Komatsu Galeo HD325-6 Operation & Maintenance Manual Download Page 202 | Manualshive

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MAINTENANCE

MAINTENANCE SCHEDULE CHART

ADJUST INJECTOR

This machine uses an engine that conforms with all exhaust gas regulations.
The exhaust gas regulations differ according to the applicable area. To ensure that the engine conforms with the
regulations in the area of use and can fully display its performance, keep to the following periodic maintenance
intervals when adjusting the injector.
If the periodic maintenance intervals are not observed correctly, the engine may not be able to display its
performance fully, and it may also not conform with the regulations.

NOTICE
When transporting a machine from an A regulation area to a B regulation area, always replace all the injector assemblies before
transporting the machine to the new area.
Check with your Komatsu distributor to confirm if your area of operation is an A regulation area or a B regulation area.

A REGULATION AREA

EPA regulation areas and areas with the regulations equivalent to EPA regulations

EVERY 2000 HOURS SERVICE

Check injector

Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please ask your Komatsu
distributor to carry out inspection or replacement. For details of the procedure if any abnormality is found, see
Section "ENGINE (PAGE 3-128)".

EVERY 4000 HOURS SERVICE

Replace injector assembly

Ask your Komatsu distributor to carry out this work.

B REGULATION AREA

Areas not applying EPA regulations or areas not applying regulations equivalent to EPA regulations

EVERY 4000 HOURS SERVICE

Check injector

Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please ask your Komatsu
distributor to carry out inspection or replacement. For details of the procedure if any abnormality is found, see
Section "ENGINE (PAGE 3-128)".

EVERY 8000 HOURS SERVICE

Replace injector nozzle tip

Ask your Komatsu distributor to carry out this work.

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Summary of Contents for Galeo HD325-6

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Page 3: ...sure that you understand them fully Keep this manual in the storage location for the operation and maintenance manual given below and have all personnel read it periodically If this manual has been lost or has become dirty and cannot be read request a replacement manual immediately from Komatsu or your Komatsu distributor If you sell the machine be sure to give this manual to the new owners togeth...

Page 4: ... FOREWORD FOREWORD 1 3 ...

Page 5: ... FOREWORD FOREWORD 1 4 ...

Page 6: ...ituation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This word is used also to alert against unsafe practices that may cause property damage Example of safety message using signal word WARNING When standing up from the operator s seat always place the lock lever in the LOCK posi...

Page 7: ...inside a triangle and the method of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any proceduresor actions not specifically recommended or allowed in this manual ar...

Page 8: ... USE INTENDED USE DIRECTIONS OF MACHINE In this manual the directions of the machine front rear left right are determined according to the view from the operator s seat in the direction of travel front of the machine 1 7 ...

Page 9: ...parts please inform your Komatsu distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE It is located on the left front end of the frame The design of the nameplate differs according to the territory ENGINE SERIAL NO PLATE POSITION It is at the top left side of the engine cylinder block and the engine cylinder head as seen from the fan 1 8 ...

Page 10: ...ND DISTRIBUTOR SERVICE METER POSITION It is located on the right side of the meter section TABLE TO ENTER SERIAL NO AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Distributor name Address Service Personnel Phone Fax 1 9 ...

Page 11: ...TRANSPORTATION 2 23 BATTERY 2 24 TOWING 2 26 PRECAUTIONS FOR MAINTENANCE 2 27 PRECAUTIONS WITH TIRES 2 33 OPERATION 3 1 GENERAL VIEW 3 2 GENERAL VIEW OF MACHINE 3 2 GENERAL VIEW OF CONTROLS AND GAUGES 3 3 EXPLANATION OF COMPONENTS 3 5 MACHINE MONITOR 3 5 SWITCHES 3 23 CONTROL LEVERS AND PEDALS 3 32 MECHATRONICS EQUIPMENT CONTROLLER 3 36 BODY PIVOT PIN 3 37 DUST INDICATOR 3 37 LOCATION OF FIRE EXTI...

Page 12: ...13 BEFORE STORAGE 3 113 DURING STORAGE 3 113 AFTER STORAGE 3 113 PRECAUTIONS BEFORE TRAVELING AFTER LONG TERM STORAGE 3 113 TROUBLESHOOTING 3 114 AFTER RUNNING OUT OF FUEL 3 114 METHOD OF TOWING MACHINE 3 116 IF BATTERY IS DISCHARGED 3 121 OTHER TROUBLE 3 125 MAINTENANCE 4 1 GUIDES TO MAINTENANCE 4 2 OUTLINE OF SERVICE 4 4 HANDLING OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 4 OUTLINE OF ELECTRIC...

Page 13: ...TION OF COMPONENTS 6 15 METHOD OF USING KEY 6 17 METHOD OF USE 6 18 REVO TACHOGRAPH TCO 15 7 6 20 EXPLANATION OF COMPONENTS 6 20 METHOD OF USE 6 23 USING DIFFERENTIAL LOCK 6 25 DIFFERENTIAL LOCK PEDAL 6 25 PRECAUTIONS AND METHOD OF USE 6 26 OPERATION OF ABS AND ABS ASR 6 27 EXPLANATION OF COMPONENTS 6 27 OPERATION METHOD 6 29 PRECAUTIONS FOR USE 6 30 TROUBLESHOOTING 6 30 HANDLING AUTO GREASING SYS...

Page 14: ... FOREWORD CONTENTS METHOD OF USE 6 49 INDEX 7 1 1 13 ...

Page 15: ... ...

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Page 17: ...2 12 MOUNTING AND DISMOUNTING 2 12 CRUSHING OR CUTTING PREVENTION 2 12 PREVENTION OF BURNS 2 13 FIRE PREVENTION 2 13 ACTION IF FIRE OCCURS 2 14 WINDOW WASHER LIQUID 2 14 PRECAUTIONS WHEN USING ROPS Roll Over Protective Structure 2 14 PRECAUTIONS FOR ATTACHMENTS OPTIONS 2 15 UNAUTHORIZED MODIFICATION 2 15 SAFETY AT WORKSITE 2 15 WORKING ON LOOSE GROUND 2 15 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 2 ...

Page 18: ...NG 2 26 WHEN TOWING 2 26 PRECAUTIONS FOR MAINTENANCE 2 27 WARNING TAG 2 27 KEEP WORK PLACE CLEAN AND TIDY 2 27 APPOINT LEADER WHEN WORKING WITH OTHERS 2 27 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2 28 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2 29 PROPER TOOLS 2 29 HANDLING SUSPENTION CYLINDER 2 30 PERSONNEL 2 30 WORK UNDER THE MACHINE 2 30 NOISE 2 30 PRECAUTIONS WHEN U...

Page 19: ... always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way 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 l...

Page 20: ...FETY LABELS SAFETY LABELS 1 Roll over protective structure ROPS 09620 30202 2 Caution for checking engine room 09667 A0880 3 Caution for opening hydraulic tank cap Caution for opening radiator cap 09653 A0641 2 5 ...

Page 21: ...der 09659 A0881 5 Warnings for electric wire Warnings for crush hazard when inspection and maintenance Warnings for inspection of emergency steering system secondary brake system Warning for leaving operator s seat stopping engine Warning for retarder oil temperature 569 93 61730 2 6 ...

Page 22: ...ELS 6 Cautions before starting Cautions when traveling in reverse Cautions for operating hoist control lever dump lever 569 93 61720 7 Caution when handling battery cable 09808 A1681 8 Exhaust pipe is hot 09817 A1103 2 7 ...

Page 23: ...Y LABELS SAFETY SAFETY LABELS 9 Caution for avoiding falling down 09805 C0881 10 Caution when handling battery This plate is stick on the machine by the battery maker 11 Precautions for high voltage 7872 10 1600 2 8 ...

Page 24: ... SAFETY SAFETY LABELS SAFETY SAFETY LABELS 12 Jump start prohibited 09842 A0481 This plate is stuck to the starting motor 2 9 ...

Page 25: ...ecessary action taken Do not operate the machine until the problem has been corrected CLOTHING AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories There is a hazard that they may catch on dump lever or other protruding parts If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful no...

Page 26: ...d to your shoes your foot may slip and this may cause a serious accident Do not leave parts or tools lying around the operator s compartment Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use cellular telephones inside the operator s compartment when driving or operating the machine Never bring any dangerous objects such as flammable or explosive...

Page 27: ...etting on or off the machine Never climb on the engine hood or covers where there are no non slip pads Before getting on or off the machine check the handrails and steps and if there is any oil grease or mud on them wipe it off immediately In addition repair any damage and tighten any loose bolts Do not get on or off the machine while holding tools in your hand MOUNTING AND DISMOUNTING Never jump ...

Page 28: ...reeze and window washer liquid are particularly flammable and can be hazardous To prevent fire always observe the following Do not smoke or use any flame near fuel or oil Stop the engine before refueling Do not leave the machine while adding fuel or oil Tighten all fuel and oil caps securely Do not spill fuel on overheated surfaces or on parts of the electrical system Use well ventilated areas for...

Page 29: ...ause serious injury When taking the electrical power for the lighting from the machine itself follow the instructions in this manual ACTION IF FIRE OCCURS If a fire occurs escape from the machine as follows Turn the start switch OFF to stop the engine Use the handrails and steps to get off the machine WINDOW WASHER LIQUID Use an ethyl alcohol base washer liquid Methyl alcohol base washer liquid ma...

Page 30: ... check the area for any unusual conditions that could be dangerous Check the terrain and condition of the ground at the worksite and determine the safest method of operation Do not operate where there is a hazard of landslides or falling rocks Take necessary measures to prevent any unauthorized person from entering the operating area When traveling or operating in shallow water or on soft ground c...

Page 31: ...high voltage cables do not let anyone near the machine If the machine should come too close or touch the electric cable to prevent electric shock the operator should not leave the operator s compartment until it has been confirmed that the electricity has been shut off Also do not let anyone near the machine ENSURE GOOD VISIBILITY This machine is equipped with mirrors to improve the visibility but...

Page 32: ...gnals and signs before starting work EMERGENCY ESCAPE FROM OPERATOR S CAB The cab installed on this machine has doors on the left and right sides If the door on one side does not open escape through the door on the other side ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsites handling demolit...

Page 33: ...y to carry out operations and check that there is no damage or wear to the seat belt or mounting clamps Check that the gauges and instruments work properly check the angle of the mirror and check that the gearshift lever is at neutral and the dump lever is at HOLD Before starting the engine make sure that the dump lever lock is in the LOCK position Adjust the mirrors so that the rear of the machin...

Page 34: ...rt the engine with a different power source There is a hazard that this will ignite the battery and cause the battery to explode Before charging or starting the engine with a different power source melt the battery electrolyte and check that there is no leakage of electrolyte before starting Before starting operations and after finishing operations drain the water from the air tank If there is no ...

Page 35: ...ore travelling check again that there is no one in the surrounding area and that there are no obstacles Before travelling sound the horn to warn people in the area Always operate the machine only when seated If another person is allowed on the machine that person may sit only in the assistant s seat Check that the backup alarm backup warning buzzer works properly Always close the door and the wind...

Page 36: ...ng wheel suddenly Travel on grass fallen leaves or wet steel plates with low speed Even with slight slopes there is a hazard that the machine may slip If the engine should stop on a slope apply the brakes fully and apply the parking brake also to stop the machine Do not shift gear while traveling downhill or travel downhill with the transmission in neutral It is dangerous if the engine has no brak...

Page 37: ... traveling on snow covered roads never use the foot brake to make sudden stops Shift down to use the engine brake and carry out double braking depress the brake pedal several times to stop the machine When the loaded materials in the dump body are frozen do not dump There is a danger that the machine could tip over PARKING MACHINE Park the machine on firm level ground Select a place where there is...

Page 38: ...y Run the engine at low speed drive the machine at low speed and operate slowly Never correct your steering on the ramps If necessary drive off the ramps correct the direction then enter the ramps again When loading or unloading to an embankment or platform make sure that it has suitable width strength and grade After loading the machine always lock the door There is danger that the door may open ...

Page 39: ... with large amount of water If acid gets into your eyes flush them immediately with large amount of water and seek medical attention Before working with batteries turn the starting switch to the OFF position As there is a hazard that sparks will be generated always do as follows Do not let tools or other metal objects make any contact between the battery terminals Do not leave tools or other metal...

Page 40: ... machine There is a hazard that the machine will move when the power is connected Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground side first when removing them When removing the booster cables be careful not to let the booster cable clips touch each other or to let the clips touch the machine Always wear safety glasses and rubber ...

Page 41: ... OF TOWING MACHINE PAGE 3 116 Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed Never use a wire rope which has cut strands A reduced diameter B or kinks C There is danger that the rope may break during the towing operation Always wear leather gloves when handling wire rope Never tow a machine on a slope During the towing oper...

Page 42: ...viceman is carrying out service or maintenance of the machine it may lead to serious injury KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean and tidy to enable you to carry out operations safely If the work place is not kept clean and tidy there i...

Page 43: ...NANCE Stop the machine on firm level ground Select a place where there is no hazard of landslides falling rocks or flooding Lower the dump body and stop the engine Set parking brake valve lever to the PARKING position and put blocks 1 under the tires to prevent the machine from moving 2 28 ...

Page 44: ...moving In addition set parking brake valve lever 2 to the PARKING position to prevent the machine from moving When carrying out operations near the fan fan belt or other rotating parts there is a hazard of being caught in the parts so be careful not to come close Do not touch the gear shift lever or dump lever If the gear shift lever or dump lever must be operated give a signal to the other worker...

Page 45: ...in securely When you use body pivot pin see BODY PIVOT PIN PAGE 3 37 NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time wear ear covers or ear plugs while working If the noise from the machine is too loud it may cause temporary or permanent hearing problems PRECAUTIONS WHEN USING HAMMER When using a hammer pins may fly out or metal particles may...

Page 46: ...pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly If you are hit by a jet of high pressureoil and suffer injury to your skin or eyes wash the place with clean water and consult a doctor immediately for medical attention PRECAUTIONS FOR HIGH PRESSURE FUEL When the engine is running high pressure is generated in the engine fuel piping ...

Page 47: ...PRESSED AIR When carrying out cleaning with compressed air there is a hazard of serious injury caused by flying particles When using compressed air to clean elements or the radiator always wear safety glasses dust mask gloves and other protective equipment PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS In order for the machine to be operated safely for a long time it is necessary to add oil and to ...

Page 48: ...arts do not fit the tire there is a problem with the tire or rim parts Always contact your Komatsu distributor for repairs If the rim parts are not fitted properly when the tire is being pumped up there is danger that the rim parts may fly off so set up a protective fence around the tire and do not stand directly in front of the rim Stand beside the tread when pumping up the tire Do not adjust the...

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Page 50: ... 3 1 ...

Page 51: ... OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE 1 2 3 Dump body Rear wheel Front wheel 4 5 Turn signal light Head lamp 3 2 ...

Page 52: ...eering wheel Machine monitor Retarder control lever Cigarette lighter Shift lever Parking brake valve lever 10 11 11 12 13 14 15 16 Shift limiter switch Power mode selector switch 4WD switch HD325 only the machine of 4WD specifications Secondary brake lever Emergency steering switch Accelerator pedal Brake pedal Differential lock pedal if equipped 3 3 ...

Page 53: ... 3 4 Caution Pilot lamp bulb check switch Starting switch AISS LOW switch Power mode selector switch HD325 The machine of 4WD specifications 5 6 7 8 Night lighting dimmer switch Hazard lamp switch Front brake cut off switch Exhaust brake switch if equipped 3 4 ...

Page 54: ...ere is probably a failure or disconnection in that circuit therefore contact your Komatsu distributor to have the circuit checked When the starting switch is at the ON position if the shift lever is not at the neutral position then the transmission shift lever position pilot lamp 1 and the central warning lamp will flash and the alarm buzzer will continue to sound intermittently At this time when ...

Page 55: ...rvice code number Contact Komatsu distributor telling them the service code number for repair If E and any user code between 01 07 are displayed in turn on user code display 1 stop the machine check the user code then take the corrective action given below User codes 02 Park the machine at a safe location and contact your Komatsu distributor 04 Carry out an emergency stop Stop the engine and conta...

Page 56: ...e applicable item in CAUTION ITEMS PAGE 3 8 to carry out inspection and maintenance If only 01 is displayed check the service code and ask for repairs If 03 05 06 or 07are displayed and the user code is displayed even after the above corrective action is taken check the service code and ask for repairs 3 7 ...

Page 57: ...y abnormallity for the caution items the monitor for the corresponding abnormal area lights up 1 2 3 4 Radiator water level Emergency steering Parking brake Dump body actuation caution 5 6 Transmission filter clogging on the valve side Fuel level RADIATOR WATER LEVEL This monitor 1 warns the operatorthat the radiator water level has dropped If it lights up and displays user code 01 at the same tim...

Page 58: ...applied It goes on and out respectively responding to the parking brake lever shifting of PARK TRAVEL DUMP BODY ACTUATION CAUTION This monitor 4 lights up when the dump body control lever is at any position other than FLOAT or when the body is lifted Always set the lever to the FLOAT position and lower the body during traveling TRANSMISSION FILTER CLOGGING This monitor 5 identifies the operator th...

Page 59: ... OPERATION EXPLANATION OF COMPONENTS FUEL LEVEL This monitor 6 flashes when the level of the fuel in the fuel tank goes below 60 liters 15 84 US gal If it flashes check the fuel level and add fuel 3 10 ...

Page 60: ...tion lights up or flashes and the central warning light flashes 1 2 3 4 5 Air pressure Engine water temperature Torque converter oil temperature Retarder oil temperature Engine oil pressure 6 7 8 9 Battery charge Angle warning Rear brake caution lamp Steering oil temperature if equipped AIR PRESSURE This monitor 1 warns the operator that the air pressure inside the air tank has dropped If it flash...

Page 61: ...r no load at a mid range speed until the torque converter oil temperature gauges enters the green range RETARDER OIL TEMPERATURE This monitor 4 warns the operator that the retarder oil temperature has risen If it flashes and displays user code 05 at the same time stop the machine place the shift lever at the N neutral position then run the engine under no load at a mid range speed until the warnin...

Page 62: ...machine to a safe stable place REAR BRAKE CAUTION LAMP This monitor 8 lights up if the brake oil pressure drops under the normal value If it lights up and display user code 04 at the same time immediately check the rear brake system After checking and repairing depress the rod for the overstroke sensor on the brake chamber If depressing is not carried out the rear brake caution lamp will continue ...

Page 63: ...lot lamp Shift limiter pilot lamp 7 8 9 10 11 12 High beam Turn signal pilot lamp Shift indicator with lockup display Transmission shift lever position pilot lamp Auto suspension mode display lamp Power mode display lamp PREHEATING MONITOR This monitor 1 lights up when the electrical heater for preheating the engine is being actuated When the starting switch is turned to the ON position in cold we...

Page 64: ...foot brake is depressed or the retarder control lever is pulled and the rear brake is applied DIFFERENTIAL LOCK PILOT If equipped This pilot lamp 4 lights up when the differential lock pedal if equipped is depressed and the differential lock is actuated LOCKUP PILOT LAMP This pilot lamp 5 lights up when the torque converter lockup is engaged and the transmission is shifted to direct drive 3 15 ...

Page 65: ...mps are set to high beam TURN SIGNAL PILOT LAMP This pilot lamp 8 flashes at the same time as the turn signal lamp flashes SHIFT INDICATOR This monitor 9 displays the transmission shift range speed range When the key was turned ON if the shift lever is operated it will display 2 at the lever position D 1 at the 5 L position and R at the R position even if the engine is stopped 3 16 ...

Page 66: ...racteristics of the suspension according to the size of the load use of the brake operation of the steering and operation of the dump control Normally it is set to the soft mode when the dump truck is traveling empty and to the medium mode when it is traveling loaded When the foot brake is operated or the machine is suddenly turned or the dump control is operated the suspension mode is switched to...

Page 67: ...meter Service meter Odometer Fuel gauge 6 7 8 9 Air pressure gauge Engine water temperature gauge Torque converter oil temperature gauge Retarder oil temperature gauge SPEEDOMETER This meter 1 indicates the travel speed of the machine A speedometer for MPH is also available 3 18 ...

Page 68: ...achine If the engine is running the service meter will advance even if the machine is not moving The meter advances by 1 for every one hour of operation regardless of the engine speed ODOMETER This meter 4 indicates the distance traveled in kilometers An odometer for MILES is also available FUEL GAUGE This gauge 5 indicates the amount of fuel in the fuel tank The green range should be lighted up d...

Page 69: ...o load at a mid range speed and wait until the green range lights up If the red range lights up the engine output of the machine equipped with an electronic governor is automatically limited TORQUE CONVERTER OIL TEMPERATURE GAUGE This gauge 8 indicates the torque converter oil temperature The green range should be lit up during operation If the red range lights up during operation the alarm buzzer...

Page 70: ...alarm buzzer sounds intermittently Stop the machine then take appropriate corrective action according to the user code 1 2 Engine Mechatronics related Automatic transmission Mechatronics related 3 Mechatronics related parts Excluding 1 and 2 above ENGINE Mechatronics related If an abnormality is detected in the mechatronics related parts of the engine control system this lamp 1 flashes to warn of ...

Page 71: ...ING LAMP If the machine is in the following condition this lamp will flash If the fuel level goes below 60 liters 15 84 US gal the fuel level monitor flashes and only the red range on the fuel gauge lights up If the machine is in the following condition this lamp will flash and at the same time the alarm buzzer will sound intermittently When an abnormality has occurred in any of EMERGENCY STOP ITE...

Page 72: ...bulb check switch Exhaust brake switch if equipped Front brake cut off switch Hazard lamp switch Night lighting dimmer switch Power mode selector switch 9 11 12 13 14 15 16 17 18 AISS LOW switch Emergency steering switch Secondary brake lever Shift limiter switch Parking brake valve lever Cigarette lighter Horn button Wiper switch Room lamp switch 3 23 ...

Page 73: ...mp bulb check switch Exhaust brake switch if equipped Front brake cut off switch Hazard lamp switch Night lighting dimmer switch Power mode selector switch 9 10 11 12 13 14 15 16 17 18 AISS LOW switch 4WD switch Emergency steering switch Secondary brake lever Shift limiter switch Parking brake valve lever Cigarette lighter Horn button Wiper switch Room lamp switch 3 24 ...

Page 74: ...eating monitor lights up After the preheating is completed the monitor goes out START position This is the engine start position Keep the key at this position during cranking Immediately after starting the engine release the key It will automatically return to the ON position LAMP SWITCH This switch 2 lights up the head lamps side clearance lamps tail lamps machine monitor lighting and rear lamps ...

Page 75: ...BRAKE SWITCH If equipped This switch 4 shows the operating condition of the exhaust brake If it is pushed once it lights up and it goes off when it is pushed again OFF position Light is off The exhaust brake is actuated when the brake pedal is depressed or the retarder control lever is operated if the torque converter is in the lockup condition ON position Light is on The exhaust brake is actuated...

Page 76: ... the front wheels If the switch is pressed again the lamp goes out and the front brake cut function is canceled OFF position Light is off When the brake pedal is depressed the brakes are applied to both the front and rear wheels ON position Light is on When the brake pedal is depressed the front brakes are not applied The brakes are applied only to the rear wheels HAZARD LAMP SWITCH This switch 6 ...

Page 77: ...ns AISS LOW SWITCH Using this switch 9 it is possible to switch the AISS freely between AUTO and LOW Use each position as follows If the switch is depressed it lights up and if it is depressed once again the light goes off OFF position Light is off AUTO position At normal operation ON position Light is on Low speed position When the delicate start and operation is needed like putting the machine i...

Page 78: ...ill be actuated automatically in the following cases When hydraulic pump for steering has trouble When engine has stopped during operation When the automatic emergency steering is actuated stop the machine promptly and perform inspection If the key switch is turned ON when the machine is stopped and the parking brake switch is OFF the auto emergency steering is actuated after 1 second so turn the ...

Page 79: ...rake valve PARKING Parking brake actuated TRAVEL Parking brake is released When the lever is set to the PARKING position the parking brake pilot lamp lights up When the lever is set to the PARKING position if the gear shift lever is at any position other than N the central warning lamp will flash and the alarm buzzer will sound If the air pressure drops and goes below 0 32MPa 3 2kgf cm2 45 4 PSI t...

Page 80: ...ill sound WIPER SWITCH This switch 17 is used to operate the wiper INT position Wiper moves intermittently OFF LOW position Wiper moves at low speed HI position Wiper moves at high speed When the switch is pressed washer fluid is sprayed out ROOM LAMP SWITCH This switch 18 is used to switch the room lamp on or off a OFF b ON 3 31 ...

Page 81: ...NTS CONTROL LEVERS AND PEDALS 1 2 3 4 Brake pedal Accelerator pedal Shift lever Dump lever lock 5 6 7 Dump lever Retarder control lever Differential lock pedal if equipped BRAKE PEDAL This pedal 1 is used to apply the wheel brakes 3 32 ...

Page 82: ...ever is not at the FLOAT position Set the dump lever to the FLOAT position before moving the shift lever to the R position 5 L position These positions are used in places where it is difficult to travel at high speed or when traveling on soft ground or when starting the machine off on a slope when it is loaded They are also used when going downhill if it is needed to use the braking force of the e...

Page 83: ...nd The shift lever must not be returned to the N neutral position while traveling Release the accelerator pedal and run the engine at low idle when moving the shift lever from the N position to the forward or reverse position When moving the gear shift lever from the N neutral position to the R reverse position or from the D positions to position 5 or other lower position press the lock button on ...

Page 84: ...ulled the greater the braking force becomes When the retarder is actuated the rear brake pilot lamp lights up For details see TRAVELING DOWNHILL PAGE 3 88 When leaving the operator s seat always apply the parking brake DIFFERENTIAL LOCK PEDAL If equipped This pedal 7 is used to actuate the differential lock control When the pedal is depressed the differential lock is actuated and when it is releas...

Page 85: ...troller 2 to identify the location of the abnormality When the condition is normal 0 0 is displayed For the mothod of checking the service code when an abnormality occurs see TROUBLESHOOTING PAGE 3 114 4 WHEEL DRIVE CONTROLLER HD325 The machine of 4WD specifications A 2 digit failure code is displayed in the inspection window of this controller 3 to inform of the location of the abnormality When t...

Page 86: ... pins 1 Always insert the body pivot pins on both sides STOWING BODY PIVOT PIN The safety pins are stored at the bottom rear of the dump body Insert body pivot pins 1 then insert lock pins 2 to stow in position DUST INDICATOR This device indicates clogging of the air cleaner Depending on the degree of clogging of the element red line 1 appears in the transparent portion If red line 1 indicates 0 0...

Page 87: ...in the rear cover inside the cab FUSES The fuses protect the electrical equipment and wiring from burning out If the fuse becomes corroded or white powder can be seen or the fuse is loose in the fuse holder replace the fuse NOTICE When replacing any fuse always turn the power off turn the starting switch to OFF When replacing the fuse always use a fuse of the same capacity and type 3 38 ...

Page 88: ...oid 10 10A T M controller exhaust brake switch shift limiter switch power mode selector switch transmission cut relay Fuse box II No Fuse capacity Circuit name 11 10A Engine controller fuel cut relay hazard relay hazard lamp relay 12 10A Electronic display panel caution pilot lamp central warning lamp buzzer AISS switch 13 5A Suspension controller 14 5A Payload meter if equipped Payload meter rela...

Page 89: ...or 24 10A Air conditioner compressor 25 10A Spare 26 10A Spare Fuse box IV No Fuse capacity Circuit name 27 30A Power source for fuse box Fuse box V HD325 Only the machine of 4WD specifications No Fuse capacity Circuit name 28 5A 4WD controller 29 5A 4WD controller 30 5A Spare 31 5A Spare 32 5A Spare 33 5A Spare Contact your Komatsu distributor before using any spare fuse terminal 3 40 ...

Page 90: ...ch Volume Tone control knob Display Clock button Displaying frequency AST 6 7 8 9 Preset switch Seek Band selector switch Tuning switch POWER SWITCH VOLUME When this switch 1 is turned to the right it clicks and the power is turned on If it is turned further the speaker volume is adjusted 3 41 ...

Page 91: ... frequency and the operating mode CLOCK BUTTON DISPLAYING FREQUENCY When this button 4 is pressed the display changes to the time If it is pressed again it displays the frequency AST When this button 5 is pressed the preset stations are called up in turn When the desired broadcasting station is reached press the button again to stop it If the button is kept pressed continuously for 2 seconds it is...

Page 92: ...matically searches for stations that can be received and when it receives a station it stops BAND SELECTOR SWITCH When this switch 8 BAND is pressed the band is switched between FM and MW AM The reception band and frequency are displayed on the display TUNING SWITCH When the TUNE button U of switch 9 is pressed the frequency goes up when the V button is pressed the frequency goes down If it is kep...

Page 93: ...d tone as desired 5 To turn the radio OFF turn VOL knob 1 to the left until a click is heard METHOD OF AUTOMATIC TUNING When the SEEK switch is pressed it moves up to higher frequencies and when it finds a station that can be received it stops automatically METHOD OF MANUAL TUNING When the TUNE button U is pressed the frequency goes up when the V button is pressed the frequency goes down If it is ...

Page 94: ...tched off all the preset settings are deleted Carry out the presetting operation again It is possible to preset 6 AM MW stations and 6 FM stations METHOD OF AUTOMATIC MEMORY If the AST button is pressed for 2 seconds the broadcasting stations that can be received in the area are called up in turn and the broadcasting stations are automatically saved in the preset memory AUTOMATIC SWITCHING RECEPTI...

Page 95: ...IONS FOR USE Stow the antenna when traveling in places with low overhead clearance To ensure safety always keep the sound to a level where it is possible to hear outside sounds during operation If water gets into the speaker case or radio it may lead to an unexpected failure so be careful not to get water on the equipment Do not wipe the scales or buttons with solvent such as benzene or thinner Wi...

Page 96: ...Loudness button Time Radio display selector button Tape eject button 8 9 10 11 12 13 14 Cassette door Fast forward rewind buttons Preset buttons Metal tape button Manual tuning buttons Seek tuning buttons Band selector button A B C D Band display Metal tape display FM stereo reception display Loudness display E F G Tape direction display Preset channel display Time Frequency display 3 47 ...

Page 97: ...y is memorized in the auto store REMARK The auto store function cannot be used when the channel display is flashing When the display is flashing the preset scan function is being used Preset scan If this button is pressed for less than 0 5 second while in radio reception programs from the six preset stations in the same band will be broadcast one after another for 5 seconds each starting from No 1...

Page 98: ...easily by emphasizing the low tone when the low tones are weak Push button Actuated ON Push button again Canceled OFF TIME RADIO DISPLAY SELECTOR BUTTON This button 6 is used to switch between the Radio tape display and the Time display Correcting the time Press the button to set the time display A Correcting hour Keep the DISP button pressed and press the bottom H of the TUNING button to correct ...

Page 99: ... press the button pointing in the same direction as the lighted arrow indicating the direction of play the tape will be fast forwarded if you press the button pointing in the opposite direction the tape will rewind To stop the tape lightly press the button that is not locked The fast forward or rewind operation will be canceled If the fast forward and rewind buttons are pressed at the same time th...

Page 100: ...z for FM when TUN button is pressed the frequency goes down 9 kHz for AM or 0 1 MHz for FM If the button is pressed down and held the frequency will change continuously SEEK TUNING BUTTONS These buttons 13 are used to seek tuning When the SEEK UP button is pressed the search automatically goes up when the SEEK DN button is pressed the search automatically goes down When the next station that can b...

Page 101: ...3 Press manual memory button 2 or seek tuning button 3 4 Press preset button 4 of the number to be preset for 2 seconds while the frequency display is being shown on the display The preset channel and frequency are displayed and the presetting is completed 5 Repeat Steps 2 to 4 to preset other stations REMARK Use Steps 2 to 4 also when changing the setting of a preset switch to another station Whe...

Page 102: ...ette when listening to the radio the tape will start to play LISTENING TO CASSETTE TAPE 1 Turn the starting switch ON then turn power switch 1 ON 2 Set the cassette with the exposed portion of the tape on the right side and push it past the cassette door The tape will automatically start playing If the arrow indicating the direction of play is pointing to the right the top side is being played if ...

Page 103: ...ns with solvent such as benzene or thinner Wipe with a dry soft cloth If the dirt cannot be removed easily soak the cloth with alcohol NOTICE Handling cassette tape Clean the tape head approx once a month with a commercially available head cleaning tape Do not leave the tape any place where it is exposed to direct sunlight any place that is excessively dusty or any place where there is a magnetic ...

Page 104: ...ronment even on dusty jobsites GENERAL LOCATIONS ON CONTROL PANEL 1 2 3 Fan switch Air conditioner switch Mode selector switch 4 5 RECIRC FRESH selector switch Temperature control switch FAN SWITCH This switch 1 can be used to adjust the air flow to 4 stages This switch also acts as the main switch for the air conditioner When the switch is pressed the indicator lamp above the switch lights up to ...

Page 105: ...five vent modes are available FACE FACE FOOT FOOT FOOT DEF DEF When the switch is pressed the indicator lamp above the switch lights up to display the vent mode RECIRC FRESH SELECTOR SWITCH This switch 4 changes between recirculation of the internal air RECIRC or intake of external air FRESH When pressing the switch the indicator lamp on the top of switch lights up RECIRC This switch 4 is used whe...

Page 106: ...switch to set the temperature The settings for each mode are retained in memory even when the starting switch is turned OFF However in the following cases the settings must be made again When the machine has been out of use for more than 7 days When the battery voltage is extremely low When there has been abnormal interference from outside When the fan switch is turned OFF the setting is not kept ...

Page 107: ... USING THE AIR CONDITIONER REGURARLY To lubricate each part of the compressor operate cooling dehumidifying and heating for 3 to 5 minutes once a month at low idle Also check the amount of cooling gas twice a year REMARK If the temperature inside the cab is low the air conditioner may not work In such cases use the recirculated air to warm up the inside of the cab then turn the air conditioner swi...

Page 108: ...e at low speed and set the temperature control lever to the central position Clean the air filter and check the refrigerant For details see CLEAN AIR CONDITIONER AIR FILTER PAGE 4 28 and CHECK REFRIGERANT GAS LEVEL PAGE 4 29 To enable the air conditioner to perform to the full and to maintain a pleasant working environment always contact your Komatsu distributor to have the air conditioner refille...

Page 109: ... carry out repairs if any problem is found 2 Remove dirt from around engine battery radiator and aftercooler Check that there is no dirt or dust accumulated around the engine radiator or aftercooler Check also that there is no flammable material dry leaves twigs etc accumulated around the battery or engine muffler turbocharger or other high temperature parts of the engine Remove any dirt or flamma...

Page 110: ...en or if the clamps are broken or deformed replace the seat belt 11 Check cracks and damage of ROPS if equipped and check for loose bolts Check if any bolt is loose or damaged If it is loose tighten it torque 1520 to 1910 Nm 155 to 195 kgm 1121 1 to 1410 4 lbft If it is broke then replace it with Komatsu genuine bolt 12 Inspect tires WARNING If worn or damaged tires are used they may burst and cau...

Page 111: ...this condition there is a hazard of burns Wait for the temperature to go down then turn the cap slowly to release the pressure and remove it carefully 1 Check that the cooling water in sub tank 1 is between the FULL and LOW marks 2 If the level is LOW remove cap 2 and add the engine coolant up to the FULL mark 3 If there is no cooling water in the subtank remove the cover at the top of the radiato...

Page 112: ... When checking the oil level park the machine on level ground lower the body and check with the engine idling CHECK DUST INDICATOR 1 Check that the red line in the transparent portion of dust indicator 1 does not indicate 0 0075 MPa 30 INCHES H2O 0 076 kg cm2 1 1 PSI 2 If the red line indicates 0 0075 MPa 30 INCHES H2O 0 076 kg cm2 1 1 PSI clean or replace the air cleaner element immediately For d...

Page 113: ...n plug 1 and loosen drain valve 2 to drain the excess engine oil then check the engine oil level again 6 If the oil level is correct tighten the handle of the oil filler cap securely REMARK When checking the oil level after the engine has been operated wait for at least 15 minutes after stopping the engine The dipstick has the oil level marked on both sides ENGINE STOPPED for measuring when the en...

Page 114: ...ight gauge G1 as a guide line and make the final check with G2 When checking the oil level with the engine stopped wait for 20 minutes after stopping the engine and check with sight gauge G1 CHECK OIL LEVEL IN HYDRAULIC TANK ADD OIL WARNING If the oil filler cap is removed without releasing the internal pressure oil will spurt out so turn the oil filler cap slowly to release the internal pressure ...

Page 115: ...nstalled in the side of the fuel tank 2 After completing operations add fuel through fuel filler F to fill the tank Fuel tank capacity 500 liters 132 1 US gal 3 After adding fuel tighten the cap securely REMARK If breather hole 1 in the cap becomes clogged the pressure inside the tank will go down and the fuel may not flow so clean the breather hole from time to time To prevent the engine from suc...

Page 116: ...olts for that wheel CHECK CENTRAL WARNING LAMP Carry out the following checks to prevent warning failures caused by a broken lamp bulb in central warning lamp 1 or defective operation of the buzzer If there is any problem please ask your Komatsu distributor to carry out inspection Stop the engine turn the starting switch to the ON position set the parking brake valve lever to the PARK position mov...

Page 117: ... check that no caution lamp or pilot lamp bulb is blown If the monitor lamp caution lamp or pilot lamp do not light up there is probably a failure or disconnection therefore contact your Komatsu distributor for inspection CHECK BRAKING CAPACITY OF SECONDARY BRAKE WARNING If the machine moves it will lead to the serious human injury If the machine starts to move while checking the braking capacity ...

Page 118: ...tion 2 Place the gear shift lever in the R position and check that the backup alarm is working CHECK ELECTRIC WIRING WARNING If the fuses frequently blow or if there are traces of short circuits in the electrical wiring locate the cause and immediately perform repairs or contact your Komatsu distributor for repairs Keep the top surface of the battery clean and check the breather hole in the batter...

Page 119: ...00 kg cm2 99 4 PSI 18 00 33 32PR if equipped 0 56 MPa 5 75 kg cm2 81 7 PSI 18 00 33 28PR if equipped 0 49 MPa 5 00 kg cm2 71 0 PSI HD405 Tire size Inflation pressure 18 00R33 0 69 MPa 7 00 kg cm2 99 4 PSI NOTICE If the tires are used when the inflation pressure is less than the value given in the table above the rim may be damaged Always keep the tire inflation pressure within 0 to 0 03 MPa 0 3 kg...

Page 120: ...ver 2 up set the seat angle to the desired position then release the lever Adjustment range Seat surface approx 2 7 up and down C Setting seat for operator s weight Turn grip 3 under the seat to adjust weight adjustment scale 4 to your own weight Adjustment range 50 to 120 kg 110 to 265 lb REMARK To make the seat softer adjust the weight to make it lighter to make the seat harder adjust the weight...

Page 121: ...he belt twisted Fastening and removing belt 1 Sit on the seat depress the brake pedal fully and adjust the seat so that your back is pressed against the backrest 2 Sit on the seat take buckle 1 and tongue 3 in your left and right hands insert tongue 3 into buckle 1 and pull the belt to check that it is securely locked 3 When removing the belt press button 2 of buckle 1 to release the belt Fasten t...

Page 122: ...TILT WARNING Always stop the machine before adjusting the tilt of the steering wheel The tilt of the steering wheel can be adjusted to the front and rear and up and down Pull lever up and set the steering wheel to the desired position then push lever down to lock the steering wheel securely in position Adjustment range Front rear 5 degrees Up 30 mm 1 2 in Down 20 mm 0 8 in 3 73 ...

Page 123: ... position 1 Check that parking brake valve lever 1 is at the PARKING position 2 Check that gear shift lever 2 is at the N position REMARK If the shift lever is not at the N neutral position the engine will not start If the starting switch is turned to the ON position when the shift lever is not at N neutral the transmission shift lever position pilot lamp and the central warning lamp will flash an...

Page 124: ...enance caution lamp if equipped when the key in starting switch 5 is turned to the ON position HD325 only the machine of 4WD specifications 6 Check that 4 wheel drive switch 6 does not flash when the key in starting switch 5 is turned to the ON position If it flashes then contact your Komatsu distributor 3 75 ...

Page 125: ...ng the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not accelerate the engine suddenly before completing the warming up operation Do not keep the starting motor rotating continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes before trying to start the engine again 1 Release the accelerator pedal or depress it lightly...

Page 126: ...ing the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not accelerate the engine suddenly before completing the warming up operation Do not keep the starting motor rotating continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes before trying to start the engine again If the accelerator pedal is kept depressed after sta...

Page 127: ...ot put your foot on the accelerator pedal during this time Guideline for idling time Cold temperature 15 seconds or more When first starting engine after changing engine oil and replacing engine oil filter 20 seconds REMARK Immediately after the engine is started the turbo protect function is actuated Even if the accelerator pedal is depressed the engine speed will not rise above 1 000 rpm Cooling...

Page 128: ...ime given below and the engine sound is different In addition it functions to make the acceleration gradual during this time Engine water temperature Injection characteristics change time Above 20 C 68 F 0 sec 0 C to 20 C 32 F to 68 F 0 to 6 sec 20 C to 0 C 4 F to 32 F 6 to 12 sec 30 C to 20 C 22 F to 4 F 12 to 15 sec 3 79 ...

Page 129: ...e to run the engine at idle apply a load from time to time or run the engine at a mid range speed After the engine starts do not start operating the machine immediately First carry out the following operations and checks 1 Immediately after starting the engine do not operate the accelerator pedal or dump body for the time given below Even after this time has passed avoid sudden acceleration of the...

Page 130: ...ngine at low idle for about 5 minutes to cool down gradually 2 Turn the key of starting switch 1 to the OFF position to stop the engine 3 Remove the key from starting switch 1 CHECKS AFTER STOPPING ENGINE 1 Walk around the machine and check the work equipment bodywork and undercarriage and check also for oil and water leakage 2 Fill the fuel tank 3 Check the engine compartment for paper and debris...

Page 131: ...4WD specifications Lights off position 2 wheel drive rear wheel drive Lights on position 4 wheel drive all wheel drive NOTICE Switch 4 wheel drive 2 wheel drive only when the travel speed is less than 10 km h 6 2 MPH Shifting at a higher speed will cause failure REMARK When the engine speed is 1080 rpm or above the front wheel starts to drive 2 Check that there is no warning display on the machine...

Page 132: ...ing from N to R or F 6 Depress accelerator pedal 7 to move the machine off NOTICE If the gearshift lever is shifted to a position other than N when the parking brake has not been released the central warning lamp will flash and the alarm buzzer will sound If the gearshift lever is shifted to a position other than N when the dump lever is at a position other than FLOAT or the body is raised the cen...

Page 133: ...dal 2 to move the machine off NOTICE The machine cannot travel in reverse if the dump lever is not at the FLOAT position Place the dump lever at the FLOAT position before operating to the R position When shifting between FORWARD and REVERSE stop the machine completely and run the engine at low idle when shifting the lever After moving the gear shift lever do not depress the accelerator until you d...

Page 134: ...s or when parking the machine after stopping it NORMAL STOPPING Release accelerator pedal 1 and depress brake pedal 2 to stop the machine STOPPING IN EMERGENCY If there should be a failure in the foot brake stop the machine as follows WARNING When the machine stops put blocks under the tires immediately Immediately after making an emergency stop the parking brake disc will be at high temperature s...

Page 135: ...rake valve lever 3 to the right to the PARKING position 4 If an emergency stop has been made put blocks under the tires immediately then try to find the cause and repair it on site 5 After the emergency operation of parking brake and secondary brake see RELEASE METHOD WHEN PARKING BRAKE AND SECONDARY BRAKE HAVE BEEN ACTUATED IN EMERGENCY PAGE 3 119 in case that it is necessary to release the brake...

Page 136: ...on clutch has engaged Do not operate the gear shift lever with the accelerator pedal depressed This will cause a big shock and will also reduce the service life of the machine SHIFTING UP 1 When accelerator pedal 2 is depressed to accelerate the machine the lockup clutch is engaged to shift the transmission to direct drive 2 If the machine is accelerated further the transmission will automatically...

Page 137: ...er oil temperature monitor on the machine monitor flashes when using the retarder shift down to travel downhill When this happens the central warning lamp flashes and the alarm buzzer sounds If the monitor lamp does not go out even when the transmission is shifted down stop the machine immediately set the shift lever to the N position run the engine at the 2000 rpm and wait for the monitor to go o...

Page 138: ... makes it necessary to travel downhill in 1st set the gear shift lever to any position except D 5 4 3 L 3 When traveling downhill operate retarder control lever 2 run the engine at a speed of 1800 to 2200 rpm and travel so that the retarder brake oil temperature gauge is in the green range For machines equipped with an exhaust brake using the exhaust brake can provide more secure braking force for...

Page 139: ...dicular line down 3 Take the point where it crosses the line for travel resistance 11 as B and draw a horizontal line 4 Take the point where it crosses the performance curve as C and draw a perpendicular line down Take the point where this line crosses the travel speed scale as D 5 The following information can be obtained from this procedure From point D Maximum permissible speed 28 km h 17 4 MPH...

Page 140: ... OPERATION OPERATION HD325 HD325 of 4WD specifications HD405 3 91 ...

Page 141: ... OPERATION OPERATION Brake performance Downhill distance 450 m 1476 ft HD325 HD325 of 4WD specifications HD405 3 92 ...

Page 142: ... OPERATION OPERATION Brake performance Downhill distance 600 m 1968 ft HD325 HD325 of 4WD specifications HD405 3 93 ...

Page 143: ... OPERATION OPERATION Brake performance Downhill distance 900 m 2952 ft HD325 HD325 of 4WD specifications HD405 3 94 ...

Page 144: ... OPERATION OPERATION Brake performance Downhill distance 1500 m 4921 ft HD325 HD325 of 4WD specifications HD405 3 95 ...

Page 145: ... OPERATION OPERATION Brake performance Downhill distance Continuous HD325 HD325 of 4WD specifications HD405 3 96 ...

Page 146: ... fully to the left or right the steering wheel will turn a little at a time but this is not a failure LOADING OPERATIONS When using a large wheel loader to load large rocks if the rocks are loaded directly into the dump body parts of the dump body may be deformed To prevent this when loading large rocks first load sand or soil to act as a cushion then load the rocks on top of this to reduce the im...

Page 147: ...he PARKING position 2 Move dump lever 3 to the RAISE position then depress the accelerator pedal to raise the dump body If the dump lever is released when it is at the RAISE position it is held at the RAISE position and the dump body will continue to rise The dumping speed increases in proportion to the engine speed 3 When the dump body rises to the previously set position dump body positioner adj...

Page 148: ...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 If the central warning lamp and pilot lamp for any EMERGENCY item on the machine monitor should flash and the buzzer sounds during operation stop the machine immediately and inves...

Page 149: ...e may move suddenly and this may lead to a serious injury or death Before leaving the operator s compartment always set the parking brake valve lever securely to the PARKING position The retarder must not be used as a parking brake Do not use the retarder for long term parking regardless of the engine speed CAUTION To prevent damage to the parking brake apply the parking brake only when parking th...

Page 150: ... not stop the engine suddenly Run it at a mid range speed to cool it gradually before stopping DRAIN WATER FROM AIR TANK 1 After starting the engine pull ring 1 of the tank drain valve to drain the water from the tank 2 Carry out the same operation after completing work NOTICE In cold areas there is danger of the water freezing so drain the water from the air tank after operations when it is still...

Page 151: ...re used under severe conditions that bear no comparison with the tires used on cars buses or ordinary trucks so they are specially designed to withstand these conditions Compared with ordinary tires far greater heat is produced in the rubber internal parts of off road tires when the machine is traveling If they are used continuously under conditions which exceed the permitted load and travel speed...

Page 152: ...tructure CR Code No E4 TRA 214 192 170 158 When empty front wheel standard 27 24 21 20 When loaded rear wheel standard 17 15 14 13 HD325 4WD specifications Tire T Km P H for ambient temperature Max speed for continuous travel for ambient temperature km h 16 C 27 C 38 C 49 C 16 C 27 C 38 C 49 C Size 18 00R33 standard structure CR Code No E4 TRA 214 192 170 158 When empty front wheel standard 27 24 ...

Page 153: ...re Max speed for continuous travel for ambient temperature km h 16 C 27 C 38 C 49 C 16 C 27 C 38 C 49 C Size 18 00R33 standard structure CR Code No E4 TRA 214 192 170 158 When empty front wheel standard 27 24 21 20 When loaded rear wheel standard 17 15 14 13 3 104 ...

Page 154: ...e day when the tires are cold and adjust to the following inflation pressure Do not reduce the tire inflation pressure when traveling HD325 Tire size Inflation pressure 18 00 33 28PR standard 0 49 MPa 5 00 kg cm2 71 0 PSI 18 00 33 32PR if equipped 0 56 MPa 5 75 kg cm2 81 7 PSI 18 00R33 if equipped 0 69 MPa 7 00 kg cm2 99 4 PSI HD325 4WD specifications Tire size Inflation pressure 18 00R33 standard...

Page 155: ...ake failure Make the road as straight as possible and particularly in intermediate areas with curves where the machine is traveling at high speed make the radius of the curve as large as possible Small S curves are particularly dangerous so avoid such curves The radius of the curve must be a minimum of 12 to 15 m 39 ft 4 in to 49 ft 3 in Make the radius of curves as large as possible Make the road...

Page 156: ...ng to the type of tires and type of dump body METHOD OF SECURING MACHINE After loading the machine in the specified position secure it in place as follows 1 Set the parking brake valve lever to the PARKING position to apply the parking brake 2 Turn the key in the starting switch to the OFF position to stop the engine 3 Remove the key from the starting switch 4 To prevent the machine from moving du...

Page 157: ...ther than the posture given in the procedure below or using lifting equipment other than in the procedure below There is a hazard that the machine may lose its balance NOTICE This method of lifting applies to the standard specification machine The method of lifting differs according to the attachments and options installed For details of the procedure for machines that are not the standard specifi...

Page 158: ...ifting equipment to match the weight of the machine and fit the wire ropes to the lifting positions REMARK The lifting positions for the machine differs according to the conditions Machine with body Positions 1 and 3 Total 4 places 2 at front 2 at rear Machine without body Positions 1 and 2 Total 4 places 2 at front 2 at rear 4 Fit protector blocks at the contact points between the lifting equipme...

Page 159: ... or when handling coolant containing antifreeze that has been drained when repairing the radiator please contact your Komatsu distributor or request a specialist company to carry out the operation Antifreeze is toxic Do not let it flow into drainage ditches or spray it onto the ground surface Antifreeze is flammable Do not bring any flame close Do not smoke when handling antifreeze NOTICE Use Koma...

Page 160: ...m freezing INSTALLATION OF RADIATOR CURTAIN If equipped If the engine water temperature gauge does not enter the green range install a radiator curtain The amount that the radiator curtain is opened can be adjusted from fully closed to one window open or two windows open Adjust the amount of opening according to the ambient temperature so that the engine water temperature gauge enters the green ra...

Page 161: ... AFTER COLD WEATHER When the season changes and the weather becomes warmer do as follows Replace the fuel and oil for all parts with oil of the viscosity specified For details see RECOMMENDED FUEL COOLANT AND LUBRICANT PAGE 4 10 3 112 ...

Page 162: ...he cooling system with Supercoolant AF NAC or permanent type antifreeze density between 30 and 68 DURING STORAGE WARNING If it is necessary to perform the rust prevention operation while the machine is indoors open the doors and windows to improve ventilation and prevent gas poisoning During the storage period operate the machine once a month to prevent loss of the oil film at the lubricated parts...

Page 163: ... If there is any dirt stuck to the fuel line use fuel to wash it off completely Be careful when opening the air bleed plug at the fuel filter head and the air bleeder of the supply pump The system is still under pressure and fuel may spurt out 1 Remove fuel filter cartridge 1 fill the inside of the filter with clean fuel taking care not to let dirt or dust get in then install it again Add fuel fro...

Page 164: ...of the supply pump 6 Pump priming pump 4 approx 90 to 100 times until no more bubbles come out with the fuel from air bleeder 5 then tighten air bleeder 5 Tightening torque 4 9 to 6 9 Nm 0 5 to 0 7 kgm 3 6 to 5 1 lbft 7 Continue pumping until priming pump 4 becomes stiff 8 Push in the knob of priming pump 4 and tighten it 9 Turn the key in the starting switch to the START position and start the en...

Page 165: ...load is applied suddenly to the towing wire or drawbar and the towing wire or drawbar may break Move the machine gradually to a constant speed Be extremely careful if there is a failure in the engine or brake system the brakes will not work If the steering and the brakes on the disabled machine cannot be operated do not let anyone ride on the disabled machine NOTICE The permissible towing capacity...

Page 166: ...e angle between the center lines of the two machines to within 30 degrees Towing may be carried out under various differing conditions so it is impossible to determine beforehand the requirements for towing Towing on flat horizontal roads will require the minimum rimpull while towing on slopes or on uneven road surfaces will require the maximum rimpull If the pressure in the air tank has dropped a...

Page 167: ...ine to allow the steering and brakes to be used WHEN ENGINE DOES NOT RUN The brakes will not work so be extremely careful Connect the towing machine securely to the towed machine Use two towing machines of the same class or larger than the machine being towed connect one machine each to the front and rear of the machine being towed If it is necessary to change the direction of the machine being to...

Page 168: ...at the surrounding area is safe If the parking brake must be released on a slope because of an emergency or some other unavoidable reason put blocks under the wheels before releasing the brake After the parking brake has been actuated in an emergency if the parking brake is not released when the parking brake valve lever is set to the TRAVEL position do as follows to release the parking brake 1 Re...

Page 169: ...the secondary brake tank check that the surrounding area is safe and always put blocks under the tires before starting the operation After actuation of the secondary brake if the secondary brake is not released when the secondary brake valve lever is placed at the TRAVEL position release the secondary brake as follows 1 When the preparations for towing the machine are completed pull rings 1 of the...

Page 170: ...tor When handling batteries always wear safety glasses and rubber gloves When removing the battery first disconnect the cable from the ground normally the negative terminal When installing install the positive terminal first If a tool touches the positive terminal and the chassis there is danger that it will cause a spark so be extremely careful If the terminals are loose there is danger that the ...

Page 171: ... charger to the negative terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or dry up and this may cause the battery to catch fire and explode If the battery electrolyte is ...

Page 172: ...he battery When disconnecting the booster cable take care not to bring the clips in contact with each other or with the machine body NOTICE The size of the booster cable and clip should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the problem machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are...

Page 173: ...TART position and start the engine If the engine doesn t start at first try again after 2 minutes or so DISCONNECTING THE BOOSTER CABLES After the engine has started disconnect the booster cables in the reverse of the order in which they were connected 1 Remove one clip of booster cable B from the engine block of the problem machine 2 Remove the other clip of booster cable B from the negative term...

Page 174: ...or belt tension See EVERY 250 HOURS SERVICE Lamp flickers while engine is running Charge monitor lights up while running engine Defective alternator Defective wiring Replace Check repair Abnormal noise is generated from alternator Defective alternator Replace Starting motor does not turn when starting switch is turned to ON Defective wiring Defective starting switch Insufficient battery charge Def...

Page 175: ...rake Make tire inflation pressure uniform See CHECK BEFORE STARTING Check wear of front brake pad For details see EVERY 500 HOURS SERVICE Braking effect is poor when brake pedal is depressed Pad has reached wear limit Rear disc has reached wear limit Insufficient air pressure Insufficient brake oil Air in brake circuit Replace pad Replace pad Charge to specified pressure Add brake oil See CHECK BE...

Page 176: ...hile the engine runs at low idling when the pedal is released The engine speed varies depending on the load After moving the machine to a safe place by operating the accelerator pedal contact your Komatsu distributor for repairs There are two methods when operating the accelerator pedal either release the pedal and set to the OFF low idling position or depress the pedal fully 1500 rpm If the accel...

Page 177: ... 250 HOURS SERVICE Change coolant clean inside of cooling system See WHEN REQUIRED Clean or repair See EVERY 500 HOURS SERVICE Replace water temperature gauge Replace thermostat Replace thermostat seal Tighten or replace cap Repair connect wiring Radiator cooling water level monitor lights up Engine water temperature gauge is in red range Engine water temperature monitor flashes Engine water tempe...

Page 178: ... Worn piston ring cylinder liner Defective compression Defective turbocharger Defective exchaust brake Defective injecter Clean or replace See WHEN REQUIRED Check repair See Defective valve clearance above Check replace Check replace repair Check adjust repair Engine hunts Air entering suction side of fuel line Repair place where air is leaking in Combustion noise ocaasionally makes breathing soun...

Page 179: ... speedometer 2 and user code display 3 release the check switch for caution pilot lamp bulb and check the service code Immediately after checking the service code stop the engine 4 After checking the service code contact your Komatsu distributor for repairs REMARK The first two digits are shown on speedometer 2 and the last two digits are displayed on user code display panel 3 The first digit is a...

Page 180: ...nector 1 connector No A 1 A 2 black 1 pin connector and insert again then operate the shift lever to move the machine without depressing the accelerator pedal If the shift lever is operated with the accelerator pedal depressed the emergency escape function will not work Furthermore the emergency escape function may also not work for some failure modes While the emergency escape function is working...

Page 181: ...g lamp and 4 wheel drive switch do not stop flashing or the alarm buzzer continues to sound even when the 4 wheel drive switch is turned OFF do not try to move the machine 5 Check the self diagnostic display then contact your Komatsu distributor for repairs REMARK The normal self diagnostic display shows 2WD 3 2 4WD A The indicates the gearshift range Example I F1 B R A shifting PAYLOAD METER PRIN...

Page 182: ... 4 1 ...

Page 183: ...ays report to the person in charge and carry out suitable action In addition when replacing the engine oil filter fill the new filter with the specified clean oil then install it OIL CHANGE If your machine is equipped with a fuel strainer do not remove it while fueling WELDING INSTRUCTIONS Turn off the engine starting switch Do not apply more than 200 V continuously Connect grounding the cable wit...

Page 184: ... in the circuit See WHEN REQUIRED PAGE 4 23 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace with new parts When doing this be careful not to forget to assemble the O rings and gaskets When installing the hoses do not twist them or bend them sharply If they are installed so their service life...

Page 185: ...re high pressure and deteriorates with use Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the Operation and Maintenance Manual Even if the oil is not dirty always change the oil at the specified interval Oil corresponds to blood in the human body always be careful when handling it to prevent any impurities water metal particles dirt etc from getti...

Page 186: ...t has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of antifreeze coolant is essential Komatsu machines are supplied with Komatsu Supercoolant AF NAC Komatsu Supercoolant AF NAC has excellent anticorrosion antifreeze and cooling propertiesand can be used continuously for 2 years or 4000 hours Komatsu Supercool...

Page 187: ...peratures given in this Operation and Maintenance Manual Grease fittings not included in the maintenance section are grease fittings for overhaul so they do not need grease If any part becomes stiff after being used for long time add grease Always wipe off all of the old grease that is pushed out when greasing Be particularly careful to wipe off the old grease in places where sand or dirt sticking...

Page 188: ... Plasma analyzer to measure the density of iron copper and other metal wear particles in the oil Measurement of quantity of particles This uses a PQI Particle Quantifier Index measurer to measure the quantity of iron particles of 5µm or more enabling early detection of failures Others Measurements are made of items such as the ratio of water in the oil density of the antifreeze coolant ratio of fu...

Page 189: ... distributor When replacing the engine oil filter fill the new filter with the specified clean oil then install it Do not open packs of spare filters until just before they are to be used Use of Komatsu genuine filter elements is strongly recommended OUTLINE OF ELECTRIC SYSTEM It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged This will cause...

Page 190: ...OURS Hydraulic filter 07063 01142 07000 F5175 Element O ring 1 1 Corrosion resistor 600 411 1171 Cartridge 1 Air cleaner 600 185 5100 Element Ass y 2 600 185 5110 Outer element 2 Payload meter paper if equipped 7818 27 2910 Paper 1 Payload meter inner battery if equipped 7818 27 2860 Battery 1 HD325 The machine of 4WD specifications Item Part No Part Name Q ty Replacement frequency Engine oil filt...

Page 191: ... according to the ambient temperature in the chart below Specified capacity means the total amount of oil including the oil in the tank and the piping Refill capacity means the amount of oil needed to refill the system during inspection and maintenance When starting the engine in temperatures below 0 C 32 F be sure to use the recommended multi grade oil even if the ambient temperature may become h...

Page 192: ... MAINTENANCE RECOMMENDED FUEL COOLANT AND LUBRICANT USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE HD325 HD405 ASTM American Society of Testing and Material 4 11 ...

Page 193: ...on RECOMMENDED BRANDS RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL PAGE 4 15 at the end of this chapter Note 2 Powertrain oil has different properties from engine oil Be sure to use the recommended oils Note 3 Hyper grease G2 T G2 TE has a high performance When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings the...

Page 194: ... MAINTENANCE RECOMMENDED FUEL COOLANT AND LUBRICANT HD325 4WD specifications ASTM American Society of Testing and Material 4 13 ...

Page 195: ...D BRANDS RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL PAGE 4 15 at the end of this chapter Note 2 Amount of oil in transmission case includes the amount of oil in front final drive Note 3 Powertrain oil has different properties from engine oil Be sure to use the recommended oils Note 4 Hyper grease G2 T G2 TE has a high performance When it is necessary to improve the lubricating...

Page 196: ...ENDED BRANDS RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil or when checking the latest specifications refer to the Komatsu web page or consult your Komatsu distributor 4 15 ...

Page 197: ...3 5 50 0 62 0 67 5 84 5 84 0 105 0 180 8 227 8 253 2 314 6 361 7 448 4 488 2 611 2 607 6 759 5 27 30 33 36 39 41 46 50 55 60 1320 1720 2210 2750 3280 135 0 175 0 225 0 280 0 335 0 976 5 1265 8 1627 4 2025 2 2423 1 1180 1470 1520 1910 1960 2450 2450 3040 2890 3630 120 0 150 0 155 0 195 0 200 0 250 0 250 0 310 0 295 0 370 0 868 0 1085 0 1121 1 1410 4 1446 6 1808 3 1808 3 2242 2 2133 7 2676 2 NOTICE ...

Page 198: ...deformation or cracking replace the clamps at the same time as the hoses Also perform the following checks with hydraulic hoses which need to be replaced periodically Tighten all loose clamps and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time SAFETY CRITICAL PARTS No Safety critical parts for periodic replacement Replac...

Page 199: ...replace air cleaner 4 23 Clean inside of cooling system 4 25 Check level of window washer fluid add fluid 4 28 Clean air conditioner air filter 4 28 Check refrigerant gas level 4 29 Check dump body 4 29 Check electric intake air heater 4 29 Check length of suspension cylinder check oil level 4 30 Bleed air from rear brake 4 31 Bleed air from front brake 4 32 Adjust parking brake 4 33 Bleed air fro...

Page 200: ...RY 500 HOURS SERVICE Change oil in engine oil pan replace engine oil filter cartridge 4 55 Replace additional fuel filter cartridge 4 56 Clean fuel tank strainer 4 57 Replace transmission oil filter element valve inlet side return side 4 58 Replace element of front drive oil filter 4 59 Check wear of front disc brake pads 4 59 Clean check radiator fins and after cooler fins 4 60 Check fan belt ten...

Page 201: ...turbocharger rotor 4 75 EVERY 4000 HOURS SERVICE Check water pump 4 76 Check air compressor 4 76 Check fan pulley and tension pulley 4 76 Check vibration damper 4 76 Check injector all areas except EPA exhaust gas regulation areas 4 76 Replace injector assembly EPA exhaust gas regulation areas only 4 76 Checking for looseness of high pressure clamp hardening of rubber 4 76 Checking for missing fue...

Page 202: ...a or a B regulation area A REGULATION AREA EPA regulation areas and areas with the regulations equivalent to EPA regulations EVERY 2000 HOURS SERVICE Check injector Check the exhaust gas color visually If there is any abnormality in the exhaust gas color please ask your Komatsu distributor to carry out inspection or replacement For details of the procedure if any abnormality is found see Section E...

Page 203: ... engine oil filter cartridge Replace fuel filter cartridge Replace transmission oil filter element valve inlet side return side Change oil in transmission case Replace hydraulic filter element Change oil in hydraulic tank Change oil in final drive case Change oil in differential case For details of the method of replacing or maintaining see EVERY 500 HOURS EVERY 1000 HOURS and EVERY 2000 HOURS SER...

Page 204: ... 3 After checking cleaning or replacing press the top of dust indicator 1 to return the red line to its original position NOTICE Do not clean the element until the dust indicator shows 0 0075 MPa 30 INCHES H2O 0 076 kg cm2 1 1 PSI If the element is cleaned frequently before the dust indicator shows 0 0075 MPa 30 INCHES H2O 0 076 kg cm2 1 1 PSI the air cleaner will not be able to display its basic ...

Page 205: ...mpressed air After cleaning install it again NOTICE If small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning and drying replace the element When cleaning the element do not hit it or beat it against something Do not use an element whose folds or gasket or seal are damaged 5 Install the cleaned element then install cover 3 REPLACING INNER ELEM...

Page 206: ...he inside of the cooling system and when changing coolant Permanent type antifreeze All season type Every year autumn or every 2000 hours whichever comes first Permanent type antifreeze shall meet the requirements of ASTM D3306 03 Stop the machine on level ground when cleaning or changing the coolant The coolant has the important function of preventing corrosion as well as preventing freezing Even...

Page 207: ...reful not to get water containing antifreeze coolant on you If it gets in your eyes flush your eyes with large amount of fresh water and see a doctor at once Use antifreeze and appropriate water for diluting for details see COOLANT AND WATER FOR DILUTION PAGE 4 5 We recommend use of an antifreeze density gauge to control the mixing proportions Prepare a container whose capacity is larger than the ...

Page 208: ...ent 8 After the cleaning open drain valve 3 and drain plug 4 and 5 and drain all of the water 9 Close drain valve 3 and drain plug 4 and 5 10 Replace the corrosion resistor then set valve 1 to the OPEN position to open it For replacing corrosion resistor see REPLACE CORROSION RESISTOR CARTRIDGE PAGE 4 64 11 Add coolant mixed with antifreeze until it overflows from the water filler Decide the propo...

Page 209: ...ILTER If the air filter at the suction port of the air conditioner unit or the air filter at the fresh air intake port become clogged the cooling or heating capacity will drop so clean the filters once a week 1 Remove cover 1 at the front of the cab 2 Pull out the air filter and clean it by blowing it with compressed air 3 Release the catch of cover 2 on the right side of the accelerator pedal to ...

Page 210: ...r guard REMARK Run the engine at idle and if bubbles appear in the sight glass when the air conditioneris set to cooling the refrigerant level is low so please contact your Komatsu distributor to have it refilled CHECK DUMP BODY Check that there are no cracks in the 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 we...

Page 211: ...checks CHECK LENGTH OF CYLINDER Front Check that the bottom of the suspension cylinder cover is within the proper range on the label when the machine is unloaded and on flat ground Front and rear At the same time measure the distance from the shoulder at the head of the suspension cylinder rod to the top of the flange with the machine unloaded After checking the front and rear suspension cylinders...

Page 212: ...r 1 Pull the retarder brake lever loosen air bleed plug 1 to bleed the air from the circuit then tighten plug 1 and release the retarder brake lever 2 Remove the cap of bleeder plug 1 insert a vinyl hose inside diameter 8 mm 0 31 in to release the air then loosen the bleeder screw approx 3 4 turns and depress the foot brake pedal slowly Repeat this procedure until no more bubbles come out from the...

Page 213: ... 3 4 turns and depress the brake pedal slowly After tightening the bleeder screw release the brake pedal Repeat this procedure until no more bubbles come out from the vinyl hose Do not keep the brake pedal depressed continuously Depress it each time slowly to bleed the air After bleeding the air tighten bleeder screw 2 securely and fit the cap 4 After completion of the air bleeding procedure fill ...

Page 214: ... gauge is in the green range then release the parking brake 2 Turn bolt 1 clockwise to bring pad 2 into tight contact with disc 3 3 Turn bolt 1 back 2 3 turns 4 clicks in the counterclockwise direction Measure the thickness of the pad and if it is less than 1 5 mm 0 06 in contact your Komatsu distributor to have it replaced When making the first adjustment after replacing the pad turn bolt 1 turn ...

Page 215: ... hose and supply oil to the tank up to a level a little higher than the specified level WHEN PIPING AROUND MOTOR HAS BEEN REPLACED After the motor or its piping has been replaced its case must be filled with oil similarly to the pump The motor case is filled with oil however if oil is supplied to the tank Accordingly it is not necessary to supply oil to the motor case particularly Since the hydrau...

Page 216: ... operate the gear shift lever or dump control lever for any reason always give a signal to your fellow workers to tell them to move to a safe place If the materials or tools are dropped onto fan or belts they fly away or cut Never drop or insert materials or tools With the positioner device it is possible to automatically stop the dump body when it rises to the desired position to the dump body el...

Page 217: ...on Using a bar move the coupling in the direction of the circumference and check the play in the circumferential direction at the outside diameter of the coupling Standard Max 15 mm 0 6 in REMARK If the play range is exceeded the engine fan will start to rotate so when inspecting the play check first that the engine fan is not rotating If the result of the measurement shows that it is greater than...

Page 218: ...ditions of use and the weight of the attachments of the machine Use the following table Since the travel speed indicated on the speedometer varies with the tire size consult your Komatsu distributor when using optional tires Max load kg lb Size Operating model Remarks Front wheel 10 900 24 035 18 00R33 HD325 if equipped HD325 4WD specifications standard HD405 standard Type 1 for construction equip...

Page 219: ...ation pressure with a tire pressure gauge while the tires are cool before starting work Inflation of tires Adjust the inflation pressure properly When inflating a tire use an air chuck which can be fixed to the air valve of the tire as shown in the figure Do not work in front of the rim but work on the tread side of the tire The proper inflation pressure is shown below HD325 Tire size Inflation pr...

Page 220: ...r on the rear wheels there are hub nuts at 3 places on the inside but these are for temporary assembly so there is no need to tighten the inside hub nuts after the outside hub nuts are tightened DRAIN WATER FROM WATER SEPARATOR When float 2 is at or above red line 1 drain the water according to the following procedure 1 Loosen drain plug 3 and drain the accumulated water until the float reaches th...

Page 221: ...heck oil level in engine oil pan add oil Check oil level in transmission case add oil Check oil level in hydraulic tank add oil Drain water sediment from fuel tank Check fuel level add fuel Check wheel hub nuts tighten Check central warning lamp Check braking effect Check machine monitor system Check braking capacity of secondary brake Check manual emergency steering Check auto emergency steering ...

Page 222: ...that was pushed out Carry out the greasing operation every day when operating in places where the grease flows out easily such as when traveling through mud or water 1 Dump body hinge pin left and right 1 place each 2 Rear suspension left and right 2 places each 3 Rear axle support left and right 4 places each Portion a is for centralized greasing 4 places 4 Hoist cylinder pin left and right 2 pla...

Page 223: ... MAINTENANCE SERVICE PROCEDURE MAINTENANCE SERVICE PROCEDURE 5 Front suspension left and right 2 places each 6 Steering linkage 13 places Portion b is for centralized greasing 5 places 4 42 ...

Page 224: ...or then remove the cap and fill with 1 4 liters 0 37 US gal of methyl alcohol through the filler port During the season check every 100 hours on the service meter and add methyl alcohol At the end of the season loosen drain valve 2 and drain the methyl alcohol together with the moisture REMARK This machine uses compressed air for operating When operating the machine in cold areas there is danger t...

Page 225: ...the plug hole 2 If the oil level is too low add oil through the plug hole until the oil overflows CHECK OIL LEVEL IN FINAL DRIVE CASE ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped and may cause serious burns Wait for the temperature to go down before starting the operation If there is still pressure remaining inside the case the oil or plug may fly out Turn ...

Page 226: ...seals 5 places 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 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 distri...

Page 227: ...or a battery do the replenishment before the day s work on the next day Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is possible to check the electrolyte level from the side of the battery check as follows 1 Remove hook 1 then open inspection cover 2 2 Use a wet cloth to cle...

Page 228: ...d water or commercially available battery filler solution to the bottom of the sleeve UPPER LEVEL Use the diagram below for reference and check if the electrolyte reaches the bottom of the sleeve 3 After adding distilled water tighten cap 3 securely REMARK If water is added to above the bottom tip of the sleeve use a pipette to remove electrolyte Neutralize the removed electrolyte with sodium bica...

Page 229: ...and nuts 1 2 and 5 to secure alternator 3 4 Reinstall the cover removed in step 1 Confirm that no part of the cover touches any moving part of the alternator REMARK Check each pulley for breakage and wear of the V groove In particular check that the V belt does not touch the bottom of the V groove If any abnormality is found ask your Komatsu distributor for replacement of the pulley If the V belt ...

Page 230: ...ey and drive pulley is approx 10 mm 0 4 in when pressed with a finger force of approx 58 8 N 6 kg 3 Tighten nuts 1 and 4 and bolts 2 and 3 to secure the compressor in position 4 Check each pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove 5 Replace the V belt if there is no more tolerance to adjus...

Page 231: ...irt from around the breather then remove the breather and wash out the dirt from inside with clean diesel oil or flushing oil Transmission case Hydraulic tank 1 Remove nut 1 then remove cover 2 and wash element 3 2 Install element 3 then install cover 2 and nut 1 4 50 ...

Page 232: ...oves it will lead to serious injury or death If machine begins to move during the inspection of braking capacity lower the engine speed immediately set shifting lever at N position and then set parking brake valve lever at PARKING position Check the braking capacity of the foot brake as follows 1 Set the air pressure to the maximum with the machine on flat ground and depress foot brake 1 2 Set shi...

Page 233: ...ECK BRAKING CAPACITY OF PARKING BRAKE WARNING If the machine moves it will lead to serious injury or death If machine begins to move during the inspection of braking capacity lower the engine speed immediately set gear shift lever at N position and then depress the foot brake Check the braking capacity of the parking brake as follows 1 Set the air pressure to the maximum with the machine on flat g...

Page 234: ... to operate the gear shift lever or dump control lever for any reason always give a signal to your fellow workers to tell them to move to a safe place If the materials or tools are dropped onto fan or belts they fly away or cut Never drop or insert materials or tools 1 When bolts of inspection cover 1 are loosened and the cover is moved to the side the inspection hole can be seen 2 Check the posit...

Page 235: ... 2 Direct dry compressed air less than 0 69 MPa 7 kg cm2 99 4 PSI to the element from inside along its folds then direct it from outside along its folds and again from inside 3 Install the element in the air cleaner then install wing nut 1 4 Remove bolts 2 then remove cover 3 5 Remove 3 breathers from inside the box then rinse out the dirt inside with cleaner diesel fuel or flushing oil 6 Check th...

Page 236: ...g torque Drain plug 1 drain plug 2 68 6 9 8 Nm 7 1 kgm 50 6 7 2 lbft 5 Using the filter wrench turn filter cartridge 3 to the left to remove it When doing this to prevent getting oil on yourself do not carry out this operation from immediately under the cartridge In particular if this operation is carried out immediately after stopping the engine a large amount of oil will come out so wait for 10 ...

Page 237: ... the injection system Always avoid using substitute parts When carrying out inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt is stuck to any part use fuel to wash it off completely Container to catch the oil Prepare a filter wrench 1 Set the container to catch the fuel under the additional fuel filter cartridge 2 Using a filter wrench turn fi...

Page 238: ... tightened securely Tightening torque 0 2 to 0 45 Nm 0 02 to 0 046 kgm 0 1 to 0 3 lbft 8 When carrying out standard replacement of the fuel filter cartridge every 1000 hours replace the cartridge and bleed the air For details see REPLACE FUEL FILTER CARTRIDGE PAGE 4 62 9 Start the engine check that there is no leakage of fuel from the filter seal surface or water separator mounting surface then ru...

Page 239: ... Assemble the new element to the case set the case in position and install with center bolt 3 Be careful not to tighten center bolt 3 too far Tightening torque 167 to 196 Nm 17 to 20 kgm 123 to 144 7 lbft 7 Run the engine for a short time at idling then stop the engine and check that the oil is up to the specified level For details see CHANGE OIL IN TRANSMISSION CASE CLEAN TRANSMISSION CASE STRAIN...

Page 240: ...d it is dangerous If the period of wear limit approaches check frequently the condition to change the pad at proper time Perform inspection every 250 hours if the work site is covered by lots of earth and sand and if it is at the location where the foot brake is frequently used 1 Insert the inspection gauge into the wear inspection hole 1 and check 2 When the stepped part of the gauge touch the ca...

Page 241: ...ing jets of air steam or water but be careful not to let the nozzle contact the fin Air pressure Max 0 98 MPa 10 kg cm2 142 PSI Steam pressure Max 0 39 MPa 4 kg cm2 56 8 PSI When using compressed air or steam keep the nozzle at a right angle to the radiator and after cooler Examine the rubber hose and if any cracks or brittle places are found replace the hose In addition check also for loose hose ...

Page 242: ... 13 to 15 mm 0 51 to 0 59 in 3 Check for damage to the pulleys and wear of the groove and belt Be particularly careful to check that the belt is not in contact with the bottom of the groove If the belt is stretched and there is no allowance for adjustment or it is cut or cracked replace it with a new belt LUBRICATE TENSION PULLEY 1 PLACE 1 Using a grease pump pump in grease through the grease fitt...

Page 243: ...tem is still under pressure and fuel may spurt out NOTICE Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing the filter cartridge always use a genuine Komatsu part 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 genui...

Page 244: ... air bleed plug 3 and open supply valve 1 10 Loosen the knob of priming pump 4 then pump the knob and check that fuel comes out from air bleed plug 3 11 Tighten air bleed plug 3 Tightening torque 7 8 to 9 8 Nm 0 8 to 1 kgm 5 8 to 7 2 lbft 12 Loosen air bleeder 5 of the supply pump 13 Pump priming pump 4 until no more bubbles come out with the fuel from air bleeder 5 then tighten air bleeder 5 Tigh...

Page 245: ...an the filter holder coat the steel surface of the new filter cartridge with clean engine oil then install it 5 When installing tighten until the gasket contacts the seal surface of the filter holder then tighten a further 2 3 turns If the filter cartridge is tightened too far the gasket will be damaged and this will lead to leakage of water If the filter is too loose water will also leak from the...

Page 246: ...fill capacity 90 liters 23 78 US gal 1 Set the container to catch the oil directly under the drain plug P Remove drain plug P drain the oil then tighten the plug again 2 Remove bolt 1 then remove cover 2 and take out the strainer 3 Remove any dirt stuck to the strainer then wash in clean diesel fuel or flushing oil If the strainer is damaged replace it 4 After installing the strainer add oil throu...

Page 247: ...ion case so when changing the oil change the transmission oil at the same time The oil is drained from the front final drive cover but the oil is added and the oil level is checked at the transmission end Add oil after adding oil at the transmission end Refill capacity 22 liters 5 8 US gal each both left and right 1 Stop the machine so that drain plugs P1 and P2 are at the top and bottom 2 Remove ...

Page 248: ...al pressure then remove it carefully Refill capacity 36 liters 9 5 US gal 1 Open drain valve 1 drain the oil then close drain valve 1 again 2 Remove bolt 2 and coupling 3 then remove piping 4 3 Remove the strainer 4 Remove any dirt stuck to the strainer then wash it in clean diesel oil Replace the strainer if it is damaged 5 Install the strainer piping and coupling 6 After installing the strainer ...

Page 249: ...owly to release the internal pressure then remove it 1 Turn the cap of oil filler F slowly to release the internal pressure then remove the cap 2 Remove bolt 1 then remove cover 2 3 Take out the element then wash the inside of the case and the removed parts 4 Install the new element then install cover 2 with bolt 1 Run the engine at high idling and when the oil is warmed up if the hydraulic filter...

Page 250: ...ump in grease through grease fittings marked by arrows 2 After greasing wipe off any old grease that was pushed out 1 Transmission mount 1 place 2 Automatic suspension link left and right 1 place each 3 Parking brake linkage 3 places 4 Dump control link 3 places 4 69 ...

Page 251: ... the retarder lever is pulled Gauge Part No 567 98 41301 3 Turn the starting switch to the ON position and check that the air pressure gauge is in the green range 4 If the air pressure is low start the engine and run the engine at 2 000 rpm until the air pressure gauge enters the green range When it enters the green range turn the starting switch OFF 5 Operate the retarder control lever slowly ove...

Page 252: ...the oil filler cap turn it slowly to release the internal pressure then remove it Refill capacity 129 liters 34 06 US gal 1 Lower the dump body and stop the engine 2 Turn the cap of oil filler F to release the internal pressure before removing the cap 3 Taking care not to get any oil on you remove drain plug P drain the oil then tighten the plug again 4 Pour in the specified amount of engine oil f...

Page 253: ...ough the hole for plug G to the specified level 4 After adding oil check that the oil is at the specified level See CHECK OIL LEVEL IN FINAL DRIVE CASE ADD OIL PAGE 4 44 CHANGE OIL IN DIFFERENTIAL CASE WARNING The parts and oil are at high temperature after the engine is stopped and may cause serious burns Wait for the temperature to go down before starting the operation If there is still pressure...

Page 254: ...igh temperature after the engine is stopped and may cause serious burns Wait for the temperature to go down before cleaning the engine breather When using compressed air there is a hazard that dirt may be blown up and cause serious injury Always use safety glasses dust mask or other protective equipment 1 Wipe off the dirt from around the breather 2 Loosen the clamp then remove the hose 3 Remove t...

Page 255: ...OCEDURE CLEAN AIR DRYER FILTER AND DEFLECTOR If equipped Always clean once every 6 months regardless of the operating hours 1 Remove bolt 3 then remove cap 4 2 Disassemble deflector 1 and filter 2 and wash in diesel oil 4 74 ...

Page 256: ...distributor for inspection or repair If the engine is started frequently carry out inspection every 1000 hours CHECK ADJUST ENGINE VALVE CLEARANCE Special tools are needed for inspection and maintenance so contact your Komatsu distributor CHECK INJECTOR See Section A REGULATION AREA PAGE 4 21 CLEAN CHECK TURBOCHARGER Contact your Komatsu distributor for cleaning or inspection CHECK PLAY OF TURBOCH...

Page 257: ... of drop in the level of the damper fluid and runout of the concave surface So please contact your Komatsu distributor to inspect or replace CHECK INJECTOR See Section B REGULATION AREA PAGE 4 21 REPLACE INJECTOR ASSEMBLY See Section A REGULATION AREA PAGE 4 21 CHECKING FOR LOOSENESS OF HIGH PRESSURE CLAMP HARDENING OF RUBBER Check visually and touch with your fingers to check that there are no lo...

Page 258: ...the rubber is hardened please contact your Komatsu distributor for repairs Install rubber caps 1 to 10 with the slit facing the cylinder block Install rubber caps 11 to 16 with the slit facing down NOTICE The fuel spray prevention cap and fuel spray prevention cover are protective parts to prevent fire if leaking fuel should spray on high temperature parts of the engine Always check that the fuel ...

Page 259: ...d 4000 hours service should be carried out at the same time REPLACE INJECTOR NOZZLE TIP See Section B REGULATION AREA PAGE 4 21 REPLACE HIGH PRESSURE PIPING CLAMP Ask your Komatsu distributor to carry out this work REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to carry out this work 4 78 ...

Page 260: ... 4000 and 8000 hours service should be carried out at the same time CHECK REPLACE STEERING A ARM MOUNTING BOLT Check and replace the A arm mounting bolts lock plate and holder Please consult your Komatsu distributor when checking and replacing 1 A arm 2 Front suspension 3 Lock plate 4 Bolt 5 Holder 4 79 ...

Page 261: ... ...

Page 262: ... 5 1 ...

Page 263: ... Dumping speed at 2100 rpm raised sec 10 Name of engine Komatsu SAA6D140E 3 diesel engine Flywheel horsepower kW HP rpm 379 508 2000 Max torque Nm kgf m lbft rpm 2166 221 1598 5 1400 A Overall length mm ft in 8365 27 5 B Overall height mm ft in 4000 13 1 C Overall height when dumping mm ft in 7960 26 1 D Overall width mm ft in 3660 12 E Min ground clearance bottom of rear axle mm ft in 500 1 8 Min...

Page 264: ... 6 1 ...

Page 265: ...tion neutral detection and other signals and calculates the weight of the load using its built in micro computer It displays the results on the panel and also uses the external display lamps to show the condition of the load In addition the data saved in memory can be printed out together with the date the load was dumped and the number of loads NAME OF PARTS 1 2 3 4 5 Calibration switch Night lig...

Page 266: ...l the lamps light up for 10 seconds after the power is turned ON To prevent overloading use the lamps for loading up to the point where the 3 green lamps light up PREDICTION DISPLAY In the case where the weight of the load changes as each bucket is emptied into the dump body the average weight of the load up to that point is calculated to predict what the weight of the load will be if one more buc...

Page 267: ... ATTACHMENTS OPTIONS HANDLING PAYLOAD METER HD325 HD325 of 4WD specifications 6 4 ...

Page 268: ... ATTACHMENTS OPTIONS HANDLING PAYLOAD METER HD405 6 5 ...

Page 269: ... point and the load displayed at the dumping point Save the data to memory when the dump lever is raised When the machine is completely stopped it is possible to carry out accurate calculation if the load is dumped when the swaying of the machine has completely stopped We recommend that the slope at the dumping point be kept to within 5 degrees When the value displayed by the payload meter becomes...

Page 270: ...ashing CAL to a flashing SCH When calibration switch 1 is pressed again the display will return to the normal display CARRYING OUT SENSOR CHECK 1 Drive the machine unloaded on flat ground 2 Set the shift lever to N and press calibration switch 1 for at least 2 seconds then press calibration switch 1 again for at least 2 seconds The letters SCH will flash 3 When traveling at a speed of approx 10 km...

Page 271: ...e minute display correctly 2 When time adjustment switch 2 is pressed for at least 2 seconds the hour display will flash Press time adjustment increase switch 3 to set the hour display correctly 3 Following this each time that time adjustment switch 2 is pressed the flashing point changes to day month and year Press time adjustment increase switch 3 to correct any item that needs correcting 4 Afte...

Page 272: ...r 7818 27 2910 1 Open the roll of printer paper fold the paper at a point approx 3 cm 1 2 in from the end of the paper then cut the paper straight along the fold Never cut the paper in the way shown on the right It will cause the paper to jam 2 Set the print paper with the printing side facing up and insert it straight into the paper feed hole If the FEED switch is pressed while feeding in the pap...

Page 273: ...hen the starting switch key is turned to the OFF position the payload meter uses the internal battery to prevent the load data from being deleted If the battery voltage drops error message E 33 is displayed so replace the battery as follows Replacing battery Move the machine to a place where it is safe to carry out the replacement operation Parts to prepare Crosshead screwdriver Socket wrench for ...

Page 274: ... battery down straight to connect them to the printboard 8 Fit the battery band then fix the battery to the payload meter with the nut M4 and washer flat spring Check that the battery has not moved out of position 9 Install the top cover 10 Install the payload meter to its original position on the panel After replacing the battery do as follows 1 Turn the starting switch to the ON position 2 Press...

Page 275: ...is impossible to install it again Always be extremely careful not to let any dust or metal particles inside the controller If the paper jams PAPE is displayed on the load display so move the machine to a safe place and clear the paper jam as follows 1 Turn the starting switch key to the OFF position 2 Remove the screws M6 x 4 holding the payload meter then pull the payload meter out to the front 3...

Page 276: ...h the flat of your fingers to move the head If gear 4 is turned counterclockwise the head will move to the right 5 After removing the paper install the connectors before installing the top cover 6 Remove the printer paper remaining inside the printer and cut the leading end of the paper For details of the method of cutting the end of the paper see METHOD OF CUTTING PRINTER PAPER PAGE 6 10 7 Turn t...

Page 277: ... ATTACHMENTS OPTIONS SELECTING DUMP BODY SELECTING DUMP BODY HD325 HD325 only the machine of 4WD specifications Select the dump body from the following table 6 14 ...

Page 278: ...lamp Speed indication confirmation lamp Odometer Period indicating label Speed recording stylus Operator change recording stylus 12 13 14 15 16 17 18 19 20 21 Travel distance recording stylus Adjustment screw for speed warning lamp Speed confirmation aperture for speed warning lamp indication Clock setting knob Chart support Pressing ring Cutting knife Instrument lighting lamp Name plate Voltage i...

Page 279: ...sing the confirmation switch to light up the confirmation lamp during checks before starting always check for any disconnection in the three indication confirmation lamps Models with the speed warning lamp do not have the speed indication confirmation lamp ODOMETER This meter 8 displays the total distance km traveled by the machine PERIOD INDICATING LABEL This label 9 indicates that it is for 7 da...

Page 280: ...he voltage METHOD OF USING KEY There are three types of key Key 1 with no mark is used for opening and locking the instrument Key 2 marked with No 1 is change key 1 and key 3 marked with No 2 is change key 2 With these three keys it is possible to know the details of the operation and the change of operator To use the change key remove the instrument open lock key and insert change key 1 in the sa...

Page 281: ...e code No date etc Fill in the above items with a steel pen Handle the charts carefully with clean hands and do not fold or scratch them 5 Push down pressing ring 4 holding the charts turn counterclockwise and pull out the pressing ring at the point where it contacts the stopper then remove the charts 6 Insert new charts Remove pressing ring 4 then set the charts under cutting knife 5 When doing t...

Page 282: ...OPTIONS TACHOGRAPH TCO 15 6 Replacing instrument lighting lamp bulb Raise contact piece 7 and take out the old bulb with a pincette It comes out easily After replacing check that the contact piece is holding down the lamp base firmly Use a 24 V bulb 6 19 ...

Page 283: ... RPM indicator Speed recording stylus Travel distance recording stylus Adjustment screw for speed warning lamp 14 15 16 17 18 19 20 21 22 23 24 25 Speed confirmation aperture for speed warning lamp indication Clock setting knob Chart support Pressing ring Cutting knife Instrument lighting lamp Name plate Voltage indication label RPM recording stylus Adjustment screw for RPM warning lamp Speed conf...

Page 284: ...s Models with the speed warning lamp do not have the speed indication confirmation lamp ODOMETER This meter 7 displays the total distance km traveled by the machine PERIOD INDICATING LABEL This label 8 indicates that it is for 7 days RPM SCALE This 9 is the scale for the momentary speed in revolutions per minute rpm RPM INDICATOR This 10 shows the momentary speed in revolutions per minute rpm SPEE...

Page 285: ...the instrument NAME PLATE This 20 indicates the type and model VOLTAGE INDICATION LABEL This label 21 indicates the voltage RPM RECORDING STYLUS This 22 records the momentary engine speed on the chart ADJUSTMENT SCREW FOR RPM WARNING LAMP The speed at which the lamp gives a warning can be set as desired with this screw 23 SPEED CONFIRMATION APERTURE FOR RPM WARNING LAMP INDICATION This 24 is the s...

Page 286: ... used charts Push down pressing ring 3 holding the charts turn counterclockwise and pull out the pressing ring at the point where it contacts the stopper then remove the charts Handle the charts carefully with clean hands and do not fold or scratch them 5 Insert new chart Remove pressing ring 3 then set the charts under cutting knife 4 and below fan shaped rotating transfer shaft 5 on the right Wh...

Page 287: ...OPTIONS REVO TACHOGRAPH TCO 15 7 Replacing instrument lighting lamp bulb Raise contact piece 7 and take out the old bulb with a pincette It comes out easily After replacing check that the contact piece is holding down the lamp base firmly Use a 24 V bulb 6 24 ...

Page 288: ...vide a powerful drive force This also helps to extend the service life of the tires 1 Differential lock pedal WARNING Do not use the differential lock pedal when traveling at high speed 4th gear 20 km h 12 4 MPH and above Do not use the differential lock pedal when turning NOTICE Do not use the differential lock pedal when the wheels are already slipping This may reduce the durability First stop t...

Page 289: ... becomes impossible to escape stop the machine then depress the differential lock pedal and start the machine again When traveling on road surfaces where the tires may slip be particularly careful to avoid sudden changes in travel speed decelerating or accelerating Do not use the differential lock pedal when traveling at high speed 4th gear 20 km h 12 4 MPH and above Do not use the differential lo...

Page 290: ...this system has a function to prevent slipping of the drive wheels caused by excessive torque Accordingly the machine can start and travel normally even on a bad or frozen road surface EXPLANATION OF COMPONENTS 1 2 Warning lamp ASR information lamp 3 4 ABS ASR main switch Troubleshooting switch WARNING LAMP Red This lamp 1 lights up at engine start continues to light up until the speed exceeds app...

Page 291: ... ATTACHMENTS OPTIONS OPERATION OF ABS AND ABS ASR ABS ASR MAIN SWITCH This switch 3 is used to turn the ABS ASR system on off TROUBLESHOOTING SWITCH This switch 4 is used for troubleshooting 6 28 ...

Page 292: ... ASR main switch 3 Start the truck When the speed rises to about 10 km h 6 2 MPH the warning lamp 2 will go off ASR OPERATION WARNING Turn on the troubleshooting switch 1 only when performing troubleshooting on the machine The ABS ASR system will not function while the troubleshooting switch is turned on 1 Since the ASR and ABS are interlocked if the ABS is turned on the ASR is also turned on auto...

Page 293: ...system is automatically turned off and the ABS ASR system does not function Even if the ABS ASR system is installed the secondary brake function is maintained If the ABS ASR main switch is turned on with the brake pedal depressed or the retarder control lever pulled exhaust sound will be momentarily emitted from the ABS valve This does not indicate a fault If both rear wheels slip at the same spee...

Page 294: ...h is turned ON OFF repeatedly greasing will automatically start due to the function of the supplemental circuit immediately after the starting switch is turned ON After display of the 7 segment LED and greasing in progress LED as shown in the LUBRICATION CONTROLLER DISPLAY TABLE the above condition will be returned 2 Centralized greasing is carried out in accordance with the set time and frequency...

Page 295: ...ition Do not press start button 3 of lubrication controller 2 Operating when desired It is possible to start the system and carry out one cycle of greasing regardless of the time count To do this press the button 3 for the lubrication controller inside the console box The count for the greasing time is canceled and the electric pump starts the count again automatically after it is stopped 6 32 ...

Page 296: ...after 300 hours on the hourmeter when normal operation NOTICE Be careful since the life of grease cartridge will be shortened if the greasing interval becomes shorter Also if the greasing interval becomes shorter the amount of grease dripping from the tip of the working machine increases It may make the machine and sorrounding area dirty Setting greasing time in cold areas In cold temperatures the...

Page 297: ...lock at LOCK position and set the starting switch at ON position 3 Turn the starting switch ON and start the engine 4 Press the LEVEL and ITEM keys at the same time to set to the setting mode 5 Press the ITEM key one or more times to select the item to be set REMARK Each time the ITEM key is pressed the setting item is changed a b c a 6 When the item to be set flashes press the LEVEL key The set i...

Page 298: ... to leave the setting mode REMARK Even if it is desired to change only one item always carry out the setting according to Steps 1 to 5 After completing the setting always press the ESC key to leave the setting mode If the power is then turned ON the count for the greasing interval will start immediately after the ESC key is pressed Part of the display segment flashes to indicate that the system is...

Page 299: ...ate of the grease pump against the greasing surface then insert the pump and set special cover 1 to the pail Then operate the handle of the pump and confirm that clean grease comes out of the hose end 2 Remove the cap of the grease filler of the pump and screw in the hose fitting then operate the pump 3 When grease is supplied for the first time there is usually some air under the follower plate 2...

Page 300: ...diately TROUBLESHOOTING If any problem occurs in the greasing system the error codes will flash alternately to display the type of problem Error code Item Cause Remedy E a Defective pressurizing of pump Air in main piping Air inside pump Grease tank is empty Grease leaking from main piping Run pump as necessary and release grease from end of piping to bleed air Release grease from air bleed in pum...

Page 301: ...he retarder brake may be damaged Always set the speed so that it does not exceed the maximum permissible speed When the ARSC is actuated on slippery roads the tires may lock If this happens cancel the ARSC If any abnormality occurs in the system and braking cannot be carried out properly the alarm sounds and the system is turned OFF to cancel the ARSC If necessary control the machine with the reta...

Page 302: ...RSC system when the system switch is ON It lights up for 3 seconds when the starting switch is turned ON to check the bulb CENTRAL WARNING LAMP This lamp 5 lights up together with the ARSC caution lamp if there is a serious abnormality in the ARSC system when the system switch is ON RETARDER CONTROL LEVER Even when the ARSC is in operation the retarder can be operated with this lever 6 ACCELERATOR...

Page 303: ...he selection of the gearshift lever as follows When the gearshift lever is at the D 5 4 3 or L positions the range for the set speed is 10 to 55 km h 6 2 to 34 2 MPH It is impossible to set the speed when the gearshift lever is at the N or R positions METHOD OF CARRYING OUT FINE ADJUSTMENT OF SET TRAVEL SPEED To raise the set travel speed 1 km h 0 6 MPH push the ARSC set lever forward once To decr...

Page 304: ...isplay shows 0 Method 2 If the system switch is turned OFF the control is canceled When this happens the set speed display goes out REMARK For Method 1 cancel operation must be continued for at least 1 second different from other switches to cancel the control This is to prevent any problem of the control being canceled if the switch is touched by mistake RELATIONSHIP WITH EXHAUST BRAKE If the exh...

Page 305: ... Short circuit with ground in READY lamp system 2 15 5 5 Short circuit with ground in central warning lamp system or buzzer system 2 16 6 0 Failure in engine speed sensor system 1 17 7 0 Disconnection short circuit in set speed display up output 2 18 7 1 Disconnection short circuit in set speed display down output 2 19 7 2 Disconnection short circuit in set speed display clear output 2 20 7 3 Shor...

Page 306: ...e in the system switch so even if the system switch is turned OFF the central warning lamp and ARSC caution lamp will flash and the buzzer will sound Remedy pattern 2 When only the ARSC caution lamp flashes The ARSC system continues to be actuated but an abnormality has occurred in the system Turn the system switch OFF to stop use of the ARSC When the system switch is turned OFF the ARSC caution l...

Page 307: ... DISPLAYING MODEL SELECTION TIRE LARGE DIAMETER SMALL DIAMETER FAILURE CODE When the starting switch is turned ON the codes below are automatically displayed in the following order on the controller LED 1 LEDs all light up 2 Model Code 32 3 Tire diameter Code 4 Latest failure code 5 Failure code that occurred immediately before the failure code in 4 6 Failure code that occurred immediately before ...

Page 308: ...ontrol lever Accelerator pedal Brake pedal SYSTEM SWITCH This switch 1 is used to turn the ASR system on off ASR OPERATION LAMP This lamp 2 lights up when the system detects slippage of the rear wheels and the ASR starts functioning ASR CAUTION LAMP This 3 flashes if there is any abnormality in the ASR system when the system switch is ON It lights up for 3 seconds when the machine starting switch ...

Page 309: ... abnormality occurs in the system and the travel cannot be controlled securely the system is turned off with the warning buzzer sound and the operation of the system stops Stop the machine in a safe place immediately to turn off the system switch Even with the ASR system installed there may be instances where the machine can not travel safely such as on a road having an extremely low coefficient o...

Page 310: ... 1 15 6 3 Failure in transmission output axis revolution sensor system 1 16 8 1 Short circuit with ground in pressure control valve system right 1 17 8 2 Short circuit with ground in pressure control valve system left 1 18 8 3 Disconnection short circuit in pressure control valve system right 1 19 8 4 Disconnection short circuit in pressure control valve system left 1 20 8 5 Failure in pressure co...

Page 311: ...ARGE DIAMETER SMALL DIAMETER FAILURE CODE When the starting switch is turned ON the codes below are automatically displayed in the following order on the controller LED 1 LEDs all light up 2 Model Code 32 3 Tire diameter Code 4 Latest failure code 5 Failure code that occurred immediately before the failure code in 4 6 Failure code that occurred immediately before the failure code in 5 METHOD OF CL...

Page 312: ...ion oil filter Hydraulic filter 10 11 12 13 14 Maintenance timer Replacement interval check switch oil Replacement switch Cancel switch Replacement interval check switch filter METHOD OF USE CHECK BEFORE STARTING These all light up for 3 seconds when the starting switch is turned ON and after 3 seconds only the items requiring maintenance stay lighted up or flash For details of the meaning of ligh...

Page 313: ... Corrosion resistor 1000 Transmission oil filter 500 Hydraulic filter 1000 3 When the displayed time lights up it shows the time remaining to replacement If the time display flashes it shows the time that has elapsed since replacement was due OPERATING SWITCH WHEN REPLACING OIL FILTERS 1 After replacing the oil and filters use the procedure for checking the replacement interval to reset the displa...

Page 314: ...7 E EXPLANATION OF COMPONENTS 3 5 F FOREWORD 1 2 FUSES 3 38 G GENERAL PRECAUTIONS 2 10 GENERAL VIEW 3 2 GENERAL VIEW OF CONTROLS AND GAUGES 3 3 GENERAL VIEW OF MACHINE 3 2 GUIDES TO MAINTENANCE 4 2 H HANDLING AUTO GREASING SYSTEM 6 31 METHOD OF OPERATING AUTO GREASING SYSTEM 6 31 PRECAUTIONS WHEN HANDLING AUTO GREASING SYSTEM 6 37 TROUBLESHOOTING 6 37 HANDLING OIL FILTER CAUTION 6 49 METHOD OF USE...

Page 315: ...OMMENDED BRANDS RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4 15 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4 11 REVO TACHOGRAPH TCO 15 7 6 20 EXPLANATION OF COMPONENTS 6 20 METHOD OF USE 6 23 S SAFETY 2 2 SAFETY CRITICAL PARTS 4 17 SAFETY INFORMATION 1 5 SAFETY LABELS 2 4 SELECTING DUMP BODY 6 14 SERVICE PROCEDURE 4 22 CHECK BEFORE STARTING 4 40 EVERY ...

Page 316: ... FUEL 3 114 IF BATTERY IS DISCHARGED 3 121 METHOD OF TOWING MACHINE 3 116 OTHER TROUBLE 3 125 U USING DIFFERENTIAL LOCK 6 25 DIFFERENTIAL LOCK PEDAL 6 25 PRECAUTIONS AND METHOD OF USE 6 26 W WEAR PARTS 4 9 WEAR PARTS LIST 4 9 7 3 ...

Page 317: ... HD325 6 HD325 6 4 WHEEL DRIVE HD405 6 DUMP TRUCK Form No PEN00041 05 2008 KOMATSU All Rights Reserved Printed in Japan 05 08 ...

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