Page 1 EENAM03550 Maintenance Manual HD465 HD605 DUMP TRUCK SERIAL NUMBERS HD465-8 - 30001 and up HD605-8 - 30001 and up WARNING Unsafe use of this machine may cause serious injury or ORIGINAL INSTRUCTIONS death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 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).
Page 4 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.
Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 6: Noise
NOISE FOREWORD NOISE Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulat- ed working cycle). The maximum value of the standard deviation of the measured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201 VIBRATION - OPERATING CONDITION (Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading and...
Page 7 FOREWORD NOISE • Travel at low speed when travelling around sharp curves Minimize vibrations for long work cycle or long distance travelling • Reduce speed to prevent bounce • Transport machines long distances between worksites The following guidelines can be effective to minimize risks of low back pain •...
Page 8: Vibration Level
ISO 7096. FOR HD465-8 : The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s , the uncertainty for this value is 0.08 m/s...
Page 9: Introduction
FOREWORD INTRODUCTION INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: Traveling with a load DIRECTIONS OF MACHINE (A) Front (D) Right (B) Rear (E) Operator's seat (C) Left In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine.
Page 10: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is provided on the front right of the machine.
Page 11: Fluorinated Greenhouse Gases
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU LTD. Address: 2-3-6 Akasaka Minato-ku, Tokyo 107-8414 Japan Authorised representative: KOMATSU EUROPE INT. Address: Mechelsesteenweg 586 B-1800 Vilvoorde Belgium Distributor name Address Service personnel Phone/Fax...
Page 12: Serial Plate
SERIAL PLATE FOREWORD SERIAL PLATE EI000001 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER OPERATING MASS AUTHORISED REPRESENTATIVE 1-10...
Page 13: Declaration Of Conformity
FOREWORD DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer/Authorised representative The manufacturer Authorised representative KOMATSU LTD. KOMATSU EUROPE INT. 2-3-6 Akasaka Mechelsesteenweg 586 Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde Japan Belgium Declares that this machine: HD465-8 HD605-8 Fulfils all the relevant provisions of following EC Directives:...
Page 14: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-3 NOISE............................... 1-4 .................................. 1-4 VIBRATION - OPERATING CONDITION ................... 1-4 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-4 VIBRATION LEVEL........................... 1-6 INTRODUCTION ............................
Page 15 OTHER TROUBLE......................... 3-260 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 16 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 1-14...
Page 17: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 18: Safety Labels
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. •...
Page 19: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 20 SAFETY LABELS SAFETY...
Page 21: Contents Of Safety Labels
SAFETY SAFETY LABELS (*) Only for the machine with dump body heating specifications (1) Caution for modification of ROPS/FOPS (10) Caution for handling battery cable (2) Caution against rotating parts (11) Caution for hot exhaust pipe (3) Caution when checking engine room (12) Caution against falling (4) Caution when releasing radiator cap (13) Caution for handling battery...
Page 22 SAFETY LABELS SAFETY • Always wear seat belt when moving. (2) Caution against rotating parts “09667-A0880” • Sign indicates a hazard of rotating parts, such as belt. • Turn off before inspection and maintenance. (3) Caution when checking engine room “09667-A0880”...
Page 23 SAFETY SAFETY LABELS (5) Caution when opening hydraulic tank cap “09653-A0641” • Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. • Allow radiator or hydraulic tank to cool before removing cap.
Page 24 SAFETY LABELS SAFETY caution when leaving operator's seat and when stopping engine, caution for re- tarder oil temperature “561-93-82410” • If the machine comes too close to electric cables, there is danger of electrocution. Always keep a safe dis- tance from electric cables. •...
Page 25 SAFETY SAFETY LABELS 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. •...
Page 26 SAFETY LABELS SAFETY • Read the operator's manual before working with batteries. • Caution - explosive gases. (14) Prohibition of start by short-circuiting “09842-A0362” • Start the 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.
Page 27 SAFETY SAFETY LABELS (16) Caution against high temperature “09817-A1103”, “09817-K088B” • Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation. • Never touch when hot. (17) Caution for using seat belt “09848-A0480”...
Page 28: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 29: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 30 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
Page 31: Precautions When Getting On Or Off Machine
Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi- cation process (regeneration).
Page 32 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Do not grip the control levers when getting on or off the machine. • Never climb on the engine hood or covers where there are no non-slip pads. • Do not get on or off the machine with tools in your hand. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death.
Page 33: Do Not Get Caught In Work Equipment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE When leaving the machine, always lower the dump body com- pletely, lock with dump lever lock knob (1), set gear shift lever (2) to NEUTRAL position (N), set parking brake switch (3) to “PARKING”...
Page 34: Unauthorized Modification
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 35: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 36 Prohibit other personnel from coming close to the machine during operation. • Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. 2-20...
Page 37: Start Engine
SAFETY PRECAUTIONS FOR OPERATION START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine. If the warning tag is ignored and the machine is operated, the person performing inspection or maintenance may be caught in the rotating parts or moving parts.
Page 38: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the following. • Start the engine only while sitting down in the operator's seat. •...
Page 39 SAFETY PRECAUTIONS FOR OPERATION • Fasten the seat belt. When the brakes are applied sudden- ly, the operator may be thrown out of the operator's seat. It is dangerous and may cause personal injury. • Check the operation of travel, steering and brake systems, and dump body control system.
Page 40 This may cause the tires to burst. If a tire bursts, it produces a large destructive force, and this may cause serious injury or death. If you are going to drive the machine continuously, consult your Komatsu distributor. •...
Page 41: Transportation
SAFETY PRECAUTIONS FOR OPERATION • Frozen road becomes soft when the temperature rises, and the machine may tip over or be not able to es- cape. Be particularly careful when working on frozen road. • When traveling on snow-covered roads, always fit tire chains. •...
Page 42: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY • Consult your Komatsu distributor to disassemble the machine for transportation. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 43: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 44 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 45 SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the maintenance with the engine running, always observe the following. • One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 46 PRECAUTIONS FOR MAINTENANCE SAFETY • Place attachments that have been removed from the ma- chine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area. PRECAUTIONS FOR WORKING AT HIGH PLACES When working at high places, use a step ladder or other stand to ensure that the work can be performed safely.
Page 47: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE USE PROPER TOOLS Use the tools suited to the task and use them correctly. Using damaged, deformed, or low quality tools, or making improper use of the tools may cause serious personal injury or death. PRECAUTIONS FOR CHECK AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Page 48 PRECAUTIONS FOR MAINTENANCE SAFETY Danger from dilute sulphuric acid When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the battery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explosion, or fire. Always ob- serve the following.
Page 49 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 50 • 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.
Page 51: Tires
• Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and spe- cial technology, so always ask your Komatsu distributor to perform these operations. • Use only specified tires and inflate them to the specified pressure.
Page 52 • If the tire inflation pressure goes down abnormally or the rim parts do not fit the tire, there is a problem with the tire or rim parts. Always contact your Komatsu distributor for repairs. • If the rim parts are not fitted properly when the tire is being pumped up, there is a danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim.
Page 53: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 54: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Fog lamp (9) Side lamp (2) Headlamp (low beam) (10) Brake sub-tank (3) Headlamp (high beam) (11) Front suspension (4) Turn signal lamp (12) Front wheel (5) Dump body (13) Staircase lighting (if equipped) (6) Rear wheel (14) Air Cleaner (7) Hoist cylinder...
Page 55: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Wiper and window washer switch (12) Hazard lamp switch (2) Lamp switch, dimmer switch, turn signal lever (13) Secondary steering switch (3) Switch panel (14) Front brake off switch (4) Monitor brightness selector switch (15) AISS LOW switch (5) Side lamp switch (16) Starting switch...
Page 56 GENERAL VIEW OPERATION (22) Cigarette lighter (28) Dump lever lock knob (23) Engine shutdown secondary switch (29) Rearview monitor brightness adjustment switch (24) Power window switch (left) (30) Gear shift lever (25) Power window switch (right) (31) Parking brake switch (26) Heated wire mirror switch (32) Room lamp 2 switch (27) Dump lever...
Page 57 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME Machine monitor (A) LCD unit (C) Meter unit (B) LED unit (1) Engine coolant temperature caution lamp (15) Engine tachometer (2) Engine coolant temperature gauge (16) Speedometer (3) ECO gauge (17) Fuel level caution lamp (4) Air conditioner display section (18) Fuel gauge (5) Clock...
Page 58 GENERAL VIEW OPERATION Liquid crystal unit display (A-1) Standard screen (ARSC setting: ON, payload (C) Maintenance time warning screen meter: OFF) (D) Warning screen (A-2) Standard screen (ARSC setting: ON, payload (E) User menu screen meter: ON) (B) ECO guidance screen (29) Message display (37) Front brake off pilot lamp (30) Retarder pilot lamp...
Page 59: Other Equipment Name
OPERATION GENERAL VIEW (46) Guidance icon (48) Seat belt caution lamp (47) Warning display (49) Action level • At places (29), (31), (32), and (42), 2 types of pilot lamp are prepared. • At place (36), 3 types of pilot lamp are prepared. OTHER EQUIPMENT NAME Inside of cab (1) Open knob for cab door...
Page 60 GENERAL VIEW OPERATION Outside of cab (1) KDPF (8) Toolbox (2) Cab door handle (9) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator (3) Dust indicator (10) Battery disconnect switch (4) Circuit breaker (11) System operating lamp (5) Fuse (12) Rearview camera...
Page 61: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT FF: Failure display screen (A) Warning display...
Page 62 NOTICE If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring may have breakage. In this case, ask your Komatsu distributor for repair. REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat- tery condition.
Page 63 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While the engine shutdown secondary switch (1) is turned on (engine is stopped), when the starting switch key is turned to ON position, the screen shown in the figure is displayed and the engine does not start.
Page 64 OPERATION End screen with message If there is any message from your Komatsu distributor, it is displayed on the end screen DD for 5 seconds, and then the screen goes out. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 65 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third party.
Page 66 EXPLANATION OF COMPONENTS OPERATION If there is maintenance time warning when starting the engine When the machine monitor is started, if the time to the next maintenance of any item is 30 hours or less, the starting screen AA is displayed for 2 seconds and then it is changed to the maintenance time warning screen When the menu switch displayed in the guidance icon is press- ed, “Maintenance”...
Page 67 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF. When ENTER switch displayed in the guidance icon is press- ed, “Current Abnormality”...
Page 68 EXPLANATION OF COMPONENTS OPERATION (1) Engine coolant temperature caution lamp (7) Seat belt caution lamp (2) Warning display (8) Brake oil pressure caution lamp (3) Warning display (9) Retarder oil temperature caution lamp (4) Guidance icon (10) Fuel level caution lamp (5) Centralized warning lamp (11) Torque converter oil temperature caution lamp (6) Action level display...
Page 69 Stop the operation and move the machine to a safe Sounds inter- Lights up place, then ask your Komatsu distributor for the in- mittently spection and maintenance. If there is an overrun related display, reduce the en-...
Page 70 (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.
Page 71 OPERATION EXPLANATION OF COMPONENTS Ask your Komatsu distributor for the telephone number registration if necessary. (G) Guidance icon On “Current Abnormality” screen, the following switches displayed in the guidance icon (G) can be operated. UP switch Move to the previous page.
Page 72 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. Action level is not displayed and lamp lights up in red If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in red.
Page 73 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. STEERING OIL PRESSURE CAUTION LAMP The steering oil pressure caution lamp warns the operator that the steering oil pressure is below the specified value.
Page 74 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. SECONDARY STEERING MOTOR CAUTION LAMP The secondary steering motor caution lamp warns that the sec- ondary steering motor has been operating for a long period.
Page 75 EXPLANATION OF COMPONENTS 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.
Page 76 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 77 OPERATION EXPLANATION OF COMPONENTS Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance.
Page 78 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 79 PAN, ADDING OIL (3-146)”. If the oil level drops again in a short time, the engine oil may be leaking. Ask your Komatsu distributor for inspection and repair. ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp warns the operator that the engine speed is higher than the allowable range.
Page 80 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. FAN-REVERSE OPERATION CAUTION LAMP The wrong operation in fan reverse mode caution lamp warns about misoperation while the fan is rotating in reverse.
Page 81 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 maintenance. ARSC OVERHEAT NOTICE CAUTION LAMP...
Page 82 If the caution lamp lights up in yellow and the action level “L01” is displayed, always perform the inspection and maintenance after the operation is finished. Ask your Komatsu distributor for the inspection and mainte- nance as needed. OVERSPEED CAUTION LAMP The overspeed caution lamp warns about the overspeed of the travel speed while the overload speed limit function is actuated.
Page 83 By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches 30 hours. However, you can change this setting. To change the setting, ask your Komatsu distributor. CENTRALIZED WARNING LAMP The centralized warning lamp lights up in red and at the same time the alarm buzzer sounds intermittently when the machine is under the following condition.
Page 84 EXPLANATION OF COMPONENTS OPERATION Machine conditions under which centralized warn- Monitor display ing lamp lights up When the wrong operation in fan reverse mode caution lamp is lit. When the dump body float caution lamp (red) is lit. When the inclination caution lamp is lit. When the charge voltage caution lamp is lit.
Page 85 OPERATION EXPLANATION OF COMPONENTS PILOT DISPLAY AND METER DISPLAY Pilot display (1) Turn signal pilot lamp (11) Secondary steering pilot lamp (2) Headlamp (high beam) pilot lamp (12) Shift indicator (3) Clearance lamp pilot lamp (13) Shift lever position display (4) Retarder pilot lamp (14) Parking brake pilot lamp (5) KTCS pilot lamp (if equipped)
Page 86 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY The pilot display consists of the pilot lamps to check the actuation of each function. When the starting switch is in ON position, the pilot lamps light up when the display items are functioning. TURN SIGNAL PILOT LAMP The turn signal pilot lamp flashes synchronously with the turn signal lamp, when it is turned on.
Page 87 OPERATION EXPLANATION OF COMPONENTS KTCS PILOT LAMP (if equipped) The KTCS pilot lamp lights up when “KTCS Setting” is set to “ON” and when the system detects slipping of a rear wheel. KTCS OFF PILOT LAMP (if equipped) The KTCS off pilot lamp lights up while “KTCS Setting” is set to “OFF”.
Page 88 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 message, see “CHECK MESSAGE (3-96)”. Lights up in green There is an unread message.
Page 89 OPERATION EXPLANATION OF COMPONENTS 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. For the procedures of the regeneration disable, see “PROCE- DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-133)”.
Page 90 EXPLANATION OF COMPONENTS OPERATION SHIFT LEVER POSITION DISPLAY The gear shift lever position display indicates the gear shift lev- er position. The character for the selected gear shift lever position is en- larged. PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake is applied.
Page 91 OPERATION EXPLANATION OF COMPONENTS 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 hardness of the suspension becomes soft. FRONT BRAKE OFF PILOT LAMP The front brake off pilot lamp lights up while the front brake off function is actuated.
Page 92 EXPLANATION OF COMPONENTS OPERATION ARSC SET TRAVEL SPEED INDICATOR The ARSC set travel speed indicator indicates the travel speed which is set with the ARSC travel speed set lever. When the set travel speed has been reset, “-” is displayed. When the “ARSC Setting”...
Page 93 OPERATION EXPLANATION OF COMPONENTS GUIDANCE TO RECOMMEND SHIFTING UP Even when the engine speed reaches shift up speed during traveling, if the upshift disable condition by gear shift lever con- tinues for 5 seconds or longer, the upshift recommendation message is displayed on the machine monitor. This message is as well displayed when the machine travels in reverse.
Page 94 EXPLANATION OF COMPONENTS OPERATION ENGINE TACHOMETER The engine tachometer indicates the engine speed. If the engine speed is higher than the allowable range during operation, the engine overrun caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Page 95 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE Fuel gauge shows the amount of fuel in the fuel tank. If the indicator is in red range (C), the fuel level caution lamp lights up in red. The fuel level is 126 ℓ or below. Check the fuel level, and add fuel.
Page 96 EXPLANATION OF COMPONENTS OPERATION Odometer display Indicates the total distance that machine has traveled in unit of km. Clock display Indicates the current time. 12-hour system display The clock is displayed in 12-hour mode with am or pm. 24-hour system display The clock is displayed in 24-hour mode.
Page 97 OPERATION EXPLANATION OF COMPONENTS Split (under measurement) display Displays the split fuel consumption under measurement. Split (measurement is stopped) display Displays the value after the measurement of split fuel con- sumption is stopped. REMARK Display on the fuel consumption gauge can be switched between the average fuel consumption per day and the average fuel consumption during a selected period (split fuel consumption).
Page 98 EXPLANATION OF COMPONENTS OPERATION SWITCH PANEL (1) UP switch (5) RETURN switch (2) Air conditioner switch and numeric keypad (6) DOWN switch (3) Menu switch (7) Guidance icon (4) ENTER switch These are used for the operation of the machine monitor or air conditioner. The function of each switch varies depending on the screen of the machine monitor.
Page 99 OPERATION EXPLANATION OF COMPONENTS MENU SWITCH When the menu switch is pressed on the standard screen, the following user menu screen is displayed. However, the user menu screen is not displayed during traveling. For the user menu, see “USER MENU (3-49)”. When normal “Energy Saving Guidance”...
Page 100 EXPLANATION OF COMPONENTS OPERATION UP SWITCH Pressing UP switch moves the cursor up by one item. When on the top line, the cursor moves to the bottom line. On the value input screen, the value is increased by one. DOWN SWITCH Pressing DOWN switch moves the cursor down by one item.
Page 101 OPERATION EXPLANATION OF COMPONENTS USER MENU When the menu switch is pressed on the standard screen while the machine is stopped, the user menu screen is displayed to enable you to configure and confirm the machine settings. The user menu consists of the following kinds. The menu screen can be changed by pressing the menu switch.
Page 102 EXPLANATION OF COMPONENTS OPERATION (C) “Aftertreatment Devices Regeneration” • Setting of “Regeneration Disable” • Operation of “Manual Stationary Regeneration” (D) “Maintenance” • Check and resetting of various maintenance remaining times (E) “Monitor Setting” • “Rearview Monitor Setting” • “Meter Display Selection” •...
Page 103 OPERATION EXPLANATION OF COMPONENTS (4) ENTER switch Enters any selection or changes and proceeds to the next screen. (5) Menu switch Moves to the right menu screen. When on the right end menu screen, it moves to the left end menu screen. REMARK •...
Page 104 EXPLANATION OF COMPONENTS OPERATION Operations on “Operation Records” screen When “Average Fuel Consumption Display” is set to “1 Day”. “1 Day” is displayed on the place shown with arrow in “Opera- tion Records”. You can perform the following operations with switches (1) to (3) on the switch panel.
Page 105 OPERATION EXPLANATION OF COMPONENTS (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 and press ENTER switch (4). You can perform the following operations with switches (1) to (4) on the switch panel.
Page 106 EXPLANATION OF COMPONENTS OPERATION 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 switches (1) to (3) on the switch panel.
Page 107 OPERATION EXPLANATION OF COMPONENTS (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 and press ENTER switch (4). You can perform the following operations with switches (1) to (4) on the switch panel.
Page 108 EXPLANATION OF COMPONENTS OPERATION Operations on “Average Fuel Consumption Record” screen You can perform the following operations with 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.
Page 109 OPERATION EXPLANATION OF COMPONENTS Deletion of “Average Fuel Consumption Record” When ENTER switch (4) is pressed, the confirmation screen is displayed. 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”...
Page 110 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE The display of the fuel consumption gauge can be set to the value on daily basis or during split measurement period. Select “Average Fuel Consumption Display” on “Configura- tions” menu screen, then press ENTER switch (4). Select “1 Day”...
Page 111 OPERATION EXPLANATION OF COMPONENTS 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 “Configurations” menu screen. REMARK Setting of “1 Day”...
Page 112 EXPLANATION OF COMPONENTS OPERATION 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”...
Page 113 OPERATION EXPLANATION OF COMPONENTS Use UP switch (1) or DOWN switch (2) to set the value, then press ENTER switch (4). You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Increases the target fuel consumption value by 1 ℓ/h. (2) DOWN switch Decreases the target fuel consumption value by 1 ℓ/h.
Page 114 EXPLANATION OF COMPONENTS OPERATION “ECO Guidance Display” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. You can perform the following operations with switches (1) to (4) on the switch panel.
Page 115 OPERATION EXPLANATION OF COMPONENTS Select “ECO Guidance Display at Key OFF” on “Configura- tions” menu screen, then press ENTER switch (4). “ECO Guidance Display at Key OFF” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” Displays the operational advice on the end screen.
Page 116 EXPLANATION OF COMPONENTS OPERATION • Setting of “Radiator Fan Reverse Mode” • Display and setting of “Payload Meter” • “KTCS Setting” (if equipped) • “ARSC Setting” • Display and resetting of “Dumping Counter” (if equipped) • Display of “Reverse Travel Odometer” •...
Page 117 OPERATION EXPLANATION OF COMPONENTS “Radiator Fan Reverse Mode” screen is displayed. Press ENTER switch (4), and the fan rotates in reverse, then the screen returns to the standard screen. REMARK When not performing the fan reverse rotation, press RE- TURN switch (3). If the dump body is not seated or the engine is running, the screen as shown in the figure appears, and the fan rotation cannot be switched.
Page 118 EXPLANATION OF COMPONENTS OPERATION When the screen shown in the figure appears, press EN- TER switch (4) to return the radiator fan to the normal rota- tion mode. REMARK If the engine compartment is highly heated when the fan is ro- tated in reverse, the controller may stop the air conditioner to protect itself from being damaged.
Page 119 OPERATION EXPLANATION OF COMPONENTS Select “ON” or “OFF”, then press ENTER switch (4). “OFF” KTCS does not operate. The KTCS off pilot lamp lights up. “ON” KTCS operates automatically. REMARK This setting is maintained even after turning the starting switch to OFF position.
Page 120 EXPLANATION OF COMPONENTS OPERATION “OFF” The ARSC is disabled. The ARSC off pilot lamp lights up. “ON” The ARSC is ready to operate. The ARSC pilot lamp lights up. REMARK This setting is maintained even after turning the starting switch key to OFF position.
Page 121 OPERATION EXPLANATION OF COMPONENTS Press ENTER switch (4) to reset, or press RETURN switch (3) to cancel the resetting. REVERSE TRAVEL ODOMETER The total reverse travel distance can be checked with the “Re- verse Travel Odometer”. TRIP METER The overall travel distance after the previous resetting can be checked by using “Trip Meter”.
Page 122 EXPLANATION OF COMPONENTS OPERATION Method for resetting “Trip Meter” Select “Trip Meter” on “Machine Setting and Information” menu screen, then press ENTER switch (4). The screen changes to “Trip Meter” resetting confirmation screen. Press ENTER switch (4), and “Trip Meter” is reset. The screen returns to “Machine Setting and Information”...
Page 123 OPERATION EXPLANATION OF COMPONENTS Select “F 1 Start at D Position Setting”, then press ENTER switch (4). Select “F1” or “F2”, then press ENTER switch (4). “F1” Starts the machine travel at 1st speed when the gear shift lever is set to D position. “F2”...
Page 124 EXPLANATION OF COMPONENTS OPERATION Select “A/C ECO Mode Setting”, then press ENTER switch (4). Select “ON” or “OFF”, then press ENTER switch (4). “ON” Sets the air conditioner to the ECO mode operation. “OFF” Turns on the normal air conditioner operation. REMARK If the ambient temperature is 30 °C or higher, or the set tem- perature of the air conditioner is 18 °C (maximum cooling), air...
Page 125 OPERATION EXPLANATION OF COMPONENTS Select “Retarder Lever Release Sound Setting”, then press ENTER switch (4). Select “ON” or “OFF”, then press ENTER switch (4). “ON” Generates the cancel sound. “OFF” Does not generate the cancel sound. REMARK This setting is maintained even after turning the starting switch to OFF position.
Page 126 EXPLANATION OF COMPONENTS OPERATION • The indicator of the engine coolant temperature gauge is over position (A), and the warm-up operation is finished. You can change the set time to operate the auto idle stop func- tion on “Auto Idle Stop Timer Setting” screen, Select “Auto Idle Stop Timer Setting”...
Page 127 OPERATION EXPLANATION OF COMPONENTS When the idling time reaches 30 seconds before the set time, the machine monitor returns to the standard screen and changes to the countdown screen. If one of the following operations is performed according to the screen instructions, the machine monitor stops count- down and the screen returns to the standard screen.
Page 128 The replacement interval in “Air Cleaner Cleaning or Change” is not set initially. If you want to change the setting for the maintenance interval and the maintenance notice time, consult your Komatsu distributor. METHOD FOR RESETTING REMAINING TIME FOR MAINTENANCE After performing the maintenance, reset the remaining time for maintenance according to the following proce- dure.
Page 129 (6), then press ENTER switch (4). REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. 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”.
Page 130 EXPLANATION OF COMPONENTS OPERATION Select “Rearview Monitor Setting” on “Monitor Setting” menu screen, then press ENTER switch (4). “Rearview Monitor Setting” menu screen is displayed. 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).
Page 131 OPERATION EXPLANATION OF COMPONENTS Select “Guide Line Display Mode” on “Rearview Monitor Setting” menu screen, then press ENTER switch (4). “Guide Line Display Mode” screen is displayed. Select “ON” or “OFF” on “Guide Line Display Mode” screen, then press ENTER switch (4). “ON”...
Page 132 EXPLANATION OF COMPONENTS OPERATION Select “Reverse-interlock Selection mode” on “Rearview Monitor Setting” menu screen, then press ENTER switch (4). “Reverse-interlock Selection mode” screen is displayed. Select “ON” or “OFF” on “Reverse-interlock Selection mode” screen, then press ENTER switch (4). “OFF” Always displays images on the rearview monitor.
Page 133 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY SELECTION This is used for the selection of the items to be displayed on L.H. meter display (A) or R.H. meter display (B). Select “Meter Display Selection” on “Monitor Setting” menu screen, then press ENTER switch (4). “Meter Display Selection”...
Page 134 EXPLANATION OF COMPONENTS OPERATION Select “LH Meter Display Selection” on “Meter Display Se- lection” menu screen, then press ENTER switch (4). “LH Meter Display Selection” screen is displayed. Select the item to be displayed from the following 3 items on “LH Meter Display Selection” screen, then press EN- TER switch (4).
Page 135 OPERATION EXPLANATION OF COMPONENTS Select “RH Meter Display Selection” on “Meter Display Se- lection” menu screen, then press ENTER switch (4). “RH Meter Display Selection” screen is displayed. Select the item to be displayed from the following 4 items on “RH Meter Display Selection” screen, then press EN- TER switch (4).
Page 136 EXPLANATION OF COMPONENTS OPERATION Select “Screen Adjustment” on “Monitor Setting” menu screen, then press ENTER switch (4). “Screen Adjustment” screen is displayed. Press UP switch (1) and DOWN switch (2) on “Screen Ad- justment” screen to adjust the brightness, then press EN- TER switch (4).
Page 137 OPERATION EXPLANATION OF COMPONENTS Select “Clock Adjustment” on “Monitor Setting” menu screen, then press ENTER switch (4). “Clock Adjustment” menu screen is displayed. The items related to “Clock Adjustment” are the following 5 items. • “GPS Synchronization” • “Calendar” • “Time”...
Page 138 EXPLANATION OF COMPONENTS OPERATION Select “GPS Synchronization” on “Clock Adjustment” menu screen, then press ENTER switch (4). “GPS Synchronization” screen is displayed. Select “ON” or “OFF” on “GPS Synchronization” screen, then press ENTER switch (4). “ON” Date and time on the machine monitor are automatically adjusted in accordance with the clock of GPS.
Page 139 OPERATION EXPLANATION OF COMPONENTS REMARK As long as “GPS Synchronization” is turned “ON”, the item in “Calendar” is not selectable. Select “Calendar” from “Clock Adjustment” menu screen, then press ENTER switch (4). “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display.
Page 140 EXPLANATION OF COMPONENTS OPERATION When day display (C) is highlighted in yellow, operate the switches as follows to change day display. When it is not necessary to change the day setting, press ENTER switch (4). (1) UP switch Advances the numeral by 1. (2) DOWN switch Puts back the numeral by 1.
Page 141 OPERATION EXPLANATION OF COMPONENTS (4) ENTER switch Proceeds to setting for minute. When minute display (E) is highlighted in yellow, operate the switches as follows to change minute display. When it is not necessary to change minute display, press ENTER switch (4). (1) UP switch Advances the numeral by 1.
Page 142 EXPLANATION OF COMPONENTS OPERATION (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”...
Page 143 OPERATION EXPLANATION OF COMPONENTS (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. This setting of “Daylight Saving Time” is held even if the starting switch is turned to OFF position. The default is “OFF”.
Page 144 When the operator identification function is disabled, “Operator ID” screen is not displayed on “Monitor Setting” menu screen. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP If the already registered ID is inputted when the starting switch is turned to ON position, the identified ID is displayed in “Oper-...
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “Operator ID” on “Monitor Setting” menu screen, then press ENTER switch (4) for 1 second. “Operator ID Change” screen is displayed. REMARK When the ID change is not necessary, press RETURN switch (3). • Input the already registered ID on “Operator ID Change”...
Page 146 EXPLANATION OF COMPONENTS OPERATION • On “Operator ID Change” screen, if you press ENTER switch (4) after inputting the ID which is not registered, a message is displayed at the bottom and the screen changes to “Monitor Setting” menu screen and the ID number is not changed.
Page 147 On machines equipped with KOMTRAX, when message pilot lamp is lit on the standard screen, you can see the messages from your Komatsu distributor on the mail check menu screen by pressing the menu switch. Message is distinguished as follows according to the lighting states of the message display.
Page 148 • When the message display lights up in blue, it means that no reply has been made yet to any read mes- sage to your Komatsu distributor. Reply to the message in accordance with the replying method mentioned below. •...
Page 149 OPERATION EXPLANATION OF COMPONENTS REPLY TO MESSAGE When replying to a message which requests reply, input the selected item number shown in the text of the mes- sage by using the air conditioner switch and numeric key- pad (6). (3) RETURN switch If there is no input value, the screen returns to the stand- ard screen.
Page 150 EXPLANATION OF COMPONENTS OPERATION Press UP switch (1) while holding down DOWN switch (3) with the starting switch in OFF position. Service meter (A) and odometer (B) are displayed while both switches are held down. 3-98...
Page 151: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) Monitor brightness selector switch (7) Secondary steering switch (2) Side lamp switch (8) Front brake off switch (3) Staircase lighting switch (if equipped) (9) AISS LOW switch (4) Fog lamp switch (10) Starting switch (5) Horn button (11) Wiper and window washer switch (6) Hazard lamp switch...
Page 152 EXPLANATION OF COMPONENTS OPERATION (13) Parking brake switch (18) Power window switch (R.H.) (14) Rearview monitor brightness adjustment switch (19) Heated wire mirror switch (15) Cigarette lighter (20) Room lamp 2 switch (16) Engine shutdown secondary switch (21) Room lamp 1 switch (17) Power window switch (L.H.) STARTING SWITCH Starting switch is used to start or stop the engine.
Page 153 OPERATION EXPLANATION OF COMPONENTS Keep the starting switch key at ON position (B) while the engine is running. This machine is equipped with an engine automatic preheating device that functions to start the engine preheat- ing automatically. When the starting switch is turned to ON position (B) at low ambient temperature, the automatic preheating starts and the preheating pilot lamp lights up.
Page 154 EXPLANATION OF COMPONENTS OPERATION When the monitor brightness selector switch is set to the night mode, the machine monitor and rear view moni- tor are dimmed. The lamp switch can be switched regardless of the position of the turn signal lever. DIMMER SWITCH The dimmer switch is used to turn on or off the headlamps (high beam).
Page 155 OPERATION EXPLANATION OF COMPONENTS HORN BUTTON When the horn button at the center of the steering wheel is pressed, the horn sounds. NOTICE If the horn is sounded continuously (the horn button is kept pressed), its service life is shortened. Avoid continuous use except in an emergency.
Page 156 EXPLANATION OF COMPONENTS OPERATION SECONDARY STEERING SWITCH WARNING Do not use the secondary steering pump for longer than 90 seconds. If the secondary steering pump is used continuously for longer than that, the motor may get burnt or get damaged, or a fire may be caused. The secondary steering switch is used to operate the secon- dary steering.
Page 157 OPERATION EXPLANATION OF COMPONENTS REMARK When the automatic warm-up is turned on, this switch position stops it, and set a low idle speed to a rather low level. (B) AISS LOW switch OFF Use this switch position for the normal operation. AISS function is actuated to produce the states described below.
Page 158 EXPLANATION OF COMPONENTS OPERATION NOTICE • Do not use the parking brake switch for braking when traveling except for an emergency. If the park- ing brake switch is used during traveling, the parking brake may break and a serious accident may result.
Page 159 OPERATION EXPLANATION OF COMPONENTS The power window switch is used to open and close the win- dow glasses. This switch can only be used when the starting switch is at ON position. Position (A) Glass goes up. Position (B) Glass goes down. When the glass reaches the top or bottom and stops, release the switch.
Page 160 EXPLANATION OF COMPONENTS OPERATION ENGINE SHUTDOWN SECONDARY SWITCH NOTICE The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Ask for repair of the problem part as soon as possible.
Page 161: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS When getting on or off the machine, the staircase lighting can be turned on with the one staircase lighting switch, and can be turned off with the other staircase lighting switch. Staircase lighting switch inside the operator's cab Position (A) The staircase lighting lights up.
Page 162 EXPLANATION OF COMPONENTS OPERATION BRAKE PEDAL The brake pedal is used to apply the wheel brakes. Use it when stopping or decelerating the machine. REMARK • The wheel brakes can be operated by depressing the brake pedal even while ARSC system is in operation. •...
Page 163 R position and the gear speed is fixed at NEUTRAL. Automatic gear shifting range in each position Max. speed Position Gear shift range HD465-8 HD605-8 2nd speed torque converter to 7th speed direct 70.0 km/h 70.0 km/h 1st speed torque converter to 6th speed direct 52.5 km/h...
Page 164 EXPLANATION OF COMPONENTS OPERATION When shifting the gear shift lever from NEUTRAL position (N) to D (FORWARD) or R (REVERSE), release the accelerator pedal, set the engine speed at low idle, then press the lock but- ton of the gear shift lever to operate. RETARDER CONTROL LEVER CAUTION Do not use retarder brake to park the machine.
Page 165 OPERATION EXPLANATION OF COMPONENTS DUMP LEVER CAUTION Make sure to lower the dump body and set the dump lever to “FLOAT” when you travel. The dump lever is used to operate the dump body. (A) “RAISE” position (B) “HOLD” position The dump body remains in the position where it was stopped.
Page 166: Other Equipment
EXPLANATION OF COMPONENTS OPERATION OTHER EQUIPMENT CAB DOOR CAUTION • Make sure that the cab door is securely locked when it is closed. • Always place the machine on a level ground when opening or closing the door. Avoid opening or closing the door on a slope, since there is a danger that the operating effort may sudden- ly change.
Page 167 OPERATION EXPLANATION OF COMPONENTS CAB DOOR INNER LOCK While the cab door is closed, it can be locked by pressing the cab door inner lock. (L) LOCK position It locks the cab door. It is used when operating the machine. (F) FREE position It unlocks the cab door.
Page 168 EXPLANATION OF COMPONENTS OPERATION CUP HOLDER The cup holders are located at two places of the center console and the rear left of the operator's seat. ASHTRAY The ashtray is at the front of the center console. Always extinguish your cigarette before putting it in the ashtray, and be sure to close the lid.
Page 169 OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Make sure to turn start and battery disconnect switches to OFF, before you replace a fuse. • The fuses protect the electrical component and wiring from burning out. • If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 170 EXPLANATION OF COMPONENTS OPERATION Fuse box II (BT2) Capaci- Name of circuit Engine room lamp (if equipped) (continuous pow- (16) 15 A er supply) (17) 15 A Terminal B (continuous power supply) (18) 5 A Air conditioner (continuous power supply) (19) 5 A Retarder controller (continuous power supply) Transmission controller (continuous power sup- (20) 15 A...
Page 171 OPERATION EXPLANATION OF COMPONENTS Fuse box IV (BT4) Capaci- Name of circuit (46) 5 A Parking brake (47) 15 A Retarder controller (48) 5 A Gear shift lever, starting motor cut-off relay (49) 5 A Switch panel (50) (51) 10 A Automatic secondary steering (52) 15 A ABS controller (if equipped) (53)
Page 172 EXPLANATION OF COMPONENTS OPERATION Fuse box VI (in battery box) Capaci- Name of circuit (76) 120 A Power supply for engine heater Fuse box VII (in battery box) Capaci- Name of circuit (77) 15 A Power supply for secondary steering Precautions when changing electrical component CAUTION Do not modify the machine electrical system.
Page 173 OPERATION EXPLANATION OF COMPONENTS NOTICE • Keep the battery disconnect switch in ON position except the following cases. • When the machine is stored for a long time (more than a month) • When repairing the electrical system • When performing the electric welding •...
Page 174 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. 3-122...
Page 175 OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This device indicates clogging of the air cleaner. Depending on the degree of clogging of the element, red line (1) appears in the transparent portion. If red line (1) indicates 7.5 kPa {0.076 kg/cm }, clean the ele- ment immediately.
Page 176 EXPLANATION OF COMPONENTS OPERATION HANDLE REAR VIEW MONITOR WARNING • Never perform the switch operation when traveling. If you perform switch operation when traveling, you may make an error in the machine travel opera- tion, or neglect to watch the hauling road ahead for safety, and this may lead to serious personal injury or death.
Page 177 (reverse travel interlock, constant display) and the gear shift lever position. If the rearview monitor or the camera does not work, ask your Komatsu distributor for repair since it has a failure or open circuit in electric wiring.
Page 178 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. •...
Page 179 OPERATION EXPLANATION OF COMPONENTS NOTICE During the KDPF regeneration, aftertreatment devices regeneration display (1) lights up on the machine monitor and the idle speed is set rather high regardless of ON or OFF of AISS LOW switch. After the automatic regeneration is finished, aftertreatment devices regeneration display (1) goes out and the idle speed is returned to the level corresponding to the AISS LOW switch.
Page 180 Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 181 OPERATION EXPLANATION OF COMPONENTS When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in yellow (action level (4): “L01”), screen (A) is displayed first. • The action level goes out 2 seconds later and the screen changes to the standard screen (B).
Page 182 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR MANUAL STATIONARY REGENERATION CAUTION • Exhaust gas temperature may become higher than the previous models during the aftertreatment devices regeneration. Avoid getting near the exhaust pipe outlet to prevent being burnt. Also, do not bring any combustible material close to the outlet of the exhaust pipe to prevent a fire. •...
Page 183 OPERATION EXPLANATION OF COMPONENTS Set the parking brake switch to “PARKING” position (A), and apply the parking brake. When the parking brake has been applied, the parking brake pilot lamp lights up on the machine monitor. Press the menu switch to display “Aftertreatment Devices Regeneration”...
Page 184 EXPLANATION OF COMPONENTS OPERATION REMARK • The explanation of the manual stationary regeneration is 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.
Page 185 OPERATION EXPLANATION OF COMPONENTS REMARK During the manual stationary regeneration, idle speed is set rather high. • The progress of the manual stationary regeneration performed when soot is accumulated can be checked by the number of lighting lamps of soot accumulation level (3). The manual stationary regeneration starts at soot accumulation level “4”...
Page 186 EXPLANATION OF COMPONENTS OPERATION Press the menu switch to select “Aftertreatment Devices Regeneration” menu screen, and “Aftertreatment Devices Regeneration” menu screen is displayed. Select “Regeneration Disable” and press ENTER switch. The regeneration function is disabled and the regeneration is not performed. REMARK •...
Page 187 OPERATION EXPLANATION OF COMPONENTS WHILE REGENERATION IS BEING PERFORMED: STOPPING PROCEDURE FOR REGENERATION (When the aftertreatment devices regeneration display is lit on the standard screen) When the menu switch is pressed on the standard screen, “Aftertreatment Devices Regeneration” screen is dis- played.
Page 188 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 189 When the battery disconnect switch is turned to OFF position, it prevents the battery power from being con- sumed, but the functions of KOMTRAX Plus stop at the same time. • If the power supply cable of KOMTRAX Plus system device has to be disconnected, contact your Komatsu distributor. 3-137...
Page 190: Machine Operations And Controls
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.
Page 191 OPERATION MACHINE OPERATIONS AND CONTROLS Check for oil leakage from the undercover and oil drop trace on the ground. Check the tires, wheels, and wheel hub bolts and nuts for damage and wear, and check the wheel hub bolts and nuts for looseness. Check the tires for cracks or peeling and check the wheels (side ring, rim base, lock ring) for cracks or wear.
Page 192 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK The date indicated on the seat belt is the manufactured date. It is the start of the 5-year period. The manufactured date of the seat belt is printed on the la- bel indicated by the arrow in the figure. Check the seat belt and mounting hardware (1) (2 places) for abnormality.
Page 193 OPERATION MACHINE OPERATIONS AND CONTROLS 19. Check the antenna. Check the satellite communication antenna (1), GPS an- tenna (2), wireless LAN antenna (3), and cables for dam- ages. Replace it with a new one if there is any damage. Clean the antenna if it is dirty. METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day.
Page 194 MACHINE OPERATIONS AND CONTROLS OPERATION Run the engine at low idle and check the oil level with the “Low temperature” scale on the sight gauge (G2). It is correct if the oil level is between marks H and L. REMARK Use the sight gauge (G1) as a guide for checking the oil level when the engine is stopped.
Page 195 OPERATION MACHINE OPERATIONS AND CONTROLS Loosen the wing bolts (1) and open the fuel prefilter cover (2). Water separator (3) is integrated with the fuel prefilter and located in the lower part. Check for water and sediment accumulated in the fuel pre- filter.
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION Fill the fuel tank with fuel through the fuel filler port (F). Move the switch (9) for the fuel feed pump to ON posi- tion, and bleed air from the fuel circuit. After the fuel feed pump stops automatically and the lamp (10) goes out, move the fuel feed pump switch (9) to ON position again.
Page 197 OPERATION MACHINE OPERATIONS AND CONTROLS Check the oil level with the sight gauge (H). If the oil is seen from the sight gauge (H), the oil level is correct. If the oil is not seen from the sight gauge (H), add the oil through the oil filler port (F).
Page 198 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check it with the reservoir tank when the engine is cold. • Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radia- tor.
Page 199 • If fuses are frequently blown out or if there are traces of short-circuiting on the electric wiring, im- mediately ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 200 Check the tire inflation pressure before starting work while the tires are cold. Measure the tire inflation pressure with an air pressure gauge. Adjust the tire inflation pressure properly. The proper tire inflation pressure is shown below. HD465-8/HD605-8 Tire size Tire inflation pressure kPa { kg/cm 24.00R35★★...
Page 201 METHOD FOR CHECKING BRAKE Check that the parking brake, foot brake, and retarder brake work sufficiently. If any abnormality is found, ask Komatsu distributor to repair. METHOD FOR CHECKING SECONDARY BRAKE PERFORMANCE WARNING The machine may start moving during the checking of the secondary brake performance. As a result, serious personal injury or death may occur.
Page 202 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 distributor for repair. Self-check of the secondary steering is not performed in the following cases.
Page 203 Turn the steering wheel (3) and check that the steering can be operated. If the steering cannot be operated when the steering wheel (3) is turned, ask your Komatsu distributor for repair. METHOD FOR CHECKING AUTOMATIC SECONDARY STEERING Turn the starting switch (1) to START position and start the engine.
Page 204 Operate the fore-aft adjustment lever upward, set the seat to the desired position, then release the fore-aft adjustment lever. Adjustment amount: 152.4 mm Number of stages for adjustment: 12 stages Adjustment amount per 1 stage: 12.7 mm If the seat backlash is found, ask your Komatsu distributor for adjustment. 3-152...
Page 205 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR RECLINING SEAT Pull up the reclining adjustment lever, and move the back cush- ion forward or backward. Sit with your back against the backrest when adjusting the re- clining angle. If your back is not on the backrest, it may sud- denly return to the original position.
Page 206 Fore-aft adjustment range: 60 mm If the seat backlash is found, ask your Komatsu distributor for adjustment. METHOD FOR ADJUSTING HEADREST ANGLE Move the headrest back and forth to set it to the desired angle.
Page 207 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION Move the headrest up or down to the desired height. Adjustment amount: 108 mm METHOD FOR ADJUSTING ARMREST ANGLE Turn the knob to adjust the armrest angle. Adjustment amount: 35 ° (Forward tilt 12 °, backward tilt 23 °) REMARK You can flip up the armrest.
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION Adjust the damping force of the suspension damper by operat- ing the suspension damper hardness adjustment knob. (A), (B) Low position The suspension damper becomes softer and its damping force is reduced. The shock to the seat is further decreased. (C) Recommended position Normally, this position is recommended.
Page 209 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the seat heater switch to ON position (A). The heater in the seat cushion operates, and the seat cushion and backrest become warm. Turn the seat heater switch to OFF position (B) when the temperature of cushion becomes suitable.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION • When using the seat heater Set the seat heater and ventilation selector switch (1) to the seat heating position (A). Set the air flow control switch (2) to HIGH position (D) or LOW position (E). The heater in the seat cushion operates, and the seat cushion and backrest become warm.
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing adjustment. • The machine is placed on a level ground. • The dump body is seated. •...
Page 212 Otherwise serious personal injury or death by such as an electric shock may occur. • Install only the Komatsu genuine camera. As shown in the figure, stop the machine on a flat ground, and make the machine unloaded. 3-160...
Page 213 When the machine dimensions are changed due to replacement of tires or installation of an optional attachment, set the guide lines to the non-display mode, and then contact your Komatsu distributor. Make sure that the images on the rear view monitor are normal as shown in the illustration. Then, confirm that machine width guide line (3) matches with tire outside width (1) and distance guide line (4) matches with body rear end (2).
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION ADJUST SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. • Even if no problem can be seen in the belt, replace it in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes sooner.
Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CONNECTING SHOULDER BELT AND WAIST BELT Insert the tongue (2) of the shoulder belt into the buckle tongue (1) of the waist belt. Rotate the tongue (2) of the shoulder belt and make sure that it is securely fixed to the buckle tongue (1) of the waist belt.
Page 216 Do not operate the lever with and excessive force. (Op- erating effort of lever: 147 N to 176 N {15 kg to 17.9 kg}) The lever can be loosened or its angle can be dis- placed. In such case, ask your Komatsu distributor for the in- spection. 3-164...
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING • Make sure that the gear shift lever is set to NEUTRAL position (N) and that the parking brake switch is in “PARKING” position then start the engine. •...
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION Check that the dump lever (3) is in “HOLD” position (B). Check that the retarder control lever (5) has been set up- ward. Check that the cover of the engine shutdown secondary switch (4) is closed. Insert the key into the starting switch (5) and turn it to ON position (B).
Page 219 If the pilot lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring may have breakage. In this case, ask your Komatsu distributor for repair. REMARK • When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery condition.
Page 220: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION • When the starting switch is turned to ON position, the secondary steering self-check function may operate. When the standard screen is displayed while the self-check is in operation, the secondary steering pilot lamp (11) lights up. REMARK While the secondary steering self-check function is in operation, the machine monitor may go out temporari-...
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • Do not accelerate the engine abruptly until it is warmed up. • Do not turn the start switch for more than 20 seconds. • Wait for 2 minutes before you turn start switch again. •...
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK If the ambient temperature is low, the engine may not start even when the key in starting switch (1) is kept at START position for 20 seconds. In such case, return the key in starting switch (1) to OFF position once, then in approximately 2 minutes, repeat the operation from the start.
Page 223: Method For Operations And Checks After Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS After the preheating time passes, turn the key in starting switch (1) to START position. The engine starts. If the engine cannot be started with the above procedure, wait for at least 2 minutes, then repeat the procedure again from the step 1.
Page 224 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 225: Method For Stopping Engine
Check that the steering operation is normal, the lamps light up and go out normally, the horn sounds, and the exhaust gas color, sound, and vibration are normal. If any of them is abnormal, ask your Komatsu distributor for inspection and repair. METHOD FOR STOPPING ENGINE Keep away from the exhaust pipe immediately after stopping the engine.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not stop the engine abruptly except in an emergen- cy. Otherwise, the service lives of component parts of the engine will be reduced. Allow the engine to cool down gradually before stopping it. •...
Page 227: Method For Checking After Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key in starting switch (4) to OFF position (A), and stop the engine. Remove the key from the starting switch (4). METHOD FOR CHECKING AFTER STOPPING ENGINE Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION Set the dump lever (2) to “FLOAT” position (C). Check that the dump body float caution lamp is not lit. If the dump body float caution lamp is lit, operate the dump lever (2) to “HOLD” position once, then operate it to “FLOAT”...
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • If the gear shift lever is shifted to a position other than NEUTRAL position (N) when the parking brake has not been released, the centralized warning lamp will light up and the alarm buzzer will sound.
Page 230 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.
Page 231 After the machine is stopped, set the parking brake switch (3) to “PARKING” position (A). When the machine is stopped in emergency, chock the tires immediately. Investigate the failure on the brake and ask your Komatsu distributor for repair. 3-179...
Page 232: Method For Shifting Gears
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SHIFTING GEARS WARNING • When traveling or when traveling downhill, never set the gear shift lever to NEUTRAL position (N). Always keep it in a speed range while traveling. • If the gear shift lever is set to NEUTRAL position (N) while the machine is traveling at the travel speed of 4 km/h or higher {2.5 MPH or higher} ...
Page 233: Method For Traveling Downhill
OPERATION MACHINE OPERATIONS AND CONTROLS • When downshift (deceleration) Release the accelerator pedal (2). The machine is decelerated and the transmission automat- ically shifts down. Downshift inhibit If the gear shift lever is operated when the machine is traveling, the travel speed may be faster than the maxi- mum speed allowed for the new speed range.
Page 234 If the retarder still has not effect even when the retarder control lever is operated again, return the retarder control lever completely to “RELEASE” position, and depress the brake pedal to stop the machine, then contact your Komatsu distributor for repair. •...
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Return the accelerator pedal (1) back before entering a downhill slope. Operate the retarder control lever (2) to decelerate the ma- chine. Leave he shift lever in D position. It is automatically downshifted to the optimal gear speed when reducing the travel speed.
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION HANDLE Automatic Retarder Speed Control (ARSC) Pressing the set switch of the ARSC travel speed set lever when the travel speed becomes the desirable speed on downhill automatically actuates the retarder to keep the travel speed, and the retarder operation becomes easier.
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS Drive the machine at the desired travel speed to be set as the set speed in ARSC, and press the setting switch (2) of the ARSC travel speed set lever. The travel speed is set as the travel speed for traveling downhill.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING ARSC SET TRAVEL SPEED FINE CONTROL Operate the ARSC speed set lever according to the following in order to finely adjust the travel speed that has been set. The travel speed can be adjusted by ±5 km/h of the set travel speed while driving the machine with the ARSC function (while the foot is off from the accelerator pedal).
Page 239 The travel speed displayed on the ARSC set travel 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: HD465-8 How to read the brake performance curve Example) Downhill distance: 1500 m Traveling resistance: -11 % (Grade resistance: -13 %, rolling resistance: 2 %)
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION This maximum permissible speed is a reference obtained from the retarder brake performance. Determine a safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the green range when traveling.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 600 m” Tire size: 24.00R35★★ Brake performance “Downhill distance: 900 m” Tire size: 24.00R35★★ 3-189...
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 1500 m” Tire size: 24.00R35★★ Brake performance “Downhill distance: Continuous” Tire size: 24.00R35★★ BRAKE PERFORMANCE CURVE: HD605-8 How to read the brake performance curve Example) Downhill distance: 1500 m Traveling resistance: -11 % (Grade resistance: -13 %, rolling resistance: 2 %) Payload: 63 t 3-190...
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS Obtain the maximum permissible speed and the gear speed range from the graph when traveling downhill under the above conditions. Use the brake performance curve for downhill distance of 1500 m. Starting from the point (A) which corresponds to the gross machinery weight, draw a perpendicular line down.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 450 m” Tire size: 24.00R35★★ Brake performance “Downhill distance: 600 m” Tire size: 24.00R35★★ 3-192...
Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 900 m” Tire size: 24.00R35★★ Brake performance “Downhill distance: 1500 m” Tire size: 24.00R35★★ 3-193...
Page 246: Method For Turning Machine
MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: Continuous” Tire size: 24.00R35★★ METHOD FOR TURNING MACHINE WARNING Do not steer at high speed or on steep slope, you may cause the machine to tilt. CAUTION • If the steering wheel has been turned fully to the right or left, do not continue to apply force to turn it further.
Page 247: Handle Overload Speed Limit Function
OPERATION MACHINE OPERATIONS AND CONTROLS HANDLE OVERLOAD SPEED LIMIT FUNCTION WARNING If the alarm buzzer sounds due to a failure while the overload speed limit function is enabled, stop the machine on a level ground with the brake pedal or the retarder control lever. If the speed limit function cannot be controlled due to a trouble in the system, it may lead to serious injury or death.
Page 248 “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. Whether the systems continue or discon-...
Page 249: Method For Loading
Although the following functions are installed, you do not need to change them for the standard operation. If set- ting 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...
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION Display section of payload While the machine monitor displays the standard screen, the payload is displayed as shown in the figure. External display lamp The external display lamps (2 places) are installed to the rear left of the cab and right (right side of the machine body).
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Data download connector outside the cab Connecting port for communication cable outside the cab is in- side the data download box on the left front side of the ma- chine. PAYLOAD DISPLAY Payload is displayed on the machine monitor and with the external display lamps. The state displayed on the machine monitor may be different from that displayed with the external display lamps depending on the machine condition.
Page 252 In such case, consult your Komatsu distributor. Display of prediction Loading state and prediction are indicated by the lamps in different colors and their lighting status (lighting up or flashing).
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS The predicted load display and actual payload display are shown at the same time. Expected number of bucket loads: 4 Payload display and predicted payload when loading of 13 t per one bucket is loaded onto HD465. 1st time •...
Page 254 Download the recorded data to a personal computer installed with special software (optional). • When you need to correct the date and time in the downloaded data, consult your Komatsu distributor. • There is some error in the directory where the data is downloaded by the special software, there may be a mistake in the setting for the machine.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS Set the parking brake switch to “PARKING” position to ap- ply the parking brake. Turn the starting switch to OFF position. Open the cover of the download box. Use the starting switch key to open or close the cover. Connect the accompanying download cable of the special software to the connector (1) for downloading.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR USING DOWNLOAD SOFTWARE Start up the personal computer and use the special software to download the data. For details of installing the software, see the instruction manual of the download software. When the installation is completed, the icon shown in the figure is created.
Page 257 OPERATION MACHINE OPERATIONS AND CONTROLS 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.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION Press the menu switch (1) to display “Machine Setting and Information” menu, select “Payload Meter”, then press EN- TER switch (2). Select “Accumulated Payload and Total Cycles”, then press ENTER switch (2). The accumulated payload and the total number of cycles are displayed as shown in the figure.
Page 259 OPERATION MACHINE OPERATIONS AND CONTROLS DISPLAY FUEL CONSUMPTION RECORD You can display the average daily working fuel consumption (ton/l) in the last 1 week. You can reset that value. Press the menu switch (1) to display “Machine Setting and Information” menu, select “Payload Meter”, then press EN- TER switch (2).
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION 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. Press ENTER switch (2) while the pop-up window shown in the figure is displayed.
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS Press ENTER switch (2). The pop-up window opens and displays the currently set machine ID. Input the machine ID. • The settable range is from 0 to 200. • Each time UP switch (3) is pressed, ID increases by 1. Each time DOWN switch (4) is pressed, ID decreases by 1.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Perform the calibration on a level place. • Perform the calibration while traveling straight. A straight road approximately 100 m long is necessary for the calibration. • Do not perform the calibration while an error is generated. •...
Page 263: Method For Dumping
OPERATION MACHINE OPERATIONS AND CONTROLS Press ENTER switch (2) while the pop-up window shown in the figure is displayed. If you press RETURN switch (3), the window closes without starting the calibration. When the display becomes as shown in the figure, drive the machine at speed of 10 km/h.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION Set the gear shift lever (1) to NEUTRAL position (N), and set the parking brake switch (2) to “PARKING” position. When the parking brake has been applied, the parking brake pilot lamp lights up on the machine monitor. Move the dump lever (3) to “RAISE”...
Page 265: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS When the dump body has moved down a certain distance, move the dump lever (3) to “FLOAT” position (C). (When you release the lever, it returns to “FLOAT” position (C).) The dump body will then move down under its own weight. REMARK If the dump body is not completely lowered, the gear speed is fixed at 1st anywhere the gear shift lever position...
Page 266: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Park the machine on a solid level ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, set the parking brake switch to “PARKING”...
Page 267: Method For Checking After Finishing Work
OPERATION MACHINE OPERATIONS AND CONTROLS Place the gear shift lever (3) to NEUTRAL position (N), then set the parking brake switch (4) to “PARKING” posi- tion (A) to apply the parking brake. When in the operator's compartment, pull the retarder con- trol lever (5) fully to apply the retarder.
Page 268 MACHINE OPERATIONS AND CONTROLS OPERATION (1) Data download box (2) Battery box (3) Battery disconnect box (4) Fuel tank filler port cap (5) Transmission case oil filler port cap (if equipped) (6) Steering and hoist oil tank filler port cap (if equipped) (7) Radiator reservoir tank coolant filler port cap (if equipped) (8) Operator's cab door (R.H.
Page 269 OPERATION MACHINE OPERATIONS AND CONTROLS Insert the starting switch key into the key slot. Turn 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 Remove the starting switch key.
Page 270 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING OIL FILLER CAP OF STEERING AND HOIST OIL TANK (if equipped) PROCEDURES FOR OPENING OIL FILLER CAP OF STEERING AND HOIST OIL TANK Insert the starting switch key into the key slot. Turn the starting switch key to “OPEN”...
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS PROCEDURES FOR OPENING RADIATOR RESERVOIR TANK COOLANT FILLER PORT CAP Insert the starting switch key into the key slot. 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)
Page 272: Handle Tire
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING OPERATOR CAB DOOR Insert the starting switch key into the key slot (1). Turn the starting switch key to “OPEN” position (A), and then remove the starting switch key. Position (A) OPEN Position (B) LOCK Hold the cab door handle (2) to open the cab door.
Page 273 Total operating hours in a day includes the break time and downtime. *The T.Km.P.H value in the table varies depending on the manufacturers of tire. Ask your Komatsu distributor when the work is to be performed with the travel speed near the travel speed shown in the table.
Page 274 Check the tire inflation pressure before starting for the day when the tires are cold, and adjust to the follow- ing inflation pressure. • Do not reduce the tire inflation pressure when traveling. HD465-8/HD605-8 Tire size Tire inflation pressure kPa { kg/cm 24.00R35★★...
Page 275: Handle Air Conditioner
If the air condi- tioner system caution lamp lights up, ask your Komatsu distributor for the inspection and repair. Ventilation while cooling •...
Page 276: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Fan switch (7) Air conditioner display (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Defroster switch (5) Auto switch Air conditioner display (A) Air flow bar (E) Vent display...
Page 277 OPERATION HANDLE AIR CONDITIONER FAN SWITCH You can adjust the air flow by using the fan switch. The air flow can be adjusted to 6 levels. Press the △ switch to increase the air flow; press the ▽ • switch to decrease the air flow. •...
Page 278 HANDLE AIR CONDITIONER OPERATION REMARK If the mode is set to automatic operation and the temperature setting is set to 18 °C or 32 °C, the air flow from the fan is always set to “HIGH” and does not change even when the temperature reaches the set temperature. VENT SELECTOR SWITCH The vent selector switch is used to select the vents.
Page 279 OPERATION HANDLE AIR CONDITIONER AUTO SWITCH Auto switch is used to switch the operation to the automatic op- eration. It changes the air flow and vents, recirculated air and fresh air automatically according to the set temperature and the ambient environment.
Page 280 HANDLE AIR CONDITIONER OPERATION AIR CONDITIONER DISPLAY The air conditioner display displays the state of air flow (A), op- eration of air conditioner (B), set temperature (C), FRESH/ RECIRC air (D), vents (E), automatic operation (F), and de- froster (G). AIR CONDITIONER SWITCH Use the air conditioner switch to start and stop the cooling, heating, or drying function.
Page 281: Method For Operating Air Conditioner
OPERATION HANDLE AIR CONDITIONER DEFROSTER SWITCH The defroster switch is used to set the vents in the defroster mode. • Use this mode to clear the front glass mist, etc. • When the defroster switch is pressed during automatic op- eration, the automatic operation symbol on the air condi- tioner display goes out and the defroster mark is dis- played.
Page 282 HANDLE AIR CONDITIONER OPERATION Press switch △ or switch ▽ of the temperature control switch to set to the desired temperature. The air flow and combination of the vents are automatically selected according to the set temperature and environ- ment, and the air conditioner is operated automatically to provide the set temperature.
Page 283 OPERATION HANDLE AIR CONDITIONER Press the air conditioner switch. The air conditioner operation symbol lights up on the air conditioner display. Press switch △ or switch ▽ of the temperature control switch to set to the desired temperature. REMARK The air temperature is so adjusted that the temperature in the cab becomes the set temperature when the set tem- perature display is 18.5 to 31.5 °C even during the manual operation.
Page 284 HANDLE AIR CONDITIONER OPERATION METHOD FOR STOPPING MANUAL OPERATION Press the air conditioner OFF switch. The display on the monitor goes out and the operation stops. METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. Press fan switch and adjust the air flow.
Page 285 OPERATION HANDLE AIR CONDITIONER Turn air conditioner switch ON. Adjust fan switch, temperature control switch and FRESH/ RECIRC air selector switch to the desired positions. METHOD FOR OPERATING DEFROSTER Press the fan switch and adjust the air flow. 3-233...
Page 286 HANDLE AIR CONDITIONER OPERATION When doing this, check that the temperature setting (A) and air flow (B) of the display monitor are displayed. Press the vent selector switch or defroster switch, and set the vent display on the display monitor to (F) or (G) as shown in the figure.
Page 287 OPERATION HANDLE AIR CONDITIONER When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn on the air conditioner switch. 3-235...
Page 288: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them.
Page 289: Method For Controlling Radio
OPERATION HANDLE RADIO PRESET BUTTON If you register the desired stations to the preset button beforehand, you can select each station by touching this button once. It is possible to preset 6 stations each for both AM and FM. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display.
Page 290 HANDLE RADIO OPERATION Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency. Press the △ button, and the frequency increases; • press the ▽ button, and the frequency decreases. Hold down the △...
Page 291 OPERATION HANDLE RADIO METHOD FOR ADJUSTING SOUND BALANCE Press sound control button (1) to light up “BAL” on the dis- play. You can adjust the sound (balance). Press tuning/time adjustment button (2) to adjust the sound (balance). Press the △ button, and the speaker output on the R •...
Page 292 HANDLE RADIO OPERATION Press display selector button (1) to cancel time adjustment. The screen returns to the clock display. 3-240...
Page 293: Dump Body Heating Specifications
When loading the combustible materials, change the machine specification to the specification without dump body heating. Contact your Komatsu distributor for changing the machine specification to the specification without dump body heating. In case the combustible materials are loaded, momentarily avoid a fire in the following procedure.
Page 294: Determine And Maintain Travel Road
DETERMINE AND MAINTAIN TRAVEL ROAD OPERATION DETERMINE AND MAINTAIN TRAVEL ROAD Determining and performing maintenance of the road in the jobsite are the extremely important factors both for reasons of safety and for reducing the cycle time. To ensure safety in operations, do as follows. Determine travel road •...
Page 295: Transportation
Always obey the traffic regulations when transporting the machine by road. WARNING This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. SELECT TRANSPORTATION METHOD As a basic rule, always transport the machine on a trailer.
Page 296 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 specification machine, see “Weight table”.
Page 297 OPERATION TRANSPORTATION Location of lifting position mark Weight table Center of gravity Machine weight Load on front axle Load on rear axle (from front axle) HD465-8 48420 kg 25511 kg 22989 kg 2038 mm HD605-8 51620 kg 26109 kg 25591 kg 2126 mm PROCEDURE FOR LIFTING MACHINE Lifting work is allowed for only machines having lifting marks.
Page 298 TRANSPORTATION OPERATION Stop the engine, and set the parking brake switch to “PARKING” position (A) to apply the parking brake. Select the lifting tools such as wire ropes, slings, or spreader beams to match the weight of the machine, and fit them to the lifting hooks (at lifting hook marks) at 4 pla- ces in total (2 places at front, 2 places at rear).
Page 299: Cold Weather Operation
When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, request a qualified company to perform the operation or contact your Komatsu distributor. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 300: Precautions After Daily Work Completion
COLD WEATHER OPERATION OPERATION 1.24 1.25 1.26 1.27 1.23 1.24 1.25 1.26 • When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it from the machine to place it in the warm place. Restore it again before the operation. •...
Page 301: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. Perform the following items when using the machine after long-term storage. • Wipe off the grease from the hydraulic cylinder rods.
Page 302: Preparation Before Traveling After Long-Term Storage
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE Check all the oil and water levels before traveling. When traveling after long-term storage, travel forward at a speed of 10 to 15 km/h for 5 minutes or 1 km to run the machine in, then change to normal travel.
Page 303: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill it up with fuel and bleed air from the fuel system before starting. Always check the fuel level to prevent running out of fuel. If the engine has stopped because of running out of fuel, all the air in the fuel circuit must be bled by using the fuel feed pump.
Page 304 (6) clockwise, and tighten the lock nut (7). Turn the head side grip (5) clockwise, and tighten the lock nut (4). Install the cover (2). If the dump body cannot be lowered even if the above method is used, consult your Komatsu distributor. 3-252...
Page 305: Precautions For Towing Machine
The maximum towing capacity for this machine is as follows. Do not tow any load greater than this. HD465-8: 356500 N {36340 kg} HD605-8: 380400 N {38770 kg} • For towing a failed machine, consult your Komatsu distributor. This machine must not be towed except in emergency. However, if it is unavoidable to tow the machine, pay attention to the following precautions. •...
Page 306 TROUBLES AND ACTIONS OPERATION • Towing device has hooks for towing on the front bottom of the frame and holes for towing on the rear bottom of the axle. Use the shackles (1) (4 pieces) (permitted load: 10 t or more) of class S which is prescribed in ISO2415 for tow- ing at rear side.
Page 307 OPERATION TROUBLES AND ACTIONS • The operator should get on the machine being towed and operate the steering in the direction that the ma- chine is towed. • Always run the engine to allow the steering and brakes to be used. When engine does not run •...
Page 308: Precautions For Discharged Battery
TROUBLES AND ACTIONS OPERATION Remove the plug (1) of the rear axle brake. Plugs (1) are installed 10 pieces on the right, 10 pieces on the left. Attach the washer to the prepared bolt, and put them into the plug hole. Tighten the bolts evenly.
Page 309 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY CAUTION • When removing the battery cables, remove the ground cable (normally connected to the negative (-) terminal) first. If any tool touches between the positive (+) terminal and the chassis, there is a hazard of sparks being generated.
Page 310 TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Follow the instruction manual accompanying the battery charger, and observe the following. •...
Page 311 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never connect the posi- tive (+) and negative (-) terminals. • Wear the protective eyeglasses and rubber gloves al- ways when starting the engine by using the jumper ca- ble.
Page 312: 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...
Page 313 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...
Page 314 Operate the accelerator pedal to move the machine to a safe place, then check the failure code and contact your Komatsu distributor. When operating the accelerator pedal, release the pedal to turn it to OFF position (low idle) or depress it fully to set it to 1500 rpm.
Page 315 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution lamp Oil in oil pan is insufficient.
Page 316 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Starting motor operates but engine Fuel is insufficient. Add fuel. See CHECK BEFORE does not start. STARTING Air in fuel system Repair place where air is sucked. (*) No fuel in fuel filter Fill filter with fuel by referring to EVERY 1000 HOURS MAINTE- NANCE.
Page 317 Apply the parking brake and press ENTER switch (3). “Current Abnormality” 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. 3-265...
Page 318 REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-266...
Page 319: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 320: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 321: Avoid Mixing Oil
MAINTENANCE PRECAUTIONS FOR MAINTENANCE • Inspect the dust indicator frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. • Clean the radiator fins, aftercooler fins, air conditioner condenser fins, and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged.
Page 322 PRECAUTIONS FOR MAINTENANCE MAINTENANCE • Stop the engine. • The machine should be empty when you jack-up. • Use the hydraulic jack of 50 t. Front (The machine is jacked up on the left side as shown in the illustration.) • When you jack up the front axle to replace the front tire or such, insert the plate such as an iron plate (3) between the holder portion (1) of the bottom of the kingpin and the jack...
Page 323: Outline Of Maintenance
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu...
Page 324 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 325 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 326: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 327: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 328 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Taper seal Width Tightening torque Outside di- acros ameter of Target value Allowable range s flats hose “a” “b” (mm) (mm) 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132 8.5 to 13.5...
Page 329: Maintenance Schedule
When using the engine oil for cold district, the maintenance intervals of the engine oil and filter cartridge are changed to for every 250 hours. • Ask your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .......... 4-13 WHEN REQUIRED ............................
Page 330 MAINTENANCE SCHEDULE TABLE MAINTENANCE METHOD FOR CHECKING AND LUBRICATING ALTERNATOR AND AIR CONDITIONER COMPRESSOR DRIVE BELT............................4-60 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP ......4-61 EVERY 2000 HOURS MAINTENANCE ......................4-62 METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT ........4-62 METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ...............
Page 331: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance after the first 250 hours only for the new machine. • Replacing element in the transmission oil filter • Changing oil in transmission case and brake sub-tank •...
Page 332 MAINTENANCE PROCEDURE MAINTENANCE Clean the element when the yellow piston shown in dust indica- tor (1) display entered the red (7.5 kPa {0.076 kg/cm }) posi- tion. After the cleaning, press the dust indicator button to reset it. If the yellow piston enters the red (7.5 kPa {0.076 kg/cm }) po- sition soon after the cleaning, the element must be replaced.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE If any dust is attached to the vacuator valve (6) installed to the cover (2), remove it. Check that the lip of vacuator valve (6) has no crack. If there is any crack, replace it with a new one. When the outer element has been cleaned 6 times or used for 1 year, replace it.
Page 334 MAINTENANCE PROCEDURE MAINTENANCE Check that O-ring (7) is fitted to cover (2). Align the cover (2) with the element. Insert the cover (2) with vacuator valve (6) right at the bottom into air cleaner body (5). Lock the tips of clips (1) (12 places) on the protrusions of the air cleaner body (5).
Page 335: Method For Cleaning Inside Of Cooling System
MAINTENANCE MAINTENANCE PROCEDURE If any dust is attached to the vacuator valve (6) installed to the cover (2), remove it. Check that the lip of vacuator valve (6) has no crack. If there is any crack, replace it with a new one. Remove the inner element (4), and then quickly install the new inner element.
Page 336 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, request a qualified company to perform the operation or contact your Komatsu distributor. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 337 MAINTENANCE MAINTENANCE PROCEDURE Items to be prepared • A container whose capacity is enough to receive the specified capacity of coolant • A hose to add coolant Stop the engine. Remove the bolts (1) (4 pieces), and remove the cover (2) on top of the sub-tank.
Page 338 MAINTENANCE PROCEDURE MAINTENANCE Open the drain valve (7) at the lower part of the radiator and drain the coolant. After draining the coolant, close the drain valve (7). Pour the tap water through the filler port of radiator. Add water until it fills the radiator. Tighten the radiator caps (5) and (6).
Page 339: Method For Cleaning Radiator Fins, Aftercooler Fins, Oil Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING RADIATOR FINS, AFTERCOOLER FINS, OIL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS WARNING • If the compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by use of it, there is a danger of personal injury. Wear the protective equipment such as the protective eyeglasses and dust mask.
Page 340 MAINTENANCE PROCEDURE MAINTENANCE Select “Radiator Fan Reverse Mode” on “Machine Setting and Information” menu screen, then press ENTER switch (1). Press ENTER switch (1) to rotate the fan in the reverse di- rection. If the fan reverse operation is performed without satisfying the condition for reversing the fan, the screen shown in the figure is displayed, and the fan rotation direction cannot be switched.
Page 341: Method For Cleaning Fin With Compressed Air
MAINTENANCE MAINTENANCE PROCEDURE 12. Check that the fan rotation is stopped. 13. Turn the starting switch to ON position. 14. Select “Radiator Fan Reverse Mode” on “Machine Setting and Information” menu screen, then press ENTER switch (1). REMARK If one of the following conditions is satisfied, the fan rota- tion returns from reverse direction to normal direction (nor- mal rotation direction).
Page 342: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE PROCEDURE MAINTENANCE Blow off mud, dirt, leaves, etc. in radiator fins (3), aftercool- er fins (4), air conditioner condenser fins (5), and oil cooler fins (6) with compressed air. NOTICE Steam or water may be used instead of the com- pressed air.
Page 343: Method For Checking Dump Body
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant (gas) level is low, so ask your Komatsu distributor to add refrigerant. If the air conditioner continues to run with low refrigerant (gas) level, it will cause damage to the compressor.
Page 344 Dimension (B) 245 to 265 mm Reference (C) 515 to 535 mm Ask your Komatsu distributor for inspection if there is any problem found when checking the front suspension. Install the cover (3) with bolts (2) (4 pieces). 4-26...
Page 345: Method For Bleeding Air From Brake Circuit
Dimension (D) 194 to 214 mm Ask your Komatsu distributor for inspection if there is any prob- lem found when checking the rear suspension. METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT WARNING Park the machine on a solid level ground and lower the work equipment to the ground.
Page 346 MAINTENANCE PROCEDURE MAINTENANCE 12) Install the cap to the bleeder screw (1). Bleed air from rear brake. Remove the cap of the bleeder screw (2) of the rear brake. Insert a vinyl hose to the bleeder screw (2). Use a commercially available vinyl hose. Place a container with oil in it.
Page 347: Method For Bleeding Air From Fuel Circuit
MAINTENANCE MAINTENANCE PROCEDURE Check that no bubble comes out through the vinyl hose. Tighten the bleeder screw (2) securely. Install the cap to the bleeder screw (2). Adjust the oil level in the transmission case to the specified level. METHOD FOR BLEEDING AIR FROM FRONT BRAKE Start the engine.
Page 348: Method For Checking Play Of Output Coupling Of Output Shaft
MAINTENANCE PROCEDURE MAINTENANCE Check that supply valve (1) of the fuel tank is opened. Move the switch for the fuel feed pump (2) to ON position. Lamp (3) flashes and the fuel feed pump operates. After the specified time (approximately 7 minutes), lamp (3) goes out automatically and the fuel feed pump stops.
Page 349: Select And Check Tires
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...
Page 350 Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the tires in the following table. The speed display varies with the tire size. Consult your Komatsu distributor when using the optional tires. Maximum load [ kg] Size...
Page 351: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE 24.00R35★★ 680 to 700 {6.9 to 7.1} NOTICE If the tires are used when the tire inflation pressure is less than the value given in the table above, the rim may be damaged. Maintain the tire inflation pressure within0 to +30 kPa {0 to +0.3 kg/cm PRECAUTIONS FOR REPLACING TIRES After tightening the hub bolts (1) when replacing the tire, drive the machine for 5 to 6 km, tighten the bolts again to settle all...
Page 352 MAINTENANCE PROCEDURE MAINTENANCE By using a grease pump, pump in grease through the grease fitting. Check visually that the greasing has been performed properly. 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.
Page 353: Method For Checking And Adding Oil In Deferential Case
MAINTENANCE MAINTENANCE PROCEDURE Front suspension (1 place each of right and left) Perform the greasing when the steering is set to the straight travel. Steering cylinder pin (4 places) Steering link pin (5 places) Steering linkage (3 places each of right and left) METHOD FOR CHECKING AND ADDING OIL IN DEFERENTIAL CASE WARNING •...
Page 354: Method For Checking Oil Level In Final Drive Case, Adding Oil
Check that there is no problem such as loose connection of the drive shaft, play in the splines and bearings, runout of the shaft, etc. If any problem is found, ask your Komatsu distributor for repair. METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL Perform this procedure before operating the machine.
Page 355 If the battery refilling liquid exceeds the maximum level line (UPPER LEVEL), use a syringe to lower the level to the maximum level line (UPPER LEVEL). Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 356: Method For Cleaning Transmission Case Breather
If the battery fluid is added to the level above the bottom of the sleeve, use a syringe to remove it until the level becomes under the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicar- bonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 357: Method For Cleaning Steering And Hoist Oil Tank Breather
MAINTENANCE MAINTENANCE PROCEDURE Remove mud and dirt around the breather (1). Remove the breather (1). Take care to prevent dirt from entering through the mount- ing section of the breather. Remove the bolt (2) of breather (1). Remove the cover (3). Rinse the breather (4) in clean diesel fuel or flushing oil, and remove the dirt inside.
Page 358: Method For Checking Frame
If the machine does not move when the engine speed is increased to 1810 rpm, it is normal. If any problem is found, ask your Komatsu distributor for repair. Decrease the engine speed and set the gear shift lever to NEUTRAL position (N).
Page 359: Method For Checking Retarder Brake Performance
If the machine starts to move during the test, reduce the engine speed, set the gear shift lever to NEU- TRAL (N) and engage the parking brake. Consult your Komatsu distributor for inspection and repair. Make sure to repair the brake before opera- tion.
Page 360: Method For Checking And Cleaning Automatic Suspension
If the machine does not move when the engine speed is increased to 1670 rpm, it is normal. If any problem is found, ask your Komatsu distributor for repair. Decrease the engine speed and set the gear shift lever to NEUTRAL position (N).
Page 361: Method For Checking Function Of Accumulator
(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 accumulator temporarily.
Page 362: Every 500 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE Turn the starting switch to ON position (B). Depress the brake pedal several times. After the brake pedal is depressed some times, the brake oil pressure caution lamp (1) lights up. • If the brake oil pressure caution lamp lights up when the brake pedal is depressed 4 times or less, the gas pressure in the accumulator may be low.
Page 363 Check the drained oil. If there are excessive metal particles or foreign materials, contact your Komatsu distributor. Remove the drain hose, and tighten the drain valve (2) and drain plug (1). Tightening torque: 68.6±9.8 Nm {7±1 kgm} Turn the filter cartridges (3) (3 pieces) counterclockwise by using the filter wrench, and remove it.
Page 364: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 365 MAINTENANCE MAINTENANCE PROCEDURE Place a container under the fuel prefilter to catch the fuel. Loosen the drain valve (5) and drain water and sediments from transparent cup (6), and also drain all the fuel from fuel prefilter cartridge (4). Turn the fuel prefilter cartridge (4) counterclockwise by us- ing the filter wrench, and remove it.
Page 366: Method For Replacing Transmission Oil Filter Element
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT 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. Items to be prepared Container to catch the drained oil Remove the bolts (1) (3 pieces) and remove the cover (2).
Page 367: Method For Checking And Replacing Alternator And Air Conditioner Compressor Drive Belt
It is reaching to the wear limit. 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.
Page 368 MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (1) (8 pieces) and remove the cover (2). Check the belt. If the belt shows the following state, it must be replaced. • There is a vertical flaw (4) that crosses horizontal flaw (3). •...
Page 369: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Loosen the lock nut (4) of adjustment bolt (3), tighten the adjusting bolt (3) fully, and press the tension pulley (5). Belt (6) becomes loose. Replace the belt (6). Loosen the adjustment bolt (3) until the threaded part comes out for approximately 90 mm, and tighten the lock nut (4).
Page 370 MAINTENANCE PROCEDURE MAINTENANCE Stop the engine. Drain the oil in the transmission case. Place a container to catch oil just under the drain plug (1). Remove the drain plug (1). Loosen the drain valve (2) and drain the oil. After draining the oil, tighten the drain valve (2). Install the drain plug (1).
Page 371 MAINTENANCE MAINTENANCE PROCEDURE Remove the retarder drain plug (9), and drain the oil from the brake chamber. Install the retarder drain plug (9) after the oil is drained from the brake chamber. Install the plug (8). Add 170 ℓ of oil through the oil filler port (F) without starting the engine.
Page 372 MAINTENANCE PROCEDURE MAINTENANCE For the procedure to bleed air from the brake, see “METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT (4-27)”. NOTICE • Do not reuse the oil drained when bleeding the air. Doing so will cause damage to the equipment.
Page 373: Method For Replacing Brake Oil Filter Element
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING BRAKE OIL FILTER ELEMENT 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. •...
Page 374: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 375: Method For Replacing Fuel Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE When installing the filter cartridge, tighten it by hand until the packing surface contacts the sealing surface of the filter head, then tighten the filter cartridge 1/2 to 3/4 turns. NOTICE • Do not fill the new filter cartridge with fuel. •...
Page 376: Method For Lubricating
MAINTENANCE PROCEDURE MAINTENANCE Remove the nut (2) of breather assembly (1). Remove the cover (3). Replace the breather element (4) with a new one. Install the cover (3) and nut (2). Lower the dump body. METHOD FOR LUBRICATING Stop the engine. By using a grease pump, pump in grease through the grease fitting shown by arrow.
Page 377: Method For Checking Rear Brake Disc Wear Amount
If the slit (3) of rod (2) enters beyond the guide end face (4), it means that the disc has reached the wear limit. Ask your Komatsu distributor for inspection and mainte- nance in such case. Install the cap nut (1) which is removed in the step 3.
Page 378: Method For Checking And Lubricating Alternator And Air Conditioner Compressor Drive Belt
Remove the bolts (1) (8 pieces) and remove the cover (2). Check the pulley for play and the grease for leakage. If any problem is found, ask your Komatsu distributor for repair and replacement. Install the cover (2) with bolt (1) after inspection.
Page 379: Method For Checking For Looseness Of Engine Intake Pipe Clamp
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP Check for looseness in the air intake piping clamps between the air cleaner, turbocharger, aftercooler, and engine. Retighten any loose clamps. Tightening torque of clamp (1): 8.8±0.5 Nm {0.90±0.05 kgm} Tightening torque of clamp (2): 10.5±0.5 Nm {1.07±0.05 kgm} Clamp (3): Tighten with the impact wrench until the dimen- sion (A) becomes the following value.
Page 380: Every 2000 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 2000 HOURS MAINTENANCE Maintenance for every 250, 500, and 1000 hours services should be performed out at the same time. METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 381: Method For Changing Oil In Final Drive Case
MAINTENANCE MAINTENANCE PROCEDURE Stop the engine. Turn the cap of oil filler port (F) to release the internal pres- sure before removing the cap. Remove the bolts (1) (4 pieces) and remove the cover (2). Remove the O-ring (3), spring (4), valve (5), strainer (6), and element (7).
Page 382: Method For Changing Oil In Deferential Case
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN DEFERENTIAL CASE 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. •...
Page 383: Method For Cleaning Hydraulic Tank Strainer
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING HYDRAULIC TANK STRAINER 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. •...
Page 384: Method For Checking Accumulator Gas Pressure
The brush may be worn and the grease in the bearings may have dried out. Ask your Komatsu distributor for inspection and repair. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. METHOD FOR REPLACING KCCV FILTER ELEMENT WARNING •...
Page 385 MAINTENANCE MAINTENANCE PROCEDURE • Container to catch the drained oil • Special wrench for KCCV The KCCV ventilator is located in the position shown in the fig- ure. For the use of the special wrench, see the figure. Loosen the ring (3) of KCCV ventilator (1) by using the special wrench.
Page 386 MAINTENANCE PROCEDURE MAINTENANCE 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.
Page 387: Every 4000 Hours Maintenance
High pressure circuit hose Brake system Brake oil pressure hose Retarder control valve rubber parts Torque converter, trans- Transmission circuit hose Ask your Komatsu distributor mission system for replacement. Work equipment hydraulic Main pump delivery hose system Main pump delivery hose other than described...
Page 388: Method For Lubricating Drive Shaft
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 CHECKING STARTING MOTOR The brush may be worn and the grease in the bearings may have dried out.
Page 389 Check the clamps (1) to (24) for high-pressure pipe visually and with your fingers that there are no loose mount- 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,...
Page 390: Every 4500 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 250 and 500 hours services should be performed out at the same time.
Page 391: Every 9000 Hours Maintenance
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.
Page 393: Specifications
SPECIFICATIONS...
Page 394: Specifications: Hd465-8
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: HD465-8 Item Unit HD465-8 Overall weight (unloaded weight + maximum payload + 1 opera- kg 103500 tor (80 kg)) Unloaded weight kg 48420 Unloaded weight (without dump body) kg 38065 Maximum payload kg 55000 Struck m Dump body capacity Heaped (2:1) m...
Page 395: Specifications: Hd605-8
38065 Maximum payload kg 63000 Struck m Dump body capacity Heaped (2:1) m Dumping speed (2000 rpm) (raised) Second 11.5 KOMATSU Engine model SAA6D170E-7 diesel engine Engine rated horsepower SAE J1995 (gross) 578/2000 • ISO14396 • kW/ min 578/2000 ISO 9249 /SAE J1349 (net) •...
Page 396 SPECIFICATIONS SPECIFICATIONS Item Unit HD605-8 km/h 11.4 km/h 15.8 km/h 21.3 Forward km/h 28.8 Travel speed km/h 38.8 km/h 52.0 km/h 70.0 Reverse km/h 11.8 Operating temperature range °C -20 to 45...
Page 397: Attachments And Options
ATTACHMENTS AND OP- TIONS Before reading this chapter, read and understand the SAFETY.
Page 398: Body Selection
BODY SELECTION ATTACHMENTS AND OPTIONS BODY SELECTION Select the dump body from the following list. HD465–8 Dump body type Features Dump body shape Suitable for the sites where the ma- chine performs the soil loading opera- tions. Linerless dump Carry soil body The liner is not installed.
Page 399: Handle Engine Room Lamp
ATTACHMENTS AND OPTIONS HANDLE ENGINE ROOM LAMP HANDLE ENGINE ROOM LAMP Engine room lamp is a lamp that illuminates the oil level gauge for checking the engine oil level. Do not use it except checking the engine oil level. (1) Engine room lamp switch (2) Engine room lamp METHOD FOR USING ENGINE ROOM LAMP Remove the cap, turn the engine room lamp switch (1) to...
Page 400: Handle Komatsu Traction Control System (Ktcs)
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) ATTACHMENTS AND OPTIONS HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) WARNING • KTCS is enabled when “KTCS Setting” is set to "ON". • When the system cannot be properly controlled due to a trouble in the system, the machine monitor displays an action level and the system may stop operation depending on the failure condition.
Page 401: Handle Speed Limit Function
ATTACHMENTS AND OPTIONS HANDLE SPEED LIMIT FUNCTION HANDLE SPEED LIMIT FUNCTION WARNING If the alarm buzzer sounds due to a failure while the speed limit function is enabled, stop the machine on a level ground with the brake pedal or retarder control lever. If the speed limit function cannot be controlled due to a trouble in the system, it may lead to serious injury or death.
Page 402: Operation If Troubles On System Occur
“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. Whether the systems continue or discon-...
Page 403: Replacement Parts
REPLACEMENT PARTS...
Page 404: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 405: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 406: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 407 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT • The symbols used in the lubrication chart are explained as follows. Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil...
Page 408: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient temperature, degrees Recommended Celsius ( °C) Reservoir Fluid type Komatsu Fluids EOS5W30-LA Engine oil for KDPF used in cold (KES Diesel En- terrain gine Oil) (Oil Change interval 250 hours) EOS5W40-LA (Note.1)
Page 409 The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with KES Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 410: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
In this case, fill up the tank with pre-diluted fluid. (Never dilute the Non-Amine Engine Coolant with ordinary water.) RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 411: Index
Alternator and air conditioner compressor drive belt - Brake pedal............3-110 Check / Replace..........4-49 Brake pedal - Test..........3-149 Alternator and air conditioner compressor drive belt - Brake performance curve........3-187 Lubricate............4-60 Brake performance curve - HD465-8....3-187 Brake performance curve - HD605-8....3-190...
Page 412 INDEX Brake sub-tank - Check oil level / Add oil... 3-144 Directions of machine..........1-7 Braking capacity of parking brake - Check... 4-41 Display..............3-237 Display selector button........3-237 Display setting - Change........3-57 Display warning tag during inspection and mainte- Cab door............. 3-114 nance.............
Page 413 INDEX Engine intake pipe clamps - Check for looseness 4-61 Front suspension cylinder - Check length.....4-26 Engine oil level caution lamp........ 3-27 Fuel................. 4-5 Engine oil pan - Change oil / Engine oil filter cartridge Fuel - Check level / Add........3-148 - Replace............
Page 414 Keep machine clean..........2-12 Machine monitor - Basic operation when starting en- Komatsu Closed Crankcase Ventilation (KCCV) 3-136 gine while engine shutdown secondary switch is Komatsu Diesel Particulate Filter (KDPF) - Handle..ON..............3-11 ..............3-126 Machine monitor - Basic operation when starting Komatsu genuine lubricants........4-2...
Page 415 Payload meter system caution lamp..... 3-29 Manual stationary regeneration - Operate..3-130 People on dump body........... 2-16 Menu switch............3-47 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Message - Check..........3-96 Periodic replacement of defined life parts.....2-35 Message - Reply........... 3-97 Phenomena and actions for engine related parts..
Page 416 INDEX Precautions to prevent fire........2-13 Refrigerant (gas) - Check level......4-24 Precautions when dumping........2-24 Remaining time for maintenance - Reset....3-76 Precautions when installing hydraulic hoses..4-3 Replace defined life parts........4-69 Precautions when leaving machine...... 2-16 Retarder brake performance - Check....4-41 Precautions when loading and unloading.....
Page 417 Sound control button...........3-237 Transmission - Act against trouble......3-251 Specifications............5-2 Transmission and rear brake cooling oil filter element Specifications - HD465-8........5-2 - Replace............4-54 Specifications - HD605-8........5-3 Transmission case - Check oil level / Add oil..3-141 Speed limit function - Handle........6-5 Transmission case / Brake sub tank - Change oil / Speedometer............
Page 418 INDEX Wiper and window washer switch....... 3-102 Work place - Clean / Tidy........2-27 Your machine serial numbers and distributor..1-9...

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