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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.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 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. 1 - 7...
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 It is located on the left front end of the frame.
Page 10: Service Meter Position
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SERVICE METER POSITION It is located on the right side of the meter section. 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 ENGINE SERIAL NO. PLATE POSITION 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- 15 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 16 TORQUE LIST...
Page 13 FOREWORD CONTENTS SERVICE PROCEDURE 4- 22 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 22 WHEN REQUIRED 4- 23 CHECK BEFORE STARTING 4- 40 EVERY 50 HOURS SERVICE 4- 41 EVERY 100 HOURS SERVICE 4- 43 EVERY 250 HOURS SERVICE 4- 44 EVERY 500 HOURS SERVICE 4- 55...
Page 14 FOREWORD CONTENTS METHOD OF USE 6- 49 INDEX 1 - 13...
Page 16 2 - 1...
Page 17: Safety
SAFETY SAFETY SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS 2- 10 SAFETY RULES 2- 10 IF ABNORMALITIES ARE FOUND 2- 10 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 10 FIRE EXTINGUISHER AND FIRST AID KIT 2- 10 SAFETY FEATURES 2- 11 KEEP MACHINE CLEAN...
Page 18 SAFETY SAFETY PRECAUTIONS DURING OPERATION 2- 18 STARTING ENGINE 2- 18 CHECKS BEFORE STARTING ENGINE, ADJUST 2- 18 PRECAUTIONS WHEN STARTING 2- 18 PRECAUTIONS IN COLD AREAS 2- 19 OPERATION 2- 20 CHECKS BEFORE STARTING OPERATION 2- 20 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 20 PRECAUTIONS WHEN TRAVELING 2- 21...
Page 19: 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. POSITION FOR ATTACHING SAFETY LABELS...
Page 20: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Roll-over protective structure (ROPS) (09620-30202) (2) Caution for checking engine room (09667-A0880) (3) Caution for opening hydraulic tank cap Caution for opening radiator cap (09653-A0641) 2 - 5...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Warning for handling suspension cylinder (09659-A0881) (5) Warnings for electric wire Warnings for crush hazard when inspection and maintenance Warnings for inspection of emergency steering system, secondary brake system Warning for leaving operator's seat, stopping engine Warning for retarder oil temperature (569-93-61730) 2 - 6...
Page 22 SAFETY SAFETY LABELS (6) Cautions before starting Cautions when traveling in reverse Cautions for operating hoist control lever (dump lever) (569-93-61720) (7) Caution when handling battery cable (09808-A1681) (8) Exhaust pipe is hot! (09817-A1103) 2 - 7...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (9) Caution for avoiding falling down (09805-C0881) (10) Caution when handling battery (This plate is stick on the machine by the battery maker.) (11) Precautions for high voltage (7872-10-1600) 2 - 8...
Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Jump start prohibited (09842-A0481) (This plate is stuck to the starting motor) 2 - 9...
Page 25: 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 26: 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 27: 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 handrails and steps marked by arrows in the diagram below when getting on or off the machine. A: For use when getting on or off the operator's seat from the left door B: For use when getting on or off the operator's seat from the...
Page 28: 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 29: Action If Fire Occurs
If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be maintained. In this case, be sure to ask your Komatsu distributor about repair method. Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect you properly. Always fasten your seat belt when operating the machine.
Page 30: Precautions For Attachments, Options
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 31: Do Not Go Close To High-Voltage Cables
SAFETY GENERAL PRECAUTIONS DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 32: Precautions Related To Ventilation Of Exhaust Gas
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 17...
Page 33: Precautions During Operation
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS DURING OPERATION STARTING ENGINE If there is a warning tag hanging from gear shift lever (1), 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. PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows.
Page 37: Precautions For Accumulated Snow, Ice
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS FOR ACCUMULATED SNOW, ICE Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 38: 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 39: 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 40: 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 41: 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 3-116)" Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed.
Page 42: 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 43: 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 and stop the engine. Set parking brake valve lever to the PARKING position and put blocks (1) under the tires to prevent the machine from moving.
Page 44: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 45: Handling Suspention Cylinder
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 46: Removing Battery Terminal
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 47: Precautions For High Voltage
If it is necessary to touch the injector terminal or the inside of the engine controller, please contact your Komatsu distributor. WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials.
Page 48: 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 51: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Dump body Turn signal light Rear wheel Head lamp Front wheel 3 - 2...
Page 52: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Dump lever lock (10) Shift limiter switch Dump lever (11) Power mode selector switch Lamp switch, Turn signal lever, Dimmer switch (11) 4WD switch Steering wheel (HD325 only the machine of 4WD specifications) Machine monitor (12) Secondary brake lever...
Page 53 OPERATION GENERAL VIEW Enlargement of machine monitor Caution/Pilot lamp bulb check switch Night lighting dimmer switch Starting switch Hazard lamp switch AISS LOW switch Front brake cut-off switch Power mode selector switch Exhaust brake switch (if equipped) (HD325 The machine of 4WD specifications) 3 - 4...
Page 54: Explanation Of Components
3 seconds, and the alarm buzzer will sound for approx. one second. When this happens, the speedometer will display 88. If no monitor lamp lights up, then there is probably a failure or disconnection in that circuit, therefore contact your Komatsu distributor to have the circuit checked.
Page 55 02: Park the machine at a safe location and contact your Komatsu distributor. 04: Carry out an emergency stop. Stop the engine and contact your Komatsu distributor. 01: Carry out inspection and maintenance after completing operation or when changing operators.
Page 56 OPERATION EXPLANATION OF COMPONENTS NOTICE If 01 is displayed and the warning monitor lights up, follow the applicable item in "CAUTION ITEMS (PAGE 3-8)" to carry out inspection and maintenance. If only 01 is displayed, check the service code and ask for repairs. If 03, 05, 06, or 07 are displayed, and the user code is displayed even after the above corrective action is taken, check the service code and ask for repairs.
Page 57 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If any of the warning monitors lights up, carry out the inspection and maintenance of the appropriate item as soon as possible. If it is left without the inspection and maintenance, it will lead to the trouble or failure. If there is any abnormallity for the caution items, the monitor for the corresponding abnormal area lights up.
Page 58 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STEERING This monitor (2) lights up when the emergency steering is actuated. If any abnormality should occur in the steering oil pressure circuit when the machine is traveling, the auto emergency steering is actuated and the related lamp lights up. PARKING BRAKE This (3) lights up when the parking brake is applied.
Page 59 OPERATION EXPLANATION OF COMPONENTS FUEL LEVEL This monitor (6) flashes when the level of the fuel in the fuel tank goes below 60 liters (15.84 US gal). If it flashes, check the fuel level and add fuel. 3 - 10...
Page 60 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEM CAUTION If any of these monitor lights up or flashes, stop the engine immediately or put the engine in low idling, then check the corresponding area and carry out the action. If the abonormaliy is found in the emergency items, the waring buzzer sounds and the monitor corresponds to the abnormal section lights up or flashes, and the central warning light flashes.
Page 61 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER TEMPERATURE This monitor (2) warns the operator that the engine cooling water temperature has risen. When it is flashing, the engine output is automatically limited. User code "05" is displayed at the same time when the lamp flashes, so stop machine and run the engine under no load at a mid-range speed until the engine water temperature gauge enters the green range.
Page 62 OPERATION EXPLANATION OF COMPONENTS BATTERY CHARGE This monitor (6) informs the operator that there is an abnormality in the charging system when the engine is running. User code "02" is displayed at the same time when the lamp lights up, so stop the machine in a safe place and check the charging circuit.
Page 63 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. Preheating monitor High beam Exhaust brake pilot (if equipped) Turn signal pilot lamp Rear brake pilot (retarder) Shift indicator (with lockup display) Differential lock pilot (if equipped)
Page 64 OPERATION EXPLANATION OF COMPONENTS EXHAUST BRAKE PILOT (If equipped) This pilot lamp (2) lights up when the exhaust brake is actuated. REAR BRAKE PILOT (Retarder) This pilot lamp (3) lights up when the foot brake is depressed or the retarder control lever is pulled, and the rear brake is applied. DIFFERENTIAL LOCK PILOT (If equipped) This pilot lamp (4) lights up when the differential lock pedal (if...
Page 65 OPERATION EXPLANATION OF COMPONENTS SHIFT LIMITER PILOT LAMP This pilot lamp (6) lights up when the shift limiter switch is actuated. HIGH BEAM This monitor (7) lights up when the head lamps are set to high beam. TURN SIGNAL PILOT LAMP This pilot lamp (8) flashes at the same time as the turn signal lamp flashes.
Page 66 OPERATION EXPLANATION OF COMPONENTS TRANSMISSION SHIFT LEVER POSITION PILOT LAMP This monitor (10) indicates the position of the transmission shift lever. AUTO SUSPENSION MODE DISPLAY LAMP (The machine equipped with automatic suspension) This monitor (11) displays the suspension mode, when the machine is equipped with the suspension controller.
Page 67 OPERATION EXPLANATION OF COMPONENTS METERS Speedometer Air pressure gauge Engine tachometer Engine water temperature gauge Service meter Torque converter oil temperature gauge Odometer Retarder oil temperature gauge Fuel gauge SPEEDOMETER This meter (1) indicates the travel speed of the machine. A speedometer for MPH is also available.
Page 68 OPERATION EXPLANATION OF COMPONENTS ENGINE TACHOMETER This meter (2) indicates the speed of the engine. While operating the machine, if the red range lights up, simultaneously the warning buzzer sounds and the central warning lamp flashes, then operate the machine while lowering the engine speed and the traveling speed.
Page 69 OPERATION EXPLANATION OF COMPONENTS AIR PRESSURE GAUGE This gauge (6) indicates the air pressure inside the air tank. The green range should be lit up during operation. If the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, and the air pressure monitor lamp will also flash at the same time.
Page 70 OPERATION EXPLANATION OF COMPONENTS MECHATRONIC CAUTION LAMP PORTION If an abnormality is detected in the mechatronics-related parts of the control system, the monitor lamp and the central warning lamp light up and the alarm buzzer sounds intermittently. Stop the machine, then take appropriate corrective action according to the user code.
Page 71 OPERATION EXPLANATION OF COMPONENTS AUTOMATIC TRANSMISSION (Mechatronics-related) If an abnormality is detected in the mechatronics- related parts of the transmission control system, this lamp (2) flashes to warn of the abnormality. MECHATRONICS-RELATED PARTS (Excluding 1. and 2. above) If an abnormality is detected in the mechatronics-related parts of the control system other than those of the engine and transmission, this lamp (3) flashes to warn of the abnormality.
Page 72: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (HD325, HD405) Starting switch AISS LOW switch Lamp switch (11) Emergency steering switch Turn signal lever (12) Secondary brake lever (13) Shift limiter switch Dimmer switch Caution/Pilot lamp bulb check switch (14) Parking brake valve lever Exhaust brake switch (if equipped) (15) Cigarette lighter...
Page 73 OPERATION EXPLANATION OF COMPONENTS (HD325 The machine of 4WD specifications) Starting switch AISS LOW switch Lamp switch (10) 4WD switch Turn signal lever (11) Emergency steering switch Dimmer switch (12) Secondary brake lever Caution/Pilot lamp bulb check switch (13) Shift limiter switch Exhaust brake switch (if equipped) (14) Parking brake valve lever...
Page 74 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position The key can be inserted or with drawn. The switches for the electric system are all turned off and the engine is stopped. ON position In this position, electric current flows in the charging and lamp circuits.
Page 75 OPERATION EXPLANATION OF COMPONENTS DIMMER SWITCH This switch (2) is used to switch the head lamps between high beam and low beam. (A) Low beam (B) High beam CAUTION/PILOT LAMP BULB CHECK SWITCH Press this switch (3) when the starting switch is at the ON position to check for any blown bulbs.
Page 76 OPERATION EXPLANATION OF COMPONENTS FRONT BRAKE CUT-OFF SWITCH WARNING When traveling on icy roads, on snow, or on other slippery road surfaces, set the front brake cut-off switch to the ON position and travel slowly at a safe speed. If the front brake cut-off switch is set to the OFF position when traveling on icy road, on snow, or on other slippery road surfaces, there is danger that the steering will be impossible to control.
Page 77 OPERATION EXPLANATION OF COMPONENTS POWER MODE SELECTOR SWITCH The power mode switch (8) can be switched to allow the machine to travel economically in a way suited to the operating conditions. If depressed once, it lights up; if depressed once again, the light goes off. OFF position: High power (general operations) This is used for general operating conditions.
Page 78 OPERATION EXPLANATION OF COMPONENTS 4WD SWITCH (HD325 only the machine of 4WD specifications) When the switch (10) is pressed, it lights up; if it is pressed once again, the light goes off. OFF: 2WD (Rear wheel drive) travel ON: 4WD (All wheel drive) travel Change from 4WD travel to 2WD travel and back at a travel speed below 10 km/h (6.2 MPH).
Page 79 OPERATION EXPLANATION OF COMPONENTS SHIFT LIMITER SWITCH This switch (13) is used to limit the maximum speed range when the transmission shift lever is in the "D" or "L" position. When the switch is pressed, the shift-limit function is actuated to limit the maximum speed to F6 in the D range and to only F1 in the L range.
Page 80 OPERATION EXPLANATION OF COMPONENTS HORN BUTTON When the horn button (16) in the center of the steering wheel is pressed, the horn will sound. WIPER SWITCH This switch (17) is used to operate the wiper. INT position: Wiper moves intermittently LOW position: Wiper moves at low speed HI position: Wiper moves at high speed When the switch is pressed, washer fluid is sprayed out.
Page 81: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Brake pedal Dump lever Accelerator pedal Retarder control lever Shift lever Differential lock pedal (if equipped) Dump lever lock BRAKE PEDAL This pedal (1) is used to apply the wheel brakes. 3 - 32...
Page 82 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 83 OPERATION EXPLANATION OF COMPONENTS Before shifting between forward and reverse, stop the machine completely and then run the engine at low idle. When starting the engine, if the gear shift lever is not at the N position, the engine will not start. When the starting switch is turned to the ON position, if the shift lever is not at the N (neutral) position, the transmission shift lever position pilot lamp and the central warning lamp will flash and the alarm buzzer will sound.
Page 84 OPERATION EXPLANATION OF COMPONENTS RETARDER CONTROL LEVER CAUTION The retarder must not be used as a parking brake. This lever (6) is used to operate the retarder, which applies the rear wheel brake when going downhill. The more the lever is pulled, the greater the braking force becomes.
Page 85: Mechatronics Equipment Controller
OPERATION EXPLANATION OF COMPONENTS MECHATRONICS EQUIPMENT CONTROLLER Transmission controller 4WD controller Engine controller (HD325 the machine of 4WD specifications) Suspension controller (if equipped) TRANSMISSION CONTROLLER A two-digit number followed by the service code is displayed in the inspection window of this controller (1) to identify the location of the abnormality.
Page 86: Body Pivot Pin
OPERATION EXPLANATION OF COMPONENTS BODY PIVOT PIN WARNING When raising the dump body to inspect the machine, always place the dump lever at the HOLD position, apply the lock, and then use the body pivot pins. This is a safety device for the dump body, and is used when carrying out inspection or maintenance with the dump body raised.
Page 87: Location Of Fire Extinguisher
OPERATION EXPLANATION OF COMPONENTS LOCATION OF FIRE EXTINGUISHER Fire extinguisher (1) is on top of the piping at the front of the air cleaner. LOCATION OF FIRST AID KIT First aid box (1) is in the rear cover inside the cab. FUSES The fuses protect the electrical equipment and wiring from burning out.
Page 88 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND CIRCUIT NAME Fuse box I Fuse Circuit name capacity Car radio, car stereo Horn relay Cigarette lighter Fog lamp (if equipped) Engine start relay, transmission neutral relay Head lamp (low beam), service brake relay, rear brake pilot relay, room lamp Head lamp (high beam), side clearance lamp, tail lamp, night lighting...
Page 89 Fuse box V (HD325 Only the machine of 4WD specifications) Fuse Circuit name capacity (28) 4WD controller (29) 4WD controller (30) Spare (31) Spare (32) Spare (33) Spare Contact your Komatsu distributor before using any spare fuse terminal. 3 - 40...
Page 90: Car Radio
OPERATION EXPLANATION OF COMPONENTS CAR RADIO 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 91 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 92 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 3-45)".) 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 93 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 94 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 95 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 96: 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 97 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 98 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 99 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 100 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 101 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 102 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 103 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 104: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER (If equipped) 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 Fan switch RECIRC/FRESH selector switch...
Page 105 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 106 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) steplessly from low temperature to high temperature. The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the green lamps light up, the lower the temperature is.
Page 107 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION Switch Air conditioner Temperature RECIRC/FRESH Mode selector Fan switch switch control switch selector switch switch Condition of use Rapid All green RECIRC FACE Cooling More than half Normal HI - LO FRESH FACE are green Dehumidifying, More than half...
Page 108 4-28)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-29)". 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. 3 - 59...
Page 109: 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 110 Check if any bolt is loose or damaged. If it is loose, tighten it (torque: 1520 to 1910 Nm (155 to 195 kgm , 1121.1 to 1410.4 lbft). If it is broke then replace it with Komatsu genuine bolt. 12. Inspect tires.
Page 111 OPERATION OPERATION CHECK BEFORE STARTING Always perform the procedures in this section before starting the engine 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 sub tank.
Page 112 OPERATION OPERATION CHECK OIL LEVEL IN FRONT BRAKE OIL TANK, ADD OIL CAUTION When adding oil to the brake oil tank, always use the recommended oil. For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-10)". 1. Check that the oil is between the FULL and LOW marks on sight gauge (G).
Page 113 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 114 OPERATION OPERATION CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL 1. After starting the engine, run the engine at low idle and check the oil level with sight gauge (G2). 2. If the oil level is low, add oil through oil filler (F). NOTICE The oil level changes according to the oil temperature, so carry out the check after completing the warming-up operation.
Page 115 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 116 (1) or defective operation of the buzzer. If there is any problem, please ask your Komatsu distributor to carry out inspection. Stop the engine, turn the starting switch to the ON position, set the parking brake valve lever to the PARK position, move the shift lever to any position other than N, and check.
Page 117 If the monitor lamp, caution lamp, or pilot lamp do not light up, there is probably a failure or disconnection, therefore contact your Komatsu distributor for inspection. CHECK BRAKING CAPACITY OF SECONDARY BRAKE WARNING If the machine moves, it will lead to the serious human injury. If the machine starts to move while checking the braking capacity, lower the engine speed and set the shift lever to N position.
Page 118 Check the wiring of the "battery", "starting motor"and "alternator"carefully, in particular. 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. 3 - 69...
Page 119 OPERATION OPERATION CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work. Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts). The proper inflation pressure is shown below.
Page 120 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) to the right, set the seat to the desired position, then release the lever.
Page 121 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 122 OPERATION OPERATION OPERATION OPERATION To make belt longer: Set the belt holding the buckle or tongue end at right angles to the buckle or tongue, and pull. ADJUST STEERING WHEEL TILT WARNING Always stop the machine before adjusting the tilt of the steering wheel. The tilt of the steering wheel can be adjusted to the front and rear, and up and down.
Page 123 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING WARNING When starting the engine, check that the gear shift lever is set in the N (neutral) position and that the parking brake valve lever is at PARKING position. Before standing up from the operator's seat, place the gear shift lever at neutral, and set the parking brake valve lever to the PARKING position.
Page 124 (HD325 only the machine of 4WD specifications) 6. Check that 4-wheel drive switch (6) does not flash when the key in starting switch (5) is turned to the ON position. If it flashes, then contact your Komatsu distributor. 3 - 75...
Page 125: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause 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 126 OPERATION OPERATION 4. Immediately after starting the engine, run it at idling. Do not put your foot on the accelerator pedal during this time. Guideline for idling time Normal temperature: 10 seconds When first starting engine after changing engine oil or replacing engine oil filter: 20 seconds STARTING IN COLD WEATHER WARNING Start the engine only after sitting down in the operator's seat.
Page 127 OPERATION OPERATION OPERATION OPERATION 4. Release the accelerator pedal or depress it lightly. 5. When the engine starts, release the key in starting switch (1). The key will return automatically to the ON position. 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 128 OPERATION OPERATION To improve the ease of starting in cold weather, the low idling speed becomes slightly higher for the time given below and the engine sound is different. In addition, it functions to make the acceleration gradual during this time. Injection characteristics Engine water temperature change time...
Page 129: Operations, Checks After Starting Engine
BREAKING-IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 130: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is suddenly stopped without allowing it to cool down, there is danger that the life of the engine parts will be shortened, so never stop the engine suddenly except in emergency. Allow the engine to cool down gradually before stopping it. 1.
Page 131: 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 132 OPERATION OPERATION OPERATION OPERATION 5. Check that retarder pilot lamp (5) has gone out, then set shift lever (6) 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 133 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 134 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 135 AND SECONDARY BRAKE HAVE BEEN ACTUATED IN EMERGENCY (PAGE 3-119)" in case that it is necessary to release the brake. 6. If emergency stop has been made, it is necessary to re-adjust the parking brake. Ask Komatsu distributor for adjustment. 3 - 86...
Page 136: Shifting Gear
OPERATION OPERATION SHIFTING GEAR When shifting gear, do as follows. This machine has an automatic transmission, so set gear shift lever (1) to the desired position, and the transmission will automatically shift to a position to match the travel speed. When the dump body has risen, the speed range is locked to 2nd speed at the D position and 1st speed at the 5 - L position.
Page 137: Traveling Downhill
2. If the retarder still has no effect even when the retarder lever is operated again, return the retarder lever completely to the released position, then depress the brake pedal to stop the machine, and contact your Komatsu distributor for repairs.
Page 138 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. Leave the gear shift lever in position D. When the machine reduces speed, the transmission will automatically shift down to the appropriate gear range.
Page 139 OPERATION OPERATION BRAKE PERFORMANCE CURVE Method of using graph Example: Downhill distance: 1500 m (4921 ft) Travel resistance -11% [grade resistance -13%, rolling resistance 2%] Load: 32 tons for HD325, HD325(4WD sepecifications), 40 tons for HD405 Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
Page 140 OPERATION OPERATION HD325, HD325 of 4WD specifications HD405 3 - 91...
Page 141 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1476 ft)] HD325, HD325 of 4WD specifications HD405 3 - 92...
Page 142 OPERATION OPERATION Brake performance [Downhill distance: 600 m (1968 ft)] HD325, HD325 of 4WD specifications HD405 3 - 93...
Page 143 OPERATION OPERATION Brake performance [Downhill distance: 900 m (2952 ft)] HD325, HD325 of 4WD specifications HD405 3 - 94...
Page 144 OPERATION OPERATION Brake performance [Downhill distance: 1500 m (4921 ft)] HD325, HD325 of 4WD specifications HD405 3 - 95...
Page 145 OPERATION OPERATION Brake performance [Downhill distance: Continuous] HD325, HD325 of 4WD specifications HD405 3 - 96...
Page 146: 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 apply force to the steering wheel when it has been turned fully to the left or right.
Page 147: 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 148: Precautions For Operation
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 149: 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 and set parking brake valve lever to the PARKING position.
Page 150: 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 151: Handling Tires
Tires where radial cracks extend to the carcass 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. T.Km.P.H (Ton-Km-Per-Hour Rating) Tires for construction equipment are used under severe conditions that bear no comparison with the tires used on cars, buses, or ordinary trucks, so they are specially designed to withstand these conditions.
Page 152 OPERATION OPERATION TIRE T.Km.P.H.AND MAXIMUM SPEED FOR CONTINUOUS TRAVEL (REFERENCE) HD325 Tire T.Km.P.H.for ambient Max.speed for continuous travel for ambient temperature temperature (km/h) 16 ° C 27 ° C 38 ° C 49 ° C 16 ° C 27 ° C 38 °...
Page 153 OPERATION OPERATION HD405 Tire T.Km.P.H.for ambient Max.speed for continuous travel for ambient temperature temperature (km/h) 16 ° C 27 ° C 38 ° C 49 ° C 16 ° C 27 ° C 38 ° C 49 ° C When empty Size 18.00R33 (front wheel (standard)
Page 154 The total operating hours per day includes the stopping time and rest periods. * The T.Km.P.H. in the table may differ slightly according to the tire maker, so concerning operations which require travel near the travel speed given in the table, consult your Komatsu distributor. 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 155: 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 156: 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 157: 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 "SPECIFICATIONS (PAGE 5-2)"...
Page 158 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 dump lever to the FLOAT position, and check that the body operation caution lamp goes out.
Page 159: 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 160: 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 161: 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)". 3 - 112...
Page 162: Long-Term Storage
Before operating the dump body, wipe off the grease on the hydraulic piston rod. 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 163: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting the engine after it has run out of fuel, fill the fuel tank with clean fuel, then fill the fuel filter cartridge with clean fuel and bleed the air from the fuel system before starting. PROCEDURE FOR BLEEDING AIR CAUTION This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will...
Page 164 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING 3. Loosen the knob of priming pump (4), then pump the knob and check that fuel comes out from air bleed plug (2). 4. Tighten air bleed plug (2). Tightening torque: 7.8 to 9.8 Nm (0.8 to 1 kgm , 5.8 to 7.2 lbft) 5.
Page 165: 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. 3 - 116...
Page 166 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 167 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 168 METHOD OF RELEASING PARKING BRAKE Please ask your Komatsu distributor to release the parking brake. WARNING If there is a failure in the air circuit, the brakes will not work. It is dangerous to drive the machine in this condition, so always tow the machine at low speed.
Page 169 OPERATION TROUBLESHOOTING METHOD OF RELEASING SECONDARY BRAKE Please ask your Komatsu distributor to release the secondary brake. WARNING When the secondary brake has been actuated, never drive the machine. This will cause burning out of the brake disc or lining, or failure of the torque converter or transmission.
Page 170: 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 171 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 3-121)" and the instructions given in the charger manual, and always do as follows.
Page 172 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 173 OPERATION TROUBLESHOOTING STARTING THE ENGINE CAUTION Make sure that the parking brake valve lever 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 174: 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 175 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 176 1500 rpm when the accelerator pedal is depressed, while the engine runs at low idling when the pedal is released. The engine speed varies depending on the load. After moving the machine to a safe place by operating the accelerator pedal, contact your Komatsu distributor for repairs.
Page 177 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 178 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 179 Immediately after checking the service code, stop the engine. 4. After checking the service code, contact your Komatsu distributor for repairs. REMARK The first two digits are shown on speedometer (2) and the last two digits are displayed on user code display panel (3).
Page 180 OPERATION TROUBLESHOOTING TRANSMISSION CONTROLLER If any abnormality occurs in the transmission, reduce the travel speed by using the brake, stop the machine on a safe place. Gear shifting may not work for some failure modes. If necessary, move the shift lever to the N position, remove emergency escape connector (1) (connector No.
Page 181 4. If the central warning lamp and 4-wheel drive switch do not stop flashing or the alarm buzzer continues to sound even when the 4-wheel drive switch is turned OFF, do not try to move the machine. 5. Check the self-diagnostic display, then contact your Komatsu distributor for repairs. REMARK The normal self-diagnostic display shows 2WD "3.2"...
Page 182 4 - 1...
Page 183: 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 184 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 185: 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. 4 - 4...
Page 186 Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 187 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 188 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. 4 - 7...
Page 189: 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 190: 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 191: 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 192: 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 HD325, HD405 ASTM: American Society of Testing and Material 4 - 11...
Page 193 Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS ( High-Temperature High-Shear Viscosity 150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. If these oils are not available, follow the instruction "RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL (PAGE 4-15)"...
Page 194 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT HD325 4WD specifications ASTM: American Society of Testing and Material 4 - 13...
Page 195 Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS ( High-Temperature High-Shear Viscosity 150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. If these oils are not available, follow the instruction "RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL (PAGE 4-15)"...
Page 196: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to the Komatsu web page or consult your Komatsu distributor. 4 - 15...
Page 197: 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 198: 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 199: 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- 55 Replace fuel filter cartridge 4- 62 Replace transmission oil filter element (valve inlet side, return side) 4- 58 Change oil in transmission case 4- 65...
Page 200 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 250 HOURS SERVICE Check oil level in differential case, add oil 4- 44 Check oil level in final drive case, add oil 4- 44 Lubricate drive shaft (5 places) 4- 45 Check drive shaft 4- 45 Check level of battery electrolyte 4- 46 Check alternator belt tension, adjust...
Page 201 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 2000 HOURS SERVICE Change oil in hydraulic tank 4- 71 Change oil in final drive case 4- 72 Change oil in differential case 4- 72 Clean differential case breather 4- 73 Clean engine breather element 4- 73 Clean air dryer filter and deflector (if equipped) 4- 74...
Page 202: Adjust Injector
When transporting a machine from an A regulation area to a B regulation area, always replace all the injector assemblies before transporting the machine to the new area. Check with your Komatsu distributor to confirm if your area of operation is an A regulation area or a B regulation area. A REGULATION AREA...
Page 203: 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 filter cartridge Replace transmission oil filter element (valve inlet side, return side) Change oil in transmission case Replace hydraulic filter element...
Page 204: When Required
MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN OR REPLACE AIR CLEANER WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 205 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 2. Remove outer element (5). 3. Clean the air cleaner body interior and the cover. 4. Direct dry compressed air (less then 0.69 MPa (7 kg/cm , 99.4 PSI)) along the folds of the element from the inside. Next, blow with air along the folds from the outside, then blow with air again from the inside.
Page 206: Clean Inside Of Cooling System
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 207 MAINTENANCE SERVICE PROCEDURE Mixing rate of water and antifreeze ° C Above -10 Min. atmospheric temperature ° F Above 14 Liters 26.7 32.1 36.5 41.0 44.5 Amount of antifreeze US gal 7.06 8.49 9.65 10.84 11.76 Liters 62.3 56.9 52.5 48.0 44.5 Amount of water...
Page 208 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Open drain valve (3) under the radiator, drain plug (4) at the side face of the engine, and drain plug (5) under the vibration damper, and drain the coolant. 4. After draining the coolant, close drain valve (3) and drain plugs (4) and (5), and fill with city water.
Page 209: 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 210: Check Refrigerant (Gas) Level
Contact your Komatsu distributor for details of the repair procedure. CHECK ELECTRIC INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.
Page 211: Check Length Of Suspension Cylinder, Check Oil Level
At the same time, measure the distance from the shoulder at the head of the suspension cylinder rod to the top of the flange with the machine unloaded. After checking the front and rear suspension cylinders, contact your Komatsu distributor if any abnormality is found. 4 - 30...
Page 212: Bleed Air From Rear Brake
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM REAR 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. 1.
Page 213: 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. 1. Start the engine and raise the pressure to the maximum position in the green range on the air pressure gauge. 2.
Page 214: Adjust Parking Brake
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 the first adjustment after replacing the pad, turn bolt (1) turn (6 clicks) in the counterclockwise direction.
Page 215: Bleed Air From Hydraulic Circuit Of Front Drive
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM HYDRAULIC CIRCUIT OF FRONT DRIVE (HD325 only the machine of 4WD specifications) If the hydraulic pump or motor for the front drive has been removed or installed and if the hydraulic hoses, pipes, etc. has been disconnected, bleed air according to the following procedure.
Page 216: Adjust Body Positioner
MAINTENANCE SERVICE PROCEDURE ADJUST BODY POSITIONER WARNING If for any reason the maintenance is performed while the engine is running, strictly follow the next rules. One should sit on the operator's seat, preparing to stop the engine at any moment, and contact with the other. Set the dump lever at HOLD position to prevent the dump body from moving.
Page 217: 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. 4 - 36...
Page 218: 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 219 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 220: Drain Water From Water Separator
MAINTENANCE SERVICE PROCEDURE PRECAUTIONS WHEN REPLACING TIRE If the hub nuts have been tightened again after replacing the tire, travel for 5 to 6 km, then tighten again to settle all the contacting parts. In particular, there are more contacting parts on the rear wheels than on the front wheels, so it will take time for the parts to settle.
Page 221: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-62)". Check coolant level, add coolant Check oil level in front brake oil tank, add oil Check oil level in front drive oil tank, add oil Check dust indicator Drain water from air tank Check oil level in engine oil pan, add oil...
Page 222: 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. 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 223 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (5) Front suspension (left and right: 2 places each) (6) Steering linkage (13 places) Portion "b" is for centralized greasing (5 places) 4 - 42...
Page 224: Every 100 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 100 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. CHECK ALCOHOL LEVEL IN ALCOHOL INJECTOR, ADD ALCOHOL (Machines equipped with alcohol injector) Before the cold season starts, loosen filler (1) (safety valve) of the alcohol injector gradually to release the remaining pressure inside the injector, then remove the cap and fill with 1.4 liters (0.37 US gal) of methyl alcohol through the filler port.
Page 225: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 and 100 hours service should be carried out at the same time. 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.
Page 226: Lubricate Drive Shaft (5 Places)
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. 4 - 45...
Page 227: 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. 4 - 46...
Page 228 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 229: Check 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 230: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING The belt should normally deflect by 10 mm (0.4 in) when pressed with the thumb (with a force of approx. 58.8 N (6 kg)) at a point midway between the air compressor pulley and drive pulley. ADJUSTING 1.
Page 231: Clean Breathers
MAINTENANCE SERVICE PROCEDURE CLEAN BREATHERS Remove the mud and dirt from around the breather, then remove the breather and wash out the dirt from inside with clean diesel oil or flushing oil. Transmission case Hydraulic tank 1. Remove nut (1), then remove cover (2) and wash element (3). 2.
Page 232: Check Frame
2. Check all parts of the frame for damage. In particular, check the colored 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. CHECK BRAKING CAPACITY OF FOOT BRAKE WARNING If the machine moves, it will lead to serious injury or death.
Page 233: Check Braking Capacity Of Retarder Brake
If the machine does not move even when the engine speed reaches 1200 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. CHECK BRAKING CAPACITY OF PARKING BRAKE WARNING If the machine moves, it will lead to serious injury or death.
Page 234: Check, Clean Automatic Suspension
When the dump lever is at any position other than FLOAT: hard. If any problem is found, please contact your Komatsu distributor for inspection and adjustment. If operations are carried out on muddy or wet ground, mud will stick to the link, and the movement may become slow, so check and clean.
Page 235: Clean Central Breather Box And Central Breather Air Cleaner
MAINTENANCE SERVICE PROCEDURE CLEAN CENTRAL BREATHER BOX AND CENTRAL BREATHER AIR CLEANER (Dusty area specification machine) WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. 1.
Page 236: Every 500 Hours Service
3. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 4. Tighten drain valve (2) and drain plug (1).
Page 237: Replace Additional Fuel Filter 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 238: Clean Fuel Tank Strainer
MAINTENANCE SERVICE PROCEDURE 6. 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 239: Replace Transmission Oil Filter Element (Valve Inlet Side, Return Side)
MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION 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. VALVE INLET SIDE 1.
Page 240: Replace Element Of Front Drive Oil Filter
So, change the pad. After the inspection, if it is necessary to change the pad, contact your Komatsu distributor. Left and right wheels are not always the same in terms of the amount of wear of the pad. So, perform the inspection for both left and right.
Page 241: Clean, Check Radiator Fins And After Cooler Fins
MAINTENANCE SERVICE PROCEDURE 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 242: Lubricate Tension Pulley (1 Place)
MAINTENANCE SERVICE PROCEDURE ADJUSTING 1. Loosen nut (1). 2. Use adjustment bolt (2) to move pulley (3) so that the deflection is approx. 17 to 19 mm (0.67 to 0.75 in) when a point midway between the fan pulley and tension pulley is pressed with the thumb with a force of 98 N (10 kg).
Page 243: 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 244 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE NOTICE When filling the filter cartridge with fuel, carry out the filling operation with cap (A) fitted. Cap (A) acts to prevent the entry of dirt or dust into the filter cartridge. 5. Fill the filter cartridge with clean fuel through the 8 small holes (B) in the new filter cartridge.
Page 245: Replace Corrosion Resistor Cartridge
MAINTENANCE SERVICE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE WARNING All the engine parts are at high temperature after the engine has been operated, so never replace the cartridge immediately after finishing operations. Wait for the oil to cool down before replacing the cartridge. Prepare a filter wrench 1.
Page 246: Change Oil In Transmission Case, Clean Transmission Case Strainer
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE, 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.
Page 247: Change Oil In Front Final Drive
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FRONT FINAL DRIVE (HD325 only the machine of 4WD specifications) 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.
Page 248: Change Oil In Front Drive Oil Tank, Clean Front Drive Oil Tank Strainer
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FRONT DRIVE OIL TANK, CLEAN FRONT DRIVE OIL TANK STRAINER (HD325 only the machine of 4WD specifications) 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.
Page 249: Replace Hydraulic Filter Element
MAINTENANCE SERVICE PROCEDURE 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. 1.
Page 250: 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. (1) Transmission mount (1 place) (2) Automatic suspension link (left and right: 1 place each) (3) Parking brake linkage (3 places) (4) Dump control link (3 places) 4 - 69...
Page 251: Check Wear Of Rear Brake Disc
8. Remove the disc wear measurement gauge and install air bleed plug (1). 9. Bleed all the air from the circuit. For details, see "BLEED AIR FROM REAR BRAKE (PAGE 4-31)". CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 4 - 70...
Page 252: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK 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.
Page 253: Change Oil In Final Drive Case
MAINTENANCE SERVICE PROCEDURE 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. 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 254: Clean Differential Case Breather
MAINTENANCE SERVICE PROCEDURE CLEAN DIFFERENTIAL CASE BREATHER 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 cleaning the engine breather. When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Page 255: Clean Air Dryer Filter And Deflector (If Equipped)
MAINTENANCE SERVICE PROCEDURE CLEAN AIR DRYER FILTER AND DEFLECTOR (If equipped) Always clean once every 6 months regardless of the operating hours. 1. Remove bolt (3), then remove cap (4). 2. Disassemble deflector (1) and filter (2) and wash in diesel oil. 4 - 74...
Page 256: Clean Emergency Relay Valve
Check the breather hose, and if any deteriorated oil is stuck to the inside, replace the hose with a new hose. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair.
Page 257: Every 4000 Hours Service
Ask your Komatsu distributor to carry out this work. CHECK FAN PULLEY AND TENSION PULLEY Check for play of the pulley and leakage of grease. If any problem is found, please contact your Komatsu distributor. CHECK VIBRATION DAMPER There is the possibility of drop in the level of the damper fluid and runout of the concave surface. So, please contact your Komatsu distributor to inspect or replace.
Page 258: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
Check for any missing fuel spray prevention caps (1) to (16) or fuel spray prevention cover (17), and check also for any hardened rubber portions. If there are any missing caps or cover or the rubber is hardened, please contact your Komatsu distributor for repairs. Install rubber caps (1) to (10) with the slit facing the cylinder block.
Page 259: Every 8000 Hours Service
REPLACE INJECTOR NOZZLE TIP See Section "B REGULATION AREA (PAGE 4-21)". 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. 4 - 78...
Page 260: Every 15000 Hours Service
Maintenance for every 50, 100, 250, 500, 1000, 2000, 4000 and 8000 hours service should be carried out at the same time. CHECK, REPLACE STEERING A ARM MOUNTING BOLT Check and replace the A arm mounting bolts, lock plate, and holder. Please consult your Komatsu distributor when checking and replacing. (1) A arm (2) Front suspension (3) Lock plate...
Page 262 5 - 1...
Page 263: Specifications
Dump body capacity (cu · yd) Heaped (2 : 1) 24 (31.4) 27.3 (35.7) Dumping speed (at 2100 rpm) (raised) Name of engine Komatsu SAA6D140E-3 diesel engine Flywheel horsepower kW (HP)/rpm 379 (508)/2000 Nm(kgf · m, Max. torque 2166 (221, 1598.5)/1400...
Page 264 6 - 1...
Page 265: Attachments, Options
ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HANDLING PAYLOAD METER There are two types of payload meter: a card type and a printer type. The explanation for the payload meter given here is for the printer type. For details of handling the card type payload meter, see the separate operation manual for payload meter II.
Page 266: External Display Lamps
ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER EXTERNAL DISPLAY LAMPS When the actual load is displayed, the lamps light up as follows. HD325, HD325 of 4WD specifications Lamp 1 (green): Displays load between 10 tons and 14 tons Lamp 2 (green): Displays load between 14 tons and 29 tons Lamp 3 (green): Displays load between 29 tons and 35 tons Lamp 4 (yellow): Displays load between 35 tons and 38 tons Lamp 5 (red): Displays load over 38 tons...
Page 267 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HD325, HD325 of 4WD specifications 6 - 4...
Page 268 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HD405 6 - 5...
Page 269: Operating Payload Meter
ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER OPERATING PAYLOAD METER Resetting power (the power can be reset by turning the power ON.) The display for the first 3 seconds is 88:88, and after that, the time is displayed for 7 seconds. After 10 seconds, the normal display is given. The printer feeds one line of paper and stops at the home position.
Page 270 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER METHOD OF CARRYING OUT CALIBRATION 1. Set the machine with the dump body empty. 2. Place the shift lever at the N position, and press calibration switch (1) for at least 2 seconds. (The letters CAL flash) 3.
Page 271 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER DELETING DATA FROM MEMORY 1. Print out the necessary data before clearing the memory. 2. Press memory data clear switch (1) for at least 2 seconds. (The letters CLEA will flash) 3. Press memory data clear switch (1) again for at least 2 seconds to complete the data clearing operation.
Page 272 Press the FEED switch to feed out the remaining paper. Never try to pull the paper out forcibly. Always use Komatsu genuine printer paper (7818-27-2910). 1. Open the roll of printer paper, fold the paper at a point approx. 3 cm (1.2 in) from the end of the paper, then cut the paper straight along the fold.
Page 273 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER METHOD OF CUTTING PRINTER PAPER 1. Press the FEED switch to feed the paper out to the necessary position. 2. Put the paper in contact with the cutter on the lid, then pull up to cut the paper from one side to the other. Do not pull the paper out and cut it without using the paper cutter.
Page 274 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HANDLING PAYLOAD METER 4. Remove the connectors, remove the screws (top: M4 x 8, rear: M4 x 3) of top cover (1) of the payload meter, then remove top cover (1). 5. Remove the nut (M4) and the band holding the battery. Do not wear gloves when carrying out this operation.
Page 275 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER OPERATION AFTER REPLACING CONTROLLER After replacing the controller, always carry out calibration, and operate the dump lever FLOAT → LOWER → FLOAT with the dump body empty. IF ERROR MESSAGE "PAPE" FLASHES (PAPER JAM) NOTICE Never touch the printer head (white).
Page 276 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HANDLING PAYLOAD METER 4. Use tweezers to remove the paper caught between printer head (2) and guide (3). Do not wear gloves when carrying out this operation. When using tweezers to remove the jammed paper, press the guide with your finger to make a clearance between the printer head and guide to make it easier to remove the paper.
Page 277: Selecting Dump Body
ATTACHMENTS, OPTIONS SELECTING DUMP BODY SELECTING DUMP BODY (HD325, HD325 only the machine of 4WD specifications) Select the dump body from the following table. 6 - 14...
Page 278: Tachograph (Tco 15-6)
ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) TACHOGRAPH (TCO 15-6) EXPLANATION OF COMPONENTS Instrument lock (12) Travel distance recording stylus Clock dial (13) Adjustment screw for speed warning lamp Clock operation confirmation aperture (14) Speed confirmation aperture for speed warning Speed scale lamp indication Speed indicator (15)
Page 279 ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) INSTRUMENT LOCK This (1) can be used for the instrument lock key when replacing the charts, or for operator change identification keys 1 and 2. CLOCK DIAL One line here (2) indicates one minute. CLOCK OPERATION CONFIRMATION APERTURE It is possible to check the action of the second hand with this (3) when the clock is working.
Page 280: Method Of Using Key
ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) CLOCK SETTING KNOB Turn this knob (15) clockwise to advance the hand, and counterclockwise to turn the hand back. CHART SUPPORT This (16) is the rotating part of the clock and has teeth to prevent the chart from slipping. PRESSING RING This ring (17) is a ring that presses the chart and holds it against the chart support.
Page 281: Method Of Use
Stop the engine completely before inserting the new charts. Use Komatsu genuine charts (P/N: YZ762929-980) for 90 km/h (55.9 MPH) 7 days. 7. Close the cover. Lift up the cover to close it, then turn the instrument open/lock key 90° clockwise.
Page 282 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) TACHOGRAPH (TCO 15-6) Replacing instrument lighting lamp bulb Raise contact piece (7), and take out the old bulb with a pincette. It comes out easily. After replacing, check that the contact piece is holding down the lamp base firmly.
Page 283: Revo Tachograph (Tco 15-7)
ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) REVO TACHOGRAPH (TCO 15-7) EXPLANATION OF COMPONENTS Instrument lock (14) Speed confirmation aperture for speed warning Clock dial lamp indication Speed scale (15) Clock setting knob Speed indicator (16) Chart support Speed warning lamp (17) Pressing ring Speed indication confirmation lamp...
Page 284 ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) INSTRUMENT LOCK This (1) can be used for the key to open when replacing the chart. CLOCK DIAL One line here (2) indicates one minute. SPEED SCALE This (3) is the scale for the machine travel speed. SPEED INDICATOR This (4) indicates the machine travel speed.
Page 285 ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) CHART SUPPORT This (16) is the rotating part of the clock and has teeth to prevent the chart from slipping. PRESSING RING This ring (17) is a ring that presses the chart and holds it against the chart support. CUTTING KNIFE This knife (18) cuts the tape connecting the charts.
Page 286: Method Of Use
Stop the engine completely before inserting the new charts. Use Komatsu genuine charts (P/N: YZ762929-730) for 90 km/h (55.9 MPH) 7 days. 6. Close the cover. Lift up the cover to close it, then turn the instrument open/lock key 90° clockwise. When operating the machine, remove the instrument open/lock key.
Page 287 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) REVO TACHOGRAPH (TCO 15-7) Replacing instrument lighting lamp bulb Raise contact piece (7), and take out the old bulb with a pincette. It comes out easily. After replacing, check that the contact piece is holding down the lamp base firmly.
Page 288: Using Differential Lock
ATTACHMENTS, OPTIONS USING DIFFERENTIAL LOCK USING DIFFERENTIAL LOCK DIFFERENTIAL LOCK PEDAL The differential lock is used on snow-covered or muddy areas where the tires are likely to slip. The left and right wheels on the rear axle are locked together to prevent slipping and to provide a powerful drive force.
Page 289: Precautions And Method Of Use
ATTACHMENTS, OPTIONS USING DIFFERENTIAL LOCK DIFFERENTIAL LOCK PEDAL This pedal (1) actuates the differential lock control. When the pedal is depressed, the differential lock is actuated; when the pedal is released, the differential lock is cancelled. REMARK When traveling on soft ground where the wheel on one side slips, or when traveling on road surfaces where the tires are likely to slip, depress the differential lock pedal.
Page 290: Operation Of Abs And Abs/Asr
ATTACHMENTS, OPTIONS OPERATION OF ABS AND ABS/ASR OPERATION OF ABS AND ABS/ASR [ABS (ANTI-SKID BRAKE SYSTEM), ASR (AUTOMATIC SPIN REGULATOR)] ABS: When the machine is braked suddenly or braked on a slippery snow-covered road, etc., this system works to prevent the tires from locking and skidding. Accordingly, a stable machine behavior and good steering performance is secured.
Page 291 ATTACHMENTS, OPTIONS OPERATION OF ABS AND ABS/ASR ABS/ASR MAIN SWITCH This switch (3) is used to turn the ABS/ASR system on/off. TROUBLESHOOTING SWITCH This switch (4) is used for troubleshooting. 6 - 28...
Page 292: Operation Method
ATTACHMENTS, OPTIONS OPERATION OF ABS AND ABS/ASR OPERATION METHOD ABS OPERATION WARNING Always stop the machine before turning on the ABS/ASR main switch (3). If it is turned on while the machine is running, the ABS/ASR may not function normally. 1.
Page 293: Precautions For Use
If the ABS/ASR system malfunctions while being used, the warning lamp (Red) will light up. In this case, stop the machine at a safe place immediately, then ask your Komatsu distributor to carry out repair. The positions of each switch and the statuses of the corresponding warning lamps are as follows.
Page 294: Handling Auto-Greasing System
ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM With this system, the grease is automatically supplied through the computer controls. METHOD OF OPERATING AUTO-GREASING SYSTEM 1. Turn the starting switch ON. REMARK Immediately after the power is turned on, all display lamps on the lubrication controller inside the console box will light up for several seconds.
Page 295 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM ACTUATION OF AUTO-GREASING When engine starting switch (1) is turned one stage, the auto-greasing system is automatically set to the actuation condition. Do not press start button (3) of lubrication controller (2). Operating when desired It is possible to start the system and carry out one cycle of greasing regardless of the time count.
Page 296 If the machine is used in ambient temperatures below -20°C (-4°F), set the greasing time to 20 minutes (code No. 7). In addition, use lithium-based grease No. 0. For details of setting the time, see "METHOD OF SETTING (PAGE 6-34)". When changing the set value, please contact your Komatsu distributor. 6 - 33...
Page 297 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM METHOD OF SETTING When setting the various items, the value is not input directly. Select the code number from the set code table below, and set as follows. Setting code table NOTICE When using the machine at ambient temperatures of below -20°C (-4°F), set to greasing time (b) at code No. 7. Procedure for setting 1.
Page 298 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM 8. When the code number that is to be set flashes, press the SET key to carry out the setting. 9. Repeat Steps 6 to 8 to set all of the items a, b, and c. After completing the setting, press the ESC key to leave the setting mode.
Page 299 HANDLING AUTO-GREASING SYSTEM GREASING WARNING Air bleeding of pump involves danger because of high pressure. Ask your Komatsu distributor for air bleeding. NOTICE After greasing, be sure to reset the count of the controller. (See "TROUBLESHOOTING (PAGE 6-37)".) Be sure to use the special grease pump (566-96-6A840) and supply grease with it according to the following procedures, taking care not to let air or dust get in to the grease.
Page 300: Precautions When Handling Auto-Greasing System
ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM Basically, the power source input to the lubrication controller should be DC24V, but use a maximum limit of 30V. The grease nipple installed to the service port used for initial charging of the divider valve has a ball check structure, so it may leak if dirt gets stuck in it.
Page 301: Arsc (Automatic Retarder Speed Control)
ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) ARSC (AUTOMATIC RETARDER SPEED CONTROL) When traveling downhill, if the switch is pressed at the speed that is to be maintained, the retarder is automatically actuated to prevent the travel speed from exceeding the set speed, so this makes retarder operations easy. WARNING The ARSC system is actuated when the system switch is ON.
Page 302 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) ARSC (AUTOMATIC RETARDER SPEED CONTROL) Decrease speed Increase speed Cancel SYSTEM SWITCH This switch (1) is used to turn the ARSC system ON/OFF. ARSC SET LEVER This lever (2) is used in the following cases: When setting the travel speed When making fine adjustments to the set speed (tap up/tap down) When canceling the speed setting...
Page 303: Method Of Operation
ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF OPERATION ACTUATION OF ARSC SYSTEM The ARSC system is actuated when the system switch is ON. If the set switch on the ARSC set lever is pressed, the travel speed at that moment is set as the downhill travel speed.
Page 304 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF DECREASING SET TRAVEL SPEED If it is desired to decrease the set speed, operate the retarder control lever to reduce speed, and when the desired set travel speed is reached, press the set switch on the ARSC set lever. The set travel speed will be changed to the new speed.
Page 305: Troubleshooting
ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) TROUBLESHOOTING WHEN A PROBLEM OCCURS IN THE SYSTEM This system is equipped with a self-diagnostic function. If any problem occurs, a failure code is displayed by the controller LED under the assistant's seat. Failure Remedy Detail...
Page 306 In the case of patterns 1 and 2 above, turn the system switch OFF quickly, stop use of the ARSC and contact your Komatsu distributor for repairs. The set travel speed display is also equipped with a self- diagnostic function, and a failure code is displayed on the...
Page 307 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) WHEN SYSTEM IS NORMAL The code is displayed on the controller LED under the assistant's seat. Code Condition When accelerator pedal is being depressed ("." is not shown for 0 on the right) 0.0.
Page 308: Asr-Ii (Automatic Spin Regulator Ii)
ATTACHMENTS, OPTIONS ASR-II (AUTOMATIC SPIN REGULATOR II) ASR-II (AUTOMATIC SPIN REGULATOR II) ASR is a function to prevent slipping of the drive wheels caused by excessive torque. Accordingly, the machine can start and travel normally even on a bad or frozen road surface. EXPLANATION OF COMPONENTS System switch Retarder control lever...
Page 309: Actuation Of Asr-Ii System
ATTACHMENTS, OPTIONS ASR-II (AUTOMATIC SPIN REGULATOR II) RETARDER CONTROL LEVER When ASR is operated, if the retarder gets started with this lever (5), ASR system stopps its operation. ACCELERATOR PEDAL ASR system operates only when the pedal (6) is depressed with the travel speed range of 0 to 30km/h (0 to 18.6 MPH).
Page 310: Troubleshooting
ATTACHMENTS, OPTIONS ASR-II (AUTOMATIC SPIN REGULATOR II) TROUBLESHOOTING WHEN A PROBLEM OCCURS IN THE SYSTEM This system is equipped with a self-diagnostic function. If any problem occurs, a failure code is displayed by the controller LED behind the assistant's seat. Failure Remedy Details...
Page 311 When the system switch is turned OFF, the ASR caution lamp will go out. In the case of patterns 1 and 2 above, turn the system switch OFF quickly, stop use of the ASR and contact your Komatsu distributor for repairs. WHEN SYSTEM IS NORMAL The code (0.0) is displayed by the controller LED behind the assistant's seat.
Page 312: Handling Oil Filter Caution
ATTACHMENTS, OPTIONS HANDLING OIL FILTER CAUTION HANDLING OIL FILTER CAUTION The oil filter caution is a device to warn the operator by using a caution lamp to inform that the filter is clogged or that the replacement interval for the oil or filters has passed. Display items for oil filter replacement interval Timer switch related items Engine oil...
Page 313 ATTACHMENTS, OPTIONS HANDLING OIL FILTER CAUTION WHEN CHECKING OIL, FILTER REPLACEMENT INTERVAL 1. All lamps light up when the starting switch is turned ON, and after 3 seconds, the display shows the engine oil replacement interval. 2. When checking the oil replacement interval, press the left replacement interval check switch; when checking the filter replacement interval, press the right replacement interval check switch.
Page 314 INDEX INDEX <A> <G> AIR CONDITIONER 3- 55 GENERAL PRECAUTIONS 2- 10 ARSC (AUTOMATIC RETARDER GENERAL VIEW SPEED CONTROL) 6- 38 GENERAL VIEW OF CONTROLS AND EXPLANATION OF COMPONENTS 6- 38 GAUGES METHOD OF OPERATION 6- 40 GENERAL VIEW OF MACHINE TROUBLESHOOTING 6- 42 GUIDES TO MAINTENANCE...
Page 315 BEFORE STORAGE 3-113 RECOMMENDED BRANDS, DURING STORAGE 3-113 RECOMMENDED QUALITY FOR PRECAUTIONS BEFORE PRODUCTS OTHER THAN TRAVELING AFTER LONG-TERM KOMATSU GENUINE OIL 4- 15 STORAGE 3-113 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO <M> AMBIENT TEMPERATURE 4- 11 MACHINE MONITOR...
Page 316 INDEX AFTER RUNNING OUT OF FUEL 3-114 IF BATTERY IS DISCHARGED 3-121 METHOD OF TOWING MACHINE 3-116 OTHER TROUBLE 3-125 <U> USING DIFFERENTIAL LOCK 6- 25 DIFFERENTIAL LOCK PEDAL 6- 25 PRECAUTIONS AND METHOD OF 6- 26 <W> WEAR PARTS WEAR PARTS LIST 7 - 3...

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Komatsu HD325-6 Operation & Maintenance Manual

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