Komatsu HD465-8 Operation & Maintenance Manual Download | Manualshive

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HD465

-8

HD605

-8

SERIAL NUMBERS

HD465-8 - 30001 and up
HD605-8 - 30001 and up

DUMP TRUCK

Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.

Operation &
Maintenance Manual

EENAM03550

WARNING

ORIGINAL INSTRUCTIONS

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Summary of Contents for HD465-8

Page 1: ...injury or 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 EENAM03550 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: ...it at any time Keep it in the pocket behind the operator s seat If this manual is lost damaged or unreadable 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 the machine model name and the serial No see the machine serial No plate In order to arrange the prop er Operation and Maintenance Manual y...

Page 5: ... safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used...

Page 6: ...systems Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedule time to maintain terrain conditions 4 Use a seat that meets ISO 7096 and keep the seat maintained and adjusted Adjust the seat and suspen...

Page 7: ...nce Transport machines long distances between worksites 8 The following 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 FOREWORD NOISE 1 5 ...

Page 8: ... than or equal to 0 5 m s2 the uncertainty for this value is 0 28 m s2 according to EN12096 1997 FOR HD605 8 The actual acceleration value for the hands and arms is less than or equal to 2 5 m s2 the uncertainty for this value is 0 09 m s2 according to EN12096 1997 The actual acceleration value for the body is less than or equal to 0 5 m s2 the uncertainty for this value is 0 30 m s2 according to ...

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: ...ION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is provided on the front right of the machine The design of the nameplate varies according to the district LOCATION OF ENGINE NUMBER PLATE It is located on the upper left side of the engine cylinder block if you look from the fan side PRODUCT INFORMATION FOREWORD 1 8 ...

Page 11: ...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 566 93 8L620 HFC 134a GWP 1430 1 2 kg 1 72 t CO2 eq FOREWORD PRODUCT INFORMATION 1 ...

Page 12: ... 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 SERIAL PLATE FOREWORD 1 10 ...

Page 13: ...okyo 107 8414 Japan KOMATSU EUROPE INT Mechelsesteenweg 586 B 1800 Vilvoorde Belgium Declares that this machine HD465 8 HD605 8 Fulfils all the relevant provisions of following EC Directives Machinery Directive 2006 42 EC Electro Magnetic Compatibility Directive 2014 30 EU Radio Equipment Directive 2014 53 EU FOREWORD DECLARATION OF CONFORMITY 1 11 ...

Page 14: ...PERATION 2 12 PRECAUTIONS TO PREVENT FIRE 2 13 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 15 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 17 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 17 UNAUTHORIZED MODIFICATION 2 18 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2 18 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 18 PRECAUTIONS FOR OPERATION 2 19 PRECAUTIONS FOR JOBSITE 2 19 START ENGINE 2 21 ...

Page 15: ...NSPORTATION 3 243 SELECT TRANSPORTATION METHOD 3 243 METHOD FOR SECURING MACHINE 3 243 PRECAUTIONS FOR LIFTING MACHINE 3 243 COLD WEATHER OPERATION 3 247 COLD WEATHER OPERATION INFORMATION 3 247 PRECAUTIONS AFTER DAILY WORK COMPLETION 3 248 AFTER COLD WEATHER SEASON 3 248 PRECAUTIONS FOR LONG TERM STORAGE 3 249 PREPARATION FOR LONG TERM STORAGE 3 249 MAINTENANCE DURING LONG TERM STORAGE 3 249 STAR...

Page 16: ...CE 4 62 EVERY 4000 HOURS MAINTENANCE 4 69 EVERY 4500 HOURS MAINTENANCE 4 72 EVERY 8000 HOURS MAINTENANCE 4 72 EVERY 9000 HOURS MAINTENANCE 4 73 EVERY 15000 HOURS MAINTENANCE 4 73 SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 SPECIFICATIONS HD465 8 5 2 SPECIFICATIONS HD605 8 5 3 ATTACHMENTS AND OPTIONS 6 1 BODY SELECTION 6 2 HANDLE ENGINE ROOM LAMP 6 3 METHOD FOR USING ENGINE ROOM LAMP 6 3 HANDLE KOMATSU T...

Page 17: ...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 18: ...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 19: ...LOCATION OF SAFETY LABELS SAFETY SAFETY LABELS 2 3 ...

Page 20: ...SAFETY LABELS SAFETY 2 4 ...

Page 21: ...reverse caution for operating hoist control lever 10 Caution for handling battery cable 11 Caution for hot exhaust pipe 12 Caution against falling 13 Caution for handling battery 14 Prohibition of start by short circuiting This plate is fixed to the starting motor 15 Caution for blast site only machine with KOM TRAX 16 Caution for high temperature 17 Caution for using seat belt CONTENTS OF SAFETY ...

Page 22: ...on when checking engine room 09667 A0880 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance 4 Caution when releasing radiator 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 SAFETY LABELS SAFETY 2 6 ...

Page 23: ...g injury Do not disassemble the suspension make holes in it weld it cut it hit it roll it or bring it near flame 7 Caution for handling accumulator and gas spring 09659 A057B There is the hazard of explosion causing injury Do not disassemble accumulator and gas spring make holes in it weld it cut it hit it roll it or bring it near flame 8 Caution for electric cables caution against falling when pe...

Page 24: ...embly assembly or transportation of machine When leaving operator seat 1 Lower dump body 2 Park the machine on level ground 3 Stop engine and apply parking brake completely 4 Take out the key If the retarder oil temperature caution lamp light up stop machine immediately Or the brakes will fail set the shift lever to the N position Run the engine under no load at a mid range speed and wait for the ...

Page 25: ...lectric hazard from handling the cable Read manual for safe and proper handling 11 Caution for hot exhaust pipe 09817 K088B Sign indicates a burn hazard from touching heated parts exhaust pipe and body during or right after operation Never touch when hot 12 Caution against falling 09805 C0881 There is the hazard of falling Do not step here 13 Caution for handling battery 09664 62F11 Never smoke or...

Page 26: ...wn in the operator s seat Do not attempt to start the engine by shot circuiting the en gine starting circuit Such an act may cause a serious bodi ly injury or fire 15 Caution for blast site 09845 00480 Sign indicates an explosion hazard caused by active radio transmitter at a blast zone Keep machine at a safe distance from a blast zone and detonator SAFETY LABELS SAFETY 2 10 ...

Page 27: ...en operating the machine to re duce risk of injury or death in case of a roll over Always check for damage or wear of the seat belt damage of the connecting brackets and tightness of bolts Adjust seat position to allow full brake pedal travel with op erator s back against seat back After adjusting seat position get off the seat and tighten the tether belts located between the floor and seat if equ...

Page 28: ...ATION 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 operations If ...

Page 29: ...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 30: ...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 31: ...sion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting with anti explosion specifications PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine always observe the following Use the handrails and steps indicated by arrow A in the f...

Page 32: ...P 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 operator s seat to adjust the opera tor s seat always lower the dump body completely lock with dump lever lock knob 1 set gear shift lever 2 to NEUTRAL position N set parking brake switch 3 to PARKING posi tion t...

Page 33: ... such as a radar station some abnormal phenomena may be observed The display on the monitor panel may behave erratically The warning buzzer may sound These effects do not signify a malfunction and the machine will return to normal as soon as the source of inter ference is removed DO NOT GET CAUGHT IN WORK EQUIPMENT The clearance in the area around the dump body changes ac cording to the movement o...

Page 34: ...product failures physical loss or damage or influ ence on the environment resulting from modifications made without authorization from Komatsu Any modification made without authorization from Komatsu can create hazards Before making a modifica tion consult your Komatsu distributor Do not try to increase the capacity of the dump body or make any other modifications Such modifications will cause a d...

Page 35: ...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 36: ...camera gives 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 Se...

Page 37: ...t 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 pedal or brake pedal and check that the pedals work properly Adjust the operator s seat to a position where it is easy to perform operations and ...

Page 38: ... Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables When connecting a normal machine to a failed machine with the jumper cables always use the normal machine with the same battery voltage as the failed machine When starting the engine with the jumper cables perform the starting operation with 2 workers one worker sitting in the operator s seat a...

Page 39: ... sure to perform the above precautions even when the machine is equipped with mirrors and cam eras WHEN TRAVELING Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact Always observe the following Never turn the key in the starting switch to OFF position when the machine is traveling If the engine stops when the machine is traveling the st...

Page 40: ...HINE When using the machine to prevent serious personal injury or death caused by the work equipment or by the machine tipping over due to overloading do not use the machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine When operating in tunnels or under bridges or under electric wires or in other places where the height is limi...

Page 41: ...m level ground Select a place where there is no hazard of landslides falling rocks or flooding When leaving the machine always lower the dump body completely lock with dump lever lock knob 1 set gear shift lever 2 to NEUTRAL position N set parking brake switch 3 to PARKING position then stop the engine Always close the operator s cab door and use the key to lock all the equipment in order to preve...

Page 42: ...e ramps If necessary drive off the ramps onto the ground correct the di rection then enter the ramps again When unloading to an embankment or platform make sure that it has suitable width strength and grade For machines equipped with a cab always lock the door after loading the machine To prevent the door from opening during transportation When it is necessary to remove handrails and steps take ca...

Page 43: ...ce clean the tidy to enable you to perform operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop the machine on a firm level ground Select a place where there is no hazard of landslides falling rocks or flooding ONLY AUTHORIZED PERSONNEL As long as mainte...

Page 44: ...f you are caught or pinched between the work equipment during operation or exposed to high temperature or high pressure liquids it is dangerous and may cause serious personal injury or death Always observe the fol lowing Stop the engine before performing any inspection and maintenance Lower the dump body set dump lever 1 to HOLD posi tion lock with dump lever lock knob 2 then stop the en gine Set ...

Page 45: ...t the rotating parts 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 the maintenance work stop the regener ation of KDPF Lower the dump body completely set dump lever 1 to HOLD position lock with dump lever lock knob 2 to pre vent the dump body from moving Set parking...

Page 46: ...ine hood and cover 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 LO...

Page 47: ...ied 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 hydrogen gas is generated and may explode In addition the ba...

Page 48: ... 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 49: ...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 50: ...les 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 leased Ask your Komatsu distributor to perform this work PRECAUTIONS FOR COMPRESSED AIR When performing cleaning with compressed air there is a hazard of serious pers...

Page 51: ...eat belt Replacement of the defined life parts See PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 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 inspecti...

Page 52: ...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 53: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 54: ...mp high beam 4 Turn signal lamp 5 Dump body 6 Rear wheel 7 Hoist cylinder 8 Steering and hoist oil tank 9 Side lamp 10 Brake sub tank 11 Front suspension 12 Front wheel 13 Staircase lighting if equipped 14 Air Cleaner 15 Fuel tank 16 Rear suspension GENERAL VIEW OPERATION 3 2 ...

Page 55: ...se lighting switch if equipped 7 Fog lamp switch 8 Machine monitor 9 Horn button 10 Steering wheel 11 Retarder control lever 12 Hazard lamp switch 13 Secondary steering switch 14 Front brake off switch 15 AISS LOW switch 16 Starting switch 17 Accelerator pedal 18 Brake pedal 19 ARSC travel speed set lever 20 Steering tilt lock lever 21 Secondary brake pedal OPERATION GENERAL VIEW 3 3 ...

Page 56: ...w switch left 25 Power window switch right 26 Heated wire mirror switch 27 Dump lever 28 Dump lever lock knob 29 Rearview monitor brightness adjustment switch 30 Gear shift lever 31 Parking brake switch 32 Room lamp 2 switch 33 Room lamp 1 switch GENERAL VIEW OPERATION 3 4 ...

Page 57: ...ilot lamp 10 Turn signal pilot lamp R H 11 Brake oil pressure caution lamp 12 Clearance lamp pilot lamp 13 Retarder oil temperature gauge 14 Retarder oil temperature caution lamp 15 Engine tachometer 16 Speedometer 17 Fuel level caution lamp 18 Fuel gauge 19 R H meter 20 L H meter 21 Torque converter oil temperature gauge 22 Torque converter oil temperature caution lamp 23 Air conditioner switch a...

Page 58: ...32 KTCS off pilot lamp if equipped 33 ARSC set travel speed indicator 34 Shift indicator 35 Shift lever position display 36 Automatic suspension mode pilot lamp if equip ped 37 Front brake off pilot lamp 38 Torque converter lockup pilot lamp 39 Preheating pilot lamp 40 Fan reverse rotation pilot lamp 41 Secondary steering pilot lamp 42 Aftertreatment devices regeneration pilot lamp 42 Aftertreatme...

Page 59: ... of pilot lamp are prepared At place 36 3 types of pilot lamp are prepared OTHER EQUIPMENT NAME Inside of cab 1 Open knob for cab door 2 Cab door inner lock 3 Rearview monitor 4 Magazine box 5 Cup holder 2 places 6 Drink box 7 Fuse 8 AUX 9 Lunch box tray 10 12 V power supply 11 Ashtray OPERATION GENERAL VIEW 3 7 ...

Page 60: ...ator 4 Circuit breaker 5 Fuse 6 Grease pump holder 7 Battery 8 Toolbox 9 Komatsu Closed Crankcase Ventilation hereafter KCCV ventilator 10 Battery disconnect switch 11 System operating lamp 12 Rearview camera 13 Body pivot pin GENERAL VIEW OPERATION 3 8 ...

Page 61: ...ings of the displays EXPLANATION OF MACHINE MONITOR EQUIPMENT FF Failure display screen A Warning display B Pilot display C Meter display D Switch panel REMARK 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 10 black or white spots this is not a failure or a d...

Page 62: ...creen BB 3 The pointer of engine tachometer D swings once 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...

Page 63: ...ngine does not start If the engine shutdown secondary switch 1 is turned OFF normal the machine monitor switches to the standard screen and the engine can be started with usual starting switch key operation BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR MAL SITUATION When the starting switch is turned to OFF position the screen goes out In the following cases the end screen is disp...

Page 64: ...on with SKIP is set the opening screen AA switches to the ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting the ID number for operator identification function without SKIP is set the opening screen AA switches to the ID number input screen MM without SKIP when the starting switch is turned to ON posi tion On the ID number input screen LL with SKIP o...

Page 65: ...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 anti theft effect Be careful not to use it for the purpose of security enhance ment Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong us...

Page 66: ...e starting screen AA is displayed for 2 seconds and then it is changed to the maintenance time warning screen GG When the menu switch displayed in the guidance icon is press ed Maintenance menu screen is displayed After displaying the maintenance time warning screen GG for 30 seconds the screen returns to the standard screen BB EXPLANATION OF COMPONENTS OPERATION 3 14 ...

Page 67: ...s a trouble if any of the action levels L01 to L04 is displayed on the machine moni tor Take appropriate actions following the list of action level displays and required actions These caution lamps do not guarantee the condition of the machine Do not simply rely on the caution lamp when performing check before starting start up inspection Always get off the machine and check each item directly Whe...

Page 68: ... they are displayed on warning displays 2 and 3 When more than 3 types of warning are generated they are displayed on warning displays 2 and 3 alter nately at intervals of 2 seconds ACTION LEVEL DISPLAY Action level display indicates the degree of urgency of the ab normality currently generated on the machine by L01 to L04 The larger the number in the table is the more serious effects the abnormal...

Page 69: ... no load If there is a secondary steering related display avoid a long time usage of the secondary steering If the condition is not improved check the failure code and ask your Komatsu distributor for inspection and maintenance L01 OFF Does not sound Yellow Some functions may be restricted for use but the ma chine can operate When you finish the operation always perform the in spection and mainten...

Page 70: ...Current Abnormality screen is not dis played A Caution lamp B Action level C Failure code Code to indicate the content of the failure Notify it when calling your Komatsu distributor D Failure name E Message Take appropriate actions according to the displayed message F Contact telephone number The telephone number of your Komatsu distributor is displayed If the telephone number of the contact has n...

Page 71: ...rns the screen to the standard screen ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about over heating of the engine coolant If the engine coolant temperature is abnormally high the cau tion lamp lights up in red and action level L02 is displayed At the same time the centralized warning lamp lights up and alarm buzzer sounds intermittently Place the machine ...

Page 72: ... to NEUTRAL position N and run the engine at a medium speed under no load until the caution lamp goes out FUEL LEVEL CAUTION LAMP The fuel level caution lamp warns about low level of remaining fuel The lamp lights up in red if the fuel level is 126 ℓ or below Add fuel as soon as possible BRAKE OIL PRESSURE CAUTION LAMP The brake oil pressure caution lamp warns that the brake oil pressure is below ...

Page 73: ...the inspection and maintenance as needed STEERING OIL PRESSURE CAUTION LAMP The steering oil pressure caution lamp warns the operator that the steering oil pressure is below the specified value When action level L03 is displayed If the steering 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 li...

Page 74: ...nance 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 SECONDARY STEERING MOTOR CAUTION LAMP The secondary steering motor caution lamp warns that the sec ondary steering motor has been operating for a long period The caution la...

Page 75: ... CAUTION LAMP 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 ...

Page 76: ...ion 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 filtering function of KDPF occurs 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 and per form the manual stationary regeneration The manual stationary regenera...

Page 77: ... 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 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 di...

Page 78: ...ction and maintenance When action level L01 is displayed The 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 KTCS SYSTEM CAUTION LAMP if equipped The KTCS system caution lamp warns about abnormality in the KTCS system If the caution lamp lights up in yellow and action leve...

Page 79: ...e with moderate engine speed and travel speed RADIATOR COOLANT LEVEL CAUTION LAMP Radiator coolant level caution lamp warns about low level of ra diator coolant If the caution lamp lights up in yellow and action level L01 is displayed check the coolant level in the reservoir tank and add coolant See METHOD FOR CHECKING COOLANT LEVEL ADDING COOLANT 3 146 If it occurs again in a short time the coola...

Page 80: ...form the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed FAN REVERSE OPERATION CAUTION LAMP The wrong operation in fan reverse mode caution lamp warns about misoperation while the fan is rotating in reverse If the gear shift lever is set to any position other than NEU TRAL position N or the dump body is not seated while the fan is rotating in re...

Page 81: ...l temperature caused by usage of ARSC The ARSC overheat notice caution lamp lights up in yellow when the retarder oil temperature increased sharply and the overheating is estimated to occur in 5 seconds while ARSC is being used Decrease the travel speed which is set in ARSC PAYLOAD METER SYSTEM CAUTION LAMP The payload meter system caution lamp warns about abnor mality in the payload meter system ...

Page 82: ...THOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT 4 62 AUTO SUSPENSION SYSTEM CAUTION LAMP if equipped The auto suspension system caution lamp warns about abnor mality in the automatic suspension system If the caution lamp lights up in yellow and the action level L01 is displayed always perform the inspection and maintenance after the operation is finished Ask your Komatsu distributor for t...

Page 83: ...e see Maintenance menu screen On the standard screen when the menu switch is pressed while the caution lamp is lit the screen changes directly to Maintenance menu screen For operations on Maintenance menu screen see MAINTENANCE SCREEN SETTING 3 75 By default the maintenance time caution lamp yellow is set to light up when the remaining time reaches 30 hours However you can change this setting To c...

Page 84: ...on 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 OFF When the gear shift lever is set to NEUTRAL posi tion N during traveling at travel speed 4 km h or more The current gear shift lever position flashes When the travel speed becomes 4 km h or more while the gea...

Page 85: ...dary steering pilot lamp 12 Shift indicator 13 Shift lever position display 14 Parking brake pilot lamp 15 Automatic suspension mode if equipped 16 Front brake off pilot lamp 17 ARSC pilot lamp 17 ARSC off pilot lamp 18 ARSC set travel speed indicator 19 ECO guidance Meter display 20 Speedometer 21 Engine tachometer 22 Engine coolant temperature gauge 23 Torque converter oil temperature gauge 24 R...

Page 86: ...ned 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 lights up when the clearance lamps are turned on RETARDER PILOT LAMP The retarder pilot lamp lights up when the retarder is in opera tion The retarder operates in the following cases When the retarder control lever is pull...

Page 87: ...ights up while KTCS Setting is set to OFF TORQUE CONVERTER LOCKUP PILOT LAMP The torque converter lockup pilot lamp lights up when the tor que converter lockup is actuated and the transmission is shift ed to the direct drive FAN REVERSE ROTATION PILOT LAMP The fan reverse rotation pilot lamp lights up when the radiator fan is set in fan reverse rotation mode OPERATION EXPLANATION OF COMPONENTS 3 3...

Page 88: ... CHECK MESSAGE 3 96 Lights up in green There is an unread message Lights up in blue There is any read message to which no reply is made OFF There is no message AFTERTREATMENT DEVICES REGENERATION PILOT LAMP k k CAUTION Stay away from the exhaust pipe outlet to prevent injury Keep flammable materials away from the exhaust pipe to avoid fire When there are thatched houses dry leaves or pieces of pap...

Page 89: ...e aftertreatment devices regeneration is disabled when the manual stationary regeneration is necessary the KDPF soot accumulation caution lamp lights up If the KDPF soot accumulation caution lamp lights up cancel the regenera tion disable setting and perform the manual stationary regener ation For the procedures of cancellation of the regeneration disable setting and setting of the manual stationa...

Page 90: ...oading state with without the load the operating state of the brakes steering and dump control H hard mode The automatic suspension becomes the hard mode in any of the following cases and the hardness of the suspension be comes hard The machine travels or turns at high speed when it is load ed The brake pedal is depressed when the machine is load ed The dump lever is in the position other than FLO...

Page 91: ...omes soft FRONT BRAKE OFF PILOT LAMP The front brake off pilot lamp lights up while the front brake off function is actuated ARSC PILOT LAMP The ARSC pilot lamp indicates the ARSC setting state Lights up in green ARSC Setting is ON and ARSC is actuated Lights up in white ARSC Setting is ON and ARSC is not actuated ARSC OFF PILOT LAMP The ARSC off pilot lamp lights up when ARSC Setting is OFF OPERA...

Page 92: ...NCE TO AVOID HOIST RELIEF When relief of the hoist oil pressure is continued for more than 5 seconds while the accelerator pedal is depressed the hoist pressure relief deterrence message is displayed on the ma chine monitor Relief of the host oil pressure occurs if you set the dump lever to RAISE position while the dump body is raised to the maxi mum height or to LOWER position while the dump body...

Page 93: ...the message to restrict the accelerator operation during the dump body lowering operation is displayed on the machine monitor When the dump body is lowering restrict the accelerator oper ation in order to reduce the fuel consumption The message to restrict the accelerator operation during dump body lowering operation goes out automatically after 10 sec onds GUIDANCE TO AVOID STEERING RELIEF If the...

Page 94: ...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 95: ...ffect on the operation it leads to energy saving oper ation to reduce the fuel consumption REMARK Even if the indication of ECO 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 L H AND R H METER DISPLAY The L H meter indicates either of the following which can be selected Service meter Odometer Clock The R H meter i...

Page 96: ...ock is displayed in 24 hour mode REMARK If the battery is disconnected for a long period for storage etc the time information may be lost Fuel consumption gauge display Indicates the average fuel consumption of the machine One day display Displays the average fuel consumption of the period from the operation starting time until now during 0 00 a m of the day through 0 00 a m of the next day EXPLAN...

Page 97: ...between the average fuel consumption per day and the average fuel consumption during a selected period split fuel consumption PAYLOAD METER DISPLAY Payload meter display is a display of the payload value during the statistics which is being processed by payload meter func tion Payload meter display may not be as accurate as that of the data which is saved as the operated load Regard the displayed ...

Page 98: ...on of the machine monitor or air conditioner The function of each switch varies depending on the screen of the machine monitor REMARK The switches available on each screen can be checked with the guidance icon This function is not available when you press a switch not marked by the guidance icon or you press the guidance icon itself EXPLANATION OF COMPONENTS OPERATION 3 46 ...

Page 99: ...an reverse rotation pilot lamp lights up Machine Setting and Information menu screen is displayed When the message display lights up Displays the message display menu screen When the menu switch is pressed on the user menu screen the menu screen changes ENTER SWITCH Pressing ENTER switch on the user menu screen decides any selection and changes and proceeds to the next screen When ENTER switch is ...

Page 100: ...conditioner switch and numeric keypad consist of 10 switches Press the air conditioner switch and numeric keypad and re lease them The confirmation sound is heard when they are re leased Air conditioner switch For explanation of each air conditioner switch see EXPLANATION OF AIR CONDITIONER EQUIPMENT 3 224 Numeric keypad function These switches can be used as a numeric keypad to enter a numeric va...

Page 101: ...A to F are for setting and confirming the fol lowing items A Energy Saving Guidance Check of Operation Records Check of ECO Guidance Records Check and resetting of Average Fuel Consumption Re cord Configurations B Machine Setting and Information Setting of Radiator Fan Reverse Mode Display and setting of Payload Meter KTCS Setting if equipped ARSC Setting Display and resetting of Dumping Counter i...

Page 102: ...Language Setting Operator ID F Message display Check of message contents and reply to message On the user menu screen you can perform the following opera tions with the switches 1 UP switch Moves to the item above When on the first item it moves to the last item 2 DOWN switch Moves to the item below When on the last item moves to the first item 3 RETURN switch Cancels a selection or changes and re...

Page 103: ...tion Records on Energy Saving Guidance menu screen then press ENTER switch 4 On Operation Records screen the following information on a daily basis or during the split measurement period is displayed Working Hours Engine On The time during which the engine is running Average Fuel Consumption Average of the fuel con sumed while the engine is running Actual Working Hours The time spent for traveling...

Page 104: ...measurement B Date and time when measurement is started To stop the split measurement see the guidance icon and press ENTER switch 4 You can perform the following operations with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line ...

Page 105: ...reen 4 ENTER switch Starts the split measurement When the confirmation screen is displayed press ENTER switch 4 again to start the split measurement or press RE TURN switch 3 to cancel the start CHECK ECO GUIDANCE RECORD Select ECO Guidance Records on Energy Saving Guidance menu screen then press ENTER switch 4 On ECO Guidance Records screen the frequency of display of the ECO guidance on a daily ...

Page 106: ...ing measurement B Date and time when measurement is started To stop the split measurement see the guidance icon and press ENTER switch 4 You can perform the following operations with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last l...

Page 107: ... 4 ENTER switch Starts the split measurement When the confirmation screen is displayed press ENTER switch 4 again to start the split measurement or press RE TURN switch 3 to cancel the start CHECK FUEL CONSUMPTION RECORD Select Average Fuel Consumption Record on Energy Saving Guidance menu screen then press ENTER switch 4 On Average Fuel Consumption Record screen the graph of hourly average fuel c...

Page 108: ...on rate may differ from the actual value due to the operating conditions of the customers fuel weather or work contents etc Switching of the displayed graph On Average Fuel Consumption Record screen if you press the menu switch 5 graph display changes be tween the hourly average fuel consumption during the last 12 hours and the daily fuel consumption during the last 7 days Last 12 hours display La...

Page 109: ... Consumption Display Switching display non display of ECO Gauge Display Setting for ECO Gauge Display Fuel Target Value Switching display non display of ECO Guidance Switching display non display of ECO Guidance Display at Key OFF Operations on Configurations screen You can perform the following operations with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above...

Page 110: ...sumption in 1 day from 0 00 a m of the day to 0 00 a m of the next day It will be reset at 0 00 a m of the next day Split Time Displays the average fuel consumption during the split measurement period after the measurement is started until it is finished Select Split Time to start the split measurement automatically You can perform the following operations with switches 1 to 4 on the switch panel ...

Page 111: ...tion Records and ECO Guidance Records SWITCH DISPLAY NON DISPLAY OF ECO GAUGE Display non display of ECO gauge can be switched 1 Select ECO Gauge Display on Configurations menu screen then press ENTER switch 4 2 ECO Gauge Display screen is displayed Select ON or OFF then press ENTER switch 4 ON Displays the ECO gauge OFF Does not display the ECO gauge You can perform the following operations with ...

Page 112: ...e selected change and returns the screen to Configurations menu screen REMARK If OFF is selected on ECO Gauge Display screen the items of ECO Gauge Display Fuel Target Value are not displayed SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE ECO Gauge Display Fuel Target Value A the upper limit val ue of the green range can be changed 1 Select ECO Gauge Display Fuel Target Value on Config u...

Page 113: ...t fuel consumption value setting and returns the screen to Configurations menu screen The default is 119 ℓ h REMARK If the target fuel value is increased the fuel consumption indicated when the ECO gauge is at the maximum is also increased commensurately If the target fuel value is decreased the fuel consumption indicated when the ECO gauge is at the maximum is also decreased commensurately SWITCH...

Page 114: ...Configurations menu screen 4 ENTER switch Allocates the selected change and returns the screen to Configurations menu screen The default is ON REMARK If ECO Guidance Display is set to OFF the items of ECO Guidance Display at Key OFF and ECO Guidance Records are not displayed but ECO Guidance Records is not reset SWITCH DISPLAY NON DISPLAY OF GUIDANCE WHEN KEY IS OFF The display non display of Oper...

Page 115: ...panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected change and returns the screen to Configurations menu screen 4 ENTER switch Allocates the selected change and returns the screen to Configurations...

Page 116: ...ed RADIATOR FAN REVERSE MODE k k CAUTION When you rotate the fan in the opposite direction to clean the dust around the fan make sure that no persons or obstructions are around the area The Fan Reverse Mode can be used to clean the dusts or insects stuck to the radiator etc by operating the machine monitor to rotate the fan in reverse 1 Seat the dump body and stop the engine 2 Turn the starting sw...

Page 117: ...vel or operate the dump body while the fan rotates in reverse wrong operation in fan re verse mode caution lamp lights up At the same time the centralized warning lamp lights up and the alarm buzzer sounds intermittently 5 After finishing cleaning stop the engine A certain time after the starting switch key is turned to OFF position the fan is returned to the normal rotation mode automatically Che...

Page 118: ...y stop the air conditioner to protect itself from being damaged PAYLOAD METER You can display and set the following items related to the pay load meter Accumulated Payload and Total Cycles Average Fuel Consumption Record Machine ID Setting Open ID Setting Calibration KTCS SYSTEM SETTING if equipped You can set ON or OFF of the KTCS system 1 Select KTCS Setting then press ENTER switch 4 EXPLANATION...

Page 119: ...perates automatically REMARK This setting is maintained even after turning the starting switch to OFF position The default is ON ARSC SETTING You can set ON or OFF of the ARSC system 1 Select ARSC Setting then press ENTER switch 4 2 Select ON or OFF then press ENTER switch 4 OPERATION EXPLANATION OF COMPONENTS 3 67 ...

Page 120: ...osition 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 following procedure 1 Select Dumping Counter then press ENTER switch 4 EXPLANATION OF COMPONENTS OPERA...

Page 121: ...l the resetting REVERSE TRAVEL ODOMETER The total reverse travel distance can be checked with the Re verse Travel Odometer TRIP METER The overall travel distance after the previous resetting can be checked by using Trip Meter OPERATION EXPLANATION OF COMPONENTS 3 69 ...

Page 122: ...resetting confirmation screen Press ENTER switch 4 and Trip Meter is reset The screen returns to Machine Setting and Information menu screen REMARK When reset is not necessary press RETURN switch 3 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 70 ...

Page 123: ...er is set to D position Normal NOTICE Select F2 usually If the machine travels in F1 while F1 is not necessary the service life of the machine may be shortened REMARK This setting is maintained even after turning the starting switch to OFF position The default is F2 AIR CONDITIONER ECO MODE SETTING You can turn ON or OFF the air conditioner ECO mode to improve the fuel efficiency by reducing effic...

Page 124: ...r higher or the set tem perature of the air conditioner is 18 C maximum cooling air conditioner may not be operated in the ECO mode even if A C ECO Mode Setting is turned to ON This setting is maintained even after turning the starting switch 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 contr...

Page 125: ...o idle stop function stops the engine automatically when the engine is operated continuously at idle for a set time The auto idle stop works only when all of the following conditions are met The accelerator pedal is not depressed The 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 mach...

Page 126: ...ure then press ENTER switch 4 You can perform the following operations with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected change and returns the screen to Machin...

Page 127: ...sual When the auto idle stop operates while the parking brake is in TRAVEL position set the parking brake switch to PARKING position and then to TRAVEL position again and the parking brake is released AFTERTREATMENT DEVICES REGENERATION Each item of Aftertreatment Devices Regeneration menu screen is for settings and operations of the aftertreatment devi ces regeneration MAINTENANCE SCREEN SETTING ...

Page 128: ...s 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 distributor METHOD FOR RESETTING REMAINING TIME FOR MAINTENANCE After performing the ...

Page 129: ...RK When reset is not necessary press RETURN switch 3 4 Press ENTER switch 4 on Maintenance Due Time Re set screen the remaining time is reset and the screen re turns to Maintenance menu screen REMARK When reset is not necessary press RETURN switch 3 If the remaining time and the replacement interval are equal the remaining time cannot be reset MONITOR SETTINGS Each item of Monitor Setting menu scr...

Page 130: ...t is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Monitor Setting menu screen 4 ENTER switch The screen changes to the setting screen for the selected item GUIDE LINE DISPLAY MODE This is used to change the display or non displa...

Page 131: ...is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Rearview Monitor Setting menu screen 4 ENTER switch Allocates the selected setting and returns the screen to Rearview Monitor Setting menu screen The setting of Guide Line Displ...

Page 132: ...tches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Rearview Monitor Setting menu screen 4 ENTER switch Allocates the selected setting and returns t...

Page 133: ...h panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Monitor Setting menu screen 4 ENTER switch The screen changes to the setting screen for the selected item SEL...

Page 134: ...s with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Meter Display Selection menu screen 4 ENTER switch The screen changes to the ...

Page 135: ... clock You can perform the following operations with switches 1 to 4 on the switch panel 1 UP switch Moves to the previous item 1 line above When it is on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Cancels the selected item and returns the screen to Meter Display Selection menu sc...

Page 136: ...h Allocates the change and returns the screen to Monitor Setting menu screen 5 Menu switch The brightness returns to the initial state REMARK The brightness in the day and night modes can be adjusted individually When the screen is adjusted with the lamp switch in OFF position the brightness in the day mode can be adjusted When the screen is adjusted with the lamp switch in ON position and when th...

Page 137: ...es to the next item 1 line below When it is on the last line it moves to the first line 3 RETURN switch Returns the screen to Monitor Setting menu screen 4 ENTER switch Displays the setting screen for the selected item REMARK After a long term storage the 2 items of Calendar and Time are reset Accordingly you must readjust them When GPS Synchronization is ON the 2 items of Calendar and Time are re...

Page 138: ...en on the first line it moves to the last line 2 DOWN switch Moves to the next item 1 line below When on the last line it moves to the first line 3 RETURN switch Cancels the selected setting and returns the screen to Clock Adjustment menu screen 4 ENTER switch Allocates the selected setting and returns the screen to Clock Adjustment menu screen REMARK When the machine is in the environment where t...

Page 139: ... numeral by 1 2 DOWN switch Puts back the numeral by 1 3 RETURN switch Cancels the change and returns the screen to Clock Adjustment menu screen 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 the numeral...

Page 140: ...time of the machine monitor can be adjusted on Time screen REMARK While GPS Synchronization is turned on the item of Time cannot be selected 1 Select Time from Clock Adjustment menu screen then press ENTER switch 4 2 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 ...

Page 141: ... returns the screen to Clock Adjustment menu screen 12 HOUR AND 24 HOUR DISPLAY MODE On 12hour or 24hour Mode screen you can set the display mode of clock 1 Select 12hour or 24hour Mode from Clock Adjustment menu screen then press ENTER switch 4 2 12hour or 24hour Mode screen is displayed Select 12hour or 24hour then press ENTER switch 4 12hour Select 12 hour display AM PM 24hour Select 24 hour di...

Page 142: ...G On Daylight Saving Time screen you can set the clock display forward 1 hour 1 Select Daylight Saving Time from Clock Adjustment menu screen then press ENTER switch 4 2 Daylight Saving Time screen is displayed ON The clock is displayed in daylight saving time summer time Displays the time 1 hour forward OFF The clock is displayed in normal time You can perform the following operations with switch...

Page 143: ...anish Portuguese Italian German Swedish Dutch Danish Norwegian Fin nish Icelandic Czech Hungarian Polish Slovak Slovene Romanian Croatian Estonian Latvian Lithuanian Bulgarian Greek Serbian Turkish 1 Select Language Setting on Monitor Setting menu screen then press ENTER switch 4 2 Language Setting screen is displayed Select the language to be displayed on Language Setting screen then press ENTER ...

Page 144: ...Setting menu screen 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 If the already registered ID is inputted when the starting switch is turned to ON position the identified ID is displayed in Oper ator ID column on Monitor Setting menu screen If SKI...

Page 145: ...switch 4 A message is displayed below the screen returns to Monitor Setting menu screen and the identified ID is changed The changed ID is displayed at Operator ID column on Monitor Setting menu screen When you press the menu switch 5 on Operator ID Change screen a message is displayed below and the screen changes to Monitor Setting menu screen On Monitor Setting menu screen is displayed in the co...

Page 146: ...WITHOUT SKIP When the operator identification function is available without SKIP the identified ID number is not displayed in the Operator ID column of Monitor Setting menu screen 1 Select Operator ID on Monitor Setting menu screen then press ENTER switch 4 for 1 second 2 Operator ID Change screen is displayed REMARK When the ID change is not necessary press RETURN switch 3 Input the already regis...

Page 147: ...conds or longer the screen changes to Monitor Setting menu screen and the ID number is not changed MESSAGE DISPLAY On machines equipped with KOMTRAX when message pilot lamp is lit on the standard screen you can see the messages from your Komatsu distributor on the mail check menu screen by pressing the menu switch Message is distinguished as follows according to the lighting states of the message ...

Page 148: ...ge the message will be dis played on the end screen and when the monitor is started next time the message will change to a read message the message display lights up in blue The message is deleted when it becomes out of date or when a new message reaches CHECK MESSAGE Select the message confirmation menu screen and you can read the arrived message A Subject of message When no message has been rece...

Page 149: ...ower right of each switch 2 After inputting a selected item number press ENTER switch 4 3 When Do you send Numeric Input is displayed press ENTER switch 4 again The input value is sent out REMARK To cancel sending press RETURN switch 3 The input value is cleared REMARK If the message is replied Numeric Input Done is displayed for it OTHER FUNCTIONS OF MACHINE MONITOR Confirming method of the servi...

Page 150: ...s UP switch 1 while holding down DOWN switch 3 with the starting switch in OFF position Service meter A and odometer B are displayed while both switches are held down EXPLANATION OF COMPONENTS OPERATION 3 98 ...

Page 151: ...g switch if equipped 4 Fog lamp switch 5 Horn button 6 Hazard lamp switch 7 Secondary steering switch 8 Front brake off switch 9 AISS LOW switch 10 Starting switch 11 Wiper and window washer switch 12 Lamp switch dimmer switch turn signal lever OPERATION EXPLANATION OF COMPONENTS 3 99 ...

Page 152: ...G SWITCH Starting switch is used to start or stop the engine A OFF position The electrical current to the electrical system is cut and the en gine stops The key can be inserted into or removed from the starting switch REMARK Even when the starting switch is at OFF position the horn haz ard lamp secondary steering and room lamp 1 can operate B ON position Electric current flows through the charging...

Page 153: ...extend the engine preheating time longer than the automatic preheating time In that case turn the starting switch to the manual preheat position D When it is released it automatically returns to OFF position A Immediately turn it to START position C and start the engine CIGARETTE LIGHTER The cigarette lighter is used to light the cigarettes When the cigarette lighter is pushed in it will return to...

Page 154: ... to flash the turn signal lamps R Right turn Push the lever forward L Left turn Pull the lever backward When the lever 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 wiper and window washer switch is used to operate the wiper for the front glass NO...

Page 155: ...sition Sets the machine monitor and rearview monitor to the night mode Monitor screen loses the brightness REMARK When the lamp switch is turned to OFF position operating this switch does not change the brightness SWITCH FOR MIRROR WITH HEATED WIRE Heated mirror switch is used to turn on and off the heater for side view mirrors Position A Wire heater ON Position B Wire heater OFF REMARK The wire h...

Page 156: ...e starting switch is at ON position and the parking brake switch is at TRAVEL position the secondary steering operates automatically after 1 second To prevent this set the parking brake switch to PARKING position REARVIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH The rearview monitor brightness adjustment switch is used to adjust the brightness of the rearview monitor The brightness in the day and nigh...

Page 157: ...f switch to ON position to drive the machine slowly with a safe speed on the fro zen road snow road and slippery road You can change the braking method of the brake according to the road condition with the front brake off switch Set the front brake to be disabled by turning off the front brake off switch since the machine may go into a skid when the front brake is applied on the soft road surface ...

Page 158: ...mp lights up on the machine moni tor When the parking brake switch is set to PARKING position A if the gear shift lever is at any position other than NEU TRAL position N the centralized warning lamp lights up and the alarm buzzer sounds intermittently B TRAVEL position The parking brake is released REMARK If the engine is stopped while the parking brake switch is kept in TRAVEL position B the park...

Page 159: ...mp goes out ROOM LAMP1 SWITCH The room lamp 1 switch is used to turn on and off the room lamp 1 Position A OFF Position B Lights up when the cab door opens Position C Lights up REMARK The room lamp lights up even when the starting switch is at OFF position so when leaving the operator s seat set the switch to the position A or B When performing the operations with the door fully opened set the swi...

Page 160: ...n it There is a switch under the cover 2 Raise the engine shutdown secondary switch to upper po sition A and the engine stops After 2 seconds from stop ping of the engine Engine Shutdown Secondary SW in Operation is displayed and the alarm buzzer sounds inter mittently A ENGINE STOP When abnormal switch is set to upper position B Normal When normal switch is set to lower position When cover 1 is c...

Page 161: ...aircase lighting goes out Staircase lighting switch at the step REMARK The staircase lighting lights up even when the starting switch is at OFF position Always turn off the staircase lighting when leaving the machine otherwise the battery will be consumed CONTROL LEVERS AND PEDALS 1 Retarder control lever 2 Gear shift lever 3 ARSC travel speed set lever 4 Accelerator pedal 5 Brake pedal 6 Secondar...

Page 162: ... while the accelerator pedal is released If the accelerator pedal is depressed while the ARSC is in operation the ARSC system stops operation The KTCS system can operate while the accelerator pedal is depressed and the gear speed is at any of the 1st speed through 4th speed or REVERSE If the accelerator pedal is released while the KTCS is in operation the KTCS system stops operation GEAR SHIFT LEV...

Page 163: ...rect 11 5 km h 11 4 km h R Reverse torque converter 12 0 km h 11 8 km h The machine moves off at 2nd speed or 1st speed when the gear shift lever is set to D position Do not set the gear shift lever to NEUTRAL position N during the travel Before performing the directional selection stop the machine completely and run the engine at low idle When starting the engine if the gear shift lever is in any...

Page 164: ...y the parking brake REMARK When the ARAC system is in operation the retarder control lever has some play at the start of stroke It does not mean that the retarder does not work but that it is the range of the ARSC system operation Sud den operation of the retarder lever will cause sudden braking Take care If the retarder is operated with retarder control lever while the KTCS is in operation the KT...

Page 165: ... the engine is started again with the dump body raised the dump body is held in HOLD condition and the dump body float caution lamp lights up DUMP LEVER LOCK KNOB k k WARNING To inspect the machine with the dump body lifted set the dump lever to HOLD and lock with knob Then use the body pivot pin The dump lever lock knob is a locking device for the dump lev er To set it to FREE position F pull out...

Page 166: ... the door handle and knob whenever opening or closing the door Be careful not to get your hands caught between the front pillar or center pillar When there is anyone inside the cab always call out a warning before opening or closing the door CAB DOOR HANDLE Pull the cab door handle while it is not locked and the door opens to the full open position OPEN KNOB FOR CAB DOOR Pull the open knob for the...

Page 167: ...the setting of the air conditioner blows into the drink box Turn the knob counterclockwise and pull the cover up and open it L LOCK position The cover is locked F FREE position The cover is unlocked When closing the cover lock it by turning the knob clockwise while pressing the cover LUNCH BOX TRAY The lunch box tray is located at the rear of the operator s seat MAGAZINE BOX The magazine box is pr...

Page 168: ... at the front of the center console Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid POWER SUPPLY OUTLET 12V power supply 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 EXPLANATION OF COMPONENTS OPERATION 3 116 ...

Page 169: ...acity and type FUSE CAPACITIES AND CIRCUIT NAMES Fuse box I BT1 No Capaci ty Name of circuit 1 10 A Main lamp clearance lamp 2 15 A Headlamp Hi 3 15 A Headlamp Lo 4 10 A Stop lamp 5 15 A Backup lamp alarm buzzer 6 30 A Heated wire mirror power supply 7 10 A Heated wire mirror upper R H 8 10 A Heated wire mirror L H 9 10 A Heated wire mirror lower R H 10 15 A Auto greasing if equipped 11 20 A DC co...

Page 170: ...ower supply 26 10 A KOMTRAX Plus 27 10 A Download continuous power supply 28 5 A ABS controller if equipped 29 10 A Auto greasing if equipped continuous power supply 30 20 A Spare continuous power supply Fuse box III BT3 No Capaci ty Name of circuit 31 20 A Air conditioner blower motor 32 10 A Air conditioner compressor clutch 33 10 A Radio 34 20 A Front wiper 35 10 A Room lamp 2 door solenoid 36 ...

Page 171: ... Preheat relay 55 20 A Spare 56 15 A Staircase lighting continuous power supply if equipped 57 5 A Radio continuous power supply 58 10 A Hazard lamp continuous power supply 59 10 A Room lamp system operating lamp continuous power supply 60 15 A Horn continuous power supply Fuse box V BT5 No Capaci ty Name of circuit 61 5 A Smart sensor 1 62 5 A Smart sensor 2 63 64 10 A AUX 65 66 67 68 69 70 10 A ...

Page 172: ...the front left side of the machine GREASE PUMP HOLDER The grease pump holder is in the battery box Wipe off the grease attached to the grease pump after use Insert the grease pump into the grease pump holder and fix it with the rubber band when not in use BATTERY DISCONNECT SWITCH k k CAUTION Do not turn the battery disconnect switch to OFF while engine operates or immediately after engine is stop...

Page 173: ...side the battery disconnect switch cover on the front right side of the machine Battery disconnect switch 1 is used to cut out the electricity from the battery REMARK Operate this switch while the system operating lamp 2 is not lit O OFF position The switch key 3 can be pulled out and inserted and the cur rent from the battery is cut out I ON position The current from the battery flows into the ci...

Page 174: ...o START position Circuit breaker 2 may have open circuit if the electric de vices do not operate after the fuse has been replaced REMARK A circuit breaker is a circuit protection device installed to a high capacity current circuit Similarly to an ordinary fuse it protects electrical parts and wir ing from burning out caused by abnormal current It can be op erated without replacement after the abno...

Page 175: ...spect the machine with the dump body lifted set the dump lever to HOLD and lock with knob Then use the body pivot pin The body pivot pin is a safety device to fix the dump body Use it when performing the inspection and maintenance with the dump body raised Raise the dump body fully insert the body pivot pins Always insert the body pivot pin on both of right and left sides STORAGE FOR BODY PIVOT PI...

Page 176: ...ent from the actual state appears on an image on the rearview monitor So look at the center of the screen as a guide Actuate rearview monitor 1 when driving the machine in re verse to check the rear of the machine Guide line 2 on the rearview monitor is used to check the side and rear of the machine roughly The guide line is set for the machine with no load on the flat ground When the machine is l...

Page 177: ... 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 178: ...r or alcohol Sometimes an image on the rearview monitor display is blurred due to the 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 ...

Page 179: ...k can be continued unless when the KDPF soot accumulation caution lamp 2 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 l...

Page 180: ...ic regeneration may be performed and the manual sta tionary 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 noncombustible material in the exhaust gas and i...

Page 181: ...onds 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 L03 is displayed in red on the action level 4 If the machine is stopped completely the screen changes to the Aftertreatment Devices Regeneration...

Page 182: ...s seat during the regeneration of the aftertreatment devices The manual stationary regeneration can be performed while the KDPF soot accumulation caution lamp 2 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 stati...

Page 183: ...he dump body and set the fan rotation in the normal direction If the dump body is operated during the manual stationary regeneration the regeneration may stop REMARK After 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 the KDPF soot accumulation abnormal...

Page 184: ...nary regen eration disappears and the screen returns to the standard screen At this time to display the explanation of the manual stationary regeneration again press the menu switch on the standard screen to display the Aftertreatment Devices Regeneration screen 8 This screen is displayed during the manual stationary re generation It may take more than 40 minutes to complete the manual stationary ...

Page 185: ...y regeneration stop the regeneration temporarily and move the machine by referring to the aftertreatment devices regeneration disable and cancel procedures described below When restarting the manual stationary regeneration secure the safety of the machine and around it then cancel the regeneration disable 9 After the manual stationary regeneration is completed the screen automatically returns to t...

Page 186: ...starting switch to OFF position When the automatic re generation needs to be kept disabled perform the above procedure each time you start the engine During the regeneration to protect the system even if the regeneration disable is set aftertreatment devices regen eration display 1 may light up but this does not indicate abnormality Also during the regeneration to protect the system the regenerati...

Page 187: ...tem may not be stopped but this is not a failure PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING k k CAUTION Before you start the cancel regeneration disable operation park the machine in a safe area Make sure that no persons or flammable matter s are around the area 1 Press the menu switch on the standard screen when the aftertreatment devices regeneration is disabled ...

Page 188: ...l antenna or cables This may cause failure or fire on the wireless equipment or the machine itself Near the blasting jobsite there may be a danger of unexpected explosion due to use of the wireless equipment and resulting serious personal injury or death If you have to operate the machine within 12 m from the remote controlled blasting device the pow er supply cable of the wireless communication d...

Page 189: ...rating lamp is not lit set the battery disconnect switch to OFF position When the battery disconnect switch is turned to OFF position it prevents the battery power from being con sumed but the functions of KOMTRAX Plus stop at the same time If the power supply cable of KOMTRAX Plus system device has to be disconnected contact your Komatsu distributor OPERATION EXPLANATION OF COMPONENTS 3 137 ...

Page 190: ...ck 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 3 Check around the engine ...

Page 191: ...nd retighten the bolts 13 Check the lamp and rearview camera for damage If any part is damaged replace it with new one Clean off any dirt on the surface 14 Check the side mirror and under view mirror Check that the mirrors are not damaged If any one is damaged replace it with a new one Clean the surfaces of the mirrors and adjust the angle so that the area at the rear and lower portions can be see...

Page 192: ...s k k WARNING If worn or damaged tires are used they may burst and cause serious injury or death To ensure safety do not use the following tires Wear Tires with the tread groove depth of 15 or less of that of a new tire Tires with the abnormal wear such as uneven wear or stepped wear Damage Tires with damage that has reached cords 1 or with cracks in the rubber Tires with cut or broken cords 1 Tir...

Page 193: ...the wheel hub bolts 1 for that wheel If any bolt is loose retighten it Tightening torque 1519 to 1852 Nm 155 to 189 kgm Insert a socket wrench in a pipe then apply a force of 1685 N 172 kg at point 1 m from the fulcrum This will give a tighten ing torque of 1685 Nm 172 kgm When the hub bolts are tightened after the tires are replaced drive the machine for 5 to 6 km and check the tightening tor que...

Page 194: ...D REPLACING AIR CLEANER 4 13 2 After cleaning or replacing press the top of dust indicator to return the red line to its original position METHOD FOR CHECKING BATTERY DISCONNECT SWITCH Check that battery disconnect switch S is in ON position I METHOD FOR CHECKING WATER SEPARATOR DRAINING WATER AND SEDI MENT k k WARNING Immediately after the engine is stopped all of parts are still very hot Avoid d...

Page 195: ...efilter 3 Put a container to catch the water under the plug 5 4 Loosen the plug 5 and drain the water 5 When fuel starts to be drained from the plug 5 tighten the plug 5 immediately to stop draining If the drain plug 5 is hard to turn apply the grease to O ring 6 of plug 5 according to the following pro cedure 1 Place a container under the plug 5 to catch the fuel 2 Loosen the plug 5 and drain all...

Page 196: ...e temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully 1 Check the oil level with the sight gauge G If the oil is seen from the sight gauge G the oil level is correct 2 If the oil is not seen from the sight gauge G add the oil through the oil filler port F METHOD FOR CHECKING ...

Page 197: ...EAR BRAKE OIL COLLECTION TANK 1 Check that no oil leaks from the overflow tube at the rear brake oil collection tank 2 Collect the oil according to the following procedure if it is being leaked 1 Place a container to catch oil just under the drain plug P 2 Remove the drain plug P and drain the oil Collect the oil from the brake tanks on the right and left sides 3 Tighten the drain plug P OPERATION...

Page 198: ...move the cap F and add the coolant up to FULL mark If no coolant is left in reservoir tank add coolant according to the following procedure 1 Remove the bolts 2 and remove the cover 3 2 Add coolant to the radiator through the coolant filler port 4 on top of the radiator 3 Add it to the reservoir tank as well If more coolant is added than usual then check for water leakage 2 Check that there is no ...

Page 199: ...h ENGINE STOP PED mark and check while the engine is stopped If the oil level is below L mark add oil through oil filler port F If the oil level is above H mark remove the drain plug 1 and loosen the drain valve 2 to drain the excessive oil 3 Check the oil level again 4 If the oil level is proper tighten the oil filler cap F secure ly METHOD FOR CHECKING ELECTRIC WIRING k k CAUTION If fuses are fr...

Page 200: ...vel is low When the remaining fuel level is low add fuel 2 Open the fuel filler cap F of the fuel tank 3 Add fuel through the fuel filler port Fuel tank capacity 800 ℓ 4 After adding fuel securely close the fuel filler port cap F of the fuel tank After finishing the work fill the fuel tank REMARK If the breather hole in the cap is clogged the pressure inside the tank will go down and this may caus...

Page 201: ...NG SECONDARY BRAKE PERFORMANCE k k WARNING The machine may start moving during the checking of the secondary brake performance As a result serious personal injury or death may occur Observe the following Select the flat and large area which gives the machine an enough braking distance to stop securely If the machine starts moving during the inspection of the secondary brake performance immediate l...

Page 202: ... more than 90 seconds to avoid damage or fire Self check function for secondary steering k k CAUTION Do not operate the steering during the test to avoid sudden movements The secondary steering is started automatically when the starting switch is turned to ON position to check the secondary steering functions If defective operation of the secondary steering motor is found ask your Komatsu distribu...

Page 203: ...tion and check that the secondary steering motor operates in 1 sec ond While the secondary steering motor is in operation the secondary steering pilot lamp 5 lights up 7 After checking set the parking brake switch 4 to PARK ING position 8 Turn the starting switch 1 back to OFF position REMARK If the secondary steering motor operates 60 seconds or longer the secondary steering motor long operation ...

Page 204: ...just it before starting operation or when operators change shift Adjust the position of the operator s seat so that you can depress the brake pedal fully with your back against the seat backrest METHOD FOR ADJUSTING SEAT UNIT IN FORE AND AFT DIRECTION Operate the fore aft adjustment lever upward set the seat to the desired position then release the fore aft adjustment lever Adjustment amount 152 4...

Page 205: ...t adjustment lever upward move the front of the seat cushion up and down to adjust it to the desired position then release the tilt adjustment lever Adjustment amount Forward tilt 5 Backward tilt 5 METHOD FOR ADJUSTING SEAT HEIGHT NOTICE Avoid using the height adjustment switch continuously for 1 minute or longer since such practice can damage the air compressor Turn the starting switch to ON posi...

Page 206: ... the seat height to the desired position more quickly by pressing the switch while reducing the load on the seat METHOD FOR ADJUSTING SEAT CUSHION IN FORE AFTER DIRECTION Pull up the fore and aft adjustment lever set the seat cushion to the desired position then release the fore and aft adjust ment lever Fore aft adjustment range 60 mm If the seat backlash is found ask your Komatsu distributor for...

Page 207: ... SUPPORT NOTICE Avoid operating the air lumbar support continuously for 1 minute or longer since such practice can damage the air compressor Operate the air lumbar support adjustment switch to give a proper tension to the waist part A Position for air inflation Air is pumped in the air bag in the backrest and the air bag is inflated B Position for air bleeding Air is bled from the air bag in the b...

Page 208: ...ecreased Adjustment amount 5 stages METHOD FOR USING SEAT HEATER k k CAUTION Using the heater for a long time may cause low temperature burn blister etc Do not put heavy luggage on the cushion Do not stick the cushion with needles nails etc Do not put blanket cushion or other heat retaining material on the seat cushion Doing so may cause overheat If water or beverage etc spills on the seat cushion...

Page 209: ... Do not put heavy luggage on the cushion Do not stick the cushion with needles nails etc Do not put blanket cushion or other heat retaining material on the seat cushion Doing so may cause overheat If water or beverage etc spills on the seat cushion immediately wipe it off with soft cloth etc and dry out the seat cushion before using it REMARK The seat heater and the ventilation cannot be used at t...

Page 210: ...en the temperature of the cushion becomes suitable The heater in the seat cushion stops When using the ventilation 1 Set the seat heater and ventilation selector switch 1 to the ventilation position B 2 Set the air flow control switch 2 to HIGH position D or LOW position E The ventilator operates and air blows out from the cushion seat and backrest C OFF position The ventilation function stops D H...

Page 211: ...ew View range Mirror A Hatched area A the area around tire s ground contact point A ground A and the top edge of the dump body must be in view Mirror B Hatched area B and a part of the machine body must be in view Mirror C Hatched area C and a part of the machine body must be in view Mirror D Hatched area D the area around tire s ground contact point D ground D and the top edge of the dump body mu...

Page 212: ...perly you cannot secure the visibility and may be injured or may lead to a serious personal injury or death When adjusting the angle of the rearview camera prepare a scaffold first in order to provide a safe working platform Otherwise serious personal injury or death by such as an electric shock may occur Install only the Komatsu genuine camera As shown in the figure stop the machine on a flat gro...

Page 213: ...guide line 4 matches with body rear end 2 When the guide line is abnormal change its setting to Non display and contact your Komatsu distributor 2 If the image on the rearview monitor is not aligned correct ly loosen mounting bolts 1 3 places and adjust the mounting angle of the rearview camera Mounting angle of the rearview camera can be adjusted within the range of 25 to 55 downward when the hor...

Page 214: ...nufactured 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 on 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 on the seat pull the right side of the...

Page 215: ...urely fixed to the buckle tongue 1 of the waist belt METHOD FOR RELEASING SEAT BELT RETRACTOR STOPPER 1 Remove the retractor from the seat A fitting can be seen from the bolt side through the oblong hole as shown in the figure 2 Pull the belt while pushing in the fitting with a ruler or such The stopper is released and you can untwist the belt if it is twisted OPERATION MACHINE OPERATIONS AND CONT...

Page 216: ... 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 and exc...

Page 217: ...ING position then start the engine Before standing up from the operator s seat be sure to set the parking brake switch to PARKING posi tion 1 Check that the battery disconnect switch S is in ON posi tion I 2 Check that the parking brake switch 1 is in PARKING position a 3 Check that the gear shift lever 2 is in NEUTRAL position N OPERATION MACHINE OPERATIONS AND CONTROLS 3 165 ...

Page 218: ...er of the engine shutdown secondary switch 4 is closed 7 Insert the key into the starting switch 5 and turn it to ON position B 8 Check that the machine monitor operates in the following manner 1 Centralized warning lamp 6 and pilot display 7 light up for 2 seconds and go out for 1 second MACHINE OPERATIONS AND CONTROLS OPERATION 3 166 ...

Page 219: ...ted 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 rearview monitor displays the software version for 5 seconds 6 If a password has been set the password input screen will be displayed on the monitor screen After inputting the passwo...

Page 220: ...ding and the engine can be started 9 When the caution lamp stays lit press ENTER switch and Current Abnormality screen is displayed For the contents and check methods for caution lamp see WARNING DISPLAY 3 15 10 When the maintenance time caution lamp lights up in red press the menu switch and Maintenance menu screen is displayed For the method of checking the maintenance time see MAINTENANCE SCREE...

Page 221: ...e engine coolant temperature is low the preheating pi lot lamp on machine monitor 2 lights up and the automat ic preheating starts 2 Keep the key in starting switch 1 at ON position B until preheating is completed and the preheating pilot lamp goes out The following shows the rough preheating time Coolant temperature Preheating time 5 C or more 25 to 5 C 20 to 45 seconds 25 C or less 45 seconds RE...

Page 222: ...t it is not a trouble 5 Do not operate the accelerator pedal immediately after starting the engine Run the engine for at least 15 seconds at low idle When the engine is started for the first time after the engine oil or engine oil filter is replaced continue the low idle run for at least 20 seconds to circulate the engine oil in the engine METHOD FOR MANUAL PREHEATING WHEN STARTING ENGINE Manual p...

Page 223: ...rger is a device that rotates at a very high speed seizure results if it is not lubricated well In order to protect above trouble the turbo protect function restricts increase of the engine speed immediately after the engine is started until its oil pressure reaches an appropriate level While the turbo protect function is operating increase of the engine speed is restricted even if the accelera to...

Page 224: ...ery badly at low idle and in the acceleration and if that condition contin ues it may damage the engine or confuse the operator s sense of driving or lower the braking effi ciency and as a result lead to an unexpected accident In that case ask your Komatsu distributor to check the engine as soon as possible When stopping the machine during the normal traveling operation check that the engine does ...

Page 225: ...on for more than 20 minutes It does not only adversely affect the environment but also cause oil leakage from the turbocharger When the warming up has not been operated enough if the parking brake switch is set to TRAV EL and the dump lever is operated the secondary steering may be actuated instantaneously 1 After the engine starts run it for 5 minutes in the range between low idle and medium spee...

Page 226: ...it Always lower the dump body and set the dump lever to FLOAT position then stop the engine 1 Set the gear shift lever 1 to NEUTRAL position N and set the parking brake switch 2 to PARKING position A 2 Lower the dump body and set the dump lever 3 to FLOAT position C 3 Run the engine at low idle for approximately 5 minutes to cool it down gradually MACHINE OPERATIONS AND CONTROLS OPERATION 3 174 ...

Page 227: ...aper and debris to avoid a fire hazard 4 Remove any mud affixed to the undercarriage METHOD FOR STARTING MACHINE TRAVEL FORWARD AND REVERSE AND STOPPING MACHINE METHOD FOR MOVING MACHINE k k WARNING When moving off the machine check that the area around the machine is safe then sound the horn before starting Keep people away from the machine Clear any obstacles from the travel path There is a blin...

Page 228: ...ase operate the parking brake switch to PARKING position A once and then move it back to TRAVEL position B to release the park ing brake 6 Check that the retarder pilot lamp is not lit on the machine monitor 1 7 Set the gear shift lever 5 to a desired position NOTICE Always place the gear shift lever securely in posi tion when operating it If the gear shift lever is not placed securely in position...

Page 229: ...confirm the safety in the direction to select There is a blind spot behind the machine so be ex tremely careful when driving the machine in reverse Always stop the machine completely before switching the travel direction NOTICE The machine cannot be driven in reverse when the dump body is raised Lower the dump body set the dump lever to FLOAT position then operate the gear shift lever to R positio...

Page 230: ...n stopping in emergency or when parking the machine af ter stopping it Release the accelerator pedal 1 then depress the brake ped al 2 to stop the machine METHOD FOR STOPPING MACHINE IN EMERGENCY 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 neces...

Page 231: ... the secondary brake the cen tralized warning lamp flashes and the alarm buzzer sounds In this case return the gear shift lever to NEUTRAL posi tion N to cancel the operation of centralized warning lamp and alarm buzzer 2 After the machine is stopped set the parking brake switch 3 to PARKING position A 3 When the machine is stopped in emergency chock the tires immediately Investigate the failure o...

Page 232: ...OTICE When switching the direction FORWARD or REVERSE stop the machine completely and run the engine at low idle then select 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 accelerator pedal depressed This will cause a big shock and will also reduce the service life...

Page 233: ... to rise the brake is automatically applied to prevent the engine speed from rising too far Neutral coast prevention function If the gear shift lever is set to NEUTRAL position N while the machine is traveling at the travel speed of 4 km h or higher the gear shift cannot be changed to neutral The centralized warning lamp flashes and the alarm buz zer sounds intermittently If the travel speed excee...

Page 234: ...s operated again return the retarder control lever completely to RELEASE position and depress the brake pedal to stop the machine then contact your Komatsu distributor for repair Operate the retarder control lever gradually Sudden braking may cause an accident due to tire slip and it is dangerous When traveling and particularly when traveling downhill never set the gear shift lever to NEUTRAL posi...

Page 235: ... the travel speed Shift the gear shift lever to the position other than D posi tion 6 5 4 3 2 L if the gear speed needs to be fixed due to the condition of road surface 4 When traveling downhill operate the retarder control lever 2 to set the engine speed to the range of 1800 to 2200 rpm and drive the machine so that the indicator of the retarder oil temperature gauge comes within the green range ...

Page 236: ...he maximum permissible speed The tires may be locked when the dump truck is running on a slippery hauling road and the ARSC system is enabled If it happens refrain from using the ARSC system When the system cannot be properly controlled due to a trouble in the system the alarm sounds and the ARSC is canceled If necessary stop the machine at a safe place by controlling the retarder control lever an...

Page 237: ...as for normal brake operations If the ARSC travel speed is set near the gear shifting point or when the grade of the slope is changed the gear speed may be changed upshift or downshift even when the ARSC is actuated The time taken for the machine to reach the set travel speed varies with the grade of the downhill slope Indication of the speedometer and the set travel speed may not always be the sa...

Page 238: ...sition after deceleration Sudden lever operation will cause sudden braking Take care 1 Operate the retarder control lever to decelerate the machine 2 When it gets to the desired travel speed press the set switch of the ARSC travel speed set lever The travel speed is changed to the low speed MEMORIZE ARSC SET TRAVEL SPEED The set travel speed is saved when the starting switch is turned to OFF posit...

Page 239: ... travel speed indicator automatically drops as well 10 km h is the lower limit value of the travel speed when it automatically drops BRAKE PERFORMANCE CURVE BRAKE PERFORMANCE CURVE HD465 8 How to read the brake performance curve Example Downhill distance 1500 m Traveling resistance 11 Grade resistance 13 rolling resistance 2 Payload 55 t Obtain the maximum permissible speed and the gear speed rang...

Page 240: ...a safe travel speed to be below the maximum permissible speed to match the conditions of the jobsite so that the retarder brake oil temperature gauge is always in the green range when traveling Brake performance Downhill distance 450 m Tire size 24 00R35 MACHINE OPERATIONS AND CONTROLS OPERATION 3 188 ...

Page 241: ...Brake performance Downhill distance 600 m Tire size 24 00R35 Brake performance Downhill distance 900 m Tire size 24 00R35 OPERATION MACHINE OPERATIONS AND CONTROLS 3 189 ...

Page 242: ...e Downhill distance Continuous Tire size 24 00R35 BRAKE PERFORMANCE CURVE HD605 8 How to read the brake performance curve Example Downhill distance 1500 m Traveling resistance 11 Grade resistance 13 rolling resistance 2 Payload 63 t MACHINE OPERATIONS AND CONTROLS OPERATION 3 190 ...

Page 243: ...s the performance curve as C and draw a perpendicular line down Take the point where this line crosses the travel speed scale as D 5 The following information can be obtained from this procedure The maximum permissible speed is 29 8 km h from the point D The gear speed is F3 from the point C This maximum permissible speed is a reference obtained from the retarder brake performance Determine a safe...

Page 244: ...Brake performance Downhill distance 450 m Tire size 24 00R35 Brake performance Downhill distance 600 m Tire size 24 00R35 MACHINE OPERATIONS AND CONTROLS OPERATION 3 192 ...

Page 245: ...Brake performance Downhill distance 900 m Tire size 24 00R35 Brake performance Downhill distance 1500 m Tire size 24 00R35 OPERATION MACHINE OPERATIONS AND CONTROLS 3 193 ...

Page 246: ...he turn will cause damage to the machine When the machine is traveling turn the steering wheel 1 to the desired direction The machine turns On roads where there are curves let the accelerator pedal back before coming to the curve shift down to the lowest speed range possible then depress the accelerator pedal again to continue driving Do not coast at high speed on a curved road REMARK The angle of...

Page 247: ...peed caution lamp The overspeed caution lamp warns about the overspeed of the travel speed while the overload speed limit func tion is actuated Retarder pilot lamp The retarder pilot lamp lights up while the retarder is being actuated by the speed limit function OPERATION OF OVERLOAD SPEED LIMIT FUNCTION The overload speed limit function judges the load if it is overloaded after the machine starts...

Page 248: ...ne monitor Take appropriate actions following the list of action level dis plays and required actions Check the failure code Notify your Komatsu distributor of the failure code and ask for repair Failure code Failure name Whether the systems continue or discon tinue the control Continue x Discontinue Engine control Retarder control CA131 Throttle Sensor High Error x x CA132 Throttle Sensor Low Err...

Page 249: ...ith weight of 300 kg or more When transporting the steel ingots HANDLING PAYLOAD METER OUTLINE OF SYSTEM The payload meter detects the signals from the suspension pressure sensors clinometer during travel and cal culates the payload by processing the data statistically The obtained payload is displayed on the machine monitor and with the external display lamps You can download the data saved in th...

Page 250: ...nd 3 red The display of the external display lamps changes according to the payload Data download connector inside the cab Communication cable connection port in the cab is inside of the cover on the rear of the operator s seat You can download the data saved in the payload meter to a personal computer through the download connector Before downloading the data remove the cables which have been con...

Page 251: ...to be stabilized in the stopped state 2 For the machine to be recognized as Loaded from Loading the machine should have traveled 160 m or more 525 ft or more continuously from the loading point 3 The Stopped means the state in which the gear shift lever is in NEUTRAL position N or the travel speed signal is zero 4 Payload is not displayed on the machine monitor immediately after the starting switc...

Page 252: ... the overloaded state Do not carry the load with this overloaded state The payload should not exceed the limit shown with the lighting of yellow lamp for the safe travel The external display lamps display the payload as follows Color of lamp HD465 HD605 1 Green 27 5 t and up 31 5 t and up 2 Yellow 49 5 t and up 56 7 t and up 3 Red 57 8 t and up 63 0 t and up Lighting of the red lamp 3 indicates th...

Page 253: ...ully so that the red lamp 3 does not light up DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER The payload meter records the data of the dumping cycle from each dumping to the next dumping Cycle data items Dumping Month Day Travel time with no load Stopped time for loading Stopped time with load Time to start dumping Travel distance with no load Travel time with load Dumping time Machine ID Trave...

Page 254: ...r There is some error in the directory where the data is downloaded by the special software there may be a mistake in the setting for the machine In such case consult your Komatsu distributor 1 Remove the connected cable 2 Connect the download cable attached to the special soft ware to the download connector 3 Connect the other end of the download cable to RS232C port of the personal computer 4 Tu...

Page 255: ...ide the download box to ON position A The display lamp 3 lights up after a while when download can be performed REMARK If 15 minutes has passed without downloading the data af ter turning the switch 2 to ON position A the switch 2 in the download box is automatically turned off while it re mains in ON position A The display lamp 3 goes out this time 7 Start up the personal computer and use the spe...

Page 256: ...n The download software is started and the screen shown in the figure is displayed 2 When the screen G1000 is displayed click PLM The screen G2000 is displayed Do not click CARD and PMC since they are not used 3 Click Parameter Setting on the screen G2000 The screen G2200 is displayed Do not click PLM Remote Control since it is not used 4 Click Unit Setting on the screen G2200 The screen G2210 is ...

Page 257: ...xt download 6 Click ENTER to return to the screen G2200 7 On the screen G2200 click BACK to return to the screen G2000 8 Click Download on the screen G2000 9 When the screen G2100 is displayed click Start Downloading starts When downloading is finished close the screen REMARK The screen G2101 Down load File ID is displayed de pending on the software version In this case input the file ID and click...

Page 258: ...since they have been last reset is displayed in Accumulated Payload and Total Cycles The display range is from 0 to 99999999 9t and 0 to 999999 cycles respectively When they reach the upper limits they are kept at the upper limits until they are reset 3 Press ENTER switch 2 The pop up window of the data reset is displayed Press RETURN switch 3 and the screen returns to Pay load Meter menu 4 Press ...

Page 259: ...Press the menu switch 1 to display Machine Setting and Information menu select Payload Meter then press EN TER switch 2 2 Select Average Fuel Consumption Record then press ENTER switch 2 The average value of the daily working fuel consumption in the last 1 week is displayed as shown in the figure OPERATION MACHINE OPERATIONS AND CONTROLS 3 207 ...

Page 260: ...t doing anything SETTING MACHINE ID AND OPEN ID You can change the setting of the machine ID and open ID which are the items in the cycle data You can check the operator and the load of each cycle afterward by setting the machine No as the machine ID and setting the operator and the load type as the open ID 1 Press the menu switch 1 to display Machine Setting and Information menu select Payload Me...

Page 261: ... 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 Select Open ID Setting on the screen of step 2 for setting the open ID The set open ID is displayed on the right side 6 The setting procedure for the open ID is the same with the machine ID Set the open ID METHOD FOR PERFORMING CALIBRATION Perform the calibration in the follo...

Page 262: ...re 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 the calibration according to the following procedure 1 Press the menu switch 1 on the standard screen and on Machine Setting and Information screen se lect Payload Meter then press ENTER switch 2 2 Sele...

Page 263: ...riving 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 METHOD FOR DUMPING k k WARNING Always follow the instructions of the signalman when performing dumping operations When dumping the large rocks operate the dump body slowly When performing the inspection or...

Page 264: ...speed When the dump body rises to the previously set position dump lever 3 returns to HOLD position B The dump body is then held at that position 3 If it is necessary to raise the dump body further operate the dump lever 3 to RAISE position A The dump body rises further If dump lever 3 is released dump lever 3 will return to HOLD position B and the dump body will stop at that position While raisin...

Page 265: ...p for any EMERGENCY item on the machine monitor should flash and the buzzer sounds during operation stop the machine immediately and investigate the cause When loading be careful to load the dump body uniformly and be particularly careful to avoid loading too much at the front When traveling on slippery road surfaces operate the retarder control lever slowly and shift the transmis sion down to pre...

Page 266: ...t the machine from moving If the gear shift lever is touched by mistake the ma chine may move suddenly and this may lead to 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 brake k k CAUTION Make sure to release the parking brake when you travel 1 Release the accelerator ...

Page 267: ...con trol lever 5 fully to apply the retarder METHOD FOR CHECKING AFTER FINISHING WORK Check the engine coolant temperature engine oil pressure and fuel level with the machine 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 OPERATION MACHINE OPERATIONS AND CONTROLS 3 215 ...

Page 268: ... common key for 1 to 8 METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP 1 Insert the starting switch key into the key slot 2 Turn the starting switch key to OPEN position A and then align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 3 Turn the fuel filler cap slowly to unlock it Click sound is heard 4 Open the fuel fil...

Page 269: ...ey slot 2 Turn the starting switch key to OPEN position A and align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 3 Turn the oil filler cap slowly to unlock it Click sound is heard 4 Open the oil filler cap METHOD FOR LOCKING TRANSMISSION CASE FILLER CAP 1 Screw in the oil filler cap 2 Insert the starting switch key into the key slot 3 Turn the starting switch key t...

Page 270: ...n the oil filler cap slowly to unlock it Click sound is heard 4 Open the oil filler cap PROCEDURES FOR LOCKING OIL FILLER CAP OF STEERING AND HOIST OIL TANK 1 Screw in the oil filler cap 2 Insert the starting switch key into the key slot 3 Turn the starting switch key to LOCK position B and then align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 4 Remove the starti...

Page 271: ...position B and then align the key slot with the match mark 1 of the cap Position A OPEN Position B LOCK 4 Remove the starting switch key METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR k k CAUTION Make sure that the cab door is locked when it is closed Always place the machine on a level ground when opening or closing the cab door Avoid opening or closing the door on a slope since there is a dang...

Page 272: ...osition B and then remove the starting switch key Position A OPEN Position B LOCK HANDLE TIRE PRECAUTIONS WHEN HANDLING TIRES k k WARNING To ensure safety the defective tires given below must be replaced with new tires Tires where the bead wire has been cut broken or greatly deformed Excessively worn tires where more than 1 4 of the circumference of the carcass ply excluding the breaker is exposed...

Page 273: ...ng more T Km P H to the tire is performed the work T Km P H value exceeds the T Km P H value particular to the tire Observe the following in such case Moderate the work condition so that the work T Km P H value goes down Change the tire to the one whose T Km P H value is higher TIRE T Km P H VALUE AND CONTINUOUS MAX TRAVEL SPEED How to obtain the work T Km P H value by calculation The work T Km P ...

Page 274: ...fore 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 HD465 8 HD605 8 Tire size Tire inflation pressure kPa kg cm2 24 00R35 680 to 700 6 9 to 7 1 NOTICE If the tires are used when the tire inflation pressure is less than the value given in the table above the rim may be damaged Maintain the tire in...

Page 275: ...e air conditioner may not work In this case circulate the recirculation air to warm the inside of the cab After that turn on the air conditioner switch and the air con ditioner will work If any abnormality is detected in any equipment or sensor used on the air conditioner the air conditioner system cau tion lamp lights up on the monitor screen If the air condi tioner system caution lamp lights up ...

Page 276: ...switch Air conditioner display A Air flow bar B Air conditioner operation symbol C Set temperature display D FRESH RECIRC selector symbol E Vent display F Automatic operation symbol G Defroster symbol 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...

Page 277: ...dium 4 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 Normally set 25 C The temperature can be set in stages of 0 5 C Air conditioner di...

Page 278: ...s When vent selector 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 Face vent 4 places B Foot vent 1 place C Front window glass vent 3 places Liquid crystal dis play Air vent mode Vent Remarks A B C Face vent Face vent foot vent Foot vent Foot vent Defroster vent Not selec...

Page 279: ... may change temporarily but this is not a failure Even if the control changes it returns automatically to control the air according to the set temperature and the ambient envi ronment after certain period of time elapses FRESH RECIRC AIR SELECTOR SWITCH Use the FRESH RECIRC air selector switch to switch the air source between recirculation of the air inside the cab and in take of fresh air from th...

Page 280: ...WITCH Use the air conditioner switch to start and stop the cooling heating or drying function Press the air conditioner switch when the fan is operating when the air flow level is shown on the display monitor The air conditioner is turned on and starts operating Press the switch again to stop the air conditioner Air conditioner cannot be operated while the fan is not op erating HANDLE AIR CONDITIO...

Page 281: ...tomatic operation symbol on the air condi tioner display goes out and the defroster mark is dis played METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually Select the method of operation as desired METHOD FOR AUTOMATIC OPERATION 1 Press AUTO switch The automatic operation symbol on the air conditioner dis play lights up OPERATION HANDLE AIR CONDITIONER...

Page 282: ...perate the temperature control switch unnecessarily It may take longer time to reach the set temperature To heat or cool the air quickly set the temperature dis play to 18 0 C max cooling or 32 0 C max heat ing If each switch is operated during automatic operation the function of that switch is applied first the automat ic operation symbol on the air conditioner display goes out and the manual ope...

Page 283: ...ven during the manual operation To heat or cool the air quickly set the temperature display to 18 0 C max cooling or 32 0 C max heating 4 Press vent selector switch and select the desired vents The liquid crystal display for the air conditioner display changes according to the selection 5 Press the FRESH RECIRC air selector switch and select the recirculation of the air inside the cab RECIRC or th...

Page 284: ...R TO FEET To operate with cold 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 3 232 ...

Page 285: ...h ON 4 Adjust fan switch temperature control switch and FRESH RECIRC air selector switch to the desired positions METHOD FOR OPERATING DEFROSTER 1 Press the fan switch and adjust the air flow OPERATION HANDLE AIR CONDITIONER 3 233 ...

Page 286: ...or switch or defroster switch and set the 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 the temperature control switch and set the tempera ture on the display monitor to 32 C of maximum heating HANDLE AIR CONDITIONER OPERATION 3 234 ...

Page 287: ...5 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 on the air conditioner switch OPERATION HANDLE AIR CONDITIONER 3 235 ...

Page 288: ... 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 is press...

Page 289: ...yed at steps of 50 kHz in certain areas C Lights up when a stereo broadcasting is heard while a FM station is selected D Lights up at the time of balance adjustment in the sound adjusting condition E Lights up at the time of treble adjustment in the sound ad justing condition F Lights up at the time of bass adjustment in the sound adjusting condition AUX You can hear the sound through the speaker ...

Page 290: ...d up it is automatically registered to preset memories 1 to 6 METHOD FOR CALLING PRESET 1 Press band AUX selector button 1 and select FM or AM 2 Press one of 1 to 6 of preset button 2 The frequency registered in the preset number of the pressed button is called up and received Example While a frequency is displayed press button 1 of preset button 2 and the preset number P 1 is displayed on the dis...

Page 291: ...REGISTER RANGE BASS 1 Press sound control button 1 to light up BAS on the dis play You can adjust the sound bass 2 Press tuning time adjustment button 2 to adjust the sound bass Press the button and the bass level increases by 1 Maximum 7 Press the button and the bass level decreases by 1 Minimum 7 METHOD FOR ADJUSTING CLOCK 1 Press display selector button 1 to display the time 2 Hold down display...

Page 292: ...6 Press display selector button 1 to cancel time adjustment The screen returns to the clock display HANDLE RADIO OPERATION 3 240 ...

Page 293: ...le 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 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 Ko...

Page 294: ...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 295: ...th of the machine After loading the machine in the specified position secure it in place as follows 1 Set the parking brake switch to PARKING position A to apply the parking brake 2 Turn the starting switch to OFF position and stop the en gine 3 Remove the key from the starting switch 4 Put the blocks in front of and behind the tires and secure the machine with chains or wire rope of a suitable st...

Page 296: ...ment than those given in the following procedures There is a danger that the machine loses its balance NOTICE This lifting method applies to the standard specification machine The method of lifting differs depending on the attachments and options installed For the procedure for the machine with other than standard specification consult your Komatsu distrib utor For the weight of the standard speci...

Page 297: ...605 8 51620 kg 26109 kg 25591 kg 2126 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 2 Set the dump lever to FLOAT position C and check that the dump body float caution lamp is not lit OPERATION TRANSPORTATION 3 245 ...

Page 298: ...position of the machine varies according to the condition For machine with a dump body Positions 1 and 3 For machine without a dump body Positions 1 and 2 5 Fit the protector blocks at contact points between the lifting tool and the dump body to prevent damage to the lifting tool 6 When the machine comes off the ground being lifted 100 to 200 mm stop the lifting operation check care fully that the...

Page 299: ...ot flammable For details on the coolant change interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE BATTERY k k WARNING Battery generates flammable gas Never bring any open flame near fuel Battery electrolyte is dangerous object If it gets in your eyes or on your skin wash it off with a large amount of water ...

Page 300: ...ich en tered inside the seal Place the machine on a firm dry ground If there is no firm and dry ground park the machine on boards This prevents the undercarriage from freezing to the ground surface and allows the machine to be started easily the next morning 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 The batter...

Page 301: ... 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 equipment wipe off all the grease from the hydraulic cylinder rods If the machine is equipped with an air conditioner operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner com...

Page 302: ...heck all the oil and water levels before traveling 2 When traveling after long term storage travel forward at a speed of 10 to 15 km h for 5 minutes or 1 km to run the machine in then change to normal travel PRECAUTIONS FOR LONG TERM STORAGE OPERATION 3 250 ...

Page 303: ...rm the following procedure 1 Turn the starting switch to ON position or start the engine 2 Disconnect pull out the limp home connector 1 No A1 female A1 male white 1 pole connector and then connect insert it again 3 Set the parking brake switch to TRAVEL position 4 Operate the gear shift lever to move the machine to a safe place without depressing the accelerator pedal If the gear shift lever is o...

Page 304: ...bottom side 6 Turn the grip 8 of valve 6 counterclockwise The oil in the hoist cylinder is discharged into the steering and hoist oil tank and the dump body lowers 7 When the dump body is lowered to the desired position turn the bottom side grip 6 clockwise and tighten the lock nut 7 8 Turn the head side grip 5 clockwise and tighten the lock nut 4 9 Install the cover 2 If the dump body cannot be l...

Page 305: ... NOTICE Tow the machine only for a short distance such as to a place for inspection and maintenance Do not tow the machine for a long distance The maximum towing capacity for this machine is as follows Do not tow any load greater than this HD465 8 356500 N 36340 kg HD605 8 380400 N 38770 kg For towing a failed machine consult your Komatsu distributor This machine must not be towed except in emerge...

Page 306: ...a danger that the machine may move suddenly Connect with the towing wire or drawbar and remove the blocks from the wheels when the towed machine is in a condition where it cannot run away When releasing the parking brake check that the area around the machine is safe If the parking brake is released the brakes will not work so pay careful attention to safety When towing on a slope use 2 towing mac...

Page 307: ...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 area around the machine is safe and always chock all the wheels before starting the work If the wheels are not chocked there is a danger that the machine may move suddenly Always stop the ...

Page 308: ...and it will at tack your clothes and skin If it gets on your clothes or on your skin immediately wash it off with a large amount of clean water If it gets in your eyes wash the eyes immediately with clean water then consult a doctor for medical treat ment When handling batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the groun...

Page 309: ... the ground cable last When replacing the battery fix the battery body with the battery mounting fixtures Securely tighten the terminal to the following tightening torque Tightening torque of wiring harness terminal 1 11 8 to 19 6 Nm 1 2 to 2 0 kgm Tightening torque of battery terminal 2 9 81 to 11 8 Nm 1 0 to 1 2 kgm Tightening torque of 1st nut 3 of mounting fixture 6 96 to 9 02 Nm 0 71 to 0 92 ...

Page 310: ...tach the clips securely Set the charging current to 1 10 or less of the value of the rated battery capacity When performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or the battery cells will dry up and this may cause the battery to catch fire and explode Do not charge the battery or start the engine with a dif ferent...

Page 311: ...dingly the normal machine must be equipped with a 24 V power supply Use the jumper cables and clips that corresponds 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...

Page 312: ...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 313: ...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 314: ...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 315: ...reakage of oil pan pipe joint Check repair Wiring to the sensor is disconnected or broken Repair the wiring or connect it Steam spurts out from top of radiator pressure valve Engine coolant is insufficient coolant leaks 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 316: ...ust gas color is white or bluish Excessive oil in oil pan Make the oil level to the speci fied level by referring to CHECKS BEFORE STARTING Piston ring and cylinder liner are worn Replace Low grade fuel being used Replace with specified fuel Turbocharger has a trouble Check replace Water entry in the aftertreatment de vices Check repair Breakage of the aftertreatment devi ces Replace the aftertrea...

Page 317: ...Y When caution lamp 1 is displayed on the machine monitor or any of L04 L03 L01 is displayed at action level 2 part of the failure display screen or action level L02 is displayed once and an action level is still dis played after performing remedies do as follows Apply the parking brake and press ENTER switch 3 Current Abnormality is displayed Take the actions according to the message shown on the...

Page 318: ...y Current Abnormality screen and telephone number for the point of contact is displayed in the message column at the bottom of the screen REMARK If no point of contact telephone number is registered no tele phone number is displayed Ask your Komatsu distributor for the telephone number regis tration if necessary TROUBLES AND ACTIONS OPERATION 3 266 ...

Page 319: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 320: ...en 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 is connected near instruments connectors etc the instruments may...

Page 321: ...d replace them with new parts When doing this be careful not to forget to assemble O rings and gaskets When installing the hoses do not twist them or bend them sharply If they are installed so their service life will be extremely shortened and they may be damaged CHECKS AFTER INSPECTION AND MAINTENANCE Unexpected problems may occur if you do not perform the necessary inspection and maintenance Alw...

Page 322: ...ift only one side of tire off the ground set the support stand 5 under the frame to make the machine stable Do not jack up by applying the jack to the A frame 6 Oth erwise the A frame will become deformed or damaged by the load of the jack Rear The machine is jacked up on the left side as shown in the illustration When you jack up the rear axle to replace the rear tire or such insert the plate suc...

Page 323: ...lways be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too much oil or too little oil are b...

Page 324: ...ed 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 Komatsu recommends the use of Non Amine Engine Coolant AF NAC If you use another coolant it may cause serious problems such as corrosion of the engine and aluminum parts of the cooling system When using antifre...

Page 325: ... of 5 μm or more en abling early detection of failures Others Measurements are made of items such as the ratio of water coolant and fuel in the oil and dynamic viscosity if necessary to enable a highly precise diagnosis of the machine and the components condition Oil sampling interval 500 hours Precautions when sampling Make sure that the oil is well mixed before sampling Perform sampling at regul...

Page 326: ...y 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 water When washing the machine be careful not to let water get into the electrical components Wipe off the water drops stuck around connectors before removing the connectors an...

Page 327: ...ter of bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 10 13 3 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 67 6 8 59 to 74 6 0 to 7 5 12 19 111 11 3 98 to 123 10 0 to 12 5 14 22 172 17 5 153 to 190 15 5 to 19 5 16 24 260 26 5 235 to 285 23 5 to 29 5 18 27 360 37 0 320 to 400 33 to 41 20 30 510 52 3 455 to 565 46 5 to 58 22 32 ...

Page 328: ... 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 329: ... CASE 4 35 METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE ADDING OIL 4 36 METHOD FOR CHECKING DRIVE SHAFT 4 36 METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 4 36 METHOD FOR CLEANING TRANSMISSION CASE BREATHER 4 38 METHOD FOR CLEANING STEERING AND HOIST OIL TANK BREATHER 4 39 METHOD FOR CHECKING FRAME 4 40 METHOD FOR CHECKING FOOT BRAKE PERFORMANCE 4 40 METHOD FOR CHECKING RETARDER BRAKE PERFORM...

Page 330: ...ING AND HOIST OIL TANK 4 69 METHOD FOR LUBRICATING DRIVE SHAFT 4 70 METHOD FOR CHECKING WATER PUMP 4 70 METHOD FOR CHECKING STARTING MOTOR 4 70 METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH PRESSURE PIPING CLAMP HARD ENING OF RUBBER 4 70 METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER 4 71 EVERY 4500 HOURS MAINTENANCE 4 72 METHOD FOR CLEANING KDPF 4 72 METHOD FOR C...

Page 331: ...laps over the peripheral red zone 7 5 kPa 0 076 kg cm2 If the element is cleaned frequently before the air cleaner clogging caution lamp on the machine monitor lights up or the yellow piston of the dust indicator laps over the peripheral red zone 7 5 kPa 0 076 kg cm2 the air cleaner will not be able to display its performance fully and the cleaning efficiency will also go down In addition during t...

Page 332: ...ng the engine failure Do not use damaged element Do not use the removed inner element more than once Make sure to replace the inner element when you replace the outer element Keep new elements dry 1 Stop the engine 2 Remove the clips 1 12 places and remove the cover 2 3 Hold the outer element 3 rock it lightly up and down and to the right and left and pull the outer element 3 out while turning it ...

Page 333: ...eats from the outside then blow again from the inside 12 After cleaning the outer element illuminate the inside of the element with an electric bulb to check If any hole or thin place is found replace the outer ele ment 13 Remove the cover of cloth or tape attached to inner ele ment 4 14 Check the seal of the cleaned or new element for sticking of dusts and oil and wipe them off if any 15 Push the...

Page 334: ...ches the red line 7 5 kPa 0 076 kg cm2 immediately after the cleaning of the outer element re place both inner and outer elements with new ones METHOD FOR REPLACING AIR CLEANER ELEMENT 1 Stop the engine 2 Remove the clips 1 12 places and remove the cover 2 3 Hold the outer element 3 rock it lightly up and down and to the right and left and pull the outer element 3 out while turning it to the right...

Page 335: ... cleaner body 5 Lock the clips 1 diagonally top and bottom right and left in the same way as when tightening the bolts 4 When the cover 2 is installed check that the clear ance between air cleaner body 5 and cover 2 is not too large If the clearance is too large remove the cover 2 and then install it again 12 Press the button of the dust indicator and return the yellow piston METHOD FOR CLEANING I...

Page 336: ...1 46 50 54 58 61 64 k k WARNING Coolant is toxic When opening the drain plug be careful not to get coolant on you If it gets in your eyes flush your eyes with large amount of fresh water and see a doctor immediately When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator request a qualified company to perform the operation or conta...

Page 337: ...nd remove the cover 2 on top of the sub tank 3 Remove the bolts 3 4 pieces and remove the cover 4 on top of the radiator 4 Check that the radiator cap is cooled enough to touch by bare hands and turn the radiator caps 5 and 6 a little to release the pressure and then turn them slowly to remove 5 Prepare a container to catch the coolant MAINTENANCE MAINTENANCE PROCEDURE 4 19 ...

Page 338: ...8 and drain the coolant from the reservoir tank 9 18 Clean the inside of reservoir tank 19 Close the drain valve 8 20 Add Non Amine Engine Coolant until it reaches to FULL 21 Start the engine Run the engine at low idle for 5 minutes to remove the air from the coolant then raise the coolant temperature to 90 C or higher and continue to run for approximately 10 minutes 22 Stop the engine Wait for 3 ...

Page 339: ...is not reversed Stop the engine and then select the fan reverse mode The fan reverse rotation pilot lamp is lit on machine monitor while the fan is rotating in reverse Do not perform the operation while it is lit If you do so the machine does not provide a good performance and overheating occurs easily The normal rotation should be used always when operating the machine For stopping the engine whi...

Page 340: ...t REMARK The fan rotation switches from the normal direction nor mal rotation direction to the reverse direction only when all of the following conditions are satisfied The engine is stopped The cooling fan is stopped 8 Start the engine The fan rotates in reverse 9 Set the engine speed to high idle and perform the cleaning Select the time for running the engine at high idle as follows according to...

Page 341: ... reverse operation is performed without satisfying the condition for reversing the fan In this case press RETURN switch 2 and then perform the procedure again REMARK When a certain time has passed after the starting switch key is turned to OFF position the fan is returned to the normal rotation normal rotation direction automatically METHOD FOR CLEANING FIN WITH COMPRESSED AIR k k WARNING Stop the...

Page 342: ... on the right side of the cab 2 Check the fluid level in window washer tank 2 1 If the window washer fluid is insufficient open the cap of window washer tank 2 add the window washer fluid for automobiles Be careful not to let dirt or dust get in when adding it 2 Close the cap of window washer tank 2 3 After checking the fluid level close the cover 1 METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIO...

Page 343: ...er fresh air filter 3 Clean the air filter fresh air filter with compressed air 4 Open the cover 2 at the rear left of the operator s seat 5 Pull out the air filter recirculation air filter 6 Remove the dust sticking to the air filter recirculation air filter with low compressed air or a soft brush METHOD FOR CHECKING DUMP BODY Check that there are no cracks in the dump body 1 Clean the dump body ...

Page 344: ...e label 1 2 Remove the bolts 2 4 pieces and remove the cover 3 of the front suspension cylinder 3 Measure the dimension B from the shoulder at the rod head of the front suspension cylinder to the top surface of the flange Dimension B 245 to 265 mm Reference C 515 to 535 mm Ask your Komatsu distributor for inspection if there is any problem found when checking the front suspension 4 Install the cov...

Page 345: ...ont brake need the air bleeding Items to be prepared Vinyl hose Container with oil in it METHOD FOR BLEEDING AIR FROM REAR BRAKE Always bleed air from the brake circuit in the order of the slack adjuster and wheel brake 1 Start the engine 2 Check with the sight gauge that the oil level in the transmission case is at the specified level 3 Check that the brake oil pressure caution lamp is not lit 4 ...

Page 346: ...el 3 Check that the brake oil pressure caution lamp is not lit 4 Bleed air from the slack adjuster 1 Remove the cap of bleeder screw 1 of the block por tion on the slack adjuster 2 Insert a vinyl hose to the bleeder screw 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 approximately 50 mm 5 Pull the retarder c...

Page 347: ...ap proximately 50 mm 9 Depress the brake pedal and keep it depressed 10 Loosen the bleeder screw 1 approximately 3 4 turns 11 Keep depressing the brake pedal and check that no bubble comes out through the vinyl hose 12 Tighten the bleeder screw 1 securely 13 Install the cap to the bleeder screw 1 14 Adjust the oil level in the transmission case to the specified level METHOD FOR BLEEDING AIR FROM F...

Page 348: ...y not be bled Stop the engine and repeat the operations of steps 4 to 7 again NOTICE Keep away from the engine while it is being started and running Do not turn the start switch for more than 20 seconds Wait for 2 minutes before you turn start switch again REMARK Move the switch for the fuel feed pump 2 to ON position then the air bleeding starts automatically The fuel feed pump is operated for 30...

Page 349: ...o the step 3 8 Measure the amount of movement L of the coupling by using the marks made in the steps 4 and 7 If amount of movement L exceeds 15 mm the rubber in side the output shaft may be deteriorated or damaged so ask your Komatsu distributor for disassembly and inspec tion 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 ...

Page 350: ...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 tire inflation pressure and abnormal fitting of the rim will cause a failure in the tire or rim In this case be sure to ask a tire repair shop for repair Be sure to observe t...

Page 351: ... BEFORE STARTING 3 141 Drain water and sediment from fuel tank Check looseness of wheel hub bolts and retighten Check oil level in transmission case add oil Check dust indicator Check battery disconnect switch Check water separator drain water and sediment Check oil level in steering and hoist oil tank add oil Check oil level in brake sub tank add oil Check oil leakage in rear brake oil collection...

Page 352: ...ery day when operating the machine in the places where the grease flows out easily such as when traveling through mud or water Dump body hinge pin 1 place each of right and left Rear suspension 2 places each of right and left Differential support 4 places each of right and left Hoist cylinder pin 2 places each of right and left Perform the greasing when the dump body is lowered MAINTENANCE PROCEDU...

Page 353: ...h of right and left METHOD FOR CHECKING AND ADDING OIL IN DEFERENTIAL CASE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the plug oil may spurt out so turn it slowly to release the internal pressure then remove it carefully MAINTENANCE MAINTENANCE PROCEDUR...

Page 354: ...y 1 Stop the machine so that TOP embossed mark is at the top and the drain plug P is at the bottom 2 Remove the plug G If the oil level is low add oil through the hole of plug G until the oil level comes close to the lower edge of the plug hole 3 Install the plug G METHOD FOR CHECKING DRIVE SHAFT Check that there is no problem such as loose connection of the drive shaft play in the splines and bea...

Page 355: ... level from the side of the battery check as follows The battery box is on the front of the machine 1 Open the cover 1 of the battery box Open the cover 1 of the battery box fully and it is se cured by rod 2 2 Clean around the electrolyte level line with a cloth wet with water 3 Check that the electrolyte level is between UPPER LEVEL line and LOWER LEVEL line 4 If the electrolyte level is below th...

Page 356: ...u add the battery fluid to the cell of cap 3 add it to other cells as well 5 After adding tighten the cap 3 securely REMARK If the battery fluid is added to the level above the bottom of the sleeve use a syringe to remove it until the level becomes under the bottom of the sleeve Neutralize the removed fluid with baking soda sodium bicar bonate then flush it away with a large amount of water If nec...

Page 357: ...LEANING STEERING AND HOIST OIL TANK BREATHER 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 1 Remove mud and dirt around the breather 2 Remove the breather Take care to prevent dirt from entering through the mount ing section of the breather 3 Remove the nut 1 of breather...

Page 358: ...diately set the gear shift lever to NEUTRAL position N and set the parking brake switch to PARKING position NOTICE When checking be sure to select F2 in F1 Start at D Position Setting and then set the gear shift lever to position D Neglecting this can damage the inside of the transmission 1 Check that F2 is selected on F 1 Start at D Position Set ting of user menu of the machine monitor 2 Place th...

Page 359: ... lever 1 fully 3 Set the gear shift lever 2 in position D and increase the engine speed gradually If the machine does not move when the engine speed is increased to 1400 rpm it is normal If any problem is found ask your Komatsu distributor for repair 4 Decrease the engine speed and set the gear shift lever to NEUTRAL position N METHOD FOR CHECKING PARKING BRAKE PERFORMANCE k k WARNING If the machi...

Page 360: ...SION if equipped k k WARNING Always observe the following One worker must always sit in the operator s seat and be ready to stop the engine at any time All workers must maintain contact with the other workers Set the parking brake switch to PARKING position A so that the machine does not move Do not touch the gear shift lever Always give a signal to your fellow workers to evacuate them to a safe p...

Page 361: ...ur Komatsu distributor for the inspection and adjustment if there is any problem found METHOD FOR CHECKING FUNCTION OF ACCUMULATOR If the engine stops during travel the brake can be operated with the oil pressure in the accumulator temporarily 1 Stop the machine on a flat ground 2 Set the parking brake switch to PARKING position A 3 Turn the starting switch to START position C and start the engine...

Page 362: ...e accumulator is normal REMARK Check the function within 5 minutes after stopping the en gine If the engine is kept stopped the gas pressure in the accu mulator lowers and cannot be checked 7 After checking turn the starting switch to OFF position A EVERY 500 HOURS MAINTENANCE Maintenance for every 250 hours service should be performed out at the same time METHOD FOR CHANGING OIL IN ENGINE OIL PAN...

Page 363: ...ed immediately after stopping the engine a large amount of oil will come out so wait for approximately 10 minutes before starting the work 8 Clean the filter head 9 Fill the new filter cartridge with clean oil 10 Apply oil or thinly apply grease to the packing surfaces and thread portion 11 Install the filter cartridge When doing this be careful not to damage the outside cylinder of the cartridge ...

Page 364: ...atsu genuine parts The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a substitute When performing inspection and maintenance of the fuel system be care...

Page 365: ...r portion on the clean side 9 Thinly apply oil to the packing surfaces 10 Remove the filter cartridge cap A and install it to the filter head When installing the cartridge tighten it by hand until the packing surface contacts the seal surface of the filter head If the filter cartridge is tightened too much the packing may be damaged and this will cause the leakage of fuel If it is not tightened en...

Page 366: ...hinly apply clean oil to the O ring and install it 8 Install a new element to the filter case 5 Tightening torque of filter case 58 8 to 78 5 Nm 6 to 8 kgm 9 Install the cover 2 with bolts 1 3 pieces 10 Start the engine Run the engine at low idle for a while 1 minute or more 11 Check that the oil level in the transmission case and that it reaches the specified level Replace the element immediately...

Page 367: ...ual Perform the check on both sides Replace all of 8 pieces if one of the pads reaches the wear lim it Wash the machine thoroughly after working in the muddy site Mud stuck to the calipers and discs promotes the wear of the pad if it remains untouched METHOD FOR CHECKING AND REPLACING ALTERNATOR AND AIR CONDI TIONER COMPRESSOR DRIVE BELT METHOD FOR CHECKING ALTERNATOR AND AIR CONDITIONER COMPRES S...

Page 368: ... Install the cover 2 with bolts 1 8 pieces METHOD FOR REPLACING ALTERNATOR AND AIR CONDITIONER COMPRES SOR DRIVE BELT k k WARNING Do not open the cover while the engine is running Stop the engine always before performing the check ing 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 1 ...

Page 369: ...nd oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully NOTICE Do not start the engine before filling with oil If the engine is started when there is no oil in the system it will cause damage to the transmission an...

Page 370: ...oil 4 After draining the oil tighten the drain valve 4 5 Install the drain plug 3 4 Wash the strainers 3 places 1 Remove the bolts 5 and remove the cover 6 2 Take out the strainer 7 3 Remove all dirt from strainer 7 then wash it in clean diesel fuel or flushing oil 4 Check the strainer 7 If the strainer is damaged replace it 5 Install the new O ring and install the strainer 7 6 Install the cover 6...

Page 371: ...ine 2 Add the oil through the oil filler port F until the oil is seen from the sight gauge H 3 Start the engine and run it at low idle 9 Run the engine at low idle for a few minutes and stop it 10 Add oil through the oil filler port F until the oil level is be tween H and L marks on the sight gauge G1 11 Bleed air 1 Remove the cap of the bleeder screw 10 2 Insert a vinyl hose to the bleeder screw ...

Page 372: ...ELEMENT k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully 1 Stop the engine 2 Turn the cap of oil filler port F to release the internal pres sure...

Page 373: ... control accumulator to 0 REMARK When the pressure in accumulator is released the depressing effort of the brake pedal decreases and no hydraulic sound is made 3 Place a container to catch oil just under the brake oil filter 4 Rotate the hexagonal portion on the bottom of the filter case 1 by using a wrench and remove the filter case 1 5 Remove the element 2 6 Clean the inside of the filter case 7...

Page 374: ...el injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a substitute When performing inspection and maintenance of the fuel system be careful not to let any foreign material g...

Page 375: ...ates After the specified time approximately 7 minutes lamp 4 goes out automatically and the fuel feed pump stops When lamp 4 goes out air bleeding is completed 2 Start the engine If the engine does not start all the air may not be bled In this case repeat the operation of step 7 8 After completing the air bleeding start the engine and check the filter seal surface for fuel leakage If there is any ...

Page 376: ...FOR LUBRICATING 1 Stop the engine 2 By using a grease pump pump in grease through the grease fitting shown by arrow 3 Check visually that the greasing has been performed properly 4 After greasing wipe off any old grease that is pushed out Transmission mount 1 place Automatic suspension link 1 place each of right and left if equipped MAINTENANCE PROCEDURE MAINTENANCE 4 58 ...

Page 377: ... the wear limit Ask your Komatsu distributor for inspection and mainte nance in such case 5 Install the cap nut 1 which is removed in the step 3 Tightening torque 128 to 186 Nm 13 to 19 kgm REMARK The position of the guide has been adjusted so that the slit 5 matches the end face of guide 4 for a new machine Therefore do not loosen the lock nut 6 except when replacing the disc If the rod is pushed...

Page 378: ...erature to go down and then start the work 1 Remove the bolts 1 8 pieces and remove the cover 2 2 Check the pulley for play and the grease for leakage If any problem is found ask your Komatsu distributor for repair and replacement 3 Install the cover 2 with bolt 1 after inspection METHOD FOR LUBRICATING ALTERNATOR AND AIR CONDITIONER COM PRESSOR DRIVE BELT k k WARNING Do not open the cover while t...

Page 379: ...cleaner turbocharger aftercooler and engine 2 Retighten any loose clamps Tightening torque of clamp 1 8 8 0 5 Nm 0 90 0 05 kgm Tightening torque of clamp 2 10 5 0 5 Nm 1 07 0 05 kgm Clamp 3 Tighten with the impact wrench until the dimen sion A becomes the following value Dimension A 15 to 18 mm MAINTENANCE MAINTENANCE PROCEDURE 4 61 ...

Page 380: ...T OIL FILTER ELEMENT k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start the work When removing the oil filler cap the oil may spurt out Turn it slowly to release the internal pres sure then remove it carefully MAINTENANCE PROCEDURE MAINTENANCE 4 62 ...

Page 381: ...hts up while the engine is running METHOD FOR CHANGING OIL IN FINAL DRIVE CASE k k WARNING Immediately after the engine is stopped its parts and oil are still very hot and may cause burn in jury Wait for the temperature to go down and then start 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 then remove it carefully...

Page 382: ...t of oil through the hole of plug G 4 After adding oil check that the oil level is in the specified range METHOD FOR CLEANING DIFFERENTIAL CASE BREATHER 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 1 Stop the engine 2 Remove mud and dirt around the breather 3 Remove the...

Page 383: ...he cap of oil filler port F gradually to release the in ternal pressure and remove the cap 3 Remove the cap 1 of hydraulic tank strainer 2 places 4 Take out the strainer from the strainer case 2 5 Clean the strainer and strainer case 2 6 After checking and cleaning set the strainer to the strainer case 2 7 Tighten the cap 1 of hydraulic tank strainer Replace the O ring at this time 8 Install the c...

Page 384: ...fore you change the filter Hot en gine components can cause injury When replacing the KCCV filter element use a stand for getting on and off safely and pay attention not to fall down NOTICE Komatsu recommends using Komatsu genuine parts for replacement parts If the engine is operated without the filter element the turbocharger and aftercooler become dirty and their performance will lower and it ca...

Page 385: ...t 5 There may be oil accumulated or sticking in the case and element Take care not to spill the oil when replacing the element 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 if the coolant level is normal it is not a problem 3 Remove the used O ring 6 sticking to the case 4 and ...

Page 386: ...atched 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 in serting take extreme care so that the protrusion 15 in the case is joined together with the rubber lip 16 of the ele ment 6 Fit the r...

Page 387: ...nt 2 Engine lubrication system Turbocharger lubrication hose Engine oil filter hose 3 Steering system High pressure circuit hose 4 Brake system Brake oil pressure hose Retarder control valve rubber parts 5 Torque converter trans mission system Transmission circuit hose 6 Work equipment hydraulic system Main pump delivery hose Main pump delivery hose other than described above Main pump LS hose Hos...

Page 388: ...rease comes out from the vent 3 Check visually that the greasing has been performed prop erly 4 After greasing wipe off any old grease that is pushed out METHOD FOR CHECKING WATER PUMP Check around the water pump for water leakage If any part is leaking ask your Komatsu distributor for inspection repair METHOD FOR CHECKING STARTING MOTOR The brush may be worn and the grease in the bearings may hav...

Page 389: ...HOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER The fuel spray prevention cap acts to prevent the fuel from coming into contact with high temperature parts of the engine and causing a fire if the fuel should leak or spray out Check the fuel spray prevention caps 1 to 14 visually or with a finger to see if any of them has slipped off or any bolt is loosened or the rubber ...

Page 390: ...mperature parts of the engine and causing a fire if the fuel should leak or spray out Check visually and touch by hand to check that there are no missing caps loose bolts or hardening of the rub ber If there are any problems the parts must be replaced Ask your Komatsu distributor for replacement EVERY 8000 HOURS MAINTENANCE Maintenance for every 250 500 1000 2000 and 4000 hours services should be ...

Page 391: ...distributor for replacement of the fuel spray prevention cap on fuel doser END OF SERVICE LIFE For safe dismantling of the machine at the end of service life please contact your Komatsu distributor EVERY 15000 HOURS MAINTENANCE Maintenance for every 250 500 and 1000 hours should be performed at the same time METHOD FOR CHECKING AND REPLACING STEERING A ARM MOUNTING BOLT Ask your Komatsu distributo...

Page 392: ......

Page 393: ...SPECIFICATIONS 5 1 ...

Page 394: ...AE J1995 gross kW min 1 578 2000 ISO14396 578 2000 ISO 9249 SAE J1349 net 540 2000 Engine max torque Nm kgm rpm 3724 380 1400 A Overall length mm 10351 B Overall height mm 4400 C Overall height when dumping mm 8800 D Overall width from the stay on the right mirror to the left mirror mm 5543 E Minimum ground clearance under the underguard mm 588 Minimum turning radius mm 8730 Travel speed Forward 1...

Page 395: ...ond 11 5 Engine model KOMATSU SAA6D170E 7 diesel engine Engine rated horsepower SAE J1995 gross kW min 1 578 2000 ISO14396 578 2000 ISO 9249 SAE J1349 net 540 2000 Engine max torque Nm kgm rpm 3724 380 1400 A Overall length mm 10351 B Overall height mm 4400 C Overall height when dumping mm 8800 D Overall width from the stay on the right mirror to the left mirror mm 5543 E Minimum ground clearance ...

Page 396: ... 8 Travel speed Forward 1st km h 11 4 2nd km h 15 8 3rd km h 21 3 4th km h 28 8 5th km h 38 8 6th km h 52 0 7th km h 70 0 Reverse 1st km h 11 8 Operating temperature range C 20 to 45 SPECIFICATIONS SPECIFICATIONS 5 4 ...

Page 397: ...ATTACHMENTS AND OP TIONS Before reading this chapter read and understand the SAFETY 6 1 ...

Page 398: ...de extension platform guard and spill guard can be installed to the dump body of these HD605 8 Use Dump body type Features Dump body shape Carry rocks Linerless dump body Wear resistant steel plate is em ployed for loading the blasted rock at quarry limestone mine and earth moving sites The liner is not installed Example Limestone mines Dump body with lin er if equipped Inner surface of the dump b...

Page 399: ...vel 1 Engine room lamp switch 2 Engine room lamp METHOD FOR USING ENGINE ROOM LAMP 1 Remove the cap turn the engine room lamp switch 1 to ON position Engine room lamp lights up 2 After checking the engine oil level turn the engine room lamp switch 1 to OFF position Engine room lamp goes out Install the cap after using ATTACHMENTS AND OPTIONS HANDLE ENGINE ROOM LAMP 6 3 ...

Page 400: ... slippery ground OPERATION OF KTCS The KTCS is ready to start the control when KTCS Setting is ON When the KTCS detects the rear wheel slipping the KTCS starts the control and the KTCS pilot lamp lights up METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND If any wheel is stuck operate the KTCS If it is impossible to get the machine out even when repeating the procedure below use a bulldo...

Page 401: ... The overspeed caution lamp warns about the overspeed of the travel speed while the speed limit function is actuated Speed limit function pilot lamp The speed limit function pilot lamp lights up while the travel speed of the machine is limited by speed limit func tion Retarder pilot lamp The retarder pilot lamp lights up while the retarder is being operated by the speed limit function OPERATION OF...

Page 402: ...d is decreased OPERATION IF TROUBLES ON SYSTEM OCCUR The machine has a trouble if any of the action levels L01 to L04 is displayed on the machine monitor Take appropriate actions following the list of action level dis plays and required actions Check the failure code Notify your Komatsu distributor of the failure code and ask for repair Failure code Failure name Whether the systems continue or dis...

Page 403: ...REPLACEMENT PARTS 7 1 ...

Page 404: ... 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 Periodical replacement parts Replacement interval 1 Fuel system ...

Page 405: ...replaced at the same time Item Part No Part name Q ty Replacement interval Engine oil filter 600 211 1340 Cartridge 3 Every 500 hours Fuel prefilter 600 319 4800 Cartridge 2 Transmission oil filter 569 16 81160 07000 12125 Element O ring 3 3 Transmission and rear brake cooling oil filter 208 60 71124 07000 F5210 Element O ring 1 1 Every 1000 hours Brake oil filter 569 43 83920 07000 12065 07001 02...

Page 406: ...d 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 low viscosity fuel with low lubricating ability is used its durability may considera bly drop ...

Page 407: ...bol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level REPLACEMENT PARTS RECOMMENDED FUEL COOLANT AND LUBRICANT 7 5 ...

Page 408: ...re degrees Celsius C Min Max Engine oil pan Engine oil for KDPF used in cold terrain Oil Change interval 250 hours Note 1 EOS5W30 LA KES Diesel En gine Oil 25 35 EOS5W40 LA KES Diesel En gine Oil 25 40 Engine oil for KDPF Oil Change interval 500 hours EO10W30 LA KES Diesel En gine Oil 20 40 EO15W40 LA KES Diesel En gine Oil 15 50 Transmission Case incl brake oil tank Power train oil Note 2 TO10 KE...

Page 409: ...s so replace oil and filter cartridge every 250 hours For changing the maintenance time of machine moni tor ask your Komatsu distributor to perform the work Note 2 Power train oil has different properties from engine oil Be sure to use the recommended oils Note 3 Hyper grease G2 TE has high performance When it is necessary to improve the lubricating ability of the grease in order to prevent squeak...

Page 410: ...the tank with pre diluted fluid Never dilute the Non Amine Engine Coolant with ordinary water RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil consult your Komatsu distributor RECOMMENDED FUEL COOLANT AND LUBRICANT REPLACEMENT PARTS 7 8 ...

Page 411: ... 4 60 Alternator and air conditioner compressor drive belt Check Replace 4 49 Alternator and air conditioner compressor drive belt Lubricate 4 60 Alternator and air conditioner compressor drive belt Replace 4 50 Always use clean washer fluid 4 2 Appoint leader when working with others 2 27 Armrest angle Adjust 3 155 ARSC Operate 3 184 ARSC off pilot lamp 3 39 ARSC overheat notice caution lamp 3 29...

Page 412: ...3 102 Directions of machine 1 7 Display 3 237 Display selector button 3 237 Display setting Change 3 57 Display warning tag during inspection and mainte nance 2 27 Display non display of ECO gauge Switch 3 59 Display non display of ECO guidance Switch 3 61 Display non display of guidance when key is OFF Switch 3 62 Do not drop things inside machine 4 2 Do not get caught in work equipment 2 17 Do n...

Page 413: ...H RECIRC air selector switch 3 227 Front brake Bleed air 4 29 Front brake off pilot lamp 3 39 Front brake off switch 3 105 Front disc brake Check wear 4 48 Front suspension cylinder Check length 4 26 Fuel 4 5 Fuel Check level Add 3 148 Fuel and lubricants 3 247 Fuel and lubricants to match the ambient temperature 4 3 Fuel circuit Bleed air 4 29 Fuel consumption gauge Set display 3 58 Fuel consumpt...

Page 414: ...k around 3 138 Machine Dump 3 211 Machine Lift 3 245 Machine Loading work 3 197 Machine Lubricate 4 33 4 58 Machine Operate if troubles occur on system 3 196 6 6 Machine Operate when tires are stuck in ground 6 4 Machine Park 3 214 Machine Running in the new machine 3 172 Machine Secure 3 243 Machine Shift gear 3 180 Machine Start 3 175 Machine Start Travel forward and reverse Stop 3 175 Machine S...

Page 415: ...isplay and meter display 3 33 Play in output shaft output coupling Check 4 30 Power button 3 236 Power supply for KOMTRAX Plus 3 136 Power supply outlet 3 116 Power window switch 3 106 Precautions after daily work completion 3 248 Precautions before starting inspection and mainte nance 2 27 Precautions before starting operation 2 12 Precautions before traveling after long term storage 3 250 Precau...

Page 416: ...onitor setting 3 77 Recommended brands and qualities other than ko matsu genuine oils 7 8 Recommended fuel coolant and lubricant 7 4 Recommended set travel speed 3 187 Refrigerant gas Check level 4 24 Remaining time for maintenance Reset 3 76 Replace defined life parts 4 69 Retarder brake performance Check 4 41 Retarder control lever 3 112 Retarder control lever cancel sound Set 3 72 Retarder oil ...

Page 417: ...120 Torque converter lockup pilot lamp 3 35 Torque converter oil temperature caution lamp 3 20 Torque converter oil temperature gauge 3 42 Total payload and number of cycles Display 3 205 Towing and being towed 2 26 Transmission Act against trouble 3 251 Transmission and rear brake cooling oil filter element Replace 4 54 Transmission case Check oil level Add oil 3 141 Transmission case Brake sub t...

Page 418: ...Wiper and window washer switch 3 102 Work place Clean Tidy 2 27 Y Your machine serial numbers and distributor 1 9 INDEX 8 8 ...

Page 419: ......

Page 420: ...HD465 8 HD605 8 Dumptruck Form No EENAM03550 2017 KOMATSU All Rights Reserved Printed in Belgium 02 2017 ...

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