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Komatsu HD325-8 Operation & Maintenance Manual

Komatsu HD325-8 Operation & Maintenance Manual

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Operation &

Maintenance Manual

HD325

HD405

DUMP TRUCK

SERIAL NUMBERS

HD325-8 - 50001 and up

HD405-8 - 50001 and up

WARNING

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read

this manual before operating or maintaining this

machine. This manual should be kept inside the cab for

reference and periodically reviewed by all personnel who

will come into contact with the machine.

-8

-8

ORIGINAL INSTRUCTIONS

EENAM03582

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Page 1 EENAM03582 Maintenance Manual HD325 HD405 DUMP TRUCK SERIAL NUMBERS HD325-8 - 50001 and up HD405-8 - 50001 and up WARNING Unsafe use of this machine may cause serious injury or ORIGINAL INSTRUCTIONS death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 Keep it in the pocket behind the operator's seat. If this manual is lost, damaged, or unreadable, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5: Komatsu Machine Operator Privacy Policy
Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un- der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to MMS.
Page 6 FOREWORD • pictures, videos and sound recordings 4. Why is your personal data processed? When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea- sons: (a) Safety and security (b) Warranty (c) Misuse and theft prevention...
Page 7 (30) days after having received the request. If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you...
Page 8: Safety Information
SAFETY INFORMATION FOREWORD SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 9: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201...
Page 10: Vibration Levels
ISO 7096. FOR HD325-8 : The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s , the uncertainty for this value is 0.99 m/s...
Page 11 FOREWORD VIBRATION LEVELS • Reduce speed to prevent bounce • Transport machines long distances between worksites The following guidelines can be effective to minimize risks of low back pain • Operate the machine only when you are in good health •...
Page 12: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: Traveling with a load DIRECTIONS OF MACHINE (A) Front (D) Right (B) Rear (E) Operator's seat (C) Left In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine.
Page 13 FOREWORD INTRODUCTION 1-11...
Page 14: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 15: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is provided on the front right of the machine.
Page 16: Fluorinated Greenhouse Gases
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU LTD. Address: 2-3-6 Akasaka Minato-ku, Tokyo 107-8414 Japan Authorised representative: KOMATSU EUROPE INT. Address: Mechelsesteenweg 586 B-1800 Vilvoorde Belgium Distributor name Address Service personnel Phone/Fax 1-14...
Page 17: Serial Plate
FOREWORD SERIAL PLATE SERIAL PLATE EI000001 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER OPERATING MASS AUTHORISED REPRESENTATIVE 1-15...
Page 18: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer/Authorised representative The manufacturer Authorised representative KOMATSU LTD. KOMATSU EUROPE INT. 2-3-6 Akasaka Mechelsesteenweg 586 Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde Japan Belgium Declares that this machine: HD325-8 HD405-8 Fulfils all the relevant provisions of following EC Directives:...
Page 19: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 KOMATSU MACHINE OPERATOR PRIVACY POLICY ................1-3 SAFETY INFORMATION .......................... 1-6 NOISE............................... 1-7 VIBRATION LEVELS ..........................1-8 VIBRATION - OPERATING CONDITION ................... 1-8 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-8 INTRODUCTION ............................
Page 20 OTHER TROUBLE......................... 3-274 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2...
Page 21 SETTING MACHINE ID AND OPEN ID.....................6-11 METHOD FOR PERFORMING CALIBRATION................6-12 BODY SELECTION..........................6-15 HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS).............. 6-16 OPERATION OF KTCS........................6-16 METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND......6-16 HANDLE SPEED LIMIT FUNCTION ....................... 6-17 OPERATION OF SPEED LIMIT FUNCTION ..................
Page 22 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-20...
Page 23: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 24: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 25: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 26 SAFETY LABELS SAFETY...
Page 27 SAFETY SAFETY LABELS (1) Caution for modification of ROPS/FOPS (10) Caution for handling battery cable (2) Caution against rotating parts (11) Caution against high temperature (3) Caution when checking engine room (12) Caution against falling (4) Caution when releasing radiator cap (13) Caution for handling battery (5) Caution when opening hydraulic tank cap (14) Caution for parking brake...
Page 28: Contents Of Safety Labels
Do not drill, cut or weld on the ROPS or FOPS structure. Any modification is prohibited. 09620-A3001 • ROPS or FOPS may provide less protection if it has been Komatsu Ltd. 2-3-6 Akasaka, Minato-ku, Tokyo, Japan 09620-A2009 structurally damaged or involved roll-over. Consult Komat- su Distributor in that case.
Page 29 SAFETY SAFETY LABELS Caution when releasing radiator cap “09653-A0641” • Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. • Allow radiator or hydraulic tank to cool before removing cap.
Page 30 SAFETY LABELS SAFETY Caution for handling accumulator and gas spring “09659-A057B” • There is the hazard of explosion causing injury. • Do not disassemble accumulator and gas spring, make holes in it, weld it, cut it, hit it, roll it or bring it near flame. Caution for electric cables, caution against falling when performing inspection and maintenance of dump body, caution for performing daily inspection, cau- tion when leaving operator's seat and when stopping engine, caution for retard-...
Page 31 SAFETY SAFETY LABELS Caution before operating, caution when traveling in reverse, caution for operat- ing hoist control lever “561-93-82380” 561‑93‑82380 • Always read the Operation and Maintenance Manual before carrying out operation maintenance, disassem- bly, assembly, or translation of the machine. •...
Page 32 SAFETY LABELS SAFETY Caution against high temperature “09817-A1103”, “09817-K120B” • Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation. • Never touch when hot. Caution against falling “09805-C0881” •...
Page 33 SAFETY SAFETY LABELS Caution for parking brake “566–93–82320” • Do not attempt to remove spring(s), saw, torch or modify this chamber, serious injury or death may result. Prohibition of start by short-circuiting “09842-A0362” • Start the engine only after sitting down in the operator's seat.
Page 34 SAFETY LABELS SAFETY Caution for handling DEF “09632-61480” • DEF only. To avoid engine damage or fire, fill with DEF only. • Never use diesel fuel. Caution for using seat belt “09848-A0640” • Always use seat belt when operating the machine to re- duce risk of injury or death in case of a roll-over.
Page 35: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 36: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 37 Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). 2-15...
Page 38: Precautions When Getting On Or Off Machine
In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...
Page 39 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it. LIFTING OF PERSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel.
Page 40: Do Not Get Caught In Work Equipment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY In addition, lock all places and always take the key with you and keep it in the specified location. EMERGENCY EXIT FROM OPERATOR'S CAB The machine equipped with the cab has the doors on its right and left sides. If either door does not open, es- cape from the other door.
Page 41: Unauthorized Modification
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 42: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 43 Prohibit other personnel from coming close to the machine during operation. • Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. 2-21...
Page 44: Start Engine
PRECAUTIONS FOR OPERATION SAFETY START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine. If the warning tag is ignored and the machine is operated, the person performing inspection or maintenance may be caught in the rotating parts or moving parts.
Page 45: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the following. • Start the engine only while sitting down in the operator's seat. •...
Page 46 PRECAUTIONS FOR OPERATION SAFETY • Fasten the seat belt. When the brakes are applied sudden- ly, the operator may be thrown out of the operator's seat. It is dangerous and may cause personal injury. • Check the operation of travel, steering and brake systems, and dump body control system.
Page 47 This may cause the tires to burst. If a tire bursts, it produces a large destructive force, and this may cause serious injury or death. If you are going to drive the machine continuously, consult your Komatsu distributor. •...
Page 48: Transportation
PRECAUTIONS FOR OPERATION SAFETY • Frozen road becomes soft when the temperature rises, and the machine may tip over or be not able to es- cape. Be particularly careful when working on frozen road. • When traveling on snow-covered roads, always fit tire chains. •...
Page 49: Towing And Being Towed
SAFETY PRECAUTIONS FOR OPERATION • Consult your Komatsu distributor to disassemble the machine for transportation. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 50: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 51 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 52 PRECAUTIONS FOR MAINTENANCE SAFETY TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the maintenance with the engine running, always observe the following. • One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 53 SAFETY PRECAUTIONS FOR MAINTENANCE • Place attachments that have been removed from the ma- chine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area. PRECAUTIONS FOR WORKING AT HIGH PLACES When working at high places, use a step ladder or other stand to ensure that the work can be performed safely.
Page 54: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY USE PROPER TOOLS Use the tools suited to the task and use them correctly. Using damaged, deformed, or low quality tools, or making improper use of the tools may cause serious personal injury or death. PRECAUTIONS FOR CHECK AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Page 55 SAFETY PRECAUTIONS FOR MAINTENANCE Danger from dilute sulphuric acid When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the battery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explosion, or fire. Always ob- serve the following.
Page 56 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 57 • Do not hit or roll it, or subject it to any impact. • Ask your Komatsu distributor when sealing gas into the cylinder or replacing gas from it. • When disposing of the accumulator, the gas must be re- leased.
Page 58: Tires
• Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and spe- cial technology, so always ask your Komatsu distributor to perform these operations. • Use only specified tires and inflate them to the specified pressure.
Page 59 • If the tire inflation pressure goes down abnormally or the rim parts do not fit the tire, there is a problem with the tire or rim parts. Always contact your Komatsu distributor for repairs. • If the rim parts are not fitted properly when the tire is being pumped up, there is a danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim.
Page 60: Precautions For Def
PRECAUTIONS FOR DEF SAFETY PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 61: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 62: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME This illustration shows HD325-8. (1) Fog lamp (9) Side lamp (2) Headlamp (low beam) (10) Brake sub-tank (3) Headlamp (high beam) (11) Front suspension (4) Turn signal lamp (12) Front wheel (5) Dump body...
Page 63: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Wiper and window washer switch (12) Hazard lamp switch (2) Lamp switch, dimmer switch, turn signal lever (13) Secondary steering switch (3) Switch panel (14) Front brake off switch (4) Monitor brightness selector switch (15) AISS LOW switch (5) Side lamp switch (16) Engine power mode selector switch...
Page 64 GENERAL VIEW OPERATION (23) Cigarette lighter (29) Dump lever lock knob (24) Engine shutdown secondary switch (30) Rearview monitor brightness adjustment switch (25) Power window switch (L.H.) (31) Gear shift lever (26) Power window switch (R.H.) (32) Parking brake switch (27) Heated wire mirror switch (if equipped) (33) Room lamp 2 switch (28) Dump lever...
Page 65 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME Machine monitor (A) LCD unit (C) Meter unit (B) LED unit (1) Engine coolant temperature caution lamp (16) Speedometer (2) Engine coolant temperature gauge (17) Fuel level caution lamp (3) ECO gauge (18) Fuel gauge (4) Air conditioner display section (19) DEF level gauge (5) Clock...
Page 66 GENERAL VIEW OPERATION Liquid crystal unit display (A-1) Standard screen (ARSC setting: ON, payload (A-2) Standard screen (ARSC setting: ON, payload meter: OFF) meter: ON) (30) Message display (38) Front brake off pilot lamp (31) Retarder pilot lamp (39) Torque converter lockup pilot lamp (32) ARSC pilot lamp (40) Preheating pilot lamp (32) ARSC off pilot lamp...
Page 67 OPERATION GENERAL VIEW (B) ECO guidance screen (D) Warning screen (C) Maintenance time warning screen (E) User menu screen (46) ECO guidance (49) Warning display (47) Maintenance time caution lamp (50) Seat belt caution lamp (48) Guidance icon (51) Action level...
Page 68: Other Equipment Name
GENERAL VIEW OPERATION OTHER EQUIPMENT NAME Inside of cab (1) Open knob for cab door (7) Fuse (2) Cab door inner lock (8) AUX (3) Rearview monitor (9) Lunch box tray (4) Magazine box (10) 12 V power supply (5) Cup holder (2 places) (11) Ashtray (6) Drink box...
Page 69 OPERATION GENERAL VIEW Outside of cab (1) DEF injector (6) DEF pump (2) KDPF assembly (7) DEF filter (3) SCR assembly (8) DEF tank (4) Cab door handle (9) Dust indicator (5) Fire extinguisher (if equipped)
Page 70 GENERAL VIEW OPERATION (10) Komatsu Closed Crankcase Ventilation (hereafter (15) Battery KCCV) ventilator (16) Grease pump holder (11) Body pivot pin (17) Battery disconnect switch (12) Rearview camera (18) System operating lamp (13) Circuit breaker (19) Toolbox (14) Fuse 3-10...
Page 71: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT FF: Failure display screen (A) Warning display...
Page 72 Speedometer (E) displays “88” for 2 seconds. The alarm buzzer sounds for 2 seconds, then stops under the normal condition. NOTICE Consult your Komatsu distributor when either the lamps, buzzers or the machine monitor does not function. REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat- tery condition.
Page 73 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While the engine shutdown secondary switch (1) is turned on (engine is stopped), when the starting switch key is turned to ON position, the screen shown in the figure is displayed and the engine does not start.
Page 74 OPERATION End screen when any message has been received If there is any message from your Komatsu distributor, it is displayed on the end screen DD for 5 seconds, and then the screen goes out. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 75 The operator identification function is not for security or protection against theft. Do not use for securi- Komatsu cannot take responsibility for any loss or damage from the wrong use of ID or unauthorized use of ID by a third person.
Page 76 EXPLANATION OF COMPONENTS OPERATION If there is the maintenance time warning when starting the engine When the machine monitor is started, if the time to the next maintenance of any item is 30 hours or less, the starting screen AA is displayed for 2 seconds and then it is changed to the maintenance time warning screen When the menu switch displayed in the guidance icon is press- ed, “Maintenance”...
Page 77 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF. When ENTER switch displayed in the guidance icon is press- ed, “Current Abnormality”...
Page 78 EXPLANATION OF COMPONENTS OPERATION (1) Engine coolant temperature caution lamp (7) Seat belt caution lamp (2) Warning display (8) Brake oil pressure caution lamp (3) Warning display (9) Retarder oil temperature caution lamp (4) Guidance icon (10) Fuel level caution lamp (5) Centralized warning lamp (11) DEF level caution lamp (6) Action level display...
Page 79 Stop the operation and move the machine to a safe Sounds inter- Lights up place, then ask your Komatsu distributor for the in- mittently spection and maintenance. If there is an overrun related display, reduce the en-...
Page 80 (A) Caution lamp (B) Action level (C) Failure code Code to indicate the content of the failure. Notify it when calling your Komatsu distributor. (D) Failure name (E) Message Take appropriate actions according to the displayed message. (F) Contact telephone number The telephone number of your Komatsu distributor is displayed.
Page 81 OPERATION EXPLANATION OF COMPONENTS Ask your Komatsu distributor for the telephone number registration if necessary. (G) Guidance icon On “Current Abnormality” screen, the following switches displayed in the guidance icon (G) can be operated. UP switch Move to the previous page.
Page 82 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. Action level is not displayed and lamp lights up in red If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in red.
Page 83 At the same time, the centralized warning lamp lights up and the alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for the inspection and maintenance. When the action level “L01” is displayed The caution lamp lights up in yellow.
Page 84 EXPLANATION OF COMPONENTS OPERATION Ask your Komatsu distributor for the inspection and maintenance as needed. STEERING OIL PRESSURE CAUTION LAMP The steering oil pressure caution lamp warns the operator that the steering oil pressure is below the specified value. When action level “L03” is displayed If the steering oil pressure drops below the specified value while the engine is running, the caution lamp lights up in red.
Page 85 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. BODY FLOAT CAUTION LAMP The dump body float caution lamp warns about the condition of the dump body.
Page 86 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 87 Whenever the caution lamp lights up in yellow, it is necessary to ask your Komatsu distributor to go off this caution lamp. When stopping the engine, stop it after running it at low idle for approximately 5 minutes.
Page 88 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 89 The caution lamp lights up in red. At the same time, the central- ized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 90 If the caution lamp lights up in yellow and action level “L01” is displayed, always perform the inspection and maintenance af- ter the operation is finished. Ask your Komatsu distributor for the inspection and mainte- nance as needed. ENGINE OIL PRESSURE CAUTION LAMP Engine oil pressure caution lamp warns about low engine lubri- cating oil pressure.
Page 91 Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. 3-31...
Page 92 If the caution lamp lights up in yellow and action level “L01” is displayed, always perform inspection and maintenance after the operation is finished. Ask your Komatsu distributor for the inspection and mainte- nance as needed. ARSC SYSTEM CAUTION LAMP The ARSC system caution lamp warns about abnormality in the ARSC system.
Page 93 If the caution lamp lights up in yellow and the action level “L01” is displayed, always perform the inspection and maintenance after the operation is finished. Ask your Komatsu distributor for the inspection and mainte- nance as needed. BRAKE COOLING OIL FILTER CLOGGING CAUTION LAMP...
Page 94 By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches 30 hours. However, you can change this setting. To change the setting, ask your Komatsu distributor. CENTRALIZED WARNING LAMP The centralized warning lamp lights up in red and at the same time the alarm buzzer sounds intermittently when the machine is under the following condition.
Page 95 OPERATION EXPLANATION OF COMPONENTS Machine conditions under which centralized warn- Monitor display ing lamp lights up When the wrong operation in fan reverse mode caution lamp is lit. When the dump body float caution lamp (red) is lit. When the inclination caution lamp is lit. When the charge voltage caution lamp is lit.
Page 96 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY AND METER DISPLAY Pilot display (1) Message display (12) Automatic suspension mode pilot lamp (if equip- ped) (2) Retarder pilot lamp (13) Front brake off pilot lamp (3) ARSC pilot lamp (14) Torque converter lockup pilot lamp (3) ARSC off pilot lamp (15) Preheating pilot lamp (4) KTCS pilot lamp (if equipped)
Page 97 OPERATION EXPLANATION OF COMPONENTS • At place (12), 3 types of pilot lamp are prepared. PILOT DISPLAY The pilot display consists of the pilot lamps to check the actuation of each function. When the starting switch is in ON position, the pilot lamps light up when the display items are functioning. TURN SIGNAL PILOT LAMP The turn signal pilot lamp flashes synchronously with the turn signal lamp, when it is turned on.
Page 98 EXPLANATION OF COMPONENTS OPERATION KTCS PILOT LAMP (if equipped) The KTCS pilot lamp lights up when “KTCS Setting” is set to “ON” and when the system detects slipping of a rear wheel. KTCS OFF PILOT LAMP (if equipped) The KTCS off pilot lamp lights up while “KTCS Setting” is set to “OFF”.
Page 99 The electrical heater for engine preheating is actuated while this lamp is lit. MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “CHECK MESSAGE (3-101)”. Lights up in green There is an unread message.
Page 100 EXPLANATION OF COMPONENTS OPERATION Lights up in blue There is any read message to which no reply has been made. Not lit There is no message. AFTERTREATMENT DEVICES REGENERATION PILOT LAMP CAUTION • Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regeneration.
Page 101 OPERATION EXPLANATION OF COMPONENTS SECONDARY STEERING SYSTEM PILOT LAMP The secondary steering pilot lamp lights up while the secon- dary steering is in operation. SHIFT INDICATOR This indicator shows the transmission shift range (gear shift). SHIFT LEVER POSITION DISPLAY The gear shift lever position display indicates the gear shift lev- er position.
Page 102 EXPLANATION OF COMPONENTS OPERATION H (hard mode) The automatic suspension becomes the hard mode in any of the following cases, and the hardness of the suspension be- comes hard. • The machine travels or turns at high speed when it is load- •...
Page 103 OPERATION EXPLANATION OF COMPONENTS ARSC PILOT LAMP The ARSC pilot lamp indicates the ARSC setting state. Lights up in green “ARSC Setting” is “ON”, and ARSC is actuated. Lights up in white “ARSC Setting” is “ON”, and ARSC is not actuated. ARSC OFF PILOT LAMP The ARSC off pilot lamp lights up when “ARSC Setting”...
Page 104 EXPLANATION OF COMPONENTS OPERATION GUIDANCE TO AVOID HOIST RELIEF When relief of the hoist oil pressure is continued for more than 5 seconds while the accelerator pedal is depressed, the hoist pressure relief deterrence message is displayed on the ma- chine monitor.
Page 105 OPERATION EXPLANATION OF COMPONENTS GUIDANCE TO AVOID STEERING RELIEF If the steering oil pressure is relieved for more than 10 sec- onds, the steering relief restriction message is displayed on the machine monitor. Relieving of steering oil pressure occurs when you steer the wheel fully to the right or left.
Page 106 EXPLANATION OF COMPONENTS OPERATION ENGINE COOLANT TEMPERATURE GAUGE Engine coolant temperature gauge shows the engine coolant temperature. When the indicator is in white range (A) or green range (B) dur- ing operation, it is normal. If the indicator is in red range (C), the engine coolant tempera- ture caution lamp lights up in red, and action level “L02”...
Page 107 OPERATION EXPLANATION OF COMPONENTS ECO GAUGE ECO gauge indicates the instantaneous fuel consumption (fuel consumption rate at each moment). The instantaneous fuel consumption varies depending on the operation ways (accelerator operation, travel speed, gear speed, etc.) and the given load during travel (load weight, slope, ground condition, etc.).
Page 108 EXPLANATION OF COMPONENTS OPERATION Clock display Indicates the current time. 12-hour system display The clock is displayed in 12-hour mode with am or pm. 24-hour system display The clock is displayed in 24-hour mode. REMARK If the battery is disconnected for a long period for storage etc., the time information may be lost. Fuel consumption gauge display Indicates the average fuel consumption of the machine.
Page 109 OPERATION EXPLANATION OF COMPONENTS Split (measurement is stopped) display Displays the value after the measurement of split fuel con- sumption is stopped. REMARK Display on the fuel consumption gauge can be switched between the average fuel consumption per day and the average fuel consumption during a selected period (split fuel consumption).
Page 110 EXPLANATION OF COMPONENTS OPERATION Payload meter display is a display of the payload value during the statistics which is being processed by payload meter func- tion. Payload meter display may not be as accurate as that of the data which is saved as the operated load. Regard the value displayed on the payload meter as a guide.
Page 111 OPERATION EXPLANATION OF COMPONENTS REMARK • The switches available on each screen can be checked with the guidance icon. • This function is not available when you press a switch not marked by the guidance icon or you press the guidance icon itself.
Page 112 EXPLANATION OF COMPONENTS OPERATION RETURN SWITCH Pressing RETURN switch cancels a selection or changes, and returns the screen to the previous screen or the standard screen. UP SWITCH Pressing UP switch moves the cursor up by one item. When on the top line, the cursor moves to the bottom line.
Page 113 OPERATION EXPLANATION OF COMPONENTS Press the air conditioner switch and numeric keypad to enter the numerals 0 to 9, which is indicated at the lower right of each switch. USER MENU When the menu switch is pressed on the standard screen while the machine is stopped, the user menu screen is displayed to enable you to configure and confirm the machine settings.
Page 114 EXPLANATION OF COMPONENTS OPERATION (C) “Aftertreatment Devices Regeneration” • Setting of “Regeneration Disable” • Operation of “Manual Stationary Regeneration” (D) “SCR Information” • Check of DEF level • Information on DEF system (E) “Maintenance” • Check and resetting of various maintenance remaining times (F) “Monitor Setting”...
Page 115 OPERATION EXPLANATION OF COMPONENTS On the user menu screen, you can perform the following opera- tions with the switches. (1) UP switch Moves to the item above. When on the first item, it moves to the last item. (2) DOWN switch Moves to the item below.
Page 116 EXPLANATION OF COMPONENTS OPERATION CHECK OPERATING RECORD Select “Operation Records” on “Energy Saving Guidance” menu screen, then press ENTER switch (4). On “Operation Records” screen, the following information on a daily basis or during the split measurement period is displayed. •...
Page 117 OPERATION EXPLANATION OF COMPONENTS When “Average Fuel Consumption Display” is set to “Split Time”, and the split time is measured (A) Display during measurement (B) Date and time when measurement is started To stop the split measurement, see the guidance icon and press ENTER switch (4).
Page 118 EXPLANATION OF COMPONENTS OPERATION When the confirmation screen is displayed, press ENTER switch (4) again to start the split measurement, or press RE- TURN switch (3) to cancel the start. CHECK ECO GUIDANCE RECORD Select “ECO Guidance Records” on “Energy Saving Guidance” menu screen, then press ENTER switch (4).
Page 119 OPERATION EXPLANATION OF COMPONENTS When “Average Fuel Consumption Display” is set to “Split Time”, and the split time is measured (A) Display during measurement (B) Date and time when measurement is started To stop the split measurement, see the guidance icon and press ENTER switch (4).
Page 120 EXPLANATION OF COMPONENTS OPERATION When the confirmation screen is displayed, press ENTER switch (4) again to start the split measurement, or press RE- TURN switch (3) to cancel the start. CHECK FUEL CONSUMPTION RECORD Select “Average Fuel Consumption Record” on “Energy Saving Guidance”...
Page 121 OPERATION EXPLANATION OF COMPONENTS • Last 12 hours display • Last 7 days display REMARK The graph of “Last 12 hours” is updated every hour of the service meter reading. The graph of “Last 7 days” is updated every day. Deletion of “Average Fuel Consumption Record”...
Page 122 EXPLANATION OF COMPONENTS OPERATION CHANGE DISPLAY SETTING Select “Configurations” on “Energy Saving Guidance” menu screen, then press ENTER switch (4). You can perform the following operations on “Configurations” menu. • Setting for “Average Fuel Consumption Display” • Switching display/non-display of “ECO Gauge Display” •...
Page 123 OPERATION EXPLANATION OF COMPONENTS Select “Average Fuel Consumption Display” on “Configura- tions” menu screen, then press ENTER switch (4). Select “1 Day” or “Split Time”, then press ENTER switch (4). The default is “1 Day”. To cancel, press RETURN switch (3). “1 Day”...
Page 124 EXPLANATION OF COMPONENTS OPERATION SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE Display/non-display of ECO gauge can be switched. Select “ECO Gauge Display” on “Configurations” menu screen, then press ENTER switch (4). “ECO Gauge Display” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON”...
Page 125 OPERATION EXPLANATION OF COMPONENTS (4) ENTER switch Allocates the selected change and returns the screen to “Configurations” menu screen. REMARK If “OFF” is selected on “ECO Gauge Display” screen, the items of “ECO Gauge Display Fuel Target Value” are not displayed. SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE ECO gauge display fuel target value (A) (the upper limit value of the green range) can be changed.
Page 126 EXPLANATION OF COMPONENTS OPERATION Use UP switch (1) or DOWN switch (2) to set the value, then press ENTER switch (4). You can perform the following operations with the switches (1) to (4) on the switch panel. (1) UP switch Increases the target fuel consumption value by 1 ℓ/h.
Page 127 OPERATION EXPLANATION OF COMPONENTS “ECO Guidance Display” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. You can perform the following operations with the switches (1) to (4) on the switch panel.
Page 128 EXPLANATION OF COMPONENTS OPERATION Select “ECO Guidance Display at Key OFF” on “Configura- tions” menu screen, then press ENTER switch (4). “ECO Guidance Display at Key OFF” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” Displays the operational advice on the end screen.
Page 129 OPERATION EXPLANATION OF COMPONENTS • Setting of “Radiator Fan Reverse Mode” • Display and setting of “Payload Meter” (if equipped) • “KTCS Setting” (if equipped) • “ARSC Setting” • Display and resetting of “Dumping Counter” (if equipped) • Display of “Reverse Travel Odometer” •...
Page 130 EXPLANATION OF COMPONENTS OPERATION “Radiator Fan Reverse Mode” screen is displayed. Press ENTER switch (4), and the fan rotates in reverse, then the screen returns to the standard screen. REMARK When not performing the fan reverse rotation, press RE- TURN switch (3). If the dump body is not seated or the engine is running, the screen as shown in the figure appears, and the fan rotation cannot be switched.
Page 131 OPERATION EXPLANATION OF COMPONENTS When the screen shown in the figure appears, press EN- TER switch (4) to return the radiator fan to the normal rota- tion mode. REMARK If the engine compartment is highly heated when the fan is ro- tated in reverse, the controller may stop the air conditioner to protect itself from being damaged.
Page 132 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press ENTER switch (4). “OFF” KTCS does not operate. The KTCS off pilot lamp lights up. “ON” KTCS operates automatically. REMARK This setting is maintained even after turning the starting switch to OFF position.
Page 133 OPERATION EXPLANATION OF COMPONENTS “OFF” The ARSC is disabled. The ARSC off pilot lamp lights up. “ON” The ARSC is ready to operate. The ARSC pilot lamp lights up. REMARK This setting is maintained even after turning the starting switch key to OFF position.
Page 134 EXPLANATION OF COMPONENTS OPERATION Press ENTER switch (4) to reset, or press RETURN switch (3) to cancel the resetting. REVERSE TRAVEL ODOMETER The total reverse travel distance can be checked with “Reverse Travel Odometer”. TRIP METER The overall travel distance after the previous resetting can be checked with “Trip Meter”.
Page 135 OPERATION EXPLANATION OF COMPONENTS Method for resetting “Trip Meter” Select “Trip Meter” on “Machine Setting and Information” menu screen, then press ENTER switch (4). The screen changes to “Trip Meter” reset confirmation screen. Press ENTER switch (4), and “Trip Meter” is reset. The screen returns to “Machine Setting and Information”...
Page 136 EXPLANATION OF COMPONENTS OPERATION Select “F 1 Start at D Position Setting”, then press ENTER switch (4). Select “F1” or “F2”, then press ENTER switch (4). “F1” Starts the machine travel at 1st speed when the gear shift lever is set to D position. “F2”...
Page 137 OPERATION EXPLANATION OF COMPONENTS Select “A/C ECO Mode Setting”, then press ENTER switch (4). Select “ON” or “OFF”, then press ENTER switch (4). “ON” Sets the air conditioner to the ECO mode operation. “OFF” Turns on the normal air conditioner operation. REMARK If the ambient temperature is 30 °C or higher, or the set tem- perature of the air conditioner is 18 °C (maximum cooling), air...
Page 138 EXPLANATION OF COMPONENTS OPERATION Select “Retarder Lever Release Sound Setting”, then press ENTER switch (4). Select “ON” or “OFF”, then press ENTER switch (4). “ON” Generates the cancel sound. “OFF” Does not generate the cancel sound. REMARK This setting is maintained even after turning the starting switch to OFF position.
Page 139 OPERATION EXPLANATION OF COMPONENTS • The indicator of the engine coolant temperature gauge is over position (A), and the warm-up operation is finished. You can change the set time to operate the auto idle stop func- tion on “Auto Idle Stop Timer Setting” screen, Select “Auto Idle Stop Timer Setting”...
Page 140 EXPLANATION OF COMPONENTS OPERATION When the idling time reaches 30 seconds before the set time, the machine monitor returns to the standard screen and changes to the countdown screen. If one of the following operations is performed according to the screen instructions, the machine monitor stops count- down and the screen returns to the standard screen.
Page 141 The replacement interval in “Air Cleaner Cleaning or Change” is not set initially. If you want to change the setting for the maintenance interval and the maintenance notice time, consult your Komatsu distributor. METHOD FOR RESETTING REMAINING TIME FOR MAINTENANCE After performing the maintenance, reset the remaining time for maintenance according to the following proce- dure.
Page 142 (6), then press ENTER switch (4). REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. The screen changes to “Maintenance Due Time Reset” screen. Press ENTER switch (4) on “Maintenance Due Time Re- set” screen, and the screen changes to the reconfirmation screen for “Maintenance Due Time Reset”.
Page 143 OPERATION EXPLANATION OF COMPONENTS MONITOR SETTINGS Each item of “Monitor Setting” menu screen is to make the set- tings for the machine monitor. • “Rearview Monitor Setting” • “Meter Display Selection” • “Screen Adjustment” • “Clock Adjustment” • “Language Setting” •...
Page 144 EXPLANATION OF COMPONENTS OPERATION Select “Guide Line Display Mode” on “Rearview Monitor Setting” menu screen, then press ENTER switch (4). “Guide Line Display Mode” screen is displayed. Select “ON” or “OFF” on “Guide Line Display Mode” screen, then press ENTER switch (4). “ON”...
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “Reverse-interlock Selection mode” on “Rearview Monitor Setting” menu screen, then press ENTER switch (4). “Reverse-interlock Selection mode” screen is displayed. Select “ON” or “OFF” on “Reverse-interlock Selection mode” screen, then press ENTER switch (4). “OFF” Always displays images on the rearview monitor.
Page 146 EXPLANATION OF COMPONENTS OPERATION METER DISPLAY SELECTION This is used for the selection of the items to be displayed on the L.H. meter display (A) or the R.H. meter display (B). Select “Meter Display Selection” on “Monitor Setting” menu screen, then press ENTER switch (4). “Meter Display Selection”...
Page 147 OPERATION EXPLANATION OF COMPONENTS Select “LH Meter Display Selection” on “Meter Display Se- lection” menu screen, then press ENTER switch (4). “LH Meter Display Selection” screen is displayed. Select the item to be displayed from the following 3 items on “LH Meter Display Selection” screen, then press EN- TER switch (4).
Page 148 EXPLANATION OF COMPONENTS OPERATION Select “RH Meter Display Selection” on “Meter Display Se- lection” menu screen, then press ENTER switch (4). “RH Meter Display Selection” screen is displayed. Select the item to be displayed from the following 4 items on “RH Meter Display Selection” screen, then press EN- TER switch (4).
Page 149 OPERATION EXPLANATION OF COMPONENTS Select “Screen Adjustment” on “Monitor Setting” menu screen, then press ENTER switch (4). “Screen Adjustment” screen is displayed. Press UP switch (1) and DOWN switch (2) on “Screen Ad- justment” screen to adjust the brightness, then press EN- TER switch (4).
Page 150 EXPLANATION OF COMPONENTS OPERATION Select “Clock Adjustment” on “Monitor Setting” menu screen, then press ENTER switch (4). “Clock Adjustment” menu screen is displayed. The items related to “Clock Adjustment” are the following 5 items. • “GPS Synchronization” • “Calendar” • “Time”...
Page 151 OPERATION EXPLANATION OF COMPONENTS Select “GPS Synchronization” on “Clock Adjustment” menu screen, then press ENTER switch (4). “GPS Synchronization” screen is displayed. Select “ON” or “OFF” on “GPS Synchronization” screen, then press ENTER switch (4). “ON” Date and time on the machine monitor are automatically adjusted in accordance with the clock of GPS.
Page 152 EXPLANATION OF COMPONENTS OPERATION REMARK As long as “GPS Synchronization” is turned “ON”, the item in “Calendar” is not selectable. Select “Calendar” from “Clock Adjustment” menu screen, then press ENTER switch (4). “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display.
Page 153 OPERATION EXPLANATION OF COMPONENTS When day display (C) is highlighted in yellow, operate the switches as follows to change day display. When it is not necessary to change the day setting, press ENTER switch (4). (1) UP switch Advances the numeral by 1. (2) DOWN switch Puts back the numeral by 1.
Page 154 EXPLANATION OF COMPONENTS OPERATION (4) ENTER switch Proceeds to setting for minute. When minute display (E) is highlighted in yellow, operate the switches as follows to change minute display. When it is not necessary to change minute display, press ENTER switch (4). (1) UP switch Advances the numeral by 1.
Page 155 OPERATION EXPLANATION OF COMPONENTS (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected setting, and returns the screen to “Clock Adjustment” menu screen. (4) ENTER switch Allocates the selected setting, and returns the screen to “Clock Adjustment”...
Page 156 EXPLANATION OF COMPONENTS OPERATION (3) RETURN switch Cancels the selected setting, and returns the screen to “Clock Adjustment” menu screen. (4) ENTER switch Allocates the selected setting, and returns the screen to “Clock Adjustment” menu screen. This setting of “Daylight Saving Time” is held even if the starting switch is turned to OFF position. The default is “OFF”.
Page 157 When the operator identification function is disabled, “Operator ID” screen is not displayed on “Monitor Setting” menu screen. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP If the already registered ID is inputted when the starting switch is turned to ON position, the identified ID is displayed in “Oper-...
Page 158 EXPLANATION OF COMPONENTS OPERATION Select “Operator ID” on “Monitor Setting” menu screen, then press ENTER switch (4) for 1 second. “Operator ID Change” screen is displayed. REMARK When the ID change is not necessary, press RETURN switch (3). • Input the preregistered ID on “Operator ID Change” screen by using the numeric keypad (6), and press ENTER switch (4).
Page 159 OPERATION EXPLANATION OF COMPONENTS • On “Operator ID Change” screen, if you press ENTER switch (4) after inputting the ID which is not registered, a message is displayed at the bottom and the screen changes to “Monitor Setting” menu screen and the ID number is not changed.
Page 160 On machines equipped with KOMTRAX, when the message pi- lot lamp is lit on the standard screen, you can see the messag- es from your Komatsu distributor on the mail check menu screen by pressing the menu switch. Message is distinguished as follows according to the lighting states of the message display.
Page 161 • When the message display lights up in blue, it means that no reply has been made yet to any read mes- sage to your Komatsu distributor. Reply to the message in accordance with the replying method mentioned below. •...
Page 162 EXPLANATION OF COMPONENTS OPERATION REPLY TO MESSAGE When replying to a message which requests reply, input the selected item number shown in the text of the mes- sage by using the air conditioner switch and the numeric keypad (6). (3) RETURN switch If there is no input value, the screen returns to the stand- ard screen.
Page 163 OPERATION EXPLANATION OF COMPONENTS Press UP switch (1) while holding down DOWN switch (3) with the starting switch in OFF position. Service meter (A) and odometer (B) are displayed while both switches are held down. 3-103...
Page 164: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES (1) Monitor brightness selector switch (8) Front brake off switch (2) Side lamp switch (9) AISS LOW switch (3) Staircase lighting switch (if equipped) (10) Engine power mode selector switch (4) Fog lamp switch (11) Starting switch (5) Horn button (12) Wiper and window washer switch (6) Hazard lamp switch...
Page 165 OPERATION EXPLANATION OF COMPONENTS (14) Parking brake switch (19) Power window switch (R.H.) (15) Rearview monitor brightness adjustment switch (20) Heated wire mirror switch (if equipped) (16) Cigarette lighter (21) Room lamp 2 switch (17) Engine shutdown secondary switch (22) Room lamp 1 switch (18) Power window switch (L.H.) STARTING SWITCH Starting switch is used to start or stop the engine.
Page 166 EXPLANATION OF COMPONENTS OPERATION Keep the starting switch key at ON position (B) while the engine is running. This machine is equipped with an engine automatic preheating device that functions to start the engine preheat- ing automatically. When the starting switch is turned to ON position (B) at low ambient temperature, the automatic preheating starts and the preheating pilot lamp lights up.
Page 167 OPERATION EXPLANATION OF COMPONENTS When the monitor brightness selector switch is set to the night mode, the machine monitor and rear view moni- tor are dimmed. The lamp switch can be switched regardless of the position of the turn signal lever. DIMMER SWITCH The dimmer switch is used to turn on or off the headlamps (high beam).
Page 168 EXPLANATION OF COMPONENTS OPERATION HORN BUTTON When the horn button at the center of the steering wheel is pressed, the horn sounds. NOTICE If the horn is sounded continuously (the horn button is kept pressed), its service life is shortened. Avoid continuous use except in an emergency.
Page 169 OPERATION EXPLANATION OF COMPONENTS HAZARD LAMP SWITCH Hazard lamp switch is used when it is unavoidable to place the machine on the road due to any abnormality such as failure, etc. Position (A) The right and left turn signal lamps and right and left turn signal pilot lamps flash.
Page 170 EXPLANATION OF COMPONENTS OPERATION AISS LOW switch is used to switch the AISS functions. AISS (Automatic Idling Setting System) adjusts the low idle speed automatically depending on the engine coolant tempera- ture and operating situations. (A) AISS LOW switch ON Use this switch position when fine start control is needed such as when putting the machine into the garage.
Page 171 OPERATION EXPLANATION OF COMPONENTS ENGINE POWER MODE SELECTOR SWITCH The engine power mode selector switch is used to shift the op- timum power mode for economical operation depending on the operation condition.. (A): Economy mode (operations on a flat ground) Use this mode for the operation with emphasis on fuel con- sumption, such as operation on flat ground where the maxi- mum power is not needed.
Page 172 EXPLANATION OF COMPONENTS OPERATION The parking brake switch is used to apply and release the park- ing brake. (A) PARKING position The parking brake is applied. When the parking brake switch is set to “PARKING” position (A), the parking brake pilot lamp lights up on the machine moni- tor.
Page 173 OPERATION EXPLANATION OF COMPONENTS SIDE LAMP SWITCH The side lamp switch is used to turn on and off the side lamp. Position (A) Side lamp lights up. Position (B) Side lamp goes out. ROOM LAMP1 SWITCH The room lamp 1 switch is used to turn on and off the room lamp 1.
Page 174 EXPLANATION OF COMPONENTS OPERATION ENGINE SHUTDOWN SECONDARY SWITCH NOTICE The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Ask for repair of the problem part as soon as possible.
Page 175: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS When getting on or off the machine, the staircase lighting can be turned on with the one staircase lighting switch, and can be turned off with the other staircase lighting switch. Staircase lighting switch inside the operator's cab Position (A) The staircase lighting lights up.
Page 176 EXPLANATION OF COMPONENTS OPERATION BRAKE PEDAL The brake pedal is used to apply the wheel brakes. Use it when stopping or decelerating the machine. REMARK • The wheel brakes can be operated by depressing the brake pedal even while ARSC system is in operation. •...
Page 177 OPERATION EXPLANATION OF COMPONENTS Positions 6 to L Use these positions when traveling on soft ground or places where it is difficult to travel at high speed, when starting on slope with the machine loaded, or when traveling downhill with engine brake. The transmission is fixed to the 1st speed and is not changed while the dump body is raised.
Page 178 EXPLANATION OF COMPONENTS OPERATION When shifting the gear shift lever from NEUTRAL position (N) to D (FORWARD) or R (REVERSE), release the accelerator pedal, set the engine speed at low idle, then press the lock but- ton of the gear shift lever to operate. RETARDER CONTROL LEVER CAUTION Do not use retarder brake to park the machine.
Page 179 OPERATION EXPLANATION OF COMPONENTS DUMP LEVER CAUTION Make sure to lower the dump body and set the dump lever to “FLOAT” when you travel. The dump lever is used to operate the dump body. (A) “RAISE” position (B) “HOLD” position The dump body remains in the position where it was stopped.
Page 180: Other Equipment
EXPLANATION OF COMPONENTS OPERATION OTHER EQUIPMENT CAB DOOR CAUTION • Make sure that the cab door is locked when it is closed. • Always place the machine on a level ground when opening or closing the cab door. Avoid opening or closing the door on a slope, since there is a danger that the operating effort may sudden- ly change.
Page 181 OPERATION EXPLANATION OF COMPONENTS CAB DOOR INNER LOCK While the cab door is closed, it can be locked by pressing the cab door inner lock. (L) LOCK position It locks the cab door. It is used when operating the machine. (F) FREE position It unlocks the cab door.
Page 182 EXPLANATION OF COMPONENTS OPERATION CUP HOLDER The cup holders are located at two places of the center console and the rear left of the operator's seat. ASHTRAY The ashtray is at the front of the center console. Always extinguish your cigarette before putting it in the ashtray, and be sure to close the lid.
Page 183 OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Make sure to turn start and battery disconnect switches to OFF, before you replace a fuse. • The fuses protect the electrical component and wiring from burning out. • If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 184 EXPLANATION OF COMPONENTS OPERATION Fuse box II (BT2) Capaci- Name of circuit (16) (17) 15 A Terminal B (continuous power supply) (18) 5 A Air conditioner (continuous power supply) (19) 5 A Retarder controller (continuous power supply) Transmission controller (continuous power sup- (20) 15 A ply) (21)
Page 185 OPERATION EXPLANATION OF COMPONENTS Fuse box IV (BT4) Capaci- Name of circuit (46) 5 A Parking brake (47) 15 A Retarder controller (48) 5 A Gear shift lever, starting motor cut-off relay (49) 5 A Switch panel (50) 15 A Payload meter controller (if equipped) (51) 10 A Automatic secondary steering...
Page 186 Precautions when changing electrical component CAUTION Do not modify the machine electrical system. If you want to make any change to the electrical system, contact your Komatsu distributor. TOOL BOX Toolbox is inside the box under the step at the left side of the machine.
Page 187 OPERATION EXPLANATION OF COMPONENTS The fire extinguisher is installed to the left front of the machine. BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running. The large current generated by the alternator may burn the electric parts and cause a fire. Operate the battery disconnect switch only when the engine is stopped.
Page 188 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute leakage of current and not an abnormal phenomenon.
Page 189 If the operating effort is still large after the reset button has been pushed in, the electrical circuit may be open. In such case, ask your Komatsu distributor for repair. DUST INDICATOR This device indicates clogging of the air cleaner.
Page 190 EXPLANATION OF COMPONENTS OPERATION The body pivot pin is a safety device to fix the dump body. Use it when performing the inspection and maintenance with the dump body raised. Raise the dump body fully, insert the body pivot pins. Always insert the body pivot pin on both of right and left sides.
Page 191 OPERATION EXPLANATION OF COMPONENTS The guide line (2) on the rearview monitor is used to check the side and rear of the machine roughly. The guide line is set for the machine with no load on the flat ground. When the machine is loaded or the road surface is uneven, the guide line deviates from the actual machine position.
Page 192 (reverse travel interlock, constant display) and the gear shift lever position. If the rearview monitor or the camera does not work, ask your Komatsu distributor for repair since it has a failure or open circuit in electric wiring.
Page 193 OPERATION EXPLANATION OF COMPONENTS HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
Page 194 EXPLANATION OF COMPONENTS OPERATION The KDPF regeneration is performed automatically. However, the accumulated soot may not be burnt sufficiently and the fil- tering function may not be improved under certain operating conditions. In that case, the KDPF soot accumulation caution lamp (2) lights up.
Page 195 Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 196 EXPLANATION OF COMPONENTS OPERATION When the degree of emergency is high • The KDPF soot accumulation caution lamp (2) lights up in red, and “L03” is displayed in red on the action level dis- play (4). • If the machine is stopped completely, the screen changes to “Aftertreatment Devices Regeneration”...
Page 197 OPERATION EXPLANATION OF COMPONENTS Release the accelerator pedal. Set the gear shift lever to NEUTRAL position (N). Set the parking brake switch to “PARKING” position (A), and apply the parking brake. When the parking brake has been applied, the parking brake pilot lamp lights up on the machine monitor.
Page 198 EXPLANATION OF COMPONENTS OPERATION REMARK After ENTER switch is pressed in step 7, the screen shown in the figure may be displayed. This indicates that the operations in steps 1 to 5 were not performed correctly or there is trouble other than the KDPF soot accumulation abnormality.
Page 199 OPERATION EXPLANATION OF COMPONENTS REMARK During the manual stationary regeneration, idle speed is set rather high. • The progress of the manual stationary regeneration performed when soot is accumulated can be checked by the number of lighting lamps of the soot accumulation level (3). The manual stationary regeneration starts at soot accumulation level “4”...
Page 200 EXPLANATION OF COMPONENTS OPERATION Press the menu switch to select “Aftertreatment Devices Regeneration” menu screen, and “Aftertreatment Devices Regeneration” menu screen is displayed. Select “Regeneration Disable” and press ENTER switch. The regeneration function is disabled and the regeneration is not performed. REMARK •...
Page 201 OPERATION EXPLANATION OF COMPONENTS WHILE REGENERATION IS BEING PERFORMED: STOPPING PROCEDURE FOR REGENERATION (When the aftertreatment devices regeneration display is lit on the standard screen) Press the menu switch on the standard screen, and “After- treatment Devices Regeneration” screen is displayed. Press ENTER switch after selecting “Regeneration Disa- ble”, and the regeneration stops.
Page 202 Urea SCR systems by utiliz- ing visible and audible alerts , and engine power derate in addition. Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions.
Page 203 In addition, it may cause fail- ures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu dis- tributor. About the operation of Urea SCR system The Urea SCR System automatically starts operating as soon as the engine is started.
Page 204 EXPLANATION OF COMPONENTS OPERATION Inducement strategy when the DEF tank Level becomes low When the amount of DEF in the tank goes low, the Inducement strategy will be activated. If Inducement starts, add DEF to the DEF tank immediately. The DEF level caution lamp (1) on the monitor lights up, the audible alert starts, and the action level is dis- played, and Inducement strategy is activated.
Page 205 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (4): 1 “DEF low level warning appears.” Add DEF to the DEF tank immediately. • Continuous Warning: The audible alert sounds in repetition of “Intermittent alarm”. 2 gradations of the DEF level gauge light up in the red range.
Page 206 EXPLANATION OF COMPONENTS OPERATION • Severe Inducement: The audible alert sounds in “Continuous alarm”. No gradation of the DEF level gauge lights up. The DEF level caution lamp (1) lights up in red. The action level “L04” is displayed in red (5). Press the menu switch to display the “SCR Information”...
Page 207 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 208 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 209 “Severe Inducement”, the engine power will be fur- ther derated. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 210 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (5): 1 “Please inspect and maintain SCR system.” Engine power is derated. Move the machine to the safe place and contact your Ko- matsu distributor. If operation continues for 5 hours after “Warning” started without taking any actions instructed by the action level ta- ble, Inducement advances to “Continuous Warning”.
Page 211 Komatsu distributor. Inducement strategy when abnormality is found in the EGR Valve System by the...
Page 212 EXPLANATION OF COMPONENTS OPERATION Perform the following procedure. Press the menu switch to display the “SCR Information” screen. After a lapse of 3 seconds to stop the machine, “SCR Informa- tion” screen is displayed. “SCR Information” screen displays remaining time to the next Inducement status in the column (6), and information on the Urea SCR System condition (4), and the current status of In- ducement (5).
Page 213 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (5): 2 “Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu distributor. The duration time of “Continuous Warning” is 5 hours. The remaining time (Hours and Minutes) till the next Induce- ment status of “Low level Inducement”...
Page 214 “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In- ducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor. Temporary Restoration from Inducement Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 215 OPERATION EXPLANATION OF COMPONENTS Press the enter switch (2) while the pop-up menu screen B is displayed. The “Engine power Recovery” window pops up. If the enter switch (2) is not pressed for 30 seconds, “Standard Screen” will be displayed, and start again by pressing the menu switch (1).
Page 216 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and contact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
Page 217 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 218 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 219: Machine Operations And Controls
Clean any flammable materials that accumulate around the machine in areas such as exhaust sys- tem, battery, cooling system. • Repair and clean any fuel and oil leaks. If there are any defects, consult your Komatsu distributor. • Allow lamps to cool to touch before you perform maintenance.
Page 220 Check the pipe between the KDPF and SCR and also the SCR connections for leakage of exhaust gas (and urea deposit). If any problem is found, ask your Komatsu distributor for repair. 10. Check for oil leakage from the transmission case, differential case, final drive case, hydraulic tank, brake control oil tank, hoses, and joints.
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS 18. Check the seat belt and mounting hardware. WARNING Inspect the condition of seat belt and replace any parts that are damaged. Replace the seat belt 3-year from when it was installed or 5-year from when it was made.
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear • Tires with the tread groove depth of 15 % or less of that of a new tire •...
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS, RETIGHTEN- ING BOLTS Check the wheel hub bolts (1) for breakage or looseness. If any wheel hub bolt (1) of a wheel is broken, replace all the wheel hub bolts (1) for that wheel.
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING BATTERY DISCONNECT SWITCH Check that battery disconnect switch (S) is in ON position (I). METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT WARNING • Allow parts and oils to cool to touch before you perform maintenance. •...
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS Remove the drain valve (3). At this time, take care that the grease will not stick to the water drain port (A) and the threaded portion (7) of the plug. Tighten the drain valve (3) by hand until it contacts the bottom.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN BRAKE SUB TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check it with the reservoir tank when the engine is cold. • Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radia- tor.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION Loosen the cap of the coolant filler port (8) of the sub- tank. Add coolant to the radiator through the coolant filler port (9) on top of the radiator. Add the coolant through the coolant filler port (8) of the sub-tank.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS Open the engine side cover. Pull out the dipstick (G) and wipe the oil off with a cloth. Fully insert the dipstick (G) into the dipstick pipe, then pull it out. It is correct if the oil level is between marks H and L. The oil levels stamped on either side of the dipstick are for when the engine is stopped (ENGINE STOPPED) or when the engine is running at low idle (ENGINE IDLING).
Page 230 • If fuses are frequently blown out or if there are traces of short-circuiting on the electric wiring, im- mediately ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 231 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION Check the DEF level gauge (1) on the machine monitor. After checking, turn the starting switch back to OFF posi- tion (A). Open the cover (2) at the side of the fuel tank. Turn the cap of filler port (3) counterclockwise. The cap of filler port is opened.
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS After adding, align claw (10) of the cap with groove (11) of the filler port and close the cap securely by turning it clock- wise by 90 °. Close the cover (2). REMARK • It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto stop function to add DEF.
Page 234 METHOD FOR CHECKING BRAKE Check that the parking brake, foot brake, and retarder brake work sufficiently. If any abnormality is found, ask Komatsu distributor to repair. METHOD FOR CHECKING SECONDARY BRAKE PERFORMANCE WARNING The machine may start moving during the checking of the secondary brake performance. As a result, serious personal injury or death may occur.
Page 235 The secondary steering is started automatically when the starting switch is turned to ON position to check the secondary steering functions. If defective operation of the secondary steering motor is found, ask your Komatsu distributor for repair. Self-check of the secondary steering is not performed in the following cases.
Page 236 Turn the steering wheel (3) and check that the steering can be operated. If the steering cannot be operated when the steering wheel (3) is turned, ask your Komatsu distributor for repair. METHOD FOR CHECKING AUTOMATIC SECONDARY STEERING Turn the starting switch (1) to START position and start the engine.
Page 237 Operate the fore-aft adjustment lever upward, set the seat to the desired position, then release the fore-aft adjustment lever. Adjustment amount: 152.4 mm Number of stages for adjustment: 12 stages Adjustment amount per 1 stage: 12.7 mm If the seat backlash is found, ask your Komatsu distributor for adjustment. 3-177...
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR RECLINING SEAT Pull up the reclining adjustment lever, and move the back cush- ion forward or backward. Sit with your back against the backrest when adjusting the re- clining angle. If your back is not on the backrest, it may sud- denly return to the original position.
Page 239 Fore-aft adjustment range: 60 mm If the seat backlash is found, ask your Komatsu distributor for adjustment. METHOD FOR ADJUSTING HEADREST ANGLE Move the headrest back and forth to set it to the desired angle.
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION Move the headrest up or down to the desired height. Adjustment amount: 108 mm METHOD FOR ADJUSTING ARMREST ANGLE Turn the knob to adjust the armrest angle. Adjustment amount: 35 ° (Forward tilt 12 °, backward tilt 23 °) REMARK You can flip up the armrest.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the damping force of the suspension damper by operat- ing the suspension damper hardness adjustment knob. (A), (B) Low position The suspension damper becomes softer and its damping force is reduced. The shock to the seat is further decreased. (C) Recommended position Normally, this position is recommended.
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the seat heater switch to ON position (A). The heater in the seat cushion operates, and the seat cushion and backrest become warm. Turn the seat heater switch to OFF position (B) when the temperature of cushion becomes suitable.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS • When using the seat heater Set the seat heater and ventilation selector switch (1) to the seat heating position (A). Set the air flow control switch (2) to HIGH position (D) or LOW position (E). The heater in the seat cushion operates, and the seat cushion and backrest become warm.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing adjustment. • The machine is placed on a level ground. • The dump body is seated. •...
Page 245 When adjusting the angle of the rearview camera, prepare a scaffold first in order to provide a safe working platform. Otherwise serious personal injury or death by such as falling may occur. • Install only the Komatsu genuine camera. As shown in the figure, stop the machine on a flat ground, and make the machine unloaded. 3-185...
Page 246 When the machine dimensions are changed due to replacement of tires or installation of an optional attachment, set the guide lines to the non-display mode, and then contact your Komatsu distributor. Make sure that the images on the rear view monitor are normal as shown in the illustration. Then, confirm that the machine width guide line (3) matches with the tire outside width (1) and the distance guide line (4) matches with the body rear end (2).
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUST SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. • Even if no problem can be seen in the belt, replace it in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes sooner.
Page 248 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CONNECTING SHOULDER BELT AND WAIST BELT Insert the tongue (2) of the shoulder belt into the buckle tongue (1) of the waist belt. Rotate the tongue (2) of the shoulder belt and make sure that it is securely fixed to the buckle tongue (1) of the waist belt.
Page 249 Do not operate the lever with and excessive force. (Op- erating effort of lever: 147 N to 176 N {15 kg to 17.9 kg}) The lever can be loosened or its angle can be dis- placed. In such case, ask your Komatsu distributor for the in- spection. 3-189...
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING • Make sure to set the gear shift lever to NEUTRAL (N) and parking brake switch to “PARKING” before you start the engine. • Make sure to set the parking brake switch to “PARK- ING”...
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the dump lever (3) is in “HOLD” position (B). Check that the retarder control lever (5) has been set up- ward. Check that the cover of the engine shutdown secondary switch (4) is closed. Insert the key into the starting switch (5) and turn it to ON position (B).
Page 252 The speedometer (10) displays “88” for 2 seconds. The alarm buzzer sounds for 2 seconds, then stops under the normal condition. NOTICE Consult your Komatsu distributor when either the lamps, buzzers or the machine monitor does not function. REMARK •...
Page 253: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS • When the starting switch is turned to ON position, the secondary steering self-check function may operate. When the standard screen is displayed while the self-check is in operation, the secondary steering pilot lamp (11) lights up. REMARK While the secondary steering self-check function is in operation, the machine monitor may go out temporari-...
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not increase the engine idle speed before the en- gine becomes warm. • Do not start the engine for more than 20 seconds inter- vals. • Wait 2 minutes between attempts. • When starting the engine, do not depress the accelera- tor pedal.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS If the preheating pilot lamp does not light up, or it lights up and then goes out to inform that the engine preheating has been completed, turn the key in starting switch (1) to START position (C). The engine starts.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION The preheating pilot lamp on the machine monitor (2) lights up and preheating of the engine starts. (Preheating continues while the key in starting switch (1) is held coun- terclockwise.) While preheating is being performed, the preheating pilot lamp lights up to indicate that the preheating is being per- formed.
Page 257: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 258 Check that the steering operation is normal, the lamps light up and go out normally, the horn sounds, and the exhaust gas color, sound, and vibration are normal. If any of them is abnormal, ask your Komatsu distributor for inspection and repair. 3-198...
Page 259: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING ENGINE Keep away from the exhaust pipe immediately after stopping the engine. NOTICE • Do not stop the engine immediately while loaded. This can cause the engine to run hot and accelerate wear of components.
Page 260: Method For Checking After Stopping Engine
MACHINE OPERATIONS AND CONTROLS OPERATION Lower the dump body and set the dump lever (3) to “FLOAT” position (C). Run the engine at low idle for approximately 5 minutes to cool it down gradually. Turn the key in the starting switch (4) to OFF position (A), and stop the engine.
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS Check that there is no warning display on the machine monitor (1). Fasten the seat belt. Set the dump lever (2) to “FLOAT” position (C). Check that the dump body float caution lamp is not lit. If the dump body float caution lamp is lit, operate the dump lever (2) to “HOLD”...
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION Set the gear shift lever (5) to a desired position. NOTICE • Always place the gear shift lever securely in posi- tion when operating it. If the gear shift lever is not placed securely in position, the shift lever position pilot lamp on the machine monitor may start flash- ing and the centralized warning lamp may light up, and the alarm buzzer may sound.
Page 263 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • The machine cannot be driven in reverse when the dump body is raised. Lower the dump body, set the dump lever to “FLOAT” position, then operate the gear shift lever to R position. •...
Page 264 If the parking brake is used to make an emergency stop, the performance of the parking brake may drop below the standard value, so it is necessary to repair and adjust the parking brake. Ask your Komatsu distributor to perform this work. If the machine is not stopped by depressing the brake pedal, perform the following.
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS Pull the retarder control lever (1) fully to apply the retarder. If operating the retarder control lever (1) does not give enough braking force, depress the secondary brake pedal (2). The secondary brake actuates both the front brake and the parking brake at the same time.
Page 266: Method For Shifting Gears
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SHIFTING GEARS WARNING • Do not move transmission lever to NEUTRAL (N) when you travel. Make sure the transmission is in L when you travel downhill. • If the gear shift lever is shifted to NEUTRAL position (N) during traveling or traveling downhill, the engine brake is disabled and steering operation becomes heavy.
Page 267: Method For Traveling Downhill
OPERATION MACHINE OPERATIONS AND CONTROLS • When downshift (deceleration) Release the accelerator pedal (2). The machine is decelerated and the transmission automat- ically shifts down. Downshift inhibit If the gear shift lever is operated when the machine is traveling, the travel speed may be faster than the maxi- mum speed allowed for the new speed range.
Page 268 If the retarder still has not effect even when the retarder control lever is operated again, return the retarder control lever completely to “RELEASE” position, and depress the brake pedal to stop the machine, then contact your Komatsu distributor for repair. •...
Page 269 OPERATION MACHINE OPERATIONS AND CONTROLS Return the accelerator pedal (1) back before entering a downhill slope. Operate the retarder control lever (2) to decelerate the ma- chine. Leave the gear shift lever (3) in D position. It is automatically downshifted to the optimal gear speed when reducing the travel speed.
Page 270 MACHINE OPERATIONS AND CONTROLS OPERATION HANDLE Automatic Retarder Speed Control (ARSC) Pressing the set switch of the ARSC travel speed set lever when the travel speed becomes the desirable speed on downhill automatically actuates the retarder to keep the travel speed, and the retarder operation becomes easier.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS Drive the machine at the desired travel speed to be set as the set speed in ARSC, and press the setting switch (2) of the ARSC travel speed set lever. The travel speed is set as the travel speed for traveling downhill.
Page 272 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING ARSC SET TRAVEL SPEED FINE CONTROL Operate the ARSC speed set lever according to the following in order to finely adjust the travel speed that has been set. The travel speed can be adjusted by ±5 km/h of the set travel speed while driving the machine with the ARSC function (while the foot is off from the accelerator pedal).
Page 273 The travel speed displayed on the ARSC set travel speed indicator automatically drops as well. 10 km/h is the lower limit value of the travel speed when it automatically drops. BRAKE PERFORMANCE CURVE BRAKE PERFORMANCE CURVE: HD325-8 How to read the brake performance curve Example) Downhill distance: 1500 m Traveling resistance: –11 % (Grade resistance: –13 %, rolling resistance: 2 %)
Page 274 MACHINE OPERATIONS AND CONTROLS OPERATION This maximum permissible speed is a reference obtained from the retarder brake performance. Determine a safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the green range when traveling.
Page 275 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 450 m” Tire size: 18.00R33★★ 3-215...
Page 276 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 600 m” Tire size: 18.00R33★★ 3-216...
Page 277 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 900 m” Tire size: 18.00R33★★ 3-217...
Page 278 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 1500 m” Tire size: 18.00R33★★ 3-218...
Page 279 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: Continuous” Tire size: 18.00R33★★ BRAKE PERFORMANCE CURVE: HD405-8 How to read the brake performance curve Example) Downhill distance: 1500 m Traveling resistance: –11 % (Grade resistance: –13 %, rolling resistance: 2 %) Payload: 40 t Obtain the maximum permissible speed and the gear speed range from the graph when traveling downhill under the above conditions.
Page 280 MACHINE OPERATIONS AND CONTROLS OPERATION This maximum permissible speed is a reference obtained from the retarder brake performance. Determine a safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the green range when traveling.
Page 281 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 450 m” Tire size: 21.00R33★★ 3-221...
Page 282 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 600 m” Tire size: 21.00R33★★ 3-222...
Page 283 OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: 900 m” Tire size: 21.00R33★★ 3-223...
Page 284 MACHINE OPERATIONS AND CONTROLS OPERATION Brake performance “Downhill distance: 1500 m” Tire size: 21.00R33★★ 3-224...
Page 285: Method For Turning Machine
OPERATION MACHINE OPERATIONS AND CONTROLS Brake performance “Downhill distance: Continuous” Tire size: 21.00R33★★ METHOD FOR TURNING MACHINE WARNING Do not steer at high speed or on steep slope, you may cause the machine to tilt. CAUTION • If the steering wheel has been turned fully to the right or left, do not continue to apply force to turn it further.
Page 286: Method For Loading
MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • The angle of the steering wheel may change (the position of the spoke may change slightly) when the ma- chine is traveling, but this is not a failure. • If force is applied to the steering wheel when the tires have been turned fully to the right or left, the steering wheel will turn a little at a time, but this is not a failure.
Page 287 OPERATION MACHINE OPERATIONS AND CONTROLS Set the gear shift lever (1) to NEUTRAL position (N), and set the parking brake switch (2) to “PARKING” position. When the parking brake has been applied, the parking brake pilot lamp lights up on the machine monitor. Move the dump lever (3) to “RAISE”...
Page 288: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION When the dump body has moved down a certain distance, move the dump lever (3) to “FLOAT” position (C). (When you release the lever, it returns to “FLOAT” position (C).) The dump body will then move down under its own weight. REMARK If the dump body is not completely lowered, the gear speed is fixed at 1st anywhere the gear shift lever position...
Page 289: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Park the machine on solid level ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, set the parking brake switch to “PARKING”...
Page 290: Method For Checking After Finishing Work
MACHINE OPERATIONS AND CONTROLS OPERATION Place the gear shift lever (3) to NEUTRAL position (N), then set the parking brake switch (4) to “PARKING” posi- tion (A) to apply the parking brake. When in the operator's compartment, pull the retarder con- trol lever (5) fully to apply the retarder.
Page 291 OPERATION MACHINE OPERATIONS AND CONTROLS (1) Toolbox (2) Battery box (3) Battery disconnect box (4) Transmission case oil filler port cap (5) Steering and hoist oil tank filler port cap (6) Operator's cab door (R.H. and L.H.) (7) Fuel tank filler port cap (8) DEF filler port cover (9) Fuel tank drain cover (10) Reservoir tank...
Page 292 MACHINE OPERATIONS AND CONTROLS OPERATION Insert the starting switch key into the key slot. Turn the starting switch key to “LOCK” position (B), and then align the key slot with the match mark (1) of the cap. Position (A) OPEN Position (B) LOCK Remove the starting switch key.
Page 293 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING OIL FILLER CAP OF STEERING AND HOIST OIL TANK PROCEDURES FOR OPENING OIL FILLER CAP OF STEERING AND HOIST OIL TANK Insert the starting switch key into the key slot. Turn the starting switch key to “OPEN”...
Page 294: Handle Tire
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING OPERATOR CAB DOOR Insert the starting switch key into the key slot (1). Turn the starting switch key to “OPEN” position (A), and then remove the starting switch key. Position (A) OPEN Position (B) LOCK Hold the cab door handle (2) to open the cab door.
Page 295 Total operating hours in a day includes the break time and downtime. *The T.Km.P.H value in the table varies depending on the manufacturers of tire. Ask your Komatsu distributor when the work is to be performed with the travel speed near the travel speed shown in the table.
Page 296 MACHINE OPERATIONS AND CONTROLS OPERATION Size: 18.00R33★★ When unloa- (Standard) Structure: CR (Stand- Code: No. E4 ard for (TRA) the front wheel) When loaded (Stand- ard for the rear wheel) HD405–8 T.Km.P.H of the tire at each tempera- Travel speed with which the continuous traveling ture is possible at each temperature ( km/h) 16 °C...
Page 297 OPERATION MACHINE OPERATIONS AND CONTROLS • The maximum travel speed must be kept to 40 km/h or lower. Stop for at least 1 hour for every 1 hour of travel to allow the tires and other components to cool down. • Never drive the machine with “water”...
Page 298: Handle Air Conditioner
If the air condi- tioner system caution lamp lights up, ask your Komatsu distributor for the inspection and repair. Ventilation while cooling •...
Page 299: Explanation Of Air Conditioner Equipment
OPERATION HANDLE AIR CONDITIONER EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Fan switch (7) Air conditioner display (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Defroster switch (5) Auto switch Air conditioner display (A) Air flow bar (E) Vent display...
Page 300 HANDLE AIR CONDITIONER OPERATION FAN SWITCH You can adjust the air flow by using the fan switch. The air flow can be adjusted to 6 levels. Press the △ switch to increase the air flow; press the ▽ • switch to decrease the air flow. •...
Page 301 OPERATION HANDLE AIR CONDITIONER REMARK If the mode is set to automatic operation and the temperature setting is set to 18 °C or 32 °C, the air flow from the fan is always set to “HIGH” and does not change even when the temperature reaches the set temperature. VENT SELECTOR SWITCH The vent selector switch is used to select the vents.
Page 302 HANDLE AIR CONDITIONER OPERATION AUTO SWITCH Auto switch is used to switch the operation to the automatic op- eration. It changes the air flow and vents, recirculated air and fresh air automatically according to the set temperature and the ambient environment.
Page 303 OPERATION HANDLE AIR CONDITIONER AIR CONDITIONER DISPLAY The air conditioner display displays the state of air flow (A), op- eration of air conditioner (B), set temperature (C), FRESH/ RECIRC air (D), vents (E), automatic operation (F), and de- froster (G). AIR CONDITIONER SWITCH Use the air conditioner switch to start and stop the cooling, heating, or drying function.
Page 304: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION DEFROSTER SWITCH The defroster switch is used to set the vents in the defroster mode. • Use this mode to clear the front glass mist, etc. • When the defroster switch is pressed during automatic op- eration, the automatic operation symbol on the air condi- tioner display goes out and the defroster mark is dis- played.
Page 305 OPERATION HANDLE AIR CONDITIONER Press switch △ or switch ▽ of the temperature control switch to set to the desired temperature. The air flow and combination of the vents are automatically selected according to the set temperature and environ- ment, and the air conditioner is operated automatically to provide the set temperature.
Page 306 HANDLE AIR CONDITIONER OPERATION Press the air conditioner switch. The air conditioner operation symbol lights up on the air conditioner display. Press switch △ or switch ▽ of the temperature control switch to set to the desired temperature. REMARK The air temperature is so adjusted that the temperature in the cab becomes the set temperature when the set tem- perature display is 18.5 to 31.5 °C even during the manual operation.
Page 307 OPERATION HANDLE AIR CONDITIONER METHOD FOR STOPPING MANUAL OPERATION Press the air conditioner OFF switch. The display on the monitor goes out and the operation stops. METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. Press fan switch and adjust the air flow.
Page 308 HANDLE AIR CONDITIONER OPERATION Turn air conditioner switch ON. Adjust fan switch, temperature control switch and FRESH/ RECIRC air selector switch to the desired positions. METHOD FOR OPERATING DEFROSTER Press the fan switch and adjust the air flow. 3-248...
Page 309 OPERATION HANDLE AIR CONDITIONER When doing this, check that the temperature setting (A) and air flow (B) of the display monitor are displayed. Press the vent selector switch or defroster switch, and set the vent display on the display monitor to (F) or (G) as shown in the figure.
Page 310 HANDLE AIR CONDITIONER OPERATION When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn on the air conditioner switch. 3-250...
Page 311: Handle Radio
OPERATION HANDLE RADIO HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them.
Page 312: Method For Controlling Radio
HANDLE RADIO OPERATION PRESET BUTTON If you register the desired stations to the preset button beforehand, you can select each station by touching this button once. It is possible to preset 6 stations each for both AM and FM. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display.
Page 313 OPERATION HANDLE RADIO Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency. Press the △ button, and the frequency increases; • press the ▽ button, and the frequency decreases. Hold down the △...
Page 314 HANDLE RADIO OPERATION METHOD FOR ADJUSTING SOUND BALANCE Press sound control button (1) to light up “BAL” on the dis- play. You can adjust the sound (balance). Press tuning/time adjustment button (2) to adjust the sound (balance). Press the △ button, and the speaker output on the R •...
Page 315 OPERATION HANDLE RADIO Press display selector button (1) to cancel time adjustment. The screen returns to the clock display. 3-255...
Page 316: Determine And Maintain Travel Road
DETERMINE AND MAINTAIN TRAVEL ROAD OPERATION DETERMINE AND MAINTAIN TRAVEL ROAD Determining and performing maintenance of the road in the jobsite are the extremely important factors both for reasons of safety and for reducing the cycle time. To ensure safety in operations, do as follows. Determine travel road •...
Page 317: Transportation
Always obey the traffic regulations when transporting the machine by road. WARNING This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. SELECT TRANSPORTATION METHOD As a basic rule, always transport the machine on a trailer.
Page 318 This lifting method applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For the procedure for the machine with other than standard specification, consult your Komatsu distrib- utor. For the weight of the standard specification machine, see “Weight table”.
Page 319 OPERATION TRANSPORTATION Location of lifting position mark Weight table Center of gravity Load on front Load on rear Machine weight axle axle (from front axle) HD325-8 34230 kg 19374 kg 14856 kg 1630 mm HD405-8 37370 kg 20292 kg 17078 kg 1715 mm PROCEDURE FOR LIFTING MACHINE Lifting work is allowed for only machines having lifting marks.
Page 320 TRANSPORTATION OPERATION Select the lifting tools such as wire ropes, slings, or spreader beams to match the weight of the machine, and fit them to the lifting hooks (at lifting hook marks) at 4 pla- ces in total (2 places at front, 2 places at rear). The lifting position of the machine varies according to the condition.
Page 321: Cold Weather Operation
If DEF or the machine equipped with DEF system is stored at the outside temperature lower than – 11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 322: Precautions After Daily Work Completion In Cold Weather
COLD WEATHER OPERATION OPERATION When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be started easily in the next morning.
Page 323 FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. • If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by re- peated freeze, ask your Komatsu distributor to inspect. 3-263...
Page 324: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. Perform the following items when using the machine after long-term storage. • Wipe off the grease from the hydraulic cylinder piston rods.
Page 325: Preparation Before Traveling After Long-Term Storage
If SCR system has any abnormality, stop the engine, and then start it again. If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If the DEF is kept in the DEF tank for more than 1 year, replace it.
Page 326: Troubles And Actions
TROUBLES AND ACTIONS OPERATION TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill it up with fuel and bleed air from the fuel system before starting. Always check the fuel level to prevent running out of fuel. If the engine has stopped because of running out of fuel, all the air in the fuel circuit must be bled by using the fuel feed pump.
Page 327: Precautions For Towing Machine
(6) clockwise, and tighten the lock nut (5). Turn the head side grip (3) clockwise, and tighten the lock nut (2). If the dump body cannot be lowered even if the above method is used, consult your Komatsu distributor. PRECAUTIONS FOR TOWING MACHINE WARNING...
Page 328 TROUBLES AND ACTIONS OPERATION • When towing a machine, tow it at a low speed of 2 km/h or lower, and for a distance of a few meters to a place where repairs can be performed. This method is applied only in an emergency. If the machine must be moved a long distance, use a trans- porter.
Page 329 METHOD FOR RELEASING PARKING BRAKE See the following procedure if it is necessary to release the parking brake when towing or moving the machine. Ask your Komatsu distributor if it is necessary to release the parking brake. WARNING •...
Page 330 TROUBLES AND ACTIONS OPERATION Push down the lock portion of parking brake adjustment screw (1), then turn the adjustment screw (1) clockwise. Check that there is a clearance between the parking brake pad and brake disc. When the parking brake is released, tow the machine im- mediately to a safe place.
Page 331: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 332 TROUBLES AND ACTIONS OPERATION Tightening torque of wiring harness terminal (1): 11.8 to 19.6 Nm {1.2 to 2.0 kgm} Tightening torque of battery terminal (2): 9.8 to 11.8 Nm {1.0 to 1.2 kgm} Tightening torque of 1st nut (3) of mounting fixture: 7 to 9 Nm {0.71 to 0.92 kgm} Tightening torque of 2nd nut (4) of mounting fixture: 35 to 45 Nm {3.57 to 4.59 kgm}...
Page 333 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never connect the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 334: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 335 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 336 Operate the accelerator pedal to move the machine to a safe place, then check the failure code and contact your Komatsu distributor. When operating the accelerator pedal, release the pedal to turn it to OFF position (low idle) or depress it fully to set it to 1500 rpm.
Page 337 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 338 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Starting motor turns but engine does Lack of fuel Add fuel. See CHECKS BE- not start. FORE STARTING. Air in fuel system Repair place where air is sucked. (*) No fuel in fuel filter Fill filter with fuel.
Page 339 REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-279...
Page 341: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 342: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 343: Precautions For Kdpf
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR KDPF When performing inspection and maintenance during or just after regeneration, take care of the high tempera- ture parts. Even after the engine stops the parts around KDPF may be at high temperature. PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance.
Page 344: Fuel And Lubricants To Match The Ambient Temperature
PRECAUTIONS FOR MAINTENANCE MAINTENANCE • Increase the engine speed to check for the leakage of fuel or oil. • Check if the inspected and serviced area is normally operated. FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE It is necessary to select fuel or lubricant according to the ambient temperature. PRECAUTIONS FOR JACK-UP •...
Page 345: Outline Of Maintenance
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu...
Page 346 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 347 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 348 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 349: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 350: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 351 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Taper seal Width Tightening torque Outside di- acros ameter of Target value Allowable range s flats hose “a” “b” (mm) (mm) 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132 8.5 to 13.5...
Page 352: Maintenance Schedule
See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”. • Ask your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .......... 4-15 WHEN REQUIRED ............................
Page 353: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE MAINTENANCE SCHEDULE METHOD FOR LUBRICATING PARKING BRAKE.................. 4-63 METHOD FOR LUBRICATING ....................... 4-64 METHOD FOR CHECKING REAR BRAKE DISC WEAR AMOUNT ............4-65 METHOD FOR COLLECTING LEAKED OIL FROM FLOATING SEAL ........... 4-65 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP ......4-66 METHOD FOR REPLACING DEF TANK BREATHER ELEMENT............
Page 354 MAINTENANCE SCHEDULE MAINTENANCE Replace the fuel main filter cartridge When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed with bio-fuel, and when the machine is operated further 250 hours. After that, replace it within 1000 hours as a periodic replacement by the service meter reading.
Page 355: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance after the first 250 hours only for the new machine. • Replacing element in the transmission oil filter • Changing oil in transmission case and brake sub-tank •...
Page 356 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING AIR CLEANER Clean the element when the yellow piston shown in the dust in- dicator (1) display entered the red (7.5 kPa {0.076 kg/cm }) po- sition. After the cleaning, press the dust indicator button to reset it. If the yellow piston enters the red (7.5 kPa {0.076 kg/cm }) po- sition soon after the cleaning, the element must be replaced.
Page 357 MAINTENANCE MAINTENANCE PROCEDURE Clean the dust sticking inside the air cleaner body (5) and on the cover (2) by using a clean cloth or brush. If any dust is attached to the vacuator valve (6) installed to the cover (2), remove it. Check that the lip of vacuator valve (6) has no crack.
Page 358 MAINTENANCE PROCEDURE MAINTENANCE Check that O-ring (7) is fitted to cover (2). Align the cover (2) with the element. Insert the cover (2) with vacuator valve (6) right at the bottom into air cleaner body (5). Lock the tips of clips (1) (6 places) on the protrusions of the air cleaner body (5).
Page 359: Method For Cleaning Inside Of Cooling System
MAINTENANCE MAINTENANCE PROCEDURE If any dust is attached to the vacuator valve (6) installed to the cover (2), remove it. Check that the lip of vacuator valve (6) has no crack. If there is any crack, replace it with a new one. Remove the inner element (4), and then quickly install the new inner element.
Page 360 When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 361 MAINTENANCE MAINTENANCE PROCEDURE Items to be prepared • A container whose capacity is enough to receive the specified capacity of coolant • A hose to add coolant Stop the engine. Remove the bolts (1) (4 pieces), and remove the cover (2) on top of the sub-tank.
Page 362 MAINTENANCE PROCEDURE MAINTENANCE Remove the cover of the engine underguard. Remove the cover on the right side of the machine. Put the containers to catch the coolant under the drain valve (8) at the bottom of the oil cooler and under the drain plug (9) at the side of the cylinder block.
Page 363 MAINTENANCE MAINTENANCE PROCEDURE 15. Loosen the drain valve (8) and the drain plug (9), and drain the tap water. 16. After draining the tap water, close the drain valve (8) and the drain plug (9). 17. Turn the radiator caps (5), (6) and the sub-tank filler port cap (7) slowly to remove.
Page 364: Method For Cleaning Radiator Fins, Aftercooler Fins, Oil Cooler Fins, And Air Conditioner Condenser Fins
MAINTENANCE PROCEDURE MAINTENANCE 28. Open the cover (11). 29. Open the cap (13) of the reservoir tank (12), and add the Non-Amine Engine Coolant (AF-NAC) to the middle be- tween FULL and LOW of the dipstick (G). 30. After adding, close the cap (13) of the reservoir tank (12). 31.
Page 365: Method For Cleaning Fins By Rotating Cooling Fan In Reverse
MAINTENANCE MAINTENANCE PROCEDURE Perform this procedure if there is any mud or dirt stuck to the radiator. METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE NOTICE When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc. will not be wound in the fan.
Page 366 MAINTENANCE PROCEDURE MAINTENANCE Select “Radiator Fan Reverse Mode” on “Machine Setting and Information” menu screen, then press ENTER switch (1). Press ENTER switch (1) to rotate the fan in the reverse di- rection. If the fan reverse operation is performed without satisfying the condition for reversing the fan, the screen shown in the figure is displayed, and the fan rotation direction cannot be switched.
Page 367: Method For Cleaning Fin With Compressed Air
MAINTENANCE MAINTENANCE PROCEDURE 12. Stop the engine. 13. Check that the fan rotation is stopped. 14. Turn the starting switch to ON position. 15. Select “Radiator Fan Reverse Mode” on “Machine Setting and Information” menu screen, then press ENTER switch (1).
Page 368: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE PROCEDURE MAINTENANCE Blow off mud, dirt, leaves, etc. in radiator fins (3), aftercool- er fins (4), air conditioner condenser fins (5), and oil cooler fins (6) with compressed air. NOTICE Steam or water may be used instead of the com- pressed air.
Page 369: Method For Checking Dump Body
(C) Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so ask your Komatsu distributor to add the refrigerant. If the air conditioner continues to run with low refrigerant gas level, it will cause damage to the compressor.
Page 370: Method For Checking Length Of Suspension Cylinder
MAINTENANCE If any cracks or abnormal wear are found, perform repairs. Contact your Komatsu distributor for details of the repair procedure. METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER If the machine reacts to the rough ground conditions when traveling, such as making high bounds or the cylinder retracting and hitting the stopper, check the length of the suspension cylinder.
Page 371: Method For Bleeding Air From Brake Circuit
223 to 243 mm Reference (C) 441 to 461 mm Ask your Komatsu distributor for inspection if there is any problem found when checking the front suspension. Install the cover (3) with bolts (2) (2 pieces). METHOD FOR CHECKING LENGTH OF REAR SUSPENSION CYLINDER Loosen the clamp (1).
Page 372 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR BLEEDING AIR FROM REAR BRAKE Always bleed air from the brake circuit in the order of the slack adjuster and wheel brake. Start the engine. Check with the sight gauge that the oil level in the transmission case is at the specified level. Check that the brake oil pressure caution lamp is not lit.
Page 373: Method For Bleeding Air From Fuel Circuit
MAINTENANCE MAINTENANCE PROCEDURE Check that the front brake off switch is at (B) position. Remove the cap of the bleeder screw (1). Insert a vinyl hose to the bleeder screw (1). Use a commercially available vinyl hose whose inside di- ameter is 8 mm.
Page 374: Method For Checking Play Of Output Coupling Of Output Shaft
MAINTENANCE PROCEDURE MAINTENANCE Check that supply valve (1) of the fuel tank is opened. Move the switch for the fuel feed pump (2) to ON position. Lamp (3) flashes and the fuel feed pump operates. After the specified time (approximately 7 minutes), lamp (3) goes out automatically and the fuel feed pump stops.
Page 375: Select And Check Tires
If amount of movement (L) exceeds 15 mm, the rubber in- side the output shaft may be deteriorated or damaged, so ask your Komatsu distributor for disassembly and inspec- tion of the internal parts of the output shaft. SELECT AND CHECK TIRES...
Page 376 Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the tires in the following table. The speed display varies with the tire size. Consult your Komatsu distributor when using the optional tires. HD325–8 Maximum load ( kg)
Page 377: Method For Releasing Parking Brake
MAINTENANCE MAINTENANCE PROCEDURE Do not work in front of the rim but work on the tread side of the tire. Measure the tire inflation pressure with a tire inflation pressure gauge. Adjust the tire inflation pressure properly. The proper tire inflation pressure is shown below. HD325–8 Tire size Tire inflation pressure kPa{ kg/cm...
Page 378: Checks Before Starting
(1) and turn it back clockwise 360±15° (1 turn). After adjustment, check the parking brake performance. If the machine moves, ask your Komatsu distributor for in- spection. CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING”.
Page 379: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE • Check braking performance of secondary brake • Check automatic secondary steering • Check manual secondary steering • Check automatic secondary steering • Check dump body positioner operation • Check backup alarm operation • Check horn operation EVERY 250 HOURS MAINTENANCE METHOD FOR LUBRICATING Stop the engine.
Page 380: Method For Checking And Adding Oil In Differential Case
MAINTENANCE PROCEDURE MAINTENANCE Hoist cylinder pin (2 places each of right and left) Perform the greasing when the dump body is lowered. Front suspension (2 places each of right and left) Perform the greasing when the steering is set to the straight travel.
Page 381: Method For Checking Oil Level In Final Drive Case, Adding Oil
Check that there is no problem such as loose connection of the drive shaft, play in the splines and bearings, runout of the shaft, etc. If any problem is found, ask your Komatsu distributor for repair. METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL Perform this procedure before operating the machine.
Page 382 Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer. Release the lock of battery box cover (1), and close the cover.
Page 383: Method For Cleaning Transmission Case And Brake Sub-Tank Breather
If the battery fluid is added to the level above the bottom of the sleeve, use a syringe to remove it until the level becomes under the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicar- bonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 384: Method For Cleaning Steering And Hoist Oil Tank Breather
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (1), and remove the cover (2). Remove mud and dirt around the breather (3). Remove the breather (3). Take care to prevent entry of dusts through the mounting section of the breather. Remove the bolt (4) of breather (3). Remove the cover (5).
Page 385: Method For Checking Frame
Check that there is no damage to the frame. In particular, check the shaded area in the figure. If any cracks or other damage are found, perform the repairs. Contact your Komatsu distributor for the repair procedure. METHOD FOR CHECKING FOOT BRAKE PERFORMANCE WARNING If the machine moves when the braking capacity is being checked, it may lead to serious personal injury or death.
Page 386: Method For Checking Retarder Brake Performance
If the machine does not move when the engine speed is increased to 1550 rpm, it is normal. If any problem is found, ask your Komatsu distributor for repair. Decrease the engine speed and set the gear shift lever to NEUTRAL position (N).
Page 387: Method For Checking Parking Brake Performance
If the machine does not move when the engine speed is increased to 1600 rpm, it is normal. If any problem is found, ask your Komatsu distributor for repair. Decrease the engine speed and set the gear shift lever to NEUTRAL position (N).
Page 388: Method For Checking Function Of Accumulator
(C) Hard When setting the dump lever to the position other than “FLOAT” Ask your Komatsu distributor for the inspection and adjustment if there is any problem found. METHOD FOR CHECKING FUNCTION OF ACCUMULATOR If the engine stops during travel, the brake can be operated with the oil pressure in the accumulator temporarily.
Page 389: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Run the engine at medium speed for 1 minute, turn the starting switch to OFF position (A), and then stop the en- gine. Turn the starting switch to ON position (B). Depress the brake pedal several times. After the brake pedal is depressed some times, the brake oil pressure caution lamp (1) lights up.
Page 390 Check the drained oil. If there are excessive metal particles or foreign materials, contact your Komatsu distributor. Remove the drain hose, and tighten the drain valve (2) and drain plug (1). Tightening torque: 68.6±9.8 Nm {7±1 kgm} Open the engine side cover.
Page 391: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 392 MAINTENANCE PROCEDURE MAINTENANCE Close the fuel supply valve (1) of the fuel tank. Place a container to catch the fuel under the drain hose (2). Loosen the drain valve (3) and drain water and sediments from transparent cup (4), and also drain all the fuel accu- mulated in the fuel prefilter cartridge (5).
Page 393: Method For Replacing Transmission Oil Filter Element
MAINTENANCE MAINTENANCE PROCEDURE 13. Open the fuel supply valve (1) of the fuel tank. 14. When replacing the fuel main filter cartridge (every 1000 hours), perform cartridge replacement and air bleeding. Do not supply fuel into the fuel main filter cartridge. 15.
Page 394: Method For Checking Wear Of Front Disc Brake Pads
Replace the pad since it has reached the wear limit. Ask your Komatsu distributor for replacement of the pad (5). The wear amount of pads on the right and left wheels are not equal. Perform the check on both sides.
Page 395: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Remove the cover on the left side of the machine. Remove the bolts (1) (9 pieces) and remove the cover (2). Remove the bolts (3) (6 pieces) and remove the cover (4). Check the belt. If the belt shows the following state, it must be replaced. •...
Page 396 MAINTENANCE PROCEDURE MAINTENANCE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. • When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres- sure, then remove it carefully.
Page 397 MAINTENANCE MAINTENANCE PROCEDURE Clean the strainers (2 places) of the transmission case. Remove the bolts (5), and remove the cover (6). Take out the strainer (7). Remove all dirt from strainer (7), then wash it in clean diesel fuel or flushing oil. Check the strainer (7).
Page 398 MAINTENANCE PROCEDURE MAINTENANCE Check the oil level of the brake sub-tank during running the engine at low idle. Perform the following steps if the oil level is below the sight gauge (H). Stop the engine. Add the oil through the oil filler port (F) until the oil is seen in the sight gauge (H).
Page 399: Method For Replacing Brake Oil Filter Element
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 400: Method For Replacing Fuel Main Filter Cartridge
MAINTENANCE PROCEDURE MAINTENANCE REMARK When the pressure in accumulator is released, the depressing effort of the brake pedal decreases, and no hydraulic sound is made. Remove the bolts (1), and remove the cover (2). Place a container to catch oil just under the brake oil filter. Rotate the hexagonal portion on the bottom of the filter case (3) by using a wrench, and remove the filter case (3).
Page 401 The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 402: Method For Replacing Fuel Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE When installing the filter cartridge, tighten it by hand until the packing surface contacts the sealing surface of the filter head, then tighten the filter cartridge 1/2 to 3/4 turns. NOTICE • Do not fill the new filter cartridge with fuel. •...
Page 403: Method For Lubricating Parking Brake
MAINTENANCE MAINTENANCE PROCEDURE Remove the nut (2) of breather assembly (1). Remove the cover (3). Replace the breather element (4) with a new one. Install the cover (3) and nut (2). Remove the body pivot pin. Lower the dump body. METHOD FOR LUBRICATING PARKING BRAKE WARNING •...
Page 404: Method For Lubricating
MAINTENANCE PROCEDURE MAINTENANCE By using a grease pump, pump in grease through fittings (1) and (2) (2 places) in the parking brake body and fitting (3) (1 place) in the slack adjuster. NOTICE Do not use air pressure or oil pressure to perform high pressure greasing.
Page 405: Method For Checking Rear Brake Disc Wear Amount
If the slit (3) of rod (2) enters beyond the guide end face (4), it means that the disc has reached the wear limit. Ask your Komatsu distributor for inspection and mainte- nance in such case. Install the cap nut (1) which is removed in the step 3.
Page 406: Method For Checking For Looseness Of Engine Intake Pipe Clamp
MAINTENANCE PROCEDURE MAINTENANCE Place the oil container to catch the oil just under the drain plug (P). Remove the drain plug (P) and drain the oil. Collect the oil from the brake tanks on the right and left sides. After draining the oil, tighten the drain plug (P). METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP Check for looseness in the air intake piping clamps between the air cleaner, turbocharger, aftercooler, and engine.
Page 407 If the machine is operated without the DEF tank breather element attached, or with the element oth- er than Komatsu genuine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without the DEF tank breather element attached, nor use the element other than Komatsu genuine parts.
Page 408: Method For Checking And Lubricating Drive Belt Tension Pulley Assembly Of Compressor For Alternator And Air Conditioner
Remove the bolts (1) (6 pieces) and remove the cover (2). Check the pulley for play and the grease for leakage. If any problem is found, ask your Komatsu distributor for repair and replacement. Install the cover (2) with bolts (1) (6 pieces).
Page 409: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Open the engine side cover. Pump in the grease through the grease fittings shown by arrows by using a grease pump. After greasing, wipe off any old grease that is pushed out. Close the engine side cover. EVERY 2000 HOURS MAINTENANCE Maintenance for every 250, 500, and 1000 hours services should be performed out at the same time.
Page 410: Method For Changing Oil In Final Drive Case
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (1) (4 pieces) and remove the cover (2). Remove the O-ring (3), spring (4), valve (5), strainer (6), and element (7). Wash the inside of the case, valve (5), and strainer (6). Prepare a new element. Install the element, strainer, valve, and spring to the case.
Page 411: Method For Changing Oil In Deferential Case
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN DEFERENTIAL CASE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 412: Method For Cleaning Hydraulic Tank Strainer
2000 hour or every year service. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. METHOD FOR REPLACING KCCV FILTER ELEMENT WARNING •...
Page 413 MAINTENANCE PROCEDURE NOTICE • Komatsu recommends using Komatsu genuine parts for replacement parts. • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and it can cause engine problems such as overrun caused by suc- tion of oil.
Page 414 MAINTENANCE PROCEDURE MAINTENANCE After the ring (3) comes off, remove the case (4) from body (2), and remove the element (5). There may be oil accumulated or sticking in the case and element. Take care not to spill the oil when replacing the element.
Page 415: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 416 MAINTENANCE PROCEDURE MAINTENANCE After the engine is stopped, the devices are still operated for a few minutes. Before replacing the filter, clean around the DEF pump first after the DEF system devices stop. Items to be prepared • DEF filter removal tool •...
Page 417 MAINTENANCE MAINTENANCE PROCEDURE Insert the filter removal tool (5) into the lower part of the DEF pump and thrust in by hand. Check that the filter removal tool (5) is fully inserted to the end. Insert the filter removal tool (5) to the end where you can- not thrust it in any further.
Page 418: Every 4000 Hours Maintenance
High pressure circuit hose Brake system Brake oil pressure hose Retarder control valve rubber parts Torque converter, trans- Transmission circuit hose Ask your Komatsu distributor mission system for replacement. Work equipment hydraulic Main pump delivery hose system Main pump delivery hose other than described...
Page 419: Method For Lubricating Drive Shaft
METHOD FOR CHECKING WATER PUMP Check around the water pump for water leakage. If any part is leaking, ask your Komatsu distributor for inspection/repair. METHOD FOR CHECKING ALTERNATOR Remove the belt every 4000 hours or every 1 year whichever comes sooner, and check that it rotates smoothly.
Page 420: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
Check the clamps (1) to (19) for high-pressure pipe visually and with your fingers that there are no loose mount- ing bolts or hardening of the rubber. If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,...
Page 421: Every 4500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 250 and 500 hours services should be performed out at the same time.
Page 422: Every 8000 Hours Maintenance
Ask your Komatsu distributor for replacement of the engine high-pressure piping. METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps. METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR Ask your Komatsu distributor to perform this work.
Page 423: Every 9000 Hours Maintenance
END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. EVERY 15000 HOURS MAINTENANCE Maintenance for every 250, 500 and 1000 hours should be performed at the same time.
Page 425: Specifications
SPECIFICATIONS...
Page 426: Specifications: Hd325-8
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: HD325-8 Item Unit HD325-8 Overall weight (unloaded weight + maximum payload + 1 opera- kg 70810 tor (80 kg)) Unloaded weight kg 34230 Unloaded weight (without dump body) kg 26720 Maximum payload kg 36500 Struck m 16.9...
Page 427: Specifications: Hd405-8
Maximum payload kg 40000 Struck m 20.0 Dump body capacity Heaped (2:1) m 27.3 Dumping speed (2000 rpm) (raised) Second Komatsu Engine model SAA6D140E-7 diesel engine Engine rated horsepower SAE J1995 (gross) 386 /2000 • ISO 14396 • kW/ min 386 /2000 ISO 9249 /SAE J1349 (net) •...
Page 428 SPECIFICATIONS SPECIFICATIONS Item Unit HD405-8 km/h km/h 15.0 km/h 20.1 Forward km/h 27.2 Travel speed km/h 36.4 km/h 49.6 km/h 66.2 Reverse km/h 10.2 Operating temperature range °C -20 to 45...
Page 429: Attachments And Options
ATTACHMENTS AND OP- TIONS Before reading this chapter, read and understand the SAFETY.
Page 430: Handling Payload Meter
Although the following functions are provided, you do not need to change them for the standard operation. If setting is required, ask your Komatsu distributor. Setting of Loading End Travel Dist The payload meter judges that loading is completed when the machine travels continuously 160 m from the...
Page 431: Payload Display
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER External display lamp The external display lamps (2 places) are installed to the rear left of the cab and right (right side of the machine body). The external display lamps are installed so that the operator on the loader can see them.
Page 432: External Display Lamp
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS (*1) For the machine to be recognized as "Loading" from "Unloaded", the payload must be approximately 10 % or more of the rated payload, and the machine must wait for the payload to be stabilized in the stopped state. (*2) For the machine to be recognized as "Loaded"...
Page 433: Details Of Data Stored In Memory Of Payload Meter
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER In such case, consult your Komatsu distributor. Display of prediction Loading state and prediction are indicated by the lamps in different colors and their lighting status (lighting up or flashing). When the load changes in steps for each bucket loaded, the payload meter automatically estimates the predict- ed total payload if one more bucket is loaded, and indicates the predicted payload by flashing of the appropriate lamp.
Page 434: Method For Downloading Data From Connector For Download
Download the recorded data to a personal computer installed with special software (optional). • When you need to correct the date and time in the downloaded data, consult your Komatsu distributor. • There is some error in the directory where the data is downloaded by the special software, there may be a mistake in the setting for the machine.
Page 435 ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER Double-click the icon. The download software is started and the screen shown in the figure is displayed. When the screen “G1000” is displayed, click “PLM”. The screen “G2000” is displayed. Do not click “CARD” and “PMC”, since they are not used. Click “Parameter Setting”...
Page 436: Display Total Payload And Number Of Cycles
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS Click “ENTER” to return to the screen “G2200”. On the screen “G2200”, click “BACK” to return to the screen “G2000”. Click “Download” on the screen “G2000”. When the screen “G2100” is displayed, click “Start”. Downloading starts.
Page 437 ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER Press the menu switch (1) to display “Machine Setting and Information” menu, select “Payload Meter”, then press EN- TER switch (2). Select “Accumulated Payload and Total Cycles”, then press ENTER switch (2). The accumulated payload and the total number of cycles are displayed as shown in the figure.
Page 438: Display Fuel Consumption Record
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS DISPLAY FUEL CONSUMPTION RECORD You can display the average daily working fuel consumption (ton/l) in the last 1 week. You can reset that value. Press the menu switch (1) to display “Machine Setting and Information”...
Page 439: Setting Machine Id And Open Id
ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER Press ENTER switch (2). The pop-up window of the data reset is displayed. Press RETURN switch (3), and the screen returns to “Pay- load Meter” menu. Press ENTER switch (2) while the pop-up window shown in the figure is displayed.
Page 440: Method For Performing Calibration
HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS Press ENTER switch (2). The pop-up window opens and displays the currently set machine ID. Input the machine ID. • The settable range is from 0 to 200. • Each time UP switch (3) is pressed, ID increases by 1. Each time DOWN switch (4) is pressed, ID decreases by 1.
Page 441 ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER NOTICE • Perform the calibration on a level place. • Perform the calibration while traveling straight. A straight road approximately 100 m long is necessary for the calibration. • Do not perform the calibration while an error is generated. •...
Page 442 HANDLING PAYLOAD METER ATTACHMENTS AND OPTIONS PressENTER switch (2) while the pop-up window shown in the figure is displayed. If you press RETURN switch (3), the window closes without starting the calibration. When the display becomes as shown in the figure, drive the machine at speed of 10 km/h.
Page 443: Body Selection
ATTACHMENTS AND OPTIONS BODY SELECTION BODY SELECTION Select the dump body from the following list. Dump body type Features Dump body shape Entire inner surface of the dump body is lined for loading the blasted rock at quarry, limestone mine, and earth Carry rocks Dump body for rock moving sites.
Page 444: Handle Komatsu Traction Control System (Ktcs)
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) ATTACHMENTS AND OPTIONS HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) WARNING • KTCS is enabled when “KTCS Setting” is set to "ON". • When the system cannot be properly controlled due to a trouble in the system, the machine monitor displays an action level and the system may stop operation depending on the failure condition.
Page 445: Handle Speed Limit Function
ATTACHMENTS AND OPTIONS HANDLE SPEED LIMIT FUNCTION HANDLE SPEED LIMIT FUNCTION WARNING If the alarm buzzer sounds due to a failure while the speed limit function is enabled, stop the machine on a level ground with the brake pedal or retarder control lever. If the speed limit function cannot be controlled due to a trouble in the system, it may lead to serious injury or death.
Page 446: Operation If Troubles On System Occur
“L04” is displayed on the machine monitor. Take appropriate actions following the list of action level dis- plays and required actions. Check the failure code. Notify your Komatsu distributor of the failure code and ask for repair. Whether the systems continue or discon-...
Page 447: Replacement Parts
REPLACEMENT PARTS...
Page 448: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 449: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 450: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 451 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT • The symbols used in the lubrication chart are explained as follows. Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil...
Page 452: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
Change brake oil filter Replace DEF tank breather element Replace DEF filter METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient tem- perature Recommended Komatsu Flu- Reservoir Fluid type °C EOS5W30-LA Engine oil for KDPF used in cold ter- rain...
Page 453 250 hours. For changing the maintenance time of machine moni- tor, ask your Komatsu distributor to perform the work. Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Page 454: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Note 5: DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after the engine is started. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 455: Index
Brake pedal - Test..........3-174 AISS LOW switch..........3-109 Brake performance curve........3-213 Allowable water depth.........3-228 Brake performance curve - HD325-8....3-213 Alternator - Check..........4-79 Brake performance curve - HD405-8....3-219 Alternator and air conditioner compressor drive belt - Brake sub-tank - Check oil level / Add oil... 3-166 Check.............4-54...
Page 456 INDEX Centralized warning lamp........3-34 Dimmer switch............ 3-107 Charge level caution lamp........3-31 Directions of machine........... 1-10 Chassis - Act for phenomena......3-275 Display..............3-252 Check drained oil and used filter......4-2 Display selector button........3-252 Check service meter reading........4-2 Display setting - Change........3-62 Check signs and signalman's signals....
Page 457 INDEX Engine - Start with jumper cables....... 3-273 Foot brake performance - Check......4-45 Engine - Stop............3-199 Frame - Check............4-45 Engine coolant temperature caution lamp.... 3-21 Frequency - Adjust..........3-252 Engine coolant temperature gauge.......3-46 Frequency - Auto preset........3-253 Engine high-pressure piping - Replace....4-82 Fresh and clean lubricants........4-2 Engine high-pressure piping clamp - Check for loose-...
Page 458 Machine monitor - Basic operation when starting en- Komatsu Closed Crankcase Ventilation (KCCV) 3-142 gine in normal situation........3-12 Komatsu Diesel Particulate Filter (KDPF) - Handle..Machine monitor - Basic operation when starting en- ..............3-133 gine while engine shutdown secondary switch is Komatsu genuine lubricants........4-2...
Page 459 Payload meter system caution lamp..... 3-33 Menu switch............3-51 People on dump body........... 2-17 Message - Check..........3-101 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Message - Reply..........3-102 Periodic replacement of defined life parts.....2-36 Message display......... 3-39,3-100 Pilot display............3-37 Meter display............3-45...
Page 460 INDEX Precautions for lifting machine......3-257 Read this manual............ 1-2 Precautions for long distance travel....3-236 Rear brake - Bleed air...........4-32 Precautions for long-term storage.......3-264 Rear brake disc - Check wear.......4-65 Precautions for maintenance......2-28,4-2 Rear brake oil collection tank - Check oil leakage..Precautions for noise..........
Page 461 Sound control button...........3-252 Transmission - Act against trouble......3-266 Specifications............5-2 Transmission and rear brake cooling oil filter element Specifications - HD325-8........5-2 - Replace............4-59 Specifications - HD405-8........5-3 Transmission case - Check oil level / Add oil..3-163 Speed limit function - Handle........ 6-17 Transmission case / Brake sub tank - Change oil / Speedometer............
Page 462 INDEX Vent selector switch - Select....... 3-241 Vibration levels............1-8 Visibility from operator's seat........ 1-10 Volume control button......... 3-251 Warning display.............3-17 Water pump - Check..........4-79 Water separator - Check / Drain water and sediment...............3-164 Wear well-fitting clothes and protective equipment................2-13 Wheel hub bolts - Check / Retighten....
Page 464 HD325-8,HD405-8 Dump Truck Form No. EENAM03582 ©2018 KOMATSU All Rights Reserved Printed in Belgium 06-2018...

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Hd405-8