Komatsu ecot3 HD465-7E0 Operation & Maintenance Manual
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Komatsu ecot3 HD465-7E0 Operation & Maintenance Manual

Dump truck
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Table of Contents

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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.
HD465
HD605
SERIAL NUMBERS
WARNING
NOTICE
TEN00439-07
-7E0
-7E0
HD465-10739
and up
HD605-10739

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Summary of Contents for Komatsu ecot3 HD465-7E0

  • 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 or death 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 GENERAL VIEW AND 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 (3 ft 3in) from the outside surface of the machine at a height of 1.5 m (4 ft 11 in) 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 When requesting service or ordering replacement parts, contact 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 displayed 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 GENERAL VIEW AND 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 SWITCHES 3- 37 BODY PIVOT PIN 3- 47 LOCATION OF FIRE EXTINGUISHER 3- 48 DUST INDICATOR 3- 48 FUSES 3- 49 CAR RADIO 3- 52 CAR STEREO 3- 54 AIR CONDITIONER 3- 59 OPERATION 3- 64 CHECK BEFORE STARTING ENGINE 3- 64 STARTING ENGINE 3- 91...
  • Page 11 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 16 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 17 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 18 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 19 TORQUE LIST...
  • Page 12 FOREWORD CONTENTS HANDLING ANTI SKID BRAKE SYSTEM (ABS) 6- 18 EXPLANATION OF COMPONENTS 6- 18 ABS SYSTEM CHECK AFTER STARTING ENGINE 6- 19 OPERATION OF ABS 6- 20 PRECAUTION WHEN USING ABS SYSTEM 6- 20 TROUBLESHOOTING 6- 21 HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) 6- 22 OUTLINE OF SYSTEM 6- 22...
  • Page 14 2 - 1...

  • Page 15: Safety

    SAFETY IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION 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...
  • Page 16 SAFETY IMPORTANT SAFETY INFORMATION 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...
  • Page 17 SAFETY IMPORTANT SAFETY INFORMATION 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...

  • 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. There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way.

  • 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) Caution for modification of ROPS/FOPS (09620-A2000) (2) Caution for rotation of front drive shaft (09667-53000) (3) Caution for rotation of engine fan, fan belt (without side cover for engine) (09667-23001) (3) Caution for rotation of engine fan, fan belt (with side cover for engine) (09667-03001) 2 - 7...
  • Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for opening hydraulic tank cap (09653-03001) (5) Caution for opening radiator cap (09668-03001) (6) Caution for handling suspension (09659-33000) 2 - 8...
  • Page 22 SAFETY SAFETY LABELS (7) Warnings for electric wire Warnings for crush hazard when inspection and maintenance (56B-93-12180) (8) Caution before starting Caution when traveling in reverse (569-93-81730) (9) Caution for handling battery cable (09808-03000) 2 - 9...
  • Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Exhaust pipe is hot! (09817-K088B) (11) Caution for avoiding falling down (09805-13000) (12) Caution when handling battery (09664-30011) (For North America only) 2 - 10...
  • Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (13)Caution for handling battery (This plate is fixed in position by the battery maker) (14)Jump start prohibited (09842-A0481) (This plate is stuck on the starting motor.) (15) Precautions for handling external power source type electric heater (09804-10480) (For the machine with external power source type electric heater)

  • 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 performing 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 perform 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 starting 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 open flame 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 or death caused by slipping or falling off the machine, always observe the following.

  • 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 or death, 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 performing inspection and maintenance of the machine. If the warning sign is ignored and the machine is operated, there is danger that the person performing 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 performed 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 performing 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, 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 perform 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, contact your Komatsu distributor to have the work performed. For the procedure when transporting, see "TRANSPORTATION (PAGE 3-130)".

  • 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 3-141)"...

  • 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 performing inspection and maintenance of the machine.
  • Page 43 SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE PERFORMING INSPECTION AND MAINTENANCE Always stop the machine before performing any inspection and maintenance. Lower the dump body completely, set dump lever (1) to 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 perform maintenance with the engine running. If maintenance must be performed with the engine running, perform the operation with at least 2 workers and observe the following. 1 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 performed by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when performing welding, so never allow any unqualified personnel to perform 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, 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 4-20)".

  • 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 perform 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 HD465-7. Dump body Step Steering and Hoist oil tank (10) Radiator Operator's cab (11) Aftercooler Rear view mirror (12) Rear combination lamp Under mirror (13) Back-up lamp Combination lamp (14) Tail lamp...

  • Page 56: General View Of Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Lamp switch,Turn signal switch,Dimmer switch Accelerator pedal Machine monitor (10) Brake pedal Retarder control lever (11) Secondary brake pedal Auto retarder (ARSC) set lever (12) Dump lever lock knob Starting switch (13) Dump lever Cigarette lighter...

  • Page 57: Dashboard

    OPERATION GENERAL VIEW DASHBOARD Side lamp switch (if equipped) Front brake cut-off switch (if equipped) Machine monitor bulb check switch Auto retarder (ARSC) switch Monitor lighting dimmer switch (10) ASR switch (if equipped) Hazard lamp switch (11) ABS switch (if equipped) Emergency steering switch (12) Machine monitor mode selector switch 2...

  • Page 58: Explanation Of Components

    OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS This section explains about the components needed for operation. In order to carry out work correctly, safely and comfortably, it is important to correctly understand the method of operating the components and the contents of the displays. GENERAL VIEW OF MACHINE Rear view mirror Handrail and step...
  • Page 59 OPERATION EXPLANATION OF COMPONENTS REAR VIEW MIRROR Use this rear view mirror (1) to check the area at the rear of the machine from the operator's seat. Before starting operations, adjust the angle of the mirror to ensure a good view to the rear. To ensure that the angle of the mirror does not change during operation, check that there is no looseness of the mount.
  • Page 60 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP This head lamp (4) lights up the road and the area ahead when the machine is traveling at night. Turn the lamp on and off with this lamp switch. Use the dimmer switch to switch between high beam and low beam.

  • Page 61: Operator's Cab

    OPERATION EXPLANATION OF COMPONENTS OPERATOR'S CAB Door lock knob Door pocket Sun visor Door handle Dashboard pocket Door lock First aid kit storage box 3 - 8...
  • Page 62 OPERATION EXPLANATION OF COMPONENTS DOOR LOCK KNOB Use this door lock knob (1) to lock the door from inside the operator's compartment. Raise knob:It be able to open door Lower knob:It be able to lock door There are doors on the left and right. SUN VISOR The angle of this sun visor (2) can be adjusted to prevent the sun from shining in your eyes from the front of the machine when traveling.

  • Page 63: Control Levers And Pedals

    OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Steering wheel Brake pedal Retarder control lever Secondary brake pedal Auto retarder (ARSC) set lever Dump lever lock knob Gear shift lever Dump lever Accelerator pedal STEERING WHEEL NOTICE When the steering wheel is turned fully to the right or left, do not apply force to try to turn it further. The temperature of the steering hydraulic circuit will rise and cause overheating, and this will lead to damage of steering related components.
  • Page 64 OPERATION EXPLANATION OF COMPONENTS RETARDER CONTROL LEVER WARNING Do not use the retarder control lever instead of the parking brake. If the retarder is used as a parking brake when the starting switch is ON, the braking force will gradually become weaker. If the machine is parked on a slope, the machine may move off without the operator and cause serious personal injury.
  • Page 65 OPERATION EXPLANATION OF COMPONENTS GEAR SHIFT LEVER Use this gear shift lever (4) to select the speed range for the transmission to match the travel conditions. The relationship between the range of the transmission for each position of the gear shift lever and the direction of travel and a maximum travel speed is as follows.
  • Page 66 OPERATION EXPLANATION OF COMPONENTS Position D : This is the position for normal travel. If the dump body is still raised, the transmission is fixed in 1st speed and will not shift to any other speed range. When traveling, lower the dump body, set the dump control lever to FLOAT, then press the lock button on the lever and move the lever to position D.
  • Page 67 OPERATION EXPLANATION OF COMPONENTS SECONDARY BRAKE PEDAL Use secondary brake pedal (7) to apply the front brake and parking brake to stop the machine. Use this brake when the brake suddenly does not work due to damage to the brake pedal. REMARK If the pressure of accumulated in the brake hydraulic circuit accumulator goes down, the secondary brake will be actuated...
  • Page 68 OPERATION EXPLANATION OF COMPONENTS DUMP LEVER LOCK KNOB DANGER When carrying out inspection with the dump body raised, always set the dump control lever to the HOLD position, set the dump control lever lock knob to the LOCK position, then insert the body pivot pin. If the body pivot pin is not inserted, the dump body may go down when the dump control lever is operated, and catch or cause serious injury or even death to the person carrying out the inspection.

  • Page 69: Machine Monitor

    OPERATION EXPLANATION OF COMPONENTS MACHINE MONITOR Torque converter oil temperature (18) Emergency steering pilot lamp Engine water temperature (19) Dump body pilot lamp Engine tachometer (20) Retarder pilot lamp Power mode pilot lamp (21) Character display Lockup pilot lamp (22) Central warning lamp Shift indicator (23)
  • Page 70 OPERATION EXPLANATION OF COMPONENTS TORQUE CONVERTER OIL TEMPERATURE This torque converter oil temperature gauge (1) shows the torque converter oil temperature. Range (A) (white range): Indicator should be in this range during normal operations Range (B) (red range): If indicator enters red range during operations, oil is overheating If this happens, caution lamp (C) inside the torque converter oil temperature gauge...
  • Page 71 OPERATION EXPLANATION OF COMPONENTS ENGINE TACHOMETER NOTICE If the engine overruns, it may cause serious damage to the engine, and the engine will need an overhaul. If the engine speed enters range (B), release the accelerator pedal, depress the brake pedal, and reduce the machine speed.
  • Page 72 OPERATION EXPLANATION OF COMPONENTS SHIFT INDICATOR This shift indicator (6) shows the transmission shift position (speed range) selected by the gear shift lever. The letter or numeral showing the shift position (speed range) selected by the gear shift lever lights up. TURN SIGNAL PILOT LAMP(LEFT) This turn signal pilot lamp (left) (7) shows the turn signal lamp is flashing, at the left side of machine.
  • Page 73 OPERATION EXPLANATION OF COMPONENTS TURN SIGNAL PILOT LAMP(RIGHT) This turn signal pilot lamp (right) (9) shows the turn signal lamp is flashing, at the right side of machine. When the turn signal lever is operated to the right, the turn signal lamp flashes, and when the turn signal lever is returned to the center position, the lamp goes out.
  • Page 74 OPERATION EXPLANATION OF COMPONENTS AUTO SUSPENSION MODE PILOT LAMP (if equipped) This auto suspension pilot lamp (11) shows the suspension mode being used. With this machine, an automatic suspension system is available as an option. This system automatically selects the hardness of the suspension according to the condition of the machine load and the operating condition of the brakes, steering, and dump control.
  • Page 75 OPERATION EXPLANATION OF COMPONENTS AUTO RETARDER SET SPEED INDICATOR This auto retarder set speed indicator (14) shows the travel speed set by the auto retarder (ARSC) set lever. When the set speed has been cancelled, "0" is displayed. When the switch of the auto retarder (ARSC) set lever is turned OFF, the indicator goes out.
  • Page 76 OPERATION EXPLANATION OF COMPONENTS PREHEATING PILOT LAMP This preheating pilot lamp (17) shows if the engine preheating electrical heater is actuated. When the starting switch is turned ON, if the engine water temperature is low, the preheating electrical heater is actuated and the pilot lamp lights up.
  • Page 77 OPERATION EXPLANATION OF COMPONENTS CHARACTER DISPLAY This character display (21) shows the following items. Service meter Odometer Reverse travel odometer Action code display Filter, oil replacement time display Payload display (if equipped) For details of the display, see "DISPLAY OF CHARACTER DISPLAY (PAGE 3-29)".
  • Page 78 OPERATION EXPLANATION OF COMPONENTS SEAT BELT CAUTION LAMP This seatbelt monitor lamp (24) shows if the operator is wearing the seatbelt. If the operator is not wearing the seatbelt, the lamp lights up. When operating the machine, always wear the seatbelt and check that the seatbelt caution lamp goes out.
  • Page 79 OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE CAUTION LAMP This engine oil pressure caution lamp (27) shows that there is a problem in the engine oil pressure. If any problem occurs in the pressure of the engine lubricating oil when the engine is running, the caution lamp lights up, the alarm buzzer sounds intermittently, the central warning lamp lights up, "E02 CHECK RIGHT NOW "...
  • Page 80 OPERATION EXPLANATION OF COMPONENTS ENGINE SYSTEM CAUTION LAMP This engine system caution lamp (30) shows that there is a problem in the engine system controller. If any problem is detected in the control system of the engine controller, the caution lamp lights up, the alarm buzzer sounds intermittently, the central warning lamp lights up, and "E03 CHECK RIGHT NOW "...
  • Page 81 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE MONITOR CAUTION LAMP This maintenance monitor caution lamp (34) lights up if maintenance is necessary, and "E01" and the location of the place requiring maintenance are displayed on the character display. Carry out inspection or replacement, or add fluid at the indicated location.

  • Page 82: Display Of Character Display

    OPERATION EXPLANATION OF COMPONENTS DISPLAY OF CHARACTER DISPLAY The following items can be displayed on the character display. Service meter Action code display Odometer Filter, oil replacement time display Reverse travel odometer Payload display (if equipped) Normally, service meter (1) is displayed on the top line and odometer (2) is displayed on the bottom line. Reverse travel odometer (3) and payload display (6) can be displayed by switching the display.
  • Page 83 If an overheat related display is given, stop the machine and run at the engine at a mid-range speed under no load. After taking the above action, if an action code is displayed, check the failure code and ask your Komatsu distributor to carry out repairs.
  • Page 84 OPERATION EXPLANATION OF COMPONENTS FILTER,OIL REPLACEMENT TIME DISPLAY This display appears after completion of the system check. The top line shows the ID number and the filter or oil that is approaching time for replacement. The bottom line shows the remaining time. The display is given for 30 seconds.
  • Page 85 OPERATION EXPLANATION OF COMPONENTS 2) Explanation of filter, oil replacement procedure For details of the replacement procedure for filters and oil, see the appropriate item listed below. Fuel pre-filter "REPLACE FUEL PREFILTER CARTRIDGE (PAGE 4-64)" Fuel main filter "REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-66)" Engine oil filter "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-63)"...

  • Page 86: Other Functions Of Character Display

    OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF CHARACTER DISPLAY DISPLAY MEYHOD 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 ON position and wait for the above display to be given.
  • Page 87 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 88 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 89 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 90: Switches

    OPERATION EXPLANATION OF COMPONENTS SWITCHES Side lamp switch (if equipped) (11) Automatic idling setting system (AISS LOW) Machine monitor bulb check switch switch Lamp switch (12) Front brake cut-off switch Turn signal lever (13) Auto retarder (ARSC) switch Dimmer switch (14) Wiper, window washer switch Monitor lighting dimmer switch...
  • Page 91 OPERATION EXPLANATION OF COMPONENTS SIDE LAMP SWITCH (if equipped) Use this side lamp switch (1) to turn the side lamps on or off. When portion (A) of the switch is pressed, the side lamp lights up and the monitor lamp inside portion (A) of the switch also lights up. When portion (B) of the switch is pressed, the side lamp goes out and the monitor lamp inside portion (A) of the switch also goes out.
  • Page 92 OPERATION EXPLANATION OF COMPONENTS DIMMER SWITCH Use this dimmer switch (3) to switch the head lamp between high beam and low beam. When the turn signal lever is moved up in direction (A), the head lamps switch to high beam and the head lamp high beam pilot lamp on the machine monitor lights up.
  • Page 93 OPERATION EXPLANATION OF COMPONENTS HAZARD LAMP SWITCH When this hazard lamp switch (6) is operated, the left and right turn signals flash at the same time. Use this when the machine is stopped. When portion (A) of the switch is pressed, the left and right turn signal lamps flash at the same time and the monitor lamp inside portion (A) of the switch also lights up.
  • Page 94 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Use this starting switch (9) to start or stop the engine. When the key is inserted in the starting switch, it can be turned to the following positions. OFF position: In this position, the key can be inserted or removed. When it is turned to the OFF position, all the electrical systems on the machine are turned off and the engine stops.
  • Page 95 OPERATION EXPLANATION OF COMPONENTS AUTOMATIC IDLING SETTING SYSTEM (AISS LOW) SWITCH Use this switch (11) to switch between automatic and low speed for the AISS system. Use each position as follows. (A): Low speed (LOW) position Use this position when fine control of the travel speed is needed, such as when parking the machine.
  • Page 96 OPERATION EXPLANATION OF COMPONENTS AUTO RETARDER (ARSC) SWITCH Use this auto retarder (ARSC) switch (13) to turn the auto retarder (ARSC) system on or off. When portion (A) of the switch is pressed, the auto retarder (ARSC) is turned ON and the monitor lamp inside portion (A) of the switch lights up.
  • Page 97 OPERATION EXPLANATION OF COMPONENTS FOG LAMP SWITCH (if equipped) Use this fog lamp switch (16) to switch the fog lamp on and off. When portion (A) of the switch is pressed, the fog lamp lights up and the monitor lamp inside portion (A) of the switch also lights up. When portion (B) of the switch is pressed, the fog lamp goes out and the monitor lamp inside portion (A) of the switch also goes out.
  • Page 98 OPERATION EXPLANATION OF COMPONENTS POWER WINDOW SWITCH (RIGHT) (LEFT) (The right power window is optional.) WARNING Before closing the window glass, make sure that no one has put his head or hand through the window. If the hands or head are caught between the frame and the window glass, there is danger of serious injury if someone's hand is caught, and there is danger of death if someone's head is caught.
  • Page 99 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE SWITCH CAUTION When stopping or parking the machine, always apply the parking brake. On slopes, there is danger that the machine may move off without any operator on board, leading to serious personal injury involving people in the area around the machine. Use this parking brake switch (20) to apply and release the parking brake.

  • Page 100: Body Pivot Pin

    OPERATION EXPLANATION OF COMPONENTS BODY PIVOT PIN DANGER Always carry out the operation to remove or insert the body pivot pin with at least two workers. This operation is carried out with the dump body raised, so if the dump body goes down during the operation, it will lead to serious injury or even death. When carrying out inspection with the dump body raised, always set the dump control lever to the HOLD position, set the dump control lever lock knob to the LOCK position, then insert the body pivot pin.

  • Page 101: Location Of Fire Extinguisher

    OPERATION EXPLANATION OF COMPONENTS STOWING BODY PIVOT PIN Store the body pivot pin under the rear of the dump body. Insert body pivot pin (1), then insert lock pin (2) to stow the body pivot pin. 1. Start the engine. 2.

  • Page 102: Fuses

    OPERATION EXPLANATION OF COMPONENTS FUSES NOTICE When replacing any fuse, always replace it with a fuse of the same capacity and same type. If the capacity of the fuse is too low, the fuse will blow when the power is turned on; if it is too high, excessive current will flow in the circuit and this may damage the electrical equipment.
  • Page 103 OPERATION EXPLANATION OF COMPONENTS Fuse box BT2 No. Capacity Name of circuit (11) Machine monitor, payload meter 2 controller Back camera (if equipped), (12) KOMTRAX Plus down load (13) Parking brake electric circuit (14) Power window (left) (15) Power window (right) (16) Payload meter 2 controller (17)
  • Page 104 OPERATION EXPLANATION OF COMPONENTS Fuse box BT4 No. Capacity Name of circuit (41) Room lamp (42) Engine preheat power (43) Yellow rotating lamp (if equipped) (44) Side lamp (if equipped) Electric operator's seat heater (if equipped), (45) Air suspension seat (if equipped) (46) Payload external display lamp (if equipped) (47)

  • Page 105: Car Radio

    OPERATION EXPLANATION OF COMPONENTS CAR RADIO EXPLANATION OF COMPONENTS Power switch/Volume knob Clock button/Displaying frequency Tone control knob Seek button Display AST button Preset button Band selector button Tuning button POWER SWITCH/VOLUME KNOB When Power switch/Volume knob (1) is turned to the right, it clicks and the power is turned on. If it is turned further, the speaker volume is adjusted.
  • Page 106 OPERATION EXPLANATION OF COMPONENTS CLOCK BUTTON When Clock button (6) is pressed, the display changes to the time. If it is pressed again, it displays the frequency. REMARK Adjusting time 1. Turn the radio power on. If the display is showing the frequency, press the CLOCK button to display the time.

  • Page 107: Car Stereo

    OPERATION EXPLANATION OF COMPONENTS CAR STEREO (if equipped) EXPLANATION OF COMPONENTS 3 - 54...
  • Page 108 OPERATION EXPLANATION OF COMPONENTS Details of display Band display Tape direction display Metal tape display Preset channel display FM stereo reception display Time/Radio display Loudness dispalay Power switch/Volume knob Fast forward, rewind buttons Auto-store/Preset scan button (10) Preset buttons Bass control knob (11) Metal tape button Treble control knob...
  • Page 109 OPERATION EXPLANATION OF COMPONENTS LOUDNESS BUTTON Loudness button (5) is used when playing at low volume. It makes it possible to hear more easily by emphasizing the low tone when the low tones are weak. When the loudness is operated, the loudness display mark is shown on the display. Push button: Actuated (ON) Push button again:Canceled (OFF) TIME/RADIO DISPLAY SELECTOR BUTTON...
  • Page 110 OPERATION EXPLANATION OF COMPONENTS DISPLAY Display (12) shows the following. (A)Band display This shows the band selected by the band selector button. (B)Metal tape display When metal tape is used and the metal tape button is pressed, "MTL" is displayed to show that the setting is for metal tape.
  • Page 111 OPERATION EXPLANATION OF COMPONENTS PRECAUTIONS FOR USE To ensure safety, adjust the sound to a level where it is possible to hear outside sounds during operation. If water gets inside the speaker case or stereo (auto tuning), it may cause a serious problem, take care not to let water get in these items.

  • Page 112: 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 113 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 114 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 115 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 116 FILTER (PAGE 4-33)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-34)" for details. 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 perform other checks. 3 - 63...

  • Page 117: Operation

    Remove any flammable material and repair fuel and oil leaks. If this action is not taken, it may lead to fire. If it is impossible to repair, please ask your Komatsu distributor to carry out repairs. The content of these items shows the items that must be checked at the beginning of each day. Carry out these checks in combination with CHECK BEFORE STARTING (PAGE 3-69).
  • Page 118 OPERATION OPERATION Check the dump body, frame, cylinders, linkage, and hoses for cracks or excessive wear or play. Check the dump body, frame, cylinders, linkage, and hoses for cracks or excessive wear or play, and carry out repairs if any problem is found. Remove dirt from around engine, battery, radiator, and aftercooler.
  • Page 119 Check for damage to seat belt and mounting clamps. If damages are found, replace with the new one. Check that there are no loose bolts in the mounting clamps mounting the seat belts to the machine. If any loose bolts are found, contact your Komatsu distributor and have them tightened to the specified tightening torque.
  • Page 120 OPERATION OPERATION Inspect tires. WARNING If any worn or damaged tire is used, there is danger that the tire may suddenly explode or be damaged, and this may lead to serious personal injury. If any defective tires are found during inspection, replace them with new tires or tires with no problems.
  • Page 121 OPERATION OPERATION Inspect rims. WARNING If rims or rings are used when they are deformed, corroded, damaged, or cracked, the ring may fly off when the tires are inflated and cause damage or serious personal injury. If any problem is found when inspecting the rims or rings, replace with a new rim or ring or with a rim or ring that has no problem.
  • Page 122 OPERATION OPERATION CHECK BEFORE STARTING WARNING During operation, or during inspection and maintenance, if any problem is noticed on the machine (noise, vibration, smell, wrong display by gauges, smoke, oil leakage, or problem displays on the warning devices or monitors), stop the machine on flat ground where it does not obstruct any other machines, then report immediately to the jobsite supervisor and carry out the necessary repairs.
  • Page 123 4. Check that there is no oil in the cooling water. If there is oil in the cooling water, there is probably some problem with the engine. Please contact your Komatsu distributor to have the engine inspected. 5. After adding water, tighten the cap securely.
  • Page 124 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Immediately after the engine is stopped, the oil and parts are at high temperature, so there is danger of suffering burns during the operation. Wait for the temperature to go down before starting the operation. Before starting the engine, check the level of the oil in the engine oil pan with dipstick (G).
  • Page 125 OPERATION OPERATION CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL NOTICE The oil level changes according to the oil temperature, so check the oil level after carrying out the warming-up operation. If the machine is used when check is carried out with the oil at low temperature, the oil level may not be correct and this may damage the equipment.
  • Page 126 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 127 OPERATION OPERATION DRAIN WATER, SEDIMENT FROM FUEL TANK If the sediment or water inside the fuel tank flows to the engine, it will cause engine trouble. Drain the sediment and water collected at the bottom of the fuel tank. 1. Set a container under the fuel tank to catch the fuel. 2.
  • Page 128 Komatsu distributor to carry out inspection. CHECK BRAKING EFFECT Check that the parking brake, foot brake, and retarder brake work properly. If there is any problem, please contact your Komatsu distributor for repair. 3 - 75...
  • Page 129 5. Lower the engine speed and set the shift lever to "N" position and set the parking brake switch to the "PARKING" position. 6. If there is a problem in the brake, ask your Komatsu distributor to carry out repairs. REMARK "Secondary brake"...
  • Page 130 1. Turn starting switch to the ON position. 2. Turn emergency steering switch (1) ON, and check that the steering wheel can be operated. If the steering wheel cannot be operated, ask your Komatsu distributor. REMARK The emergency steering pump can be used for a maximum of 90 seconds.
  • Page 131 If a fuse blows or there are traces of a short circuit in the electric wiring, check for the cause immediately and ask your Komatsu distributor to carry out repairs. If short circuits in the electric wiring are left as they are and not repaired, there is danger that the electrical equipment will be damaged and it may become impossible to operate the machine.
  • Page 132 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 133 CHECK FUNCTION OF HORN 1. Turn the starting switch to 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 - 80...
  • Page 134 OPERATION OPERATION ADJUSTMENT BEFORE OPERATION GETTING INTO OPERATOR'S COMPARTMENT WARNING Never jump on the machine. There is danger that your feet will slip, and you will fall and be injured. Never jump off the machine. There is danger that you will break a bone or suffer other injury when landing. When entering the operator's compartment, wipe off all mud and oil from the soles of your shoes.
  • Page 135 OPERATION OPERATION WARNING When standing up from the operator's seat, place the gear shift lever in N position and set the parking brake switch to PARKING position. Place the dump control lever at HOLD and lock with the lock knob, then stop the engine. If you touch the gear shift lever or dump control lever, the machine may suddenly move and cause serious personal injury.
  • Page 136 OPERATION OPERATION HEIGHT ADJUSTMENT OF OPERATOR'S SEAT 1. Operate lever (2) up or down to adjust the height of the seat cushion. 2. Set the seat cushion to the desired height, then release lever (2). This adjustment procedure is also used for adjusting the seat angle, so adjust the seat angle as desired.
  • Page 137 OPERATION OPERATION WARNING If the height of the headrest is not properly adjusted, the headrest cannot protect your head from being thrown back if the machine is hit from behind, and this may lead to serious injury. Before starting to travel, adjust the height of the headrest so that the center of the headrest is at the back of your head.
  • Page 138 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 sooner.
  • Page 139 Lever operating force: 98.1 N to 127 N {10 kgf to 13 kgf} The lever (1) may become loose or get out of angle. In this case, Ask your Komatsu distributor to perform repairs. The bolts (2) and (3) on steering column are the left-hand screw.
  • Page 140 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 141 OPERATION OPERATION (Z): Ground contact point of tire used as base 3 - 88...
  • Page 142 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING 1. Set the parking brake switch (1) to the PARKING position. 2. Set the shift lever (2) to N position. REMARK If the gear shift lever is not at the N position and the starting switch is turned to the ON position, the gear shift lever position pilot lamp and the central warning lamp will flash, and the alarm buzzer will sound.
  • Page 143 "KOMATSU SYSTEM CHECK" is displayed on the character display for 3 seconds. If no display appears, there is probably a failure or disconnection in the wiring, so ask your Komatsu distributor to carry out repairs.

  • Page 144: Starting Engine

    OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING When starting the engine, sit in the operator's seat, sound the horn to warn people in the surrounding area that the machine is about to move, then start the engine. If the machine is started off without giving a warning, there is danger that the people in the area around the machine may suffer serious personal injury.
  • Page 145 OPERATION OPERATION STARTING IN COLD WEATHER WARNING When starting the engine, sit in the operator's seat, sound the horn to warn people in the surrounding area that the machine is about to move, then start the engine. If the machine is started off without giving a warning, there is danger that the people in the area around the machine may suffer serious personal injury.
  • Page 146 OPERATION OPERATION OPERATION OPERATION 2. Turn the key of starting switch (1) to the START position. The engine will start. REMARK When the engine is started, the machine monitor may flash while the starting motor is rotating, but if it goes out after the engine starts, there is no problem.

  • Page 147: Operations, Checks After Starting Engine

    Immediately after the engine is started, if the steering oil temperature is low, the steering will be slightly heavy, so avoid traveling at high speed. If there are any problems, please ask your Komatsu distributor to carry out adjustment and repairs. 3 - 94...

  • Page 148: Stopping Engine

    OPERATION OPERATION STOPPING ENGINE NOTICE Except when stopping in emergencies, run the engine at low idle to cool it down gradually after operations. If the engine is stopped without allowing it to cool down, the turbocharger is still rotating under inertia, so there will be lack of lubricating oil and this will reduce the service life of the machine.

  • Page 149: Moving Machine Off (Forward, Reverse), Stopping

    OPERATION OPERATION MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING MOVING MACHINE FORWARD WARNING When operating the machine, always sit in the operator's seat. If you do not sit in the operator's seat, it will be impossible to stop operations if an problem occurs and there is danger that this may lead to serious personal injury. Do not allow any other person on the machine unless they are sitting in the assistant's seat.
  • Page 150 OPERATION OPERATION OPERATION OPERATION 4. Depressed the brake pedal fully. 5. Set the parking brake switch (4) to the TRAVEL position to release the parking brake. REMARK If the engine is stopped with the parking brake switch at TRAVEL, the parking brake will be applied automatically even though the parking brake switch is at TRAVEL.
  • Page 151 OPERATION OPERATION MOVING MACHINE IN REVERSE WARNING When operating the machine, always sit in the operator's seat. If you do not sit in the operator's seat, it will be impossible to stop operations if an problem occurs and there is danger that this may lead to serious personal injury. Do not allow any other person on the machine unless they are sitting in the assistant's seat.
  • Page 152 OPERATION OPERATION OPERATION OPERATION 4. Place gear shift lever (1) in the R position and depress accelerator pedal (2) gradually. The machine will move in reverse. REMARK The machine cannot travel in reverse when the dump body is raised. Lower the dump body, set the dump lever to the FLOAT position, then set the shift lever to the R position.
  • Page 153 OPERATION OPERATION STOPPING MACHINE WARNING When stopping the machine, reduce speed gradually. Do not stop the machine suddenly. If the machine is stopped suddenly, there is danger that the machine will turn to one side. This may lead to serious personal injury.
  • Page 154 3. When the machine stops, set parking brake switch (3) to the PARKING position. 4. After making an emergency stop, put blocks under the tires immediately. Investigate the failure of the front brakes and ask your Komatsu distributor to carry out repairs. 3 - 101...

  • Page 155: 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 156 OPERATION OPERATION SHIFTING DOWN Release accelerator pedal (2). The machine decelerates and the transmission is automatically shifted 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 eath gear position, the transmission is not shifted immediately but is shifted down when the travel speed drops.

  • Page 157: Traveling Downhill

    Komatsu distributor to carry out repairs. If the retarder control lever is operated when traveling downhill, the transmission can be shifted down sooner than with normal deceleration.
  • Page 158 OPERATION OPERATION OPERATION OPERATION 1. Before starting to travel downhill, release accelerator pedal (1). 2. Operate retarder control lever (2) to reduce the travel speed to the set speed limit. REMARK details setting speed limit, "BRAKE PERFORMANCE CURVE (PAGE 3-109)". 3.
  • Page 159 OPERATION OPERATION 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 If the travel speed is set at a speed that exceeds the maximum permissible speed obtained from the brake performance graph, the brakes will overheat and make it impossible to provide the braking force.
  • Page 160 OPERATION OPERATION OPERATION OPERATION 5. When traveling downhill, if the machine starts to exceed the set travel speed, the retarder is actuated automatically. While it is being actuated, retarder pilot lamp (5) lights up. REMARK The set travel speed is saved to memory and displayed on the ARSC set speed indicator on the machine. If the accelerator pedal is depressed while the ARSC is being actuated, the actuation of the ARSC is canceled and the machine accelerates.
  • Page 161 OPERATION OPERATION 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 162 OPERATION OPERATION BRAKE PERFORMANCE CURVE HD465-7 Method of using graph Example: Downhill distance: 1500 m (4921 ft) Travel resistance: -11% [grade resistance: -13%, rolling resistance: 2%] Load: 55 tons Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
  • Page 163 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1,476 ft)] (Tire size: 24.00-35-36PR) Brake performance [Downhill distance: 600 m (1,968 ft)] (Tire size: 24.00-35-36PR) 3 - 110...
  • Page 164 OPERATION OPERATION Brake performance [Downhill distance: 900 m (2,952 ft)] (Tire size: 24.00-35-36PR) Brake performance [Downhill distance: 1,500 m (4,921 ft)] (Tire size: 24.00-35-36PR) 3 - 111...
  • Page 165 OPERATION OPERATION Brake performance [Downhill distance: Continuous] (Tire size: 24.00-35-36PR) 3 - 112...
  • Page 166 OPERATION OPERATION HD605-7 Method of using graph Example: Downhill distance: 1500 m (4921 ft) Travel resistance: -11% [grade resistance: -13%, rolling resistance: 2%] Load: 63 tons Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill under the above conditions.
  • Page 167 OPERATION OPERATION Brake performance [Downhill distance: 450 m (1,476 ft)] (Tire size: 24.00R35 Brake performance [Downhill distance: 600 m (1,968 ft)] (Tire size: 24.00R35 3 - 114...
  • Page 168 OPERATION OPERATION Brake performance [Downhill distance: 900 m (2,952 ft)] (Tire size: 24.00R35 Brake performance [Downhill distance: 1,500 m (4,921 ft)] (Tire size: 24.00R35 3 - 115...
  • Page 169 OPERATION OPERATION Brake performance [Downhill distance: Continuous] (Tire size: 24.00R35 3 - 116...

  • Page 170: Steering The Machine

    OPERATION OPERATION STEERING THE MACHINE WARNING Do not operate the steering when traveling at high speed or on steep slopes. There is danger that the machine may tip over and cause serious damage or serious personal injury to people in the area around the machine.

  • Page 171: Dump Operations

    OPERATION OPERATION DUMP OPERATIONS WARNING It is difficult to confirm the situation in the area around the dumping point from the operator's seat, so there is danger of serious personal injury if anyone is in the surrounding area. When dumping the load from the dump body, follow the signals from a signalman.
  • Page 172 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. 3 - 119...

  • Page 173: Precautions For Operation

    OPERATION OPERATION PRECAUTIONS FOR OPERATION When traveling on roads in rain or snow, or when traveling on muddy or soft ground, consider the loaded condition of the machine and be extremely careful not to let the tires slip or the machine spin and sink into the ground. If the engine should stop when the machine is traveling, stop the machine immediately, then move the gear shift lever to the N position, and start the engine again.

  • Page 174: Parking Machine

    OPERATION OPERATION PARKING MACHINE WARNING Park the machine on firm, horizontal ground. If the machine is parked on a slope, it may suddenly move and cause serious personal injury. If the machine has to be parked on a slope, always put blocks under the tires. When leaving the operator's compartment, set the parking brake switch to the PARK position, set the gear shift lever to the N position and the dump control lever to the HOLD position, then turn the starting switch...

  • Page 175: Checks After Stopping Engine

    OPERATION OPERATION CHECKS AFTER STOPPING ENGINE 1. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. 2. Fill the fuel tank. 3. Remove any mud affixed to the undercarriage. 4. Walk around the machine and check the dump body, body work, and undercarriage, and check also for leakage of oil and water.

  • Page 176: Handling Tires

    Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use. Please contact your Komatsu distributor when replacing the tires. Always be careful when jacking up the machine. If the machine is not jacked up properly, the machine may lose its balance, come down, and cause a serious accident.
  • Page 177 OPERATION OPERATION TIRE T.Km.P.H.AND MAXIMUM SPEED FOR CONTINUOUS TRAVEL (REFERENCE) HD465-7 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 24.00-35-36PR When empty (standard)
  • Page 178 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 WARNING Always maintain the tire inflation pressure at the specified value.
  • Page 179 OPERATION OPERATION STORING TIRE WARNING Tires for construction equipment are extremely heavy, so if mistakes are made in handling them, it may cause serious personal injury. Always do as follows. As a basic rule, store the tires in a warehouse where unauthorized people cannot enter. If the tires must be stored outside, always put up a fence and "NO ENTRY"...

  • Page 180: 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 for reasons of safety. To ensure safety in operations, do as follows. DETERMINING TRAVEL ROAD To prevent contact with machines traveling in the opposite direction, restrict the travel road to one-way traffic as far as possible.

  • Page 181: Worksite

    OPERATION WORKSITE WORKSITE WARNING Before starting operations, check that there is no danger on the worksite. If you do not understand the dangers of the worksite before starting operations, there is danger that the machine may fall, or that the ground will collapse, or there will be a rock fall, leading to injury or damage.

  • Page 182: Do Not Go Close To High-Voltage Cable

    OPERATION WORKSITE DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE Do not travel or carry out operations near electric cables. There is danger of suffering electric shock. Always do as follows on worksites where there is danger of the machine coming into contact with electric cables. Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

  • Page 183: Transportation

    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. When transporting the machine, there is danger of damage or serious personal injury from accidents. Always do as follows.

  • Page 184: Method Of Securing Machine

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

  • Page 185: Method Of Lifting Machine

    This method of lifting applies to the standerd specification machine. The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not tha standard specification, please consult your Komatsu distributor.
  • Page 186 OPERATION TRANSPORTATION LOCATION OF LIFTING POSITION MARK WEIGHT TABLE Machine Front wheel Rear wheel Center of gravity weight load load (from front axle) 43100kg 20257kg 22843kg 2280mm HD465-7 (95063 lb) (44667 lb) (50369 lb) (7 ft 6 in) 46200kg 21714kg 24486kg 2280mm HD605-7...
  • Page 187 OPERATION TRANSPORTATION LIFTING PROCEDURE Lifting work can be carried out only with machines displaying a lifting mark. When performing 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 188: Cold Weather Operation

    NOTICE 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). Coolant is already diluted with distilled water, so it is not flammable.
  • Page 189 OPERATION COLD WEATHER OPERATION BATTERY WARNING Do not bring any flame close to the battery. During the charging operation, hydrogen and oxygen gas are generated, so there is danger of explosion. If battery electrolyte (dilute sulphuric acid) gets into your eyes, there is danger of losing your sight. When handling the battery, always wear protective glasses and rubber gloves.

  • Page 190: Precautions After Completion Of Work

    OPERATION COLD WEATHER OPERATION PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions. Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused by water in mud or dirt getting inside the seal and freezing.

  • Page 191: Long-Term Storage

    OPERATION LONG-TERM STORAGE LONG-TERM STORAGE BEFORE STORAGE When keeping in long-term storage (more than 1 month), store as follows. Wash and clean all parts and house the machine in a dry building. Never leave it outdoors. If the machine must be stored outdoors, select a flat area and cover the machine with a waterproof sheet. Completely fill the fuel tank.

  • Page 192: Troubleshooting

    OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When the dump truck has run out of fuel, fill the fuel tank with fuel, bleed air from the fuel system and start up the engine again. For an air bleeding method, see "BLEED AIR FROM FUEL CIRCUIT (PAGE 4-38)". IF TRANSMISSION HAS TROUBLE If the transmission has any trouble, operate the machine according to the following procedure.

  • Page 193: 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, consult your Komatsu distributor. 3 - 140...

  • Page 194: Method Of Towing Machine

    When towing the dump truck for a transportation purpose, limit towing only to a nearby inspection and maintenance station and avoid a long haul. A long haul can cause damage to the power train of the dump truck. Please consult your Komatsu distributor for information about towing a disabled machine. 3 - 141...
  • Page 195 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 196 OPERATION TROUBLESHOOTING When the parking brake is released, the brakes cannot be used, so check carefully that the situation is safe. When towing down a slope, use two towing machines. One machine should be uphill from the disabled machine and should be connected with towing wire or a drawbar to pull the disabled machine back and keep it stable. The other machine should tow the disabled machine downhill.
  • Page 197 If it is necessary to use the towing machine to move the failed machine, and the parking brake must be released, use the following method to release the brake. After moving the machine, please ask your Komatsu distributor to carry out repairs. METHOD OF RELEASING PARKING BRAKE IN EMERGENCY WARNING Before releasing the parking brake, always put blocks under the tires.

  • Page 198: If Battery Is Discharged

    OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING Do not charge the battery when it is mounted on the machine. Always remove it before charging it. If it is charged while still mounted on the machine, if the cable comes off during the charging operation, the clip and parts of the machine will come in contact.
  • Page 199 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING 5. When installing the battery, connect positive (+) terminal (3) from the battery relay first. 6. Install connection cable (2) between the 2 batteries. 7. Connect ground terminal (negative (-) terminal) (1) to the battery. NOTICE If the battery is not secured in position, the battery will move during operation.
  • Page 200 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows. PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING If any mistake is made in the method of connecting the booster cables, the battery may explode.
  • Page 201 OPERATION TROUBLESHOOTING STARTING THE ENGINE WARNING Apply the parking brakes, set the gear shift lever to the N position on both the normal machine and the problem machine to prevent the machine from moving during the starting operation. If the machine moves, it may lead to serious personal injury. 1.

  • Page 202: Action If Fire Occurs

    OPERATION TROUBLESHOOTING ACTION IF FIRE OCCURS WARNING Always provide a fire extinguisher for use if a fire occurs. It is possible to prevent damage to the machine if a fire is extinguished immediately. Check the fire extinguisher periodically and make sure that you know the way of using it. If a fire occurs on the machine, escape from the machine as follows to ensure your own safety.

  • Page 203: 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, ask your Komatsu distributor for repairs. Problem Main causes Remedy Defective wiring...
  • Page 204 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy Leakage of oil or entry of air due...
  • Page 205 Use the accelerator pedal to move the machine to a safe place, then check the failure code and contact your Komatsu distributor. When operating the accelerator pedal, use one of the two following positions: release the pedal completely to set it to the OFF position (low idle);...
  • Page 206 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy Insufficient oil in oil pan Add oil to specified level.
  • Page 207 OPERATION TROUBLESHOOTING Problem Main causes Remedy Fuel stops from time to time Crushed fuel tank breather tube ( Replace breather tube) Oil leakage ( Check, repair) Excessive oil in oil pan Add oil to specified level. See Excessive oil consumption CHECK BEFORE STARTING.
  • Page 208 If mode than one failure has occurred, the next failure code is display. 3. Check the failure code, then contact your Komatsu distributor and report the failure code 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 210 4 - 1...

  • Page 211: Maintenance

    MAINTENANCE GUIDES TO MAINTENANCE GUIDES TO MAINTENANCE WARNING During inspection and maintenance of the machine, if anyone starts the engine or operates the machine, and there is a serviceman carrying out inspection, he may suffer serious personal injury. Always do as follows. o When carrying out inspection and maintenance, always hang a "DO NOT OPERATE"...
  • Page 212 Use Komatsu genuine parts specified in the Parts Book as replacement parts. Please consult Komatsu distributor for 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 WINDOW WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
  • Page 213 The suspension cylinder and accumulator are charged with high-pressure nitrogen gas. It is dangerous if any mistake is made in handling them. When charging with nitrogen gas or when releasing the gas, ask your Komatsu distributor to carry out the operation. 4 - 4...
  • Page 214 Do not to carry out any unauthorized modification of the machine. If the machine is modified, problems may occur with safety, and this may lead to serious personal injury. Before making any modification, always consult your Komatsu distributor. Consult your Komatsu distributor regarding modifications. If you carry out modifications without consulting anyone, the machine may not function properly and problems may occur with safety.
  • Page 215 If any loose hose or piping mounts are found, or there is oil or fuel leaking from the mounts, stop operations and tighten to the specified tightening torque. If any damage or deformation of the hoses or piping is found, consult your Komatsu distributor. If the following conditions are found, replace the hose. Damaged or leaking hydraulic fitting.
  • Page 216 MAINTENANCE GUIDES TO MAINTENANCE PRECAUTION WHEN REMOVING HYDRAULIC PIPING: WARNING The hydraulic circuit is always under internal pressure. When inspecting or replacing the hoses or piping, check that the pressure in the circuit has been released. Failure to do this may cause serious personal injury. Always do as follows. Never carry out inspection or replacement when the piping is under pressure.
  • Page 217 When changing the oil or coolant, or replacing filters, put all waste coming from the machine in a container. Considering the effect of these waste materials on the environment, ask a specialist disposal company or your Komatsu distributor to dispose of waste materials. 4 - 8...
  • Page 218 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 50-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 219: Secondary Materials For Operation

    When using commercially available oil, it may be necessary to reduce the replacement interval for the oil. In this case, we also recommend that you use the Komatsu oil clinic. For details of the oil clinic, see "CARRYING OUT KOWA(Komatsu Oil Wear Analysis) (PAGE 4-11)". 4 - 10...
  • Page 220 Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods.
  • Page 221 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 222 When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are found, consult your Komatsu distributor. Do not open packs of spare filters until just before they are to be used. Use of Komatsu genuine filter elements is strongly recommended. 4 - 13...

  • Page 223: 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, consult your Komatsu distributor.

  • Page 224: 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 225: 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 226: 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 - 17...

  • Page 227: 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 228: 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 229: 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 230: Maintenance Schedule Chart

    MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Replace transmission valve oil filter element 4- 68 Change oil in transmission case, brake sub tank 4- 73 Replace transmission and rear brake cooling oil filter element 4- 76 Replace steering, hoist oil tank filter element 4- 82...
  • Page 231 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE Change oil in engine oil pan, replace engine oil filter cartridge 4- 63 Replace fuel prefilter cartridge 4- 64 Replace fuel main filter cartridge 4- 66 Replace transmission valve oil filter element 4- 68 Check wear of front disc brake pads 4- 69...

  • Page 232: 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. Replace transmission valve oil filter element Change oil in transmission case, brake sub tank Replace transmission and rear brake cooling oil filter element Replace steering, hoist oil tank filter element Change oil in final drive case Change oil in differential case...

  • Page 233: 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 4-28)".
  • Page 234 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 protective eyeglasses, dust mask, and other protective equipment.
  • Page 235 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 pleats, then direct it from outside along its pleats and again from inside. 8.
  • Page 236 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 12. Push the head of dust indicator (1) to cancel the clogging display. 4 - 27...
  • Page 237 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 perform the operation, there is danger of falling and suffering injury. 1.
  • Page 238 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 239: Clean Inside Of Cooling System

    (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 coolant is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC).
  • Page 240 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 241 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 10. Open drain valve (4) and drain the water from sub tank (5). 11. Flush the inside of sub tank (5) with tap water, then close drain valve (4). 12. Add water to sub tank (5) until the coolant level is between the FULL and LOW marks.

  • Page 242: Check Level Of Window Washer Fluid, Add Fluid

    MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID If air gets into the window washer fluid when the window washer fluid is being sprayed out, check and add fluid. Check the level of the fluid in window washer tank (1), and if it is low, fill with automobile window washer fluid.

  • Page 243: Check Refrigerant (Gas) Level

    If the condition of sight glass (2) is "insufficient" as shown in the diagram on the right, there is lack of refrigerant, so ask your Komatsu distributor to charge with refrigerant. (After the air conditioner switch is turned ON, bubbles can be seen continuously.)

  • Page 244: 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, perform repairs. Contact your Komatsu distributor for details of the repair procedure. 4 - 35...

  • Page 245: Check Length Of Suspension Cylinder, Check Oil Level

    239 to 259 mm (9.4 to 10.2 in) 506 to 526 mm Reference (C) (19.9 to 20.7 in) 50 mm Flange thickness (D) (2.0 in) After checking, contact your Komatsu distributor for repairs if any problem is found. 4 - 36...
  • Page 246 Measure dimension (E) from the shoulder of the rod head of the suspension cylinder to the top surface of the flange. 194 to 214 mm (7.6 to 8.4 in) 65 mm Flange thickness (F) (2.6 in) After checking, contact your Komatsu distributor for repairs if any problem is found. 4 - 37...

  • Page 247: Bleeding Air From Fuel Circuit

    MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM FUEL CIRCUIT This machine is equipped with an electric priming pump to bleed the air from the fuel circuit. In the following cases, use the procedure below to bleed the air. When fuel filter has been replaced When engine has run out of fuel When starting the engine for the first time after replacing the supply pump or modifying the piping or any other parts...
  • Page 248 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Operate switch (3) of the electric priming pump to ON position. Lamp (4) will flash and the electric priming pump will start. REMARK The electric priming pump switch has a built-in timer, and this actuates and stops the pump automatically. While the lamp is flashing, the electric priming pump will stop, but this does not indicate any abnormality.
  • Page 249 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 8. Close air bleeding valve (2). 9. Start the engine. If the engine does not start, try again by following the steps below. 1) Check that air bleeding valve (2) is closed. 2) Tilt electric priming pump switch (3) to ON position. 3) Try to start the engine while the electric priming pump is in operation.

  • Page 250: Bleed Air From Rear Brake

    MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM REAR BRAKE WARNING When bleeding the air, the brakes are released, so the machine may move and cause serious personal injury. When carrying out the air bleed operation, always park the machine on level ground and put blocks under the tires. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air.

  • Page 251: Bleed Air From Front Brake

    MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM FRONT BRAKE WARNING When bleeding the air, the brakes are released, so the machine may move and cause serious personal injury. When carrying out the air bleed operation, always park the machine on level ground and put blocks under the tires. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air.

  • Page 252: Bleed Air From Parking Brake

    MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM PARKING BRAKE WARNING When bleeding the air, the brakes are released, so the machine may move and cause serious personal injury. When carrying out the air bleed operation, always park the machine on level ground and put blocks under the tires. To make it easier to bleed the air, warm the oil up to a temperature of at least 40°C (104°F) before bleeding the air.

  • Page 253: Clean, Check Radiator Fins And After Cooler Fins

    When the clogged was found, clean the radiator fin. When vent of fin was found, please contact your Komatsu distributor for repair. 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 254: 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 255: Selection And Inspection Of Tires

    To maintain the performance and ensure the service life of the machine, tires must be selected to match the conditions of use and the weight of the attachment installed to the machine. Always use the tires specified by Komatsu and maintain the specified inflation pressure.
  • Page 256 MAINTENANCE SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING If any mistake is made when inflating the tire, the tire may explode or be damaged, and the rim may fly off, causing serious personal injury. To ensure safety, always do as follows.
  • Page 257 MAINTENANCE SERVICE PROCEDURE Inflation of tires WARNING Always maintain the tire inflation pressure at the specified value. If the tire is not at the proper inflation pressure, the rim will be damaged. If the rim is damaged, there is danger that the ring may fly off when the tire is inflated and cause serious personal injury. Adjust the inflation pressure properly.

  • Page 258: Check Before Starting

    MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-69)". 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 259: Every 250 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the oil level check operation. Wait for the temperature to go down before starting the operation. When loosening the plug, loosen it slowly.

  • Page 260: Lubrication

    MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Stop the engine. 2. By using a grease pump, pump in grease through the grease fittings marked by the arrows. 3. After greasing, wipe off any old grease that was pushed out. Carry out the greasing operation every day when operating in places where the grease flows out easily after traveling through mud or water.

  • Page 261: Check Drive Shaft

    (8) Steering linkage (left and right: 3 places each) 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 - 52...

  • Page 262: Check Level Of Battery Electrolyte

    MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Perform this procedure before operating the machine. WARNING Do not use the battery when the level of the battery electrolyte is below the LOWER LEVEL line. If the battery is used when the electrolyte level is below the LOWER LEVEL line, the inside of the battery will deteriorate.
  • Page 263 If distilled water is added to above U.L. line, use a syringe to lower the level to 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 - 54...
  • Page 264 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 INDICATOR TO CHECK ELECTROLYTE LEVEL (if equipped) If it is possible to use and the indicator to check the electrolyte level, follow the instruction given.

  • Page 265: Clean Breathers

    MAINTENANCE SERVICE PROCEDURE CLEAN BREATHERS Remove the mud and dirt from around the breathers, then remove the breathers and wash out the dirt with clean diesel oil or flushing oil. Transmission case (3 places) Steering, hoist oil tank 4 - 56...

  • Page 266: 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. 4 - 57...

  • Page 267: Check Braking Capacity Of Foot Brake

    3. Lower the engine speed, set gear shift lever at N position, and then set parking brake valve lever at PARKING position. If any problem is found, ask 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 268: Check Braking Capacity Of Retarder Brake

    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 269: Check Braking Capacity Of Parking Brake

    1670rpm. If the machine does not move, it is normal. 3. Lower the engine speed, set gear shift lever at N position. If any problem is found, ask your Komatsu distributor for repair. 4 - 60...

  • Page 270: 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 271: 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 272: Every 500 Hours Service

    3. Check the drained oil, and if there are excessive metal particles or foreign material, contact your Komatsu distributor. 4. Remove the drain hose, then tighten drain valve (2) and drain plug (1).

  • Page 273: 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 274 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 5. Clean transparent cup (3) and remove seal (4). Coat the new seal with clean fuel or oil. 6. Install transparent cup (3) to the new filter cartridge. Tightening torque for cup: 10 Nm {1.0 kgm, 7.2 lbft} NOTICE It is not necessary to fill the filter cartridge with oil.

  • Page 275: Replace Fuel Main Filter Cartridge

    The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 276 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 6. Remove filter cartridge cap (A) and install to the filter holder. NOTICE Do not fill the filter cartridge with fuel. Cap (A) is installed to prevent dirt from entering the inside of the filter cartridge.

  • Page 277: Replace Transmission Valve Oil Filter Element

    MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION VALVE OIL FILTER ELEMENT WARNING Immediately after the engine is stopped, the oil and parts are at high temperature, so there is danger of suffering burns during the operation. Wait for the temperature to go down before starting the operation. 1.

  • Page 278: Check Wear Of Front Disc Brake Pads

    (A):Near wear limit (B):Wear limit reached, so replace pad After the inspection, if it is necessary to change the pad, contact your Komatsu distributor. Left and right wheels are not always the same in terms of the amount of wear of the pad. So, perform the inspection for both left and right.

  • Page 279: Check Fan Belt For Wear And Replace

    MAINTENANCE SERVICE PROCEDURE CHECK FAN BELT FOR WEAR AND REPLACE WARNING When carrying out inspection and maintenance, always hang a "DO NOT OPERATE" warning sign on the gear shift lever. If anyone operates the machine when someone is carrying out inspection, that person may be caught in the rotating or moving parts of the machine and suffer serious injury.
  • Page 280 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Loosen bolt (4), put bracket (5) back to the original position, install two bolts (3) and connect grease hose (6). ADJUSTING 1. Loosen three bolts (3) and (4) until bracket (5) can be moved. 2.

  • Page 281: Check, Replace Compressor Drive Belt For Alternator, Air Conditioner

    MAINTENANCE SERVICE PROCEDURE CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER CHECKING If the alternator drive belt is in any of the following conditions, the belt must be replaced. When horizontal scratch (1) crosses vertical scratch (2) When there are tears (3) in part of the belt In case (4) where there are horizontal scratches only, there is no need to replace the belt.

  • Page 282: Every 1000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Carry out maintenance for EVERY 250 HOURS and EVERY 500 HOURS SERVICE at the same time. CHANGE OIL IN TRANSMISSION CASE, BRAKE SUB TANK, WASH STRAINER WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the oil level check operation.
  • Page 283 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 14. Remove plug (8). If the plug is removed, it is easier to drain the oil from the brake chamber. 15. Remove retader drain plug (9) and drain the oil from brake chamber. NOTICE Drain the oil from the brake chamber on both the left and right sides.
  • Page 284 MAINTENANCE SERVICE PROCEDURE 20. Remove the cap from bleeder screw (10) 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. Loosen bleeder screw (10) approx. 3/4 turns and run the engine at low idling until no more bubbles come out from the vinyl hose.

  • Page 285: Replace Transmission And Rear Brake Cooling Oil Filter Element

    MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the oil level check operation. Wait for the temperature to go down before starting the operation. When loosening the cap, do not loosen it suddenly.

  • Page 286: Replace Brake Oil Filter Element

    MAINTENANCE SERVICE PROCEDURE REPLACE BRAKE OIL FILTER ELEMENT WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the oil level check operation. Wait for the temperature to go down before starting the operation. When loosening the plug, loosen it slowly.

  • Page 287: Lubrication

    MAINTENANCE SERVICE PROCEDURE LUBRICATION 1. Stop the engine. 2. By using a grease pump, pump in grease through grease fittings marked by arrows. 3. 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 (3 places) Pump in grease through the grease fitting until grease oozes out...

  • Page 288: Check Wear Of Rear Brake Disc

    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 289: Recover Oil Leaking From Floating Seal

    MAINTENANCE SERVICE PROCEDURE RECOVER OIL LEAKING FROM FLOATING SEAL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. If there is still pressure remaining inside the case, the oil or plug may fly out.

  • Page 290: Check, Grease Compressor Drive Belt Tension Pulley Assembly For Alternator, Air Conditioner

    ALTERNATOR, AIR CONDITIONER CHECKING Check the pulley for play and leakage of grease. If there is any abnormality, ask your Komatsu distributor for disassembly and repair or replacement. LUBRICATING Using a grease pump, pump in grease through the grease fittings shown by arrow.

  • Page 291: 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 Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the oil level check operation.

  • Page 292: Clean Hydraulic Tank Strainer

    MAINTENANCE SERVICE PROCEDURE CLEAN HYDRAULIC TANK STRAINER WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the operation. Wait for the temperature to go down before starting the operation. When loosening the oil filler cap, do not loosen it suddenly.

  • Page 293: Change Oil In Differential Case

    MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DIFFERENTIAL CASE WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the oil level check operation. Wait for the temperature to go down before starting the operation. When loosening the plug, loosen it slowly.

  • Page 294: 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 295: Every 4000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 4000 HOURS SERVICE Maintenance for every 250, 500, 1000 and 2000 hours service should be performed at the same time. CHANGE OIL IN STEERING, HOIST OIL TANK WARNING Immediately after the engine is stopped, the parts and oil are at high temperature, and there is danger that this may cause burns during the operation.

  • Page 296: 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, perform inspection every 1000 hours. CHECK WATER PUMP Check around the water pump for water leakage.

  • Page 297: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber

    Check visually and touch by hand to check that there are no loose mounting bolts for high-pressure piping clamps (1) to (20) in the diagram and no hardening of any rubber parts. If any problem is found, the part must be replaced. In this case, ask your Komatsu distributor to perform the replacement. NOTICE If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure piping.

  • Page 298: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber

    Check visually that there are no missing caps or loose bolts, and feel with your finger to check that the rubber has not hardened. If there is any problem, the problem part must be replaced. Ask your Komatsu distributor for part replacement. 4 - 89...

  • Page 299: 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 perform this work. REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to perform this work.

  • Page 300: Every 15000 Hours Service

    Maintenance for every 250, 500, 1000 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...
  • Page 302 5 - 1...

  • Page 303: Specifications

    Dump body capacity Heaped (2 : 1) (cu.yd) 34.2 (44.7) 40 (52.3) Dumping speed (at 2,000 rpm) (raised) 11.5 Engine type Komatsu SAA6D170E-5 diesel engine (Net) kW (HP)/rpm 533 (715)/2,000 (ISO 9249 / SAE J1349) Engine rated horsepower (Gross) kW (HP)/rpm...
  • Page 304 SPECIFICATIONS SPECIFICATIONS 5 - 3...
  • Page 306 6 - 1...

  • Page 307: Attachments, Options

    ATTACHMENTS, OPTIONS SELECTING DUMP BODY SELECTING DUMP BODY Only HD465-7 can be selected. Select the dump body from the following table. 6 - 2...

  • Page 308: Handling Tachograph (Tco20-90W)

    ATTACHMENTS, OPTIONS HANDLING TACHOGRAPH (TCO20-90W) HANDLING TACHOGRAPH (TCO20-90W) EXPLANATION OF COMPONENTS Keyhole (11) Spare recording indicator Clock scale (12) Odometer recording indicator Clock hand (13) Nameplate Model display label (14) Crimped ring Operator shift change knob (15) Panel lighting lamps (x3) Odometer (16) Cutter...
  • Page 309 ATTACHMENTS, OPTIONS HANDLING TACHOGRAPH (TCO20-90W) KEYHOLE This keyhole (1) is the keyhole to use when opening the cover to replace the chart paper. CLOCK SCALE This clock scale (2) shows the minutes: each mark shows 1 minute. CLOCK HAND This hand (3) points to the hours. MODEL DISPLAY LABEL The tachograph model is written on this model display label (4).

  • Page 310: Method Of Use

    ATTACHMENTS, OPTIONS HANDLING TACHOGRAPH (TCO20-90W) PANEL LIGHTING LAMPS These panel lighting lamps (15) are the lamps do illuminate the gauges. (There are three lamps.) CUTTER This cutter (16) is the blade to cut the connecting tape of the chart paper. TIME ADJUSTMENT SWITCH This time adjustment switch (17) is used to adjust the hands of the clock.
  • Page 311 ATTACHMENTS, OPTIONS HANDLING TACHOGRAPH (TCO20-90W) SETTING TIME When adjusting the time, always turn so that the needle moves clockwise when setting. If the clock is fast, turn the needle back about 10 minutes, then move it forward to set the time. If this is not done, the time will not be set properly.
  • Page 312 Always use Komatsu genuine chart paper. If any other chart paper is used, it may cause failure of the tachograph. When adjusting the time on the chart paper between 22:40 and 24:00, always set the cutter at the bottom of the first sheet of chart paper.
  • Page 313 ATTACHMENTS, OPTIONS HANDLING TACHOGRAPH (TCO20-90W) STORING CHART PAPER Keep the chart paper in a place where there is no direct sunlight, where no water can get on the paper, and where there is no high humidity. Select a place where there is good ventilation and low humidity. REPLACING LAMP The tachograph illumination lamp is 24V.

  • Page 314: Handling Air Suspension Seat

    ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT HANDLING AIR SUSPENSION SEAT OPERATOR'S SEAT ADJUSTMENT WARNING If you try to adjust the operator's seat during operations, the seat will move during the adjustment operation, and there is danger that this will cause mistaken operation which may lead to serious personal injury. Always stop the machine on level ground in a safe place before adjusting the operator's seat.
  • Page 315 ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT ADJUSTING OPERATOR'S SEAT ANGLE BACKWARD 1. Pull up lever (2) and apply your weight to the rear of the seat cushion. The seat cushion will tilt to the rear. 2. Set the seat cushion to the desired angle, then release lever (2).
  • Page 316 ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT SETTING OPERATOR'S SEAT FOR OPERATOR'S WEIGHT 1. Turn the starting switch to ON position. 2. With your body slightly raised, operate switch (5) and adjust the strength of the suspension. Press the + portion to make the operator's seat suspension stronger.
  • Page 317 ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT ADJUSTING ARMREST ANGLE Turn knob (7) on the left armrest and adjust the angle of the left armrest. Amount of adjustment:73° (front:54°; rear:19°) REMARK It is possible to make the armrest spring up. (Both left and right sides) ADJUSTING LUNBAR SUPPORT TENSION 1.

  • Page 318: Removal And Installation Of Headrest

    ATTACHMENTS, OPTIONS HANDLING AIR SUSPENSION SEAT REMOVAL AND INSTALLATION OF HEADREST REMOVAL When replacing the headrest, 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 319: 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. If slipping of the drive shaft is detected, the ASR is actuated.

  • Page 320: Actuation Of Asr System

    ATTACHMENTS, OPTIONS HANDLING AUTOMATIC SPIN REGULATOR (ASR) ASR ACTUATION LAMP This ASR actuation lamp (2) lights up when the ASR switch is ON, and the system detects slipping of the rear wheels and actuates the ASR. CHARACTER DISPLAY If any problem occurs in the ASR system, the action code is displayed on this character display (3). ACTUATION OF ASR SYSTEM If slipping of the rear wheels is detected, the ASR system acts to prevent the machine from spinning.

  • Page 321: Troubleshooting

    This system is equipped with a self-diagnostic function and displays an action code on the character display of machine monitor. If any action code is displayed, move the machine to a safe place, and stop the machine. In addition check the code. For details, see"ACTION CODE (PAGE 3-155)". Please contact your Komatsu distributor for repair .

  • Page 322: Bleeding Air From Asr Circuit

    ATTACHMENTS, OPTIONS HANDLING AUTOMATIC SPIN REGULATOR (ASR) BLEEDING AIR FROM ASR CIRCUIT WARNING When bleeding the air, the brakes are released, so the machine may move and cause serious personal injury. When carrying out the air bleed operation, always park the machine on level ground and put blocks under the tires. If the piping or valves in the ASR circuit have been replaced, bleed the air from the ASR circuit as follows.

  • Page 323: Handling Anti Skid Brake System (Abs)

    ATTACHMENTS, OPTIONS HANDLING ANTI SKID BRAKE SYSTEM (ABS) HANDLING ANTI SKID BRAKE SYSTEM (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 324: Abs System Check After Starting Engine

    The ABS operation lamp flashes and the ABS check system starts. When any problem occurs in ABS system, the action code is displayed on charactor display. Check the error code. For details, see "TROUBLESHOOTING (PAGE 6-21)". Please your Komatsu distributor to carry out repair.

  • Page 325: Operation Of Abs

    ATTACHMENTS, OPTIONS HANDLING ANTI SKID BRAKE SYSTEM (ABS) OPERATION OF ABS The ABS system automatically controls slipping caused by locking of the wheels, and shortens the braking distance. Use the ABS system when traveling on snow-covered or slippery road surfaces. The ABS system can be actuated when the ABS switch is turned ON.

  • Page 326: Troubleshooting

    This system is equipped with a self-diagnostic function and displays an action code on the character display of machine monitor. If any action code is displayed, move the machine to a safe place, and stop the machine. In addition check the code. For details, see"ACTION CODE (PAGE 3-155)". Please contact your Komatsu distributor for repair .

  • Page 327: Handling Payload Meter (Komtrax Plus Built-In Type)

    The date stored in the payload meter can be downloaded to a personal computer using the separately sold special software. For details of the special software, please consult your Komatsu distributor. To ensure accuracy when operating the system, apply the parking brake when dumping, set the grar shift lever to N, release the retarder brake, and set so that the machine and payload display are both stable before starting the dumping operation.

  • Page 328: Normal Operation Display

    ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) Download connector outside the operator's cab (end marked PLM) NORMAL OPERATION DISPLAY Machine condition Machine monitor display External display lamps When starting switch is ON Light up for 30 sec Stopped (*1) Standard display (*2)
  • Page 329 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) Example of payload display Example of payload display when error occurs If an error occurs in the suspension pressure sensors or in the clinometer sensor, it becomes impossible to calculate the payload, so [-----] is displayed.

  • Page 330: External Display Lamps

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) EXTERNAL DISPLAY LAMPS CAUTION If the red lamp lights up, the machine is overloaded. If the machine carries an excessive load, the machine will be damaged. To prevent overloading, continue loading until the yellow lamp lights up. If the red lamp flashes, stop loading immediately. The external lamps display the payload as follows.

  • Page 331: Performing Calibration

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) PERFORMING CALIBRATION Carry out calibration of payload meter at the following occasions. When the machine or payload meter are received Once every month When the suspension cylinder gas pressure and oil amount have been adjusted (when the suspension has been adjusted) When the suspension pressure sensor has been replaced When the machine has been modified and the weight of the machine when empty has changed more than 100...

  • Page 332: Data Stored In Payload Meter

    ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) 3) Press the () of machine monitor selector switch 1 (1) and display CALIBRATION. Then, press the () and check that the word CALIBRATION flashes. 5.
  • Page 333 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) Download the recorded data using the RS232C port of a personal computer which has the separately sold special software installed. The downloaded date is saved in the specified location on the personal computer as a text file (CSV file). For details, see the instruction manual for the special software.

  • Page 334: Procedure When Downloading

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) PROCEDURE WHEN DOWNLOADING NOTICE If any mistake is made in handling the cables and connectors, the cables or connectors may be damaged and it may become impossible to download the data. Always do as follows. Never pull the cable by force.
  • Page 335 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) DOWNLOADING FROM GROUND LEVEL DOWNLOAD BOX OUTSIDE CAB WARNING When downloading, set the parking brake switch to the PARKING position, return the gear shift lever to N, and set the dump control lever to the HOLD position.
  • Page 336 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) DOWNLOAD SOFTWARE For details of installing the software, see the instruction manual provided with the download software. 1. When the installation is completed, the icon shown in the diagram on the right is created. 2.
  • Page 337 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) 4. Click [Unit Setting] on screen [G2200]. Screen [G2210] is displayed. [User's Comment] is not used, so do not click it. 5. On screen [G2210] it is possible to select the communication port (Com1, Com2), specify the destination for saving the downloaded data, specify the file name, and select the unit for the data.

  • Page 338: Machine Id, Open Id

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) MACHINE ID, OPEN ID It is possible to change the machine ID and open ID, which are cycle data items. When changing the machine Serial No. for the machine ID or the operator or type of load for the open ID, set the value specified by the customer beforehand to make it possible to use to check the operator and type of load for the applicable cycle afterwards.
  • Page 339 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) 5. Press the () of machine monitor selector switch 1 to display the screen shown in the diagram on the right. The available settings range from 0 to 200; input in order from the first digit.

  • Page 340: Payload (Cycle Data Item)

    The method for processing and confirming the payload in Step 2 above is useful if the dumping point is at an angle. If you wish to change the method of confirming the haul payload, please ask your Komatsu distributor to carry out the change.

  • Page 341: Handling Payload Meter Ii (Card Type)

    REMARK The personal computer software supplied by Komatsu is necessary for downloading the date, reading the date from a memory card to a personal computer, and processing the date. Please consult your Komatsu distributor.

  • Page 342: 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 343: General Locations

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) GENERAL LOCATIONS CONTROLLER SCREEN When not inserting or removing memory card (7), always keep cover (6) colsed. Display panel Cover MODE switch Memory card Reception pilot lamp (Rx busy) Light/increment switch Transmission pilot lamp (Tx busy) Total/shift switch Memory card access lamp (CARD busy) (10)
  • Page 344 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) LEFT FACE OF CONTROLLER 6 - 39...
  • Page 345 Do not touch any switch except "7" and "B". If you wish to adjust any switch except "7" and "B" to compensate the payload calculation value or speed or distance calculation value, please contact your Komatsu distributor. REMARK The weight is given in units of metric tons or short tons. The meaning of these units is as follows.
  • Page 346 Large-tire Komatsu engine HD405-6 Quarry Large-tire Komatsu engine HD985-3/-5 STD 30.00-51 Komatsu engine HD605-5/-7 Quarry Large-tire Komatsu engine HD785-5 STD Large-tire Komatsu engine PERMITTED/PROHIBITED SETTING TABLE FOR SWITCHES Left side switch "8" Left side switch "5" Operation of all switches is permitted Up (permitted) Left side switch "8"...
  • Page 347 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 (side marked PLM) When downloading, remove the cable that is connected. After completing the download operation, always return the cable to its original position.

  • Page 348: 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 349 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) DISPLAY DURING NORMAL OPERATIONS gear shift 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 Stopped...
  • Page 350 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 351 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) NOTICE If the operation is not carried out properly, the payload will not be measured correctly, so the payload meter data or external lamp display will not be correct. When the machine is unloaded, when it is stopped for loading, or when it is stopped when loaded, always place the gear shift lever at N.

  • Page 352: External Display Lamps

    ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) EXTERNAL DISPLAY LAMPS DISPLAY LEVEL FOR LAMPS CAUTION If the red lamp lights up, the machine is overloaded. If the machine carries an excessive load, the machine will be damaged. To prevent overloading, continue loading until the yellow lamp lights up. If the red lamp flashes, stop loading immediately. The external lamps display the payload as follows.
  • Page 353 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, payload meter estimates the predicted load and display the predicted load by flashing the lamp. When red lamp flashed, next load will carry over loading.

  • Page 354: 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 memory. This data are retained even when the power is switched OFF, so they can be used later as follows. (1) The data can be downloaded to a personal computer through a cable connected to the RS-232C port, and the personal computer can be used to display these data or to print them out using a printer.
  • Page 355 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 memory every time the load is dumped.
  • Page 356 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) ENGINE ON/OFF DATA When the engine is started or stopped, these data are recorded in memory. 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 357 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) PROBLEM, WARNING DATA When an problem or warning occurs or is restored in the payload meter system, these data are recorded in memory. The maximum limit for problem/warning data is 230 sets of occur/restore. Item Unit Range...
  • Page 358 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 359: 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 6-55)" "FORCED DISPLAY OF TOTAL PAYLOAD AND OVERALL NUMBER OF CYCLES (PAGE 6-56)" "FORCED DISPLAY OF PROBLEMS, WARNINGS WHEN THEY HAVE OCCURRED (PAGE 6-56)"...
  • Page 360 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) CARRYING OUT CALIBRATION WHEN CARRYING OUT CALIBRATION 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 361 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 362 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 363 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 364 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 365 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 shift 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 366 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 367 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 368 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 369 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 370 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 371 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 372 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 373 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 374 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 375 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 376 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 377 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. Each time LIGHT/INC switch (1) is pressed, the number increases by "1".
  • Page 378 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 distributer. SETTING FORCED PROHIBITION FOR SWITCHES For details, see "LEFT FACE OF CONTROLLER (PAGE 6-39)". In addition, when setting forced prohibition for the switches, please ask your Komatsu distributor. 6 - 73...
  • Page 379 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 380: Problem And Warning Display (Error Code)

    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 381 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 6 - 76...
  • Page 382 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 6 - 77...
  • Page 383 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 6 - 78...
  • Page 384 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 385 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 386 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 387: 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 OFF position. If the voltage of the battery drops, F-09 is displayed as an error message, so replace the battery as follows.
  • Page 388 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) HANDLING PAYLOAD METER II (CARD TYPE) 5. Remove screws (3) (top surface: M3 x 6; rear face: M3 x 3) from the top cover of the payload meter, then remove top cover (2).
  • Page 389 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 momentariy 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 390: 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 datahave 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 recognised by the controller may be different from the actual condition.
  • Page 391 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) CARRYING OUT FORCED INITIALIZATION When this function is performed, all of the date 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. 1.
  • Page 392 ATTACHMENTS, OPTIONS HANDLING PAYLOAD METER II (CARD TYPE) 4. Keep CAL/CLR switch (4) pressed for at least 2 seconds. The display changes to 00:00 (lights up for two seconds), and when the forced initialization is completed, it automatically displays F.CAL. After this, carry out the procedure given in "OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED (PAGE 6-85)".

  • Page 393: 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 394 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 395 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 396: 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 397: 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 398: 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 399: 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 to -40°C (-4 to -40 °F), or even in temperatures above that if it is difficult to start the engine because of the cold. Use an external power source (single phase AC 200 to 250V), to warm the engine coolant and the oil in the engine oil pan to make it easier to start the engine.
  • Page 400 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 401 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 - 96...
  • Page 402 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 6-94)".
  • Page 403 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 to -40°C (-4 to -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 404 ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER CIRCUIT DIAGRAM FOR EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER Engine oil pan heater (0.6kW) Terminal box (2.7kW) Coolant heater (1.5kW) Female connector for external power supply Engine oil pan heater (0.6kW) 6 - 99...

  • Page 405: 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 406: Handling Battery Isolator

    ATTACHMENTS, OPTIONS HANDLING BATTERY ISOLATOR HANDLING BATTERY ISOLATOR CAUTION When the engine is running, do not operate the battery isolator switch to shut off the electrical circuit. When the circuit is shut off, electric noise is generated, and this may damage the electric circuit or the controllers. The battery isolator prevents consumption of the battery power caused by short circuits or electrical leakage from the equipment during long-term storage.
  • Page 407 ATTACHMENTS, OPTIONS HANDLING BATTERY ISOLATOR REMARK When the battery isolator switch is turned "OFF", the whole electrical system of the machine does not work. Preset memories in the radio, the clock in the monitor and radio broadcasting stations are lost. Preset them again at the next use.

  • Page 408: Handling Machines Equipped With Komtrax Plus

    KOMTRAX Plus communications terminal. 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 Plus communications terminal or to perform action to stop communications.

  • Page 409: Procedure When Downloading

    Never disassemble, repair, modify, or move the KOMTRAX Plus, communications terminal, antenna, or cables. This may cause failure or fire on the KOMTRAX Plus communications terminal or the machine itself. (Your Komatsu distributor will perform removal and installation of the KOMTRAX Plus and communications terminal.) Do not allow cables or cords to become caught;...

  • Page 410: Check Before Starting

    When using this machine, there is no particular need to operate this system, but be sure to carry out daily inspection in order to maintain the function and performance of the system. If there is any problem, please consult your Komatsu distributor. 1. Check for loose, damaged, or dirty mounts of the sensors or antenna.
  • Page 411 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus KOMTRAX Plus controller (3) Orbcomm controller (4) (if equipped) Download connector (5) Ground level download box (6) Blow-by sensor (7) 6 - 106...
  • Page 412 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus Exhaust temperature sensor (8) Ambient temperature sensor (9) Ambient temperature sensor (9) is inside box (A). Remove box (A) when carrying out inspection. 6 - 107...

  • Page 414: Index

    INDEX INDEX <A> PRECAUTIONS BEFORE STARTING AIR CONDITIONER 3- 59 OPERATION 2- 12 PRECAUTIONS RELATED TO <B> ATTACHMENTS AND OPTIONS 2- 18 BEFORE READING THIS MANUAL PRECAUTIONS RELATED TO BODY PIVOT PIN 3- 47 PROTECTIVE STRUCTURES 2- 17 PRECAUTIONS WHEN GETTING ON <C>...
  • Page 415 INDEX CHECK BEFORE STARTING 6-105 IMPORTANT SAFETY INFORMATION KOMTRAX Plus AND INTENDED USE COMMUNICATIONS TERMINAL GENERAL VIEW AND DIRECTIONS INSTALLED 6-103 OF MACHINE KOMTRAX Plus INSTALLED, USE OF MACHINE COMMUNICATIONS TERMINAL NOT VISIBILITY FROM OPERATOR'S INSTALLED 6-103 SEAT PROCEDURE WHEN DOWNLOADING 6-104 <L>...
  • Page 416 RECOMMENDED BRANDS, METHOD OF TOWING MACHINE 3-141 RECOMMENDED QUALITY FOR OTHER TROUBLE 3-150 PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 18 <U> USE OF FUEL, COOLANT AND USE OF REAR VIEW MONITOR 6- 88 LUBRICANTS ACCORDING TO CAUTIONS WHEN USING REAR...
  • Page 417 HD465-7E0, HD605-7E0 DUMP TRUCK Form No. TEN00439-07 © 2013 KOMATSU All Rights Reserved Printed in Japan 10-13...

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