Page 1 HM300 SERIAL NUMBERS 2001 and up NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. if a foreign language manual is necessary, contact your local distributor for availability. WARNING Unsafe Use of this machine may cause serious injury or Death.Operators and maintenance personnel must read...
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Page 3: Foreword
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
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Page 5 FOREWORD FOREWORD https://www.besttruckmanuals.com/ 1 - 4...
Page 6: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Intended Use
FOREWORD INTENDED USE INTENDED USE DIRECTIONS OF MACHINE In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine. FRONT RIGHT REAR OPERATOR'S SEAT...
Page 9: Location Of Plates, Table To Enter Serial No. And Distributor
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the rear right of the cab.
Page 10: Service Meter Position
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SERVICE METER POSITION It is at the center bottom of the machine monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel...
Page 11: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS...
Page 12 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 11 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 13 TORQUE LIST...
Page 13 FOREWORD CONTENTS SAFETY CRITICAL PARTS 4- 16 MAINTENANCE SCHEDULE CHART 4- 17 MAINTENANCE SCHEDULE CHART 4- 17 SERVICE PROCEDURE 4- 19 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 19 WHEN REQUIRED 4- 20 CHECK BEFORE STARTING 4- 39 EVERY 50 HOURS SERVICE 4- 40...
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Page 15: Safety
SAFETY SAFETY SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS 2- 11 SAFETY RULES 2- 11 IF ABNORMALITIES ARE FOUND 2- 11 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11 FIRE EXTINGUISHER AND FIRST AID KIT 2- 11 SAFETY FEATURES 2- 12 KEEP MACHINE CLEAN...
Page 16 SAFETY SAFETY PRECAUTIONS DURING OPERATION 2- 20 STARTING ENGINE 2- 20 CHECKS BEFORE STARTING ENGINE, ADJUST 2- 20 PRECAUTIONS WHEN STARTING 2- 20 PRECAUTIONS IN COLD AREAS 2- 21 OPERATION 2- 22 CHECKS BEFORE STARTING OPERATION 2- 22 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22 PRECAUTIONS WHEN TRAVELING 2- 23...
Page 17: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. https://www.besttruckmanuals.com/...
Page 18: Position For Attaching Safety Labels
SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS https://www.besttruckmanuals.com/ 2 - 5...
Page 19: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution for modification of ROPS/FOPS (09620-A2000) (2) Caution for checking engine room (09667-A0880) (3) Caution when releasing radiator cap (09653-A0641) (4) Caution when releasing hydraulic tank cap (09653-A0641) https://www.besttruckmanuals.com/ 2 - 6...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (5) Caution when handling suspension (09659-A0641) (6) Caution for handling accumulator (09659-A057B) (7) Warnings for electric wire Warnings for crush hazard when inspection and maintenance (56B-93-12980) https://www.besttruckmanuals.com/ 2 - 7...
Page 21 SAFETY SAFETY LABELS (8) Cautions before starting Cautions when traveling in reverse (569-93-61720) (9) Caution when handling battery cable (09808-A1681) (10) Exhaust pipe is hot! (09817-A1103) https://www.besttruckmanuals.com/ 2 - 8...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (11) Prohibited to enter (09162-C0881) (12) Cation for articulate lock (09161-C0881) (13)Precautions when handling battery (The battery manufacturer sticks this caution plate on the battery. ) https://www.besttruckmanuals.com/ 2 - 9...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (14) Caution for parking brake (This plate is fixed in position by the chamber maker) (15) Prohibited to jump start (09842-A0481) (This plate is fixed to the starting motor) https://www.besttruckmanuals.com/ 2 - 10...
Page 24: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 25: Safety Features
SAFETY GENERAL PRECAUTIONS SAFETY FEATURES Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features.
Page 26: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the parts marked by arrows in the diagram when getting on or off the machine. A: For getting on or off machine using left door B: For getting on or off machine using right door To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and...
Page 27: Prevention Of Burns
SAFETY GENERAL PRECAUTIONS PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 28: Fire Prevention
SAFETY GENERAL PRECAUTIONS FIRE PREVENTION Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling.
Page 29: Window Washer Liquid
Always read the instruction manual for the attachment. UNAUTHORIZED MODIFICATION If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility.
Page 30: Working On Loose Ground
SAFETY GENERAL PRECAUTIONS WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.
Page 31: Ensure Good Visibility
SAFETY GENERAL PRECAUTIONS ENSURE GOOD VISIBILITY This machine is equipped with mirrors to improve the visibility, but even with mirrors, there are places, which cannot be seen from the operator's seat, so always be careful when operating. When operating or traveling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious personal injury.
Page 32: Asbestos Dust Hazard Prevention
Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. https://www.besttruckmanuals.com/ 2 - 19...
Page 33: Precautions During Operation
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS DURING OPERATION STARTING ENGINE If there is a warning tag hanging from the shift lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE, ADJUST Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 34: Precautions In Cold Areas
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the gear shift lever or dump lever are operated, the reaction of the machine will be slow or may change suddenly, and this may cause an accident.
Page 35: Operation
SAFETY PRECAUTIONS DURING OPERATION OPERATION CHECKS BEFORE STARTING OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of the steering, travel, and brake systems.
Page 36: Precautions When Traveling
The explosion of the tire is very destructive, and it can lead to serious injury or death. Contact with your Komatsu distributor before doing long continuous traveling. Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a slope.
Page 37: Precautions When Operating Dump Body
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN OPERATING DUMP BODY Before starting the dumping operation, check to be sure there is no person or object behind the machine. Stop the machine in the correct position, and check again that there is no person or object behind the machine. Give the determined signal, then slowly operate the dump body.
Page 38: Parking Machine
SAFETY PRECAUTIONS DURING OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. When leaving the machine, always place shift lever (1) at neutral and set parking brake switch (2) to the PARKING position. Lower the dump body, set the dump lever to the HOLD position, lock with the dump lever lock knob, then stop the engine.
Page 39: Transportation
PRECAUTIONS DURING OPERATION TRANSPORTATION This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 40: Battery
SAFETY PRECAUTIONS DURING OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 41: Starting With Booster Cables
SAFETY PRECAUTIONS DURING OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 42: Towing
SAFETY PRECAUTIONS DURING OPERATION TOWING WHEN TOWING When towing or being towed, mistakes in the method of selecting and inspecting the wire rope or drawbar, or in the method of towing may lead to serious personal injury. For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-127)" Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed.
Page 43: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Attach the DO NOT OPERATE warning tag to shift lever in the operator's cab during the inspection and maintenance. Attach additional warning tags around the machine if necessary. Warning tag Part No. 09963-03001 Keep the warning tag in the tool box when it is not used.
Page 44: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the dump body, set dump lever (1) to the HOLD position, lock with dump lever lock knob (2), then stop the engine.
Page 45: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Lock with articulation lock (4) so that the machine that does not articulate. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running.
Page 46: Proper Tools
Do not make holes in it, weld it, or use a cutting torch. Do not bear any shock by hammering, rolling or similar activity. Ask for your Komatsu distributor when sealing gas into the cylinder or releasing gas from it. PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine.
Page 47: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, and bearings are hit with a hammer, there is danger that small pieces will fly off;...
Page 48: Handling High-Pressure Hoses, Piping
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 49: Periodic Replacement Of Safety-Critical Parts
SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Page 50: Precautions With Tires
To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations. Use only the specified tires and inflate them to the specified pressure.
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Page 53: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Hydraulic tank Turn signal lamp Dump body Head lamp Rear wheel Air cleaner Hoist cylinder Fuel tank Front wheel (10) Fire extinguisher (if equipped) https://www.besttruckmanuals.com/ 3 - 2...
Page 54: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Dump lever Shift lever Lamp switch, Turn signal lever, Dimmer switch Parking brake switch Steering wheel Accelerator pedal Machine monitor (10) Brake pedal Retarder control lever (11) Dump lever lock knob Cigarette lighter https://www.besttruckmanuals.com/ 3 - 3...
Page 55 OPERATION GENERAL VIEW Enlargement of machine monitor Machine monitor mode selector switch 2 Night lighting dimmer switch Machine monitor mode selector switch 1 Hazard lamp switch Fog lamp switch (if equipped) (10) Emergency steering switch Yellow rotating lamp switch (if equipped) (11) Power mode selector switch Side lamp switch (if equipped)
Page 56: Explanation Of Components
After a 3-second system check, the meter starts to function. The character display shows "KOMATSU" for 3 seconds. If the lamps do not work, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection. When the starting switch is turned ON, if the shift lever is not at the neutral position, after completion of the system check, the shift lever position pilot lamp and the central warning lamp will light up, and the alarm buzzer will continue to sound intermittently.
Page 57 The meters start the operations after the system is checked for 3 seconds. The character display displays "KOMATSU" for 3 seconds. If the machine monitor does not operate as explained above, there is probably a failure, so please contact your Komatsu distributor for inspection.
Page 58 OPERATION EXPLANATION OF COMPONENTS CHARACTER DISPLAY The character display can display the following items. Service meter Action code display Odometer Filter, oil replacement time display Reverse travel odometer Normally, the service meter/odometer is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action.
Page 59 ( ) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection. ODOMETER This meter (2) indicates the total distance traveled in kilometers.
Page 60 ACTION CODE DISPLAY CAUTION If action code E03 is displayed, stop the machine immediately. Then see "ACTION CODE (PAGE 3-140)" and contact your Komatsu distributor for repairs. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed on this panel (4) to recommend suitable action.
Page 61 If "MAINTENANCE" is displayed together with E01, check the failure code and contact your Komatsu distributor for repairs. REMARK "E01" is displayed on the top line of the character display and "MAINTENANCE"...
Page 62 OPERATION EXPLANATION OF COMPONENTS Items for display of filter, oil replacement time Replacement Item Character display ID number interval Fuel prefilter FUEL P FILT Engine oil filter ENG FILT Engine oil ENG OIL Fuel main filter 1000 FUEL FILT Corrosion resistor 1000 CORR RES Transmission oil...
Page 63 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the monitor lights up during travel, inspect the location of the problem quickly and take the necessary action. Seat belt caution lamp Emergency steering pilot lamp Parking brake pilot lamp Fuel level caution lamp Dump body pilot lamp Maintenance caution lamp SEAT BELT CAUTION LAMP...
Page 64 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE PILOT LAMP This monitor (2) lights up when the parking brake is applied. DUMP BODY PILOT LAMP This monitor (3) lights up when the dump body is raised or the dump body lever is at any position other than "FLOAT". After the starting switch has been turned to the ON position, the dump body is held in position regardless of the position of the dump lever, so when canceling, turn the lamp off (see "CANCELING...
Page 65 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This monitor (6) lights up if any of the the following are applicable. When it lights up, action code "E01" and the location needing maintenance are displayed on the character display at the same time, so carry out inspection, filling, or replacement.
Page 66 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEM CAUTION If the monitor lights up, stop operations immediately, then check the corresponding area and carry out the action. If any problem is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor for the location of the problem and the central warning lamp will light up.
Page 67 OPERATION EXPLANATION OF COMPONENTS TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP This monitor (2) warns the operator that the torque converter oil temperature has risen. When it lights up, "E02 TC OVERHEAT" is displayed on the character display at the same time, so stop the machine in a safe place, set the shift lever to the N position, and run the engine under no load at a mid-range speed until the lamp goes out.
Page 68 OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE CAUTION LAMP This monitor (6) lights up to warn the operator that the engine lubricating oil pressure has dropped. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display, and the engine output is automatically limited. Stop the machine immediately at a safe place, then stop the engine and carry out inspection.
Page 69 OPERATION EXPLANATION OF COMPONENTS ENGINE SYSTEM CAUTION LAMP This monitor (10) lights up when a problem has been detected in the system controlled by the engine controller. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.
Page 70 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION PILOT DISPLAY PORTION When the starting switch is ON, the pilot display lights up when the display items are functioning. Engine pre-heating pilot lamp Head lamp high beam pilot lamp Retarder pilot lamp Turn signal pilot lamp Inter-axle differential lock pilot lamp Shift indicator...
Page 71 OPERATION EXPLANATION OF COMPONENTS RETARDER PILOT LAMP This monitor (2) lights up when the retarder control lever is pulled and the retarder is actuated. INTER-AXLE DIFFERENTIAL LOCK PILOT LAMP This monitor (3) lights up when the inter-axle differential lock is actuated.
Page 72 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP HIGH BEAM PILOT LAMP This monitor (6) lights up when the head lamps are set to high beam. TURN SIGNAL PILOT LAMP This pilot lamp (7) flashes at the same time as the turn signal lamp flashes.
Page 73 OPERATION EXPLANATION OF COMPONENTS POWER MODE PILOT LAMP This monitor (10) displays the power mode. When the mode is selected with the power mode selector switch, either High Power (P) or Economy (E) lights up. https://www.besttruckmanuals.com/ 3 - 22...
Page 74 OPERATION EXPLANATION OF COMPONENTS METERS Speedometer Engine water temperature gauge Engine tachometer Torque converter oil temperature gauge Fuel gauge Retarder oil temperature gauge SPEEDOMETER This meter (1) indicates the travel speed of the machine. ENGINE TACHOMETER This meter (2) shows the engine speed. If the gauge indicator the red range during operations, the alarm buzzer will sound and the central warning lamp will light up at the same time, so reduce the engine speed and the machine travel...
Page 75 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE This meter (3) shows the amount of fuel remaining in the fuel tank. When the fuel level caution lamp lights up, it indicates that there is less than 57 liters (15.06 US gal) of fuel remaining in the tank, so check and add fuel.
Page 76 OPERATION EXPLANATION OF COMPONENTS CENTRAL WARNING LAMP If the machine is in the following condition, this lamp will flash, and at the same time, the alarm buzzer will sound intermittently. When a problem has occurred in any of "EMERGENCY STOP ITEM (PAGE 3-15)".
Page 77: Other Functions Of Machine Monitor
OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF MACHINE MONITOR DISPLAY METHOD FOR REVERSE TRAVEL ODOMETER Use this when checking the total travel distance in reverse. 1. Check that the character display is showing the service meter/odometer, or the action code. If it is giving any other display, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display to be given.
Page 78 OPERATION EXPLANATION OF COMPONENTS RESET METHOD FOR FILTER, OIL REPLACEMENT TIME The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1. Press the ( ) of machine monitor mode selector switch 1, and display the reverse travel in odometer. 2.
Page 79 OPERATION EXPLANATION OF COMPONENTS INPUT METHOD FOR TELEPHONE NUMBER When an error for action code "E03" occurs, it is possible to display the telephone number. 1. Press the ( ) of machine monitor mode selector switch 1 and display the reverse travel odometer. 2.
Page 80 OPERATION EXPLANATION OF COMPONENTS METHOD FOR SELECTING LANGUAGE Use this when switching the language displayed on the character display. 1. Press the ( ) of machine monitor mode selector switch 1 and display the reverse travel odometer. 2. Press (>) or (<) of machine monitor mode selector switch 2 and display "LANGUAGE".
Page 81: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch (11) Fog lamp switch (if equipped) Lamp switch (12) Side lamp switch (if equipped) Turn signal lever (13) Working lamp (front) switch Dimmer switch (14) Switch for rear window glass with heated wire Hazard lamp switch (15) Yellow rotating lamp switch (if equipped)
Page 82 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position : At this position, the starting switch key can be inserted or removed. When the key is turned to this position, all the electric circuits are switched off and the engine stops.
Page 83 OPERATION EXPLANATION OF COMPONENTS DIMMER SWITCH This switch (2) is used to switch the head lamps between high beam and low beam. Each time switch (2) is moved up in direction (a), the head lamps switch between high beam and low beam. When the switch is released, it automatically returns to its original position (b).
Page 84 OPERATION EXPLANATION OF COMPONENTS POWER MODE SELECTOR SWITCH This switch (5) is used to switch the power mode. This makes it possible to travel economically in a way suited to the operating conditions. If portion (a) of the switch is pressed, high-power mode pilot lamp (P) lights up and the system is switched to the high-power mode.
Page 85 OPERATION EXPLANATION OF COMPONENTS SHIFT HOLD SWITCH This switch (7) actuates the gearshift limiter. Activating the shift hold function will restrict the automatic shifting of the transmission to gear speeds below the gearshift lever gear shifting. The shift hold function can be canceled by [1] moving the gearshift lever or [2] activating the shift hold switch located on the gearshift lever.
Page 86 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE SWITCH WARNING When parking or leaving the machine, always apply the parking brake. This switch (8) is used to actuate and release the parking brake valve. (a): Parking The parking brake is applied. (b): Travel The parking brake is released.
Page 87 OPERATION EXPLANATION OF COMPONENTS AISS LOW SWITCH Using this switch (9), it is possible to switch the AISS freely between AUTO and LOW. Use each position as follows. (a): AUTO position For normal operations (b): LOW position When fine control of the machine is needed, such as when putting it into a garage.
Page 88 OPERATION EXPLANATION OF COMPONENTS SIDE LAMP SWITCH (If equipped) This switch (12) is used to switch on the side lamp. (a): Side lamp goes out (b): Side lamp lights up When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.
Page 89 OPERATION EXPLANATION OF COMPONENTS POWER WINDOW SWITCH (RIGHT) (LEFT) (The right power window is optional.) WARNING When closing the window glass, be careful not to get anyone's hands or head caught. There is danger of serious injury if anyone is caught in the window glass. CAUTION After fully opening or fully closing the window glass, release the switch immediately.
Page 90 OPERATION EXPLANATION OF COMPONENTS HORN BUTTON When the horn button (20) in the center of the steering wheel is pressed, the horn will sound. WIPER, WINDOW WASHER SWITCH This switch (21) is used to operate the wiper for the front glass and rear glass. Using the wiper when the glass is dry will scratch the glass.
Page 91: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Brake pedal Dump lever Accelerator pedal Retarder control lever Shift lever Dump lever lock knob BRAKE PEDAL This pedal (1) is used to apply the wheel brakes. https://www.besttruckmanuals.com/ 3 - 40...
Page 92 OPERATION EXPLANATION OF COMPONENTS ACCELERATOR PEDAL This pedal (2) is used to adjust the engine speed. It can be operated freely between the engine low idle position and the full throttle position. GEAR SHIFT LEVER The gear range can be selected with this lever (3) to match the travel conditions.
Page 93 OPERATION EXPLANATION OF COMPONENTS 5 - 1 position: These positions are used in places where it is difficult to travel at high speed, or when traveling on soft ground, or when starting the machine off on a slope when it is loaded. They are also used when going downhill if it is needed to use the braking force of the engine.
Page 94 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS When moving the shift lever from the N (neutral) position to the R1 (reverse) position or from the N position to the D position, press the lock button on the shift lever before operating it. Activating the shift hold function will restrict the automatic shifting of the transmission to gear speeds below the gearshift lever gear shifting.
Page 95 OPERATION EXPLANATION OF COMPONENTS RETARDER CONTROL LEVER CAUTION The retarder must not be used as a parking brake. Use this lever (5) to operate the retarder when traveling downhill. The more the lever is pulled, the greater the braking force becomes.
Page 96: Body Pivot Pin
OPERATION EXPLANATION OF COMPONENTS BODY PIVOT PIN WARNING When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the dump lever lock knob, then use the body pivot pin. This is a safety device for the dump body, and is used when carrying out inspection or maintenance with the dump body raised.
Page 97: Location Of Fire Extinguisher
If the reset button comes out soon after it is pushed in, there may be a short circuit in the electric circuit. In this case, ask your Komatsu distributor for repair. (1) For primary power supply (30 A)
Page 98: Fuses
OPERATION EXPLANATION OF COMPONENTS FUSES The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. NOTICE When replacing any fuse, always turn the power off (turn the starting switch to OFF).
Page 99 OPERATION EXPLANATION OF COMPONENTS Fuse box II (BT2) No. Capacity Name of circuit (11) Engine controller (12) KOMTRAX (13) Machine monitor (14) Parking brake (15) Rear view monitor (16) Front wiper (17) Rear wiper (18) Machine monitor, KOMTRAX (19) Retarder controller (20) Terminal ‚a (21)
Page 100 If the electrical equipment system is changed, problems may occur in the machine control. Do not make any changes to the electrical system. If you want to make any change to the electrical system, please contact your Komatsu distributor. https://www.besttruckmanuals.com/...
Page 101: Car Radio
OPERATION EXPLANATION OF COMPONENTS CAR RADIO (If equipped) EXPLANATION OF COMPONENTS Power switch/Volume Preset switch Tone control knob Seek Display Band selector switch Clock button/Displaying frequency Tuning switch POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on.
Page 102 OPERATION EXPLANATION OF COMPONENTS TONE CONTROL KNOB If this knob (2) is turned to the right, the high tone is emphasized; if it is turned to the left, the high tone is reduced. DISPLAY This display (3) shows the radio reception frequency and the operating mode.
Page 103 OPERATION EXPLANATION OF COMPONENTS PRESET SWITCH With this switch (6), each button can be set to one station each for FM and MW (AM). (For details of the method of resetting, see "METHOD OF PRESET (PAGE 3-54)".) SEEK When this switch (7) ("SEEK") is pressed, it automatically searches for stations that can be received, and when it receives a station, it stops.
Page 104 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION LISTENING TO RADIO 1. This switches on power (1) for the radio. 2. "BAND" switch (2) is used to select MW (AM) or FM. 3. Use the preset switch or tuning switch (3) to select the station. 4.
Page 105 OPERATION EXPLANATION OF COMPONENTS METHOD OF PRESET 1. Select the desired preset station. Use the "BAND" button to select MW (AM) or FM, and use the "TUNE" button to select the frequency of the broadcasting station. 2. Decide the number of the button to be preset, and keep it pressed for 2 seconds.
Page 106 OPERATION EXPLANATION OF COMPONENTS ADJUSTING TIME 1. Turn the radio power ON. If the display shows the frequency, set the CLOCK button to the time display. 2. To set the time, keep the CLOCK button pressed and Press the button to change the minutes Press the button to change the hours PRECAUTIONS FOR USE...
Page 107: Car Stereo
OPERATION EXPLANATION OF COMPONENTS CAR STEREO (If equipped) EXPLANATION OF COMPONENTS Power switch/Volume Cassette door Auto-store/Preset scan button Fast forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/Radio display selector button (13) Seek tuning buttons...
Page 108 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions.
Page 109 OPERATION EXPLANATION OF COMPONENTS TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized LOUDNESS BUTTON This button (5) is used when playing at low volume.
Page 110 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).
Page 111 OPERATION EXPLANATION OF COMPONENTS METAL TAPE BUTTON (used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, "MTL"...
Page 112 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
Page 113 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set band selector button (2) to AM or FM. 3. Select the station with the preset buttons or manual tuning button (3).
Page 114 OPERATION EXPLANATION OF COMPONENTS REVERSING TAPE When listening to the tape, press both FAST FORWARD, REWIND buttons (A) and (B) at the same time lightly. When this is done, the tape direction display will be reversed. PRECAUTIONS FOR USE Stow the antenna when traveling in places with low overhead clearance. To ensure safety during operations, keep the volume at a level where it is possible to hear other machines.
Page 115: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS ON CONTROL PANEL ON/OFF switch DEF switch...
Page 116 OPERATION EXPLANATION OF COMPONENTS MODE SELECTOR SWITCH Use this switch (4) to select the vents. There are three combinations of vents: FACE, FACE/FOOT, and FOOT. Each time the switch is pressed, the vent display on the air conditioner monitor changes in the order FACE, FACE/FOOT, FOOT, FACE.
Page 117 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH Use this switch (7) to adjust the temperature of the air blowing out from the vents. The adjustment can be made to 8 levels from low temperature to high temperature. The temperature of the air blowing out from the vents is displayed on temperature bar (D) on the monitor. The lower the number of segments lighted up on the bar, the lower the temperature is.
Page 118 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION With the FACE vents, it is possible to adjust the direction of the air flow and to turn it on or off. However, do not set to the FACE mode with the vents closed. COOLING 1.
Page 119 OPERATION EXPLANATION OF COMPONENTS DEHUMIDIFYING, DEFROSTING 1. Press ON/OFF switch (1) to turn on the air conditioner power. 2. Press fan switch (2) to set to the desired air flow. 3. Press temperature control switch (3) to set to the desired temperature.
Page 120 4-29)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-30)". To enable the air conditioner to perform to the full and to maintain a pleasant working environment, always contact your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks. https://www.besttruckmanuals.com/...
Page 121: Operation
Leakage of oil or fuel, or accumulation of flammable material around the battery or high temperature parts of the engine, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any problem is found, repair it or contact your Komatsu distributor. Always carry out the following items before starting the engine each day.
Page 122 OPERATION OPERATION 9. Check rear view mirror, under view mirror Check that the mirrors are not damaged. Replace them if they are damaged. Clean the surface of the mirrors and adjust the angle so that the operator can see the area to the rear and under the machine from the operator's seat. 10.
Page 123 OPERATION OPERATION CHECK BEFORE STARTING Perform the contents of this section before starting the work of each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the reservoir tank.
Page 124 OPERATION OPERATION CHECK DUST INDICATOR 1. Check that the red line in the transparent portion of dust indicator (1) does not indicate 7.5 kPa (30 INCHES H (0.076 kg/cm , 1.1 PSI). 2. If the red line indicates 7.5 kPa (30 INCHES H O) (0.076 kg/cm , 1.1 PSI), clean or replace the air cleaner element immediately.
Page 125 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 126 OPERATION OPERATION CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL 1. Keeping the engine running at low idling after startup, check the engine oil level with sight gauge (G) while it still remains at a low temperature (LOW TEMP). 2. If the oil level is low, add oil through oil filler (F). NOTICE The oil level changes according to the oil temperature, so check the oil level after completing the warming-up operation.
Page 127 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, take care that it will not overflow. Overflow of fuel can cause a fire. If any fuel spills, wipe it off. If fuel spills onto dirt and sand sticking to the machine, remove it and dirt and sand together. Since fuel is flammable and dangerous, do not bring fire near it.
Page 128 Komatsu distributor for inspection. CHECK BRAKING EFFECT Check if the braking capacity of the parking brake, foot brake, and retarder brake. If any abnormality is found, ask Komatsu distributor to repair. CHECK EMERGENCY STEERING Check manual emergency steering 1. Turn starting switch key to the ON position.
Page 129 Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of any problems found. CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
Page 130 OPERATION OPERATION DOES BODY POSITIONER OPERATE NORMALLY? 1. Turn the starting switch key to the START position and start the engine. 2. Operate the dump control lever to the RAISE position, then release it. Check that the dump body stops before the end of the stroke. REMARK If the dump body reaches the end of the stroke, the contact of the body will cause an impact.
Page 131 OPERATION OPERATION ADJUSTMENT BEFORE OPERATION ADJUSTING OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat before starting operations or when changing operators. Adjust the position of the operator's seat so that you can depress the brake pedal fully with your back against the seat backrest. (A) Fore-and-aft adjustment Move lever (1) up, move the seat to the desired position, then release the lever.
Page 132 OPERATION OPERATION (E) Seat height adjustment Move lever (2) up or down to move the seat up or down as desired. Lever (2) is also used for adjusting the seat angle, so set the seat to the desired height while adjusting the angle. Adjustment range: 60 mm (2.4 in) (F) Adjusting headrest height Move the headrest up or down to the desired height.
Page 133 OPERATION OPERATION ADJUST SEAT BELT WARNING Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
Page 134 OPERATION OPERATION ADJUSTING MIRROR WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Loosen mirror securing bolt (1), screw (2) and nut (3) and adjust the mirror position the way it assures the best view from the operator's seat.
Page 135 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING WARNING When starting the engine, check that the shift lever is set in the N (neutral) position and that the parking brake switch is at PARKING position. Before standing up from the operator's seat, place the shift lever at N (neutral) position, and set the parking brake switch to the PARKING position.
Page 136: Starting Engine
OPERATION OPERATION STARTING ENGINE WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 137 OPERATION OPERATION OPERATION OPERATION 2. After the preheater pilot lamp goes off, turn the key of the starting switch to the START position, and the engine will start. REMARK When starting the engine, the monitor may flash while the starting motor is turning, but if the monitor lamp goes out after the engine is started, there is no problem.
Page 138: Operations, Checks After Starting Engine
3. Check that the steering operation is normal, the lamps light up and go off 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/repair.
Page 139: Stopping Engine
OPERATION OPERATION CANCELING DUMP BODY HOLD CONDITION WARNING If the HOLD is canceled when the dump body is raised, the body will go down under its own weight. This is very dangerous. Always lower the dump body before stopping the engine. After the engine has been started, if the dump lever is operated to HOLD, the dump body is held in position until the lever is operated to FLOAT, RAISE, or LOWER.
Page 140: Moving Machine Off (Forward, Reverse), Stopping
OPERATION OPERATION MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING MOVING MACHINE FORWARD WARNING When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people to get near the machine. Clear the machine's travel path of any obstacle.
Page 141 OPERATION OPERATION OPERATION OPERATION 5. Check that retarder pilot lamp (3) is not lighted up, then set shift lever (4) to the desired position. NOTICE When operating the shift lever, be sure to set it in position securely. If the lever is not placed in position properly, the shift position display on the panel may go out and the transmission warning monitor lamp may light up.
Page 142 OPERATION OPERATION MOVING MACHINE IN REVERSE WARNING When switching between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so use extreme caution when reversing the machine. Always stop the machine completely before shifting between FORWARD and REVERSE.
Page 143 OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. If the foot brake is used repeatedly or is kept depressed for a long time, the brake may overheat and its life will be shortened. If the parking brake is used to stop the machine, the brake will be damaged.
Page 144 Immediately after making an emergency stop, the parking brake disc will be at high temperature, so wait for it to cool before carrying out repair or adjustment. Ask Komatsu distributor for repair and adjustment. 1. Pull retarder control lever (1) fully to apply the retarder.
Page 145: Shifting Gear
OPERATION OPERATION SHIFTING GEAR WARNING Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a slope. Always place the transmission in gear before traveling. If the transmission is in Neutral, the engine cannot provide any braking effect and the steering wheel will become heavier. In addition, there will be lack of cooling oil for the retarder, so there is danger that it will overheat or that the actuation of the brake will be poor.
Page 146 OPERATION OPERATION SHIFTING DOWN If accelerator pedal (2) is released, the machine speed will be reduced, and the transmission will automatically shift down. DOWN SHIFT INHIBIT If the shift lever is operated when the machine is traveling, and the travel speed is faster than the maximum speed for each gear position, the transmission is not shifted immediately but is shifted down when the travel speed drops.
Page 147: Traveling Downhill
2. If the retarder still has no effect even when the retarder control lever is operated again, return the retarder control lever completely to the released position, then depress the brake pedal to stop the machine, and contact your Komatsu distributor for repairs.
Page 148 OPERATION OPERATION OPERATION OPERATION 1. Before starting to travel downhill, release accelerator pedal (1) and operate retarder control lever (2) to slow the machine down. 2. Move the shift lever to a position (5, 4, 3, 2) that matches the maximum permissible speed retarder brake...
Page 149 OPERATION OPERATION BRAKE PERFORMANCE CURVE Method of using graph Example: Machine equipped with exhaust brake Downhill distance: 1500 m (4921 ft) Travel resistance: -11% [grade resistance: -13%, rolling resistance: 2%] Load: 27 tons Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
Page 150 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1476 ft)] Brake performance [Downhill distance: 600 m (1968 ft)] https://www.besttruckmanuals.com/ 3 - 99...
Page 151 OPERATION OPERATION Brake performance [Downhill distance: 900 m (2952 ft)] Brake performance [Downhill distance: 1500 m (4921 ft)] https://www.besttruckmanuals.com/ 3 - 100...
Page 152 OPERATION OPERATION Brake performance [Downhill distance: Continuous] https://www.besttruckmanuals.com/ 3 - 101...
Page 153: Steering The Machine
OPERATION OPERATION STEERING THE MACHINE WARNING If the machine is turned at high speed or on a steep slope, there is danger that it will turn over, so do not operate the steering in such conditions. CAUTION Do not continue to turn the steering wheel when it has been turned fully to the left or right.
Page 154: Operation Using Differential Lock
OPERATION OPERATION OPERATION USING DIFFERENTIAL LOCK When traveling on roads where the tires are likely to slip, avoid sudden changes in speed, and use the differential lock (inter-axle differential lock) when traveling. Operate the inter-axle differential lock switch to actuate the differential lock 5 to 10 m (16 ft 5 in to 32 ft 10 in) before entering a road surface where the tires are likely to slip.
Page 155: Loading Operations
OPERATION OPERATION WHEN TIRES ARE STUCK IN GROUND If the wheels get stuck, to stop the wheels from spinning, do as follows. If it is impossible to get the machine out even when repeating the procedure below, use a bulldozer to tow the machine out.
Page 156: Dump Operations
OPERATION OPERATION DUMP OPERATIONS WARNING When dumping a load, always carry out the dumping operation in accordance with the signals from the flagman. When dumping large rocks, operate the dump body slowly. Do not load the dump body while it is still raised. When carrying out inspection with the dump body raised, always use the body pivot pins, set the dump lever to the HOLD position and lock it securely.
Page 157 OPERATION OPERATION OPERATION OPERATION 4. When dump lever (3) is moved to the LOWER position, the dump body will start to move down. 5. When the dump body has moved down a certain distance, move dump lever (3) to the FLOAT position. (When the lever is released, it will return to the FLOAT position.) The dump body will then move down under its own weight.
Page 158: Cab Tilt Operation
OPERATION OPERATION CAB TILT OPERATION WARNING To prevent serious injury or death if the cab comes down, always observe the following strictly when tilting the cab. Precautions before performing cab tilt operation Perform the cab tilt operation on a flat place. To prevent interference between the cab and machine body when performing the tilt operation, set the machine facing directly to the front and secure the front and rear frames with the articulation lock.
Page 159 OPERATION OPERATION WHEN USING CRANE 1. Remove lock bolt (2) from guard (1) at the rear of the cab, then lock guard (1) in position with rod (3). 2. Remove pin (4) in the mount at the rear of the cab, and insert it in hole (6).
Page 160 OPERATION OPERATION WHEN USING TILT CYLINDER (If equipped) 1. Remove lock bolt (2) from guard (1) at the rear of the cab, then lock guard (1) in position with rod (3). 2. Remove pin (4) in the mount at the rear of the cab, and insert it in hole (6).
Page 161: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION When traveling on roads in rain or snow, or when traveling on muddy or soft ground, consider the loaded condition of the machine and be extremely careful not to let the tires slip or the machine spin and sink into the ground. If the engine should stop when the machine is traveling, stop the machine immediately, then move the gear shift lever to the N position, and start the engine again.
Page 162: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Park the machine on firm, horizontal ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, put blocks under the tires to prevent the machine from moving.
Page 163: Checks After Completion Of Work
OPERATION OPERATION OPERATION OPERATION 3. When in the operator's compartment, pull retarder control lever (5) fully to apply the retarder. NOTICE The retarder must not be used as a parking brake. Do not use the retarder for long-term parking, regardless of the engine speed.
Page 164: Handling Tires
Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use. Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. PRECAUTIONS FOR LONG DISTANCE TRAVEL If the machine travels continuously at high speed for a long distance, there will be a marked increase in the generation of heat in the tire.
Page 165: Determining And Maintaining Travel Road
OPERATION DETERMINING AND MAINTAINING TRAVEL ROAD DETERMINING AND MAINTAINING TRAVEL ROAD Determining and traveling the road in the jobsite is an extremely important factor both for reasons of safety and for reducing the cycle time.To ensure safety in operations, do as follows. DETERMINING TRAVEL ROAD As far as possible, restrict the travel road to one-way travel.
Page 166: Transportation
PRECAUTIONS WHEN TRANSPORTING Always obey the traffic regulations when transporting the machine by road. WARNING This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. STEPS FOR TRANSPORTATION As a basic rule, always transport the machine on a trailer.
Page 167: Method Of Securing Machine
OPERATION TRANSPORTATION METHOD OF SECURING MACHINE After loading the machine in the specified position, secure it in place as follows. 1. Set the parking brake switch to the PARKING position to apply the parking brake. 2. Turn the key in the starting switch to the OFF position to stop the engine.
Page 168: Method Of Lifting Machine
The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For the weight of the standard specification machine, see "WEIGHT TABLE (PAGE 3-118)".
Page 169 OPERATION TRANSPORTATION LOCATION OF LIFTING POSITION MARK WEIGHT TABLE Machine Front wheel Center wheel Rear wheel Center of gravity weight load load load (from front axle) 24040 kg 13410 kg 5670 kg 4960 kg 2165 mm HM300-2 (53008 lb) (29569 lb) (12502 lb) (10937 lb) (7 ft 1 in)
Page 170 OPERATION TRANSPORTATION LIFTING PROCEDURE Lifting work can be carried out only with machines displaying a lifting mark. When carrying out the lifting operation, stop the machine on firm level ground, and do as follows. 1. Start the engine, set the machine facing directly to the front, place the dump lever at the FLOAT position, and check that the dump body pilot lamp goes out.
Page 171 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 4. Select wire ropes, slings, spreader bars and other lifting equipment to match the weight of the machine, and fit the wire ropes to the lifting hooks at the front of the front frame and the rear of the rear frame (lifting hook marks).
Page 172: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 173: Precautions After Completion Of Work
OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 174: After Cold Weather
OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER When the season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-10)". https://www.besttruckmanuals.com/ 3 - 123...
Page 175: Long-Term Storage
Before operating the work equipment, wipe off all the grease from hydraulic piston rods. AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 176: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL If you have run out of fuel, add fuel to the fuel tank and bleed air from the fuel system and then start the engine. PROCEDURE FOR BLEEDING AIR CAUTION The fuel injection pump and nozzle of this engine consist of more precise parts than the conventional ones. If foreign matter enters them, it can cause a trouble.
Page 177: If Transmission Has Trouble
4. Tighten grip (5) and locknut (4) and install cover (2). If the dump body does not go down even when the above method is used, please consult your Komatsu distributor. https://www.besttruckmanuals.com/ 3 - 126...
Page 178: Method Of Towing Machine
Towing is only permitted in order to move a disabled machine to a place where it is possible to carry out inspection and maintenance. It must not be towed for long distances. Please consult your Komatsu distributor for information about towing a disabled machine. https://www.besttruckmanuals.com/...
Page 179 OPERATION TROUBLESHOOTING This machine must not be towed except in emergencies. When towing the machine, take the following precautions. When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance of a few meters to a place where repairs can be carried out.
Page 180 OPERATION TROUBLESHOOTING WHEN ENGINE RUNS If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of mud or to move it for a short distance to the edge of the road. Check the effect of the brakes, and if the brakes do not work properly, take the action given in "When engine does not run".
Page 181 It is necessary to tow or move the machine, the parking brake must be released. Release the parking brake as follows. METHOD OF RELEASING PARKING BRAKE Please ask your Komatsu distributor to release the parking brake. WARNING If any abnormality occurs in the hydraulic circuit, there is danger that the wheel brakes may not be applied properly, so always travel at low speed when towing the machine.
Page 182: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 183 OPERATION TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE When the charging the battery, if the battery is mistakenly handled, there is danger of explosion. Follow the precautions in "IF BATTERY IS DISCHARGED (PAGE 3-131)" and the instructions given in the charger manual, and always do as follows.
Page 184 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows. PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses and rubber gloves.
Page 185 OPERATION TROUBLESHOOTING STARTING THE ENGINE CAUTION Make sure that the parking brake switch is at PARKING position and the shift lever is at N (neutral) position for both normal machine and the problem machine. 1. Make sure the clips are firmly connected to the battery terminals. 2.
Page 186: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even...
Page 187 OPERATION TROUBLESHOOTING CHASSIS ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Torque converter oil temperature Leakage of oil or entry of air due...
Page 188 After using the accelerator pedal to move the machine to a safe place, check the service code and contact your Komatsu distributor. There are two methods when operating the accelerator pedal: either release the pedal (check switch is OFF, low idle), or depress the pedal fully (1500 rpm).
Page 189 OPERATION TROUBLESHOOTING ENGINE ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights Insufficient oil in oil pan Add oil to specified level.
Page 190 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Excessive oil consumption Oil leakage ( Check, repair) Excessive oil in oil pan Add oil to specified level. See CHECK BEFORE STARTING Worn piston, ring, cylinder liner ( Replace) Exhaust gas is white or bluish Improper fuel Replace with specified fuel Defective turbocharger...
Page 191 If more than one failure has occurred, the next failure code is displayed. 3. Check the failure code, then contact your Komatsu distributor for repairs. REMARK The 6-digit code displayed on the left of the line at the top of the character display is the failure code.
Page 192 https://www.besttruckmanuals.com/ 4 - 1...
Page 193: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: For lubrication of the machine, use the 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 194 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently.
Page 195: Outline Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. https://www.besttruckmanuals.com/...
Page 196 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. For details, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-26)".
Page 197 MAINTENANCE OUTLINE OF SERVICE GREASE Grease is used to prevent seizure and noises at the joints. This construction equipment is used under heavy-duty conditions. Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 198 Make sure that the oil is well mixed before sampling. Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. https://www.besttruckmanuals.com/ 4 - 7...
Page 199: Outline Of Electric System
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 200: Wear Parts
The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.
Page 201: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 202: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ASTM: American Society of Testing and Material https://www.besttruckmanuals.com/ 4 - 11...
Page 203: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%. RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. https://www.besttruckmanuals.com/ 4 - 12...
Page 204: Standard Tightening Torques For Bolts And Nuts
The tightening torque is determined by the width across the flats (b) of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 205 MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS Face seal Width Tightening torque Nominal - across No. of Target value Permissible range flats (b) threads (a) Nm kgm lbft lbft (mm) 9/16 -18UNF 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0 11/16 -16UN 54.2...
Page 206: Periodic Replacement Of Safety Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 207: Safety Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Replacement interval Remarks Fuel hose (fuel tank - injection pump) Fuel hose (injection pump - fuel tank) Spill hose (engine output connector - fuel tank) Water separator (case, O-ring, plug) Every 4000 hours Rubber hose for brake piping...
Page 208: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Change oil in engine oil pan, replace engine oil filter cartridge 4- 53 Replace fuel prefilter cartridge 4- 54 Replace fuel main filter cartridge 4- 60 Replace transmission filter element (valve side, brake cooling side) 4- 62...
Page 209 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE Change oil in engine oil pan, replace engine oil filter cartridge 4- 53 Replace fuel prefilter cartridge 4- 54 Lubricate cab mount pin (left and right: 1 place each) 4- 55 Check oil level in final drive case, add oil 4- 55 Check oil level in differential case, add oil 4- 56...
Page 210: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance only after the first 250 hours. Change oil in engine oil pan, replace engine oil filter cartridge Replace fuel prefilter cartridge Replace fuel main filter cartridge Replace transmission filter element (valve side, brake cooling side) Change oil in transmission case...
Page 211: When Required
MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN OR REPLACE AIR CLEANER After the outer element has been cleaned 6 times, or if the air cleaner element has been used for one year, replace the outer element, inner element, and O-ring. For details of the procedure for replacement, see "REPLACE ELEMENT (PAGE 4-24)".
Page 212 MAINTENANCE SERVICE PROCEDURE CLEAN OUTER ELEMENT WARNING Dirt will fly if compressed air is used for cleaning. If dirt gets into your eyes it may cause blindness, and if you breathe in the dust it may damage your lungs. To prevent these problems, always wear safety glasses, dust mask, and other protective equipment.
Page 213 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Blow dry compressed air (0.69 MPa {7 kg/cm }) from the inside of outer element (6) along the folds. Next, blow along the folds from the outside, then blow again from the inside. 8.
Page 214 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 12. Push the head of dust indicator (1) to cancel the clogging display. https://www.besttruckmanuals.com/ 4 - 23...
Page 215 MAINTENANCE SERVICE PROCEDURE REPLACE ELEMENT WARNING When pulling out the air cleaner element, make sure that you are standing on a firm place. If your footing is not secure when you carry out the operation, there is danger of falling and suffering injury. 1.
Page 216 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 9. Replace O-ring (9) with a new part. Next, set so that vacuator valve (8) of dust cup (4) is at the bottom, and insert it into the air cleaner body. 10. Clip hooks (5) of dust cup (4) to the protruding parts of the air cleaner body to lock in position.
Page 217: Clean Inside Of Cooling System
30% and 68%. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. When no corrosion resistor is used, use the special cover (600-411-9000). Please consult your Komatsu distributor about the method of installing. https://www.besttruckmanuals.com/...
Page 218 MAINTENANCE SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100).
Page 219 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Loosen radiator cap (3) a little to release the residual pressure and then remove it. 5. Open drain valve (4) at the bottom of the radiator and drain valve (5) of the oil cooler and drain the coolant. 6.
Page 220: Check Level Of Window Washer Fluid, Add Fluid
MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID Carry out this check if there is air in the window washer fluid. Check the level of the fluid in window washer tank (1), and if it is low, fill with automobile window washer fluid. Be careful not to let dirt or dust get in when adding fluid.
Page 221: Check Refrigerant (Gas) Level
If the condition of sight glass (2) is "insufficient" as shown in the diagram on the right, there is lack of refrigerant, so ask your Komatsu distributor to charge with refrigerant. (After the air conditioner switch is turned ON, bubbles can be seen continuously.)
Page 222: Check Dump Body
2. Check all parts of the dump body for damage. If any cracks or abnormal wear are found, carry out repairs. Contact your Komatsu distributor for details of the repair procedure. CHECK LENGTH OF SUSPENSION CYLINDER When traveling, if the unevenness of the road surface is transmitted directly to the chassis (the machine bounces or the cylinders retract and hit the stopper), carry out the following checks.
Page 223: Bleed Air From Front Brake
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM FRONT BRAKE WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air. Bleed the air from the front brakes in the same way on both the left and right sides.
Page 224: Bleed Air From Center Brake
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM CENTER BRAKE WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air. Bleed the air from the center brakes in the same way on both the left and right sides.
Page 225: Check Play Of Output Coupling Of Output Shaft
If the result of the measurement shows that it is greater than the standard value, please contact your Komatsu distributor for disassembly and inspection. https://www.besttruckmanuals.com/ 4 - 34...
Page 226: Selection And Inspection Of Tires
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the following table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
Page 227 MAINTENANCE SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING When inflating a tire, check that any person will not enter the working area and use an air chuck which has a clip and which can be fixed to the air valve.
Page 228: Adjust Parking Brake
3. Turn bolt (1) clockwise by 240° ± 15°(turn by 2/3 turn). Measure the thickness of the pad, and if it is less than 1.5 mm (0.06 in), contact your Komatsu distributor to have it replaced. When making an adjustment for the first time after replacing the pads, turn bolt (1) counterclockwise by 360°...
Page 229: Cleaning Hydraulic Tank Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 230: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-72)". Check coolant level, add coolant Check dust indicator Check oil level in engine oil pan, add oil Check oil level in transmission case, add oil Check oil level in hydraulic tank, add oil Drain water, sediment from fuel tank Check fuel level, add fuel...
Page 231: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE LUBRICATION 1. Stop the engine. 2. Use the grease pump to pump in grease through the grease fitting marked by the arrow. 3. Check visually that the greasing has been carried out properly. 4.
Page 232: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATION 1. Stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 233 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (4) Body hinge pin (2 places) (5) Hitch bearing (2 place) https://www.besttruckmanuals.com/ 4 - 42...
Page 234: Check Drive Shaft
SERVICE PROCEDURE CHECK DRIVE SHAFT If there is any problem, such as looseness of the drive shaft connection, play in the spline or bearing portion, or runout of the shaft, please contact your Komatsu distributor for repair. https://www.besttruckmanuals.com/ 4 - 43...
Page 235: Clean Overflow Hose
MAINTENANCE SERVICE PROCEDURE CLEAN OVERFLOW HOSE WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. The overflow hoses are installed to the front and center wheels. Remove and clean all of the 4 hoses. 1.
Page 236: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. https://www.besttruckmanuals.com/...
Page 237 If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 238: Check Fan Belt And Alternator Belt Tension, Adjust
V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
Page 239: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING Press the middle of the belt between the air conditioner compressor pulley (1) and drive pulley (2) with the thumb (about 58.8 N {6 kg}). If deflection (A) is 10 mm, the belt tension is normal. ADJUSTING 1.
Page 240: Check Frame, A-Arm
2. Check all parts of the frame and A-frame for damage. In particular, check the hatched portions in the diagram, and if any cracks or damage are found, repair the damage. Please contact your Komatsu distributor for details of the repair procedure. https://www.besttruckmanuals.com/...
Page 241: Check Braking Capacity Of Foot Brake
1440 rpm, it is normal. 3. Lower the engine speed, set shifting lever at N position, and then set parking brake at PARKING position. If any abnormality is found, ask your Komatsu distributor for repair. NOTICE There is danger of damage inside the transmission, so always do this with the shift lever at the "D" position. Do not use any other position.
Page 242: Check Braking Capacity Of Parking Brake
1490 rpm, it is normal. 3. Lower the engine speed, set gear shift lever at N position. If any problem is found, ask your Komatsu distributor for repair. NOTICE There is danger of damage inside the transmission, so always do this with the shift lever at the "D" position. Do not use any other position.
Page 243: Check Of Accumulator Gas Pressure
If the brake oil pressure caution lamp lights up when the brake pedal is depressed 4 times or less, the gas pressure in the accumulator may be low. Ask your Komatsu distributor for inspection. If the brake oil pressure caution lamp does not light up when the brake pedal is depressed 5 times, the gas pressure in the accumulator is normal.
Page 244: Every 500 Hours Service
4. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 5. Tighten drain valve (3) and drain plug (2).
Page 245: Replace Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 246: Lubricate Cab Mount Pin (Left And Right: 1 Place Each)
MAINTENANCE SERVICE PROCEDURE 9. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
Page 247: Check Oil Level In Differential Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for the temperature to go down before starting the work. When removing the plug, oil may spurt out, so turn the plug slowly to release the internal pressure, then remove it carefully. 1.
Page 248: Clean, Check Radiator Fins And After Cooler Fins
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Rear CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. If the radiator fins become clogged or bent, this may cause overheating of the engine, so always clean or carry out inspection and take the necessary actions.
Page 249: Recover Oil Leaking From Floating Seal
MAINTENANCE SERVICE PROCEDURE RECOVER OIL LEAKING FROM FLOATING SEAL There are 4 oil suction openings. Collect all oil with the hand pump attached to the machine. REMARK If oil is flowing out of the overflow hose, collect the oil, even if before 500 hours.
Page 250 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Center axle (left, right) https://www.besttruckmanuals.com/ 4 - 59...
Page 251: Every 1000 Hours Service
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 252: Replace Corrosion Resistor Cartridge
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Loosen wing bolt (4) which is fixing lever (5) of priming pump (3). Move lever (5) up and down to let fuel flow out of air bleeding plug (2) until bubbles do not come out any more. 8.
Page 253: Replace Transmission Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. VALVE SIDE Prepare a filter wrench 1.
Page 254: Change Oil In Transmission Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. Refill capacity: 77.5 liters (20.48 US gal) (including oil in the brake oil tank and each filter case) Carry out the following items at the same time in order to drain oil completely.
Page 255 MAINTENANCE SERVICE PROCEDURE Make sure that the oil level in the brake oil tank does not go down below the mark in the sight gauge (H) while the engine is running at low idling. If the oil level goes down below (H) mark, stop the engine and raise the oil level in the brake oil tank.
Page 256: Change Oil In Brake Oil Tank, Replace Brake Oil Filter Element
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 257 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE REMARK Steps 6 to 8 are identical with those in "CHANGE OIL IN TRANSMISSION CASE (PAGE 4-63)". NOTICE Do not start up the engine without the transmission being filled with oil. If the engine is started up while the transmission is empty or short of oil, the transmission hydraulic pump will suffer damage.
Page 258 MAINTENANCE SERVICE PROCEDURE 11. After finishing air bleeding, stop the engine (for 2 to 3 minutes), and adjust the oil level so that it reaches the specified level. For details, see "CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL (PAGE 3-75)". https://www.besttruckmanuals.com/ 4 - 67...
Page 259: Lubrication
MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Using a grease pump, pump in grease through grease fittings marked by arrows. 2. After greasing, wipe off any old grease that was pushed out. Carry out the greasing operation every day when operating in places where the grease flows out easily, such as when traveling through mud or water.
Page 260: Check Wear Of Brake Disc
"B". If the disc has reached the wear limit, please contact your Komatsu distributor for inspection and maintenance. 6. Tighten cap nut (1) removed in Step 3. Tightening torque: 14.7 to 19.6 Nm (1.5 to 2.0 kgm, 10.8 to 14.5 lbft)
Page 261: Check Of Engine Air Intake Piping Clamps For Looseness
MAINTENANCE SERVICE PROCEDURE CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS Check the clamps between the air cleaner, turbocharger, aftercooler, and engine for looseness. If any clamp is loosened, retighten it. Tightening torque of clamp (1): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm, 6.5 ± 0.4 lbft} Tightening torque of clamp (2): 9.8 ±...
Page 262: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 263: Change Oil In Differential Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DIFFERENTIAL CASE WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Turn the plug slowly to release the pressure, then remove it carefully.
Page 264: Replace Hydraulic Filter Element
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Rear REPLACE HYDRAULIC FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 265: Clean Transmission Case Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN TRANSMISSION CASE STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. Drain the oil from the transmission case before starting the operation.
Page 266 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Hydraulic tank Differential case (front) Differential case (center) Differential case (rear) Final drive case (front, left) https://www.besttruckmanuals.com/ 4 - 75...
Page 267: Check Accumulator Gas Pressure
2000 hour or every year service. CHECK ALTERNATOR There is the possibility that the brush has worn out, or the bearing has run short of grease, so call on your Komatsu distributor for an inspection or repairs.
Page 268: Every 4000 Hours Service
HYDRAULIC TANK, ADD OIL (PAGE 3-75)". CHECK STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 269: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber
Check visually and touch with your fingers to check that there are no loose bolts or hardening of rubber parts at clamps (1) to (14). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement. CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER Check for any missing fuel spray prevention caps (1) to (11) or fuel spray prevention cover (12), and check also for any hardened rubber portions.
Page 270: Every 6000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 6000 HOURS SERVICE Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. LUBRICATE DRIVE SHAFT When greasing, use lithium grease (G2-LI), and carry out the greasing every 6000 hours or every 2 years.
Page 271: Every 8000 Hours Service
Maintenance for every 50, 250, 500, 1000, 2000, 4000 and 6000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to carry out this work. REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to carry out this work.
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Page 273: Specifications
27300 (60197) Struck (cu.yd) 12.9 (16.9) Dump body capacity Heaped (2 : 1) (cu.yd) 16.6 (21.7) Dumping speed (at 2000 rpm) (raised) Komatsu SAA6D125E-5 Name of engine – diesel engine Flywheel horsepower kW (HP)/rpm 254 (340)/2000 Nm (kgm, Max. torque...
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Page 275: Attachments, Options
ATTACHMENTS, OPTIONS HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC) HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC) This is a system to automatically activate the retarder when an operator wants to use it on a downslope or slow down on a flat hauling road. It enables the retarder to automatically function according to the present selected gear speed and engine revolution, thus making it easier for an operator to use the retarder.
Page 276: Method Of Operation
ATTACHMENTS, OPTIONS HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC) AUTOMATIC RETARDER, ACCELERATOR CONTROL SWITCH This switch (1) is used to turn on and off the ARAC system. (A): The ARAC system begins to function when a travel speed is over 7 km/h and the accelerator pedal is released, and the retarder pilot lamp lights on.
Page 277: Use Of Rear View Monitor
ATTACHMENTS, OPTIONS USE OF REAR VIEW MONITOR USE OF REAR VIEW MONITOR WARNING Never operate any of the switches while in running. If you do so, there is the fear that you may make an error in the truck operation, or neglect to watch the hauling road ahead for safety, and as a result cause a serious personal injury. The rear view monitor is an aid for checking obstacles in the rear.
Page 278 ATTACHMENTS, OPTIONS USE OF REAR VIEW MONITOR MANUAL SWITCH When this switch (2) is pressed, an image of a camera appears on the monitor display. At that time, a mark "CAM1" appears on the upper left side of the display and a figure "5" on the upper right side of the display. REMARK When the manual switch is pressed to call an image and the operation is suspended thereafter, the image disappears in...
Page 279 ATTACHMENTS, OPTIONS USE OF REAR VIEW MONITOR BRIGHT/DIM LIGHT SELECTOR SWITCH When this switch is pressed, the brightness of the monitor display lowers. A mark of "DIM" appears on the upper left side of the display then. When the switch is pressed again, the brightness returns to the original level, and "DIM"...
Page 280: Setting Of Rear View Monitor
Do not use the monitor if it is suspected of defect. There is a fear 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 281: Handling Dumping Counter
ATTACHMENTS, OPTIONS HANDLING DUMPING COUNTER HANDLING DUMPING COUNTER The dumping counter is an automatic counting function to count the number of loads that have been dumped. The number of loads dumped is displayed on the character display. METHOD OF DISPLAYING, RESETTING DUMPING COUNTER 1.
Page 282: Handling Machines Equipped With Komtrax
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
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Page 284: Index
INDEX INDEX <A> <H> AIR CONDITIONER 3- 64 HANDLING AUTOMATIC RETARDER, ARTICULATE LOCK 3- 45 ACCELERATOR CONTROL(ARAC) EXPLANATION OF COMPONENTS <B> METHOD OF OPERATION BODY PIVOT PIN 3- 45 HANDLING DUMPING COUNTER HANDLING MACHINES EQUIPPED <C> WITH KOMTRAX CAB TILT OPERATION 3-107 BASIC PRECAUTIONS CAR RADIO...
Page 285 OTHER TROUBLE 3-135 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR <U> PRODUCTS OTHER THAN USE OF REAR VIEW MONITOR KOMATSU GENUINE OIL 4- 12 CAUTIONS WHEN USING REAR USE OF FUEL, COOLANT AND VIEW MONITOR LUBRICANTS ACCORDING TO NAME AND FUNCTON OF EACH...
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Komatsu ecot3 GALEO HM300-2 Operation And Maintenance Manual

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