HD785.985-5 Operation Manual
HD785.985-5 Operation Manual
HD785.985-5 Operation Manual
WARNING
Unsafe Use of this machine may cause serious injury or
Death.Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
NOTICE
Komatsu has Operation & Maintenance Manuals written
in some other languages. if a foreign language manual
is necessary, contact your local distributor for
availability.
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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
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FOREWORD FOREWORD
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FOREWORD FOREWORD
1-4
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SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
1-5
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Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
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INTENDED USE
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
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1-8
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Distributor name
Address
Service Personnel
Phone/Fax
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTENDED USE 1- 7
DIRECTIONS OF MACHINE 1- 7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8
ENGINE SERIAL NO. PLATE POSITION 1- 8
SERVICE METER POSITION 1- 8
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
PRECAUTIONS DURING OPERATION 2- 19
BEFORE STARTING ENGINE 2- 19
AFTER STARTING ENGINE 2- 21
BATTERY 2- 24
TOWING 2- 26
PRECAUTIONS FOR MAINTENANCE 2- 27
PRECAUTIONS WITH TIRES 2- 33
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
MACHINE MONITOR 3- 5
SWITCHES 3- 22
CONTROL LEVERS AND PEDALS 3- 30
MECHATRONICS EQUIPMENT CONTROLLER 3- 34
SAFETY PIN 3- 35
DUST INDICATOR 3- 35
FUSES 3- 36
CAR STEREO 3- 38
AIR CONDITIONER 3- 47
CAR HEATER 3- 52
LOCATION OF FIRE EXTINGUISHER 3- 53
LOCATION OF FIRST AID KIT 3- 53
OPERATION 3- 54
CHECK BEFORE STARTING ENGINE 3- 54
STARTING ENGINE 3- 70
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 73
STOPPING ENGINE 3- 74
CHECKS AFTER STOPPING ENGINE 3- 74
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 75
SHIFTING GEAR 3- 80
TRAVELING DOWNHILL 3- 81
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FOREWORD CONTENTS
1 - 11
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CONTENTS FOREWORD
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 36
EVERY 100 HOURS SERVICE 4- 37
EVERY 250 HOURS SERVICE 4- 38
EVERY 500 HOURS SERVICE 4- 53
EVERY 1000 HOURS SERVICE 4- 58
EVERY 2000 HOURS SERVICE 4- 63
EVERY 4000 HOURS SERVICE 4- 69
EVERY 15000 HOURS SERVICE 4- 71
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
HANDLING PAYLOAD METER 6- 2
NAME OF PARTS 6- 2
EXTERNAL DISPLAY LAMPS 6- 3
OPERATING PAYLOAD METER 6- 5
TACHOGRAPH (TCO 15-6) 6- 13
EXPLANATION OF COMPONENTS 6- 13
METHOD OF USING KEY 6- 15
METHOD OF USE 6- 15
REVO TACHOGRAPH (TCO 15-7) 6- 17
EXPLANATION OF COMPONENTS 6- 17
METHOD OF USE 6- 19
USING DIFFERENTIAL LOCK 6- 21
DIFFERENTIAL LOCK PEDAL 6- 21
PRECAUTIONS AND METHOD OF USE 6- 22
OPERATION OF ABS AND ABS/ASR 6- 23
EXPLANATION OF COMPONENTS 6- 23
OPERATION METHOD 6- 25
PRECAUTIONS FOR USE 6- 26
TROUBLESHOOTING 6- 26
ARSC (AUTOMATIC RETARDER SPEED CONTROL) 6- 27
EXPLANATION OF COMPONENTS 6- 28
METHOD OF OPERATION 6- 30
TROUBLESHOOTING 6- 32
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
OPERATION AND MAINTENANCE) 6- 35
CHECK BEFORE STARTING 6- 35
ABNORMALITY DISPLAYED DURING OPERATION 6- 35
HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS 6- 35
MESSAGE FOR OPERATION AND MAINTENANCE (MOM) 6- 36
ASR-II (AUTOMATIC SPIN REGULATOR II) 6- 41
EXPLANATION OF COMPONENTS 6- 41
ACTUATION OF ASR-II SYSTEM 6- 42
PRECAUTIONS WHEN USING 6- 42
TROUBLESHOOTING 6- 43
HANDLING AUTO-GREASING SYSTEM 6- 45
OUTLINE OF AUTO-GREASING SYSTEM 6- 45
SETTING GREASE CAN 6- 46
INITIAL SETTING OF AUTO-GREASING SYSTEM 6- 47
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FOREWORD CONTENTS
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SAFETY INFORMATION
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
SAFETY RULES 2- 11
IF ABNORMALITIES ARE FOUND 2- 11
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11
FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
SAFETY FEATURES 2- 11
KEEP MACHINE CLEAN 2- 12
INSIDE OPERATOR'S COMPARTMENT 2- 12
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 12
HANDRAILS AND STEPS 2- 13
MOUNTING AND DISMOUNTIN 2- 13
PREVENTION OF BURNS 2- 14
FIRE PREVENTION 2- 14
ACTION IF FIRE OCCURS 2- 15
WINDOW WASHER LIQUID 2- 15
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 16
PRECAUTIONS FOR ATTACHMENTS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 16
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 17
ENSURE GOOD VISIBILITY 2- 17
PRECAUTIONS ON INDOOR VENTILATION 2- 18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 18
ASBESTOS DUST HAZARD PREVENTION 2- 18
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2-3
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SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY LABELS
(1) Roll-over protective structure (ROPS)
(09620-30201) (for North America)
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2-9
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GENERAL PRECAUTIONS
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.
SAFETY FEATURES
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
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PREVENTION OF BURNS
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature where it
is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the cap
or plug slowly to relieve the internal pressure before removing
the cap or plug.
FIRE PREVENTION
Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of the
electrical system.
Use well-ventilated areas for adding or storing oil and fuel.
Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
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2 - 15
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UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not operate where there is a hazard of landslides or falling rocks.
Take necessary measures to prevent any unauthorized person from entering the operating area.
When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting operations.
Always design and maintain the roads on the jobsite so that the machines can travel safely.
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When leaving the machine, place the gear shift lever (1) at
neutral and set the parking valve lever (2) to the 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 prevent any unauthorized person from
moving the machine. Always remove the key, take it with you,
and leave it in the specified place.
If it is necessary to park the machine on a slope, set blocks
under the wheels to prevent the machine from moving.
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BATTERY
Before working with batteries, turn the starting switch to the OFF position.
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2 - 25
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TOWING
WHEN TOWING
When towing or being towed, mistakes in the method of selecting and inspecting the wire rope or drawbar, or in the
method of towing may lead to serious personal injury.
For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-104)"
Always confirm that the wire rope or drawbar used for towing
has ample strength for the weight of the machine being towed.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing
machine and the machine being towed.
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When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in
the parts, so be careful not to come close.
Do not touch any control levers. If any control lever must be operated, give a signal to the other workers to warn
them to move to a safe place.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
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PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers
or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel
to carry out welding.
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WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
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COMPRESSED AIR
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
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GENERAL VIEW
GENERAL VIEW OF MACHINE
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3-3
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(1) Caution/pilot lamp bulb check switch (5) Panel dimmer switch
(2) Starting switch (6) Hazard lamp switch
(3) Preheating switch (7) Front brake cut-off switch
(4) AISS LOW switch (8) Exhaust brake switch
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EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
MACHINE MONITOR
NOTICE
When the starting switch is turned to the ON position before the engine is started, all the monitors, gauges, and the central
warning lamp will light up for approx. 3 seconds, and the alarm buzzer will sound for approx. one second. When this happens, the
speedometer will display 88.
If no monitor lamp lights up, then there is probably a failure or disconnection in that circuit, therefore contact your Komatsu
distributor to have the circuit checked.
When the starting switch is at the ON position, if the shift lever is not at the neutral position, then the transmission shift lever
position pilot lamp (1) and the central warning lamp will flash and the alarm buzzer will continue to sound intermittently. At this
time, when the lever is placed in neutral, letter N is displayed, the central warning lamp goes out and the buzzer stops.
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WARNING
If user code 02 or 04 is displayed, stop the machine immediately. See "SERVICE CODE (PAGE 3-118)", and check the service code
number. Contact Komatsu distributor, telling them the service code number, for repair.
If letter "E-" and any user code of "01 to 07" is displayed in turn at the upper right of the liquid crystal display on the
monitor panel, stop the machine once. Then, take the corrective action as follows after checking user code (1).
User code
02: Park the machine at a safe location and contact your Komatsu distributor.
04: Carry out an emergency stop. Stop the engine and contact your Komatsu distributor.
01: Carry out checks and maintenance according to the Operation and Maintenance Manual.
03: Operate the machine keeping the engine at low revolution and low travel speed.
05: Stop the machine. Run the engine at a mid-range speed under no load.
06: Restart the engine. Idle the engine for a while.
07: Do not raise the dump body.
If the user code is displayed again even after taking the corrective action shown above when the user code 01,
03, 05, 06, or 07 is displayed, check the sevice code.
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CAUTION ITEMS
CAUTION
If any of the warning monitors lights up, carry out the inspection and maintenance of the appropriate item as soon as possible.
If it is left without the inspection and maintenance, it will lead to the trouble or failure.
If there is any abnormallity for the caution items, the monitor for the corresponding abnormal area lights up.
BATTERY CHARGE
This (1) notifies the operator of any abnormality in the charging
system when the engine is running. If it lights up and
simultaneously displays user code 01, check the charging circuit.
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EMERGENCY STEERING
This (2) lights up when the emergency steering is actuated.
If any abnormality should occur in the steering oil pressure circuit
when the machine is traveling, the auto emergency steering is
actuated and the related lamp lights up.
PARKING BRAKE
This (3) lights up when the parking brake is applied.
It goes on and out respectively responding to the parking brake
lever shifting of PARK/TRAVEL.
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FUEL LEVEL
This monitor (6) flashes when the level of the fuel in the fuel tank
goes below 170 liters (44.88 US gal).
If it flashes, check the fuel level and add fuel.
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If the abonormaliy is found in the emergency items, the waring buzzer sounds and the monitor corresponds to the
abnormal section lights up or flashes, and the central warning light flashes.
AIR PRESSURE
This monitor (1) warns the operator that the air pressure inside the
air tank has dropped. If it flashes and displays the user code "05"
at the same time, stop the machine, run the engine under no load
at a mid-range speed, and wait until the lamp goes out.
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The lamp lights up if the engine lubricating oil pressure goes below
the specified value when the engine is running,
If the engine is not running, the lamp does not light up.
ANGLE WARNING
When the dump body is raised, this monitor (7) warns the operator
that the machine has tilted beyond the safety range to the left or
right.
If it lights up and displays action code "07" at the same time, lower
the body and move the machine to a safe, stable place.
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PREHEATING MONITOR
This lamp lights up when the electrical heater for preheating the
engine is being actuated.
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HIGH BEAM
This monitor (7) lights up when the head lamps are set to high
beam.
SHIFT INDICATOR
This monitor (9) displays the transmission shift range (speed
range).
When the key was turned ON, if the shift lever is operated, it will
display "2" at the lever position "D", "1" at the "5" - "L" position, and
"R" at the R position even if the engine is stopped.
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H : Hard mode
M : Medium mode
S : Soft mode
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METERS
SPEEDOMETER
This meter (1) indicates the travel speed of the machine.
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ENGINE TACHOMETER
This meter (2) indicates the speed of the engine.
While operating the machine, if the red range lights up,
simultaneously the warning buzzer sounds and the central warning
lamp flashes, then operate the machine while lowering the engine
speed and the traveling speed.
SERVICE METER
This meter (3) shows the total hours of operation of the machine.
If the engine is running, the service meter will advance even if the
machine is not moving.
The meter advances by 1 for every one hour of operation,
regardless of the engine speed.
ODOMETER
This (4) indicates the distance traveled in kilometers.
FUEL GAUGE
This gauge (5) indicates the amount of fuel in the fuel tank.
The green range should be lighted up during operation.
If only the red range remains lighted during operation, it indicates
that there is less than 120 liters (31.68 US gal) of fuel remaining in
the tank, so check and add fuel.
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REMARK
If the air pressure drops further, the parking brake is automatically
applied.
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ENGINE
(Mechatronics-related)
If an abnormality is detected in the mechatronics-related parts of
the engine control system, this lamp (1) flashes to warn of the
abnormality.
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AUTOMATIC TRANSMISSION
(Mechatronics-related)
If an abnormality is detected in the mechatronics- related parts of
the transmission control system, this lamp (2) flashes to warn of
the abnormality.
MECHATRONICS-RELATED PARTS
(Excluding 1. and 2. above)
If an abnormality is detected in the mechatronics-related parts of
the control system other than those of the engine and
transmission, this lamp (3) flashes to warn of the abnormality.
If the machine is in the following condition, this lamp will flash, and
at the same time, the alarm buzzer will sound intermittently.
When an abnormality has occurred in any of "EMERGENCY
STOP ITEM (PAGE 3-10)".
When "MECHATRONIC CAUTION LAMP PORTION (PAGE
3-20)" flashes.
If the parking brake is applied, but the shift lever is not at neutral.
When the dump lever is not at the FLOAT position and the shift lever is not at neutral.
When engine tachometer red range lights up.
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SWITCHES
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STARTING SWITCH
This switch (1) is used to start or stop the engine.
OFF position
At this position, the starting switch key can be inserted or removed.
When the key is turned to this position, all the electric circuits are
switched off and the engine stops.
ON position
In this position, electric current flows in the charging and lamp
circuits.
Keep the starting switch key at the ON position while the engine is
running.
When turning the starting switch ON or OFF, if the starting switch is held at a position between ON and OFF, the
controller may detect this as a problem. If this happens, return the starting switch to the OFF position, then operate
it as usual to the ON position.
START position
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately
after the engine has been started. The key will return to the ON position when released.
LAMP SWITCH
This (2) lights up the head lamps, side clearance lamps, tail lamps,
machine monitor lighting, and rear lamps.
(a) position: OFF
(b) position: Side clearance lamps, tail lamps, rear lamps, machine
monitor lighting light up
(c) position: The head lamps light up in addition to the lamps in the
(b) position
The lamp switch can be operated regardless of the position of the
lever.
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DIMMER SWITCH
This (2) is used to switch the head lamps between high beam and
low beam.
(a) Low beam
(b) High beam
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WARNING
When traveling on icy roads, on snow, or on other slippery road surfaces, set the front brake cut-off switch to the ON position
and travel slowly at a safe speed.
If the front brake cut-off switch is set to the OFF position, it becomes dangerously difficult to control the steering when
traveling under the abovementioned conditions.
This switch (5) switches the braking method according to the road
surface conditions.
If the switch is pressed, the lamp lights up, the front brake cut
function is actuated, and the brakes are not applied to the front
wheels.
If the switch is pressed again, the lamp goes out and the front
brake cut function is canceled.
When traveling at high speed, on a road surface that has been properly watered, set the front brake cut-off switch
to OFF position (lamp off), and normally use the retarder control lever to control the travel speed (retarder braking
is applied only to the rear wheels).
To control the machine whenever emergency action is needed, such as when the machine slips to the side or when
the machine has to be stopped suddenly, use the brake pedal to operate the brakes on the front wheels to give extra
braking force.
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PREHEATING SWITCH
This switch (9) operate an electric heater to heat the intake air for
the engine. If it is pushed, it lights up and perform preheating. If it
is released, it returns to the original position.
Press this switch if the engine does not start when only automatic
preheating is carried out or when post-heating is required after the
engine is started.
When the switch is released, it will return automatically to the
automatic preheating position.
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If the key switch is turned ON when the machine is stopped and the parking brake switch is OFF, the auto
emergency steering is actuated after 1 second, so turn the parking brake switch to the ON (PARKING) position.
If the pressure in the air tank drops below 0.22 MPa (2.2 kgf/cm2,
31.24 PSI), the emergency brake is automatically applied.
If the emergency brake is applied because of a failure in the air
system, the central warning lamp flashes and the alarm buzzer
sounds.
For details of releasing the brake when the emergency brake has
been applied because of a failure in the air system, see "RELEASE
METHOD WHEN PARKING BRAKE AND EMERGENCY BRAKE
HAVE BEEN ACTUATED IN EMERGENCY (PAGE 3-107)"
3 - 27
.
WARNING
When parking or leaving the machine, always apply the parking brake.
During loading operations, do not apply the parking brake. Pull the retarder lever to apply the brake.
If the air pressure drops and goes below 0.22MPa(2.2kgf/cm2, 31.24PSI), the emergency brake and parking brake
are automatically applied.
For details of releasing the brake when the emergency brake has been applied because of a failure in the air system,
see "RELEASE METHOD WHEN PARKING BRAKE AND EMERGENCY BRAKE HAVE BEEN ACTUATED IN
EMERGENCY (PAGE 3-107)"
Use this switch (15) if the engine will not stop even when the
starting switch is turned to the OFF position.
3 - 28
.
CIGARETTE LIGHTER
This (16) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its original
position after several seconds, so pull it out and use it to light your
cigarette.
HORN BUTTON
When the horn button (17) in the center of the steering wheel is
pressed, the horn will sound.
WIPER SWITCH
This switch (18) is used to operate the wiper.
INT position: Wiper moves intermittently
OFF
LOW position: Wiper moves at low speed
HI position: Wiper moves at high speed
When the switch is pressed, washer fluid is sprayed out.
3 - 29
.
BRAKE PEDAL
This pedal (1) is used to apply the wheel brakes.
3 - 30
.
ACCELERATOR PEDAL
This pedal (2) is used to adjust the engine speed.
It can control freely the engine between the low idle and the full
throttle.
D position:
This is used for normal travel.
If the lever is placed in this position, the transmission is shifted
automatically from 2nd (torque converter drive) to 7th (direct drive)
to match the travel speed of the machine.
If the dump body is raised, the speed range is fixed at 2nd when the
shift lever is at D position. Always lower the dump body when
traveling.
The maximum speed in D position is 65 km/h (40.4 MPH).
R position:
This is used when traveling in reverse.
This position uses the torque converter drive.
The machine cannot travel in reverse if the dump lever is not at the FLOAT position. Set the dump lever to the
FLOAT position before moving the shift lever to the R position.
5 - L position:
These positions are used in places where it is difficult to travel at high speed, or when traveling on soft ground, or
when starting the machine off on a slope when it is loaded. They are also used when going downhill if it is needed
to use the braking force of the engine.
If the dump body is raised, it is impossible to shift up from 1st. Always lower the dump body when traveling.
3 - 31
.
Before shifting between forward and reverse, stop the machine completely and then run the engine at low idle.
When starting the engine, if the gear shift lever is not at the N position, the engine will not start.
When the starting switch is turned to the ON position, if the shift lever is not at the N (neutral) position, the
transmission shift lever position pilot lamp and the central warning lamp will flash and the alarm buzzer will sound.
If shift lever is not at N (neutral) position when the parking brake is applied, the central warning lamp will flash and
the alarm buzzer will sound.
When the dump lever is not at the FLOAT position and when the dump body has risen, if the shift lever is not at the
N (neutral) position, the central warning lamp will flash and the alarm buzzer will sound.
The shift lever must not be returned to the N (neutral) position while traveling.
Release the accelerator pedal and run the engine at low idle when moving the shift lever from the N (neutral) position
to the forward or reverse position.
When moving the gear shift lever from the N (neutral) position to the R (reverse) position or from the D positions to
position 5 (or other lower position), press the lock button on the gear shift lever before moving it.
SAFETY LOCK
WARNING
When raising the dump body to inspect the machine, always place the dump lever at the HOLD position, apply the lock, and then
use the safety pins.
3 - 32
.
DUMP LEVER
WARNING
To prevent damage to the dump body through vibration from the road surface, always lower the dump body and set at FLOAT
position before traveling.
CAUTION
The retarder must not be used as a parking brake.
This lever (6) is used to operate the retarder, which applies the rear
wheel brake when going downhill.
The more the lever is pulled, the greater the braking force
becomes.
When the retarder is actuated, the rear brake pilot lamp lights up.
3 - 33
.
TRANSMISSION CONTROLLER
A two-digit number followed by the service code is displayed in the inspection window of this controller (1) to identify
the location of the abnormality. When the condition is normal, "0.0" or "0.C" is displayed.
For the mothod of checking the service code when an abnormality occurs, see "TRANSMISSION CONTROLLER
(PAGE 3-119)".
ENGINE CONTROLLER
For this controller (2), the last two-digit number of the service code is displayed in the inspection window to identify
the location of the abnormality. When the condition is normal, "0.0" is displayed.
For the method to check the service code when the abnormality occurs, see "SERVICE CODE (PAGE 3-118)".
SUSPENSION CONTROLLER
For this controller (3), the last two-digit number of the service code is displayed in the inspection window to identify
the location of the abnormality. When the condition is normal, "0.0" is displayed.
For the method to check the service code when the abnormality occurs, see "SERVICE CODE (PAGE 3-118)".
3 - 34
.
SAFETY PIN
WARNING
When raising the dump body to inspect the machine, always place the dump lever at the HOLD position, apply the lock, and then
use the safety pins.
This is a safety device for the dump body, and is used when
carrying out inspection or maintenance with the dump body raised.
Raise the dump body fully, insert safety pins (1). Always insert the
safety pins on both sides.
DUST INDICATOR
This device indicates clogging of the air cleaner element.
When red piston (1) appears in the transparent part of this
indicator, the element is clogged. Immediately clean the element.
After cleaning, push indicator button (2) to return the red piston to
the original position.
3 - 35
.
FUSES
WARNING
When replacing any fuse, always turn the power off (turn the starting switch to OFF).
When replacing the fuse, always use a fuse of the same capacity and type.
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Fuse box I
Fuse
No. Circuit name
capacity
1 10A Car radio, car stereo
2 10A Horn switch
3 10A Cigarette lighter
4 20A Turn signal indicator lamp, fog lamp (if equipped)
5 10A Engine start relay, neutral relay
6 20A Head lamp (low beam), stop lamp, room lamp
Head lamp (high beam), side clearance lamp,
7 20A
tail lamp, night lighting
8 10A Backup lamp, backup buzzer
Ribon heater relay, front brake cut-off solenoid,
9 10A
BCV relay solenoid
Overrun prevention solenoid, transmission
10 10A
controller, exhaust brake solenoid
3 - 36
.
Fuse box II
Fuse
No. Circuit name
capacity
11 10A Engine controller, governor cut relay
Electronic display panel, caution pilot lamp,
12 10A central warning lamp, buzzer, PMC (if equipped),
MOM( if equipped)
Suspension control solenoid,
13 5A
suspension controller
Payload meter (if equipped),
14 5A
payload relay (if equipped)
15 20A Payload external display lamp (if equipped)
16 5A PMC (if equipped)
Start switch, radio back-up, emergency engine
17 10A stop solenoid (if equipped electronic governor),
engine stop motor
T/M controller, engine controller (if equipped),
18 10A
PMC (if equipped)
19 10A Emergency steering
20 10A Direct from battery (spare)
Fuse
No. Circuit name
capacity
21 10A AISS motor
22 20A Wiper motor, washer motor
23 20A Air conditioner blower motor
24 10A Air conditioner compressor
25 10A Spare
26 10A Spare
3 - 37
.
CAR STEREO
(If equipped)
EXPLANATION OF COMPONENTS
3 - 38
.
POWER SWITCH/VOLUME
Turn this knob (1) to the right until it clicks to turn the power on.
Turn it further to increase the volume.
REMARK
The auto-store function cannot be used when the channel display
is flashing.
When the display is flashing, the preset scan function is being
used.
Preset scan
If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations
in the same band will be broadcast one after another for 5 seconds each, starting from No. 1 through No. 6
stations consecutively.
When the desired station is found, press the button again. This stops the preset scan tuning process and switches
to ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.
3 - 39
.
LOUDNESS BUTTON
This button (5) is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when the
low tones are weak.
Push button: Actuated (ON)
Push button again: Canceled (OFF)
3 - 40
.
CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right
side and insert it through the cassette door (8).
PRESET BUTTONS
These buttons (10) are used to call up the broadcast station
frequencies preset in memory for each of buttons No. 1 to No. 6.
It is possible to preset 18 stations (FM: 12; AM: 6) with these
buttons.
3 - 41
.
3 - 42
.
METHOD OF OPERATION
1. If you are playing a cassette, press the tape eject button to stop
the tape.
2. Select the station to be preset.
Use band selector button (1) to select MW (AM), FM1, or FM2,
then use the manual tuning button to select the frequency of
the broadcasting station.
3. Press manual memory button (2) or seek tuning button (3).
4. Press preset button (4) of the number to be preset for 2
seconds while the frequency display is being shown on the
display. (The preset channel and frequency are displayed and
the presetting is completed).
5. Repeat Steps 2 to 4 to preset other stations.
REMARK
Use Steps 2 to 4 also when changing the setting of a preset
switch to another station.
When the power is disconnected, such as when the battery is
replaced, all the settings are deleted, so preset the stations
again.
3 - 43
.
LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch (1) ON.
2. Set band selector button (2) to AM or FM.
3. Select the station with the preset buttons or manual tuning
button (3).
4. Adjust the volume, balance, and tone as desired.
5. When turning the radio OFF, turn power switch (1) to the left
until it clicks.
REMARK
To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape.
If you insert a cassette when listening to the radio, the tape will start to play.
3 - 44
.
REVERSING TAPE
When listening to the tape, press both FAST FORWARD,
REWIND buttons (A) and (B) at the same time lightly.
When this is done, the tape direction display will be reversed.
3 - 45
.
NOTICE
Handling cassette tape
Clean the tape head approx. once a month with a commercially available head cleaning tape.
Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place where
there is a magnetic field.
Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the machine.
If the tape is slack, it easily gets caught up inside the machine. Use a pencil to wind in the tape to remove any slack.
Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to get
the tape out of the machine.
3 - 46
.
AIR CONDITIONER
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it
possible to provide a pleasant working environment even on dusty jobsites.
FAN SWITCH
This switch (1) can be used to adjust the air flow to 4 stages.
This switch also acts as the main switch for the air conditioner.
When the switch is pressed, the indicator lamp above the switch
lights up to indicate the air flow.
3 - 47
.
RECIRC
This switch (4) is used when wishing to quickly cool or warm the
cab or when the air inside the cab is stale.
FRESH
This switch (4) is used to cool or warm the cab with the fresh. Also,
it is used for fresh air intake or to remove condensation on
windows.
3 - 48
.
The color of the indicator lamp changes while the switch is being
pressed.
When the temperature reaches the desired level, release the
switch to set the temperature.
The settings for each mode are retained in memory even when the
starting switch is turned OFF.
However, in the following cases, the settings must be made again.
When the machine has been out of use for more than 7 days
When the battery voltage is extremely low
When there has been abnormal interference from outside
When the fan switch is turned OFF (the setting is not kept in
memory with only the air conditioner switch)
3 - 49
.
METHOD OF OPERATION
Switch
Air conditioner Temperature RECIRC/FRESH Mode selector
Fan switch
switch control switch selector switch switch
Condition of use
Rapid HI ON All green RECIRC FACE
Cooling More than half
Normal HI - LO ON FRESH FACE
are green
Dehumidifying, More than half
HI - LO ON FRESH FOOT
heating are red
Rapid HI OFF All red RECIRC FOOT
Heating More than half
Normal HI - LO OFF FRESH FOOT
are red
More than half
Defroster HI ON FRESH DEF
are red
Vetilation or
HI - LO OFF All green FRESH FACE
pressurizing
When carrying out the defrosting, if the temperature control switch is set so that all lamps are red, this will improve
the performance for defrosting and demisting.
With the FACE vents, it is possible to adjust the direction of the air flow and to turn it on or off.
However, do not set to the FACE mode with the vents closed.
REMARK
If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recirculated air to
warm up the inside of the cab, then turn the air conditioner switch on. The air conditioner will be run.
Carry out ventilation from time to time when using the cooling.
If you smoke when using the cooling, your eyes may start to sting, so in such a case, carry out ventilation and
cooling for a short time to remove the smoke.
When using the air conditioner for a long period of time, carry out ventilation process at least once every hour.
3 - 50
.
Clean the air filter and check the refrigerant. For details, see "CLEAN AIR CONDITIONER AIR FILTER (PAGE
4-24)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-25)".
To enable the air conditioner to perform to the full and to maintain a pleasant working environment, always contact
your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks.
3 - 51
.
CAR HEATER
HEATER SWITCH
This switch is used for turning the heater ON/OFF and for adjusting
the air flow.
Stopped:OFF
(1) Low
(2) High
3 - 52
.
3 - 53
.
OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or
leakage of oil, fuel, or coolant, and check the condition of the hydraulic system.
Check also for loose wiring, play, and accumulation of dust in places that get very hot and are exposed to extremely
high temperatures.
WARNING
Be sure to attach the warning sign on the operaation lever of the machine.
Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or
turbocharger, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
Always carry out the following items before starting the engine each day.
1. Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play.
Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and carry out
repairs if any problem is found.
4. Check for oil leakage from transmission case, differential case, final drive case, brake oil tank, hydraulic tank,
hose, joint
Check that there is no oil leakage. If any problem is found, repair the place where the oil is leaking.
Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.
3 - 54
.
OPERATION OPERATION
8. Check for damage to gauges, lamps on the instrument panel and loose bolts.
Check for damage to the panel, gauges and lamps. If any problem is found, replace the parts. Clean off any dirt on
the surface. Tighten any loose bolts.
10. Check for damage to the seat belt and mounting clamps.
Check for damage to seat belt and mounting clamps. If damages are found, replace with the new one.
Check for any loose bolts of the clamps mounting the equipment to the machine. Tighten any loose bolts.
When the belt has been used for a long time, if any external damage or fraying of the belt can be seen, or if the
clamps are broken or deformed, replace the seat belt.
11. Check cracks and damage of ROPS (if equipped) and check for loose bolts
Check if any bolt is loose or damaged. If it is loos, tighten up (torque: 1720 ± 196 N·m 175 ± 20kgf·m, 1265.8
± 144.7 lbft). If it is loose replace it with Komatsu genuine bolt.
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 a tread grooves of less than 15% of that of a new tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage that has reached the cords, or with cracks in the
rubber
Tires with cut or pulled cords
Tires with peeled (separated) surface
Tires with damaged bead
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires, which do not
seem usable
WARNING
Check the rims (wheels) and rings for deformation, corrosion and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
3 - 55
.
OPERATION OPERATION
WARNING
Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go
down, then turn the cap slowly to release the pressure before removing it.
1. Check that the cooling water level is between the FULL and
LOW marks on radiator reserve tank gauge (G).
If the water level is low, add water through the water filler (1) of
the reserve tank to the FULL level.
2. Check that there is no oil in the coolant or any other
abnormality.
3. After adding coolant, tighten the cap securely.
4. If the volume of coolant added is more than usual, check for
possible water leakage.
CAUTION
When adding oil to the brake oil tank, always use the recommended oil. For details, see "RECOMMENDED FUEL, COOLANT, AND
LUBRICANT (PAGE 4-9)".
1. Check that the oil is between the FULL and LOW marks on
sight gauge (G).
If the oil level is low, add oil through oil filler (F).
3 - 56
.
OPERATION OPERATION
NOTICE
In cold areas, there is danger of the water freezing, so drain the water from
the air tank after operations when it is still warm.
3 - 57
.
OPERATION OPERATION
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
5. If the oil is above the H mark, remove drain plug (1), and loosen
drain valve (2) to drain the excess engine oil, then check the
engine oil level again.
6. If the oil level is correct, tighten the handle of the oil filler cap
securely.
REMARK
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine.
The dipstick has the oil level marked on both sides: ENGINE STOPPED for measuring when the engine is
stopped, and ENGINE IDLING for measuring when the engine is idling.
When checking the oil level, stop the engine and check with the ENGINE STOPPED side of the dipstick.
It is also possible to check when the engine is idling, but the following procedure must be used.
• Check that the engine water temperature is in the green range.
• Use the ENGINE IDLING side of the dipstick.
• Remove the oil filler cap.
3 - 58
.
OPERATION OPERATION
NOTICE
The oil level changes according to the oil temperature, so carry out the
check after completing the warming-up operation.
Check that the torque converter oil temperature gauge is in green range
(A) on the monitor panel.
During operations, or when the engine is running at idling after
operations, the oil level be above (G2).
When checking the oil level with the engine stopped, check with sight
gauge (G1) as a guide line, and make the final check with (G2).
3 - 59
.
OPERATION OPERATION
CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK, ADD OIL
WARNING
If the oil filler cap is removed without releasing the internal pressure, oil will
spurt out, so turn the oil filler cap slowly to release the internal pressure,
then remove it carefully.
CHECK OIL LEVEL IN REAR BRAKE COOLING OIL TANK, ADD OIL
WARNING
When removing the oil filler cap, oil may spurt out, so turn the cap slowly
to release the internal pressure before removing the cap.
3 - 60
.
OPERATION OPERATION
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any
fuel is spilled, wipe it up completely. Never bring flames near fuel because
it is highly flammable and dangerous.
1. Check the fuel level with fuel gauge (G), which is installed in the
side of the fuel tank.
2. After completing operations, add fuel through fuel filler (F) to fill
the tank.
Fuel tank capacity: 1250 liters (330 US gal)
REMARK
If the breather hole in the cap becomes clogged, the pressure
inside the tank will go down and the fuel may not flow, so clean the
breather hole from time to time.
If any stud bolt used to install the rim is broken, replace all the stud
bolts for that wheel.
3 - 61
.
OPERATION OPERATION
REMARK
When this is done, the speedometer should display 88.
When the starting switch is turned to the ON position, the pilot lamp at the transmission shift lever position will
flash if the shift lever is not at the N position. When the shift lever is moved to the N position, N is displayed.
After the engine is stopped, the monitor cannot be checked until at least 30 seconds have passed.
3. When checking the monitor, check for blown bulbs in the the
caution lamps and pilot lamps at the same time. Before starting
the engine, turn the starting switch to the ON position, press
bulb check switch (1), and check that no caution lamp or pilot
lamp bulb is blown.
If the monitor lamp, caution lamp, or pilot lamp do not light up,
there is probably a failure or disconnection, therefore contact
your Komatsu distributor for inspection.
3 - 62
.
OPERATION OPERATION
WARNING
If the machine moves, it will lead to the serious human injury. If the machine starts to move while checking the braking capacity,
lower the engine speed and set the shift lever to N position. Then set the parking brake lever to PARKING position.
3 - 63
.
OPERATION OPERATION
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately
perform repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electrical
wiring. Check also for loose terminals and tighten any loose parts.
Check the wiring of the "battery", "starting motor"and "alternator"carefully, in particular.
Always check if there is any accumulation of flammable material around the battery, and remove such flammable
material.
Please contact your Komatsu distributor for investigation and correction of any problems found.
NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim may be damaged.
Always keep the tire inflation pressure within +0 to +0.03 MPa (0.3 kgf/cm2, 4.3 PSI) of the value in the table above.
3 - 64
.
OPERATION OPERATION
WARNING
Adjust the seat position at the beginning of each shift or when operators change.
Adjust the seat so that the brake pedal can be depressed all the way with the operators back against the backrest.
REMARK
To make the seat softer, adjust the weight to make it lighter; to
make the seat harder, adjust the weight to make it heavier.
When traveling on rough road surfaces, make the seat harder
before starting operations.
3 - 65
.
OPERATION OPERATION
WARNING
Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage,
replace.
Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is
woven on the reverse side of the belt.
Adjust and fasten the seat belt before operating the machine.
Always use the seat belt when operating the machine.
Do not use the seat belt with either half of the belt twisted.
Fasten the belt along your body without kinking it. Adjust the
lengths of the belt on both the buckle and the tongue sides so
that the buckle is located at the front, mid-point of your body.
3 - 66
.
OPERATION OPERATION
WARNING
Always stop the machine before adjusting the tilt of the steering wheel.
The tilt of the steering wheel can be adjusted to the front and rear,
and up and down. Pull lever up and set the steering wheel to the
desired position, then push lever down to lock the steering wheel
securely in position.
Adjustment range: Front-rear: 5 degrees
Up: 30 mm (1.2 in)
Down: 20 mm (0.8 in)
3 - 67
.
OPERATION OPERATION
REMARK
If the gear shift lever is not at the N (neutral) position, the engine will
not start. If the starting switch is turned to the ON position when the
gear shift lever is not at N (neutral), the transmission shift lever
position pilot lamp and the central warning lamp will flash and the
alarm buzzer will sound.
3 - 68
.
OPERATION OPERATION
3 - 69
.
OPERATION OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
Sit down in the operator's seat before starting the engine.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious bodily injury or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not keep the starting motor rotating continuously for more than 20 seconds.
If the engine will not start, wait for at least 2 minutes before trying to start the engine again.
1. Turn the key of starting switch (1) to the START position to start
the engine.
2. When the engine starts, release the key in starting switch (1).
The key will return automatically to the ON position.
3 - 70
.
OPERATION OPERATION
NOTICE
Do not keep the starting motor rotating continuously for more than 20 seconds.
If the engine will not start, wait for at least 2 minutes before trying to start the engine again.
REMARK
When starting the engine, the monitor may flash while the starting
motor is turning, but if the monitor lamp goes out after the engine
is started, there is no problem.
3 - 71
.
OPERATION OPERATION
4. When the engine starts, release the key in starting switch (1).
The key will return automatically to the ON position.
3 - 72
.
OPERATION OPERATION
WARMING-UP OPERATION
NOTICE
Do not accelerate the engine suddenly until the warming-up operation has been completed.
Do not run the engine at low idle or high idle continuously for more than 20 minutes.
If it is necessary to continue to run the engine at idle, apply a load from time to time or run the engine at a mid-range speed.
After starting the engine, do not immediately start operations. First, perform the following operations and checks.
1. After starting the engine, run the engine at idle for 5 minutes for warming up operation.
2. After the warming-up operation, check that the machine monitor is normal.
If there is any problem, carry out maintenance or repair.
Run the engine under a light load until the engine water temperature gauge and air pressure gauge enter the
green range.
When the AISS switch is at the AUTO position and the engine water temperature is still low, high idling revolution
is automatically maintained (for optional electronic governor specification).
3. Check if there is no abnormality in the steering operation, flashing of lights, sound of horn, exhaust gas color,
noise, or vibration. If any abnormality is found, repair it.
3 - 73
.
OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is suddenly stopped without allowing it to cool down, there is
danger that the life of the engine parts will be shortened, so never stop the
engine suddenly except in emergency.
Allow the engine to cool down gradually before stopping it.
1. Run the engine at low idle for about 5 minutes to cool down
gradually.
2. Turn the key of starting switch (1) to the OFF position to stop
the engine.
3. Remove the key from starting switch (1).
3 - 74
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OPERATION OPERATION
2. Check that your seat belt is fastened and that dump lever (1) is
at the FLOAT position.
3. Depress the brake pedal fully. Check that air pressure gauge
(2) is in the green range, then set parking brake valve lever (3)
to the TRAVEL position to release the parking brake.
3 - 75
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OPERATION OPERATION
4. Check that retarder pilot lamp (4) has gone out, then set shift
lever (5) to the desired position.
NOTICE
When operating the shift lever, be sure to set it in position securely.
If the lever is not placed in position properly, the shift position display
on the panel may go out and the transmission warning monitor lamp
may light up.
Always release the accelerator pedal before shifting from N to R or F.
NOTICE
If the parking brake is not released, and the shift lever is shifted to a
position other than N, the central warning lamp will flash and the alarm
buzzer will sound.
If the dump lever is not at the FLOAT position, and the shift lever is
shifted to a position other than N, the central warning lamp will flush and
the alarm buzzer will sound.
Do not operate the shift lever with the accelerator pedal depressed. This
will cause a big shock, and will also reduce the life of the machine.
3 - 76
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OPERATION OPERATION
Place gear shift lever (1) in the R position, then gradually depress
accelerator pedal (2) to move the machine off.
NOTICE
The machine cannot travel in reverse if the dump lever is not at the
FLOAT position. Place the dump lever at the FLOAT position before
operating to the R position.
When shifting between FORWARD and REVERSE, stop the machine
completely, and run the engine at low idle when shifting the lever.
After moving the gear shift lever, do not depress the accelerator until
you detect that the transmission clutch has engaged.
Do not operate the gear shift lever with the accelerator pedal depressed.
This will cause a big shock, and will also reduce the life of the machine.
3 - 77
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OPERATION OPERATION
STOPPING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
If the foot brake is used repeatedly or is kept depressed for a long time,
the brake may overheat and its life will be shortened.
If the parking brake is used to stop the machine, the brake will be
damaged. Do not use the parking brake except when stopping in
emergencies or when parking the machine after stopping it.
NORMAL STOPPING
Release accelerator pedal (1), and depress brake pedal (2) to stop
the machine.
STOPPING IN EMERGENCY
If there should be a failure in the foot brake, stop the machine as
follows.
WARNING
When the machine stops, put blocks under the tires immediately.
Immediately after making an emergency stop, the parking brake disc
will be at high temperature, so wait for it to cool before carrying out
repair or adjustment. Ask Komatsu distributor for repair and
adjustment.
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OPERATION OPERATION
3. Set parking brake valve lever (3) to the right (to the PARKING)
position.
4. If an emergency stop has been made, put blocks under the
tires immediately, then try to find the cause, and repair it on
site.
5. After the emergency operation of parking brake and
emergency brake, see "RELEASE METHOD WHEN
PARKING BRAKE AND EMERGENCY BRAKE HAVE BEEN
ACTUATED IN EMERGENCY (PAGE 3-107)" in case that it is
necessary to release the brake.
6. If emergency stop has been made, it is necessary to re-adjust
the parking brake. Ask Komatsu distributor for adjustment.
3 - 79
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OPERATION OPERATION
SHIFTING GEAR
When shifting gear, do as follows.
This machine has an automatic transmission, so set gear shift
lever (1) to the desired position, and the transmission will
automatically shift to a position to match the travel speed.
When the dump body has risen, the speed range is locked to 2nd
speed at the D position and 1st speed at the 5 - L position. While
traveling, lower the dump body.
NOTICE
When shifting between FORWARD and REVERSE, stop the machine
completely, and run the engine at low idle when shifting the lever. After
moving the gear shift lever, do not depress the accelerator until you
detect that the transmission clutch has engaged.
Do not operate the gear shift lever with the accelerator pedal depressed.
This will cause a big shock, and will also reduce the service life of the
machine.
SHIFTING UP
1. When accelerator pedal (2) is depressed to accelerate the
machine, the lockup clutch is engaged to shift the transmission
to direct drive.
2. If the machine is accelerated further, the transmission will
automatically shift up.
SHIFTING DOWN
If accelerator pedal (2) is released, the machine speed will be
reduced, and the transmission will automatically shift down.
3 - 80
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OPERATION OPERATION
TRAVELING DOWNHILL
When traveling downhill, travel at a safe speed which matches the width of the road, the condition of the road
surface, and other conditions of the jobsite.
WARNING
If the machine is stopped, put blocks under the wheel immediately.
For the maximum permissible speed when traveling downhill using the retarder, see the brake performance graph for the
downhill distance and grade. Traveling continuously downhill at a speed greater than the maximum permitted speed on the
brake performance graph is dangerous as the retarder brake may be damaged.
If the retarder oil temperature monitor on the machine monitor flashes when using the retarder, shift down to travel downhill.
(When this happens, the central warning lamp flashes and the alarm buzzer sounds.)
If the monitor lamp does not go out even when the transmission is shifted down, stop the machine immediately, set the shift
lever to the N position, run the engine at the 2000 rpm, and wait for the monitor to go out.
If the retarder loses its effect when it is used for traveling downhill, do as follows.
1. Release the retarder brake completely, then operate the retarder lever again.
2. If the retarder still has no effect even when the retarder lever is operated again, return the retarder lever completely to the
released position, then depress the brake pedal to stop the machine, and contact your Komatsu distributor for repairs.
Operate the retarder slowly. If the brakes are applied suddenly, there is danger that the machine will skid.
NOTICE
If the retarder lever is operated when traveling downhill, the transmission can be shifted down sooner than with normal
deceleration. It is also possible to travel without shifting up.
When traveling downhill, do not use the foot brake except in an emergency. Using the foot brake will cause overheating of the
front brake and reduce the life.
Do not accelerate or shift up when using the retarder. The engine speed will rise and this may cause the alarm buzzer to sound
and the central warning lamp to flash.
3 - 81
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OPERATION OPERATION
For machines equipped with an exhaust brake, using the exhaust brake can provide more secure braking force for
increased safety, and will also improve the durability of the brake.
For details of handling the exhaust brake, see "EXHAUST BRAKE SWITCH (PAGE 3-24)".
3 - 82
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OPERATION OPERATION
Obtain the maximum permissible speed and the transmission speed range from the graph when traveling downhill
under the above conditions.
1. Use the brake performance graph for the downhill distance of 1,500 m (4,921 ft).
2. Starting from point (A) which corresponds to the overall weight of the machine, draw a perpendicular line down.
3. Take the point where it crosses the line for travel resistance -11% as (B) and draw a horizontal line.
4. Take the point where it crosses the performance curve as (C), and draw a perpendicular line down. Take the
point where this line crosses the travel speed scale as (D).
5. The following information can be obtained from this procedure.
Without exhaust brake
From point D: Maximum permissible speed =27 km/h (16.8 MPH)
From point C: Speed range = F4
With exhaust brake (if equipped)
From point F: Maximum permissible speed =36 km/h (22.4 MPH)
From point E: Speed range = F5
This maximum permissible speed is one guideline determined from the retarder brake performance, so on an actual
jobsite, determine a safe downhill travel speed (below the maximum permissible speed) to match the conditions of
the jobsite so that the retarder brake oil temperature gauge is always in the green range.
3 - 83
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OPERATION OPERATION
Brake performance
[Downhill distance: 450 m (1476 ft)] (Tire size: 27.00R49!!)
Brake performance
[Downhill distance: 600m (1968ft)] (Tire size: 27.00R49!!)
3 - 84
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OPERATION OPERATION
Brake performance
[Downhill distace: 900m (2952ft)] (Tire size: 27.00R49!!)
Brake performance
[Downhill distace: 1500m (4921ft)] (Tire size: 27.00R49!!)
3 - 85
.
OPERATION OPERATION
Brake performance
[Downhill distace: Continuous] (Tire size: 27.00R49!!)
3 - 86
.
OPERATION OPERATION
CAUTION
Do not continue to apply force to the steering wheel when it has been turned fully to the left or right. This will make the oil
temperature in the circuit rise and will cause overheating.
To turn the machine when traveling, turn steering wheel (1) in the
direction of the turn.
When traveling around a curve, release the accelerator pedal
before entering the curve, shift down to a lower speed range, then
depress the accelerator pedal to travel around the curve. Never
coast around the curves at high speed.
REMARK
The angle of the steering wheel may change (the position of the
spoke may change slightly) when the machine is traveling, but
this is not a failure.
If force is applied to the steering wheel when the tires have been
turned fully to the left or right, the steering wheel will turn a little
at a time, but this is not a failure.
LOADING OPERATIONS
When using a large wheel loader to load large rocks, if the rocks are loaded directly into the dump body parts of the
dump body may be deformed. To prevent this, when loading large rocks, first load sand or soil to act as a cushion,
then load the rocks on top of this to reduce the impact on the dump body.
In addition, when loading rocks that exceed the following conditions, install the optional dump body reinforcement
plate.
Rocks with one side over 0.5 m (1 ft 8 in)
Rocks of hardness more than 4.5 (Mohs scale)
Rocks with a weight of more than 300 kg (662 lb)
When transporting steel ingots
NOTICE
When traveling, always set the dump lever to the FLOAT position regardless of whether the dump body is empty or loaded.
If the dump lever is not at the FLOAT position and the shift lever is not at the N position, the central warning lamp will flush and
the alarm buzzer will sound.
3 - 87
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OPERATION OPERATION
DUMP OPERATIONS
WARNING
When dumping a load, always carry out the dumping operation in
accordance with the signals from the flagman.
When dumping large rocks, operate the dump body slowly.
Do not load the dump body while it is still raised.
When carrying out inspection with the dump body raised, always use
the safety pins, set the dump lever to the HOLD position and lock it
securely. For details, see "SAFETY PIN (PAGE 3-35)".
2. Move dump lever (3) to the RAISE position, then depress the
accelerator pedal to raise the dump body.
3. When the dump body rises to the previously set position (dump
body positioner adjustment position), dump lever (3) is
returned to the HOLD position. The dump body is then held at
that position.
3 - 88
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OPERATION OPERATION
When the dump body has risen, the speed range is locked to
2nd if shift lever is at the D position. While traveling, lower the
dump body.
3 - 89
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OPERATION OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Park the machine on firm, horizontal ground.
Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a slope, put blocks
under the tires to prevent the machine from moving and set parking
brake valve lever to the PARKING position.
If the shift lever is touched by mistake, the machine may move
suddenly, and this may lead to a serious injury or death. Before leaving
the operator's compartment, always set the parking brake valve lever
securely to the PARKING position.
The retarder must not be used as a parking brake.
Do not use the retarder for long-term parking, regardless of the engine
speed.
CAUTION
To prevent damage to the parking brake, apply the parking brake only when
parking the machine.
2. Move shift lever (3) to the N position, then move parking brake
valve lever (4) to the PARKING position to apply the parking
brake.
3 - 90
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OPERATION OPERATION
NOTICE
The retarder must not be used as a parking brake.
Do not use the retarder for long-term parking, regardless of the engine
speed.
NOTICE
In cold areas, there is danger of the water freezing, so drain the water from
the air tank after operations when it is still warm.
3 - 91
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OPERATION OPERATION
LOCKING
Always lock the following places.
(1) Fuel filler cap of fuel tank
(2) Cab door (left, right)
REMARK
The starting switch key is used for locking places (1) and (2).
3 - 92
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OPERATION OPERATION
HANDLING TIRES
Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without
taking due care.
Compared with ordinary tires, far greater heat is produced in the rubber internal parts of off-road tires when the
machine is traveling. If they are used continuously under conditions which exceed the permitted load and travel
speed of the tire, the internal temperature will exceed the limit, and the rubber may become soft and heat separation
occur.
To prevent such problems from occurring, the T.Km.P.H. is used as a standard to allow the machine to travel safely.
If operations are carried out which exceed the T.Km.P.H. of the tire (when the T.Km.P.H. of the work exceeds the
T.Km.P.H. of the tires), tire trouble will occur more frequently. In such cases, do as follows.
Make the operating conditions easier so that the operation T.Km.P.H. of the work is lowered.
Increase the size of the tires to a tire with a high T.Km.P.H.
3 - 93
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OPERATION OPERATION
Tire T.Km.P.H. for Max. speed for continuous travel for each ambient
ambient temperature temperature
16°C 27°C 38°C 49°C 16°C 27°C 38°C 49°C
Size: 27.00R49!! When empty
40 36 32 28
(standard) (front wheel standard)
648 580 513 445
Structure: GP When loaded
24 22 19 17
Code No.: E4 (TRA) (rear wheel standard)
Size: 27.00-49-48 PR When empty
31 29 27 25
(if equipped) (front wheel standard)
495 463 431 399
Structure: GP When loaded
Code No.: E4 (TRA) 19 17 16 15
(rear wheel standard)
Size: 27.00-49-48 PR When empty
24 22 21 19
(if equipped) (front wheel standard)
380 358 336 313
Structure: CR When loaded
Code No.: E4 (TRA) 14 13 12.6 12
(rear wheel standard)
The total operating hours per day includes the stopping time and rest periods.
* The T.Km.P.H. in the table may differ slightly according to the tire maker, so concerning operations which require
travel near the travel speed given in the table, consult your Komatsu distributor.
NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim may be damaged.
Always keep the tire inflation pressure within +0 to +0.03 MPa (0.3 kgf/cm2, 4.3 PSI) of the value in the table above.
The maximum travel speed must be kept to less than 40 km/h (24.9 MPH). Stop for at least one hour for every
one hour of travel to allow the tires and other components to cool down.
Never travel with water or dry ballast in the tires.
3 - 94
.
3 - 95
.
TRANSPORTATION OPERATION
TRANSPORTATION
PRECAUTIONS WHEN TRANSPORTING
Always obey the traffic regulations when transporting the machine by road.
WARNING
This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu
distributor.
3 - 96
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OPERATION TRANSPORTATION
2. Turn the key in the starting switch to the OFF position to stop
the engine.
NOTICE
Always retract the antenna and reassemble the mirrors so that they are
within the width of the machine.
3 - 97
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TRANSPORTATION OPERATION
WARNING
The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
Never raise the machine with any worker on it.
Always make sure that the wire rope is of ample strength for the weight of this machine.
When lifting, keep the machine horizontal.
Always stop the engine and apply the brake before starting the lifting operation.
Never enter the area around or under the machine when it is raised.
Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting
equipment other than in the procedure below.
There is a hazard that the machine may lose its balance.
NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs according to the attachments and options installed.
For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor.
For the weight of the standard specification machine, see "SPECIFICATIONS (PAGE 5-2)"
NOTICE
Use protectors to prevent the wire rope from being cut on sharp corners and to prevent the wire rope from cutting into the
machine bodywork.
When using a spreader bar, select an ample width to prevent contact with the machine.
Please consult your Komatsu distributor before carrying out lifting work.
3 - 98
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OPERATION TRANSPORTATION
LIFTING PROCEDURE
Lifting work can be carried out only with machines displaying a lifting mark.
When carrying out the lifting operation, stop the machine on firm level ground, and do as follows.
1. Start the engine, set the dump lever to the FLOAT position, and
check that the body operation caution lamp goes out.
2. Stop the engine, apply the brake, and check that the area
around the operator's compartment is safe.
REMARK
The lifting positions for the machine differs according to the
conditions.
Machine with body:Positions (1) and (3)
Total:4 places (2 at front, 2 at rear)
Machine without body:Positions (1) and (2)
Total:4 places (2 at front, 2 at rear)
3 - 99
.
COOLANT
WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash
it off with large amounts of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
Use Komatsu Supercoolant wherever available, or use permanent type antifreeze coolant.
Never use methanol, ethanol, or propanol-based antifreeze.
Do not use any water leakage prevention agent, either alone, or in combination with antifreeze.
Do not mix one brand of antifreeze with a different brand.
For details on the amount of antifreeze mixture and on when to change the coolant, see "CLEAN INSIDE OF
COOLING SYSTEM (PAGE 4-21)".
3 - 100
.
BATTERY
WARNING
The battery generates flammable gas. Do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the
battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Electrolyte
Temperature
20 0 -10 -20
Charging (°C)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
3 - 101
.
3 - 102
.
LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than one month), store as follows.
After every part is washed and dried, house the machine in a dry building. Never leave it outdoors.
In case it is indispensable to leave it outdoors, park the machine on the flat ground and cover it with canvas etc.
Completely fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
Lock the dump lever at the HOLD position with the safety lock, and apply the parking brake.
Set the tire inflation pressure for each tire to within the range of the specified inflation pressure for the type of tire.
Open the drain valve of the air tank, release the air, then tighten the drain valve again.
Push the retarder control lever forward to the OFF position.
Place the gear shift lever at the N position and turn the starting switch OFF.
To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type antifreeze
(density between 30% and 68%).
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
Operate the engine and move the machine for a short distance once a month so that a new film of oil will be coated
over movable parts and component surfaces. At the same time, also charge the battery.
Before operating the work equipment, wipe off all the grease from hydraulic piston rods.
AFTER STORAGE
NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after
starting the engine. If there is water in the oil, change all the oil.
3 - 103
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TROUBLESHOOTING OPERATION
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When starting after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting.
For details of the method of bleeding the air, see REPLACE FUEL FILTER CARTRIDGE (PAGE 4-55).
NOTICE
The permissible towing capacity for this machine is 491935N (50163 kg). Do not tow any load greater than this.
Towing is only permitted in order to move a disabled machine to a place where it is possible to carry out inspection and
maintenance. It must not be towed for long distances.
Please consult your Komatsu distributor for information about towing a disabled machine.
3 - 104
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OPERATION TROUBLESHOOTING
This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance of a few meters
to a place where repairs can be carried out. The machine should be towed only in emergencies. If the machine
must be moved long distances, use a transporter.
Use a towing machine of the same class as the machine being towed.
Check that the towing machine has ample braking power, weight, and rimpull to allow it to control both machines
on slopes or on the tow road.
Use the specified hook for both the towing machine and the machine being towed.
To protect the operator if the towing wire or towing bar breaks, install protective plates on both the towing machine
and the machine being towed.
There are towing hooks installed to the bottom of the front frame and to the rear axle. Do not use any other place
as a towing hook.
When fitting the towing wire, check the condition of the hook to make sure that there is no problem.
Keep the angle of the towing wire as small as possible.
Keep the angle between the center lines of the two machines to within 30 degrees.
Towing may be carried out under various differing conditions, so it is impossible to determine beforehand the
requirements for towing.
Towing on flat horizontal roads will require the minimum rimpull, while towing on slopes or on uneven road
surfaces will require the maximum rimpull.
If the pressure in the air tank has dropped abnormally because of leakage of air from the air circuit, the parking
brake and emergency brake are applied, so release both brakes before towing the machine.
Before releasing the parking brake, always put blocks under all four wheels. If the wheels are not blocked, there
is danger that the machine may move.
Connect with the towing wire or drawbar, and remove the blocks from the wheels when the disabled machine is
in a condition where it cannot run away.
When carrying out the operation to release the parking brake, check that the surrounding area is safe.
If the parking brake is released, the brakes will not work, so pay careful attention to safety.
When towing down a slope, use two towing machines. One machine should be uphill from the disabled machine
and should be connected with towing wire or a drawbar to pull the disabled machine back and keep it stable. The
other machine should tow the disabled machine downhill.
3 - 105
.
TROUBLESHOOTING OPERATION
If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the
machine out of mud or to move it for a short distance to the edge of the road.
Check the effect of the brakes, and if the brakes do not work properly, take the action given in "When engine does
not run".
Check if it is possible to steer the machine. If the machine cannot be steered, follow the procedure given in
"WHEN ENGINE DOES NOT RUN".
The operator should sit on the machine being towed and operate the steering in the direction that the machine
is towed.
Always run the engine to allow the steering and brakes to be used.
3 - 106
.
OPERATION TROUBLESHOOTING
RELEASE METHOD WHEN PARKING BRAKE AND EMERGENCY BRAKE HAVE BEEN ACTUATED
IN EMERGENCY
If the pressure in the air tank has dropped abnormally because of leakage of air from the air circuit, the parking brake
and emergency brake are applied automatically. After emergency actuation of the brakes, if they are not released,
release the brakes as follows.
WARNING
If there is a failure in the air circuit, the brakes will not work. It is dangerous to drive the machine in this condition, so always
tow the machine at low speed. When towing, run the engine so that it is possible to steer the machine.
When releasing the parking brake, carry out the operation on flat ground and check that the surrounding area is safe. If the
parking brake must be released on a slope because of an emergency or some other unavoidable reason, put blocks under the
wheels before releasing the brake.
After emergency actuation of the parking brake, if the parking brake is not released even when the parking brake
valve lever is placed at the TRAVEL position, release the parking brake as follows.
1. Remove air charge socket (1) installed to the front air tank.
2. Remove the air hose from parking brake chamber (2), then
install removed socket (1) to chamber (2).
3. Install one end of air charge hose (3) (supplied with the
machine) to air charge socket (1). (The hose and socket can be
installed at a touch.)
4. Push the other end of air charge hose (3) into valve (4) of the
tire. Air is supplied to the parking brake chamber, and the
parking brake is released.
5. When the parking brake is released, tow the machine immediately to a safe position. For details of the method
of towing, see "METHOD OF TOWING MACHINE (PAGE 3-104)".
3 - 107
.
TROUBLESHOOTING OPERATION
WARNING
When the emergency brake has been actuated, never drive the machine. This will cause burning out of the brake disc or lining,
or failure of the torque converter or transmission.
When releasing the air pressure from the emergency brake tank, check that the surrounding area is safe, and always put blocks
under the tires before starting the operation.
After actuation of the emergency brake, if the emergency brake is not released when the emergency brake lever is
placed at the TRAVEL position, release the emergency brake as follows.
1. When the preparations for towing the machine are completed,
pull rings (1) of the air tank drain valve (4 places), and release
the air pressure to release the emergency brake.
2. After releasing the emergency brake, release rings (1).
3 - 108
.
OPERATION TROUBLESHOOTING
IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging.
When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes near the battery, or do
anything that will cause sparks.
Battery electrolyte is dilute sulfuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin,
immediately wash it off with a large amount of water. If it gets in your eyes, wash it out with fresh water and consult a doctor.
When handling batteries, always wear safety glasses and rubber gloves.
When removing the battery, first disconnect the cable from the ground (normally the negative (-) terminal). When installing,
install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.
When removing or installing the terminals, check which is the positive (+) terminal and which is the negative (-) terminal.
3 - 109
.
TROUBLESHOOTING OPERATION
3 - 110
.
OPERATION TROUBLESHOOTING
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, wear safety glasses and
rubber gloves.
Be careful not to let the normal machine and problem machine contact
each other. This prevents sparks from generating near the battery which
could ignite the hydrogen gas given off by the battery.
Make sure that there is no mistake in the booster cable connections.
The final connection is to the engine block of the problem machine, but
sparks will be generated when this is done, so connect to a place as far
as possible from the battery.
When disconnecting the booster cable, take care not to bring the clips
in contact with each other or with the machine body.
NOTICE
The size of the booster cable and clip should be suitable for the battery size.
The battery of the normal machine must be the same capacity as that of the problem machine.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
3 - 111
.
TROUBLESHOOTING OPERATION
CAUTION
Make sure that the parking brake valve lever is at PARKING position and the shift lever is at N (neutral) position for both normal
machine and the problem machine.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, try again after 2 minutes or so.
3 - 112
.
OPERATION TROUBLESHOOTING
OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 113
.
TROUBLESHOOTING OPERATION
CHASSIS
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 114
.
OPERATION TROUBLESHOOTING
If the pedal depression depth is not detected correctly due to a failure of the accelerator pedal or incorrect electric
wiring, the engine controller or PMC (if equipped) controls the engine speed responding to the signal from this check
switch. The engine runs at 1400 rpm when the accelerator pedal is depressed, while the engine runs at low idling
when the pedal is released. The engine speed varies depending on the load.
After moving the machine to a safe place by operating the accelerator pedal, check the service code, then contact
your Komatsu distributor for repairs.
There are two methods when operating the accelerator pedal: either release the pedal and set to the OFF (low idling)
position, or depress the pedal fully (1400 rpm).
If the accelerator pedal is held at an intermediate position, the system may not be able to judge if the accelerator
pedal is being operated or not.
REMARK
If the engine controller or PMC (if equipped) can not receive the signal of the accelerator pedal depth, the central
warning lamp flashes and simultaneously the alarm buzzer sounds and user code 02 appears.
3 - 115
.
TROUBLESHOOTING OPERATION
ENGINE
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 116
.
OPERATION TROUBLESHOOTING
3 - 117
.
TROUBLESHOOTING OPERATION
SERVICE CODE
If any abnormality occurs, stop the machine, apply the parking brake and check the service code, then contact your
Komatsu distributor for repairs.
REMARK
Upper 2 digits are displayed on speedometer (2); and lower 2 digits are displayed on user code display (3).
First 1 digits is in English letter; next 3 digits are numerical.
After the display of service code for 3 seconds, the display returns to normal. If multiple failures occur
simultaneously, each service code shows up for 3 seconds one by one.
3 - 118
.
OPERATION TROUBLESHOOTING
TRANSMISSION CONTROLLER
If any abnormality occurs in the transmission, reduce the travel
speed by using the brake, stop the machine on a safe place. Gear
shifting may not work for some failure modes.
3 - 119
.
4-1
.
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual.
OIL CHANGE:
If your machine is equipped with a fuel strainer, do not remove it while fueling.
WELDING INSTRUCTIONS:
Turn off the engine starting switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
Do not use the area around the hydraulic cylinders as the grounding point.
Sparks will cause damage to the plated portion.
4-2
.
DUSTY WORKSITES:
When working at dusty worksites, do as follows:
Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
4-3
.
OUTLINE OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil.
When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the
old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the
small amount of oil remaining in the piping mixes with the new oil.)
Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed
in the table below.
Item Type
Engine oil pan Engine oil EO15W40DH (Komatsu genuine parts)
Transmission case Power train oil TO30 (Komatsu genuine parts)
Front brake oil tank
Hydraulic tank
Steering,hoist oil tank
Power train oil TO10 (Komatsu genuine parts)
Rear brake cooling oil tank
Front suspension
Rear suspension
Differential case
Power train oil TO30 (Komatsu genuine parts)
Final drive case
Radiator Supercoolant AF-NAC (Density:30% or above)(Komatsu genuine parts)
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil at the specified interval.
Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems 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 both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil.
4-4
.
FUEL
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperatures below -15°C
(5°F)), so it is necessary to use the fuel that is suitable for the temperature.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
If there is any foreign material in the fuel tank, wash the tank and fuel system.
GREASE
Grease is used to prevent seizure and noises at the joints.
This construction equipment is used under heavy-duty conditions. Always use the recommended grease and
follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance
Manual.
The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease.
If any part becomes stiff after being used for long time, add grease.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.
4-5
.
Others
Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of
fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
OIL SAMPLING
Sampling interval
250 hours: Engine
500 hours: Other components
4-6
.
FILTERS
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are found,
contact your Komatsu distributor.
When replacing the engine oil filter, fill the new filter with the specified clean oil, then install it.
Do not open packs of spare filters until just before they are to be used.
Use of Komatsu genuine filter elements is strongly recommended.
4-7
.
WEAR PARTS
Wear parts such as the filter element, air cleaner element, etc. are to be replaced at the time of periodic maintenance
or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
When ordering parts, please check the part number in the parts book.
4-8
.
4-9
.
4 - 10
.
Reservoir Rear
Differential Final drive Cooling
suspension Fuel tank
case case (each) system
Capacity (each)
Specified Liters 17.5 132 59 1250 228
amount of oil US gal 4.62 34.85 15.58 330 60.19
Refill Liters – 132 59 – –
amount of oil US gal – 34.85 15.58 – –
Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS ( High-Temperature High-Shear
Viscosity 150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most
suitable oils. If these oils are not available, follow the instruction "RECOMMENDED BRANDS,
RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL (PAGE 4-11)"
at the end of this chapter.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
4 - 11
.
Thread Width
Tightening torque [N·m (kgf·m)]
diameter across
of bolt flats
Target value Permissible range
(mm) (a) (mm) (b)
6 10 13.2 (1.35) 11.8 - 14.7 (1.2 - 1.5)
8 13 31 (3.2) 27 - 34 (2.8 - 3.5)
10 17 66 (6.7) 59 - 74 (6.0 - 7.5)
12 19 113 (11.5) 98 - 123 (10.0 - 12.5)
14 22 177 (18.0) 157 - 196 (16.0 - 20.0)
16 24 279 (28.5) 245 - 309 (25.0 - 31.5)
18 27 382 (39.0) 343 - 425 (35.0 - 43.5)
20 30 549 (56.0) 490 - 608 (50.0 - 62.0)
22 32 745 (76.0) 662 - 829 (67.5 - 84.5)
24 36 927 (94.5) 824 - 1030 (84.0 - 105.0)
27 41 1320 (135.0) 1180 - 1470 (120.0 - 150.0)
30 46 1720 (175.0) 1520 - 1910 (155.0 - 195.0)
33 50 2210 (225.0) 1960 - 2450 (200.0 - 250.0)
36 55 2750 (280.0) 2450 - 3040 (250.0 - 310.0)
39 60 3280 (335.0) 2890 - 3630 (295.0 - 370.0)
NOTICE
When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use excessive torque: doing
so will damage the plastic parts. Pay enough attention when you tighten up.
4 - 12
.
4 - 13
.
4 - 14
.
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Change oil in engine oil pan, replace engine oil filter cartridge 4- 53
Replace fuel filter cartridge 4- 55
Replace transmission oil filter element 4- 56
Change oil in transmission case 4- 59
Replace steering, hoist oil tank and rear brake cooling oil tank filter element 4- 60
Change oil in steering, hoist oil tank 4- 63
Change oil in rear brake cooling oil tank 4- 64
Change oil in final drive case 4- 65
Change oil in differential case 4- 65
Check, adjust engine valve clearance 4- 66
WHEN REQUIRED
Check, clean and replace air cleaner 4- 19
Clean inside of cooling system 4- 21
Check level of window washer fluid, add fluid 4- 24
Clean air conditioner air filter 4- 24
Check refrigerant (gas) level 4- 25
Check dump body 4- 25
Check electric intake air heater 4- 25
Check length of suspension cylinder, check oil level 4- 26
Bleed air from rear brake 4- 28
Bleed air from front brake 4- 28
Adjust parking brake 4- 29
Adjust body positioner 4- 30
Replace fan belt, adjust auto tensioner 4- 32
Check play of output coupling of output shaft 4- 33
Selection and inspection of tires 4- 33
4 - 15
.
4 - 16
.
4 - 17
.
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Perform the following maintenance only after the first 250 hours.
Change oil in engine oil pan, replace engine oil filter cartridge
Replace fuel filter cartridge
Replace transmission oil filter element
Change oil in transmission case
Replace steering, hoist oil tank and rear brake cooling oil tank filter element
Change oil in steering and hoist oil tank
Change oil in rear brake cooling oil tank
Change oil in final drive case
Change oil in differential case
Check engine valve clearance, adjust
For details of the method of replacing or maintaining, see EVERY 500 HOURS, EVERY 1000 HOURS and EVERY
2000 HOURS SERVICE.
4 - 18
.
WHEN REQUIRED
CHECKING
Clean the air clearner element if the dust indicator (1) shows red.
NOTICE
Do not clean the air cleaner element before red piston in dust indicator
appears.
If the element is cleaned frequently before the red piston appears, the air
cleaner will not be able to display its performance fully, and the cleaning
efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element
will fall inside the inner element.
3. Direct dry compressed air (less than 0.69 MPa (7 kgf/ cm2, 99.4
PSI)) to the element from inside along its folds, then direct it
from outside along its folds and again from inside.
1) Remove one seal from the element whenever the element
has been cleaned.
2) Replace the outer element if it has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace both inner and outer elements when the dust
indicator red piston appears soon after installing the
cleaned outer element even though it has not been
cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if necessary, retighten.
4 - 19
.
NOTICE
When cleaning the element, do not hit or beat it against anything.
Do not use an element whose folds, gasket or seal are damaged.
REMARK
For both of inner element and outer element, when the element is attached, nuts should be tighten up with the
shaking motion of element in the way that the sealing rubber of the tip of the element closely contact with the inside
of the body.
4 - 20
.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table
below.
Stop the machine on level ground when cleaning or changing the coolant.
The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
4 - 21
.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing
table given below.
It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio.
The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume
(antifreeze/total amount of coolant x 100).
The freezing temperature of undiluted antifreeze is -15°C (5°F). Do not store undiluted antifreeze at a temperature
of below -15°C (5°F).
WARNING
Antifreeze coolant is flammable, so keep it away from flame.
Antifreeze coolant is toxic. When removing the drain plug, be careful not to get water containing antifreeze coolant on you. If it
gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Use antifreeze and appropriate water for diluting (for details, see "COOLANT AND WATER FOR DILUTION (PAGE
4-5)")
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to supply antifreeze coolant and water.
1. Stop the engine and close the valve (1) of corrosion resistor
cartridge.
4 - 22
.
4 - 23
.
Check the level of the fluid in window washer tank (1), and if it is
low, fill with automobile window washer fluid.
Be careful not to let dirt or dust get in when adding fluid.
4 - 24
.
REMARK
Run the engine at idle, and if bubbles appear in the sight glass
when the air conditioner is set to cooling, the refrigerant level is low,
so please contact your Komatsu distributor to have it refilled.
4 - 25
.
At the same time, when the machine is not loaded, remove cover (1), then measure dimension (B) from the shoulder
of the rod head of the suspension cylinder to the top surface of the flange.
Standard Buffering
specification specification
252 - 272 mm 236 - 256 mm
(B)
(9.9 - 10.7 in) (9.3 - 10.1 in)
Reference 474 - 494 mm 474 - 494 mm
(C) (18.7 - 19.5 in) (18.7 - 19.5 in)
Flange thickness
49 mm (1.9 in) 65 mm (2.6 in)
(D)
After checking, contact your Komatsu distributor for repairs if any problem is found.
4 - 26
.
Rear
Measure dimension (E) from the shoulder of the rod head of the suspension cylinder to the top surface of the flange.
Standard Buffering
specification specification
230 - 250 mm 210 - 230 mm
(E)
(9.1 - 9.9 in) (8.3 - 9.1 in)
Flange thickness
50 mm (2.0 in) 70 mm (2.8 in)
(F)
After checking, contact your Komatsu distributor for repairs if any problem is found.
4 - 27
.
4 - 28
.
Measure the thickness of the pad, and if it is less than 1.5 mm (0.06
in), contact your Komatsu distributor to have it replaced.
When making the first adjustment after replacing the pad, turn bolt
(1) turn (6 clicks) in the counterclockwise direction.
4 - 29
.
ADJUSTING
1. Set the dump lever to the HOLD position.
3. Raise the dump body until the hoist cylinder is 50 mm (2.0 in) before the end of its stroke, then stop the engine.
4 - 30
.
4. Loosen locknut (3), put plate (4) into contact with bracket (2),
then tighten locknut (3).
Reference dimension B: 147 mm (5.8 in)
5. After adjusting, start the engine, operate the dump lever, and check that the lever is automatically returned to
the HOLD position when the dump body rise to a point 50 mm (2.0 in) before the end of the hoist cylinder stroke.
REMARK
Check the operation of the body positioner before starting operations each day.
4 - 31
.
REPLACEMENT
1. Loosen lock nut (2), then loosen adjustment bolt (1). After that,
remove yoke (3) with locknut (2) still installed.
There is danger of losing parts, so do not remove bolt (1) from
bracket (4).
4 - 32
.
ADJUSTMENT
1. Install adjustment bolt (1) and locknut (2) to yoke (3).
2. Tighten adjustment bolt (1) until the clearance is 0 mm (0 in)
between the both ends of the oblong hole of yoke (3) and pin
(6) of tension pulley (5), then tighten a further 3 turns.
Tighten locknut (2) to hold in position.
3. Run for one hour, then check the clearance between the end
of the oblong hole of yoke (3) and pin (6) of tension pulley (5).
If there is any clearance, repeat Step 2 to adjust again.
If the fan belt makes any abnormal noise, adjust in the same
way.
REMARK
If the play range is exceeded, the engine fan will start to rotate, so
when inspecting the play, check first that the engine fan is not
rotating.
4 - 33
.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and the weight of the attachments on the machine. Use only specified tires and
inflate them to the specified pressure.
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the
following table.
Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when
using optional tires.
4 - 34
.
WARNING
When inflating a tire, check that any person will not enter the working
area and use an air chuck which has a clip and which can be fixed to the
air valve.
While inflating the tire, check the inflation pressure occasionally so that
it will not rise too high.
If the rim is not fitted normally, it may be broken and scattered while the
tire is inflated. Accordingly, place a guard around the tire and do not
work in front of the rim but work on the tread side of the tire.
Abnormal drop of inflation pressure and abnormal fitting of the rim
indicate a trouble in the tire or rim. In this case, be sure to ask a tire
repair shop for repair.
Be sure to observe the specified inflation pressure.
Do not adjust the inflation pressure of the tires just after high-speed
travel or heavy-load work.
Check
Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
Inflation of tires
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not
work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown below.
NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim may be damaged.
Always keep the tire inflation pressure within +0 to +0.03 MPa (0.3 kgf/cm2, 4.3 PSI) of the value in the table above.
4 - 35
.
4 - 36
.
During the cold season, check the ethyl alcohol level every 100
hours on the service meter.
When removing filler cap (1) of the alcohol injector to carry out the
inspection, loosen it slowly to release the remaining pressure
before removing it.
If the alcohol level is low, add alcohol to the bottom surface of the
threaded portion of the filler cap.
REMARK
On this machine, air is used to operate the brakes. When the machine is operated in cold weather, the moisture
in the air will freeze and cause problems such as defective operation of the valve, so add ethyl alcohol to the air
system to lower the freezing point.
When filling the alcohol injector with alcohol before the cold season, release the remaining pressure, remove the
cap, then add 1.4 liters (0.37 US gal) of ethyl alcohol through the filler port.
After the cold season, loosen drain valve (2) and drain the ethyl alcohol.
4 - 37
.
1. Remove plug (G) and check that the oil level is near the bottom
of the plug hole.
2. If the oil level is too low, add oil through the plug hole until the
oil overflows.
1. Stop the machine so that casting line (1) is horizontal and drain
plug (P) is immediately at the bottom.
2. Remove plug (G) and check that the oil level is near the bottom
of the plug hole.
3. If the oil level is too low, add oil through the plug hole until the
oil overflows.
4 - 38
.
LUBRICATION
1. Stop the engine.
2. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
3. After greasing, wipe off any old grease that was pushed out.
(1) Dump body hinge pin (left and right: 1 place each)
(2) Rear suspension (left and right: 2 places each)
4 - 39
.
4 - 40
.
4 - 41
.
WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from
freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
2. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.
4 - 42
.
REMARK
If distilled water is added to above the U.L. line, use a syringe to
lower the level to the U.L. line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.
2. Remove cap (3) at the top of the battery and look through the
filler port to check the electrolyte level. If the electrolyte is not
up to the sleeve, immediately add distilled water (or
commercially available battery filler solution) to the bottom of
the sleeve (UPPER LEVEL).
4 - 43
.
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
REMARK
If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the
sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount
of water or consult your Komatsu distributor or battery maker.
4 - 44
.
CHECKING
The belt should normally deflect by above 15 mm (0.6 in) when
pressed with the thumb (with a force of approx. 58.8 N (6 kgf) at a
point midway between the drive pulley and alternator pulley.
ADJUSTING
1. Loosen bolt (1) and lock nut (2).
2. Rotate adjusting nut (3) so that the deflection is approx. 15 mm
(0.6 in) (at a force of approx. 58.8 N (6 kgf).)
3. After adjustment, tighten lock nut (2) and bolt (1) securely.
REMARK
Check each pulley for breakage and wear of the V-groove. In
particular, check that the V-belt does not touch the bottom of the
V-groove.
If any abnormality is found, ask your Komatsu distributor for
replacement of the pulley.
If the V-belt is so lengthened that it cannot be adjusted any more
or if it has any cuts or cracks, replace it.
When adjusting the V-belt, do not press the alternator directly
with a bar, but put a wood piece, etc. in-between them.
If the V-belt has been replaced with a new part, there will be
initial elongation, so inspect and adjust it again after one-hour of
operation.
4 - 45
.
CHECKING
The belt should normally deflect by 10 mm (0.4 in) when pressed
with the thumb (with a force of approx. 58.8 N (6 kgf)) at a point
midway between the air compressor pulley and drive pulley.
ADJUSTING
1. Loosen bolt (1) and lock nut (3).
2. Rotate adjusting nut (2) so that the deflection is approx. 10 mm
(0.4 in) (at a force of approx. 58.8 N (6 kgf)).
3. After adjustment, tighten lock nut (3) and bolt (1) securely.
4. Check for damage to the pulleys, and wear of the V-groove and
V-belt. Be particularly careful to check that the V-belt is not in
contact with the bottom of the V-groove.
5. If the V-belt is so lengthened that it cannot be adjusted any
more or if it has any cuts or cracks, replace it.
6. If the V-belt has been replaced with a new part, there will be
initial elongation, so adjust the belt again after operating for 2
to 3 days.
4 - 46
.
CLEAN BREATHERS
Remove the mud and dirt from around the breathers, then remove the breathers and wash out the dirt with clean
diesel oil or flushing oil.
Hydraulic tank
1. Remove nut (1), then remove cover (2) and wash element (3).
2. Install element (3), then install cover (2) and nut (1).
4 - 47
.
CHECK FRAME
WARNING
When the inspection is performed with the dump body raised, be sure to lock the dump lever at HOLD position, and use safety
pins.
4 - 48
.
4 - 49
.
Measure the thickness of the pad, and if it is less than 1.5 mm (0.06
in), contact your Komatsu distributor.
4 - 50
.
If any problem is found, please contact your Komatsu distributor for inspection and adjustment.
If operations are carried out on muddy or wet ground, mud will stick to the link, and the movement may become slow,
so check and clean.
4 - 51
.
2. Turn the engine emergency stop switch to the STOP position (Position to stop the engine), and confirm that the
engine stops.
The engine will stop 10 to 20 sec later. If it fails to stop, ask your Komatsu distributor for inspection and
adjustment.
4 - 52
.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
The parts and oil is at high temperature after the engine has been operated, and it can result in a burn. Wait for the oil to cool down
before changing it.
1. Set a container to catch the oil immediately under the drain valve under the chassis.
2. Remove drain plug (1), then loosen drain valve (2) slowly to
avoid getting oil on yourself, and drain the oil. Be careful not to
loosen the drain valve too far and deform the stopper pin inside
the valve.
When draining the oil, fit a standard hose to the drain valve to
prevent the oil from spraying out.
3. Check the drained oil, and if there are excessive metal
particles or foreign material, please contact your Komatsu
distributor.
4. Tighten drain valve (2) and drain plug (1).
Tightening torque
Drain plug (1), drain valve (2): 68.6 ± 9.8N·m
(7 ± 1 kgf·m, 50.6 ± 7.2 lbft)
5. Using the filter wrench, turn 4 full-flow filter cartridges (3) and
2 bypass filter cartridges (4) to the left to remove them.
When doing this, to prevent getting oil on yourself, do not carry
out this operation from immediately under the cartridge.
In particular, if this operation is carried out immediately after
stopping the engine, a large amount of oil will come out, so wait
for 10 minutes before starting the operation.
6. Clean the filter holder, fill the new filter cartridge with oil, then
coat the seal and thread of the filter cartridge with oil (or coat
thinly with grease) and install.
7. When installing the filter cartridge, tighten until the packing
face is in contact with the filter holder, then tighten a further 3/4
- 1 turn.
4 - 53
.
8. Pour in the specified amount of engine oil from oil filler (F).
9. Run the engine for a short time at idling, then check if the oil is
at the specified level. For details, see CHECK OIL LEVEL IN
ENGINE OIL PAN, ADD OIL (PAGE 3-58).
4 - 54
.
When the engine is started after stopping because fuel is used up, if misfirming or black exhaust emission occur,
bleed air from the fuel line according to the following procedure.
10. Loosen the air bleed plugs of both injection pumps, bleed air by operating both feed pumps as explained in Steps
6 - 8 above.
4 - 55
.
1. Set the container to catch the oil under the filter case.
2. Remove drain plug (1) at the bottom of the filter case, drain the
oil, then tighten the plug again.
3. Hold down case (2), loosen center bolt (3), then remove case
(2).
4. Remove the element and clean the inside of the case.
5. Replace the filter gasket and O-ring with new parts. Coat the
gasket and O-ring thinly with clean engine oil before installing.
6. Assemble the new element to the case, set the case in position, and install with center bolt (3).
Be careful not to tighten center bolt (3) too far.
Tightening torque: 152 ± 14.7 N·m (15.5 ± 1.5 kgf·m, 112.1 ± 10.8 lbft)
7. Run the engine for a short time at idling, then stop the engine, and check that the oil is up to the specified level.
For details, see "CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER
(PAGE 4-59)".
Run the engine at high idling, and when the oil is warmed up, if the transmission filter clogging monitor lamp flashes,
replace the element immediately.
4 - 56
.
The pad wear is not necessarily the same for the left and right
wheels, so always check the pads on both the left and right. If any
of the pads has reached the wear limit, always replace all 4 pads.
If the work is performed on the muddy and watery ground, the mud
sticks to caliper or disc. Leaving the mud will increase the wear of
pad, so wash out thoroughly with water.
If the radiator fins become clogged or bent, this may cause overheating of the engine, so always clean or carry out
inspection and take the necessary actions.
Cleaning can be carried out by using jets of air, steam, or water,
but be careful not to let the nozzle contact the fin.
Air pressure : Max. 0.98 MPa (10 kgf/cm2, 142 PSI)
Steam pressure : Max. 0.39 MPa (4 kgf/cm2, 56.8 PSI)
When using compressed air or steam, keep the nozzle at 90
degrees to the radiator.
Examine the rubber hose, and if any cracks or brittle places are
found, replace the hose. In addition, check also for loose hose
clamps.
The machine is equipped with an auto-tensioner, so there is no need to carry out any adjustment until the belt is
replaced.
For details of replacing the fan belt, see REPLACE FAN BELT, ADJUST AUTO TENSIONER (PAGE 4-32).
4 - 57
.
4 - 58
.
1. Set the container to catch the oil directly under the drain plug.
Remove drain plug (1), then loosen drain valve (2) slowly to
avoid getting oil on yourself, and drain the oil, then tighten the
plug again.
2. Remove bolt (3), then remove the cover and take out strainer
(4).
3. Remove any dirt stuck to the strainer, then wash in clean diesel
fuel or flushing oil. If the strainer is damaged, replace it.
4. After installing the strainer, add oil through oil filler (F) to the
specified level.
5. After adding oil, check that the oil is at the specified level. See
"CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL
(PAGE 3-59)".
4 - 59
.
REPLACE STEERING, HOIST OIL TANK AND REAR BRAKE COOLING OIL TANK FILTER
ELEMENT
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the
temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Turn the cap of oil filler (F) slowly to release the internal
pressure, then remove the cap.
2. Remove bolt (1), then remove cover (2).
3. Take out the element, then wash the inside of the case and the
removed parts.
4. Install the new element, then install cover (2) with bolt (1).
LUBRICATION
1. Using a grease pump, pump in grease through grease fittings marked by arrows.
2. After greasing, wipe off any old grease that was pushed out.
4 - 60
.
4 - 61
.
1. Stop the machine on level ground, set the parking brake valve lever to the PARKING position, then check that
the other brakes are not applied before starting inspection.
2. Remove plug (1) from the rear brake and install the disc wear
measurement gauge.
When doing this, tighten the nipple fully and pull the rod of the
disc wear measurement gauge out fully. If it is not pulled out,
there is danger that the rod may fly out under hydraulic
pressure when the retarder lever is pulled.
Part number for gauge: 561-98-61122
3. Turn the starting switch to the ON position and check that the
air pressure gauge is in the green range.
4. If the air pressure is low, start the engine and run the engine at
2,000 rpm until the air pressure gauge enters the green range.
When it enters the green range, turn the starting switch OFF.
5. Operate the retarder control lever slowly over approx. 10 seconds to apply the brake.
In this condition, push the gauge rod in slowly until it contacts the piston.
6. If mark (A) of the disc wear measurement gauge goes in
beyond the end face of the case, this means that the disc has
reached the wear limit.
If this happens, please contact your Komatsu distributor for
inspection and maintenance.
If the rod is released suddenly after measurement, there is
great danger that the rod may fly out under hydraulic pressure.
Keep the rod held down and let it back slowly. When it reaches
the end of its stroke, release it.
7. Return the retarder control lever.
8. Remove the disc wear measurement gauge and install plug (1).
9. Bleed all the air from the circuit. For details, see "BLEED AIR FROM REAR BRAKE (PAGE 4-28)".
4 - 62
.
4 - 63
.
3. Remove drain plug (1), then loosen drain plug (2) slowly to
avoid getting oil on yourself, and drain the oil.
4. Pour in the specified amount of engine oil from oil filler (F).
5. For details of the oil to use, see CHECK OIL LEVEL IN REAR
BRAKE COOLING OIL TANK, ADD OIL (PAGE 3-60).
4 - 64
.
1. Stop the machine so that casting line (1) is horizontal and drain
plug (P) is at the bottom.
2. Remove drain plug (P), drain the oil, then tighten the plug
again.
3. Add oil through the hole for plug (G) to the specified level.
4. After adding oil, check that the oil is at the specified level. See
"CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
(PAGE 4-38)".
1. Remove drain plug (P), drain the oil, then tighten the plug
again.
2. Add oil through the hole for plug (G) to the specified level.
3. After adding oil, check that the oil is at the specified level. See
"CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL
(PAGE 4-38)".
4 - 65
.
Remove the mud and dirt from around the breather, then remove
the breather and wash out the dirt from inside with clean diesel oil
or flushing oil.
4 - 66
.
4 - 67
.
REPLACE PLUG WITH STRAINER FROM MAKE-UP TANK OF REAR BRAKE CHAMBER
Replace this part every 2000 hours or every year, whichever comes sooner.
1. Change the oil in the rear brake cooling oil tank, and at the
same time remove the hose and tee installed to the top of the
make-up tank, then remove plug (1) and replace it with a new
plug.
2. When replacing the plug, check the oil in the tank, then add the
same type of oil as the brake cooling oil to fill to the top of the
tank.
3. Install the hose and tee to the top of the plug.
4 - 68
.
4 - 69
.
Tightening torque of strainer (1): 11.3 ± 1.5 N·m (1.15 ± 0.15 kgf·m, 8.3 ± 1.1 lbft)
4 - 70
.
(1) A arm
(2) Front suspension
(3) Lock plate
(4) Bolt
(5) Holder
4 - 71
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
HD785-5
Item Unit
Overall weight
kg (lb) 158605 (349724)
(unladen weight + max. payload + 1 operator (80kg(176lb)))
Unladen weight kg (lb) 66930 (147581)
Unladen weight (without body) kg (lb) 50900 (112235)
Max. payload kg (lb) 91000 (200655)
Struck m (cu·yd)
3
40 (51.8)
Dump body capacity
Heaped (2 : 1) m (cu·yd)
3
60 (77.7)
Komatsu SA12V140 diesel
Engine type
engine
Flywheel horsepower of engine kW(HP)/rpm 753.15 (1011) / 2000rpm
A Overall length mm (ft in) 10490 (34'5")
B Overall height mm (ft in) 5050 (16'7")
C Overall height at dumping mm (ft in) 10080 (33'1")
D Overall width mm (ft in) 5210 (17'1")
E Min. ground clearance (bottom of rear axle) mm (ft in) 810 (2'8")
Min. turning radius mm (ft in) 9900 (32'6")
1st km/h (MPH) 11.0 (6.8)
2nd km/h (MPH) 15.5 (9.3)
3rd km/h (MPH) 20 (12.4)
Forward 4th km/h (MPH) 27 (16.8)
Travel speed
5th km/h (MPH) 36 (22.4)
6th km/h (MPH) 49 (30.5)
7th km/h (MPH) 65 (40.4)
Reverse 1st km/h (MPH) 11 (6.8)
Sound level
Surrounding (sound power level L WA) dB (A) dB (A) 84
Operator's (sound pressure level L PA) dB (A)
dB (A) 79.2
measurement procedures described in ISO6394 or 86/622/EEC
Vibration level
Hands/Arms The weighted root mean square acceleration m/S2 2.07
Whole body Measurement standards: ISO7096 m/S 2
0.50
5-2
.
SPECIFICATIONS SPECIFICATIONS
5-3
.
6-1
.
The payload meter inputs the signals from the pressure sensors, clinometer, body float detection, neutral detection,
and other signals, and calculates the weight of the load using its built-in micro computer. It displays the results on
the panel and also uses the external display lamps to show the condition of the load.
In addition, the data saved in memory can be printed out together with the date the load was dumped and the
number of loads.
NAME OF PARTS
6-2
.
6-3
.
PREDICTION DISPLAY
In the case where the weight of the load changes as each bucket is emptied into the dump body, the average
weight of the load up to that point is calculated to predict what the weight of the load will be if one more bucket
is loaded. The appropriate lamp flashes, so it is possible to adjust the weight of the next load when operating the
loader.
The prediction display for the load level and the actual load display are shown at the same time.
Example:
1st bucket: 23 tons
2nd bucket: 21 tons (44 tons)
3rd bucket: 22 tons (66 tons)
4th bucket: 24 tons (90 tons)
If the load changes as above, the external display lamps will give the display in the table below.
6-4
.
CONTENT OF DISPLAY
When the dump lever is at FLOAT and the shift lever is at neutral, the actual load is displayed.
When the load is less than 3.9 tons, or if the dump lever is not at FLOAT, the display is 0.
If the dump lever is at FLOAT but the shift lever is not at neutral, the time display is given.
A maximum of 200 cycles of data can be written to memory. If this level is exceeded, FULL is displayed. If FULL
is displayed, print out the data and clear the data from the memory. For details, see "DELETING DATA FROM
MEMORY (PAGE 6-7)".
After completion of operations, we recommend that you stop the machine, print out the data, and clear the data
from memory.
There may be a slight change between the load displayed at the loading point and the load displayed at the
dumping point.
Save the data to memory when the dump lever is raised.
When the machine is completely stopped, it is possible to carry out accurate calculation if the load is dumped
when the swaying of the machine has completely stopped. We recommend that the slope at the dumping point
be kept to within ±5 degrees.
When the value displayed by the payload meter becomes stable, move the dump lever to the RAISE position. If
the machine is still swaying violently when the dump lever is moved to the RAISE position, ***** is printed when
the print out is made.
When the dump lever is returned from LOWER to FLOAT, wait for at least 5 seconds before turning the starting
switch OFF.
OPERATION OF SWITCHES
6-5
.
PRINTING OUT
1. When print out switch (1) is pressed for at least 2 seconds, the
data are printed out.
2. When print feed switch (2) is pressed for at least 2 seconds, the
paper is fed.
To stop the print during the printout, press the print switch
again for at least 2 seconds.
Do not hold the paper coming out from the printer during the
printout. This will cause the print to overlap.
6-6
.
RESETTING TIME
WARNING
Never try to reset the time when traveling.
6-7
.
1. Open the roll of printer paper, fold the paper at a point approx.
3 cm (1.2 in) from the end of the paper, then cut the paper
straight along the fold.
Never cut the paper in the way shown on the right. It will cause the
paper to jam.
2. Set the print paper with the printing side facing up, and insert
it straight into the paper feed hole. If the FEED switch is
pressed while feeding in the paper, the paper will feed
automatically.
3. When the paper comes out from the printer, pass it through the
slit in the lid of the printer, then close the lid.
6-8
.
Do not pull the paper out and cut it without using the paper
cutter.
Replacing battery
Move the machine to a place where it is safe to carry out the replacement operation.
Parts to prepare
Crosshead screwdriver
Socket wrench (for M4 nut)
New battery (7818-27-2860)
1. Turn the starting switch key to the ON position, press the PRINT switch for at least 2 seconds, and print out the
load data from memory.
Do not start the engine when doing this.
2. Turn the starting switch back to the OFF position.
3. Remove the screws (M6 x 4) holding the payload meter, then
pull the payload meter out to the front.
6-9
.
5. Remove the nut (M4) and the band holding the battery.
Do not wear gloves when carrying out this operation.
Be careful not to let dirt, dust, or metal particles get inside the
controller. Be careful not to drop any nuts or washers inside the
controller.
6 - 10
.
If the paper jams, PAPE is displayed on the load display, so move the machine to a safe place and clear the paper
jam as follows.
1. Turn the starting switch key to the OFF position.
2. Remove the screws (M6 x 4) holding the payload meter, then
pull the payload meter out to the front.
6 - 11
.
6. Remove the printer paper remaining inside the printer, and cut
the leading end of the paper.
For details of the method of cutting the end of the paper, see
"METHOD OF CUTTING PRINTER PAPER (PAGE 6-9)".
7. Turn the starting switch key to the ON position, and press the
FEED switch.
For details of the method of inserting the paper, see "SETTING
PAPER IN PRINTER (PAGE 6-8)" .
8. Turn the starting switch key to the OFF position, remove the
connectors, then assemble to the original condition.
6 - 12
.
INSTRUMENT LOCK
This (1) can be used for the instrument lock key when replacing the charts, or for operator change identification keys
1 and 2.
CLOCK DIAL
One line here (2) indicates one minute.
SPEED SCALE
This (4) is the scale for the machine travel speed.
6 - 13
.
SPEED INDICATOR
This (5) indicates the machine travel speed.
Models with the speed warning lamp do not have the speed indication confirmation lamp.
Models with the speed warning lamp do not have the speed indication confirmation lamp.
ODOMETER
This meter (8) displays the total distance (km) traveled by the machine.
CHART SUPPORT
This (16) is the rotating part of the clock and has teeth to prevent the chart from slipping.
PRESSING RING
This ring (17) is a ring that presses the chart and holds it against the chart support.
CUTTING KNIFE
This knife (18) cuts the tape connecting the charts.
6 - 14
.
NAME PLATE
This (20) indicates the type and model.
The change key will only turn in the direction of its number.
The change keys cannot be used to open the instrument.
METHOD OF USE
1. Check the operation of clock.
Watch through clock operation confirmation aperture (1) to
confirm that the clock is working.
The clock is electric, so there is no need to wind it up.
2. Open the cover.
Insert the instrument open/lock key in hole (2), turn
counterclockwise 90°, then pull open carefully.
The cover can be opened approx. 115°. Do not open it further
than that, or pull it strongly, or put anything heavy on the cover,
as these will cause failures.
6 - 15
.
4. Fill in chart.
Before inserting new chart paper, always fill in the required items. (Operator code No., machine code No., date,
etc.)
Fill in the above items with a steel pen.
Handle the charts carefully with clean hands, and do not fold or scratch them.
5. Push down pressing ring (4) holding the charts, turn counterclockwise, and pull out the pressing ring at the point
where it contacts the stopper, then remove the charts.
6. Insert new charts.
Remove pressing ring (4), then set the charts under cutting knife (5). When doing this, align the time on the
charts (for example when the starting time is 9 am) exactly with red point (6) on the instrument body.
Use Komatsu genuine charts (P/N: YZ762929-980) for 90 km/h (55.9 MPH) 7 days.
6 - 16
.
(1) Instrument lock (14) Speed confirmation aperture for speed warning
(2) Clock dial lamp indication
(3) Speed scale (15) Clock setting knob
(4) Speed indicator (16) Chart support
(5) Speed warning lamp (17) Pressing ring
(6) Speed indication confirmation lamp (18) Cutting knife
(7) Odometer (19) Instrument lighting lamp
(8) Period indicating label (20) Name plate
(9) RPM scale (21) Voltage indication label
(10) RPM indicator (22) RPM recording stylus
(11) Speed recording stylus (23) Adjustment screw for RPM warning lamp
(12) Travel distance recording stylus (24) Speed confirmation aperture for RPM warning
(13) Adjustment screw for speed warning lamp lamp indication
(25) Total revolution counter
INSTRUMENT LOCK
This (1) can be used for the key to open when replacing the chart.
CLOCK DIAL
One line here (2) indicates one minute.
SPEED SCALE
This (3) is the scale for the machine travel speed.
6 - 17
.
SPEED INDICATOR
This (4) indicates the machine travel speed.
Models with the speed warning lamp do not have the speed indication confirmation lamp.
Models with the speed warning lamp do not have the speed indication confirmation lamp.
ODOMETER
This meter (7) displays the total distance (km) traveled by the machine.
RPM SCALE
This (9) is the scale for the momentary speed in revolutions per minute (rpm).
RPM INDICATOR
This (10) shows the momentary speed in revolutions per minute (rpm).
CHART SUPPORT
This (16) is the rotating part of the clock and has teeth to prevent the chart from slipping.
PRESSING RING
This ring (17) is a ring that presses the chart and holds it against the chart support.
CUTTING KNIFE
This knife (18) cuts the tape connecting the charts.
6 - 18
.
NAME PLATE
This (20) indicates the type and model.
METHOD OF USE
1. Open the cover.
Insert the instrument open/lock key in hole (1), turn
counterclockwise 90°, then pull open carefully.
Always set the time with the time setting knob. Turn the hand
in the direction of rotation 10 minutes beyond the correct time,
then turn back to the correct time.
Check the clock operation with the movement of minute hand.
The clock is electric, so there is no need to wind it up.
3. Fill in chart.
Before inserting new chart paper, always fill in the required items. (Operator code No., machine code No., date,
etc.)
Fill in the above items with a steel pen.
Handle the charts carefully with clean hands, and do not fold or scratch them.
6 - 19
.
Handle the charts carefully with clean hands, and do not fold or scratch them.
Use Komatsu genuine charts (P/N: YZ762929-730) for 90 km/h (55.9 MPH) 7 days.
6 - 20
.
WARNING
Do not use the differential lock pedal when traveling at high speed (4th gear, 20 km/h (12.4 MPH) and above).
Do not use the differential lock pedal when turning.
NOTICE
Do not use the differential lock pedal when the wheels are already slipping. This may reduce the durability.
First, stop the machine, then depress the differential lock pedal, and start the machine again.
6 - 21
.
REMARK
When traveling on soft ground where the wheel on one side slips,
or when traveling on road surfaces where the tires are likely to slip,
depress the differential lock pedal. This actuates the differential
lock and makes both the left and right wheels rotate at the same
speed to prevent slipping.
REMARK
Using the differential lock before the tires slip makes it possible to obtain the full capacity of the differential lock, and
also extends the tire life.
If the differential lock is applied when the tires are already slipping, the durability may be reduced.
Do not actuate the differential lock when the tires are slipping.
If the tires should slip and it becomes impossible to escape, stop the machine, then depress the differential lock
pedal and start the machine again.
When traveling on road surfaces where the tires may slip, be particularly careful to avoid sudden changes in travel
speed (decelerating or accelerating).
Do not use the differential lock pedal when traveling at high speed (4th gear, 20 km/h (12.4 MPH) and above).
Do not use the differential lock pedal when turning.
If the differential lock is used when turning, it will cause the following problems.
It will be more difficult to turn than when the differential lock is not used, so the truck may be unable to turn on
curves where it could normally turn easily.
The inside wheels and outside wheels will turn at the same speed when turning, so one side will spin and
reduce the tire life, and it may also damage the road surface.
In order to absorb the difference in rotation of the left and right tires which is caused when the machine turns,
the differential lock disc will slip, and this will reduce the durability of the differential lock.
An excessive load will be brought to bear on the final drive, and this may reduce the life of the final drive.
NOTICE
If the tires are likely to slip on the road surface on curves, carry out maintenance of the road surface to reduce this problem.
6 - 22
.
ABS: When the machine is braked suddenly or braked on a slippery snow-covered road, etc., this system works to
prevent the tires from locking and skidding. Accordingly, a stable machine behavior and good steering
performance is secured.
ABS/ASR: In addition to the above functions of the ABS, this system has a function to prevent slipping of the drive
wheels caused by excessive torque. Accordingly, the machine can start and travel normally even on a
bad or frozen road surface.
EXPLANATION OF COMPONENTS
WARNING LAMP
This lamp (1) lights up at engine start and when the ABS/ASR is turned off or malfunctions.
6 - 23
.
TROUBLESHOOTING SWITCH
This switch (4) is used for troubleshooting.
6 - 24
.
OPERATION METHOD
ABS OPERATION
WARNING
Always stop the machine before turning on the ABS/ASR main switch (3). If it is turned on while the machine is running, the
ABS/ASR may not function normally.
1. Turn on the starting switch (1). At this time, warning lamp (2)
will light up.
ASR OPERATION
WARNING
Turn on the troubleshooting switch (1) only when performing troubleshooting on the machine. The ABS/ASR system will not
function while the troubleshooting switch is turned on.
1. Since the ASR and ABS are interlocked, if the ABS is turned
on, the ASR is also turned on automatically.
6 - 25
.
The machine can be travel normally even if the ABS/ASR main switch is turned off. In this case, however, watch
out for lateral skidding of the machine.
Even if the ABS/ASR system malfunctions, the machine can be travel normally. Watch out for lateral skidding in
this case, however, while traveling on slippery roads. If the warning lamp lights up, the system is automatically
turned off and the ABS/ASR system does not function.
Even if the ABS/ASR system is installed, the emergency brake function is maintained.
If the ABS/ASR main switch is turned on with the brake pedal depressed or the retarder control lever pulled,
exhaust sound will be momentarily emitted from the ABS valve. This does not indicate a fault.
If both rear wheels slip at the same speed, the ASR will not function. In this case, adjust the engine output with
the accelerator pedal.
When installing a wireless device on the machine, select one which does not violate the wireless device-related
laws/regulations and use it according to law. Mount it as far away from the devices and wiring harness of the
ABS/ASR system as possible.
TROUBLESHOOTING
When the starting switch is turned on, if the warning lamp does not light up, it may be broken. In this case, replace
the lamp.
If the ABS/ASR system malfunctions while being used, the warning lamp (Red) will light up. In this case, stop the
machine at a safe place immediately, then ask your Komatsu distributor to carry out repair.
The positions of each switch and the statuses of the corresponding warning lamps are as follows.
ABS/ASR
Starting switch Warning lamp
Main switch
OFF OFF Goes off
OFF ON Goes off
ON OFF Lighted (Normal)
Stays lighted until travel speed rises to about 10 km/h (6.2 MPH),
ON ON then goes off (Normal).
Lights up when a fault occurs (Malfunction).
6 - 26
.
WARNING
The ARSC system is actuated when the system switch is ON. Before traveling downhill, check that the system switch is ON.
If the speed is set to a speed that exceeds the maximum permissible speed obtained from the brake performance graph, there
is danger that there will be overheating and that the retarder brake may be damaged. Always set the speed so that it does not
exceed the maximum permissible speed.
When the ARSC is actuated on slippery roads, the tires may lock. If this happens, cancel the ARSC.
If any abnormality occurs in the system and braking cannot be carried out properly, the alarm sounds and the system is turned
OFF to cancel the ARSC. If necessary, control the machine with the retarder control lever and foot brake to stop the machine
in a safe place, then turn the system switch OFF.
6 - 27
.
EXPLANATION OF COMPONENTS
The position of system switch (1) may differ according to the combination of optional equipment.
SYSTEM SWITCH
This switch (1) is used to turn the ARSC system ON/OFF.
6 - 28
.
ACCELERATOR PEDAL
The ARSC is actuated only when the accelerator pedal (7) is not being pressed.
BRAKE PEDAL
This pedal (8) operates the wheel brake even when the ARSC is being operated.
READY LAMP
When this lamp (9) is lighted up, it shows that the travel speed is set and that operation of the ARSC is possible.
When it is out, the ARSC is not actuated.
It lights up for 3 seconds when the starting switch is turned ON to check the bulb.
6 - 29
.
METHOD OF OPERATION
WARNING
If the speed is set to a speed that exceeds the maximum permissible speed obtained from the brake performance graph, there is
danger that there will be overheating and that the retarder brake may be damaged. Always set the speed so that it does not exceed
the maximum permissible speed.
If the actual machine speed during the setting operation is less than 10 km/h (6.2 MPH), the speed is set to 10 km/h
(6.2 MPH). In all other cases, it is set to the actual travel speed.
The travel speeds that can be set depend on the selection of the gearshift lever as follows.
When the shift lever is at the D, 5, 4, 3, or L positions, the range for the set speed is 10 to 55 km/h (6.2 to 34.2 MPH).
It is impossible to set the speed when the shift lever is at the N or R positions.
REMARK
Release the ARSC set lever after changing the set travel speed.
If the set and cancel operations are carried out at the same time, the cancel operation is given priority.
If the set and tap up operations are carried out at the same time, the tap up operation is given priority.
If the set and tap down operations are carried out at the same time, the tap down operation is given priority.
The tap up and tap down operations are used for making fine adjustment of the set travel speed.
It is possible to adjust the set travel speed up to ± 5 km/h (3.1 MPH) when traveling in ARSC (when the accelerator
pedal is released). When the accelerator pedal is being depressed, the ARSC is canceled, so it is possible to adjust
the set speed freely in a range from 10 to 55 km/h (from 6.2 to 34.1 MPH).
6 - 30
.
REMARK
After using the retarder control lever to reduce the speed, return it to its original position.
REMARK
When traveling at a speed greater than the set speed displayed on the travel speed display, the ARSC is not
actuated even when the accelerator pedal is released. When this happens, the READY lamp (green) also does not
light up. Always adjust the travel speed to a speed lower than the set speed displayed on the travel speed display,
and check that the READY lamp lights up.
REMARK
For Method 1, cancel operation must be continued for at least 1 second (different from other switches) to cancel the
control. This is to prevent any problem of the control being canceled if the switch is touched by mistake.
OVERHEAT WARNING
If there is danger that the retarder oil may overheat, the ARSC caution lamp lights up and the set travel speed is
automatically reduced 1 km/h (0.6 MPH) every 3 seconds. The lower value for the set travel speed when the speed
is automatically reduced is 10 km/h (6.2 MPH).
6 - 31
.
TROUBLESHOOTING
Failure Remedy
No. Detail
code pattern*
1 0.1 Abnormality in power source 1
2 1.0 Disconnection, short circuit with ground, short circuit in engine speed sensor system 1
Disconnection, short circuit with ground, short circuit in transmission output shaft
3 1.3 1
speed sensor system
4 1.5 Short circuit with ground in retarder oil temperature sensor system 1
5 1.7 Disconnection, short circuit with ground, short circuit in accelerator signal 1
6 1.8 Disconnection, short circuit with ground in suspension pressure sensor (left) system 1
7 1.9 Disconnection, short circuit with ground in suspension pressure sensor (right) system 1
8 4.2 Disconnection, short circuit in exhaust brake signal system 2
9 4.3 Disconnection, short circuit in ARSC caution lamp system 1
10 4.4 Disconnection in READY lamp system 2
11 4.5 Disconnection, short circuit in central warning lamp system or buzzer system 2
12 5.2 Short circuit with ground in exhaust brake signal system 2
13 5.3 Short circuit with ground in ARSC caution lamp system 1
14 5.4 Short circuit with ground in READY lamp system 2
15 5.5 Short circuit with ground in central warning lamp system or buzzer system 2
16 6.0 Failure in engine speed sensor system 1
17 7.0 Disconnection, short circuit in set speed display up output 2
18 7.1 Disconnection, short circuit in set speed display down output 2
19 7.2 Disconnection, short circuit in set speed display clear output 2
20 7.3 Short circuit with ground in set speed display up output 2
21 7.4 Short circuit with ground in set speed display down output 2
22 7.5 Short circuit with ground in set speed display clear output 2
23 8.1 Short circuit with ground in pressure control valve system 1
24 8.3 Short circuit with ground in pressure control valve system 1
Failure in pressure control valve (retarder remains applied) or failure in pressure
25 8.5 1
switch 1 system
Failure in pressure control valve (retarder has no effect) or failure in pressure switch
26 8.7 1
1 system
27 8.9 Short circuit with ground in pressure cracking valve 1
28 9.0 Disconnection, short circuit in pressure cracking valve 1
Failure in pressure cracking valve (remains open) or failure in pressure switch 2
29 9.1 1
system
Failure in pressure cracking valve (does not open) or failure in pressure switch 2
30 9.2 1
system
31 9.3 Disconnection, short circuit in system switch system 1
32 9.4 Short circuit with ground in system switch system 1
33 9.5 Disconnection, short circuit with ground in travel speed set switch system 1
*See next page.
6 - 32
.
Remedy pattern 1
If the central warning lamp and the ARSC caution lamp flash and the buzzer sounds, it means that a serious problem
has occurred in the ARSC system.
Operation of the ARSC system is stopped. Operate the brake pedal or retarder lever as necessary to ensure safety.
When the system switch is turned OFF, the central warning lamp and ARSC caution lamp go out and the buzzer
stops.
REMARK
If the starting switch is turned ON when the air pressure in the air tank has dropped, failure code "9.2" may be
displayed. If this happens, start the engine and raise the air pressure to the normal level, then start again.
If the failure code is "9.3" or "9.4", it shows that there is a failure in the system switch, so even if the system switch
is turned OFF, the central warning lamp and ARSC caution lamp will flash and the buzzer will sound.
Remedy pattern 2
When only the ARSC caution lamp flashes
The ARSC system continues to be actuated, but an abnormality has occurred in the system.
Turn the system switch OFF to stop use of the ARSC.
When the system switch is turned OFF, the ARSC caution lamp will go out.
In the case of patterns 1 and 2 above, turn the system switch OFF quickly, stop use of the ARSC and contact your
Komatsu distributor for repairs.
The set travel speed display is also equipped with a self- diagnostic function, and a failure code is displayed on the
set travel speed display
Failure
No. Detail Method of resetting
code
Abnormality
1 E1 Turn the starting switch ON again or turn the system switch ON again.
in CPU
Abnormality
2 E2 Turn the starting switch ON again or turn the system switch ON again.
in memory
REMARK
If the above code is not displayed when the accelerator pedal is being depressed or not being depressed, it is
necessary to adjust the accelerator link. If it is not properly adjusted, the ARSC system will not be able to judge
correctly if the accelerator pedal is being depressed or not, so the ARSC may not work normally.
6 - 33
.
METHOD OF DISPLAYING MODEL SELECTION, TIRE LARGE DIAMETER/SMALL DIAMETER, FAILURE CODE
When the starting switch is turned ON, the codes below are automatically displayed in the following order on the
controller LED.
1. LEDs all light up.
2. Model
Code: 78
3. Tire diameter (Large/small)
REMARK
When using the ARSC for the first time, always clear the failure codes.
After clearing the codes, connect connectors CR1 and CR2.
6 - 34
.
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE)
6 - 35
.
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
OPERATION AND MAINTENANCE) ATTACHMENTS, OPTIONS
MOM is a message display for operator and service person, and has some touch switches in its surface.
MOM always informs operator of various and useful data as follows.
Machine conditions
When starting switch is turned on before starting engine
Engine start is OK or WAIT
The reason why engine start is not acceptable
When engine is running before departure
Departure is OK or WAIT
The reason why departure is not acceptable
Production data (Only when optional PLM II is installed in the machine)
Current payload
Total payload
Total numbers of cycle
Fault information at occurrence
Service code and its description
User code and its description
Others
Year/month/date, Clock
It is recommended to obey MOM's requests in order to drive safely, keep the machine good condition, and prevent
severe malfunction.
However, it is always possible to start engine and to depart because of emergency use even if MOM indicates WAIT.
6 - 36
.
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE)
The reason why engine start is not acceptable is indicated also and they are as follows.
When parking brake is not applied, "PARKING BRAKE" is indicated.
When shift lever is not neutral position, "T/M SHIFT LEVER" is indicated.
Engine is able to be started even if "PARKING BRAKE" is indicated for emergency use. When shift lever is not
neutral position, change to neutral in order to start engine.
When engine is started, (i2) is changed to the picture of initial check 2 (i3) automatically.
If any controller detects fault, (i2) is changed to the picture of warning message (i6) automatically.
6 - 37
.
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
OPERATION AND MAINTENANCE) ATTACHMENTS, OPTIONS
Machine is able to be departed even if "DEPARTURE WAIT" is indicated for emergency use.
When engine is started, (i2) is changed to the picture of initial check (i3) automatically.
If you touch LIGHT OFF area in (i3), then the back light of MOM is turned off and (i3) is turned to be dark (i7). It can
be used when annoyed by the glare during the driving at night. If the dark picture is touched, the back light lights up
again.
If any controller detects fault, (i3) is changed to the picture of warning message (i6) automatically.
Time, current payload, total payload, and total number of cycle are
indicated in this picture.
6 - 38
.
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
ATTACHMENTS, OPTIONS OPERATION AND MAINTENANCE)
This action only erases the indication in MOM, therefore the fault is still active, monitor panel keeps indicating the
user code, and the other caution areas keeps on.
Once the indication of fault is erased, the same indication is not appeared until recurrence and detection of the fault.
When all faults are recovered or erased in MOM, i6 is returned to i2, i3, or i4 automatically according to truck
condition.
6 - 39
.
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
OPERATION AND MAINTENANCE) ATTACHMENTS, OPTIONS
6 - 40
.
EXPLANATION OF COMPONENTS
SYSTEM SWITCH
This switch (1) is used to turn the ASR system on/off.
6 - 41
.
ACCELERATOR PEDAL
ASR system operates only when the pedal (6) is depressed with the travel speed range of 0 to 30km/h (0 to 18.6
MPH). If stopps depressing the pedal, ASR system stopps its operaton.
BRAKE PEDAL
When ASR is operated, if this pedal (7) is depressed, ASR system stopps its operation.
The machine can be driven normally even if the ASR system switch is turned off. In this case, however, watch
out for lateral skidding of the machine on slippery roads.
If both rear wheels slip at the same speed, the ASR will not function. In this case, adjust the engine output with
the accelerator pedal.
6 - 42
.
TROUBLESHOOTING
Failure Remedy
No. Details
code pattern
1 0.1 Abnormality in power source 1
Disconnection, short circuit with ground, short circuit in engine speed sensor
2 1.0 1
system
3 1.1 Disconnection in RR wheel revolution sensor 1
4 1.2 Disconnection in RL wheel revolution sensor 1
Disconnection, short circuit with ground, short circuit in transmission output shaft
5 1.3 1
speed sensor system
6 1.6 Failure of steering rudder angle sensor 2
7 1.7 Disconnection, short circuit with ground, short circuit in accelerator signal system 1
8 4.3 Disconnection, short circuit in ARSC & ASR caution lamp system 1
9 4.5 Disconnection, short circuit in central warning lamp system or buzzer system 2
10 5.3 Short circuit with ground in ARSC & ASR caution lamp system 1
11 5.5 Short circuit with ground in central warning lamp system or buzzer system 2
12 6.0 Failure in engine speed sensor system 1
13 6.1 Failure in RR wheel revolution sensor system 1
14 6.2 Failure in RL wheel revolution sensor system 1
15 6.3 Failure in transmission output axis revolution sensor system 1
16 8.1 Short circuit with ground in pressure control valve system (right) 1
17 8.2 Short circuit with ground in pressure control valve system (left) 1
18 8.3 Disconnection, short circuit in pressure control valve system (right) 1
19 8.4 Disconnection, short circuit in pressure control valve system (left) 1
20 8.5 Failure in pressure control valve (right) or failure in pressure switch 1 system 1
21 8.6 Failure in pressure control valve (left) or failure in pressure switch 1 system 1
22 8.7 Failure in pressure control valve (right) or failure in pressure switch 1 system 1
23 8.0 Failure in pressure control valve (left) or failure in pressure switch 1 system 1
24 8.9 Short circuit with ground in pressure cracking valve 1
25 9.0 Disconnection, short circuit in pressure cracking valve 1
Failure in pressure cracking valve (remains open) or failure in pressure switch 2
26 9.1 1
system
Failure in pressure cracking valve (does not open) or failure in pressure switch 2
27 9.2 1
system
Remedy pattern 1
If the central warning lamp and the ASR caution lamp flash and the buzzer sounds, it means that a serious problem
has occurred in the ASR system.
Operation of the ASR system is stopped.
Stop in a safe place quickly and stop using the ASR by turning the system switch off.
When the system switch is turned OFF, the central warning lamp and ASR caution lamp go out and the buzzer
stops.
6 - 43
.
Remedy pattern 2
When only the ASR caution lamp flashes
The ASR system continues to be actuated, but an abnormality has occurred in the system.
Stop at the safe place quickly and turn the system switch OFF to stop use of the ASR.
When the system switch is turned OFF, the ASR caution lamp will go out.
In the case of patterns 1 and 2 above, turn the system switch OFF quickly, stop use of the ASR and contact your
Komatsu distributor for repairs.
METHOD OF DISPLAYING MODEL SELECTION, TIRE LARGE DIAMETER/SMALL DIAMETER, FAILURE CODE
When the starting switch is turned ON, the codes below are automatically displayed in the following order on the
controller LED.
1. LEDs all light up.
2. Model
Code: 78
3. Tire diameter (Large/small)
REMARK
When the ASR is used at the first time, be sure to clear the failure code. Connect the connectors CR1 and CR2 after
the clearance.
6 - 44
.
The dashed line shows the air line and the solid line shows the grease line.
1.The air from air tank (1) passes through solenoid valve (2) and air regulator (3), and is connected to the grease
pump (4).
2.The action of timer (5) or operation of the manual lube switch (6) on the dashboard sends compressed air to push
down follower plate (7) of grease pump (4), and grease (8) inside grease pump (4) is force fed to injector (9).
3.Injector (9) is connected to all greasing points and carries out greasing.
REMARK
Normally, the timer is actuated when the starting switch is turned ON and greasing is carried out at the set interval.
The manual lube switch makes it is possible to carry out greasing as desired, and is also used for bleeding the air
and other inspections.
6 - 45
.
NOTICE
Check that there is no dent in the can. If there is a dent, the follower plate will not go down to the bottom and it will be impossible
to carry out greasing.
This brings the danger of damage caused by insufficient greasing of the machine.
1. Release 4 latches (2) of grease pump (1), and open the top of
the grease pump.
2. Insert grease can (4) into case (3) of the grease pump.
The applicable follower plate differs according to whether the grease can is used or not. Use the appropriate part
No. follower plate.
REMARK
Follower plate 427-S95-2510 is applicable for cans with an inside diameter from 275 mm to 290 mm.
3. Insert the pump tube at the top of the grease pump into the grease, then set follower plate (5) inside grease can
(4).
4. Check that there is no leakage of grease from between grease can (4) and follower plate (5).
5. Secure with latches (2) at the top of grease pump (1).
6 - 46
.
NOTICE
Use a suitable follower plate.
If the follower plate is not suitable, the grease pump will be unable to feed the grease even when there is grease remaining in the
grease can.
This brings the danger of damage caused by insufficient greasing of the machine.
1. Open top cover (1) of the timer box, then set greasing interval
adjustment screw (2) to 5 minutes.
When starting to use the auto-greasing system, grease is not supplied sufficiently to the charging portion, so set the
timer to a shorter time. After 2-3 days, the grease will fill the charging portion, so set the timer to 20 minutes. Adjust
the timer setting according to the grease condition.
REMARK
With the manual lube switch, it is possible to carry out greasing
regardless of the timer. This can be used mainly when checking
the action of the grease pump or when carrying out additional
greasing.
6 - 47
.
NOTICE
Always bleed the air from the grease circuit. If there is air in the grease circuit, the grease pressure will not rise to the specified
pressure, and this will lead to damage from insufficient lubrication at all parts of the machine.
1. Remove blind plug (2) from the tip of injector manifold (1) at the
rear right of the front axle of the machine.
4. Milky white grease mixed with air comes out from the hole for
blind plug (2) in manifold (1). When this milky white grease
changes to normal grease, turn manual lube switch (3) OFF.
6 - 48
.
6. Remove blind plug (5) from the tip of injector manifold (4) at the
rear left of the front axle of the machine.
7. Turn the starting switch ON.
8. Turn manual lube switch (3) ON.
9. Milky white grease mixed with air comes out from the hole for
blind plug (5) in manifold (4). When this milky white grease
changes to normal grease, turn manual lube switch (3) OFF.
10. Install blind plug (5) to manifold (4).
11. Remove blind plug (7) from the tip of injector manifold (6) at the
rear of the rear axle of the machine.
12. Turn the starting switch ON.
13. Turn manual lube switch (3) ON.
14. Milky white grease mixed with air comes out from the hole for
blind plug (7) in manifold (6). When this milky white grease
changes to normal grease, turn manual lube switch (3) OFF.
15. Install blind plug (6) to manifold (7).
6 - 49
.
6 - 50
.
It is possible to adjust the injector within a range of 0.128 cc to 1.28 cc for one cycle.
Set to the injector to the minimum discharge amount. When changing the discharge amount, adjust as follows.
The relationship between the adjustment nut and the discharge amount is as follows.
REMARK
After the nut contacts the stopper, turn it back counterclockwise. The discharge amount is reduced according to the
amount the nut is turned back.
6 - 51
.
Front right
(1) Right knuckle arm (right) (4) Right knuckle arm (rear)
(2) Right steering cylinder (right) (5) Right front suspension
(3) Right tie rod (right) (6) Right knuckle arm (front)
6 - 52
.
Front left
(7) Left knuckle arm (left) (13) Left steering cylinder (right)
(8) Left steering cylinder (left) (14) Center lever
(9) Left tie rod (left) (15) Left tie rod (right)
(10) Left knuckle arm (rear) (16) Right tie rod (left)
(11) Left front suspension (17) Right steering cylinder (left)
(12) Left knuckle arm (front)
6 - 53
.
Rear right
(18) Right hoist cylinder (bottom) (23) Bottom right radius rod (rear)
(19) Right hoist cylinder (top) (24) Right rear suspension (bottom)
(20) Bottom right radius rod (front) (25) Right rear suspension (top)
(21) Top right radius rod (rear) (26) Right body hinge pin
(22) Top right radius rod (front) (27) Left body hinge pin
6 - 54
.
Rear left
(28) Left hoist cylinder (bottom) (32) Top left radius rod (front)
(29) Left hoist cylinder (top) (33) Bottom left radius rod (rear)
(30) Bottom left radius rod (front) (34) Left rear suspension (bottom)
(31) Top left radius rod (rear) (35) Left rear suspension (top)
6 - 55
.
(1) Right knuckle arm (right) (4) Right knuckle arm (rear)
(2) Right steering cylinder (right) (5) Right front suspension
(3) Right tie rod (right) (6) Right knuckle arm (front)
6 - 56
.
(7) Left knuckle arm (left) (13) Left steering cylinder (right)
(8) Left steering cylinder (left) (14) Center lever
(9) Left tie rod (left) (15) Left tie rod (right)
(10) Left knuckle arm (rear) (16) Right tie rod (left)
(11) Left front suspension (17) Right steering cylinder (left)
(12) Left knuckle arm (front)
6 - 57
.
(18) Right hoist cylinder (bottom) (23) Bottom right radius rod (rear)
(19) Right hoist cylinder (top) (24) Right rear suspension (bottom)
(20) Bottom right radius rod (front) (25) Right rear suspension (top)
(21) Top right radius rod (rear) (26) Right body hinge pin
(22) Top right radius rod (front)
6 - 58
.
(27) Left body hinge pin (32) Top left radius rod (front)
(28) Left hoist cylinder (bottom) (33) Bottom left radius rod (rear)
(29) Left hoist cylinder (top) (34) Left rear suspension (bottom)
(30) Bottom left radius rod (front) (35) Left rear suspension (top)
(31) Top left radius rod (rear)
6 - 59
.
7-1
.
The hydraulic tank on the high altitude specification machine is pressurized to prevent cavitation of the hydraulic
pump.
This section gives information about parts that are different from the standard specification machine. Any part not
given here is the same as the standard specification machine, so see the manual for the standard specification
machine for details.
EXPLANATION OF COMPONENTS
PRESSURE CAUTION LAMP
This lamp lights up when the pressurizing pressure in the hydraulic
tank goes down. If it lights up, check that the pressurizing valve is
closed and that the pressurizing piping is not is disconnected.
If the body is raised to near the maximum height, the lamp may light
up, but this does not indicate any abnormality.
7-2
.
SERVICE PROCEDURE
WARNING
Always release the pressure inside the tank before removing the oil filler. If the pressure is not released, there is danger that oil
will spurt out. Close the pressurizing valve before removing the oil filler.
When carrying out any of the following operations, always stop the engine and release the pressure inside the tank
as follows.
"CHECK OIL LEVEL IN REAR BRAKE COOLING OIL TANK, ADD OIL (PAGE 3-60)",
"CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK, ADD OIL (PAGE 3-60)",
"REPLACE STEERING, HOIST OIL TANK AND REAR BRAKE COOLING OIL TANK FILTER ELEMENT (PAGE
4-60)", "CHANGE OIL IN STEERING, HOIST OIL TANK (PAGE 4-63)",
"CHANGE OIL IN REAR BRAKE COOLING OIL TANK (PAGE 4-64)".
1. Pull pressurizing valve (1) to shut off the pressure coming from
the air tank.
2. After shutting off the pressure coming from the air tank, turn the
oil filler slowly and remove it.
3. After carrying out the procedure in Steps 1 and 2, change the
oil.
NOTICE
If the pressurizing valve is not returned to its original position, it will cause
cavitation and the hydraulic pump may be damaged.
7-3
.
3. Pull the ring of drain valve (3) and release the air from the air
tank.
4. Remove plug (4) of the pressure reducing valve, then install
the pressure gauge. Use a pressure gauge that can measure
9.8 to 98 kPa (0.1 to 1.0 kgf/cm2, 1.4 to 14.2 PSI).
7-4
.
4. Operate the dump lever to the RAISE position and raise the
dump body slowly. With this operation, the indicator on the
pressure gauge will go down.
5. Operate the dump lever to the FLOAT position and lower the
dump body slowly. With this operation, the indicator on the
pressure gauge will go up to a point where the air is discharged
from the quick relief valve, and the rise in pressure stops.
6. Repeat the procedure in Steps 4 and 5 2 to 3 times and seat in
the dump body. The value indicated by the pressure gauge
when the dump body is seated is the set pressure at that point.
7. Turn knob (1) of the pressure reducing valve to set to the
specified pressure.
Specified pressure: 78.4 kPa (0.8 kgf/cm2, 11.4 PSI).
8. Repeat the procedure in Steps 4 to 7 to adjust the pressure.
7-5
.
INDEX
INDEX
<A> <G>
AIR CONDITIONER 3- 47 GENERAL PRECAUTIONS 2- 11
ARSC (AUTOMATIC RETARDER SPEED GENERAL VIEW 3- 2
CONTROL) 6- 27 GENERAL VIEW OF CONTROLS AND
EXPLANATION OF COMPONENTS 6- 28 GAUGES 3- 3
METHOD OF OPERATION 6- 30 GENERAL VIEW OF MACHINE 3- 2
TROUBLESHOOTING 6- 32 GUIDES TO MAINTENANCE 4- 2
ASR-II (AUTOMATIC SPIN REGULATOR
II) 6- 41 <H>
ACTUATION OF ASR-II SYSTEM 6- 42 HANDLING AUTO-GREASING SYSTEM 6- 45
EXPLANATION OF COMPONENTS 6- 41 METHOD OF OPERATING
PRECAUTIONS WHEN USING 6- 42 AUTO-GREASING SYSTEM 6- 47
TROUBLESHOOTING 6- 43 PRECAUTIONS WHEN HANDLING
AUTO-GREASING SYSTEM 6- 48
<C> HANDLING OIL, FUEL, COOLANT, AND
CAR HEATER 3- 52 PERFORMING OIL CLINIC 4- 4
CAR STEREO 3- 38 HANDLING PAYLOAD METER 6- 2
CHECK BEFORE STARTING ENGINE 3- 54 EXTERNAL DISPLAY LAMPS 6- 3
CHECKS AFTER COMPLETION OF NAME OF PARTS 6- 2
WORK 3- 91 OPERATING PAYLOAD METER 6- 5
CHECKS AFTER STOPPING ENGINE 3- 74 HANDLING TIRES 3- 93
COLD WEATHER OPERATION 3-100
AFTER COLD WEATHER 3-102 <I>
PRECAUTIONS AFTER COMPLETION INTENDED USE 1- 7
OF WORK 3-101 DIRECTIONS OF MACHINE 1- 7
PRECAUTIONS FOR LOW
TEMPERATURE 3-100 <L>
CONTROL LEVERS AND PEDALS 3- 30 LOADING OPERATIONS 3- 87
LOCATION OF FIRE EXTINGUISHER 3- 53
<D> LOCATION OF FIRST AID KIT 3- 53
DETERMINING AND MAINTAINING LOCATION OF PLATES, TABLE TO
TRAVEL ROAD 3- 95 ENTER SERIAL NO. AND
DETERMINING TRAVEL ROAD 3- 95 DISTRIBUTOR 1- 8
MAINTAINING TRAVEL ROAD 3- 95 ENGINE SERIAL NO. PLATE
DRAIN WATER FROM AIR TANK 3- 91 POSITION 1- 8
DUMP OPERATIONS 3- 88 PRODUCT IDENTIFICATION
DUST INDICATOR 3- 35 NUMBER (PIN)/MACHINE
SERIAL NO. PLATE 1- 8
<E> SERVICE METER POSITION 1- 8
EXPLANATION OF COMPONENTS 3- 5 TABLE TO ENTER SERIAL NO. AND
EXPLANATION OF COMPONENTS 7- 2 DISTRIBUTOR 1- 9
LOCKING 3- 92
<F> LONG-TERM STORAGE 3-103
FOREWORD 1- 2 AFTER STORAGE 3-103
FUSES 3- 36 BEFORE STORAGE 3-103
DURING STORAGE 3-103
8-1
.
INDEX
8-2
.
INDEX
8-3
.
©
2006 KOMATSU
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Printed in Japan 04-06