Komatsu HD785-5 Operation & Maintenance Manual
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Komatsu HD785-5 Operation & Maintenance Manual

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PEN00042-03
DUMP TRUCK
HD785
-5
4254
SERIAL NUMBERS
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 near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
NOTICE
Komatsu has Operation & Maintenance Manuals written
in some other languages. if a foreign language manual
is necessary, contact your local distributor for
availability.

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Questions and answers

Константин
April 27, 2025

Как ведет себя автомобиль, когда полный отказ трансмиссии. И что делать в данной ситуации водителю.

0
1 comments:
Mr. Anderson
May 14, 2025

When there is a complete transmission failure in a Komatsu HD785-5, the controller sets the transmission to Neutral to avoid damage. This may happen due to faults in the power source, controller, hydraulic, or mechanical parts. The output is automatically turned OFF.

In this situation, the driver should not continue operating the truck and should report the fault for inspection and repair to prevent further damage.

This answer is automatically generated

0
Павел
May 25, 2025

Как включить весы каматцу 785

-1

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Summary of Contents for Komatsu HD785-5

  • Page 1 . NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. if a foreign language manual is necessary, contact your local distributor for availability.
  • Page 2 1 - 1...
  • Page 3 Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
  • Page 4 FOREWORD FOREWORD 1 - 3...
  • Page 5 FOREWORD FOREWORD 1 - 4...
  • Page 6 FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
  • Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
  • Page 8 FOREWORD INTENDED USE INTENDED USE DIRECTIONS OF MACHINE In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine. 1 - 7...
  • Page 9 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE It is located on the left front end of the frame.
  • Page 10 FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 9...

  • Page 11: Table Of Contents

    FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS...

  • Page 12: Foreword

    RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12 TORQUE LIST...
  • Page 13 FOREWORD CONTENTS WHEN REQUIRED 4- 19 CHECK BEFORE STARTING 4- 36 EVERY 100 HOURS SERVICE 4- 37 EVERY 250 HOURS SERVICE 4- 38 EVERY 500 HOURS SERVICE 4- 53 EVERY 1000 HOURS SERVICE 4- 58 EVERY 2000 HOURS SERVICE 4- 63 EVERY 4000 HOURS SERVICE 4- 69 EVERY 15000 HOURS SERVICE...
  • Page 14 FOREWORD CONTENTS METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 47 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM 6- 48 POSITION OF EACH INJECTOR 6- 52 GREASING POINTS FOR EACH INJECTOR 6- 56 HIGH ALTITUDE SPECIFICATIONS EXPLANATION OF COMPONENTS SERVICE PROCEDURE CHECK BEFORE STARTING EVERY 2000 HOURS SERVICE INDEX 1 - 13...
  • Page 15 2 - 1...

  • Page 16: Safety Information

    SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS 2- 10 SAFETY RULES 2- 10 IF ABNORMALITIES ARE FOUND 2- 10 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 10 FIRE EXTINGUISHER AND FIRST AID KIT 2- 10 SAFETY FEATURES 2- 10...

  • Page 17: Safety

    SAFETY SAFETY INFORMATION PRECAUTIONS DURING OPERATION 2- 18 BEFORE STARTING ENGINE 2- 18 CHECKS BEFORE STARTING ENGINE, ADJUST 2- 18 PRECAUTIONS WHEN STARTING ENGINE 2- 18 PRECAUTIONS IN COLD AREAS 2- 19 AFTER STARTING ENGINE 2- 20 CHECK AFTER STARTING ENGINE 2- 20 PRECAUTIONS WHEN TRAVELING FORWARD OR REVERSE 2- 20...

  • Page 18: Safety Labels

    If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. 2 - 4...

  • Page 19: Position For Attaching Safety Labels

    SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS 2 - 5...

  • Page 20: Safety Labels

    SAFETY SAFETY LABELS SAFETY LABELS (1) Roll-over protective structure (ROPS) (09620-30202) (2) Caution for checking engine room (09667-A0880) (3) Caution for opening hydraulic tank cap Caution for opening radiator cap (09653-A0641) 2 - 6...
  • Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Warning for handling suspension cylinder (09659-A0881) (5) Warnings for electric wire Warnings for crush hazard when inspection and maintenance Warnings for inspection of emergency steering system, emergency brake system Warning for leaving operator's seat, stopping engine Warning for retarder oil temperature (569-93-61730) 2 - 7...
  • Page 22 SAFETY SAFETY LABELS (6) Cautions before starting Cautions when traveling in reverse Cautions for operating hoist control lever (dump lever) (569-93-61720) (7) Caution when handling battery cable (09808-A1681) (8) Exhaust pipe is hot! (09817-A1103) 2 - 8...
  • Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (9) Caution for avoiding falling down (09805-C0881) (10) Caution when handling battery (This plate is stick on the machine by the battery maker.) (11) Jump start prohibited (09842-A0481) (This plate is stick on the starting motor.) 2 - 9...

  • Page 24: General Precautions

    SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

  • Page 25: Keep Machine Clean

    SAFETY GENERAL PRECAUTIONS KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.

  • Page 26: Handrails And Steps

    SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine. A: For use when getting on or off the operator's seat from the left door B: For use when getting on or off the operator's seat from the...

  • Page 27: Prevention Of Burns

    SAFETY GENERAL PRECAUTIONS PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.

  • Page 28: Action If Fire Occurs

    SAFETY GENERAL PRECAUTIONS Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers. Fire coming from electric wiring Short circuits in the electrical system can cause fire.

  • Page 29: Precautions When Using Rops (Roll Over Protective Structure)

    Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.

  • Page 30: Working On Loose Ground

    SAFETY GENERAL PRECAUTIONS WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.

  • Page 31: Precautions On Indoor Ventilation

    Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 17...

  • Page 32: Precautions During Operation

    SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS DURING OPERATION BEFORE STARTING ENGINE If there is a warning tag hanging from gear shift lever (1), do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE, ADJUST Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.

  • Page 33: Precautions In Cold Areas

    SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.

  • Page 34: After Starting Engine

    SAFETY PRECAUTIONS DURING OPERATION AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and dump body control system.

  • Page 35: Precautions During Operation

    The explosion of the tire is very destructive, and it can lead to serious injury or death. Contact with your Komatsu distributor before doing long continuous traveling. PRECAUTIONS WHEN TRAVELING ON THE SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows.

  • Page 36: Precautions Under The Snowing And Freezing Condition

    SAFETY PRECAUTIONS DURING OPERATION RECAUTIONS UNDER THE SNOWING AND FREEZING CONDITION Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.

  • Page 37: Battery

    SAFETY PRECAUTIONS DURING OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.

  • Page 38: Starting With Booster Cables

    SAFETY PRECAUTIONS DURING OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).

  • Page 39: Towing

    SAFETY PRECAUTIONS DURING OPERATION TOWING WHEN TOWING When towing or being towed, mistakes in the method of selecting and inspecting the wire rope or drawbar, or in the method of towing may lead to serious personal injury. For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-104)" Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed.

  • Page 40: Precautions For Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Attach the DO NOT OPERATE warning tag to gear shift lever (1) in the operator's cab during the inspection and maintenance. Attach additional warning tags around the machine if necessary. Warning tag Part No. 09963-03001 Keep the warning tag in the tool box when it is not used.

  • Page 41: Stop Engine Before Carrying Out Inspection And Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the dump body and stop the engine.

  • Page 42: Two Workers For Maintenance When Engine Is Running

    SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.

  • Page 43: Handling Suspention Cylinder

    Do not make holes in it, weld it, or use a cutting torch. Do not bear any shock by hammering, rolling or similar activity. Ask for your Komatsu distributor when sealing gas into the cylinder or releasing gas from it. PERSONNEL Only authorized personnel can service and repair the machine.

  • Page 44: Removing Battery Terminal

    If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.

  • Page 45: Compressed Air

    SAFETY PRECAUTIONS FOR MAINTENANCE COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.

  • Page 46: Precautions With Tires

    To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations. Use only the specified tires and inflate them to the specified pressure.
  • Page 47 3 - 1...

  • Page 48: General View

    OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Dump body Turn signal light Rear wheel Head lamp Front wheel 3 - 2...

  • Page 49: General View Of Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Safety lock (10) Shift limiter switch Dump lever (11) Power mode selector switch (if equipped) Lamp switch, Turn signal lever, Dimmer switch (12) Emergency brake lever Steering wheel (13) Emergency steering switch Machine monitor (14) Message display for PMC (if equipped)
  • Page 50 OPERATION GENERAL VIEW Enlargement of machine monitor Caution/pilot lamp bulb check switch Panel dimmer switch Starting switch Hazard lamp switch Preheating switch Front brake cut-off switch Exhaust brake switch AISS LOW switch 3 - 4...

  • Page 51: Explanation Of Components

    3 seconds, and the alarm buzzer will sound for approx. one second. When this happens, the speedometer will display 88. If no monitor lamp lights up, then there is probably a failure or disconnection in that circuit, therefore contact your Komatsu distributor to have the circuit checked.
  • Page 52 02: Park the machine at a safe location and contact your Komatsu distributor. 04: Carry out an emergency stop. Stop the engine and contact your Komatsu distributor. 01: Carry out checks and maintenance according to the Operation and Maintenance Manual.
  • Page 53 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If any of the warning monitors lights up, carry out the inspection and maintenance of the appropriate item as soon as possible. If it is left without the inspection and maintenance, it will lead to the trouble or failure. If there is any abnormallity for the caution items, the monitor for the corresponding abnormal area lights up.
  • Page 54 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STEERING This (2) lights up when the emergency steering is actuated. If any abnormality should occur in the steering oil pressure circuit when the machine is traveling, the auto emergency steering is actuated and the related lamp lights up. PARKING BRAKE This (3) lights up when the parking brake is applied.
  • Page 55 OPERATION EXPLANATION OF COMPONENTS FUEL LEVEL This monitor (6) flashes when the level of the fuel in the fuel tank goes below 170 liters (44.88 US gal). If it flashes, check the fuel level and add fuel. MAINTENANCE CAUTION LAMP (If equipped) If the machine is in any of the following conditions, this lamp will light up.
  • Page 56 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEM CAUTION If any of these monitor lights up or flashes, stop the engine immediately or put the engine in low idling, then check the corresponding area and carry out the action. If the abonormaliy is found in the emergency items, the waring buzzer sounds and the monitor corresponds to the abnormal section lights up or flashes, and the central warning light flashes.
  • Page 57 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER TEMPERATURE This (2) warns the operator that the engine cooling water temperature has risen. For the machine equipped with an electronic governor (if equipped), the engine output is automatically limited. If it flashes and displays user code 05 at the same time, stop the machine and run the engine under no load at a mid-range speed until the engine water temperature gauge enters the green range.
  • Page 58 OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE This (6) warns the operator that the engine lubricating oil pressure has dropped. If it lights up and displays user code 04 at the same time, stop the machine safely. Then, stop the engine and carry out inspection. The lamp lights up if the engine lubricating oil pressure goes below the specified value when the engine is running, If the engine is not running, the lamp does not light up.
  • Page 59 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION PILOT DISPLAY PORTION When starting switch is ON, the pilot display lights up when display items are functioning. Preheating monitor High beam Exhaust brake pilot Turn signal pilot lamp Rear brake pilot (retarder) Shift indicator (with lockup display) (10) Transmission shift lever position pilot lamp...
  • Page 60 OPERATION EXPLANATION OF COMPONENTS EXHAUST BRAKE PILOT This pilot lamp (2) lights up when the exhaust brake is actuated. REAR BRAKE PILOT (Retarder) This pilot lamp (3) lights up when the foot brake is depressed or the retarder control lever is pulled, and the rear brake is applied. DIFFERENTIAL LOCK PILOT (If equipped) This pilot lamp (4) lights up when the differential lock pedal (if...
  • Page 61 OPERATION EXPLANATION OF COMPONENTS SHIFT LIMITER PILOT LAMP This pilot lamp (6) lights up when the shift limiter switch is actuated. HIGH BEAM This monitor (7) lights up when the head lamps are set to high beam. TURN SIGNAL PILOT LAMP This pilot lamp (8) flashes at the same time as the turn signal lamp flashes.
  • Page 62 OPERATION EXPLANATION OF COMPONENTS TRANSMISSION SHIFT LEVER POSITION PILOT LAMP This monitor (10) indicates the position of the transmission shift lever. AUTO SUSPENSION MODE DISPLAY LAMP This monitor (11) displays the suspension mode, when the machine is equipped with the suspension controller. An automatic suspension system is mounted which automatically switches the damping characteristics of the suspension according to the size of the load, use of the brake, operation of the steering,...
  • Page 63 OPERATION EXPLANATION OF COMPONENTS METERS Speedometer Air pressure gauge Engine tachometer Engine water temperature gauge Service meter Torque converter oil temperature gauge Odometer Retarder oil temperature gauge Fuel gauge SPEEDOMETER This meter (1) indicates the travel speed of the machine. 3 - 17...
  • Page 64 OPERATION EXPLANATION OF COMPONENTS ENGINE TACHOMETER This meter (2) indicates the speed of the engine. While operating the machine, if the red range lights up, simultaneously the warning buzzer sounds and the central warning lamp flashes, then operate the machine while lowering the engine speed and the traveling speed.
  • Page 65 OPERATION EXPLANATION OF COMPONENTS AIR PRESSURE GAUGE This gauge (6) indicates the air pressure inside the air tank. The green range should be lit up during operation. If the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, and the air pressure monitor lamp will also flash at the same time.
  • Page 66 OPERATION EXPLANATION OF COMPONENTS MECHATRONIC CAUTION LAMP PORTION If an abnormality is detected in the mechatronics-related parts of the control system, the monitor lamp and the central warning lamp light up and the alarm buzzer sounds intermittently. Stop the machine, then take appropriate corrective action according to the user code.
  • Page 67 OPERATION EXPLANATION OF COMPONENTS AUTOMATIC TRANSMISSION (Mechatronics-related) If an abnormality is detected in the mechatronics- related parts of the transmission control system, this lamp (2) flashes to warn of the abnormality. MECHATRONICS-RELATED PARTS (Excluding 1. and 2. above) If an abnormality is detected in the mechatronics-related parts of the control system other than those of the engine and transmission, this lamp (3) flashes to warn of the abnormality.

  • Page 68: Switches

    OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch (10) Power mode selector switch Lamp switch (11) Emergency steering switch Turn signal lever (12) Emergency brake lever Dimmer switch (13) Shift limiter switch Caution/pilot lamp bulb check switch (14) Parking brake valve lever Exhaust brake switch (15) Engine emergency stop switch...
  • Page 69 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position At this position, the starting switch key can be inserted or removed. When the key is turned to this position, all the electric circuits are switched off and the engine stops.
  • Page 70 OPERATION EXPLANATION OF COMPONENTS DIMMER SWITCH This (2) is used to switch the head lamps between high beam and low beam. (a) Low beam (b) High beam CAUTION/PILOT LAMP BULB CHECK SWITCH Press this switch (3) when the starting switch is at the ON position to check for any blown bulbs.
  • Page 71 OPERATION EXPLANATION OF COMPONENTS FRONT BRAKE CUT-OFF SWITCH WARNING When traveling on icy roads, on snow, or on other slippery road surfaces, set the front brake cut-off switch to the ON position and travel slowly at a safe speed. If the front brake cut-off switch is set to the OFF position, it becomes dangerously difficult to control the steering when traveling under the abovementioned conditions.
  • Page 72 OPERATION EXPLANATION OF COMPONENTS NIGHT LIGHTING DIMMER SWITCH This switch (7) is used to adjust the brightness of the monitor panel lighting and pilot lamps. Turn to the right to make the lighting brighter and turn it to the left to make the lighting dimmer. AISS LOW SWITCH AUTO and LOW speed can be freely switched to each other with AISS LOW switch (8).
  • Page 73 OPERATION EXPLANATION OF COMPONENTS POWER MODE SELECTOR SWITCH The power mode switch (10) can be switched to allow the machine to travel economically in a way suited to the operating conditions. If depressed once, it lights up; if depressed once again, the light goes off.
  • Page 74 OPERATION EXPLANATION OF COMPONENTS SHIFT LIMITER SWITCH This switch (13) is used to limit the maximum speed range when the transmission shift lever is in the D or L range. If the switch is depressed, it lights up, and the shifit limiter function get actuated; consequently the maximum speed for D range is limited to F6, and the speed for L range is limited to F1 only.
  • Page 75 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER This (16) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, so pull it out and use it to light your cigarette.

  • Page 76: Control Levers And Pedals

    OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Brake pedal Dump lever Accelerator pedal Retarder control lever Shift lever Differential lock pedal (if equipped) Safety lock BRAKE PEDAL This pedal (1) is used to apply the wheel brakes. 3 - 30...
  • Page 77 OPERATION EXPLANATION OF COMPONENTS ACCELERATOR PEDAL This pedal (2) is used to adjust the engine speed. It can control freely the engine between the low idle and the full throttle. GEAR SHIFT LEVER The gear range can be selected with this lever (3) to match the travel conditions.
  • Page 78 OPERATION EXPLANATION OF COMPONENTS Before shifting between forward and reverse, stop the machine completely and then run the engine at low idle. When starting the engine, if the gear shift lever is not at the N position, the engine will not start. When the starting switch is turned to the ON position, if the shift lever is not at the N (neutral) position, the transmission shift lever position pilot lamp and the central warning lamp will flash and the alarm buzzer will sound.
  • Page 79 OPERATION EXPLANATION OF COMPONENTS DUMP LEVER WARNING To prevent damage to the dump body through vibration from the road surface, always lower the dump body and set at FLOAT position before traveling. This lever (5) is used to operate the dump body. (a) RAISE (b) HOLD: The dump body stops and is held in position.

  • Page 80: Mechatronics Equipment Controller

    OPERATION EXPLANATION OF COMPONENTS MECHATRONICS EQUIPMENT CONTROLLER Transmission controller (3) Suspension controller Engine controller TRANSMISSION CONTROLLER A two-digit number followed by the service code is displayed in the inspection window of this controller (1) to identify the location of the abnormality. When the condition is normal, "0.0" or "0.C" is displayed. For the mothod of checking the service code when an abnormality occurs, see "TRANSMISSION CONTROLLER (PAGE 3-119)".

  • Page 81: Safety Pin

    OPERATION EXPLANATION OF COMPONENTS SAFETY PIN WARNING When raising the dump body to inspect the machine, always place the dump lever at the HOLD position, apply the lock, and then use the safety pins. This is a safety device for the dump body, and is used when carrying out inspection or maintenance with the dump body raised.

  • Page 82: Fuses

    OPERATION EXPLANATION OF COMPONENTS FUSES WARNING When replacing any fuse, always turn the power off (turn the starting switch to OFF). When replacing the fuse, always use a fuse of the same capacity and type. The fuses protect the electrical equipment and wiring from burning out.
  • Page 83 OPERATION EXPLANATION OF COMPONENTS Fuse box II Fuse Circuit name capacity Engine controller, governor cut relay Electronic display panel, caution pilot lamp, central warning lamp, buzzer, PMC (if equipped), MOM( if equipped) Suspension control solenoid, suspension controller Payload meter (if equipped), payload relay (if equipped) Payload external display lamp (if equipped) PMC (if equipped)

  • Page 84: Car Stereo

    OPERATION EXPLANATION OF COMPONENTS CAR STEREO (If equipped) EXPLANATION OF COMPONENTS Power switch/Volume Cassette door Auto-store/Preset scan button Fast forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/Radio display selector button (13) Seek tuning buttons...
  • Page 85 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions.
  • Page 86 OPERATION EXPLANATION OF COMPONENTS TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized LOUDNESS BUTTON This button (5) is used when playing at low volume.
  • Page 87 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).
  • Page 88 OPERATION EXPLANATION OF COMPONENTS METAL TAPE BUTTON (used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, "MTL"...
  • Page 89 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
  • Page 90 OPERATION EXPLANATION OF COMPONENTS MANUAL MEMORY BUTTON Select the station to be preset with manual tuning button (1) or seek tuning button (2), then keep button No.1 to button No.6 of button (3) pressed for 2 seconds while the frequency is being displayed to preset the station.
  • Page 91 OPERATION EXPLANATION OF COMPONENTS LISTENING TO CASSETTE TAPE 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set the cassette with the exposed portion of the tape on the right side and push it past the cassette door. The tape will automatically start playing.
  • Page 92 OPERATION EXPLANATION OF COMPONENTS PRECAUTIONS FOR USE Stow the antenna when traveling in places with low overhead clearance. To ensure safety during operations, keep the volume at a level where it is possible to hear other machines. If water gets inside the speaker case or radio (auto tuning), it may cause a serious problem, take care not to let water get in these items.

  • Page 93: Air Conditioner

    OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS ON CONTROL PANEL Fan switch RECIRC/FRESH selector switch...
  • Page 94 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
  • Page 95 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) steplessly from low temperature to high temperature. The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the green lamps light up, the lower the temperature is.
  • Page 96 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION Switch Air conditioner Temperature RECIRC/FRESH Mode selector Fan switch switch control switch selector switch switch Condition of use Rapid All green RECIRC FACE Cooling More than half Normal HI - LO FRESH FACE are green Dehumidifying, More than half...
  • Page 97 4-24)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-25)". To enable the air conditioner to perform to the full and to maintain a pleasant working environment, always contact your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks. 3 - 51...

  • Page 98: Car Heater

    OPERATION EXPLANATION OF COMPONENTS CAR HEATER GENERAL LOCATIONS ON CONTROL PANEL Heater switch Vent selector knob HEATER SWITCH This switch is used for turning the heater ON/OFF and for adjusting the air flow. Stopped:OFF (1) Low (2) High VENT SELECTOR KNOB This is used to select the vent.

  • Page 99: Location Of Fire Extinguisher

    OPERATION EXPLANATION OF COMPONENTS PRECAUTIONS WHEN HANDLING 1. When using the car heater, open valve (1) installed to the engine thermostat housing. 2. When the season for using the car heater ends, close valve (1). PRECAUTIONS ON USING HEATER In winter season always use antifreeze fluid with the density suitable to outside air temperature. Do not use antifreeze fluid stored over a period longer than its recommended serviceable life.

  • Page 100: Operation

    Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Always carry out the following items before starting the engine each day.
  • Page 101 11. Check cracks and damage of ROPS (if equipped) and check for loose bolts Check if any bolt is loose or damaged. If it is loos, tighten up (torque: 1720 ± 196 N·m 175 ± 20kgf·m, 1265.8 ± 144.7 lbft). If it is loose replace it with Komatsu genuine bolt. 12. Inspect tires.
  • Page 102 OPERATION OPERATION CHECK BEFORE STARTING Always perform the procedures in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
  • Page 103 OPERATION OPERATION CHECK DUST INDICATOR 1. Check that the red piston has not appeared in the transparent portion of dust indicator (1). 2. If the red piston has appeared, clean or replace the air cleaner element immediately. For details of the method of cleaning the element, see "CHECK, CLEAN OR REPLACE AIR CLEANER (PAGE 4-19)".
  • Page 104 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
  • Page 105 OPERATION OPERATION CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL 1. After starting the engine, run the engine at low idle and check the oil level with sight gauge (G2). 2. If the oil level is low, add oil through oil filler (F). NOTICE The oil level changes according to the oil temperature, so carry out the check after completing the warming-up operation.
  • Page 106 OPERATION OPERATION CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK, ADD OIL WARNING If the oil filler cap is removed without releasing the internal pressure, oil will spurt out, so turn the oil filler cap slowly to release the internal pressure, then remove it carefully.
  • Page 107 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
  • Page 108 CHECK BRAKING EFFECT Check if the braking capacity of the parking brake, foot brake, and retarder brake. If any abnormality is found, ask Komatsu distributor to repair. CHECK MACHINE MONITOR SYSTEM 1. Before starting the engine, turn the starting switch to the ON position.
  • Page 109 2. Turn emergency steering switch (1) ON, and check that the steering wheel can be operated. If the steering wheel cannot be operated, please contact your Komatsu distributor. Check auto-emergency steering 1. Turn the starting switch key to the START position and start the engine.
  • Page 110 Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of any problems found. CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
  • Page 111 OPERATION OPERATION ADJUSTMENT BEFORE OPERATION ADJUSTING OPERATOR'S SEAT WARNING Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way with the operators back against the backrest. (A) Fore-and-aft adjustment Move lever (1) to the right, set the seat to the desired position, then release the lever.
  • Page 112 OPERATION OPERATION ADJUST SEAT BELT WARNING Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
  • Page 113 OPERATION OPERATION OPERATION OPERATION To make belt longer: Set the belt holding the buckle or tongue end at right angles to the buckle or tongue, and pull. ADJUST STEERING WHEEL TILT WARNING Always stop the machine before adjusting the tilt of the steering wheel. The tilt of the steering wheel can be adjusted to the front and rear, and up and down.
  • Page 114 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING WARNING At the time of starting the engine, check that the shift lever is set at N (neutral) position and that the parking brake valve lever is at PARKING position. Before standing up from the operator's seat, place the gear shift lever at neutral, and set the parking brake valve lever to the PARKING position.
  • Page 115 OPERATION OPERATION OPERATION OPERATION 5. Check that there is no abnormality on the machine monitor or maintenance monitor when the key in starting switch (5) is turned to the ON position. 3 - 69...

  • Page 116: Starting Engine

    OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
  • Page 117 OPERATION OPERATION STARTING IN COLD WEATHER WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
  • Page 118 OPERATION OPERATION OPERATION OPERATION 4. When the engine starts, release the key in starting switch (1). The key will return automatically to the ON position. 3 - 72...

  • Page 119: Operations, Checks After Starting Engine

    BREAKING-IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).

  • Page 120: Stopping Engine

    OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is suddenly stopped without allowing it to cool down, there is danger that the life of the engine parts will be shortened, so never stop the engine suddenly except in emergency. Allow the engine to cool down gradually before stopping it. 1.

  • Page 121: Moving Machine Off (Forward, Reverse), Stopping

    OPERATION OPERATION MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING MOVING MACHINE FORWARD WARNING When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people to get near the machine. Clear the machine's travel path of any obstacle.
  • Page 122 OPERATION OPERATION OPERATION OPERATION 4. Check that retarder pilot lamp (4) has gone out, then set shift lever (5) to the desired position. NOTICE When operating the shift lever, be sure to set it in position securely. If the lever is not placed in position properly, the shift position display on the panel may go out and the transmission warning monitor lamp may light up.
  • Page 123 OPERATION OPERATION MOVING MACHINE IN REVERSE WARNING When switching between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so use extreme caution when reversing the machine. Always stop the machine completely before shifting between FORWARD and REVERSE.
  • Page 124 Immediately after making an emergency stop, the parking brake disc will be at high temperature, so wait for it to cool before carrying out repair or adjustment. Ask Komatsu distributor for repair and adjustment. 1. Pull retarder control lever (1) fully to apply the retarder.
  • Page 125 PARKING BRAKE AND EMERGENCY BRAKE HAVE BEEN ACTUATED IN EMERGENCY (PAGE 3-107)" in case that it is necessary to release the brake. 6. If emergency stop has been made, it is necessary to re-adjust the parking brake. Ask Komatsu distributor for adjustment. 3 - 79...

  • Page 126: Shifting Gear

    OPERATION OPERATION SHIFTING GEAR When shifting gear, do as follows. This machine has an automatic transmission, so set gear shift lever (1) to the desired position, and the transmission will automatically shift to a position to match the travel speed. When the dump body has risen, the speed range is locked to 2nd speed at the D position and 1st speed at the 5 - L position.

  • Page 127: Traveling Downhill

    2. If the retarder still has no effect even when the retarder lever is operated again, return the retarder lever completely to the released position, then depress the brake pedal to stop the machine, and contact your Komatsu distributor for repairs.
  • Page 128 OPERATION OPERATION OPERATION OPERATION 2. Move the gear shift lever to a position (5, 4, 3, L) that matches the maximum permissible speed for the retarder brake performance. 3. When traveling downhill, operate retarder lever (2), run the engine at a speed of at least 1,800 rpm, and travel so that the retarder brake oil temperature gauge is in the green range.
  • Page 129 OPERATION OPERATION BRAKE PERFORMANCE CURVE Method of using graph Example: Downhill distance: 1500 m (4921 ft) Travel resistance: - 11% Grade resistance: - 13% [rolling resistance: 2%] Load: 91 tons Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
  • Page 130 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1476 ft)] (Tire size: 27.00R49 Brake performance [Downhill distance: 600m (1968ft)] (Tire size: 27.00R49 3 - 84...
  • Page 131 OPERATION OPERATION Brake performance [Downhill distace: 900m (2952ft)] (Tire size: 27.00R49 Brake performance [Downhill distace: 1500m (4921ft)] (Tire size: 27.00R49 3 - 85...
  • Page 132 OPERATION OPERATION Brake performance [Downhill distace: Continuous] (Tire size: 27.00R49 3 - 86...

  • Page 133: Steering The Machine

    OPERATION OPERATION STEERING THE MACHINE WARNING If the machine is turned at high speed or on a steep slope, there is danger that it will turn over, so do not operate the steering in such conditions. CAUTION Do not continue to apply force to the steering wheel when it has been turned fully to the left or right. This will make the oil temperature in the circuit rise and will cause overheating.

  • Page 134: Dump Operations

    OPERATION OPERATION DUMP OPERATIONS WARNING When dumping a load, always carry out the dumping operation in accordance with the signals from the flagman. When dumping large rocks, operate the dump body slowly. Do not load the dump body while it is still raised. When carrying out inspection with the dump body raised, always use the safety pins, set the dump lever to the HOLD position and lock it securely.

  • Page 135: Precautions For Operation

    OPERATION OPERATION OPERATION OPERATION 4. When dump lever (3) is moved to the LOWER position, the dump body will start to move down. 5. When the dump body has moved down a certain distance, move dump lever (3) to the FLOAT position. (When the lever is released, it will return to the FLOAT position.) The dump body will then move down under its own weight.

  • Page 136: Parking Machine

    OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Park the machine on firm, horizontal ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, put blocks under the tires to prevent the machine from moving and set parking brake valve lever to the PARKING position.

  • Page 137: Checks After Completion Of Work

    OPERATION OPERATION OPERATION OPERATION 3. When in the operator's compartment, pull retarder control lever (5) fully to apply the retarder. NOTICE The retarder must not be used as a parking brake. Do not use the retarder for long-term parking, regardless of the engine speed.

  • Page 138: Locking

    OPERATION OPERATION LOCKING Always lock the following places. (1) Fuel filler cap of fuel tank (2) Cab door (left, right) REMARK The starting switch key is used for locking places (1) and (2). 3 - 92...

  • Page 139: Handling Tires

    Tires where radial cracks extend to the carcass Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use. Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. T.Km.P.H (Ton-Km-Per-Hour Rating) Tires for construction equipment are used under severe conditions that bear no comparison with the tires used on cars, buses, or ordinary trucks, so they are specially designed to withstand these conditions.
  • Page 140 The total operating hours per day includes the stopping time and rest periods. * The T.Km.P.H. in the table may differ slightly according to the tire maker, so concerning operations which require travel near the travel speed given in the table, consult your Komatsu distributor. PRECAUTIONS FOR LONG DISTANCE TRAVEL If the machine travels continuously at high speed for a long distance, there will be a marked increase in the generation of heat in the tire.

  • Page 141: Determining And Maintaining Travel Road

    OPERATION DETERMINING AND MAINTAINING TRAVEL ROAD DETERMINING AND MAINTAINING TRAVEL ROAD Determining and traveling the road in the jobsite is an extremely important factor both for reasons of safety and for reducing the cycle time.To ensure safety in operations, do as follows. DETERMINING TRAVEL ROAD As far as possible, restrict the travel road to one-way travel.

  • Page 142: Transportation

    PRECAUTIONS WHEN TRANSPORTING Always obey the traffic regulations when transporting the machine by road. WARNING This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. STEPS FOR TRANSPORTATION As a basic rule, always transport the machine on a trailer.

  • Page 143: Method Of Securing Machine

    OPERATION TRANSPORTATION METHOD OF SECURING MACHINE After loading the machine in the specified position, secure it in place as follows. 1. Set the parking brake valve lever to the PARKING position to apply the parking brake. 2. Turn the key in the starting switch to the OFF position to stop the engine.

  • Page 144: Method Of Lifting Machine

    The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For the weight of the standard specification machine, see "SPECIFICATIONS (PAGE 5-2)"...
  • Page 145 OPERATION TRANSPORTATION LIFTING PROCEDURE Lifting work can be carried out only with machines displaying a lifting mark. When carrying out the lifting operation, stop the machine on firm level ground, and do as follows. 1. Start the engine, set the dump lever to the FLOAT position, and check that the body operation caution lamp goes out.

  • Page 146: Cold Weather Operation

    When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.

  • Page 147: Precautions After Completion Of Work

    OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.

  • Page 148: After Cold Weather

    OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER When the season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-9)". 3 - 102...

  • Page 149: Long-Term Storage

    Before operating the work equipment, wipe off all the grease from hydraulic piston rods. AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.

  • Page 150: Troubleshooting

    Towing is only permitted in order to move a disabled machine to a place where it is possible to carry out inspection and maintenance. It must not be towed for long distances. Please consult your Komatsu distributor for information about towing a disabled machine. 3 - 104...
  • Page 151 OPERATION TROUBLESHOOTING This machine must not be towed except in emergencies. When towing the machine, take the following precautions. When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance of a few meters to a place where repairs can be carried out.
  • Page 152 OPERATION TROUBLESHOOTING WHEN ENGINE RUNS If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of mud or to move it for a short distance to the edge of the road. Check the effect of the brakes, and if the brakes do not work properly, take the action given in "When engine does not run".
  • Page 153 METHOD OF RELEASING PARKING BRAKE Please ask your Komatsu distributor to release the parking brake. WARNING If there is a failure in the air circuit, the brakes will not work. It is dangerous to drive the machine in this condition, so always tow the machine at low speed.
  • Page 154 OPERATION TROUBLESHOOTING METHOD OF RELEASING EMERGENCY BRAKE Please ask your Komatsu distributor to release the emergency brake. WARNING When the emergency brake has been actuated, never drive the machine. This will cause burning out of the brake disc or lining, or failure of the torque converter or transmission.

  • Page 155: If Battery Is Discharged

    OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
  • Page 156 OPERATION TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow the instructions in "IF BATTERY IS DISCHARGED (PAGE 3-109)" and the instruction manual accompanying the charger, and do as follows.
  • Page 157 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses and rubber gloves.
  • Page 158 OPERATION TROUBLESHOOTING STARTING THE ENGINE CAUTION Make sure that the parking brake valve lever is at PARKING position and the shift lever is at N (neutral) position for both normal machine and the problem machine. 1. Make sure the clips are firmly connected to the battery terminals. 2.

  • Page 159: Other Trouble

    TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even...
  • Page 160 OPERATION TROUBLESHOOTING CHASSIS ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Torque converter oil temperature Leakage of oil or entry of air due...
  • Page 161 After moving the machine to a safe place by operating the accelerator pedal, check the service code, then contact your Komatsu distributor for repairs. There are two methods when operating the accelerator pedal: either release the pedal and set to the OFF (low idling) position, or depress the pedal fully (1400 rpm).
  • Page 162 OPERATION TROUBLESHOOTING ENGINE ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor lights Insufficient oil in oil pan Add oil to specified level.
  • Page 163 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Excessive oil consumption Oil leakage ( Check, repair) Excessive oil in oil pan Add oil to specified level. See CHECK BEFORE STARTING. Worn piston, ring, cylinder liner ( Replace) Exhaust gas is white or bluish Improper fuel Replace with specified fuel Defective turbocharger seal...
  • Page 164 Immediately after checking the service code, stop the engine. 4. After checking the service code, contact your Komatsu distributor for repairs. REMARK Upper 2 digits are displayed on speedometer (2); and lower 2 digits are displayed on user code display (3).
  • Page 165 OPERATION TROUBLESHOOTING TRANSMISSION CONTROLLER If any abnormality occurs in the transmission, reduce the travel speed by using the brake, stop the machine on a safe place. Gear shifting may not work for some failure modes. If necessary, move the shift lever to the N position, remove emergency escape connector (1) (connector No.
  • Page 166 4 - 1...

  • Page 167: Maintenance

    KOMATSU GENUINE REPLACEMENT PARTS: Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
  • Page 168 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging.

  • Page 169: Outline Of Service

    Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. 4 - 4...
  • Page 170 Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
  • Page 171 Make sure that the oil is well mixed before sampling. Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. 4 - 6...

  • Page 172: Outline Of Electric System

    Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.

  • Page 173: Wear Parts

    The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.

  • Page 174: Recommended Fuel, Coolant, And Lubricant

    RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.

  • Page 175: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature

    MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE SAE: Society of Automotive Engineers ASTM: American Society of Testing and Material 4 - 10...

  • Page 176: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil

    Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS ( High-Temperature High-Shear Viscosity 150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. If these oils are not available, follow the instruction "RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL (PAGE 4-11)"...

  • Page 177: Standard Tightening Torques For Bolts And Nuts

    The tightening torque is determined by the width across the flats (b) of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

  • Page 178: Periodic Replacement Of Safety Critical Parts

    These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.

  • Page 179: Safety Critical Parts

    MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety parts for periodic replacement Replacement interval Remarks 1 Fuel hose (Fuel tank - hand priming pump) 2 Fuel hose (Hand priming pump - injection pump) 3 Fuel hose (Injection pump - adapter) 4 Fuel hose (Adapter - fuel filter) 5 Fuel hose (Fuel filter - adapter) 6 Fuel hose (Adapter - emergency stop valve)

  • Page 180: Maintenance Schedule Chart

    MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Change oil in engine oil pan, replace engine oil filter cartridge 4- 53 Replace fuel filter cartridge 4- 55 Replace transmission oil filter element 4- 56 Change oil in transmission case 4- 59...
  • Page 181 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 250 HOURS SERVICE Check oil level in differential case, add oil 4- 38 Check oil level in final drive case, add oil 4- 38 Lubricating 4- 39 Check level of battery electrolyte 4- 42 Check alternator belt, adjust 4- 45 Check tension of air conditioner compressor belt, adjust 4- 46...
  • Page 182 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 4000 HOURS SERVICE Check water pump 4- 69 Check air compressor 4- 69 Check fan pulley and tension pulley 4- 69 Check vibration damper 4- 69 Check injection pump rack rubber boot, replace 4- 69 Replace injection pump screen filter 4- 69 Clean injection pump oil inlet strainer...

  • Page 183: Service Procedure

    MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance only after the first 250 hours. Change oil in engine oil pan, replace engine oil filter cartridge Replace fuel filter cartridge Replace transmission oil filter element Change oil in transmission case Replace steering, hoist oil tank and rear brake cooling oil tank filter element...

  • Page 184: When Required

    MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN OR REPLACE AIR CLEANER WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
  • Page 185 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds, gasket or seal are damaged.

  • Page 186: Clean Inside Of Cooling System

    Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
  • Page 187 MAINTENANCE SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100).
  • Page 188 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Prepare the container to catch the coolant mixed water. Open drain valve (3) at the bottom of the radiator and drain the coolant. Drain the air compressor unit for the brake by opening the drain plugs (4 places).

  • Page 189: Check Level Of Window Washer Fluid, Add Fluid

    MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID Carry out this check if there is air in the window washer fluid. Check the level of the fluid in window washer tank (1), and if it is low, fill with automobile window washer fluid. Be careful not to let dirt or dust get in when adding fluid.

  • Page 190: Check Refrigerant (Gas) Level

    Contact your Komatsu distributor for details of the repair procedure. CHECK ELECTRIC INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater checked for dirt or disconnections.

  • Page 191: Check Length Of Suspension Cylinder, Check Oil Level

    474 - 494 mm 474 - 494 mm (18.7 - 19.5 in) (18.7 - 19.5 in) Flange thickness 49 mm (1.9 in) 65 mm (2.6 in) After checking, contact your Komatsu distributor for repairs if any problem is found. 4 - 26...
  • Page 192 230 - 250 mm 210 - 230 mm (9.1 - 9.9 in) (8.3 - 9.1 in) Flange thickness 50 mm (2.0 in) 70 mm (2.8 in) After checking, contact your Komatsu distributor for repairs if any problem is found. 4 - 27...

  • Page 193: Bleed Air From Rear Brake

    MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM REAR BRAKE WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air.

  • Page 194: Adjust Parking Brake

    Measure the thickness of the pad, and if it is less than 1.5 mm (0.06 in), contact your Komatsu distributor to have it replaced. When making the first adjustment after replacing the pad, turn bolt (1) turn (6 clicks) in the counterclockwise direction.

  • Page 195: Adjust Body Positioner

    MAINTENANCE SERVICE PROCEDURE ADJUST BODY POSITIONER WARNING If for any reason the maintenance is performed while the engine is running, strictly follow the next rules. One should sit on the operator's seat, preparing to stop the engine at any moment, and contact with the other. Set the dump lever at HOLD position to prevent the dump body from moving.
  • Page 196 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Loosen locknut (3), put plate (4) into contact with bracket (2), then tighten locknut (3). Reference dimension B: 147 mm (5.8 in) 5. After adjusting, start the engine, operate the dump lever, and check that the lever is automatically returned to the HOLD position when the dump body rise to a point 50 mm (2.0 in) before the end of the hoist cylinder stroke.

  • Page 197: Replace Fan Belt, Adjust Auto Tensioner

    MAINTENANCE SERVICE PROCEDURE REPLACE FAN BELT, ADJUST AUTO TENSIONER Replace the belt if the V-belt contacts the bottom of the pulley groove, or if the fan belt is lower than the outside edge of the pulley, or if there are any cracks, peeling, or other damage to the V-belt. REPLACEMENT 1.

  • Page 198: Check Play Of Output Coupling Of Output Shaft

    If the result of the measurement shows that it is greater than the standard value, please contact your Komatsu distributor for disassembly and inspection. 4 - 33...

  • Page 199: Selection And Inspection Of Tires

    Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the following table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
  • Page 200 MAINTENANCE SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING When inflating a tire, check that any person will not enter the working area and use an air chuck which has a clip and which can be fixed to the air valve.

  • Page 201: Check Before Starting

    MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For the following items, see "CHECK BEFORE STARTING (PAGE 3-56)". Check coolant level, add coolant Check oil level in front brake oil tank, add oil Check dust indicator Drain water from air tank Check oil level in engine oil pan, add oil Check oil level in transmission case, add oil Check oil level in steering and hoist oil tank, add oil Check oil level in rear brake cooling oil tank, add oil...

  • Page 202: Every 100 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 100 HOURS SERVICE CHECK ALCOHOL LEVEL IN ALCOHOL INJECTOR, ADD ALCOHOL (Machines equipped with alcohol injector) During the cold season, check the ethyl alcohol level every 100 hours on the service meter. When removing filler cap (1) of the alcohol injector to carry out the inspection, loosen it slowly to release the remaining pressure before removing it.

  • Page 203: Every 250 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 100 hours should be carried out at the same time. CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
  • Page 204 MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Stop the engine. 2. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 3. After greasing, wipe off any old grease that was pushed out. Carry out the greasing operation every day when operating in places where the grease flows out easily, such as when traveling through mud or water.
  • Page 205 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (5) Front suspension (left and right: 1 place each) (6) Steering cylinder pin (4 places) (7) Steering link pin (5 places) 4 - 40...
  • Page 206 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (8) Steering linkage (left and right: 3 places each) (9) Drive shaft (5 places) 4 - 41...

  • Page 207: Check Level Of Battery Electrolyte

    MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Perform this check before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
  • Page 208 U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows.
  • Page 209 If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

  • Page 210: Check Alternator Belt, Adjust

    V-belt does not touch the bottom of the V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
  • Page 211 MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING The belt should normally deflect by 10 mm (0.4 in) when pressed with the thumb (with a force of approx. 58.8 N (6 kgf)) at a point midway between the air compressor pulley and drive pulley. ADJUSTING 1.

  • Page 212: Clean Breathers

    MAINTENANCE SERVICE PROCEDURE CLEAN BREATHERS Remove the mud and dirt from around the breathers, then remove the breathers and wash out the dirt with clean diesel oil or flushing oil. Transmission case breather (2 places) Transmission valve, bracket section of air conditioner installment Hydraulic tank 1.

  • Page 213: Check Drive Shaft

    2. Check all parts of the frame for damage. In particular, check the colored portions in the diagram and if any cracks or damage are found, repair the damage. Please contact your Komatsu distributor for details of the repair procedure. 4 - 48...

  • Page 214: Check Braking Capacity Of Foot Brake

    1300 rpm. If the machine does not move, it is normal. 3. Lower the engine speed, set gear shift lever at N position. If any problem is found, ask your Komatsu distributor for repair. 4 - 49...

  • Page 215: Check Braking Capacity Of Parking Brake

    If the machine does not move, it is normal. 3. Lower the engine speed, set gear shift lever at N position. If any problem is found, ask your Komatsu distributor for repair. CHECK WEAR OF PARKING BRAKE PADS WARNING Never put any oil or grease on the surface of the pad or disc.

  • Page 216: Check, Clean Automatic Suspension

    When the dump lever is at any position other than FLOAT: hard. If any problem is found, please contact your Komatsu distributor for inspection and adjustment. If operations are carried out on muddy or wet ground, mud will stick to the link, and the movement may become slow, so check and clean.

  • Page 217: Inspection Of Engine Emergency Stop

    2. Turn the engine emergency stop switch to the STOP position (Position to stop the engine), and confirm that the engine stops. The engine will stop 10 to 20 sec later. If it fails to stop, ask your Komatsu distributor for inspection and adjustment.

  • Page 218: Every 500 Hours Service

    When draining the oil, fit a standard hose to the drain valve to prevent the oil from spraying out. 3. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 4. Tighten drain valve (2) and drain plug (1).
  • Page 219 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 8. Pour in the specified amount of engine oil from oil filler (F). 9. Run the engine for a short time at idling, then check if the oil is at the specified level. For details, see CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (PAGE 3-58).

  • Page 220: Replace Fuel Filter Cartridge

    MAINTENANCE SERVICE PROCEDURE REPLACE FUEL FILTER CARTRIDGE WARNING Each part is at high temperature after the engine has been operated, so never change the filter immediately after finishing operations. Wait for each part to cool down before changing it. Do not bring fire or sparks near the fuel. Prepare a filter wrench 1.
  • Page 221 MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.

  • Page 222: Check Wear Of Front Disc Brake Pad

    CHECK FAN BELT FOR WEAR AND REPLACE Since inspection and replacement of the fan belt requires special tools, contact your Komatsu distributor. The machine is equipped with an auto-tensioner, so there is no need to carry out any adjustment until the belt is replaced.

  • Page 223: Every 1000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Carry out the EVERY 100 HOURS MAINTENANCE, EVERY 250 HOURS MAINTENANCE, and EVERY 500 HOURS MAINTENANCE at the same time. REPLACE CORROSION RESISTOR CARTRIDGE WARNING All the engine parts are at high temperature after the engine has been operated, so never replace the cartridge immediately after finishing operations.

  • Page 224: Change Oil In Transmission Case, Clean Transmission Case Strainer

    MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

  • Page 225: Replace Steering, Hoist Oil Tank And Rear Brake Cooling Oil Tank Filter Element

    MAINTENANCE SERVICE PROCEDURE REPLACE STEERING, HOIST OIL TANK AND REAR BRAKE COOLING OIL TANK FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
  • Page 226 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (3) Transmission mount (1 place) (4) Automatic suspension link (left and right: 1 place each) (5) Parking brake linkage (3 places/one caliper) 4 - 61...
  • Page 227 8. Remove the disc wear measurement gauge and install plug (1). 9. Bleed all the air from the circuit. For details, see "BLEED AIR FROM REAR BRAKE (PAGE 4-28)". CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 4 - 62...

  • Page 228: Every 2000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time. CHANGE OIL IN STEERING, HOIST OIL TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

  • Page 229: Change Oil In Rear Brake Cooling Oil Tank

    MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN REAR BRAKE COOLING OIL TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

  • Page 230: Change Oil In Final Drive Case

    MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out.

  • Page 231: Clean Differential Case Breather

    Contact your Komatsu distributor to have the valve disassembled and cleaned. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.

  • Page 232: Lubricate Dump Control Linkage (5 Points)

    MAINTENANCE SERVICE PROCEDURE LUBRICATE DUMP CONTROL LINKAGE (5 places) 1. Stop the engine. 2. Use the grease pump to pump in grease through the grease fitting marked by the arrow. 3. After greasing, wipe off any old grease that was pushed out. Apply grease to the parts of (A) mark (2 places) once every year regardless of the operation time of dump control linkage.

  • Page 233: Clean Air Dryer Filter And Deflector (If Equipped)

    MAINTENANCE SERVICE PROCEDURE CLEAN AIR DRYER FILTER AND DEFLECTOR (If equipped) Always clean once every 6 months regardless of the operating hours. 1. Remove bolt (3), then remove cap (4). 2. Disassemble deflector (1) and filter (2) and wash in diesel oil. REPLACE PLUG WITH STRAINER FROM MAKE-UP TANK OF REAR BRAKE CHAMBER Replace this part every 2000 hours or every year, whichever comes sooner.

  • Page 234: Every 4000 Hours Service

    Ask your Komatsu distributor to carry out this work. CHECK FAN PULLEY AND TENSION PULLEY Check for play of the pulley and leakage of grease. If any problem is found, please contact your Komatsu distributor. CHECK VIBRATION DAMPER There is the possibility of drop in the level of the damper fluid and runout of the concave surface. So, please contact your Komatsu distributor to inspect or replace.
  • Page 235 Tightening torque of strainer (1): 11.3 ± 1.5 N·m (1.15 ± 0.15 kgf·m, 8.3 ± 1.1 lbft) ADJUST FRONT WHEEL BEARING Please ask your Komatsu distributor to carry out adjustment every 4000 hours or every 100,000 km of travel. ADJUST REAR WHEEL BEARING Please ask your Komatsu distributor to carry out adjustment every 4000 hours or every 100,000 km of travel.

  • Page 236: Every 15000 Hours Service

    Maintenance for every 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. CHECK, REPLACE STEERING A ARM MOUNTING BOLT Check and replace the A arm mounting bolts, lock plate, and holder. Please consult your Komatsu distributor when checking and replacing. (1) A arm (2) Front suspension...
  • Page 237 5 - 1...

  • Page 238: Specifications

    91000 (200655) (cu · yd) Struck 40 (51.8) Dump body capacity (cu · yd) Heaped (2 : 1) 60 (77.7) Komatsu SA12V140 diesel Engine type engine Flywheel horsepower of engine kW(HP)/rpm 753.15 (1011) / 2000rpm A Overall length mm (ft in) 10490 (34'5")
  • Page 239 SPECIFICATIONS SPECIFICATIONS 5 - 3...
  • Page 240 6 - 1...

  • Page 241: Attachments, Options

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HANDLING PAYLOAD METER There are two types of payload meter: a card type and a printer type. The explanation for the payload meter given here is for the printer type. For details of handling the card type payload meter, see the separate operation manual for payload meter II.

  • Page 242: External Display Lamps

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER EXTERNAL DISPLAY LAMPS When the actual load is displayed, the lamps light up as follows. Lamp 1 (green): Displays load between 56 tons and 67 tons Lamp 2 (green): Displays load between 67 tons and 85 tons Lamp 3 (green): Displays load between 85 tons and 91 tons Lamp 4 (yellow): Displays load between 91 tons and 96 tons Lamp 5 (red): Displays load over 96 tons...
  • Page 243 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER PREDICTION DISPLAY In the case where the weight of the load changes as each bucket is emptied into the dump body, the average weight of the load up to that point is calculated to predict what the weight of the load will be if one more bucket is loaded.

  • Page 244: Operating Payload Meter

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER OPERATING PAYLOAD METER Resetting power (the power can be reset by turning the power ON.) The display for the first 3 seconds is 88:88, and after that, the time is displayed for 7 seconds. After 10 seconds, the normal display is given. The printer feeds one line of paper and stops at the home position.
  • Page 245 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER METHOD OF CARRYING OUT CALIBRATION 1. Set the machine with the dump body empty. 2. Place the shift lever at the N position, and press calibration switch (1) for at least 2 seconds. (The letters CAL flash) 3.
  • Page 246 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER DELETING DATA FROM MEMORY 1. Print out the necessary data before clearing the memory. 2. Press memory data clear switch (1) for at least 2 seconds. (The letters CLEA will flash) 3. Press memory data clear switch (1) again for at least 2 seconds to complete the data clearing operation.
  • Page 247 Press the FEED switch to feed out the remaining paper. Never try to pull the paper out forcibly. Always use Komatsu genuine printer paper (7818-27-2910). 1. Open the roll of printer paper, fold the paper at a point approx. 3 cm (1.2 in) from the end of the paper, then cut the paper straight along the fold.
  • Page 248 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER METHOD OF CUTTING PRINTER PAPER 1. Press the FEED switch to feed the paper out to the necessary position. 2. Put the paper in contact with the cutter on the lid, then pull up to cut the paper from one side to the other. Do not pull the paper out and cut it without using the paper cutter.
  • Page 249 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HANDLING PAYLOAD METER 4. Remove the connectors, remove the screws (top: M4 x 8, rear: M4 x 3) of top cover (1) of the payload meter, then remove top cover (1). 5. Remove the nut (M4) and the band holding the battery. Do not wear gloves when carrying out this operation.
  • Page 250 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER OPERATION AFTER REPLACING CONTROLLER After replacing the controller, always carry out calibration, and operate the dump lever FLOAT → LOWER → FLOAT with the dump body empty. IF ERROR MESSAGE "PAPE" FLASHES (PAPER JAM) NOTICE Never touch the printer head (white).
  • Page 251 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER HANDLING PAYLOAD METER 4. Use tweezers to remove the paper caught between printer head (2) and guide (3). Do not wear gloves when carrying out this operation. When using tweezers to remove the jammed paper, press the guide with your finger to make a clearance between the printer head and guide to make it easier to remove the paper.

  • Page 252: Tachograph (Tco 15-6)

    ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) TACHOGRAPH (TCO 15-6) EXPLANATION OF COMPONENTS Instrument lock (12) Travel distance recording stylus Clock dial (13) Adjustment screw for speed warning lamp Clock operation confirmation aperture (14) Speed confirmation aperture for speed warning Speed scale lamp indication Speed indicator (15)
  • Page 253 ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) SPEED INDICATOR This (5) indicates the machine travel speed. SPEED WARNING LAMP When the machine exceeds the maximum set speed, the lamp (6) lights up to warn the operator. Models with the speed warning lamp do not have the speed indication confirmation lamp. SPEED INDICATION CONFIRMATION LAMP This lamp (7) is interconnected with the speedometer and is used to confirm the speed indication.

  • Page 254: Method Of Using Key

    ATTACHMENTS, OPTIONS TACHOGRAPH (TCO 15-6) NAME PLATE This (20) indicates the type and model. VOLTAGE INDICATION LABEL This label (21) indicates the voltage. METHOD OF USING KEY There are three types of key. Key (1) with no mark is used for opening and locking the instrument.
  • Page 255 Stop the engine completely before inserting the new charts. Use Komatsu genuine charts (P/N: YZ762929-980) for 90 km/h (55.9 MPH) 7 days. 7. Close the cover. Lift up the cover to close it, then turn the instrument open/lock key 90° clockwise.

  • Page 256: Revo Tachograph (Tco 15-7)

    ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) REVO TACHOGRAPH (TCO 15-7) EXPLANATION OF COMPONENTS Instrument lock (14) Speed confirmation aperture for speed warning Clock dial lamp indication Speed scale (15) Clock setting knob Speed indicator (16) Chart support Speed warning lamp (17) Pressing ring Speed indication confirmation lamp...
  • Page 257 ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) SPEED INDICATOR This (4) indicates the machine travel speed. SPEED WARNING LAMP When the machine exceeds the maximum set speed, the lamp (5) lights up to warn the operator. Models with the speed warning lamp do not have the speed indication confirmation lamp. SPEED INDICATION CONFIRMATION LAMP This lamp (6) is interconnected with the speedometer and is used to confirm the speed indication.

  • Page 258: Method Of Use

    ATTACHMENTS, OPTIONS REVO TACHOGRAPH (TCO 15-7) INSTRUMENT LIGHTING LAMP This lamp (19) is used for light up the instrument. NAME PLATE This (20) indicates the type and model. VOLTAGE INDICATION LABEL This label (21) indicates the voltage. RPM RECORDING STYLUS This (22) records the momentary engine speed on the chart.
  • Page 259 Stop the engine completely before inserting the new charts. Use Komatsu genuine charts (P/N: YZ762929-730) for 90 km/h (55.9 MPH) 7 days. 6. Close the cover. Lift up the cover to close it, then turn the instrument open/lock key 90° clockwise. When operating the machine, remove the instrument open/lock key.

  • Page 260: Using Differential Lock

    ATTACHMENTS, OPTIONS USING DIFFERENTIAL LOCK USING DIFFERENTIAL LOCK DIFFERENTIAL LOCK PEDAL The differential lock is used on snow-covered or muddy areas where the tires are likely to slip. The left and right wheels on the rear axle are locked together to prevent slipping and to provide a powerful drive force.

  • Page 261: Precautions And Method Of Use

    ATTACHMENTS, OPTIONS USING DIFFERENTIAL LOCK DIFFERENTIAL LOCK PEDAL This pedal (1) actuates the differential lock control. When the pedal is depressed, the differential lock is actuated; when the pedal is released, the differential lock is cancelled. REMARK When traveling on soft ground where the wheel on one side slips, or when traveling on road surfaces where the tires are likely to slip, depress the differential lock pedal.

  • Page 262: Operation Of Abs And Abs/Asr

    ATTACHMENTS, OPTIONS OPERATION OF ABS AND ABS/ASR OPERATION OF ABS AND ABS/ASR [ABS (ANTI-SKID BRAKE SYSTEM), ASR (AUTOMATIC SPIN REGULATOR)] ABS: When the machine is braked suddenly or braked on a slippery snow-covered road, etc., this system works to prevent the tires from locking and skidding. Accordingly, a stable machine behavior and good steering performance is secured.
  • Page 263 ATTACHMENTS, OPTIONS OPERATION OF ABS AND ABS/ASR ABS/ASR MAIN SWITCH This switch (3) is used to turn the ABS/ASR system on/off. TROUBLESHOOTING SWITCH This switch (4) is used for troubleshooting. 6 - 24...

  • Page 264: Operation Method

    ATTACHMENTS, OPTIONS OPERATION OF ABS AND ABS/ASR OPERATION METHOD ABS OPERATION WARNING Always stop the machine before turning on the ABS/ASR main switch (3). If it is turned on while the machine is running, the ABS/ASR may not function normally. 1.

  • Page 265: Precautions For Use

    If the ABS/ASR system malfunctions while being used, the warning lamp (Red) will light up. In this case, stop the machine at a safe place immediately, then ask your Komatsu distributor to carry out repair. The positions of each switch and the statuses of the corresponding warning lamps are as follows.

  • Page 266: Arsc (Automatic Retarder Speed Control)

    ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) ARSC (AUTOMATIC RETARDER SPEED CONTROL) When traveling downhill, if the switch is pressed at the speed that is to be maintained, the retarder is automatically actuated to prevent the travel speed from exceeding the set speed, so this makes retarder operations easy. WARNING The ARSC system is actuated when the system switch is ON.

  • Page 267: Explanation Of Components

    ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) EXPLANATION OF COMPONENTS The position of system switch (1) may differ according to the combination of optional equipment. System switch Retarder control lever ARSC set lever Accelerator pedal Set speed display Brake pedal ARSC caution lamp Ready lamp Central warning lamp...
  • Page 268 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) SET SPEED DISPLAY This (3) displays the speed (km/h) that has been set. The display goes out when the system switch is OFF. It displays 0 when the set value is canceled. When the starting switch is ON or the system switch is ON, the display shows -- and then shows 0. ARSC CAUTION LAMP This lamp (4) flashes if there is any abnormality in the ARSC system when the system switch is ON.

  • Page 269: Method Of Operation

    ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF OPERATION ACTUATION OF ARSC SYSTEM The ARSC system is actuated when the system switch is ON. If the set switch on the ARSC set lever is pressed, the travel speed at that moment is set as the downhill travel speed.
  • Page 270 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF DECREASING SET TRAVEL SPEED If it is desired to decrease the set speed, operate the retarder control lever to reduce speed, and when the desired set travel speed is reached, press the set switch on the ARSC set lever. The set travel speed will be changed to the new speed.

  • Page 271: Troubleshooting

    ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) TROUBLESHOOTING WHEN A PROBLEM OCCURS IN THE SYSTEM This system is equipped with a self-diagnostic function. If any problem occurs, a failure code is displayed by the controller LED under the assistant's seat. Failure Remedy Detail...
  • Page 272 In the case of patterns 1 and 2 above, turn the system switch OFF quickly, stop use of the ARSC and contact your Komatsu distributor for repairs. The set travel speed display is also equipped with a self- diagnostic function, and a failure code is displayed on the...
  • Page 273 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF DISPLAYING MODEL SELECTION, TIRE LARGE DIAMETER/SMALL DIAMETER, FAILURE CODE When the starting switch is turned ON, the codes below are automatically displayed in the following order on the controller LED. 1. LEDs all light up. 2.

  • Page 274: Pmc (Powertrain Management Controller) And Mom (Message For Operation And Maintenance)

    PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE) PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE) CHECK BEFORE STARTING 1. Turn ON the starting switch. If the maintenance caution lamp continues lighting up after all monitors and the central warning lamp light up for approx.

  • Page 275: Message For Operation And Maintenance (Mom)

    PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE) MESSAGE FOR OPERATION AND MAINTENANCE (MOM) (1) MOM panel MOM is a message display for operator and service person, and has some touch switches in its surface. MOM always informs operator of various and useful data as follows.
  • Page 276 PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE) THE PICTURE OF INITIAL MESSAGE (i1) When starting switch is turned on, the initial message (i1) is displayed for three seconds after a system message (Japanese). The picture number (i1), title, and program version number are indicated in this picture.
  • Page 277 As to details of the operation of PLM II, see another payload meter operation manual. When you want to change units of these data or adjust clock, contact your Komatsu distributor. If you touch "LIGHT OFF" area in (i4), then the back light of MOM is turned off and (i4) is changed to be dark (i7).
  • Page 278 PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE) THE PICTURE OF WARNING MESSAGE (i6) When any controller detects fault, its occurrence is informed operator of as follows. MOM indicates the fault code, user code, and their descriptions in the picture of warning message (i6).
  • Page 279 PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE) THE BACK LIGHT OF PICTURE (i7) The back light of MOM is turned off and nothing is indicated in (i7), therefore please use this picture when MOM is too glaring while operating at night.

  • Page 280: Asr-Ii (Automatic Spin Regulator Ii)

    ATTACHMENTS, OPTIONS ASR-II (AUTOMATIC SPIN REGULATOR II) ASR-II (AUTOMATIC SPIN REGULATOR II) ASR is a function to prevent slipping of the drive wheels caused by excessive torque. Accordingly, the machine can start and travel normally even on a bad or frozen road surface. EXPLANATION OF COMPONENTS System switch Retarder control lever...

  • Page 281: Actuation Of Asr-Ii System

    ATTACHMENTS, OPTIONS ASR-II (AUTOMATIC SPIN REGULATOR II) RETARDER CONTROL LEVER When ASR is operated, if the retarder gets started with this lever (5), ASR system stopps its operation. ACCELERATOR PEDAL ASR system operates only when the pedal (6) is depressed with the travel speed range of 0 to 30km/h (0 to 18.6 MPH).

  • Page 282: Troubleshooting

    ATTACHMENTS, OPTIONS ASR-II (AUTOMATIC SPIN REGULATOR II) TROUBLESHOOTING WHEN A PROBLEM OCCURS IN THE SYSTEM This system is equipped with a self-diagnostic function. If any problem occurs, a failure code is displayed by the controller LED behind the assistant's seat. Failure Remedy Details...
  • Page 283 When the system switch is turned OFF, the ASR caution lamp will go out. In the case of patterns 1 and 2 above, turn the system switch OFF quickly, stop use of the ASR and contact your Komatsu distributor for repairs. WHEN SYSTEM IS NORMAL The code (0.0) is displayed by the controller LED behind the assistant's seat.

  • Page 284: Handling Auto-Greasing System

    ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM This system uses a timer control to automatically carry out greasing for all parts of the machine. As a result, the greasing operation can be carried out easily. OUTLINE OF AUTO-GREASING SYSTEM The dashed line shows the air line and the solid line shows the grease line.

  • Page 285: Setting Grease Can

    ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM SETTING GREASE CAN NOTICE Check that there is no dent in the can. If there is a dent, the follower plate will not go down to the bottom and it will be impossible to carry out greasing. This brings the danger of damage caused by insufficient greasing of the machine.

  • Page 286: Initial Setting Of Auto-Greasing System

    ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM INITIAL SETTING OF AUTO-GREASING SYSTEM NOTICE Use a suitable follower plate. If the follower plate is not suitable, the grease pump will be unable to feed the grease even when there is grease remaining in the grease can.

  • Page 287: Precautions When Handling Auto-Greasing System

    ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM BLEEDING AIR FROM GREASE CIRCUIT WARNING When bleeding the air, the operation must be carried out by two workers who cannot see each other: one in the operator's seat and one under the machine. When carrying out the operation, maintain contact with each other and check that you understand the content of your partner's work.
  • Page 288 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM 6. Remove blind plug (5) from the tip of injector manifold (4) at the rear left of the front axle of the machine. 7. Turn the starting switch ON. 8. Turn manual lube switch (3) ON. 9.
  • Page 289 2. Check that the indicator of each injector moves up and down one stroke when greasing. If the indicator does not move one stroke, greasing is not being carried out properly. Bleed the air. If the indicator still does not move, please contact your Komatsu distributor. 6 - 50...
  • Page 290 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM ADJUSTING GREASE DISCHARGE AMOUNT It is possible to adjust the injector within a range of 0.128 cc to 1.28 cc for one cycle. Set to the injector to the minimum discharge amount. When changing the discharge amount, adjust as follows. 1.

  • Page 291: Position Of Each Injector

    ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM POSITION OF EACH INJECTOR The relationship between each injector and the greasing point is as follows. Front right Right knuckle arm (right) Right knuckle arm (rear) Right steering cylinder (right) Right front suspension Right tie rod (right) Right knuckle arm (front) 6 - 52...
  • Page 292 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Front left Left knuckle arm (left) (13) Left steering cylinder (right) Left steering cylinder (left) (14) Center lever Left tie rod (left) (15) Left tie rod (right) (10) Left knuckle arm (rear) (16) Right tie rod (left) (11) Left front suspension (17)
  • Page 293 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Rear right (18) Right hoist cylinder (bottom) (23) Bottom right radius rod (rear) (19) Right hoist cylinder (top) (24) Right rear suspension (bottom) (20) Bottom right radius rod (front) (25) Right rear suspension (top) (21) Top right radius rod (rear) (26) Right body hinge pin...
  • Page 294 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Rear left (28) Left hoist cylinder (bottom) (32) Top left radius rod (front) (29) Left hoist cylinder (top) (33) Bottom left radius rod (rear) (30) Bottom left radius rod (front) (34) Left rear suspension (bottom) (31) Top left radius rod (rear) (35)

  • Page 295: Greasing Points For Each Injector

    ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM GREASING POINTS FOR EACH INJECTOR Greasing points for front right injectors Right knuckle arm (right) Right knuckle arm (rear) Right steering cylinder (right) Right front suspension Right tie rod (right) Right knuckle arm (front) 6 - 56...
  • Page 296 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Greasing points for front left injectors Left knuckle arm (left) (13) Left steering cylinder (right) Left steering cylinder (left) (14) Center lever Left tie rod (left) (15) Left tie rod (right) (10) Left knuckle arm (rear) (16) Right tie rod (left) (11)
  • Page 297 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Greasing points for rear right injectors (18) Right hoist cylinder (bottom) (23) Bottom right radius rod (rear) (19) Right hoist cylinder (top) (24) Right rear suspension (bottom) (20) Bottom right radius rod (front) (25) Right rear suspension (top) (21) Top right radius rod (rear) (26)
  • Page 298 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Greasing point for rear left injectors (27) Left body hinge pin (32) Top left radius rod (front) (28) Left hoist cylinder (bottom) (33) Bottom left radius rod (rear) (29) Left hoist cylinder (top) (34) Left rear suspension (bottom) (30) Bottom left radius rod (front) (35)
  • Page 299 7 - 1...

  • Page 300: High Altitude Specifications

    HIGH ALTITUDE SPECIFICATIONS The hydraulic tank on the high altitude specification machine is pressurized to prevent cavitation of the hydraulic pump. This section gives information about parts that are different from the standard specification machine. Any part not given here is the same as the standard specification machine, so see the manual for the standard specification machine for details.

  • Page 301: Service Procedure

    HIGH ALTITUDE SPECIFICATIONS SERVICE PROCEDURE SERVICE PROCEDURE WARNING Always release the pressure inside the tank before removing the oil filler. If the pressure is not released, there is danger that oil will spurt out. Close the pressurizing valve before removing the oil filler. When carrying out any of the following operations, always stop the engine and release the pressure inside the tank as follows.

  • Page 302: Every 2000 Hours Service

    EVERY 2000 HOURS SERVICE REPLACE HYDRAULIC TANK PRESSURIZING COMPONENT Ask your Komatsu distributor to carry out replacement every 2000 hours or every year, whichever comes sooner. ADJUSTING PRESSURIZING PRESSURE FOR HYDRAULIC TANK When the component used to pressurize the hydraulic tank is replaced, the pressurization pressure must be adjusted, so ask your Komatsu distributor to carry out the adjustment.
  • Page 303 HIGH ALTITUDE SPECIFICATIONS SERVICE PROCEDURE ADJUSTING PRESSURIZING PRESSURE 1. Start the engine and charge the air tank with air. 2. Turn knob (1) of the pressure reducing valve clockwise and set the pressure to 49 kPa (0.5 kgf/cm , 7.1 PSI). 3.

  • Page 304: Index

    INDEX INDEX <A> <G> AIR CONDITIONER 3- 47 GENERAL PRECAUTIONS 2- 10 ARSC (AUTOMATIC RETARDER SPEED GENERAL VIEW CONTROL) 6- 27 GENERAL VIEW OF CONTROLS AND EXPLANATION OF COMPONENTS 6- 28 GAUGES METHOD OF OPERATION 6- 30 GENERAL VIEW OF MACHINE TROUBLESHOOTING 6- 32 GUIDES TO MAINTENANCE...
  • Page 305 INDEX PRECAUTIONS BEFORE TRAVELING RECOMMENDED BRANDS, AFTER LONG-TERM STORAGE 3-103 RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN <M> KOMATSU GENUINE OIL 4- 11 MACHINE MONITOR REVO TACHOGRAPH (TCO 15-7) 6- 17 MAINTENANCE SCHEDULE CHART 4- 15 EXPLANATION OF COMPONENTS 6- 17...
  • Page 306 INDEX TRAVELING DOWNHILL 3- 81 DIFFERENTIAL LOCK PEDAL 6- 21 TROUBLESHOOTING 3-104 PRECAUTIONS AND METHOD OF AFTER RUNNING OUT OF FUEL 3-104 6- 22 IF BATTERY IS DISCHARGED 3-109 METHOD OF TOWING MACHINE 3-104 <W> OTHER TROUBLE 3-113 WEAR PARTS WEAR PARTS LIST <U>...
  • Page 307 HD785-5 DUMP TRUCK Form No. PEN00042-03 © 2006 KOMATSU All Rights Reserved Printed in Japan 04-06...

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