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Komatsu HD325-8, Operation & Maintenance Manual

The Komatsu HD325-8 Operation & Maintenance Manual is a comprehensive guide that provides essential instructions for operating and maintaining this powerful heavy-duty dump truck. This useful manual is available for free download from our website, allowing users to access expert instructions and troubleshooting tips at their convenience.

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MACHINE OPERATIONS AND CONTROLS

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

METHOD FOR WALK-AROUND CHECK

Walk around the machine and look at the underside of chassis for anything unusual like loose bolts and nuts,
leakage of fuel, oil and coolant before starting the engine. Also check the condition of the work equipment and
the hydraulic system.
Check also for loose wiring, play of wiring, and accumulation of dust in places that get very hot and are exposed
to extremely high temperatures.

k

k

 WARNING

• Put the warning tag on the gear shift lever.
• Clean any flammable materials that accumulate around the machine in areas such as exhaust sys-

tem, battery, cooling system.

• Repair and clean any fuel and oil leaks. If there are any defects, consult your Komatsu distributor.
• Allow lamps to cool to touch before you perform maintenance.

 

If the machine is inclining, make it level before checking.
Always perform the following inspections and cleaning every day before starting the engine for the day's work.
1.

Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play.
Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and
perform the repairs if any problem is found.

2.

Remove dirt and debris from around the engine, battery, radiator, and aftercooler.
Check that there is no dirt or dust accumulated around the engine, radiator or aftercooler. Check also that
there is no combustible material (dry leaves, twigs, etc.) accumulated around the battery, or muffler, turbo-
charger, or other high-temperature parts of the engine. Remove any dirt or combustible materials that are
found.

3.

Check around the engine for coolant and oil leakage.
Check for oil leakage from the engine and coolant leakage from the cooling system. If any problem is found,
repair it.

4.

Check the fuel line for leakage.
Check for leakage of fuel or damage to the hoses and tubes. If any problem is found, repair it.

5.

Check DEF line for leakage.
Check DEF tank, pump, injector, and hoses and their connections for leakage. If any problem is found, ask
your Komatsu distributor for repair.

6.

Remove dirt from around the aftertreatment devices.
Check for dirt and combustible materials (dry leaves, twigs, etc.) accumulated around the aftertreatment de-
vices. If any dirt or combustible materials are found, remove them.

7.

Check around the aftertreatment devices for exhaust gas leakage.
Check the pipe connecting the turbocharger to the aftertreatment devices and also KDPF connections for
leakage of exhaust gas (and deposition of soot).
If any problem is found, ask your Komatsu distributor for repair.

8.

Check the hose to KCCV and the oil drain hose.
Check the hose to the KCCV and the oil drain hose for breakage and leakage.
If there is breakage or leakage, the emission standards are not satisfied. Ask your Komatsu distributor for
repair.

9.

Check around SCR for exhaust gas leakage.

OPERATION

MACHINE OPERATIONS AND CONTROLS

3-159

Summary of Contents for HD325-8

Page 1: ...injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual EENAM03582 WARNING ORIGINAL INSTRUCTIONS ...

Page 2: ......

Page 3: ...nuine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these recommendations could result in ineffective serv ice damage to the product or safety risks including personal injury or death 1 1 ...

Page 4: ...it at any time Keep it in the pocket behind the operator s seat If this manual is lost damaged or unreadable contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For the machine model name and the serial No see the machine serial No plate In order to arrange the prop er Operation and Maintenance Manual y...

Page 5: ...ing the processing of your personal data i e storage collection transfer etc of all information that relates to you as operator to the party with whom you have most direct relationship In principle this means that you should first and foremost refer to your employer if you are an employee or your customer if you are an independent contractor Komatsu Komatsu Europe Komatsu distributors and dealers ...

Page 6: ...ction 4 above For the purposes a to l as indicated in section 4 above as well as for the purpose of informing a third party in the context of a possible merger acquisition or demerger the processing of your personal data is necessary for our legitimate interests which in this case concern ensuring the safe and secure deployment of the machines preventing misuse and theft commercial interests which...

Page 7: ...at data b the processing is illegitimate or c the data are no longer needed for the pur poses which are outlined above but you need them to defend yourself in judicial proceedings You have the right to oppose the processing of personal data for the purposes a to l in section 4 but you are required to explain your particular circumstances on which your request for opposition is based As explained e...

Page 8: ... safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used...

Page 9: ... of the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 Sound power level emitted by the machine measured ac cording to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European directive 2000 14 EC This value includes an uncertainty of 2 0 dB...

Page 10: ...GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE The following guides can help an operator of this machine to reduce the whole body vibration levels 1 Use the correct equipment and attachments 2 Maintain the machine according to this manual Tire pressures for wheeled machines tension of crawler for crawler machines Brake and steering systems Controls hydraulic system and linkages 3 Keep the terrain whe...

Page 11: ...ng guidelines can be effective to minimize risks of low back pain Operate the machine only when you are in good health Provide breaks to reduce long periods of sitting in the same posture Do not jump down from the cab or machine Do not repeatedly handle and lift loads FOREWORD VIBRATION LEVELS 1 9 ...

Page 12: ... on the visibility standard ISO5006 and secures necessary visi bility To assist with job site organisation during use of this machine a visibility map is provided that shows an approxi mation of any masking to visibility between the 1 m rectangular boundary and the 24 m test circle Based upon the information supplied in the visibility map the site operator may wish to provide additional meas ures ...

Page 13: ...FOREWORD INTRODUCTION 1 11 ...

Page 14: ...l Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the reagent for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transpar...

Page 15: ...ON OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is provided on the front right of the machine The design of the nameplate varies according to the district LOCATION OF ENGINE NUMBER PLATE It is located on the upper left side of the engine cylinder block if you look from the fan side FOREWORD PRODUCT INFORMATION 1 13 ...

Page 16: ...DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU LTD 2 3 6 Akasaka Minato ku Tokyo 107 8414 Japan Authorised representative Address KOMATSU EUROPE INT Mechelsesteenweg 586 B 1800 Vilvoorde Belgium Distributor name Address Service personnel Phone Fax 566 93 8L620 HFC 134a GWP 1430 1 2 kg 1 72 t CO2 eq PRODUCT INFORMATION FOREWORD 1 ...

Page 17: ... B D F G H EI000001 A MACHINE DESIGNATION TYPE E ENGINE POWER B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER C YEAR OF CONSTRUCTION G MANUFACTURER D OPERATING MASS H AUTHORISED REPRESENTATIVE FOREWORD SERIAL PLATE 1 15 ...

Page 18: ...EUROPE INT Mechelsesteenweg 586 B 1800 Vilvoorde Belgium Declares that this machine HD325 8 HD405 8 Fulfils all the relevant provisions of following EC Directives Machinery Directive 2006 42 EC Electro Magnetic Compatibility Directive 2014 30 EU Outdoor Noise Directive 2000 14 EC amended by 2005 88 EC Radio Equipment Directive 2014 53 EU DECLARATION OF CONFORMITY FOREWORD 1 16 ...

Page 19: ...3 PRECAUTIONS BEFORE STARTING OPERATION 2 13 PREPARATIONS FOR SAFE OPERATION 2 13 PRECAUTIONS TO PREVENT FIRE 2 14 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 16 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 18 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 18 UNAUTHORIZED MODIFICATION 2 19 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 19 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 19 PRECAUTION...

Page 20: ...MENT 3 251 METHOD FOR CONTROLLING RADIO 3 252 DETERMINE AND MAINTAIN TRAVEL ROAD 3 256 TRANSPORTATION 3 257 PRECAUTIONS FOR TRANSPORTATION 3 257 SELECT TRANSPORTATION METHOD 3 257 METHOD FOR SECURING MACHINE 3 257 PRECAUTIONS FOR LIFTING MACHINE 3 257 COLD WEATHER OPERATION 3 261 COLD WEATHER OPERATION INFORMATION 3 261 PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 3 262 AFTER COLD WEATH...

Page 21: ...RE STARTING 4 38 EVERY 250 HOURS MAINTENANCE 4 39 EVERY 500 HOURS MAINTENANCE 4 49 EVERY 1000 HOURS MAINTENANCE 4 55 EVERY 2000 HOURS MAINTENANCE 4 69 EVERY 4000 HOURS MAINTENANCE 4 78 EVERY 4500 HOURS MAINTENANCE 4 81 EVERY 8000 HOURS MAINTENANCE 4 82 EVERY 9000 HOURS MAINTENANCE 4 83 EVERY 15000 HOURS MAINTENANCE 4 83 SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 SPECIFICATIONS HD325 8 5 2 SPECIFICATION...

Page 22: ...TS 7 3 CONSUMABLE PARTS LIST 7 3 RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 LUBRICATION CHART 7 4 METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 8 INDEX 8 1 TABLE OF CONTENTS FOREWORD 1 20 ...

Page 23: ...ase read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions strictly 2 1 ...

Page 24: ...rly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the safety labels see this manual or the actual label and place an order to your Komatsu distributor There are also other labels in addition to the warning s...

Page 25: ...LOCATION OF SAFETY LABELS SAFETY SAFETY LABELS 2 3 ...

Page 26: ...SAFETY LABELS SAFETY 2 4 ...

Page 27: ...rator s seat and when stopping engine caution for retarder oil temperature 9 Caution before operating caution when traveling in reverse caution for operating hoist control lever 10 Caution for handling battery cable 11 Caution against high temperature 12 Caution against falling 13 Caution for handling battery 14 Caution for parking brake 15 Prohibition of start by short circuiting This plate is fi...

Page 28: ...ng parts 09667 A0880 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance Caution when checking engine room 09667 A0880 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance MACHINE MODEL MAX MASS MODEL SERIAL No FOPS LEVEL No kg Lb ROPS FOPS CERTIFICATION This protective structure complies with the standard p...

Page 29: ...n opening hydraulic tank cap 09653 A0641 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool before removing cap Caution for handling suspension 09659 A0881 There is the hazard of explosion causing injury Do not disassemble the suspension make holes in it weld it cut it hit it roll it or bring it n...

Page 30: ...Always keep a safe dis tance from electric cables There is danger that the dump body may com down Before carrying out inspection or maintenance with the dump body raised always read the Operation and Maintenance Manual and take the correct action Always read the Operation and Maintenance Manual before carrying out operation maintenance disas sembly assembly or transportation of machine When leavin...

Page 31: ...injury or death Do the following before morning machine or its body Honk horn to alert people nearby Be sure no one is on near machine Use spotter if view is obstructed Follow above even if machine equipped with back up alarm and mirrors Be sure to lower dump body and keep hoist control lever at the float position during travel Caution for handling battery cable 09808 A1681 Sign indicates an elect...

Page 32: ...n against falling 09805 C0881 There is the hazard of falling Do not step here Caution for handling battery 09664 62A11 Never smoke or use any naked flame near the batteries no sparks Always wear protective eyeglasses when working with bat teries Keep children away from batteries Caution battery acid Read the operator s manual before working with batteries Caution explosive gases SAFETY LABELS SAFE...

Page 33: ...e engine only after sitting down in the operator s seat Do not attempt to start the engine by shot circuiting the en gine starting circuit Such an act may cause a serious bodi ly injury or fire Caution for blast site 09845 00480 Sign indicates an explosion hazard caused by active radio transmitter at a blast zone Keep machine at a safe distance from a blast zone and detonator SAFETY SAFETY LABELS ...

Page 34: ...amage or wear of the seat belt damage of the connecting brackets and tightness of bolts Adjust seat position to allow full brake pedal travel with op erator s back against seat back After adjusting seat position get off the seat and tighten the tether belts located between the floor and seat if equip ped Read Operation and Maintenance Manual Caution for electric shock 09804 10480 Sign indicate an ...

Page 35: ...PERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the safety related devices and use them properly Never remove any safety related devices Always keep them in good operating condition INSPECT MACHINE Check the machine before starting operations ...

Page 36: ...ire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such as flammable or explosive items into the operator s compartment PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Observe the following precautions to prepare for action if any serious personal injury or death o...

Page 37: ...l in the specified place and do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any flammable materials to a safe place before starting Fire caused by accumulation of combustible material Remove any dry leaves chips pieces of paper coal dust or any other combustible materials accumulated or affixed around the engine exhaust manifold muffler or b...

Page 38: ...nd steps marked by arrows B are for es caping in emergencies Use these only when escaping from the machine in a fire or other emergencies Always face the machine and maintain at least three point contact both feet and one hand or both hands and one foot with the handrails and steps to ensure that you sup port yourself Before getting on and off the machine check the handrails and steps if there is ...

Page 39: ...et gear shift lever 2 to NEUTRAL position N set parking brake switch 3 to PARKING posi tion then stop the engine If the control levers are touched by mistake there is danger that the machine may suddenly move and cause serious per sonal injury or death PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not taken when parking the machine the machine may suddenly move off by itself and th...

Page 40: ...ave erratically The warning buzzer may sound These effects do not signify a malfunction and the machine will return to normal as soon as the source of inter ference is removed DO NOT GET CAUGHT IN WORK EQUIPMENT The clearance in the area around the dump body changes ac cording to the movement of the dump body If you are caught this may lead to serious personal injury or death Do not allow anyone n...

Page 41: ...product failures physical loss or damage or influ ence on the environment resulting from modifications made without authorization from Komatsu Any modification made without authorization from Komatsu can create hazards Before making a modifica tion consult your Komatsu distributor Do not try to increase the capacity of the dump body or make any other modifications Such modifications will cause a d...

Page 42: ...s there is a hazard that the weight and vibration of the machine will cause the soil to collapse Before starting operations take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling DO NOT GO CLOSE TO HIGH VOLTAGE CABLES Do not drive or operate the machine near electric cables There is a hazard of electric shock which may cause serious personal injury or ...

Page 43: ...re you may fall and be injured Put proper stepladder or step on the level and firm ground and clean the camera in secure posture The rear view monitor is provided to secure the rear side visibility If however an obstacle is detected on the monitor you must confirm it with your eyes CHECK SIGNS AND SIGNALMAN S SIGNALS If signals and labels are not clear serious personal injury can result from downw...

Page 44: ...t up correctly Check the coolant level fuel level and oil level in engine oil pan check for clogging of the air cleaner and check for damage to the electric wiring Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal and check that the pedals work properly Adjust the operator s seat to a position where it is easy to perform operations and ...

Page 45: ... Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables When connecting a normal machine to a failed machine with the jumper cables always use the normal machine with the same battery voltage as the failed machine When starting the engine with the jumper cables perform the starting operation with 2 workers one worker sitting in the operator s seat a...

Page 46: ... sure to perform the above precautions even when the machine is equipped with mirrors and cam eras WHEN TRAVELING Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact Always observe the following Never turn the key in the starting switch to OFF position when the machine is traveling If the engine stops when the machine is traveling the st...

Page 47: ...n using the machine to prevent serious personal injury or death caused by the work equipment or by the machine tipping over due to overloading do not use the machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine When operating in tunnels or under bridges or under electric wires or in other places where the height is limited oper...

Page 48: ...m level ground Select a place where there is no hazard of landslides falling rocks or flooding When leaving the machine always lower the dump body completely lock with dump lever lock knob 1 set gear shift lever 2 to NEUTRAL position N set parking brake switch 3 to PARKING position then stop the engine Always close the operator s cab door and use the key to lock all the equipment in order to preve...

Page 49: ...e ramps If necessary drive off the ramps onto the ground correct the di rection then enter the ramps again When unloading to an embankment or platform make sure that it has suitable width strength and grade For machines equipped with a cab always lock the door after loading the machine To prevent the door from opening during transportation When it is necessary to remove handrails and steps take ca...

Page 50: ...ce clean the tidy to enable you to perform operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop the machine on a firm level ground Select a place where there is no hazard of landslides falling rocks or flooding ONLY AUTHORIZED PERSONNEL As long as mainte...

Page 51: ...f you are caught or pinched between the work equipment during operation or exposed to high temperature or high pressure liquids it is dangerous and may cause serious personal injury or death Always observe the fol lowing Stop the engine before performing any inspection and maintenance Lower the dump body set dump lever 1 to HOLD posi tion lock with dump lever lock knob 2 then stop the en gine Set ...

Page 52: ...hey may contact the rotating parts and break and be scattered It is dangerous If the automatic active regeneration of KDPF starts during maintenance work surroundings of KDPF become high temperature When performing the maintenance work stop the regener ation of KDPF Lower the dump body completely set dump lever 1 to HOLD position lock with dump lever lock knob 2 to pre vent the dump body from movi...

Page 53: ...ine hood and cover to prevent personal injuries from falling or failing over due to losing your footing PRECAUTIONS WHEN WORKING UNDER MACHINE Machine or dump body may fall and it is dangerous that seri ous personal injury or death may occur Always observe the fol lowing When performing inspection with the dump body raised al ways set the dump control lever to HOLD position set the lock knob to LO...

Page 54: ...ied person to perform welding HANDLE BATTERY Before inspecting or handling the battery turn the key in the starting switch to OFF position and check that the system operating lamp is off Then set the battery disconnect switch to OFF position and remove the switch key Danger of battery exploding When the battery is being charged flammable hydrogen gas is generated and may explode In addition the ba...

Page 55: ... the ground cable negative cable first When installing con nect the positive cable first then connect the ground Tighten the battery cable terminals securely Secure the battery firmly in the specified position WHEN USING HAMMER When using a hammer pins may come out or metal particles may be scattered It is dangerous and may cause serious personal injury or death Always observe the following When h...

Page 56: ...wear protective equipment such as protective eyeglasses and leather gloves High pressure oil leaking from small holes is dangerous that may penetrate your skin and cause loss of sight if it contacts your skin or eyes directly If a jet of high pressure oil hit your skin or eyes and suffer injury wash the place with clean water and consult a doctor immediately for medical attention PRECAUTIONS FOR H...

Page 57: ...les in it weld it nor use a cutting torch Do not hit or roll it or subject it to any impact Ask your Komatsu distributor when sealing gas into the cylinder or replacing gas from it When disposing of the accumulator the gas must be re leased Ask your Komatsu distributor to perform this work PRECAUTIONS FOR COMPRESSED AIR When performing cleaning with compressed air there is a hazard of serious pers...

Page 58: ...eat belt Replacement of the defined life parts See PERIODIC REPLACEMENT OF DEFINED LIFE PARTS The material of these components naturally changes over time and repeated use causes deterioration wear and fatigue As a result there is a hazard that these components may fail and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspecti...

Page 59: ...speed or operating under heavy load Never perform welding or light a fire near the tire Always release the inflation pressure from a tire prior to removing rim from tire Before removing the tire from the machine for repairs remove the valve partially to release the air from the tire gradually then remove the tire PRECAUTIONS FOR STORING TIRES Tires for construction equipment are extremely heavy it...

Page 60: ...on tainer for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is non flammable however i...

Page 61: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 62: ...ow beam 3 Headlamp high beam 4 Turn signal lamp 5 Dump body 6 Rear wheel 7 Hoist cylinder 8 Steering and hoist oil tank 9 Side lamp 10 Brake sub tank 11 Front suspension 12 Front wheel 13 Staircase lighting if equipped 14 Air cleaner 15 Fuel tank 16 Rear suspension GENERAL VIEW OPERATION 3 2 ...

Page 63: ... if equipped 7 Fog lamp switch 8 Machine monitor 9 Horn button 10 Steering wheel 11 Retarder control lever 12 Hazard lamp switch 13 Secondary steering switch 14 Front brake off switch 15 AISS LOW switch 16 Engine power mode selector switch 17 Starting switch 18 Accelerator pedal 19 Brake pedal 20 ARSC travel speed set lever 21 Steering tilt lock lever 22 Secondary brake pedal OPERATION GENERAL VIE...

Page 64: ...itch L H 26 Power window switch R H 27 Heated wire mirror switch if equipped 28 Dump lever 29 Dump lever lock knob 30 Rearview monitor brightness adjustment switch 31 Gear shift lever 32 Parking brake switch 33 Room lamp 2 switch 34 Room lamp 1 switch GENERAL VIEW OPERATION 3 4 ...

Page 65: ...10 Turn signal pilot lamp R H 11 Brake oil pressure caution lamp 12 Clearance lamp pilot lamp 13 Retarder oil temperature gauge 14 Retarder oil temperature caution lamp 15 Engine tachometer 16 Speedometer 17 Fuel level caution lamp 18 Fuel gauge 19 DEF level gauge 20 R H meter 21 L H meter 22 Torque converter oil temperature gauge 23 Torque converter oil temperature caution lamp 24 Air conditioner...

Page 66: ...ift lever position display 37 Automatic suspension mode pilot lamp if equip ped 38 Front brake off pilot lamp 39 Torque converter lockup pilot lamp 40 Preheating pilot lamp 41 Fan reverse rotation pilot lamp 42 Power mode display 43 Secondary steering pilot lamp 44 Aftertreatment devices regeneration pilot lamp 44 Aftertreatment devices regeneration disable pilot lamp 45 Payload meter display if e...

Page 67: ... C Maintenance time warning screen D Warning screen E User menu screen 46 ECO guidance 47 Maintenance time caution lamp 48 Guidance icon 49 Warning display 50 Seat belt caution lamp 51 Action level OPERATION GENERAL VIEW 3 7 ...

Page 68: ...ME Inside of cab 1 Open knob for cab door 2 Cab door inner lock 3 Rearview monitor 4 Magazine box 5 Cup holder 2 places 6 Drink box 7 Fuse 8 AUX 9 Lunch box tray 10 12 V power supply 11 Ashtray GENERAL VIEW OPERATION 3 8 ...

Page 69: ...Outside of cab 1 DEF injector 2 KDPF assembly 3 SCR assembly 4 Cab door handle 5 Fire extinguisher if equipped 6 DEF pump 7 DEF filter 8 DEF tank 9 Dust indicator OPERATION GENERAL VIEW 3 9 ...

Page 70: ...e Ventilation hereafter KCCV ventilator 11 Body pivot pin 12 Rearview camera 13 Circuit breaker 14 Fuse 15 Battery 16 Grease pump holder 17 Battery disconnect switch 18 System operating lamp 19 Toolbox GENERAL VIEW OPERATION 3 10 ...

Page 71: ...ngs of the displays EXPLANATION OF MACHINE MONITOR EQUIPMENT FF Failure display screen A Warning display B Pilot display C Meter display D Switch panel REMARK One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on the screen When there are fewer than 10 black or white spots this is not a failure or a de...

Page 72: ...nd then changes to the standard screen BB 3 The pointer of engine tachometer D swings once 4 Speedometer E displays 88 for 2 seconds 5 The alarm buzzer sounds for 2 seconds then stops under the normal condition NOTICE Consult your Komatsu distributor when either the lamps buzzers or the machine monitor does not function REMARK When the engine is started the battery voltage may suddenly drop depend...

Page 73: ...ngine does not start If the engine shutdown secondary switch 1 is turned off nor mal the machine monitor switches to the standard screen and the engine can be started with usual starting switch key operation BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION When the starting switch is turned to OFF position the screen goes out In the following cases the end screen is dis...

Page 74: ...ion function with SKIP is set the starting screen AA switches to the ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting the ID number for operator identification function without SKIP is set the starting screen AA switches to the ID number input screen MM without SKIP when the starting switch is turned to ON posi tion On the ID number input screen LL...

Page 75: ...een is displayed the engine cannot be started If you forget the ID number and cannot start the engine confirm the person in charge of the machine NOTICE The operator identification function is not for security or protection against theft Do not use for securi ty Komatsu cannot take responsibility for any loss or damage from the wrong use of ID or unauthorized use of ID by a third person BASIC OPER...

Page 76: ...the starting screen AA is displayed for 2 seconds and then it is changed to the maintenance time warning screen GG When the menu switch displayed in the guidance icon is press ed Maintenance menu screen is displayed After displaying the maintenance time warning screen GG for 30 seconds the screen returns to the standard screen BB EXPLANATION OF COMPONENTS OPERATION 3 16 ...

Page 77: ...s a trouble if any of the action levels L01 to L04 is displayed on the machine moni tor Take appropriate actions following the list of action level displays and required actions These caution lamps do not guarantee the condition of the machine Do not simply rely on the caution lamp when performing check before starting start up inspection Always get off the machine and check each item directly Whe...

Page 78: ...are generated they are displayed on warning displays 2 and 3 When more than 3 types of warning are generated they are displayed on warning displays 2 and 3 alter nately at intervals of 2 seconds ACTION LEVEL DISPLAY Action level display indicates the degree of urgency of the ab normality currently generated on the machine by L01 to L04 The larger the number in the table is the more serious effects...

Page 79: ... load If there is a secondary steering related display avoid a long time usage of the secondary steering If the condition is not improved check the failure code and ask your Komatsu distributor for inspection and maintenance L01 Not lit Does not sound Yellow Some functions may be restricted for use but the ma chine can operate When you finish the operation always perform the in spection and mainte...

Page 80: ...Current Abnormality screen is not dis played A Caution lamp B Action level C Failure code Code to indicate the content of the failure Notify it when calling your Komatsu distributor D Failure name E Message Take appropriate actions according to the displayed message F Contact telephone number The telephone number of your Komatsu distributor is displayed If the telephone number of the contact has n...

Page 81: ...rns the screen to the standard screen ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about over heating of the engine coolant If the engine coolant temperature is abnormally high the cau tion lamp lights up in red and action level L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Place the machine ...

Page 82: ...r to NEUTRAL position N and run the engine at a medium speed under no load until the caution lamp goes out FUEL LEVEL CAUTION LAMP The fuel level caution lamp warns about low level of remaining fuel The lamp lights up in red if the fuel level is 90 ℓ or less Add fuel as soon as possible BRAKE OIL PRESSURE CAUTION LAMP The brake oil pressure caution lamp warns that the brake oil pressure is below t...

Page 83: ...display Warning starts Inducement status is Warning Need to add DEF immediately When Lightning in white When fluctuation of DEF tank level is large frozen or not limited to tank level sensing is not performed correct ly When DEF is added after engine starting switch turn to OFF When DEF tank level sensor is defective SEATBELT CAUTION LAMP The seat belt caution lamp lights up in red when the seat b...

Page 84: ... while the engine is stopped the caution lamp lights up in yellow STEERING OIL TEMPERATURE CAUTION LAMP The steering oil temperature caution lamp warns about over heating of the steering oil If the steering oil temperature increases abnormally high the caution lamp lights up in red and action level L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds int...

Page 85: ...e When action level L01 is displayed The caution lamp lights up in yellow When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed BODY FLOAT CAUTION LAMP The dump body float caution lamp warns about the condition of the dump body When lamp lights up in red The gear shift lever is turned to any position ot...

Page 86: ...on lamp lights up in yellow When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed KDPF SYSTEM CAUTION LAMP The KDPF system caution lamp warns about abnormality in the KDPF system When action level L04 is displayed The caution lamp lights up in red At the same time the centralized warning lamp lights up ...

Page 87: ...nstructions Fault conditions that result in activation of the Inducement strat egy for engine derates to prompt to maintain or repair the emis sion control system Lighting in red With Action level L04 Inducement status is Severe Induce ment Engine power is under heavy deration With Action level L03 Inducement status is Low level Inducement Engine power is under deration Lighting in yellow With Act...

Page 88: ...on and maintenance as needed TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP The transmission oil filter clogging caution lamp warns about clogging of the transmission oil filter If the caution lamp lights up in yellow and the action level L01 is displayed stop the engine and check or replace the trans mission oil filter See METHOD FOR REPLACING TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT...

Page 89: ...safe place stop the engine then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed PARKING BRAKE SYSTEM CAUTION LAMP The parking brake system caution lamp warns about ab...

Page 90: ...su distributor for inspection and maintenance ENGINE OIL LEVEL CAUTION LAMP Engine oil level caution lamp warns about the drop of engine lubricating oil level It is displayed only while the engine is stopped If the caution lamp lights up in yellow and action level L01 is displayed check the oil level in the oil pan and add oil See METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN ADDING OIL 3 168 If...

Page 91: ...elt for damage then ask your Komatsu distributor for inspection and maintenance AIR CLEANER CLOGGING CAUTION LAMP Air cleaner clogging caution lamp warns about clogging of the air cleaner If the caution lamp lights up in yellow and action level L01 is displayed stop the engine then check and clean the air clean er See METHOD FOR CHECKING CLEANING AND REPLAC ING AIR CLEANER 4 15 FAN CONTROL SYSTEM ...

Page 92: ...tion lamp warns about abnormality in the ARSC system When an abnormality occurs in ARSC system the caution lamp lights up in red and the action level L03 is displayed At the same time the centralized warning lamp lights up and the alarm buzzer sounds intermittently Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for the inspection and maintenan...

Page 93: ...l filter See METHOD FOR REPLACING TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT 4 59 HYDRAULIC OIL FILTER CLOGGING CAUTION LAMP if equipped The hydraulic oil filter clogging caution lamp warns that the hy draulic oil filter is clogged If the caution lamp lights up in yellow and the action level L01 is displayed stop the engine then check and clean the hy draulic oil filter See METHOD FOR ...

Page 94: ...nce see Maintenance menu screen On the standard screen when the menu switch is pressed while the caution lamp is lit the screen changes directly to Maintenance menu screen For operations on Maintenance menu screen see MAINTENANCE SCREEN SETTING 3 81 By default the maintenance time caution lamp yellow is set to light up when the remaining time reaches 30 hours However you can change this setting To...

Page 95: ...on while the gear shift lever is in the any position oth er than NEUTRAL position N The current gear shift lever position flashes When all the signals from the gear shift lever are turned OFF When the gear shift lever is set to NEUTRAL posi tion N during traveling at travel speed 4 km h or more The current gear shift lever position flashes When the travel speed becomes 4 km h or more while the gea...

Page 96: ... Torque converter lockup pilot lamp 15 Preheating pilot lamp 16 Fan reverse rotation pilot lamp 17 Power mode display 18 Secondary steering pilot lamp 19 Aftertreatment devices regeneration pilot lamp 19 Aftertreatment devices regeneration disable pilot lamp 20 ECO guidance 21 DEF low level guidance Meter display 22 Engine tachometer 23 Speedometer 24 R H meter 25 L H meter 26 Torque converter oil...

Page 97: ...gnal lamp when it is turned on HEADLAMP HIGH BEAM PILOT LAMP The headlamp high beam pilot lamp lights up when the head lamps are set to high beam CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lights up when the clearance lamps are turned on RETARDER PILOT LAMP The retarder pilot lamp lights up when the retarder is in opera tion The retarder operates in the following cases When the retard...

Page 98: ...ear wheel KTCS OFF PILOT LAMP if equipped The KTCS off pilot lamp lights up while KTCS Setting is set to OFF POWER MODE DISPLAY The power mode display indicates the set state of the power mode By selecting power mode selector switch one of the following lamps lights up Economy mode Power mode EXPLANATION OF COMPONENTS OPERATION 3 38 ...

Page 99: ...de PREHEATING PILOT LAMP The preheating pilot lamp lights up when the automatic pre heating function of the engine is being actuated and goes out when preheating is completed This lamp also lights up during manual preheating The electrical heater for engine preheating is actuated while this lamp is lit MESSAGE DISPLAY The message display lights up when there is a message from Komatsu To read the m...

Page 100: ... treatment devices regeneration The aftertreatment devices regeneration pilot lamp lights up during regeneration of the exhaust gas aftertreatment devices It goes out when the regeneration is completed REMARK The lighting cycle becomes shorter when the ambient tempera ture is lower or working load is smaller AFTERTREATMENT DEVICES REGENERATION DISABLE PILOT LAMP Aftertreatment devices regeneration...

Page 101: ...the selected gear shift lever position is en larged PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake is applied AUTO SUSPENSION MODE PILOT LAMP if equipped The auto suspension mode pilot lamp indicates which mode is used for suspension The automatic suspension system is a function that automatically changes the hardness of the suspension ac cording to the load...

Page 102: ...mode in any of the following cases and the hardness of the suspension be comes normal The machine is operated normally when it is loaded The brake pedal is depressed when the machine is un loaded S soft mode If the dump lever is not operated the dump lever is at FLOAT position when the machine is unloaded and the brake pedal is not depressed the automatic suspension becomes the soft mode and the h...

Page 103: ...een reset is displayed When the ARSC Setting is OFF the set travel speed goes out ECO GUIDANCE ECO guidance is displayed during the operation and supports the fuel saving operation The details of the guidance are as follows EXCESSIVE IDLING GUIDANCE If the engine continues running idle for more than 5 minutes the excessive idling message is displayed on the machine monitor When waiting for loading...

Page 104: ...ANCE TO RECOMMEND SHIFTING UP Even when the engine speed reaches shift up speed during traveling if the upshift disable condition by gear shift lever con tinues for 5 seconds or longer the upshift recommendation message is displayed on the machine monitor This message is as well displayed when the machine travels in reverse It is however not displayed when the machine travels downhill with retarde...

Page 105: ...latest average DEF consumption is shorter than 8 hours the low DEF level message is displayed The low DEF level message goes out more than 15 seconds after or when ENTER switch is pressed REMARK While monitor displays DEF level low error or maintenance warnings DEF level low guidance is not displayed METER DISPLAY SPEEDOMETER The speedometer indicates the travel speed of the machine ENGINE TACHOME...

Page 106: ... oil tem perature caution lamp lights up in red and action level L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Place the machine in a safe place set the gear shift lever to NEUTRAL position N and run the engine at a medium speed with no load until the torque converter oil tem perature caution lamp goes out RETARDER OIL TEMPERATURE G...

Page 107: ...nge A it is not a machine trouble Target fuel consumption B displayed by ECO gauge can be changed as necessary L H AND R H METER DISPLAY The L H meter indicates either of the following which can be selected Service meter Odometer Clock The R H meter indicates either of the following which can be selected Fuel consumption gauge Service meter Odometer Clock Service meter display Indicates the integr...

Page 108: ...od for storage etc the time information may be lost Fuel consumption gauge display Indicates the average fuel consumption of the machine One day display Displays the average fuel consumption of the period from the operation starting time until now during 0 00 a m of the day through 0 00 a m of the next day Split under measurement display Displays the split fuel consumption under measurement EXPLAN...

Page 109: ... DEF cannot be detected DEF level caution lamp 1 lights up in white REMARK Immediately after turning the starting switch to ON position and during the engine is running DEF level cau tion lamp 1 lights up in white However this does not indicate abnormality In cold weather DEF level cannot be detected and DEF level caution lamp 1 lights up in white for approxi mately 1 hour However this does not in...

Page 110: ...e operated load Regard the value displayed on the payload meter as a guide SWITCH PANEL 1 UP switch 2 Air conditioner switch and numeric keypad 3 Menu switch 4 ENTER switch 5 RETURN switch 6 DOWN switch 7 Guidance icon These are used for the operation of the machine monitor or air conditioner The function of each switch varies depending on the screen of the machine monitor EXPLANATION OF COMPONENT...

Page 111: ...ion lamp lights up Aftertreatment Devices Regeneration menu screen is dis played When the maintenance caution lamp lights up Maintenance menu screen is displayed When the fan reverse rotation pilot lamp lights up Machine Setting and Information menu screen is displayed When the message display lights up Displays the message display menu screen When the menu switch is pressed on the user menu scree...

Page 112: ... line it moves to the first line On the value input screen the value is decreased by one AIR CONDITIONER SWITCH AND NUMERIC KEYPAD The air conditioner switch and numeric keypad consist of 10 switches Press the air conditioner switch and numeric keypad and re lease them The confirmation sound is heard when they are re leased Air conditioner switch For explanation of each air conditioner switch see ...

Page 113: ...CR Information E Maintenance F Monitor Setting G Message Display These menus A to G are for setting and confirming the following items A Energy Saving Guidance Check of Operation Records Check of ECO Guidance Records Check and resetting of Average Fuel Consumption Re cord Configurations B Machine Setting and Information Setting of Radiator Fan Reverse Mode Display and setting of Payload Meter if e...

Page 114: ...EF level Information on DEF system E Maintenance Check and resetting of various maintenance remaining times F Monitor Setting Rearview Monitor Setting Meter Display Selection Screen Adjustment Clock Adjustment Language Setting Operator ID G Message Display Check of message contents and reply to message EXPLANATION OF COMPONENTS OPERATION 3 54 ...

Page 115: ...on the right end menu screen it moves to the left end menu screen REMARK If no switch is operated for 30 seconds on the user menu screen the screen automatically returns to the previous screen or the standard screen The user menu screen is displayed only while the machine is stopped completely If the machine travels while the user menu screen is displayed the screen automatically returns to the st...

Page 116: ...rk equipment and accelerator are not oper ated Economy Mode Ratio Percentage of E mode operation in the engine running hours REMARK The displayed value of fuel consumption and the fuel consump tion rate may differ from the actual value due to the operating conditions of the customers fuel weather or work contents etc Operations on Operation Records screen When Average Fuel Consumption Display is s...

Page 117: ...ption Display is set to Split Time and the split time is not measured NOTICE When the measurement is started the previous split time measurement results Average Fuel Con sumption Display Operation Records and ECO Guidance Records are reset C Display while measurement is stopped D Dates and times when the measurement is started and stopped To start the split time measurement see the guidance icon a...

Page 118: ...equently is displayed The ECO guidance count increases when display condi tions are satisfied even if the ECO guidance is not dis played Operations on ECO Guidance Records screen When Average Fuel Consumption Display is set to 1 Day 1 Day is displayed on the place shown with arrow in ECO Guidance Records screen You can perform the following operations with the switches 1 to 3 on the switch panel 1...

Page 119: ...ption Display is set to Split Time and the split time is not measured NOTICE When the measurement is started the previous split time measurement results Average Fuel Con sumption Display Operation Records and ECO Guidance Records are reset C Display while measurement is stopped D Dates and times when the measurement is started and stopped To start the split time measurement see the guidance icon a...

Page 120: ...eather or work contents etc Operations on Average Fuel Consumption Record screen You can perform the following operations with the switches 3 to 5 on the switch panel 3 RETURN switch Returns the screen to Energy Saving Guidance menu screen 4 ENTER switch Clears the graph data 5 Menu switch Switches the graphical displays of the average fuel consump tion REMARK The displayed value of fuel consumpti...

Page 121: ...ion of Average Fuel Consumption Record 1 When ENTER switch 4 is pressed the confirmation screen is displayed 2 When ENTER switch 4 is pressed graphs of data of Last 12 hours and Last 7 days are both deleted and the screen returns to Average Fuel Consumption Record screen REMARK When canceling the data deletion clear press RETURN switch 3 OPERATION EXPLANATION OF COMPONENTS 3 61 ...

Page 122: ...igurations screen You can perform the following operations with the switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Returns the screen to Energy Saving Guidance menu screen 4 ENTER swi...

Page 123: ... Split Time to start the split measurement automatically You can perform the following operations with the switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected change a...

Page 124: ...gauge OFF Does not display the ECO gauge You can perform the following operations with the switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected change and returns the s...

Page 125: ... items of ECO Gauge Display Fuel Target Value are not displayed SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE ECO gauge display fuel target value A the upper limit value of the green range can be changed 1 Select ECO Gauge Display Fuel Target Value on Config urations menu screen then press ENTER switch 4 OPERATION EXPLANATION OF COMPONENTS 3 65 ...

Page 126: ...rget fuel consumption value setting and returns the screen to Configurations menu screen The default is 79 ℓ h REMARK If the target fuel value is increased the fuel consumption indicated when the ECO gauge is at the maximum is also increased commensurately If the target fuel value is decreased the fuel consumption indicated when the ECO gauge is at the maximum is also decreased commensurately SWIT...

Page 127: ...o Configurations menu screen 4 ENTER switch Allocates the selected change and returns the screen to Configurations menu screen The default is ON REMARK If ECO Guidance Display is set to OFF the items of ECO Guidance Display at Key OFF and ECO Guidance Records are not displayed but ECO Guidance Records is not reset SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF The display non display of Op...

Page 128: ...h panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected change and returns the screen to Configurations menu screen 4 ENTER switch Allocates the selected change and returns the screen to Configuratio...

Page 129: ...ing RADIATOR FAN REVERSE MODE k k CAUTION When you rotate the fan in the opposite direction clean the dust around the fan Make sure that no per sons or obstructions are around the area The Fan Reverse Mode can be used to clean the dusts or insects stuck to the radiator etc by operating the machine monitor to rotate the fan in reverse 1 Seat the dump body and stop the engine 2 Turn the starting swi...

Page 130: ...el or operate the dump body while the fan rotates in reverse wrong operation in fan re verse mode caution lamp lights up At the same time the centralized warning lamp lights up and the alarm buzzer sounds intermittently 5 After finishing cleaning stop the engine A certain time after the starting switch key is turned to OFF position the fan is returned to the normal rotation mode automatically Chec...

Page 131: ... the air conditioner to protect itself from being damaged PAYLOAD METER if equipped You can display and set the following items related to the pay load meter Accumulated Payload and Total Cycles Average Fuel Consumption Record Machine ID Setting Open ID Setting Calibration KTCS SYSTEM SETTING if equipped You can set ON or OFF of the KTCS system 1 Select KTCS Setting then press ENTER switch 4 OPERA...

Page 132: ...perates automatically REMARK This setting is maintained even after turning the starting switch to OFF position The default is ON ARSC SETTING You can set ON or OFF of the ARSC system 1 Select ARSC Setting then press ENTER switch 4 2 Select ON or OFF then press ENTER switch 4 EXPLANATION OF COMPONENTS OPERATION 3 72 ...

Page 133: ... position The default is ON DUMPING COUNTER if equipped The dumping counter is the function that automatically counts and displays the number of loads dumped If the dumping counter is not installed on the machine Dumping Counter is not displayed The number of times can be reset according to the following procedure 1 Select Dumping Counter then press ENTER switch 4 OPERATION EXPLANATION OF COMPONEN...

Page 134: ...cancel the resetting REVERSE TRAVEL ODOMETER The total reverse travel distance can be checked with Reverse Travel Odometer TRIP METER The overall travel distance after the previous resetting can be checked with Trip Meter EXPLANATION OF COMPONENTS OPERATION 3 74 ...

Page 135: ...r reset confirmation screen Press ENTER switch 4 and Trip Meter is reset The screen returns to Machine Setting and Information menu screen REMARK When reset is not necessary press RETURN switch 3 D RANGE F1 START SETTING Use this setting to change the starting gear speed when the gear shift lever is set to D position OPERATION EXPLANATION OF COMPONENTS 3 75 ...

Page 136: ...er is set to D position Normal NOTICE Select F2 usually If the machine travels in F1 while F1 is not necessary the service life of the machine may be shortened REMARK This setting is maintained even after turning the starting switch to OFF position The default is F2 AIR CONDITIONER ECO MODE SETTING You can turn ON or OFF the air conditioner ECO mode to improve the fuel efficiency by reducing effic...

Page 137: ...r higher or the set tem perature of the air conditioner is 18 C maximum cooling air conditioner may not be operated in the ECO mode even if A C ECO Mode Setting is turned to ON This setting is maintained even after turning the starting switch to OFF position The default is OFF RETARDER CONTROL LEVER CANCEL SOUND SETTING This is used for selecting ON or OFF of the cancel sound of the retarder contr...

Page 138: ... stop function stops the engine automatically when the engine is operated continuously at idle for a set time The auto idle stop works only when all of the following conditions are met The accelerator pedal is not depressed The gear shift lever is in NEUTRAL position N The dump lever is placed in FLOAT position and dump body is seated When the dump body float caution lamp is not lit The machine is...

Page 139: ...e then press ENTER switch 4 You can perform the following operations with the switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected change and returns the screen to Mach...

Page 140: ...At the same time the parking brake is applied Turn the unnecessary switches to OFF position to prevent the battery to run out REMARK When restarting the engine turn the starting switch as usual When the auto idle stop operates while the parking brake is in TRAVEL position set the parking brake switch to PARKING position and then to TRAVEL position again and the parking brake is released AFTERTREAT...

Page 141: ... A Maintenance item B Default maintenance interval settings h C Time remaining to maintenance h When the time remaining to the next Maintenance for any item is less than the maintenance notice time initial setting 30 hours the remaining time display C is displayed in yellow When the time remaining to the maintenance becomes 0 hours the remaining time display C is displayed in red The time after th...

Page 142: ...ARK For the setting changing or canceling the password ask your Komatsu distributor 3 The screen changes to Maintenance Due Time Reset screen Press ENTER switch 4 on Maintenance Due Time Re set screen and the screen changes to the reconfirmation screen for Maintenance Due Time Reset REMARK When reset is not necessary press RETURN switch 3 4 Press ENTER switch 4 on Maintenance Due Time Re set scree...

Page 143: ...d You can perform the following operations with the switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Monitor Setting menu screen 4 EN...

Page 144: ... is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Rearview Monitor Setting menu screen 4 ENTER switch Allocates the selected setting and returns the screen to Rearview Monitor Setting menu screen The setting of Guide Line Disp...

Page 145: ...tches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Rearview Monitor Setting menu screen 4 ENTER switch Allocates the selected setting and returns t...

Page 146: ...e switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Monitor Setting menu screen 4 ENTER switch The screen changes to the setting screen for the selected item...

Page 147: ...s with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Meter Display Selection menu screen 4 ENTER switch The screen changes to the ...

Page 148: ... clock You can perform the following operations with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Meter Display Selection menu sc...

Page 149: ...tch Allocates the change and returns the screen to Monitor Setting menu screen 5 Menu switch The brightness returns to the initial state REMARK The brightness in the day and night modes can be adjusted individually When the screen is adjusted with the lamp switch in OFF position the brightness in the day mode can be adjusted When the screen is adjusted with the lamp switch in ON position and when ...

Page 150: ...Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Returns the screen to Monitor Setting menu screen 4 ENTER switch Displays the setting screen for the selected item REMARK After a long term storage the 2 items of Calendar and Time are reset Accordingly you must readjust them When GPS Synchronization is ON the 2 items of Calendar and Time are...

Page 151: ...en on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Clock Adjustment menu screen 4 ENTER switch Allocates the selected setting and returns the screen to Clock Adjustment menu screen REMARK When the machine is in the environment where t...

Page 152: ... numeral by 1 2 DOWN switch Puts back the numeral by 1 3 RETURN switch Cancels the change and returns the screen to Clock Adjustment menu screen 4 ENTER switch Proceeds to setting for month 3 When month display B is highlighted in yellow operate the switches as follows to change month display When it is not necessary to change the month setting press ENTER switch 4 1 UP switch Advances the numeral...

Page 153: ...time of the machine monitor can be adjusted on Time screen REMARK While GPS Synchronization is turned on the item of Time cannot be selected 1 Select Time from Clock Adjustment menu screen then press ENTER switch 4 2 Time screen is displayed When time display D is highlighted in yellow operate the switches as follows to change time display When it is not necessary to change the time setting press ...

Page 154: ... returns the screen to Clock Adjustment menu screen 12 HOUR AND 24 HOUR DISPLAY MODE On 12hour or 24hour Mode screen you can set the display mode of clock 1 Select 12hour or 24hour Mode from Clock Adjustment menu screen then press ENTER switch 4 2 12hour or 24hour Mode screen is displayed Select 12hour or 24hour then press ENTER switch 4 12hour Select 12 hour display AM PM 24hour Select 24 hour di...

Page 155: ...G On Daylight Saving Time screen you can set the clock display forward 1 hour 1 Select Daylight Saving Time from Clock Adjustment menu screen then press ENTER switch 4 2 Daylight Saving Time screen is displayed ON The clock is displayed in daylight saving time summer time Displays the time 1 hour forward OFF The clock is displayed in normal time You can perform the following operations with switch...

Page 156: ...ish Portuguese Italian German Swedish Dutch Danish Norwegian Fin nish Icelandic Czech Hungarian Polish Slovak Slovene Romanian Croatian Estonian Latvian Lithuanian Bulgarian Greek Serbian Turkish 1 Select Language Setting on Monitor Setting menu screen then press ENTER switch 4 2 Language Setting screen is displayed Select the language to be displayed on Language Setting screen then press ENTER sw...

Page 157: ...Setting menu screen REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identi fication function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP If the already registered ID is inputted when the starting switch is turned to ON position the identified ID is displayed in Oper ator ID column on Monitor Setting menu screen If SKI...

Page 158: ...tch 4 A message is displayed below the screen returns to Monitor Setting menu screen and the identified ID is changed The changed ID is displayed at Operator ID column on Monitor Setting menu screen When you press the menu switch 5 on Operator ID Change screen a message is displayed below and the screen changes to Monitor Setting menu screen On Monitor Setting menu screen is displayed in the colum...

Page 159: ...BLE WITHOUT SKIP When the operator identification function is available without skip the identified ID number is not displayed in Operator ID column on Monitor Setting menu screen 1 Select Operator ID on Monitor Setting menu screen then press ENTER switch 4 for 1 second 2 Operator ID Change screen is displayed REMARK When the ID change is not necessary press RETURN switch 3 Input the preregistered...

Page 160: ...ds or longer the screen changes to Monitor Setting menu screen and the ID number is not changed MESSAGE DISPLAY On machines equipped with KOMTRAX when the message pi lot lamp is lit on the standard screen you can see the messag es from your Komatsu distributor on the mail check menu screen by pressing the menu switch Message is distinguished as follows according to the lighting states of the messa...

Page 161: ...ge the message will be dis played on the end screen and when the monitor is started next time the message will change to a read message the message display lights up in blue The message is deleted when it becomes out of date or when receiving a new message CHECK MESSAGE Select the message confirmation menu screen and you can read the received message A Subject of message When no message has been r...

Page 162: ... the lower right of each switch 2 After inputting a selected item number press ENTER switch 4 3 When Do you send Numeric Input is displayed press ENTER switch 4 again The input value is sent out REMARK To cancel sending press RETURN switch 3 The input value is cleared REMARK If the message is replied Numeric Input Done is displayed for it OTHER FUNCTIONS OF MACHINE MONITOR Confirming method of the...

Page 163: ...s UP switch 1 while holding down DOWN switch 3 with the starting switch in OFF position Service meter A and odometer B are displayed while both switches are held down OPERATION EXPLANATION OF COMPONENTS 3 103 ...

Page 164: ...d 4 Fog lamp switch 5 Horn button 6 Hazard lamp switch 7 Secondary steering switch 8 Front brake off switch 9 AISS LOW switch 10 Engine power mode selector switch 11 Starting switch 12 Wiper and window washer switch 13 Lamp switch dimmer switch turn signal lever EXPLANATION OF COMPONENTS OPERATION 3 104 ...

Page 165: ...TARTING SWITCH Starting switch is used to start or stop the engine A OFF position The electrical current to the electrical system is cut and the en gine stops The key can be inserted into or removed from the starting switch REMARK Even when the starting switch is at OFF position the horn haz ard lamp secondary steering and room lamp 1 can operate B ON position Electric current flows through the ch...

Page 166: ...extend the engine preheating time longer than the automatic preheating time In that case turn the starting switch to the manual preheat position D When it is released it automatically returns to OFF position A Immediately turn it to START position C and start the engine CIGARETTE LIGHTER The cigarette lighter is used to light the cigarettes When the cigarette lighter is pushed in it will return to...

Page 167: ... to flash the turn signal lamps R Right turn Push the lever forward L Left turn Pull the lever backward When the lever is operated the turn signal pilot lamp also flashes The lever returns automatically when the steering wheel is turned back If the lever does not return move it by hand WIPER WINDOW WASHER SWITCH The wiper and window washer switch is used to operate the wiper for the front glass NO...

Page 168: ...tch is set to the day position A monitor screen does not lose the brightness A Day position Sets the machine monitor and rearview monitor to the day mode B Night position Sets the machine monitor and rearview monitor to the night mode Monitor screen loses the brightness REMARK When the lamp switch is turned to OFF position operating this switch does not change the brightness SWITCH FOR MIRROR WITH...

Page 169: ...limit the travel speed to 5 km h or less The secondary steering operates automatically in the following cases When the steering oil pressure drops abnormally When the engine stops during operation When the secondary steering operates stop the machine immediately and check it When the engine stops if the starting switch is at ON position and the parking brake switch is at TRAVEL position the second...

Page 170: ...r low level in order to reduce fuel consumption when the machine is stopped REMARK While the automatic warm up is turned on the idle speed is not set low even if the parking brake or retarder brake is applied FRONT BRAKE OFF SWITCH k k WARNING Turn the front brake off switch to the position A to drive the machine slowly with a safe speed on the frozen road snow road and slippery road You can chang...

Page 171: ...WITCH k k WARNING Make sure to set the parking brake before you leave the operator seat to avoid sudden machine move ment Depress the brake pedal until the parking brake pilot lamp comes on while the parking brake is set to PARKING NOTICE Do not use the parking brake switch for braking when traveling except for an emergency If the park ing brake switch is used during traveling the parking brake ma...

Page 172: ...kept in TRAVEL position B the parking brake is applied automat ically When starting the engine again set the parking brake switch to PARKING position A and then set it back to TRAVEL posi tion B to release the parking brake FOG LAMP SWITCH The fog lamp switch is used to turn on or off the fog lamp Position A Fog lamp lights up Position B Fog lamp goes out POWER WINDOW SWITCH k k CAUTION When the w...

Page 173: ...when the cab door opens Position C Lights up REMARK The room lamp lights up even when the starting switch is at OFF position so when leaving the operator s seat set the switch to the position A or B When performing the operations with the door fully opened set the switch to the position A ROOM LAMP2 SWITCH Room lamp 2 switch is used to turn on and off the room lamp 2 Position A Lamp goes out Posit...

Page 174: ...n it There is a switch under the cover 2 Raise the engine shutdown secondary switch to upper po sition A and the engine stops After 2 seconds from stop ping of the engine Engine Shutdown Secondary SW in Operation is displayed and the alarm buzzer sounds inter mittently A ENGINE STOP When abnormal switch is set to upper position B Normal When normal switch is set to lower position When cover 1 is c...

Page 175: ...aircase lighting goes out Staircase lighting switch at the step REMARK The staircase lighting lights up even when the starting switch is at OFF position Always turn off the staircase lighting when leaving the machine otherwise the battery will be consumed CONTROL LEVERS AND PEDALS 1 Retarder control lever 2 Gear shift lever 3 ARSC travel speed set lever 4 Accelerator pedal 5 Brake pedal 6 Secondar...

Page 176: ... while the accelerator pedal is released If the accelerator pedal is depressed while the ARSC is in operation the ARSC system stops operation The KTCS system can operate while the accelerator pedal is depressed and the gear speed is at any of the 1st speed through 4th speed or REVERSE If the accelerator pedal is released while the KTCS is in operation the KTCS system stops operation GEAR SHIFT LEV...

Page 177: ...irect 10 0 km h 9 8 km h R R torque converter to direct 10 4 km h 10 2 km h The machine moves off at 2nd speed or 1st speed when the gear shift lever is set to the position D Do not set the gear shift lever to NEUTRAL position N during the travel Before performing the directional selection stop the machine completely and run the engine at low idle When starting the engine if the gear shift lever i...

Page 178: ...y the parking brake REMARK When the ARSC system is in operation the retarder control lever has some play at the start of stroke It does not mean that the retarder does not work but that it is the range of the ARSC system operation Sud den operation of the retarder lever will cause sudden braking Take care If the retarder is operated with retarder control lever while the KTCS is in operation the KT...

Page 179: ... the engine is started again with the dump body raised the dump body is held in HOLD condition and the dump body float caution lamp lights up DUMP LEVER LOCK KNOB k k WARNING To inspect the machine with the dump body lifted set the dump lever to HOLD and lock with knob Then use the body pivot pin The dump lever lock knob is a locking device for the dump lev er To set it to FREE position F pull out...

Page 180: ...b door handle and knob whenever opening or closing the cab door Be careful not to get your hands caught between the front pillar or center pillar When there is anyone inside the cab always call out a warning before opening or closing the door CAB DOOR HANDLE Pull the cab door handle while it is not locked and the door opens to the full open position OPEN KNOB FOR CAB DOOR Pull the open knob for th...

Page 181: ...the setting of the air conditioner blows into the drink box Turn the knob counterclockwise and pull the cover up and open it L LOCK position The cover is locked F FREE position The cover is unlocked When closing the cover lock it by turning the knob clockwise while pressing the cover LUNCH BOX TRAY The lunch box tray is located at the rear of the operator s seat MAGAZINE BOX The magazine box is pr...

Page 182: ...at the front of the center console Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid POWER SUPPLY OUTLET 12V power supply The outlet for 12 V power is provided in the rear right side of the operator s seat Capacity of this power supply is 60 W 12 V x 5 A EXPLANATION OF COMPONENTS OPERATION 3 122 ...

Page 183: ...d type FUSE CAPACITIES AND CIRCUIT NAMES Fuse box I BT1 No Capaci ty Name of circuit 1 10 A Main lamp clearance lamp 2 15 A Headlamp Hi 3 15 A Headlamp Lo 4 10 A Stop lamp 5 15 A Backup lamp alarm buzzer 6 30 A Heated wire mirror power supply if equipped 7 10 A Heated wire mirror upper R H if equipped 8 10 A Heated wire mirror L H if equipped 9 10 A Heated wire mirror lower R H if equipped 10 11 2...

Page 184: ...power supply 26 10 A Payload meter controller if equipped 27 10 A Download continuous power supply 28 29 30 20 A Spare continuous power supply Fuse box III BT3 No Capaci ty Name of circuit 31 20 A Air conditioner blower motor 32 10 A Air conditioner compressor clutch 33 10 A Radio 34 20 A Front wiper 35 10 A Room lamp 2 door solenoid 36 10 A Turn signal lamp 37 15 A Side lamp 38 39 30 A Engine con...

Page 185: ...0 A Preheat relay 55 20 A Spare 56 15 A Staircase lighting continuous power supply if equipped 57 5 A Radio continuous power supply 58 10 A Hazard lamp continuous power supply 59 10 A Room lamp system operating lamp continuous power supply 60 15 A Horn continuous power supply Fuse box V BT5 No Capaci ty Name of circuit 61 62 63 64 65 66 15 A Additional heater if equipped 67 68 69 70 71 72 10 A Sma...

Page 186: ...chine electrical system If you want to make any change to the electrical system contact your Komatsu distributor TOOL BOX Toolbox is inside the box under the step at the left side of the machine GREASE PUMP HOLDER The grease pump holder is in the battery box Wipe off the grease attached to the grease pump after use Insert the grease pump into the grease pump holder and fix it when not in use FIRE ...

Page 187: ...en replacing the fuse etc Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit If the battery disconnect switch is turned to OFF position while the system operating lamp is lit the data in the controller may be lost If the battery disconnect switch is turned to OFF position all the electrical system is cut out and the functions of KOMTRAX stop In additio...

Page 188: ...osition the controller may operate The system operating lamp lights up at this time but it is not a failure After the starting switch has been turned off the system operating lamp may stay lit for a long time In such case consult your Komatsu distributor The system operating lamp may look slightly luminous in the dark after it is turned off It is due to the minute leakage of current and not an abn...

Page 189: ...n Operating effort of the reset button becomes larger when the circuit is open than when the circuit is not open If the operating effort is still large after the reset button has been pushed in the electrical circuit may be open In such case ask your Komatsu distributor for repair DUST INDICATOR This device indicates clogging of the air cleaner Depending on the degree of clogging of the element re...

Page 190: ...hauling road ahead for safety and this may lead to serious per sonal injury or death The rearview monitor is an device for supporting a visual check if there is any obstacle in the rear or the area around the machine An image displayed on the monitor is limited So when traveling in reverse do not rely solely on the monitor but be sure to make a visual check for safety Never drive the machine in re...

Page 191: ...tment of the guide line and of the rearview monitor angle is needed For the other settings of the rearview monitor see REAR VIEW MONITOR SETTING 3 83 and for the setting of guide line see METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 3 185 REMARK The screen may be hard to see in the dark place at night but it is not a trouble The guide line does not synchronize with the steering angle The guide line...

Page 192: ...ric shock as high voltage power is conducted internally Do not use the rearview monitor while it is broken There is a danger of electric shock or fire should it be used in spite of a defect In that case ask your Komatsu distributor for repair or replacement If foreign materials enter into the rearview monitor or if the rearview monitor gets wet or if smoke comes out of it or it gives a bad smell s...

Page 193: ... display 1 goes out and the idle speed is returned to the level corresponding to the AISS LOW switch KDPF is a device to capture soot in the exhaust gas to purify the exhaust gas If soot is accumulated to a certain level in the filter a purifica tion process to burn the soot is performed automatically to keep the filtering performance of KDPF high This purification process is called Regeneration I...

Page 194: ...el L03 is shown and the caution lamp 2 for KDPF soot accumulation is red engine derate is activated To cancel engine derate it is necessary to perform PROCEDURE FOR MANUAL STATIONARY RE GENERATION If soot accumulated in the KDPF exceed the defined level without performing PROCEDURE FOR MANUAL STA TIONARY REGENERATION the Action level L04 lights up in red Stop the machine immediately and ask your K...

Page 195: ...erval of KDPF filters adversely affect the engine such as deteriorated oil may reduce lubricating function and it may cause failure In addition the regeneration interval may be shortened and the fuel consumption may increase If the mixing ratio of the bio fuel in the diesel fuel is high the regeneration of KDPF may become more fre quent When the degree of emergency is low If the KDPF soot accumula...

Page 196: ...ONARY REGENERATION k k CAUTION Stay away from the exhaust pipe outlet to prevent injury Keep flammable materials away from the exhaust pipe to avoid fire Do not leave the operator s seat during the regeneration of the aftertreatment devices The manual stationary regeneration can be performed while the KDPF soot accumulation caution lamp 2 is lit REMARK On this machine the manual stationary regener...

Page 197: ...ationary Regeneration check again safety of the area around the machine and make sure that there is no person or combustible matter around the machine then press ENTER switch If the machine needs to be moved again to secure the safety move it to a safe place and repeat the proce dure from step 1 REMARK When performing the manual stationary regeneration lower the dump body and set the fan rotation ...

Page 198: ... displayed in 3 parts on the machine monitor When ENTER switch is pressed the regeneration can be started immediately regardless of which part is dis played When RETURN switch is pressed the display returns to the standard screen If no machine monitor switch is operated for 30 sec onds the explanation of the manual stationary regen eration disappears and the screen returns to the standard screen A...

Page 199: ...egeneration stop the regeneration temporarily and move the machine by referring to the aftertreatment devices regeneration disable and cancel procedures described below When restarting the manual stationary regeneration secure the safety of the machine and around it then cancel the regeneration disable 9 After the manual stationary regeneration is completed the screen automatically returns to the ...

Page 200: ...arting switch to OFF position When the automatic re generation needs to be kept disabled perform the above procedure each time you start the engine During the regeneration to protect the system even if the regeneration disable is set the aftertreatment devices re generation display 1 may light up but this does not indi cate abnormality Also during the regeneration to protect the system the regener...

Page 201: ...ystem may not be stopped but this is not a failure PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING k k CAUTION Before you start the cancel regeneration disable operation park the machine in a safe area Make sure no person or flammable matter is in the area 1 Press the menu switch on the standard screen when the aftertreatment devices regeneration is disabled After treat...

Page 202: ...ed HANDLE UREA SCR SYSTEM WARNING Urea SCR system is a device which converts toxic nitrogen oxides NOx in the exhaust gas into harmless nitro gen and water By spraying DEF into the exhaust gas it decomposes and hydrolyzes to form ammonia NH3 and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water The Komatsu Urea SCR System continuously monitors its operati...

Page 203: ...e injector and the supply pump back to the DEF tank It does not indicate any abnormality When DEF has been returned to the tank the devices stop Do not turn OFF the battery disconnect switch while the devices are still in operation When the devices com plete their shutdown process the system operating lamp will go out and the battery disconnect switch may be disconnected About the operation in col...

Page 204: ...be derated in steps In action level L03 Low level Inducement and L04 Severe Inducement engine power will be derated When action level 03 or 04 is displayed move the machine to a safe place and add DEF The content of the warning can be checked on the SCR Infor mation screen of the user menu Perform the following procedure Press the menu switch on the standard screen to display the SCR Information s...

Page 205: ...the SCR Information screen SCR Information screen message 4 2 Without treat ment engine power will be derated Add DEF to the DEF tank immediately Low level Inducement The audible alert sounds in Intermittent alarm 1 gradation of the DEF level gauge light up in red The DEF level caution lamp 1 lights up in red The action level L03 is displayed in red 5 Press the menu switch to display the SCR Infor...

Page 206: ...trategy when abnormalities are detected in the Urea SCR System devices Except abnormalities in the KDPF and the EGR system If any abnormality is detected in the DEF quality or in the Urea SCR system the Inducement strategy is activa ted The inducement strategy progresses in 4 levels Warning Continuous Warning Low level Inducement and Severe In ducement The Inducement strategy includes visual alert...

Page 207: ...unds in repetition of Intermittent alarm The DEF system caution lamp 1 lights up in yellow If operation continues for 5 hours after Warning started without taking any actions instructed by the action level ta ble Inducement advances to Continuous Warning Press the menu switch to display the SCR Information screen SCR Information screen message 4 2 Without treat ment engine power will be derated Mo...

Page 208: ... 4 4 Engine power is under heavy deration Due to the further deration of engine power capability the machine will be limited further Severe Inducement is the final status of Inducement Unless all the SCR system abnormalities are corrected engine power will be kept derated Engine power can be restored temporarily from power derate If Inducement advances to Severe Induce ment and it becomes necessar...

Page 209: ...ther derated If L03 is displayed move the machine to a safe place and contact your Komatsu distributor The content of the warning can be checked on the SCR Information screen of the user menu Perform the following procedure Press the menu switch to display the SCR Information screen of the user menu After a lapse of 3 seconds to stop the machine SCR Informa tion screen is displayed SCR Information...

Page 210: ... of Continuous Warning is 5 hours The remaining time Hours and Minutes till the next Induce ment status of Low level Inducement is displayed in the column 6 of SCR Information screen In Low level Inducement engine power will be derated Low level Inducement The audible alert sounds in Intermittent alarm The KDPF system caution lamp 1 lights up in red The DEF system caution lamp 2 lights up in red T...

Page 211: ...his manual If Inducement advances to Severe In ducement and it becomes necessary to restore engine power use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor Inducement strategy when abnormality is found in the EGR Valve System by the Urea SCR system If any abnormality is detected in the EGR Valve System through the Urea SCR system the ...

Page 212: ...s the menu switch to display the SCR Information screen SCR Information screen message 5 1 Please inspect and maintain SCR system Engine power is derated Move the machine to the safe place and contact your Ko matsu distributor If operation continues for 5 hours after Warning started without taking any actions instructed by the Action Level table Inducement advances to Continuous Warning Continuous...

Page 213: ... to the reduction of engine power the machine normal operation will be limited The duration time of Low level Inducement is 10 hours The remaining time Hours and Minutes to Severe In ducement is displayed in the column 6 of SCR Informa tion screen In Severe Inducement engine power will be derated fur ther Move the machine to the safe place and contact your Ko matsu distributor Severe Inducement Th...

Page 214: ...ving the machine to a safe place for adding DEF or troubleshooting and correcting abnor malities of the Urea SCR system For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of Low level Inducement through the machine monitor Note that Tempo rary Restoration from Inducement does not regain full engine power Temporary Restoration from ...

Page 215: ... Engine power Recov ery window is displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Low level Inducement for the maximum of 30 minutes The remaining time minutes seconds of Temporary Re storation from Inducement is displayed in the column 4 on the SCR Information screen If it is decided NOT to activate Temporary Restoration from I...

Page 216: ...an the amount of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the previous Inducement and whether the new abnormality abnormalities is the same as the previous ones or not it is judged as a recurrence If a recurrence occurs Severe Inducement will be activated Inducement in the recurrence ...

Page 217: ...ly manages the machines equipped with the KOM TRAX device by using satellite communication or portable radio communication The GPS Global Positioning System receiver and communication system are equipped in the vehicle man agement system The machine information such as the machine maintenance maintenance management operating situation management and machine location management is gathered from the...

Page 218: ...the machine has been lent out by the customer the borrower or another third party may have been using the KOMTRAX Confirm with the lessor about using condition of KOMTRAX Komatsu may suspend KOMTRAX communication in the following cases When Komatsu judges that KOMTRAX is used by an unregistered customer When Komatsu judges that KOMTRAX is used in a country or region where its use is not authorized...

Page 219: ...ed around the engine radiator or aftercooler Check also that there is no combustible material dry leaves twigs etc accumulated around the battery or muffler turbo charger or other high temperature parts of the engine Remove any dirt or combustible materials that are found 3 Check around the engine for coolant and oil leakage Check for oil leakage from the engine and coolant leakage from the coolin...

Page 220: ...the part If any valve cap is missing install a new one 12 Check the air cleaner mounting bolts for looseness Check the mounting bolts for looseness If any loose bolts are found retighten them 13 Check the dump body mount rubbers Check for any cracks caught foreign objects or loose bolts 14 Check for damage to the handrail and loose bolts If any breakage is found repair it and retighten the bolts 1...

Page 221: ...manufactured date of the seat belt is printed on the la bel indicated by the arrow in the figure Check the seat belt and mounting hardware 1 2 places for abnormality If any part is damaged replace it with a new one Check for looseness of the bolts 1 2 places of mounting hardware which is installed to the machine Retighten them if any loose bolts are found Tightening torque 37 3 to 41 2 Nm 3 8 to 4...

Page 222: ... corrosion and cracks In particular check the side rings lock rings and rim flanges thoroughly 21 Check the antenna Check the satellite communication antenna 1 if equip ped GPS antenna 2 and cables for damages Replace it with a new one if there is any damage Clean the antenna if it is dirty METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each d...

Page 223: ...eration Consider the oil level check when the engine is stopped only as a guide Some bubbles may be seen in the sight gauge after the machine travels at high speed however it is not a trouble Wait until the bubbles disappear and then check the oil level in the transmission case 1 Start the engine 2 Run the engine at low idle and check the oil level with the Low temperature scale on the sight gauge...

Page 224: ...mulated in the fuel pre filter The water level and sediment are seen through transpar ent cup 2 REMARK If the transparent cup is so dirty that the inside cannot be seen clean the transparent cup when replacing the fuel prefilter 2 Place a container to catch the water under the drain hose 4 3 Loosen the drain valve 3 and drain the water 4 When fuel starts draining from the drain hose 4 tighten the ...

Page 225: ...h 8 to ON po sition again Check again that the lamp 9 has gone out METHOD FOR CHECKING OIL LEVEL IN STEERING AND HOIST OIL TANK ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the ...

Page 226: ... is seen from the sight gauge H the oil level is correct 2 If the oil is not seen from the sight gauge H add the oil through the oil filler port F METHOD OF CHECKING OIL LEAKAGE IN REAR BRAKE OIL COLLECTION TANK 1 Check that no oil leaks from the overflow tube at the rear brake oil collection tank 2 Collect the oil according to the following procedure if it is being leaked 1 Place a container to c...

Page 227: ...t for the temperature to go down turn the cap slowly to release the pressure then re move the cap with care 1 Open the cover 1 2 Check that the coolant level in reservoir tank 2 is be tween FULL and LOW marks of the level gauge G If it is insufficient remove the cap 3 of the reservoir tank 2 and add the coolant up to FULL mark If the coolant level in the reservoir tank is LOW or less add the coola...

Page 228: ...r must be bled from the circuit Perform the replacement of the coolant by referring to METHOD FOR CLEANING INSIDE OF COOLING SYSTEM METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN ADDING OIL k k WARNING Allow parts and oils to cool to touch before you perform maintenance REMARK Wait for at least 15 minutes after stopping the engine after the engine has been operated and check the oil level The oil...

Page 229: ... PED mark and check while the engine is stopped If the oil level is below L mark add oil through oil filler port F If the oil level is higher than H drain the excessive oil according to the following procedure 1 Remove the cover of the engine underguard 2 Remove the drain plug 1 3 Loosen the drain valve P and drain the excessive oil 4 After draining the oil close the drain valve 2 5 Install the dr...

Page 230: ...eck if there is any accumulation of combustible material around the battery and remove such combusti ble material METHOD FOR CHECKING FUEL LEVEL ADDING FUEL k k WARNING Fuel is highly flammable and dangerous Do not bring any open flame close Before adding fuel stop the engine and do not let anyone get on the machine Do not allow fuel to spill If any fuel spills wipe it up completely If fuel spills...

Page 231: ...nated area and emit toxic gas NOTICE Do not add DEF more than the line F of sight gauge 4 DEF may leak through the breather When DEF may freeze in cold weather do not add it more than the line 9 of sight gauge 4 Be careful of the DEF line when performing operations on a slope or traveling on a rough ground When the remaining DEF level is low it may become the warning level if DEF pump sucks air or...

Page 232: ...e 4 add DEF through the filler port until float 5 reaches line F 6 Line 7 in the sight gauge indicates approximately 5 ℓ be low the line F and the line 8 indicates approximately 10 ℓ below the line F Line 9 is the upper limit line for adding when DEF may freeze in cold weather REMARK When all gradations of the DEF level gauge go off DEF re filling amount is approximately 24 3 ℓ 6 427 U S Gal to fi...

Page 233: ... while checking the sight gauge Add only DEF in clearly marked DEF tanks that have the blue cap METHOD FOR CHECKING TIRE PRESSURE Check the tire inflation pressure before starting work while the tires are cold 1 Measure the tire inflation pressure with an air pressure gauge 2 Adjust the tire inflation pressure properly The proper tire inflation pressure is shown below HD325 8 Tire size Tire inflat...

Page 234: ... personal injury or death may occur Observe the following Select the flat and large area which gives the machine an enough braking distance to stop securely If the machine starts moving during the inspection of the secondary brake performance immediate ly reduce the engine speed set the gear shift lever to NEUTRAL position N set the parking brake to PARKING position and stop the machine While the ...

Page 235: ... more than 90 seconds to avoid damage or fire Self check function for secondary steering k k CAUTION Do not operate the steering during the test to avoid sudden movements The secondary steering is started automatically when the starting switch is turned to ON position to check the secondary steering functions If defective operation of the secondary steering motor is found ask your Komatsu distribu...

Page 236: ...ion and check that the secondary steering motor operates in 1 sec ond While the secondary steering motor is in operation the secondary steering pilot lamp 5 lights up 7 After checking set the parking brake switch 4 to PARK ING position 8 Turn the starting switch 1 back to OFF position REMARK If the secondary steering motor operates 1 minute or longer the secondary steering motor long operation cau...

Page 237: ...just it before starting operation or when operators change shift Adjust the position of the operator s seat so that you can depress the brake pedal fully with your back against the seat backrest METHOD FOR ADJUSTING SEAT UNIT IN FORE AND AFT DIRECTION Operate the fore aft adjustment lever upward set the seat to the desired position then release the fore aft adjustment lever Adjustment amount 152 4...

Page 238: ...t adjustment lever upward move the front of the seat cushion up and down to adjust it to the desired position then release the tilt adjustment lever Adjustment amount Forward tilt 5 Backward tilt 5 METHOD FOR ADJUSTING SEAT HEIGHT NOTICE Avoid using the height adjustment switch continuously for 1 minute or longer since such practice can damage the air compressor Turn the starting switch to ON posi...

Page 239: ... the seat height to the desired position more quickly by pressing the switch while reducing the load on the seat METHOD FOR ADJUSTING SEAT CUSHION IN FORE AFTER DIRECTION Pull up the fore and aft adjustment lever set the seat cushion to the desired position then release the fore and aft adjust ment lever Fore aft adjustment range 60 mm If the seat backlash is found ask your Komatsu distributor for...

Page 240: ...roper tension to the waist part METHOD FOR ADJUSTING AIR LUMBAR SUPPORT if equipped NOTICE Avoid operating the air lumbar support continuously for 1 minute or longer since such practice can damage the air compressor Operate the air lumbar support adjustment switch to give a proper tension to the waist part A Position for air inflation Air is pumped in the air bag in the backrest and the air bag is...

Page 241: ...ecreased Adjustment amount 5 stages METHOD FOR USING SEAT HEATER k k CAUTION Using the heater for a long time may cause low temperature burn blister etc Do not put heavy luggage on the cushion Do not stick the cushion with needles nails etc Do not put blanket cushion or other heat retaining material on the seat cushion Doing so may cause overheat If water or beverage etc spills on the seat cushion...

Page 242: ... Do not put heavy luggage on the cushion Do not stick the cushion with needles nails etc Do not put blanket cushion or other heat retaining material on the seat cushion Doing so may cause overheat If water or beverage etc spills on the seat cushion immediately wipe it off with soft cloth etc and dry out the seat cushion before using it REMARK The seat heater and the ventilation cannot be used at t...

Page 243: ...en the temperature of the cushion becomes suitable The heater in the seat cushion stops When using the ventilation 1 Set the seat heater and ventilation selector switch 1 to the ventilation position B 2 Set the air flow control switch 2 to HIGH position D or LOW position E The ventilator operates and air blows out from the cushion seat and backrest C OFF position The ventilation function stops D H...

Page 244: ...ew range Mirror A Hatched area A the area around tire s ground contact point A ground A and the top edge of the dump body must be in view Mirror B Hatched area B must be in view Mirror C Hatched area C and a part of the machine body must be in view Mirror D Hatched area D the area around tire s ground contact point D ground D and the top edge of the dump body must be in view Mirror E Hatched area ...

Page 245: ...rearview camera is not adjusted properly you cannot secure the visibility and it may lead to a serious personal injury or death When adjusting the angle of the rearview camera prepare a scaffold first in order to provide a safe working platform Otherwise serious personal injury or death by such as falling may occur Install only the Komatsu genuine camera As shown in the figure stop the machine on ...

Page 246: ...guide line 4 matches with the body rear end 2 When the guide line is abnormal change its setting to non display and contact your Komatsu distributor 2 If the image on the rearview monitor is not aligned correct ly loosen the mounting bolts 5 3 places and adjust the mounting angle of the rearview camera Mounting angle of the rearview camera can be adjusted within the range of 25 to 55 downward when...

Page 247: ...nufactured date It is the start of the 5 year period It is not the start of the 3 year period of actual usage METHOD FOR FASTENING AND UNFASTENING SEAT BELT Fit the seat belt so that it fits tightly without being too tight 1 Sit on the seat and depress the brake pedal fully Under this condition adjust the seat so that your back is fitted to the backrest 2 Sit on the seat pull the right side of the...

Page 248: ...urely fixed to the buckle tongue 1 of the waist belt METHOD FOR RELEASING SEAT BELT RETRACTOR STOPPER 1 Remove the retractor from the seat A fitting can be seen from the bolt side through the oblong hole as shown in the figure 2 Pull the belt while pushing in the fitting with a ruler or such The stopper is released and you can untwist the belt if it is twisted MACHINE OPERATIONS AND CONTROLS OPERA...

Page 249: ... sonal injury or death You can adjust the lengthwise position and height of the steering wheel 1 Raise the lever to FREE position F and adjust the steer ing wheel to a desired position 2 Push down the lever to LOCK position L and fix the steering wheel securely Tilting amount Forward 5 backward 10 Telescopic adjustment amount Upward 20 mm downward 20 mm NOTICE Do not operate the lever with and exc...

Page 250: ...the engine Make sure to set the parking brake switch to PARK ING before you leave the operator seat to avoid sud den machine movement 1 Check that the battery disconnect switch S is in ON posi tion I 2 Check that the parking brake switch 1 is in PARKING position A 3 Check that the gear shift lever 2 is in NEUTRAL position N MACHINE OPERATIONS AND CONTROLS OPERATION 3 190 ...

Page 251: ...f the engine shutdown secondary switch 4 is closed 7 Insert the key into the starting switch 5 and turn it to ON position B 8 Check that the machine monitor operates in the following manner 1 The centralized warning lamp 6 and the pilot display 7 are lit for 2 seconds and go out for 1 second OPERATION MACHINE OPERATIONS AND CONTROLS 3 191 ...

Page 252: ...denly drop depending on the temperature and the battery condition In such case the machine monitor may go out temporarily or restart but it is not a trouble In approximately a second the rearview monitor displays the software version for 5 seconds 6 If a password has been set the password input screen will be displayed on the monitor screen After inputting the password press ENTER switch REMARK Fo...

Page 253: ...ding and the engine can be started 9 When the caution lamp stays lit press ENTER switch and Current Abnormality screen is displayed For the contents and check methods for caution lamp see WARNING DISPLAY 3 17 10 When the maintenance time caution lamp lights up in red press the menu switch and Maintenance menu screen is displayed For the method of checking the maintenance time see MAINTENANCE SCREE...

Page 254: ... start the engine preheat ing automatically 1 Turn the key in starting switch 1 to ON position B If the engine coolant temperature is low the preheating pi lot lamp on machine monitor 2 lights up and the automat ic preheating starts 2 Keep the key in starting switch 1 at ON position B until preheating is completed and the preheating pilot lamp goes out The following shows the rough preheating time...

Page 255: ... The key in starting switch 1 automatically returns to ON position B REMARK At starting of the engine battery voltage may drop abruptly depending on the ambient temperature or battery condi tion and the machine monitor may go out temporarily or restart but it is not a trouble 5 Do not operate the accelerator pedal immediately after starting the engine Run the engine for at least 15 seconds at low ...

Page 256: ...3 may swing once and 88 may be displayed on the speedometer 4 however it is not a trouble REMARK If a password has been set the password input screen will be displayed on the monitor screen but the preheating pilot lamp lights up in the same way as on the standard screen TURBOCHARGER PROTECTION FUNCTION Since the turbocharger is a device that rotates at a very high speed seizure results if it is n...

Page 257: ...there is no abnormal noise when the engine is idling or when the engine speed rises slightly When there is an abnormal noise at the engine startup and if that condition continues the engine may be dam aged In that case ask your Komatsu distributor to check the engine as soon as possible METHOD FOR CHECKING LOW SPEED RUN AND ACCELERATION OF ENGINE k k CAUTION Perform these checks in a safe place wa...

Page 258: ...rature is low and AISS LOW switch is returned to OFF position within a specific time after engine is started the automatic warm up is resumed METHOD FOR WARM UP OPERATION NOTICE Do not increase the engine speed sharply during the warm up operation It can shorten the service life of the engine parts Do not continue the low idle or high idle operation for more than 20 minutes It does not only advers...

Page 259: ...to run hot and accelerate wear of components Park the machine engage the park brake and run the engine until cool down before shut down Always lower the dump body and set the dump lever to FLOAT position then stop the engine 1 Set the gear shift lever 1 to NEUTRAL position N and set the parking brake switch 2 to PARKING position A OPERATION MACHINE OPERATIONS AND CONTROLS 3 199 ...

Page 260: ...y problems are found repair them 2 Fill the fuel tank 3 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove any mud affixed to the undercarriage METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND STOPPING MACHINE METHOD FOR MOVING MACHINE k k WARNING When moving off the machine check that the area around the machine is safe then ...

Page 261: ... brake pedal 3 fully 5 Then set the parking brake switch 4 to TRAVEL position B to release the parking brake REMARK If the engine is stopped with the parking brake switch at TRAVEL position B the parking brake will be automati cally applied even though the parking brake switch is at TRAVEL position B In this case operate the parking brake switch to PARKING position A once and then move it back to ...

Page 262: ...en released the centralized warn ing lamp will light up and the alarm buzzer will sound If the gear shift lever is shifted to a position other than NEUTRAL N when the dump lever is in a po sition other than FLOAT or the dump body is raised the centralized warning lamp lights up the body float caution lamp lights up in red and the alarm buzzer sounds Do not operate the gear shift lever with the acc...

Page 263: ...erator pedal depressed This will cause a big shock and will also reduce the service life of the machine 1 Set the gear shift lever 1 to R position 2 Depress the accelerator pedal 2 gradually to move off METHOD FOR STOPPING MACHINE k k WARNING Avoid a sudden stop Stop the machine gradually If the brake pedal is used repeatedly or is kept depressed for a long time the brake may be worn excessively o...

Page 264: ...s immediately If the parking brake is used to make an emergency stop the performance of the parking brake may drop below the standard value so it is necessary to repair and adjust the parking brake Ask your Komatsu distributor to perform this work If the machine is not stopped by depressing the brake pedal perform the following MACHINE OPERATIONS AND CONTROLS OPERATION 3 204 ...

Page 265: ... secondary brake the cen tralized warning lamp flashes and the alarm buzzer sounds In this case return the gear shift lever to NEUTRAL posi tion N to cancel the operation of centralized warning lamp and alarm buzzer 2 After the machine is stopped set the parking brake switch 3 to PARKING position A 3 When the machine is stopped in emergency chock the tires immediately Investigate the failure on th...

Page 266: ... do not accelerate un til it is detected that the transmission clutch is engag ed Do not operate the gear shift lever with the accelerator pedal depressed This will cause a big shock and will also reduce the service life of the machine Set the gear shift lever 1 to a desired position This machine is equipped with automatic transmission so the transmission will shift automatically to match the trav...

Page 267: ... the brake is automatically applied to prevent the engine speed from rising too far Neutral coast prevention function If the gear shift lever is set to NEUTRAL position N while the machine is traveling at the travel speed of 4 km h or higher the gear shift cannot be changed to neutral The centralized warning lamp flashes and the alarm buz zer sounds intermittently If the travel speed exceeds 4 km ...

Page 268: ...s operated again return the retarder control lever completely to RELEASE position and depress the brake pedal to stop the machine then contact your Komatsu distributor for repair Operate the retarder control lever gradually Sudden braking may cause an accident due to tire slip and it is dangerous When traveling and particularly when traveling downhill never set the gear shift lever to NEUTRAL posi...

Page 269: ...reducing the travel speed Shift the gear shift lever to the position other than D posi tion 6 5 4 3 2 L if the gear speed needs to be fixed due to the condition of road surface 4 When traveling downhill operate the retarder control lever 2 to set the engine speed to the range of 1800 rpm and drive the machine so that the indicator of the retarder oil temperature gauge comes within the green range ...

Page 270: ...he maximum permissible speed The tires may be locked when the dump truck is running on a slippery hauling road and the ARSC system is enabled If it happens refrain from using the ARSC system When the system cannot be properly controlled due to a trouble in the system the alarm sounds and the ARSC is canceled If necessary stop the machine at a safe place by controlling the retarder control lever an...

Page 271: ...way as for normal brake operations If the ARSC travel speed is set near the gear shifting point or when the grade of the slope is changed the gear speed may be changed upshift or downshift even when the ARSC is actuated The time taken for the machine to reach the set travel speed varies with the grade of the downhill slope Indication of the speedometer and the set travel speed may not always be th...

Page 272: ...sition after deceleration Sudden lever operation will cause sudden braking Take care 1 Operate the retarder control lever to decelerate the machine 2 When it gets to the desired travel speed press the set switch of the ARSC travel speed set lever The travel speed is changed to the low speed MEMORIZE ARSC SET TRAVEL SPEED The set travel speed is saved when the starting switch is turned to OFF posit...

Page 273: ...ravel speed indicator automatically drops as well 10 km h is the lower limit value of the travel speed when it automatically drops BRAKE PERFORMANCE CURVE BRAKE PERFORMANCE CURVE HD325 8 How to read the brake performance curve Example Downhill distance 1500 m Traveling resistance 11 Grade resistance 13 rolling resistance 2 Payload 32 t Obtain the maximum permissible speed and the gear speed range ...

Page 274: ...er brake performance Determine a safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the green range when traveling MACHINE OPERATIONS AND CONTROLS OPERATION 3 214 ...

Page 275: ...Brake performance Downhill distance 450 m Tire size 18 00R33 OPERATION MACHINE OPERATIONS AND CONTROLS 3 215 ...

Page 276: ...Brake performance Downhill distance 600 m Tire size 18 00R33 MACHINE OPERATIONS AND CONTROLS OPERATION 3 216 ...

Page 277: ...Brake performance Downhill distance 900 m Tire size 18 00R33 OPERATION MACHINE OPERATIONS AND CONTROLS 3 217 ...

Page 278: ...Brake performance Downhill distance 1500 m Tire size 18 00R33 MACHINE OPERATIONS AND CONTROLS OPERATION 3 218 ...

Page 279: ...or downhill distance of 1500 m 2 Starting from the point A which corresponds to the gross machinery weight draw a perpendicular line down 3 Take the point where it crosses the line for traveling resistance 11 as B and draw a horizontal line 4 Take the point where it crosses the performance curve as C and draw a perpendicular line down Take the point where this line crosses the travel speed scale a...

Page 280: ...er brake performance Determine a safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the green range when traveling MACHINE OPERATIONS AND CONTROLS OPERATION 3 220 ...

Page 281: ...Brake performance Downhill distance 450 m Tire size 21 00R33 OPERATION MACHINE OPERATIONS AND CONTROLS 3 221 ...

Page 282: ...Brake performance Downhill distance 600 m Tire size 21 00R33 MACHINE OPERATIONS AND CONTROLS OPERATION 3 222 ...

Page 283: ...Brake performance Downhill distance 900 m Tire size 21 00R33 OPERATION MACHINE OPERATIONS AND CONTROLS 3 223 ...

Page 284: ...Brake performance Downhill distance 1500 m Tire size 21 00R33 MACHINE OPERATIONS AND CONTROLS OPERATION 3 224 ...

Page 285: ...nd cause overheating When the steering wheel is turned near the right or left end turn it more slowly Turning the steering wheel suddenly to the end of the turn will cause damage to the machine When the machine is traveling turn the steering wheel 1 to the desired direction The machine turns On roads where there are curves let the accelerator pedal back before coming to the curve shift down to the...

Page 286: ...eration of the retarder brake do not stop the engine during the loading work If large rocks are loaded directly onto the dump body by using a large sized loader etc the dump body may be deformed locally 1 When loading the large rocks load the soil and sand first as cushion material 2 After loading the soil and sand load the rock onto them The impacts to the dump body are reduced by this method In ...

Page 287: ...When the dump body rises to the previously set position the dump lever 3 returns to HOLD position B The dump body is then held at that position 3 If it is necessary to raise the dump body further operate the dump lever 3 to RAISE position A The dump body rises further If the dump lever 3 is released the dump lever 3 will re turn to HOLD position B and the dump body will stop at that position While...

Page 288: ...p for any EMERGENCY item on the machine monitor should flash and the buzzer sounds during operation stop the machine immediately and investigate the cause When loading be careful to load the dump body uniformly and be particularly careful to avoid loading too much at the front When traveling on slippery road surfaces operate the retarder control lever slowly and shift the transmis sion down to pre...

Page 289: ...g lever securely at the PARKING posi tion when leaving the operator seat to avoid sudden and unexpected machine movement Sudden and unexpected machine movement can cause personal injury or death The retarder must not be used as a parking brake k k CAUTION To prevent damage to the parking brake apply the parking brake only when parking the machine performing loading operations or performing dumping...

Page 290: ...con trol lever 5 fully to apply the retarder METHOD FOR CHECKING AFTER FINISHING WORK Check the engine coolant temperature engine oil pressure and fuel level with the machine monitor If the engine has overheated do not stop the engine suddenly Run it at a mid range speed to cool it gradu ally before stopping LOCK Always lock the following places MACHINE OPERATIONS AND CONTROLS OPERATION 3 230 ...

Page 291: ... 1 to 10 METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP 1 Insert the starting switch key into the key slot 2 Turn the starting switch key to OPEN position A and then align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 3 Turn the fuel filler cap slowly to unlock it Click sound is heard 4 Open the fuel filler cap PROCED...

Page 292: ...t 2 Turn the starting switch key to OPEN position A and align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 3 Turn the oil filler cap slowly to unlock it Click sound is heard 4 Open the oil filler cap METHOD FOR LOCKING TRANSMISSION CASE FILLER CAP 1 Screw in the oil filler cap 2 Insert the starting switch key into the key slot 3 Turn the starting switch key to LOCK...

Page 293: ...urn the starting switch key to LOCK position B and then align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 4 Remove the starting switch key METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR k k CAUTION Make sure that the cab door is locked when it is closed Always place the machine on a level ground when opening or closing the cab door Avoid opening or closing the d...

Page 294: ...osition B and then remove the starting switch key Position A OPEN Position B LOCK HANDLE TIRE PRECAUTIONS WHEN HANDLING TIRES k k WARNING To ensure safety the defective tires given below must be replaced with new tires Tires where the bead wire has been cut broken or greatly deformed Excessively worn tires where more than 1 4 of the circumference of the carcass ply excluding the breaker is exposed...

Page 295: ...anding more T Km P H to the tire is performed the work T Km P H value exceeds the T Km P H value particular to the tire Observe the following in such case Moderate the work condition so that the work T Km P H value goes down Change the tire to the one whose T Km P H value is higher TIRE T Km P H VALUE AND CONTINUOUS MAX TRAVEL SPEED How to obtain the work T Km P H value by calculation The work T K...

Page 296: ...for a long distance there will be a remarkable increase in the generation of heat in the tire This may cause premature damage to the tire so observe the following Drive the machine only under unloaded condition Check the tire inflation pressure before starting for the day when the tires are cold and adjust to the follow ing inflation pressure Do not reduce the tire inflation pressure when travelin...

Page 297: ...pt to 40 km h or lower Stop for at least 1 hour for every 1 hour of travel to allow the tires and other components to cool down Never drive the machine with water or dry ballast in the tires OPERATION MACHINE OPERATIONS AND CONTROLS 3 237 ...

Page 298: ...conditioner may not work In this case circulate the recirculation air to warm the inside of the cab After that turn on the air conditioner switch and the air con ditioner will work If any abnormality is detected in any equipment or sensor used on the air conditioner the air conditioner system cau tion lamp lights up on the monitor screen If the air condi tioner system caution lamp lights up ask yo...

Page 299: ...switch Air conditioner display A Air flow bar B Air conditioner operation symbol C Set temperature display D FRESH RECIRC selector symbol E Vent display F Automatic operation symbol G Defroster symbol OFF SWITCH The OFF switch is used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen OPERAT...

Page 300: ...dium 4 Air flow high TEMPERATURE CONTROL SWITCH Use the temperature control switch to adjust the temperature inside the cab The temperature can be set between 18 to 32 C Press the switch to raise the set temperature press the switch to lower the set temperature The set temperature is indicated on the display monitor Normally set 25 C The temperature can be set in stages of 0 5 C Air conditioner di...

Page 301: ...When the vent selector switch is pressed the LC display on the monitor display switches and air blows out from the vents displayed During automatic operation the vents are automatically selected A Face vent 4 places B Foot vent 1 place C Front window glass vent 3 places Liquid crystal dis play Air vent mode Vent Remarks A B C Face vent Face vent foot vent Foot vent Foot vent Defroster vent Not sel...

Page 302: ... may change temporarily but this is not a failure Even if the control changes it returns automatically to control the air according to the set temperature and the ambient envi ronment after certain period of time elapses FRESH RECIRC AIR SELECTOR SWITCH Use the FRESH RECIRC air selector switch to switch the air source between recirculation of the air inside the cab and in take of fresh air from th...

Page 303: ...WITCH Use the air conditioner switch to start and stop the cooling heating or drying function Press the air conditioner switch when the fan is operating when the air flow level is shown on the display monitor The air conditioner is turned on and starts operating Press the switch again to stop the air conditioner Air conditioner cannot be operated while the fan is not op erating OPERATION HANDLE AI...

Page 304: ...tomatic operation symbol on the air condi tioner display goes out and the defroster mark is dis played METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of operation as desired METHOD FOR AUTOMATIC OPERATION 1 Press AUTO switch The automatic operation symbol on the air conditioner dis play lights up HANDLE AIR CONDITIONER OPERATION...

Page 305: ...perate the temperature control switch unnecessarily It may take longer time to reach the set temperature To heat or cool the air quickly set the temperature dis play to 18 0 C max cooling or 32 0 C max heat ing If each switch is operated during automatic operation the function of that switch is applied first the automat ic operation symbol on the air conditioner display goes out and the manual ope...

Page 306: ...ven during the manual operation To heat or cool the air quickly set the temperature display to 18 0 C max cooling or 32 0 C max heating 4 Press vent selector switch and select the desired vents The liquid crystal display for the air conditioner display changes according to the selection 5 Press the FRESH RECIRC air selector switch and select the recirculation of the air inside the cab RECIRC or th...

Page 307: ...R TO FEET To operate with cold air blowing to the face and warm air blowing to the feet set as follows 1 Press fan switch and adjust the air flow When doing this check that temperature setting A and air flow B are displayed on the monitor 2 Press vent selector switch and set the vent display on the display monitor to the display shown in the figure OPERATION HANDLE AIR CONDITIONER 3 247 ...

Page 308: ...h ON 4 Adjust fan switch temperature control switch and FRESH RECIRC air selector switch to the desired positions METHOD FOR OPERATING DEFROSTER 1 Press the fan switch and adjust the air flow HANDLE AIR CONDITIONER OPERATION 3 248 ...

Page 309: ...or switch or defroster switch and set the vent display on the display monitor to F or G as shown in the figure 3 Press FRESH RECIRC air selector switch and set it to FRESH mode 4 Press the temperature control switch and set the tempera ture on the display monitor to 32 C of maximum heating OPERATION HANDLE AIR CONDITIONER 3 249 ...

Page 310: ...5 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air turn on the air conditioner switch HANDLE AIR CONDITIONER OPERATION 3 250 ...

Page 311: ... Preset button 6 Display selector button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX on it Press the button again to turn the power off BAND AUX SELECTOR BUTTON Press band AUX selector button to select the desired band or AUX Each time the button is press...

Page 312: ...yed at steps of 50 kHz in certain areas C Lights up when a stereo broadcasting is heard while a FM station is selected D Lights up at the time of balance adjustment in the sound adjusting condition E Lights up at the time of treble adjustment in the sound ad justing condition F Lights up at the time of bass adjustment in the sound adjusting condition AUX You can hear the sound through the speaker ...

Page 313: ...d up it is automatically registered to preset memories 1 to 6 METHOD FOR CALLING PRESET 1 Press band AUX selector button 1 and select FM or AM 2 Press one of 1 to 6 of preset button 2 The frequency registered in the preset number of the pressed button is called up and received Example While a frequency is displayed press button 1 of preset button 2 and the preset number P 1 is displayed on the dis...

Page 314: ...REGISTER RANGE BASS 1 Press sound control button 1 to light up BAS on the dis play You can adjust the sound bass 2 Press tuning time adjustment button 2 to adjust the sound bass Press the button and the bass level increases by 1 Maximum 7 Press the button and the bass level decreases by 1 Minimum 7 METHOD FOR ADJUSTING CLOCK 1 Press display selector button 1 to display the time 2 Hold down display...

Page 315: ...6 Press display selector button 1 to cancel time adjustment The screen returns to the clock display OPERATION HANDLE RADIO 3 255 ...

Page 316: ...d continues in a straight line If there are curves in high speed travel areas make the radius of the curve as large as possible Small S curves are particularly dangerous so avoid such curves The radius of the curve must be a mini mum of 12 m to 15 m Make the radius of curves as large as possible Make the road wider at curves than it is in straight areas Make the surface of the road slightly higher...

Page 317: ...ne for transport After loading the machine in the specified position secure it in place as follows 1 Set the parking brake switch to PARKING position A to apply the parking brake 2 Turn the starting switch to OFF position and stop the en gine 3 Remove the key from the starting switch 4 Put the blocks in front of and behind the tires and secure the machine with chains or wire rope of a suitable str...

Page 318: ...ment than those given in the following procedures There is a danger that the machine loses its balance NOTICE This lifting method applies to the standard specification machine The method of lifting differs depending on the attachments and options installed For the procedure for the machine with other than standard specification consult your Komatsu distrib utor For the weight of the standard speci...

Page 319: ... FOR LIFTING MACHINE Lifting work is allowed for only machines having lifting marks When performing the lifting operation place the machine on a firm level ground and do as follows 1 Start the engine 2 Set the dump lever to FLOAT position C and check that the dump body float caution lamp is not lit 3 Stop the engine and set the parking brake switch to PARKING position A to apply the parking brake ...

Page 320: ...ndition For machine with a dump body Positions 1 and 3 For machine without a dump body Positions 1 and 2 5 Fit the protector blocks at contact points between the lifting tool and the dump body to prevent damage to the lifting tool 6 When the machine comes off the ground being lifted 100 to 200 mm stop the lifting operation check care fully that the machine is balanced and that the wire ropes are n...

Page 321: ...is not flammable For details on the coolant change interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand and the devices in the tank may be broken or the parts may be affected Add DEF to the specified amount for cold weather below the leve...

Page 322: ... machine may get stuck and does not move due to mud and water which become frozen around the under carriage of the machine Observe the following in order to prevent the machine from being frozen Remove all the mud and water from the machine body In particular wipe the hydraulic cylinder rods clean to prevent the seal from being damaged by mud or dirt together with drops of water on the rod which e...

Page 323: ...referring to METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE If the machine is parked for long time in the cold weather condition quality of DEF may be affected by re peated freeze ask your Komatsu distributor to inspect OPERATION COLD WEATHER OPERATION 3 263 ...

Page 324: ... DURING LONG TERM STORAGE k k WARNING If it is necessary to perform the rust prevention operation while the machine is indoors open the doors and windows to improve ventilation and prevent gas poisoning During storage operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts At the same time charge the battery as well When operating the work eq...

Page 325: ...and the audible alert sounds If SCR system has any abnormality stop the engine and then start it again If SCR system still has abnormality after the engine is restarted contact your Komatsu distributor If the DEF is kept in the DEF tank for more than 1 year replace it Dispose of the drained DEF according to the local regulations and rules Aged DEF may have smell of ammonia Replace the DEF in a wel...

Page 326: ...sition or start the engine 2 Disconnect pull out the limp home connector 1 No A1 female A1 male white 1 pole connector and then connect insert it again 3 Set the parking brake switch to TRAVEL position 4 Operate the gear shift lever to move the machine to a safe place without depressing the accelerator pedal If the gear shift lever is operated with the accelerator pedal depressed the limp home fun...

Page 327: ... or kinks C There is a danger that the rope may break during the towing operation Wear the leather gloves always when handling the wire ropes Never tow a machine on a slope During the towing operation never stand between the towing machine and the towed machine If the machine moves suddenly a load is applied sud denly to the towing wire or drawbar and the towing wire or drawbar may break Move the ...

Page 328: ...ible to determine beforehand the requirements for towing Towing on flat level roads will require the minimum rim pull while towing on slopes or on uneven road surfa ces will require the maximum rim pull Always release the parking brake before towing Before releasing the parking brake always chock the all wheels If the wheels are not chocked there is a danger that the machine may move suddenly Conn...

Page 329: ...ders then perform the towing operation When removing the hoses block the hoses with plugs and fit oil containers to the mouthpiece of the cylin der to prevent oil from draining to the ground METHOD FOR RELEASING PARKING BRAKE See the following procedure if it is necessary to release the parking brake when towing or moving the machine Ask your Komatsu distributor if it is necessary to release the p...

Page 330: ...ment screw 1 then turn the adjustment screw 1 clockwise 4 Check that there is a clearance between the parking brake pad and brake disc 5 When the parking brake is released tow the machine im mediately to a safe place TROUBLES AND ACTIONS OPERATION 3 270 ...

Page 331: ... battery first disconnect the cable from the ground normally the negative terminal When installing first connect the cable to the positive terminal If a tool touches the positive terminal and the chassis it is dangerous that it may cause a spark Be extremely careful If the terminals are loose it is dangerous that the de fective contact may generate sparks and it may cause an explosion Install the ...

Page 332: ... the positive terminal of the battery then connect the negative charger clip of the battery charger to the negative terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 or less of the value of the rated battery capacity When performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak ...

Page 333: ...bles and clips for damage or corrosion Make sure that the cables and clips are firmly connected To prevent damage of the electric devices of the failed machine turn the starting switch of the failed machine to OFF position and then turn the battery disconnect switch key to OFF position before connecting the jumper cables REMARK If the battery disconnect switch is turned to OFF position all the ele...

Page 334: ...umper cable A from the positive terminal of battery C on the failed machine OTHER TROUBLE PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM For the remedies indicated with in the remedy column always contact your Komatsu distributor In cases of problems or causes which are not listed below ask your Komatsu distributor for repairs Problem Main causes Remedy Lamp does not glow brightly even when the engin...

Page 335: ... relay Replace Blown fuse of heater Replace PHENOMENA AND ACTIONS FOR CHASSIS For the remedies indicated with in the remedy column always contact your Komatsu distributor In cases of problems or causes which are not listed below ask your Komatsu distributor for repairs Problem Main causes Remedy Torque converter oil temperature cau tion lamp flashes Leakage of oil or entry of air due to damage or ...

Page 336: ...accelerator pedal has failed The accelerator pedal is equipped with a potentiometer that detects the amount that the accelerator pedal is depressed In addition there is a switch that judges if the accelerator pedal is being depressed or if it has been released If it is impossible to detect correctly the amount that the accelerator pedal is depressed because of breakage of the accelerator pedal or ...

Page 337: ... radiator pressure valve Lowered coolant level leakage of coolant Check add coolant See CHECKS BEFORE STARTING The coolant level caution lamp lights up and the machine monitor displays low coolant level as L01 Dirt or scale accumulated in cooling system Change coolant clean inside of cooling system See WHEN RE QUIRED Indicator of engine coolant tempera ture gauge is in red range Engine coolant tem...

Page 338: ... ring cylinder liner Replace Low grade fuel being used Replace with specified fuel Defective turbocharger Check replace Water entry in the aftertreatment de vice Check repair Breakage of the aftertreatment devi ces Replace the aftertreatment devi ces Exhaust gas is black Clogged air cleaner element Clean or replace See WHEN REQUIRED Worn piston ring cylinder liner Check repair Defective compressio...

Page 339: ...en is displayed Take the actions according to the message shown on the monitor and check the failure code and then ask your Komatsu distributor for repair as necessary Telephone number for the point of contact when an error occurs When the guidance icon is displayed on the machine monitor press ENTER switch and Current Abnormality screen is dis played and the telephone number for the point of cont...

Page 340: ......

Page 341: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 342: ...ling oil or fuel PRECAUTIONS FOR ADDING DEF Do not remove the strainer while adding DEF It is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop function to add DEF PRECAUTIONS FOR WELDING When conducting weld repair turn the starting switch to OFF position and after confirming that the system operating lamp is turned off set the battery disconnect...

Page 343: ...ck bar etc If inspection or maintenance is performed with inspection cover not locked in position there is a danger that it may be suddenly shut by the wind and cause personal injury BLEED AIR FROM HYDRAULIC CIRCUIT When hydraulic equipment is repaired or replaced or the hydraulic piping is disconnected the air must be bled from the circuit PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing...

Page 344: ...as an iron plate 3 between the holder portion 1 of the bottom of the kingpin and the jack 2 and apply the jack Be careful that the bolt 4 does not touch the iron plate 3 this time When you lift only one side of tire off the ground set the support stand 5 under the frame to make the machine stable Do not jack up by applying the jack to the A frame 6 Oth erwise the A frame will become deformed or da...

Page 345: ...rty always change the oil at the specified interval Oil corresponds to blood in the human body always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different gra...

Page 346: ...t function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of coolant is essential Komatsu machines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu recommends the use of Non Am...

Page 347: ... used to prevent seizure and noises at the joints This construction equipment is used under heavy duty conditions Komatsu recommends using the recom mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual Grease fittings not included in the periodic maintenance section are the grease fittings for overhaul so they do not...

Page 348: ... sheet or take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first STORE DEF Completely seal up its container for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container Make sure that transfer equip ment and...

Page 349: ...leakage and may lead to malfunction of the machine Do not wash the inside of the operator s cab with water When washing the machine be careful not to let water get into the electrical components Wipe off the water drops stuck around connectors before removing the connectors and do not let water drops get into the connectors when removing the connectors of electrical components after washing the ma...

Page 350: ...er of bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 10 13 3 1 35 11 8 to 14 7 1 2 to 1 5 8 13 31 3 2 27 to 34 2 8 to 3 5 10 17 67 6 8 59 to 74 6 0 to 7 5 12 19 111 11 3 98 to 123 10 0 to 12 5 14 22 172 17 5 153 to 190 15 5 to 19 5 16 24 260 26 5 235 to 285 23 5 to 29 5 18 27 360 37 0 320 to 400 33 to 41 20 30 510 52 3 455 to 565 46 5 to 58 22 32 6...

Page 351: ... 41 216 22 0 177 to 245 18 0 to 25 0 36 46 245 25 0 197 to 294 20 0 to 30 0 42 55 294 30 0 246 to 343 25 0 to 35 0 Face seal Nominal No of threads a Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 9 16 18UN 19 44 4 5 34 to 54 3 5 to 5 5 11 16 16UN 22 74 7 5 54 to 93 5 5 to 9 5 13 16 16UN 27 103 10 5 84 to 132 8 5 to 13 5 1 14UNS 32 157 16 0 128 to 186 13 0 to 1...

Page 352: ...4 34 SELECT AND CHECK TIRES 4 35 METHOD FOR RELEASING PARKING BRAKE 4 37 CHECKS BEFORE STARTING 4 38 EVERY 250 HOURS MAINTENANCE 4 39 METHOD FOR LUBRICATING 4 39 METHOD FOR CHECKING AND ADDING OIL IN DIFFERENTIAL CASE 4 40 METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE ADDING OIL 4 41 METHOD FOR CHECKING DRIVE SHAFT 4 41 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 4 41 METHOD FOR CLEANING TRA...

Page 353: ...RE PIPING CLAMP HARD ENING OF RUBBER 4 80 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 80 EVERY 4500 HOURS MAINTENANCE 4 81 METHOD FOR CLEANING KDPF 4 81 METHOD FOR CLEANING DEF TANK 4 81 METHOD FOR CLEANING FUEL DOSER 4 81 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING HARDENING OF RUBBER 4 81 METHOD FOR CHECKING EXHAUST PIPE FIRE...

Page 354: ...esel fuel has been changed to the diesel fuel mixed with bio fuel Operating hours of the machine Service meter When changed 250 hours after chang ing 500 hours after chang ing Every 500 hours Every 1000 hours Within 500 operating hours after changing After 500 op erating hours after chang ing Within 500 operating hours after changing After 500 op erating hours after chang ing Fuel pre fil ter cart...

Page 355: ... poor be careful not to fall because of the re action when pulling out the outer element NOTICE Do not clean the element before the air cleaner clogging caution lamp on the machine monitor lights up or the yellow piston of the dust indicator laps over the peripheral red zone 7 5 kPa 0 076 kg cm2 If the element is cleaned frequently before the air cleaner clogging caution lamp on the machine monito...

Page 356: ...UTER ELEMENT NOTICE Never remove the inner element Dusts may enter causing the engine failure Do not use damaged element Do not use the removed inner element more than once Make sure to replace the inner element when you replace the outer element Keep new elements dry 1 Stop the engine 2 Remove the clips 1 6 places and remove the cover 2 3 Hold the outer element 3 rock it lightly up and down and t...

Page 357: ... along the pleats 11 Blow along the pleats from the outside then blow again from the inside 12 After cleaning the outer element illuminate the inside of the element with an electric bulb to check If any hole or thin place is found replace the outer ele ment 13 Remove the cover of cloth or tape attached to inner ele ment 4 14 Check the seal of the cleaned or new element for sticking of dusts and oi...

Page 358: ...ches the red line 7 5 kPa 0 076 kg cm2 immediately after the cleaning of the outer element re place both inner and outer elements with new ones METHOD FOR REPLACING AIR CLEANER ELEMENT 1 Stop the engine 2 Remove the clips 1 6 places and remove the cover 2 3 Hold the outer element 3 rock it lightly up and down and to the right and left and pull the outer element 3 out while turning it to the right ...

Page 359: ...ner body 5 Lock the clips 1 diagonally top and bottom right and left in the same way as when tightening the bolts 4 When the cover 2 is installed check that the clear ance between air cleaner body 5 and cover 2 is not too large If the clearance is too large remove the cover 2 and then install it again 12 Press the button of the dust indicator and return the yellow piston METHOD FOR CLEANING INSIDE...

Page 360: ...46 50 54 58 61 64 k k WARNING Coolant is toxic When opening the drain plug be careful not to get coolant on you If it gets in your eyes flush your eyes with large amount of fresh water and see a doctor immediately When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator contact your Komatsu distributor or request a qualified com...

Page 361: ...nd remove the cover 2 on top of the sub tank 3 Remove the bolts 3 4 pieces and remove the cover 4 on top of the radiator 4 Check that the radiator cap 5 is cooled enough to touch by bare hands and turn it a little to release the pressure and then turn it slowly to remove it 5 Remove the radiator cap 6 and the sub tank filler port cap 7 MAINTENANCE MAINTENANCE PROCEDURE 4 21 ...

Page 362: ...he drain plug 9 and drain the coolant 10 After draining the coolant close the drain valve 8 and the drain plug 9 11 Pour the tap water through the filler port of radiator Pour the tap water until it fills the radiator 12 Install the radiator caps 5 6 and the sub tank filler port cap 7 13 Start the engine Run the engine at low idle and raise the water tempera ture to 90 C or higher and run the engi...

Page 363: ... tank filler port cap 7 and add the coolant from radiator caps 5 and 6 When the radiator caps 5 6 area is filled with coolant first close the radiator caps 5 and 6 and then add the coolant from the sub tank filler port 7 19 Close the radiator caps 5 6 and the sub tank filler port cap 7 while engine is stopped 20 Install the cover on the right side of the machine 21 Install the cover of the engine ...

Page 364: ...oolant filler port When adding the coolant the sub tank filler port cap 7 area is filled with coolant faster than the radia tor caps 5 6 area and the coolant may overflow from the cap 7 At that time close the sub tank filler port cap 7 and add the coolant from radiator caps 5 and 6 When the radiator caps 5 6 area is filled with coolant first close the radiator caps 5 and 6 and then add the coolant...

Page 365: ... occurs easily The normal rotation should be used always when operating the machine For stopping the engine while the fan is rotating in reverse reduce the engine speed to low idle then stop the engine For performing the cleaning of fins by rotating the cooling fan in reverse it should be after the oper ation or after warming up the hydraulic oil The fan speed is kept low in order to protect the h...

Page 366: ...EMARK The fan rotation switches from the normal direction nor mal rotation direction to the reverse direction only when all of the following conditions are satisfied The engine is stopped The cooling fan is stopped The dump body is seated 9 Start the engine The fan rotates in reverse 10 Set the engine speed to high idle and perform the cleaning Select the time for running the engine at high idle a...

Page 367: ...not be switched if the fan reverse operation is performed without satisfying the condition for reversing the fan In this case press RETURN switch 2 and then perform the procedure again REMARK When a certain time has passed after the starting switch is turned to OFF position the fan is returned to the normal rotation normal rotation direction automatically METHOD FOR CLEANING FIN WITH COMPRESSED AI...

Page 368: ...ETHOD FOR CHECKING WINDOW WASHER FLUID LEVEL ADDING FLUID 1 Open the cover 1 on the right side of the cab 2 Check the fluid level in the window washer tank 2 1 If the window washer fluid is insufficient open the cap of window washer tank 2 add the window washer fluid for automobiles Be careful not to let dirt or dust get in when adding it 2 Close the cap of window washer tank 2 3 After checking th...

Page 369: ...CONDITIONER AIR FILTERS If the air filter at the suction port of the air conditioner unit or the air filter at the fresh air intake port become clogged the cooling or heating capacity will drop so clean the filters 1 Open the cover 1 on the side of the cab 2 Pull out the air filter fresh air filter 3 Clean the air filter fresh air filter with compressed air 4 Open the cover 2 at the rear left of t...

Page 370: ...inder retracting and hitting the stopper check the length of the suspension cylinder Check the front suspension 1 and the rear suspension 2 with the machine unloaded METHOD FOR CHECKING LENGTH OF FRONT SUSPENSION CYLINDER 1 Check on a level ground that the bottom end of the front suspension cylinder cover is within the range A shown by arrow in the label 1 2 Remove the bolts 2 2 pieces and remove ...

Page 371: ...OM BRAKE CIRCUIT k k WARNING Stop the machine on a flat ground turn the parking brake switch to PARKING position chock the tires and then bleed air When air bleeding is performed the brake may be released and the machine may start moving It may lead to serious personal injury or death Stop the machine on a level ground and chock the wheels before bleeding the air When any brake circuit device is r...

Page 372: ...y 3 4 turns 10 Keep pulling the retarder control lever and check that no bubble comes out through the vinyl hose 11 Tighten the bleeder screw 1 securely 12 Install the cap to the bleeder screw 1 5 Bleed air from the rear brake 1 Remove the cap of the bleeder screw 2 of the rear brake 2 Insert a vinyl hose to the bleeder screw 2 3 Place a container with oil in it 4 Put the other end of the hose in ...

Page 373: ...e 12 Tighten the bleeder screw 1 securely 13 Install the cap to the bleeder screw 1 14 Adjust the oil level in the transmission case to the specified level METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT This machine is equipped with the fuel feed pump to bleed air from the fuel circuit In the following cases bleed air according to the following procedure When the fuel filter is replaced When fuel is us...

Page 374: ...e air may not be bled Stop the engine and repeat the operations of steps 4 to 7 again NOTICE Keep away from the engine while it is being started and running Do not start the engine for more than 20 seconds intervals Wait 2 minutes between attempts REMARK Move the switch for the fuel feed pump 2 to ON position then the air bleeding starts automatically The fuel feed pump is operated for 30 seconds ...

Page 375: ...o the step 3 8 Measure the amount of movement L of the coupling by using the marks made in the steps 4 and 7 If amount of movement L exceeds 15 mm the rubber in side the output shaft may be deteriorated or damaged so ask your Komatsu distributor for disassembly and inspec tion of the internal parts of the output shaft SELECT AND CHECK TIRES k k WARNING If a tire or a rim is handled improperly the ...

Page 376: ...r chuck with a clip that can be fixed to the air valve To prevent the tire inflation pressure from becoming too high measure the pressure from time to time with an air gauge while pumping up the tire If the rim is not fitted normally it may be broken and scattered while the tire is inflated Accordingly place a guard around the tire and do not work in front of the rim but work on the tread side of ...

Page 377: ...htening the hub bolts 1 after replacing the tire drive the machine for 5 to 6 km then tighten the bolts again to settle all the contacting parts In particular there are more contacting parts on the rear wheels than on the front wheels so it will take time for the parts to settle For this reason repeat the tightening process during the first 50 hours after installation METHOD FOR RELEASING PARKING ...

Page 378: ...justment check the parking brake performance If the machine moves ask your Komatsu distributor for in spection CHECKS BEFORE STARTING For the following items see OPERATION METHOD FOR CHECKING BEFORE STARTING Drain water and sediment from fuel tank Check looseness of wheel hub bolts and retighten Check oil level in transmission case add oil Check dust indicator Check battery disconnect switch Check...

Page 379: ...gh the grease fitting 3 Check visually that the greasing has been performed properly 4 After greasing wipe off any old grease that is pushed out Perform the greasing work every day when operating the machine in the places where the grease flows out easily such as when traveling through mud or water Dump body hinge pin 1 place each of right and left Rear suspension 2 places each of right and left R...

Page 380: ...L CASE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the plug oil may spurt out so turn it slowly to release the internal pressure then remove it carefully 1 Remove the plug G 2 Check that the oil level is close to the lower edge of the plug hole If the oi...

Page 381: ...G If the oil level is close to the lower edge of the plug hole the oil level is appropriate 3 If the oil level is too low add oil through the plug hole until the oil overflows 4 Install the plug G METHOD FOR CHECKING DRIVE SHAFT Check that there is no problem such as loose connection of the drive shaft play in the splines and bearings runout of the shaft etc If any problem is found ask your Komats...

Page 382: ...the battery box Open the cover 1 of the battery box fully and it is se cured by rod 2 2 Clean around the electrolyte level line with a cloth wet with water 3 Check that the electrolyte level is between UPPER LEVEL line and LOWER LEVEL line 4 If the electrolyte level is below the middle between UPPER LEVEL and LOWER LEVEL lines immediately remove the cap 3 and add the purified water such as a comme...

Page 383: ...ded to the level above the bottom of the sleeve use a syringe to remove it until the level becomes under the bottom of the sleeve Neutralize the removed fluid with baking soda sodium bicar bonate then flush it away with a large amount of water If necessary consult your Komatsu distributor or a battery manufacturer 6 Release the lock of battery box cover 1 and close the cover METHOD FOR CHECKING EL...

Page 384: ... 6 10 Install the cover 5 and bolt 4 11 Install the breather 3 12 Install the cover 2 with bolts 1 13 Remove the body pivot pin 14 Lower the dump body METHOD FOR CLEANING STEERING AND HOIST OIL TANK BREATHER k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Wait for the temperature to go down and then start the work 1 Remove mud and ...

Page 385: ...pair procedure METHOD FOR CHECKING FOOT BRAKE PERFORMANCE k k WARNING If the machine moves when the braking capacity is being checked it may lead to serious personal injury or death If the machine moves lower the engine speed immediately set the gear shift lever to NEUTRAL position N and set the parking brake switch to PARKING position NOTICE When checking be sure to select F2 in F1 Start at D Pos...

Page 386: ... checking be sure to select F2 in F1 Start at D Position Setting and then set the gear shift lever to the position D Neglecting this can damage the inside of the transmission Make the dump body seated securely before the inspection Check that the dump body float caution lamp is not lit When the dump body is not seated and the parking brake is at TRAVEL the gear speed is F1 while the gear shift lev...

Page 387: ...sition Set ting of user menu of the machine monitor 2 Set the parking brake switch 1 to PARKING position on a flat ground 3 Set the gear shift lever 2 in the position D and increase the engine speed gradually If the machine does not move when the engine speed is increased to 1600 rpm it is normal If any problem is found ask your Komatsu distributor for repair 4 Decrease the engine speed and set th...

Page 388: ...l not depressed when having no load B Medium With the brake pedal not depressed when having no load C Hard When setting the dump lever to the position other than FLOAT Ask your Komatsu distributor for the inspection and adjustment if there is any problem found METHOD FOR CHECKING FUNCTION OF ACCUMULATOR If the engine stops during travel the brake can be operated with the oil pressure in the accumu...

Page 389: ...pressure in the accumulator may be low Ask your Ko matsu distributor for inspection If the brake oil pressure caution lamp does not light up when the brake pedal is depressed 5 times the gas pressure in the accumulator is normal REMARK Check the function within 5 minutes after stopping the en gine If the engine is kept stopped the gas pressure in the accu mulator lowers and cannot be checked 7 Aft...

Page 390: ... drained oil 3 Remove the drain plug 1 4 Install the drain hose of accessory tool 5 When draining the oil loosen the drain valve 2 slowly so that you will not get oil on yourself Be careful not to loosen the drain valve 2 too far and de form the stopper pin inside the valve 6 Check the drained oil If there are excessive metal particles or foreign materials contact your Komatsu distributor 7 Remove...

Page 391: ...d oil may be milky white because of water vapor in the blowby gas However if the coolant level is normal it is not a problem There is no problem even if the emulsified matter cannot be removed completely after changing the oil METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE k k WARNING Allow parts and oils to cool to touch before you perform maintenance While the engine is running high pressure is g...

Page 392: ...es on the dirty side After filling with fuel remove the cap A and in stall the fuel filter Always fill with clean fuel Be careful not to let any dirt or dust get into the fuel In particular center portion is the clean side so do not remove the cap A when filling with fuel Be careful not to let dirt or dust get into the center portion on the clean side 9 Thinly apply oil to the packing surfaces 10 ...

Page 393: ... go down and then start the work Items to be prepared Container to catch the drained oil 1 Place a container to catch the drained oil under the trans mission oil filter 1 2 Remove the plug 2 of the transmission oil filter 1 and drain the oil 3 After draining the oil tighten the plug 2 Tightening torque of drain plug 49 to 58 8 Nm 5 to 6 kgm 4 Loosen the hexagonal portion 4 of the filter case 3 and...

Page 394: ...is 3 mm A It is reaching to the wear limit B Replace the pad since it has reached the wear limit Ask your Komatsu distributor for replacement of the pad 5 The wear amount of pads on the right and left wheels are not equal Perform the check on both sides Be sure to replace all of 4 pieces if one of the pads reaches the wear limit Wash the machine thoroughly after working in the muddy site Mud stuck...

Page 395: ...ement is not required when only horizontal flaw 8 is found on it 5 Install the cover 4 with bolts 3 6 pieces 6 Install the cover 2 with bolts 1 9 pieces 7 Install the cover on the left side of the machine EVERY 1000 HOURS MAINTENANCE Maintenance for every 250 and 500 hours services should be performed out at the same time METHOD FOR CHANGING OIL IN TRANSMISSION CASE AND BRAKE SUB TANK CLEANING STR...

Page 396: ... brake sub tank cleaning strainer Replacing transmission and rear brake cooling oil filter element Replacing brake oil filter element Items to be prepared Container to catch the drained oil Vinyl hose Use a commercially available vinyl hose Container with oil in it 1 Stop the engine 2 Drain the oil in the transmission case 1 Place a container to catch oil just under the drain plug 1 2 Remove the d...

Page 397: ...he oil from the brake chamber easier 2 Remove the retarder drain plug 9 and drain the oil from the brake chamber 3 Install the retarder drain plug 9 after the oil is drained from the brake chamber 4 Install the plug 8 6 Add 80 ℓ of oil through the oil filler port F without starting the engine Since the oil has not filled all the pipings yet the oil level exceeds the level of the sight gauge G1 whe...

Page 398: ...e the vinyl hose 8 Install the cap to the bleeder screw 10 9 Perform the warm up operation of the engine until the torque converter oil temperature gauge goes to 40 C or higher 10 When the torque converter oil temperature gauge rises to 40 C or higher bleed air from the brakes For the procedure to bleed air from the brake see METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 4 31 NOTICE Do not reuse the ...

Page 399: ...ng to the case 7 Replace the O ring with a new one apply thin film of oil to it and install it 8 Install the cover 2 with bolts 1 4 pieces Replace the element immediately if the retarder oil temperature gauge indicates the white range and the brake cooling oil filter clogging caution lamp if equipped lights up while the engine is running METHOD FOR REPLACING BRAKE OIL FILTER ELEMENT k k WARNING Im...

Page 400: ... filter case 3 Tightening torque 78 4 to 98 0 Nm 8 to 10 kgm 12 Install the cover 2 with bolts 1 METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE k k WARNING After the engine stops all parts are still very hot so do not replace the filter immediately Wait for all parts to cool down before starting the work While the engine is running high pressure is generated in the engine fuel piping When replaci...

Page 401: ...wash it off thoroughly with fuel After removing the filter cartridge fuel drops from the filter head In order to prevent the fuel from flowing out be sure not to leave the machine without the filter car tridge After replacing the fuel prefilter cartridge replace the fuel main filter cartridge For replacing the fuel prefilter cartridge see METHOD FOR REPLACING FUEL PREFILTER CAR TRIDGE Items to be ...

Page 402: ...y and the fuel feed pump stops When lamp 4 goes out air bleeding is completed 2 Start the engine If the engine does not start all the air may not be bled In this case repeat the operation of step 9 11 After completing the air bleeding start the engine and check the filter seal surface for fuel leakage If there is any leakage of fuel check the tightening condition of the filter cartridge If there i...

Page 403: ...ag that can be seen clearly to prevent any other person from operating the parking brake switch Never put any oil or grease on the surface of the brake disc or pad 1 Stop the machine on a level place 2 Chock the tires to prevent the machine from moving 3 Raise the dump body 4 Fix the dump body with the dump body pivot pin 5 Before starting operations raise the brake oil pressure sufficiently to pr...

Page 404: ...the fitting 1 12 Lower the dump body 13 Check the parking brake performance If the machine moves during the performance check ad just the parking brake For the performance check of the parking brake see METHOD FOR CHECKING PARKING BRAKE PER FORMANCE METHOD FOR LUBRICATING NOTICE Do not use air pressure or oil pressure to perform high pressure greasing 1 Stop the engine 2 By using a grease pump pum...

Page 405: ... the wear limit Ask your Komatsu distributor for inspection and mainte nance in such case 5 Install the cap nut 1 which is removed in the step 3 Tightening torque 128 to 186 Nm 13 to 19 kgm REMARK The position of the guide has been adjusted so that the slit 5 matches the end face of guide 4 for a new machine Therefore do not loosen the lock nut 6 except when replacing the disc If the rod is pushed...

Page 406: ... METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP 1 Check for looseness in the air intake piping clamps between the air cleaner turbocharger aftercooler and engine 2 If clamp is loose retighten it Tightening torque of clamp 1 10 5 0 5 Nm 1 07 0 05 kgm METHOD FOR REPLACING DEF TANK BREATHER ELEMENT k k WARNING Allow parts and oils to cool to touch before you perform maintenance MAINTEN...

Page 407: ...ways stop the engine and clean around the DEF tank before replacing After the engine is stopped the DEF system devices automatically purge the DEF in the DEF injec tor and DEF pump and return it to the DEF tank to prevent malfunction of the devices caused by freezing of the DEF or deposition of urea After the engine is stopped the devices are operated for a few minutes Replace the element after th...

Page 408: ...eft side of the machine 2 Remove the bolts 1 6 pieces and remove the cover 2 3 Check the pulley for play and the grease for leakage If any problem is found ask your Komatsu distributor for repair and replacement 4 Install the cover 2 with bolts 1 6 pieces 5 Install the cover on the left side of the machine METHOD FOR LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF COMPRESSOR FOR ALTERNATOR AND A...

Page 409: ...ame time METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully 1 Stop the engine 2 Turn th...

Page 410: ...CASE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work If there is remaining pressure inside the case the oil or plug may jump out Turn the plug slowly to release the pressure then remove it carefully Refill capacity 15 0 ℓ each of right and left Items to be prepared Contai...

Page 411: ... through the hole of plug G 4 After adding oil check that the oil level is in the specified range METHOD FOR CLEANING DIFFERENTIAL CASE BREATHER k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Wait for the temperature to go down and then start the work 1 Stop the engine 2 Remove mud and dirt around the breather 3 Remove the breathe...

Page 412: ...e the O ring at this time 8 Install the cap of oil filler port F METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE Contact your Komatsu distributor to have the gas pressure checked when making periodically replacement of safety parts or performing the legally required 2000 hour or every year service METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and ...

Page 413: ...result the turbocharger and aftercooler become dirty and the per formance lowers or the crankcase pressure increases Never reuse the filter element since it can cause an engine failure After the filter element is replaced if KCCV is not assembled correctly oil or blowby gas may leak Replace the filter element in the correct procedure Items to be prepared Container to catch the drained oil Special ...

Page 414: ...ed O ring 6 sticking to the case 4 and in stall a new O ring contained in the service kit Apply the engine oil to the new O ring 4 While matching the marks 7 of the new element with the mark 8 of the body label insert the element firmly into the end of the body The element can be installed only when its claws 9 are correctly inserted in grooves 10 of the filter body Bases 11 and 12 are oval When i...

Page 415: ... filter attached or with the filter other than Komatsu gen uine parts foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine Never operate the machine without the DEF filter attached nor use the filter other than Komatsu genuine parts The DEF filter cannot be flushed Flushing or regenerating of it will degrade the performance of fil ter and will cause the...

Page 416: ...o be prepared DEF filter removal tool Torque wrench 1 Remove the bolts 1 6 pieces and remove the cover 2 The DEF filter is located at the position shown in the fig ure 2 Remove the filter cap 3 at the lower part of DEF pump and remove the element 4 3 Turn the cap 6 of filter removal tool 5 and remove it 4 Check the installation of spacer 7 MAINTENANCE PROCEDURE MAINTENANCE 4 76 ...

Page 417: ...e it out together with the filter removal tool 5 If filter 8 cannot be removed from the DEF pump grip the filter removal tool 5 pull it down then it will be removed 8 Slide the filter 8 down and remove the spacer 7 from the filter removal tool 5 9 Pull the filter 8 up while pushing in the tip of filter removal tool 5 and remove it 10 Return the removed spacer 7 to the filter removal tool 5 and kee...

Page 418: ... 3 Steering system High pressure circuit hose 4 Brake system Brake oil pressure hose Retarder control valve rubber parts 5 Torque converter trans mission system Transmission circuit hose 6 Work equipment hydraulic system Main pump delivery hose Main pump delivery hose other than described above Main pump LS hose Hose for hydraulic drive fan External work equipment hose Hoist circuit hose 7 Others ...

Page 419: ... through the grease fitting shown by arrow Grease the spider part until grease comes out from the cap seal 3 Check visually that the greasing has been performed prop erly 4 After greasing wipe off any old grease that is pushed out METHOD FOR CHECKING WATER PUMP Check around the water pump for water leakage If any part is leaking ask your Komatsu distributor for inspection repair METHOD FOR CHECKIN...

Page 420: ...nt ing bolts or hardening of the rubber If there is any problem the related parts must be replaced Ask your Komatsu distributor for replacement METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER The fuel spray prevention cap acts to prevent the fuel from coming into contact with high temperature parts of the engine and causing a fire if the fuel should leak or spray out ...

Page 421: ... to prevent the fuel from coming into contact with high temperature parts of the engine and causing a fire if the fuel should leak or spray out Check visually and touch by hand to check that there are no missing caps loose bolts or hardening of the rub ber If there are any problems the parts must be replaced Ask your Komatsu distributor for replacement METHOD FOR CHECKING EXHAUST PIPE FIRE PREVENT...

Page 422: ...all the cover 5 with bolts 4 EVERY 8000 HOURS MAINTENANCE Maintenance for every 250 500 1000 2000 and 4000 hours services should be performed out at the same time METHOD FOR REPLACING ENGINE HIGH PRESSURE PIPING CLAMP Special techniques and tools are required for this work Ask your Komatsu distributor for replacement of the engine high pressure piping METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP...

Page 423: ...matsu distributor for replacement of the fuel spray prevention cap on fuel doser END OF SERVICE LIFE For safe dismantling of the machine at the end of service life please contact your Komatsu distributor EVERY 15000 HOURS MAINTENANCE Maintenance for every 250 500 and 1000 hours should be performed at the same time METHOD FOR CHECKING AND REPLACING STEERING A ARM MOUNTING BOLT Ask your Komatsu dist...

Page 424: ......

Page 425: ...SPECIFICATIONS 5 1 ...

Page 426: ... engine Engine rated horsepower SAE J1995 gross kW min 1 386 2000 ISO 14396 386 2000 ISO 9249 SAE J1349 net 383 2000 Engine maximum torque Nm kgm rpm 2170 221 3 1400 A Overall length mm 9245 B Overall height mm 4185 C Overall height when dumping mm 8030 D Overall width mm 4400 E Minimum ground clearance mm 510 Minimum turning radius mm 7200 Travel speed Forward 1st km h 10 0 2nd km h 15 3 3rd km h...

Page 427: ...7 3 Dumping speed 2000 rpm raised Second 10 Engine model Komatsu SAA6D140E 7 diesel engine Engine rated horsepower SAE J1995 gross kW min 1 386 2000 ISO 14396 386 2000 ISO 9249 SAE J1349 net 383 2000 Engine maximum torque Nm kgm rpm 2170 221 3 1400 A Overall length mm 9245 B Overall height mm 4255 C Overall height when dumping mm 8100 D Overall width mm 4400 E Minimum ground clearance mm 580 Minim...

Page 428: ...5 8 Travel speed Forward 1st km h 9 8 2nd km h 15 0 3rd km h 20 1 4th km h 27 2 5th km h 36 4 6th km h 49 6 7th km h 66 2 Reverse 1st km h 10 2 Operating temperature range C 20 to 45 SPECIFICATIONS SPECIFICATIONS 5 4 ...

Page 429: ...ATTACHMENTS AND OP TIONS Before reading this chapter read and understand the SAFETY 6 1 ...

Page 430: ...lculation Although the following functions are provided you do not need to change them for the standard operation If setting is required ask your Komatsu distributor Setting of Loading End Travel Dist The payload meter judges that loading is completed when the machine travels continuously 160 m from the loading pit If a dumping is performed before the machine travels continuously 160 m the payload...

Page 431: ...YLOAD DISPLAY Payload is displayed on the machine monitor and with the external display lamps The state displayed on the machine monitor may be different from that displayed with the external display lamps depending on the machine condition Machine state Machine monitor External display lamp Engine is stop ped When starting switch is in ON po sition Clock display All lamps are lit for 30 sec onds ...

Page 432: ...erence only Example of payload display Example of payload display when an error occurs When an error occurs in the suspension pressure sensor clinometer sensor etc t is dis played on the machine monitor since the payload cannot be calculated All the external display lamps are flashing this time The payload displayed in the loading pit just after loading may be a little different from the value dis...

Page 433: ...ed total payload at the next loading is 45 0 t Green lamp 1 and yellow lamp 2 light up and they give a warning that the total payload is 32 9 t or more Red lamp 3 flashes and it warns that the predicted total payload of the 5th loading is 38 3 t or more Perform the loading carefully so that the red lamp 3 does not light up DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER The payload meter records...

Page 434: ...d to correct the date and time in the downloaded data consult your Komatsu distributor There is some error in the directory where the data is downloaded by the special software there may be a mistake in the setting for the machine In such case consult your Komatsu distributor 1 Remove the cap 2 Connect the download cable attached to the special soft ware to the download connector 3 Connect the oth...

Page 435: ... The screen G2210 is displayed Do not click User s Comment since it is not used On the screen G2210 you can select the communication ports COM1 COM2 specify the place to save the down loaded data specify the file to create and select the unit for the created data For details see the instruction manual of the download software 5 Check Summary Data File and Cycle Data File of File In HD325 and HD405...

Page 436: ...ng is finished close the screen REMARK The screen G2101 Down load File ID is displayed de pending on the software version In this case input the file ID and click OK then down loading starts DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES You can display the accumulated payload and the total number of cycles which are integrated at each dumping You can reset those values as well HANDLING PAYLOAD METER ...

Page 437: ...ince they have been last reset is displayed in Accumulated Payload and Total Cycles The display range is from 0 to 99999999 9t and 0 to 999999 cycles respectively When they reach the upper limits they are kept at the upper limits until they are reset 3 Press ENTER switch 2 The pop up window of the data reset is displayed Press RETURN switch 3 and the screen returns to Pay load Meter menu 4 Press E...

Page 438: ...ess the menu switch 1 to display Machine Setting and Information menu select Payload Meter then press EN TER switch 2 2 Select Average Fuel Consumption Record then press ENTER switch 2 The average value of the daily working fuel consumption in the last 1 week is displayed as shown in the figure HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS 6 10 ...

Page 439: ...doing anything SETTING MACHINE ID AND OPEN ID You can change the setting of the machine ID and open ID which are the items in the cycle data You can check the operator and the load of each cycle afterward by setting the machine No as the machine ID and setting the operator and the load type as the open ID 1 Press the menu switch 1 to display Machine Setting and Information menu select Payload Mete...

Page 440: ...ime is set as ID and the windows closes If you press RETURN switch 5 the window closes without changing the value of ID 5 Select Open ID Setting on the screen of step 2 for setting the open ID The set open ID is displayed on the right side 6 The setting procedure for the open ID is the same with the machine ID Set the open ID METHOD FOR PERFORMING CALIBRATION Perform the calibration in the followi...

Page 441: ... to completely remove all the soil remaining inside the dump body 2 Run in the machine 3 While running the engine set the gear shift lever to NEUTRAL position N and stop the machine 4 Prepare for the calibration according to the following procedure 1 Press the menu switch 1 on the standard screen and on Machine Setting and Information screen se lect Payload Meter then press ENTER switch 2 2 Select...

Page 442: ...e drive the machine at speed of 10 km h REMARK To cancel at this time press RETURN switch 3 while the screen in the figure is displayed 6 Continue driving the machine at speed of 10 km h Keep the travel speed at approximately 10 km h during the travel The display changes as shown in the figure in approxi mately 30 seconds and the calibration is completed HANDLING PAYLOAD METER ATTACHMENTS AND OPTI...

Page 443: ... of the dump body is lined for loading the blasted rock at quarry limestone mine and earth moving sites Example Limestone mines Carry soil Linerless dump body Suitable for the sites where the ma chine performs the soil loading opera tions The liner is not installed Example Sites for collecting the land fill soil ATTACHMENTS AND OPTIONS BODY SELECTION 6 15 ...

Page 444: ...slippery ground OPERATION OF KTCS The KTCS is ready to start the control when KTCS Setting is ON When the KTCS detects the rear wheel slipping the KTCS starts the control and the KTCS pilot lamp lights up METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND If any wheel is stuck operate the KTCS If it is impossible to get the machine out even when repeating the procedure below use a bulldoz...

Page 445: ... The overspeed caution lamp warns about the overspeed of the travel speed while the speed limit function is actuated Speed limit function pilot lamp The speed limit function pilot lamp lights up while the travel speed of the machine is limited by speed limit func tion Retarder pilot lamp The retarder pilot lamp lights up while the retarder is being actuated by the speed limit function OPERATION OF...

Page 446: ...d is decreased OPERATION IF TROUBLES ON SYSTEM OCCUR The machine has a trouble if any of the action levels L01 to L04 is displayed on the machine monitor Take appropriate actions following the list of action level dis plays and required actions Check the failure code Notify your Komatsu distributor of the failure code and ask for repair Failure code Failure name Whether the systems continue or dis...

Page 447: ...REPLACEMENT PARTS 7 1 ...

Page 448: ... perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the defined life parts DEFINED LIFE PARTS LIST No Periodical replacement parts Replacement interval 1 Fuel system ...

Page 449: ...1340 Cartridge 2 Every 500 hours Fuel prefilter 600 319 4800 Cartridge 1 Transmission oil filter 569 16 81160 07000 12125 07000 12014 Element O ring O ring 2 2 2 Fuel main filter 600 319 3841 Cartridge 1 Every 1000 hours Transmission and rear brake cooling oil filter 208 60 71124 07000 F5210 Element O ring 1 1 Transmission strainer 07000 72105 O ring 2 Brake oil filter 569 43 83920 07000 12065 070...

Page 450: ...re needed so consult your Komatsu distributor NOTICE The fuel used must be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high preci...

Page 451: ...bol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level REPLACEMENT PARTS RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 ...

Page 452: ...omatsu Flu ids Ambient tem perature C Min Max Engine oil pan Engine oil for KDPF used in cold ter rain Oil change interval 250 hours Note 1 EOS5W30 LA KES Diesel Engine Oil 25 35 EOS5W40 LA KES Diesel Engine Oil 25 40 Engine oil for KDPF Oil change interval 500 hours EO10W30 LA KES Diesel Engine Oil 20 40 EO15W40 LA KES Diesel Engine Oil 15 50 Transmission Case incl brake oil tank Power train oil ...

Page 453: ...ce Note 1 KDPF engine oil for cold district is deteriorated easily than that for normal area replace every 500 hours so replace oil and filter cartridge every 250 hours For changing the maintenance time of machine moni tor ask your Komatsu distributor to perform the work Note 2 Power train oil has different properties from engine oil Be sure to use the recommended oils Note 3 Hyper grease G2 TE ha...

Page 454: ...uted In this case fill up the tank with pre diluted fluid Never dilute the Non Amine Engine Coolant with ordinary water Note 5 DEF freezes at 11 C If thawing is necessary DEF system is automatically heated and thawed after the engine is started RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil consult your Komatsu...

Page 455: ...s use clean washer fluid 4 2 Appoint leader when working with others 2 28 Armrest angle Adjust 3 180 ARSC Operate 3 210 ARSC off pilot lamp 3 43 ARSC overheat notice caution lamp 3 32 ARSC pilot lamp 3 43 ARSC set travel speed indicator 3 43 ARSC setting 3 72 ARSC system caution lamp 3 32 ARSC travel speed set lever 3 118 Ashtray 3 122 Attachments and options 6 1 Auto idle stop timer Set 3 78 Auto...

Page 456: ...40 Differential case breather Clean 4 71 Dimmer switch 3 107 Directions of machine 1 10 Display 3 252 Display selector button 3 252 Display setting Change 3 62 Display warning tag during inspection and mainte nance 2 28 Display non display of ECO gauge Switch 3 64 Display non display of ECO guidance Switch 3 66 Display non display of guidance when key is OFF Switch 3 67 Do not drop things inside m...

Page 457: ...e oil 4 70 Final drive case Check oil level Add oil 4 41 Fire extinguisher 3 126 Floating seal Collect leaked oil 4 65 Fluorinated greenhouse gases 1 14 Fog lamp switch 3 112 Foot brake performance Check 4 45 Frame Check 4 45 Frequency Adjust 3 252 Frequency Auto preset 3 253 Fresh and clean lubricants 4 2 FRESH RECIRC air selector switch 3 242 Front brake Bleed air 4 32 Front brake off pilot lamp...

Page 458: ...ettings 3 96 Lifting of personnel prohibited 2 17 Location of engine number plate 1 13 Location of product identification number PIN machine serial No plate 1 13 Lock 3 230 Lock inspection cover 4 3 Lubrication chart 7 4 Lumbar support Adjust 3 180 Lunch box tray 3 121 M Machine Check after stopping engine 3 200 Machine Check walk around 3 159 Machine Dump 3 226 Machine Lift 3 259 Machine Loading ...

Page 459: ...Adjust 4 37 Parking brake Lubricate 4 63 Parking brake Release 3 269 Parking brake performance Check 4 47 Parking brake pilot lamp 3 41 Parking brake switch 3 111 Parking brake system caution lamp 3 29 Payload display 6 3 Payload meter 3 71 Payload meter Handle 6 2 Payload meter display 3 49 Payload meter system caution lamp 3 33 People on dump body 2 17 Perform KOWA Komatsu Oil Wear Analysis 4 7 ...

Page 460: ...tion lamp 3 31 Radiator curtain 3 262 Radiator fan reverse mode 3 69 Radiator fins aftercooler fins oil cooler fins and air conditioner condenser fins Clean 4 24 Radio Control 3 252 Radio Handle 3 251 Read this manual 1 2 Rear brake Bleed air 4 32 Rear brake disc Check wear 4 65 Rear brake oil collection tank Check oil leakage 3 166 Rear suspension cylinder Check length 4 31 Rearview camera Adjust...

Page 461: ...der Accumulator Gas spring Handle 2 35 Suspension damper hardness Adjust 3 180 Switch panel 3 50 Switches 3 104 System caution lamp 3 26 System operating lamp 3 128 T T Km P H Ton Km Hour Rating 3 235 Temperature control switch 3 240 Time Set 3 93 Tire Handle 2 36 3 234 Tire Select Check 4 35 Tire inflation pressure Check 3 173 Tire inflation pressure Check Inflate 4 36 Tire T Km P H value and con...

Page 462: ...k Drain water and sediment 3 164 Wear well fitting clothes and protective equipment 2 13 Wheel hub bolts Check Retighten 3 163 When operating on snow or frozen ground 2 25 When required 4 15 Window washer fluid Check level Add 4 28 Window washer fluid select 2 36 Wiper and window washer switch 3 107 Work place Clean Tidy 2 28 Y Your machine serial numbers and distributor 1 14 INDEX 8 8 ...

Page 463: ......

Page 464: ...HD325 8 HD405 8 Dump Truck Form No EENAM03582 2018 KOMATSU All Rights Reserved Printed in Belgium 06 2018 ...

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