepare for the calibration according to the following procedures.
1) Press the menu switch on the standard screen to display
"Machine Setting / Information" and select the "Payload
Meter".

2) Select "Calibration".

3) Press the enter switch and select "Yes".

6-15
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS

5. When the display as shown in the right figure appears, travel

the machine at 10 km/h (6.2 MPH).
REMARK
When canceling at this time, press the return switch while the right
figure is displayed.

6. Travel the machine at travel speed 10 km/h (6.2 MPH) contin-

uously, and then the calibration is end when the display as
shown in the right figure appears after approximately 30
seconds.

NOTICE
• Perform calibration on the level ground.
• During calibration, travel the machine straight (distance: approximately 100 m (328 ft)). During travel,
keep the travel speed at approximately 10 km/h (6.2 MPH).
• Do not perform calibration when an error occurs.
• Perform calibration with the body seated and with the damp lever set to FLOAT position. When the
body pilot lamp goes out, the body is seated.

6-16
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER

PAYLOAD OF CYCLE DATA (HM400-M710-100-K-02-A)

• The payload is recorded data and the hauling payload in the related cycle.
• To determine the hauling payload, process the statistics of data sampled during travel from loading site to
dumping site, determine the operation payload when dumping, and record it.
The payload displayed in the machine monitor is the value before the above statistical process. This value
may be more inaccurate than the payload in the recorded data.
Use the value displayed in the machine monitor as a guide.

SERVICE FUNCTION (HM400-M710-04C-K-00-A)

The following functions are available. However, change in the setting is not required in normal use. If the setting is
necessary, consult your Komatsu distributor.
• Setting of travel distance to recognize completion of loading
The payload meter recognizes the completion of loading by continuously traveling 160 m from the loading site.
Dumping before reaching 160 m is not recognized as dumping. The cycle data is not completed at this time.
This setting is used to change the distance to recognize the completion of loading, such as when the loading
site is close to the dumping site.

THE OTHER INFORMATION (HM400-M710-043-K-03-A)

• If the date and time in the download data must be corrected, consult your Komatsu distributor.
• If the payload and external indicator lamp display is different, or 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.
In such case, consult your Komatsu distributor.
• Serial communication (RS232C) is used for data download.
For computers without an RS232C port, it may be possible to use a third party USB-RS232 conversion adapt-
er. (Product operation checked, manufactured by I O DATA, USB-RSAQ2)
However, this does not guarantee the operation. The download software supports COM1 and COM2, so
check which port it can be connected to.

6-17
HANDLING CENTRALIZED BREATHERS ATTACHMENTS AND OPTIONS

HANDLING CENTRALIZED BREATHERS (HM400-RA1L-100-K-00-A)

This item describes only parts related to centralized breathers which is different from standard specification. Items
other than this item, see the title applicable to the item. In centralized breathers, position of breather is different. Al-
so, air cleaners are added at 2 places. The breather is centralized type and they are located each on front and rear.
Air cleaner removes sand, dust, and etc., in the box.

EVERY 250 HOURS MAINTENANCE (ALL-33B0-015-A-00-A)

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

CLEAN BREATHER (HM400-RA1L-255-K-04-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
• When using compressed air, there is a danger that dirt may be blown up and cause personal injury.
Always wear protective equipment such as protective eyeglasses and dust mask.

Remove any mud or dirt from around the breather, then remove the breather and use clean diesel fuel or flushing
oil to flush out the dirt inside.

When getting on or off the machine with carrying breather, a tool,

etc., place it once in part (A) to ensure your safety.

Remove cover (1).

It is on upper surface of the hydraulic tank.

• Differential case (front) (2)

• Final drive case (front, left) (3)

6-18
ATTACHMENTS AND OPTIONS HANDLING CENTRALIZED BREATHERS

• Final drive case (front, left)

It is located rear inside of front right wheel.

Remove cover (4).

It is at center of rear frame.

• Differential case (center) (5)

• Final drive case (center) (5)
• Differential case (rear) (6)

REMARK
Remove sand, dust, and etc., if any found on the bottom of the box.

6-19
HANDLING CENTRALIZED BREATHERS ATTACHMENTS AND OPTIONS

EVERY 2000 HOURS MAINTENANCE (ALL-33E0-015-A-02-A)

Maintenance for every 50, 250, 500 and 1000 hours should be performed at the same time.

REPLACE BREATHER ELEMENT IN HYDRAULIC TANK (HM400-PM39-923-K-01-A)

WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.

1. Remove bolts (1), then remove cover (2).

2. Remove nut (4) of breather assembly (3) at the top of the hy-
draulic tank, then remove cover (5).
3. Replace breather element (6) with a new one.
4. Install cover (5) and nut (4).

6-20
ATTACHMENTS AND OPTIONS HANDLING CENTRALIZED BREATHERS

EVERY 4000 HOURS MAINTENANCE (ALL-33F0-015-A-05-A)

Every 50, 250, 500, 1000 and 2000 hours maintenance should be performed at the same time.

REPLACE AIR CLEANER ELEMENT (HM400-A921-923-K-02-A)

WARNING
• Dirt will fly if compressed air is used for cleaning. If dirt gets into your eyes it may cause blindness,
and if you breathe in the dust it may damage your lungs. To prevent these problems, always wear pro-
tective eyeglasses, dust mask, and other protective equipment.
• When pulling out the air cleaner element, make sure that you are standing on a firm place. If your foot-
ing is not secure when you perform the operation, there is a danger of falling and suffering injury.

Front side
1. Remove sand, etc., attached to cover (1) by compressed air.
2. Remove cover (1).

3. Remove screw (3) on the upper part of air cleaner (2).

4. Open the lid (4), replace the elements to the new ones.

REMARK
Remove dust, etc., if any found on the bottom when replacing elements.

6-21
HANDLING CENTRALIZED BREATHERS ATTACHMENTS AND OPTIONS

Rear side
1. Remove sand, etc., attached to cover (1) by compressed air.
2. Remove cover (1).

3. Remove screw (3) on the upper part of air cleaner (2).

4. Open the lid (4), replace the elements to the new ones.

REMARK
Remove dust, etc., if any found on the bottom when replacing elements.

6-22
ATTACHMENTS AND OPTIONS HANDLING CENTRALIZED BREATHERS

CONSUMABLE PARTS LIST (HM400-0000-20N-K-02-A)

The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No. Part name Q'ty
interval
Engine oil filter 600-211-1340 Cartridge 2
500 hours
Fuel prefilter 600-319-4500 Cartridge 1
Fuel main filter 600-319-3841 Cartridge 1
Transmission
714-07-28713 Cartridge 2
oil filter (valve side)
Transmission
208–60–71123 Element 1
oil filter
(07000-F5210) (O-ring) (1)
(brake cooling side) 1000 hours
569-43-83920 Element 1
Brake oil filter (07000-12065) (O-ring) (1)
(07001-02065) (Back-up ring) (1)
Fuel tank breather 421–60–35170 Element 1
207–60–71182 Element 1
Hydraulic oil filter
(07000-F5200) (O-ring) (1)
419–60–15250 Element 1
Hydraulic tank breather 2000 hours
(419–60–15270) (O-ring) (1)
Air cleaner 600-185-6100 Element ass'y 1 ―
Air cleaner
(for centralized breathers) 56B-92-3A790 Element 2 4000 hours

6-23
HANDLING FUEL QUICK CHARGE SYSTEM ATTACHMENTS AND OPTIONS

HANDLING FUEL QUICK CHARGE SYSTEM (HM400_U45-AD32-100-K-00-A)

The quick coupler for adding fuel is installed.

You can perform refilling work within a shorter time than the normal refilling method.

PROCEDURE FOR REFUELING (HM400_U45-AD32-100-K-01-A)

WARNING
When adding fuel, never spill the fuel or let it overflow. The fuel may cause fire. If any fuel has spilled, wipe
it up completely. Fuel is highly flammable and dangerous. Do not bring any open flame near fuel.

1. Turn the starting switch key to OFF position (A) to stop the
engine.

2. Remove cap (1) and start adding fuel.

Fuel tank capacity 513l (135.53 US gal)
3. After adding fuel, install cap (1).

6-24
ATTACHMENTS AND OPTIONS HANDLING FUEL QUICK CHARGE SYSTEM

CHECK AND MAINTENANCE (HM400_U45-AD32-001-K-00-A)

WHEN REQUIRED (ALL-3370-001-A-00-A)

CLEAN FUEL TANK BREATHER (HM400_U45-AD1D-92D-K-00-A)

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Wait
for the temperature to go down, and then start the work.

1. Stop the engine, and wait for the temperature of each part to
go down.
2. Remove any mud or dirt from around the breather.

3. Remove nut (2) of breather assembly (1) and remove cover

(3).
4. Clean the breather element (4).
When cleaning the breather element (4), use clean diesel oil
or flushing oil to rinse the inside dirt out.
5. Install cover (3) and nut (2).

6-25
ROLLOVER AVOIDANCE S<S7E0 ATTACHMENTS AND OPTIONS

ROLLOVER AVOIDANCE 6<67E0

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6-26
$77$&+0(176$1'237,216 ROLLOVER AVOIDANCE S<S7E0

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6-2
ROLLOVER AVOIDANCE S<S7E0 ATTACHMENTS AND OPTIONS

6-28
7 REPLACEMENT PARTS

REPLACEMENT PARTS

7-1
DEFINED LIFE PARTS REPLACEMENT PARTS

DEFINED LIFE PARTS

• For using the machine safely for a long period, always perform periodic inspection of the defined life parts
that have a particularly close relation to safety, such as hoses and the seat belt.
• 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.
Check if there is any abnormality in wear or deterioration on them before work and at the regular maintenance.
• Replace immediately the hose if any defect is found by checking. If any of the hose clamps show deterioration
like deformation or cracking, replace the clamps at the same time as the hoses.
• 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.

DEFINED LIFE PARTS LIST

No. Target parts Inspection /Replacement interval
1 Fuel system Every 2 years or every 4000
Fuel hose hours, whichever comes sooner.
Spill hose
2 Engine lubrication system Turbocharger lubrication hose
Engine oil filter hose
3 Steering system High pressure circuit hose
4 Brake system Brake oil pressure hose
5 Torque converter, trans-
Transmission circuit hose
mission system
6 Work equipment hydraulic Main pump delivery hose Replace if any of the damages
system were found when the daily check
Main pump delivery hose other than described or periodical maintenance.
above
Pump branch hose
Main pump LS hose
Hose for hydraulic drive fan
External work equipment hose
• Hoist circuit hose
7 Others PPC accumulator
Every 3 years from start of
usage or 5 years after
Seat belt
manufacturing of seat belt,
whichever comes sooner.

7-2
REPLACEMENT PARTS CONSUMABLE PARTS

CONSUMABLE PARTS (HM300-0000-202-K-00-A)

Consumable parts such as the filter element, air cleaner element, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits. The wear parts should be changed correctly in order to use the ma-
chine more [Link] replacing parts, Komatsu recommends using Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your Ko-
matsu distributor of the machine serial number and check for the latest part number when ordering parts.

CONSUMABLE PARTS LIST (HM400-0000-20N-K-01-A)

The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No. Part name Q'ty
interval
Engine oil filter 600-211-1340 Cartridge 2
500 hours
Fuel prefilter 600-319-4500 Cartridge 1
Fuel main filter 600-319-3841 Cartridge 1
Transmission
714-07-28713 Cartridge 2
oil filter (valve side)
Transmission
208-60-71123 Element 1
oil filter
(07000-F5210) (O-ring) (1)
(brake cooling side) 1000 hours
569-43-83920 Element 1
Brake oil filter (07000-12065) (O-ring) (1)
(07001-02065) (Back-up ring) (1)
Fuel tank breather 421-60-35170 Element 1
207-60-71182 Element 1
Hydraulic oil filter
(07000-F5200) (O-ring) (1)
419-60-15250 Element 1
Hydraulic tank breather 2000 hours
(419-60-15270) (O-ring) (1)
Coolant filter 600-411-5110 Cartridge 1 4000 hours
Air cleaner 600-185-6100 Element ass'y 1 ―

7-3
RECOMMENDED FUEL, COOLANT, AND
LUBRICANT REPLACEMENT PARTS

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

NOTICE
• Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construc-
tion equipment and components.
In order to keep your machine in the best condition for long period of time, it is essential to follow the
instructions in this Operation and Maintenance Manual.
• Failure to follow these recommendations may result in shortened life or excessive wear of the engine,
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 oil according to the ambient temperature as recommended in the chart below.
• When starting the engine in temperatures below 0°C (32°F), be sure to use the recommended multi-
grade oil, even if the ambient temperature may become higher during the course of the day.
• If the machine is operated at a temperature of -20°C (-4°F) and below, a separate device is needed, so
consult your Komatsu distributor.
• When the fuel sulfur content is less than 0.2%, change the engine oil according to the period inspec-
tion table given in this Operation and Maintenance Manual.
If the fuel sulfur content is more than 0.2%, change the oil according to the following table.
Sulfur content (%) Oil change interval
Less than 0.2% 500 hours
0.2 to 0.5% 250 hours
0.5% and up Not recommendable (*)
* If these fuels are used, there is a danger that serious trouble may occur because of early deterioration of the en-
gine oil or early wear of the internal parts of the engine. If the local situation makes it necessary to use these fuels,
always remember the following.
1. Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil based
on the result.
2. Always be aware that oil change interval is extremely shorter than standard.
3. Be sure to perform periodic engine inspection by distributor's expert since change interval of periodic replace-
ment parts and overhaul interval are also shorter.
The ASTM D975 diesel fuel can contain 5 % or less of biofuel.
The EN590 diesel fuel can contain 7 % or less of biofuel.
NOTICE
When you use biofuel other than the preceding diesel fuel and its mixing ratio is up to 20 %, obey the
precautions that follow.
• It is necessary to consult with the local regulatory authorities of engine exhaust gas regulation
whether the biofuel can be used or not.
• The fuel can possibly leak because of the deterioration of rubber material of the fuel hose. Replace it
with the fuel hose applicable for biofuel. Consult your Komatsu distributor for replacement of the
fuel hose.
• Biofuel cannot be stored for a long time because it is easy to deteriorate and change in quality. Use
the fuel in the storage tank or the fuel tank of the machine within 6 months.
If the deteriorated and altered biofuel is used, it can cause bad effects on the engine parts.
When you store the machine which uses the diesel fuel mixed with the biofuel for more than 3
months, do the procedure that follows.
• Replace it with pure diesel fuel or the new diesel fuel mixed with the biofuel at the lowest possi-
ble mixing ratio.
• After you change the fuel, run the engine for a minimum of 30 minutes before you store the ma-
chine.

7-4
 RECOMMENDED FUEL, COOLANT, AND
REPLACEMENT PARTS LUBRICANT

• Because the biofuel dissolves the materials stuck to the fuel tank and fuel line, the fuel filter can be
clogged with them.
When you change the diesel fuel to the biofuel, replace the fuel main filter cartridge and fuel prefilter
cartridge with new ones. When you replace the fuel main filter cartridge and fuel prefilter cartridge,
make the replacement interval half the normal time until the second replacement after you
change the diesel fuel to the biofuel.
• Because the biofuel absorbs moisture easily, it can possibly cause a growth of microorganism.
When the microorganism grows in the biofuel, it can cause corrosion of the fuel system and the
clogging of the fuel filter.
Drain the water from the fuel tank before you start the operation.
When you complete the operation, fill the fuel tank to reduce the air layer.
• If the biofuel is used in the conditions of the specific operation, the fuel can possibly get mixed into
the engine oil.
The fuel level in the engine oil must not exceed 5 %. Deteriorated engine oil can cause adverse ef-
fects on the engine parts such as a reduction of lubricating function. It is recommended to take a
sample of the oil on a periodic basis.
• The characteristics of the biofuel change when outside air temperature is low. The fuel filter can be
clogged and the fuel inside the fuel tank can solidified. Store the biofuel in the warm building or in
the storage tank.

NOTICE
Use the paraffin-based fuel which agrees with EN15940:2016 and ASTM D975.
As long as the fuel agrees with EN15940:2016 and D975, its mixing ratio can be up to 100 %.

LUBRICATION CHART (HM400-2131-930-A-03-A)

• The lubrication standard chart uses symbols to show the lubrication points and types of lubricant by each lu-
brication interval.
Keep this standard chart in the magazine box inside the cab so that the people concerned can reference it
any time needed during lubrication.
• Even if the same symbol is used in the lubrication standard chart, the recommended genuine oil may differ ac-
cording to the lubricated location and the ambient temperature. For details, see "RECOMMENDED FUEL,
COOLANT, AND LUBRICANT（PAGE 7-4）".
• For details of lubrication, see "MAINTENANCE SCHEDULE（PAGE 4-11）".

7-4-1
RECOMMENDED FUEL, COOLANT, AND
LUBRICANT REPLACEMENT PARTS

7-4-2
 RECOMMENDED FUEL, COOLANT, AND
REPLACEMENT PARTS LUBRICANT

7-5
RECOMMENDED FUEL, COOLANT, AND
LUBRICANT REPLACEMENT PARTS

• The symbols used in the lubrication standard chart are explained as follows.

7-6
 RECOMMENDED FUEL, COOLANT, AND
REPLACEMENT PARTS LUBRICANT

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT

TEMPERATURE (HM400-RA1B-05A-K-03-A)

• ASTM: American Society of Testing and Material

7-7
RECOMMENDED FUEL, COOLANT, AND
LUBRICANT REPLACEMENT PARTS

Transmis- Front Rear Front final

sion case suspension suspension drive case
Engine oil Hydraulic
(including (each of (each of Front differ- (each of
pan oil tank
brake oil right and right and ential case right and
tank) left) left) left)
Specified Liters 58.0 295.0 245.0 7.8 2.4 26.0 6.0
capacity US gal 15.32 77.94 64.73 2.10 0.63 6.87 1.59
Refill Liters 50.0 125.0 167.0 7.8 2.4 26.0 5.5
capacity US gal 13.21 33.02 44.12 2.10 0.63 6.87 1.45
Fuel tank
Center final Rear final
(quick
Center dif- drive case drive case
charge
Rear differ- Cooling
ferential (each of (each of Fuel tank
system) system
case right and ential case right and
(if
left) left)
equipped)
Specified Liters 43.0 5.5 39.0 6.0 525 513 120
capacity US gal 11.36 1.50 10.30 1.59 138.71 135.53 31.70
Refill Liters 43.0 5.0 39.0 5.5 - - 114
capacity US gal 11.36 1.30 10.30 1.45 - - 30.10

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 inspection and maintenance.
Note 1: HTHS (High-Temperature High-Shear viscosity at 150°C) must be equal to or higher than 3.5 cP. Komatsu
EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-TE) has high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bush-
ings, the use of G2-T or G2-TE is recommended.
Note 4: Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing.
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.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2. For details of the density of Non-Amine Engine Coolant (AF-NAC), see "CLEAN INSIDE OF COOLING SYS-
TEM（PAGE 4-20）".
Non-Amine Engine Coolant (AF-NAC) is supplied already diluted. In this case, fill up the tank with already-di-
luted fluid. (Never dilute the Non-Amine Engine Coolant with ordinary water.)

7-8
 RECOMMENDED FUEL, COOLANT, AND
REPLACEMENT PARTS LUBRICANT

RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN

KOMATSU GENUINE OIL (PC-RA1B-05A-K-01-A)
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.

7-9
RECOMMENDED FUEL, COOLANT, AND
LUBRICANT REPLACEMENT PARTS

7-10
8 INDEX

INDEX

8-1
 INDEX

INDEX E
Emergency escape hammer .................................. 3-92
A Engine number plate ................................................ 1-6
After daily work completion........................ 3-188, 3-198 Every 50 hours maintenance.................................. 4-40
Always use clean washer fluid ................................. 4-2 Every 250 hours maintenance....................... 4-41, 6-18
Articulation lock .................................................... 3-122 Every 500 hours maintenance................................ 4-56
Ashtray ................................................................... 3-90 Every 1000 hours maintenance.............................. 4-63
Auxiliary electric power......................................... 3-112 Every 2000 hours maintenance..................... 4-76, 6-20
Avoid mixing oil......................................................... 4-3 Every 4000 hours maintenance..................... 4-82, 6-21
Every 6000 hours maintenance.............................. 4-85
Every 8000 hours maintenance.............................. 4-87
B Explanation of components ...................................... 3-7
Before reading this manual....................................... 1-2
Before storage ...................................................... 3-199 F
Bleed air from hydraulic circuit ................................. 4-3
Body pivot pins ..................................................... 3-123 Fire prevention........................................................ 2-18
Fresh and clean lubricants ....................................... 4-2
Fuel and lubricants to match the ambient tempera-
C ture.......................................................................... 4-3
Fuse...................................................................... 3-113
Cab power tilt............................................................ 6-2
Cab tilt operation .................................................. 3-180
Caution for refilling oil or fuel .................................... 4-2 G
Check and maintenance......................................... 6-25
General precautions common to operation and mainte-
Check drained oil and used filter .............................. 4-2
nance .................................................................... 2-15
Checks after inspection and maintenance ............... 4-3
General view............................................................. 3-2
Checks after stopping engine............................... 3-158
General view of controls and gauges ....................... 3-3
Checks and adjustment before starting engine.... 3-126
General view of machine .......................................... 3-2
Checks before starting ........................................... 4-39
Cigarette lighter ...................................................... 3-90
Circuit breaker ...................................................... 3-121 H
Cold weather operation ........................................ 3-197
Handling air conditioner.......................................... 3-93
Cold weather operation information ..................... 3-197
Handling automatic retarder, accelerator control
Consumable parts .................................................... 7-3
(ARAC) ............................................................... 3-173
Consumable parts list ...................................... 6-23, 7-3
Handling centralized breathers .............................. 6-18
Contents ................................................................... 1-8
Handling electrical components ............................... 4-8
Control levers and pedals....................................... 3-86
Handling fuel quick charge system......................... 6-24
Cup holder .............................................................. 3-91
Handling Komatsu Traction Control System
(KTCS) ................................................................ 3-175
D Handling machines equipped with KOMTRAX .... 3-124
Handling oil, fuel, coolant, and performing oil clin-
Defined life parts ....................................................... 7-2
ic ............................................................................. 4-4
Defined life parts list.................................................. 7-2
Handling payload meter ........................................... 6-4
Determine and maintain travel road ..................... 3-190
Handling rear view monitor................................. 3-123-1
Determine travel road ........................................... 3-190
Directions of machine ............................................... 1-4 Handling tires........................................................ 3-189
Discharged battery ............................................... 3-205 Handy tray .............................................................. 3-91
Do not drop things inside machine ........................... 4-2
Do not get caught in work equipment ..................... 2-23 I
Drink box................................................................. 3-90
Dumping ............................................................... 3-178 If transmission has trouble.................................... 3-201
During storage ...................................................... 3-199 Initial 250 hours maintenance (only after the first
Dust indicator........................................................ 3-121 250 hours)............................................................. 4-14
Dusty jobsites ........................................................... 4-2 Introduction ............................................................... 1-4

K
Komatsu genuine lubricants ..................................... 4-2
Komatsu genuine replacement parts ....................... 4-2

8-2
INDEX

L R
Lifting machine ..................................................... 3-193 Recommended brands and quality for products other
Loading work ........................................................ 3-177 than Komatsu genuine oil ....................................... 7-9
Locking ................................................................. 3-188 Recommended fuel, coolant, and lubricant.............. 7-4
Locking inspection covers ........................................ 4-3 Rollover avoidance system .................................... 6-26
Long-term storage ................................................ 3-199 Rules for maintenance ............................................. 4-2
Lowering dump body in emergency...................... 3-201 Running out of fuel................................................ 3-200
Lubrication chart ....................................................... 7-4
S
M Safety........................................................................ 2-2
Machine monitor ....................................................... 3-7 Safety information..................................................... 1-3
Machine operation ................................................ 3-159 Safety labels ...............................................2-4–2-5, 2-8
Machine operations and controls ......................... 3-126 Securing machine................................................. 3-192
Magazine box ......................................................... 3-91 Service meter location .............................................. 1-7
Maintain travel road .............................................. 3-190 Service meter reading .............................................. 4-2
Maintenance procedure.......................................... 4-14 Shifting gears........................................................ 3-164
Maintenance schedule ........................................... 4-11 Specifications ........................................................... 5-2
Maintenance schedule table .................................. 4-11 Standard tightening torque for bolts and nuts .......... 4-9
Starting engine ............................................ 2-27, 3-150
Steering machine.................................................. 3-172
O Storage for fire extinguisher ................................. 3-118
Open and close cab door ..................................... 3-117 Storage for tools ................................................... 3-118
Operate with inter-axle differential lock ............ 3-172-1
Operation ..................................................... 2-30, 3-186
Operations and checks after starting engine........ 3-155
T
Operation if troubles on system occur..................... 6-27 Tightening torque list ................................................ 4-9
Other trouble......................................................... 3-209 Tires ........................................................................ 2-47
Outline of maintenance ............................................ 4-4 Towing .................................................................... 2-35
Towing machine.................................................... 3-202
P Transportation ............................................. 2-34, 3-191
Transportation procedure ..................................... 3-191
Parking machine................................................... 3-187 Traveling downhill ................................................. 3-166
Precautions before starting inspection and mainte- Troubles and actions ............................................ 3-200
nance .................................................................... 2-36 12 m circumference visibility .................................... 1-5
Precautions before starting operation .................... 2-15
Precautions before traveling after long-term stor-
age ...................................................................... 3-199 U
Precautions for inspection and maintenance ......... 2-42
Precautions for jobsite ............................................ 2-25 Unauthorized modification...................................... 2-23
Precautions for maintenance.................................. 2-36 Use of fuel, coolant and lubricants according to ambi-
Precautions for operation ....................................... 2-25 ent temperature ...................................................... 7-7
Precautions related to attachments and options .... 2-23 Use of machine......................................................... 1-4
Precautions related to protective structures........... 2-23
Precautions when getting on or off machine .......... 2-20 W
Precautions when installing hydraulic hoses ........... 4-3
Precautions when running engine inside building.. 2-24 Welding instructions ................................................. 4-2
Precautions when working on machine..............2-41-1 When required ............................................... 4-15, 6-25
Preparations for safe operation .............................. 2-16
Procedure for refueling ........................................... 6-24 Y
Product Identification Number (PIN)/Machine Serial
No. Plate ................................................................. 1-6 Your machine serial numbers and distributor ........... 1-7
Product information .................................................. 1-6

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HM400-3R ARTICULATED DUMP TRUCK
Form No.PEN00635-23

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