Komatsu ecot3 HD325-7 Operation & Maintenance Manual
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Komatsu ecot3 HD325-7 Operation & Maintenance Manual

Komatsu ecot3 HD325-7 Operation & Maintenance Manual

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DUMP TRUCK
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.
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
HD325
HD405
SERIAL NUMBERS
WARNING
NOTICE
TEN00425-07
-7
-7
HD325- 7611
and up
HD405- 7611

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  • Page 1 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.
  • Page 2 1 - 1...

  • Page 3: Before Reading This Manual

    If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see "TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-7)".

  • Page 4: Safety Information

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.

  • Page 5: Intended Use

    INTENDED USE INTENDED USE USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: Traveling with a load 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.

  • Page 6: Visibility From Operator's Seat

    FOREWORD INTENDED USE VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. VISIBILITY IN IMMEDIATE AREA The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below.

  • Page 7: Location Of Plates, Table To Enter Serial No. And Distributor

    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE It is located on the left front end of the frame.

  • Page 8: Service Meter Position

    FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SERVICE METER POSITION It is at the center bottom of the machine monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel...

  • Page 9: Table Of Contents

    FOREWORD CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL SAFETY INFORMATION INTENDED USE USE OF MACHINE DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE SERVICE METER POSITION TABLE TO ENTER SERIAL NO.
  • Page 10 FOREWORD CONTENTS FUSES 3- 46 CAR RADIO 3- 49 CAR STEREO 3- 55 AIR CONDITIONER 3- 64 OPERATION 3- 69 CHECK BEFORE STARTING ENGINE 3- 69 STARTING ENGINE 3- 89 OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 91 STOPPING ENGINE 3- 92 CHECKS AFTER STOPPING ENGINE 3- 92 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING...
  • Page 11 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 14 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15 TORQUE LIST...
  • Page 12 FOREWORD CONTENTS OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED 6- 63 ARSC (AUTOMATIC RETARDER SPEED CONTROL) 6- 66 EXPLANATION OF COMPONENTS 6- 67 METHOD OF OPERATION 6- 70 USE OF REAR VIEW MONITOR 6- 73 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR 6- 73 SETTING OF REAR VIEW MONITOR...
  • Page 14 2 - 1...

  • Page 15: Safety

    SAFETY SAFETY SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12 PRECAUTIONS BEFORE STARTING OPERATION 2- 12 ENSURING SAFE OPERATION 2- 12 UNDERSTANDING THE MACHINE 2- 12 PREPARATIONS FOR SAFE OPERATION 2- 12 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 12...
  • Page 16 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 19 PRECAUTIONS FOR JOBSITE 2- 19 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 19 WORKING ON LOOSE GROUND 2- 19 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19 ENSURE GOOD VISIBILITY 2- 20 CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 20 BEWARE OF ASBESTOS DUST 2- 20...
  • Page 17 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE 2- 29 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 29 KEEP WORKPLACE CLEAN AND TIDY 2- 29 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 29 ONLY AUTHORIZED PERSONNEL 2- 29 APPOINT LEADER WHEN WORKING WITH OTHERS...

  • 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 - 5...

  • Page 19: Position For Attaching Safety Labels

    SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS 2 - 6...

  • Page 20: Safety Labels

    SAFETY SAFETY LABELS SAFETY LABELS (1) Precaution about modifying ROPS (09620-B2000) (2) Caution for rotation of engine fan, fan belt (09667-23001) (3) Caution for opening radiator cap (09668-03001) (4) Caution for opening hydraulic tank cap (09653-03001) 2 - 7...
  • Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (5) Warning for handling suspension (09659-33000) (6) Warnings for electric wire Warnings for crush hazard when inspection and maintenance (56B-93-12181) 2 - 8...
  • Page 22 SAFETY SAFETY LABELS (7) Caution before starting Caution when traveling in reverse (569-93-81730) (8) Caution when handling battery cable (09808-03000) (9) Exhaust pipe is hot! (09817-A1103) 2 - 9...
  • Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Caution for avoiding falling down (09805-13000) (11) Precautions for handling accumulator (09659-53000) (12) Caution when handling battery (09664-30011) (For North America only) (13) Caution when handling battery This safety label is provided by the battery manufacturer. 2 - 10...
  • Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (14) Jump start prohibited (09842-A0481) This safety label is fixed to the engine starting motor. (15) Precautions for handling external power source type electric heater (09804-10480) (For the machine with external power source type electric heater) (16) Caution blast site (09845-00480) (only when equipped with KOMTRAX)

  • Page 25: General Precautions Common To Operation And Maintenance

    SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.

  • Page 26: Keep Machine Clean

    SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE KEEP MACHINE CLEAN If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.

  • Page 27: Fire Prevention

    SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION ACTION IF FIRE OCCURS Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine. Do not jump off the machine. There is the danger of falling and suffering serious injury. PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, COOLANT or window washer fluid Do not bring any flame or fire close to flammable substances...

  • Page 28: Precautions When Getting On Or Off Machine

    SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Explosion caused by lighting equipment When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications. PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine, always do as follows.

  • Page 29: Precautions When Standing Up From Operator's Seat

    SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT Before standing up from the operator's seat to adjust the operator's seat, always lower the dump body completely, lock with dump lever lock knob (1), set gear shift lever (2) to the N position, set parking brake switch (3) to the PARKING position, then stop the engine.

  • Page 30: Do Not Get Caught In Dump Body

    If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu distributor for advice on the method of repair.

  • Page 31: Precautions Related To Attachments And Options

    Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact your Komatsu distributor for advice.

  • Page 32: Precautions For Operation

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm that there is no danger on the jobsite. Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.

  • Page 33: Ensure Good Visibility

    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 - 20...

  • Page 34: Starting Engine

    SAFETY PRECAUTIONS FOR OPERATION STARTING ENGINE USE WARNING TAGS If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine. If the warning sign is ignored and the machine is operated, there is danger that the person carrying out inspection or maintenance may be caught in the rotating parts or moving parts and suffer serious personal injury or death.

  • Page 35: Precautions When Starting Engine

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING ENGINE Start and operate the machine only while seated. When starting the engine, sound the horn as a warning. If another person is allowed on the machine, that person may sit only in the assistant's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit.

  • Page 36: Operation

    SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful attention to the surrounding area.

  • Page 37: Precautions When Traveling

    This may cause the tires to burst. If a tire bursts, it produces a large destructive force, and this may cause serious injury or death. If you are going to travel continuously, please consult your Komatsu distributor. When travelling, and particularly when travelling downhill, never set the gear shift lever to the Neutral position.

  • Page 38: Precautions When Loading Dump Body

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN LOADING DUMP BODY Do not load the dump body so that the load is on one side. Always carry out loading that the load is spread uniformly. Do not leave or return to the operator's seat while the dump body is being loaded. PRECAUTIONS WHEN OPERATING DUMP BODY Before starting the dumping operation, check to be sure there is no person or object behind the machine.

  • Page 39: Parking Machine

    SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. When leaving the machine, always lower the dump body completely, lock with dump lever lock knob (1), set gear shift lever (2) to the N position, set parking brake switch (3) to the PARKING position, then stop the engine.

  • Page 40: Transportation

    The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. For the procedure when transporting, see "TRANSPORTATION (PAGE 3-118)".

  • Page 41: Towing

    SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or towing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-129)"...

  • Page 42: Precautions For Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine.

  • Page 43: Stop Engine Before Carrying Out Inspection And Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Always stop the machine before performing any inspection and maintenance. Lower the dump body completely, set dump lever (1) to the HOLD position, lock with dump lever lock knob (2), then stop the engine.

  • Page 44: Two Workers For Maintenance When Engine Is Running

    SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. One worker must always sit in the operator's seat and be ready to stop the engine at any time.

  • Page 45: Installing, Removing, Or Storing Attachments

    SAFETY PRECAUTIONS FOR MAINTENANCE INSTALLING, REMOVING, OR STORING ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.

  • Page 46: Precautions For Inspection And Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.

  • Page 47: Precautions When Using Hammer

    SAFETY PRECAUTIONS FOR MAINTENANCE Danger of sparks There is hazard that sparks will be generated, so always observe the following. Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying around near the battery.

  • Page 48: Precautions With High-Pressure Oil

    If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, please consult your Komatsu distributor. Replace the hose if any of the following problems are found.

  • Page 49: Handling Suspension Cylinder, Accumulator, Gas Spring

    Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. Ask your Komatsu distributor when sealing gas into the cylinder or replacing gas from it.

  • Page 50: Periodic Replacement Of Safety Critical Parts

    SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS For using the machine safely for an extended period of time, replace safety-critical parts like hoses and seat belts periodically. Replacement of safety-critical parts: See "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-16)".

  • Page 51: 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 specified tires and inflate them to the specified pressure.

  • Page 52: Precautions When Storing Tires

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN STORING TIRES Tires for construction equipment are extremely heavy, it may lead to serious personal injury or death. To maintain safety, always do as follows. As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter.
  • Page 54 3 - 1...

  • Page 55: Operation

    OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE This illustration shows the HD325-7. Dump body Turn signal light Rear wheel Head lamp Front wheel 3 - 2...

  • Page 56: General View Of Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Dump lever Parking brake switch Lamp switch, Turn signal lever, Dimmer switch Accelerator pedal Steering wheel (10) Brake pedal Machine monitor (11) Secondary brake pedal Retarder control lever (12) Dump lever lock knob Cigarette lighter (13) Auto retarder (ARSC) set lever (if equipped)
  • Page 57 OPERATION GENERAL VIEW Enlargement of machine monitor Machine monitor mode selector switch 2 Emergency steering switch Machine monitor mode selector switch 1 (10) Power mode selector switch Fog lamp switch (if equipped) (11) AISS LOW switch Yellow rotating lamp switch (if equipped) (12) Front brake cut-off switch Side lamp switch (if equipped)

  • Page 58: Explanation Of Components

    After a 3-second system check, the meter starts to function. The character display shows "KOMATSU" for 3 seconds. If the lamps do not work, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection. When the starting switch is turned ON, if the shift lever is not at the neutral position, after completion of the system check, the shift lever position pilot lamp and the central warning lamp will light up, and the alarm buzzer will continue to sound intermittently.
  • Page 59 When this happens, the character display shows the machine model and the software version of the machine monitor. The gauges that do not function have probably failed, so please contact your Komatsu distributor for inspection. 3 - 6...
  • Page 60 OPERATION EXPLANATION OF COMPONENTS CHARACTER DISPLAY The character display can display the following items. Service meter Action code display Odometer Filter, oil replacement time display Reverse travel odometer Normally, the service meter/odometer is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action.
  • Page 61 ( ) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection. ODOMETER This meter (2) indicates the total distance traveled in kilometers.
  • Page 62 ACTION CODE DISPLAY CAUTION If action code E03 is displayed, stop the machine immediately. Then see "ACTION CODE (PAGE 3-141)" and contact your Komatsu distributor for repairs. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed on this panel (4) to recommend suitable action.
  • Page 63 If "MAINTENANCE" is displayed together with E01, check the failure code and contact your Komatsu distributor for repairs. REMARK "E01" is displayed on the top line of the character display and "MAINTENANCE"...
  • Page 64 OPERATION EXPLANATION OF COMPONENTS Items for display of filter, oil replacement time Replacement Item Character display ID number interval Fuel prefilter FUEL P FILT Engine oil filter ENG FILT Engine oil ENG OIL Transmission oil filter (Pump outlet port) TM FILT Fuel main filter 1000 FUEL FILT...
  • Page 65 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the monitor lights up during travel, inspect the location of the problem quickly and take the necessary action. Seat belt caution lamp Emergency steering pilot lamp Parking brake pilot lamp Fuel level caution lamp Dump body pilot lamp Maintenance caution lamp SEAT BELT CAUTION LAMP...
  • Page 66 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE PILOT LAMP This monitor (2) lights up when the parking brake is applied. DUMP BODY PILOT LAMP This monitor (3) lights up when the dump body is raised or the dump body lever is at any position other than "FLOAT". EMERGENCY STEERING PILOT LAMP This monitor (4) lights up when the emergency steering is actuated.
  • Page 67 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This monitor (6) lights up if any of the the following are applicable. When it lights up, action code "E01" and the location needing maintenance are displayed on the character display at the same time, so carry out inspection, filling, or replacement.
  • Page 68 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEM CAUTION If the monitor lights up, stop operations immediately, then check the corresponding area and carry out the action. If any problem is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor for the location of the problem and the central warning lamp will light up.
  • Page 69 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER TEMPERATURE CAUTION LAMP This monitor (1) warns the operator that the engine coolant temperature has risen. When it lights up, "E02 ENGINE OVERHEAT" is displayed on the character display at the same time, and the engine output is automatically limited.
  • Page 70 OPERATION EXPLANATION OF COMPONENTS STEERING OIL TEMPERATURE CAUTION LAMP This monitor (5) lights up to warn the operator that the steering oil temperature has risen. When it lights up, "E02 STRG OVERHEAT" is displayed on the character display at the same time, so stop the machine in a safe place, set gear the shift lever to the N position, and run the engine under no load at a mid-range speed until the lamp goes out.
  • Page 71 OPERATION EXPLANATION OF COMPONENTS MACHINE MONITOR, OPTION SYSTEM CAUTION LAMP This monitor (9) lights up when a problem has been detected in the machine monitor or in the system for an installed option. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.
  • Page 72 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION PILOT DISPLAY PORTION When the starting switch is ON, the pilot display lights up when the display items are functioning. Preheating pilot lamp Shift indicator Retarder pilot lamp Shift lever position pilot lamp Lockup pilot lamp Power mode pilot lamp Head lamp high beam pilot lamp...
  • Page 73 OPERATION EXPLANATION OF COMPONENTS RETARDER PILOT LAMP This monitor (2) lights up when the retarder control lever is pulled and the retarder is actuated. LOCKUP PILOT LAMP This monitor (3) lights up when the torque converter lockup is engaged and the transmission is shifted to direct drive. HEAD LAMP HIGH BEAM PILOT LAMP This monitor (4) lights up when the head lamps are set to high beam.
  • Page 74 OPERATION EXPLANATION OF COMPONENTS SHIFT INDICATOR This monitor (6) shows the transmission shift range (speed range). SHIFT LEVER POSITION PILOT LAMP This monitor (7) displays the position of the shift lever. The letter or number for the speed range selected by the shift lever lights up.
  • Page 75 OPERATION EXPLANATION OF COMPONENTS AUTO SUSPENSION MODE PILOT LAMP (If equipped) This monitor (9) displays the suspension mode, when the machine is equipped with the suspension controller. On machines equipped with an automatic suspension system, the suspension system automatically switches damping characteristics of the suspension according to the size of the load, use of the brake, operation of the steering, and operation of the...
  • Page 76 OPERATION EXPLANATION OF COMPONENTS METERS Speedometer Engine water temperature gauge Engine tachometer Torque converter oil temperature gauge Fuel gauge Retarder oil temperature gauge SPEEDOMETER This meter (1) indicates the travel speed of the machine. ENGINE TACHOMETER This meter (2) shows the engine speed. If the gauge indicator the red range during operations, the alarm buzzer will sound and the central warning lamp will light up at the same time, so reduce the engine speed and the machine travel...
  • Page 77 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE This meter (3) shows the amount of fuel remaining in the fuel tank. When the fuel level caution lamp lights up, it indicates that there is less than 60 liters (15.85 US gal) of fuel remaining in the tank, so check and add fuel.
  • Page 78 OPERATION EXPLANATION OF COMPONENTS CENTRAL WARNING LAMP If the machine is in the following condition, this lamp will flash, and at the same time, the alarm buzzer will sound intermittently. When a problem has occurred in any of "EMERGENCY STOP ITEM (PAGE 3-15)".

  • Page 79: Other Functions Of Machine Monitor

    OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF MACHINE MONITOR DISPLAY METHOD FOR REVERSE TRAVEL ODOMETER Use this when checking the total travel distance in reverse. 1. Check that the character display is showing the service meter/odometer, or the action code. If it is giving any other display, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display to be given.
  • Page 80 OPERATION EXPLANATION OF COMPONENTS RESET METHOD FOR FILTER, OIL REPLACEMENT TIME The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1. Press the ( ) of machine monitor mode selector switch 1, and display the reverse travel in odometer. 2.
  • Page 81 OPERATION EXPLANATION OF COMPONENTS METHOD FOR SELECTING LANGUAGE Use this when switching the language displayed on the character display. 1. Press the ( ) of machine monitor mode selector switch 1 and display the reverse travel odometer. 2. Press (>) or (<) of machine monitor mode selector switch 2 and display "LANGUAGE".
  • Page 82 OPERATION EXPLANATION OF COMPONENTS INPUT METHOD FOR TELEPHONE NUMBER When an error for action code "E03" occurs, it is possible to display the telephone number. 1. Press the ( ) of machine monitor mode selector switch 1 and display the reverse travel odometer. 2.

  • Page 83: Switches

    OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch (10) Front brake cut-off switch Lamp switch (11) Fog lamp switch (if equipped) Turn signal lever (12) Side lamp switch (if equipped) Dimmer switch (13) Yellow rotating lamp switch (if equipped) Machine monitor bulb check switch (14) Power window switch (right) (if equipped) Hazard lamp switch...
  • Page 84 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 85 OPERATION EXPLANATION OF COMPONENTS DIMMER SWITCH This switch (2) is used to switch the head lamps between high beam and low beam. Each time switch (2) is moved up in direction (a), the head lamps switch between high beam and low beam. When the switch is released, it automatically returns to its original position (b).
  • Page 86 OPERATION EXPLANATION OF COMPONENTS POWER MODE SELECTOR SWITCH This switch (6) is used to switch the power mode. This makes it possible to travel economically in a way suited to the operating conditions. If portion (a) of the switch is pressed, high-power mode pilot lamp (P) lights up and the system is switched to the high-power mode.
  • Page 87 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE SWITCH WARNING When parking or leaving the machine, always apply the parking brake. This switch (8) is used to actuate and release the parking brake valve. (a): Parking The parking brake is applied. (b): Travel The parking brake is released.
  • Page 88 OPERATION EXPLANATION OF COMPONENTS AISS LOW SWITCH Using this switch (9), it is possible to switch the AISS freely between AUTO and LOW. Use each position as follows. (a): AUTO position For normal operations (b): LOW position When fine control of the machine is needed, such as when putting it into a garage.
  • Page 89 OPERATION EXPLANATION OF COMPONENTS FOG LAMP SWITCH (If equipped) This switch (11) is used to switch on the fog lamp. (a): Fog lamp goes out (b): Fog lamp lights up When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.
  • Page 90 OPERATION EXPLANATION OF COMPONENTS POWER WINDOW SWITCH (RIGHT) (LEFT) (The right power window is optional.) WARNING When closing the window glass, be careful not to get anyone's hands or head caught. There is danger of serious injury if anyone is caught in the window glass. CAUTION After fully opening or fully closing the window glass, do not keep the switch operated in the same direction.
  • Page 91 OPERATION EXPLANATION OF COMPONENTS HORN BUTTON When the horn button (18) in the center of the steering wheel is pressed, the horn will sound. NOTICE To sound the horn continuously (keep pressing the horn button) makes its service life shortened, and it may cause failure on early stage. Avoid the continuous usage of the horn except in an emergency.

  • Page 92: Control Levers And Pedals

    OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Brake pedal Retarder control lever Accelerator pedal Dump lever lock knob Gear shift lever Secondary barke pedal Dump lever BRAKE PEDAL This pedal (1) is used to apply the wheel brakes. 3 - 39...
  • Page 93 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS When the wheel brake is applied, part (A) of the stop / tail lamp lights up. ACCELERATOR PEDAL This pedal (2) is used to adjust the engine speed. It can be operated freely between the engine low idle position and the full throttle position.
  • Page 94 OPERATION EXPLANATION OF COMPONENTS 6 - L position: These positions are used in places where it is difficult to travel at high speed, or when traveling on soft ground, or when starting the machine off on a slope when it is loaded. They are also used when going downhill if it is needed to use the braking force of the engine.
  • Page 95 OPERATION EXPLANATION OF COMPONENTS DUMP LEVER CAUTION To prevent damage to the dump body through vibration from the road surface, always lower the dump body before traveling. This lever (4) is used to operate the dump body. (a) RAISE (b) HOLD: The dump body stops and is held in position. (c) FLOAT: The dump body moves freely under external force.
  • Page 96 OPERATION EXPLANATION OF COMPONENTS DUMP LEVER LOCK KNOB WARNING When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the dump lever lock knob, then use the body pivot pin. This device (6) is used to lock the dump lever.

  • Page 97: Body Pivot Pin

    OPERATION EXPLANATION OF COMPONENTS BODY PIVOT PIN WARNING When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the dump lever lock knob, then use the body pivot pin. This is a safety device for the dump body, and is used when carrying out inspection or maintenance with the dump body raised.

  • Page 98: Dust Indicator

    OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This device indicates clogging of the air cleaner. Depending on the degree of clogging of the element, red line (1) appears in the transparent portion. If red line (1) indicates 7.5 kPa (30 INCHES H O) (0.076 kg/cm , 1.1 PSI), clean the element immediately.

  • Page 99: Fuses

    OPERATION EXPLANATION OF COMPONENTS FUSES The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. NOTICE When replacing any fuse, always turn the power off (turn the starting switch to OFF).
  • Page 100 OPERATION EXPLANATION OF COMPONENTS Fuse box II No. Capacity Name of circuit Machine monitor, (11) Payload meter II (if equipped), Controller (if equipped) Rear view monitor (if equipped) (12) Download ACC (13) Parking brake circuit (14) Power window (left) (15) Power window (right) (16) Payload meter II controller (if equipped)
  • Page 101 If the electrical equipment system is changed, problems may occur in the machine control. Do not make any changes to the electrical system. If you want to make any change to the electrical system, please contact your Komatsu distributor. 3 - 48...

  • Page 102: Car Radio

    OPERATION EXPLANATION OF COMPONENTS CAR RADIO (If equipped) EXPLANATION OF COMPONENTS (1) Power switch/Volume (6) Preset switch (2) Tone control knob (7) Seek (3) Display (8) Band selector switch (4) Clock button/Displaying frequency (9) Tuning switch (5) AST POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on.
  • Page 103 OPERATION EXPLANATION OF COMPONENTS TONE CONTROL KNOB If this knob (2) is turned to the right, the high tone is emphasized; if it is turned to the left, the high tone is reduced. DISPLAY This display (3) shows the radio reception frequency and the operating mode.
  • Page 104 OPERATION EXPLANATION OF COMPONENTS PRESET SWITCH With this switch (6), each button can be set to one station each for FM and MW (AM). (For details of the method of resetting, see "METHOD OF PRESET (PAGE 3-53)".) SEEK When this switch (7) ("SEEK") is pressed, it automatically searches for stations that can be received, and when it receives a station, it stops.
  • Page 105 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION LISTENING TO RADIO 1. This switches on power (1) for the radio. 2. "BAND" switch (2) is used to select MW (AM) or FM. 3. Use the preset switch or tuning switch (3) to select the station. 4.
  • Page 106 OPERATION EXPLANATION OF COMPONENTS METHOD OF PRESET 1. Select the desired preset station. Use the "BAND" button to select MW (AM) or FM, and use the "TUNE" button to select the frequency of the broadcasting station. 2. Decide the number of the button to be preset, and keep it pressed for 2 seconds.
  • Page 107 OPERATION EXPLANATION OF COMPONENTS ADJUSTING TIME 1. Turn the radio power ON. If the display shows the frequency, set the CLOCK button to the time display. 2. To set the time, keep the CLOCK button pressed and Press the button to change the minutes Press the button to change the hours PRECAUTIONS FOR USE...

  • Page 108: Car Stereo

    OPERATION EXPLANATION OF COMPONENTS CAR STEREO (If equipped) EXPLANATION OF COMPONENTS (1) Power switch/volume (8) Cassette door (2) Auto-store/preset scan button (9) Fast forward, rewind buttons (3) Bass control knob (10) Preset buttons (4) Treble control knob (11) Metal tape button (5) Loudness button (12) Manual tuning buttons (6) Time/radio display selector button...
  • Page 109 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 110 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 111 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 112 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 113 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 114 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 115 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 116 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 117: Air Conditioner

    OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER (If equipped) By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS ON CONTROL PANEL ON/OFF switch DEF switch...
  • Page 118 OPERATION EXPLANATION OF COMPONENTS MODE SELECTOR SWITCH Use this switch (4) to select the vents. There are three combinations of vents: FACE, FACE/FOOT, and FOOT. Each time the switch is pressed, the vent display on the air conditioner monitor changes in the order FACE, FACE/FOOT, FOOT, FACE.
  • Page 119 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH Use this switch (7) to adjust the temperature of the air blowing out from the vents. The adjustment can be made to 8 levels from low temperature to high temperature. The temperature of the air blowing out from the vents is displayed on temperature bar (D) on the monitor. The lower the number of segments lighted up on the bar, the lower the temperature is.
  • Page 120 OPERATION EXPLANATION OF COMPONENTS DEHUMIDIFYING, DEFROSTING 1. Press ON/OFF switch (1) to turn on the air conditioner power. 2. Press fan switch (2) to set to the desired air flow. 3. Press temperature control switch (3) to set to the desired temperature.
  • Page 121 4-30)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-31)". 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 - 68...

  • Page 122: Operation

    Leakage of oil or fuel, or accumulation of flammable material around the battery or high temperature parts of the engine, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any problem is found, repair it or contact your Komatsu distributor. Perform the following inspections and cleaning every day before starting engine for the day's work.
  • Page 123 OPERATION OPERATION 8. Check dump body mount rubber Check for any cracks, embedded foreign objects, or loose bolts. 9. Check for damage to handrail, loose bolts Repair any damage and tighten any loose bolts. 10. Check for damage to gauges, lamps on the instrument panel and loose bolts. Check for damage to the panel, gauges and lamps.
  • Page 124 OPERATION OPERATION CHECK BEFORE STARTING Always perform the procedures in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub-tank.
  • Page 125 OPERATION OPERATION CHECK DUST INDICATOR 1. Check that the red line in the transparent portion of dust indicator (1) does not indicate 7.5 kPa (30 INCHES H (0.076 kg/cm , 1.1 PSI). 2. If the red line indicates 7.5 kPa (30 INCHES H O) (0.076 kg/cm , 1.1 PSI), clean or replace the air cleaner element immediately.
  • Page 126 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 127 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 128 OPERATION OPERATION CHECK OIL LEVEL IN BRAKE SUB-TANK, ADD OIL WARNING Immediately after the machine is stopped, the pressure inside the tank is high, so if the cap is opened, hot oil will spurt out and may cause burns. Turn the cap slowly to release the pressure inside the tank before opening the oil filler cap. 1.
  • Page 129 OPERATION OPERATION DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve (1) at the bottom of the fuel tank, and drain the water and sediment collected at the bottom of the tank together with the fuel. 3 - 76...
  • Page 130 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 131 Komatsu distributor for inspection. CHECK BRAKING EFFECT Check if the braking capacity of the parking brake, foot brake, and retarder brake. If any abnormality is found, ask Komatsu distributor to repair. CHECK BRAKING CAPACITY OF SECONDARY BRAKE WARNING If the machine moves, it will lead to serious injury.
  • Page 132 Check the wiring of the "battery", "starting motor"and "alternator"carefully, in particular. Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of any problems found. 3 - 79...
  • Page 133 OPERATION OPERATION CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work. Check for damage or wear to the tires and the rims. Check for loose wheel hub bolts. The proper inflation pressure is shown below.
  • Page 134 CHECK FUNCTION OF HORN 1. Turn the starting switch to the ON position. 2. Check that the horn sounds immediately when the horn button is pressed. If the horn does not sound, ask your Komatsu distributor for repair. 3 - 81...
  • Page 135 OPERATION OPERATION ADJUSTMENT BEFORE OPERATION ADJUSTING OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat before starting operations or when changing operators. Adjust the position of the operator's seat so that you can depress the brake pedal fully with your back against the seat backrest. (A) Fore-and-aft adjustment Pull lever (1) up, set the seat to the desired position, then release the lever.
  • Page 136 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 are no signs of damage, replace belts in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
  • Page 137 Do not operate the lever (1) continuously by excessive force. The lever (1) may become loose or get out of angle. In this case, please ask your Komatsu distributor to carry out repairs. The bolts (2) and (3) on steering column are the left-hand screw.
  • Page 138 OPERATION OPERATION ADJUSTING MIRROR WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Loosen the bolt and nut installing the mirror, then adjust the mirror to a position which gives the best view from the operator's seat.
  • Page 139 OPERATION OPERATION (Z): Ground contact point of tire used as base 3 - 86...
  • Page 140 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING WARNING When starting the engine, check that the gear shift lever is set in the N (neutral) position and that the parking brake switch is at PARKING position. Before standing up from the operator's seat, place the gear shift lever at N (neutral) position, and set the parking brake switch to the PARKING position.
  • Page 141 OPERATION OPERATION OPERATION OPERATION 4. Check that retarder control lever (4) is at the RELEASED position. 5. Check that there is no problem in the machine monitor when starting switch (5) is turned to the ON position. 3 - 88...

  • Page 142: Starting Engine

    OPERATION OPERATION STARTING ENGINE WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
  • Page 143 OPERATION OPERATION OPERATION OPERATION 2. After the preheater pilot lamp goes off, turn the key of the starting switch to the START position, and the engine will start. REMARK When starting the engine, the monitor may flash while the starting motor is turning, but if the monitor lamp goes out after the engine is started, there is no problem.

  • Page 144: 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 145: 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 146: 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 147 OPERATION OPERATION OPERATION OPERATION 5. Check that retarder pilot lamp (3) is not lighted up, then set gear shift lever (4) to the desired position. NOTICE When operating the shift lever, be sure to set it in position securely. If the lever is not placed in position properly, the shift position display on the panel may go out and the Transmission system caution lamp may light up.
  • Page 148 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 149 OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. If the foot brake is used repeatedly or is kept depressed for a long time, the brake may overheat and its life will be shortened. If the parking brake is used to stop the machine, the brake will be damaged.
  • Page 150 Immediately after making an emergency stop, the brake disc will be at high temperature, so wait for it to cool down before carrying out repair or adjustment. Ask your Komatsu distributor for repair and adjustment. 1. Pull retarder control lever (1) fully to apply the retarder.

  • Page 151: Shifting Gear

    OPERATION OPERATION SHIFTING GEAR WARNING Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a slope. Always place the transmission in gear before traveling. If the transmission is in Neutral, the engine cannot provide any braking effect and the steering wheel will become heavier. In addition, there will be lack of cooling oil for the retarder, so there is danger that it will overheat or that the actuation of the brake will be poor.
  • Page 152 OPERATION OPERATION SHIFTING DOWN If accelerator pedal (2) is released, the machine speed will be reduced, and the transmission will automatically shift down. DOWN SHIFT INHIBIT If the gear shift lever is operated when the machine is traveling, and the travel speed is faster than the maximum speed for each gear position, the transmission is not shifted immediately but is shifted down when the travel speed drops.

  • Page 153: Traveling Downhill

    2. If the retarder still does not work even when the retarder control lever is operated again, release the retarder control lever fully. Then depress the brake pedal, stop the machine, and ask your Komatsu distributor to carry out repairs.
  • Page 154 OPERATION OPERATION OPERATION OPERATION 1. Before starting to travel downhill, release accelerator pedal (1) and operate retarder control lever (2) to slow the machine down. 2. Leave the gear shift lever in position D. When the machine reduces speed, the transmission will automatically shift down to the appropriate gear range.
  • Page 155 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 HD325: 32 tons HD405: 40 tons Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
  • Page 156 OPERATION OPERATION HD325 HD405 3 - 103...
  • Page 157 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1476 ft)] HD325 HD405 3 - 104...
  • Page 158 OPERATION OPERATION Brake performance [Downhill distance: 600 m (1968 ft)] HD325 HD405 3 - 105...
  • Page 159 OPERATION OPERATION Brake performance [Downhill distance: 900 m (2952 ft)] HD325 HD405 3 - 106...
  • Page 160 OPERATION OPERATION Brake performance [Downhill distance: 1500 m (4921 ft)] HD325 HD405 3 - 107...
  • Page 161 OPERATION OPERATION Brake performance [Downhill distance: Continuous] HD325 HD405 3 - 108...

  • Page 162: Steering The Machine

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

  • Page 163: Dump Operations

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

  • Page 164: Precautions For Operation

    The dump control is carried out electrically. If there is any problem in the sensors or valves, a failure code is displayed and the dump body is held in position. If it is desired to move the dump body forcibly for inspection or repair, please ask your Komatsu distributor to carry out the operation. PRECAUTIONS FOR OPERATION When traveling on roads in rain or snow, or when traveling on muddy or soft ground, consider the loaded condition of the machine and be extremely careful not to let the tires slip or the machine spin and sink into the ground.

  • Page 165: Parking Machine

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

  • Page 166: Checks After Completion Of Work

    OPERATION OPERATION CHECKS AFTER COMPLETION OF WORK Use the machine monitor to check the engine water temperature, engine oil pressure, and fuel level. If the engine has overheated, do not stop the engine suddenly. Run it at a mid-range speed to cool it gradually before stopping. LOCKING Always lock the following places.

  • Page 167: 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 168 OPERATION OPERATION TIRE T.Km.P.H.AND MAXIMUM SPEED FOR CONTINUOUS TRAVEL (REFERENCE) HD325 Tire T.Km.P.H.for Max.speed for continuous travel ambient temperature for ambient temperature (km/h) 16 ° C 27 ° C 38 ° C 49 ° C 16 ° C 27 ° C 38 ° C 49 ° C Size 18.00-33-32PR When empty (standard)
  • Page 169 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 170: 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 171: 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 172: Method Of Lifting Machine

    The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For the weight of the standard specification machine, see "WEIGHT TABLE (PAGE 3-120)".
  • Page 173 OPERATION TRANSPORTATION LOCATION OF LIFTING POSITION MARK WEIGHT TABLE Machine Front wheel Rear wheel Center of gravity weight load load (from front axle) 31600 kg 16337 kg 15263 kg 1811 mm HD325-7 (69678 lb) (36023 lb) (33655 lb) (5 ft 11 in) 34400 kg 17440 kg 16960 kg...
  • Page 174 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 pilot lamp goes out.

  • Page 175: Cold Weather Operation

    NOTICE Please use Komatsu genuine SUPERCOOLANT (AF-NAC) for the COOLANT. As a basic rule, we do not recommend the use of any COOLANT other than SUPERCOOLANT (AF-NAC).

  • Page 176: 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 177: 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 4-12)". 3 - 124...

  • Page 178: 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 179: Troubleshooting

    OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL If you have run out of fuel, add fuel to the fuel tank and bleed air from the fuel system and then start the engine. PROCEDURE FOR BLEEDING AIR CAUTION The fuel injection pump and nozzle of this engine consist of more precise parts than the conventional ones. If foreign matter enters them, it can cause a trouble.

  • Page 180: If Transmission Has Trouble

    OPERATION TROUBLESHOOTING IF TRANSMISSION HAS TROUBLE If the transmission has any trouble, operate the machine according to the following procedure. 1. Decelerate the machine with the brake and stop it on a safe place. 2. Set the gear shift lever to the N position, then set the parking brake switch to the PARKING position. 3.

  • Page 181: Method Of Lowering Dump Body In Emergency

    4. When the dump body goes down to the desired position, turn grip (3) clockwise to close the valve, then tighten locknut (2). If the dump body does not go down even when the above method is used, please consult your Komatsu distributor. 3 - 128...

  • Page 182: Method Of Towing Machine

    Towing is only permitted in order to move a disabled machine to a place where it is possible to carry out inspection and maintenance. It must not be towed for long distances. Please consult your Komatsu distributor for information about towing a disabled machine. 3 - 129...
  • Page 183 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 184 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 185 METHOD OF RELEASING PARKING BRAKE IN EMERGENCY Please ask your Komatsu distributor to release the parking brake. WARNING If any abnormality occurs in the hydraulic circuit, there is danger that the wheel brakes may not be applied properly, so always travel at low speed when towing the machine.

  • Page 186: If Battery Is Discharged

    OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when installed on a machine. Make sure that it is removed 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 187 OPERATION TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE When the charging the battery, if the battery is mistakenly handled, there is danger of explosion. Follow the precautions in "IF BATTERY IS DISCHARGED (PAGE 3-133)" and the instructions given in the charger manual, and always do as follows.
  • Page 188 OPERATION TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect one clip of booster cable (A) to the positive (+) terminal of the problem machine.

  • Page 189: 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 190 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 191 After using the accelerator pedal to move the machine to a safe place, check the service code and contact your Komatsu distributor. There are two methods when operating the accelerator pedal: either release the pedal (check switch is OFF, low idle), or depress the pedal fully (1500 rpm).
  • Page 192 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 caution lamp Insufficient oil in oil pan Add oil to specified level.
  • Page 193 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Excessive oil consumption Oil leakage ( Check, repair) Excessive oil in oil pan Add oil to specified level. See CHECK BEFORE STARTING. Worn piston, ring, cylinder liner ( Replace) Exhaust gas is white or bluish Improper fuel Replace with specified fuel Defective turbocharger...
  • Page 194 If more than one failure has occurred, the next failure code is displayed. 3. Check the failure code, then contact your Komatsu distributor for repairs. REMARK The 6-digit code displayed on the left of the line at the top of the character display is the failure code.
  • Page 196 4 - 1...

  • Page 197: Maintenance

    Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
  • Page 198 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently.
  • Page 199 MAINTENANCE GUIDES TO MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE: If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been performed correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...
  • Page 200 MAINTENANCE GUIDES TO MAINTENANCE JACKING UP MACHINE Stop the machine on flat ground, set the parking brake switch to the PARKING position, then put blocks under the tires. Stop the engine. With the machine unloaded, jack the machine up. Use a 30-ton hydraulic jack. Front (The diagram shows the situation when the left side is jacked up.) When jacking up the front axle, such as when replacing the front...

  • Page 201: 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 - 6...
  • Page 202 If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability. COOLANT AND WATER FOR DILUTION Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing.
  • Page 203 MAINTENANCE OUTLINE OF SERVICE GREASE Grease is used to prevent seizure and noises at the joints. This construction equipment is used under heavy-duty conditions. Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
  • Page 204 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 - 9...

  • Page 205: 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 206: 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 207: 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 208: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature

    MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ASTM: American Society of Testing and Material 4 - 13...

  • Page 209: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil

    G2-T or G2-TE is recommended. Note 4: COOLANT 1) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.

  • Page 210: 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 211: 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 212: Safety Critical Parts

    MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Replacement interval Remarks 1 Fuel hose (Fuel tank - Fuel prefilter) 2 Fuel hose (Fuel prefilter - Feed pump) 3 Fuel hose (Engine - Fuel tank) 4 Spill hose (Engine output connector - Fuel tank) 5 Water separator (Case, O-ring, plug) Every 4000 hours...

  • Page 213: Maintenance Schedule Chart

    MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Change oil in engine oil pan, replace engine oil filter cartridge 4- 55 Replace fuel prefilter cartridge 4- 56 Replace transmission oil filter element (pump outlet port) 4- 58 Change oil in transmission case, brake sub tank 4- 63...
  • Page 214 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 250 HOURS SERVICE Check oil level in differential case, add oil 4- 43 Check oil level in final drive case, add oil 4- 43 Lubrication 4- 44 Lubrication drive shaft (*) 4- 45 Check drive shaft 4- 45 Check level of battery electrolyte 4- 46...
  • Page 215 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 4000 HOURS SERVICE Change oil in steering, hoist oil tank 4- 79 Grease extended greasing interval drive shaft (*) 4- 79 Check starting motor 4- 80 Check water pump 4- 80 Check fan pulley and tension pulley 4- 80 Check accumulator 4- 80...

  • Page 216: Service Procedure

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

  • Page 217: When Required

    MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN OR REPLACE AIR CLEANER After the outer element has been cleaned 6 times, or if the air cleaner element has been used for one year, replace the outer element, inner element, and O-ring. For details of the procedure for replacement, see "REPLACE ELEMENT (PAGE 4-26)".
  • Page 218 MAINTENANCE SERVICE PROCEDURE CLEAN OUTER ELEMENT WARNING Dirt will fly if compressed air is used for cleaning. If dirt gets into your eyes it may cause blindness, and if you breathe in the dust it may damage your lungs. To prevent these problems, always wear safety glasses, dust mask, and other protective equipment.
  • Page 219 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Direct dry compressed air (less than 0.2 MPa (2.1 kg/cm , 30.0 PSI)) to the outer element from inside along its folds, then direct it from outside along its folds and again from inside. 8.
  • Page 220 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 12. Push the head of dust indicator (1) to cancel the clogging display. 4 - 25...
  • Page 221 MAINTENANCE SERVICE PROCEDURE REPLACE ELEMENT WARNING When pulling out the air cleaner element, make sure that you are standing on a firm place. If your footing is not secure when you carry out the operation, there is danger of falling and suffering injury. 1.
  • Page 222 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 9. Replace O-ring (9) with a new part. Next, set so that vacuator valve (8) of dust cup (4) is at the bottom, and insert it into the air cleaner body. 10. Clip hooks (5) of dust cup (4) to the protruding parts of the air cleaner body to lock in position.
  • Page 223 (AF-NAC) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing.Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
  • Page 224 When changing the coolant or when handling the coolant containing COOLANT that has been drained during repair of radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. COOLANT is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
  • Page 225 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 10. Drain the cooling water from inside subtank (4), flush the inside of the subtank, then fill with water to a point between the FULL and LOW marks. CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID Carry out this check if there is air in the window washer fluid.

  • Page 226: Check Dump Body

    1. Clean the dump body to make it easier to check. 2. Check all parts of the dump body for damage. If any cracks or abnormal wear are found, carry out repairs. Contact your Komatsu distributor for details of the repair procedure. 4 - 31...

  • Page 227: Check Length Of Suspension Cylinder, Check Oil Level

    223 - 243 mm (8.8 - 9.6 in) Reference (C) 441 - 461 mm (17.4 - 18.2 in) Flange thickness (D) 50 mm (2.0 in) After checking, contact your Komatsu distributor for repairs if any problem is found. 4 - 32...
  • Page 228 Measure dimension (E) from the shoulder of the rod head of the suspension cylinder to the top surface of the flange. 166 - 186 mm (6.5 - 7.3 in) Flange thickness (F) 65 mm (2.6 in) After checking, contact your Komatsu distributor for repairs if any problem is found. 4 - 33...

  • Page 229: 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. Bleed the air from the rear brakes in the same way on both the left and right sides.

  • Page 230: Bleed Air From Front Brake

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

  • Page 231: Adjust Parking Brake

    3. Turn bolt (1) back 2/3 turns in the clockwise direction. 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 in the clockwise direction.

  • Page 232: Clean, Check Radiator Fins And After Cooler Fins

    If radiator fins (1) or aftercooler fins (2) become clogged or bent, it will cause overheating of the engine, so always clean or carry out inspection, and ask your Komatsu distributor to take the necessary action. Cleaning can be carried out by using jets of air, steam, or water, but be careful not to let the nozzle contact the fin.

  • Page 233: Check Play Of Output Coupling Of Output Shaft

    If amount of movement (L) is more than 15 mm (0.6 in), the rubber inside the output shaft may be deteriorated or damaged, so contact your Komatsu distributor and ask for disassembly and inspection of the internal parts of the output shaft.

  • Page 234: 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 235 MAINTENANCE SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING When inflating the tire, check that no one can enter the area around the tire, and always use an air chuck with a clip that can be fixed to the air valve.
  • Page 236 MAINTENANCE SERVICE PROCEDURE PRECAUTIONS WHEN REPLACING TIRE If the hub nuts (1) have been tightened again after replacing the tire, travel for 5 to 6 km, then tighten again to settle all the contacting parts. In particular, there are more contacting parts on the rear wheels than on the front wheels, so it will take time for the parts to settle.

  • Page 237: Check Before Starting

    MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-71)". Check coolant level, add coolant Check dust indicator Check oil level in engine oil pan, add oil Check oil level in transmission case, add oil Check oil level in steering and hoist oil tank, add oil Check oil level in brake sub-tank, add oil Check for leakage of oil from rear brake oil recovery tank breather...

  • Page 238: Every 250 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause 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 239: Lubrication

    MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Stop the engine. 2. Use the grease pump to pump in grease through the grease fitting marked by the arrow. 3. After greasing, wipe off any old grease that was pushed out. Carry out the greasing operation every day when operating in places where the grease flows out easily, such as when traveling through mud or water.

  • Page 240: Lubrication Drive Shaft (*)

    CHECK DRIVE SHAFT If there is any problem, such as looseness of the drive shaft connection, play in the spline or bearing portion, or runout of the shaft, please contact your Komatsu distributor for repair. 4 - 45...

  • Page 241: Check Level Of Battery Electrolyte

    If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 46...
  • Page 242 If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL (If equipped) If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

  • Page 243: Check Alternator Belt Tension, Adjust

    V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.

  • Page 244: Check Air Conditioner Compressor Belt Tension, Adjust

    MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING Press the middle of the belt between the air conditioner compressor pulley (1) and drive pulley (2) with the thumb (about 58.8 N {6 kg}). If deflection (A) is 10 mm (0.4 in), the belt tension is normal. ADJUSTING 1.

  • Page 245: Clean Breathers

    MAINTENANCE SERVICE PROCEDURE CLEAN BREATHERS Remove the mud and dirt from around the breather, then remove the breather and wash out the dirt from inside with clean diesel fuel or flushing oil. Transmission, brake sub tank (2 places) Steering, hoist oil tank 1.

  • Page 246: Check Frame

    2. Check all parts of the frame for damage. In particular, check the colored portions in the diagram and if any cracks or damage are found, repair the damage. Please contact your Komatsu distributor for details of the repair procedure. CHECK BRAKING CAPACITY OF FOOT BRAKE WARNING If the machine moves, it will lead to serious injury.

  • Page 247: Check Braking Capacity Of Retarder Brake

    1200 rpm, it is normal. 3. Lower the engine speed, set gear shift lever at N position. If any problem is found, ask your Komatsu distributor for repair. NOTICE If the dump body is not seated and the parking brake is at "TRAVEL", the speed range is set to F1, even when the gear shift lever is at the "D"...

  • Page 248: 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 249: Check Of Accumulator Gas Pressure

    If the brake oil pressure caution lamp lights up when the brake pedal is depressed 4 times or less, the gas pressure in the accumulator may be low. Ask your Komatsu distributor for inspection. If the brake oil pressure caution lamp does not light up when the brake pedal is depressed 5 times, the gas pressure in the accumulator is normal.

  • Page 250: Every 500 Hours Service

    Be careful not to loosen drain valve (2) too much. This will deform the stopper pin inside the valve. 3. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 4. Remove the drain hose, then tighten drain valve (2) and drain plug (1).

  • Page 251: Replace Fuel Prefilter Cartridge

    The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 252 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE NOTICE When filling the filter cartridge with fuel, carry out the filling operation with cap (A) fitted. Cap (A) acts to prevent the entry of dirt or dust into the filter cartridge. 7. Fill the filter cartridge with clean fuel through the 8 small holes (B) in the new filter cartridge.

  • Page 253: Replace Transmission Oil Filter Element (Pump Outlet Port)

    MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION OIL FILTER ELEMENT PUMP OUTLET PORT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

  • Page 254: Check Wear Of Front Disc Brake Pads

    (B): Wear limit reached, so replace pad After the inspection, if it is necessary to change the pad, contact your Komatsu distributor. The pad wear is not necessarily the same for the left and right wheels, so always check the pads on both the left and right.

  • Page 255: Check Fan Belt Tension, Adjust

    MAINTENANCE SERVICE PROCEDURE CHECK FAN BELT TENSION, ADJUST TESTING Press the belt with your thumb with a force of approx. 98 N {10 kg} (for each belt) at the midpoint between fan pulley (1) and crankshaft pulley (2). Standard deflection (A): 17 - 19 mm (0.67 - 0.74 in) ADJUSTING 1.

  • Page 256: Every 1000 Hours Service

    The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 257 MAINTENANCE SERVICE PROCEDURE 5. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.

  • Page 258: Change Oil In Transmission Case, Brake Sub Tank, Wash Strainer

    MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE, BRAKE SUB TANK, WASH 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 259 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 15. Remove retarder drain plug (8) and drain the oil from the brake chamber. NOTICE Drain the oil from the brake chamber on both the left and right sides. 16. After completely draining the oil from the brake chamber, install plug (7) and retarder drain plug (8).
  • Page 260 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 20. Remove the cap from bleeder screw (9) and insert a vinyl hose. (Use a commercially available vinyl hose.) 21. Put the other end of the vinyl hose approx. 50 mm into a container of oil. 22.

  • Page 261: Replace Transmission And Rear Brake Cooling Oil Filter Element

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

  • Page 262: Replace Brake Oil Filter Element

    MAINTENANCE SERVICE PROCEDURE REPLACE BRAKE OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. Prepare a filter wrench 1.

  • Page 263: Lubrication

    MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Using a grease pump, pump in grease through grease fittings marked by arrows. 2. After greasing, wipe off any old grease that was pushed out. (1) Transmission mount (1 place) (2) Automatic suspension link (left and right: 1 place each) (3) Tension pulley and fan pulley (2 places) Pump in grease through the grease fitting until grease oozes out from the seal.

  • Page 264: Lubricating Parking Brake

    MAINTENANCE SERVICE PROCEDURE LUBRICATING PARKING BRAKE WARNING When carrying out maintenance, raise the brake oil pressure sufficiently to prevent the parking brake from being automatically applied. In addition, hang a warning tag that can be seen clearly to prevent any other person from operating the parking brake switch.
  • Page 265 MAINTENANCE SERVICE PROCEDURE IF BREATHER IS INSTALLED If the breather is installed at (1) instead of the relief valve, carry out the lubrication according to the following procesude. 1. Supply grease to the parking brake by carrying out steps 1 to 5 of "LUBRICATING PARKING BRAKE (PAGE 4-69)".

  • Page 266: Check Wear Of Rear Brake Disc

    4. If slit (3) of rod (2) goes in beyond guide end face (4), it means that the disc has reached the wear limit. If this happens, please contact your Komatsu distributor for inspection and maintenance. 5. Install cap nut (1) removed in Step 2.

  • Page 267: Recover Oil Leaking From Floating Seal

    MAINTENANCE SERVICE PROCEDURE RECOVER OIL LEAKING FROM FLOATING SEAL 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 268: Check Of Engine Air Intake Piping Clamps For Looseness

    MAINTENANCE SERVICE PROCEDURE CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS Check the clamps between the air cleaner, turbocharger, aftercooler, and engine for looseness. If any clamp is loosened, retighten it. Tightening torque of clamp (1): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm, 6.5 ± 0.4 lbft} Tightening torque of clamp (2): 10.5 ±...

  • Page 269: Every 2000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Carry out maintenance for EVERY 250 HOURS, EVERY 500 HOURS and EVERY 1000 HOURS SERVICE at the same time. REPLACE STEERING, HOIST 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.

  • Page 270: Clean Hydraulic Tank Strainer

    MAINTENANCE SERVICE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. If there is still pressure remaining inside the case, the oil or plug may fly out. Turn the plug slowly to release the pressure, then remove it carefully.

  • Page 271: Change Oil In Differential Case

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

  • Page 272: Check Front Wheel Bearing

    1. Collect the oil not from near the drain plug of the final drive case, but from near the filler port, and then perform the oil clinic. 2. If there is any sign of damage to the wheel bearing, ask your Komatsu distributor for inspection and adjustment. Hereafter, perform the inspection every 4,000 hours.

  • Page 273: Check Alternator

    CHECK ALTERNATOR When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE, remove the belt and check that the alternator rotates smoothly. If it does not rotate smoothly, please ask your Komatsu distributor to carry out inspection and repair.

  • Page 274: Every 4000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 4000 HOURS SERVICE Maintenance for every 250, 500, 1000 and 2000 hours service should be carried out 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 275: Check Starting Motor

    MAINTENANCE SERVICE PROCEDURE CHECK STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours. CHECK WATER PUMP Check around the water pump for water leakage.

  • Page 276: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber

    Check that no spray prevention caps (1) to (11) are missing and that there is no hardening of any rubber parts. If any missing caps or hardening of rubber are found, please ask your Komatsu distributor to install or replace.

  • Page 277: Every 8000 Hours Service

    Maintenance for every 250, 500, 1000, 2000, and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to carry out this work. REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to carry out this work.

  • Page 278: Every 15000 Hours Service

    Maintenance for every 250, 500, 1000, 2000, 4000, 6000, 8000 and hours of service should be performed at the same time. CHECK, REPLACE STEERING A ARM MOUNTING BOLT Check and replace the A arm mounting bolts, lock plate, and holder. Please consult your Komatsu distributor when checking and replacing. (1) A arm (2) Front suspension (3) Lock plate...
  • Page 280 5 - 1...

  • Page 281: Specifications

    18 (23.5) 20 (26.2) Dump body capacity Heaped (2 : 1) (cu · yd) 24 (31.4) 27.3 (35.7) Dumping speed (at 2100 rpm) (raised) Komatsu SAA6D140E-5 Engine type diesel engine kW(HP)/rpm 371 (498)/2000 (ISO 9249 / SAE J1349) Horsepower Gross...
  • Page 282 SPECIFICATIONS SPECIFICATIONS 5 - 3...
  • Page 284 6 - 1...

  • Page 285: Attachments, Options

    ATTACHMENTS, OPTIONS SELECTING DUMP BODY SELECTING DUMP BODY (Set for HD325-7 only) Select the dump body from the following table. 6 - 2...

  • Page 286: Handling Air Suspension Seat

    ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT HANDLING AIR SUSPENSION SEAT SEAT ADJUSTMENT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat before starting operations or when changing operators. Adjust the position of the operator's seat so that you can depress the brake pedal fully with your back against the seat backrest.
  • Page 287 ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT (G) Adjusting headrest angle Rotate the headrest to the front or rear. Amount of adjustment: Front tilt: 13 degrees Rear tilt: 13 degrees (H) Adjusting headrest height Move the headrest up or down. Amount of adjustment: 80 mm (3.2 in) (I) Adjusting armrest angle Rotate the knob (7) and adjust the angle of the armrest.

  • Page 288: Removal And Installation Of Headrest

    ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT REMOVAL AND INSTALLATION OF HEADREST REMOVAL If the headrest is not needed, remove it as follows. 1. Pull up the headrest to the position where it stops. 2. From the top of the seat back, turn stopper (1) (under the material at the top of the seat) of the headrest bar on one side in the direction of the arrow, and pull up the headrest.

  • Page 289: Handling Automatic Spin Regulator (Asr)

    ATTACHMENTS, OPTIONS HANDLING AUTOMATIC SPIN REGULATOR (ASR) HANDLING AUTOMATIC SPIN REGULATOR (ASR) 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 (1) ASR switch (4) Accelerator pedal...

  • Page 290: Actuation Of Asr System

    ATTACHMENTS, OPTIONS HANDLING AUTOMATIC SPIN REGULATOR (ASR) ASR ACTUATION LAMP When the ASR switch is ON, this lamp (2) lights up if the system detects slipping from the rear wheels and actuates the ASR. RETARDER CONTROL LEVER When the ASR is actuated and this lever (3) is used to actuate the retarder, the actuation of the ASR system is canceled.

  • Page 291: Bleeding Air From Asr Circuit

    ATTACHMENTS, OPTIONS HANDLING AUTOMATIC SPIN REGULATOR (ASR) BLEEDING AIR FROM ASR CIRCUIT If the piping or valves in the ASR circuit have been replaced, bleed the air from the ASR circuit as follows. 1. Start the engine, check that the oil in the transmission case is the specified level, and check if the brake oil pressure caution lamp is out.

  • Page 292: Handling Abs

    ATTACHMENTS, OPTIONS HANDLING ABS HANDLING ABS The ABS (anti-skid brake system) is a brake system that ensures the steering ability and stable machine posture. It works by automatically suppressing the skidding caused by the wheels locking when the brakes are applied suddenly or are applied on snow-covered roads or other slippery road surfaces.
  • Page 293 ATTACHMENTS, OPTIONS HANDLING ABS ABS SYSTEM CHECK SWITCH This switch (3) is used to check the ABS system after the engine is started. RETARDER CONTROL LEVER When the retarder is being actuated with this lever (4), the ABS is actuated if there is a tendency for the tires to lock. BRAKE PEDAL When the wheel brakes are being applied with this pedal (5), the ABS is actuated if there is a tendency for the tires to lock.

  • Page 294: Abs System Check After Starting Engine

    ATTACHMENTS, OPTIONS HANDLING ABS ABS SYSTEM CHECK AFTER STARTING ENGINE After starting the engine, check the ABS system. 1. Set the machine in the following condition. If the machine is not in the following condition, the ABS system cannot be checked. Parking brake applied Brake oil pressure normal ABS main switch ON...

  • Page 295: Precautions When Using

    ATTACHMENTS, OPTIONS HANDLING ABS PRECAUTIONS WHEN USING WARNING When the ABS is actuated on a slippery road surface, the stopping distance will become slightly longer. In addition, when traveling at extremely low speed, the wheels may lock, so be very careful when driving. When traveling on roads with an extremely low friction coefficient (icy roads, etc.) or when traveling up or down a steep hill, it may not be possible to ensure safe travel even with the ABS installed.

  • Page 296: Handling Payload Meter Ii (Card Type)

    REMARK When reading the data to a PC, it is necessary to use the PC software provided by Komatsu. When using a card system, a memory card and memory card reader are needed. It is possible to set the machine ID, open ID, and travel speed limit for each payload meter (in other words, for each machine).

  • Page 297: Method Of Using Accurately

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) METHOD OF USING ACCURATELY 1. Recorded payload data When the dump lever is operated from FLOAT to any position other than the FLOAT, the payload is recorded. The reason for this is the following two points. To measure the payload that has actually been carried The payload can be measured more accurately by measuring the load that is actually dumped after subtracting the loss caused by spillage of the load during travel.

  • Page 298: General Locations

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) GENERAL LOCATIONS CONTROLLER SCREEN CAUTION When not inserting or removing memory card (9), always keep cover (10) closed. Display panel Calibration/clear switch Reception pilot lamp (Rx busy) Total/shift switch Transmission pilot lamp (Tx busy) Light/increment switch Memory card access lamp (CARD busy) Memory card...
  • Page 299 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) LEFT FACE OF CONTROLLER 6 - 16...
  • Page 300 Do not touch any switch except No. 7 and No. B. If you wish to adjust any switch except No. 7 and No. B to compensate the payload calculation value or speed or distance calculation value, please contact your Komatsu distributor. 6 - 17...
  • Page 301 HANDLING PAYLOAD METER II (CARD TYPE) MODEL SELECTION CODE CHART Model selection Model code display HD1200-1 STD Large-tire Cummins engine HD785-3 STD Large-tire Komatsu engine HD465-5/-7 STD Small-tire Komatsu engine HD325-6/-7 STD Large-tire Komatsu engine HD785-3 STD Small-tire Komatsu engine...
  • Page 302 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) EXTERNAL DISPLAY LAMPS Green lamp Yellow lamp Red lamp COMMUNICATIONS CABLE CONNECTION PORT FOR PERSONAL COMPUTER Download connector (rear of assistant's seat) 6 - 19...

  • Page 303: Content Of Display (Controller, External Display Lamps)

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS) WHEN THE POWER IS ON When the power is turned ON, the displays on the controller display and external display lamps are as follows. If the engine is started during this flow of displays, even if there are items remaining which should still be displayed, the display switches after several seconds to the display given during normal operations.
  • Page 304 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) DISPLAY DURING NORMAL OPERATIONS Gearshift Dump lever position Condition of machine lever Display panel External display lamps (*1) position Stopped FLOAT Payload display (*2) Payload display When empty Traveling Except N FLOAT Time display During Stopped...
  • Page 305 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) *1: Between the start of the loading operation and the start of the dumping operation, always keep the dump lever at the FLOAT position. If the dump lever is operated to any position other than FLOAT, the data will not be recorded when dumping, or the data will be recorded, but the data for time, distance, and speed will not be recorded accurately.
  • Page 306 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) NOTICE When stopping the machine empty, stopping it during loading, or stopping it when loaded, always set to the gearshift lever at the N position. (See "DISPLAY DURING NORMAL OPERATIONS (PAGE 6-21)".) If this is not done, the time that the machine is stopped will not be calculated, and it will be included in the travel time when empty or the travel time when loaded.

  • Page 307: External Display Lamps

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) EXTERNAL DISPLAY LAMPS DISPLAY LEVEL FOR LAMPS WARNING If the red lamp lights up, the machine is overloaded. Do not haul a load under this condition. To prevent overloading, we recommend loading only up to a range where the yellow lamp lights up. The external lamps display the payload as follows.
  • Page 308 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) ESTIMATE DISPLAY When the load changes in steps for each bucket loaded, the system estimates the total payload if one more bucket is loaded, and flashes the appropriate lamp to prevent overloading. The predicted load display and actual payload display are shown at the same time.

  • Page 309: Details Of Data Stored In Memory Of Payload Meter

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER The payload meter stores the data in this section in non-volatile RAM. This data are retained even when the power is switched OFF, so they can be used later as follows. (1) Using the communications cable (RS-232C), it is possible to send (download) the data to a PC, and to save these data to a CSV type text file.
  • Page 310 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) CYCLE DATA One cycle is taken as the time from the point where the load is dumped to the point where the next load is dumped, and the data between these two points are recorded. The cycle data are sent to the RAM every time the load is dumped.
  • Page 311 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) ENGINE ON/OFF DATA When the engine is started or stopped, these data are recorded in RAM. The maximum limit for engine ON/OFF data is 115 sets of ON/OFF. Item Unit Range Engine operation No. Integer 1 - 65535 Consecutive numbers for engine operation (*1)
  • Page 312 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) PROBLEM, WARNING DATA When a problem or warning occurs or is restored in the payload meter system, these data are recorded in RAM. The maximum limit for problem/warning data is 230 sets of occur/restore. Item Unit Range...
  • Page 313 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) TOTAL PAYLOAD, OVERALL NUMBER OF CYCLES DATA The total payload and overall number of cycles from any desired time are calculated and are recorded with each act of dumping. The calculation of both values is started from the point where the ZERO CLEAR switch is pressed for the total payload and overall number of cycles.

  • Page 314: Operation Of Switches

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) OPERATION OF SWITCHES By operating the switches on the payload meter, it is possible to force the following operations. "CARRYING OUT CALIBRATION (PAGE 6-32)" "FORCED DISPLAY OF TOTAL PAYLOAD AND OVERALL NUMBER OF CYCLES (PAGE 6-33)" "FORCED DISPLAY OF PROBLEMS, WARNINGS WHEN THEY HAVE OCCURRED (PAGE 6-33)"...
  • Page 315 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) CARRYING OUT CALIBRATION WHEN CARRYING OUT CALIBRATION NOTICE Carry out calibration in the following cases. When delivering the machine, and once a month after that. When the oil and gas pressure for the suspension cylinder has been adjusted. (When the suspension is adjusted.) When the chassis has been modified and the mass of the machine when empty has changed more than 100 kilograms.
  • Page 316 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) FORCED DISPLAY OF TOTAL PAYLOAD AND OVERALL NUMBER OF CYCLES FORCED DISPLAY OF PROBLEMS, WARNINGS WHEN THEY HAVE OCCURRED The payload meter displays the total payload when the load is dumped, but it is also possible to use the following operation to display the total payload and overall number of cycles.
  • Page 317 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) Method of clearing total payload and overall number of cycles 1. Press TOTAL/SFT switch (1) to display the total payload and overall number of cycles. 2. Keep CAL/CLR switch (2) pressed for at least 2 seconds. The total payload or overall number of cycles display will flash.
  • Page 318 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) OPERATOR CHECK MODE By using the operator check mode, it is possible to forcibly display, set, or correct the following. (a) Memory card dump The data stored in the payload meter is written en bloc to the memory card installed in the payload meter. REMARK This function only works when switch "5"...
  • Page 319 Use this to set the time and date on the payload meter. Of the functions in the operator check mode, the following can also be set from the personal computer using the personal computer download software supplied by Komatsu. Machine ID setting...
  • Page 320 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) METHOD OF OPERATION The operator check mode is actuated when the dump lever is at the FLOAT position and the gearshift lever is at the N position during display for normal operations. However, it does not work during the period from the start of the loading operation to completion of the loading operation.
  • Page 321 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) *1: This is actuated only when switch No. 5 (memory card switch) on the left side face of the controller is set to "used". *2: This is actuated only when switch No. 5 (memory card switch) on the left side face of the controller is set to "not used".
  • Page 322 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (a) Memory card dump operation 1. When the display is Cd:dP (Cd lights up, dP flashes), press TOTAL/SFT switch (1). The lighted up Cd display will change and start flashing. REMARK If you wish to stop the memory card dump operation when the display is Cd:dP (both Cd and dP are flashing), press MODE switch (2).
  • Page 323 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (b) Data all clear operation 1. When the display is A.CLE (A lights up, CLE flashes), keep CAL/CLR switch (1) pressed for at least 2 seconds. The lighted up A display will change and start flashing. REMARK If you wish to stop the data all clear operation when the display is A.CLE (both A and CLE are flashing), press MODE switch (2).
  • Page 324 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (c) Display of existing problems/warnings/restore status, status of input signals 1. When the display is F.CHE (flashing), press TOTAL/SFT switch (1). The existing problems or warnings will be shown as follows. 1) If there are no existing problems or warnings, F.--- (flashing for 6 sec.) is displayed.
  • Page 325 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) 4) Condition of signal for battery charge Display: C4:XX (lights up for 3 sec.) Engine running: C4:oo Engine stopped: C4:-- 5) Condition of signal for analog spare input 1 Display: C5:XX (lights up for 3 seconds) XX: Input signal (V) 6) Condition of signal for analog spare input 2 Display: C6:XX (lights up for 3 seconds)
  • Page 326 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (d) Machine ID setting 1. With the display at d.XXX (d.XX lights up, digit for units flashes), if it is necessary to correct the digit for the units, press LIGHT/INC switch (1) and correct the number. 2.
  • Page 327 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 4. If TOTAL/SFT switch (2) is pressed again, the flashing digit will return to the digit for the units and it becomes possible to correct the units again.
  • Page 328 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (e) Open ID setting 1. With the display at O.XXX (O.XX lights up, digit for units flashes), if it is necessary to correct the digit for the units, press LIGHT/INC switch (1) and correct the number. 2.
  • Page 329 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 4. If TOTAL/SFT switch (2) is pressed again, the flashing digit will return to the digit for the units and it becomes possible to correct the units again.
  • Page 330 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (f) Speed limit setting 1. With the display at SP.XX (SP.X lights up, digit for units flashes), if it is necessary to correct the digit for the units, press LIGHT/INC switch (1) and correct the number. 2.
  • Page 331 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (g) Option code setting 1. With the display at OP.XX (OP.X lights up, digit for units flashes), if it is necessary to correct the digit for the units, press LIGHT/INC switch (1) and correct the number. 2.
  • Page 332 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) (h) Adjusting time, date 1. With the display at XX.XX (Time display lights up, Minute display flashes), if it is necessary to correct the minute display, press LIGHT/INC switch (1) and correct the number. 2.
  • Page 333 If you wish to adjust any switch except No. 7 and No. B to compensate the payload calculation value or speed or distance calculation value, please contact your Komatsu distributor. SETTING FORCED PROHIBITION FOR SWITCHES For details, see "LEFT FACE OF CONTROLLER (PAGE 6-16)". In addition, when setting forced prohibition for the switches, please ask your Komatsu distributor. 6 - 50...
  • Page 334 By operating the service check mode, it is possible to carry out display, setting, and correction forcibly of the following items. If it is designed to correct the method of operation and setting, please ask your Komatsu distributor. (a) Detailed display of calibration data This display shows the data, suspension pressure, etc.
  • Page 335 This inputs, corrects, or sets the payload range for the lamps to light up when displaying the payload. Of the functions in the service check mode, the following can also be set from the personal computer using the personal computer download software supplied by Komatsu. Calibration data...

  • Page 336: Problem And Warning Display (Error Code)

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) PROBLEM AND WARNING DISPLAY (ERROR CODE) The payload meter always carries out self-diagnosis of the system, and if any problem or warning occurs, it is displayed by the monitor panel and the external display lamps. For details of the detection items and displays, see the problem and warning item table.
  • Page 337 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 6 - 54...
  • Page 338 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 6 - 55...
  • Page 339 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 6 - 56...
  • Page 340 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) *1: Warning display when memory is full 1. Cycle data 1) If more than 2600 cycles are recorded (less than 300 cycles remaining): L: FUL flashes 7 times flashes 1 time This is repeated. 2) If more than 2900 cycles are recorded (0 cycles remaining): L: FUL lights up (3 sec.) flashes 1 time...
  • Page 341 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) 4. Data for total payload, overall number of cycles 1) If the overall number of cycles goes above 9994 (less than 5 times remaining) or the difference between the total payload recorded in memory and 999900 tons (maximum limit) is less than 5 times the rated payload: H: FUL flashes 7 times (3 sec.) flashes This is repeated.
  • Page 342 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) *2: Defective cycle data payload The payload meter carries out the detection of the payload based on the signal from the suspension pressure sensor. It is always carrying out this detection, but the result is somewhat inaccurate because of the dynamic friction of the suspension during loading and immediately after loading.

  • Page 343: When Error Code F-09 Is Displayed (Procedure For Replacing Battery)

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY) The payload meter has an internal battery to prevent the recorded data from being deleted when the key in the starting switch is turned to the OFF position. If the voltage of the battery drops, F-09 is displayed as an error message, so replace the battery as follows.
  • Page 344 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 5. Remove the cover of the payload meter. As seen from the top, battery holder (5) is installed at position (B) in the diagram on the right stop using procedure (A) shown in the diagram, remove battery (7) from battery holder (5) without removing connector (6), then put it carefully on top of the motherboard.
  • Page 345 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) PROCEDURE AFTER REPLACING BATTERY When the battery is replaced, the backup power for the non-volatile memory inside the payload meter is momentarily cut, so mistaken data (garbage) may enter the memory and cause mistakes in the payload meter's recognition of the condition of the machine.

  • Page 346: Operation When Error Code F.cal Is Displayed Or Controller Has Been Replaced

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED If F.CAL is displayed, mistaken data have probably been written to the memory inside the payload meter. In addition, when the controller is replaced, old data may be recorded to the new controller, or the machine condition recognized by the controller may be different from the actual condition.
  • Page 347 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) CARRYING OUT FORCED INITIALIZATION CAUTION When this function is performed, all of the data recorded in the payload meter are deleted. Do not carry out this operation unless necessary. Check the date and time before starting, and always be sure that the machine is empty. This operation is possible only when the power is ON.
  • Page 348 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) 3. Keep CAL/CLR switch (4) pressed for at least 2 seconds. The 00:00 display will light up for 2 seconds, and when all the data is cleared, the display will automatically change to F.CAL. After this, carry out the procedure given in "OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED (PAGE 6-63)".

  • Page 349: 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 auto retarder (ARSC) switch is at the ON position.

  • Page 350: Explanation Of Components

    ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) EXPLANATION OF COMPONENTS Auto retarder (ARSC) switch Accelerator pedal Auto retarder (ARSC) set lever Brake pedal Auto retarder set speed indicator Auto retarder READY pilot lamp Central warning lamp Retarder pilot lamp Retarder control lever (A) Set (C) Decrease speed (B) Increase speed...
  • Page 351 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) AUTO RETARDER (ARSC) SET LEVER It is possible to use this lever (2) to set, cancel, or make fine adjustment of the ARSC set speed. (a) Set (b) Increase speed (tap up) (c) Decrease speed (tap down) (d) Cancel AUTO RETARDER SET SPEED INDICATOR This display (3) shows the set travel speed (km/h or MPH).
  • Page 352 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) AUTO RETARDER READY PILOT LAMP When this lamp (8) is lighted up, it shows that operation of the ARSC is possible at the set travel speed. When it is out, the ARSC is not actuated. It lights up for 3 seconds when the starting switch is turned ON to check the bulb.

  • Page 353: Method Of Operation

    ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF OPERATION ACTUATION OF ARSC SYSTEM The ARSC system is actuated when the auto retarder (ARSC) switch is ON. When the set switch of the auto retarder (ARSC) set lever is pressed, the travel speed at that point is set as the downhill travel speed.
  • Page 354 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) METHOD OF INCREASING SET TRAVEL SPEED If it is desired to increase the set speed, depress the accelerator pedal to increase speed, and when the desired set travel speed is reached, press the set switch on the auto retarder (ARSC) set lever. The set travel speed will be changed to the new speed.
  • Page 355 ATTACHMENTS, OPTIONS ARSC (AUTOMATIC RETARDER SPEED CONTROL) RECOMMENDED SET TRAVEL SPEED Set the travel speed so that the engine speed is at least 1800 rpm, and travel so that the retarder oil temperature gauge is in the white range. If there is danger that the retarder oil temperature may overheat, the retarder oil temperature caution lamp lights up and the set travel speed is automatically reduced in 1 km/h (0.6 MPH) steps every 3 seconds.

  • Page 356: Use Of Rear View Monitor

    ATTACHMENTS, OPTIONS USE OF REAR VIEW MONITOR USE OF REAR VIEW MONITOR WARNING Never operate any of the switches while in running. If you do so, there is the fear that you may make an error in the truck operation, or neglect to watch the hauling road ahead for safety, and as a result cause a serious personal injury. The rear view monitor is an aid for checking obstacles in the rear.
  • Page 357 ATTACHMENTS, OPTIONS USE OF REAR VIEW MONITOR MANUAL SWITCH When this switch (2) is pressed, an image of a camera appears on the monitor display. At that time, a mark "CAM1" appears on the upper left side of the display and a figure "5" on the upper right side of the display. REMARK When the manual switch is pressed to call an image and the operation is suspended thereafter, the image disappears in...
  • Page 358 ATTACHMENTS, OPTIONS USE OF REAR VIEW MONITOR BRIGHT/DIM LIGHT SELECTOR SWITCH When this switch is pressed, the brightness of the monitor display lowers. A mark of "DIM" appears on the upper left side of the display then. When the switch is pressed again, the brightness returns to the original level, and "DIM"...

  • Page 359: Setting Of Rear View Monitor

    Do not use the monitor if it is suspected of defect. There is a fear of electric shock or fire, should it be used in spite of a defect. In that case, ask your Komatsu distributor for repair or replacement.

  • Page 360: External Power Source Type Electric Heater

    ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER When the engine has been stopped, to make it easier to start the engine again next time and to carry out operations, this external electric heater is provided to heat all parts of the machine and maintain the temperature. The power source for this heater can be taken from an external commercial power supply to the socket on the side of the machine.

  • Page 361: Restarting Engine

    ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER RESTARTING ENGINE HANDLING ENGINE HEATER If the ambient temperature is below -40°C (-40°F), even if electricity is passed through the electric heater, it may be difficult to start the engine again depending on how much time has passed since the engine was stopped. Before starting the engine, use the hot air heater to preheat the engine and engine room.

  • Page 362: Handling External Power Source Type Electric Heater

    ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER This is a starting aid to use in seasons when the ambient temperature goes down to -20 - -40°C (-4 - -40 °F), or even in temperatures above that if it is difficult to start the engine because of the cold.
  • Page 363 ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER MANUFACTURING EXTERNAL POWER SOURCE INPUT CABLE It is required to purchasing and processing the external power source input cable locally to match the conditions. This does not mean that any cable can used. When purpose the cable, make sure that it the following specifications.
  • Page 364 ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER 3. Modify the other end of the cable so that it can be connected to the power supply facility shown in Diagram 1. When the connection modification is finished, the external power source input cable is completed. 6 - 81...
  • Page 365 ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER ESTABLISHING POWER SUPPLY When using this preheater, it is necessary to set up a power source facility as shown in "PROCEDURE FOR SETTING UP EXTERNAL POWER SOURCE FOR EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER (PAGE 6-79)".
  • Page 366 ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER HANDLING PROCEDURE This is a starting aid to use in seasons when the ambient temperature goes down to -20 - -40°C (-4 - -40 °F), or even in temperatures above that if it is difficult to start the engine because of the cold. CONTROL METHOD WARNING Stop the machine on level ground before starting the operation.
  • Page 367 ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER CIRCUIT DIAGRAM FOR EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER Coolant heater (1.5kW) Terminal box (2.7kW) Engine oil pan heater (0.6kW) Female connector for external power supply 6 - 84...

  • Page 368: Handling Dumping Counter

    ATTACHMENTS, OPTIONS HANDLING DUMPING COUNTER HANDLING DUMPING COUNTER The dumping counter is an automatic counting function to count the number of loads that have been dumped. The number of loads dumped is displayed on the character display. METHOD OF DISPLAYING, RESETTING DUMPING COUNTER 1.

  • Page 369: Handling Machines Equipped With Komtrax

    Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.

  • Page 370: Index

    INDEX INDEX <A> DO NOT GET CAUGHT IN DUMP AIR CONDITIONER 3- 64 BODY 2- 17 ARSC (AUTOMATIC RETARDER FIRE PREVENTION 2- 14 SPEED CONTROL) 6- 66 PRECAUTIONS BEFORE STARTING EXPLANATION OF COMPONENTS 6- 67 OPERATION 2- 12 METHOD OF OPERATION 6- 70 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...
  • Page 371 3-125 RECOMMENDED BRANDS, BEFORE STORAGE 3-125 RECOMMENDED QUALITY FOR DURING STORAGE 3-125 PRODUCTS OTHER THAN PRECAUTIONS BEFORE KOMATSU GENUINE OIL 4- 14 TRAVELING AFTER LONG-TERM USE OF FUEL, COOLANT AND STORAGE 3-125 LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13 7 - 2...
  • Page 372 INDEX <S> AFTER RUNNING OUT OF FUEL 3-126 SAFETY IF BATTERY IS DISCHARGED 3-133 SAFETY CRITICAL PARTS 4- 17 METHOD OF TOWING MACHINE 3-129 SAFETY INFORMATION OTHER TROUBLE 3-136 SAFETY LABELS POSITION FOR ATTACHING <U> SAFETY LABELS USE OF REAR VIEW MONITOR 6- 73 SAFETY LABELS CAUTIONS WHEN USING REAR...
  • Page 373 HD325-7, HD405-7 DUMP TRUCK Form No. TEN00425-06 © 2012 KOMATSU All Rights Reserved Printed in Japan 03-12...

This manual is also suitable for:

Ecot3 hd405-7Ecot3 hd325-7611Ecot3 hd405-7611

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