980E Operation Manual

CEAM030103
Operation & Maintenance

Manual
980E-4
DUMP TRUCK
SERIAL NUMBERS 980E-4 A40003 – A40051

ENGINE 18V170
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2017 Komatsu

Printed in U.S.A
March 2017 Komatsu America Corp.
INTRODUCTION
FOREWORD .................................................................................................................................. 1-2
ABOUT THIS MANUAL ................................................................................................................... 1-3
WARNINGS.................................................................................................................................... 1-4
California Proposition 65 Warnings ..................................................................................... 1-4
ALERTS ......................................................................................................................................... 1-5
TRUCK MODEL ILLUSTRATION ..................................................................................................... 1-6
NON-OEM PARTS IN CRITICAL SYSTEMS..................................................................................... 1-7
STANDARD CHARTS AND TABLES
GENERAL INFORMATION .............................................................................................................. 2-2
Effect Of Special Lubricants ............................................................................................... 2-2
Suggested Sources For Rust Preventive Grease ................................................................. 2-2
STANDARD TIGHTENING TORQUES ............................................................................................. 2-3
Class 10.9 Capscrews And Class 10 Nuts........................................................................... 2-3
SAE Grade 5 And Grade 8 Capscrews................................................................................ 2-4
SAE Grade 9 Capscrews ................................................................................................... 2-5
T-Bolt Clamps.................................................................................................................... 2-5
Split Flange Clamps........................................................................................................... 2-6
Flared Tube And Hose Fittings ........................................................................................... 2-6
JIC 37° Swivel Nuts ........................................................................................................... 2-7
Pipe Thread Fittings........................................................................................................... 2-8
O-Ring Boss Fittings .......................................................................................................... 2-9
O-Ring Face Seal Fittings ................................................................................................ 2-10
CONVERSION MULTIPLIERS ........................................................................................................2-11
Metric To English ..............................................................................................................2-11
English To Metric ............................................................................................................. 2-12
Temperature Conversions ................................................................................................ 2-13
GENERAL SAFETY
GENERAL SAFETY ........................................................................................................................ 3-2
Safety Rules...................................................................................................................... 3-2
Truck Safety Features........................................................................................................ 3-2
Clothing And Personal Items .............................................................................................. 3-2
Unauthorized Modification .................................................................................................. 3-2
Leaving The Operator’s Seat.............................................................................................. 3-2
Mounting And Dismounting ................................................................................................ 3-2
Fire Extinguishers And First Aid Kits ................................................................................... 3-3
Precautions For High Temperature Fluids............................................................................ 3-3
Asbestos Dust Hazard Prevention ...................................................................................... 3-3
Fire Prevention .................................................................................................................. 3-3
ROPS Precautions............................................................................................................. 3-3
Preventing Injury From Work Equipment ............................................................................. 3-4
Precautions For Optional Attachments ................................................................................ 3-4
Precautions When Starting The Machine............................................................................. 3-4
PRECAUTIONS FOR TRUCK OPERATION ..................................................................................... 3-5
Safety Is Thinking Ahead ................................................................................................... 3-5
Safety At The Worksite ...................................................................................................... 3-5
Preparing For Operation..................................................................................................... 3-5
Ventilation For Enclosed Areas ........................................................................................... 3-5
Mirrors, Windows, And Lights ............................................................................................. 3-5
Before Starting The Engine ................................................................................................ 3-5
Seat Belts And Tethers....................................................................................................... 3-5
Emergency Egress Ladders ............................................................................................... 3-6
OPERATING THE MACHINE........................................................................................................... 3-7
General Information ........................................................................................................... 3-7
980E-4 3
Starting The Engine ........................................................................................................... 3-7
Traveling In The Machine ................................................................................................... 3-7
Traveling In Reverse .......................................................................................................... 3-8
Traveling On Slopes .......................................................................................................... 3-8
Traveling On Snow ............................................................................................................ 3-8
Traveling Near High Voltage Cables.................................................................................... 3-8
Traveling On Loose Ground ............................................................................................... 3-8
Ensuring Good Visibility ..................................................................................................... 3-8
Avoid Damage To The Dump Body ..................................................................................... 3-8
Safe Parking Of The Machine............................................................................................. 3-9
Loading The Machine ........................................................................................................ 3-9
Dumping The Machine ....................................................................................................... 3-9
Towing The Machine .......................................................................................................... 3-9
EXTERIOR LIGHTING .................................................................................................................. 3-10
Fog Lights ....................................................................................................................... 3-10
Headlights....................................................................................................................... 3-10
Ladder Lights and Deck Mounted Flood Lights .................................................................. 3-10
Mirror Mounted Backup Lights ...........................................................................................3-11
Brake Light.......................................................................................................................3-11
Retard Light .....................................................................................................................3-11
Clearance/Turn Signal Lights.............................................................................................3-11
Retard Lights....................................................................................................................3-11
Brake Lights .....................................................................................................................3-11
Backup Alarm...................................................................................................................3-11
LED Backup Lights ...........................................................................................................3-11
PRECAUTIONS FOR MAINTENANCE........................................................................................... 3-12
BEFORE PERFORMING MAINTENANCE............................................................................... 3-12
Electrical System Isolation................................................................................................ 3-12
Securing The Dump Body ................................................................................................ 3-13
DURING MAINTENANCE....................................................................................................... 3-14
Warning Tag .................................................................................................................... 3-14
Proper Tools.................................................................................................................... 3-14
Attachments .................................................................................................................... 3-14
Working Under The Machine ............................................................................................ 3-14
Keeping The Machine Clean ............................................................................................ 3-15
Adding Fuel Or Oil To The Machine .................................................................................. 3-15
Radiator Coolant Level..................................................................................................... 3-15
Use Of Lighting................................................................................................................ 3-15
Handling High Pressure Hoses ......................................................................................... 3-15
Precautions With High Pressure Oil .................................................................................. 3-15
Maintenance Near High Temperatures And High Pressures................................................ 3-16
Rotating Fan And Belts .................................................................................................... 3-16
Waste Materials............................................................................................................... 3-16
Use Of Tie-Off Anchor During Maintenance ....................................................................... 3-16
Handling Tires ................................................................................................................. 3-16
Tire Maintenance ............................................................................................................. 3-17
Storing Tires After Removal.............................................................................................. 3-17
Battery Hazard Prevention ............................................................................................... 3-17
Jump Starting With Jumper Cables ................................................................................... 3-18
Jump Starting With Receptacles ....................................................................................... 3-18
WHEN REPAIRS ARE NECESSARY ............................................................................................. 3-20
Observe The Following Precautions.................................................................................. 3-20
SPECIAL PRECAUTIONS............................................................................................................. 3-21
Preliminary Procedures Before Welding Or Performing Maintenance .................................. 3-21
4 980E-4
Engine Shutdown Procedure Before Welding or Performing Maintenance ........................... 3-21
Before Welding On The Machine, Obey The Following Guidelines: ..................................... 3-21
Discharging Control Cabinet Capacitors ............................................................................ 3-22
WARNING AND CAUTIONS
PIN PLATE ..................................................................................................................................... 4-2
GRADE SPEED CHART ................................................................................................................. 4-3
MACHINE SAFETY......................................................................................................................... 4-3
KEY SWITCH ................................................................................................................................. 4-6
OIL FILL AND CHECK .................................................................................................................... 4-6
HIGH PRESSURES ........................................................................................................................ 4-7
BATTERY AND ISOLATION BOX .................................................................................................... 4-9
HIGH VOLTAGE ........................................................................................................................... 4-13
WELDING .................................................................................................................................... 4-16
LIFTING POINTS.......................................................................................................................... 4-17
EMERGENCY DUMPING.............................................................................................................. 4-18
ROPS/FOPS ................................................................................................................................ 4-19
TOWING ...................................................................................................................................... 4-19
LUBRICATION CHART ................................................................................................................. 4-19
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION ...................................................................................................... 5-2
Safety Is Thinking Ahead ................................................................................................... 5-2
Walk Around Inspection ..................................................................................................... 5-2
RETRACTABLE LADDER SYSTEM (If Equipped)............................................................................. 5-7
General Information ........................................................................................................... 5-7
Ladder System Description ................................................................................................ 5-7
Ladder System Operation................................................................................................... 5-7
Retractable Ladder Switch ................................................................................................. 5-7
Ground Level Ladder Down Switch ..................................................................................... 5-8
Emergency Down Valve ..................................................................................................... 5-8
PRE-SHIFT BRAKE TEST............................................................................................................... 5-9
Operation .......................................................................................................................... 5-9
Service Brake Test........................................................................................................... 5-10
Parking Brake Test........................................................................................................... 5-10
Retard System Test ..........................................................................................................5-11
Brake Test Exit Criteria......................................................................................................5-11
TRUCK OPERATION .................................................................................................................... 5-12
ENGINE START-UP SAFETY ................................................................................................. 5-12
After Engine Has Started.................................................................................................. 5-12
MACHINE OPERATION SAFETY PRECAUTIONS................................................................... 5-13
Machine Operation On The Haul Road.............................................................................. 5-14
Starting On A Grade With A Loaded Truck ........................................................................ 5-14
Retarding On A Grade ..................................................................................................... 5-14
Passing........................................................................................................................... 5-15
Loading........................................................................................................................... 5-15
Dumping ......................................................................................................................... 5-15
Lowering The Dump Body (When Dumping On Flat Ground) .............................................. 5-16
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crusher)....................... 5-17
SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION ................... 5-17
EMERGENCY STEERING SYSTEM ....................................................................................... 5-18
Operation ........................................................................................................................ 5-18
Pre-Operation Testing ...................................................................................................... 5-18
Additional Guidelines ....................................................................................................... 5-19
FUEL DEPLETION................................................................................................................. 5-19
980E-4 5
SAFE PARKING PROCEDURES ............................................................................................ 5-19
NORMAL ENGINE SHUTDOWN PROCEDURE ...................................................................... 5-19
DISABLED TRUCK CONNECTORS .............................................................................................. 5-21
GENERAL INFORMATION ..................................................................................................... 5-21
HOIST SYSTEM .................................................................................................................... 5-21
Hookup ........................................................................................................................... 5-21
Dumping Procedure ......................................................................................................... 5-21
TOWING ...................................................................................................................................... 5-23
SPECIAL WIRING HARNESS................................................................................................. 5-23
TOWING PROCEDURE ......................................................................................................... 5-23
PAYLOAD METER IV SYSTEM ..................................................................................................... 5-26
Data Summary ................................................................................................................ 5-26
Data Gathering ................................................................................................................ 5-26
COMPONENT DESCRIPTION................................................................................................ 5-26
Electronic Dash Display ................................................................................................... 5-26
Operator Input Switches................................................................................................... 5-26
Brake Lock Switch ........................................................................................................... 5-27
Payload Meter Module (PLM) ........................................................................................... 5-27
Load Lights ..................................................................................................................... 5-28
Keyswitch Input ............................................................................................................... 5-28
Payload Meter (PLM) Power............................................................................................. 5-29
OPERATOR’S DISPLAY AND SWITCH ................................................................................... 5-29
Setting The Operator ID ................................................................................................... 5-29
Load And Ton Counter ..................................................................................................... 5-29
Viewing Live Sensor Data ................................................................................................ 5-29
PAYLOAD OPERATION & CALCULATION .............................................................................. 5-30
Description of Haul Cycle States....................................................................................... 5-30
Haul Cycle Description..................................................................................................... 5-30
Load Calculation.............................................................................................................. 5-31
Carry Back ...................................................................................................................... 5-31
Measurement Accuracy ................................................................................................... 5-31
SOURCES FOR PAYLOAD ERROR........................................................................................ 5-31
Payload Error .................................................................................................................. 5-31
Critical Suspension Factors: ............................................................................................. 5-31
Loading Conditions .......................................................................................................... 5-31
Pressure Sensors ............................................................................................................ 5-32
Swingloads ..................................................................................................................... 5-32
Speed and Distance ........................................................................................................ 5-32
HAUL CYCLE WARNING FLAGS ........................................................................................... 5-32
Haul Cycle Data .............................................................................................................. 5-32
Haul Cycle Warning Flags ................................................................................................ 5-35
Alarm Records ................................................................................................................ 5-36
Frame Torque Data.......................................................................................................... 5-38
SYSTEM CONFIGURATION................................................................................................... 5-38
Connecting To The Payload Meter IV Web Server.............................................................. 5-38
Configuring Static IP Address ........................................................................................... 5-38
Real Time Data Page....................................................................................................... 5-41
Payload Meter IV System Configuration ............................................................................ 5-41
Truck Model .................................................................................................................... 5-43
PLM IV Mounting Orientation (for Onboard Inclinometers) .................................................. 5-43
Gauge Display Units ........................................................................................................ 5-44
Pressure Sensor Units (for RTD web page only) ................................................................ 5-44
Date and Time................................................................................................................. 5-44
6 980E-4
Payload Gain Factor ........................................................................................................ 5-44
Payload Light Test ........................................................................................................... 5-44
Truck Tare Reset ............................................................................................................. 5-44
Truck Data Configuration.................................................................................................. 5-45
Inclinometer Calibration ................................................................................................... 5-45
Overload Threshold ......................................................................................................... 5-46
Clean Truck Tare ............................................................................................................. 5-47
Tare Reset ...................................................................................................................... 5-49
Custom Truck Configuration ............................................................................................. 5-49
Field Software Update...................................................................................................... 5-50
Viewing Haul Cycle Data .................................................................................................. 5-52
Downloading Haul Cycle Data .......................................................................................... 5-53
Viewing Alarm Data ......................................................................................................... 5-54
Downloading Alarm Data.................................................................................................. 5-55
UPLOADING DATA.......................................................................................................... 5-57
Creating a Query ............................................................................................................. 5-58
Detailed Multi-Page Report .............................................................................................. 5-58
Creating Graphs .............................................................................................................. 5-58
Field Software Update Procedure ..................................................................................... 5-58
AUTOMATIC LUBRICATION SYSTEM........................................................................................... 5-67
COMPONENT DESCRIPTION................................................................................................ 5-67
Filter ............................................................................................................................... 5-68
Hydraulic Motor and Pump ............................................................................................... 5-68
Grease Reservoir ............................................................................................................ 5-68
Pressure Reducing Valve ................................................................................................. 5-68
Flow Control Valve........................................................................................................... 5-68
Solenoid Valve................................................................................................................. 5-69
Vent Valve....................................................................................................................... 5-69
Interface Module.............................................................................................................. 5-69
Injectors .......................................................................................................................... 5-71
Grease Pressure Failure Switch ....................................................................................... 5-71
Relief Valve (unloader valve) ............................................................................................ 5-71
SYSTEM OPERATION ........................................................................................................... 5-71
Filling The Reservoir ........................................................................................................ 5-71
Priming The Automatic Lubrication System........................................................................ 5-72
PREVENTIVE MAINTENANCE PROCEDURES ...................................................................... 5-72
Daily Lubrication System Inspection.................................................................................. 5-72
250 Hour Inspection......................................................................................................... 5-73
1000 Hour Inspection....................................................................................................... 5-73
SYSTEM CHECKOUT .................................................................................................................. 5-74
General Checks............................................................................................................... 5-74
Lubrication Cycle Operation ............................................................................................. 5-74
RESERVE ENGINE OIL SYSTEM (if equipped) .............................................................................. 5-75
Operation ........................................................................................................................ 5-75
LED Monitor Light............................................................................................................ 5-76
Changing Oil ................................................................................................................... 5-76
OPERATOR CAB AND CONTROLS
CAB INTERIOR .............................................................................................................................. 6-2
STEERING WHEEL AND CONTROLS............................................................................................. 6-3
Horn Button....................................................................................................................... 6-3
Tilt / Telescope Lever ......................................................................................................... 6-3
Multi-Function Turn Signal Switch ....................................................................................... 6-3
Turn Signal Operation ........................................................................................................ 6-3
980E-4 7
High Beam Headlight Operation ......................................................................................... 6-3
Windshield Wiper Operation ............................................................................................... 6-3
PEDALS AND RETARDER LEVER .................................................................................................. 6-5
Dynamic Retarding ............................................................................................................ 6-5
Retarder Lever .................................................................................................................. 6-5
Brake/Retarder Pedal ........................................................................................................ 6-5
Accelerator Pedal .............................................................................................................. 6-5
OVERHEAD PANEL AND DISPLAYS............................................................................................... 6-6
Radio Speakers................................................................................................................. 6-6
Warning Alarm Buzzer ....................................................................................................... 6-6
Cab Radio......................................................................................................................... 6-6
Air Cleaner Vacuum Gauges .............................................................................................. 6-6
KomVision™ Panel ............................................................................................................ 6-6
CENTER CONSOLE ....................................................................................................................... 6-7
Directional Control Lever.................................................................................................... 6-7
Override/Fault Reset Switch ............................................................................................... 6-7
Engine Stop Switch............................................................................................................ 6-7
Window Control Switches................................................................................................... 6-8
Hoist Control Lever ............................................................................................................ 6-8
Raising The Dump Body .................................................................................................... 6-8
Lowering The Dump Body .................................................................................................. 6-8
Retard Speed Control (RSC) Adjust Dial ............................................................................. 6-8
Retard Speed Control (RSC) Switch ................................................................................... 6-9
Data Store Button .............................................................................................................. 6-9
12v Auxiliary Power Outlets................................................................................................ 6-9
Fire Suppression Control Outlet.......................................................................................... 6-9
Communication Radio Outlet .............................................................................................. 6-9
DIAGNOSTIC PORTS................................................................................................................... 6-10
KOMTRAX Plus .............................................................................................................. 6-10
Interface Module (IM)....................................................................................................... 6-10
PC Local Area Network (PC LAN) .................................................................................... 6-10
Drive System Controller (DSC) ......................................................................................... 6-10
Engine (Cense) ............................................................................................................... 6-10
Engine (Quantum) ........................................................................................................... 6-10
OPERATOR SEAT (Standard) ........................................................................................................6-11
Seat Belts And Tethers......................................................................................................6-11
Adjustment.......................................................................................................................6-11
PASSENGER SEAT (Standard) ..................................................................................................... 6-13
Seat Belts And Tethers..................................................................................................... 6-13
Adjustment...................................................................................................................... 6-13
OPERATOR SEAT (Optional) ........................................................................................................ 6-14
Adjustment...................................................................................................................... 6-14
PASSENGER SEAT (Optional) ...................................................................................................... 6-16
Adjustment...................................................................................................................... 6-16
HEATER / AIR CONDITIONER CONTROLS................................................................................... 6-17
Fan Speed Control Knob.................................................................................................. 6-17
Temperature Control Knob ............................................................................................... 6-17
Air Flow Directional Knob ................................................................................................. 6-17
Heater/Air Conditioner Vents ............................................................................................ 6-17
INSTRUMENT PANEL .................................................................................................................. 6-18
Control Symbols .............................................................................................................. 6-18
Heater / Air Conditioner Vents .......................................................................................... 6-19
8 980E-4
Status Indicator Light Panel.............................................................................................. 6-19
Hydraulic Oil Temperature Gauge ..................................................................................... 6-19
Coolant Temperature Gauge ............................................................................................ 6-19
Speedometer/Digital Display ............................................................................................ 6-19
Fuel Level Gauge ............................................................................................................ 6-19
Drive System Temperature Gauge .................................................................................... 6-20
Hazard Warning Light Switch............................................................................................ 6-20
Pre-Shift Brake Test Switch .............................................................................................. 6-20
Wheel Brake Lock Control Switch ..................................................................................... 6-20
Rest Switch ..................................................................................................................... 6-20
Engine Warm Up ............................................................................................................. 6-21
Heated Mirror Switch (Optional)........................................................................................ 6-21
Retractable Ladder Switch ............................................................................................... 6-21
Key Switch ...................................................................................................................... 6-21
Warning Light .................................................................................................................. 6-22
Digital Display Contrast Buttons........................................................................................ 6-22
Turn Signal Indicators ...................................................................................................... 6-22
Panel Light Dimmer ......................................................................................................... 6-22
Mode Switches ................................................................................................................ 6-22
Fog Light Switch .............................................................................................................. 6-22
Backup Light Switch ........................................................................................................ 6-22
Ladder Light Switch ......................................................................................................... 6-22
Headlight/Panel Illumination Light Switch .......................................................................... 6-22
STATUS INDICATOR LIGHT PANEL .............................................................................................. 6-23
STATUS INDICATOR LIGHT SYMBOLS.................................................................................. 6-23
Body Up.......................................................................................................................... 6-23
Parking Brake.................................................................................................................. 6-23
Propel System Not Ready ................................................................................................ 6-23
No Propel........................................................................................................................ 6-24
Engine Warm Up ............................................................................................................. 6-24
Engine Shutdown Delay ................................................................................................... 6-24
Retarding Grid Dryer........................................................................................................ 6-24
Wheel Brake Lock ........................................................................................................... 6-24
Traction Control ............................................................................................................... 6-24
Repair Monitor................................................................................................................. 6-24
Retractable Ladder Down................................................................................................. 6-24
Snapshot In Progress ...................................................................................................... 6-24
Pantograph Energized ..................................................................................................... 6-24
Pantograph Up ................................................................................................................ 6-25
Service Brake.................................................................................................................. 6-25
Dynamic Retarding .......................................................................................................... 6-25
No DC Link Voltage ......................................................................................................... 6-25
DIGITAL DISPLAY OPERATION .................................................................................................... 6-26
Toggling Through Main Level Screens............................................................................... 6-26
Toggling Through Warning Screens .................................................................................. 6-27
Entering Payload Meter Data............................................................................................ 6-28
KOMTRAX Plus ............................................................................................................................ 6-29
KOMTRAX Plus OPERATION ................................................................................................. 6-29
Basic Precautions............................................................................................................ 6-29
Interface Module.............................................................................................................. 6-30
DOWNLOADING KOMTRAX Plus DATA ................................................................................. 6-31
General Information ......................................................................................................... 6-31
KOMTRAX Plus Downloading Procedure .......................................................................... 6-31
Location Of Downloaded Files .......................................................................................... 6-32
980E-4 9
UPLOADING KOMTRAX Plus DATA ....................................................................................... 6-32
ORBCOMM .................................................................................................................................. 6-34
KOMATSU WIRELESS BRIDGE (KWB) ......................................................................................... 6-35
VHMS DOWNLOADS............................................................................................................. 6-35
VHMS Downloading Procedure ........................................................................................ 6-36
ONBOARD CONTROLLER ACCESS ...................................................................................... 6-36
Wireless Access .............................................................................................................. 6-36
Wireless Access Procedure.............................................................................................. 6-36
Wired Access .................................................................................................................. 6-37
Wired Access Procedure.................................................................................................. 6-37
CHANGING A LAPTOP'S IP ADDRESS .................................................................................. 6-37
CONNECTING TO A WIRELESS NETWORK .......................................................................... 6-38
FUSES AND CIRCUIT BREAKERS ............................................................................................... 6-40
VEHICLE ELECTRICAL CENTER 89 ...................................................................................... 6-40
CIRCUIT BREAKERS............................................................................................................. 6-46
LUBRICATION AND SERVICE
HYDRAULIC SYSTEM SERVICE.............................................................................................. 7-2
Hydraulic Tank................................................................................................................... 7-2
Hydraulic Filters................................................................................................................. 7-3
Hydraulic Pump Drive Shaft................................................................................................ 7-3
WHEEL MOTOR SERVICE....................................................................................................... 7-4
COOLANT LEVEL SERVICE .................................................................................................... 7-4
Radiator Filling Procedure .................................................................................................. 7-4
Coolant Specifications........................................................................................................ 7-4
Unacceptable Practices ..................................................................................................... 7-4
RESERVE ENGINE OIL SERVICE............................................................................................ 7-4
Reserve Oil Tank Filling Procedure (Remote Fill) ................................................................. 7-5
Inline Screen ..................................................................................................................... 7-5
CAB AIR FILTER SERVICE ...................................................................................................... 7-5
FUEL SYSTEM SERVICE......................................................................................................... 7-6
Fuel Tank Cleaning ............................................................................................................ 7-6
Fuel Filter Service.............................................................................................................. 7-6
INTAKE AIR CLEANER SERVICE............................................................................................. 7-7
FRONT WHEEL SERVICE ....................................................................................................... 7-8
Oil Sampling...................................................................................................................... 7-8
FRONT ENGINE MOUNT TRUNNION SERVICE....................................................................... 7-8
QUICK FILL SERVICE CENTER ............................................................................................... 7-8
TIE ROD INSPECTION AND TORQUE PROCEDURE ............................................................... 7-9
LUBRICATION CHART ................................................................................................................. 7-10
EVERY 10 HOUR (DAILY) MAINTENANCE ....................................................................................7-11
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION............................................ 7-13
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.......................................... 7-14
EVERY 250 HOUR LUBRICATION AND MAINTENANCE ............................................................... 7-15
EVERY 500 HOUR LUBRICATION AND MAINTENANCE ............................................................... 7-17
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE ........................................................... 7-19
EVERY 2500 HOUR MAINTENANCE ............................................................................................ 7-20
EVERY 3000 HOUR LUBRICATION AND MAINTENANCE ............................................................. 7-21
10 980E-4
EVERY 18,000 HOUR MAINTENANCE.......................................................................................... 7-24
SPECIFICATIONS
MAJOR COMPONENT DESCRIPTION ............................................................................................ 8-2
Truck and Engine ..................................................................................................................... 8-2
Traction Alternator .................................................................................................................... 8-2
Main Control Cabinet ................................................................................................................ 8-2
AC Induction Traction Motorized Wheels.................................................................................... 8-2
Suspension.............................................................................................................................. 8-2
Operator's Cab......................................................................................................................... 8-2
Power Steering ........................................................................................................................ 8-2
Dynamic Retarding Grid............................................................................................................ 8-2
Brake System .......................................................................................................................... 8-2
SPECIFICATIONS .......................................................................................................................... 8-3
Engine..................................................................................................................................... 8-3
AC Electric Drive System .......................................................................................................... 8-3
Dynamic Retarding................................................................................................................... 8-3
Battery Electric System............................................................................................................. 8-3
Service Capacities.................................................................................................................... 8-3
Hydraulic Systems.................................................................................................................... 8-3
Service Brakes......................................................................................................................... 8-4
Steering................................................................................................................................... 8-4
Standard Dump Body Capacities and Dimensions ...................................................................... 8-4
Tires ........................................................................................................................................ 8-4
Weight Distribution ................................................................................................................... 8-4
Overall Truck Dimensions ......................................................................................................... 8-4
RADIO
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER ............................................................... 9-2
Phone/Bluetooth Button ............................................................................................................ 9-2
Digital Display .......................................................................................................................... 9-2
CD Slot.................................................................................................................................... 9-2
Volume Knob/OK Button ........................................................................................................... 9-2
SRC/PWR (Source/Power) Button............................................................................................. 9-3
NEXT Button............................................................................................................................ 9-3
Eject Button ............................................................................................................................. 9-3
USB Connection Port ............................................................................................................... 9-3
Auxiliary Jack Port.................................................................................................................... 9-3
SCAN/ASCN (Scan/Autoscan) Button........................................................................................ 9-3
PREV (Previous) Button ........................................................................................................... 9-3
DISP (Display) Button............................................................................................................... 9-4
ESC (Escape) Button ............................................................................................................... 9-4
RDM (Random) Button ............................................................................................................. 9-4
RPT (Repeat) Button ................................................................................................................ 9-4
Clock/Alarm Button................................................................................................................... 9-4
Browse Button ......................................................................................................................... 9-4
Play/Pause Button.................................................................................................................... 9-4
Preset Buttons ......................................................................................................................... 9-4
GENERAL FEATURES ................................................................................................................... 9-5
Audio Sources ......................................................................................................................... 9-5
Bluetooth Pairing...................................................................................................................... 9-5
RADIO OPERATION ....................................................................................................................... 9-6
Tuning ..................................................................................................................................... 9-6
Scanning ................................................................................................................................. 9-6
Performing a Regular Scan ....................................................................................................... 9-6
Performing an Autoscan ........................................................................................................... 9-6
980E-4 11
Station Presets......................................................................................................................... 9-6
Storing Radio Station Presets ................................................................................................... 9-7
Tuning Radio Station Presets .................................................................................................... 9-7
CD OPERATION............................................................................................................................. 9-8
Using the CD Player ................................................................................................................. 9-8
Playing a CD............................................................................................................................ 9-8
Ejecting a CD........................................................................................................................... 9-8
IPOD OPERATION ......................................................................................................................... 9-9
iPod Support ............................................................................................................................ 9-9
Connecting an iPod .................................................................................................................. 9-9
Accessing iPod Menus ............................................................................................................. 9-9
USB DEVICE OPERATION ........................................................................................................... 9-10
Supported USB Devices ......................................................................................................... 9-10
Supported File Types.............................................................................................................. 9-10
Connecting a USB Device....................................................................................................... 9-10
Accessing USB Folders .......................................................................................................... 9-10
Accessing USB Playlists ......................................................................................................... 9-10
Scanning a USB Device...........................................................................................................9-11
AUXILIARY DEVICE OPERATION................................................................................................. 9-12
BLUETOOTH OPERATION ........................................................................................................... 9-13
Bluetooth Menu...................................................................................................................... 9-13
Enabling/Disabling Bluetooth................................................................................................... 9-13
Pairing a Bluetooth Device ...................................................................................................... 9-13
Deleting Previously Paired Devices ......................................................................................... 9-13
Connecting a Device .............................................................................................................. 9-14
Disconnecting a Device .......................................................................................................... 9-14
RECEIVER SYSTEM SETTINGS................................................................................................... 9-15
AUDIO CONTROL MENU....................................................................................................... 9-15
Adjusting Audio Settings .................................................................................................. 9-15
Audio Adjustment Options ................................................................................................ 9-15
Adjusting the Clock .......................................................................................................... 9-16
Setting an Alarm .............................................................................................................. 9-16
Canceling an Alarm ......................................................................................................... 9-17
Turning off or Snoozing an Activated Alarm ....................................................................... 9-17
USER MENU ......................................................................................................................... 9-17
Adjusting User Settings .................................................................................................... 9-17
User Adjustment Options ................................................................................................. 9-17
TROUBLESHOOTING .................................................................................................................. 9-19
Radio Troubleshooting............................................................................................................ 9-19
CD Player Troubleshooting ..................................................................................................... 9-19
iPod Troubleshooting.............................................................................................................. 9-20
USB Troubleshooting.............................................................................................................. 9-20
Bluetooth Troubleshooting ...................................................................................................... 9-21
12 980E-4
INTRODUCTION
980E-4 1-1
FOREWORD INTRODUCTION
FOREWORD F.1-0000051238
This manual is written for use by the operator and/or the service technician and is designed to help these persons
become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
All operators and maintenance personnel must read and understand the materials in this manual before
operating the truck or performing maintenance and/or operational checks on the truck. All safety notices,
warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
The illustrations used in this manual are typical of the component shown and may not be an exact reproduction
of what is found on the truck.
A product identification plate is located on the frame in front of the right side front wheel and designates the
truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle
Weight) rating.
The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system;
The letter “E”, when present, designates an Electrical wheel motor drive system.
The product identification number (vehicle serial number) contains information which will identify the original
manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many
service parts and/or warranty consideration.
The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design
and application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle
Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from
the GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload.
To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as
often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
• Unsafe use of this machine may cause serious injury or death. Operators and maintenance
personnel must read and understand this manual before operating or maintaining this machine.
• This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
1-2 980E-4
INTRODUCTION ABOUT THIS MANUAL
ABOUT THIS MANUAL F.2-0000051237
This manual is written for use by the operator and/or the service technician. It is designed to help these persons
learn how to operate the truck and its systems in order to keep it operating safely and efficiently. All operators
and maintenance personnel must read and understand the materials in this manual before operating the truck
or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions
should be understood and followed when operating or performing repairs on the truck.
The front cover of this manual includes a form number. This form number should be referenced when ordering
additional copies of this manual, or for any other correspondence regarding the coverage in this manual.
Direct all inquiries to:
Komatsu America Corp
Literature Services
100 Komatsu Dr.
Cartersville, GA 30121
United States of America
Phone: 678-721-3310
Email: KACTECHPUBS@KOMATSUNA.COM
If there is ever a question regarding the information in a particular section, refer to the manual form number, and
use the address shown above to correspond.
The illustrations used in this manual are typical of the component shown and may not be an exact reproduction
of what is found on the truck.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right”,
“left”, “front”, or “rear” are made with respect to the operator's normal seated position, unless specifically stated
otherwise.
When assembly instructions are provided without references to torque values, standard torque values should be
assumed. Standard torque requirements are shown in torque charts in the following section and in the General
Information section of the truck service manual. Individual torques when provided in the text are in bold face
type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
980E-4 1-3
WARNINGS INTRODUCTION
WARNINGS F.3-0000051687
This material is proprietary to Komatsu America

Corp (KAC), and is not to be reproduced, used,
or disclosed except in accordance with written
authorization from KAC.
It is the policy of the company to improve

products whenever it is possible and practical
to do so. The company reserves the right to
make changes or add improvements at any time
without incurring any obligation to install such
changes on products sold previously.
Because of continuous research and

development, periodic revisions may be made to
this publication. Customers should contact their
local Komatsu distributor for information on the
latest revision.
• Unsafe use of this machine may cause serious injury or death. Operators and maintenance
personnel must read and understand this manual before operating or maintaining this machine.
• This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
California Proposition 65 Warnings
• Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
• Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer, birth defects or other reproductive harm. Wash
hands after handling.
• Mercury and mercury compounds are known to the State of California to cause developmental
problems. This machine may be equipped with optional HID lamps which contain mercury. There
is no risk of exposure unless the lamps are broken. However, the lamps must be reused, recycled
or properly disposed of in accordance with Local, State and Federal Laws at the end of their useful
lives.
1-4 980E-4
INTRODUCTION ALERTS
ALERTS D.2-0000051268
The ALERT symbol is used with the following signal words:

• DANGER
• WARNING
• CAUTION
This symbol is used to alert the reader of hazards that can arise from improper operating and maintenance
practices.
• DANGER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if
proper precautions are not taken.
• WARNING identifies a specific potential hazard WHICH COULD RESULT in either INJURY OR DEATH
if proper precautions are not taken.
• CAUTION is used for general reminders of proper safety practices OR to direct the reader’s attention
to avoid unsafe or improper practices which may result in damage to the machine.
980E-4 1-5
TRUCK MODEL ILLUSTRATION INTRODUCTION
TRUCK MODEL
ILLUSTRATION A.1-0000072471
1-6 980E-4
INTRODUCTION NON-OEM PARTS IN CRITICAL SYSTEMS
NON-OEM PARTS IN CRITICAL SYSTEMS C.3-0000051235
For safety reasons, Komatsu America Corp. strongly recommends against the use of non-OEM replacement
parts in critical systems of all Komatsu equipment. Critical systems include but are not limited to steering, braking
and operator safety systems
Replacement parts manufactured and supplied by unauthorized sources may not be designed, manufactured
or assembled to Komatsu's design specifications; accordingly, use of such parts may compromise the safe
operation of Komatsu products and place the operator and others in danger should the part fail.
Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems.
Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the Komatsu product on the supplier
and user. Komatsu will not in any case accept responsibility for the failure or performance of non-OEM parts in
its products, including any damages or personal injury resulting from such use.
980E-4 1-7
NON-OEM PARTS IN CRITICAL SYSTEMS INTRODUCTION
1-8 980E-4
STANDARD CHARTS AND TABLES
980E-4 2-1
GENERAL INFORMATION STANDARD CHARTS AND TABLES
If special friction-reducing lubricants are used with
GENERAL INFORMATION E.2-0000051234 the standard torque values listed in this chapter,
excessive stress and possible breakage of the
This manual provides dual dimensioning for many fasteners may result.
specifications. Metric units are specified first, with
U.S. standard units in parentheses. When torque Where the torque tables specify “Lubricated Threads”
values are not specified in the assembly instructions for the standard torque values listed, these standard
contained in this manual, use the standard torque torque values are to be used with simple lithium
value for the hardware being used. Standard value base chassis grease (multi-purpose EP NLGI) or a
torque tables are contained in this chapter for metric rust-preventive grease (see below) on the threads
and SAE hardware. and seats unless specified otherwise.
This truck is assembled with both metric and SAE NOTE: Ensure the threads of fasteners and tapped
(U.S.) hardware. Reference the correct table when holes are free of burrs and other imperfections before
determining the proper torque value. assembling.
Suggested Sources For Rust Preventive

• References throughout the manual to Grease
standard torques or other standard values NOTE: This list represents the current engineering
will be to one of the following tables. Do not approved sources for use in Komatsu manufacture. It
use standard values to replace specific torque is not exclusive. Other products may meet the same
values in assembly instructions. specifications of this list.
• American Anti-Rust Grease #3-X from Standard Oil
For values not shown in any of the charts or tables,
Company (also American Oil Co.)
standard conversion factors for most commonly used
measurements are provided in the following tables. • Gulf NoRust #3 from Gulf Oil Company.
• Mobilarma 355, Product No. 66705 from Mobil Oil
Effect Of Special Lubricants Corporation.
The Komatsu engineering department does not • Rust Ban 326 from Humble Oil Company.
recommend the use of special friction-reducing
lubricants, such as Copper Coat, Never-Seez®, and • Rustolene B Grease from Sinclair Oil Co.
other similar products, on the threads of standard • Rust Preventive Grease - Code 312 from the
fasteners where standard torque values are applied. Southwest Grease and Oil Company.
The use of special friction-reducing lubricants will
significantly alter the clamping force being applied to
fasteners during the tightening process.
2-2 980E-4
STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES
STANDARD TIGHTENING Table 2-1

TORQUES F.7-0000051233 Standard Tightening Torque for Metric
Class 10.9 Capscrews And Class 10 Nuts Class 10.9 Capscrews & Class 10 Nuts
The following specifications apply to required

assembly torques for all metric class 10.9 finished
hexagon head capscrews and class 10 nuts.
DO NOT lubricate capscrew threads and seats during Capscrew Torque Torque Torque
assembly. These specifications are based on the Size N·m ft·lb kg·m
following hardware: M6 x1 12 9 1.22
• All capscrews M8 x 1.25 30 22 3.06
• All nuts M10 x 1.5 55 40 5.61
• All hardened washers being phosphate and oil M12 x 1.75 95 70 9.69
coated
M14 x 2 155 114 15.81
NOTE: If zinc-plated hardware is used, each piece M16 x 2 240 177 24.48
must be lubricated with simple lithium base chassis
grease (multi-purpose EP NLGI) or a rust preventive M20 x 2.25 465 343 47.43
grease (see list, this page) to achieve the same M24 x 3 800 590 81.6
clamping forces provided below.
M30 x 3.5 1600 1180 163.2
NOTE: Torques are calculated to give a clamping
M36 x 4 2750 2028 280.5
force of approximately 75% of proof load. The
maximum torque tolerance shall be within ±10% of
the torque value shown.
In the following table under “Capscrew Size”, the first
number represents the shank diameter (mm). The
second number represents thread pitch in millimeters.
Example: M20 x 2.25

M20 = shank diameter (20 mm)
2.25 = thread pitch in millimeters
980E-4 2-3
STANDARD TIGHTENING TORQUES STANDARD CHARTS AND TABLES
SAE Grade 5 And Grade 8 Capscrews Standard Tightening Torque for SAE Hex
The following specifications apply to required Head Capscrew And Nut Assembly
assembly torques for all grade 5 and grade 8
capscrews.
NOTE: Capscrew threads and seats shall be
lubricated when assembled. Unless instructions Cap-
specifically recommend otherwise, these standard Torque Torque
screw
torque values are to be used with simple lithium base Grade 5 Grade 8
Size
chassis grease (multi-purpose EP NLGI) or a rust-
preventive grease (see list, previous page) on the N·m ft·lb kg·m N·m ft·lb kg·m
threads. 9/16-18 129 95 13.1 183 135 18.7
NOTE: Torques are calculated to give a clamping 5/8-11 169 125 17.3 237 175 24.2
maximum torque tolerance shall be within ±10% of 5/8-18 183 135 18.7 258 190 26.2
the torque value shown. 3/4-10 298 220 30.4 420 310 42.8
In the following table under Capscrew Size, the first 3/4-16 319 235 32.5 454 335 46.3
number represents the shank diameter (in.). The
7/8-9 475 350 48.4 678 500 69.2
second number represents threads per inch.
7/8-14 508 375 51.9 719 530 73.3
Example: 7/16 - 20 1.0-8 712 525 72.6 1017 750 103.7
7/16 = shank diameter (7/16 inch (0.438 inch))
20 = threads per inch 1.0-12 759 560 77.4 1071 790 109.3
1.0-14 773 570 78.8 1085 800 110.6
Table 2-2
1 1/8-7 881 650 89.9 1424 1050 145
Standard Tightening Torque for SAE Hex
Head Capscrew And Nut Assembly 1 1/8-12 949 700 96.8 1546 1140 158
1 1/4-7 1234 910 125.9 2007 1480 205
1 1/4-12 1322 975 134.8 2142 1580 219
1 3/8-6 1627 1200 166 2630 1940 268
Cap-
Torque Torque 1 3/8-12 1776 1310 181 2874 2120 293
screw
Grade 5 Grade 8 1 1/2-6 2142 1580 219 3471 2560 354
Size
N·m ft·lb kg·m N·m ft·lb kg·m 1 1/2-12 2305 1700 235 3756 2770 383
1/4-20 9.5 7 0.97 13.6 10 1.38

1/4-28 10.8 8 1.11 14.9 11 1.52
5/16-18 20.3 15 2.07 28 21 2.90
5/16-24 22 16 2.21 30 22 3.04
3/8-16 34 25 3.46 47 35 4.84
3/8-24 41 30 4.15 54 40 5.5
7/16-14 54 40 5.5 79 58 8.0
7/16-20 61 45 6.2 84 62 8.57
1/2-13 88 65 9 122 90 12.4
1/2-20 95 70 9.7 129 95 13.1
9/16-12 122 90 12.4 169 125 17.3
2-4 980E-4
SAE Grade 9 Capscrews Standard Tightening Torque for SAE Hex

The following specifications apply to required Head and 12-Point, Grade 9 Capscrews
assembly torques for SAE Hex Head and 12-point,
grade 9 (170,000 psi minimum tensile), capscrews.
NOTE: Capscrew threads and seats shall be
lubricated when assembled. Unless instructions
specifically recommend otherwise, these standard Capscrew Torque Torque Torque
torque values are to be used with simple lithium base Size 1 N·m ft·lb kg·m
chassis grease (multi-purpose EP NLGI) or a rust- 1.125 - 12 1800 1330 184
preventive grease (see list, this page) on the threads.
1.250 - 7 2325 1715 237
NOTE: Torques are calculated to give a clamping
1.250 - 12 2495 1840 254
maximum torque tolerance shall be within ±10% of 1.375 - 6 3080 2270 313
the torque value shown. 1.375 - 12 3355 2475 342
Table 2-3 1.500 - 6 4040 2980 411
Standard Tightening Torque for SAE Hex 1.500 - 12 4375 3225 445
Head and 12-Point, Grade 9 Capscrews
T-Bolt Clamps
Table 2-4
Tightening Torque For T-Bolt Type Hose

Capscrew Torque Torque Torque
Clamp (SAE J1508 Type TB)
Size 1 N·m ft·lb kg·m
0.250 - 20 16 12 1.7
0.312 - 18 33 24 3.3
0.375 - 16 57 42 5.8
0.438 -14 95 70 9.7
Newton Inch
0.500 -13 142 105 14.5 Thread Band
meters Pounds
Size Width
0.562 - 12 203 150 20.7 (N·m) (in·lb)
0.625 - 11 278 205 28.3 0.25-28 19.05 mm
8.5 ± 0.6 75 ± 5
UNF (0.75 in.)
0.750 - 10 488 360 49.7
0.875 - 9 780 575 79.4
1.000 - 8 1166 860 119
1.000 - 12 1240 915 126
1.125 - 7 1670 1230 170
1. Shank Diameter (in) — Threads per inch
980E-4 2-5
Split Flange Clamps

Table 2-5
Tightening Torque For Split Flange Clamp Bolts
Capscrew
Width Newton Foot Kilogram
Thread
Across meters Pounds meters (kg·m)
Diameter
Flat (mm) (N·m) ± 10% (ft·lb) ± 10% ± 10%
(mm)
10 14 66 48 6.7
12 17 112 83 11.5
16 22 279 206 28.5
Flared Tube And Hose Fittings

Table 2-6
Tightening Torque For Flared Tube And Hose Fittings
Kilogram
Thread Width Newton Foot
meters
Diameter of Across meters Pounds
(kg·m) ±
Nut (mm) Flat (mm) (N·m) ± 10% (ft·lb) ± 10%
10%
14 19 25 18 2.5
18 24 50 36 5
22 27 80 58 8
24 32 140 101 14
30 36 175 130 18
33 41 195 145 20
36 46 245 180 25
42 55 295 215 30
2-6 980E-4
JIC 37° Swivel Nuts

Table 2-7
Torque Chart For JIC 37° Swivel Nuts With Or Without O-ring Seals
Newton
Size Tube Size Threads Foot Pounds
meters
Code (OD) UNF-2B (ft·lb)
(N·m)
– 2 0.125 0.312 – 24 5 ± 1 4 ± 1
– 3 0.188 0.375 – 24 11 ± 4 8 ± 3
– 4 0.250 0.438 – 20 16 ± 4 12 ± 3
– 5 0.312 0.500 – 20 20 ± 4 15 ± 3
– 6 0.375 0.562 – 18 24 ± 7 18 ± 5
– 8 0.500 0.750 – 16 40 ± 7 30 ± 5
– 10 0.625 0.875 – 14 54 ± 7 40 ± 5
– 12 0.750 1.062 – 12 75 ± 7 55 ± 5
– 14 0.875 1.188 – 12 88 ± 7 65 ± 5
– 16 1.000 1.312 – 12 108 ± 7 80 ± 5
– 20 1.250 1.625 – 12 136 ± 14 100 ± 10
– 24 1.500 1.875 – 12 163 ± 14 120 ± 10
– 32 2.000 2.500 – 12 312 ± 27 230 ± 20
980E-4 2-7
Pipe Thread Fittings

Table 2-8
Torque Chart For Pipe Thread Fittings
With With Without Without

Size Pipe Thread
Sealant Sealant Sealant Sealant
Code Size
N·m ft·lb N·m ft·lb
–2 0.125 – 27 20 ± 4 15 ±3 27 ± 7 20 ± 5
–4 0.250 – 18 27 ± 7 20 ±5 34 ± 7 25 ± 5
–6 0.375 – 18 34 ± 7 25 ±5 48 ± 7 35 ± 5
–8 0.500 – 14 48 ± 7 35 ±5 61 ± 7 45 ± 5
– 12 0.750 – 14 61 ± 7 45 ±5 75 ± 7 55 ± 5
– 16 1.000 – 11.50 75 ± 7 55 ±5 88 ± 7 65 ± 5
– 20 1.250 – 11.50 95 ± 7 70 ±5 108 ± 7 80 ± 5
– 24 1.500 – 11.50 108 ± 7 80 ±5 129 ± 14 95 ± 10
– 32 2.000 – 11.50 129 ± 14 95 ±10 163 ± 14 120 ± 10
2-8 980E-4
O-Ring Boss Fittings

Table 2-9
Torque Chart For O-ring Boss Fittings
Newton Foot
Tube Size Threads
Size Code meters Pounds
(OD) UNF-2B
(N·m) (ft·lb)
– 2 0.125 0.312 – 24 4 ± 3 4 ± 2
– 3 0.188 0.375 – 24 7 ± 3 5 ± 2
– 4 0.250 0.438 – 20 11 ± 4 8 ± 3
– 5 0.312 0.500 – 20 14 ± 4 10 ± 3
– 6 0.375 0.562 – 18 18 ± 4 13 ± 3
– 8 0.500 0.750 – 16 33 ± 7 24 ± 5
– 10 0.625 0.875 – 14 43 ± 7 32 ± 5
– 12 0.750 1.062 – 12 65 ± 7 48 ± 5
– 14 0.875 1.188 – 12 73 ± 7 54 ± 5
– 16 1.000 1.312 – 12 98 ± 7 72 ± 5
– 20 1.250 1.625 – 12 109 ± 7 80 ± 5
– 24 1.500 1.875 – 12 109 ± 7 80 ± 5
– 32 2.000 2.500 – 12 130 ± 14 96 ± 10
980E-4 2-9
O-Ring Face Seal Fittings

Table 2-10
Torque Chart For O-ring Face Seal Fittings
Foot
Size Tube Size Threads Newton
Pounds
Code (O.D.) UNF-2B meters (N·m)
(ft·lb)
– 4 0.250 0.438 – 20 15 ± 1 11 ± 1
– 6 0.375 0.562 – 18 24 ± 3 18 ± 2
– 8 0.500 0.750 – 16 48 ± 5 35 ± 4
– 10 0.625 0.875 – 14 69 ± 7 51 ± 5
– 12 0.750 1.062 – 12 96 ± 10 71 ± 7
– 16 1.000 1.312 – 12 133 ± 8 98 ± 6
– 20 1.250 1.625 – 12 179 ± 10 132 ± 7
– 24 1.500 1.875 – 12 224 ± 20 165 ± 15
2-10 980E-4
STANDARD CHARTS AND TABLES CONVERSION MULTIPLIERS
CONVERSION
MULTIPLIERS G.3-0000051232
Metric To English
Table 2-11
Common Conversion Multipliers Metric To English
To Convert From To Multiply By
millimeter (mm) inch (in.) 0.0394
centimeter (cm) inch (in.) 0.3937
meter (m) foot (ft) 3.2808
meter (m) yard (yd) 1.0936
kilometer (km) mile (mi) 0.6210
square centimeters (cm2) square inch (in.2) 0.1550
square centimeters (cm2) square feet (ft2) 0.001
cubic centimeters (cm3) cubic inch (in.3) 0.061
liters (L) cubic inch (in.3) 61.02
cubic meters (m3) cubic feet (ft3) 35.314
liters (L) cubic feet (ft3) 0.0353
grams (g) ounce (oz) 0.0353
milliliter (mL) fluid ounce (fl oz) 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pounds (lb) 0.2248
Newton meters (N·m) kilogram force meters (kgf·m) 0.102
Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram force meters (kgf·m) foot pounds (ft lb) 7.2329
kilogram force meters (kgf·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038
kilograms/cm2 (kg/cm2) pounds/square inch (psi) 14.2231
kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
kilogram (kg) short ton (tn) 0.0011
metric ton short ton (tn) 1.1023
liters (L) quart (qt) 1.0567
liters (L) gallon (gal) 0.2642
Watts (W) horsepower (hp) 0.00134
kilowatts (kW) horsepower (hp) 1.3410
980E-4 2-11
CONVERSION MULTIPLIERS STANDARD CHARTS AND TABLES
English To Metric
Table 2-12
Common Conversion Multipliers English to Metric
To Convert From To Multiply By
inch (in.) millimeter (mm) 25.40
inch (in.) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61
square inch (in.2) square centimeters (cm2) 6.45
square feet (ft2) square centimeters (cm2) 929
cubic inches (in.3) cubic centimeters (cm3) 16.39
cubic inches (in.3) liters (L) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft.3) liters (L) 28.3
ounce (oz) kilogram (kg) 0.028
fluid ounce (fl oz) milliliter (ml) 29.573
pound (lb) kilogram (kg) 0.454
pound (lb) Newton (N) 4.448
inch pounds (in. lb) Newton meters (N·m) 0.113
foot pounds (ft lb) Newton meters (N·m) 1.356
foot pounds (ft lb) kilogram force meters (kgf·m) 0.138
kilogram meters (kgm) Newton meters (N·m) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
kilograms/square centimeter
pounds/square inch (psi) 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (L) 0.946
gallon (gal) liters (L) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745
2-12 980E-4
STANDARD CHARTS AND TABLES CONVERSION MULTIPLIERS
Temperature Conversions
Table 2-13
Temperature Conversions
Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F°
Fahrenheit Celsius Fahrenheit Celsius Fahrenheit

Celsius C°
F° C° F° C° F°
121 250 2 482 63 145 293 4 40 104

118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 – 1 30 86
113 235 455 54 130 266 – 4 25 77
110 230 446 52 125 257 – 7 20 68
107 225 437 49 120 248 – 9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 – 4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
2. The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a
number in this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert
to degrees Fahrenheit (F°). If starting with a known temperature (either C° or F°), find that temperature in the marked
column and read the converted temperature in the center, unmarked column.
980E-4 2-13
CONVERSION MULTIPLIERS STANDARD CHARTS AND TABLES
2-14 980E-4
GENERAL SAFETY
980E-4 3-1
GENERAL SAFETY GENERAL SAFETY
Unauthorized Modification
GENERAL SAFETY E.58-0000051262 Any modification made to this vehicle without
authorization from Komatsu America Corp. can
Safety Rules
possibly create hazards.
Safety records of most organizations will show that
the greatest percentage of accidents are caused by Before making any modification, consult your
unsafe acts of persons. The remainder are caused by authorized regional Komatsu America Corp.
unsafe mechanical or physical conditions. Report all distributor. Komatsu will not be responsible for
unsafe conditions to the proper authority. any injury or damage caused by any unauthorized
modification.
The following safety rules are provided as a guide
for the operator. However, local conditions and Leaving The Operator’s Seat
regulations may add many more to this list.
NOTE: DO NOT touch any controls while leaving the
operators seat.
• Read and follow all safety precautions. Failure To prevent accidental operations from occurring,
to do so may result in serious injury or death. always perform the following:
• DO NOT apply the wheel brake lock. Move the
• Only trained and authorized personnel can operate directional control lever to the PARK position (this
and maintain the machine. will apply the parking brake).
• Follow all safety rules, precautions and instructions • Turn the key switch to the OFF position and wait for
when operating or performing maintenance on the the engine to stop.
machine.
• After the engine has stopped, wait two minutes
• When working with another operator or a person before exiting the cab. DO NOT leave the cab if
on work site traffic duty, ensure all personnel any warning messages are displayed or warning
understand all hand signals that are to be used. horns are sounding. Notify maintenance personnel
immediately.
Truck Safety Features
• When exiting the machine, always lock
Ensure all guards and covers are in their proper compartments, and take the keys with you to
position. Repair any damaged guards and covers. prevent entry from unauthorized persons.
(Refer to Walk Around Inspection, page 5-2.)
Learn the proper use of safety features such as safety Mounting And Dismounting
locks, safety pins, and seat belts. Always use these When mounting and dismounting the machine obey
safety features properly. the following guidelines:
Never remove any safety features. Always keep • Never jump on or off the machine. Never climb on
safety features in good operating condition. Improper or off a machine while it is moving.
use of safety features may result in serious bodily
injury or death. • When climbing on or off a machine, face the
machine and use the hand-hold and steps.
Clothing And Personal Items • Never hold any control levers when getting on or off
Avoid wearing loose a machine.
clothing, jewelry, and
loose long hair. They can • Always maintain three-point contact with the
catch on controls or in hand-holds and steps to ensure that you support
moving parts and cause yourself.
serious injury or death. • When bringing tools up to the operating deck,
Additionally, never wear always pass them by hand or pull them up by rope.
oily clothes as they are
flammable. • If there is any oil, grease, or mud on the hand-holds
or steps, wipe them clean immediately. Always
Wear a hard hat, safety glasses, safety shoes, a mask keep these components clean. Repair any damage
and gloves when operating or maintaining a machine. and tighten any loose bolts.
Always wear the proper safety equipment required for
the job. Also, ensure that the work area is clear of
other personnel during hazardous jobs.
3-2 980E-4
Fire Extinguishers And First Aid Kits • Use an approved respirator, when necessary.
Ensure fire extinguishers
are accessible and proper Fire Prevention
usage techniques are
known. Provide a first aid
kit at the storage point.
Know what to do in the event of a fire and keep phone

numbers of persons you must contact in case of an
emergency in the cab.
Precautions For High Temperature Fluids

Immediately after
machine operation,
engine coolant, engine NOTE: DO NOT operate the machine near open
oil, and hydraulic oil are flames. Always ensure a fire extinguisher is present
hot and pressurized. If and in proper working condition.
the cap is removed or the
system is opened in any Remove any debris from the engine compartment.
way, there is danger of Check and repair any fuel, lubrication, and hydraulic
serious burns. systems leaks. Clean any excess oil, fuel or other
flammable fluids, and dispose of properly.
Allow heat and pressure to dissipate before
performing such tasks and follow proper procedures Keep oil and fuel in a designated location and
as outlined in the service manual. accessible by authorized personnel only. Fuel, oil,
and antifreeze can be ignited by a flame. These fluids
To prevent hot coolant from spraying: are extremely flammable and hazardous.
1. Stop the engine, and wait for the coolant When handling fuel and oil obey the following
temperature to decrease. guidelines:
2. Depress the pressure relief button on the
• Keep flames away from flammable fluids.
radiator cap.
• Stop the engine while refueling.
3. Turn the radiator cap slowly to allow pressure
to dissipate. • Never smoke while refueling.
To prevent hot engine oil spray: • Tighten all fuel and oil tank caps securely.
1. Stop the engine. • Refuel and maintain oil in well ventilated areas.
2. Wait for the oil temperature to cool down. ROPS Precautions

3. Turn the cap slowly to allow pressure to NOTE: When modifying or repairing the ROPS,
dissipate. always consult your nearest Komatsu distributor.
Even with the ROPS installed, the operator must
Asbestos Dust Hazard Prevention always use the seat belt when operating the machine.
Asbestos dust is
hazardous to your The ROPS is intended to protect the operator if the
health when inhaled. If machine rolls over. It is designed not only to support
you handle materials the load of the machine, but also to absorb the
containing asbestos energy of the impact. ROPS structures installed on
fibers, follow the equipment manufactured and designed by Komatsu
guidelines below: fulfills all of the regulations and standards for all
countries. If the ROPS is modified or repaired without
• Never use compressed air for cleaning. authorization from Komatsu, or is damaged when the
machine rolls over, the strength of the structure will
• Use water for cleaning and to control dust.
not be able to fulfill its intended purpose. Optimum
• Operate the machine or perform tasks with the wind strength of the structure can only be achieved if it is
to your back, whenever possible. repaired or modified as specified by Komatsu.
980E-4 3-3
Preventing Injury From Work Equipment Any injuries, accidents, and product failures resulting
from the use of unauthorized attachments will not be
Never position any part of your body between movable
the responsibility of Komatsu America Corp., or the
parts such as the dump body, chassis or cylinders.
authorized regional Komatsu distributor.
If the work equipment is operated, clearances will
change and may cause serious bodily injury or death.
Precautions When Starting The Machine
Precautions For Optional Attachments Never attempt to start the
engine by shorting across
NOTE: DO NOT use attachments that are the starter terminals. This
not authorized by Komatsu, or the authorized may cause fire, or serious
regional Komatsu distributor. Use of unauthorized injury or death to anyone
attachments could create a safety problem and in the machine’s path.
adversely affect the proper operation and useful life Start the engine from the
of the machine. operators seat only.
When installing and using optional equipment, read
the instruction manual for the attachment and the
information related to attachments in this manual.
3-4 980E-4
GENERAL SAFETY PRECAUTIONS FOR TRUCK OPERATION
PRECAUTIONS FOR TRUCK Mirrors, Windows, And Lights

OPERATION F.14-0000051230 Remove any dirt from the surface of the windshield,
cab windows, mirrors and lights. Good visibility may
Safety Is Thinking Ahead
prevent an accident. Adjust the mirrors to a position
Prevention is the best safety program. Prevent a where the operator can see best from the operator's
potential accident by knowing the employer's safety seat. Ensure headlights, work lights and taillights are
requirements and all necessary job site regulations. in proper working order. Ensure that the machine
In addition, know the proper use and care of all is equipped with the proper work lamps needed for
the safety equipment on the truck. Only qualified the operating conditions. Always replace any broken
operators or technicians may attempt to operate or mirrors, windows or lights.
maintain a Komatsu machine.
Before Starting The Engine
Safety At The Worksite
NOTE: DO NOT leave tools or spare parts lying
When walking to and from a truck, maintain a safe around or allow trash to accumulate in the cab of the
distance from all machines even when the operator truck. Keep all unauthorized reading material out of
is visible. Before starting the engine, thoroughly the truck cab. Keep the cab floor, controls, steps, and
check the area for any unusual conditions that could handrails free of oil, grease, snow, and excess dirt.
be dangerous. Examine the road surface at the job
site and determine the best and safest method of Before starting the engine perform the following:
operation. Choose an area where the ground is as • Read and understand the contents of the Operation
horizontal and firm as possible before performing the & Maintenance manual. Read safety and operating
operation. If you need to operate on or near a public instructions with special attention. Become
road, protect pedestrians and cars by designating a thoroughly acquainted with all gauges, instruments
person for work site traffic duty or by installing fences and controls before attempting operation of the
around the work site. truck.
Before operating the machine, the operator must • Read and understand the WARNING and
check the work area for obstacles and road conditions. CAUTION decals in the operator’s cab.
Always determine the travel roads to be used at the
work site. Travel roads must be maintained in order • Ensure the steering wheel, horn, controls and
to ensure safe machine travel. If travel through wet pedals are free of any oil, grease, or mud.
areas is necessary, check the depth and flow of water • Check operation of the windshield wiper, condition
before crossing the shallow parts. of wiper blades, and check the washer fluid
reservoir level.
Preparing For Operation • Be familiar with all steering and brake system
Normally use handrails and the diagonal stairway controls, warning devices, road speeds and loading
when mounting or dismounting the truck. Become capabilities, before operating the truck.
familiar with the emergency egress paths and their
operation. Always face vertical ladders and use Seat Belts And Tethers
handrails. Check the deck areas for debris, loose
hardware, and tools. Check for people and objects On both driver and passenger seats, check the seat
that remain on or around the truck. belt and tether fabric, buckles, all belt retractors, and
hardware for damage or wear. Replace any worn or
Become familiar with and use all protective equipment damaged parts immediately.
devices on the truck and ensure that these items
(anti-skid material, grab bars, seat belts, etc.) are Even if there are no signs of damage, replace both
securely in place. driver and passenger seat belts five years after seat
belt manufacture, or every three years after start
of use, whichever comes first. The passenger seat
Ventilation For Enclosed Areas belt date of manufacture label is sewn into the seat
If it is necessary to start belt near the buckle. The driver seat belt date of
the engine in an enclosed manufacture label is sewn into the shoulder harness
area, provide adequate belt, near the retractor end.
ventilation. Exhaust
fumes from the engine
can be lethal.
980E-4 3-5
PRECAUTIONS FOR TRUCK OPERATION GENERAL SAFETY
Emergency Egress Ladders
1. Emergency Egress Latch
Figure 3-1 EMERGENCY EGRESS GATE

Be familiar with the emergency egress locations
and their operations. At each emergency egress
location, there is a gate that allows access to the
ladder. Lift up on emergency egress latch (1, Figure
3-1 EMERGENCY EGRESS GATE, page 3-6) to gain
access to the emergency egress ladder.
3-6 980E-4
GENERAL SAFETY OPERATING THE MACHINE
OPERATING THE
MACHINE G.4-0000051287 • A tire and rim assembly may explode if
General Information subjected to excessive heat. Personnel must
move to a remote or protected location if there
While operating the truck obey the following is a fire near the tire and wheel area or if the
guidelines: smell of burning rubber or excessively hot
• Wear seat belts at all times. Only authorized brakes is evident.
persons are allowed to ride in the truck. • If the truck must be approached, such as to
fight a fire, those personnel must do so only
• Passengers must be in the cab and belted in the while facing the tread area of the tire (front or
passenger seat. back), unless protected by use of large heavy
• DO NOT allow anyone to ride on the decks or on equipment as a shield. Stay at least 15 m (50
the steps of the truck. ft) from the tread of the tire.
• In the event of fire in the tire and wheel area
• DO NOT allow anyone to get on or off the truck while (including brake fires), stay away from the
it is in motion. truck for at least 8 hours or until the tire and
• DO NOT move the truck in or out of a building wheel are cool.
without a signal person present.
• Check for flat tires periodically during a shift. If
• Keep serviceable fire fighting equipment on hand.
the truck has been operating on a “flat”, the truck
Report used extinguishers for replacement or
must not be parked indoors until the tire cools. DO
refilling.
NOT stand in front of the rim and locking ring when
• Always move the directional control lever to PARK inflating a tire mounted on the machine. Observers
(this will apply the parking brake) when the truck is must not be permitted in the area and must be kept
parked and unattended. DO NOT leave the truck away from the side of such tires.
unattended while the engine is running.
NOTE: DO NOT use wheel brake lock when parking
Starting The Engine
the truck. • DO NOT attempt to start the machine by shorting
across the starter terminals. This may cause fire,
• Park the truck a safe distance away from other
or serious injury or death to anyone in machine’s
vehicles as determined by the supervisor.
path.
• Stay alert at all times! In the event of an emergency,
• DO NOT start the engine if a warning tag has been
be prepared to react quickly and avoid accidents.
attached to the controls.
If an emergency arises, know where to get prompt
assistance. When starting the engine, sound the horn as an alert.
• Know and obey hand signal communications Start and operate the machine only while seated in
between the operator and spotter. Use a signal the operator’s seat. DO NOT allow any unauthorized
person when other machines and personnel are persons in the operator's compartment or any other
present, the operator must move in and out of place on the machine.
buildings, and traveling through traffic.
Traveling In The Machine
• Immediately report any adverse conditions on haul
road, pit or dump area that may cause an operating When traveling on rough ground, travel at low speeds.
hazard. When changing direction, avoid turning suddenly.
Lower the dump body before traveling. If the engine
stops when the machine is in motion, emergency
steering and secondary braking enable the truck to
be steered and stopped. A fixed amount of reserve
oil provides temporary steering and braking to briefly
allow the truck to travel to a safe area. Apply
the brakes immediately and stop the machine as
quickly and safely as possible (off of the haul road, if
possible). Apply the parking brake.
980E-4 3-7
OPERATING THE MACHINE GENERAL SAFETY
Traveling In Reverse Minimum Safe

Before operating the Voltage
Distance
machine or work
equipment, do as follows: 50 kV or Less 3.1 m (10 ft.)
50 kV to 200 kV 4.6 m (15 ft.)
200 kV to 350 kV 6.1m (20 ft.)
• Ensure the backup alarm works properly.
350 kV to 500 kV 7.7 m (25 ft.)
• Sound the horn to warn people in the area. 500 kV to 750 kV 10.7 m (35 ft.)
• Check for personnel near the machine. Do a 750 kV to 1000 kV 13.8 m (45 ft.)
thorough check behind the machine.
• When necessary, designate a person to watch The following actions are effective in preventing
the area for the truck operator. This is particularly accidents while working near high voltages:
necessary when traveling in reverse.
• Wear shoes with rubber or leather soles.
• When operating in hazardous areas and areas with
• Use a signalman to give warning if the machine
poor visibility, designate a person to direct work site
approaches an electric cable.
traffic.
• If the work equipment touches an electric cable, the
NOTE: DO NOT allow any one to enter the line operator must not leave the cab.
of travel of the machine. This rule must be strictly
obeyed even with machines equipped with a back-up • When performing operations near high voltage
alarm or rear view mirror. cables, DO NOT allow anyone to approach the
machine.
Traveling On Slopes • Check with the electrical maintenance department
Traveling on slopes could result in the machine tipping about the voltage of the cables before starting
over or slipping. The retarder must be used to reduce operations.
speed when traveling downhill. If the engine shuts
down on a slope, apply the service brakes to fully stop Traveling On Loose Ground
the machine. Park the machine.
Avoid operating the machine near cliffs, overhangs,
• DO NOT change direction on slopes. To ensure and deep ditches. If these areas collapse, the
safety, drive to level ground before turning. machine could fall or tip over and result in serious
injury or death. Remember that ground surfaces in
• DO NOT travel up and down on grass, fallen leaves, these areas may be weakened after heavy rain or
or wet steel plates. These materials may make the blasting. Freshly laid soil and the soil near ditches is
machine slip on even the slightest slope. Avoid loose. Avoid these areas whenever possible.
traveling sideways, and always keep travel speed
low.
Ensuring Good Visibility
• DO NOT turn the steering wheel suddenly.
When working in dark places, install work lamps and
• DO NOT use the foot brake except in an emergency. head lamps. Discontinue operations if visibility is poor,
such as in mist, snow, or rain. Wait for the weather to
Traveling On Snow improve to allow the operation to be performed safely.
When working on snowy or icy roads, there is danger
that the machine may slip to the side on even the Avoid Damage To The Dump Body
slightest slope. Always travel slowly and avoid sudden
starting, turning, or stopping in these conditions. Be
extremely careful when clearing snow. The road • Driving with a raised dump body or raising the
shoulder and other objects are buried in the snow and dump body in an enclosed area, may result
cannot be seen. in serious damage and bodily injury or death.
Always drive with the dump body resting on
Traveling Near High Voltage Cables the frame.
Driving near high-voltage cables can cause electric

shock. Always maintain the safe distances between
the machine and the electric cable as listed below.
3-8 980E-4
GENERAL SAFETY OPERATING THE MACHINE
When working in tunnels, on bridges, under electric slowly operate the dump body. If necessary, use
cables, or when entering an enclosed area where chocks for the wheels or position a flagman. When
there are height limits, always use extreme caution. dumping on slopes, machine stability is poor and
The dump body must be completely lowered before there is danger of tip over. Always perform such
driving. operations using extreme care. Never travel with the
dump body raised.
Safe Parking Of The Machine
Towing The Machine
The operator must continue to use safety precautions
when preparing for parking and stopping the engine. Improper towing methods may lead to serious
personal injury and/or damage.
NOTE: In the event that the machine is being
used in consecutive shifts, any questionable truck Please refer to the following towing methods:
performance the operator may have noticed must be
• Tow with a solid tow bar. DO NOT tow with a cable.
checked by maintenance personnel before the truck
is released to another operator. • Use a towing device with ample strength for the
weight of this machine.
Park the truck on level ground, if possible. If it is
necessary to park on a grade, the truck must be • Towing vehicle must have adequate pulling and
positioned at right angles to the grade. Turn the braking capacity to both move and stop the towed
wheels into a suitable bank, when possible. truck under all conditions, including towing on a
grade.
Haul roads are not safe parking areas. In an
emergency, pick the safest spot most visible to other • When connecting a machine to be towed, DO NOT
machines in the area. If the truck becomes disabled allow anyone to go between the tow machine and
where traffic is heavy, mark the truck with warning the disabled machine.
flags in daylight, or flares at night. • Set the coupling of the disabled machine in a
straight line with the towing portion of the tow
Loading The Machine machine, and secure it in position.
NOTE: DO NOT leave the operator's seat during the • DO NOT stand next to the towing device while the
loading operation. truck is moving.
Ensure the surrounding area is safe. If so, stop the Refer to Operating Instructions - TOWING, page 5-23
machine in the correct loading position and evenly for the towing procedure.
load the body.
Dumping The Machine

Before dumping, check that there is no person or
objects behind the machine. Stop the machine in the
desired location. Give the determined signal, then
980E-4 3-9
EXTERIOR LIGHTING GENERAL SAFETY
EXTERIOR LIGHTING B.7-0000053605
1. Fog Lights 5. Deck Mounted Flood Lights

2. Headlights 6. Brake Lights
3. Ladder Lights 7. Retard Lights
4. Mirror Mounted Backup Lights 8. Clearance/Turn Signal Lights
Figure 3-2 FRONT LIGHTS

Fog Lights the high beam function on the multi-function lever.
The headlight switch must be on for the high beam
Fog lights (1, Figure 3-2 FRONT LIGHTS, page 3-10)
headlights to work. These lights are functional
illuminate when the operator actuates the fog light
regardless of key switch position.
switch located on the dash. The fog lights are low
beam, low level lights used to illuminate a foggy work
area. Ladder Lights and Deck Mounted Flood
Lights
Headlights
Ladder lights (3) illuminate the diagonal ladder steps
Headlights (2) consist of high beam and low beam and deck mounted flood lights (5) illuminate the
headlights. Low beam headlights illuminate when walkway of the deck when the operator actuates the
the operator actuates the headlight switch. The light switch at the base of the ladder. These lights
multi-function lever must be in the low beam position can also be activated by using the ladder light switch
for the low beam headlights to work. High beam in the cab.
headlights illuminate when the operator actuates
3-10 980E-4
GENERAL SAFETY EXTERIOR LIGHTING
Mirror Mounted Backup Lights Retard Light

Mirror mounted backup lights (4) illuminate when Retard light (7) will illuminate when the operator uses
the operator moves the directional control lever to the retard function to slow the truck. The amber light
REVERSE. The lights can also be activated by using signals to traffic that the truck is slowing.
the backup light switch in the cab. Using the switch
turns the lights on regardless of directional control Clearance/Turn Signal Lights
lever position.
Clearance/turn signal lights (8) are dual function
amber lights. When the headlights are on, a low beam
Brake Light clearance light will illuminate. When the operator
Brake light (6) will illuminate when the operator signals a left turn using the multi-function lever, the
depresses the brake pedal. The red light signals to left light will flash. When the operator signals a right
traffic that the truck is stopping. turn using the multi-function lever, the right light will
flash. These lights are functional regardless of key
switch position.
1. Retard Light 3. Backup Alarm

2. Brake Light 4. LED Backup Light
Figure 3-3 REAR AXLE LIGHT BAR

NOTE: The brake light is functional at all times Backup Alarm
regardless of key switch position. All other lights (and
Backup alarms (3) will sound when the operator
the backup alarm) are only functional with the key
moves the directional control lever to REVERSE. The
switch in the RUN position.
alarm can also be turned on by using the backup
light switch. Using the switch turns the alarm on
Retard Lights regardless of directional control lever position.
Retard lights (1, Figure 3-3 REAR AXLE LIGHT BAR,
page 3-11) illuminate when the operator uses the LED Backup Lights
retard function to slow the truck. The amber light
LED backup lights (4) illuminate when the operator
signals to traffic that the truck is slowing.
moves the directional control lever to REVERSE. The
lights can also be activated by using the backup light
Brake Lights switch in the cab. Using the switch turns the lights on
Brake lights (2) will illuminate when the operator regardless of directional control lever position.
depresses the brake pedal. The red light signals to
traffic that the truck is slowing.
980E-4 3-11
PRECAUTIONS FOR MAINTENANCE GENERAL SAFETY
PRECAUTIONS FOR disconnect switch (4) and propel lockout lever (5).
MAINTENANCE C.3-0000051285 The isolation box is located on top of the front bumper,
on the left hand side. To disable the 24VDC electrical
BEFORE PERFORMING system, move both disconnect switches and the
MAINTENANCE A.3-0000072531 propel lockout lever to the OFF position. When the
switches and propel lockout lever are in the OFF
Before performing maintenance on the machine, position, LED lights (8) will be illuminated. The
perform the following: battery disconnect switches and propel lockout lever
• Before performing inspections or maintenance, stop can be padlocked in the OFF position to prevent
the machine on firm, flat ground. Lower the dump unauthorized truck operation. When the switches and
body, place the directional control lever to the PARK the propel lockout lever are in the ON position, LED
position (this will apply the parking brake), and turn lights (7) will be illuminated. Refer to the following
the key switch to the OFF position and wait for the table to ensure the correct disconnect is used to
engine to stop. isolate a desired circuit or system.
• Wait two minutes after the engine has stopped, and NOTE: This is the recommended usage of the battery
if no warning message is displayed, then turn the disconnect and propel lockout switches. Local
battery disconnect switches to the OFF position. regulations may be different.
Verify that the disconnects are functioning.
• Place wheel chocks around the wheels to prevent Recommended
Action
the truck from rolling. Isolation
• If the engine must be operated during maintenance,
24V Electrical
always move the directional control lever to the Starter Lockout
Troubleshooting
PARK position (this will apply the parking brake).
Always perform this work with two people. One 24V Electrical
Master Lockout
person must be in the operator's seat to stop the Maintenance/Repair
engine if necessary. Never move any controls not High Voltage/Propulsion
related to the task at hand during these situations. None
Troubleshooting
Apply the propel lockout lever to prevent the truck
from moving if the engine must operate during High Voltage
Master Lockout
maintenance. When the propel lockout lever is in Maintenance/Repair
the OFF position and the LED light is illuminated, Hydraulic
the drive system is locked out and the truck will Propel Lockout
Troubleshooting
not propel. When the propel lockout lever is in the
ON position and LED light is illuminated, the drive Hydraulic
Starter Lockout
system is active and the truck can be driven. Maintenance/Repair
• When servicing the machine, use care not to touch Engine Troubleshooting Propel Lockout
any moving parts. Never wear loose clothing. Engine Repair Master Lockout
• When performing service with the dump body Mechanical Repair Starter Lockout
raised, always place the dump lever in the HOLD Master Lockout &
position, and apply the lock (if equipped). Install Weld Repair
Alternator Isolation
the body-up safety cable securely.
Fueling Starter Lockout
• Use caution in the work area and be aware of any
potential overhead debris or objects. Lube/General
Starter Lockout
Maintenance
Electrical System Isolation Shift Change Walk
Starter Lockout
Isolation box (6, Figure 3-4 ISOLATION BOX Around
ASSEMBLY (COVERS REMOVED), page 3-13) Oil Sample Collection Propel Lockout
contains master disconnect switch (3), starter
3-12 980E-4
GENERAL SAFETY PRECAUTIONS FOR MAINTENANCE
1. Engine Shutdown Switch 4. Starter Disconnect Switch 7. LED Lights (On)

2. Access Ladder Light Switch 5. Propel Lockout Lever 8. LED Lights (Off)
3. Master Disconnect Switch 6. System Busy Light
Figure 3-4 ISOLATION BOX ASSEMBLY (COVERS REMOVED)

Securing The Dump Body
• To avoid serious personal injury or death,

the body retention sling must be installed
whenever personnel are required to perform
maintenance on the truck while the dump
body is in the raised position.
• The Komatsu body-up safety sling can only be
used with a Komatsu body. Non-OEM body
may not accommodate the Komatsu body-up
safety sling. The end user must ensure that a
proper cable/sling is used.
980E-4 3-13
DURING MAINTENANCE G.26-0000051281
Warning Tag
Always attach a warning tag to the control lever in the

operator's cab to alert others that you are working on
the machine. Attach additional warning tags around
1. Rear Body Ear 3. Body Retention Sling the machine, if necessary. Never start the engine
2. Shackle and Pin or operate the controls while a person is performing
maintenance. Serious injury or death may result.
Figure 3-5 BODY RETENTION SLING
These tags are available from your Komatsu
INSTALLATION
distributor. Part No. 09963-A1640
To hold the dump body in the up position, perform the
following: Proper Tools
1. Raise the body to its maximum height. Use only tools suited to the task. Using damaged, low
quality, faulty, or makeshift tools can cause personal
2. Install two shackles (2, Figure 3-5 BODY injury. Extra precaution must be used when grinding,
RETENTION SLING INSTALLATION, page welding, and using a sledge-hammer.
3-14) and body retention sling (3) between rear
body ear (1) and the axle housing. Attachments
3. Secure the shackle pins with cotter pins. Place attachments, that
have been removed from
4. Move the hoist lever to the FLOAT position the machine, in a safe
to slowly lower the body until the cable is place and manner to
supporting the full weight of the body. Then prevent them from falling.
move the hoist lever to the HOLD position.
5. After maintenance work is completed, return
the sling to stored position. Working Under The Machine
Always lower all movable
work equipment to
the ground or to their
lowest position before
performing service
or repairs under the
machine.
Always chock the tires of the machine securely. Never
work under the machine if the machine is poorly
supported.
3-14 980E-4
Keeping The Machine Clean • Always tighten the cap of the fuel and oil fillers
securely.
• Never use fuel for washing any parts.
• If equipped, DO NOT aim high pressure spray
equipment at or near the Retractable Ladder • Always stop the engine before adding fuel or oil.
System (RLS) power pack, actuator box,
• Always add fuel and oil in a well-ventilated area.
bearings or electrical harnesses. Moisture
introduced in the electrical harnesses may Radiator Coolant Level
result in uncontrolled ladder movement. If it is necessary to add
coolant to the radiator,
Spilled oil, grease, stop the engine. Allow
scattered tools, etc. can the engine and radiator
cause you to slip or to cool down before
trip. Always keep your adding the coolant. Lift
machine clean. the pressure relief lever
on the radiator cap and
slowly loosen the cap to
If water gets into the electrical system, there is danger relieve pressure during
that the machine may move unexpectedly and/or removal.
damage to components may occur. DO NOT use
Use Of Lighting
water or steam to clean any sensors, connectors, or
the inside of the operator’s compartment. When checking
fuel, oil, coolant, or
NOTE: DO NOT spray water into the retarding grids. battery electrolyte,
Excess water in the retarding grids can cause a always use lighting
ground fault, which will prevent propulsion. Never with anti-explosion
spray water into the rear wheel electric motor covers. specifications. If lighting
Damage to the wheel motor armatures may occur. without this protection is
used, there is a danger of
Use extreme care when washing the electrical control
explosion.
cabinet. DO NOT allow water to enter the control
cabinet around the doors or vents. DO NOT allow Handling High Pressure Hoses
any water to enter the cooling air inlet duct above
the electrical control cabinet. If water enters the DO NOT bend high-pressure hoses or hit them with
control cabinet (through any opening or crevice) major hard objects. DO NOT use any bent or cracked piping,
damage to the electrical components may occur. tubes or hoses. They may burst during use. Always
repair any loose or broken hoses. Fuel and/or oil leaks
Adding Fuel Or Oil To The Machine may result in a fire.
Precautions With High Pressure Oil
When working with high pressure oil, obey the

following guidelines:
• Always remember that work equipment circuits are
always under pressure.
When adding fuel or oil to the machine, obey the
following guidelines: • DO NOT add oil, drain oil, or perform maintenance
or inspections before completely releasing the
• Spilled fuel and oil may cause slipping. Always internal pressure.
clean up spills, immediately.
• Small, high pressure pin-hole leaks are extremely
dangerous. The jet stream of high-pressure oil
980E-4 3-15
can pierce the skin and eyes. Always wear safety Use Of Tie-Off Anchor During
glasses and thick gloves. Use a piece of cardboard Maintenance
or a sheet of wood to check for oil leakage. While working at
• If you are hit by a jet of high-pressure oil, consult a heights during assembly,
doctor immediately for medical attention. maintenance or repair
of the haul truck,
Maintenance Near High Temperatures workers should wear an
appropriate fall protection
And High Pressures harness and attach it to
Immediately after a tie-off anchor or tie-off
stopping the truck, the point.
engine coolant and
operating oils are at high Komatsu anchor (58B-98-75190) is available for use
temperature and under with fall protection harnesses. Carefully read and
high pressure. understand the harness maker’s instructions before
using any fall protection harness.
In these conditions, opening the system or replacing
filters may result in burns or other injury. Wait for the The load carrying capacity of anchor (58B-97–75190)
temperature to cool and pressure to subside before is 2 270 kg (5,000 lbs).
performing the inspection and/or maintenance as NOTE: The anchor must not be used for lifting.
outlined in the service manual.
Handling Tires
Rotating Fan And Belts
Keep a safe distance
from rotating parts such • DO NOT stand in front of a rim and locking ring
as the radiator fan and when inflating a tire mounted on the machine.
fan belts. Serious bodily Observers must not be permitted in the area.
injury may result from • DO NOT weld or heat the rim assembly with
direct or indirect contact the tire mounted on the rim. Resulting gases
with rotating parts and inside the tire may ignite, causing explosion
flying objects. of the tire and rim.
Waste Materials Rim and tire maintenance can be hazardous unless

Obey appropriate laws the correct procedures are followed by trained
and regulations when personnel.
disposing of harmful
objects such as oil, fuel, Improperly maintained or inflated tires can overheat
coolant, solvent, filters, and burst due to excessive pressure. Improper
batteries, and others. inflation can also result in cuts in the tire caused by
sharp stones. Both of these conditions can lead to
Always put fluids drained from your machine in tire damage, serious personal injury, or even death.
appropriate containers. Never drain fluids directly
To safely maintain a tire, adhere to the following
onto the ground. Never dump oil or other harmful
conditions:
fluids into a sewer system, rivers, etc.
• Before a tire is removed from a vehicle for tire
The machine may be equipped with optional high
repair, the valve core must be partially removed to
intensity discharge lamps which contain mercury.
allow deflation, and then the tire/rim assembly can
These lamps must be reused, recycled or properly
be removed. During deflation, persons must stand
disposed of in accordance with applicable local, state
outside of the potential trajectory of the locking ring
and federal laws.
of a multi-piece wheel rim.
• After the tire/rim assembly is installed on the
vehicle, inflate the tires to their specified pressure.
Abnormal heat is generated, particularly when the
inflation pressure is too low.
• Use the specified tires.
3-16 980E-4
To prevent injury from the wheel rims during tire Mounted tires stored as spares must be inflated to the
inflation, use one of the following: minimum inflation pressure necessary to keep the tire
beads properly seated. Maximum inflation pressure
1. A wheel cage or other restraining device that of the stored tire must, in no instance, exceed 15% of
will constrain all wheel rim components during the tire’s cold inflation pressure.
an explosive separation of a multi-piece wheel
rim, or during the sudden release of air.
Battery Hazard Prevention
2. A stand-off inflation device which permits
a person to stand outside of the potential
trajectory of the wheel components.
The tire inflation pressure and permissible speeds,
given in this manual, are general values. The actual
values may differ, depending on the type of tire and
the specific operating conditions. For details, please
consult the tire manufacturer.
NOTE: DO NOT weld near the rim or tire if the tire is
inflated.
When the tires become overheated, a flammable
gas is produced inside the tire which can ignite. Before repairing the electrical system or when
It is particularly dangerous if the tires become performing welding, turn the key switch to the OFF
overheated while the tires are pressurized. If the position. Wait two minutes after the engine has
gas generated inside the tire ignites, the internal stopped, and if no warning message is displayed,
pressure will suddenly rise, and the tire will explode, then turn the master disconnect switch and starter
resulting in danger and/or death to personnel in the disconnect switch to the OFF position.
area. Explosions differ from punctures or tire bursts
Battery electrolyte contains sulfuric acid and can
because the destructive force of the explosion is
quickly burn the skin and eat holes in clothing. If
extremely large.
electrolyte comes in contact with skin, immediately
flush the area with water.
Tire Maintenance
Battery acid can cause blindness if splashed into the
If the proper procedure for performing maintenance or
eyes. Always wear safety glasses or goggles when
replacement of the wheel or tire is not used, the wheel
working with batteries. If acid gets into the eyes, flush
or tire may burst, causing damage, serious injury, or
them immediately with large quantities of water and
even death. When performing such maintenance,
see a doctor immediately.
consult your shop manual, your authorized regional
Komatsu distributor, or the tire manufacturer. If acid is accidentally ingested, drink a large quantity
of water, milk, beaten eggs or vegetable oil. Call a
Storing Tires After Removal doctor or poison prevention center immediately.
When working with batteries, obey the following
guidelines:
• Batteries generate hydrogen gas. Hydrogen gas
is very explosive, and is easily ignited with a small
spark or flame.
• Before working with batteries, stop the engine
and turn the key switch to the OFF position. Wait
Store the tires in a warehouse in which unauthorized
two minutes after the engine has stopped. If no
persons cannot enter. If the tires are stored outside,
warning message is displayed, then turn the battery
erect a fence around the tires with warning signs.
disconnect switches to the OFF position.
Stand the tire on level ground, and chock it securely
so that it cannot roll or fall over. If the tire falls, flee • Avoid short-circuiting the battery terminals through
the area as quickly as possible. The tires for mining accidental contact with metallic objects, such as
equipment are extremely heavy. DO NOT attempt to tools, across the terminals.
hold a tire upright when the tire is falling. The weight
of these tires may lead to serious injury or death.
980E-4 3-17
• When removing or installing a battery, positively When jump starting the machine with jumper cables,
identify the positive (+) terminal and negative (-) obey the following guidelines:
terminal and use precautions not to short circuit
between the terminals. 1. Ensure the parking brake is applied on both
machines. The engine on the good machine
• This truck is equipped with a master disconnect must be operating.
switch on the battery ground circuit. When
disconnecting battery cables, always move the 2. Ensure the size of the jumper cables and clips
master disconnect switch to the OFF position. are suitable for the battery size. Inspect the
Disconnect the positive (+) battery cables first, then cables and clips for any damage or corrosion.
disconnect the negative (-) battery cables. 3. Ensure the key switch and the master battery
disconnect switch on the disabled machine are
in the OFF position.
4. Connect the batteries in parallel: positive to
positive and negative to negative.
5. Connect the positive (24VDC +) cable from the
good machine to the (24VDC +) on the disabled
machine first.
6. Then connect the ground cable from the
negative (-) battery terminal on the good
machine to the frame of the disabled machine,
as far away as possible from the batteries.
This will prevent a spark from possibly starting
a battery fire.
1. Off 3. System Busy Light
7. Move the master battery disconnect switch to
2. On
the ON position. Allow time for the batteries to
Figure 3-6 MASTER DISCONNECT SWITCH charge.
NOTE: If the master disconnect switch is OFF, and 8. If starting with a jumper cable, perform the
a wrench on the negative (-) terminal touches the operation with two people. One person must
battery box frame, a spark will occur if any electrical be in the cab of the disabled machine, the
component on the truck was left in the ON position. other person must be working with the jumper
cables.
NOTE: Do not turn the Master Disconnect Switch
OFF if the green System Busy Light is illuminated. 9. If the batteries are low, DO NOT attempt to
Electrical components are still operating and damage start the machine with only one set of jumper
can occur if the 24 volt power is removed before those cables installed. Install the second set of
components properly shutdown. jumper cables in the same way as already
described.
• When connecting battery cables, always move
the master disconnect switch to the OFF position. 10. Attempt to start the disabled machine.
Connect the negative (-) cables first, then the 11. For jumper cable removal, disconnect the
positive cables (+) last. ground or negative (-) cable first, then the
• Tighten battery terminals securely. Loose terminals (24VDC +) cable last.
can generate sparks and could lead to an explosion. NOTE: If any tool touches between the positive (+)
• Tighten battery caps securely. terminal and the chassis, it will cause sparks. Always
use caution when using tools near the batteries.
Jump Starting With Jumper Cables Jump Starting With Receptacles
• Always wear safety glasses or goggles when • Always wear safety glasses or goggles when
starting the machine with jumper cables. DO starting the machine with jumper cables. DO
NOT allow the two machines to touch while NOT allow the two machines to touch while
jump starting with another machine. jump starting with another machine.
3-18 980E-4
When jump starting the machine with receptacles, be in the cab of the disabled machine, the
obey the following guidelines: other person must be working with the jumper
cables.
1. Ensure the parking brake is applied on both
machines. The engine on the good machine 7. If the batteries are low, DO NOT attempt to
must be operating. start the machine with only one set of jumper
cables installed. Install the second set of
2. Inspect the cables and connectors for any jumper cables in the same way as already
damage or corrosion. described.
3. Ensure the key switch and master battery 8. Turn the master battery disconnect switch
disconnect switch on the disabled machine are to the ON position and attempt to start the
in the OFF position. disabled machine.
4. Connect the jumper cable to the receptacle 9. For jumper cable removal, disconnect the
on the good machine to the receptacle on the cables from each machine.
disabled machine.
NOTE: If any tool touches between the positive (+)
5. Allow time for the batteries to charge.
terminal and the chassis, it will cause sparks. Always
NOTE: The batteries will charge even with the master use caution when using tools near the batteries.
battery disconnect switch in the OFF position.
6. If starting with a jumper cable, perform the
operation with two people. One person must
980E-4 3-19
WHEN REPAIRS ARE NECESSARY GENERAL SAFETY
WHEN REPAIRS ARE all current regulations for handling and recycling
NECESSARY E.8-0000051280 refrigerants are followed.
• Follow package directions carefully when using
Observe The Following Precautions
cleaning solvents.
• If an auxiliary battery assist is needed, refer to Jump
• Any operating fluid, such as hydraulic oil Starting with Jumper Cables or Jump Starting with
or brake fluid escaping under pressure, can Receptacles earlier in this section.
have sufficient force to enter a person's body
• Before performing any welding on the truck, always
by penetrating the skin. Serious injury and
turn the battery disconnect switches to the OFF
possibly death may result if proper medical
position and disconnect the alternator positive
treatment by a physician familiar with this
cable. Failure to do so may seriously damage the
injury is not received immediately.
battery and electrical equipment. It is not necessary
to disconnect or remove any control circuit cards
on electric drive dump trucks.
• DO NOT stand in front of a rim and locking ring Always fasten the welding machine ground (-) lead
when inflating a tire mounted on the machine. to the piece being welded; the grounding clamp
Observers must not be permitted in the area. must be attached as near as possible to the weld
• DO NOT weld or heat the rim assembly with area. Never allow welding current to pass through
the tire mounted on the rim. Resulting gases ball bearings, roller bearings, suspensions, or
inside the tire may ignite, causing explosion hydraulic cylinders. Always avoid laying welding
of the tire and rim. cables over or near the vehicle electrical harnesses.
Welding voltage could be induced into the electrical
harness and cause damage to components.
• Only qualified maintenance personnel who
understand the systems being repaired must • If a truck is to be towed for any reason, use a rigid
attempt repairs. tow bar. Check the truck cab for decals for special
towing precautions. (Refer to TOWING, page 5-23.)
• Many components on the Komatsu truck are large
and heavy. Ensure that lifting equipment - hoists, • Drain, clean and ventilate fuel tanks and/or
slings, chains, lifting eyes - are of adequate capacity hydraulic tanks before making any welding repairs.
to handle the lift.
• Relieve pressure in lines or hoses before making
• DO NOT stand under a suspended load. DO NOT any disconnects.
work under raised body unless body safety cables,
• After adjustments or repairs, replace all shields,
props, or pins are in place to hold the body in up
screens and clamps.
position.
• Working near tires can be dangerous. Use extreme
• DO NOT repair or service the truck while the engine
caution when working around tires.
is running, except when adjustments can only be
made under such conditions. Keep a safe distance • Only a qualified operator or experienced
from moving parts. maintenance personnel who are also qualified in
operation can move the truck under its own power
• When servicing any air conditioning system with
in the repair facility or during road testing after
refrigerant, wear a face shield and cold resistant
repairs are complete.
gloves for protection against freezing. Ensure
3-20 980E-4
GENERAL SAFETY SPECIAL PRECAUTIONS
SPECIAL PRECAUTIONS F.25-0000051279
Preliminary Procedures Before Welding • Notify your Komatsu service representative,

Or Performing Maintenance immediately. Only qualified personnel,
specifically trained for servicing the A-C drive
system, must perform this service.
• Before opening any cabinets or touching a
grid element or a power cable, the engine 6. Replace all covers and doors and place the
must be shutdown and the red drive system GF cutout switch and battery disconnect
warning lights must not be illuminated. switches in their original positions. Reconnect
all harnesses prior to starting the truck.
Prior to welding and/or repairing, maintenance 7. Leave the drive system in the rest mode until
personnel must attempt to notify a Komatsu service the truck is to be moved.
representative. Only qualified personnel, specifically
trained for servicing the AC drive system, must Before Welding On The Machine, Obey
perform this service.
The Following Guidelines:
Engine Shutdown Procedure Before • Before doing any welding on the truck, always
Welding or Performing Maintenance disconnect the battery charging alternator lead
Normal operation of the drive system at shutdown will wire.
leave the system safe to maintain. However, in the • DO NOT weld on the rear of the control cabinet. The
event of a system failure, performing the following metal panels on the back of the cabinet are part of
procedure prior to any maintenance activities will capacitors and cannot be heated.
ensure that no hazardous voltages are present in the
AC drive system. • DO NOT weld on the retard grid exhaust louvers
- they are made of stainless steel. Some power
1. Before shutting down the engine, verify there cable panels throughout the truck are also made of
are no warning messages being displayed on aluminum or stainless steel. They must be repaired
the instrument panel. with the same material or the power cables may be
damaged.
2. If any drive system warnings are illuminated
on the status indicator light panel, DO NOT • Power cables must be cleated in wood or other
attempt to open any cabinets, disconnect any non-ferrous materials. DO NOT repair cable cleats
cables, or reach inside the retarder grid cabinet by encircling the power cables with metal clamps or
without a trained drive system technician hardware. Always inspect power cable insulation
present - even if engine is off. prior to servicing the cables and prior to returning
the truck to service. Discard cables with broken
3. If there are no drive system warning messages,
insulation.
refer to Safe Parking Of The Machine, page 3-9
for parking instructions. • Power cables and wiring harnesses must be
protected from weld spatter and heat.
4. After the engine has been off for at least five
minutes, inspect the link voltage lights on • Always fasten the welding machine ground (-) lead
the exterior of the main control cabinet. If all to the piece being welded; the grounding clamp
lights are off, the retard grids, wheel motors, must be attached as near as possible to the weld
alternator, and related power cables are safe area.
to work on.
• Always avoid laying welding cables over or near the
5. Ensure both battery disconnect switches are vehicle electrical harnesses. Welding voltage could
in the OFF position. Verify that the battery be induced into the electrical harness and cause
disconnects are functioning. damage to components.
NOTE: If the red lights on the exterior of the control • Never allow welding current to pass through ball
cabinet and/or the back wall of the center console bearings, roller bearings, suspensions, or hydraulic
continue to be illuminated after the above procedure, cylinders.
a fault has occurred. Leave all cabinet doors in place;
DO NOT touch the retard grid elements; DO NOT
disconnect any power cables, or use them as hand
or foot holds.
980E-4 3-21
SPECIAL PRECAUTIONS GENERAL SAFETY
Discharging Control Cabinet Capacitors Because a danger can still exist with the capacitor
charge lights off, refer to the shop manual “Manual
The control cabinet is equipped with two capacitor
Discharge of Capacitors” before servicing the drive
charge lights, one on the exterior of the cabinet and
system. Adhere to the proper procedures for disabling
one in the interior. The capacitor charge lights, when
the drive system. Only authorized service personnel
off, indicate to service personnel that the drive system
are allowed to service the drive system.
is safe to work on. Certain drive system failures,
however, can result in a condition where one or more
capacitors can remain in a charged state even though
the capacitor charge lights are off.
3-22 980E-4
WARNING AND CAUTIONS
980E-4 4-1
GENERAL INFORMATION WARNING AND CAUTIONS
because of customer options, individual trucks may
GENERAL INFORMATION C.3-0000051318 have plates and decals that are different from those
shown here.
The following pages give an explanation of the
warning, caution, and service instruction plates and The plates and decals must be kept clean and legible.
decals attached to the truck. The plates and decals If any decal or plate becomes illegible or damaged, it
listed here are typical of this Komatsu model, but must be replaced with a new one.
PIN PLATE A.4-0000073410
A product identification plate is located on the frame

in front of the right side front wheel and shows the
truck model number, maximum GVW and Product
Identification Number (PIN).
NOTE: This product identification plate may vary
depending on engine options.
The PIN consists of 19 total characters. The first and
last characters are tamper preventative symbols (*).
The remaining 17 alpha/numeric characters are used
to identify 5 characteristics of the machine. The 5
characteristics are detailed below.
WMC - Character positions 1, 2 and 3 identify the
Worldwide Manufacturer Code (WMC). The WMC
designates the manufacturer of the product. Komatsu
brand products are identified with the letters KMT.
MDS - Character positions 4, 5, 6, 7 and 8 identify the
Machine Descriptor Section (MDS). The MDS code
identifies general information regarding machine
specifications. The MDS is a code for the machine
type and model.
CL - Character position 9 identifies the Check Letter
(CL). The CL is used to verify the accuracy of the
individual PIN.
YDC - Character position 10 identifies the year
designation code which refers to the year the machine
was completed
PC - Character position 11 identifies the plant code
which defines the location of manufacture.
SN - Character positions 12, 13, 14, 15, 16, and 17
identify the Serial Number (SN). The SN is a unique
sequential number.
4-2 980E-4
WARNING AND CAUTIONS GRADE SPEED CHART
GRADE SPEED CHART A.1-0000072551
A grade/speed retard chart is located on the left

front post of the operator's cab and provides the
recommended maximum speeds to be used when
descending various grades with a loaded truck.
Always refer to the decal in operator's cab. This
decal may change with optional truck equipment such
as wheel motor drive train ratios, retarder grids, tire
sizes, etc.
MACHINE SAFETY D.8-0000051326
Warning plates are mounted on the frame in front of,

and to the rear, of both front tires. All personnel are
warned that the clearances change when the truck is
steered and could cause serious injury.
980E-4 4-3
MACHINE SAFETY WARNING AND CAUTIONS
Warning plates are attached to both the hydraulic tank

and fuel tank to alert technicians not to work on the
truck with the body in the raised position unless the
body-up retention device (cable/sling) is in position.
A caution decal is also attached to the door of the rear

hatch cover to alert personnel that hot exhaust air is
present and may cause injury.
This caution decal is also placed around the retarding
grid cabinet.
This information decal is placed on the outside of the

door panel on the control cabinet wall that faces the
right side of the operator cab.
This decal is located by the emergency ladder on both

sides of the truck.
4-4 980E-4
WARNING AND CAUTIONS MACHINE SAFETY
This decal is located in the cab on the overhead dash

panel. Wireless signals from the truck’s KOMTRAX
Plus system can interfere with other wireless signals
in the area. This interference can cause a malfunction
in a blast zone resulting in an unintended detonation.
Know the locations of blast zones in the area and
keep a safe distance to avoid unintentional blasts.
Operating frequency of KOMTRAX Plus is 148 MHz
to 150 MHz.
This decal is located on the drive shaft guard, the

alternator belt guard, and the A/C compressor belt
guard.
980E-4 4-5
KEY SWITCH WARNING AND CAUTIONS
KEY SWITCH E.2-0000051325
A warning decal is located below the key switch, to the

right of the steering column on the instrument panel.
The warning stresses the importance of reading the
operator's manual before operation.
OIL FILL AND CHECK C.3-0000051324
A plate on the side of the hydraulic tank furnishes

instructions for filling the hydraulic tank.
Keep the system open to the atmosphere only as
long as absolutely necessary to lessen the chances
of system contamination. Service the tank with clean
Type C-4 hydraulic oil. All oil being put into the
hydraulic tank must be filtered using filters rated at
three microns.
A caution decal is attached below the hydraulic tank

oil level sight gauge. Check level with body down,
engine stopped, and key switch OFF. Add oil per filling
instructions, if oil level is below top of sight glass.
4-6 980E-4
WARNING AND CAUTIONS HIGH PRESSURES
A wheel motor oil level decal is attached to the gear

cover on both electric wheel motors. This decal
stresses the fact that the truck must be on a level
surface and parked for 20 minutes prior to checking
the oil level. This is necessary in order to get an
accurate reading.
HIGH PRESSURES F.36-0000051323
A warning plate is mounted on top of the radiator

surge tank cover near the radiator cap. The engine
cooling system is pressurized. Always turn the key
switch OFF and allow the engine to cool before
removing the radiator cap. Unless the pressure
is first released, removing the radiator cap after the
engine has been operating for a time will result in the
hot coolant being expelled from the radiator. Serious
scalding and burning may result.
These danger plates are mounted on the outside

of each frame rail by the steering accumulators,
brake accumulators and the accessory accumulators.
These danger plates alert technicians to read the
warning labels attached to the side of each of the
accumulators (see below) prior to releasing internal
nitrogen pressure or disconnecting any hydraulic
lines or hardware. There are similar decals mounted
on top of each of the accumulators (steering, brake
and accessory) with the same danger message.
Warning decals are applied to the inside of the

brake system cabinet behind the operator cab.
These decals remind servicing technicians to close
the accumulator drain valves after they have been
opened to bleed brake pressure. It further warns not
to over-tighten the drain valves to prevent damage to
the valve seat(s).
980E-4 4-7
HIGH PRESSURES WARNING AND CAUTIONS
This warning plate is located on the inside and outside

of the brake system cabinet doors. This warning plate
alerts the technician to stop the engine, turn the key
switch OFF, and open the drain valves on all three
accumulators to bleed the hydraulic system pressure
before disconnecting a brake line.
This danger plate is attached to all four suspensions.

The plate contains instructions for releasing internal
pressure before disconnecting any hardware. Serious
injury can occur if these directions are not followed.
• Any operating fluid, such as hydraulic oil

or brake fluid escaping under pressure, can
have sufficient force to enter a person's body
by penetrating the skin. Serious injury and
possibly death may result if proper medical
treatment by a physician familiar with this
injury is not received immediately.
A warning plate is attached to the hydraulic tank to

inform technicians that high pressure hydraulic oil
is present during operation. When it is necessary
to open the hydraulic system, ensure the engine
is stopped and key switch is OFF to bleed down
hydraulic pressure. There is always a chance of
residual pressure being present. Open fittings slowly
to allow all pressure to bleed off before removing any
connections.
4-8 980E-4
WARNING AND CAUTIONS BATTERY AND ISOLATION BOX
This warning decal is located below the battery

disconnect switches and on the front of the battery
box to warn personnel not to disconnect the batteries
during the first 90 seconds after turning the key switch
off.
Turn the key switch to the OFF position and wait for
the engine to stop. After the engine has stopped, wait
two minutes, and if no warning message is displayed,
then turn the battery disconnect switches to the OFF
position.
The first 90 seconds after the key switch is turned
off is the bleeddown process. Turning the battery
disconnect switches off within 90 seconds could
interrupt the bleeddown process and leave stored
energy in the accumulator. Wait two minutes
after the engine has stopped, then observe for
bleeddown malfunction warning message on the
instrument panel. If warning is being displayed,
notify maintenance immediately. Turning the battery
disconnect switches to the OFF position sooner than
two minutes could mask a problem that was detected
during the bleeddown process.
This decal is placed on both front wheel hubs to warn

about hot oil inside the wheel hubs. Remove the oil
level plug carefully to avoid injury.
BATTERY AND ISOLATION

BOX D.35-0000051322
This plate is placed on isolation box cover and the
battery box cover to indicate that the battery system
(24VDC) is a negative (-) ground system.
980E-4 4-9
BATTERY AND ISOLATION BOX WARNING AND CAUTIONS
This decal is located on the battery box cover.

It details the correct procedure for disconnecting
the battery cables from the batteries. Before
disconnecting the battery cables, turn the key switch
to the OFF position and wait for the engine to stop.
After the engine has stopped, wait two minutes, and
if no warning message is displayed, then turn the
battery disconnect switches to the OFF position.
This decal is placed on the cover for the ground

level engine shutdown switch to indicate where
the emergency shutdown control is located. The
shutdown switch is mounted above the isolation box.
This decal is located below the engine shutdown

switch. It is used for emergency shutdown only. Push
the button in to stop the engine.
This decal is located on the isolation box. The

isolation box contains the disconnect switches that
can be used to isolate the cranking motor, battery
and propulsion system circuits.
4-10 980E-4
WARNING AND CAUTIONS BATTERY AND ISOLATION BOX
These plates are located above the battery disconnect

switches on the isolation box to indicate the OFF and
ON positions of the switches.
If the system busy light, green LED light, is
illuminated, do not turn off 24V power to the truck.
Electrical system components are still in operation
and must be shut down.
The master switch will disconnect the batteries from
the entire electrical system.
The cranking motor switch will disconnect the power
supply to the two cranking motors. This will prevent
the truck from starting, but will allow for diagnostic
testing of the electrical system if the master switch is
still ON.
Stop the engine and turn the key switch to the OFF
position. After the engine has stopped, wait two
minutes, and if no warning message is displayed,
then turn the battery disconnect switches to the
OFF position. After the key switch is turned OFF,
the interface module remains on, monitoring the
park brake function and the accumulator bleeddown
function. If a failure in either system is detected, an
alarm will sound to notify the operator of a failure in
that system. If the battery disconnect switches are
turned OFF without waiting two minutes, a potential
failure could be masked. Always use the battery
disconnect switches before:
• Storing the machine for more than one month
• Replacing electrical system components
• Performing welding maintenance
• Handling batteries, or starting with jumper cables
• Replacing fuses or fusible links
980E-4 4-11
BATTERY AND ISOLATION BOX WARNING AND CAUTIONS
This plate is located above the propel lockout lever on

the isolation box to indicate the OFF and ON positions
of the lever. When this lever is placed in the OFF
position, the truck’s AC electric drive system is locked
out and the truck will not propel. When the lever is
placed in the ON position, the truck’s AC electric drive
system will function and the truck can be driven.
• Sulfuric acid is corrosive and toxic. Use

proper safety gear, goggles, rubber gloves
and rubber apron when handling and
servicing batteries. Get proper medical help
immediately, if required
Attached to the exterior of both battery compartments

is a danger plate. This plate stresses the need
to keep from making any sparks near the battery.
When another battery or 24VDC power source is
used for auxiliary power, all switches must be OFF
prior to making any connections. When connecting
auxiliary power cables, positively maintain correct
polarity. Connect the positive (+) posts together and
then connect the negative (-) lead of the auxiliary
power cable to a good frame ground. DO NOT
connect to the negative posts of the truck battery
or a ground near the battery box. This hookup
completes the circuit but minimizes danger of sparks
near the batteries.
4-12 980E-4
WARNING AND CAUTIONS HIGH VOLTAGE
HIGH VOLTAGE E.28-0000051321
A high voltage danger plate is attached to the door of

the rear hatch cover. High voltage may be present!
Only authorized personnel can access this rear
housing.
980E-4 4-13
HIGH VOLTAGE WARNING AND CAUTIONS
These warning plates are mounted on all of the AC

drive control housings and cabinets.
High voltage may be present, with or without, the
engine running.
Only authorized personnel can access these
cabinets.
4-14 980E-4
WARNING AND CAUTIONS HIGH VOLTAGE
This decal is placed near two different indicator lights:

• On the front of the control box which is mounted on
the right side of the main control cabinet.
• On the outside of the left control cabinet wall that
faces the right side of the operator cab.
NOTE: When any of these indicator lights are on,
high voltage is present throughout the propulsion and
retarding system. Extreme care must be exercised!
This caution decal is placed on the back of the control

cabinet to alert service technicians that this area
contains capacitors and must not be disturbed in any
manner.
980E-4 4-15
WELDING WARNING AND CAUTIONS
WELDING E.6-0000051320
This caution decal is on the front of the battery box

to alert servicing technicians that before doing any
welding on the truck, always disconnect the battery
charging alternator lead wire before making any
welding repairs.
Turn the key switch to the OFF position and wait for
the engine to stop. After the engine has stopped, wait
two minutes, and if no warning message is displayed,
then turn the battery disconnect switches to the
OFF position. Then disconnect the battery charging
alternator lead wire.
NOTE: Always fasten the welding machine ground (-)

lead to the piece being welded; grounding clamp must
be attached as near as possible to the weld area.
Never allow welding current to pass through ball

bearings, roller bearings, suspensions, or hydraulic
cylinders. Always avoid laying welding cables over
or near the vehicle electrical harnesses. Welding
voltage could be induced into the electrical harness
and possibly cause damage to components.
4-16 980E-4
WARNING AND CAUTIONS LIFTING POINTS
LIFTING POINTS E.31-0000051319
This page illustrates a variety of decals which are

mounted on deck mounted cabinets, housings, and
structures which must be lifted in a specific manner,
and from specific points, in order to safely move or lift
any of these structures.
If any of these decals are damaged or defaced, so that
it is no longer legible, it must be replaced immediately.
NOTE: Maintenance personnel must follow these
lifting instructions.
980E-4 4-17
EMERGENCY DUMPING WARNING AND CAUTIONS
EMERGENCY DUMPING E.2-0000051378
A decal plate located on the frame near the left hoist

cylinder provides the operator or technician with the
hook-up procedure for dumping a loaded, disabled
truck. The use of a functional truck for hydraulic power
is required.
Refer to the shop manual for additional instructions for
using this procedure.
4-18 980E-4
WARNING AND CAUTIONS ROPS/FOPS
ROPS/FOPS D.2-0000051375
A plate attached to the right rear corner of the cab

states the Rollover Protective Structure (ROPS) and
Falling Object Protective Structure (FOPS) meet
various SAE performance requirements.
NOTE: DO NOT make modifications to this structure,
or attempt to repair damage without written approval
from Komatsu. Unauthorized repairs will void
certification.
TOWING E.16-0000051374
A decal plate is located on the frame near the

hydraulic tank. It provides the operator or technician
with the hydraulic hook-up procedure before towing a
disabled truck, by using a functional truck for hydraulic
power. Refer to the TOWING PROCEDURE, page
5-23 in this manual for additional instructions on
towing.
A decal plate is located near the tow bumper.

It provides the operator or technician with the
instructions for towing an empty truck. Refer to the
TOWING PROCEDURE, page 5-23 in this manual
for additional instructions on towing.
LUBRICATION CHART E.26-0000051373
The lubrication chart is mounted on the left hand

side of the radiator grille structure. Refer to the lube
chart in the lubrication and service section later in this
manual for more complete lubrication instructions.
980E-4 4-19
LUBRICATION CHART WARNING AND CAUTIONS
4-20 980E-4
OPERATING INSTRUCTIONS
980E-4 5-1
PREPARING FOR OPERATION OPERATING INSTRUCTIONS
inspection is a systematic ground level inspection of
PREPARING FOR the truck and its components to ensure that the truck
is safe to operate before entering the operator's cab.
OPERATION A.4-0000072557
Start at the left front corner of the truck (Figure 5-1
The safest trucks are those which have been properly
WALK AROUND INSPECTION, page 5-3), and move
prepared for operation. At the beginning of each shift,
in a counter-clockwise direction. Move front-to-rear,
a careful check of the truck must be made by the
across the rear, and continuing forward up the
operator before starting the engine.
opposite side of the truck to the original starting point.
Safety Is Thinking Ahead If these steps are performed in sequence, and are
repeated from the same point and in the same
Prevention is the best safety program. Prevent a direction before every shift, many potential problems
potential accident by knowing the employer's safety may be avoided, or scheduled for maintenance.
requirements, all necessary job site regulations, as Unscheduled downtime and loss of production can
well as use and care of the safety equipment on the be reduced as a result.
truck. Only qualified operators or technicians can
operate or maintain a Komatsu truck. Local work practices may prevent an operator from
performing all tasks suggested here. To the extent
Safe practices start before the operator gets to the permitted, the operator must follow this or a similar
equipment! routine.
• Wear the proper clothing. Loose fitting clothing,
unbuttoned sleeves and jackets, jewelry, etc., can
catch on a protrusion and cause a potential hazard. • High voltage may be present on this truck!
DO NOT open any electrical cabinet doors on
• Always use the personal safety equipment provided
the truck while the engine is operating! Never
for the operator such as hard hats, safety shoes,
climb on any power cables or use power
safety glasses or goggles. There are some
cables for handholds or footholds, unless the
conditions when protective hearing devices must
engine has been shut off and the system has
also be worn for operator safety.
been verified as at rest!
• When walking to and from the truck, maintain a safe
distance from all machines, even if the operator is
visible.
Walk Around Inspection

At the beginning of each shift, a careful walk around
inspection of the truck must be performed before the
operator attempts engine start-up. A walk around
5-2 980E-4
OPERATING INSTRUCTIONS PREPARING FOR OPERATION
1. Operator Cab 10. Hoist Filters 19. Rear Axle Hatch

2. Engine Mounted Fuel Filters 11. Steering Filter 20. AC Electric Motor
3. Auto Lubrication 12. Fuel Tank 21. Hydraulic Tank
4. Radiator 13. Hoist Cylinder 22. Steering Pump
5. Reserve Oil System 14. Rear Axle Housing 23. Hoist Pump
6. Engine 15. Wheel Motor Transmission 24. Hydraulic Brake Filter
7. Front Suspension 16. Rear Tires 25. Steering Accumulators
8. Wet Disc Brake 17. Wet Disc Brake 26. Alternator
9. Brake Accumulators 18. Rear Suspension 27. Auxiliary Accumulator
Figure 5-1 WALK AROUND INSPECTION
1. Start at left front of the truck. While performing all lights and safety equipment for external
the walk around inspection, visually inspect damage from rocks or misuse. Ensure lenses
980E-4 5-3
are clean and unbroken. Make sure that the 12. Look under the lower edge of the chassis to
battery box covers are in place and secure. ensure the flexible duct that carries the air from
the blower to the final drive housing is in good
2. Inspect auto lube system. Refer to
condition with no holes or breakage. Also,
AUTOMATIC LUBRICATION SYSTEM, page
look up at the main hydraulic pumps to see
5-67, for specific details concerning the auto
that there is no leakage or any other unusual
lube system.
condition with the pumps or the pump drive
3. Move in front of the left front tire. Inspect the shafts.
hub and brake assemblies for leaks and any
13. Move around the left side dual tires. Ensure
abnormal conditions.
that all wheel nuts/studs are in place and tight.
4. Check that all suspension attaching hardware Inspect the wheel for any oil that would indicate
is secure and inspect the mounting key area for brake leakage or wheel motor leakage.
evidence of wear. Check that the suspension
14. Check the dual tires for cuts, damage or
rod extension is correct, and that there are
bubbles. Check for evidence of incorrect tire
no leaks. Ensure the suspension protective
inflation. If the truck has been operating on a
boot is in good condition. Inspect the hub and
flat tire, the tire must be cool before moving
brakes for any unusual conditions. Check the
the truck inside a building. Check for any rocks
entire area for leaks.
that might be lodged between the dual tires.
5. Inspect the anchor end of the steering cylinder
15. Inspect the left rear suspension for damage
for proper greasing and all parts are secure.
and for correct rod extension. Check for leaks.
6. Inspect air conditioner belts for correct tension, Ensure that the covers over the chrome piston
obvious wear, and tracking. Check the security rod are in good condition. Inspect for proper
and condition of the fan guard. When leaving greasing.
this point, turn off the service light, if used.
16. Open the rear hatch cover (19), turn on the
7. Move outside of the front wheel. Ensure that work light if necessary. Inspect for leaks
all of the mounting nuts/studs are in place and around wheel motor mounting to rear housing,
tight. Check the tires for cuts, damage, or and also brake hoses and fittings. Ensure
bubbles. Check for evidence of incorrect tire that covers on wheel motor sump are in place,
inflation. and that there are no rags or tools left behind.
Inspect condition of hatch cover gasket, report
8. Move behind the front wheel and ensure the
any bad gasket to maintenance. Turn off work
steering cylinder is properly greased and that
light if used, close and latch hatch.
the mounting hardware is tight. Ensure all
suspension attaching hardware is secure and 17. While standing in front of the rear hatch, look
inspect the mounting key area for evidence of up to see that rear lights are in good condition,
wear. Check that the suspension rod extension along with the back-up horns. Look up at the
is correct, and that there are no leaks. Ensure anti-sway bar to see that it is getting proper
the suspension protective boot is in good greasing. Also look at both body hinge pins
condition. Inspect the hub and brakes for any for greasing and any abnormal condition.
unusual conditions. Check the entire area for Check the hoist limit switch and clear any
leaks. mud/debris. Check integrity and condition of
the body-up limit switch. Remove any mud/dirt
9. Inspect the sight glass on hydraulic tank. With
accumulation from the switch.
the engine stopped and the body down, the
hydraulic oil level must be visible in the center 18. Perform the same inspection on the right rear
of the upper sight glass. suspension as done on the left.
10. If equipped, verify all hydraulic tank shut off 19. Move in behind the right dual tires. Check the
valves are locked in their fully open positions. dual tires for cuts, damage or bubbles. Check
for evidence of incorrect tire inflation. If the
11. Move around the hydraulic tank and in front of
truck has been operating on a flat tire, the tire
the rear dual tires. Inspect hoist cylinder for
must be cool before moving the truck inside a
any damage and leaks. Inspect both upper
building. Check for any rocks that might be
and lower hoist cylinder pins for integrity and
lodged between the dual tires.
for proper greasing.
5-4 980E-4
OPERATING INSTRUCTIONS PREPARING FOR OPERATION
20. Ensure that all wheel nuts/studs are in place are in place and in good condition. Ensure that
and tight. Inspect the wheel for any oil that the battery disconnect switches are activated.
would indicate brake leakage or wheel motor Ensure the isolation and lockout switches are
leakage. on (closed).
21. Move in front of the right dual tires and inspect 30. Always use handrails and the ladder when
hoist cylinder in the same manner as the left mounting or dismounting the truck. Clean the
side. ladder and steps and hand rails of any foreign
material, such as ice, snow, oil or mud.
22. Move around the fuel tank. Inspect the
mounting hardware for the fuel tank at the 31. Use the stairs and handrails while climbing
upper saddles and at the lower back side of from the first level to the cab deck.
the tank. Check the hoist filters for leaks.
23. Move in behind the right front wheel. Ensure
that the steering cylinder is properly greased • Always mount and dismount ladders facing
and the mounting hardware is secure. Check the truck. Never attempt to mount or dismount
the suspension mounting hardware and while the truck is in motion.
suspension extension. Ensure that the
suspension protective boot is in good condition. 32. If equipped with a retractable ladder system:
Inspect the hub and brakes for any unusual
a. Visually inspect the ladder for mechanical
conditions. Inspect for leaks around the
damage. If movement is impaired in any
auxiliary accumulator. Check the entire area
way, the assembly must be repaired.
for leaks.
b. Visually inspect for cleanliness. Ensure the
24. Move outside of the front wheel. Ensure that
ladder is dry and free from grease and oil.
all of the mounting nuts/studs are in place and
tight. Check the tires for cuts, damage, or c. Check for loose parts or any adverse noise
bubbles. Check for evidence of incorrect tire conditions.
inflation.
d. Ensure the movement alarm operates
25. Move in behind the front of the right front correctly.
wheel, check the hub and brakes for leaks
e. Check for any change in equipment
and any unusual condition. Inspect the
appearance, especially that which will
steering cylinder for secureness and for proper
affect ladder system stability.
greasing. Inspect the engine compartment for
any leaks and unusual conditions. Inspect the 33. Use the coolant level sight gauge to check the
fan guard and belts. Check for any rags or coolant level in the radiator. If it is necessary
debris behind the radiator. to remove the radiator cap, ensure that the
engine is off, then relieve the coolant pressure
26. With the engine stopped, check the engine oil
by slowly removing the radiator cap.
level. To obtain an accurate measurement,
remove the dipstick and wipe it off. Then
reinsert the dipstick and remove it again to
check the oil level. Use the service light if • If the engine has been running, allow the
necessary. coolant to cool before removing the fill cap
or draining the radiator. Serious burns may
27. If the truck is equipped with an engine oil result if skin comes in contact with hot
reserve tank, check that the oil level is visible coolant.
in the upper sight glass.
28. While in front of the radiator, inspect for any 34. Inspect the covers over the retarding grids and
debris in the radiator and remove. Check for ensure they are secure. Inspect the main air
any coolant leaks. Inspect headlights and fog inlet to ensure it is clear. Ensure all cabinet
lights. door latches are secure.
29. Before climbing the ladder to first level, ensure 35. Move to the back of the cab. Open the doors
that the ground level engine shutdown switch to the brake cabinet and inspect for leaks.
is ON. If equipped, inspect the fire control
36. Clean the cab windows and mirrors. Clean out
actuator. Ensure that the safety pin and the
the cab floor as necessary. Ensure steering
plastic tie that prevents accidental actuation
980E-4 5-5
wheel, controls and pedals are free of any oil, 38. Adjust the seat and the steering wheel for use.
grease or mud.
39. Read and understand the description of all
37. Stow personal gear in the cab in a manner that operator controls. Become familiar with
does not interfere with truck operation. Dirt all control locations and functions before
or trash buildup, specifically in the operator's operating the truck.
cab, must be cleaned. DO NOT carry tools or
supplies in the cab of the truck or on the decks.
5-6 980E-4
OPERATING INSTRUCTIONS RETRACTABLE LADDER SYSTEM (If Equipped)
RETRACTABLE LADDER SYSTEM • When in the truck’s cab, always use the retractable
(If Equipped) B.13-0000051682 ladder switch to raise the ladder.
• Report defects to maintenance personnel
General Information
immediately.
Ladder System Description

The RLS is a hydraulic ladder powered by the truck’s
auxiliary hydraulic system. The RLS provides a
means to mount and dismount the truck under normal
and emergency conditions. There is a controller on
the retractable ladder system that monitors the park
brake and activates alarms and lights via the IM
module.
Ladder System Operation

During normal operation, a person can activate the
RLS by using the following components:
• In-cab retractable ladder switch
• Ground level down switch located on the front edge
of the left or right hand platform
• Emergency down valve located on the left or right
hand side of grille
As an added measure to prevent damage to the
ladder, the RLS monitors the parking brake and
requires the parking brake to be set before the ladder
Figure 5-2 RETRACTABLE LADDER SYSTEM can be operated under normal conditions. The RLS
The following safety procedures, at a minimum, must will automatically raise the ladder if the operator
be followed to ensure safe operation and use of the releases the parking brake and fails to use the
Retractable Ladder System (RLS). retractable ladder switch before attempting to drive
the truck.
• DO NOT run or jump on the ladder.
Retractable Ladder Switch
• DO NOT overload the ladder. Use the ladder one
person at a time.
• Hold onto the handrail when using the ladder. • When in the operator’s cab, always use the
retractable ladder system button to raise
• DO NOT attempt to ride on the ladder while it is
the ladder instead of releasing the parking
being raised or lowered or while the truck is in
brake. The automatic operation of the ladder
motion.
when the parking brake is released is an
• Visually check the ladder before use to ensure the emergency feature only. DO NOT release the
unit has not been damaged. parking brake to raise the ladder as part of
normal operation. If the ladder down light
• Ensure the ladder is in the fully down position before
flashes, stop immediately or ladder damage
boarding.
may result.
• Keep hands and fingers away from pinch points
while the ladder is in motion.
Raising the Ladder
• Check to ensure no personnel are on or in the
The ladder will typically be in the lowered position
immediate vicinity of the ladder while it is in motion.
on a stationary truck. The status indicator panel
• The ladder must be kept clean and free of moisture, will illuminate indicating that the ladder is DOWN by
grease and oil. illuminating the retractable ladder down light.
980E-4 5-7
RETRACTABLE LADDER SYSTEM (If Equipped) OPERATING INSTRUCTIONS
To raise the ladder, press and momentarily hold the Lowering the Ladder
in-cab retractable ladder switch, in the UP position.
To lower the ladder, push in ground level ladder down
The ground level alarm will sound for 15 seconds.
switch (1). Ladder operation via this switch overrides
After five seconds, the ladder will start to raise. When
the controller and any in-cab swtch states. The ladder
the ladder is completely raised, the retractable ladder
will remain down until ladder down switch (1) is pulled
down light on the status indicator light panel will be off.
out. The ladder will then resume normal operation
Lowering the Ladder once the switch is pulled out.
NOTE: The parking brake must be applied before the
ladder can be lowered.
Emergency Down Valve
To lower the ladder, press and hold (temporarily) the

retractable ladder switch, located in the cab, in the
DOWN position. The ground level alarm will sound
for 15 seconds. After five seconds the ladder will start
to lower.
When the ladder starts to move, the retractable ladder
down light on the status indicator panel will be on.
Ground Level Ladder Down Switch
1. Emergency Down Valve
Figure 5-4 EMERGENCY DOWN VALVE

In an emergency, the RLS ladder can be lowered
by using the emergency down valve (1, Figure 5-4
EMERGENCY DOWN VALVE, page 5-8) located on
the left or right hand side of grille. The emergency
down valve relieves ladder system hydraulic pressure
and allows the ladder to smoothly lower to the ground.
1. Ground Level Ladder
Down Switch To lower the ladder, pull the button on the valve.
Figure 5-3 GROUND LEVEL LADDER DOWN To reset the ladder, push the button, the ladder will
SWITCH return to normal functionality.
Ground level ladder down switch (1, Figure 5-3 NOTE: The button on the emergency down valve must
GROUND LEVEL LADDER DOWN SWITCH, page be pressed to the IN position before activating the
5-8) is located on the front edge of the left hand ladder again.
platform. It contains a push button switch to lower the
ladder.
NOTE: The ladder cannot be raised by the in cab
switch if the ground level switch is pushed in.
5-8 980E-4
OPERATING INSTRUCTIONS PRE-SHIFT BRAKE TEST
PRE-SHIFT BRAKE TEST C.13-0000051315 For example if the engine is off:

NOTE: Komatsu recommends that operators perform • ERROR: Entering Brake Test, Engine Not Running
static brake tests to verify that the braking systems
If the Truck is loaded:
are adequate at the beginning of each shift before
operating the truck. • ERROR Entering Brake Test, Truck is NOT Empty
The static brake test allows the operator to check If all of the conditions are correct, except the brakes
the service brake, parking brake and the dynamic are not set correctly, an error message will be
retarder. The purpose of these tests is to verify the displayed. For example, if the service brake and
functionality of the service brake, parking brake and parking brake are both applied together:
retarder systems at the time they are tested.
• ERROR Entering Brake Test, Set Brakes for Test
After performing each test, it is the operator’s
responsibility to determine if the truck passed each Table 5-1 BRAKE TEST SETTINGS
test and if the truck is safe for operation. Wheel Service Directional
Test
The order of performing the brake tests, (service Brake Brake Control
Type
brake, parking brake or retard system) does not Lock Pedal Lever
matter. Each brake test is a separate test, where one
Service Fully
brake system or all three can be tested at any time. Off Neutral
Brake Applied
If an operator has questions during brake testing, refer Parking
to the drive system Diagnostic Information Display Off Released Park
Brake
(DID) panel, located on the back wall of the cab for
guidance. Retard
Off Released Park
Test
• If the truck fails any brake test, notify NOTE: The drive system will not enter any brake test
maintenance personnel immediately. Do not if the truck is loaded.
resume operation unless the truck passes all Before performing any brake test, the following
brake tests. conditions must be met:
• Dump body is empty.
Operation • Truck located outside on a flat area, where truck
The operator can choose which brake test to perform, movement is allowed.
and will set the truck controls based on the settings in
Table 5-1 BRAKE TEST SETTINGS, page 5-9. The
drive system will detect the position of the directional • Ensure the area around the truck is free of
control lever, and will prepare for the appropriate test. personnel and objects. Some truck movement
The operator will then press the brake test switch. could occur during brake testing.
• The drive system is unable to determine if the
If the brake check light is illuminated solid after truck is on a hill or in a parking ditch. Testing
pressing the brake test switch, the system is in brake during these conditions will affect test results.
test mode and is ready for the chosen test to be
initiated by the operator. After testing, the operator
will then determine if the truck passed the brake tests, Before performing any brake test, the truck must be in
and if it is safe for operation. the following state:
If the brake check light does not illuminate • Engine at (low idle)
immediately after pressing the brake test switch, there • Drive system ready (Ready Mode)
is most likely a problem with the setup. Refer to the
setup conditions and take action to prepare the truck • Dump body down
for a brake test. • No drive system warning messages displayed
If there is a problem with the truck setup, the DID panel • Can not be in LIMP mode
will display the problem.
• Zero ground speed
980E-4 5-9
PRE-SHIFT BRAKE TEST OPERATING INSTRUCTIONS
Service Brake Test 8. Place the directional control lever in the PARK
position. Release the service brake pedal.
9. If the truck failed the service brake test, notify
• If the truck fails any brake test, notify
maintenance personnel immediately.
maintenance personnel immediately. Do not
resume operation unless the truck passes all NOTE: If the operator partially or fully releases
brake tests. the accelerator pedal during the test, torque will
be reduced and the brake check light will go back
To perform the service brake test, obey the following on solid when torque falls below the test set point.
guidelines: The operator can re-apply the accelerator pedal to
increase torque and the brake check light will again
1. Firmly depress the service brake pedal. flash when the torque is at the test limit.
2. Place the directional control lever in the If the test exits abnormally, or if the operator simply
NEUTRAL position. Ensure the wheel brake does not press the accelerator pedal far enough to
lock switch is OFF. achieve the torque level for the service brake test, the
3. Press the brake test switch and wait for the DID panel will display:
brake check light to be on solid. “Brake Test ERROR, Test did NOT complete”
4. Fully depress the service brake pedal. Ensure
full brake application is reached. Failure to
Parking Brake Test
reach full brake application will affect the
service brake test results.
The DID panel will display: maintenance personnel immediately. Do not
resume operation unless the truck passes all
“Service Brake Test READY, Press Accel Pedal
brake tests.
to Start”
5. With the service brake pedal still fully applied,
To perform the parking brake test, obey the following
fully depress the accelerator pedal. The drive
guidelines:
system controller will enter propel mode and
generate torque up to the service brake limit. 1. Place the directional control lever in the PARK
Maintain full service brake pressure during the position.
test.
2. Press the brake test switch and wait for the
The DID panel will display: brake check light to be on solid.
“Service Brake Test ACTIVE, Check Truck The DID panel will display:
Movement when Light Flashes”
“Parking Brake or Retard Test READY, Press
NOTE: The drive system can only detect if the service Accelerator or Retard Pedal to Start”
brakes are applied. It can not detect the percentage
3. Fully depress the accelerator pedal. The drive
of application. It is up to the operator to press hard
system controller will enter propel mode and
enough on the service brake pedal to achieve a full
generate torque up to the park brake limit.
brake application.
The DID panel will display:
6. Once torque has reached the limit for the
service brake test, the brake check light will “Park Brake Test ACTIVE, Check Truck
begin to flash. This is the indication for the Movement when Light Flashes”
operator to make a determination as to the
4. Once the torque has reached the limit for the
status of the service brake system.
parking brake test, the brake check light will
• If the truck did not move, the service brake begin to flash. This is the indication for the
system passed the test. operator to make a determination as to the
status of the parking brake system.
• If the truck moved during the test, the service
brake system failed the test. • If the truck did not move, the park brake
system passed the test.
7. Release the accelerator pedal and the torque
will be reduced, the test will stop and the brake • If the truck moved during the test, the
check light will turn off. park brake test has failed. Release the
5-10 980E-4
OPERATING INSTRUCTIONS PRE-SHIFT BRAKE TEST
accelerator pedal. If the truck starts to roll, “Retard System Test ACTIVE, RP1, RP2,
apply the service brakes to hold the truck RP3, CHOP” (Elements are added as the test
stationary. Notify maintenance personnel progresses.)
immediately.
Upon successful completion of the test, the
5. When the operator releases the accelerator light will flash for 10 seconds indicating a
pedal, torque will be reduced. The test will successful test. The DID panel will display:
stop and the brake check light will turn off.
“Retard System Test PASSED”
Retard System Test “Retard System Test FAILED or Incomplete”
NOTE: If the brake check light never flashes, but turns
off, the test has failed.
maintenance personnel immediately. Do not 5. When the operator releases the retard pedal,
resume operation unless the truck passes all the test will stop and the brake check light will
brake tests. turn off.
6. If the retard system failed the test, notify
To perform the retard system test, obey the following maintenance personnel immediately. Do not
guidelines: resume operation unless the truck passes all
brake tests.
1. Place the directional control lever in the PARK
position.
Brake Test Exit Criteria
2. Press the brake test switch and wait for the
Conditions which may interrupt a brake test, including
brake check light to be on solid.
the following:
The DID panel will display:
• Any of the setup conditions becoming false
“Parking Brake or Retard Test READY, Press
Accel or Retard Pedal to Start” • Drive system fault which restricts the LINK or Propel
mode
3. Fully depress the retard pedal. The drive
system controller will ramp up the engine • Truck Speed greater than 3.2 kph (2.0 mph)
speed, close RP1, close RP2, close RP3 • Drive system at torque level for more than 30
(if present), turn on the choppers, and test seconds
the retarding system. The system will verify
current flow through each grid leg and the grid • Brake test requested, but not initiated by the
blower motor. operator within 60 seconds after pressing the brake
test switch
4. The DID panel will display the current status of
the test.
980E-4 5-11
TRUCK OPERATION OPERATING INSTRUCTIONS
TRUCK OPERATION D.1-0000051314 7. After the engine has started, place the rest
switch in the OFF position to enable the drive
ENGINE START-UP SAFETY C.91-0000051311 system.
NOTE: The electric cranking motors have a 30
• Never attempt to start the engine by shorting second time limit. If the 30 second limit is reached,
across the cranking motor terminals. This cranking will be prohibited for two minutes. After two
may cause a fire, or serious injury or death to minutes, cranking will be allowed. If the 30 second
anyone in the machine’s path. limit is reached seven consecutive times, the key
switch must be turned to the OFF position. This will
allow the interface module to power down and reset,
NOTE: Start the engine from the operator’s seat only. which requires seven minutes to complete. A warning
Always obey the following guidelines when starting the will appear in the digital display if the 30 second time
engine: limit or seven attempts reached.
1. Ensure all personnel are clear of the truck NOTE: In cold ambient conditions and when the
before starting the engine. Always sound engine is cold, the engine rpm will not increase above
the horn as a warning before actuating any low idle speed until the engine controller determines
operational controls. If the truck is in an it is safe to do so. This time delay will vary from 30
enclosure, ensure there is adequate ventilation seconds to 11 minutes which allows the coolant and
before start-up. Exhaust fumes are dangerous! engine oil to warm up.
2. The retractable ladder, if equipped, must be in

After Engine Has Started
the UP position before starting.
1. Become thoroughly familiar with steering and
3. Move the rest switch to the ON position to put
emergency controls. After the engine has
the drive system in rest mode of operation.
been started, DO NOT accelerate engine
Refer to the INSTRUMENT PANEL, page 6-18
speed or drive truck until low pressure and
section for information about the rest switch.
warning systems are normal, and the coolant
4. If the truck is equipped with auxiliary cold temperature is at least 71° C (160° F).
weather heater system(s), DO NOT attempt
2. With the service brakes applied, move the
to start the engine while the heaters are in
directional control to the NEUTRAL position,
operation. Damage to coolant heaters will
then apply the wheel brake lock. Release
result!
the service brakes. Test the truck steering in
5. The key switch is a four position (ACC, OFF, extreme right and left directions. If the steering
RUN, START) switch. The ACC position is not system is not operating properly, shut the
currently used. When the switch is rotated one engine off immediately. Determine the steering
position clockwise, it is in the RUN position system problem and have it repaired before
and all electrical circuits (except START) are resuming operation.
activated. Turn key switch to the RUN (not
3. Operate each of the truck's brake circuits
START) position. Verify that all indicator lights
at least twice prior to operating and moving
and gauges are functioning.
the truck. These circuits include individual
6. With the directional control lever in PARK, activation from the operator's cab of the service
and after the message “System Initializing” brake, parking brake, and wheel brake lock.
is displayed on the dash, rotate the key With the engine running and with the hydraulic
switch fully clockwise to the START position, circuit fully charged, activate each circuit
and hold this position until the engine starts individually.
(see NOTE below). The START position is
To operate each brake circuit, perform the
spring-loaded and will return to RUN when the
following:
key is released.
a. Park the truck on level ground.
NOTE: This truck is equipped with an engine prelube
system. With this feature, a noticeable time delay b. To operate the park brake, place the
may occur (while the engine lube oil passages are directional control lever in the PARK
being filled and pressurized) before engine cranking position.
will begin.
5-12 980E-4
OPERATING INSTRUCTIONS TRUCK OPERATION
c. To operate the wheel brake lock, apply

the service brake and move directional
control lever to neutral. Release service • The truck is equipped with traction control
brakes, and apply wheel brake lock. Turn (often referred to as "slip/slide" control). If
the wheel brake lock OFF, then back ON this function becomes inoperative, operating
again. the truck with stalled or free spinning wheel
motors may cause serious damage to wheel
d. Release wheel brake lock and apply motors! If the truck does not begin to move
service brakes several times. within ten seconds after depressing the
e. With service brakes applied, move throttle pedal (directional control lever in
directional control lever to PARK. a drive position), release the throttle pedal
and allow wheels to regain traction before
4. If any application or release of any brake circuit accelerating again.
appears sluggish or improper, or if warning
alarms are activated on application or release,
shut the engine off and notify maintenance • Always look to the rear before reversing the truck.
personnel. DO NOT operate the truck until the Watch for and obey the ground spotter's hand
brake circuit in question is fully operational. signals before traveling in reverse. Sound the horn
(three blasts). The spotter will have a clear view of
5. Check the gauges, check for warning the total area at the rear of the truck.
messages and instruments before moving
the truck to ensure proper system operation • Operate the truck only while properly seated with
and proper instrument functioning. Pay seat belt fastened. Keep hands and feet inside the
special attention to braking and steering circuit cab compartment while the truck is in operation.
hydraulic warning messages. If any warning • Check gauges and instruments frequently during
messages are displayed, shut off the engine operation for proper readings.
immediately and determine the cause.
• Observe all regulations pertaining to the job site's
6. Ensure the headlights, work lights and taillights traffic patterns. Be alert to any unusual traffic
are in proper working order. Good visibility may patterns. Obey the spotter's signals.
prevent an accident. Check operation of the
windshield wipers. • Match the truck speed to haul road conditions and
slow the truck in congested areas. Keep a firm grip
7. After engine startup, allow the reserve engine on the steering wheel at all times.
oil pumping unit to run for 5 minutes before
operating the truck. Check the operation of the • DO NOT allow the engine to run at idle for extended
pumping unit. Refer to LED Monitor Light, page periods of time.
5-76 in Reserve Engine Oil System. • Check the brake lock performance periodically to
8. Any time the truck is moving and engine speed ensure safe loading and dumping.
is above 1,200 rpm and the throttle pedal is
released, engine speed will hold at 1,200 rpm.
• DO NOT use the brake lock for parking.
MACHINE OPERATION SAFETY When the engine is turned off, hydraulic
pressure will bleed down, allowing the brakes
PRECAUTIONS H.27-0000051309
to release!
After the truck engine is started and all systems are
functioning properly, the operator must follow all local • Proceed slowly on rough terrain to avoid deep ruts
safety rules to ensure safe machine operation. or large obstacles. Avoid traveling close to soft
edges and near the edges of a fill area.
• If the red warning light is illuminated and • Truck operation requires a concentrated effort by
any warning messages are displayed, or if the driver. Avoid distractions of any kind while
any gauge reads in the red area during truck operating the truck.
operation, a malfunction is indicated. Stop the
truck as soon as safety permits, and stop the
engine. Have the problem corrected before
resuming truck operation.
980E-4 5-13
Machine Operation On The Haul Road speeds for descending various grades with a loaded
truck.
While traveling on the haul road, obey the following
guidelines: • When operating the truck in darkness, or when
visibility is poor, DO NOT move the truck unless
• Always stay alert. If unfamiliar with the haul road, all headlights, clearance lights, and tail lights are
drive with extreme caution. Cab doors must remain on. DO NOT back the truck if the back-up alarm or
closed at all times if the truck is in motion or lights are inoperative. Always dim the headlights
unattended. when approaching oncoming vehicles.
• Obey all road signs. Keep the truck under control • Check the tires for proper inflation during each
at all times. Govern truck speed by the road shift. If the truck has been operating on a flat or
conditions, weather and visibility. Report poor under-inflated tire, the truck must remain outside of
haul road conditions immediately. Muddy or icy any buildings until the tire cools.
roads, pot holes or other obstructions can present
hazards.
Starting On A Grade With A Loaded Truck
• Initial propulsion with a loaded truck must begin
Initial propulsion with a loaded truck should begin from
from a level surface whenever possible. At times,
a level surface whenever possible. If the truck must be
starting on a hill or grade cannot be avoided. Refer
started on a hill or grade, use the following procedure:
to Starting On A Grade With A Loaded Truck, page
5-14 later in this chapter. 1. Apply the wheel brake lock.
• Before traveling in reverse, give a back-up signal of 2. Release the service brake pedal. Do not use
three blasts with the horn and wait until the area is the retarder to hold the truck on the grade.
clear. Before starting forward, signal with two blasts
with the horn and wait until the area is clear. These 3. With the brake lock applied, move the
signals must be given each time the truck is moved directional control lever to a drive position
forward or backward. (FORWARD or REVERSE) and increase the
engine RPM with the throttle pedal.
• Use extreme caution when approaching a haul
road intersection. Maintain a safe distance from NOTE: Releasing and reapplying dynamic retarding
oncoming vehicles. during a hill start will result in loss of propulsion.
• Maintain a safe distance when following another Retarding On A Grade

vehicle. Never approach another vehicle from the
rear, in the same lane, closer than 15 m (50 ft). The grade/speed retard chart provides the
When driving on a down grade, this distance must recommended maximum retarding limits for
not be less than 30 m (100 ft). descending grades with a fully loaded truck.
• If the warning light on the dash panel illuminates and The decal in the truck may differ from the decal shown
a warning message is displayed on the dash panel here due to optional truck equipment such as wheel
during operation, steer the truck immediately to a motor drive train ratios, retarder grids, tire sizes, etc.
safe area away from other traffic, if possible, and Always refer to the decal in the operator's cab and
stop the truck. follow the recommendations for truck operation.
• DO NOT stop or park on a haul road unless The operator must reference this chart before
unavoidable. If the truck must be stopped on a haul descending any grade with a loaded truck. Proper
road, park in a safe place, move the directional use of dynamic retarding will maintain a safe speed.
control lever to PARK, and shut the engine off
The list is matched to the truck at maximum Gross
before leaving the cab. Block the wheels securely
Vehicle Weight (GVW). The ratings are guidelines
and notify maintenance personnel for assistance.
for proper usage of the retard function on downhill
• While driving on a slope, maintain a speed that will grades. The numbers on the chart indicate the
ensure safe driving and provide effective retarding combination of speeds and grades at which the
under all conditions. Refer to Dynamic Retarding, vehicle can safely negotiate for unlimited time or
page 6-5. Refer to the grade/speed retard chart in distance during retarding.
the operator's cab to determine maximum safe truck
5-14 980E-4
3. When approaching or leaving a loading area,

watch for other vehicles and for personnel
working in the area.
4. When pulling in under a loader or shovel, follow
the spotter’s or the shovel operator’s signals.
The truck operator may speed up loading by
observing the location and loading cycle of the
truck being loaded ahead, and then following a
similar pattern.
5. During loading, the operator must stay in the
truck cab with the engine running. Place the
directional control lever in NEUTRAL and apply
the brake lock.
6. When loaded, pull away from the shovel as
quickly as possible with extreme caution.
1. Grade Speed Chart
Dumping
Figure 5-5 GRADE SPEED CHART LOCATION
It is possible to exceed the thermal capacity of the
• DO NOT move the truck with the dump body
drive system components. A warning buzzer will
raised except for emergency purposes only.
sound alerting the operator 15 seconds before the
Failure to lower the body before moving
reduction in retarding performance takes place and
the truck may cause damage to the hoist
the need for a reduction in speed. A warning message
cylinders, frame and/or body hinge pins.
will be displayed on the instrument panel to reduce
truck speed. The operator must control the speed
of the truck in accordance to the speeds on the
grade/speed chart. The operator must use the retard • Dumping very large rocks (10% of payload
speed control (RSC) or retard lever to quickly slow or greater) or sticky material (loads that do
the truck to the maximum retarding limits (or less) not flow freely from the body) may allow
based on the grade the truck is currently traveling. If the material to move too fast and cause the
additional braking effort is required to slow the truck body to move rapidly and suddenly. This
down to (or below) recommended speeds, use the sudden movement may jolt the truck violently,
brake pedal as necessary. possibly causing injury to the operator and/or
DO NOT exceed these recommended maximum damage to the hoist cylinders, frame, and/or
speeds when descending grades with a loaded truck. body hinge pins.
Passing Perform the following

• DO NOT pass another truck on a hill or on a blind when raising the dump
curve. body:
• Before passing, ensure the road ahead is clear. If a 1. Approach the dump area with extreme caution.
disabled truck is blocking your lane, slow down and Ensure the area is clear of persons and
pass with extreme caution. obstructions, including overhead utility lines.
• Use only the areas designated for passing. Obey signals as directed by the spotter, if
present.
Loading 2. Avoid unstable areas. Keep a safe distance
To load the truck, perform the following: from the edge of the dump area. Position the
truck on a solid, level surface before dumping.
1. Approach the loading area with caution.
3. Carefully maneuver the truck into the dump
Remain at a safe distance while the truck
position. When backing the truck into the dump
ahead is being loaded.
position, use only the brake pedal to stop and
2. DO NOT drive over unprotected power cables. hold the truck. DO NOT rely on the brake lock
980E-4 5-15
to stop the truck. This control is not modulated Lowering The Dump Body (When
and applies the rear service brakes only. Dumping On Flat Ground)
4. When the truck is stopped and in dump
position, apply the brake lock and move the
directional control lever to the NEUTRAL • DO NOT move the truck with the dump body
position. raised except for emergency purposes only.
Failure to lower the body before moving
5. Pull the hoist lever to the rear (to RAISE the truck may cause damage to the hoist
position) to actuate the hoist circuit. (Releasing cylinders, frame and/or body hinge pins.
the lever anywhere during the raise cycle will
hold the body at that position.)
Perform the following
when lowering the dump
body:
• As the body raises, the truck center of gravity
will move. The truck must be on level surface
It is very likely when
to prevent tipping/rolling!
dumping on flat ground
that the dumped material
will build up enough to
prevent the body from
lowering.
In this case, the truck will have to be driven forward

a short distance (just enough to clear the material)
before the body can be lowered.
1. Shift the directional control lever to FORWARD,
release the brake lock, depress the override
button and drive just far enough forward for
the body to clear the material. Stop, shift the
directional control lever to NEUTRAL, and
apply the brake lock.
2. Move the hoist lever forward to the LOWER
position and release. Releasing the lever
places the hoist control valve in the FLOAT
position, allowing the body to return to the
frame.
1. Raise 3. Float If dumped material builds up at the rear of the

2. Hold 4. Lower body and the body cannot be lowered, then
perform the following steps:
Figure 5-6 HOIST CONTROL
a. Move the hoist lever back to the RAISE
6. Raise the engine rpm to accelerate the hoist position to fully raise the dump body. Then
speed. release the lever so it returns to the HOLD
7. Reduce the engine rpm as the last stage of position.
the hoist cylinder begins to extend. Keep the b. Move the directional control lever to
engine speed at low idle as the last stage FORWARD, release the brake lock,
reaches half-extension. depress the override button, and drive
8. Release the hoist lever as the last stage of the forward to clear the material.
hoist cylinder reaches full extension. c. Stop, move the directional control lever to
NOTE: If the directional control lever is in REVERSE NEUTRAL, apply the brake lock, and lower
when the dump body is raised, reverse propel is the body.
inhibited. To deactivate, lower the dump body and
move the directional control lever out of REVERSE.
5-16 980E-4
NOTE: When an attempt to lower the body is the brake lock, and carefully leave the dump
unsuccessful because of material obstruction, raise area.
the body back up. This will help to prevent the body
from suddenly dropping when pulling away from the SUDDEN LOSS OF ENGINE POWER
obstruction. OR LOSS OF DRIVE SYSTEM
3. With the body returned to the frame, move the FUNCTION F.13-0000051428
directional control lever to FORWARD, release The loss of engine power and/or drive system will
the brake lock, and carefully leave the dump result in loss of retard/propel functions on the truck.
area. Under loss of retard/propel conditions, the truck
should be immediately stopped using the service
Lowering The Dump Body (When brakes. In all cases, the service brakes should be
Dumping Over A Berm Or Into A Crusher) utilized to stop the truck.
• DO NOT move the truck with the dump body • Dynamic retarding will not be available. DO
raised except for emergency purposes only. NOT use the service brakes for continuous
Failure to lower the body before moving retarding purposes.
the truck may cause damage to the hoist
cylinders, frame and/or body hinge pins.
If the engine and/or drive system functionality is lost,
there is enough hydraulic pressure stored in the brake
Perform the following and steering accumulators to allow the operation of
when lowering the dump the steering and brake functions. However, this oil
body: supply is limited so it is important to stop the truck as
quickly and safely as possible.
1. Move the hoist lever to the LOWER position
and release. Releasing the lever places the If the brake supply pressure drops to a pre-determined
hoist control valve in the FLOAT position, level, the red warning light will illuminate and a
allowing the body to return to the frame. buzzer will sound. If the brake pressure continues
to decrease, the auto-apply feature will activate and
NOTE: If dumped material builds up at the rear of the the service brakes will apply automatically to stop the
body and the body cannot be lowered, perform Steps truck.
a and b below:
When loss of engine power or drive system function
a. Move the hoist lever back to the RAISE occurs, perform the following:
position to fully raise the dump body.
Release the hoist lever to return it to the 1. Bring the truck to a safe stop as quickly as
HOLD position. possible by using the foot pedal to apply the
service brakes. If possible, safely steer the
NOTE: DO NOT drive forward if the tail of the body will truck to the side of the road while braking.
not clear the crusher wall in the fully raised position.
2. As soon as the truck has stopped moving, park
b. Move the directional control lever to the truck.
FORWARD, release the brake lock.
Depress the override button and drive 3. Slowly release the service brakes to check the
forward to clear the material. Stop, shift capacity of the parking brake. If the parking
the directional control lever to NEUTRAL, brake can not hold the truck stationary, apply
apply the brake lock and lower the body the service brakes and hold them ON. DO NOT
again. turn the key switch OFF, and DO NOT release
the service brakes.
NOTE: When an attempt to lower the body is
4. Notify maintenance personnel immediately.
unsuccessful because of material obstruction, raise
the body back up. This will help to prevent the body 5. If the truck is on level ground, or if the parking
from suddenly dropping when pulling away from the brake can hold the truck stationary and the
obstruction. truck is in a stable condition, it is then OK to
turn the key switch OFF.
2. With the body returned to the frame, move the
directional control lever to FORWARD, release 6. If safe to do so, have maintenance personnel
place wheel chocks or other mechanisms in
980E-4 5-17
front or behind the wheels, depending on the 3. Check the hydraulic tank oil level. The oil level
slope, to reduce the risk of the truck rolling. must be visible in the center of the upper sight
glass and must not cover the entire upper sight
7. If traffic is heavy near the disabled machine,
glass. Add oil if necessary. DO NOT overfill.
mark the truck with warning flags during
daylight hours or use flares at night. Adhere to 4. Turn the key switch to the ON position, but DO
local regulations. NOT start the engine.
• If any warning messages are displayed
EMERGENCY STEERING immediately notify maintenance personnel.
SYSTEM F.7-0000051427 DO NOT operate the truck until the problem
Operation is corrected.
This truck is equipped with an emergency steering 5. Start the engine and allow the steering
system. This system is a backup in the event of accumulators to fully charge. Turn the steering
loss of oil supply to the main steering system. The wheel so that the front wheels are straight.
emergency steering system was designed to meet or 6. Check the hydraulic tank oil level while the
exceed SAE J1511 and ISO 5010 standards. engine is on.
If the red warning light and alarm are activated, a • If the oil level is visible in center of the lower
failure in the hydraulic oil supply to the steering and sight glass and does not cover the entire
brake system exists. When the alarm is activated, lower sight glass, the steering accumulators
typically there is enough hydraulic pressure stored are adequately charged. Proceed to Step 7.
in the brake and steering accumulators to allow
brief operation of the steering and brake functions. • If the oil level is below the lower sight
However, this oil supply is limited. Therefore, it is glass, the steering accumulators are not
important to stop the truck as quickly and safely as adequately charged. Stop the engine and
possible after the alarm is first activated. turn the key switch to the OFF position.
Immediately notify maintenance personnel.
If the oil pressure continues to decrease, the brake DO NOT operate the truck until the problem
auto-apply feature will activate the service brakes to is corrected.
stop the truck.
7. Shut the engine off by using the engine stop
Pre-Operation Testing button located on the center console. Leave
the key switch in the ON position. This
NOTE: Komatsu recommends that operators perform allows the steering accumulators to retain their
this test to verify that the steering accumulator hydraulic charge.
precharge pressure is adequate at the beginning of
each shift before operating the truck. • If the red warning light and buzzer do
activate, turn the key switch OFF and notify
maintenance personnel. DO NOT operate
the truck until the problem is corrected.
• Ensure no one is near the front tires during
this test. All personnel are warned that • If the steering accumulators are adequately
clearances change when the steering wheel charged, the red warning light and buzzer will
is turned and this could cause serious injury. not activate. Continue to the next step.
8. Turn the steering wheel from stop to stop. The
This test can only be performed with an empty truck. front wheels must turn fully to the left and to
the right. Eventually, the red warning light will
1. Park the empty truck on flat, level ground.
illuminate and the warning buzzer will sound.
Lower the dump body onto the frame and stop
This is normal.
the engine. Ensure the key switch is in the
OFF position. 9. If the front wheels cannot be turned fully to
the left and right, or if the red warning light
2. Wait at least 90 seconds to verify that all
and buzzer do not activate, immediately notify
hydraulic pressure has been relieved from
maintenance personnel. DO NOT operate the
the steering accumulators. Turn the steering
truck until the problem is corrected.
wheel from stop to stop. If the front wheels do
not move, there is no hydraulic pressure. If the truck passes this test, the emergency steering
system is functioning properly.
5-18 980E-4
Additional Guidelines 2. Turn the key switch to the OFF position and
wait for the engine to stop. This could take
• When the truck body is raised, DO NOT allow
up to three minutes for a hot engine to cool
anyone below it unless the body-up retaining cable
down. After the engine has stopped, wait two
is in place.
minutes before exiting the cab. If any warning
• DO NOT use the fire extinguisher for any purpose messages are displayed, or the warning buzzer
other than putting out a fire! If an extinguisher is is sounding, DO NOT leave the cab. Notify
discharged, report the occurrence so the used unit maintenance personnel immediately.
can be refilled or replaced.
3. When exiting the machine, always lock
• DO NOT allow unauthorized personnel to ride in the compartments, and take the keys with you to
truck. DO NOT allow anyone to ride on the ladder prevent entry from unauthorized persons.
or outside of the truck cab. Passengers must be
4. Place wheel chocks around the wheels to
belted into the passenger seat during travel.
prevent the truck from rolling.
• DO NOT leave the truck unattended while the
NOTE: If the engine is running, and the truck is
engine is running. Move the directional control
stationary and no brakes are applied, the red warning
lever to PARK, then shut the engine off before
light will illuminate and fault code will appear in the
getting out of the cab.
digital display. The operator must apply one of the
following braking systems: the service brakes, the
FUEL DEPLETION D.3-0000051426
wheel brake lock or the parking brake to prevent truck
roll away and to clear the warning/fault code.
• Operating the truck to fuel depletion forces
the injector train into a no-follow condition.
NORMAL ENGINE SHUTDOWN
No fuel flow between the plungers may cause PROCEDURE G.12-0000051424
damage to the injectors and the overhead due 1. Park on a level surface, free of overhead power
to adhesive wear, resulting in costly repairs lines or other objects that could prevent raising
and unnecessary downtime. the dump body. Reduce engine speed to idle
and place the directional control lever in PARK.
This will apply the parking brake. DO NOT
apply the wheel brake lock.
• Allowing the Komatsu truck to operate
until fuel depletion can lead to unsafe Ensure the parking brake indicator light is
operating conditions possibly resulting in an illuminated.
uncontrollable vehicle and/or personal injury. NOTE: If the truck starts to roll, apply the
service brakes and notify maintenance personnel
DO NOT allow the fuel tank to become empty. The immediately.
high pressure injection (HPI) fuel system uses fuel 2. Place the rest switch in the ON position to put
to adjust fuel delivery timing. Metered fuel is also the AC drive system in rest mode. Ensure the
used to lubricate the injector plunger and barrel. The no propel indicator light is illuminated.
maximum demand for metered fuel is required during
high speed / low load conditions. 3. Turn the key switch counterclockwise to the
OFF position to stop the engine.
SAFE PARKING NOTE: There is also an engine stop switch located
PROCEDURES F.6-0000051425 at ground level at the right or left front corner of the
Ensure the truck body is empty. Completely lower the truck. When this switch is activated, the engine will
dump body. If the machine must be parked on a slope, stop immediately, with no cooling off time.
follow local regulations to secure the truck to prevent The engine may continue to run for up to
the machine from moving. three minutes after the key switch is turned
Refer to the following procedure to park the machine: OFF, if the parking brake has been set. The
engine may stop before three minutes has
1. Move the directional control lever to PARK (this elapsed if the engine coolant is not too hot,
will apply the parking brake). DO NOT apply and the engine speed and fuel delivery have
the wheel brake lock. been low for a period of time before the key
980E-4 5-19
switch was placed in the OFF position. The 6. Verify both link voltage lights on the electrical
engine shutdown delay indicator light will be cabinet are off. Notify maintenance personnel
illuminated during the shutdown sequence. if the lights remain illuminated longer than five
minutes after the engine has been stopped.
NOTE: When the key switch is turned OFF, the
parking brake will automatically be set, even if it was 7. If equipped, lower the retractable ladder.
not set already by the operator. The wheel brake lock 8. Close and lock all windows. Remove the
will be disabled, even if it was set by the operator. key from the key switch and lock the cab to
4. With the key switch OFF and engine stopped, prevent possible unauthorized truck operation.
wait at least two minutes. If any warning Properly dismount the truck. Put wheel chocks
messages are displayed, notify maintenance in place.
personnel immediately.
NOTE: If the engine must be shut down immediately,
5. Ensure the steering circuit is completely bled stop the truck, shift the directional control lever to
down by turning the steering wheel back PARK, turn the key switch OFF, then pull up on the
and forth several times. No front wheel engine stop switch located in the operator cab center
movement will occur when hydraulic pressure console. Push the switch back down to enable engine
is relieved. If the front tires continue to steer operation.
after the engine is stopped, notify maintenance
personnel.
5-20 980E-4
OPERATING INSTRUCTIONS DISABLED TRUCK CONNECTORS
DISABLED TRUCK Hookup

CONNECTORS D.1-0000051229 Ensure there is an adequate, clear area to dump the
loaded truck. When the operational truck is in position,
GENERAL INFORMATION C.1-0000051423
stop the engine and wait two minutes to allow the
Refer to the Shop Manual for repair and hydraulic system to bleed down. Ensure hydraulic
troubleshooting procedures for the hoist system pressure has bled off before connecting hoses.
components and steering system components. Refer
to the Shop Manual for repair and troubleshooting Obey the following guidelines when hooking up the
procedures for the hydraulic brake system disabled truck to the operational truck.
components. 1. With the operational truck parked as close
as possible to the disabled truck, attach a
HOIST SYSTEM B.10-0000053844 hose from power up quick disconnect (4), of
the operational truck, to power down quick
Sometimes it is necessary to dump a load from the
disconnect (3) of the disabled truck. (Hose
body of a truck when the hoist system is inoperable.
must be rated to withstand 17 237 kPa (2,500
To use this feature, two hoses (supply and return)
psi) or greater pressure.
must be connected to a hydraulic source (such as an
operational truck or an auxiliary power unit). NOTE: The power down circuit will use a smaller
diameter hose (tube) than the power up circuit.
2. Connect another hose from power down quick
disconnect (3) of the operational truck to power
up quick disconnect (4) of the disabled truck.
NOTE: If both trucks are the same model, the hoses
will be installed at the quick disconnects but will be
crossed when connected.
Dumping Procedure
To raise the body, perform the following:
1. On the disabled truck, move the hoist control
lever to power up and then release it to place
1. Hoist Valve the hoist pilot valve in the HOLD position (leave
2. Tubes to LH Hoist Cylinder in this position during entire procedure).
3. Power Down Quick Disconnect
4. Power Up Quick Disconnect 2. Start the engine on the good truck, place
5. Over Center Valve the hoist control in the LOWER position and
increase engine rpm to high idle to dump the
Figure 5-7 HOIST CONNECTIONS disabled truck. If the body of the disabled truck
fails to raise, increase the operational trucks
NOTE: The matching quick disconnect coupling for
power down relief pressure as follows:
items (3 & 4) is PB4684.
a. Stop the engine and wait two minutes to
Quick disconnect fittings (3 and 4, Figure 5-7 HOIST
allow the hydraulic system pressure to
CONNECTIONS, page 5-21) are provided on the
bleed down.
over center valve to allow operation of the hoist
circuit for temporary truck operation if the hoist pump, b. Remove the cap from the hoist pilot valve
hoist valve or other hoist system component is not relief valve located in the hydraulic brake
operational. This will allow maintenance personnel to cabinet behind the cab. While counting
raise the truck body to dump the load before moving the number of turns, slowly screw the relief
the disabled truck. valve adjustment screw clockwise until it
bottoms.
Figure 5-7 HOIST CONNECTIONS, page 5-21 shows
a typical hookup from an operational truck. The To lower the body, perform the following:
disabled truck may be another of the same model, or
1. Place the hoist lever of the good truck in FLOAT
a different Komatsu electric drive truck model.
to lower the body. If necessary, momentarily
place the hoist control in the RAISE position
980E-4 5-21
DISABLED TRUCK CONNECTORS OPERATING INSTRUCTIONS
until the body is able to descend in FLOAT. Do adjustment counterclockwise the same number
not accelerate the engine. of turns as required in step 2b of the body
dumping procedure.
2. After body is lowered, stop the engine and wait
two minutes to allow the hydraulic system to 4. Check power down relief pressure using
bleed down. Then disconnect the hoses. instructions in the shop manual.
3. Reduce power down relief valve pressure 5. Check hydraulic tank oil level.
to normal on the good truck by turning the
5-22 980E-4
OPERATING INSTRUCTIONS TOWING
TOWING F.3-0000051288 • Switch (2) must be connected to the other end of the
harness so the operator can use the switch while
seated in the cab.
• Before towing a truck, many factors must be • The harness must be fitted with connector (4) to
carefully considered. Serious personal injury allow it to be plugged into parking brake solenoid
and/or significant property damage may result (3) inside the brake cabinet. Ground wire (5) leading
if important safety practices, procedures and from this connector must be long enough to connect
preparation for moving heavy equipment are to a ground block using the second ring terminal.
not observed.
Connector (4) consists of:
A disabled machine may be towed after the following • one housing (PB8538)
precautions have been taken.
• two sockets (08191-05430)
• DO NOT exceed 8 kph (5 mph) while towing.
• one wedge (PB8540)
• DO NOT tow with a cable. Use a solid tow bar. Use
a towing device with ample strength for the weight
of this truck.
• Towing vehicle must have adequate pulling and
braking capacity to both move and stop the towed
truck under all conditions, including towing on a
grade.
• Inspect towing components, such as tow bars and
couplings, for any signs of damage. Never use
damaged or worn components to tow a disabled
vehicle.
• Keep a safe distance from the trucks and towing
apparatus while towing a vehicle.
• When connecting a truck that is to be towed, do not
allow anyone to go between the tow vehicle and the
disabled vehicle.
• Set the coupling of the truck being towed in a
straight line with the towing portion of the tow truck
and secure it in position.
• An operator must remain in the cab of the towed 1. 24VDC Bus Bar 4. Connector
vehicle at all times during the towing procedure. Terminal 5. Ground Wire
2. Switch (ON/OFF)
SPECIAL WIRING HARNESS E.4-0000051420
3. Park Brake Solenoid
Before towing, a special wiring harness must be made Figure 5-8 PARKING BRAKE HARNESS
in order to release the parking brake. The harness CONNECTION DIAGRAM
will require approximately 9 meters (30 ft) of #14 wire, TOWING PROCEDURE C.13-0000060791
one ON/OFF switch (capable of carrying 2 amps of
current) and two ring terminals. 1. Turn off the engine.
Refer to Figure 5-8 PARKING BRAKE HARNESS 2. Block the wheels on the disabled truck to
CONNECTION DIAGRAM, page 5-23 for a diagram prevent movement while preparing the truck
of the special wiring harness circuit. for towing and while attaching the tow bar.
• Using a ring terminal, one end of the harness 3. Towing vehicle must have adequate pulling
must connect to 24VDC Bus Bar Terminal (1) in and braking capacity to both move and stop
the auxiliary control cabinet to supply 24V to the the towed truck under all conditions, including
parking brake solenoid. towing on a grade.
4. Ensure that the tow bar has adequate strength
(approximately 1.5 times the empty vehicle
980E-4 5-23
TOWING OPERATING INSTRUCTIONS
weight of truck being towed). Install tow bar NOTE: If truck is being towed using a tow truck
between the two vehicles. (front wheels off ground), it is not necessary for
operator to remain in truck during transport. Move
5. If necessary, install quick disconnect fittings to
the directional control lever to the Neutral position
the bleeddown manifold to allow the hydraulic
releasing the park brake. The retractable ladder
system to be operational. Install hydraulic
will automatically raise. From ground have another
connections for steering/braking between the
person push emergency stop button, located on front
tow vehicle and the disabled vehicle. An
bumper, to lower retractable ladder. After operator
auxiliary power unit can also be used.
has reached ground level pull emergency stop button
6. After the hydraulic connections are made, to raise retractable ladder.
check the disabled vehicle braking and steering
10. Tow the disabled truck. Sudden movement
systems for normal operation. Install 24 100
may cause tow bar failure. Smooth, gradual
kPa (3,500 psi) pressure gauges on both the
truck movement is preferred. Do not exceed 8
BF test port and the BR test port on the brake
kph (5 mph) while towing.
manifold in the brake cabinet. Ensure proper
pressure is displayed on the gauge when NOTE: Minimize the tow angle at all times. Never
depressing the brake pedal. exceed 30 degrees. The towed truck must be steered
in the direction of the tow bar.
7. The parking brakes must be released before
towing. To release the parking brakes, use 11. When the desired location has been reached,
the following steps to install the special wiring the operator in the towed vehicle must apply
harness. the service brakes, then move the switch to
the OFF position. This will apply the parking
a. Ensure that the ON/OFF switch is in the
brakes.
OFF position.
12. Block the wheels on the towing vehicle and on
b. Connect one lead of the special wiring
the disabled truck to prevent roll-away.
harness to a 24VDC terminal on bus bar
(1, Figure 5-9 AUXILIARY CONTROL 13. Turn off the engine in the towing vehicle.
CABINET, page 5-24) on the left side wall
14. If installed, disconnect the hydraulic hoses at
of the auxiliary control cabinet for the 24V
the quick disconnect fittings on the bleeddown
supply power.
manifold.
c. Disconnect the truck wiring harness from
15. Disconnect the special wiring harness from the
parking brake solenoid (2, Figure 5-10
truck. Connect the truck wiring harness to the
BRAKE CABINET, page 5-25). Connect
parking brake solenoid.
the special wiring harness to the parking
brake solenoid. Connect the ground wire 16. Disconnect the tow bar.
from the connector to a ground block in the
right side of the brake cabinet.
d. Lower the window and place the switch
end of the special wiring harness inside the
cab so the operator can control the parking
brake with the ON/OFF switch.
8. When ready to tow the disabled truck, remove
the blocking from the wheels.
9. The operator in the disabled truck should now
move the ON/OFF switch to the ON position.
This will release the parking brakes.
1. 24VDC Bus Bar
Figure 5-9 AUXILIARY CONTROL CABINET
5-24 980E-4
OPERATING INSTRUCTIONS TOWING
1. Brake Manifold 2. Parking Brake

Solenoid
Figure 5-10 BRAKE CABINET
980E-4 5-25
PAYLOAD METER IV SYSTEM OPERATING INSTRUCTIONS
PAYLOAD METER IV
SYSTEM A.2-0000071708
GENERAL INFORMATION B.7-0000071844
Payload Meter IV (PLM IV) measures, displays

and records the weight of material being carried by
an off-highway truck. The pressure data from the
suspensions is combined with incline, speed and
other inputs to calculate the weight of the payload
carried in the truck body. The payload weight is
displayed to the operator through the digital display on
the dashboard as the shovel operator loads the truck
body, and through the Red/Amber/Green payload
lights or optional “Scoreboard” monitor mounted to
the side of the truck.
Data Summary Figure 5-11 TRUCK ELECTRONIC DISPLAY UNIT

The payload meter creates and stores more than Operator Input Switches
10,000 haul cycles in memory. Each haul cycle is The operator Input
recorded with information described in data structure Switches allow the
Table . Oldest data records will be overwritten as the toggling through warning
internal memory is filled. screens and various truck
information.
Data Gathering
NOTE: Precise calibrations and configurations are
important to ensure accurate payload calculations.
The PLM IV uses an Internet browser interface For PLM IV, they are used to:
instead of a stand-alone software program. For
users with previous PLM III experience, there is no • Enter the operator ID number (0000–9999)
additional software required to download and view • View and Clear the total loads and payload counter
payload meter data and fault information. for a shift period
The user can directly log into the payload meter by • View live readings from the inclinometer and
entering the PLM IV controller’s assigned IP address pressure sensors
into the address bar of a standard web browser such
as Internet Explorer® or Google Chrome®. See The operator switches are
System Configurations for instructions on configuring
1. SELECT – The left showing an UP and DOWN
PLM IV.
arrow. This is used to step through the various
screens or displays as described in the manual.
COMPONENT DESCRIPTION A.17-0000071858
2. OK – The right switch showing an “OK.” This
Electronic Dash Display is used to select an option for the displayed
The Electronic Dash Display is used to display screen.
payload information. See DIGITAL DISPLAY For troubleshooting purpose, the inputs from the
OPERATION, page 6-26. switches to the payload meter are normally open
The Payload Meter (PLM) uses the lower display for circuit and the switch makes momentary contact.
payload information in conjunction with the operator
switches to navigate to different modes and enter
information, as well as to display of various status
messages. The bottom display does include units.
Payload can be displayed in short tons, long tons or
metric tons.
5-26 980E-4
OPERATING INSTRUCTIONS PAYLOAD METER IV SYSTEM
Brake Lock Switch

The brake lock is used to lock the rear brakes on the
truck. Locking the rear brakes is necessary for the
accurate calculation of swing loads during the loading
process. Without the brake lock applied, the payload
meter will not calculate swing loads. Without the brake
lock, the payload meter will assume that the truck was
loaded using a continuous load and the system will
flag the haul cycles record. All other functions will be
normal regardless of brake lock usage.
NOTE: It is very important for user to use Brake 1. USB 2.0 Type-A Connectors
Lock for accurate payload state detection. The drive 2. LEDs
selector switch should be in NEUTRAL during loading, 3. 10/100 Mbps Ethernet RJ45 Connector
and the PARK BRAKE should not be engaged.
Figure 5-13 PLM IV COMMUNICATION MODULE
Payload Meter Module (PLM)
The PLM IV is housed in a black housing.
NOTE: Opening the payload meter housing will result
in voiding the warranty.
1. USB Memory Flash Drive
Figure 5-14 FLASH DRIVE COMMUNICATIONS

The PLM provides two USB ports for Real Time data
collection and Field Software reprogramming. At any
point of time only one USB port shall be active. The
USB drive does not add memory storage capacity to
the PLM IV and cannot be used to download payload
data from the device.
1. PLM IV Controller
The USB 2.0 connectors allow flash drives to become
2. PLM IV Communication Module accessible to the payload meter.
Figure 5-12 PLM IV LOCATION The PLM uses the USB ports for the following two
functions:
The connections to the truck wiring are made on
one end of the PLM while the other end provides 1. Upon USB memory flash drive insertion, the
connection points for diagnostics and technical system will begin recording real time data at 50
service. samples per second to the drive. A new file will
be created for every new haul cycle, and will
• One 10/100Mbps Ethernet RJ45 connector for
be named according to the corresponding haul
direct connection to a network or computer.
cycle number.
• Two USB 2.0 Type - A Connectors for memory flash
2. USB memory flash drives that store a payload
drive connection.
meter software update can be used in
conjunction with the web server to upload new
system software to PLM IV.
Follow the Field Software Update procedure for field
software reprogramming instructions.
980E-4 5-27
To collect real time data: The load lights are illuminated only when the brake
lock is applied.
1. Turn OFF the truck Key Switch for 2 minutes (or
until all the LEDs on the communication board
turn OFF).
2. Insert a 2 GB memory disk or 4 GB USB 2.0
A memory flash disk (formatted with windows
FAT 32 default) into either USB port of payload
meter.
3. Turn ON the Key Switch and operate the truck
normally.
4. Turn OFF the Key Switch and wait for 2 minutes
or all LEDs on the communication board turn 1. Load Lights
OFF before removing the USB memory flash 2. PLM Scoreboard (Optional)
drive.
Figure 5-15 LOAD LIGHTS AND SCOREBOARD
The PLMr provides 5 visual LED indicators to monitor
A flashing green light indicates the next swingload will
system status:
make the measured load greater than 50% of rated
• The USB1and USB2 indicators are active when the load. A solid green light indicates that the current load
drive is providing power. The lights are inactive is greater than 50% of rated capacity.
for overcurrent or initialization errors, and can be
A flashing amber light indicates the next swingload will
cleared by a system reset.
make the measured load greater than 90% of rated
• The LINK indicator is for Ethernet connectivity, and load. A solid amber light indicates that the current load
blinks during intersystem communication. is greater than 90% of rated capacity.
• The PULSE indicator is toggled ON/OFF every A flashing red light indicates the next swingload will
second to indicate the system is working. As long make the measured load greater than 105% of rated
as it is blinking the system is running. load. A solid red light indicates that the current load is
greater than 105% of rated capacity.
• The HAUL indicator is reserved for future use.
Ignore status of this indicator. The optimal loading target is a solid green and amber
lights with a flashing red light. This indicates that the
NOTE: While collecting real time data by USB memory
load is between 90% and 105% of rated load for the
disk or field software update, always remember to
truck and the next swingload will load the truck over
take the USB memory flash drive out of the payload
105%.
meter after completion of the task. USB memory
flash drive should not be left in its communication slot Keyswitch Input
permanently. Real time data is written at 50 samples
per second could fill USB flash drive. Once the USB The PLM monitors the status of the keyswitch.
flash drive is full, Payload meter stops writing data. Turning the keyswitch ON alerts the PLM IV to
power on. When the keyswitch is turned OFF, the
Load Lights payload meter will begin the process of powering
off. The payload meter does not receive its electrical
PLM IV uses load lights (1, Figure 5-15 LOAD LIGHTS power from the keyswitch circuit. The PLM will
AND SCOREBOARD, page 5-28 or an optional remain ON for several seconds after the keyswitch is
score board to indicate to the shovel operator the removed. When the keyswitch power is removed, the
approximate weight of the material in the truck. payload meter performs a series of internal memory
operations before turning itself off. To allow these
The score board reads the current weight in tons.
operations to complete, the keyswitch should be
The load lights progressively indicate to the shovel turned OFF for at least 30 seconds before turning the
operator the approximate weight of the material in the keyswitch back ON, or wait until all the LEDs on PLM
truck. IV Communication Board turns OFF.
5-28 980E-4
Payload Meter (PLM) Power To get to the “Load and Ton Counter” display use
the Left Arrow of the operator switches to scroll to
The PLM receives its power from the battery circuit
the Payload Data” main level screen. Press OK to
on the truck. Removing battery power from the PLM
enter the Payload Data sub-menu. Press the Up and
before removing keyswitch and waiting 15 seconds
Down Arrows to navigate to the Load Counter/Total
may result in lost haul cycle data or data file corruption.
Ton Counter display.
The PLM turns itself off approximately 30 seconds
after the keyswitch power is removed. Clearing the total ton counter or total load counter
clears both records. To clear the total ton and total
NOTE: It is very important to use the keyswitch to
load counter, perform the following:
shutdown the payload meter before removing battery
power. Failure to do so may result in data corruption. 1. Using the operator switches, scroll through the
displays until the “Payload Data” screen.
OPERATOR’S DISPLAY AND 2. Once in the “Payload Data” screen, scroll until
SWITCH A.1-0000073399 you reach the “Load and Ton Counter” screen.
Setting The Operator ID 3. Press “OK” to clear the counter. Refer to
The current operator ID number is recorded with each DIGITAL DISPLAY OPERATION, page 6-26.
haul cycle. The number can be between 0 and 9999.
Viewing Live Sensor Data
Press OK to enter the Payload Data sub-menu. There are two ways to view Live Sensor Data.
Press the Up and Down Arrows navigate to Driver
ID display. Once in the Driver ID display, pressing • Using the PLM IV web server, navigate to the Real
the Up and Down Arrows will scroll through the Time Data Page. This will be covered later in the
alphanumeric characters as well as Delete and Apply. document.
When the desired character is found press OK to
• Using the Electronic Dash.
select that character. The displayed ID number cursor
will automatically go to the next character position. The display can be used to quickly show the current
Repeat for the next characters. After the ID has been readings from the four suspension pressure sensors
changed navigate to the Apply (looks like a right and the inclinometer. This can be used during
arrow) icon and press OK. If at any time you want to regularly scheduled service periods to check the
delete a character in the ID navigate to the Delete state of the suspensions. These displays are live and
(looks like a trash can) icon and press OK to delete will update as the values change. The live displays
the current character. cannot be cleared and the OK position of the operator
switch will have no effect.
If no buttons are pressed for 30 seconds, the display
will return to Warning List Display, the number being The units for the display are controlled by the
entered will be lost and the operator ID returns to the configuration of the electronic dash display. Refer to
previous number. DIGITAL DISPLAY OPERATION, page 6-26 for unit
configuration instructions.
Load And Ton Counter All four of the suspension pressure sensors and the
PLM IV allows the truck operator to monitor and track inclinometer angle are shown on one display. To get
the total tons hauled and the number of haul cycles to the live sensor display use the Left Arrow of the
during the shift. This display can be cleared at the operator switches to scroll to the “PAYLOAD DATA”
beginning of each shift to allow the operator to record main level screen. Press OK to enter the Payload
how many loads and tons have been hauled during Data sub-menu. Press the Up and Down Arrows to
the shift. navigate to the live sensor display.
The total ton counter records the number of tons The inclinometer displays whole degrees of positive
hauled since the last time it was cleared. This display incline is truck nose up (symbol + followed by degrees)
is in 100’s of tons. For example, if the display shows or negative incline is truck nose down (symbol –
432, the total tons is 43,200. followed by angle).
980E-4 5-29
PAYLOAD OPERATION & The second method to switch from Empty state to
CALCULATION A.1-0000073480 Loading state is through continuous loading. This can
happen if the brake lock is not used during loading.
Description of Haul Cycle States If the load increases above 50% of rated load for 10
The typical haul cycle can be broken down into eight seconds without the brake lock applied, the meter will
distinct stages or states. Each state requires the switch to loading and record the continuous_loading
payload meter to make different calculations and flag in the haul cycle.
store different data. The payload meter switches from Loading to
"States" or stages of a typical haul cycle Maneuvering as soon as the truck begins moving.
The maneuvering zone is 160 m and is designed to
1. Tare Zone allow the operator to reposition the truck under the
2. Empty shovel. More payload can be added anytime within
the maneuvering zone. Once the truck travels 160 m
3. Loading (0.1 miles) the payload meter switches to the Final
4. Maneuvering Zone and begins calculating payload. If the body is
raised while the payload meter is in the Maneuvering
5. Final Zone state, the NO FINAL LOAD flag will be recorded in
6. Hauling the haul cycle record, no payload will be calculated,
and the meter will switch to the Dumping state.
7. Dumping
While in the Final Zone moving faster than 5 km/h (3
8. After Dump mph), the payload meter calculates the loaded sprung
weight of the truck. The same advanced algorithm
Haul Cycle Description is used to calculate the empty and loaded sprung
A new haul cycle is started after the load has been weights. The payload meter will switch from the Final
dumped from the previous cycle. The payload meter Zone to the Dumping state if the body up signal is
will stay in the After Dump state for up to 11 seconds, received. If the truck has moved for less than 1 minute
or until the truck reaches 8 km/h (5 mph), to confirm in the Final Zone, the payload meter will calculate the
that the load has actually been dumped. If the final payload using an averaging technique which may
current payload is less than 20% of rated load, the be less accurate. If this happens, the average_load
payload meter will switch to the Tare Zone and begin flag will be recorded in the haul cycle.
calculating a new empty tare. If, after dumping, the The payload meter switches to the Dumping state
payload has not dropped below 20% of rated load the when the dump body rises. The payload meter will
meter will either return to the Maneuvering or Hauling switch from Dumping to After Dump when the dump
states. In this case, the False_Body_Up flag will be body comes back down. From the after_dump, the
recorded in the haul cycle record. payload meter will switch to one of three states:
While in the Tare Zone state, and moving faster than 1. If the average payload is greater than 20%
5 km/h (3 mph), the payload meter calculates the of rated load and no final payload has been
empty sprung weight of the truck. This tare value calculated, the payload meter will return to
will be subtracted from the loaded sprung weight to the Maneuvering state. After the truck travels
calculate the final payload. The payload meter will 160 m (0.1 mile) the meter will switch to
switch from the Tare Zone to the Loading state if the Final Zone and attempt to calculate the
swingloads are detected. By raising the dump body payload again. The False_Body_Up flag will
while in the Empty or Tare Zone states, the payload be recorded in the haul cycle record.
meter can be manually switched back to the Tare
Zone to calculate a new tare. 2. If the average payload is greater than 20%
of rated load and the final payload has been
From the Empty state, the payload meter will switch calculated, the payload meter will switch back
to the Loading state through one of two means. If to the Hauling state. The False_Body_Up flag
the brake lock is applied, the payload meter will will be recorded in the haul cycle record.
be analyzing the suspension pressures to detect a
swingload. If a swingload is detected, the meter will 3. If the average payload is less than 20% of rated
switch to the Loading state. The minimum size for load, the payload meter will switch to the Tare
swingload detection is 10% of rated load. Swingload Zone and begin to calculate a new empty tare.
detection usually takes 4- 6 seconds.
5-30 980E-4
Load Calculation suspensions. If the suspensions are not properly

maintained, the payload meter cannot determine an
The final load calculation is different from the last
accurate value for payload. The two critical factors
swingload calculation. The accuracy of the swingload
are proper oil height and proper nitrogen charge.
calculation depends on loading conditions and
the position of the truck during Loading. The last
swingload calculation is not the value recorded in
Critical Suspension Factors:
memory as the final load. The final load is determined • Proper oil height.
by a series of calculations made while the truck is
• Proper charge with nitrogen to the correct
traveling to the dump site.
suspension extension. See service manual for
correct extension.
Carry Back
If the suspensions are overcharged, the payload
Carry back is calculated as the difference between the
meter will not be able to determine the empty sprung
new truck tare and the clean truck tare. The clean
weight of the truck. The suspension cylinder must be
truck tare is calculated using the PC software. When
able to travel up and down as the truck drives empty.
the suspensions are serviced or changes are made
The pressure in an overcharged suspension can push
that may affect the sprung weight of the truck, a new
the suspension rod to full extension. In this case,
clean truck tare should be calculated.
the pressure inside the cylinder does not accurately
represent the force necessary to support that portion
Measurement Accuracy of the truck.
Payload measurements are typically repeatable within
If the suspensions are undercharged, the payload
1%. Accuracy for a particular scale test depends
meter will not be able to determine the loaded sprung
on specific combinations of pressure sensors and
weight of the truck. The suspension cylinder must be
payload meters as well as the specifics of each scale
able to travel up and down as the truck drives loaded.
test. Comparisons from different scale tests are often
If the pressure in an undercharged suspension
made without considering the differences introduced
cannot support the load, the suspension will collapse
by the specific installation and operation of the scales
and make metal-to-metal contact. In this case, the
for each test. In addition, each pressure sensor and
pressure inside the cylinder does not accurately
payload meter introduces it’s own nonlinearity. Each
represent the force necessary to support that portion
truck becomes an individual combination of sensors
of the truck.
and payload meter. Errors from these sources can
introduce up to a ±7% bias in the payload meter Low oil height can also introduce errors by not
calculations for a specific scale test, for an individual correctly supporting a loaded truck. This is why the
truck. correct oil height and nitrogen charge are the most
critical factors in the measurement of payload. If the
Because the payload meter calculates a new empty
suspensions are not properly maintained, accurate
tare for each payload, a detailed scale test must
payload measurement is not possible. In addition,
weigh the trucks empty and loaded for each haul
suspension maintenance is very important to the life
cycle. Using a simple average of two or three empty
of the truck.
truck weights as an empty tare for the entire scale
test will introduce significant errors when comparing
scale weights to PLM IV weights. Loading Conditions
Brake Lock engagement without using the Park Brake
SOURCES FOR PAYLOAD is critical during the loading process.
ERROR A.3-0000073398
NOTE: Only by engaging the Brake Lock with the
Payload Error truck in Neutral, No Park Brake, will the Payload Meter
properly calculate swingloads.
The number one source of errors in payload
calculation is improperly serviced suspensions. The In addition, this condition reduces stress on the
payload meter calculates payload by measuring suspensions, drive system, brakes, and frame.
differences in the sprung weight of the truck when it A large number of "Continuous Loading" flags in
is empty and when it is loaded. The sprung weight is payload data can be an indication of poor loading site
the weight of the truck supported by the suspensions. practices. Addressing these "Continuous Loading"
The only method for determining sprung weight is flags will create an opportunity for site improvement
by measuring the pressure of the nitrogen gas in the leading to better production.
980E-4 5-31
The final load is calculated as the truck travels away meter uses this frequency to calculate speeds and
from the shovel. Variations in road conditions and distances. The meter assumes a single value for
slope are compensated for in the complex calculations the rolling radius of the tire. The rolling radius may
performed by the payload meter. change at difference speeds by growing larger at
higher speeds. The actual rolling radius of the tire
Pressure Sensors will also change between a loaded and empty truck.
The payload meter does not compensate for these
Small variations in sensors can also contribute to changes.
payload calculation errors. Every pressure sensor
is slightly different. The accuracy differences of
HAUL CYCLE WARNING
individual sensors along the range from 0 to 4000
psi can add or subtract from payload measurements. FLAGS A.7-0000073397
This is also true of the sensor input circuitry within Haul Cycle Data
individual payload meters. These differences can
stack up 7% in extreme cases. These errors will be All data is calculated and stored in metric units within
consistent and repeatable for specific combinations the payload meter. The data can be downloaded
of payload meters and sensors on a particular truck. directly into the .CSV file format. Units for displaying
haul cycle data and for downloading haul cycle data
Swingloads file should be configured in the System Configuration
web page. Whether the user has configured Metric,
Swingload calculations can be affected by conditions Short or Long tons, the data on both the real time
at the loading site. Parking the truck against the data page and the view haul cycle data page will be
berm or large debris can cause the payload meter converted to the selected unit. The haul cycle file
to inaccurately calculate individual swingloads. download will be in the selected unit.
While the payload meter system uses an advanced
calculation algorithm to determine swingloads, Refer to Table 5-2 HAUL CYCLE DATA, page 5-33 for
loading site conditions can affect the accuracy. It's details on each column of the haul cycle record.
critical the Brake Lock is used without the Park Brake. NOTE: Pressure Sensor selection is only for Real
NOTE: The Payload Meter will not calculate Time data display.
swingloads unless the Brake Lock, without the Park
Brake, is used during the loading process.
Speed and Distance

The payload meter receives the same speed signal
as the speedometer. This signal is a frequency that
represents the speed of the truck. The payload
5-32 980E-4
Figure 5-16 PLM IV CONFIGURATION
The units noted in table below are the actual units are referenced in seconds since the haul cycle start
stored in the data file. The value for the haul cycle time. The following information is recorded for each
start time is the number of seconds since January 1, haul cycle.
1970 to start of the haul cycle. All other event times
Table 5-2 HAUL CYCLE DATA

Data Unit Remark
Haul Cycle Record
Number Haul cycle number since the start of the file
Number
Up to 22 characters can be stored in this field to identify the truck.
Truck # alpha-numeric
Typically this field will be just the truck number
980E-4 5-33
Data Unit Remark

Haul Cycle Start Date of haul cycle start, haul cycle starts when the meter transitions
MM/DD/YYYY
Date from Dumping to Empty state after the previous haul cycle
Haul Cycle Start Time of haul cycle start, haul cycle starts when the meter transitions
HH:MM:SS
Time from Dumping to Empty state after the previous haul cycle
Payload tons Net calculated payload of the haul cycle
Number of Swing
number The number of swing loads detected by the payload meter
loads
This is a 4 digit number that can be entered by the operator at the
Operator ID number
start of the shift
Each letter represents a particular warning message about the haul
Status Flags alpha
cycle
Carry Back tons The difference between the latest empty tare and the clean truck tare
Total Cycle Time HH:MM:SS Time from the start to the end of the haul cycle
Empty Run Time HH:MM:SS Time in the Tare Zone and Empty states with the truck moving
Empty Stop Time HH:MM:SS Time in the Tare Zone and Empty states with the truck stopped
Loading Time HH:MM:SS Time in the Loading state
Time in the Maneuvering, Final Zone and loaded states with the truck
Loaded Run Time HH:MM:SS
moving
Time in the Maneuvering, Final Zone and loaded states with the truck
Loaded Stop Time HH:MM:SS
stopped
Dumping Time HH:MM:SS Time in the Dumping state
Actual start time when the meter transitions from empty to Loading
Loading Start Time HH:MM:SS
state
Loading Dump Actual start time when the meter switches from loaded to Dumping
HH:MM:SS
Time state
Loaded Haul
m Distance traveled while loaded
Distance
Empty Haul
m Distance traveled while empty
Distance
Loaded Max Speed km/h Maximum speed recorded while the truck is loaded
Loaded Max Speed
HH:MM:SS Time stamp when the max speed occurred
Time
Empty Max Speed km/h Maximum speed recorded while the truck is empty
Empty Max Speed
HH:MM:SS Time stamp when the max speed occurred
Time
Peak Positive Positive frame torque is measured as the frame twists in the clockwise
ton-meter
Frame Torque direction as viewed from the operator's seat
Peak Positive
HH:MM:SS Time stamp when the positive peak torque occurred
Frame Torque Time
Peak Negative Negative frame torque is measured as the frame twists in the
ton-meter
Frame Torque counter-clockwise direction as viewed from the operator's seat
Peak Negative
HH:MM:SS Time stamp when the negative peak torque occurred
Frame Torque Time
5-34 980E-4
Data Unit Remark

Peak Sprung Load tons Peak dynamic load calculation
Peak Sprung Load
HH:MM:SS Time stamp when the peak instantaneous load calculation occurred
Time
Front-Left
t-km/h Tire ton-km/h for haul cycle
Tire-Ton-km/h
Front-Right
Tire-Ton-km/h
Average Rear
Tire-Tonkm/h
Micro Fail Torque No unit Micro Fail from Rainflow torque Counting
Micro Fail Sprung
No unit Micro Fail from Rainflow Sprung Weight Counting
Weight
Maneuvering Torque average collected during Maneuvering while driving at greater
ton-meter
Torque than 3 mph
Torque average collected during Final Zone while driving at greater
Final Zone Torque ton-meter
than 3 mph
The empty (tare) sprung weight calculated while the truck was driving
Tare Sprung Weight tons
empty
Payload Estimate
tons The payload value of the last swingload calculated at the loading site
@ Shovel
Quick Payload The payload estimate calculated as the truck is driving away from
tons
Estimate the loading site
Gross Payload tons The payload estimate of the full load (Net Payload + Carry Back)
Unique Serial # number Haul cycle number since the first haul cycle
Fuel Consumption Liters/Gallons Fuel consumed for complete haul cycle
These values are internal calculations used in the continued
Reserved 2-10 number
development of the PLM IV system and should be ignored
Haul Cycle Warning Flags may be a problem with the wiring or the brake lock
was not used. The payload meter will not measure
The payload meter expects haul cycles to progress in
swingloads unless the brake lock is used during the
a particular way. When something unexpected takes
loading process.
place, the system records a warning flag.
Loading to Dumping Transition (B)
Several events within the haul cycle can cause a
This message indicates the payload meter senses
warning flag to be generated. Each one indicates an
a body up input during the loading process.
unusual occurrence during the haul cycle. They do
This message is usually accompanied by a
not necessarily indicate a problem with the payload
“No_Final_Load (C)” flag.
meter or payload calculation.
No Final Load (C)
Continuous Loading (A)
This message indicates the payload meter is unable to
This message indicates the truck is loaded over 50%
determine the final payload in the truck. Typically, this
full without the payload meter sensing swingloads.
means that the payload meter switched from a loaded
This indicates that a continuous loading operation
state to the dumping state before the load could be
was used to load the truck. It may also indicate
accurately measured.
that the payload meter did not receive the brake
lock input while the truck was being loaded. There
980E-4 5-35
Maneuvering to Dumping Transition (D) the payload meter was shut down. This can happen
This message indicates the payload meter senses a when the main battery disconnect is used to shut the
body-up input during the maneuvering or repositioning truck down instead of the key switch. A haul cycle with
process indicating that the operator has dumped the this warning flag should not be considered accurate.
load. It may also be generated if the body-up signal Haul cycles with this warning are displayed in red on
is not properly reaching the payload meter and the the Payload Summary window and are not included in
weight in the truck falls dramatically while the truck is the summary statistics for reports on display.
maneuvering or repositioning.
Haul Cycle Too Long (M)
Average Load or Tare Used (E) This message indicates that the haul cycle took longer
This message indicates that the recorded payload than 18.2 hours to complete. The times stored for
may not be as accurate as a typical final load particular events may not be accurate. This does not
calculation. Typically, this is recorded when loading affect the payload calculation.
begins before an accurate tare is calculated or the
Sensor Input Error (N)
load is dumped before the load can be accurately
This message indicates an alarm was set for one of
measured.
the critical sensor inputs during the haul cycle. Critical
Final Zone to Dumping Transition (F) sensors are the four pressure sensors, the speed
This message indicates the payload meter senses sensors, and the inclinometer. Any flat suspension
a body-up while it is calculating the final payload or machine speed alarms will set this flag as well.
indicating that the operator has dumped the load. Without these inputs, the payload meter cannot
It may also be generated if the body-up signal is calculate payload. A haul cycle with this warning flag
not properly reaching the payload meter and the should not be considered accurate.
weight in the truck falls dramatically while the truck is
False Swingload (O)
calculating the final payload.
This message indicates the payload meter detected
False Body Up (H) a swingload, but less than 20% load was measured
This message indicates that the body was raised on the truck after it had driven 160 meters from
during the haul cycle without the load being dumped. the loading site. When this condition occurred, the
The body-up signal indicated that the truck was payload meter considered the swingload to be “false”
dumping, but the weight of the truck did not fall below and returned to the “tare zone” state. All distance and
20% of the rated load. speed statistical calculations that occurred during the
“false swingload” are recorded as part of the empty
Body Up Signal Failed (I) statistics.
This message indicates that the load was dumped
without a body-up signal being received by the
payload meter. The weight of the truck fell below
Alarm Records
20%, but the payload meter did not receive a body-up The payload meter stores alarm records to give
signal from the sensor. service personnel a working history of the system.
All codes are viewed by downloading alarm data files
New Tare Not Calculated (K)
from PLM IV or directly logging onto PLM IV web
This message indicates the payload meter was not
server. Refer to Download Alarm Data procedure for
able to accurately calculate a new empty sprung
more information. Active alarms could be viewed by
weight for the truck to use as the tare value for the
logging onto PLM IV web server. Each code has a
haul cycle. The tare value from the last haul cycle
specific cause and should lead to an investigation
was used to calculate payload.
for correction. Some failures can be overcome by
Incomplete Haul Cycle (L) payload meter, such as Haul Cycle Too Long or False
This message indicates the payload meter did not Body Up. However, failures with the suspension or
have proper data to start the haul cycle after powering inclinometer sensors cannot be overcome. Haul cycle
up. When the PLM IV powers off, it records the data data will indicate an alarm condition was present
from the haul cycle in progress into memory. This flag during the cycle.
indicates that this data was not recorded the last time
5-36 980E-4
Table 5-3 PAYLOAD METER ALARMS

Fault Code Name Description
Left front
sensor
1 Input current > 22 ma
malfunction
- signal high
Left front
sensor
2 Input current < 2 ma
malfunction
- signal low
Right front
sensor
malfunction
- signal high
Right front
sensor
malfunction
- signal low
Left rear
sensor
malfunction
- signal high
Left rear
sensor
malfunction
- signal low
Right rear
sensor
malfunction
- signal high
Right rear
sensor
malfunction
- signal low
Inclinometer
Duty cycle upper limit 95% (incorrect mounting or malfunction
9 malfunction -
inclinometer device)
signal high
Inclinometer
Duty cycle lower limit 57% (incorrect mounting or malfunction
10 malfunction -
inclinometer device)
signal low
Speed input
11 Failed to receive the speed signal from drive system.
failure
Body-up input Payload meter detects dumping activity without receiving a body up
13
failure signal
Checksum
14
failed
Memory write Indicates possible memory problem at power up. Cycle power and
16
failure recheck.
980E-4 5-37
Fault Code Name Description

Memory read Indicates possible memory problem at power up. Cycle power and
17
failure recheck.
Rear right
Rear right suspension locked in as flat. 5 bad suspension haul cycles
18 suspension
in a row.
flat
Rear left
Rear left suspension locked in as flat. 5 bad suspension haul cycles
19 suspension
in a row.
flat
20 Time change PLM IV time has been changed by more than 10 minutes.
Tare value User selected to reset the tare value. Payload for corresponding haul
21
reset cycle will be not be accurate.
Excessive
22 Carryback is excessive and requires clean tare calibration.
carryback
User switch
Select switch ON for more than 2 minutes, may indicate short to
26 fault -
ground.
SELECT
User switch
27 Set switch ON for more than 2 minutes, may indicate short to ground.
fault - SET
Frame Torque Data Once connected, use a web browser like Internet
Explorer® or Google Chrome™ to access the web
Payload meter records the maximum peak positive
server.
and negative frame torque values as part of a haul
cycle record. The frame torque is a measure of the NOTE: The service computer static IP address must
twisting action along the centerline of the truck. be configured within the same network range as the
payload meter.
Positive frame torque is measured when the
suspension forces on the front of the truck act to
twist the frame in the clockwise direction as viewed Configuring Static IP Address
from the operators seat. Negative frame torque is The service computer must have an IP address
measured when the forces from the suspension act in the same network as the payload meter for
in the opposite direction. communication to occur. A static IP address must be
set on the service computer if:
For example, if the left front and right rear pressure
raises as the right front and left rear pressure drops, 1. The service computer is directly connected to
the truck frame experience twisting motion along the the RJ45 port on the payload meter;
longitudinal centerline. In this case, the payload meter
will record a positive frame torque. or
2. The service computer and payload meter are
SYSTEM CONFIGURATION A.3-0000073396 connected to the same Ethernet switch and
there is no device on the switch acting as a
Connecting To The Payload Meter IV Web DHCP server.
Server
To configure static IP Address for laptop connection
The PLM IV webserver allows users to configure the follow the steps listed below.
payload meter system, view real time data, update
the payload meter software, and download haul cycle 1. Right click on a Wired Connection icon in the
and alarm record data. PLM IV can be connected bottom right corner.
to a service computer via Cat5e cable connection
2. Click on “Open Network and Sharing Center.”
from the RJ45 Ethernet Port on the payload meter
communication board or it can be connected to a 3. On the Network and Sharing Center window,
wireless radio on the truck if wireless connection is click on “Change adapter setting” on the left
desired. hand bar.
5-38 980E-4
4. Right click on the computer's Wired Connection a. Set the service computer’s IP address
Device. within the same IP address range of
PLM IV. For example if PLM IV has an
5. Click on "Properties.
assigned IP address of 192.168.3.128,
6. Click on "Internet Protocol Version 4 set the IP address of service computer
(TCP/IPv4) to highlight the option. 192.168.3.XXX ( here XXX is any number
between 1 and 254, but not 128, because
7. Click on "Properties."
128 is already assigned to PLM IV in this
8. Select "Use the following IP address:." example.)
9. Fill in the following IP Settings: b. Subnet mask to 255.255.255.0
10. Click "OK."
11. Click "OK."
NOTE: To return the service computer’s network card
to normal operation, follow steps 1 through 7, but in
step 8 select “Obtain an IP address automatically.”
980E-4 5-39
Figure 5-17 STATIC IP ADDRESS CONFIGURATION
Once the PC’s IP Address is set: • At the login page, enter Username “plm” and
Password “pass”
• Open Internet Explorer on PC
• Click “Connect”
• Enter the IP Address of PLM IV on a particular truck
(or Default Static IP Address)
5-40 980E-4
Real Time Data Page

The Real Time Data (RTD) page is mainly for
observing the data and time, suspension pressure
values, truck speed, haul cycle status, digital outputs
and other vital information. The page is refreshed
itself every 1 second. With every refresh this page
indicates normal operation of PLM IV. The suspension
pressures are inputs from each four pressure sensors.
Incline-angle is read from the on-board inclinometers.
The suspension pressures are inputs from each of
the four pressure sensors.
Incline-angle is read from the on-board Inclinometers.
Connecting to PLM IV may take several seconds
depending on the speed of local Ethernet activity. NOTE: The units are displayed here not on the
Allow at least 30 seconds for PLM IV box to boot after electronic digital display on the truck.
turning truck Key Switch ON. If the connection fails to
open, verify the CAT5e cable is good. On the service Each digital output lists the present condition “ON” or
laptop go to ‘Network and Sharing’ settings, choose “OFF” and diagnostic status of “NORMAL”, “OPEN” or
“Change Adapter Settings” option, by right clicking “SHORT”. Typical condition is NORMAL. If there is no
choose “Disable” and then “Enable” on “Local Area lamp connected, or there is a broken wire, then the
Connection Network” icon. status will be OPEN. If there is electrical short circuit,
the output will be disabled until the system restart and
If the connection problem persists then reboot the status will be displayed as “SHORT”.
PLM IV by turning truck Key Switch OFF and Turning
ON after all LED on Communication board turned off. Status Flags are “Haul Cycle Warning Flags,” indicate
situations that the payload meter defines as abnormal
All payload meter configurations are set from the to a standard haul cycle process.
web server. After log-in credentials are entered, the
PLM IV homepage looks like Figure 5-18 PLM IV Clean Tare Status will display the status “CLEAN
HOMEPAGE, page 5-41 below. TARE COMPLETE” normally as-well-as the final
Clean Tare value, unless the user is performing a new
clean tare. The operation typically takes 15 minutes.
During this operation the Clean Tare Status shows
“Clean Tare in Progress…”
Figure 5-19 REAL TIME DATA

Payload Meter IV System Configuration
The configuration page has option to permanently
save several truck specific settings. There is no need
Figure 5-18 PLM IV HOMEPAGE to reboot the payload meter after updating any of
these configurations.
980E-4 5-41
NOTE: Some of the configuration parameters

require a password to change. The password for all
parameters except the Payload Gain is “Kac2300”.
This is case sensitive. The password for the payload
gain, which is a critical setting, is not included in this
document.
Figure 5-20 PAYLOAD METER IV CONFIGURATIONS
There are ten configuration parameters on this page. • Pressure Sensor Units (for RTD web page only)
Below is a description of each.
• Date and Time
• Truck Model
• Payload Gain Factor
• PLM IV Mounting Orientation
• Payload Light Test
• Gauge Display Units
• Truck Tare Reset
5-42 980E-4
• Drive System type

• Truck Tire Monitor (Michelin Truck Tire Monitoring
System)
Truck Model
There are many different truck models available for
selection. The correct truck model must be selected
for the payload meter to accurately estimate payloads.
Figure 5-21 TRUCK MODEL SELECTION

PLM IV Mounting Orientation (for
Onboard Inclinometers)
It is important to configure the payload meter
according to its mounted position in the auxiliary
control cabinet. Refer to Figure 5-22 PAYLOAD
METER MOUNTING ORIENTATION, page 5-44 for
configuring the positions inside the auxiliary control
cabinet. Match the wall that the payload meter is
mounted on, to the number of the wall in the image.
980E-4 5-43
• Position (1) Right Tire • Position (3) Truck Forward

• Position (2) Truck Rear • Position (4) Left Tire
Figure 5-22 PAYLOAD METER MOUNTING ORIENTATION

Gauge Display Units keep the system powered on to recharge the clock
power supply. Format for Date and Time: MM/DD/YY
These units can be displayed in Metric, Short or Long
HH:MM:SS
Tons.
• When viewing in either Short or Long Tons, the Payload Gain Factor
speed and distance are displayed in miles.
• When viewing in Metric Tons, the speed and
• DO NOT modify unless required.
distance are displayed in kilometers.
Pressure Sensor Units (for RTD web Default payload gain factor is 100, but the user has
page only) the option to adjust this value between 90 to 110.
It is advised NOT to change the default payload
When viewing the Pressure Sensor Units on the Real gain value, as this change will affect all payload
Time Data (RTD) web page, the units can be displayed calculations.
in either Kg/cm2 or PSI. When recording the RTD to a
USB memory flash drive, the Pressure Sensor Units Payload Light Test
are always recorded in Kg/cm2.
This allows the user to test the Green, Amber, and
Date and Time Red lights in a case where a new harness cable
is made or the lights are replaced. Checking the
The current payload meter time is shown on the Real check-box corresponding to the light and clicking the
Time Data Page, page 5-41. It is important to set TestPayloadLights button will cause that light to turn
correct date and time information, see Payload Meter on. The light will remain on for five minutes, before
IV System Configuration, page 5-41 for settings. returning to original state. More than one light may
Each time the truck is powered ON, PLM IV receives be turned on at a time.
a date & time message from Komtrax Plus. If the
truck does not have a Komtrax Plus it retains the Truck Tare Reset
user saved date & time values. The payload meter
will hold a date and time for approximately 30 days
without power if the battery is charged fully. If the date • DO NOT modify unless required.
and time is lost, reset the current information, and
5-44 980E-4
This option allows user to reset the Truck Tare to its warranty claims. The Komatsu distributor number
default. DO NOT use this function unless the payload goes in this field. This field holds 20 alphanumeric
meter state machine is locked up or has calculated characters.
an unusually low tare value. Check the system for a
Komatsu assigns a number to each customer. The
SENSOR LOW PRESSURE alarm.
KMS Customer field can hold the name of the mine
or operation where the truck is in service. This
Truck Data Configuration number is used for warranty claims. This Komatsu
This page allows the user to configure Haul Cycle customer number goes in this field. This field holds
Data headers, Real Time Data and Alarm Data for 20 alphanumeric characters.
data download files. These fields include the truck
OS (Operating System) Version Number and PLM IV
frame serial number, customer unit number, distributor
Software Version Number are automatically updated
information, and customer information.
after a software update. The user has to visit this page
to verify the software version number.
If the user fails to enter the Frame Serial Number,
Customer Unit number and distributor number, the
default “Unknown” will be saved. The user is required
to save these fields only once. In the case of field
software updates the previously saved data will be
retained.
NOTE: A password is required to make changes to
these parameters. “Kac2300”
Inclinometer Calibration
The inclinometer calibration procedure is designed to
compensate for variations in the mounting position of
the inclinometer. The inclinometer input is critical to
the payload calculation.
To calibrate the inclinometer use the instructions
below or those provided on the Payload Meter IV
Configurations screen.
1. This procedure should be performed
on relatively flat ground like that of the
maintenance area. Make sure that the
Figure 5-23 TRUCK DATA INFORMATION SCREEN
suspensions are properly serviced.
The frame serial number is found on the plate
2. With the truck stopped and the parking brake
mounted to the truck frame located on the lower right
engaged, turn the steering wheel quickly left
rail facing the right front tire. It is important to enter
and right to loosen the suspensions. Press
the correct frame serial number as this is one of the
the “START Sample 1” button to take the first
key fields used in off-truck databases.
inclinometer sample.
The customer unit, or truck number, is the specific
3. Turn the truck around and park in the exact
truck number assigned to each piece of equipment
same spot as before, but facing the other
for quick identification at the mine site. This number,
direction.
or name, can be entered in the Customer Unit
Number field. It is important to enter the unique 4. With the truck stopped and the parking brake
truck number as this is one of the key fields used in engaged, turn the steering wheel quickly left
off-truck databases. This field holds 20 alphanumeric and right to loosen the suspensions. Press the
characters. “START Sample 2” button to take the second
inclinometer sample.
Komatsu assigns a number to each distributor. The
KMS Distributor is the name of the distributor that 5. Press the “CalibrateInclinometer” button for the
helped install the system. This number is used for payload meter to average the two samples and
determine the mounting offset value.
980E-4 5-45
Figure 5-24 PAYLOAD METER IV CONFIGURATION

Overload Threshold
This option can be adjusted to set the load carrying
capacity at which truck speed becomes limited. The
speed limitation will help prevent frame or suspension
damage in the event of an overload. By default this
value is 110% of the rated load capacity.
5-46 980E-4
Figure 5-25 OVERLOAD THRESHOLD VALUE

Clean Truck Tare The Clean Truck Tare should only be initiated if the
payload meter is in the TARE_ZONE or EMPTY
The payload meter uses the clean truck tare value
states. If you attempt to initiate a Clean Truck Tare
to calculate the carryback load of each haul cycle.
while the truck is loaded, the Clean Truck Tare
The carryback value in the haul cycle record is the
calculations will not start. It will show “ Truck should
calculated empty truck tare minus the clean truck tare.
be in Empty or Tare Zone state.”
This procedure should be performed after service
NOTE: The truck must be driven continuously for
to the suspensions or when significant changes are
11 minutes at a minimum speed of 5 Km/hr (3.1
made to the sprung weight of the truck. Before
mph). The payload meter does not calibrate while the
performing this procedure, it is critical that the truck
machine is stopped.
is cleaned, the suspensions are filled to the proper oil
height and charged to the proper nitrogen pressure. NOTE: Drive on actual haul roads during the
calibration process; otherwise, inaccurate payload
Once the clean tare is started, the payload meter will
readings may result.
begin to calculate the clean empty sprung weight of
the truck. This calculation continues while the truck NOTE: DO NOT use the wheel brake lock during
drives to the next loading site. Once the procedure calibration. Inaccurate payload readings may result.
is started, the status of the process progress can be
monitored in Real Time Data page. The truck does
not need to be moving to start this procedure.
980E-4 5-47
Once the calibration is complete, confirm that the may record a very low empty sprung weight value. In
payload meter states “CLEAN TARE COMPLETE” on this case, after the body is installed, the payload meter
the Real Time Data display page. Verify the displayed may mistakenly conclude that the weight of the body
value is in the expected range for the truck type. alone constitutes a load, and refuse to return the truck
Once complete, the payload meter is ready to begin to the empty (TARE_ZONE) condition. In unusual
loading. conditions such as this, the Clean Truck Tare option
will allow the user to override the measured empty
Remember, this operation should only be performed in sprung weight value with a default value and force the
special circumstances. For instance, if the truck was truck back to the empty (TARE_ZONE) condition.
driven without the body installed, the payload meter
Figure 5-26 CLEAN TRUCK TARE CONFIGURATION
5-48 980E-4
Tare Reset conditions such as this, the Clean Truck Tare option
will allow the user to override the measured empty
Resets the vehicle tare weight to the default value
sprung weight value with a default value and force
(around 40% of rated payload).
the truck back to the empty (Tare Zone) condition.
This operation should only be performed in special
circumstances. For instance, if the truck was driven Custom Truck Configuration
without the body installed, the payload meter may
Visit the Custom Truck Configuration web page to
record a very low empty sprung weight value. In this
configure certain custom dump truck bodies.
case, after the body is installed, the payload meter
may mistakenly conclude that the weight of the body NOTE: If custom load light thresholds have been
alone constitutes a load, and refuse to return the configured, the load light percentages must be
truck to the empty (Tare Zone) condition. In unusual re-saved to use the updated unsprung weight.
Figure 5-27 CUSTOM TRUCK CONFIGURATION SCREEN

First, select the correct truck model so the payload
meter can accurately estimate payloads.
980E-4 5-49
Figure 5-28 SELECTING TRUCK MODEL

Next, the Custom Truck Configuration Page allows the number is always follows 58B06026xx. Here xx is
user to set the load threshold percentages for the load sub version number. For example the latest software
lights. file is 58B0602604.S19). The file to be downloaded
is the same as the part number. This disk is then
The default is Green (50%), Amber (90%), and Red inserted into either of the USB ports on the payload
(105%). meter communication board. Once the user enters
the Admin Password from Figure 5-29 START FLASH
Field Software Update PROGRAM SCREEN, page 5-51, the new software
PLM IV has the capability to update its software in image can be uploaded to the payload meter.
the field. The user can obtain the latest released NOTE: It is advised not to update the software unless
version of software from the Komatsu ExtraNet, then there is a fix or enhancement that is related to the
unzip and copy the file to a FAT32 formatted USB specific truck which the payload meter is installed.
memory drive, preferably 2 GB. It is important to
only have one file on the USB drive. The software
5-50 980E-4
Figure 5-29 START FLASH PROGRAM SCREEN

The software update process is initialized by pressing This entire process will take between 20 and 25
“Program Now” on Figure 5-30 SOFTWARE FIELD minutes. At the end of the install, the payload meter
UPDATE STATUS SCREEN, page 5-52. will restart causing the web server to disconnect.
NOTE: Follow the instructions on the web page. Login to the payload meter web server again and
Failure to follow the instructions could result in Figure 5-23 TRUCK DATA INFORMATION SCREEN,
unusable PLM IV hardware. page 5-45 to verify that the software version number
has successfully updated.
980E-4 5-51
Figure 5-30 SOFTWARE FIELD UPDATE STATUS SCREEN

NOTE: It is important that the payload meter Does Not Viewing Haul Cycle Data
lose power during this process. Power loss before the
PLM IV records several parameters important
install is complete can cause corruption of the payload
to analyzing each haul cycle. This data can be
meter application.
downloaded or viewed from the web server. For quick
NOTE: In case of failure to field software update, viewing, this page displays 25 haul cycles at a time.
please contact Komatsu Support Team for help.
A haul cycle number can be entered in the field at the
top of the page, and when the “Next” button is pressed
the records starting with that number will be displayed.
5-52 980E-4
Figure 5-31 HAUL CYCLE DATA SCREEN

Downloading Haul Cycle Data The payload meter will store up to nine files with up
to 2048 haul cycles in each file. Each file will have a
To download the haul cycle record of payload meter,
separate download link under “Download Haul Cycle
press the link underneath “Download Haul Cycle
Data,” with the most recent file on the bottom of the
Data.” This will start the download of payload data
list. Once full it will delete the oldest file.
in CSV format to the user’s service computer. This
file can be opened in Microsoft Excel® for viewing or NOTE: User must save downloaded Alarm file with
analysis. unique name on service PC.
980E-4 5-53
Figure 5-32 HAUL CYCLE DATA DOWNLOAD

Viewing Alarm Data An alarm number can be entered in the field at the top
of the page, and when the “GoNext” button is pressed
PLM IV tracks several parts of the payload meter
the records starting with that number will be displayed.
system for abnormalities in operation. These
abnormalities create alarms that can be downloaded
or viewed from the web server. For quick viewing,
this page displays 25 alarms at a time.
5-54 980E-4
Figure 5-33 ALARM RECORDS SCREEN

Downloading Alarm Data with the most recent file on the bottom of the list. The
maximum number of Alarm Records at any point of
To download the alarm history of payload meter, press
time is 3648. At that point the oldest files will be
the link underneath “Download Alarm Data.” This
deleted to save new files.
will start the download of the alarm history in CSV
format to the user’s service computer. This file can be NOTE: User has to save downloaded Alarm file with
opened in Microsoft Excel® for viewing or analysis. unique name on service PC.
The payload meter will store up to two files with up
to 1824 alarms in each file. The two files will have a
separate download link under “Download Alarm Data,”
980E-4 5-55
Figure 5-34 ALARM DATA DOWNLOAD
5-56 980E-4
UPLOADING DATA
Figure 5-35 UPLOADING HAUL CYCLE AND ALARM DATA
The Payload Meter (PLM) application uses data that the left side of the screen, and enter the specific
has been uploaded and stored on the server. The information about the location, distributor, and
reports generated by the application are in PDF customer.
(Adobe) format. CSV files are also available for
2. Click the “Browse” button to locate the file
special analysis. The upload feature allows you to
desired for uploading. Multiple files can be
send the PLM data stored on your computer to the
submitted at once by clicking a new “Browse”
server.
button for each file.
To access the PLM application, perform the following:
NOTE: An uploaded file can either contain data for a
1. Open the internet browser and go to group of trucks or an individual truck. The uploaded
https://www.mykomatsu.com. User id and file can also contain previously uploaded data with
password is required. If you need access, recent data. The application will automatically sort the
either contact your administrator or click machines.
“Register Now”. 3. When all the files have been selected, click the
2. Once logged in, there will be “Go To” links for “Upload” button. The time it takes to complete
the applications that you have access to. Click the upload will depend on the number and size
“Go to PLM” to access the PLM application. of the file(s) submitted.
NOTE: If no link exists, send an email to: 4. Once the uploading is finished, click “Process
servicesystems@komatsuna.com. Include your the file(s)”.
company and contact information. 5. When the files are finished processing, a
To upload PLM information to the server, perform the report will be generated that will display graphs
following: corresponding to what months were included
within the PLM data for each truck.
1. Once logged in and at the “Payload
Management” screen, click “Data Upload”, on
980E-4 5-57
NOTE: If you receive a “Mismatch” error, it means Detailed Multi-Page Report

that a specific truck was not registered on the
The detail report starts with the summary report and
system beforehand. Please send an email to
follows with pages of data for each haul cycle. The
servicesystems@komatsuna.com to register the
report shows date, time, payload, cycle times, cycle
machine. Be sure to include the truck serial number
distances, speeds and the number of swing loads.
and ownership information.
The detailed report contains the information listed
Payload data can be uploaded to
below:
“www.MyKomatsu.com” where a payload
management report can be generated to analyze • Customer Information
payload data. The data analysis tools allow the user
• Machine Information
to monitor the performance of the payload systems
across the fleet. Analysis begins when the "View • Reporting Period
Payload Data" button is pressed. This starts an "all
• Load Distribution
trucks, all dates, all times" query of the database and
displays the results in the Payload Summary Form. • Alarms
The user can change the query by changing the dates, • Critical Warning Flags
times, or trucks to include in the query for display.
• Non-Critical Warning Flags
NOTE: Data can be uploaded in any units, Metric • Productivity
tons, Short tons, or Long tons. The database always
maintains a common unit of Metric tons. User has • Swingload Occurrence
option to generate the detailed report in Metric tons • Haul Distance
or Short tons.
• Weekly Activity
NOTE: It is recommended that data be uploaded in
only one unit of measure, either metric (long ton) or • Daily Activity
English (short ton). When data is uploaded in multiple • Speed and Tire
units some resolution may be lost due to rounding.
• Weight and Torque
Creating a Query NOTE: Some haul cycles may contain the Sensor
The program defaults to show all trucks, all types, all Input warning flag. This warning indicates that one
dates and all times for the initial query. The display of the four pressure sensors or the inclinometer was
can be narrowed by selecting which trucks or types to not functioning properly during the haul cycle. Haul
view and for what dates and times. It is important to cycles with this warning are displayed in red on the
carefully select the query data and press the “Query Payload Summary window and are not included in the
Database & Display” button before printing a report. summary statistics for reports or display.
Choosing one particular truck number will limit the
Creating Graphs
data in the displays, summaries and reports to the one
selected truck. To create reports for truck number 374, The PLM data could be downloaded directly in .CSV
select 374 from the pull-down menu and hit the “Query format and user could generate graphs that quickly
Database and Display” button. summarize payload data. These graphs can be
customized by choosing required date range.
The truck type is the size of the truck from the family of
Komatsu trucks. This allows the user to quickly view User could use Microsoft Internet Explorer® or Google
results from different types of trucks on the property. Chrome® or any other browsers to connect to PLM
For example, a separate report can be generated for device and no PC Software required for downloading
830E and 930E trucks. The default query starts in PLM data.
1995 and runs through the current date on the PC. To
narrow the range to a specific date, change the “From” Field Software Update Procedure
and “To” dates.
The user shall follow the instructions listed below
The time range sorts the times of the day for valid carefully for successful software reprogramming. This
dates. Changing the time range to 6:00AM to 6:00PM process is required to perform only when there is a
will limit the payloads displayed to the loads that new software release available in Komatsu Extranet
occurred between those times for each day of the or there is published Parts & Service News (PSN)
date range. Times are entered in 24:00 format. with new features or field change requests.
5-58 980E-4
This operation should only be performed in special conditions such as this, the Clean Truck Tare option
circumstances. For instance, if the truck was driven will allow the user to override the measured empty
without the body installed, the payload meter may sprung weight value with a default value and force
record a very low empty sprung weight value. In this the truck back to the empty (Tare Zone) condition.
case, after the body is installed, the payload meter
From PLM IV home page, select Field Software
may mistakenly conclude that the weight of the body
Update link to reprogram payload meter firmware.
alone constitutes a load, and refuse to return the
truck to the empty (Tare Zone) condition. In unusual
Figure 5-36 FIELD SOFTWARE UPDATE
NOTE: The process might take up to 25 minutes. NOTE: The firmware file name will be the software
part number. For example 58B0602604.S19 is the
NOTE: Do not power down or disconnect the USB latest version of the software available in Extranet
memory disk during the software process. where 04 is sub version number.
NOTE: Doing so may result in permanent damage to NOTE: Do not modify the file name or edit the file
payload meter IV. contents.
1. Download the latest version of the payload 3. Format a 2GB USB memory disk and copy the
meter firmware from the Komatsu Extranet. 58B06026XX.S19 file on to it.
2. Unzip the 58B060260xx.zip file.
980E-4 5-59
NOTE: A memory disk larger than 2GB takes more 6. Turn the Keyswitch ON.
time to mount & unmount
7. Login to PLM IV web server and click on
4. Keep only one copy of the files on the USB StartProgram button by navigating onto Field
memory disk. Software Update screen.
5. Insert the USB disk into one of the USB slots 8. The next screen is initiate the software update.
on Payload Meter Communication Board.
Figure 5-37 PROGRAM NOW

If the USB disk is mounted successfully, then the next
screen will be displayed “software re-programming
initialization is in progress.”
Figure 5-38 INITIALIZATION
5-60 980E-4
If the USB is not mounted or file is not detected

or corrupted then “USB Error” messages will be
displayed.
Figure 5-39 ERROR/FILE CORRUPTION

In case if the software is previously installed the very latest software version, then reboot the PLM
successfully, the system does not detects the USB IV. Turn OFF Key Switch and wait until all the LED’s
disk then the message “Verify the software version on Communication Board is turned OFF and then turn
number” will be displayed. If user chooses to update ON the Key Switch.
Figure 5-40 VERIFY THE SOFTWARE VERSION

If user has to repeat the above step, reboot PLM initializing the software re-programming as described
IV, with correct firmware version until the message in 5-38 INITIALIZATION, page 5-60, the next screen
as in 5-38 INITIALIZATION, page 5-60 Software will displayed as in 5-41 USB MEMORY DISK
re-program initialization appears. After successfully VERIFICATION, page 5-62.
980E-4 5-61
Figure 5-41 USB MEMORY DISK VERIFICATION

Successful completion of the memory disk verification
the complete file checksum verification will be
initialized. As shown in the 5-42 COMPLETE FILE
CHECKSUM VERIFICATION (7 MINUTES), page
5-62.
Figure 5-42 COMPLETE FILE CHECKSUM VERIFICATION (7 MINUTES)

The file checksum process might take up to 7 minutes.
The message with appropriate decrementing time is
displayed.
5-62 980E-4
After successfully completing the file checksum

the payload meter flash memory will be erased to
reprogram new firmware.
Figure 5-45 ERASE MEMORY PROGRESS
Memory erasing could take 2 to 3 minutes to complete. Appropriate error messages will be displayed in
Reprogramming progress status messages will be case of erase failure. User has to contact Komatsu
displayed after successfully erasing the flash memory. Customer Support Team with error details.
Figure 5-46 APPLICATION REPROGRAMMING INITIALIZATION
980E-4 5-63
Application reprogramming could take around 8

minutes to complete, the progress messages will be
displayed starting with 5%, 15%, 25% etc.
Figure 5-47 APPLICATION REPROGRAMMING PROGRESS 5%
5-64 980E-4
Within a few seconds of the program successfully NOTE: After a successful software update, if the PLM
reaching 100%, the PLM IV will automatically reboot. IV does not reboot immediately, the user must wait
Click Reboot PLM IV if the payload meter does until the PLM IV reboots, or turn the keyswitch OFF
not reboot automatically within 10 seconds. It is until all the LEDs on the PLM IV Communication Board
recommended to remove the USB memory disk turns OFF before turning the keyswitch ON.
when 100% complete message is displayed. When
the PLM IV reboots the web page will ask user to
reconnect.
Figure 5-50 APPLICATION REPROGRAMMING SUCCESSFUL

Finally, the user must login and verify the software
version number by navigating to Truck Configuration
web page.
980E-4 5-65
Figure 5-51 VERIFY THE SOFTWARE VERSION NUMBER
5-66 980E-4
OPERATING INSTRUCTIONS AUTOMATIC LUBRICATION SYSTEM
AUTOMATIC LUBRICATION COMPONENT DESCRIPTION A.4-0000061594

SYSTEM C.3-0000051429
GENERAL INFORMATION E.21-0000051468
The automatic lubrication system is a pressurized

lubricant delivery system which delivers a controlled
amount of lubricant to designated lube points. The
system is controlled by logic in the Interface Module
which signals a solenoid valve to operate a hydraulic
motor powered grease pump. Hydraulic oil for pump
operation is supplied by the truck steering circuit.
A 24VDC solenoid mounted on the manifold turns the
pump on and off. The pump is driven by the rotary
motion of the hydraulic motor, which is then converted
to reciprocating motion through an eccentric crank
mechanism. The pump is a positive displacement,
double-acting type as grease output occurs on both
the up and the down stroke.
1. Hose From Filter 7. Vent Valve

2. Outlet to Injectors 8. Pipe Plug
3. Hydraulic Motor 9. Pump Assembly
4. Pressure Reducing 10. Flow Control Valve
Valve 11. Grease Reservoir
5. Solenoid Valve
6. Override Switch
Figure 5-52 PUMP & RESERVOIR COMPONENTS
980E-4 5-67
AUTOMATIC LUBRICATION SYSTEM OPERATING INSTRUCTIONS
assembly is mounted on the grease reservoir and

filters the grease prior to refilling the reservoir. Bypass
• Over-pressurizing the system, modifying indicator (1) alerts service personnel when the filter
parts, using incompatible chemicals and requires replacement.
fluids, or using worn or damaged parts may
result in equipment damage and/or serious Hydraulic Motor and Pump
personal injury.
• This equipment generates very high grease Rotary hydraulic motor and pump is a fully
pressure. Extreme caution must be used hydraulically-operated grease pump. An integrated
when operating this equipment. Pressurized pump control manifold is incorporated with the motor
fluid leaking from loose or ruptured to control input flow and pressure.
components can result in fluid being injected
The pump crankcase oil level must be maintained to
into the skin and body causing serious
the level of pipe plug (17, Figure 5-54 LUBRICATION
injury and possibly the need for amputation.
INJECTORS, page 5-70). If equipped, use the
Adequate protection is recommended to
dipstick on top of the pump housing to check the oil
prevent splashing of material onto skin or
level. Add 10W-30 motor oil, if necessary.
into the eyes.
• If any fluid appears to penetrate the skin, get
emergency medical care immediately! Do not
treat as a simple cut. Tell attending physician • Hydraulic oil supply inlet pressure must not
exactly what fluid was injected. exceed 24 132 kPa (3,500 psi). Exceeding the
rated pressure may result in damage to the
system components and personal injury.
Filter
Grease Reservoir
Reservoir (11, Figure 5-52 PUMP & RESERVOIR
COMPONENTS, page 5-67) has an approximate
capacity of 41 kg (90 lbs.) of grease. When the
grease supply is replenished by filling the system at
the service center, the grease is passed through the
filter to remove contaminants before it flows into the
reservoir.
Pressure Reducing Valve

Pressure reducing valve (4), located on the manifold,
reduces the hydraulic supply pressure (from the truck
steering circuit) to a suitable operating pressure for the
hydraulic motor used to drive the lubricant pump.
NOTE: The pressure reducing valve has been
factory adjusted and the setting should not be
disturbed unless grease output pressure is outside
the recommendations.
A pressure gauge can be installed where pipe plug (8)
is located. The pressure gauge will indicate hydraulic
1. Bypass Indicator 6. Spring oil pressure to the inlet of the hydraulic motor. Normal
2. Housing 7. Bowl pressure is 2241 - 2413 kPa (325 - 350 psi).
3. O-Ring 8. O-Ring
4. Backup Ring 9. Plug Flow Control Valve
5. Filter Element
Flow control valve (10) mounted on the manifold,
Figure 5-53 FILTER ASSEMBLY controls the amount of oil flow to the hydraulic motor.
Filter element (5, Figure 5-53 FILTER ASSEMBLY, NOTE: The flow control valve has been factory
page 5-68) must be replaced if bypass indicator adjusted and the setting should not be disturbed.
(1) shows excessive element restriction. The filter
5-68 980E-4
Solenoid Valve Interface Module

Solenoid valve (5) when energized, allows oil to flow The interface module provides a 24 VDC timed
to the hydraulic motor. interval signal to energize solenoid valve, providing oil
flow to operate the grease pump motor. This interface
Vent Valve module is mounted in the auxiliary control cabinet.
With vent valve (7) closed, the pump continues to
operate until maximum grease pressure is achieved.
As this occurs, the vent valve opens and allows the
grease pressure to drop to zero, so the injectors can
recharge for their next output cycle.
980E-4 5-69
1. L.H. Suspension, Bottom 9. R.H. Suspension, Bottom 17. Pipe Plug (Oil Level)
Bearing Bearing 18. Pressure Switch, N.O.
2. L.H. Hoist Cylinder, Bottom 10. R.H. Hoist Cylinder, Bottom 19. Grease Pump
Bearing Bearing 20. Vent Valve
3. L.H. Anti-Sway Bar Bearing 11. Rear Axle Pivot Pin 21. Filter
4. L.H. Suspension, Top Bearing 12. R.H. Anti-Sway Bar Bearing 22. Grease Supply to Injectors
5. L.H. Body Pivot Pin 13. R.H. Suspension, Top Bearing 23. Injectors
6. L.H. Hoist Cylinder, Top Bearing 14. R.H. Body Pivot Pin
7. R.H. Hoist Cylinder, Top Bearing 15. Truck Frame
8. Grease Supply From Pump 16. Vent Hose
Figure 5-54 LUBRICATION INJECTORS
5-70 980E-4
Injectors to the injector banks. When this occurs, the injectors

are then able to recharge for the next lubrication
Each injector delivers a controlled amount of
cycle.
pressurized lubricant to a designated lube point.
Refer to Figure 5-54 LUBRICATION INJECTORS, NOTE: The system will remain at rest until the next
page 5-70 for locations. lubrication cycle turns on and initiates a new grease
cycle. During the normal lubrication cycle, if grease
Grease Pressure Failure Switch pressure fails to reach 13 790 kPa (2,000 psi) at the
Pressure switch (18) is a normally open switch set at pressure switch located on the rear axle housing,
13 789 kPa (2,000 psi). This switch monitors grease a repair indicator light will illuminate on the monitor
pressure in the injector bank on the rear axle housing. display panel. In addition, fault A190 “Auto Lube
If the appropriate grease pressure is not achieved Fault” will be shown in the repair fault menu.
during the normal pump cycle, the warning system
will be activated. The repair light will illuminate and a Filling The Reservoir
message will be displayed on the dash panel to notify
the operator that a problem exists in the lubrication
system.
Relief Valve (unloader valve)

There is a relief valve that protects the pump from high
pressures. The relief valve is set at 27 580 kPa (4,000
psi).
SYSTEM OPERATION A.14-0000053765
During truck operation, the lubrication cycle logic (in

the interface module) will energize the system at a
preset time interval. The interface module provides
a path to ground to energize the pump solenoid valve
allowing hydraulic oil provided by the steering pump 1. Automatic Lubrication Fill Connector
circuit to flow to the pump motor and initiate a pumping
cycle. Figure 5-55 SERVICE CENTER
The hydraulic oil from the steering circuit is directed The grease reservoir has an approximate capacity of
through the pressure reducing valve and the flow 41 kg (90 lb) of grease. When the grease supply is
control valve before entering the motor. Pump replenished by filling the system at the service center,
pressure can be read on optional pressure gauge the grease is passed through the filter to remove
mounted on the manifold. With oil flowing into contaminants before it flows into the reservoir.
the hydraulic motor, the grease pump will operate, To fill the automatic lubrication system reservoir,
pumping grease from the reservoir to the injectors, perform the following:
through a check valve, and to the vent valve. During
this period, the injectors will meter the appropriate 1. Connect an external grease supply to
amount of grease to each lubrication point. automatic lubrication fill connector (1, Figure
5-55 SERVICE CENTER, page 5-71) of the
NOTE: Each lube injector services only one grease service center.
point. In case of pump malfunction, each injector is
equipped with a covered grease fitting to allow the use 2. Remove the vent hose from the reservoir.
of external lubricating equipment. 3. Pump grease into the reservoir, from the
When grease pressure reaches the setting of pressure service center, until grease is seen through the
switch, the switch contacts will close and energize vent hose port. Once grease is present, stop
the relay. Energizing this relay removes power from filling.
the hydraulic motor/pump solenoid and the pump 4. Disconnect external grease supply from the
will stop. The relay will remain energized until the service center and reconnect the vent hose to
interface module completes its 120 second ON cycle. the reservoir.
After the pump solenoid valve is de-energized,
hydraulic pressure in the manifold drops and the vent
valve will open releasing grease pressure in the lines
980E-4 5-71
Lubricant Required For Automatic Lubrication 2. Remove injector manifold plug (5, Figure
System 5-57 INJECTOR MANIFOLD, page 5-72) from
injector manifold. Always start with the injector
Grease requirements will depend on ambient
manifold closest to the pump. The last grease
temperatures encountered during truck operation:
line to be purged should be the main grease
• Above 32°C (90°F) - Use NLGI No. 2 multipurpose line to the rear axle (longest grease line).
grease (MPG). 3. Disconnect main supply line (2, Figure 5-56
• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 AUTO LUBE MAIN SUPPLY LINE, page 5-72)
multipurpose grease (MPG). from vent valve (1). Connect an external
grease supply to main supply line (2).
• Below -32°C (-25°F) - Refer to local supplier for
extreme cold weather lubricant requirements. 4. Pump grease in main supply line (2) until
grease appears at the injector manifold plug.
Priming The Automatic Lubrication 5. Re-install the injector manifold plug. Repeat for
System remaining injector groups.
The system must be full of grease and free of air After all main supply lines are purged of air, the injector
pockets to function properly. After maintenance, if circuits must now be primed.
primary or secondary lubrication lines were replaced,
it will be necessary to prime the system to eject all To prime the secondary supply lines, perform the
entrapped air. following:
1. If necessary, disconnect an injector grease
line from the component that particular injector
supplies grease to.
2. Remove injector grease zerk cap (4, Figure
5-57 INJECTOR MANIFOLD, page 5-72)
from each injector and connect an external
grease supply to injector grease zerk (2) on
the injector.
3. Pump grease into the injector until grease
appears at the far end of the individual grease
line or the joint being greased.
1. Vent Valve 2. Main Supply Line
4. Reconnect injector grease line to the
component, remove the external grease
Figure 5-56 AUTO LUBE MAIN SUPPLY LINE supply, and reinstall injector grease zerk cap.
5. Repeat steps 1 through 4 until all secondary
supply lines have been primed.
6. After all grease lines are primed, use the
override switch to cycle the automatic
lubrication pump a few times to lube the
components.
PREVENTIVE MAINTENANCE
PROCEDURES E.6-0000051465
Use the following maintenance procedures to ensure
1. Injector Indicator 4. Injector Grease Zerk proper system operation.
2. Injector Grease Zerk Cap
3. Injector Cover 5. Injector Manifold Plug Daily Lubrication System Inspection
1. Check the grease reservoir level after each
Figure 5-57 INJECTOR MANIFOLD shift of operation. Grease usage should be
To prime the main supply lines, perform the following: consistent from day-to-day operations. Lack of
lubricant usage would indicate an inoperative
1. Fill lube reservoir with lubricant, if necessary.
5-72 980E-4
system. Excessive usage would indicate a It is good practice to manually lube each
broken supply line. bearing point at the grease fitting provided on
each Injector. This will indicate if there are
2. Check filter bypass indicator when filling
any frozen or plugged bearings, and it will help
reservoir. Replace element if bypassing.
flush the bearings of contaminants.
3. Check all grease hoses from the injectors to the
5. System Checkout
lubrication points.
a. Remove all injector cover caps to allow
a. Repair or replace all damaged feed line
visual inspection of the injector cycle
hoses.
indicator pins during system operation.
b. Ensure that all air is purged and all new
b. Start truck engine.
feed line hoses are filled with grease before
returning the truck to service. c. Actuate lube system override switch. The
hydraulic motor and grease pump should
4. Inspect the key lubrication points for a bead
operate.
of lubricant around seal. If a lubrication point
appears dry, troubleshoot and repair problem. d. With the grease under pressure, check
each injector assembly. The cycle indicator
250 Hour Inspection pin should be retracted inside the injector
body.
1. Check all grease hoses from the injectors to the
lubrication points. e. When the system is at 16 203 - 17 237 kPa
(2,350 - 2,500 psi), the pump should shut
a. Repair or replace all worn or broken hoses. off and the pressure in the system should
b. Ensure that all air is purged and all new drop to zero, venting back to the grease
feed line hoses are filled with grease before reservoir.
returning the truck to service. f. After the system has vented, check the
2. Check all grease supply line hoses from the injector indicator pins. All of the pins should
pump to the injectors. be visible. Replace or repair any defective
injectors.
a. Repair or replace all worn / broken supply
lines. g. Install all injector cover caps.
b. Ensure that all air is purged and all new h. Initiate one or more lubrication cycles to
supply line hoses are filled with grease check the system operation.
before returning the truck to service. NOTE: Turning the key switch to the ON position will
3. Check the grease reservoir level. not initiate a lube cycle. To initiate a lube cycle while
the truck is stationary, select manual lube using the
a. Fill the reservoir if the grease level is low. dash display panel, or use the switch on the lubrication
Check the filter bypass indicator when pump. The system should build 13 790 kPa (2,000
filling the reservoir. Replace the element if psi) at the rear axle during normal pump cycle.
bypassing.
i. If the system is working properly, the
b. Check the reservoir for contaminants. machine is ready for operation.
Clean the reservoir, if required.
j. If the system is malfunctioning,
c. Ensure that all filler plugs, covers and immediately report problem to
breather vents on the reservoir are intact maintenance personnel.
and free of contaminants.
4. Inspect all bearing points for a bead of lubricant 1000 Hour Inspection
around the bearing seal. 1. Using the dipstick, check the pump housing
oil level. If necessary, refill with SAE 10W-30
motor oil.
980E-4 5-73
SYSTEM CHECKOUT OPERATING INSTRUCTIONS
SYSTEM CHECKOUT C.9-0000051738
General Checks
To check system operation, proceed as follows:
1. Remove the dust covers from the injectors.
2. Start the engine.
3. Actuate the manual override button at the pump
assembly and observe pin movement at each
injector.
4. Check for pump, hose or injector damage or
leakage with the system under pressure.
5. After checking system, stop the engine.
Observing normal precautions regarding high
voltage present in the propulsion system before
attempting to repair lube system.
6. Re-install the injector dust covers.
Lubrication Cycle Operation

The time between lube events is determined by the
setting selected in the dash panel. Refer to Figure
5-58 LUBRICATION MENU, page 5-74 for lubrication
menu screens. With the key switch ON, scroll through
the display menu screens and select either 8, 15, 24 or
30 minutes between lube cycles. The default setting
is 15 minutes.
NOTE: To activate access to the lube interval screen
the Operator ID must be changed to 5625. After
making a change the ID should be reset to any value
other than 5625. Refer to Toggling Through Main
Level Screens, page 6-26 for menu screens to follow
when changing the Operator ID.
NOTE: Turning the key switch to the ON position
will not initiate a lube cycle. To initiate a lube cycle
while the truck is stationary, select manual lube using
the dash display panel, or use the switch on the
lubrication pump. The truck must be moving before
the lube system will initiate lube cycles based on the
time interval selected.
Figure 5-58 LUBRICATION MENU
5-74 980E-4
OPERATING INSTRUCTIONS RESERVE ENGINE OIL SYSTEM (if equipped)
RESERVE ENGINE OIL SYSTEM (if Operation

equipped) A.16-0000071908
The reserve engine oil system works by constantly
circulating the engine oil between the engine oil pan
and a supplementary external reserve tank while
maintaining the appropriate running oil level. The
intent is that a larger volume of engine oil slows the
oil deterioration, allowing longer periods between oil
changes.
The normal reserve system capacity of oil carried
in the tank can be one half or nearly the same
(depending on tank size) volume inside the engine.
In the process of continuous adjustment of the engine
oil level, there is a constant circulation of oil between
the engine and the reserve tank. The volume of
oil in the tank becomes part of the working oil for
the engine. Oil change intervals may usually be
extended in proportion to the increased working oil
volume. Extension beyond a proportional increase
is often possible, but should be undertaken only
as determined by oil sampling and analysis. Local
conditions such as engine application, climate, and
fuel quality should be taken into consideration before
determining permissible oil life.
A heated suction line is installed between the reserve
oil pump and engine oil pan which allows the pump
to function down to minimum ambient temperature
of -30C (-22F). Engine oil becomes more viscous
in lower temperatures, causing the pumps to work
harder and wear more quickly. Heating the oil
keeps the oil less viscous, thus maintaining the
corresponding flow rate at the inlet of the reserve
pump.
An optional heated return line is available which 1. Reserve Tank 8. Fill Cap
extends the minimum ambient temperature to -40C 2. Sight Gauge 9. Oil Level Switch
(-40F). 3. Thermostat Switch 10. Air Relief Valve
4. Suction Line from 11. Return Line to Engine
Engine Oil Pan Oil Pan
5. Pumping Unit 12. Fill Valve
6. Remote Fill Line 13. Oil Strainer Screen
7. Inline Screen
Figure 5-59 RESERVE TANK COMPONENTS

Engine oil is circulated between the engine sump
and the reserve tank by two electrically driven pumps
within a single pumping unit (5, Figure 5-59 RESERVE
TANK COMPONENTS, page 5-75). The pumping
unit, which is mounted on the side of the reserve tank,
is equipped with two LED monitor lights: red on one
side, green on the other side.
980E-4 5-75
RESERVE ENGINE OIL SYSTEM (if equipped) OPERATING INSTRUCTIONS
Pump 1 and Pump 2 are interlocked. Once the engine Table 5-4 PUMP AND LED ACTION CHART
is started, the pumps run continuously. This action
Description Green LED Red LED
returns oil from the reserve tank and raises the engine
oil level until air is no longer drawn by Pump 1. A Flashing Flashing
The oil level is continuously adjusted at the control B Solid Flashing
point by alternating between the withdrawal and return C Flashing Off
of oil in the engine oil pan. Pump 1 draws oil from the
engine oil pan at a preset control point determined by Flashing/Solid
the height of the suction tube. Pump 2 returns oil back D Off
to the engine oil pan. Oil above this point is withdrawn (Mixed
and transferred to the reserve tank. This lowers the Flashing)
level in the engine oil pan until air is drawn.
LED Monitor Light

The following light indications should be used to
understand pump operation.
After engine startup, allow the pumping unit to run for
5 minutes before operating the truck. The green LED,
see Figure 5-60 PUMPING UNIT, page 5-76, will
alternate between flashing and solid (mixed flashing)
and red LED (4) should be off. This verifies that
the system is working properly, pumps 1 and 2 are
synchronized and pumping oil, and the engine oil
level is correct.
1. Pump 1 3. Green LED
Use Table 5-4 PUMP AND LED ACTION CHART, 2. Pump 2 4. Red LED
page 5-76 below to help identify the various LED
status indicators. Figure 5-60 PUMPING UNIT
A. If both LED lights are flashing the unit is operating Changing Oil
with no oil pumping through pumps 1 or 2. Obey the following guidelines when changing the oil.
B. If the green LED light is solid and the red LED 1. Drain both the engine sump and the reserve
is flashing the unit is running oil through only pump tank. Refill both the engine and reserve tank
1. Pump 1 is withdrawing oil from the engine oil pan with new oil to proper levels.
and the reserve tank is low on oil. This is an unlikely
scenarios, but it is possible for short periods of time. 2. Change engine and reserve tank filters as
If pump 1 is pumping oil from the engine, the tank required.
probably has not run dry. 3. Check that the oil strainer screen is not clogged
C. If the green LED is flashing and the red LED is off, or damage.
the pump is receiving air from the engine oil pan (the 4. Start the engine and check for proper
oil level is below the withdrawal point of the pickup operation.
tube). This is normal for short periods of time, but
if this persists for too long, it is advised to check the NOTE: DO NOT use the oil in the reserve tank to fill
pumping unit and tank oil level. Normally, the reserve the engine sump. Both must be at proper level before
oil pump should return oil back to the engine oil pan, starting the engine.
continuously adjusting the oil level until air is no longer 5. The engine oil level must be checked with the
drawn by the reserve oil pump. engine dipstick at every shift change. If the oil
D. If the green LED is in a mixed flashing cycle level in the engine is incorrect, check for proper
(Flashing/Solid) and the red LED is Off the unit is operation of the reserve engine oil system.
running oil through pumps 1 and 2 simultaneously. 6. The oil level in the reserve tank must also be
This indicates that pump 1 is alternately pumping oil checked at every shift change. Use the sight
and air. This only happens when the engine oil level glasses to check oil level. If oil is visible in
is correct and indicates that the complete system is the lower sight glass the truck can run at least
operating correctly.
5-76 980E-4
OPERATING INSTRUCTIONS RESERVE ENGINE OIL SYSTEM (if equipped)
one shift. If necessary, add oil to the reserve Oil must always be visible in lower sight gauge
tank by using the quick fill system utilizing tank (2).
fill valve (12). For filling instructions, refer to
Lubrication and Service- RESERVE ENGINE
OIL SERVICE, page 7-4 in this manual.
980E-4 5-77
RESERVE ENGINE OIL SYSTEM (if equipped) OPERATING INSTRUCTIONS
5-78 980E-4
OPERATOR CAB AND CONTROLS
980E-4 6-1
CAB INTERIOR OPERATOR CAB AND CONTROLS
CAB INTERIOR A.35-0000070600
1. Steering Wheel 7. Instrument Panel 12. AM/FM Radio / CD Player

2. Retard Pedal 8. Grade/Speed Retard Chart 13. KomVision Monitor
3. Throttle/Accelerator Pedal 9. Radio Speakers 14. Heater/Air Conditioner Vents
4. Retarder Lever 10. Warning Alarm Buzzer 15. Air Cleaner Vacuum Gauges
5. Heater/Air Conditioner Controls 11. Windshield Wipers 16. Cup Holder
6. Recirculation Filter
Figure 6-1 CAB INTERIOR - OPERATOR VIEW
6-2 980E-4
OPERATOR CAB AND CONTROLS STEERING WHEEL AND CONTROLS
STEERING WHEEL AND Multi-Function Turn Signal Switch

CONTROLS E.26-0000051460
Steering wheel (1, Figure 6-2 STEERING WHEEL &
CONTROLS, page 6-3) can be telescoped "in" and
"out" and the tilt angle can be adjusted to provide
a comfortable steering wheel position for most
operators.
Multi-function turn signal switch (4) is used to activate

the turn signal lights, the windshield wipers, and to
select either high or low beam headlights.
Turn Signal Operation

Move the lever upward to
signal a right turn. Move
the lever downward to
signal a left turn. An
indicator in the top, center
of the instrument panel
will illuminate to indicate
turn direction selected.
Refer to Instrument Panel
and Indicator Lights in
1. Steering Wheel 4. Multi-Function Turn this section.
2. Horn Button Signal Switch
3. Tilt/Telescope Lever 5. Retarder Lever NOTE: If the truck is not equipped with a
self-canceling turn signal, the turn signal will
Figure 6-2 STEERING WHEEL & CONTROLS not automatically cancel after the turn has been
completed.
Horn Button
The horn is actuated by pushing the horn button (2) High Beam Headlight Operation
in the center of the steering wheel. Ensure that the Pulling the lever inward
horn operates before moving the truck. Observe all (toward the rear of
local safety rules regarding the use of the horn as a the cab) changes the
warning signal device before starting the engine and headlights to high beam.
moving the vehicle. When the high beams
are selected, the indicator
Tilt / Telescope Lever in the top center of the
The steering column can be telescoped or the wheel instrument panel will
tilted with lever (3). illuminate.
Adjust the tilt of the steering wheel by pulling the lever Moving the switch back to the original position will
toward the steering wheel and moving the wheel to the return the headlights to low beam.
desired angle. Releasing the lever will lock the wheel
in the desired location. Windshield Wiper Operation
Adjust the telescope function by pushing the lever For windshield wiper operations refer to Table 6-1
forward to unlock. After positioning as desired, WINDSHIELD WIPER OPERATION, page 6-4
release the lever to the lock position.
980E-4 6-3
STEERING WHEEL AND CONTROLS OPERATOR CAB AND CONTROLS
Table 6-1 WINDSHIELD WIPER OPERATION High Speed

Windshield Wipers OFF Depressing the button at the end of
Intermittent - Long Delay the lever will activate the windshield
washer.
Intermittent - Medium Delay
NOTE: The windshield wipers will not come on
Intermittent - Short Delay
automatically when activating the washer. This must
Low Speed be done manually.
6-4 980E-4
OPERATOR CAB AND CONTROLS PEDALS AND RETARDER LEVER
PEDALS AND RETARDER • When the lever is rotated to full “down” (clockwise)
LEVER B.53-0000060899 position, it is in the full ON/retard position.
• For long downhill hauls, the lever may be positioned
Dynamic Retarding
to provide desired retarding effort, and it will remain
Dynamic retarding is a braking torque (not a brake) where it is positioned.
produced through electrical generation by the
wheelmotors when the truck motion (momentum) is NOTE: The retarder lever must be rotated back to the
the propelling force. OFF position before the truck will resume the propel
mode of operation.
For normal truck operation, dynamic retarding must be
used to slow and control truck speed. The lever and foot-operated retarder/service brake
pedal can be used simultaneously or independently.
Dynamic retarding is available in The Drive System Controller (DSC) will determine
FORWARD/REVERSE at all truck speeds above 0 which device is requesting the most retarding effort
kph/mph; however, as the truck speed slows below 5 and apply that amount.
kph (3 mph), the available retarding force may not be
effective. Use the service brakes to bring the truck Brake/Retarder Pedal
to a complete stop.
Brake/retarder pedal (2, Figure 6-1 CAB INTERIOR
Dynamic retarding will not hold a stationary truck on - OPERATOR VIEW, page 6-2) is a single,
an incline. Use the parking brake or wheel brake lock foot-operated pedal that controls both retarding and
for this purpose. service brake functions. The first portion of pedal
travel commands retarding effort through a rotary
Dynamic retarding is available in NEUTRAL only when
potentiometer. The second portion of pedal travel
truck speed is above 5 kph (3 mph).
modulates service brake pressure directly through a
When dynamic retarding is in operation, engine rpm hydraulic valve. Thus, the operator must first apply,
will automatically go to an advance retard speed and maintain, full dynamic retarding in order to apply
setting. This rpm will vary depending on temperature the service brakes. Releasing the pedal returns brake
of several electrical system components. and retarder to the OFF position.
Dynamic retarding will be applied automatically if the For normal truck operation, dynamic retarding (lever
speed of the truck obtains the maximum speed setting or foot-operated pedal) should be used to slow and
programmed in the control system software. control the speed of the truck.
When dynamic retarding is activated, an indicator light Service brakes should be applied only when dynamic
will illuminate. The grade/speed retard chart must retarding requires additional braking force to slow the
always be used to determine safe downhill speeds. truck speed quickly or when bringing the truck to a
Refer to the grade speed chart in the cab. complete stop.
Retarder Lever Accelerator Pedal

Retarder lever (5, Figure 6-2 STEERING WHEEL & Accelerator pedal (3) is a foot-operated pedal which
CONTROLS, page 6-3) mounted on the right side allows the operator to control engine rpm depending
of the steering column can be used to modulate on pedal depression.
retarding effort. The lever will command the full range
It is used by the operator to request torque from the
of retarding and will remain at a fixed position when
motors when in forward or reverse. In this mode, the
released.
propulsion system controller commands the correct
• When the lever is rotated to full “up” engine speed for the power required. In NEUTRAL,
(counterclockwise) position, it is in the OFF/no this pedal controls engine speed directly.
retard position. An adjustable detent holds the
lever in the OFF position. Refer to the shop manual
for adjustment procedures.
980E-4 6-5
OVERHEAD PANEL AND DISPLAYS OPERATOR CAB AND CONTROLS
OVERHEAD PANEL AND functions. Individual customers may use this area for
DISPLAYS D.15-0000054540 other purposes, such as a two-way communications
radio.
The items listed below are located on the overhead
panel. Refer to Figure 6-1 CAB INTERIOR - Air Cleaner Vacuum Gauges
OPERATOR VIEW, page 6-2 for the location of
each item. A brief description of each component is Air cleaner vacuum gauges provide a continuous
documented below. reading of the maximum air cleaner restriction
reached during operation. The air cleaner(s) must
Radio Speakers be serviced when the gauge(s) shows the maximum
recommended restriction of 635 mm (25 in.) of H2O
Radio speakers for the AM/FM Radio / CD Player are vacuum.
located at the far left and right of the overhead panel.
NOTE: After service, push the reset button on face of
Warning Alarm Buzzer gauge to allow the gauge to return to zero.
Warning alarm buzzer will sound when activated KomVision™ Panel

by any one of several truck functions. Refer to
INSTRUMENT PANEL, page 6-18 in this section for The KomVision system is a 360 degree camera/radar
a detailed description of functions and indicators that system. The KomVision monitor displays warnings
will activate this alarm. that will alert the operator to the presence of nearby
obstacles so the operator can stop, slow down or
Cab Radio steer the truck away from a potential hazard. The
KomVision system does not operate when the truck
This panel will normally contain AM/FM Radio/CD speed is more than 15 kph (9 mph).
Player. Refer to RADIO OPERATION, page 9-6 for
a more complete description of the radio and its
6-6 980E-4
OPERATOR CAB AND CONTROLS CENTER CONSOLE
CENTER CONSOLE D.89-0000051505 PARK, or damage may occur to the park brake. When
the key switch is ON, and the control lever is in PARK,
the parking brake indicator light will be illuminated.
NOTE: The directional control lever must be in PARK
to start the engine. DO NOT move the directional
control lever to the PARK position at the shovel or
dump.
Select FORWARD drive by moving the control lever to
the F position.
Select REVERSE drive by moving the control lever
to the R position. DO NOT allow the control lever
to travel too far and go into the PARK position when
REVERSE is desired.
NOTE: The truck must be completely stopped before
the control lever is moved to a drive position or into
PARK. A drive system fault will be recorded if the
control lever is placed into the PARK position while
the truck is still moving.
Override/Fault Reset Switch

Override/fault
reset switch (3) is
1. Center Console 8. Retarder Speed spring-loaded to the OFF
2. Directional Control Control Dial position. When pushed
Lever 9. Retarder Speed in and held, this switch
3. Override/Fault Reset Control Switch may be used for several
Switch 10. Data Store Button functions.
4. Engine Stop Switch 11. 12V Auxiliary Power 1. This switch permits the operator to override
5. LH Window Control Outlets the body-up limit switch and move the truck
Switch 12. Fire Suppression forward when the directional control lever is in
6. RH Window Control Control Outlet FORWARD, the dump body is raised, and the
Switch 13. Communication brakes are released.
7. Hoist Control Lever Radio Outlet
Use of the override switch for this purpose is
Figure 6-3 CENTER CONSOLE intended for emergency situations only!
Directional Control Lever 2. The push button deactivates the retard pedal
Directional control lever (2, Figure 6-3 CENTER function when truck speed is below 5 kph (3
CONSOLE, page 6-7) is mounted on a console to the mph).
right of the operator's seat. It is a four position lever 3. The override switch is also used to reset an
that controls the park, reverse, neutral, and forward electric system fault when the truck is stopped.
motion of the truck. Before moving the directional
control lever, apply the service brakes to completely Engine Stop Switch
stop the truck. Depress the button on the side to Engine stop switch (4) is
release the detent lock, then move the control lever to used to stop the engine.
the desired position. When the control lever is in the Pull the switch up to
center N position, it is in NEUTRAL. When the control stop the engine. Push
lever is in the P position, it is in PARK, and the parking the switch back down to
brake will be applied. The parking brake is spring enable engine operation.
applied and hydraulically released. It is designed
to hold the truck stationary when the engine is off Use this switch to stop the engine if the key switch fails
and the key switch is turned OFF. The truck must be to operate, or to stop the engine without turning off the
completely stopped before moving the control lever to 24 VDC electrical circuits.
980E-4 6-7
CENTER CONSOLE OPERATOR CAB AND CONTROLS
A ground level engine stop switch is also located at 4. Release hoist control lever as the last stage
the right or left front corner of the truck, depending on reaches full extension.
ladder access.
5. After material being dumped clears the body,
lower the body to frame.
Window Control Switches
Refer to Dumping, page 5-15 for more
The window control switch (5, 6) controls the operation complete details concerning this control.
of the window. The switch is spring-loaded to the OFF
position. Lowering The Dump Body
• Pushing the front of the switch raises the cab Move hoist control lever forward to DOWN position
window. and release. Releasing the lever places hoist control
• Pushing the rear of the switch lowers the window. valve in the FLOAT position allowing the body to return
to frame.
Hoist Control Lever
Retard Speed Control (RSC) Adjust Dial
Hoist control lever (7) is a four position hand-operated
The retard speed setting will be displayed to the
lever located between the operator seat and the
operator on the digital display in the instrument panel.
center console (see Figure 6-4 HOIST CONTROL,
page 6-8). Retard speed control (RSC) adjust dial (8, Figure 6-3
CENTER CONSOLE, page 6-7 allows the operator
to vary the downhill truck speed that the retard speed
control system will maintain when descending a
grade. This function can be overridden by either the
accelerator or retard pedal.
When the dial is rotated
counterclockwise toward
this symbol, the truck will
descend a grade at lower
speeds.
When the dial is rotated

clockwise toward this
symbol, the truck speed
will increase.
Always refer to the Grade/Speed Chart in the

1. Raise 3. Float operator's cab and follow the recommendations
2. Hold 4. Lower for truck operation. DO NOT exceed these
recommended MAXIMUM speeds when descending
Figure 6-4 HOIST CONTROL
grades with a loaded truck.
Raising The Dump Body Throttle pedal position will override RSC setting.
1. Pull the hoist control lever to the rear to actuate If operator depresses throttle pedal to increase
hoist circuit. (Releasing the lever anywhere truck speed, dynamic retarding will not come on
during “hoist up” will place the body in HOLD unless truck over speed setting is reached or the
at that position.) brake/retarder pedal (or retarder lever) is used. When
throttle pedal is released and RSC switch is on,
2. Raise engine rpm to increase hoist speed.
dynamic retarding will come on at, or above, the
3. Reduce engine rpm as the last stage of the RSC dialed speed and will adjust truck speed to, and
hoist cylinders begin to extend and then let the maintain, the dialed speed. The dialed speed will
engine go to low idle as the last stage reaches be displayed on the digital display in the instrument
half-extension. panel.
6-8 980E-4
OPERATOR CAB AND CONTROLS CENTER CONSOLE
To adjust RSC control, pull switch (9) ON and start Retard Speed Control (RSC) Switch
with dial (8) rotated toward fastest speed while driving Retard speed control
truck at desired maximum speed. Relax throttle pedal (RSC) switch (9) turns the
to let truck coast and turn RSC adjusting dial slowly system on and off. Push
counterclockwise until dynamic retarding is activated. the knob in for OFF and
Dynamic retarding will now be activated automatically pull the knob out to turn
anytime the “set” speed is reached, the RSC switch is the system ON.
on, and throttle pedal is released.
Data Store Button
With RSC switch on and dial adjusted, the system
will function as follows: As truck speed increases to Data store button (10) is for use by qualified
the “set” speed and throttle pedal released, dynamic maintenance personnel to record in memory a
retarding will apply. As truck speed tries to increase, snapshot of the AC drive system.
the amount of retarding effort will automatically adjust
to keep the selected speed. When truck speed 12v Auxiliary Power Outlets
decreases, the retarding effort is reduced to maintain Outlets (11) can be used to provide 12VDC power for
the selected speed. If truck speed continues to tools and accessories.
decrease to approximately 5 kph (3 mph) below “set”
speed, dynamic retarding will turn off automatically. Fire Suppression Control Outlet
If truck speed must be reduced further, the operator Outlet (12) can be used to provide power for an
can turn the adjust dial to a new setting or depress optional fire suppression control system with the key
the brake/retarder pedal (or use the retarder lever). switch ON.
If the operator depresses the brake/retarder pedal or
uses the retarder lever and the retard effort called
Communication Radio Outlet
for is greater than that from the automatic system, Outlet (13) can be used to provide power for an
the brake/retarder pedal or retarder lever will override optional 2-way communication radio with the key
RSC. switch ON.
980E-4 6-9
DIAGNOSTIC PORTS OPERATOR CAB AND CONTROLS
DIAGNOSTIC PORTS B.2-0000071907 Interface Module (IM)

Interface module (IM) diagnostic port (2) is used
to connect the interface module to a computer for
installing software.
PC Local Area Network (PC LAN)

PC LAN diagnostic port (3) is used to download data
from the payload meter and GE systems. Refer to
PAYLOAD METER IV SYSTEM, page 5-26 for a more
complete description of the payload meter and its
functions.
Drive System Controller (DSC)

Drive system controller (DSC) diagnostic port (4) is
1. KOMTRAX Plus 4. Drive System used to access diagnostic information for the Drive
Diagnostic Port Controller Port System Controller (DSC) .
2. Interface Module 5. Engine Diagnostic
Diagnostic Port Port (CENSE) Engine (Cense)
3. PC Local Area 6. Engine Diagnostic Engine diagnostic port (CENSE) (5) is a three pin
Network (PC LAN) Port (QUANTUM) connector used to access diagnostic information for
Port the engine monitoring system.
Figure 6-5 DIAGNOSTIC PORTS
Engine (Quantum)
The diagnostic ports shown in Figure 6-5
DIAGNOSTIC PORTS, page 6-10 are located on the Engine diagnostic port (QUANTUM) (6) is a nine pin
back wall of the cab next to the D.I.D. Panel. connector used to access diagnostic information for
the engine control system.
KOMTRAX Plus
KOMTRAX Plus diagnostic port (1) is used to
download truck operation data from the KOMTRAX
Plus controller.
6-10 980E-4
OPERATOR CAB AND CONTROLS OPERATOR SEAT (Standard)
OPERATOR SEAT use, whichever comes first. The passenger seat

(Standard) G.5-0000051504 belt date of manufacture label is sewn into the seat
belt near the buckle. The driver seat belt date of
manufacture label is sewn into the shoulder harness
belt, near the retractor end.
• Check the condition of the tethers at the same time
the seat belts are checked. Look for worn, frayed
or torn material and check all hardware, as well.
Replace worn or damaged parts immediately.
Adjustment
The following adjustments must be made while sitting
in the seat. Refer to Figure 6-6 OPERATOR SEAT
CONTROLS, page 6-11.
• Headrest - Move headrest (1) up or down to the
desired position. It can also be tilted forward by
pulling on the top of the headrest. There are four
positions. Pulling the headrest completely forward
will release the ratchet mechanism and return the
headrest to the furthest back position.
• Seat Height - Push and hold seat height switch (2)
to adjust the height of the seat. Release the switch
when the desired height is reached. Optimum
ride height is obtained when the suspension is at
the middle of its stroke. To properly adjust, raise
the seat to its highest level. Then, lower the seat
approximately 51 mm (2 in.) to the middle of the
suspension stroke.
• Lumbar Support - Move lumbar support (3) to
adjust the lumbar support to the desired position.
1. Headrest 7. Backrest Recline • Armrest Tilt - Rotate armrest tilt (4) until the armrest
2. Seat Height Switch 8. Seat Cushion Fore is in desired position.
3. Lumbar Support and Aft • Seat Belt - The operator must always have seat
4. Armrest Tilt 9. Suspension belt (5) buckled and properly adjusted whenever the
5. Seat Belt Dampener truck is being operated.
6. Seat Tether 10. Seat Tilt
11. Fore and Aft • Tether - Tether belts (6) should be adjusted with the
12. Shoulder Height seat in the highest position and all the way forward.
Adjustment Knob With the seat in this position, adjust the tether belts
so they have some slack. This allows for a slight
Figure 6-6 OPERATOR SEAT CONTROLS extension when the seat deflects and rebounds.
The operator seat provides a fully adjustable • Backrest Recline - Lift backrest recline (7) to select
cushioned ride for driver comfort and easy operation. the desired backrest recline. Release the handle to
set the position.
Seat Belts And Tethers • Fore/Aft Location of Seat Cushion (if equipped)
• On both driver and passenger seats, check the seat - Lift and hold fore/aft (8) and move the seat cushion
belt fabric, buckle, all belt retractors and hardware to a comfortable position. Release the lever to lock
for damage or wear. Replace any worn or damaged the position adjustment.
parts immediately.
• Suspension Dampener - Adjust suspension
• Even if there are no signs of damage, replace both dampener (9) to obtain the desired stiffness of the
driver and passenger seat belts five years after seat adjustable shock absorber. Move the lever upward
belt manufacture, or every three years after start of to stiffen the absorbency of the shock. Move the
980E-4 6-11
OPERATOR SEAT (Standard) OPERATOR CAB AND CONTROLS
lever downward to soften the ride. Five detented Shoulder Height Adjustment Knob - Push knob
settings are available. (12) to move height adjuster up or down creating
a comfortable space between neck or shoulders.
NOTE: This seat contains a fixed rate shock absorber Release lever and gently tug belt to ensure adjuster
in addition to the adjustable shock absorber that is is locked in place.
controlled by the suspension dampener.
NOTE: The seat compressor must be allowed to
• Seat Cushion Tilt (if equipped) - Lift and hold
cool down for ten minutes for every one minute of
lever (10) and tilt the seat cushion to a comfortable
continuous operation. The compressor must not be
position. Release the lever to lock the position
operated continuously for more than three minutes.
adjustment.
• Fore/Aft Location of Seat - Lift and hold lever (11)
and move the seat to a comfortable height. Release
the lever to lock the fore/aft location.
6-12 980E-4
OPERATOR CAB AND CONTROLS PASSENGER SEAT (Standard)
PASSENGER SEAT • Even if there are no signs of damage, replace both

(Standard) E.5-0000051503 driver and passenger seat belts five years after seat
belt manufacture, or every three years after start of
use, whichever comes first. The passenger seat
belt date of manufacture label is sewn into the seat
Adjustment
in the seat. Refer to Figure 6-7 PASSENGER SEAT
• Fore/Aft Location of Seat Cushion (if equipped)
- Lift and hold fore/aft lever (1) and move the seat
cushion to a comfortable position. Release the lever
to lock the position adjustment.
• Seat Height - Pull up on seat height (2), then adjust
the height of the seat. When the desired height is
reached, release the lever.
• Weight Adjustment- Rotate weight adjustment (3)
1. Seat Cushion Fore 4. Fore and Aft until the weight indicator next to the knob is pointing
and Aft 5. Seat Tether to the weight of the person that will be riding in the
2. Seat Height seat. This will provide the most comfortable ride
3. Weight Adjustment setting.
• Fore/Aft Location of Seat - Lift and hold fore/aft
Figure 6-7 PASSENGER SEAT CONTROLS
lever (4) and move the seat to a comfortable height.
The passenger seat provides a fully adjustable Release the lever to lock the fore/aft location.
cushioned ride for driver comfort and easy operation.
• Seat Tether - Tether belts (5) should be adjusted
with the seat in the highest position and all the way
Seat Belts And Tethers forward. With the seat in this position, adjust the
• On both driver and passenger seats, check the seat tether belts so they have some slack. This allows
belt fabric, buckle, all belt retractors and hardware for a slight extension when the seat deflects and
for damage or wear. Replace any worn or damaged rebounds.
parts immediately.
980E-4 6-13
OPERATOR SEAT (Optional) OPERATOR CAB AND CONTROLS
OPERATOR SEAT use, whichever comes first. The passenger seat

(Optional) E.4-0000053881 belt date of manufacture label is sewn into the seat
Adjustment
in the seat. Refer to Figure 6-8 OPERATOR SEAT
• Headrest - The headrest (1) moves up, down, fore
or aft by adjusting headrest to desired position.
• Backrest Angle - Lift backrest adjustment handle
(2) to release and select the backrest angle.
Release the control handle to set.
• Seat Tether - Tether belts (3) should be adjusted
with the seat in the highest position and all the way
forward. With the seat in this position, adjust the
tether belts so they have some slack. This allows
for a slight extension when the seat deflects and
rebounds.
• Seat Belt - The operator must have seat belt (4)
buckled in place and properly adjusted whenever
vehicle is in motion.
• Air Lumbar Support - Each rocker switch (5)
controls an air pillow. One switch controls the lower
air pillow and the other switch controls the upper
air pillow. To inflate, press on top of the rocker
1. Headrest 7. Fore and Aft switch and hold for desired support, then release.
2. Backrest Angle 8. Seat Height To deflate, press on the bottom of the rocker switch
3. Seat Tether 9. Seat Cushion Fore and hold for desired support, then release. Adjust
4. Seat Belt and Aft each pillow for desired support.
5. Lumbar Support 10. Seat Tilt
6. Suspension 11. Armrest Tilt • Suspension Dampener - Press rocker switch (6)
Dampener on top to increase ride firmness. Press on lower
part of rocker switch to decrease ride firmness.
Figure 6-8 OPERATOR SEAT CONTROLS • Fore/Aft Location of Seat - Lift fore and aft lever
The operator seat provides a fully adjustable (7) and hold. Bend knees to move seat to a
cushioned ride for driver comfort and easy operation. comfortable position. Release the control lever to
lock the adjustment.
Seat Belts And Tethers • Seat Height - Press rocker switch (8) on top to
• On both driver and passenger seats, check the seat increase ride height. Press on lower part of rocker
belt fabric, buckle, all belt retractors and hardware switch to decrease ride height.
for damage or wear. Replace any worn or damaged • Fore/Aft Location of Seat Cushion - Lift and
parts immediately. hold lever (9) and move the seat cushion to a
• Even if there are no signs of damage, replace both comfortable position. Release the lever to lock the
driver and passenger seat belts five years after seat position adjustment.
6-14 980E-4
OPERATOR CAB AND CONTROLS OPERATOR SEAT (Optional)
• Seat Tilt - Lift seat slope lever (10) and hold to • Armrests - Rotate adjusting knob (11) until the
adjust the slope of the seat. Release the lever to armrest is in the desired position.
980E-4 6-15
PASSENGER SEAT (Optional) OPERATOR CAB AND CONTROLS
PASSENGER SEAT manufacture label is sewn into the shoulder harness

(Optional) B.4-0000054284 belt, near the retractor end.
Adjustment
in the seat. Refer to Figure 6-9 PASSENGER SEAT
• Headrest - The headrest (1) moves up, down, fore
or aft by adjusting it to the desired position.
• Seat Height - Press rocker switch (2) on top to
increase ride height. Press on lower part of rocker
switch to decrease ride height.
• Fore/Aft Location of Seat Cushion - Lift and
hold lever (3) and move the seat cushion to a
comfortable position. Release the lever to lock the
position adjustment.
• Seat Tilt - Lift seat slope lever (4) and hold to adjust
the slope of the seat. Release the lever to lock the
adjustment.
• Fore/Aft Location of Seat - Lift fore and aft lever
(5) and hold. Bend knees to move seat to a
comfortable position. Release the control lever to
• Suspension Dampener - Press rocker switch (6)
1. Headrest 6. Suspension
on top to increase ride firmness. Press on lower
2. Seat Height Dampener
part of rocker switch to decrease ride firmness.
3. Seat Cushion Fore 7. Lumbar Support
and Aft 8. Seat Belt • Air Lumbar Support - Each rocker switch (7)
4. Seat Tilt 9. Seat Tether controls an air pillow. One switch controls the lower
5. Fore and Aft 10. Backrest Angle air pillow and the other switch controls the upper
air pillow. To inflate, press on top of the rocker
Figure 6-9 PASSENGER SEAT CONTROLS switch and hold for desired support, then release.
The passenger seat provides a fully adjustable To deflate, press on the bottom of the rocker switch
cushioned ride for passenger comfort and easy and hold for desired support, then release. Adjust
operation. each pillow for desired support.
• Seat Belt - The operator must have seat belt (8)
Seat Belts And Tethers buckled in place and properly adjusted whenever
vehicle is in motion.
• On both driver and passenger seats, check the seat
belt fabric, buckle, all belt retractors and hardware • Seat Tether - Tether belts (9) should be adjusted
for damage or wear. Replace any worn or damaged with the seat in the highest position and all the way
parts immediately. forward. With the seat in this position, adjust the
tether belts so they have some slack. This allows
• Even if there are no signs of damage, replace both
for a slight extension when the seat deflects and
driver and passenger seat belts five years after seat
rebounds.
use, whichever comes first. The passenger seat • Backrest Angle - Lift backrest adjustment handle
belt date of manufacture label is sewn into the seat (10) to release and select the backrest angle.
belt near the buckle. The driver seat belt date of Release the control handle to set.
6-16 980E-4
OPERATOR CAB AND CONTROLS HEATER / AIR CONDITIONER CONTROLS
HEATER / AIR CONDITIONER selected by rotating the control knob clockwise to the
CONTROLS E.6-0000051502 desired position. OFF is in the full counter-clockwise
position. The control knob must be switched ON for
The heater/air conditioner compartment contains the air conditioner to function.
heater/air conditioner controls and some of the
heater/air conditioner components, such as the Temperature Control Knob
blower motor assembly and the heater coil. Optimum
cab air climate can be selected by using the following Temperature control knob (2) allows the operator to
controls in various combinations. select a comfortable air temperature.
The control knob determines the operation of the air
conditioning and heater modes.
Rotating the control knob counter-clockwise
(blue zone 3) will cause the A/C compressor to
operate and result in cooler air temperatures. Full
counter-clockwise position is the coldest air setting.
Rotating the control knob clockwise (red zone 4)
will affect coolant flow through the heater core and
result in warmer air temperatures. The full clockwise
position is the warmest heater setting.
Air Flow Directional Knob

Air flow directional knob (5) controls the direction of
airflow as follows:
Provides airflow to floor vents, only.
Provides airflow to upper vents and floor

vents.
(Blue Icon) Provides dehumidified air to
upper vents and floor vents.
Defrost - Provides dehumidified air to the
windshield.
1. Fan Speed Control 4. Red Zone
Knob 5. Air Flow Directional Defrost - Provides dehumidified air to the
2. Temperature Control Knob windshield as well as to floor vents.
Knob 6. Heater/Air
3. Blue Zone Conditioner Vents Heater/Air Conditioner Vents
Figure 6-10 HEATER / AIR CONDITIONER Heater/air conditioner vents (6) may be rotated 360°.
CONTROLS There are three vents in the heater/air conditioner
compartment, four vents across the top of the
Fan Speed Control Knob instrument panel, and one vent each in the RH and LH
Fan speed control knob (1, Figure 6-10 HEATER / AIR instrument panels. There are also an additional four
CONDITIONER CONTROLS, page 6-17) is provided vents under the instrument panel. Air flow through
to control the cab air fan motor. The fan motor is a the vents is controlled by manually opening, closing
3-speed motor (low, medium and high). Speeds are or turning the louvers.
980E-4 6-17
INSTRUMENT PANEL OPERATOR CAB AND CONTROLS
INSTRUMENT PANEL B.52-0000051679
1. Heater/Air Conditioner Vents 14. Not Used in This Application

2. Status Indicator Light Panel 15. Ladder Up/Down (If Equipped)
3. Hydraulic Oil Temperature Gauge 16. Key Switch
4. Coolant Temperature Gauge 17. Warning Light
5. Speedometer/Digital Display 18. Digital Display Contrast Buttons
6. Fuel Level Gauge 19. Turn Signal Indicators
7. Drive System Temperature Gauge 20. Panel Lights Dimmer Switch
8. Hazard Light Switch 21. Mode Switch #1
9. Brake Test Switch 22. Mode Switch #2
10. Wheel Brake Lock Switch 23. Fog Light Switch
11. AC Drive System Rest Switch 24. Backup Light Switch
12. Engine Warm Up Switch 25. Ladder Light Switch
13. Heated Mirrors 26. Headlight/Panel Illumination Switch
Figure 6-11 PANEL GAUGES, INDICATORS, AND CONTROLS
Control Symbols Most switches have two LED lights inside them, one
amber and one green in color. The amber is located in
The operator must understand the function and
the top portion of the switch and indicates that function
operation of each instrument and control. Many
has been activated. The green LED is located in the
control functions are identified with international
lower portion of the switch and indicates that function
symbols that the operator must learn to recognize
has not been activated.
immediately. This knowledge is essential for proper
and safe operation. • To activate a function, push on the top portion of
the switch. At this time, the amber LED will be
Items that are marked optional do not apply to every
illuminated, and the green LED will be OFF.
truck.
• To de-activate a function, push on the lower portion
The following symbols are general indicators and may of the switch. At this time, the green LED will be
appear in multiple locations and combinations on the illuminated, and the amber LED will be OFF.
instrument panel.
6-18 980E-4
OPERATOR CAB AND CONTROLS INSTRUMENT PANEL
NOTE: The green LED light in the hazard light switch, Hydraulic oil temperature
head light switch and the ladder light switch will gauge (3) indicates the
be illuminated when battery power is connected to oil temperature in the
the truck. The LED lights in the other switches will hydraulic tank. There are
illuminate when the key switch is turned to the ON two colored bands: green
position. and red.
This symbol when it Green indicates normal operation. As the needle

appears on an indicator approaches the red zone, minimum engine idle speed
or control identifies that will increase to help cool the oil. Red indicates high
this indicator or control is oil temperature in the hydraulic tank. Continued
NOT used. operation could damage components in the hydraulic
system. If this occurs, the operator should safely
stop the truck, move directional control lever to PARK
This symbol identifies and operate the engine at 1200 - 1500 rpm to reduce
a rotary control or system temperature.
switch. Rotate the
knob clockwise or Coolant Temperature Gauge
counterclockwise for Coolant temperature
functions. gauge (4) indicates
the temperature of the
This symbol identifies coolant in the engine
a switch used to test cooling system.
or check a function.
Press the switch on the
side near the symbol to The temperature range after engine warm-up and a
perform the test. truck operating under normal conditions should be 85°
to 97°C (185° to 207°F).
Heater / Air Conditioner Vents
Speedometer/Digital Display
Heater / Air Conditioner vents (1, Figure 6-11 PANEL
GAUGES, INDICATORS, AND CONTROLS, page Speedometer/digital display (5) displays the following
6-18) may be directed by the operator to provide the information:
most comfortable cabin air flow.
• The analog speedometer indicates the truck speed
in miles per hour (mph) or in kilometers per hour
Status Indicator Light Panel (kph).
Status indicator light panel (2) contains an array • The digital display shows payload meter
of indicator lights to provide the operator with information.
important status messages concerning selected truck
functions. Refer to Figure 6-12 STATUS INDICATOR • The digital display also shows warning messages
LIGHTS, page 6-23 for a detailed description of these and fault codes indicating abnormal operating
indicators. conditions and critical problems. See DIGITAL
DISPLAY OPERATION, page 6-26 for more
Hydraulic Oil Temperature Gauge information.
Fuel Level Gauge

• If temperature gauge does not move into the Fuel level gauge (6)
green range after a few minutes, and the red indicates how much
overhead indicator light does not go out, stop diesel fuel is in the fuel
the engine and notify maintenance personnel tank. When there is
immediately. only 10% of total fuel
tank capacity remaining,
the amber low fuel level
indicator on the gauge will
illuminate.
980E-4 6-19
Drive System Temperature Gauge When pulling into shovel or dump area, stop the truck
Drive system using the foot-operated service brake pedal. When
temperature gauge (7) truck is completely stopped and in loading position,
indicates the status of move the directional control lever to NETURAL, then
the highest measured apply the brake lock by pressing the top of the rocker
temperature range in the switch. To release the brake, press the bottom of the
drive system. rocker switch.
NOTE: The wheel brake lock will not function if the
Hazard Warning Light Switch directional control lever is in the PARK position.
Hazard warning light
switch (8) flashes all
the turn signal lights. • DO NOT use the wheel brake lock control
Pressing the top side switch to stop the truck unless the
of the rocker switch foot-operated treadle valve is inoperative.
activates these lights. Use of this switch applies rear service brakes
at a reduced, unmodulated pressure. DO
When these lights are on, a red LED light will be NOT use the brake lock for parking. With the
illuminated inside the switch. Pressing on the lower engine stopped, hydraulic pressure will bleed
side of the rocker switch turns these lights off, and a down, allowing the brakes to release.
green LED light will be illuminated.
Use at shovel and dump only to hold the truck in
Pre-Shift Brake Test Switch position.
Pre-shift brake test
switch (9) is used to NOTE: The wheel brake lock will not apply when the
initiate a brake test. directional control lever is placed in the PARK position,
Press on the momentary or when the key switch is OFF, or when the engine is
switch to enter the brake not running.
test mode. If certain
conditions are met, the Rest Switch
operator can enter a Rest switch (11) is a
brake test sequence. rocker switch with a
locking device. A safety
The amber light in the top of the switch is used to tab on the switch must
indicate when the truck is in brake test mode, and is be pushed to unlock the
referred to as the brake check light. When illuminated, switch before the top
a brake test is ready. When flashing, the brake test of the switch can be
is at the validation point, or the retard system test is depressed to activate the
finished. rest mode.
Wheel Brake Lock Control Switch When activated, an internal amber lamp will
Wheel brake lock switch illuminate. The switch should be activated to
(10) should be used deenergize the AC drive system whenever the engine
with engine running for is to be shutdown or parked for a length of time with
dumping and loading the engine running.
operations only. The The directional control lever must be in PARK or
brake lock switch NEUTRAL and the vehicle not moving to enable
actuates the hydraulic this function. This will allow the engine to continue
brake system which locks running while the AC drive system is de-energized.
the rear wheel service
brakes only.
6-20 980E-4
OPERATOR CAB AND CONTROLS INSTRUMENT PANEL
Key Switch
• Activation of the rest switch alone DOES NOT
completely ensure that the drive system is
safe to work on. Refer to the Safety chapter
for more information on servicing an AC
drive. Check all "link-on", or "link energized",
indicator lights to verify the AC drive system
is de-engergized before performing any
maintenance on the drive system. DO NOT
activate the rest switch while the truck is
moving! The truck may unintentionally enter
the “rest” mode after stopping.
Engine Warm Up
Engine warm up switch
(12) is a rocker switch.
When in the ON position, Key switch (16) is a four-position (ACC, OFF, RUN,
this feature is used to START) switch. The ACC position is not currently
keep the engine warm in used.
cold conditions because
it puts a small amount of Starting
load on the engine.
When the switch is rotated one position clockwise, it
Settings in the GE config file also allows this switch is in the RUN position and all electrical circuits except
to control warming of the IGBTs in the control cabinet. START are activated.
When the inverters are turned off for traction duty, they 1. With the selector switch in PARK, rotate key
will be placed in warm-up mode. When a direction is switch fully clockwise to the START position,
selected, the inverters transition from Warm-up mode and hold this position until the engine starts.
to Traction mode. The START position is spring-loaded to return
This energy is created by passing a load through one to RUN when the key is released. If the engine
bank of the grid resistors in the retarding grid. is equipped with a prelube system, a noticeable
delay will occur before engine cranking begins.
Heated Mirror Switch (Optional) 2. After engine has started, place rest switch (4)
Heated mirror switch (13) in the OFF position, which will de-activate the
controls the operation of rest mode of operation. Refer to the discussion
the heated mirrors. of rest switch later in this chapter.
NOTE: The electric cranking motors have a 30
second time limit. If the 30 second limit is reached,
cranking will be prohibited for two minutes. After two
minutes, cranking will be allowed. If the 30 second
Retractable Ladder Switch limit is reached seven consecutive times, the key
Retractable ladder switch switch must be turned to the OFF position. This will
(15) is a rocker switch. allow the interface module to power down and reset,
When in the DOWN which requires seven minutes to complete.
position, the retractable
ladder will lower. When in
the UP position the ladder
will raise.
980E-4 6-21
Warning Light arrows are used to toggle through the different options
Red warning light (17) will and messages on the digital display. The OK position
come on to indicate that is used to acknowledge and clear warnings and faults
a truck function requires and set certain Payload Meter III settings.
immediate action by
Refer to DIGITAL DISPLAY OPERATION, page 6-26
the operator. Safely
for more information about using the digital display.
stop the truck and notify
maintenance personnel.
A warning message will
Fog Light Switch
appear on the digital Pressing the top of fog
display. light switch (23) turns the
lights on. Pressing the
Digital Display Contrast Buttons bottom of the switch turns
the lights off.
Cold ambient operating temperatures may affect
the contrast of the digital display. If necessary, use
buttons (18) to increase or decrease the contrast of
the digital display to make it easier to read. Backup Light Switch
Backup light switch (24)
Turn Signal Indicators allows the backup lights
Indicators (19) illuminate to be turned on for
to indicate that the right added visibility and safety
or left turn signals are when the directional
operating when the control lever is not in the
turn signal lever on the REVERSE position.
steering column is moved
upward or downward. Ladder Light Switch
Moving the lever to its Ladder light switch (25)
center position will turn turns the ladder lights and
the indicator off. deck lights on or off after
or before using ladder.
Panel Light Dimmer
Panel illumination light
dimmer switch (20) is
a rheostat which allows Pressing the top of the rocker switch turns the lights
the operator to vary on. Pressing the bottom of the switch turns the lights
the brightness of the off. Another switch is mounted at the front left of truck
instruments and panel near the base of ladder.
lights.
• Rotating the knob to the full clockwise position turns Headlight/Panel Illumination Light Switch
the panel lights on to the brightest condition. The instrument panel
lights, clearance lights,
• Rotating the knob counterclockwise continually and the headlights
dims the lights until OFF position is reached at full are controlled by this
counterclockwise rotation. three-position rocker type
switch (26).
Mode Switches
Mode switches (21)
OFF is selected by pressing the bottom of the switch.
and (22) are two-way
Press the top of the switch until it reaches the first
momentary rocker
position to select the panel lights, clearance lights and
switches. The
tail lights only. Press the top of the switch again until
it reaches the second position to select headlights,
panel lights, clearance lights and tail lights.
6-22 980E-4
OPERATOR CAB AND CONTROLS STATUS INDICATOR LIGHT PANEL
STATUS INDICATOR LIGHT

PANEL B.28-0000053883
1. Body Up 7. Not used in this application 13. Pantograph Energized

2. Parking Brake 8. Wheel Brake Lock 14. Pantograph Up
3. Propulsion System Not Ready 9. Traction Control 15. Service Brake
4. No Propel 10. Repair Monitor 16. Dynamic Retarding
5. Engine Warm Up 11. Retractable Ladder Down 17. No DC Link Voltage
6. Engine Shutdown Delay 12. Snapshot In Progress
Figure 6-12 STATUS INDICATOR LIGHTS

STATUS INDICATOR LIGHT If the directional control lever is in the PARK position
SYMBOLS B.3-0000053882 and the interface module (IM) detects any parking
brake abnormalities, this light will not illuminate. The
When illuminated, these amber (yellow) status lights red warning light on the dash will flash, the warning
alert the operator that the indicated truck function buzzer will sound intermittently and an error code will
requires some precaution. Refer to the following be displayed. If the red warning light and buzzer are
descriptions for explanations of the symbols. active, the operator must not leave the cab. Notify
maintenance personnel immediately.
Body Up
The body up indicator will Propel System Not Ready
illuminate when the body Propulsion system not
is not completely down on ready indicator will
the frame. The truck must illuminate during start-up
not be driven until body is much like the hour glass
down and the light is off. icon on a computer
screen.
Parking Brake
The parking brake This light indicates the computer is in the process of
indicator will illuminate performing the self-diagnostics and set-up functions at
when the parking brake start-up. Propulsion will not be available at this time.
is applied. The parking
brake is applied by
placing the directional
control lever in the PARK
position.
980E-4 6-23
STATUS INDICATOR LIGHT PANEL OPERATOR CAB AND CONTROLS
No Propel Wheel Brake Lock

The no propel indicator The wheel brake lock
will illuminate when the indicator will illuminate
rest switch is placed in the when the wheel brake
ON position. It will also lock is on.
illuminate when a fault
has occurred which has
eliminated the propulsion
capability. If this condition
occurs, the operator must
Traction Control
safely stop the truck, The traction control
move directional control indicator light, often
lever to PARK, shut down referred to as the Slip
the engine, and notify Slide indicator light, will
maintenance personnel turn on if there is a
immediately. problem detected in the
system and when traction
control is disabled.
Engine Warm Up
Engine warm up indicator Repair Monitor
will illuminate when the
The repair monitor
engine warm up switch is
indicator will illuminate if a
turned on.
“repair” fault is detected,
which must be corrected
after the operator’s shift
is done.
Engine Shutdown Delay
When the key switch Retractable Ladder Down
has been turned OFF,
The retractable ladder
and certain conditions
down indicator will
have been met, this
illuminate when the
indicator light will
power ladder is not in
illuminate to indicate
the full up position. The
that the shutdown timing
indicator will flash if the
sequence has started.
park brake is released
The engine could operate
without the ladder in the
for up to three minutes.
full up position.
• If the directional control lever is moved out of PARK,
the engine will stop immediately. Snapshot In Progress
• If the key switch is turned back ON, the engine stop The indicator will
sequence will be terminated, and the engine will illuminate when the
remain running. KOMTRAX Plus system
is in the process of
recording a “snapshot”
Retarding Grid Dryer of certain vehicle
This indicator light is not conditions.
used in this application.
Pantograph Energized
This indicator light is not
used in this application.
6-24 980E-4
OPERATOR CAB AND CONTROLS STATUS INDICATOR LIGHT PANEL
Pantograph Up Dynamic Retarding

This indicator light is not The dynamic retarding
used in this application. indicator will illuminate
whenever the retarder
pedal is operated, or
the automatic overspeed
retarding circuit is
energized. It indicates
that the dynamic
Service Brake retarding function of the
The service brake truck is being used.
indicator will illuminate
when the service brake
pedal is applied. No DC Link Voltage
The no DC link voltage
indicator will illuminate
when the rest switch in
ON, or whenever the DC
link in the control cabinet
is not providing voltage to
the propulsion system.
980E-4 6-25
DIGITAL DISPLAY OPERATION OPERATOR CAB AND CONTROLS
DIGITAL DISPLAY
OPERATION C.6-0000051680
Toggling Through Main Level Screens
6-26 980E-4
OPERATOR CAB AND CONTROLS DIGITAL DISPLAY OPERATION
Toggling Through Warning Screens
980E-4 6-27
DIGITAL DISPLAY OPERATION OPERATOR CAB AND CONTROLS
Entering Payload Meter Data
6-28 980E-4
OPERATOR CAB AND CONTROLS KOMTRAX Plus
KOMTRAX Plus C.3-0000051569
KOMTRAX Plus OPERATION C.45-0000051587 • The KOMTRAX Plus system uses wireless
components that transmit via radio waves. It
Basic Precautions is necessary to conform to local laws when
• When using this truck, there is no particular need to using this system. Proper operation of the
operate the KOMTRAX Plus system. system is dependent on good reception.
Operating in tunnels, mountain ranges and
• Never disassemble, repair, or modify the
covered areas may prevent communication of
KOMTRAX Plus system. This may cause failure or
the system. Contact your Komatsu distributor
fire on the machine or this system.
before selling or exporting a truck equipped
• Do not touch the system when operating the with KOMTRAX Plus. It may be necessary
machine. to remove the system before transfer of
ownership. Contact your Komatsu distributor
• Do not pull on the wiring harnesses, connectors.
before installing equipment that may interfere
or sensors of this system. This may cause short
with the KOMTRAX Plus system. Komatsu
circuits or disconnections that lead to failure or fire
is not responsible for any failures that result
on the machine or this system.
from neglecting KOMTRAX Plus system
• Do not get water, dirt or oil on the system controllers. precautions and instructions.
• If there is any abnormality with the KOMTRAX
Plus system, please consult the servicing Komatsu This system uses KOMTRAX Plus controller
distributor. (2, Figure 6-14 KOMTRAX Plus COMPONENT
LOCATION, page 6-30) to gather data about the
operation of the truck from sensors and other
• DO NOT disassemble, repair, or modify controllers installed on the truck. The data stored
the KOMTRAX Plus system without proper in the KOMTRAX Plus controller is collected by
authorization. Changes to the system a laptop personal computer (PC) or transmitted
may cause machine failures and fire. DO directly by communications satellite (utilizing the
NOT touch the KOMTRAX Plus system ORBCOMM controller). This data is then compiled
components during machine operation. DO at the Komatsu computer server. Based on this
NOT pull on KOMTRAX Plus system wiring information, the servicing Komatsu distributor will
harnesses, connectors, or sensors. This may suggest improvements and provide information aimed
cause short circuits or open circuits and lead at reducing machine repair costs and downtime.
to machine failure or fire. DO NOT allow water, When the data-store button (1, Figure 6-13 CENTER
dirt, or oil onto system components. The CONSOLE, REAR VIEW, page 6-30) is pressed
ORBCOMM satellite requires the installation on the back side of the center console, it will store
of a pole and antenna, adding to the overall a “snapshot” of the Statex III drive system. It will
height of the machine. The height increase also trigger the KOMTRAX Plus system to store a
is 410 mm (16.2 in). With the guard installed, “snapshot” of the truck operating system. A light on
the overall height increases another 260 mm the controller will stay illuminated while the KOMTRAX
(10.2 in). Use caution when operating in areas Plus system is recording the “snapshot”, which lasts
with height restrictions. for 7.5 minutes.
The KOMTRAX Plus system is turned on by the truck
key switch. Immediately after receiving 24V power
• Anyone with a pacemaker must remain from the key switch, the KOMTRAX Plus controller
a minimum of 22 cm (9 in) from the begins the power-up initialization sequence. This
communications antenna. Radio waves from sequence takes about three seconds, during which
the antenna can interfere with pacemaker time the red LED digits display a circular sequence of
operation. flashing LED segments.
980E-4 6-29
KOMTRAX Plus OPERATOR CAB AND CONTROLS
1. ORBCOMM 2. KOMTRAX Plus

Controller Controller
Figure 6-14 KOMTRAX Plus COMPONENT

LOCATION
Interface Module
1. Data Store Button
Figure 6-13 CENTER CONSOLE, REAR VIEW

During normal truck operation, the red LED digits on
the KOMTRAX Plus controller will count from 00-99
continuously.
When the key switch is turned OFF, the KOMTRAX
Plus controller will remain on while it finishes
processing internal data and saves the recent data
into permanent memory. When the data has been
safely stored, the two digit LED display will turn
OFF. This process could take up to three minutes to
complete.
• If 24V power is disconnected (using the

battery disconnect switches) from the
KOMTRAX Plus controller before it has
completed its shut down procedure, the
KOMTRAX Plus controller will lose all data
gathered since the key switch was last turned
ON. DO NOT disconnect battery power until
the KOMTRAX Plus controller has completed
the shut down procedure and has turned the
LED digits off.
1. Interface Module 3. PLM Communication

2. PLM Controller Board
Figure 6-15 INTERFACE MODULE LOCATION
6-30 980E-4
Interface module receives data from the sensors 3. Allow the KOMTRAX Plus controller to start up.
installed on the truck and sends this information This will take about one minute. Verify the red
to the KOMTRAX Plus controller. There is a small LED display starts counting up.
green LED light on the face of the interface module
4. Attach the KOMTRAX Plus serial cable to
controller. With the key switch ON, the light must be
KOMTRAX Plus diagnostic port (1), and the
blinking. If the light is continuously illuminated, there
other end to the PC’s serial port.
is a problem in the controller.
5. Double-click on the VHMS Technical Analysis
DOWNLOADING KOMTRAX Plus Tool Box icon on the PC's desktop.
DATA D.48-0000051588 6. Enter the appropriate User Name and
General Information Password and click the [OK] button.
Downloading data requires a laptop PC running 7. Double-click on the [Download] icon.

Windows 95/98/2000/ME/XP/Vista/7 operating 8. Select the COM port in the Port No. drop-down
systems, the VHMS Technical Analysis Toolbox box and click the [Connection] button.
software, and a serial cable to connect the PC to
the KOMTRAX Plus controller. Refer to the VHMS 9. Verify that the date and time is correct for
Technical Analysis Tool Box instruction manual for current local date and time. Also verify that the
additional information about using this software. displayed service meter hours are equal to the
When a download to a laptop PC is performed, value entered previously.
certain files are generated to store data. KOMTRAX 10. If this is the first time this PC has connected
Plus diagnostic port (1, Figure 6-16 KOMTRAX Plus to the machine, you will need to download its
PORT (D.I.D. PANEL AT REAR OF CAB), page 6-31), definition file by clicking the [OK] button.
located on the D.I.D. panel at the rear of the operator
cab, is used to download data from the controller. 11. Verify that a manual snapshot (MFAO) has
been recorded. The display will show an item
KOMTRAX Plus Downloading Procedure named “Snapshot” with the code MFAO and
text “Manual Trigger”.
12. On the Download screen, click the [Select All]
button. All items will become checked.
13. Click the [Download] button. The download
may take one to ten minutes. Generally, if there
are several snapshots in the download items,
the download will take longer.
14. Click the [OK] button to complete the download.
15. Verify that the “Download Completed”
message is displayed. Click on [Exit].
16. Select the [Machine History] option from the list
on the left side of the screen.
1. KOMTRAX Plus Diagnostic Port 17. Verify that the key ON/OFF and engine
ON/OFF records are recorded correctly.
Figure 6-16 KOMTRAX Plus PORT (D.I.D. PANEL
AT REAR OF CAB) 18. Exit any open windows on the PC.
NOTE: Always verify the full download has completed 19. Verify a full download has been taken. Refer to
before disconnecting the PC from the machine. Location of Downloaded Files on Computer for
more detailed instructions.
1. Turn the key switch to the OFF position to stop
the engine. 20. Disconnect the KOMTRAX Plus cable from the
PC and from the machine.
2. Turn the key switch to the ON position, but DO
NOT start the engine. 21. Turn the key switch to OFF.
980E-4 6-31
KOMTRAX Plus OPERATOR CAB AND CONTROLS
Location Of Downloaded Files The screenshot shows the location of where the
KOMTRAX Plus download files reside on a computer.
When a download using VHMS Technical Analysis
The Check Number folder is named in the format
Tool Box is performed, several files are downloaded
CHK000#. Each time a download is taken, it is placed
onto the computer. They are organized in a specific
in one of these folders. The first download will be in
way so that they can be used by VHMS Technical
the CHK0001 folder. If a second download is taken
Analysis Tool Box at a later time. This structure is
on the same day, will be in the CHK0002 folder, etc.
created automatically when the computer is used
to perform the download from the KOMTRAX Plus Once the appropriate folder is selected, the contents
controller. The situation may arise where the files will be shown in the right frame. These files can then
need to be sent to someone, or someone gives these be e-mailed or copied to a disk.
files to you.
If someone provides KOMTRAX Plus download
1. Open Windows Explorer by right-clicking on the files through e-mail or on a disk, the same folder
start button and choosing Explore. organization must be created in order to view them in
VHMS Technical Analysis Tool Box.
2. In the left frame, the computer's file structure
will be displayed. The right frame will show the
details for the folder that is highlighted in the left UPLOADING KOMTRAX Plus
frame. DATA E.2-0000051586
3. In the left frame, navigate to the download files. After downloading, the KOMTRAX Plus data resides
on the PC that performed the download. In order to
The basic path is as follows: make this data available to others, it must be sent
• Desktop to an online database named WebCARE. Once the
data has been uploaded (ftp'd) to WebCARE, it is
• My Computer accessible to anyone with an internet connection and
• Local Disk (C:) an ID and password.
• VHMS_Data VHMS Technical Analysis Tool Box is used to perform

the ftp upload. Perform an ftp upload as soon as the
• Model person who performed the download can obtain an
• Serial Number internet connection. All downloads must be uploaded
to WebCARE.
• Date
1. Double-click on the VHMS Technical Analysis
• Check Number Tool Boxicon on the PC's desktop.
NOTE: The date folder is named in the format 2. Enter the appropriate user name and password
“YYYYMMDD”. and click the [OK] button.
3. Double click the [FTP] icon.

4. At the ftp Client Login window, enter the ftp
User ID and Password.
a. User ID = komatsu
b. Password = vhms
5. The target directory must be set to the PC's
hard drive (usually drive C:\).
a. Double-click the VHMS_Data folder to drop
Figure 6-17 FILE LOCATION down the model folders.
6-32 980E-4
b. Double-click the appropriate model folder 7. After selecting the correct file to send, click the
to drop down the serial number folders. [Send (FTP)] button.
c. Double-click the appropriate serial number 8. Click the [Yes] button to verify that you want to
folder to drop down the date folders. upload the data to WebCARE.
d. Double-click the appropriate date folder to
drop down the check number folders.
e. Double-click the appropriate check number
folder to display its contents in the files
window.
9. If the sending file was uploaded successfully,

the file will appear in the OK window. If the
sending file was not uploaded successfully, the
file will appear in the “NG” (No Good) window.
Ensure the PC has an internet connection.
6. Some models will automatically create a

sending file during the download process.
Others need to have the sending file created at
this time. A sending file is just a compressed
version of all the other downloaded files. If
there is already a sending file in the Send File
window, you do not need to perform this step. 10. Click the [OK] button, then the [Exit] button.
If there is not a sending file in the Send File Close all other open windows.
window, click the [Make Sending File] button.
NOTE: The compressed sending file will look similar
to this file name, and will always end with a “.K”.
P_830E_-_A30761_1105208857.K
980E-4 6-33
ORBCOMM OPERATOR CAB AND CONTROLS
ORBCOMM D.22-0000051585 coaxial cable is routed through the inside of the cab
to protect it from damage. If the antenna or coaxial
cable is damaged, replace the parts.
• ORBCOMM is a two-way radio communication
device. Wireless signals from the system
can interfere with other wireless signals
in the area. This interference can cause
a malfunction in a blast zone resulting
in an unintended detonation. Know the
locations of blast zones in the area and
keep a safe distance to avoid unintentional
blasts. If the machine is operating within
a distance of 12m (40 ft) of a blast zone,
disconnect the ORBCOMM harness. Failure
to do so could result in serious injury or
death. This warning does not supersede
requirements or regulations of the area or
country where this machine is in operation.
The following specifications are provided to
ensure compliance with all of the applicable
requirements or regulations: Transmit power:
5-10 Watts Operating Frequency Range: 148
- 150 MHz
1. ORBCOMM Antenna 2. Magnetic Base
The ORBCOMM Controller transmits data through
antenna (1, Figure 6-18 ORBCOMM ANTENNA, Figure 6-18 ORBCOMM ANTENNA
page 6-34) mounted on top of the cab. The antenna
6-34 980E-4
OPERATOR CAB AND CONTROLS KOMATSU WIRELESS BRIDGE (KWB)
KOMATSU WIRELESS BRIDGE

(KWB) A.5-0000073739
General Information
The Komatsu Wireless Bridge (KWB) provides access
to two networks; one directly to the KOMTRAX Plus
controller, and one directly to the Ethernet switch
to enable all features for wireless access. These
systems allow maintenance and service personnel to
download data and access controllers on the truck
wirelessly without actually getting on the truck.
Each truck is equipped with two wireless bridge
antennas located on the LH deck handrail. See
Figure 6-19 KWB ANTENNA LOCATION, page 6-35
for locations.
1. PicoStation M2 3. CAT 5E network cable

Access Point to POE Port
2. Power over Ethernet 4. Service Laptop
(POE) Adapter
Figure 6-20 KWB TOOLS

NOTE: PicoStation M2 devices act as Access Points
for each network. One PicoStation M2 is required for
1. Antenna for Truck_Net SSID
each network.
2. Antenna for KWB_Connect SSID
Figure 6-19 KWB ANTENNA LOCATION VHMS DOWNLOADS A.1-0000073736
The KWB_Connect Bullet M2 is configured as a bridge General Information

and provides access to KOMTRAX Plus controller
VHMS downloads are accomplished by connecting
downloads via the VHMS Auto Download Tool.
the service laptop wirelessly to the KWB_Connect
The TRUCK_NET Bullet M2 is configured as a router SSID and opening the VHMS Auto Download tool.
and allows access to controllers connected to the The software used to automatically download data
Ethernet switch. This includes PLM IV and the GE from a KOMTRAX Plus controller is obtained from
drive system. Diagnostic information, alarm codes, your Komatsu distributor.
and haul cycle data can be downloaded wirelessly.
Installing this software will create an icon called
This data can also be downloaded directly by “VHMS Auto Download Tool”. Any KWB_Connect
connecting a service laptop to the Ethernet switch. Bullet M2 that is properly setup, connected to a
See Figure 6-20 KWB TOOLS, page 6-35 for powering KOMTRAX Plus controller and within range of the
the PicoStation M2 access point. Access Point (AP), will automatically download all
data from the KOMTRAX Plus controller.
The “VHMS Auto Download Tool” software will not
download from KOMTRAX Plus controllers that have
not had the vehicle data setup (this is a consideration
only when replacing or installing a KOMTRAX Plus
controller for the first time).
980E-4 6-35
KOMATSU WIRELESS BRIDGE (KWB) OPERATOR CAB AND CONTROLS
Any KWB_Connect Bullet M2 not connected to a

KOMTRAX Plus controller will not show up in the list
of available download sources.
The “VHMS Auto Download Tool” software will only
download data once every 20 hours, however, it is
possible to force a download by right clicking on a
connected vehicle in the “Download History” section
and selecting “Download ON.”
VHMS Downloading Procedure

1. Disconnect from any Wired Ethernet
connection and confirm IP settings for
the wired and wireless LAN connection
are set for Automatic when downloading
wirelessly through the Access Point (AP). (See
CHANGING A LAPTOP'S IP ADDRESS, page
6-37 for more information)
2. If the KWB_Connect Access Point is already Figure 6-22 FORCE DOWNLOAD
powered on, connect to the KWB_Connect ONBOARD CONTROLLER
SSID. Otherwise, use the provided POE ACCESS A.2-0000073735
adapter to power the KWB_Connect Access
Point. (See CONNECTING TO A WIRELESS Each truck is equipped with controllers on board
NETWORK, page 6-38 for instructions on that are connected to the Ethernet switch. These
connecting to the KWB_Connect SSID) controllers are accessed either through a wireless or
wired connection.
3. Ensure a truck with a KWB_Connect BULLET
M2 is within range and the truck is powered on. Wireless Access
4. Open the “VHMS Auto Download Tool” Wireless access to the TRUCK_NET SSID allow
maintenance and service personnel the ability to
NOTE: If this is the first time the tool has been used,
communicate with controllers connected to the
the defaults are the following:
Ethernet switch without actually getting on the truck.
• User name: user
Wireless Access Procedure
• Password: 1
1. Disconnect from any Wired Ethernet
connection and confirm IP settings for the
wired and wireless LAN connection are set
for Automatic when downloading wirelessly
through the AP. (See CHANGING A LAPTOP'S
IP ADDRESS, page 6-37 for more information)
2. If the TRUCK_NET Access Point is already
powered on, connect to the TRUCK_NET
SSID. Otherwise, use the provided POE
adapter to power the TRUCK_NET Access
Point. (See CONNECTING TO A WIRELESS
NETWORK, page 6-38 for instructions on
connecting to the KWB_Connect SSID)
Figure 6-21 LOGIN SCREEN
3. Ensure a truck with a TRUCK_NET BULLET
5. Confirm that a truck is present in the M2 is within range and the truck is powered on.
“Connecting Unit” section.
4. Open an internet browser.
6. To force a download, right click on a vehicle in
the download history that is also shown as a NOTE: Chrome is recommended for the best
connected unit, and then select download ON. browsing experience.
6-36 980E-4
5. Type trucknetap.net into the address bar and Wired Access

hit the return key.
A service laptop with direct connection to the Ethernet
6. The login screen of the TRUCK_NET Access switch on board the truck provides the ability to
Point is now shown. Links to currently communicate with controllers also connected to the
connected trucks are shown on this screen. Ethernet switch.
Wired Access Procedure

1. Disconnect from any Wireless connection
and ensure the IP settings for the wired LAN
connection is set to obtain automatically. (See
CHANGING A LAPTOP'S IP ADDRESS, page
6-37 for more information)
Figure 6-23 HYPERLINKS TO CONNECTED 2. It is not necessary for the truck to be within
WIRELESS DEVICES range of the TRUCK_NET Access Point.
Communication to controllers is possible
7. Click on the hyperlink of a Hostname to access regardless of whether or not the truck is
the login page of that particular truck. (See connected to the TRUCK_NET Access Point.
Figure 6-23 HYPERLINKS TO CONNECTED
WIRELESS DEVICES, page 6-37) 3. Plug the Ethernet cable from the switch into
the laptop. The TRUCK_NET Bullet M2 will
8. Links to the PLM4 and GE drive system automatically assign an IP address to the
webpages are shown. (See Figure 6-24 laptop.
HYPERLINKS SHOWN ON THE BULLET M2,
page 6-37) 4. Open an internet browser. Chrome
is recommended for the best browsing
experience.
5. Type the Hostname of the truck that is
connected to the Ethernet switch into the
address bar followed by .net
6. Links to the PLM IV and GE drive system
webpages are shown.
Figure 6-24 HYPERLINKS SHOWN ON THE
BULLET M2 7. Click a link to access the controller’s webpage.
9. Click a link to access the controller’s webpage. NOTE: Controllers can also be accessed directly by
NOTE: Truck webpages can also be accessed by typing in plm.net or drivesystem.net into the address
typing in the truck Hostname directly into the address bar.
bar followed by .net
CHANGING A LAPTOP'S IP
NOTE: When a truck starts it will take up to two (2) ADDRESS A.2-0000073738
minutes for it to be displayed on the trucknetap.net
webpage. The following instructions are for Windows 7 ™.
NOTE: If the TRUCK_NET Access Point is powered 1. Click Start > Control Panel
off it will take up to five (5) minutes for trucks that were 2. Open the Network and Sharing Center
previously connected to reestablish their connection
to the TRUCK_NET Access Point. • If settings are displayed by icons click
“Network and Sharing Center”
NOTE: It is recommended that the TRUCK_NET
Access Point is rarely powered off and is placed in • If settings are displayed by category click
a location where trucks frequently arrive such as a “View network status and tasks”
fueling station. 3. Click “Change Adapter settings” in the left-hand
pane
4. Right click on the adapter that needs to be
configured
980E-4 6-37
KOMATSU WIRELESS BRIDGE (KWB) OPERATOR CAB AND CONTROLS
• For WIRELESS CONNECTIONS use • Select Obtain DNS server address

Wireless Network Connection automatically radio button
• For WIRED LAN CONNECTIONS use Local • Click OK
Area Connection
• Click OK/Close
5. Click “Properties”
Figure 6-26 AUTOMATIC IP CONFIGURATION

CONNECTING TO A WIRELESS
NETWORK A.2-0000073737
Figure 6-25 ETHERNET ADAPTER PROPERTIES The following instructions are for Windows 7 ™.
6. Select “Internet Protocol Version 4 (TCP/IPV4)” 1. Click on the network icon in the system tray
(See Figure 6-25 ETHERNET ADAPTER
PROPERTIES, page 6-38) 2. Connect to the desired SSID:
7. Click “Properties” • For KWB_Connect, click on “KWB_Connect”

(See Figure 6-27 CONNECTING TO
8. FOR AUTOMATIC IP SETTINGS (See Figure KWB_CONNECT, page 6-39).
6-26 AUTOMATIC IP CONFIGURATION, page
6-38): • For TRUCK_NET, click on “TRUCK_NET”
(See Figure 6-28 CONNECTING TO
• Select Obtain an IP address automatically TRUCK_NET, page 6-39).
radio button
6-38 980E-4
Figure 6-27 CONNECTING TO KWB_CONNECT Figure 6-28 CONNECTING TO TRUCK_NET

3. Click on the “Connect” button.
4. Accept any requests from the network (it may
be listed as unsecure).
NOTE: The connection status will be shown as
“Limited.”
980E-4 6-39
FUSES AND CIRCUIT BREAKERS OPERATOR CAB AND CONTROLS
FUSES AND CIRCUIT VEHICLE ELECTRICAL CENTER

BREAKERS E.29-0000051583 89 A.5-0000073439
Before replacing a fuse, determine the cause of Vehicle Electrical Center 89 is located inside the
failure. Repair as necessary. Always replace a fuse auxiliary control cabinet.
with one of specified amperage. Never replace a fuse
with one of greater amperage.
Figure 6-29 VEHICLE ELECTRICAL CENTER 89

VEHICLE ELECTRICAL CENTER 89
LOCATION AMPS DEVICE(S) PROTECTED
F2 25 Back-Up Lamps
F3 15 Back-Up Horn
F4 15 Low Beam Headlights (Low Mount)
F5 15 Low Beam Headlights (High Mount)
F6 25 High Beam Headlights
F8 15 Marker & Tail Lights
F9 10 Brake Light
F10 20 Ladder Lights
F11 15 Turn Signal Hazard
F12 10 Steering Bleed Down
F13 10 Retard Lamps
F20 10 Auto Lube
F42 5 IM & Fuel Sensor
F43 1 Direction Selector Switch
6-40 980E-4
OPERATOR CAB AND CONTROLS FUSES AND CIRCUIT BREAKERS

Display Mode Switch, Fog Light Switch, Heated
F44 5
Mirror Switch and Switch LED Lights
F45 15 GE Drive Control & Feedback
F53 20 Heated Mirror
F56 10 Operator\Passenger Seat
F57 10 Pre-Shift Brake Test
F61 5 Unused
F62 15 Fog Lamp
F63 15 Seat Belt Alarm
F64 5 Headlight Switch
SP1 1 Spare
SP2 1 Spare
SP3 1 Spare
SP4 5 Spare
SP5 10 Spare
SP6 15 Spare
SP7 20 Spare
SP8 25 Spare
D14 3 Back-Up Diode 1
D15 3 Back-Up Diode 2
R3 Back-Up Horn Micro Relay
R8 Marker & Tail Light Micro Relay
R9 Brake Light Micro Relay
R11 Left Turn Micro Relay
R12 Right Turn Micro Relay
R13 Turn Signal Hazard Flasher Relay
R14 Steering Bleed Down Micro Relay
R15 Retard Lamps Micro Relay
R29 Unused
R39 Heated Mirror Micro Relay
R40 Fog Lamp Micro Relay
R41 Seat Belt Alarm Micro Relay
980E-4 6-41
VEHICLE ELECTRICAL CENTER

90 A.3-0000073438
Vehicle Electrical Center 90 is located inside the
auxiliary control cabinet.

F14 5 Payload Lamps
F15 5 Park Brake Status
F17 5 Payload Meter
F18 15 Ground Level Shutdown Switch
F19 10 Park Brake Control
F46 5 Payload Meter Key Switch Power
F47 5 KOMTRAX Plus Key Switch Power
F48 5 Modular Mining Conn Key Switch Power
SP1 5 Spare
SP2 5 Spare
SP3 10 Spare
SP4 10 Spare
SP5 10 Spare
SP6 15 Spare
SP7 15 Spare
SP8 20 Spare
6-42 980E-4

D1 3 Key Switch Run Diode
D2 3 Shift Selector Forward Diode
D3 3 Shift Selector Neutral Diode
D4 3 Shift Selector Reverse Diode
D5 3 Park Brake Diode
D6 3 Truck Moving Diode
D7 3 Brake Lock Diode
D8 3 Park Brake Latch Diode
D9 3 GE True Forward Signal Diode
D10 3 GE True Reverse Signal Diode
D11 3 Unused
D12 3 Unused
D13 3 Forward, Neutral, Reverse Signal Diode
D14 3 Engine Running Diode
R16 Payload Red Lamp Relay
R17 Payload Amber Lamp Relay
R18 Payload Green Lamp Relay
R19 Engine Interlock Relay
R20 Timed Engine Shutdown Relay
R21 Engine Running Relay
R22 Park Brake Request Relay
R23 Park Brake Release Relay
R24 Park Brake Switch Relay
R25 Truck Moving Relay
R26 Park Brake Latch Relay
R27 GE Interface Relay
R28 Park Brake Status Relay
980E-4 6-43
VEHICLE ELECTRICAL CENTER

91 A.3-0000073437
Vehicle Electrical Center 91 is located inside the
auxiliary control cabinet.

F21 10 Ether Start
F22 20 Operator Cab Communication Radio 12V
F23 10 Entertainment Radio 12V
F24 10 Unused
F25 10 Shutter Control
F26 15 Electronic Gauge Display Un-Switched
F27 10 IM Un-Switched # 1
F28 10 IM Un-Switched # 2
F29 10 KOMTRAX Plus & ORBCOMM
F30 20 Modular Mining Un-Switched
F31 15 Engine Oil Reserve Pump Motor
F32 15 Engine Oil Reserve Controller
F33 15 Vehicle Horn / Service Lamps
F34 15 Engine Service Lamps / Hydraulic Mod Lamp
F35 15 Ladder & Hazard Lamp Control Switch
6-44 980E-4

F36 20 Engine Un-Switched Power Fuse #1
F40 20 Operator Cab Communication Radio 24V
F41 5 Operator Cab Fire Suppression
F49 15 Operator Cab HVAC Key Switch
F50 10 Windshield Wipers
F51 10 Hoist Limit Switch
F52 5 Turn Signal Switch
F54 5 Electronic Gauge Display Key Switch
F55 5 Aux Box Dome Lamps
F56 20 Electric Window - Left
F58 20 Oil Reserve System Heated Hose PWR
F59 5 Hydraulic Ladder
F60 5 Unused
F62 20 Electric Window - Right
F63 20 Auxiliary Power Port 12V
SP1 5 Spare
SP2 5 Spare
SP3 10 Spare
SP4 10 Spare
SP5 15 Spare
SP6 15 Spare
SP7 20 Spare
SP8 20 Spare
D13 3 Turn Signal Switch Diode
D14 3 Key Switch Power or Diode
D15 3 GE Control Power or Diode
R30 Starter Enable Relay
R34 Unused
R35 Unused
980E-4 6-45

R36 Ether Start Relay
R37 Entertainment Radio Relay
R38 Unused
R39 Shutter Control Relay
CIRCUIT BREAKERS C.12-0000051607
The following circuit breaker is located on the LH wall

inside the Auxiliary Control Cabinet
CIRCUIT BREAKERS
LOCATION AMPS DEVICE(S) PROTECTED CIRCUIT
CB60 50 24VDC to 12VDC Converter
6-46 980E-4
LUBRICATION AND SERVICE
980E-4 7-1
GENERAL INFORMATION LUBRICATION AND SERVICE
Service Capacities
GENERAL U.S.
INFORMATION E.32-0000051606 System Liters
Gallons
Recommended preventive maintenance will Wheel Motors (each side) 98 26
contribute to the long life and dependability of the truck
and its components. The use of proper lubricants and Front Wheel Hub (each side) 68 18
the performance of checks and adjustments at the Fuel Tank (Diesel Fuel Only) 5300 1400
recommended intervals is most important.
Refer to LUBRICATION CHART, page 7-10 for HYDRAULIC SYSTEM
lubricant requirements. For detailed service SERVICE C.47-0000051605
requirements for specific components, refer to the
service manual section for that component. Hydraulic Tank
There are two sight gauges on the side of the
Refer to the manufacturer's service manual when
hydraulic tank. With the engine stopped, key switch
servicing any components of the drive system.
OFF, hydraulic system bled down and body down, oil
Refer to the engine manufacturer's service manual should be visible in the top sight gauge. If hydraulic
when servicing the engine or any of its components. oil is not visible in the top sight gauge, follow Adding
Oil instructions below.
The service intervals presented here are in hours
of operation. These intervals are recommended in Adding Oil
lieu of an oil analysis program which may determine
Keep the system open to the atmosphere only as
different intervals. However, if the truck is being
long as absolutely necessary to lessen the chances
operated under extreme conditions, some or all, of the
of system contamination.
intervals may need to be shortened and the service
performed more frequently. Service the tank with clean Type C-4 hydraulic oil only.
All oil being put into the hydraulic tank must be filtered
This truck is equipped with an automatic lubrication
through filters rated at three microns.
system. The initial setup for this system provides
for nominal amounts of lubricant to be delivered to 1. Ensure that the engine is stopped, key switch
each serviced point. The lubrication injectors can be is OFF, hydraulic accumulators depressurized,
adjusted to vary the amount of lubricant delivered. In and body is down.
addition, the timer for lubrication intervals is normally
adjustable. Refer to AUTOMATIC LUBRICATION 2. Remove fill cap (2, Figure 7-1 HYDRAULIC
SYSTEM, page 5-67 for adjustments to these devices. TANK SERVICE, page 7-3) and add hydraulic
oil until the oil level is visible in the center of the
Service Capacities top sight gauge.
U.S. 3. Install the fill cap.
System Liters
Gallons 4. Start the engine. Raise and lower the dump
Crankcase (including body three times.
4 oil filters) (Komatsu 341 90
5. Check the hydraulic oil level again with the
SSDA18V170 Engine)
engine stopped, key switch OFF, hydraulic
Cooling System (Komatsu accumulators depressurized, and body down.
799 211
SSDA18V170 Engine)
6. Repeat steps 1 - 5 until the oil level is
Hydraulic System (Refer maintained in the center of the top sight gauge.
to HYDRAULIC SYSTEM 1325 350
SERVICE, page 7-2)
7-2 980E-4
LUBRICATION AND SERVICE GENERAL INFORMATION
1. Brake
1. Sight Gauges 3. Drain Cocks Figure 7-4 BRAKE HYDRAULIC FILTER

2. Fill Cap Replace filter elements after the initial 50, 100, and
250 hours of operation; then at each 500 hours of
Figure 7-1 HYDRAULIC TANK SERVICE operation thereafter. Torque for hoist filter is 20 N·m
(15 ft lb) and the steering filter torque is 99 N·m (73 ft
lb). Check oil level. Add oil as necessary. (Lube Key
B).
Hydraulic Pump Drive Shaft
1. Hydraulic Tank Breathers
Figure 7-2 HYDRAULIC TANK BREATHERS

Hydraulic tank breathers (1, Figure 7-2 HYDRAULIC
TANK BREATHERS, page 7-3) need to be replaced
every 500 hours. 1. Drive Shaft Grease Fittings
Hydraulic Filters Figure 7-5 DRIVE SHAFT LUBRICATION POINTS
Add one or two applications of grease to each drive
shaft grease fitting (1, Figure 7-5 DRIVE SHAFT
LUBRICATION POINTS, page 7-3). Non - moly
grease only. Check that each bearing of the U-joint
assembly is receiving grease. Replace bearings if
any wear is detected.
1. Hoist 2. Steering
Figure 7-3 HYDRAULIC FILTERS
980E-4 7-3
WHEEL MOTOR SERVICE C.3-0000051604 4. Operate the engine for five minutes. Check the
coolant level.
Due to differences in gear ratio and component
evolution/design, wheel motor service intervals may 5. If coolant is not visible in the sight gauge,
be unit number and/or mine specific. Because of repeat Steps 1 through 4. Any excess coolant
the wide variety of factors involved, it is necessary will be discharged through the vent hose
to consult your area Komatsu representative for after the engine reaches normal operating
all wheel motor service intervals and instructions. temperature.
General intervals for oil service and sampling are
listed in the interval charts. Engine coolant must always be visible in the sight
gauge before truck operation.
COOLANT LEVEL SERVICE H.29-0000051603 Coolant Specifications
Inspect the coolant sight gauge. If coolant cannot be For ambient temperatures of -32° C (-25° F) and
seen in the sight gauge, it is necessary to add coolant above, use a standard 50/50 anti-freeze-to-water
to the system before truck operation. Refer to the mixture.
procedure below for the proper filling instructions.
For arctic climates with ambient temperatures
between -32° C (-25° F) and -54° C (-65° F), use a
60/40 anti-freeze-to-water mixture.
NOTE: Do not use propylene glycol coolant in arctic
climates. Only use ethylene glycol coolants.
NOTE: Coolant must meet Cummins Engineering
Standard 14603.
Unacceptable Practices
• Use of high-silicate anti-freeze.
• Under concentration or over concentration of
Extended Service Additive (SCA).
• Use of anti-freezes/coolants that are not fully
formulated for extended service intervals.
• Use of sealing additives (stop-leak) in the cooling
system.
1. Sight Gauge 2. Radiator Cap
• Use of soluble oils in the cooling system.
Radiator Filling Procedure • Use of poor-quality water. See the engine

manufacturer’s specifications for water quality
requirements.
• The cooling system is pressurized due to • Use of anti-freeze, Extended Service Additive
thermal expansion of coolant. DO NOT (SCA) or coolant filter(s) that do not meet the
remove the radiator cap while the engine and engine manufacturer’s specifications.
coolant are hot. Severe burns may result.
• Use of Treated Water coolant.
1. With the engine and coolant at ambient • Use of coolants with less than 40 percent antifreeze.
temperature, remove the radiator cap.
RESERVE ENGINE OIL
NOTE: If coolant is added using the quick fill service SERVICE G.8-0000051463
center, the radiator cap MUST be removed prior to
adding coolant. The reserve oil tank for the engine is designed to add
more oil capacity to the engine to reduce the frequent
2. Fill the radiator with the proper coolant mixture servicing of the engine oil. The engine oil level must
(as specified by the engine manufacturer) until still be checked every shift using the dipstick. If engine
coolant is visible in the sight gauge. oil level is not correct, check for proper operation of the
3. Install the radiator cap. reserve oil system. Never add oil to the engine unless
it has been drained.
7-4 980E-4
If the engine oil has been drained from the oil pan, the
new oil must be added to the engine oil pan before
starting. DO NOT use the oil in the reserve tank to
fill an empty engine with oil. After an oil change, both
the engine and reserve tank must be full of oil before
starting the engine.
With the engine running, check the operation of the
red LED light on the pump.
• Continuously on - Pump 1 is withdrawing oil from
the engine sump and bringing down the oil level.
• Regular pulsing - Pump 2 is returning oil to the
engine sump and raising the oil level.
• Irregular pulsing - Oil is at the correct running
level.
Oil should always be visible in the bottom sight gauge.
If not, add oil to the reserve oil tank until oil is visible
in the top sight gauge.
• Never add oil to the engine unless it has been
completely drained.
1. Remote Control Box 4. “FULL” Light
• If the engine oil has been drained from the oil pan, 2. System Switch 5. “VALVE OPEN” Light
new oil must be added to the oil pan. Do not use 3. Start Switch
the oil in the reserve oil tank to fill an empty
engine oil pan. Figure 7-6 CONTROL PANEL
After an oil change, both the engine and reserve oil Inline Screen
tank must be full of oil before starting the engine. There is an inline screen located at the inlet of the
fill valve. This screen does not require periodic
Reserve Oil Tank Filling Procedure maintenance, but it can be cleaned by removing the
(Remote Fill) screen and back flushing.
1. Remove the reserve oil fill cap to prevent it from
dislodging during remote fill. CAB AIR FILTER SERVICE D.4-0000051602
2. Connect the pressure supply hose from the

new oil supply to the quick coupler on the truck.
Open the valve on the supply hose to apply
pressure.
3. Pull out on system switch (2, Figure 7-6
CONTROL PANEL, page 7-5) to turn the
system on.
4. Push start switch (3). The VALVE OPEN light
(5) should illuminate and the filling process will
begin.
5. When tank is full, the VALVE OPEN light will
turn off and FULL light (4) will illuminate.
6. Close the oil supply valve in the fill hose. 1. Cab Filter Element 2. Filter Cover
7. Press and hold start switch (3) for a couple of
seconds. Figure 7-7 CAB AIR FILTER LOCATION
8. Disconnect the new oil supply hose.
9. Push system switch (2) in to turn system power
OFF.
980E-4 7-5
It is not necessary to remove the tank from the truck for

cleaning of sediment, however rust and scale on the
walls and baffles may require complete tank removal.
Prior to a cleaning procedure of this type, all vents, fuel
gauge, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material has been removed, the temporary plugs can
be removed. A small amount of light oil must be
sprayed into the tank to prevent rust if the tank is to
remain out of service. All openings should be sealed
for rust prevention.
1. HVAC Recirculation Filter Element
Figure 7-8 HVAC RECIRCULATION FILTER

LOCATION
1. Clean both filter elements (1, Figure 7-7
CAB AIR FILTER LOCATION, page 7-5 and
Figure 7-8 HVAC RECIRCULATION FILTER
LOCATION, page 7-6) with mild soap and
water. 1. Fuel Tank Breather
2. Rinse completely clean and air dry with a Figure 7-10 FUEL TANK BREATHER
maximum of 275 kPa (40 psi).
Remove breather (1, Figure 7-10 FUEL TANK
3. Reinstall the filters. BREATHER, page 7-6) and clean in solvent. Dry with
pressurized air and reinstall.
FUEL SYSTEM SERVICE G.60-0000051601
Fuel Tank Cleaning Fuel Filter Service
1. Fuel Tank Drain
Figure 7-9 FUEL TANK 1. Water Drain Valves

Open fuel tank drain (1, Figure 7-9 FUEL TANK, Figure 7-11 WATER SEPARATOR DRAIN
page 7-6) to drain water and sediment from the fuel
Open water drain valves (1, Figure 7-11 WATER
tank. The fuel tank is provided with a drain and a
SEPARATOR DRAIN, page 7-6) to remove water
cleaning port in the side that allows steam or solvent
from the fuel/water separators daily.
to be utilized in cleaning tanks that have accumulated
foreign material.
7-6 980E-4
INTAKE AIR CLEANER

SERVICE E.5-0000051600
• The engine must be turned off before

servicing the air cleaner assemblies or
opening the engine air intake system. Never
start the engine with the filter elements
removed. Serious engine damage can result.
During operation or after the engine has been turned

off, observe the air filter restriction gauges mounted on
the overhead panel in the cab. When a gauge shows
maximum restriction, filter service is required.
To service the intake air cleaner system, perform the
following: 2. Check tubes for plugging. Generally tubes are
self cleaning. Under special circumstances
plugging can occur. If tubes carry light dust,
remove it with a stiff brush. If heavy plugging
with fibrous material occurs, remove the
section and clean it with compressed air or
water no hotter than 72° C (160° F).
NOTE: Never clean DonacloneTMtubes with
compressed air unless both the primary and safety
filters are installed in the air cleaner.
3. Change the filter. If the new filter is not to be
installed immediately, be sure to cover the inlet
to prevent contamination.
NOTE: Before installing the new filter, inspect it for
shipping damage and gasket integrity. If there is
1. Dust Cup 2. Vacuator™ Valve damage, DO NOT install the filter.
4. Check all engine intake air plumbing, hoses
Figure 7-12 DUST CUP LOCATION and clamps. All connections must be air tight
1. Inspect and empty dust cups (1, Figure 7-12 to prevent dirt from entering. If there are holes
DUST CUP LOCATION, page 7-7). Never or damage, replace immediately.
allow the dust level to build up to the tube
(precleaner) chamber.
NOTE: On dust cups with the VacuatorTMvalve, dust
cup service is minimal; just check the valve to see
that it is not inverted, damaged or plugged. If it is
damaged, replace it immediately.
1. Filter Vacuum Gauge 2. Reset Button
Figure 7-13 VACUUM GAUGES

5. After the filters have been serviced, reset
air cleaner vacuum gauges (1, Figure 7-13
980E-4 7-7
VACUUM GAUGES, page 7-7) in the cab 1. Position fill plug (1) at the 3 o'clock position.
by pressing reset button (2) on the face of
2. Clean the area around the fill plug before
the gauge. Refer to the Shop Manual, for
removing the plug. Remove the fill plug.
more detailed instructions about the intake air
cleaner system. 3. Obtain the oil sample at the lowest point
possible inside the wheel hub.
FRONT WHEEL SERVICE A.2-0000073436
4. Install the fill plug.
5. Rotate the wheel hub to position the fill plug at
the 12 o'clock position. Remove the fill plug.
6. Add SAE 50W oil to the wheel hub assembly
using the fill hole. When properly filled, the
floating ball in the sight gauge will be at its
highest position.
7. Complete the oil sample form immediately and
submit it with the oil sample for analysis.
NOTE: For more information regarding oil sampling,
refer to the Komatsu Oil Wear Analysis (KOWA)
manual.
FRONT ENGINE MOUNT TRUNNION

SERVICE C.3-0000051638
1. Fill Plug (magnetic 3. Drain Plug
plug)
2. Sight Gauge
Figure 7-14 FRONT WHEEL DRAIN PLUG

1. Position drain plug (3, Figure 7-14 FRONT
WHEEL DRAIN PLUG, page 7-8) at the lowest
position. Remove the drain plug and allow the
oil to drain out completely. Reinstall the drain
plug.
2. Remove fill plug (1). Add SAE 50W oil to the 1. Trunnion Grease Fitting
wheel hub assembly using the fill hole. When
properly filled, the floating ball in sight gauge Figure 7-15 FRONT ENGINE MOUNT TRUNNION
(2) will be at its highest position. The wheel GREASE FITTING
hub holds approximately 68 L (18 gal) of oil. Add one or two applications of grease to trunnion
3. Inspect and clean the fill plug before reinstalling grease fitting (1, Figure 7-15 FRONT ENGINE
it. MOUNT TRUNNION GREASE FITTING, page 7-8).
(Lube key “D”).
NOTE: The oil may need to be changed more
frequently depending on mine conditions and the QUICK FILL SERVICE CENTER E.3-0000051637
results of the oil sample tests.
The service center can be located on either side of the
machine and is used to fill system fluids. The table
Oil Sampling
shows the maximum recommended fill pressures for
The truck must have been in operation for at least one the service center.
hour prior to taking an oil sample to ensure that all
contaminants are in suspension. Take the oil sample
within five minutes of stopping the truck.
7-8 980E-4
NOTE: Ensure that capscrews (5) are parallel to the

ground as shown, the gap between clamps (3) is
aligned with the slot in tie rod structure (1) and the
anti-rotation retainer is on the bottom of the rod end.
NOTE: Some slight movement of the capscrew heads
may be observed during the first couple of checks due
to torque tolerance.
6. Reapply torque to each capscrew until the
specified torque is maintained.
7. Apply an upwards force to each end of the tie
1. Hydraulic Oil 3. Engine Oil rod assembly near rod end threads. Look for
2. Radiator Coolant 4. Grease lateral movement between the tie rod ends and
tie rod structure.
Figure 7-16 SERVICE CENTER
If lateral movement is detected, visually inspect
MAXIMUM FILL PRESSURES the internal and external threads on both ends.
Replace parts that have damaged threads.
Fill System kPa psi
Use new capscrews and locknuts where thread
Engine damage to the tie rod end and tie rod structure
345 50
Crankcase is observed.
Reserve Tank 862 125 8. Ensure that sufficient grease is being supplied
Hydraulic Tank 345 50 by the auto lube system to the spherical
bearings of the tie rod and steering cylinders.
Coolant 345 50
Grease 10 342 1,500
Fuel 103 15
TIE ROD INSPECTION AND TORQUE

PROCEDURE A.31-0000061684
1. When inspecting this area or making
adjustments, turn off the engine and make sure
that the key switch is in the OFF position.
2. After the engine has been turned off, allow at
least 90 seconds for the accumulators to bleed
down.
3. Turn the steering wheel to the left and to the
right to ensure that the steering accumulator
pressure has been bled down. 1. Tie Rod 4. Locknut
2. Rod End Threads 5. Capscrew
4. Block the front and back of the rear wheels. 3. Clamp 6. Flat Washer
5. For the four capscrew clamp style tie rod
assembly tighten locknuts (4, Figure 7-17 Figure 7-17 FOUR CAPSCREW CLAMP STYLE
FOUR CAPSCREW CLAMP STYLE TIE ROD TIE ROD ASSEMBLY
ASSEMBLY, page 7-9) to 1017 ± 102 N·m (750
± 75 ft lb).
980E-4 7-9
LUBRICATION CHART LUBRICATION AND SERVICE
LUBRICATION CHART A.1-0000073435
7-10 980E-4
LUBRICATION AND SERVICE EVERY 10 HOUR (DAILY) MAINTENANCE
EVERY 10 HOUR (DAILY)

MAINTENANCE D.49-0000051636
EVERY 10 HOUR (DAILY) MAINTENANCE
Item Task
MACHINE Inspect the entire machine for leaks, worn parts, and damage. Repair as necessary.
• Check the oil level. To obtain an accurate measurement, remove the dipstick and wipe
it off. Then reinsert the dipstick and remove it again to check the oil level. Refer to the
engine manual for oil recommendations. (Lube Key “A”).
• Check the oil level in the reserve tank. The oil level must be visible in the lower sight
gauge. If it is not, add oil to the reserve tank using the reserve oil tank filling procedure.
Also, with the engine running, check the operation of the LED monitor light. Refer to
RESERVE ENGINE OIL SYSTEM (if equipped), page 5-75.
• Check the coolant level. Fill the radiator with the proper mixture as shown in COOLANT
LEVEL SERVICE, page 7-4. Refer to the engine manual for proper coolant additives.
ENGINE
• Check for abnormal noises and fluid leaks.
• Check the turbocharger for leaks, vibration or unusual noise.
• Check alternator and fan belt condition and alignment.
• Check all mounting hardware, joints, and connections. Ensure no air leaks exist and all
hardware is properly tightened.
• Inspect the exhaust piping for integrity.
• Check the operating indicator for the eliminator filter.
Check the oil level in the tank, add oil if necessary. Refer to HYDRAULIC SYSTEM
HYDRAULIC
SERVICE, page 7-2. Oil should be visible in the top sight glass. - DO NOT overfill.
TANK
(Lube Key “B”).
DRIVE
Inspect ductwork from the blower to the rear drive case. Ensure that ductwork is secure,
SYSTEM
free of damage, and unrestricted.
COOLING AIR
• Check the air cleaner vacuum gauges in the operator cab. The air cleaner(s) must be
serviced if the gauge(s) shows a restriction of 25 in. of water (625 mm of water) vacuum.
INTAKE AIR
• Check intake piping for leaks.
CLEANERS
Refer to INTAKE AIR CLEANER SERVICE, page 7-7 for servicing the intake air cleaner
system.
CAB AIR Clean the cab air filters every 250 hours. In extremely dusty conditions, service as
FILTERS frequently as required. Refer to CAB AIR FILTER SERVICE, page 7-5.
FUEL FILTERS
Drain water from the bottom drain valve on each fuel separator. Refer to FUEL SYSTEM
(Water
SERVICE, page 7-6.
Separators)
980E-4 7-11
EVERY 10 HOUR (DAILY) MAINTENANCE LUBRICATION AND SERVICE
EVERY 10 HOUR (DAILY) MAINTENANCE
Item Task
• Check the grease reservoir; fill as required. (Lube Key “D”).
• When filling the reservoir, check the grease filter indicator. Clean or replace the grease
filter if the indicator detects a problem.
• Inspect the system and check for proper operation. Ensure the following important areas
are receiving grease. (Lube Key “D”).
AUTOMATIC • Steering Linkage
LUBE SYSTEM
• Final Drive Pivot Pin
• Rear Suspension Pin Joints - Upper & Lower
• Body Hinge Pins - Both Sides
• Hoist Cylinders Pins - Upper & Lower
• Anti-sway Bar - Both Ends
• Inspect tires for proper inflation and wear.
WHEELS AND
• Check for embedded debris in tread and remove.
TIRES
• Inspect for damaged, loose, or missing wheel mounting nuts and studs.
WASHER
Check the level of washer fluid in the bottle behind the cab. Fill as needed.
FLUID
• Check the quick fill fuel receivers for excessive wear, leaks and mud buildup.
FUEL TANK • Check the vent on the back of the fuel tank at the bottom for mud buildup or any other
obstructions. Clean if necessary. See EVERY 1000 HOURS LUBRICATION AND
MAINTENANCE, page 7-19 for cleaning instructions.
TERMINALS Check for wire cuts, short-circuits, or loose terminals. Fix anything that is wrong
AND WIRES immediately.
7-12 980E-4
INITIAL 50 HOUR LUBRICATION AND
LUBRICATION AND SERVICE MAINTENANCE INSPECTION
INITIAL 50 HOUR LUBRICATION
AND MAINTENANCE
INSPECTION A.1-0000073434
NOTE: These checks are required only after the initial
50 hours of operation, such as the commissioning
of a new truck, or after a new or rebuilt component
installation.
INITIAL 50 HOUR SERVICE INSPECTION

Item Task
HYDRAULIC SYSTEM Replace filter elements only after the initial 50, 100 and 250 hours of operation;
FILTERS then at each 500 hours of operation thereafter.
Replace the fuel filters. Refer to the engine operation and maintenance manual
FUEL FILTERS
for filter replacement instructions.
Check to ensure the rim nut torque on all wheels is 2 487 ± 136 N·m (1,834
± 100 ft lb).
WHEELS
Check to ensure the rim adapter nut torque on all wheels is 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
980E-4 7-13
INITIAL 100 HOUR LUBRICATION AND
MAINTENANCE INSPECTION LUBRICATION AND SERVICE
INITIAL 100 HOUR LUBRICATION
AND MAINTENANCE
INSPECTION E.3-0000051634
NOTE: These checks are required only after the initial
100 hours of operation (such as: the commissioning
of a new truck, or after a new or rebuilt component
installation).
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION

Item Task
HYDRAULIC SYSTEM Replace filter elements only after the initial 100 and 250 hours of operation;
FILTERS then at each 500 hours of operation thereafter.
7-14 980E-4
EVERY 250 HOUR LUBRICATION AND
LUBRICATION AND SERVICE MAINTENANCE
EVERY 250 HOUR LUBRICATION
AND MAINTENANCE E.41-0000051633
NOTE: The 10 hour lubrication and maintenance
checks must also be performed at this time. “Lube
Key” references are to the lubrication chart.
EVERY 250 HOUR LUBRICATION AND MAINTENANCE

Item Task
• Change the engine oil. (Lube Key “A”).
• Replace engine oil filters.
• Check belt tension and the condition of each accessory belt. Refer to
the engine Operation & Maintenance manual for specific adjustment
instructions.
ENGINE
NOTE: If the engine is equipped with the Centinel™oil system and/or the
Eliminator™filter system, engine oil and filter change intervals are extended
beyond 250 hours. Take an engine oil sample for analysis.
Refer to the engine Operation & Maintenance manual for complete

specifications regarding engine lube oil specifications.
• Check for proper coolant mixture. Add coolant as required.
• Change coolant filters.
• Check cooling system hoses for damage and signs of deterioration.
COOLING SYSTEM
• Check the torque on the cooling fan mounting capscrews: 237 N·m (175
ft lb).
Refer to the engine maintenance manual for coolant filter replacement
instructions and proper coolant mixture instructions.
• Change the fuel filters (fuel separators). Refer to the engine Operation &
Maintenance manual for specific filter replacement instructions.
FUEL SYSTEM
• Drain water and sediment from the fuel tank. Refer to FUEL SYSTEM
SERVICE, page 7-6 for detailed instructions.
Check all mounting hardware, joints and connections. Ensure that there are
AIR INTAKE PIPING
no air leaks and all hardware is properly tightened.
• Add one or two applications of grease to each grease fitting on the pump
drive shaft. Non - moly grease only.
• Replace filter elements after the initial 250 hours of operation; then at each
HYDRAULIC SYSTEM
500 hours of operation thereafter. Refer to (Lube Key “B”).
Refer to HYDRAULIC SYSTEM SERVICE, page 7-2 for detailed
instructions.
• Check the torque on the pin retaining nuts located on the steering linkage
STEERING LINKAGE
- 420 N·m ± 40 (310 ± 30 ft lb).
Use a flashlight and a mirror on a long rod to inspect all inner and outer
REAR WHEEL MOUNTING wheel mounting nuts and studs. Check for loose, damaged or missing
hardware.
980E-4 7-15
MAINTENANCE LUBRICATION AND SERVICE

Item Task
Under normal operating conditions, clean every 250 hours. In extremely

CAB AIR FILTER dusty conditions, service as frequently as required. Refer to CAB AIR
FILTER SERVICE, page 7-5 for detailed instructions.
Remove the magnetic plugs from the front wheel hub covers and check for
FRONT WHEEL HUB
debris. Clean the plugs and perform any necessary repairs.
BATTERIES Check the electrolyte level and add water if necessary.
• Check operation of the switches.

BODY-UP & HOIST LIMIT
SWITCHES • Clean the sensing areas of any dirt accumulation and inspect the wiring for
any signs of damage.
AC DRIVE BELT Check the belt for wear or damage.

• Check all grease hoses from the injectors to the lubrication points.
• Check all grease supply line hoses from the pump to the injectors.
• Check the grease reservoir level.
AUTOMATIC LUBE SYSTEM
• Inspect all bearing points for a bead of lubricant around the bearing seal.
• Perform system checkout. Refer to the Shop Manual for detailed
instructions.
Check the pads, shims and mounting hardware for wear and proper
DUMP BODY PADS
tightening.
7-16 980E-4
AND MAINTENANCE D.63-0000051632
NOTE: Maintenance requirements for every 10 & 250
hour Lubrication and Maintenance Checks must also
be performed at this time. “Lube Key” references are
to the lubrication chart.
INITIAL 500 HOUR MAINTENANCE (Includes after rebuild)

Item Task
WHEEL MOTOR Change or filter the gear case oil.
• Check that the motors are clean (interior and exterior is free of dirt, oil, carbon
dust, etc.). Clean if necessary.
GRID BOX • Check that all electrical connections are tight.

• Listen for unusual noises especially around the bearings.
• Inspect for any cracks on fan wheels.

Item Task
• Check the gear case oil level.
• Remove and clean the gear case magnetic plugs.
• Take gear case oil sample. (Refer to the Shop Manual for oil sample
WHEEL MOTOR instructions.)
• Based on oil sample results, refer to the GE Planned Maintenance Schedule
to determine if the gear case oil is satisfactory, needs filtered or if an oil
change is required.
• Replace the filter elements. Check the oil level. Add oil as necessary. (Lube
Key B)
HYDRAULIC SYSTEM
• Replace the breather elements. Refer to HYDRAULIC SYSTEM SERVICE,
page 7-2 for detailed instructions.
Check for proper piston extension (front and rear). Refer to the Shop Manual
HYDRAIR® SUSPENSION for more information on proper suspension extension and maintenance
procedures.
Lubricate the treadle roller and hinge pins with lubricating oil. Lift the boot
THROTTLE AND BRAKE
from the mounting plate and apply a few drops of lubricating oil between
PEDAL
the mounting plate and the plunger.
HOIST ACTUATOR
Check operation. Clean, lubricate, and adjust as necessary.
LINKAGE
ACCUMULATOR Check all steering and brake accumulator pre-charge pressures. Refer to
PRECHARGE the Shop Manual for details.
• Clean the air conditioner recirculation filter. Refer to CAB AIR FILTER
SERVICE, page 7-5 for more information.
HVAC • Ensure the air conditioner cab drains are clear of any obstructions.
• Wash the air conditioner condenser with a low pressure hose. Check for any
obstructions to airflow, clean as required.
980E-4 7-17
MAINTENANCE LUBRICATION AND SERVICE
Item Task
• Wash the radiator fins with a low pressure hose. Check for any obstructions
to airflow, clean as required.
COOLING SYSTEM
• Inspect the radiator stabilizers (upper radiator stabilizers, lower radiator
stabilizers and shroud bumpers) for damage and tightness. Fix as required.
Wash the fuel cooler (if equipped), located on the front RH side of the
FUEL SYSTEM radiator, with a low pressure hose. Check for any obstructions to airflow,
clean as required.
PARKING BRAKE Refer to the Shop Manual for the recommended inspections.
FRAME AND AXLE BOX Wash the truck, clean all of the weld joints, and visually inspect the entire
INSPECTION frame and axle box for cracking or damage.
• Check the battery, oil pressure switch, junction boxes, remote control fill
box and the circuit breaker connections for tightness, corrosion and physical
damage.
RESERVE ENGINE OIL
• Examine all electrical cables over their entire length for possible damage.
SYSTEM (If Equipped)
• Examine all hoses, including those on the reserve tank and the ones leading
to and from the engine. Check for leaks, cracks or other damage. Check all
fittings for tightness, leakage or damage.
Using a laptop PC with the VHMS Technical Analysis Tool Box program,
KOMTRAX Plus DATA perform a data download from the KOMTRAX Plus controller. Send the data
DOWNLOAD to WebCARE using the FTP feature. Refer to DOWNLOADING KOMTRAX
Plus DATA, page 6-31 for more detailed instructions.
TIE ROD Refer to TIE ROD INSPECTION AND TORQUE PROCEDURE, page 7-9.
• Vacuum the dust and debris from inside the control cabinet.
• Do not use compressed air. Compressed air causes dust particles and
contaminants to be blown across the surface of the electrical cards, eroding
the varnish and driving the particles into the electrical and mechanical
CONTROL CABINET
components of the system.
• Wear the appropriate Personal Protective Equipment (PPE). A clean,
soft-bristle brush can be used in areas such as the ST transformer coils, if
needed.
7-18 980E-4
EVERY 1000 HOURS LUBRICATION AND
EVERY 1000 HOURS LUBRICATION
AND MAINTENANCE F.34-0000051631
NOTE: Maintenance for every 10, 250, & 500 hour
Lubrication and Maintenance Checks must also be
performed at this time. “Lube Key” references are to
the lubrication chart.
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE

Item Task
• Drain the hydraulic tank and clean the inlet strainer.
• Refill the tank with new oil. (Lube Key “B”).
HYDRAULIC SYSTEM
NOTE: Oil change interval can be extended to 2,500 hours if oil is sampled at
every 250 hour intervals and no abnormalities are detected.
• Clean the cooling system with a quality cleaning agent.
• Flush the system with water.
COOLING SYSTEM
• Refill the system with anti-freeze and water solution.
• Check the Coolant Specifications, page 7-4 in this chapter.
Service the fuel tank breather. Refer to FUEL SYSTEM SERVICE, page 7-6
FUEL SYSTEM
for more detailed instructions.
OPERATOR'S SEAT Apply grease to the slide rails. (Lube Key “D”).
AUTOMATIC BRAKE Ensure the brakes are automatically applied when brake pressure decreases
APPLICATION below the specified limit. Refer to the Shop Manual for more details.
AUTOMATIC LUBE Check pump housing oil level using the dipstick on top of the pump unit. If
SYSTEM necessary, add SAE 10W-30 motor oil.
• Add grease to each bearing grease fitting. Ensure that each bearing is
RETRACTABLE LADDER receiving grease.
• Add grease to the cylinder.
• Clean and check centrifuge.
ELIMINATOR FILTER
(If Equipped) Refer to engine manufacturer’s Operation & Maintenance Manual. (Service
interval is dependent on duty cycle, oil quality, etc.)
Use the front and rear brake wear indicators included in the truck’s tool group
BRAKE DISC
to check for brake disc wear. Refer to the shop manual for instructions.
980E-4 7-19
EVERY 2500 HOUR MAINTENANCE LUBRICATION AND SERVICE
EVERY 2500 HOUR

MAINTENANCE A.1-0000073433
NOTE: Maintenance for every 10, 250, & 500 hour
Lubrication and Maintenance Checks must also be
performed at this time. “Lube Key” references are to
the lubrication chart.
EVERY 2500 HOUR MAINTENANCE

Item Task
Drain and refill with oil. Refer to FRONT WHEEL SERVICE, page 7-8 for
detailed instructions on changing the oil. (Lube key “E”).
FRONT WHEELS
NOTE: The oil may need to be changed more frequently depending on mine
conditions and the results of the oil sample tests.
7-20 980E-4
AND MAINTENANCE A.1-0000061694
NOTE: Maintenance for every 10, 250, 500 & 1,000
Item Task
Change or filter the wheel motor gear oil. The oil must be filtered/changed
WHEEL MOTOR OIL
prior to 3000 hours if oil analysis indicates contaminated oil.
980E-4 7-21
EVERY 4000 HOUR MAINTENANCE LUBRICATION AND SERVICE
EVERY 4000 HOUR

be performed at this time.
Item Task
Remove the oil strainer screen and wash thoroughly in high flash point
solvent until all accumulated sludge has been removed. Blow the screen dry
RESERVE ENGINE OIL
with compressed air or leave in a well ventilated place until all the solvent
has evaporated. Inspect the screen for damage and replace if necessary.
Re-install the screen.
7-22 980E-4
LUBRICATION AND SERVICE EVERY 5000 HOUR MAINTENANCE
EVERY 5000 HOUR

MAINTENANCE E.37-0000051629
NOTE: Maintenance for every 10, 250, 500, 1000, &
3000 hour Lubrication and Maintenance Checks must
also be performed at this time. “Lube Key” references
are to the lubrication chart.
Item Task
Visually inspect the VacuatorTM valve to make sure it is not inverted or
AIR CLEANERS damaged. Refer to INTAKE AIR CLEANER SERVICE, page 7-7 for detailed
instructions.
Inspect the wheel motor sun pinion for wear and damage. Replace if
SUN PINION
necessary.
Check that the torque on the steering wheel retainer nut is 81 ± 7 N•m (60 ± 5
STEERING WHEEL
ft lb). If tightening is necessary, add Loctite® Threadlocker Blue 242 to the
RETAINER NUT
nut, then use a torque wrench to tighten the nut to 81 ± 7 N·m (60 ± 5 ft lb).
980E-4 7-23
EVERY 18,000 HOUR MAINTENANCE LUBRICATION AND SERVICE
EVERY 18,000 HOUR

EVERY 18,000 HOUR MAINTENANCE
Item Task
Even if there are no signs of damage, replace both driver and passenger
SEAT BELTS AND
seat belts five years after seat belt manufacture, or every three years after
TETHERS
start of use, whichever comes first.
7-24 980E-4
SPECIFICATIONS
980E-4 8-1
MAJOR COMPONENT DESCRIPTION SPECIFICATIONS
Operator's Cab D.26-0000051642
MAJOR COMPONENT The operator cab has been engineered for operator
DESCRIPTION C.3-0000051647 comfort and to allow for efficient and safe operation
of the truck. The cab provides wide visibility,
Truck and Engine A.2-0000072561 with an integral 4-post ROPS/FOPS structure,
The 980E dump truck is an off-highway, rear dump and an advanced analog operator environment.
truck with AC electric drive. The gross vehicle weight It includes a tinted safety-glass windshield and
is 625 277 kg (1,378,500 lbs). The engine is a power-operated side windows, a deluxe interior with
Komatsu SSDA18V170 rated at 2 611 kW (3,500 HP). a fully adjustable seat with lumbar support, a fully
adjustable tilt/telescope steering wheel, controls
Traction Alternator D.16-0000051645
mounted within easy reach of the operator, and a
digital/analog instrument panel which provides the
The diesel engine drives an in-line alternator at engine operator with all instruments and gauges which
speed. The alternator produces AC current which is are necessary to control and/or monitor the truck's
rectified to DC within the main control cabinet. operating systems.
Main Control Cabinet A.2-0000060880 Power Steering D.1-0000051641
Each phase module contains paired positive and The truck is equipped with a full time power steering
negative semiconductor switches referred to as system which provides positive steering control
insulated gate bipolar transistors (IGBT). The IGBTs with minimum operator effort. The system includes
cycle on and off at varying frequencies to create an nitrogen-charged accumulators which automatically
AC power signal from the DC supply. provide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
The AC power signal produced by each inverter
is a variable-voltage, variable-frequency (VVVF)
signal. Frequency and voltage are changed to suit Dynamic Retarding Grid E.25-0000051640
the operating conditions. The dynamic retarding grid is used to slow the truck
during normal operation or control speed coming
AC Induction Traction Motorized down a grade. The dynamic retarding ability of the
Wheels C.3-0000051644 electric system is controlled by the operator through
the activation of the retarder pedal (or by operating
The alternator output supplies electrical energy to the
a lever on the steering column) in the operator’s cab
two wheel motors attached to the rear axle housing.
and by setting the speed control. Dynamic Retarding
The motorized wheels use three-phase AC induction
is automatically activated if the truck speed goes to a
motors with full-wave AC power.
preset overspeed setting.
The two wheel motors convert electrical energy back
to mechanical energy through built-in gear trains Brake System B.14-0000060879
within the wheel motor assembly. The direction of the
Service brakes at each wheel are oil-cooled multiple
wheel motors is controlled by a forward or reverse
disc brakes applied by an all-hydraulic actuation
hand selector switch located on the center console.
system. Depressing the brake pedal actuates both
front and rear brakes after first applying the retarder.
Suspension D.3-0000051643
All wheel brakes will be applied automatically if the
Hydrair II® suspension cylinders located at each brake system pressure decreases below a preset
wheel provide a smooth and comfortable ride for the minimum.
operator and dampens shock loads to the chassis
The parking brake is a dry disc type, mounted inboard
during loading and operation.
on each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
protection (will not apply with truck moving).
8-2 980E-4
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS D.3-0000051658
Engine B.9-0000061080
Komatsu SSDA18V170
No. of Cylinders................................................................................................................................................. 18
Operating Cycle....................................................................................................................................... 4-Stroke
Rated Brake HP............................................................................................. 2 610 kW (3,500 HP) at 1900 RPM
Flywheel HP .................................................................................................. 2 495 kW (3,346 HP) at 1900 RPM
AC Electric Drive System A.3-0000073964
(AC/DC Current)
Alternator ...................................................................................................................... General Electric GTA - 39
Dual Impeller, In-Line Blower.........................................................................................340 m³/ min (12,000 cfm)
Motorized Wheels.................................................................................. GDY108C AC Induction Traction Motors
Standard Gear Ratio* ................................................................................................................................ 35.02:1
Maximum Speed........................................................................................................................61 km/h (38 mph)
*Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other
parameters. Komatsu and GE must analyze each job condition to ensure proper application.
Dynamic Retarding A.2-0000061573
Electric Dynamic Retarding .................................................................................................................... Standard

Continuous* ......................................................................................................................... 4 476 kW (6,000 HP)
*Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.
Battery Electric System G.10-0000051654
Batteries ............................ 4 x 8D 1400 CCA, 12 volt, in series/parallel, bumper mounted with isolation station
Alternator ...................................................................................................................24 Volt, 250 Ampere Output
Lighting ....................................................................................................................................................... 24 Volt
Cranking Motors (2).................................................................................................................................... 24 Volt
Service Capacities B.7-0000061077
Crankcase (including lube oil filters)................................................................................................ 341 L / 90 gal

Cooling System ............................................................................................................................. 799 L / 211 gal
Fuel Tank ................................................................................................................................. 5 300 L / 1,400 gal
Hydraulic System........................................................................................................................ 1 325 L / 350 gal
Wheel Motor Gear Box (per wheel) ................................................................................................... 98 L / 26 gal
Hydraulic Systems A.5-0000061572
Hoist and Brake Cooling Pump ....................................................................................................... Tandem Gear

Rating .................................................................931 L/min (246 gpm) at 1900 RPM and 18 960 kPa (2,750 psi)
Steering/Brake Pump ...................................................................................... Piston Pump With Unloader Valve
Rating ...................................................................246 L/min (65 gpm) at 1900 RPM and 20 685 kPa (3,000 psi)
Relief Pressure-Hoist.........................................................................................................18 960 kPa (2,750 psi)
Relief Pressure-Steering/Brake .........................................................................................27 580 kPa (4,000 psi)
Hoist Cylinders (2) .................................................................................................................... 3-Stage Hydraulic
Tank (Vertical/Cylindrical) ........................................................................................................... Non-Pressurized
Tank Capacity ....................................................................................................................947 liters (250 gallons)
Filtration.................................................................................................................... In-line replaceable elements
Suction....................................................................................................................... Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High Pressure)....................................................... Beta 12 Rating =200
980E-4 8-3
Service Brakes A.3-0000061571
Hydraulic actuated, oil-cooled multiple discs on each wheel.
Total Friction Area / Brake ..............................................................................................103 729 cm² (16,078 in²)

Maximum Apply Pressure..................................................................................................18 960 kPa (2,750 psi)
Steering A.4-0000061570
Twin hydraulic cylinders with accumulator assist to provide constant rate steering. Emergency power steering
automatically provided by accumulators.
Turning Circle (SAE)............................................................................................................. 32.0 m (105 ft. 0 in.)
Standard Dump Body Capacities and Dimensions A.3-0000061569
Capacity
Heaped @ 2:1 (SAE).................................................................................................................. 250 m3 (327 yd3)
Struck ......................................................................................................................................... 191 m3 (250 yd3)
Width (Inside) ......................................................................................................................... 8.68 m (28 ft. 6 in.)
Depth ........................................................................................................................................ 3.2 m (10 ft. 7 in.)
Loading Height ....................................................................................................................... 7.09 m (23 ft. 2 in.)
Dumping Angle .................................................................................................................................................45°
Tires A.1-0000072558
Radial Tires (standard) ......................................................................................................................... 59/80 R63

Rock Service, Deep Tread ......................................................................................................................Tubeless
Rims, standard 5 piece............................................................................................... Rated to 827 kPa (120 psi)
Weight Distribution A.2-0000072560
Empty Vehicle
Front Axle (46.7%)........................................................................................................... 122 662 kg (270,423 lb)
Rear Axle (53.3%) ........................................................................................................... 139 741 kg (308,077 lb)
Total ................................................................................................................................. 262 403 kg (578,500 lb)
Standard Komatsu Body...................................................................................................... 42 638 kg (94,000 lb)
Standard Tire Weight........................................................................................................... 32 585 kg (71,838 lb)
Loaded Vehicle
Front Axle (32.8%)........................................................................................................... 205 489 kg (453,025 lb)
Rear Axle (67.2%) ........................................................................................................... 419 788 kg (925,475 lb)
Total .............................................................................................................................. 625 839 kg (1,378,500 lb)
Nominal Payload* ............................................................................................................ 362 874 kg (800,000 lb)

NOTE: All weights shown with 50% fuel load.
*Nominal payload is defined by Komatsu America Corporation’s payload policy documentation. In general,
the nominal payload must be adjusted for the specific vehicle configuration and site application. The figures
above are provided for basic product description purposes. Please contact your Komatsu distributor for specific
application requirements.
Overall Truck Dimensions A.1-0000072559
(Empty With Standard Body)
Length .................................................................................................................................... 15.7 m (51 ft. 6 in.)

Width .................................................................................................................................... 10.0 m (32 ft. 10 in.)
Height with Canopy .................................................................................................................. 8.0 m (26 ft. 3 in.)
8-4 980E-4
Height with Dump Body Up .................................................................................................... 15.0 m (49 ft. 2 in.)
980E-4 8-5
8-6 980E-4
RADIO
980E-4 9-1
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX
PLAYER RADIO
AM/FM RADIO / CD / MP3 / USB /
iPOD™ / AUX PLAYER A.2-0000073292
1. Phone/Bluetooth Button 10. SCAN/ASCN (Scan/Autoscan) Button

2. Digital Display 11. PREV (Previous) Button
3. CD Slot 12. DISP (Display) Button
4. Volume Knob/OK Button 13. ESC (Escape) Button/Preset 6 Button
5. SRC/PWR (Source/Power) Button 14. Random Button/Preset 5 Button
6. NEXT Button 15. Repeat Button/Preset 4 Button
7. Eject Button 16. Clock/Alarm Button/Preset 3 Button
8. USB Connection Port 17. Browse Button/Preset 2 Button
9. Auxiliary Jack Port 18. Play/Pause Button/Preset 1 Button
Figure 9-1 AM/FM RADIO / CD PLAYER
Phone/Bluetooth Button A.5-0000073230 2. CD-Rs (MP3 and unprotected WMA formats).

The Phone/Bluetooth button (1, Figure 9-1 AM/FM 3. CD-RWs (MP3 and unprotected WMA
RADIO / CD PLAYER, page 9-2) is used to pair a formats).
Bluetooth enabled device to the receiver. Paired
devices can be used to play music, podcasts or Volume Knob/OK Button A.2-0000073226
audiobooks through the cab’s stereo system.
The Volume Knob/OK Button (4) is used to control the
NOTE: The receiver can be paired to a phone, but volume of the receiver and to access the Audio Control
hands-free calling is not supported. and User menus.
The volume is raised by turning the Volume Knob/OK
Digital Display A.2-0000073228
Button clockwise, and lowered by turning the Volume
The Digital Display (2) displays information about Knob/OK Button counterclockwise.
the radio, such as radio frequency band (AM, FM,
Press the Volume Knob/OK Button for less than three
WX), radio station frequency, source type, and track
seconds to access the Audio Control menu. Press the
information. The Digital Display also displays menu
Volume Knob/OK Button for more than three seconds
information and any error messages that may occur
to access the User menu.
while operating the radio.
While in the Audio Control and User menus, the
CD Slot A.2-0000073227 Volume Knob/OK Button is used to select options and
make changes. Refer to the Audio Control menu and
The CD Slot (3) is used to add or remove CDs to the
User menu sections for more information.
receiver. The receiver is able to play:
1. Most audio CDs.
9-2 980E-4
AM/FM RADIO / CD / MP3 / USB / iPOD™
RADIO / AUX PLAYER
SRC/PWR (Source/Power) Eject Button A.2-0000073223
Button A.2-0000073225 The Eject Button (7) is used to eject a CD from the
The SRC/PWR (Source/Power) button (5) is used to receiver.
turn the receiver on and off and to change the audio
source. The audio source cycles in the following USB Connection Port A.2-0000073222
order:
The USB Connection Port (8) is used to connect an
1. FM1 (first six preset FM stations) iPod, USB mass storage device or USB MP3 player
to the receiver.
2. FM2 (second six preset FM stations)
The USB Connection Port also provides up to 1 amp
3. AM
of power. Any device that requires less than 1 amp
4. Weatherband/WX (USA Only) of power will be charged while connected to the USB
Connection Port.
5. CD
6. USB/iPod Auxiliary Jack Port A.2-0000073221
7. Front Auxiliary The Auxiliary Jack Port (9) is used to connect an iPod
8. Rear Auxiliary or USB MP3 player to the receiver using a standard
3.5mm (0.125 in) stereo cable.
9. Bluetooth
To turn the receiver off, press and hold the SRC/PWR SCAN/ASCN (Scan/Autoscan)
button. To turn the receiver on or to switch the audio Button A.2-0000073240
source, press the SRC/PWR button. The SCAN/ASCN Button (10) is used to scan radio
NOTE: With the key switch OFF, receiver can still stations, CD tracks, and MP3/WMA files and folders.
be turned on by pressing the SRC/PWR button. The SCAN/ASCN Button is also used to automatically
The receiver stays on until the SRC/PWR button is scan for the strongest radio stations available.
pressed and held again, or until one hour elapses, When using a USB, iPod or the CD player, this button
whichever comes first. is used to scan through all playable files on the
selected device. Press the SCAN/ASCN Button to
NEXT Button A.3-0000073224 skip to the next file. The file plays for eight seconds,
The NEXT Button (6) is used to select the next track then the receiver skips to the next file.
or station. It can also be used to skip audio files or fast Pressing and holding the SCAN/ASCN Button starts
forward through the current track. at the first file on the selected device instead of at the
There are two radio playback configurations for the currently playing file. The file plays for eight seconds,
NEXT Button, SEEK and Fast Forward (FF), which are then the receiver skips to the next file.
set through the User menu.
PREV (Previous) Button A.3-0000073239
If playback is set to SEEK, the radio will:
The PREV (Previous) Button (11) is used to select the
• skip to the start of the next file when the NEXT prior track or station. It can also be used to skip audio
Button is short pressed. files or rewind to the beginning of the current track.
• fast forward through the current file when the NEXT There are two radio playback configurations for the
button is long pressed. The fast forward is stopped PREV Button, SEEK and Fast Reverse (FR), which
when the NEXT Button is released. are set through the User menu.
If playback is set to FF, the radio will: If playback is set to SEEK, the radio will:
• fast forward through the current file when the NEXT • skip to the start of the previous file (if the current file
Button is short pressed. The fast forward is stopped has been playing for less than ten seconds) when
when the NEXT Button is pressed again. the PREV Button is short pressed.
• skip to the start of the next file when the NEXT • skip to the start of the current file (if the current file
Button is long pressed. has been playing for longer than ten seconds) when
the PREV Button is short pressed.
980E-4 9-3
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX
PLAYER RADIO
• reverse through the current file when the PREV When using a USB, iPod or the CD player, this button
Button is long pressed. The reverse is stopped plays files on the available device in shuffle mode.
when the PREV Button is released. Pressing the RDM Button again stops shuffle.
If playback is set to FR, the radio will:
RPT (Repeat) Button A.2-0000073235
• reverse through the current file when the PREV
The RPT (Repeat) Button (15) is used to set the track
Button is short pressed. The reverse is stopped
currently playing on repeat. The RPT icon illuminates
when the PREV Button is pressed again.
on the digital display (2) when active. Press the RPT
• skip to the start of the previous file (if the current file Button again to cancel repeat play.
has been playing for less than ten seconds) when
When using a USB, iPod or the CD player, this button
the PREV Button is long pressed.
sets the file currently playing on repeat. Pressing the
• skip to the start of the current file (if the current file RPT Button again cancels repeat play.
has been playing for longer than ten seconds) when
the PREV Button is long pressed. Clock/Alarm Button A.2-0000073234
The Clock/Alarm Button (16) is used to turn off an

DISP (Display) Button A.2-0000073238
alarm set from the Audio Control menu.
The DISP (Display) Button (12) is used to change
the source display view. Pressing the DISP Button Browse Button A.2-0000073233
for more than three seconds shows the clock for a
short time. With the key switch OFF, press the DISP The Browse Button (17) is used to navigate on USB
Button to turn on the radio and show the clock for a sticks, CD MP3 discs, and iPods and select a specific
few seconds. song or play context.
ESC (Escape) Button A.2-0000073237

Play/Pause Button A.2-0000073232
The ESC (Escape) Button (13) is used to exit the The Play/Pause Button (18) is used to pause or
current menu and return to the previous menu. unpause current media.
RDM (Random) Button A.2-0000073236

Preset Buttons A.2-0000073231
The RDM (Random) Button (14) is used to play the The Preset Buttons (13-18) are used to set and access
tracks in shuffle mode. The receiver will play songs preset stations 1 thru 6 for each frequency band (FM1,
in random from the currently available list. The RDM FM2, AM, and WX).
icon illuminates on the Digital Display (2) when active.
Press again to stop shuffle mode.
9-4 980E-4
RADIO GENERAL FEATURES
GENERAL FEATURES A.2-0000073250 Bluetooth Pairing A.2-0000073248
Audio Sources A.2-0000073249 The receiver can be paired to a Bluetooth-enabled

device, such as an iPod or phone. Paired devices
The receiver is capable of playing AM, FM, and can be used to play music, podcasts or audiobooks
WX (USA only) radio stations. Audio can also be through the cab’s stereo system.
played from an iPod or other MP3 player, a mass
storage USB device, and from audio and MP3 CDs. NOTE: The receiver can be paired to a phone, but
Music from an iPod or other MP3 player or a mass hands-free calling is not supported.
storage USB device can be access through a wireless
A list of supported devices is located in the following
Bluetooth connection, a USB port, or a 3.5mm (0.125
web page:
in) audio jack.
http://www.panapacific.com/support
NOTE: It is not recommended to connect a device to
the receiver through more than one connection at a Other devices may be connected and played but
time, as the device may not function correctly (e.g., functionality cannot be guaranteed.
connecting an MP3 player through both the USB and
audio-jack, or connecting a Bluetooth-enabled iPod You can connect up to 10 devices to the radio; the
through Bluetooth pairing and the USB, at the same radio will connect to the first available paired device,
time). starting from the last paired/connected device.
980E-4 9-5
RADIO OPERATION RADIO
RADIO OPERATION A.2-0000073247 The receiver starts at the current radio

frequency and begins searching for the next
Tuning A.2-0000073246 tunable station. When a station is found, the
The radio has two tuning configurations, MANUAL receiver stays on the station for eight seconds,
and AUTO, which are set through the User menu. and then continues on to find the next available
frequency.
If tuning is set to MANUAL, the radio will:
NOTE: If a tunable station is not found the radio will
1. perform manual tuning when the NEXT or display “NO STATION FOUND”.
PREV buttons are short pressed.
3. Press the SCAN/ASCN button again to stop the
2. perform seek tuning when the NEXT or PREV scan.
buttons are long pressed.
The receiver stops scanning and stays tuned
If tuning is set to AUTO, the radio will: to the station that was playing when the SCAN/
ASCN button was pressed.
1. perform seek tuning when the NEXT or PREV
buttons are short pressed.
Performing an Autoscan A.2-0000073243
2. perform manual tuning when the NEXT or
PREV buttons are long pressed. 1. Press the SRC/PWR Button (5) to access the
radio to the desired frequency band (FM1,
Manual tuning increases the frequency by one step FM2, AM or WX).
(0.2 MHz in FM mode, 10kHz in AM mode, and 25
The desired frequency band is shown on the
kHz in WX mode). Seek tuning finds the next tunable
left hand side of the display.
station.
2. Press and hold the SCAN/ASCN button (10)
NOTE: If a tunable station is not found the radio will
until the receiver beeps.
display “NO STATION FOUND”.
The autoscan begins and the “AUTO SCAN”
Scanning A.2-0000073245 icon blinks on the Digital Display (2).
The receiver is capable of two bands of scanning; When the autoscan finishes the receiver tunes
regular scan and autoscan. the radio to the station stored in Preset 1. The
“AUTO SCAN” icon will stay illuminated while
The regular scan cycles through all radio frequencies the mode is active.
and stops when a tunable station is found.
3. Press any of the six Preset buttons (13-18) to
The autoscan finds and temporarily stores the access the six stations stored by the autoscan.
strongest six stations found on the current frequency
band. These presets are stored in the six Preset 4. To exit autoscan mode, perform any of the
buttons (13-18) until the radio is turned off or the following actions:
source is changed. a. Press and hold the SCAN/ASCN button.
NOTE: Autoscan does not store the frequencies on b. Press the SRC/PWR button.
the presets in numerical order; they are stored based
on the order in which they were found and on the c. Turn power off to the radio.
quality of the frequency. The “AUTO SCAN” icon de-illuminates on the
display and the presets are set back to their
Performing a Regular Scan A.2-0000073244 prior stations.
1. Press the SRC/PWR Button (5) to access the
radio to the desired frequency band (FM1, Station Presets A.2-0000073260
FM2, AM or WX). The receiver is capable of storing six AM preset
The desired frequency band is shown on the stations, twelve FM preset stations (FM1 and FM2),
left hand side of the display. and six WX preset stations. The preset stations are
accessed by pressing one of the six Preset buttons
2. Press but do not hold the SCAN/ASCN button (13-18).
(10).
9-6 980E-4
RADIO RADIO OPERATION
Storing Radio Station Presets A.2-0000073259 Tuning Radio Station Presets A.3-0000073258
1. Press the SRC/PWR Button (6) to access the 1. Press the SRC/PWR Button (5) to access the
radio to the desired frequency band (FM1, radio to the desired frequency band (FM1,
FM2, AM or WX). FM2, AM or WX).
The desired frequency band is shown on the The desired frequency band is shown on the
left hand side of the display. left hand side of the Digital Display (2).
2. Tune the radio to the desired frequency. 2. Press and release the desired Preset Button
(13-18).
3. Press and hold the desired Preset button
(13-18) until the radio produces a beep. The receiver tunes to the frequency stored by
the Preset Button that was pressed.
The frequency is stored in the receiver's
memory.
980E-4 9-7
CD OPERATION RADIO
CD OPERATION A.2-0000073257 Playing a CD A.2-0000073229
Using the CD Player A.2-0000073256 Use the following procedure to play a CD:
The CD player in the receiver is able to play: 1. Press the SRC/PWR Button (5) to select CD.
• Most audio CDs. CD is shown on the Digital Display (2).
• CD-Rs (MP3 and unprotected WMA formats). 2. Insert the CD into the CD Slot (3), label side up.
• CD-RWs (MP3 and unprotected WMA formats). The CD player pulls the CD into the receiver
and the CD begins playing.
NOTE: When playing any CD, CD-R, or CD-RW, the
sound quality can be reduced due to disc quality, the The receiver shows the track number, Song,
method of recording, the quality of the music that has Artist, elapsed time, and Album information on
been recorded, or the way the disc has been handled. the Digital Display, when available.
3. Use the NEXT Button (6), SCAN/ASCN Button
(10), PREV (Previous) Button (11), RDM
• Do not use damaged or warped CDs in the (Random) Button (14), RPT (Repeat) Button
CD player. Damaged CDs can cause skipping, (15), and Play/Pause Button (18) to control the
difficulty in finding tracks, and/or difficulty in track being played as needed. Refer to the
loading and ejecting the CD. description and operation of each button for
more information.
To avoid damage to the CD player:
Ejecting a CD A.2-0000073255
• Do not use scratched or damaged CDs.
To eject a CD, press the Eject Button (7). The CD is
• Do not apply labels to CDs, as the labels can get ejected partially from the CD Slot (3).
caught in the player. Use a marking pen to label the
top of the CD. NOTE: If the CD is not removed within a short period
of time, the CD is automatically pulled back into the
• Insert only one CD at a time. player.
• Keep the loading slot free of foreign materials,
liquids, and debris.
9-8 980E-4
RADIO IPOD OPERATION
IPOD OPERATION A.2-0000073254 Accessing iPod Menus A.2-0000073251
iPod Support A.2-0000073253 The receiver can access various menus on a

connected iPod, allowing the user to control what files
The receiver supports the following iPod Models: to play. Each menu contains a list of items that can be
• iPod Classic (6th generation) played, depending on which menu is being accessed.
• iPod Nano (6G) The following menus are available from a connected
iPod:
• iPod Touch (4G)
• Playlists
• iPhone (3G, 3GS, 4, and 4S)
• Artists
NOTE: Other iPods may be played, but functionality
is not guaranteed. • Albums
There may be problems with the operation and • Genres

function of an iPod in the following situations: • Podcasts
• When connecting an iPod with a version of the • Songs
firmware installed that is more recent than receiver
supports. • Composers
• When connecting an iPod with firmware installed • Audio Books

from other providers. NOTE: If the iPod is an unsupported model, it can
When an iPod is connected to the USB port, the iPod still be listened to in the vehicle by connecting to
battery recharges automatically while the vehicle is the Auxiliary Jack Port (9) using a standard 3.5mm
on. When the vehicle is turned off, the iPod shuts off (0.125 in) stereo cable. Refer to the Auxiliary Device
and stops charging. Operation section for more information.
To access an iPod menu from the receiver, perform
Connecting an iPod A.2-0000073252 the following steps:
1. Connect one end of the standard iPod USB 1. Press the Browse button (17) while an iPod is
cable to the iPod's dock connector. connected through the USB Connection Port
2. Connect the other end of the cable to the USB (7).
Connection Port (8). 2. Use the NEXT Button (6) and PREV button (11)
The receiver switches the source to USB/iPod to navigate through the different menus.
and starts playing the music on the iPod The menus available are shown one at a time
through the stereo. on the Digital Display (2).
The receiver shows the track number, song, 3. Press the Volume Knob/OK Button (4) to select
artist, elapsed time, and Album information on the menu shown on the Digital Display.
the Digital Display (2), when available.
4. Use the NEXT Button (6) and PREV button (11)
NOTE: If the iPod is an unsupported model, it can to navigate through the selected list.
still be listened to in the vehicle by connecting to
the Auxiliary Jack Port (9) using a standard 3.5mm The items available through the selected menu
(0.125 in) stereo cable. Refer to the Auxiliary Device are shown one at a time on the Digital Display
Operation section for more information. (2).
5. Press the Volume Knob/OK Button (4) to select
the item shown on the Digital Display.
The selected list or item begins playing.
980E-4 9-9
USB DEVICE OPERATION RADIO
USB DEVICE OPERATION A.2-0000073270 the top level of the drive. The receiver can read up to
four levels of sub-folders in each top level folder, for a
Supported USB Devices A.2-0000073269 total of five levels.
The receiver is capable of playing files from a USB The receiver can also only see the first 255 files in
MP3 player or a USB mass storage device. The each folder, and is capable of reading a maximum
receiver is only capable of playing from devices that of 1,000 files on the device. Files and folders above
are formatted using FAT16, FAT32, NTFS, or HFS+. these numbers cannot be accessed.
Other drive formats cannot be accessed.
To access different folders on a USB MP3 Player,
NOTE: The receiver can access portable hard drives USB mass storage device, or an MP3 CD, perform
that use only USB power, but are not supported. the following steps:
Supported File Types A.4-0000073268 1. Press the SRC/PWR Button (5) to set the
receiver to the desired file source (USB or CD).
The receiver is capable of playing unprotected MP3
and WMA files. The receiver can also access M3U 2. Press the Browse Button (17) to access the CD
and PLS playlist file types, allowing users to make MP3/USB Music menu.
playlists and play them back through the receiver. 3. Press the PREV (Previous) Button (11) and
MP3 files must meet the following requirements to be NEXT Button (6) or rotate the Volume Knob/
played: OK Button (4) to select Folder Mode.
Bit Rate: 32, 40, 48, 56, 64, 80, 96, 112, 124, 160, 4. Press the Volume Knob/OK Button (4).
192, 224, 256, or 320 kbps 5. Press the PREV (Previous) Button (11) and
Sampling Frequency: 32, 44.1 or 48 kHz NEXT Button (6) or rotate the Volume Knob/
OK Button (4) to move through the available
WMA Files must meet the following requirements to folders.
be played:
NOTE: The receiver does not display empty folders or
Version: 1, 2, 7, 8, 9 or 9.1 folders that contain only other folders.
Bit Rate: 32 to 320 kbps 6. Press the Volume Knob/OK Button (4) to
access the folder shown on the Digital Display
Sampling Frequency: 32 to 48 kHz (2).
Connecting a USB Device A.2-0000073267 The receiver plays the first valid track in the
selected folder.
1. For devices without a USB connector, connect
one end of the USB cable to the MP3 player or 7. Use the NEXT Button (6), SCAN/ASCN Button
USB storage device. (10), PREV (Previous) Button (11), RDM
(Random) Button (14), RPT (Repeat) Button
2. Connect the other end of the cable to the USB (15), and Play/Pause Button (18) to control the
Connection Port (8). track being played as needed. Refer to the
3. For devices with a USB connector, connect the description and operation of each button for
USB MP3 player or USB storage device to the more information.
USB Connection Port (8).
Accessing USB Playlists A.2-0000073265
The receiver switches the source to USB/iPod
and starts playing the music on the USB device The receiver is capable of playing M3U and PLS
through the stereo. playlists stored on a USB MP3 Player, USB mass
storage device, or on an MP3 CD.
The receiver shows the track number, song,
artist, elapsed time, and Album information on To access playlists on a USB MP3 Player, USB
the Digital Display (2), when available. mass storage device, or on an MP3 CD, perform the
following steps:
Accessing USB Folders A.2-0000073266
1. Press the SRC/PWR Button (5) to set the
Separate folders can be accessed on a USB MP3 receiver to the desired file source (USB or CD)
Player, USB mass storage device, or on an MP3 CD.
2. Press the Browse Button (17) to access the CD
The receiver is limited to reading the first 8 folders on
MP3/USB Music menu.
9-10 980E-4
RADIO USB DEVICE OPERATION
3. Press the PREV (Previous) Button (11) and To start a scan, perform the following steps:
NEXT Button (6) or rotate the Volume Knob/
1. Press the SRC/PWR Button (5) to access the
OK Button (4) to select Playlist Mode.
radio to the desired file source (USB or CD).
4. Press the Volume Knob/OK Button (4).
2. To perform a scan of the currently access folder
The first playlist available is shown on the or playlist, Press the SCAN/ASCN Button (10).
Digital Display (2).
The receiver starts at the file currently playing.
5. Press the PREV (Previous) Button and NEXT The receiver stays on the file for eight seconds,
Button or rotate the Volume Knob/ OK Button and then continues on to find the next available
to move through the available playlists. file.
6. Press the Volume Knob/OK Button to access 3. To perform a scan of the entire device being
the playlist shown on the Digital Display. accessed, press and hold the SCAN/ASCN
Button until the receiver beeps.
The receiver plays the first valid track in the
selected playlist. The receiver starts at the first track available on
the entire device file. The receiver stays on the
7. Use the NEXT Button, SCAN/ASCN Button
file for eight seconds, and then continues on to
(10), PREV (Previous) Button, RDM (Random)
find the next available file.
Button (14), RPT (Repeat) Button (15),
and Play/Pause Button (18) to control the 4. Press the SCAN/ASCN button again to stop the
track being played as needed. Refer to the scan.
description and operation of each button for
The receiver stops scanning and stays tuned
more information.
to the song that was playing when the SCAN/
ASCN button was pressed.
Scanning a USB Device A.2-0000073264
The receiver can scan files on a USB MP3 Player,

USB mass storage device, or on an MP3 CD. The
receiver can scan the currently accessed folder or
playlist, or can scan the entire device being accessed.
980E-4 9-11
AUXILIARY DEVICE OPERATION RADIO
AUXILIARY DEVICE NOTE: The rear auxiliary source is always available,

OPERATION A.2-0000073263 but the front auxiliary source is only available if an item
is connected through the Auxiliary Jack Port.
The receiver has two auxiliary connections, the
Auxiliary Jack Port (9) in the front and one in the rear. NOTE: Devices connected through the auxiliary
The connections allow other devices to be connected ports cannot be controlled through the receiver. The
through the receiver to use the speaker system, receiver can only be used to change the source to
such as iPods or MP3 payers that are not supported and from the auxiliary ports and to adjust the volume.
through a USB connection.
Devices can be connected to the receiver using
a standard 3.5mm (0.125 in) stereo cable. Both
auxiliary connections are accessed by pressing the
Source/Power Button (5).
9-12 980E-4
RADIO BLUETOOTH OPERATION
BLUETOOTH OPERATION A.2-0000073262 The Bluetooth Menu is shown on the Digital

Display (2).
Bluetooth Menu A.2-0000073261
3. Rotate the Volume Knob/OK Button (4) until the
The Bluetooth Menu is used to perform functions Digital Display shows “ADD PHONE”.
related to using the Bluetooth system, such as
enabling and disabling Bluetooth functionality, 4. Press the Volume Knob/OK Button.
adding and removing devices, and connecting or The Digital Display shows “ADDING PH” and
disconnecting a previously added device. the Bluetooth icon blinks.
The Bluetooth Menu is accessed by pressing the 5. On the device being connected to the receiver,
Phone/Bluetooth button (1) for more than 3 seconds. look for a Bluetooth-enabled device named
The Volume Knob/OK Button (4) is used to navigate “Delphi500 Radio.”
through the Bluetooth Menu.
6. Use the device to connect to the receiver.
Enabling/Disabling Bluetooth A.2-0000073280
When appropriate, use the four-digit PIN
“0000” to complete the connection.
To enable or disable Bluetooth on the receiver:
Refer to the device’s manual for more
1. Press the Phone/Bluetooth button (1) for more information on pairing the device.
than 3 seconds.
When the device is successfully paired with
The Bluetooth Menu is shown on the Digital the receiver, the Digital Display shows “PH
Display (2). CONNECTED” and then the name of the
connected device. The Phone icon illuminates
2. Rotate the Volume Knob/OK Button (4) until
on the Digital Display as well.
the Digital Display shows “BT Disable” or “BT
Enable”, depending on which option is needed. NOTE: The receiver will attempt to find a device to pair
3. Press the Volume Knob/OK Button to enable or to for three minutes after the add phone procedure
disable the Bluetooth. is started. If no Bluetooth-Enabled device is found
during the paring process, the Digital Display will show
If Bluetooth is disabled, any currently “NO PH FOUND” the Phone and arrows icons will
connected Bluetooth devices are disconnected de-illuminate.
from the receiver.
7. Press the ESC Button (13) to exit the Bluetooth
If Bluetooth is enabled, the receiver attempts to menu.
reconnect with any previously paired Bluetooth
devices. The receiver attempts to reconnect Deleting Previously Paired
with each devices in order three times before Devices A.2-0000073278
moving to the next device. The Phone Icon
illuminates and arrow icons blink on the Digital Use the following procedure to delete one or all
Display while reconnection is being attempted. previously paired devices
4. Press the ESC Button (13) to exit the Bluetooth 1. Press the Phone/Bluetooth button (1) for more
menu. than 3 seconds.
The Bluetooth menu is shown on the Digital
Pairing a Bluetooth Device A.2-0000073279 Display (2).
To pair a device to the receiver: 2. Rotate the Volume Knob/OK Button (4) until the
1. Verify Bluetooth is enabled on the receiver and Digital Display shows “DELETE PH”.
the device. The Bluetooth Menu is shown on the Digital
Refer to Enabling/Disabling Bluetooth for Display (2).
information on enabling Bluetooth on the 3. Press the Volume Knob/OK Button.
receiver.
A list of all previously connected devices are
Refer to the device’s manual for more shown one at a time on the Digital Display.
information on enabling Bluetooth on the
device. 4. Rotate the Volume Knob/OK Button until the
device to be deleted is shown. Alternately,
2. Press the Phone/Bluetooth button (1) for more
than 3 seconds.
980E-4 9-13
BLUETOOTH OPERATION RADIO
select “DELETE ALL” to delete all paired The Digital Display shows CONNECTING
devices stored in the receiver. while attempting to connect to the device.
When the device is successfully connected
The Digital Display shows “ADDING PH” and
with the receiver, the Digital Display shows
the Bluetooth icon blinks.
“PH CONNECTED” and then the name of the
5. Press the Volume Knob/OK Button. connected device. The Phone Icon illuminates
on the Digital Display as well.
The Digital Display shows “PH DELETED” and
the device(s) can no longer be connected to the 6. Press the ESC Button (13) to exit the Bluetooth
receiver. menu.
menu. Disconnecting a Device A.2-0000073276
Use the following procedure to disconnect a device

Connecting a Device A.2-0000073277 currently connected to the receiver.
Use the following procedure to connect a previously 1. Press the Phone/Bluetooth button (1) for more
paired device. than 3 seconds.
1. Press the Phone/Bluetooth button (1) for more The Bluetooth menu is shown on the Digital
than 3 seconds. Display (2).
The Bluetooth menu is shown on the Digital 2. Rotate the Volume Knob/OK Button (4) until the
Display (2). Digital Display shows “DISCONNECT PH”.
2. Rotate the Volume Knob/OK Button (4) until the 3. Press the Volume Knob/OK Button.
Digital Display shows “CONNECT PH”.
The Digital Display shows “DISCONNECT
3. Press the Volume Knob/OK Button. PH” for a short time. Once the device
is disconnected the radio will display
A list of all previously connected devices are
DISCONNECTED and then the device’s name.
shown one at a time on the Digital Display.
The Phone icon de-illuminates on the Digital
4. Rotate the Volume Knob/OK Button (4) until the Display as well.
Digital Display shows the name of the device
being connected.
menu.
5. Press the Volume Knob/OK Button.
9-14 980E-4
RADIO RECEIVER SYSTEM SETTINGS
RECEIVER SYSTEM 4. FADE

SETTINGS A.2-0000073275 5. BALANCE
The receiver contains two menus of user-adjustable 6. AUTO EQ
settings:
• Audio Control Menu Bass
• User Menu The bass is used to adjust the level of the bass
sounds. The levels range from -6 to +6. The Digital
Display (2) shows “BASS” and its current setting
AUDIO CONTROL MENU A.2-0000073274
when selected.
The Audio Control menu is used to adjust the bass,
middle, treble, fade, and balance and to set the Middle
equalizer (EQ) automatically. The Audio Control
menu is also used to set the clock time and format The middle is used to adjust the level of the mid-range
and to set alarms. sounds. The levels range from -6 to +6. The Digital
Display shows “MIDDLE” and its current setting when
The Audio Control menu is accessed by pressing selected.
the Volume Knob/OK Button (4) for less than three
seconds when the receiver is not already in another Treble
menu.
The treble is used to adjust the level of the treble
sounds. The levels range from -6 to +6. The Digital
Adjusting Audio Settings
Display shows “TREBLE” and its current setting when
1. Press the Volume Knob/OK Button (4) for less selected.
than two seconds when the receiver is not
already in another menu. Fade
The Digital Display shows “BASS” and the The fade is used to adjust the amount of sound going
current bass setting. to the front and rear speakers. The amount of sound
2. Rotate the Volume Knob/OK Button to find the ranges from F15 to R15. The Digital Display shows
desired option. “FADE” and its current setting when selected.
3. Once the desired option is shown, press the NOTE: Fade is not available in systems with only two
Volume Knob/OK Button to select that option. speakers or when the receiver is set to two channel
configuration.
4. Rotate the Volume Knob/OK Button to change
the currently displayed audio option. Balance
5. Once the option is changed to the desired The balance is used to adjust the amount of sounds
setting, press the Volume Knob/OK Button to going to the left and right speakers. The amount of
exit from the option and return to the Audio sound ranges from L15 to R15. The Digital Display
Control menu. shows “BALANCE” and its current setting when
6. Continue using the Volume Knob/OK Button to selected.
make changes to other options, as needed.
Auto EQ
7. Once all desired settings have been adjusted,
press the ESC Button (13) to exit the Audio The auto EQ is used to adjust the stereo equalizer
Control menu. (EQ) automatically to best match the selected audio
style. The Auto EQ Options are:
Audio Adjustment Options 1. Pop
The following options are available from the Audio 2. Rock
Control menu.
3. Country
1. BASS
4. News
2. MIDDLE
5. Jazz
3. TREBLE
6. Classical
980E-4 9-15
RECEIVER SYSTEM SETTINGS RADIO
7. Manual 2. Rotate the Volume Knob/OK Button until

“ALARM” is shown on the Digital Display.
The Digital Display shows “EQ” and its current setting Press the Volume Knob/OK Button to enter the
when selected. Alarm submenu.
Adjusting the Clock 3. Rotate the Volume Knob/OK Button until

“ALARM ON” is shown on the Digital Display.
1. Press the Volume Knob/OK Button (4) for less Press the Volume Knob/OK Button.
already in another menu. The current time is shown on the Digital Display
and the hours digit(s) begin to flash. The Alarm
The Digital Display (2) shows “BASS” and the icon also illuminates on the Digital Display.
current bass setting.
4. Rotate the Volume Knob/OK Button to adjust
2. Rotate the Volume Knob/OK Button until the hour shown. Press the Volume Knob/OK
“CLOCK” is shown on the Digital Display. Button to set the hour.
Press the Volume Knob/OK Button to enter the
Clock submenu. The minutes digits begin to flash on the Digital
Display.
3. Rotate the knob to change the clock format, if
desired. 5. Rotate the Volume Knob/OK Button to adjust
the minutes shown. Press the Volume
The time can be displayed in 12-hour and 24- Knob/OK Button to set the minutes.
hour format.
“SET TONE” is shown on the Digital Display.
4. Press the Volume Knob/OK Button to set the
clock format. 6. Rotate the Volume Knob/OK Button to change
between “SET TONE” and “SET MUSIC”.
The hour digit(s) begin to flash on the Digital Press the Volume Knob/OK Button to set the
Display. sound option.
5. Rotate the Volume Knob/OK Button to adjust “SET TONE” is used to play an alarm tone
the hour shown. Press the Volume Knob/OK through the speaker system. “SET MUSIC”
Button to set the hour. plays the last accessed audio source (radio,
The minutes digits begin to flash on the Digital CD player, etc.).
Display. 7. If “SET TONE” was selected, rotate the Volume
6. Rotate the Volume Knob/OK Button to adjust Knob/OK Button to select the volume level for
the minutes shown. Press the Volume the tone alarm.
Knob/OK Button to set the minutes. The tone alarm has three available option: low,
The time is now set and the receiver exits the mid, and high.
Clock submenu. 8. If “SET MUSIC” was selected, rotate the
7. Press the ESC Button (13) to exit the Audio Volume Knob/OK Button to select the volume
Control menu. level for the music alarm.
The music alarm can be set from 1 (lowest
Setting an Alarm possible volume level) to 30 (highest possible
The receiver can be used to set an alarm. The alarm volume level).
will play either and audio tone or audio from the last 9. Press the Volume Knob/OK Button to set the
accessed audio source (radio, CD player, etc.) at the alarm sound level.
selected time.
The alarm is now set and the receiver exits the
Use the following procedure to set an alarm. Alarm submenu.
1. Press the Volume Knob/OK Button (4) for less 10. Press the ESC Button (13) to exit the Audio
than two seconds when the receiver is not Control menu.
already in another menu.
The Digital Display (2) shows “BASS” and the
9-16 980E-4
RADIO RECEIVER SYSTEM SETTINGS
Canceling an Alarm The User menu is accessed by pressing the Volume

Knob/OK Button (4) for more than three seconds when
A previously set alarm can be canceled before the
the receiver is not already in another menu.
alarm is activated. Use the following procedure to
cancel and alarm.
Adjusting User Settings
1. Press the Volume Knob/OK Button (4) for less
1. Press the Volume Knob/OK Button (4) for less
The Digital Display (2) shows “BASS” and the
2. Rotate the Volume Knob/OK Button to find the
desired option.
2. Rotate the Volume Knob/OK Button until
3. Once the desired option is shown, press the
“ALARM” is shown on the Digital Display.
Volume Knob/OK Button to select that option.
Press the Volume Knob/OK Button to enter the
Alarm submenu. 4. Rotate the Volume Knob/OK Button to change
the currently displayed audio option.
3. Rotate the Volume Knob/OK Button until
“ALARM OFF” is shown on the Digital Display. 5. Once the option is changed to the desired
Press the Volume Knob/OK Button. setting, press the Volume Knob/OK Button to
exit from the option and return to the Audio
The alarm is now canceled and the receiver
Control menu.
exits the Alarm submenu.
6. Continue using the Volume Knob/OK Button to
4. Press the ESC Button (13) to exit the Audio
make changes to other options, as needed.
Control menu.
7. Once all desired settings have been adjusted,
Turning off or Snoozing an Activated press the ESC Button (13) to exit the User
Alarm menu.
When an alarm is set up, the alarm is triggered when User Adjustment Options
the time set for the alarm is reached. The receiver will
play an audio tone or music source, as directed when The following settings can be adjusted from the User
the alarm was set. menu.
An active alarm can be either turned off or postponed. 1. Speakers

To turn an active alarm off, press the Clock/ Alarm 2. Seek Sensitivity
Button (16).
3. Tune Configuration
To postpone an alarm, press any button on the
receiver except for the Clock/Alarm Button. The alarm 4. Playback Configuration
sound turns off, but will activate again nine minutes 5. Brightness
later. When the alarm activates again, the alarm can
be postponed again or turned off. 6. HUE Adjustment
NOTE: If no buttons are pressed, the alarm continues Speakers

to sound for 63 minutes and then automatically shuts
off. The speaker setting adjusts the number of audio
channels being used. There are two options available,
USER MENU A.2-0000073281 “2CH” (two channel) and “4CH” (four channel). Two
channel uses only the front speakers, while four
The User menu is used to adjust speaker channel uses the front and rear speakers. The Digital
configuration, sensitivity of radio frequency seeking, Display (2) shows “SPEAKERS” when this option is
tuning configuration, audio playback configuration, selected.
and the brightness and color setting of the Digital
Display (2).
980E-4 9-17
RECEIVER SYSTEM SETTINGS RADIO
Seek Sensitivity • skip to the start of the current file (if the current file
The seek sensitivity setting controls the sensitivity of
the PREV Button is short pressed.
the seek function when in any of the radio tuner modes
(FM1, FM2, AM and WX). A higher seek sensitivity • fast forward or reverse through the current file when
level typically finds more stations, but those stations the NEXT or PREV buttons are long pressed. The
may have weaker signals. A lower seek sensitivity fast forward or reverse is stopped when the NEXT
typically finds stations but those are the stations with or PREV Button is released.
the strongest signals in the area. The seek sensitivity
If playback is set to FAST F/F, the radio will:
can be set from -2 (lowest sensitivity) to +2 (highest
sensitivity). The Digital Display shows “SEEK SEN” • fast forward or reverse through the current file when
and the current sensitivity level when this option is the NEXT or PREV buttons are short pressed. The
selected. fast forward or reverse is stopped when the NEXT
or PREV Button pressed again.
Tune Configuration
• skip to the start of the next file when the NEXT
The tune configuration setting controls how the NEXT Button is long pressed.
Button (6) and PREV Button (11) function when in
• skip to the start of the previous file (if the current file
any of the radio tuner modes (FM1, FM2, AM and
has been playing for less than seconds) when the
WX). There are two options available, “MANUAL” and
PREV Button is long pressed.
“AUTO”.
• skip to the start of the current file (if the current file
If tuning is set to MANUAL, the radio will:
• perform manual tuning when the NEXT or PREV the PREV Button is long pressed.
buttons are short pressed.
The Digital Display shows “PLBK CFG” and the
• perform seek tuning when the NEXT or PREV current playback configuration when this option is
buttons are long pressed. selected.
If tuning is set to AUTO, the radio will:
Brightness
• perform seek tuning when the NEXT or PREV The brightness setting controls the brightness level of
buttons are short pressed. the Digital Display. This value can be adjusted from
• perform manual tuning when the NEXT or PREV -10 (very dim) to +10 (very bright). The Digital Display
buttons are long pressed. shows “DIMMING” and the current brightness value
when this option is selected.
The Digital Display shows “TUNE CFG” and the
current tuning configuration when this option is
HUE Adjustment
selected.
The HUE adjustment setting changes the color of the
Playback Configuration light in the Digital Display. Depending on the receiver
model, the following color options are available:
The playback configuration setting controls how the
NEXT Button and PREV Button function when playing • AMBER or GREEN
audio from the CD, USB/iPod, or Bluetooth source • RED or BLUE
modes. There are two options available, “SEEK” and
“FAST F/F”. NOTE: This option is only available on receiver
models equipped with a dual color system.
If playback is set to SEEK, the radio will:
The Digital Display shows “HUE ADJ” and the
• skip to the start of the next file when the NEXT currently selected color when this option is selected.
Button is short pressed.
• skip to the start of the previous file (if the current file
has been playing for less than seconds) when the
PREV Button is short pressed.
9-18 980E-4
RADIO TROUBLESHOOTING
TROUBLESHOOTING A.2-0000073291
Radio Troubleshooting A.3-0000073180
Problem Possible Cause Solution

Unable to tune into any radio Vehicle is in a weak signal area. Increase the seek sensitivity (refer
stations to the User Menu section for more
information).
CD Player Troubleshooting A.4-0000073179

“Disc Error” is shown on the The disc has an invalid or unknown Try burning the CD again with
Digital Display (2) or CD Player format. correctly formatted files.
Automatically Ejects CD
The disc is very hot. Try the disc again when the
temperature returns to normal.
The road is very rough. Try the disc again when the road
is smoother.
The disc is bent. Do not use CD in the CD player.
Continued use may cause damage
to CD player.
The air is very humid. Try the disc again later.
The disc is dirty, scratched, or wet. Carefully clean the CD and try
again.
The disc is inserted upside down. Eject the CD and try again the
correct direction.
There was a problem while burning Try burning the CD again.
the disc.
The label is caught in the CD Completely remove the label and
player. try again. Use a marker to label
CDs.
If problem continues, try another known good CD. If error message
continues, contact your dealer.
CD Player Not Functioning Temperature of the receiver is -20° Allow the vehicle’s interior
to 55°C (-4° to 131°F). temperature to adjust to within
normal operating parameters.
CD Insertion is not possible A CD is already on the CD player. Eject and remove CD before
attempting to insert new CD.
980E-4 9-19
TROUBLESHOOTING RADIO
iPod Troubleshooting A.3-0000073178

iPod does not play or there is no The iPod has not been recognized. Verify that the iPod is supported.
sound
• If the iPod is supported, reset the
The iPod does not respond to iPod and re-connect again (refer
commands from the receiver to the iPod Operation section for
UNSUPPORTED is shown on the iPod connected to receiver is not more information).
Digital Display supported. • If the iPod is not supported, use
the Auxiliary Jack Port (9) to
connect the iPod to the receiver.
NO MUSIC is shown on the Digital There are not any playable files in 1. Check to see if there are
Display the iPod. files on the iPod.
2. If there are files, then
files may not be playable.
Replace files and try again.
iPod Not Functioning Temperature of the receiver is -20° Allow the vehicle’s interior
to 55°C (-4° to 131°F). temperature to adjust to within
normal operating parameters.
USB Troubleshooting A.3-0000073177

UNSUPPORTED is shown on the USB device was not connected as Disconnect the device and try
Digital Display a mass storage device. again.
USB device connected has an 1. Check device’s file format
unsupported file format structure. structure.
2. If possible, re-format device
and try again. Refer to USB
Operation section for more
details.
Device is damaged 1. Verify device is working
properly.
2. If device is not damaged,
disconnect the device and
try again.
NO MUSIC is shown on the Digital There are not any playable files on 1. Check to see if there are
Display the USB. files on the USB device.
2. If there are files, then
files may not be playable.
Replace files and try again.
Refer to USB Operation
section for more details.
9-20 980E-4
RADIO TROUBLESHOOTING
Bluetooth Troubleshooting A.3-0000073176

Receiver does not recognize Device needs to be paired to Refer to the Bluetooth Operation
Bluetooth-enabled device receiver. section for details on pairing a
device. If device is already paired
with the receiver, delete the device
and pair it again.
Device is not turned on. Verify device is on.
Bluetooth is not enabled on Verify both receiver and device
receiver and/or device. have Bluetooth enabled. Refer to
the Bluetooth Operation section
for details on enabling Bluetooth.
Device is out of range. Move the device closer to the
receiver.
Device not communicating with Receiver may be connected to Verify receiver is connected to
receiver different Bluetooth device. correct device. Refer to the
Bluetooth Operation section for
details on connecting Bluetooth
devices.
Device requires receiver’s Refer to device’s manual for
passkey or passkey was entered information on entering a passkey.
incorrectly. Refer to the Bluetooth Operation
section for information on pairing a
device and for the correct passkey.
Device is close to other devices Move the device away from other
using radio frequencies (e.g. devices that use radio frequencies.
microwave oven, cordless phones,
802.11 wireless network)
Device’s music cannot be heard Device needs to be paired to Refer to the Bluetooth Operation
receiver. section for details on pairing a
device. If device is already paired
with the receiver, delete the device
and pair it again.
Device needs to be connected to Refer to the Bluetooth Operation
receiver. section for details on connecting
a device.
Receiver is not set to use Bluetooth Press the PWR/SRC Button (5) to
source. change the source to Bluetooth.
Volume on receiver is too low. Rotate the Volume Knob/OK
Button (4) to adjust the receiver’s
volume.
Device is paused. Verify device is not paused and try
again.
Device does not have any music Verify device has music files and
files. try again.
980E-4 9-21

980E Operation Manual

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980E Operation Manual

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CEAM030103

Operation & Maintenance

SERIAL NUMBERS 980E-4 A40003 – A40051

Copyright 2017 Komatsu

ABOUT THIS MANUAL F.2-0000051237

This material is proprietary to Komatsu America

It is the policy of the company to improve

Because of continuous research and

California Proposition 65 Warnings

The ALERT symbol is used with the following signal words:

NON-OEM PARTS IN CRITICAL SYSTEMS C.3-0000051235

Suggested Sources For Rust Preventive

STANDARD TIGHTENING Table 2-1

The following specifications apply to required

Example: M20 x 2.25

1/4-20 9.5 7 0.97 13.6 10 1.38

SAE Grade 9 Capscrews Standard Tightening Torque for SAE Hex

Tightening Torque For T-Bolt Type Hose

1. Shank Diameter (in) — Threads per inch

Split Flange Clamps

Flared Tube And Hose Fittings

Tightening Torque For Flared Tube And Hose Fittings

JIC 37° Swivel Nuts

Pipe Thread Fittings

With With Without Without

O-Ring Boss Fittings

O-Ring Face Seal Fittings

Fahrenheit Celsius Fahrenheit Celsius Fahrenheit

121 250 2 482 63 145 293 4 40 104

Know what to do in the event of a fire and keep phone

Precautions For High Temperature Fluids

2. Wait for the oil temperature to cool down. ROPS Precautions

PRECAUTIONS FOR TRUCK Mirrors, Windows, And Lights

Emergency Egress Ladders

1. Emergency Egress Latch

Figure 3-1 EMERGENCY EGRESS GATE

Traveling In Reverse Minimum Safe

Driving near high-voltage cables can cause electric

Dumping The Machine

EXTERIOR LIGHTING B.7-0000053605

1. Fog Lights 5. Deck Mounted Flood Lights

Figure 3-2 FRONT LIGHTS

Mirror Mounted Backup Lights Retard Light

1. Retard Light 3. Backup Alarm

Figure 3-3 REAR AXLE LIGHT BAR

1. Engine Shutdown Switch 4. Starter Disconnect Switch 7. LED Lights (On)

Figure 3-4 ISOLATION BOX ASSEMBLY (COVERS REMOVED)

• To avoid serious personal injury or death,

DURING MAINTENANCE G.26-0000051281

Always attach a warning tag to the control lever in the

Precautions With High Pressure Oil

When working with high pressure oil, obey the

Waste Materials Rim and tire maintenance can be hazardous unless

SPECIAL PRECAUTIONS F.25-0000051279

Preliminary Procedures Before Welding • Notify your Komatsu service representative,

PIN PLATE A.4-0000073410

A product identification plate is located on the frame

GRADE SPEED CHART A.1-0000072551

A grade/speed retard chart is located on the left

MACHINE SAFETY D.8-0000051326

Warning plates are mounted on the frame in front of,

Warning plates are attached to both the hydraulic tank

A caution decal is also attached to the door of the rear

This information decal is placed on the outside of the