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Komatsu HM400-5, Operation & Maintenance Manual

The Komatsu HM400-5 Operation & Maintenance Manual is a comprehensive guide for effectively operating and maintaining the HM400-5 model. This essential manual provides detailed instructions, troubleshooting tips, and safety guidelines to ensure optimal performance. Download this manual for free at manualshive.com to access the valuable information you need.

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METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP ............................. 4-66
METHOD FOR APPLYING LUBRICANT ON EXHAUST PIPE SPHERICAL SURFACE JOINT PORTION.....

............................................................................................................................................................ 4-67

METHOD FOR REPLACING DEF TANK BREATHER ELEMENT........................................................... 4-68
METHOD  FOR  CHECKING  DRIVE  BELT  TENSION  PULLEY  ASSEMBLY  OF  COMPRESSOR  FOR  AL-

TERNATOR AND AIR CONDITIONER ................................................................................................ 4-69

METHOD FOR LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF COMPRESSOR FOR AL-

TERNATOR AND AIR CONDITIONER ................................................................................................ 4-70

EVERY 2000 HOURS MAINTENANCE ......................................................................................................... 4-70

METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ....................................................................... 4-70
METHOD FOR CHANGING OIL IN DEFERENTIAL CASE..................................................................... 4-71
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ............................................. 4-72
METHOD FOR CLEANING TRANSMISSION CASE STRAINER............................................................ 4-73
METHOD FOR CLEANING BREATHER................................................................................................. 4-74
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE ........................................................... 4-75
METHOD FOR CHECKING ALTERNATOR ............................................................................................ 4-75
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE ...................................... 4-75
METHOD FOR REPLACING KCCV FILTER ELEMENT ......................................................................... 4-75
METHOD FOR REPLACING DEF FILTER.............................................................................................. 4-78

EVERY 4000 HOURS MAINTENANCE ......................................................................................................... 4-80

REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-80
METHOD FOR CHANGING OIL IN HYDRAULIC TANK ......................................................................... 4-81
METHOD FOR CHECKING WATER PUMP............................................................................................ 4-82
METHOD FOR CHECKING STARTING MOTOR.................................................................................... 4-82
METHOD  FOR  CHECKING  FOR  LOOSENESS  OF  ENGINE  HIGH-PRESSURE  PIPING  CLAMP,  HARD-

ENING OF RUBBER ........................................................................................................................... 4-83

METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.

............................................................................................................................................................ 4-83

METHOD FOR CHECKING EXHAUST PIPE FIRE PREVENTION COVER ........................................... 4-84

EVERY 4500 HOURS MAINTENANCE ......................................................................................................... 4-84

METHOD FOR CLEANING KDPF .......................................................................................................... 4-84
METHOD FOR CLEANING DEF TANK................................................................................................... 4-84
METHOD FOR CLEANING FUEL DOSER ............................................................................................. 4-84
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING,

HARDENING OF RUBBER ................................................................................................................. 4-84

EVERY 6000 HOURS MAINTENANCE ......................................................................................................... 4-84

METHOD FOR LUBRICATING DRIVE SHAFT ....................................................................................... 4-85

EVERY 8000 HOURS MAINTENANCE ......................................................................................................... 4-86

METHOD FOR REPLACING ENGINE HIGH-PRESSURE PIPING CLAMP ........................................... 4-86
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP............................................................ 4-86
METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR ............................................ 4-86

EVERY 9000 HOURS MAINTENANCE ......................................................................................................... 4-86

METHOD FOR REPLACING DEF HOSE ............................................................................................... 4-86
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING................. 4-86

MAINTENANCE

MAINTENANCE SCHEDULE TABLE

4-13

Summary of Contents for HM400-5

Page 1: ... death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual EENAM03380 WARNING ORIGINAL INSTRUCTIONS ...

Page 2: ......

Page 3: ...nuine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these recommendations could result in ineffective serv ice damage to the product or safety risks including personal injury or death 1 1 ...

Page 4: ...e Keep the Operation and Maintenance Manual inside of the left door If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For details regarding the machine model name and the serial No see the machine serial No plate In order to arrange the proper Operation and Maintenanc...

Page 5: ...GER This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury k k WARNING This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury k k CAUTION This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may a...

Page 6: ... of the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 Sound power level emitted by the machine measured ac cording to ISO 6395 Dynamic test method simulated working cycle This is the guaranteed value as specified in European directive 2000 14 EC This value includes an uncertainty of 4 0 dB...

Page 7: ...ling without load GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE The following guides can help an operator of this machine to reduce the whole body vibration levels 1 Use the correct equipment and attachments 2 Maintain the machine according to this manual Tire pressures for wheeled machines tension of crawler for crawler machines Brake and steering systems Controls hydraulic system and linkages 3 Ke...

Page 8: ...ng guidelines can be effective to minimize risks of low back pain Operate the machine only when you are in good health Provide breaks to reduce long periods of sitting in the same posture Do not jump down from the cab or machine Do not repeatedly handle and lift loads VIBRATION LEVELS FOREWORD 1 6 ...

Page 9: ...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 VISIBILITY FROM OPERATOR S SEAT This machine complies with the visibility standard ISO 5006 This machine maintains a proximity visibility of a height of 1 5 m at a point 1 m away from the outside surface of the machine and a visibility for a circumference ...

Page 10: ...el Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the reagent for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transpa...

Page 11: ...of the following items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE This is on the rear left side of the operator s cab The design of the nameplate differs according to the district LOCATION OF ENGINE NUMBER PLATE The is on the engine cylinder head FOREWORD PRODUCT INFORMATION 1 9 ...

Page 12: ... SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU LTD 2 3 6 Akasaka Minato ku Tokyo 107 8414 Japan Authorised representative Address KOMATSU EUROPE INT Mechelsesteenweg 586 B 1800 Vilvoorde Belgium Distributor name Address Service personnel Phone Fax PRODUCT INFORMATION FOREWORD 1 10 ...

Page 13: ... B D F G H EI000001 A MACHINE DESIGNATION TYPE E ENGINE POWER B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER C YEAR OF CONSTRUCTION G MANUFACTURER D OPERATING MASS H AUTHORISED REPRESENTATIVE FOREWORD SERIAL PLATE 1 11 ...

Page 14: ...07 8414 Japan KOMATSU EUROPE INT Mechelsesteenweg 586 B 1800 Vilvoorde Belgium Declares that this machine HM400 5 Fulfils all the relevant provisions of following EC Directives Machinery Directive 2006 42 EC Electro Magnetic Compatibility Directive 2004 108 EC Outdoor Noise Directive 2001 14 EC amended by 2005 88 EC DECLARATION OF CONFORMITY FOREWORD 1 12 ...

Page 15: ...PARATIONS FOR SAFE OPERATION 2 15 PRECAUTIONS TO PREVENT FIRE 2 16 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 18 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 20 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 20 UNAUTHORIZED MODIFICATION 2 21 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 21 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 21 PRECAUTIONS FOR OPERATION 2 22 PRECAUTIONS FOR JOBSITE 2 2...

Page 16: ...OR CHECKING AFTER FINISHING WORK 3 209 LOCK 3 209 HANDLE TIRE 3 218 HANDLE AIR CONDITIONER 3 219 EXPLANATION OF AIR CONDITIONER EQUIPMENT 3 220 METHOD FOR OPERATING AIR CONDITIONER 3 225 HANDLE RADIO 3 232 EXPLANATION OF RADIO EQUIPMENT 3 232 METHOD FOR CONTROLLING RADIO 3 234 DUMP BODY HEATING SPECIFICATIONS 3 237 DETERMINE AND MAINTAIN TRAVEL ROAD 3 238 TRANSPORTATION 3 239 PRECAUTIONS FOR TRANS...

Page 17: ...NCE SCHEDULE 4 12 MAINTENANCE SCHEDULE TABLE 4 12 MAINTENANCE PROCEDURE 4 14 INITIAL 250 HOURS MAINTENANCE ONLY AFTER THE FIRST 250 HOURS 4 14 WHEN REQUIRED 4 14 CHECKS BEFORE STARTING 4 35 EVERY 50 HOURS MAINTENANCE 4 36 EVERY 250 HOURS MAINTENANCE 4 37 EVERY 500 HOURS MAINTENANCE 4 48 EVERY 1000 HOURS MAINTENANCE 4 56 EVERY 2000 HOURS MAINTENANCE 4 70 EVERY 4000 HOURS MAINTENANCE 4 80 EVERY 4500...

Page 18: ...LIST 7 3 RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 LUBRICATION CHART 7 4 METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 8 INDEX 8 1 TABLE OF CONTENTS FOREWORD 1 16 ...

Page 19: ...ase read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions strictly 2 1 ...

Page 20: ... S CAB 2 20 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 20 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 20 UNAUTHORIZED MODIFICATION 2 21 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 21 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 21 PRECAUTIONS FOR OPERATION 2 22 PRECAUTIONS FOR JOBSITE 2 22 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2 22 PRECAUTIONS WHEN WORKING ON LOOSE GROUND 2 22 DO NOT ...

Page 21: ... DISCONNECT SWITCH TO OFF POSITION 2 35 PRECAUTIONS FOR WELDING 2 35 HANDLE BATTERY 2 35 WHEN USING HAMMER 2 36 PRECAUTIONS FOR HIGH TEMPERATURE COOLANT 2 36 PRECAUTIONS FOR HIGH TEMPERATURE OIL 2 37 PRECAUTIONS FOR HIGH TEMPERATURE PARTS 2 37 PRECAUTIONS FOR HIGH PRESSURE OIL 2 37 PRECAUTIONS FOR HIGH PRESSURE FUEL 2 37 HANDLE HIGH PRESSURE HOSES AND PIPING 2 37 PRECAUTIONS FOR HIGH VOLTAGE 2 38 ...

Page 22: ...rly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the safety labels see this manual or the actual label and place an order to your Komatsu distributor There are also other labels in addition to the warning s...

Page 23: ...LOCATION OF SAFETY LABELS SAFETY SAFETY LABELS 2 5 ...

Page 24: ...SAFETY LABELS SAFETY 2 6 ...

Page 25: ...for retarder oil temperature 9 Caution before operating caution when traveling in reverse caution for operating hoist control lever 10 Caution for handling battery cable 11 Caution for hot exhaust pipe 12 Prohibition of trespassing 13 Caution for articulation lock 14 Caution against falling 15 Caution for handling battery 16 Caution for parking brake 17 Prohibition of start by short circuiting Thi...

Page 26: ... inspection and maintenance 3 Caution when checking engine room 09667 A0641 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance MACHINE MODEL MAX MASS MODEL SERIAL No FOPS LEVEL No kg Lb ROPS FOPS CERTIFICATION This protective structure complies with the standard provided that it is properly equipped on the machine which mass is less than the specified...

Page 27: ...en opening hydraulic tank cap 09653 A0641 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool before removing cap 6 Caution for handling suspension 09659 A0641 There is the hazard of explosion causing injury Do not disassemble the accumulator make holes in it weld it cut it hit it roll it or bring ...

Page 28: ...safe dis tance from electric cables There is danger that the dump body may come down Before carrying out inspection or maintenance with the dump body raised always reed the Operation and Maintenance Manual and take the correct action Always read the Operation and Maintenance Manual before carrying out operation maintenance dissas sembly or transportation of machine When leaving operator seat 1 Low...

Page 29: ... sure no one in on or near the machine Use spotter if view is obstructed Follow above even if machine equipped with back up alarm and mirrors BE SURE TO LOWER DUMP BODY AND KEEP HOIST CONTROL LEVER AT THE FLOAT POSITION DURING TRAVEL 10 Caution for handling battery cable 09808 A1681 Sign indicates an electric hazard from handling the cable Read manual for safe and proper handling 11 Caution for ho...

Page 30: ...lating parts of vehicle Lock vehicle with lock bar to avoid movement of the vehi cle during maintenance transportation and travelling 14 Caution against falling 09805 C0481 There is the hazard of falling Do not step here 15 Caution for handling battery This plate is fixed in position by the battery maker a Never smoke or use any naked flame near the batteries no sparks b Always wear safety glasses...

Page 31: ...lt 17 Prohibition of start by short circuiting 09842 A0481 Start the engine only after sitting down in the operator s seat Do not attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury of fire 18 Caution for blast site 56D 93 31410 Sign indicates an explosion hazard caused by active radio transmitter at a blast zone Keep machine at...

Page 32: ...Never touch when hot 20 Caution for handling DEF 09632 61480 DEF only To avoid engine damage or fire fill with DEF only Never use diesel fuel 21 Caution for handling gas spring 09659 A057B There is the hazard of explosion causing injury Do not disassemble the accumulator make holes in it weld it cut it hit it roll it or bring it near flame SAFETY LABELS SAFETY 2 14 ...

Page 33: ... SAFE OPERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the safety related devices and use them properly Never remove any safety related devices Always keep them in good operating condition INSPECT MACHINE Check the machine before starting oper...

Page 34: ...may cause fire Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such as flammable or explosive items into the operator s compartment PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Observe the following precautions to prepare for action if any serious personal injury...

Page 35: ...l ventilated areas for storing oil and fuel Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any flammable materials to a safe place before starting Fire caused by accumulation of combustible material Remove any dry leaves chips pieces of paper coal dust or any other combustible materials accumu...

Page 36: ...ontains many combustible industrial wastes Objects which mainly contains combustible materials such as dry leaves chips pieces of paper and coal dusts Take appropriate actions to prevent fire For details of remedies see DUMP BODY HEATING SPECIFICATIONS 3 237 Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting with anti explosion specific...

Page 37: ...ollowing Never jump on or off the machine Never get on or off a moving machine If the machine starts to move when there is no operator on the machine do not jump on to the machine and try to stop it PEOPLE ON DUMP BODY Never let anyone ride in the dump body There is a hazard of falling and suffering serious personal injury or death WHEN STANDING UP FROM OPERATOR S SEAT Before standing up from the ...

Page 38: ... personal injury or death Do not allow anyone to come inside the articulation range The clearance in the area around the dump body changes according to the movement of the dump body If you are caught this may lead to serious personal injury or death Do not allow anyone near any of the rotating or telescopic parts PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES The operator s compartment is equipped w...

Page 39: ...Komatsu distributor Do not try to increase the capacity of the dump body or make any other modifications Such modifications will cause a drop in the braking efficiency the balance of the machine will become poor and this may lead to an unexpected accident PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS Any personal injuries product failures physical loss or damage or influence on the environment re...

Page 40: ...s there is a hazard that the weight and vibration of the machine will cause the soil to collapse Before starting operations take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling DO NOT GO CLOSE TO HIGH VOLTAGE CABLES Do not drive or operate the machine near electric cables There is a hazard of electric shock which may cause serious personal injury or ...

Page 41: ...ives a clear view The rear view monitor is provided to secure the rear side visibility If however an obstacle is detected on the monitor you must confirm it with your eyes CHECK SIGNS AND SIGNALMAN S SIGNALS If signals and labels are not clear serious personal injury can result from downward slip overturn or accidental contact with nearby people or obstacles Always observe the following Set up lab...

Page 42: ...WALK AROUND CHECK 3 150 Remove all dirt from the surface of the lens of the headlamps working lamps and combination lamps and check that they light up correctly Check the coolant level fuel level and oil level in engine oil pan check for clogging of the air cleaner and check for damage to the electric wiring Check that there is no mud or dust accumulated around the movable parts of the accelerator...

Page 43: ...his 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 START ENGINE WITH JUMPER CABLES If any mistake is made in the method of connecting the jumper cables it may cause the battery to explode so always observe the following Always...

Page 44: ...ons check that articulation lock 1 is fixed securely at FREE position PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE Always lock all the doors and windows of the operator s compartment in position regardless of whether it is open or closed Always close all the windows and doors on jobsites where there is danger of scattering fragments and things which may intrude into operator s cab If another p...

Page 45: ...ularly when traveling downhill never set the gear shift lever to NEUTRAL position N If the gear shift lever is set to NEUTRAL position N while driving the machine at travel speed of above 4 km h or traveling downhill the gear speed is not changed to neutral The centralized warning lamp flashes and the alarm buzzer sounds Always set the gear shift lever in D to 1 position while traveling WHEN TRAVE...

Page 46: ... The sta bility of the machine becomes worse and it may tip over WHEN OPERATING ON SNOW OR FROZEN SURFACES Snow covered or frozen surfaces are slippery so be extremely careful when traveling or operating the ma chine and do not perform abrupt lever operation Machine may slip even on a slight slope Be particularly careful when working on slopes Frozen road becomes soft when the temperature rises an...

Page 47: ...ons carefully Depending on the attachments installed the machine weight transportation height and overall length may differ Check beforehand that all bridges and other structures on the transportation route are strong enough to withstand the combined weight of the transporter and the machine being transported This machine needs to be divided into components for transportation depending on the regu...

Page 48: ...lways lock the door after loading the machine To prevent the door from opening during transportation For detail see TRANSPORTATION 3 239 When it is necessary to remove handrails and steps take care not to lose removed handrails and steps Install the removed handrails and steps securely TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing ...

Page 49: ...ver and injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate use tap water and avoid use of organic solvents for cleaning An organic solvent like benzene toluene or methanol can invite a chemical reaction like dissolution and decomposition on the window glass deteriorating polycarbonate in use SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop the ma...

Page 50: ...p lever 1 to HOLD posi tion lock with dump lever lock knob 2 then stop the en gine Set parking brake switch 3 to PARKING position to ap ply the parking brake then put blocks in front of and be hind the tires to prevent the machine from moving Lock the front and rear frames with articulation lock 4 PRECAUTIONS FOR MAINTENANCE SAFETY 2 32 ...

Page 51: ...s and break and be scattered It is dangerous If the automatic active regeneration of KDPF starts during maintenance work surroundings of KDPF become high temperature When performing maintenance work perform regeneration disable of KDPF according to HANDLE Komatsu Diesel Particulate Filter KDPF 3 121 Lower the dump body completely set dump lever 1 to HOLD position lock with dump lever lock knob 2 t...

Page 52: ...to prevent personal injuries from falling or failing over due to losing your footing PRECAUTIONS WHEN WORKING UNDER MACHINE Machine or dump body may fall and it is dangerous that seri ous personal injury or death may occur Always observe the fol lowing When performing inspection with the dump body raised al ways set the dump control lever to HOLD position set the lock knob to LOCK position then in...

Page 53: ...ck when performing welding so never allow any unqualified person to perform welding HANDLE BATTERY Before inspecting or handling the battery turn the key in the starting switch to OFF position and check that the system operating lamp is off Then set the battery disconnect switch to OFF position and remove the switch key Danger of battery exploding When the battery is being charged flammable hydrog...

Page 54: ... the ground cable negative cable first When installing con nect the positive cable first then connect the ground Tighten the battery cable terminals securely Secure the battery firmly in the specified position WHEN USING HAMMER When using a hammer pins may come out or metal particles may be scattered It is dangerous and may cause serious personal injury or death Always observe the following When h...

Page 55: ...wear protective equipment such as protective eyeglasses and leather gloves High pressure oil leaking from small holes is dangerous that may penetrate your skin and cause loss of sight if it contacts your skin or eyes directly If a jet of high pressure oil hit your skin or eyes and suffer injury wash the place with clean water and consult a doctor immediately for medical attention PRECAUTIONS FOR H...

Page 56: ...osion or serious personal injury or death Always observe the following Do not disassemble it Do not bring it near open flame or dispose of it in fire Do not make holes in it weld it nor use a cutting torch Do not hit or roll it or subject it to any impact Ask your Komatsu distributor when sealing gas into the cylinder or replacing gas from it When disposing of the accumulator the gas must be re le...

Page 57: ...efined life parts See PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 7 2 The material of these components naturally changes over time and repeated use causes deterioration wear and fatigue As a result there is a hazard that these components may fail and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspection or the feeling when op...

Page 58: ...speed or operating under heavy load Never perform welding or light a fire near the tire Always release the inflation pressure from a tire prior to removing rim from tire Before removing the tire from the machine for repairs remove the valve partially to release the air from the tire gradually then remove the tire PRECAUTIONS FOR STORING TIRES Tires for construction equipment are extremely heavy it...

Page 59: ...pen containers in a well ventilated area For the method of storing see STORE DEF 4 8 When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is non fla...

Page 60: ......

Page 61: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 62: ...eam 3 Fog lamp if equipped 4 Turn signal lamp and clearance lamp 5 Working lamp 6 Yellow revolving lamp if equipped 7 Side lamp 8 Front wheel 9 Center wheel 10 Rear wheel 11 Hydraulic tank 12 Fuel tank 13 Hoist cylinder 14 Dump body 15 Air Cleaner GENERAL VIEW OPERATION 3 2 ...

Page 63: ... Machine monitor 7 Retarder control lever 8 Parking brake switch 9 Gear shift lever 10 Engine shutdown secondary switch 11 Cigarette lighter 12 Fog lamp switch if equipped 13 Revolving lamp switch if equipped 14 Power window switch 15 Side lamp switch 16 Dump lever 17 Dump lever lock knob 18 Accelerator pedal 19 Brake pedal OPERATION GENERAL VIEW 3 3 ...

Page 64: ...selector switch 4 Switch panel 5 Hazard lamp switch 6 Secondary steering switch 7 Rear view monitor brightness adjustment switch 8 Engine power mode selector switch 9 AISS LOW switch 10 Automatic retarder accelerator linked control switch if equipped 11 Inter axle differential lock switch GENERAL VIEW OPERATION 3 4 ...

Page 65: ...coolant temperature gauge 11 Engine coolant temperature caution lamp 12 Torque converter oil temperature gauge 13 Torque converter oil temperature caution lamp 14 Retarder oil temperature gauge 15 Retarder oil temperature caution lamp 16 Fuel gauge 17 Fuel level caution lamp 18 ECO gauge 19 DEF level gauge 20 Air conditioner display section 21 Clock 22 L H meter 23 R H meter 24 Enter switch 25 Up ...

Page 66: ...33 Inter axle differential lock pilot lamp 34 KTCS display 35 Aftertreatment devices regeneration display 36 Secondary steering pilot lamp 37 Power mode display 38 Shift hold pilot lamp 39 Torque converter lockup pilot lamp 40 Fan reverse pilot lamp 41 Preheating pilot lamp 42 ECO guidance 43 Maintenance time caution lamp 44 Guidance icon 45 Seat belt caution lamp 46 Warning display 47 Action leve...

Page 67: ...f cab 1 Ashtray 2 Drink box 3 Cup holder 4 Handy tray 5 Magazine box 6 Emergency escape hammer 7 12 V power supply 8 Fuse 9 Cab handle 10 Open knob for cab door 11 Cab door inner lock 12 Rear view monitor OPERATION GENERAL VIEW 3 7 ...

Page 68: ...nguisher 2 Fuse 3 Battery disconnect switch 4 System operating lamp 5 Circuit breaker 6 Articulation lock pin 7 Toolbox 8 Body pivot pin 9 Komatsu Closed Crankcase Ventilation hereafter KCCV ventilator GENERAL VIEW OPERATION 3 8 ...

Page 69: ... 10 Dust indicator 11 KDPF 12 SCR assembly 13 DEF tank 14 DEF pump 15 DEF injector 16 DEF filter OPERATION GENERAL VIEW 3 9 ...

Page 70: ...UIPMENT FF Failure display screen A Warning display B Pilot display C Meter display D Switch panel REMARK For the user menu used for setting various items of the machine on the machine monitor see USER MENU 3 48 One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit on the screen When there are fewer than ...

Page 71: ...BB 3 The pointer of engine tachometer D moves one cycle 4 Speedometer E displays 88 for 2 seconds 5 The alarm buzzer sounds for 2 seconds then stops under the normal condition NOTICE If the lamps alarm buzzer etc do not work the machine monitor may be failed or the electric wiring may have breakage In this case ask your Komatsu distributor for repair REMARK When the engine is started the battery v...

Page 72: ...ned OFF nor mal the machine monitor switches to the standard screen and the engine can be started with usual starting switch key operation For the function and operating method of engine shutdown sec ondary switch 1 see ENGINE SHUTDOWN SECONDARY SWITCH 3 103 BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION When starting switch is turned to OFF position the screen goes o...

Page 73: ...WHILE OPERATOR ID INPUT IS SET If inputting ID number for operator identification function with SKIP is set the opening screen AA switches to ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting ID number for operator identification function without SKIP is set the opening screen AA switches to ID number input screen MM without SKIP when the starting s...

Page 74: ...r input screen is displayed the engine cannot be started If you forget the ID number and cannot start the engine confirm the person in charge of the machine NOTICE Since the purpose of the operator identification function is neither security enhancement nor a protec tion against theft it has no antitheft effect Be careful not to use it for the purpose of security enhance ment Komatsu cannot accept...

Page 75: ...en GG is displayed When the menu switch displayed in guidance icon 2 is press ed the Maintenance menu screen is displayed For the Maintenance menu screen and the remedies see MAINTENANCE SCREEN SETTING 3 73 After displaying the maintenance time warning screen GG for 30 seconds the screen returns to the standard screen BB BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHIN...

Page 76: ...antee the condition of the machine Do not simply rely on the caution lamp when performing checks before starting start up inspec tion Always get off the machine and check each item directly When the caution lamp is displayed in red if no action is taken the machine can be seriously affect ed Take the action immediately The engine output or engine speed is limited and the machine operation speed ma...

Page 77: ...inter mittently Red Stop the operation and move the machine to a safe place then ask your Komatsu distributor for inspec tion and maintenance L02 Lights up Sounds inter mittently Red If there is an overrun related display reduce the en gine speed and machine travel speed while continu ing operations If there is an overheat related display stop the ma chine at a safe place and run the engine at med...

Page 78: ...tion on failures that occurred on the machine and necessary remedies for action levels that are displayed When the enter switch is pressed while the guidance icon is displayed the screen changes to the Current Abnormality screen REMARK The guidance icon is displayed only while the machine is stop ped completely Even when the enter switch is pressed while the machine is not stopped completely the C...

Page 79: ...phone number of your Komatsu distributor is displayed If the telephone number of the contact has not been registered it is not displayed Ask your Komatsu distributor for the telephone number registration if necessary G Guidance icon On the Current Abnormality list screen the following switches displayed in guidance icon G can be operated UP switch Move to the previous page When on the first page m...

Page 80: ...et the gear shift lever to NEUTRAL position N and run the engine at a medium speed under no load until the caution lamp goes out TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP The torque converter oil temperature caution lamp warns about overheating of the torque converter oil If the torque converter oil temperature is abnormally high the caution lamp lights up in red and action level L02 is displa...

Page 81: ...tion lamp warns that the brake oil pressure is below the specified value When action level L03 is displayed If the brake oil pressure drops below the specified value while the engine is running the caution lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Stop the operation move the machine to a safe place stop the engine then ask ...

Page 82: ...o the next Inducement status With No Action level display DEF tank level is becomes low Warning starts Inducement status is Warning Need to add DEF immediately When Lightning in white When fluctuation of DEF tank level is large frozen or not limited to tank level sensing is not performed correct ly When DEF is added after engine starting switch turn to OFF When DEF tank level sensor is defective R...

Page 83: ...y Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for inspection and maintenance Action level is not displayed and lamp lights up in red When the engine is started the caution lamp lights up in red until the steering oil pressure rises above the specified value At the same time the centralized warning lamp lights up and alarm buzzer sounds inte...

Page 84: ...ary steering motor has been operating for a long period The caution lamp lights up in red and action level L02 is dis played At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Do not use the secondary steering for more than 90 seconds HOIST CONTROL SYSTEM CAUTION LAMP The hoist control system caution lamp warns about abnormality in the hoist control syst...

Page 85: ...AMP The inclination caution lamp warns about danger of tipping caused by inclination of the machine When the dump lever is in RAISE position if the rear part of the machine is inclined more than the lateral stable range the caution lamp lights up in red At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Lower the dump body and move the machine to a safe ...

Page 86: ... For details of KDPF see HANDLE Komatsu Diesel Particulate Filter KDPF 3 121 KDPF SOOT ACCUMULATION CAUTION LAMP The KDPF soot accumulation caution lamp warns that soot is accumulated in KDPF or the filtering function of KDPF has low ered abnormally When action level L03 is displayed The caution lamp lights up in red if much soot is accumulated in KDPF or a system trouble such as lowering of the f...

Page 87: ...f DEF system exceeds the defined number of times Whenever the caution lamp lights up in yellow it is necessary to ask your Komatsu distributor to go off this caution lamp When stopping the engine stop it after running it at low idle for approximately 5 minutes For details see METHOD FOR STOPPING ENGINE 3 183 When stopping the engine during the aftertreatment devices re generation stop the regenera...

Page 88: ...up and alarm buzzer sounds intermittently Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed RET...

Page 89: ...p lights up in yellow When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed PARKING BRAKE SYSTEM CAUTION LAMP The parking brake system caution lamp warns about abnormal ity in the parking brake system When action level L03 is displayed The lamp lights up in red At the same time the centralized warning l...

Page 90: ...N ADDING OIL 3 156 If the oil level drops again in a short time the engine oil may be leaking Ask your Komatsu distributor for inspection and repair ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp warns the operator that the engine speed is higher than the allowable range When the caution lamp lights up in red the centralized warning lamp lights up and the alarm buzzer sounds intermitt...

Page 91: ...system When action level L03 is displayed The caution lamp lights up in red At the same time the central ized warning lamp lights up and alarm buzzer sounds intermit tently Stop the operation move the machine to a safe place stop the engine then ask your Komatsu distributor for inspection and maintenance When action level L01 is displayed The caution lamp lights up in yellow When you finish the op...

Page 92: ...and the machine life will be shortened Perform necessary maintenance as soon as possible When lamp lights up in yellow The maintenance due time is approaching Prepare necessary parts for the maintenance REMARK To check the items that need maintenance see the Maintenance menu screen On the standard screen when the menu switch is pressed while the caution lamp is lit the screen changes directly to t...

Page 93: ...e caution lamp lights up When the steering oil pressure is below the speci fied value while the engine is running The steering oil pressure caution lamp lights up When the starting switch is turned to ON position while the gear shift lever is in the any position oth er than NEUTRAL position N The current gear shift lever position flashes When all the signals from the gear shift lever are turned OF...

Page 94: ...Y Pilot display 1 Turn signal lamp pilot lamp 2 Headlamp high beam pilot lamp 3 Clearance lamp pilot lamp 4 Retarder pilot lamp 5 Inter axle differential lock pilot lamp 6 KTCS display 7 Power mode display 8 Shift hold pilot lamp 9 Torque converter lockup pilot lamp 10 Fan reverse pilot lamp 11 Preheating pilot lamp 12 Message display 13 Aftertreatment devices regeneration display 14 Secondary ste...

Page 95: ...When the starting switch is in ON position the pilot lamps light up when the display items are functioning TURN SIGNAL PILOT LAMP The turn signal pilot lamp flashes synchronously with the turn signal lamp when it is turned on HEADLAMP HIGH BEAM PILOT LAMP The headlamp high beam pilot lamp lights up when the head lamps are set to high beam CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lig...

Page 96: ...ntial lock pilot lamp lights up when the in ter axle differential lock is in operation KTCS DISPLAY KTCS display indicates the operating state of KTCS A Lights up when KTCS is in operation B Lights up when setting of KTCS is turned OFF For setting of KTCS see KTCS SYSTEM SETTING 3 65 POWER MODE DISPLAY The power mode display indicates the set state of the output mode By selecting engine power mode...

Page 97: ...aftercooler fan is set in fan reverse mode For details of the method of setting the fan reverse mode see RADIATOR FAN REVERSE MODE 3 61 and AFTER COOLER FAN REVERSE MODE 3 63 PREHEATING PILOT LAMP The preheating pilot lamp lights up when the automatic pre heating function of the engine is actuated and goes out when preheating is completed This lamp also lights up during manual preheating The elect...

Page 98: ...setting method see HANDLE Komatsu Diesel Particulate Filter KDPF 3 121 Aftertreatment devices regeneration display indicates the re generation state of the exhaust gas aftertreatment devices A Lights up during regeneration of the exhaust gas aftertreat ment devices It goes out when the regeneration is complet ed B Lights up when the exhaust gas aftertreatment devices are set to Regeneration Disabl...

Page 99: ... display indicates the gear shift lev er position The character for the selected gear shift lever position is en larged PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake is applied ECO GUIDANCE ECO guidance is displayed during the operation that lowers the fuel efficiency and support energy saving oper ation for reducing the fuel consumption The details of the ...

Page 100: ... pressure relief deterrence message goes out auto matically in 10 seconds BRAKE DRAGGING PREVENTION GUIDANCE If the accelerator pedal is depressed for more than 5 seconds while applying the brake during traveling the brake dragging prevention message is displayed on the machine monitor If the accelerator is operated while the brake is used fuel con sumption is increased The brake dragging preventi...

Page 101: ...ion message is displayed on the ma chine monitor Relieving of steering oil pressure occurs when you steer the wheel fully to the right or left Restrict forcible steering operation to reduce the fuel consump tion The steering relief restriction message goes out automatically after 10 seconds REMARK Display Non display of ECO guidance can be switched For the method of switching the display see SWITC...

Page 102: ...e caution lamp goes out TORQUE CONVERTER OIL TEMPERATURE GAUGE The torque converter oil temperature gauge indicates the tor que converter oil temperature When the indicator is in green range B during operation it is normal If the indicator is in red range C the torque converter oil tem perature caution lamp lights up in red and action level L02 is displayed At the same time the centralized warning...

Page 103: ...re is no adverse effect on the operation leading to energy saving operation to reduce the fuel consumption REMARK Even if the gauge is in orange range A it is not a machine trouble Target fuel consumption B displayed by ECO gauge can be changed as necessary For the method of changing the target value see SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE 3 58 L H AND R H METER DISPLAY The L ...

Page 104: ...ning hour regardless of the en gine speed Odometer display Indicates the total distance that machine has traveled in kilo meters Clock display Indicates the current time A 12 hour display B 24 hour display REMARK If the battery is disconnected for a long period for storage etc the time information may be lost For the method of setting and correcting the time and changing the display of the clock s...

Page 105: ...ts up in red the engine output power and engine speed are limited For de tail see HANDLE UREA SCR SYSTEM WARNING 3 132 When remaining level of DEF cannot be detected DEF level caution lamp 1 lights up in white REMARK Immediately after turning the starting switch to ON position and during the engine is running DEF level cau tion lamp 1 lights up in white However this does not indicate abnormality I...

Page 106: ... during traveling For details of the user menu see USER MENU 3 48 When normal Displays the Energy Saving Guidance menu screen When KDPF soot accumulation caution lamp lights up Displays the Aftertreatment Devices Regeneration menu screen When maintenance caution lamp lights up Displays the Maintenance menu screen When fan automatic reverse display lights up Displays the Machine Setting and Informa...

Page 107: ...8 RETURN SWITCH Pressing the return switch cancels a selection or changes and returns the screen to the previous screen or the standard screen UP SWITCH Pressing the up switch moves the cursor up by one item When on the top line the cursor moves to the bottom line On the value input screen the value is increased by one DOWN SWITCH Pressing the down switch moves the cursor down by one item When on ...

Page 108: ...sed as a numeric keypad to enter a numeric value such as a password Press a desired switch to enter a numeric value 0 to 9 which is indicated at the lower right of each switch REMARK For details of other switch functions see the explanation for each screen in USER MENU 3 48 The confirmation sound is heard when the switch is press ed but a reaction is taken the switch function is operated when the ...

Page 109: ...ck and reset of Average Fuel Consumption Record Configurations B Machine Setting and Information Setting of Radiator Fan Reverse Mode Setting of Aftercooler Fan Reverse Mode Display and setting of Payload Meter if equipped KTCS setting Display and resetting of Dumping Counter if equipped Display of Reverse Travel Odometer Display and resetting of Trip Meter F1 Start at D Position Setting A C ECO M...

Page 110: ...Operator ID G Message Display Check of message contents and reply to message On the user menu screen it is possible to perform the following operations with the switches 1 Up switch Moves to the item above When on the first item moves to the last item 2 Down switch Moves to the item below When on the last item moves to the first item 3 Enter switch Enters any selection or changes and proceeds to t...

Page 111: ... A is used for displaying and setting the notification relevant to energy saving Operating Records Eco Guidance Records Average Fuel Consumption Records Configurations OPERATING RECORD The Operation Records screen displays the following informa tion on a daily basis or during the split measurement period Working Hours Engine On Average Fuel Consumption Actual Working Hours Ave Fuel Consumption Act...

Page 112: ...tes and times when measurement is started and stopped To start the split measurement see the guidance icon and press enter switch 1 When the measurement is started the previous split measure ment results Average Fuel Consumption Display Operation Records and ECO Guidance Records are reset When the confirmation screen is displayed press enter switch 1 again to start the split measurement or press r...

Page 113: ...NSUMPTION GAUGE 3 56 For the ECO guidance see ECO GUIDANCE 3 39 In the one point advice section the advice to the ECO guid ance that appeared most frequently is displayed The ECO guidance count increases when display conditions are satisfied even if the ECO guidance is not displayed When Average Fuel Consumption Display is set to 1 Day When Average Fuel Consumption Display is set to Split Time and...

Page 114: ... Records and ECO Guidance Records are reset When the confirmation screen is displayed press enter switch 1 again to start the split measurement or press return switch 2 to cancel the start FUEL CONSUMPTION RECORD The Average Fuel Consumption Record screen alternately displays the following graphs Average fuel consumption for the Last 12 hours Average fuel consumption for the Last 7 days Select Ave...

Page 115: ...ance icon and press ENTER switch 1 When the confirmation screen is displayed press ENTER switch 1 again to clear or press RETURN switch 3 to cancel clearing REMARK If clearing is performed while the graph of the Last 12 hours is displayed only the graph of the Last 12 hours is cleared If clearing is performed while the graph of the Last 7 days is displayed both graphs of the Last 12 hours and Last...

Page 116: ...guidance Switching ON OFF of ECO Guidance Display at Key OFF Select Configurations from Energy Saving Guidance menu screen then press ENTER switch 1 SET DISPLAY OF FUEL CONSUMPTION GAUGE The display of the fuel consumption gauge can be set to the value on daily basis or during split measurement period 1 Select Average Fuel Consumption Display from Configu rations menu then press enter switch 1 EXP...

Page 117: ...finished Select Split Time to start the split measurement automatically REMARK For the display of the Average Fuel Consumption Display see L H AND R H METER DISPLAY 3 43 Setting of 1 Day or Split Time is also applied to the display of the Operation Records and ECO Guidance Records When stopping the split measurement see OPERATING RECORD 3 51 or ECO GUIDANCE RECORD 3 53 SWITCH DISPLAY NON DISPLAY O...

Page 118: ...O GAUGE 3 43 If the ECO Gauge Display is set to OFF the items of ECO Gauge Display Fuel Target Value is not indicated SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE ECO Gauge Target Value A the upper limit value of the green range can be changed 1 Select ECO Gauge Display Fuel Target Value from the Configurations menu then press enter switch 1 EXPLANATION OF COMPONENTS OPERATION 3 58 ...

Page 119: ...consumption value by 1 ℓ h To cancel sending press return switch 4 The default is 74 ℓ h REMARK For the ECO gauge see ECO GAUGE 3 43 SWITCH DISPLAY NON DISPLAY OF ECO GUIDANCE Display non display of ECO guidance indicated on the standard screen can be switched 1 Select ECO Guidance Display from the Configurations menu then press enter switch 1 OPERATION EXPLANATION OF COMPONENTS 3 59 ...

Page 120: ... Guidance Display at Key OFF and ECO Guidance Record do not appear when the starting key is turned OFF The ECO Guidance Record however is not reset SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF Display non display of the Operational Advice indicated on the end screen when the key is turned to OFF position can be switched 1 Select ECO Guidance Display at Key OFF from the Con figurations me...

Page 121: ...from the Operational Ad vice indicated on ECO GUIDANCE RECORD 3 53 MACHINE SETTING AND INFORMATION In each item of Machine Setting and Information menu B setting and information of the machine are checked or changed RADIATOR FAN REVERSE MODE k k CAUTION When rotating the fan in the reverse direction beware extremely that dirt will not fly out and cloth etc will not be wound in the fan Since dust m...

Page 122: ...rse direc tion or press return switch 2 to cancel If the dump body is not seated or the engine is running the screen as shown in the figure appears and the fan rotation cannot be switched In this case press return switch 2 and then repeat the procedure from the first 4 Fan automatic reverse display 3 lights up Start the engine The fan rotates in reverse EXPLANATION OF COMPONENTS OPERATION 3 62 ...

Page 123: ... press enter switch 1 2 When the screen shown in the figure appears press enter switch 1 to return the radiator fan to the normal rotation mode REMARK When the aftercooler fan is set in the reverse mode the radia tor fan is returned to the normal rotation mode automatically If the engine compartment is heated high due to the reverse mode based reverse rotation of the fan the controller may stop th...

Page 124: ...erse direc tion or press return switch 2 to cancel If the dump body is not seated or the engine is running the screen as shown in the figure appears and the fan rotation cannot be switched In this case press return switch 2 and then repeat the procedure from the first 4 Fan automatic reverse display 3 lights up Start the engine The fan rotates in reverse EXPLANATION OF COMPONENTS OPERATION 3 64 ...

Page 125: ...n manually 1 Turn the starting switch to ON position again select After cooler Fan Reverse Mode in the Machine Setting and In formation menu and press enter key 1 2 When the screen shown in the figure appears press enter switch 1 to return the aftercooler fan to the normal rota tion mode REMARK If the radiator fan is set in the reverse mode the aftercooler fan is returned to the normal rotation au...

Page 126: ...TROL SYSTEM KTCS 3 199 This setting is held even after the starting switch key is turned to OFF position The default is ON DUMPING COUNTER if equipped The dumping counter is the function that automatically counts and displays the number of loads dumped If the dumping counter is not installed on the machine the Dumping Counter is not displayed The number of times can be reset according to the follo...

Page 127: ...nter switch 1 2 Press enter switch 1 to reset or press return switch 2 to cancel resetting REVERSE TRAVEL ODOMETER The total reverse travel distance can be checked with the Re verse Travel Odometer OPERATION EXPLANATION OF COMPONENTS 3 67 ...

Page 128: ... according to the following procedure 1 Select Trip Meter then press enter switch 1 2 Press enter switch 1 to reset or press return switch 2 to cancel resetting D RANGE F1 START SETTING Use this setting to change the starting gear speed when the gear shift lever is set to D position EXPLANATION OF COMPONENTS OPERATION 3 68 ...

Page 129: ...achine travels in F 1 while F1 is not necessary the service life of the machine may be shortened REMARK If the machine travels in F 1 while the dump body is not seated the gear speed is fixed to the 1st even if the gear shift lever is in D position This setting is held even if the starting switch is turned to OFF position The default is F 2 AIR CONDITIONER ECO MODE SETTING Turns ON or OFF the air ...

Page 130: ...bove 30 C or the set tempera ture of the air conditioner is 18 C maximum cooling air con ditioner may not be operated in the ECO mode even if the A C ECO Mode Setting is turned ON This setting is held even if the starting switch is turned to OFF position The default is OFF RETARDER CONTROL LEVER CANCEL SOUND SETTING This is used for selecting ON or OFF of the cancel sound of the retarder control l...

Page 131: ...e state continued for a predetermined time The auto idle stop works only when all of the following conditions are met The accelerator pedal is not depressed Gear shift lever is in NEUTRAL position N The dump lever is placed in FLOAT position and dump body is seated When the dump body float caution lamp is not lit The machine is stopped KDPF regeneration is not performed There is no possibility of ...

Page 132: ... to any position other than NEUTRAL position N at this point the countdown is stopped and the screen returns to the standard screen 4 If the idle state is further continued and the countdown reaches 0 second the engine stops At the same time the parking brake is applied Turn unnecessary switches to OFF position to prevent the battery to run out REMARK When the auto idle stop operates while the par...

Page 133: ...ARNING 3 132 MAINTENANCE SCREEN SETTING Each item on Maintenance menu screen E is used for dis playing and setting the notification relevant to maintenance On the Maintenance menu screen the maintenance items in the table their replacement intervals and remaining time to the next replacement are displayed Maintenance item Replacement interval h Default Air Cleaner Cleaning or Change Engine Oil Cha...

Page 134: ...e time after the replacement interval is indicated with the negative symbol If any item is displayed in red perform the maintenance for it immediately REMARK The replacement interval in Air Cleaner Cleaning or Change is not set initially If you want to change the setting for the maintenance interval and the maintenance notice time consult your Komatsu distrib utor When the maintenance time caution...

Page 135: ...by using the nu meric keypad then press enter key 1 REMARK For the setting changing or canceling the password ask your Komatsu distributor 2 The screen changes to Maintenance Due Time Reset screen When enter switch 1 is pressed the following reconfirma tion screen is displayed To cancel press return switch 2 3 On the re confirmation screen shown in the figure when enter switch 1 is pressed again t...

Page 136: ...e rearview monitor Select Rearview Monitor Setting on the Monitor Setting menu screen and press enter switch 1 Reference line display The is used to change ON OFF of the reference line on the rearview monitor 1 Select Guide Line Display Mode from the Rearview Monitor Setting menu and press enter switch 1 EXPLANATION OF COMPONENTS OPERATION 3 76 ...

Page 137: ...s ON REVERSE INTERLOCK ENABLED MODE In this mode display method of rear view monitor can be changed by switching ON OFF 1 Select Reverse interlock Selection mode on the Rear view Monitor Setting menu then press ENTER switch 1 2 Select ON or OFF then press ENTER switch 1 ON Displays images on the rear view monitor only when trav eling in reverse OFF Always displays images on the rear view monitor R...

Page 138: ...d on L H meter display A or R H meter display B Meter Display Selection on the Monitor Setting menu screen then press enter switch 1 SELECT L H METER DISPLAY This is used for the selection of the items to be displayed on the L H meter display EXPLANATION OF COMPONENTS OPERATION 3 78 ...

Page 139: ...ch 1 The following 3 items can be selected SMR Service Meter ODO Odometer Odometer CLK Clock REMARK For details of each item see L H AND R H METER DISPLAY 3 43 The default of L H meter is SMR Service Meter SELECT R H METER DISPLAY This is used for the selection of the items to be indicated on the R H meter display OPERATION EXPLANATION OF COMPONENTS 3 79 ...

Page 140: ...Fuel Consumption SMR Service Meter ODO Odometer Odometer CLK Clock REMARK For details of each item see L H AND R H METER DISPLAY 3 43 The default of R H meter is FUEL Average Fuel Consump tion SCREEN ADJUSTMENT This function is used for the adjustment of brightness of the machine monitor 1 Select Screen Adjustment on the Monitor Setting screen then press enter switch 5 EXPLANATION OF COMPONENTS OP...

Page 141: ...brightness in the night mode can be adjusted The brightness of night illumination for the switch panel gear shift lever and operation switches is adjusted synchronously with the brightness of the machine monitor CLOCK ADJUSTMENT On the clock adjustment menu you can change the setting of the clock displayed on the standard screen The following items can be changed GPS Synchronization Calendar Time ...

Page 142: ...be set manually REMARK This setting is held even if the starting switch is turned to OFF position The default is OFF When the machine is in the environment where the radio waves from GPS cannot be received the automatic setting function might be disable Turning the GPS Synchronization ON disables selecting the Calendar and Time CALENDAR SETTING Adjust the date of the machine monitor EXPLANATION OF...

Page 143: ...calendar one year 2 Down switch Put Calendar back one year 3 Return switch Cancels the change and returns the screen to Clock Adjustment menu 4 Enter switch Proceeds to setting for month 3 When month display B is highlighted in yellow operate the switches as follows to change month display When it is not necessary to change the month setting press enter switch 4 1 Up switch Advances calendar one m...

Page 144: ...of the machine monitor clock 1 Select Time from the Clock Adjustment menu and press enter switch 4 REMARK If ON is selected for the setting of GPS Synchroniza tion you cannot select the Time 2 The Time screen is displayed When time display D is highlighted in yellow operate the switches as follows to change time display When it is not necessary to change the time setting press enter switch 4 1 Up ...

Page 145: ... the screen to the Clock Adjustment screen 12 HOUR AND 24 HOUR DISPLAY MODE Choose either a 12 hour display am pm or a 24 hour display 1 Select 12hour or 24hour Mode from the Clock Adjust ment menu then press enter switch 1 2 Select 12hour or 24hour then press enter switch 1 12hour Select 12H display AM PM 24hour Select 24H display REMARK This setting is held even if the starting switch is turned ...

Page 146: ...ytime for everyday life This setting is held even if the starting switch is turned to OFF position The default is OFF LANGUAGE SETTINGS The language displayed on the machine monitor can be selected The languages that can be selected are as follows English Japanese French Spanish Portuguese Italian German Swedish Dutch Danish Norwegian Fin nish Icelandic Czech Hungarian Polish Slovak Slovene Romani...

Page 147: ...fication on the Operator ID menu The Operator ID menu is not displayed when the operator identification function is disabled REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identi fication function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted the identified ID is displa...

Page 148: ... for 1 second 2 The Operator ID Change screen is displayed Input the already registered ID on the Operator ID Change screen and press ENTER switch 1 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen On the Monitor Setting menu screen the inputted ID is displayed in the column of Operator ID EXPLANATION OF COMPONENTS OPERATI...

Page 149: ...he screen returns to the Monitor Setting menu screen In this case the identified ID is not changed On the Operator ID screen if no switch is operated for more than 30 seconds the screen automatically changes to the Monitor Setting menu screen In this case the identified ID is not changed WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is av...

Page 150: ...e identified ID is not changed On the Operator ID screen if no switch is operated for more than 30 seconds the screen automatically changes to the Monitor Setting menu screen In this case the identified ID is not changed MESSAGE DISPLAY On machines equipped with KOMTRAX you can see the mes sages from your Komatsu distributor on this User Message menu G When there is any message message display 1 o...

Page 151: ...is dis played B Serial No of message C Validity D Text E Reply field In case of a message requesting for reply the Numeric Input is displayed Make any reply to the message REPLY TO MESSAGE 1 When replying to a message input the selected item num ber shown in the text of the message by using the switch panel Each switch of the switch panel corresponds to the number shown on the lower right of the s...

Page 152: ...itch key is set to OFF position The service meter and odometer can be displayed even if the machine monitor is not turned ON 1 Press UP switch 2 while holding down DOWN switch 1 when the starting switch is in OFF position Service meter A and odometer B are displayed while both switches are held down NOTICE If the monitor screen is displayed during other operations while the starting switch is at O...

Page 153: ...ke switch 17 Shift hold switch 18 Fog lamp switch if equipped 19 Power window switch 20 Side lamp switch 21 Revolving lamp switch if equipped 22 Engine shutdown secondary switch 23 Room lamp 1 switch 24 Room lamp 2 switch STARTING SWITCH Starting switch is used to start or stop the engine A OFF position The key can be removed from the starting switch the electrical current to the electrical system...

Page 154: ...g manually see METHOD FOR MANUAL PREHEATING WHEN STARTING ENGINE 3 179 CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes When the cigarette lighter is pushed in it will return to its origi nal position after several seconds then pull it out and use it to light your cigarette If the cigarette lighter is removed the socket can be used as an 84 W 12 V x 7 A power supply LAMP SWITCH ...

Page 155: ...ver is operated the turn signal pilot lamp also flashes The lever returns automatically when the steering wheel is turned back If the lever does not return move it by hand WIPER WINDOW WASHER SWITCH The windshield wiper and window washer switch is used to operate the wiper for the front glass and rear glass NOTICE Using the wiper when the glass is dry will scratch the glass Spray with window washe...

Page 156: ...to select the brightness luminosity of the machine monitor and rear view monitor while lamp switch is turned ON When operating the machine with the headlamp lighting up dur ing the day if this switch is set to Day mode monitor screen does not loose the brightness A Day position The monitor screen is set to the day mode B Night position The monitor screen is set to the night mode REMARK When the la...

Page 157: ...urn OFF when it be comes hot so when it is not needed turn the switch manually to OFF position HAZARD LAMP SWITCH The hazard lamp switch is used to flash the R H and L H turn signal lamps Position A The turn signal lamps and the turn signal pilot lamp flash Position B The turn signal lamps and the turn signal pilot lamp go out SECONDARY STEERING SWITCH k k WARNING Do not use the secondary steering...

Page 158: ... monitor The brightness in the day and night modes can be adjusted in dividually Position A The rearview monitor becomes brighter Position B The rearview monitor becomes darker INTER AXLE DIFFERENTIAL LOCK SWITCH The inter axle differential lock switch is used to select the differential mode of the inter axle differential lock Set it to AUTO when traveling on a normal ground A MANUAL The inter axl...

Page 159: ...t control is needed such as when putting the machine into the garage The low idle speed is fixed to a rather low level REMARK When the automatic warm up is turned on this switch position stops it and set a low idle speed to a rather low level B AISS LOW switch OFF Use this switch position for the normal operation AISS function is actuated to produce the states described below When the engine coola...

Page 160: ...king brake The parking brake switch is used to actuate and release the parking brake A Parking The parking brake is applied When this switch is set to PARKING position the parking brake pilot lamp lights up on the machine monitor When the switch is set to PARKING position if the gear shift lever is at any position other than NEUTRAL position N the centralized warning lamp flashes and the alarm buz...

Page 161: ...ill grade or loading condition fix the transmission to a lower gear speed to improve the operator comfort and protect the transmission FOG LAMP SWITCH if equipped The fog lamp switch is used to turn the fog lamp ON or OFF Position A Fog lamp lights up Position B Fog lamp goes out POWER WINDOW SWITCH k k WARNING When closing the window glass be careful not to catch anyone s hands or head in the win...

Page 162: ...switch is at OFF position so when leaving the operator s compart ment set the switch to position A or B When performing operations with the door fully opened set the switch to position A ROOM LAMP2 SWITCH Room lamp 2 switch is used to turn room lamp 2 ON or OFF Position A Lamp goes out Position B Lamp lights up REVOLVING LAMP SWITCH if equipped The revolving lamp switch is used to turn the yellow ...

Page 163: ...ondary SW in Operation is displayed on the machine monitor and the alarm buzzer sounds intermittently A STOP ENGINE when abnormal B Normal REMARK When cover 1 is closed the engine shutdown secondary switch automatically returns to NORMAL position B While engine shutdown secondary switch is at the STOP ENGINE position if the starting switch is turned ON En gine Shutdown Secondary SW in Operation is...

Page 164: ...rder control lever 5 Dump lever 6 Dump lever lock knob BRAKE PEDAL The brake pedal is used to apply the wheel brakes ACCELERATOR PEDAL Use the accelerator pedal to control the engine speed It can be operated freely from low idle to full throttle EXPLANATION OF COMPONENTS OPERATION 3 104 ...

Page 165: ...um travel speed in position R1 is 6 8 km h Position R2 This is used when traveling in reverse Transmission is fixed in reverse 2nd and the travel is performed in torque converter drive or direct drive accord ing to the travel speed while position R2 is used The maximum travel speed in position R2 is 16 0 km h The machine cannot travel in reverse while the dump body is raised Lower the dump body se...

Page 166: ...sition other than FLOAT or the dump body is still raised the centralized warning lamp will light up and the alarm buzzer will sound Always place the gear shift lever securely in position when operating it If the gear shift lever is not placed securely in position the shift lever position pilot lamp on the machine monitor may start flashing and the centralized warning lamp may light up and the alar...

Page 167: ...the dump body float caution lamp lights up For method to cancel HOLD condition see METHOD FOR CANCELING TO HOLD DUMP BODY 3 181 DUMP LEVER LOCK KNOB k k WARNING When performing inspection with the dump body raised always set the dump lever to HOLD position lock it with the dump lever lock knob and use the body pivot pin The dump lever lock knob is a locking device for the dump lev er To set it to ...

Page 168: ...f the operator s seat to store drinks Hot or cold air blows into the box according to the setting of the air conditioner Turn the knob counterclockwise and pull the cover up and open it Position A Close Lock Position B Open Unlock When closing the cover lock it by turning the knob clockwise while pressing the cover MAGAZINE BOX The magazine box is provided on the front left side of opera tor s sea...

Page 169: ...s provided on the top of the console box on the right side of the operator seat Always put out your cigarette before putting it in the ashtray and be sure to close the lid POWER SUPPLY OUTLET 12V POWER SOURCE The outlet for 12 V power is provided in the rear right side of the operator seat Capacity of this power supply is 60 W 12 V x 5 A OPERATION EXPLANATION OF COMPONENTS 3 109 ...

Page 170: ...e same capacity and type FUSE CAPACITIES AND CIRCUIT NAMES Fuse box I BT1 No Capacity Name of circuit 1 15 A Retarder controller 2 10 A Automatic secondary steer ing 3 4 5 A Switch panel 5 5 A Shift lever personal lock re lay 6 10 A Preheat relay 7 20 A Air conditioner blower mo tor 8 10 A Air conditioner compressor clutch 9 10 A Heated wire mirror right if equipped 10 10 A Heated wire mirror left...

Page 171: ...9 5 A Retarder controller continu ous power supply 20 10 A Machine monitor controller continuous power supply 21 10 A KOMTRAX 22 10 A Payload meter if equipped 23 10 A Download continuous pow er supply 24 5 A Radio continuous power supply 25 10 A Hazard 26 5 A Room lamp 1 27 15 A Horn 28 5 A 29 5 A Rearview monitor 30 20 A Spare continuous power supply OPERATION EXPLANATION OF COMPONENTS 3 111 ...

Page 172: ...0 A Heated wire mirror power supply if equipped 45 20 A Spare Fuse box IV BT4 No Capacity Name of circuit 46 20 A Power window 47 20 A Front wiper 48 10 A Rear wiper 49 20 A DC converter 50 10 A Revolving lamp 51 10 A Payload meter external pilot lamp 52 5 A Heated wire mirror switch if equipped 53 5 A Controller ACC signal 54 5 A Air conditioner ACC signal 55 10 A Download ACC signal 56 10 A Park...

Page 173: ...oblems may occur in the machine control Do not make any changes to the electrical system If you want to make any change to the electrical system contact your Komatsu distributor OPEN AND CLOSE CAB DOOR k k CAUTION Make sure that the cab door is locked Always place the machine on a level ground when opening or closing the door Avoid opening or closing the door on a slope since there is a danger tha...

Page 174: ...AB DOOR Pull the open knob for the cab door and the door opens to the full open position CAB DOOR INNER LOCK When the cab door inner lock is pressed the door is locked Position A Lock Position B Canceled TOOL BOX The toolbox is stored in the front side of the hydraulic tank on the left side of the machine EXPLANATION OF COMPONENTS OPERATION 3 114 ...

Page 175: ...pairing the electrical system When performing electric welding When handling the battery When replacing the fuse etc Do not turn battery disconnect switch to OFF position while the system operating lamp is lit If the battery disconnect switch is turned OFF while this lamp is lit the data in the controller may be lost If this switch is turned to OFF position all the electrical system is cut out and...

Page 176: ...perating lamp is lit the data in the controller may be lost REMARK Even if the starting switch is in OFF position the controller may operate The system operating lamp lights up at this time but it is not a failure After the starting switch has been turned OFF the system operating lamp may stay lit for a long time In such case consult your Komatsu distributor CIRCUIT BREAKER When the circuit breake...

Page 177: ...rrounding area When transporting or raising the machine always apply the articulation lock Apply the articulation lock if necessary when performing maintenance The articulation lock is a device to lock the front frame and rear frame to prevent the machine from articulating LOCK position L Always set the lock to this position before starting transporta tion or lifting operation Set the lock to this...

Page 178: ...n the truck operation or neglect to watch the hauling road ahead for safety and this may lead to serious personal injury or death The rear view monitor is an supporting aid for checking obstacles in the rear or surroundings An image displayed on the monitor is limited So when traveling in reverse do not rely solely on the monitor but be sure to make a visual check for safety Never rely solely on t...

Page 179: ...the rear view monitor see REAR VIEW MONITOR SETTING 3 76 and for the setting of refer ence line see METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 3 169 REMARK The screen may be hard to see in the dark place at night but it is not a trouble k k WARNING The reference line dose not synchronize with steering angle The reference line does not indicate the actual moving direction or travel path The guide ...

Page 180: ... position of the gear shift lever During this period the version No of the rearview monitor is displayed at the top right of the rearview monitor After the camera image is displayed on the rearview monitor for 5 seconds the rearview monitor displays the camera image ac cording to the display mode reverse travel interlock constant display and the gear shift lever position If the rearview monitor or...

Page 181: ... camera lens being smeared In that case clean the camera lens with dry soft cloth or wet cloth after having well wrung the water out HANDLE Komatsu Diesel Particulate Filter KDPF k k CAUTION Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration Avoid getting near the exhaust pipe outlet and around ...

Page 182: ...lights up Accumulation amount of soot can be checked by soot ac cumulation level 3 on the Aftertreatment Devices Regen eration screen Operate the menu switch on the standard screen to dis play the Aftertreatment Devices Regeneration screen Automatic regeneration against accumulation of soot starts when the soot accumulation level increases 3 or above and stops a while after the soot accumulation l...

Page 183: ... soot accumulation level is low the automatic regeneration may be performed and the man ual stationary regeneration may be requested to protect the system In particular if engine is kept running with no load the regeneration frequency may increase but this is not a failure Even just after the regeneration is completed the soot accumulation level may not be 0 This is caused by the accumulated nonco...

Page 184: ...conds every 2 hours If KDPF soot accumulation caution lamp 2 lights up in yellow stop the machine in a safe place and perform the manual stationary regeneration When the degree of emergency is high KDPF soot accumulation caution lamp 2 lights up in red and the action level L03 lights up in red 4 If the machine is stopped completely the screen changes to the Aftertreatment Devices Regeneration scre...

Page 185: ...ave the operator s seat during the aftertreatment devices regeneration The manual stationary regeneration can be performed while KDPF soot accumulation caution lamp 1 is lit REMARK On this machine the manual stationary regeneration can be performed when soot accumulation level is 1 or above If there is a failure of which action level is L02 or above or the fuel level caution lamp is lit the manual...

Page 186: ...ted during the manual stationary regeneration the regeneration may stop REMARK After the enter switch is pressed in step 7 the screen shown in the figure may be displayed This indicates that the operations in steps 1 to 5 were not performed correctly or there is trouble other than KDPF soot accumulation ab normality After making sure that the engine is running nor mally the accelerator pedal is no...

Page 187: ...tationary regeneration dis appears and the screen returns to the standard screen At this time to display the explanation of the manual sta tionary regeneration again press the menu switch on the standard screen to display the Aftertreatment Devices Re generation screen 8 This screen is displayed during the manual stationary re generation It may take more than 40 minutes to complete the manual stat...

Page 188: ...tor pedal gear shift lever or parking brake switch is operated during the manual stationary regeneration the regeneration is stopped automatical ly Release the accelerator pedal return the gear shift lever to NEUTRAL position N return the parking brake to PARKING position and then repeat the pro cedure from step 7 If the machine needs to be moved during the manual stationary regeneration stop the ...

Page 189: ...it may cause the failure of KDPF or the engine WHILE REGENERATION IS NOT BEING PERFORMED SETTING PROCEDURE FOR REGENERATION DISABLE When the aftertreatment devices regeneration display is not lit on the standard screen 1 Press the menu switch on the standard screen 2 Operate the menu switch to select Aftertreatment Devices Regeneration menu C and display the Aftertreatment Devices Regeneration scr...

Page 190: ...y 2 may light up but this does not indicate abnormality Also during the regeneration to protect the system the Regeneration Disable cannot be operated When the regeneration is performed to protect the system the exhaust temperature is lower than that of when the re generation is performed to burn soot and is almost the same level as the normal exhaust gas temperature WHILE REGENERATION IS BEING PE...

Page 191: ...evices Regeneration screen is dis played If the Aftertreatment Devices Regeneration screen is not displayed display it by pressing the menu switch several times 2 Select Cancel of Regeneration Disable and press the en ter switch and the regeneration disable is canceled If soot accumulation level 1 lights up 3 or more the re generation may be started automatically REMARK When canceling the regenera...

Page 192: ...rities on engine systems that use Urea SCR systems Inducement is intended for the operator to take prompt actions to maintain and correct inappropriate behaviors of Urea SCR systems by utiliz ing visible and audible alerts and engine power derate in addition Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audib...

Page 193: ...g parking and to prevent DEF from freezing during operation In case DEF freezes during parking once the engine starts running the heating system automatically starts pro viding heat to thaw frozen DEF The pump and the injector start working only after a proper amount of DEF is thawed This may be noticed as a delay in the start of functioning of the pump and the injector The heating system is also ...

Page 194: ...d screen to display the SCR Information screen of the user menu After a lapse of 3 seconds to stop the machine SCR Informa tion screen is displayed SCR Information screen displays the DEF level caution lamp 1 the DEF level gauge 2 information on the Urea SCR Sys tem condition 3 and the current status of Inducement 4 If Inducement starts stop the machine in a safe place and add DEF Warning 2 gradat...

Page 195: ...lert sounds in short and sharp beeps 1 gradation of the DEF level gauge light up in red The DEF level caution lamp 1 lights up in red Action Level L03 is displayed in red 5 Press the menu switch to display the SCR Information screen Inducement status 4 3 Engine power is under deration Add DEF to the DEF tank immediately Severe Inducement The audible alert sounds in continuous beep No gradation of ...

Page 196: ...rning Continuous Warning Low level Inducement and Severe In ducement The Inducement strategy includes visual alert by the DEF caution lamp the KDPF system caution lamp or the Engine system caution lamp 1 and Action Level displayed on the machine monitor 2 and the audible alert by a buzzer and stepwise engine power deration that advances to speed limita tion to low idle Engine power deration starts...

Page 197: ...ion continues for 5 hour after Warning started without taking any actions instructed by the Action Level table Inducement advances to Continuous Warning Press the menu switch to display the SCR Information screen SCR Information screen message 4 2 Without treat ment engine power will be derated Move the machine to the safe place and contact your Ko matsu Distributor The duration of Continuous Warn...

Page 198: ...re engine power use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor This engine power restoration works only when the Inducement status is Severe Inducement and relieves back temporarily to the power deration of Low level Inducement The operator can restore engine power through the machine monitor For the engine power restoration proce...

Page 199: ...t Inducement status in the column 6 and information on the Urea SCR System condition 4 and the current status of In ducement 5 Warning The audible alert sounds in short and sharp beeps The KDPF system caution lamp 1 lights up in red The action level L03 lights up in red at action level dis play 3 Press the menu switch to display the SCR Information screen SCR Information screen message 5 1 Please ...

Page 200: ...beeps The KDPF system caution lamp 1 lights up in red DEF system caution lamp 2 lights up in red The action level L03 lights up in red at action level dis play 3 Press the menu switch to display the SCR Information screen SCR Information screen message 5 3 Engine power is under deration Due to the reduction of engine power the machine normal operation will be limited The duration time of Low level...

Page 201: ...ent strategy when abnormality is found in the EGR Valve System by the Urea SCR system If any abnormality is detected in the EGR Valve System through the Urea SCR system the Inducement strategy is activated The inducement strategy progresses in 4 levels Warning Continuous Warning Low level Inducement and Severe In ducement The Inducement strategy includes visual alert by the Engine system caution l...

Page 202: ...out taking any actions instructed by the Action Level table Inducement advances to Continuous Warning Continuous Warning The audible alert sounds in repetition of three beeps and a pause The Engine system caution lamp 1 lights up in red The DEF system caution lamp 2 lights up in yellow The action level L03 lights up in red at action level dis play 3 Press the menu switch to display the SCR Informa...

Page 203: ...en message 5 4 Engine power is under heavy deration Due to the further deration of engine power capability the machine will be limited further If the restoration of the KDPF system abnormality is not performed engine performance will kept be derated Engine power can be restored temporarily from power derate This engine power restoration works only when the Inducement status is Severe Inducement an...

Page 204: ...vere In ducement The maximum duration is limited to 30 minutes in each restoration operation and only 3 operations are allowed unless all the abnormalities of the Urea SCR system are corrected If the system advances to Severe Inducement utilize Temporary Restoration from Inducement immediately Procedure to activate Temporary Restoration from Inducement 1 Press the menu switch 1 to display the SCR ...

Page 205: ... Engine power Recov ery window is displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Low level Inducement for the maximum of 30 minutes The remaining time minutes seconds of Temporary Re storation from Inducement is displayed in the column 4 on the SCR Information screen If it is decided NOT to activate Temporary Restoration from I...

Page 206: ...an the amount of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the previous Inducement and whether the new abnormality abnormalities is the same as the previous ones or not it is judged as a recurrence If a recurrence occurs Severe Inducement will be activated Inducement in the recurrence ...

Page 207: ...taminate DEF pump and DEF injector which will cause the failure of the machine Never reuse the DEF filter KOMTRAX KOMTRAX equipment may not be mounted on machines for some countries or regions OUTLINE OF KOMTRAX KOMTRAX is a system that remote controls machines equipped with the KOMTRAX device by using satellite communication or portable radio communication Each customer can check the machine info...

Page 208: ...3 246 When using the battery disconnect switch turn the starting switch to OFF position and turn the battery dis connect switch key to OFF position Then remove the key When the battery disconnect switch is turned to OFF position it is possible to prevent power consumption of the battery but the functions of KOMTRAX stop at the same time For operation of the battery disconnect switch see BATTERY DI...

Page 209: ...utor judges that it is necessary to suspend KOMTRAX com munication If you do not observe the above rules neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages OPERATION EXPLANATION OF COMPONENTS 3 149 ...

Page 210: ...cooler Check that there is no dirt or dust accumulated around the engine radiator or aftercooler Check also that there is no combustible material dry leaves twigs etc accumulated around the battery or muffler turbo charger or other high temperature parts of the engine or dump body equipped with dump body heating specification Remove any dirt or combustible materials that are found For the method t...

Page 211: ...eaner mounting bolts for looseness Check for the loose bolts If loose tighten them 13 Check the dump body mount rubbers Check for any cracks caught foreign objects or loose bolts 14 Check for damage to the handrail and loose bolts If any breakage is found repair it and retighten the bolts 15 Check for damage to the lamp and rear view camera If any part is damaged replace it with new one Clean off ...

Page 212: ...eck the items in this section before starting the engine each day METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK 1 Open fuel drain valve cover 1 2 Place a container to receive drained oil under drain valve 2 at the bottom of the fuel tank 3 Loosen drain valve 2 to drain all the sediment and water accumulated at the bottom together with fuel 4 When clean fuel flows out close drain valve 2 ME...

Page 213: ...n dicator 1 does not indicate 7 5 kPa 30 INCHES H2O 0 076 kg cm2 1 08 PSI If the red line indicates 7 5 kPa 30 INCHES H2O 0 076 kg cm2 1 08 PSI clean or replace the air cleaner element immediately For the cleaning method of the element see METHOD FOR CHECKING CLEANING AND REPLACING AIR CLEANER 4 14 2 After cleaning or replacing press the top of dust indicator 1 to return the red line to its origin...

Page 214: ...es out from drain hose 4 then remove drain valve 1 4 Apply a suitable amount of grease to O ring 5 When doing this be careful not to allow the grease to ad here to water drain port 6 and threaded portion 7 of the drain valve 5 Tighten drain valve 1 by hand until it contacts the bottom of transparent cup 2 6 Remove the fuel container 7 Fill the fuel tank with fuel 8 Bleed air from the fuel system F...

Page 215: ...ft for looseness If any bolt is loose retighten it Tightening torque 245 to 309 Nm 25 to 31 5 kgm 2 Check that there are no loose or broken cab mount pins 2 right and left 1 place each METHOD FOR CHECKING COOLANT LEVEL ADDING COOLANT k k WARNING Do not open the sub tank cap unless necessary When checking the coolant level check the reservoir tank when the engine is cold Immediately after the engin...

Page 216: ...METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work REMARK When checking the oil level after the engine has been operated wait for at least 15 minutes after stopping the engine before checking If the machine ...

Page 217: ...add oil through oil filler port F If the oil level is higher than H decrease it to a proper level according to the following procedure 1 Remove the bolts and remove cover 1 2 Place the oil container right under the drain plug to re ceive the drained oil 3 Remove drain plug 2 4 Install the drain hose on the back of the hydraulic tank cover 5 Loosen drain valve 3 gradually with care not to get splas...

Page 218: ... if there is any accumulation of combustible material around the battery and remove such combusti ble material METHOD FOR CHECKING FUEL LEVEL ADDING FUEL k k WARNING When adding fuel be careful not to let the fuel overflow This may cause fire Always wipe up all the spilled fuel If fuel spills onto dirt and sand sticking to the machine remove it and dirt and sand together Fuel is highly flammable a...

Page 219: ...F may leak through the breather When the ambient temperature is low and DEF may freeze do not add it more than line 8 of sight gauge 4 Be careful of the DEF line to be added when performing operations on a slope or traveling on a rough ground When the remaining DEF level is low it may become the warning level if DEF pump sucks air or if DEF level suddenly drops If DEF is stored in unspecified cont...

Page 220: ...ler cap 3 and surrounding area Turn the cap 3 counterclockwise The caps of DEF tanks are blue as required by emission regulations 5 By sight gauge 4 add DEF through the filler port until float 5 reaches line F 6 Refill capacity of DEF tank 33 ℓ Line 7 in the sight gauge indicates approximately 5 ℓ be low line F and line 8 indicates approximately 10 ℓ Line 8 is the max adding line when DEF may free...

Page 221: ...blue cap METHOD FOR CHECKING TIRE PRESSURE Check the tire inflation pressure before starting work while the tires are cold 1 Measure the air pressure with an air pressure gauge 2 Adjust the inflation pressure properly The proper inflation pressure is shown below Tire size Inflation pressure kPa kg cm2 Front wheel Center wheel Rear wheel 29 5 R25 standard 375 3 8 390 4 0 390 4 0 875 65R29 option 44...

Page 222: ...tion of the secondary steering motor is found ask your Komatsu distributor for repair k k CAUTION If the machine is steered during self check it may move Do not steer the machine during self check Self check of the secondary steering is not performed in the following cases In this case perform Check of automatic secondary steering After the starting switch is turned ON without starting the engine ...

Page 223: ...ON position 6 Set parking brake switch 3 to TRAVEL position and check that the secondary steering motor operates in 1 sec ond 7 After checking set parking brake switch 3 to PARKING position 8 Turn the starting switch to OFF position REMARK While the secondary steering motor is in operation secondary steering pilot lamp 4 lights up If the secondary steering motor operates 1 minute or longer seconda...

Page 224: ... or backward Sit with your back against the backrest when adjusting the re clining angle If your back is not on the backrest it may sud denly return to the original position Adjustment amount Forward tilt 10 any degree is acceptable if it is greater than 10 Backward tilt 18 METHOD FOR TILTING SEAT Operate the tilt adjustment lever upward set the front of the seat cushion to the desired height then...

Page 225: ... used for this adjustment NOTICE Avoid using the seat cushion adjustment lever continuously for 1 minute or longer since such practice can damage the air compressor The suspension should be adjusted in proportion to the operator s weight to protect the operator 1 Press down the seat cushion adjustment lever and lower the seat to the lowest position 2 Pull up the seat cushion adjustment lever fully...

Page 226: ... to the desired level The suspension should be adjusted in proportion to the operator s weight to protect the operator Al ways perform this adjustment before starting the operation If you stand up from the seat or try to change the load applied to the seat during adjustment the air in the suspension may be released METHOD FOR ADJUSTING SEAT CUSHION IN FORE AFTER DIRECTION Operate the fore aft adju...

Page 227: ...rd tilt 30 backward tilt 10 METHOD FOR ADJUSTING LUMBER SUPPORT Turn the lumber support adjustment knob to the right or left and give proper tension to the waist part METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS Adjust the damping force of the suspension damper by operating the suspension damper hardness adjustment knob To increase the damping force direct knob toward outside A of the seat To d...

Page 228: ... your safety Loosen mirror mounting bolt 1 and nut 2 then adjust the mirror to the position that assures the best view from the opera tor s seat Adjust the position and angle of each mirror so that it re flects a sight 200 mm above the ground and up to 1500 mm In the adjustment make sure that a part of the machine al so comes into view View range Mirror A Machine s front side must be in view Mirro...

Page 229: ...When the direction of the camera is changed due to an accident setting must be done again Contact your Komatsu distributor Install only the Komatsu genuine camera As shown in the figure park the unloaded machine on a flat ground directing it straight forward OPERATION MACHINE OPERATIONS AND CONTROLS 3 169 ...

Page 230: ...m that machine width guide line 3 matches with tire outside width 1 and distance guide line 4 matches with body rear end 2 When the reference line is abnormal change its setting to Non display and contact your Komatsu distributor HANDLE SEAT BELT k k CAUTION The three point seat belt is installed to this machine For the safety always wear the shoulder belt even if it can be removed from the waist ...

Page 231: ... 1 is removed from waist belt buckle tongue 3 Detail A When shoulder belt tongue 1 is inserted into waist belt buckle tongue 3 2 When the winding device is locked tilt the back cushion 5 backward by operating lever 4 The shoulder belt becomes loose and the winding lock is canceled If the lock cannot be canceled shoulder belt tongue 1 cannot be pulled out after performing above operation contact yo...

Page 232: ...manufactured date It is the start of the 5 year period It is not the start of the 3 year period of actual usage METHOD FOR FASTENING AND UNFASTENING SEAT BELT Fit the seat belt so that it fits tightly without being too tight 1 Sit in the seat and depress the brake pedal fully Under this condition adjust the seat so that your back is fitted to the backrest 2 Sit in the seat pull the right side of t...

Page 233: ...ious per sonal injury or death You can adjust the lengthwise position and height of the steering wheel 1 Raise the lever to FREE position F and adjust the steer ing wheel to a desired position 2 Push down the lever to LOCK position L and fix the steering wheel securely Tilting amount Forward 5 backward 10 Telescopic adjustment amount Upward 20 mm downward 20 mm NOTICE Do not operate the lever with...

Page 234: ...L position N and that the parking brake switch is in PARKING position Before standing up from the operator s seat be sure to set the parking brake switch to PARKING posi tion 1 Check that battery disconnect switch 1 is in ON position I 2 Check that parking brake switch 2 is in PARKING posi tion MACHINE OPERATIONS AND CONTROLS OPERATION 3 174 ...

Page 235: ...down secondary switch 5 is in NORMAL position the cover is closed 6 Insert the key into starting switch 6 and turn it to ON posi tion B 7 Check that the machine monitor operates as follows 1 Centralized warning lamp 7 and pilot lamp 8 light up for 2 seconds and go out for 1 second OPERATION MACHINE OPERATIONS AND CONTROLS 3 175 ...

Page 236: ... engine is started the battery voltage may suddenly drop depending on the temperature and the battery condition In such case the machine monitor may go out temporarily or restart but it is not a trouble In approximately a second the rear view monitor displays soft version 12 for 5 seconds 6 In 2 seconds machine monitor 9 displays the stand ard screen If a password has been set the password input s...

Page 237: ...larm buzzer stops sounding and the engine can be started 8 If caution lamp 15 stays lit press the enter switch to iden tify the item lit in red and check it immediately For details of contents and check methods for caution lamp see WARNING DISPLAY 3 16 9 If the maintenance due time of that item has been passed maintenance time caution lamp 16 lights up in red for 30 seconds Press the menu switch c...

Page 238: ...oolant temperature is low preheating pilot lamp 2 lights up when the key in starting switch 1 is turned to ON position to inform the operator that preheating has been started automatically 1 Turn the key in starting switch 1 to ON position B If the engine coolant temperature is low preheating pilot lamp 2 lights up and the automatic preheating starts 2 Keep the key in starting switch 1 at ON posit...

Page 239: ...tarts release the key in the starting switch 1 The key returns to ON position B automatically REMARK When the engine is started the battery voltage may suddenly drop depending on the temperature and the battery condition In such case the machine monitor may go out temporarily or restart but it is not a trouble 5 Do not operate the accelerator pedal immediately after starting the engine Run the eng...

Page 240: ...ed For the preheat time see the table in METHOD FOR STARTING ENGINE 3 177 2 After the preheating time passes turn starting switch key 1 to START position The engine starts If the engine cannot be started with the above procedure wait for at least 2 minutes then repeat the procedure again from step 1 REMARK When the key in starting switch 1 proceeds through OFF posi tion the indicator of tachometer...

Page 241: ...rted in this condition the dump body float caution lamp will light up Return the dump control lever to HOLD position then move it to FLOAT position to cancel the dump body HOLD condition When the dump body is set to FLOAT condition the body float caution lamp will go out METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF ENGINE When starting the engine check that the engine causes no abno...

Page 242: ...ion unnecessary sudden stops and sudden changes in direction of the machine AUTOMATIC WARM UP FUNCTION This machine is equipped with the automatic warm up function While the AISS LOW switch is in OFF position or when the engine coolant temperature is low the low idle speed is automatically increased to cut down the warm up time REMARK Turning AISS LOW switch to ON position stop the automatic warm ...

Page 243: ...ed so never stop the engine suddenly except in emergency Allow the engine to cool down gradually before stopping it Always lower the dump body and set the dump lever to FLOAT position then stop the engine 1 Set the gear shift lever to NEUTRAL position N and set the parking brake switch to PARKING position 2 Lower the dump body and set the dump lever to FLOAT position 3 Run the engine at low idle f...

Page 244: ...nd spot behind the machine so be extremely careful when driving the machine in re verse 1 Check that there is no warning display on the machine monitor 2 Fasten the seat belt 3 Set dump lever 1 to FLOAT position Check that the dump body float caution lamp is OFF If the dump body float caution lamp is lit operate the dump lever to HOLD position then operate it to FLOAT posi tion to cancel the dump ...

Page 245: ...amp may light up and the alarm buzzer may sound Always release the accelerator pedal when moving the gear shift lever from positions NEUTRAL N to REVERSE R or FORWARD D or F 8 Depress accelerator pedal 5 to start the machine NOTICE If the gear shift lever is shifted to a position other than NEUTRAL position N when the parking brake has not been released the centralized warn ing lamp will light up ...

Page 246: ...erse stop the machine completely and run the engine at low idle when shifting the direction of travel After moving the gear shift lever do not accelerate until it is detected that the transmission clutch is engaged Do not operate the gear shift lever with the accel erator pedal depressed This will cause a big shock and will also reduce the service life of the machine METHOD FOR STOPPING MACHINE k ...

Page 247: ...edal perform the following k k WARNING When the machine stops chock the wheels immediately If the parking brake is used to make an emergency stop the performance of the parking brake may drop below the standard value so it is necessary to repair and adjust the parking brake Ask your Komatsu distributor to perform this work OPERATION MACHINE OPERATIONS AND CONTROLS 3 187 ...

Page 248: ...ible METHOD FOR SHIFTING GEARS k k WARNING When traveling and particularly when traveling downhill never set the gear shift lever to NEUTRAL position N If the gear shift lever is set to NEUTRAL position N while driving a machine at travel speed of above 4 km h or trav eling downhill the gear speed is not changed to neutral The centralized warning lamp flashes and the alarm buzzer sounds Always set...

Page 249: ...lerator pedal 2 gradually to accelerate the ma chine The lockup clutch is engaged and the direct drive starts If the machine is accelerated further the transmission will auto matically shift up Downshift deceleration Release decelerator pedal 2 The machine is decelerated and the transmission automatically shifts down Downshift inhibit If the gear shift lever is operated when the machine is traveli...

Page 250: ...ft down to travel downhill In this case the centralized warning lamp lights up and alarm buzzer sounds It the retarder oil temperature caution lamp does not go out even when the transmission is shifted down stop the machine immediately set the gear shift lever to NEUTRAL position N run the en gine at 1800 rpm and wait the retarder oil temperature caution lamp goes out If the retarder brake loses i...

Page 251: ...comes within the white range BRAKE PERFORMANCE CURVE How to read the graph Example Downhill distance 1500 m Traveling resistance 11 Grade resistance 13 rolling resistance 2 Payload 40 t Obtain the maximum permissible speed and the gear speed range from the graph when traveling downhill under the above conditions 1 Use the brake performance curve for downhill distance of 1500 m 2 Starting from poin...

Page 252: ...is one guideline determined from the retarder brake performance so on an actual jobsite determine a safe travel speed below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the white range when traveling Terminology of the graphs Gross vehicle weight tons Gross vehicle weight tons Empty Empty Load Load Total resistan...

Page 253: ...Brake performance Downhill distance 450 m Brake performance Downhill distance 600 m OPERATION MACHINE OPERATIONS AND CONTROLS 3 193 ...

Page 254: ...Brake performance Downhill distance 900 m Brake performance Downhill distance 1500 m MACHINE OPERATIONS AND CONTROLS OPERATION 3 194 ...

Page 255: ...OD FOR TURNING MACHINE k k WARNING If the machine is turned at high speed or on a steep slope there is danger that it will tip over so do not operate the steering in such conditions k k CAUTION If the steering wheel has been turned fully to the right or left do not continue to apply force to turn it further The oil temperature inside the steering hydraulic circuit will rise and cause overheating W...

Page 256: ...failure OPERATE WITH INTER AXLE DIFFERENTIAL LOCK During traveling on dry sandy ground etc tire may slip and the machine may be vibrated up and down In this case use the inter axle differential lock switch before driving the machine NOTICE Do not use inter axle differential lock If inter axle differential lock is used it will be more difficult to operate the steering wheel It will become more diff...

Page 257: ...s turned ON before running down on a slope The ARAC system may not assure thorough braking force to slow down depending on a slope incli nation load weight and selected gear speed In that case use the retarder control lever and brake pedal to slow down to a safe speed The tires may be locked when the dump truck is running on a slippery hauling road and the ARAC system is in service If that happens...

Page 258: ...he accelerator pedal is released Brake pedal The wheel brakes can be operated with the brake pedal even while ARAC system is in operation Retarder pilot lamp The retarder pilot lamp lights up when ARAC system operates and when the retarder is operated with the re tarder control lever If the engine speed is low even when ARAC system is actuated the retarder pilot lamp may not light up OPERATION OF ...

Page 259: ...as trouble and cannot be controlled securely the machine monitor displays an action level and the system may stop operation depending on the failure condition The machine may not travel safely on an extremely slippery road or a steep slope even if the KTCS operates If a wheel is stuck in the ground and the machine cannot escape while the KTCS operates pull out the machine with a bulldozer etc Expl...

Page 260: ...eration Brake pedal If the brake pedal is depressed while the KTCS is in operation the KTCS system stops operation KTCS system caution lamp If the KTCS system has a trouble caution lamp is displayed on the machine monitor OPERATION OF KTCS SYSTEM The KTCS system is enabled when the KTCS Setting is turned ON When KTCS system senses slip of the front wheel or center wheel KTCS operates At this time ...

Page 261: ...the dump lever to FLOAT position regardless of whether the machine is loaded or not loaded If the gear shift lever is shifted to a position other than NEUTRAL position N when the dump lever is not at FLOAT position the centralized warning lamp will light up and the alarm buzzer will sound During loading operations do not apply the parking brake Apply the retarder brake To maintain the operation of...

Page 262: ...ling fluid materials such as finely crushed soil When removing or installing the tailgate consult your Komatsu distributor METHOD FOR DUMPING k k WARNING Always follow the instructions of the signalman when performing dumping operations When dumping large rocks operate the dump body slowly When performing inspection or maintenance with the dump body raised always use the body pivot pin and lock th...

Page 263: ...ximum tilt angle release the accelerator pedal in order to avoid any impact load on the hydraulic circuit or hoist cylinder REMARK When the dump body is not seated the engine speed is limited to 1800 rpm or below to protect the work equipment pump And if the dump body is not lowered when the steering oil temperature is low 25 C or below the en gine speed is limited to 1500 rpm or below During the ...

Page 264: ...ver lock knob Chock the tires to prevent the machine from moving Always remove the pin from rear mounting position and insert it in the position for tilting before removing the cab mount Do not perform the cab tilt operation in the strong wind Precautions for cab tilt operation Do not perform the cab tilt operation when the machine is loaded Do not stand under the cab during the cab tilt operation...

Page 265: ... and fix it according to the following procedure 1 Remove mounting bolts 3 of R H bracket 2 2 Turn bracket 2 counterclockwise 90 and fix it with the bolts 3 Remove mounting bolts 5 of L H bracket 4 4 Flip up guard 1 5 Turn bracket 4 180 and hitch it on rear guard 6 6 Fix bracket 4 with the bolts OPERATION MACHINE OPERATIONS AND CONTROLS 3 205 ...

Page 266: ...r tilting 3 Remove cab mounting bolts 9 8 pieces 4 Open the engine hood 5 Install the sling to hooks 10 installed to the front of the cab on both right and left sides 6 Sling the cab 7 After tilting up the cab fix it in position with lock bar 11 Make sure that lock bar 11 is installed in the correct di rection and lock it securely with lock 12 MACHINE OPERATIONS AND CONTROLS OPERATION 3 206 ...

Page 267: ...veling on muddy or soft ground consider the loaded condition of the machine and be extremely careful not to let the tires slip or the machine spin and sink into the ground If the engine should stop when the machine is traveling stop the machine immediately then move the gear shift lever to NEUTRAL position N and start the engine again If the centralized warning lamp and pilot lamp for any EMERGENC...

Page 268: ...achine on a slope set the parking brake switch to PARKING po sition and chock the wheels to prevent the machine from moving If the gear shift lever is touched by mistake the ma chine may move suddenly and this may lead to a seri ous injury or death Before standing up from the operator s seat always set the parking brake switch securely to PARKING position The retarder must not be used as a parking...

Page 269: ...hine monitor If the engine has overheated do not stop the engine suddenly Run it at a mid range speed to cool it gradu ally before stopping LOCK Always lock the following places 1 Fuel tank filler cap 2 Engine hood 3 Battery box 4 DEF filler port cover 5 Tool box 6 Fuel drain valve cover 7 Cab door REMARK Use the starting switch key to lock and unlock all these places METHOD FOR OPENING AND CLOSIN...

Page 270: ... level ground and stop the en gine When opening the engine hood do not release the handle until the lock plate is set in LOCK posi tion securely When closing the engine hood hold the handle securely since the engine hood may moves down because of its own weight If the engine hood is not locked it may close suddenly because of wind etc Immediately after the engine is stopped the engine hood and the...

Page 271: ...ou and unlock it 4 Keep lever 2 depressed hold handle 3 of the hood and pull it up to open Open the hood until it is fixed securely METHOD FOR LOCKING ENGINE HOOD 1 Hold hood knob 1 operate lever 2 and unlock 2 Lower the hood 3 Insert the key into the key slot OPERATION MACHINE OPERATIONS AND CONTROLS 3 211 ...

Page 272: ...NING BATTERY INSPECTION COVER 1 Insert the key into the key slot 2 Turn the key clockwise to unlock Position A OPEN Position B CLOSE LOCK 3 Push in the key groove and open up the cover METHOD FOR LOCKING BATTERY INSPECTION COVER 1 Close the cover and insert the key into the key slot MACHINE OPERATIONS AND CONTROLS OPERATION 3 212 ...

Page 273: ...ment to the ground stop the engine then perform the operation When opening it do not release the handle until the stay is set in the lock position securely When closing it hold the handle securely since the DEF tank filler cap cover may move down be cause of its own weight If it is not locked it may close suddenly because of wind etc METHOD FOR OPENING DEF TANK FILLER PORT COVER 1 Insert the key i...

Page 274: ...DEF TANK FILLER PORT COVER 1 Close the cover and insert the key into the key slot 2 Turn the key clockwise and remove it Position A OPEN Position B CLOSE LOCK METHOD FOR OPENING AND CLOSING TOOL BOX COVER PROCEDURES FOR OPENING TOOL BOX COVER 1 Insert the key into the key slot MACHINE OPERATIONS AND CONTROLS OPERATION 3 214 ...

Page 275: ...ose the cover and turn the handle clockwise 2 Insert the key into the key slot 3 Turn the key counterclockwise and remove it Position A OPEN Position B CLOSE LOCK METHOD FOR OPENING AND CLOSING FUEL TANK DRAIN VALVE COVER PROCEDURES FOR OPENING FUEL TANK DRAIN VALVE COVER 1 Open the key cover 2 Insert the key into the key slot OPERATION MACHINE OPERATIONS AND CONTROLS 3 215 ...

Page 276: ...AIN VALVE COVER 1 Close the cover and insert the key into the key slot 2 Turn the key clockwise and remove it Position A OPEN Position B CLOSE LOCK 3 Close the key cover METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR LOCK When opening the door locked door 1 Insert the key into the key slot MACHINE OPERATIONS AND CONTROLS OPERATION 3 216 ...

Page 277: ...omatically 3 Pull the door handle and the door opens When locking 1 Close the door and insert the key into the key slot 2 Turn the key clockwise and the door is locked Position A OPEN Position B CLOSE LOCK The key returns to position C automatically 3 After locking pull out the key OPERATION MACHINE OPERATIONS AND CONTROLS 3 217 ...

Page 278: ...r a long distance there will be a remarkable increase in the generation of heat in the tire This may cause premature damage to the tire so observe the following Travel only unloaded Check the tire inflation pressure before starting for the day when the tires are cold and adjust to the follow ing inflation pressure Do not reduce the tire inflation pressure when traveling Tire size Inflation pressur...

Page 279: ...engine at low speed from time to time and per form cooling or dry heating for several minutes When the temperature inside the cab is low the air condi tioner may not work In this case circulate recirculation air to warm the inside of the cab After that turn the air conditioner switch ON the air conditioner will work If any abnormality is detected in any equipment or sensor used on the air conditio...

Page 280: ...ch 6 FRESH RECIRC air selector switch 7 Display monitor 8 Air conditioner switch 9 Defroster switch OFF SWITCH The OFF switch is used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen HANDLE AIR CONDITIONER OPERATION 3 220 ...

Page 281: ...Air flow high TEMPERATURE CONTROL SWITCH Use the temperature control switch to adjust the temperature inside the cab The temperature can be set between 18 to 32 C Press the switch to raise the set temperature press the switch to lower the set temperature The set temperature is indicated on the display monitor The temperature is generally set at 25 C The temperature can be set in stages of 0 5 C Mo...

Page 282: ...tor switch is pressed the LC display on the monitor display switches and air blows out from the vents displayed During automatic operation the vents are automatically selected A Rear window glass vent 2 places B Face vent 4 places C Foot vent 1 place D Front window glass vent 2 places LCD display Air vent mode Vent Remarks A B C D Face vent Face vent foot vent Foot vent Foot vent Defroster vent No...

Page 283: ...itch to switch the air source between recirculation of the air inside the cab and in take of fresh air from the outside During automatic operation the selection of inside air RE CIRC and outside air FRESH is performed automatically RECIRC Outside air is shut off and only air inside the cab is circulated Use this setting to perform rapid cooling of the cab or when outside air is dirty FRESH Outside...

Page 284: ...y heating ON or OFF Press air conditioner switch when the fan is operating when air flow level is shown on the display monitor The air conditioner is switched ON and starts to work Press the switch again to stop the air conditioner Air conditioner cannot be operated while the fan is stop ped DEFROSTER SWITCH This defroster switch is used to select the defroster mode HANDLE AIR CONDITIONER OPERATIO...

Page 285: ... OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of operation as desired METHOD FOR AUTOMATIC OPERATION 1 Turn the auto switch ON Set temperature A and air flow B are displayed 2 Use temperature control switch to set to the desired tem perature The air flow combination of vents and selection of fresh or recirculated air is automatically sel...

Page 286: ...ly limited to prevent cold air from blowing out METHOD FOR STOPPING AUTOMATIC OPERATION Press OFF switch The air conditioner stops METHOD FOR MANUAL OPERATION 1 Press fan switch and adjust the air flow When doing this check that temperature setting A and air flow B are displayed HANDLE AIR CONDITIONER OPERATION 3 226 ...

Page 287: ...selector switch and select the desired vents When this is done the display for vent C of the monitor changes according to the selection 5 Press FRESH RECIRC air selector switch and select recir culation of the air inside the cab RECIRC or intake of fresh air from outside FRESH OPERATION HANDLE AIR CONDITIONER 3 227 ...

Page 288: ...old air blowing to the face and warm air blowing to the feet set as follows 1 Press fan switch and adjust the air flow When doing this check that temperature setting A and air flow B are displayed on the monitor 2 Press vent selector switch and set the vent display on the display monitor to the display shown in the figure HANDLE AIR CONDITIONER OPERATION 3 228 ...

Page 289: ...tch ON 4 Adjust fan switch temperature control switch and FRESH RECIRC air selector switch to the desired positions METHOD FOR OPERATING DEFROSTER 1 Press fan switch and adjust the air flow OPERATION HANDLE AIR CONDITIONER 3 229 ...

Page 290: ...and set vent display on the display monitor to F or G as shown in the figure 3 Press FRESH RECIRC air selector switch and set it to FRESH mode 4 Press temperature control switch and set temperature on the display monitor to 32 C of maximum heating 5 Adjust vents A so that the air blows onto the window glass HANDLE AIR CONDITIONER OPERATION 3 230 ...

Page 291: ... D is fixed 6 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air turn air conditioner switch ON OPERATION HANDLE AIR CONDITIONER 3 231 ...

Page 292: ... button 5 Preset button 6 Display selector button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX on it Press the button again to turn the power off BAND AUX SELECTOR BUTTON Press band AUX selector button to select the desired band or AUX Each time the button...

Page 293: ...nt is ready Each time this button is pressed BAL Balance TRE Treble and BAS Bass will be selected in this order If this button is pressed while BAS is displayed the sound adjustment will be canceled For the sound adjusting method see METHOD FOR CONTROLLING RADIO 3 234 DISPLAY A Band name AUX frequency clock and other character numeric information are displayed B Frequencies are displayed at steps ...

Page 294: ... 1 Press band AUX selector button 1 and select FM or AM 2 Press tuning time adjustment button 2 to adjust the fre quency Press the button and the frequency increases press the button and the frequency decreases Hold down the button and the frequency increases continuously hold down the button and the fre quency decreases continuously Hold down the button and release it then the fre quency increase...

Page 295: ...1 of pre set button 1 and the preset number P 1 is displayed After the preset number flashes 3 times the frequency is dis played and then registered to preset number P 1 METHOD FOR ADJUSTING SOUND BALANCE 1 Press sound control button 1 to light up BAL on the dis play You can adjust the sound balance 2 Press tuning time adjustment button 2 to adjust the sound balance Press the button and the speake...

Page 296: ...play selector button 1 to flash the HOUR display portion You can adjust the hour 3 Press tuning time adjustment button 2 to adjust the hour If you press button HOUR display increases by 1 If you press button HOUR display decreases by 1 4 Press display selector button 1 to flash the MINUTE dis play portion You can adjust the minute 5 Press tuning time adjustment button 2 to adjust the minute If you...

Page 297: ...such as dry leaves chips pieces of paper and coal dusts Take appropriate actions to prevent fire The temperature around the dump body becomes high as shown in the figure Remedy to prevent fire When loading the combustible materials change the machine specification to the specification without dump body heating Contact your Komatsu distributor for changing the machine specification to the specifica...

Page 298: ...d continues in a straight line If there are curves in high speed travel areas 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 mini mum of 12 m to 15 m Make the radius of curves as large as possible Make the road wider at curves than it is in straight areas Make the surface of the road slightly higher...

Page 299: ...cting the trailer refer to the weight and dimensions shown in SPECIFICATIONS 5 2 Note that the SPECIFICATIONS for the weights and dimensions for transportation differ according to the type of tires and type of dump body METHOD FOR SECURING MACHINE After loading the machine in the specified position secure it in place as follows 1 Set the parking brake switch to PARKING position to ap ply the parki...

Page 300: ...g operation always stop the engine apply the parking brake and use the articulation lock to prevent the front frame from articulating Never enter the area under or around a lifted machine Never try to lift the machine in any other posture or by using any other lifting equipment than those given in the following procedures There is a danger that the machine loses its balance NOTICE This method of l...

Page 301: ...ont axle HM400 5 35055 kg 20035 kg 7690 kg 7340 kg 2287 mm PROCEDURE FOR LIFTING MACHINE Lifting work is allowed for only machines having lifting marks When performing the lifting operation place the machine on a firm level ground and do as follows 1 Start the engine set the machine in the straight travel posture OPERATION TRANSPORTATION 3 241 ...

Page 302: ...or s compartment set the articulation lock to LOCK position L to prevent the front frame and rear frame from articulating 5 Select wire ropes slings spreader beams and other lifting tool to match the weight of the machine and fit the wire ropes to the lifting hooks at lifting hook marks at the front of the front frame and the rear of the rear frame TRANSPORTATION OPERATION 3 242 ...

Page 303: ... damaged 6 Fit protector blocks at contact points 3 between the lifting tool and the dump body to prevent damage to the lifting tool 7 When the machine comes off the ground raised 100 to 200 mm stop the lifting operation once check carefully that the machine is balanced and that the wire ropes are not loose then continue the lifting operation slowly OPERATION TRANSPORTATION 3 243 ...

Page 304: ...nge interval and the concentration of Non Amine Engine Coolant AF NAC see METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4 19 DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break the devices in the tank The parts inside the tank may be affected Add DEF to the specified amount for cold weather below the level of when DEF may freeze For the specified amount of DEF see METHO...

Page 305: ...om getting inside the seal Place the machine on a firm dry ground If this is impossible park the machine on boards The boards prevent the tracks from freezing to the ground and allow the machine to move the next morn ing Open the drain valve at the bottom of the fuel tank to drain the water accumulated in the fuel system and prevent it from freezing In cold weather condition add DEF to the defined...

Page 306: ...DURING LONG TERM STORAGE k k 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 storage operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts At the same time charge the battery as well When operating the work equ...

Page 307: ...R system has any abnormality warning is displayed on the monitor screen and the audible alert sounds If SCR system has any abnormality stop the engine and then start it again If SCR system still has abnormality after the engine is restarted contact your Komatsu distributor If DEF is kept in DEF tank for more than 1 year ask your Komatsu distributor for replacement Dispose of drained DEF according ...

Page 308: ... lamp 2 goes out automatically and the fuel feed pump stops 3 If the engine stopped because of running out of fuel or if the supply pump is replaced after servicing of the fuel ho ses and tubes the fuel circuit is empty In such a case set fuel feed pump switch 1 to ON position again after the fuel feed pump stops the lamp goes out automatically When the lamp goes out air bleeding is completed 4 St...

Page 309: ...cape function is actuated the machine monitor shift indicator displays E and the trans mission shift range in turn METHOD FOR LOWERING DUMP BODY IN EMERGENCY When the dump body needs to be lowered to the seat while the engine cannot be started for some trouble per form the following procedure 1 Remove cover 2 from the rear of hydraulic tank 1 2 Loosen locknut 4 of manual lower valve 3 3 Turn grip ...

Page 310: ...ove a disabled machine to a place where it is possible to per form inspection and maintenance Do not tow it a long distance Consult your Komatsu distributor for information about towing a disabled machine This machine must not be towed except in emergencies However if it is avoidable to tow the machine take the following precautions When towing a machine tow it at a low speed of less than 2 km h a...

Page 311: ...safe If the parking brake is released the brakes will not work so pay careful attention to safety When towing down a slope use 2 towing machines One machine should be uphill from the disabled ma chine and should be connected with towing wire or a drawbar to pull the disabled machine back and keep it stable The other machine should tow the disabled machine downhill When engine runs If the transmiss...

Page 312: ... necessary to release the parking brake k k WARNING If any problem occurs in the brake hydraulic system there is a high probability that the wheel brakes will not work properly Always drive slow when towing the machine When releasing the parking brake check that the surrounding area is safe and always chock the all wheels before starting the work If the wheels are not chocked there is a danger tha...

Page 313: ...ving the battery first disconnect the cable from the ground normally the negative terminal When installing first connect the cable to the positive terminal If a tool touches the positive terminal and the chassis it is dangerous that it may cause a spark Be extremely careful If the terminals are loose it is dangerous that the de fective contact may generate sparks and it may cause an explosion Inst...

Page 314: ... positive charger clip of the charger to the positive terminal of the battery then connect the negative charger clip of the charger to the nega tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery capacity If the charger current is too high ...

Page 315: ...es of the jumper cables and clips should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected To prevent damage of the electric devices of the failed machine turn the starting switch of the failed machine to OFF position a...

Page 316: ...disconnect the jumper cables in the reverse of the order in which they were con nected 1 Remove the clip of jumper cable B from engine block E on the failed machine 2 Remove the clip of jumper cable B from the negative terminal of battery D on the normal machine 3 Remove the clip of jumper cable A from the positive terminal of battery D on the normal machine 4 Remove the clip of jumper cable A fro...

Page 317: ...artability at low temperature is poor if you touch the outside of the electric heater by hand after preheat ing it is not felt warm Defective wiring Check repair Wire breakage in electrical intake air heater Replace Defective operation of heater relay Replace Blown fuse of heater Replace PHENOMENA AND ACTIONS FOR CHASSIS For the remedies indicated with in the remedy column always contact your Koma...

Page 318: ...H and L H See WHEN REQUIRED Excessive difference in wear between right and left tires Replace tire Excessive difference in division of load between left and right wheels unbalanced load Make load uniform Excessive deformation of disc Overhaul brake When accelerator pedal has failed The accelerator pedal is equipped with a potentiometer that detects the amount that the accelerator pedal is depresse...

Page 319: ... tighten ing or breakage of oil pan pipe joint Check repair Disconnected broken wiring to sen sor Repair connect wiring Steam spurts out from the radiator sub tank pressure valve Lowered coolant level leakage of coolant Check add coolant See CHECKS BEFORE STARTING The coolant level caution lamp lights up and the machine monitor displays low coolant level as L01 Dirt or scale accumulated in cooling...

Page 320: ...piston ring cylinder liner Replace Low grade fuel being used Replace with specified fuel Defective turbocharger Check replace Water entry in the aftertreatment de vices Check repair Breakage of the aftertreatment devi ces Replace the aftertreatment devi ces Exhaust gas is black Clogged air cleaner element Clean or replace See WHEN REQUIRED Worn piston ring cylinder liner Check repair Defective com...

Page 321: ...ure code and then ask your Komatsu distributor for repair as necessary For the caution lamps and action levels see WARNING DISPLAY 3 16 For the operation methods and failure codes shown on Current Abnormality screen see OCCURRED FAIL URE CODE DISPLAY 3 18 Telephone number for the point of contact if an error occurs When the guidance icon is displayed on the monitor press the enter switch and the C...

Page 322: ......

Page 323: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 324: ...t remove the strainer while adding DEF PRECAUTIONS FOR WELDING When conducting weld repair turn the starting switch to OFF position and after confirming that the system operating lamp is turned off set the battery disconnect switch key to OFF position and pull it out Do not apply a voltage higher than 200 V continuously Connect grounding cable within 1 m of the area to be welded If grounding cable...

Page 325: ...CIRCUIT When hydraulic equipment is repaired or replaced or the hydraulic piping is disconnected the air must be bled from the circuit For the procedure to bleed air see WHEN REQUIRED 4 14 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace them with new parts When doing this be careful not to f...

Page 326: ...TS TO MATCH THE AMBIENT TEMPERATURE It is necessary to select fuel or lubricant according to the ambient temperature For detail see RECOMMENDED FUEL COOLANT AND LUBRICANT 7 4 PRECAUTIONS FOR MAINTENANCE MAINTENANCE 4 4 ...

Page 327: ...severe conditions high temperature high pressure and deteriorates with use Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in 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 p...

Page 328: ...sure fuel injection device requires high precision parts and lubrication if low viscosity fuel with low lubricating ability is used its durability may drop considerably And using fuel with high sulfur content can deteriorate the engine parts and KDPF catalyzer inducing failures decrease of the life and degradation in performance COOLANT AND WATER FOR DILUTION The coolant has the important function...

Page 329: ...ated in the same way Never use an iron or aluminum container when disposing DEF because toxic gas may develop and a chemical reaction may corrode the container Use a container made of resin PP PE or stainless steel when handling the fluid waste of DEF NOTICE If you add any additional additive agents or water to DEF the devices in the Urea SCR system may be detective and conformance to the exhaust ...

Page 330: ...EL Keep oil and fuel indoors to prevent any water dirt or other impurities from getting in When keeping drum cans for a long period lay the drums so that the filler ports of the drums are located in the lower part of the side to prevent moisture from being sucked in If drums have to be stored outside cov er them with a waterproof sheet or take other measures to protect them To prevent any change i...

Page 331: ... ON the power by mistake It is dangerous that causes an electric shock For the operation of the battery disconnect switch see BATTERY DISCONNECT SWITCH 3 115 It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is damaged This will cause an electrical leakage and may lead to malfunction of the machine Do not wash the inside of the operator s cab with wate...

Page 332: ...ter of bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 10 13 2 1 35 11 8 to 14 7 1 2 to 1 5 8 13 31 3 2 27 to 34 2 8 to 3 5 10 17 66 6 7 59 to 74 6 0 to 7 5 12 19 113 11 5 98 to 123 10 0 to 12 5 14 22 177 18 0 157 to 196 16 to 20 16 24 279 28 5 245 to 309 25 to 31 5 18 27 382 39 0 343 to 427 35 to 43 5 20 30 549 56 0 490 to 608 50 to 62 22 32 745 76...

Page 333: ... 41 216 22 0 177 to 245 18 0 to 25 0 36 46 245 25 0 197 to 294 20 0 to 30 0 42 55 294 30 0 246 to 343 25 0 to 35 0 Face seal Nominal No of threads a Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 9 16 18UN 19 44 4 5 34 to 54 3 5 to 5 5 11 16 16UN 22 74 7 5 54 to 93 5 5 to 9 5 13 16 16UN 27 103 10 5 84 to 132 8 5 to 13 5 1 14UNS 32 157 16 0 128 to 186 13 0 to 1...

Page 334: ...37 METHOD FOR LUBRICATING 4 37 METHOD FOR CHECKING DRIVE SHAFT 4 38 METHOD FOR CLEANING BREATHER 4 39 METHOD FOR CLEANING OVERFLOW HOSE 4 41 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 4 41 METHOD FOR CHECKING FRAME AND A ARM 4 44 METHOD FOR CHECKING FOOT BRAKE PERFORMANCE 4 44 METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE 4 45 METHOD FOR CHECKING PARKING BRAKE PERFORMANCE 4 45 METHOD FOR CHECK...

Page 335: ...8 EVERY 4000 HOURS MAINTENANCE 4 80 REPLACE DEFINED LIFE PARTS 4 80 METHOD FOR CHANGING OIL IN HYDRAULIC TANK 4 81 METHOD FOR CHECKING WATER PUMP 4 82 METHOD FOR CHECKING STARTING MOTOR 4 82 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIPING CLAMP HARD ENING OF RUBBER 4 83 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 83 METHOD FOR CHECKING EXHAUST P...

Page 336: ...17 If the air cleaner clogging caution lamp flashes and the machine monitor displays action level L01 during oper ation immediately after the outer element is cleaned replace the element even if the outer element has not been cleaned 6 times or the air cleaner element has not been used more than 1 year METHOD FOR CHECKING AIR CLEANER NOTICE Do not clean the outer element until the red line of the ...

Page 337: ...move cover 2 3 Hold the outer element 3 rock it lightly up and down and to the right and left and pull it out while turning it to the right or left 4 When outer element 3 is removed check that inner ele ment 4 does not come off or incline If it is at an angle push it straight to the bottom with your hand 5 After removing outer element 3 cover the inner element 4 with a clean cloth or tape to preve...

Page 338: ...lluminate the inside of outer element 3 with an electric bulb to check If any hole or thin place is found replace the outer ele ment 12 Remove the cover of cloth or tape attached to inner ele ment 4 13 Check the seal of the cleaned or new element for sticking of dusts and oil and wipe them off if any 14 Push outer element 3 straight into air cleaner body 5 with your hand Hold outer element 3 and r...

Page 339: ...too large remove cover 2 and then install it again 16 Push the head of dust indicator 8 to return the red line to its original position METHOD FOR REPLACING AIR CLEANER ELEMENT k k WARNING When pulling out the outer element from the air cleaner body make sure that you are standing on a firm place If your footing is not secure when you perform the operation there is danger of falling and suffering ...

Page 340: ...ner element 4 then quickly install the new inner element Install the inner element securely so that it does not move 9 Push new outer element 3 in straight with your hand into the air cleaner body Hold the element and rock it lightly up and down and to the right and left while pushing it in the element can be in serted easily 10 Install cover 2 as follows 1 Replace O ring 7 with a new one 2 Align ...

Page 341: ...nger of touching the fan Never enter in the rear part of the machine when the engine is running Place the machine on a level ground when cleaning or changing the coolant Clean the inside of the cooling system change the coolant according to the table below Coolant Interval for cleaning inside of cooling sys tem and changing coolant Non Amine Engine Coolant AF NAC Every 2 years or 4000 hours whiche...

Page 342: ...ches or drain it onto the ground surface Non Amine Engine Coolant AF NAC is already diluted with distilled water so it is not flammable For dilution see COOLANT AND WATER FOR DILUTION 4 6 Check the density with a coolant tester k k CAUTION If the air in the engine cooling system has not been completely bled it may cause damage of EGR cooler and it may lead to serious failure such as seizure inside...

Page 343: ...ank Add water until it fills the radiator sub tank and reservoir tank 8 Start the engine Run the engine at low idle for 10 minutes 9 Stop the engine and open drain valve 3 to drain the wa ter 10 After draining the water close drain valve 3 11 Fill with coolant through the coolant filler port of the sub tank up to the mouth of the port For the concentration of Non Amine Engine Coolant AF NAC see Co...

Page 344: ...CHECKING REFRIGERANT LEVEL FOR AIR CONDITIONER GAS k k WARNING If the refrigerant used in the air conditioner gets into your eyes or on your hands it may cause loss of sight or frostbite Never touch the refrigerant Do not loosen any part of the refrigerant circuit Do not bring any open flame close to any point where the refrigerant gas is leaking If the cooling effect is poor there is probably lac...

Page 345: ...ually from idle to 1500 rpm Overfilling No bubble is contained In this case both high and low pressures are high and cooling efficiency is low Insufficient Bubbles pass continuously METHOD FOR CLEANING AIR CONDITIONER AIR FILTERS 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 ...

Page 346: ...rting switch to OFF position A and turn the battery disconnect switch to OFF position Replace the slow blow fuse with the one of the same capacity Should the slow blow fuse is blown investigate the cause and take necessary actions 1 Turn the starting switch to OFF position A 2 Check that the system operating lamp goes out 3 Turn the battery disconnect switch to OFF position 4 Remove the slow blow ...

Page 347: ...ETHOD FOR CHECKING DUMP BODY Check that there are no cracks in the dump body 1 Clean the dump body so that you can check it easily 2 Check each portion of the dump body for damage If any cracks or abnormal wear are found perform repairs Contact your Komatsu distributor for details of the repair procedure METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER If the machine reacts to the rough ground co...

Page 348: ...t device is repaired or replaced or the hydraulic piping is disconnected bleed air from the brake circuit Always bleed air from the brake circuit in the order of the slack adjuster and wheel brake Warm the oil up to a temperature of at least 40 C before bleeding the air to make it easier to bleed the air Bleed the air from the slack adjuster front brakes and center brakes in the same way both on t...

Page 349: ... vinyl hose to either of the right and left bleeder screws 1 Use a commercially available vinyl hose 3 Place a container with oil in it 4 Put the other end of the hose in the oil in the container ap proximately 50 mm 5 Depress the brake pedal and keep it 6 Loosen bleeder screw 1 approximately 3 4 turns Oil containing air is discharged If the brake oil pressure caution lamp lights up while air is b...

Page 350: ...topped the oil level rises and oil is automatically supplied to the brake oil tank 7 Keep depressing the brake pedal and check that no bubble comes out through the vinyl hose 8 Next pull the retarder control lever and hold it 9 Loosen bleeder screw 1 approximately 3 4 turns Oil containing air is discharged Keep pulling the retarder control lever When no bubble is discharged through the vinyl hose ...

Page 351: ...lowing procedure 1 Tighten bleeder screw 2 2 Use sight gauge G to check if there is oil remaining in the brake oil tank If there is no oil in the tank stop the engine When the engine is stopped the oil level rises and oil is automatically supplied to the brake oil tank 7 Keep depressing the brake pedal and check that no bubble comes out through the vinyl hose 8 Tighten bleeder screw 2 securely 9 I...

Page 352: ...ils see METH OD FOR OPERATING CAB TILT 3 204 2 Bleed air through bleeder 4 3 After bleeding air lower the cab For details see METH OD FOR OPERATING CAB TILT 3 204 METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT k k WARNING To prevent the machine from moving set the parking brake switch to PARKING stop the engine then chock the wheels If any unusual noise occurs around the output shaft ...

Page 353: ... to Step 3 8 Measure the amount of movement L of the coupling by using the marks made in steps 4 and 7 If amount of movement L is more than 12 mm the rubber inside the output shaft may be deteriorated or damaged so ask your Komatsu distributor for disassembly and in spection of the internal parts of the output shaft SELECT AND CHECK TIRES k k WARNING If a tire or a rim is handled improperly the ti...

Page 354: ...ure from time to time with an air gauge while pumping up the tire If the rim is not fitted normally it may be broken and scattered while the tire is inflated Accordingly place a guard around the tire and do not work in front of the rim but work on the tread side of the tire Abnormal drop of inflation pressure and abnormal fitting of the rim indicate a trouble in the tire or rim In this case be sur...

Page 355: ...n repeat the tightening process during the first 50 hours after installation METHOD FOR ADJUSTING PARKING BRAKE k k WARNING To prevent the parking brake from being automatically applied during the adjustment operation raise the brake oil pressure to a sufficiently high level To prevent any other person from operating the parking brake switch hang a warning tag so that it can be seen clearly Never ...

Page 356: ...lacing if the clearance is 0 05 mm or less 11 After adjustment check the parking brake performance For the performance check method for the parking brake see METHOD FOR CHECKING PARKING BRAKE PERFORMANCE 4 45 If the machine moves ask your Komatsu distributor for inspection COLLECT LEAKED OIL FROM FLOATING SEAL REMARK Whenever oil flow out of the overflow hose collect the oil 1 Place the oil contai...

Page 357: ... there is clearance D between bottom face 1 of the bottom mounting and top face 2 of the frame ask your Komatsu distributor for adjustment 3 Lower the dump body and check that all 6 places of the bottom face of the bottom mounting are set evenly on top face 2 of the frame CHECKS BEFORE STARTING For the following items see OPERATION METHOD FOR CHECKING BEFORE STARTING 3 152 Drain water and sediment...

Page 358: ...eration Check horn operation EVERY 50 HOURS MAINTENANCE METHOD FOR LUBRICATING 1 Stop the engine 2 By using a grease pump pump in grease through the grease fittings 3 Check visually that the greasing has been performed properly 4 After greasing wipe off any old grease that is pushed out Perform the greasing work every day when operating in places where the grease flows out easily such as when trav...

Page 359: ...engine 3 By using a grease pump pump in grease through the grease fittings 4 Check visually that the greasing has been performed properly 5 After greasing wipe off any old grease that is pushed out Perform the greasing work every day when operating in places where the grease flows out easily such as when traveling through mud or water Steering cylinder left 2 places Steering cylinder right 2 place...

Page 360: ...Hoist cylinder right and left 2 places each Dump body hinge pin 2 places Hitch bearing 2 places METHOD FOR CHECKING DRIVE SHAFT MAINTENANCE PROCEDURE MAINTENANCE 4 38 ...

Page 361: ...rdingly wait until they have cooled down before starting the work When using compressed air there is a danger that dirt may scatter and cause personal injury Always wear protective equipment such as protective eyeglasses and dust mask When getting on or off the machine with carrying breather a tool etc place it once in part A to ensure your safety 1 Remove mud and dirt around the breather 2 Remove...

Page 362: ...ifferential case Front final drive case left It is located inside of the hydraulic tank Front final drive case right It is located rear inside of the right front wheel Center differential MAINTENANCE PROCEDURE MAINTENANCE 4 40 ...

Page 363: ...are installed to the front and center wheels Remove and clean all of the 4 hoses 1 Disconnect overflow hose 1 Front Center 2 Remove the soil and sand from inside of the disconnected hose with compressed air etc 3 Install overflow hose 1 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL Perform this procedure before operating the machine Inspect the battery electrolyte level according to the standard a...

Page 364: ...ng with purified water such as a commer cial battery fluid do the replenishment before the day s work on the next day METHOD FOR 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 k k WARNING If the battery is wiped with a dry cloth static electricity may cause a fire or explosion 1 Open the battery box cov...

Page 365: ...water e g commercially available replenish ment water for a battery so that the level reaches the bot tom of the sleeve UPPER LEVEL line A Correct level Electrolyte level is up to bottom of sleeve so surface tension causes electrolyte surface to bulge and pole plate appears to be warped B Low level Electrolyte level does not reach the bottom of sleeve so pole plate appears straight and not to be w...

Page 366: ...matsu distributor for details of the repair procedure METHOD FOR CHECKING FOOT BRAKE PERFORMANCE k k WARNING If the machine moves when the braking capacity is being checked it may lead to serious personal injury or death If the machine moves lower the engine speed immediately set the gear shift lever to NEUTRAL position N and set the parking brake switch to PARKING position NOTICE When checking be...

Page 367: ...lecting this can damage the inside of the transmission Check the braking capacity of the retarder brake as follows 1 Select F2 in D RANGE F1 START SETTING 3 68 in the user menu of the machine monitor 2 Stop the machine on flat ground and pull retarder control lever 1 fully 3 Set gear shift lever 2 in position D and increase the en gine speed gradually If the machine does not move when the engine s...

Page 368: ...shift lever to NEUTRAL position N METHOD FOR CHECKING WEAR OF PARKING BRAKE PADS k k WARNING Never put any oil or grease on the surface of the pad or disc Measure the thickness of pad 1 If thickness A is 1 5 mm or less contact your Komatsu distrib utor METHOD FOR CHECKING FUNCTION OF ACCUMULATOR For handling of the accumulator see HANDLE SUSPENSION CYLINDERS ACCUMULATOR AND GAS SPRINGS 2 38 If the...

Page 369: ...lights up when the brake pedal is depressed 4 times or less the gas pressure in the accumulator may be low Ask your Ko matsu distributor for inspection If the brake oil pressure caution lamp does not light up when the brake pedal is depressed 5 times the gas pressure in the accumulator is normal REMARK Check the function within 5 minutes after stopping the en gine If the engine is kept stopped the...

Page 370: ...il are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work Refill capacity of engine oil pan 50 ℓ Items to be prepared Container to receive drained oil Filter wrench When getting on or off the machine with carrying a filter oil container a tool etc place it once in part A to ensure your safety 1 Remove the bolts and remove cover 1 2 Place ...

Page 371: ...hen installing the filter cartridge tighten until the packing face is in contact with the filter head then tight en a further 3 4 to 1 turn 13 Add the specified amount of oil through oil filler port F 14 Run the engine at low idle for a while 15 Check that the engine oil level is in the specified range For the method to check the engine oil level see METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN...

Page 372: ...tems to be prepared Container to receive drained fuel Filter wrench When replacing the fuel main filter cartridge every 1000 hours replace the fuel prefilter cartridge first When getting on or off the machine with carrying a filter a tool etc place it once in part A to ensure your safety 1 Open the engine hood 2 Place a container under the fuel prefilter cartridge to receive the fuel 3 Loosen drai...

Page 373: ...leak from the packing so always tighten to the specified angle When tightening with a filter wrench be extremely careful not to dent or damage the filter cartridge 11 Install drain hose 4 12 After replacing the filter cartridge start the engine and run it at low idle for 10 minutes 13 Check the filter seal surface and the mounting face of the transparent cup for fuel leakage 14 If there is any lea...

Page 374: ... re move it carefully When getting on or off the machine with carrying oil a tool etc place it once in part A to ensure your safety 1 Remove plug G 2 Check that the oil level is near the lower edge of the plug hole 1 If the oil level in the front differential case is low add oil through oil filler port F Add oil until it overflows from the plug hole 2 If the oil level in the center or rear differe...

Page 375: ...tating the fan in the reverse direction beware extremely that dirt will not fly out and cloth etc will not be wound in the fan Since dust may blown up check that there is no person around while the fan is rotating in reverse You can blow off dirt sticking to the radiator or cooler by rotating the cooling fan in reverse 1 Seat the dump body and stop the engine 2 Open the engine hood 3 Turn the star...

Page 376: ...rmal rota tion mode automatically 7 Close the engine hood REMARK Blow off the dirt stuck in the radiator fins In a cold circumstance perform the cleaning by cooling fan reverse rotation within less than 5 minutes If the fan reverse rotation is performed for a long time DEF hose may freeze METHOD FOR CLEANING FIN WITH COMPRESSED AIR k k WARNING If compressed air high pressure water or steam hits yo...

Page 377: ... in radiator fins 3 and air conditioner condenser fins 4 with compressed air Steam or water may be used instead of compressed air However when performing powerful steam cleaning high pressure machine washing of the heat exchanger radia tor maintain sufficient distance from the machine If steam cleaning high pressure machine wash is per formed at close distance there is a danger that the internal f...

Page 378: ...he hose clamps for looseness METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE ADDING OIL k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work If there is remaining pressure inside the case the oil or plug may jump out Turn the plug slowly to release the pressure the...

Page 379: ...en the engine is running When replacing the filter wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter Do not bring any open flame close When using the fuel feed pump do not loosen the air bleeding plug of the fuel circuit The fuel circuit is pressurized while the fuel feed pump is operated If the air bleeding plug is loos ened at...

Page 380: ...he sealing surface of the filter head then tighten it 1 2 to 3 4 turn If the filter cartridge is tightened too far the packing will be damaged and this will lead to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing so always tighten the correct amount When tightening with a filter wrench be extremely careful not to dent or damage the filter 7 Fill the fuel t...

Page 381: ... FOR REPLACING FUEL TANK BREATHER ELEMENT k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Wait for the temperature to go down and then start the work When getting on or off the machine with carrying an element a tool etc place it once in part A to ensure your safety 1 Remove mounting bolts 2 of hydraulic tank top cover 1 2 Remove n...

Page 382: ...iner under the filter case to receive drained oil 3 Remove drain plug 3 of the filter head and drain the oil 4 After draining the oil tighten drain plug 3 5 Turn filter cartridge 4 counterclockwise by using the filter wrench and remove it 6 Clean the filter head 7 Apply clean oil to the sealing surface of the new filter car tridge 8 Install the new filter cartridge Tightening torque 54 to 64 Nm 5 ...

Page 383: ...stall the cap 17 Check that the oil level in the transmission case reaches the specified level If the oil level is low add oil REMARK When the air is bled from inside the case the transmission oil level becomes stable 18 Fix cover 2 with bolts 1 METHOD FOR CHANGING OIL IN TRANSMISSION CASE METHOD FOR CHANGING OIL IN BRAKE OIL TANK REPLACE BRAKE OIL FIL TER ELEMENT k k WARNING Immediately after the...

Page 384: ... oil container right under filter case 1 to receive the drained oil 6 Remove filter case 1 7 Remove the element 8 Clean the inside of the filter case Replace O ring 2 and backup ring 3 on the filter case with new parts apply thin film of clean oil to them then in stall them to filter case 9 Install the new element to the filter case 10 When installing the element thinly apply clean oil to its O ri...

Page 385: ...tall the cap 19 Perform the warm up operation of the engine until the torque converter oil temperature gauge goes to 40 C or above 20 When the torque converter oil temperature gauge rises to 40 C bleed the air from the brakes For the procedure to bleed air from the brake see METHOD FOR BLEEDING AIR FROM BRAKE CIR CUIT 4 26 NOTICE Do not re use the oil drained when bleeding the air It will cause da...

Page 386: ...actuation and releas ing more than 5 times Excessive grease will come out by this operation 11 Stop the engine 12 Wipe off the grease come out 13 Check the parking brake performance For the performance check method for the parking brake see METHOD FOR CHECKING PARKING BRAKE PER FORMANCE 4 45 If the machine moves during performance check adjust the parking brake For the method to adjust the parking...

Page 387: ...In addition check the retarder capacity carefully 1 Stop the machine on a flat place 2 Set parking brake switch to PARKING position 3 Chock the tires to prevent the machine from moving 4 Check that nothing is actuated other than parking brake 5 Turn the starting switch to ON position and check that the brake oil pressure caution lamp is not lit If the brake oil pressure caution lamp is lit start t...

Page 388: ... 5 ex cept when replacing the disc Perform the operation with 2 workers One worker de presses the brake pedal and the other pushes in the rod If shaft 2 is pushed in when the engine is running shaft 2 will be pushed back by the brake cooling oil pressure So always perform this operation with the engine stopped METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP When getting on or off the...

Page 389: ...R FACE JOINT PORTION k k WARNING Immediately after the engine is stopped the parts around the exhaust pipe are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work MAINTENANCE MAINTENANCE PROCEDURE 4 67 ...

Page 390: ...e element other than Komatsu genuine parts foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine Never operate the machine without DEF tank breather element at tached nor use the element other than Komatsu genuine parts Do not flush DEF tank breather element Flushing or regenerating of it will degrade the performance of element and will cause the breaka...

Page 391: ...h a new one 4 Install cover 5 and nut 4 5 Install cover 2 with bolt 1 METHOD FOR CHECKING DRIVE BELT TENSION PULLEY ASSEMBLY OF COM PRESSOR FOR ALTERNATOR AND AIR CONDITIONER Check the pulley for play and grease leakage If any abnormality is found ask your Komatsu distributor for re pair or replacement MAINTENANCE MAINTENANCE PROCEDURE 4 69 ...

Page 392: ...release the pressure then remove it carefully Front final drive case each of right and left refill capacity 5 5 ℓ Center final drive case each of right and left refill capacity 4 5 ℓ Rear final drive case each of right and left refill capacity 5 5 ℓ Items to be prepared Container to receive drained oil Change the oil of all the final drive cases front center rear Change the oil according to the fo...

Page 393: ...tial case 38 0 ℓ Items to be prepared Container to receive drained oil When getting on or off the machine with carrying oil a tool etc place it once in part A to ensure your safety Change the oil in all the differential cases front center rear Change the oil according to the following procedure 1 Remove drain plug P and drain the oil 2 After draining the oil tighten the drain plug 3 Refill with oi...

Page 394: ...Immediately after the engine is stopped its parts and oil are still very hot and may cause burn injury Accordingly wait until they have cooled down before starting the work 1 Remove mounting bolts 2 of hydraulic tank top cover 1 2 Remove cover 1 MAINTENANCE PROCEDURE MAINTENANCE 4 72 ...

Page 395: ... in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pres sure then remove it Items to be prepared Container to receive drained oil 1 Drain the oil in the transmission case For the method to drain the oil from the transmission case see METHOD FOR CHANGING OIL IN TRANSMISSION CASE...

Page 396: ...G Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When using compressed air there is a danger that dirt may scatter and cause personal injury Always wear protective equipment such as protective eyeglasses and dust mask When getting on or off the machine with carrying breath...

Page 397: ...ry hot Do not replace the filter element imme diately Wait until all of parts cool down before starting the work NOTICE If the engine is operated without the filter element the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil Therefore do not start the engine without the filter element The filter ...

Page 398: ...cumulated in or sticking to the case and ele ment When replacing the element take care that the oil will not spill out REMARK When the ambient temperature is low water or emulsified matter may stick to the inside of KCCV because of con densation of water vapor in the blowby gas However as far as the coolant level is normal it is not a problem 3 Remove used O ring 6 sticking to case 4 and install a...

Page 399: ...d with each other 5 Align the position of mark 13 on the case with that of mark 8 of the filter body label then install the case to the filter body The case can be installed only when its claws 14 are cor rectly inserted in grooves 10 of the filter body When inserting take extreme care so that protrusion 15 in the case is joined together with rubber lip 16 of the ele ment 6 Fit ring 3 to the threa...

Page 400: ...ilter other than Komat su genuine parts DEF filter cannot be flushed Flushing or regenerating of it will degrade the performance of filter and will cause the breakage of DEF tank Never reuse the element Improper assembly of DEF filter may cause leakage of DEF Replace the DEF filter in the correct pro cedure DEF freezes at 11 C If it is frozen replacement of the filter becomes difficult Replace the...

Page 401: ...hand 5 Check that filter removal tool 3 is fully inserted to the end Insert the filter removal tool 3 to the end where you can not thrust it in any further 6 Turn filter removal tool 3 in reverse and remove filter 6 Filter 6 is removed and you can take it out together with filter removal tool 3 If filter 6 cannot be removed from DEF pump grip filter removal tool 3 pull it down then it will be remo...

Page 402: ... into the bottom of DEF pump and lightly tighten them with hand 11 Tighten filter cap 1 Tightening torque 20 to 25 Nm 2 0 to 2 5 kgm EVERY 4000 HOURS MAINTENANCE Maintenance for every 50 250 500 1000 and 2000 hours service should be performed at the same time REPLACE DEFINED LIFE PARTS These parts change in material wear and deteriorate as they are aged Replace them every 2 years or every 4000 hou...

Page 403: ...e Hoist circuit hose 4 Others PPC accumulator METHOD FOR CHANGING OIL IN HYDRAULIC TANK k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the internal pres sure then remove it NOTICE ...

Page 404: ...at the hydraulic oil is at the speci fied level For the method to check the oil level in the hydraulic tank see METHOD FOR CHECKING OIL LEVEL IN HY DRAULIC TANK ADDING OIL 3 154 12 Bleed air from the hydraulic circuit For the air bleeding procedure of hydraulic circuit see METHOD FOR BLEEDING AIR FROM HYDRAULIC CIR CUIT 4 30 METHOD FOR CHECKING WATER PUMP Check around the water pump for water leak...

Page 405: ...ned rubber ask your Komatsu distributor for replacement METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER Check for any missing fuel spray prevention caps 1 to 10 or fuel spray prevention cover 11 and check also for any hardened rubber portions If there are any missing caps or cover or the rubber is hardened ask your Komatsu distributor for installation or replacement M...

Page 406: ...he same time METHOD FOR CLEANING KDPF Contact your Komatsu distributor for cleaning of the KDPF METHOD FOR CLEANING DEF TANK Ask your Komatsu distributor for cleaning of the DEF tank METHOD FOR CLEANING FUEL DOSER For cleaning the fuel doser ask your Komatsu distributor METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING HARDENING OF RUBBER The fuel spray prevention cap ...

Page 407: ... has been performed prop erly 5 After greasing wipe off any old grease that is pushed out METHOD FOR CHECKING LOCATION OF FRONT DRIVE SHAFT GREASE FIT TING k k WARNING When checking the positions of the grease holes and grease fittings ensure that the machine is stop ped It is very dangerous to check the positions of the grease holes and grease fittings while the machine is running Check that grea...

Page 408: ...eplacement of the engine high pressure piping METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR Ask your Komatsu distributor to perform this work EVERY 9000 HOURS MAINTENANCE Maintenance for every 50 250 500 1000 and 4500 hours service should be performed at the same tim...

Page 409: ...SPECIFICATIONS 5 1 ...

Page 410: ...5 gross kW min 1 353 2000 ISO14396 353 2000 ISO9249 SAE J1349 net 348 2000 Engine max torque Nm kgm rpm 2280 232 1400 A Overall length mm 11105 B Overall height mm 3735 C Overall height when dumping mm 7171 D Overall width mm 3450 E Min ground clearance bottom of center axle mm 615 Min turning radius mm 8885 Travel speed Forward 1st km h 6 6 2nd km h 10 1 3rd km h 15 5 4th km h 23 7 5th km h 36 5 ...

Page 411: ...SPECIFICATIONS SPECIFICATIONS 5 3 ...

Page 412: ......

Page 413: ...ATTACHMENTS AND OP TIONS Before reading this chapter read and understand the SAFETY 6 1 ...

Page 414: ... not perform the cab tilt operation when the machine is loaded Do not stand under the cab during the cab tilt operation When the cab is tilted up lock it securely in position with the lock bar When installing the lock bar do not enter under the cab but install it from the side of the cab While the cab is tilted up do not get on or off it While the cab is tilted up do not operate the gear shift lev...

Page 415: ...et 2 2 Turn bracket 2 counterclockwise 90 and fix it with the bolts 3 Remove mounting bolts 5 of L H bracket 4 4 Flip up guard 1 5 Turn bracket 4 180 and hitch it on rear guard 6 6 Fix bracket 4 with the bolts 7 Turn R H bracket 2 counterclockwise 90 and fix it with the bolts ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT 6 3 ...

Page 416: ...ON position to raise the cab 7 After tilting up the cab fix it in position with lock bar 12 Make sure that lock bar 12 is installed in the correct di rection and lock it securely with lock 13 8 When lowering the cab remove lock bar 12 9 Turn valve 10 counterclockwise and open it gradually The cab lowers slowly 10 After returning the cab to its original position remove pin 8 and insert pin 7 instea...

Page 417: ... 2 clockwise 90 and fix it with the bolts 3 Remove the bolts of L H bracket 4 and remove it from the rear guard 4 Lower guard 1 5 Turn bracket 4 180 and fix it with mounting bolts 5 6 Remove the bolts of R H bracket 2 7 Turn bracket 2 clockwise 90 and fix it with mounting bolts 3 ATTACHMENTS AND OPTIONS HANDLE CAB POWER TILT 6 5 ...

Page 418: ... installed you do not need to change them for the standard operation If set ting is required ask your Komatsu distributor Setting of Loading End Travel Dist The payload meter judges that loading is completed when the machine travels continuously 160 m from the loading pit If the machine dumps within 160 m the controller does not judge that dumping is performed thus the cycle data is not completed ...

Page 419: ... Traveling Clock display OFF During loading Stopped Payload display 2 Payload display Traveling Clock display OFF When loaded Stopped Payload display Payload display Traveling Clock display OFF During dumping Stopped Payload display Payload display Traveling Payload display OFF 1 The Stopped means state in which the gear shift lever is in NEUTRAL position N or the travel speed signal is zero 2 To ...

Page 420: ... each bucket loaded the system estimates the total load weight if one more bucket is loaded and flashes the appropriate lamp to prevent overloading The predicted load display and actual load weight display are shown at the same time Expected number of bucket loads 4 1st bucket 9 5 t 2nd bucket 9 5 t total 19 0 t 3rd bucket 9 5 t total 28 5 t 4th bucket 9 5 t total 38 0 t When the machine is loaded...

Page 421: ...ils see the operation and maintenance manual for the special software You can take in and check the downloaded data with the text file read function of the commercially available spreadsheet software METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWN LOAD k k WARNING When handling the cables be careful not to damage them or pull them by force Do not leave the connectors disconnected Be careful to...

Page 422: ...0 as it is For details of installing the software see the instruction manual provided with the download software When the installation is completed the icon shown in the figure is created 1 Double click the icon The download software is started and the screen shown in the figure is displayed 2 When screen G1000 is displayed click PLM Screen G2000 is displayed Do not click CARD and PMC since they a...

Page 423: ...Data File and Cycle Data File are handled Once a setting has been made there is no need to set it again when performing the next download 6 Click ENTER to return to screen G2200 7 On screen G2200 click BACK to return to screen G2000 8 Click Download on screen G2000 9 When screen G2100 is displayed click Start Downloading starts When downloading is finished close the screen REMARK Screen G2101 Down...

Page 424: ...s enter switch 2 The accumulated payload and the total number of cycles are displayed as shown in the figure The data and time of start are those when Accumulat ed Payload and Total Cycles were reset last time The date and time of finish are those of the last dump ing Accumulated Payload and Total Cycles are the inte grated values after the previous resetting The display range is from 0 to 9999999...

Page 425: ...ndow closes If you press return switch 3 nothing is done and the pop up window closes DISPLAY FUEL CONSUMPTION RECORD You can display the average daily working fuel consumption ton l in the last 1 week You can reset that value 1 Press menu switch 1 on the standard screen and display Machine Setting and Information menu Select Payload Meter and press enter switch 2 2 Select Average Fuel Consumption...

Page 426: ...t and the pop up window closes If you press return switch 3 nothing is done and the pop up window closes SETTING MACHINE ID AND OPEN ID You can change the setting of the machine ID and open ID which are items in the cycle data You can check the operator and load of each cycle by setting the machine No as the machine ID and setting the operator and the load type as the open ID 1 Press menu switch 1...

Page 427: ... 0 is displayed as ID it becomes 200 4 After inputting the machine ID press enter switch 2 The value at this time is set as ID and the windows closes If you press return switch 5 the window closes without changing the value of ID 5 When setting an open ID select Open ID Setting on the screen of step 2 The set open ID is displayed on the right side 6 The setting procedure for the open ID is the sam...

Page 428: ...that the dump body is seated by checking that the dump body float caution lamp is turned OFF 1 Empty the machine Be sure to completely remove all the soil remaining inside the dump body 2 Run in the machine 3 While running the engine set the gear shift lever to NEUTRAL position N and stop the machine 4 Prepare for calibration according to the following procedure 1 Press menu switch 1 on the standa...

Page 429: ... figure drive the machine at speed of 10 km h REMARK To cancel at this time press return switch 3 while the screen in the figure is displayed 6 Continue driving the machine at speed of 10 km h Keep the travel speed at 10 km h during the travel The display changes as shown in the figure in approxi mately 30 seconds and the calibration is completed ATTACHMENTS AND OPTIONS HANDLING PAYLOAD METER 6 17...

Page 430: ......

Page 431: ...REPLACEMENT PARTS 7 1 ...

Page 432: ...oses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses and replace defective hoses as required When replacing hoses always replace O rings gaskets and other such parts at the same time Have your Komatsu distributor replace the defined life parts DEFINED LIFE PARTS LIST No Parts for periodic replacement Replacement interval 1 F...

Page 433: ...e time Item Part No Part name Q ty Replacement interval Engine oil filter 600 211 1340 Cartridge 2 500 hours Fuel prefilter 600 319 4800 Cartridge 1 Fuel main filter 600 319 3841 Cartridge 1 1000 hours Transmission oil filter valve side 714 07 28713 Cartridge 2 Transmission oil filter brake cooling side 208 60 71124 07000 F5210 Element O ring 1 1 Brake oil filter 569 43 83920 07000 12065 07001 020...

Page 434: ...tsu distributor NOTICE The fuel used must be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this ma chine uses an electronically controlled high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high precision parts and lubrication if ...

Page 435: ...explained as follows Symbol Meaning of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Manual Greasing of the grease Change of the engine oil Check oil level in engine oil pan Change hydraulic oil Change hydraulic oil REPLACEMENT PARTS RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 ...

Page 436: ...ir Fluid Type Ambient Temperature degrees Celsius Recommended Komatsu Fluids Min Max Engine oil pan Engine oil for KDPF used in cold terrain Oil Change interval 250 hours 25 C 35 C EOS5W30 LA KES Diesel Engine Oil Note 1 25 C 40 C EOS5W40 LA KES Diesel Engine Oil Note 1 Engine oil for KDPF Oil Change interval 500 hours 20 C 40 C EO10W30 LA KES Diesel Engine Oil 15 C 50 C EO15W40 LA KES Diesel Engi...

Page 437: ...0 C AF NAC KES Note 4 Fuel tank Diesel fuel 30 C 20 C EN 590 Class 2 10 C 50 C EN 590 Grade D DEF tank DEF 30 C 50 C DEF Note 5 Engine oil pan Transmis sion case Incl brake oil tank Hydraulic tank Front sus pension each of right and left Rear sus pension each of right and left Front differ ential Front final drive case each of right and left Specified capacity ℓ 58 0 295 0 245 0 8 3 2 4 25 0 6 0 R...

Page 438: ...ing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of coolant is essential Komatsu machines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Non Amine Engine Coolant AF NAC is strongly recommended w...

Page 439: ... 98 Automatic retarder accelerator control ARAC Han dle 3 197 Automatic secondary steering Check 3 163 Automatic warm up function 3 182 AUX 3 233 Average fuel consumption display Set 3 56 Average fuel consumption record 3 54 Average fuel consumption record Display 6 13 Avoid mixing oil 4 3 B Backup alarm operation Check 3 163 Band AUX selector button 3 232 Basic operation of machine monitor 3 11 B...

Page 440: ...hange oil 4 71 Differential case Check oil level Add oil 4 52 Dimmer switch 3 95 Directions of machine 1 7 Display 3 233 Display monitor 3 223 Display selector button 3 233 Display warning tag during inspection and mainte nance 2 31 Display non display of ECO guidance Switch 3 59 Display non display of guidance when key is OFF Switch 3 60 Do not drop things inside machine 4 2 Do not get caught in ...

Page 441: ... switch 3 101 Foot brake Check braking capacity 4 44 Frame and A arm Check 4 44 Frequency Adjust 3 234 Frequency Auto preset 3 234 Fresh and clean lubricants 4 2 Freshrecirc air changeover switch 3 223 Front drive shaft Check location of grease fitting4 85 Fuel 4 6 Fuel Check level Add 3 158 Fuel and lubricants 3 244 Fuel and lubricants to match ambient temperature 4 4 Fuel circuit Bleed air 3 248...

Page 442: ...seal Collect 4 34 LH meter display selection 3 78 Location of engine number plate 1 9 Location of product identification number PIN machine serial No plate 1 9 Location of safety labels 2 5 Lock 3 209 Lock inspection cover 4 3 Lubrication chart 7 4 Lumber support Adjust 3 167 M Machine Check after stopping engine 3 183 Machine Check walk around 3 150 Machine Checks after inspection and maintenance...

Page 443: ...er 3 65 Payload meter Handle 6 6 People on dump body 2 19 Perform KOWA Komatsu Oil Wear Analysis 4 7 Periodic replacement of defined life parts 2 39 Permissible water depth 3 208 Phenomena and actions for engine related parts 3 259 Pilot display 3 35 Pilot display and meter display 3 34 Play in output shaft output coupling Check 4 30 Power button 3 232 Power mode display 3 36 Power supply outlet 3...

Page 444: ...onitor Perform self check 3 120 Rearview monitor Precautions for using 3 121 Rearview monitor Set 3 76 Recommended brands and qualities other than ko matsu genuine oils 7 8 Recommended fuel coolant and lubricant 7 4 Refrigerant gas Check level 4 22 Remaining time for maintenance Reset 3 74 Replace defined life parts 4 80 Retarder brake performance Check 4 45 Retarder control lever 3 106 Retarder l...

Page 445: ...Transmission system caution lamp 3 27 Transportation 3 239 Transportation method Select 3 239 Travel road Determine Maintain 3 238 Trip meter 3 68 Troubles and actions 3 248 Tuningtime adjustment button 3 232 Turbocharger protection function 3 181 Turn battery disconnect switch to off position 2 35 Turn signal lever 3 95 Turn signal pilot lamp 3 35 Two workers for maintenance when engine is runnin...

Page 446: ...HM400 5 ARTICULATED DUMP TRUCK Form No EENAM03380 2015 KOMATSU All Rights Reserved Printed in Belgium 09 2015 ...

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