Page 2: Foreword
This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
Page 3 1. FOREWORD...
Page 4 1. FOREWORD...
Page 5: Safety Information
Safety precautions are described in SAFETY from page 1-1. 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.
Page 6: Introduction
If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
Page 7: Location Of Plates, Table To Enter Serial Number And Distributor
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION The machine serial number plate is on the left front end of the frame. AE132020 4.2 ENGINE SERIAL NO. PLATE POSITION The engine serial number plate is on the upper left side of the cylinder block, when seen from the fan side.
Page 8: Table Of Contents
5. CONTENTS 1. Foreword ............................0- 1 2. Safety information ..........................0- 4 3. Introduction ............................0- 5 Features ............................ 0- 5 Braking in the machine ......................0- 5 4. Location of plates, table to enter serial number and distributor ..........0- 6 Machine serial No.
Page 9 5. CONTENTS 12. Operation ............................2- 46 12.1 Check before starting engine ....................2- 46 12.2 Starting engine ........................2- 64 12.3 Operations and checks after starting engine ............... 2- 67 12.4 Moving machine off ........................ 2- 68 12.5 Shifting gear ..........................2- 70 12.6 Traveling downhill ........................
Page 10: Explanation Of Components
5- 2 26.2 External display lamps ......................5- 2 26.3 Operating payload meter ....................... 5- 5 27. Selecting dump body (HD465-5 only) .................... 5-14 28. Options and attachments ........................ 5-15 29. Tachograph (TCO 15-6) ........................5-16 29.1 Explanation of components ....................
Page 11 5. CONTENTS 30. Revo tachograph (TCO 15-7) ......................5-21 30.1 Explanation of components ....................5-21 30.2 Method of use ......................... 5-24 31. Using differential lock ........................5-26 31.1 Differential lock pedal ......................5-26 31.2 Precautions and method of use .................... 5-27 32.
Page 12 SAFETY  WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equip- ment and attachments.
Page 13: General Precautions
 WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety 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.
Page 14 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 injury or damage caused by any unauthorized modification. STANDING UP FROM THE SEAT ‡...
Page 15  WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly flammable and can be hazardous. Always observe the following: ‡...
Page 16 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers, follow the guidelines given below: ‡ Never use compressed air for cleaning.
Page 17 In such a case, please contact your Komatsu distributor for advice on the method of repair. Even if ROPS is installed, it can only protect you properly if you wear the seat belt.
Page 18: Precautions During Operation
7. PRECAUTIONS DURING  WARNING: Failure to follow these safety OPERATION precautions may lead to a serious accident. 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE ‡ Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Page 19 ¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. WHEN STARTING ENGINE ‡ Walk around your machine again just before mounting it, and check for people and objects that might be in the way. ‡...
Page 20: After Starting Engine
 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.2 AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE Failure to carry out the checks properly after starting the engine will lead to delays in discovery of abnormalities, and this may lead to serious injury or damage to the machine.
Page 21  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. CHECK WHEN CHANGING DIRECTION To prevent serious injury or death, always do the following before moving the machine or doing the dumping work. ‡ Before changing between forward and reverse, reduce speed and stop the machine. ‡...
Page 22  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION TRAVELING ON SLOPES ‡ Traveling on slopes could result in the machine tipping over or slipping to the side. ‡ Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these operations.
Page 23 ¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ‡ Do not let the machine touch overhead electric cables. Even going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below between the machine and the electric cable.
Page 24  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION WORKING ON LOOSE GROUND ‡ Do not operate the machine on soft ground. It is difficult to get the machine out again. ‡...
Page 25  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PARKING MACHINE ‡ Park the machine on level ground where there is no danger of falling rocks or landslides, or of flooding if the land is low, and lower the work equipment. ‡...
Page 26  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION RECAUTIONS IN COLD AREAS ‡ Check the operation of all safety devices, switches, and sensors, and if there is any the snow or ice, clear it away.
Page 27: Shipping
 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.3 SHIPPING SHIPPING ‡ When shipping the machine on a hauling vehicle, obey all state and local laws governing the weight, width, and length of a load. Also obey all applicable traffic regulations. ‡...
Page 28: Battery
 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.4 BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. ‡...
Page 29  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always do as follows. ‡...
Page 30: Towing
‡ If the engine on the problem machine will not start or there is a failure in the brake system, please contact your Komatsu distributor for repairs. ‡ It is dangerous to tow a machine on a slope, so choose a place where there is a gradual slope.
Page 31: Precautions For Maintenance
MAINTENANCE follow these safety precautions. 8.1 BEFORE CARRYING OUT MAINTENANCE NOTIFICATION OF FAILURE Carrying out maintenance not described in the Komatsu operation and maintenance manual may lead to unexpected failures. Please contact your Komatsu distributor for repairs. WARNING TAG ‡ ALWAYS attach the “DO NOT OPERATE” warning tag to control lever 1 in the operator’s cab to alert others that you are working on the machine.
Page 32  WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip.
Page 33 When jacking up the machine to replace the tire, the jacking-up point is as given below. When carrying out such work, please consult your Komatsu distributor. 1. Check that jack 1 (30 t or 50 t) is securely set under the chassis before jacking up the machine.
Page 34 Hoses and other parts of the fuel, hydraulic, and brake system are critical parts for ensuring safety, so they must be replaced periodically. Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry out replacement.
Page 35  WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PREVENTION OF FIRE There is danger of the fuel and battery gas catching fire during maintenance, so always follow the precautions below when carrying out maintenance. ‡...
Page 36: During Maintenance
 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE 8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. Extra precaution should be used when grinding, welding, and using a sledge-hammer.
Page 37 ¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. LOCKING INSPECTION COVERS When carrying out maintenance with the inspection cover open, lock it securely with a lock bar. If maintenance is carried out with the inspection cover open and not locked in position, it may close suddenly if knocked or blown by the wind, and may cause injury to the operator.
Page 38 ‡ Depending on the type of failure, please contact your Komatsu distributor for repairs. RULES TO FOLLOW WHEN ADDING FUEL OR OIL If any flame is brought close to fuel or oil, there is danger that it will catch fire, so always follow the precautions below.
Page 39 If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs. ‡ If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
Page 40 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE Immediately after stopping operations, the engine coolant, oil at all parts, the exhaust manifold, and the muffler are at high temperature.
Page 41: Tires
¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. 8.3 TIRES HANDLING TIRES If a tire or a rim is handled wrongly, the tire may burst or may be broken and the rim may be broken and scattered, and that can cause serious injury and death.
Page 42: Position For Attaching Safety Labels
There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. 9.1 POSITION FOR ATTACHING SAFETY LABELS 1-31...
Page 43 COMPLY WITH THE FOLLOWING REQUIREMENTS: a) OSHA 29CFR. 1926. 1001 b) ISO 3471 (ROPS) c) SAE J & SAE J • Altering ROPS may weaken it. Consult Komatsu Distributor before altering.  WARNING • ROPS may provide less protection if it has been structurally dam- aged or involved in roll-over.
Page 44 ‡ Do not remove and disassemble 09653-03001 Filling and discharging of gas in this cylinder must only be done by trained Komatsu serve personnel. 09659-33000 6. Warnings for high voltage Warnings for crush hazard when inspection and maintenance Warnings for inspection of emergency steering system, emergency brake system Warning for leaving operator’s seat, stopping engine...
Page 45 HOLD in labels on machine. FLOAT Keep manual in machine cab near operator. TO PREVENT SEVERE INJURY OR DEATH. Contact Komatsu distributor for a replacement DO THE FOLLOWING BEFORE MOVING MACHINE OR ITS LOWER manual. DUMP BODY. • HONK HORN TO ALERT PEOPLE NEARBY.
Page 46: Operation
OPERATION...
Page 47 10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below. This illustration shows the HD465-5.
Page 48 10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 49 11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. 11.1 MACHINE MONITOR A.
Page 50 11. EXPLANATION OF COMPONENTS B. CAUTION ITEMS (11.1.2)  CAUTION If any of these monitors lights up, carry out the inspection and maintenance of the appropriate item as soon as possible. If there is an abnormality in any CAUTION item, the monitor for the location of the abnormality will light up.
Page 51 88. If no monitor light up, there is probably a failure or disconnection in that circuit, so please contact your Komatsu distributor to have the circuit checked. When the starting switch is at the ON position, if there is not at...
Page 52 Then, take the corrective action as follows after checking the action code. Action code 02 Park the machine at a safe location and contact Komatsu’s Service Department. 04 Carry out an emergency stop. Stop the engine and contact Komatsu’s serviceman.
Page 53 11. EXPLANATION OF COMPONENTS 11.1.2 B. CAUTION ITEMS  CAUTION If any of these monitors lights up, carry out inspection and maintenance of the appropriate item as soon as possible. 1. BATTERY CHARGE This identifies the operator of any abnormality in the charging system when the engine is running.
Page 54 11. EXPLANATION OF COMPONENTS 4. DUMP BODY ACTUATION CAUTION This lights up when the dump body control lever is at any position other than FLOAT but the body is floated. Always set the lever to the FLOAT position and lower the body during traveling. 5.
Page 55 11. EXPLANATION OF COMPONENTS 11.1.3 C. EMERGENCY STOP ITEM  CAUTION If any of these monitor lights up or flashes, stop operations immediately and carry out the following action according to the action code. 1. AIR PRESSURE This warns the operator that the air pressure inside the air tank has dropped.
Page 56 11. EXPLANATION OF COMPONENTS 4. RETARDER OIL TEMPERATURE This warns the operator that the retarder oil temperature has risen. If it flashes and displays action code “05” at the same time, stop the machine, place the shift lever at the N (neutral) position, then run the engine under no load at a mid-range speed until the warning lamp goes out.
Page 57 11. EXPLANATION OF COMPONENTS 11.1.4 D METER DISPLAY PORTION PILOT DISPLAY PORTION When the starting switch is at the ON position, this lights up when the display items are functioning. 1. COLD START PILOT When starting the engine using the APS in cold weather and the preheating is operated, this lamp lights up.
Page 58 11. EXPLANATION OF COMPONENTS 4. DIFFERENTIAL LOCK PILOT This lamp lights up when the differential lock pedal (if equipped) is depressed and the differential lock is actuated. 5. LOCKUP PILOT LAMP This lamp lights up when the torque converter lockup is engaged and the transmission is shifted to direct drive.
Page 59 11. EXPLANATION OF COMPONENTS 10. TRANSMISSION SHIFT LEVER POSITION PILOT LAMP This indicates the position of the transmission shift lever. AD132530 11. SUSPENSION MODE DISPLAY LAMP This displays the suspension mode, when the machine is equipped with the suspension controller. An automatic suspension system is mounted which automati- cally switches the damping characteristics of the suspension accord- ing to the size of the load, use of the brake, operation of the steering,...
Page 60 11. EXPLANATION OF COMPONENTS METERS 1. SPEEDOMETER This indicates the travel speed of the machine. A speedometer for MPH is also available. km/h AD132550 2. ENGINE TACHOMETER This indicates the speed of the engine. While operating the machine, if the red range lights up, simul- taneously the warning buzzer sounds and the central warning lamp flashes, then operate the machine while lowering the engine speed and the traveling speed.
Page 61 11. EXPLANATION OF COMPONENTS 5. FUEL GAUGE This gauge 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 indi- cates that there is less than 120 ¬ (31.68 US gal, 26.40 UK gal) of fuel remaining in the tank, so check and add fuel.
Page 62 11. EXPLANATION OF COMPONENTS 11.1.5 MECHATRONIC CAUTION LAMP PORTION 1. ENGINE (Mechatronic-related)) If an abnormality is detected in the mechatronics-related parts of the engine control system, this lamp flashes to warn of the abnormality. 2. AUTOMATIC TRANSMISSION (Mechatronic-related) If an abnormality is detected in the mechatronics- related parts of the transmission control system, this lamp flashes to warn of the abnormality.
Page 63 11. EXPLANATION OF COMPONENTS 11.2 SWITCHES 1. STARTING SWITCH This switch 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.
Page 64 11. EXPLANATION OF COMPONENTS 2. LAMP SWITCH This lights up the head lamps, side clearance lamps, tail lamps, machine monitor lighting, and rear lamps. 1 OFF 2 g position: Side clearance lamps, tail lamps, rear lamps, machine monitor lighting light up 3 b position: The head lamps light up in addition to the lamps in the g position...
Page 65 11. EXPLANATION OF COMPONENTS 5. FRONT BRAKE OFF SWITCH  WARNING When traveling on icy roads, on snow, or on other slippery road surfaces, it is necessary to control the steering, so set the front brake switch to the k position (ON) and travel slowly at a safe speed.
Page 66 11. EXPLANATION OF COMPONENTS 9. AISS LOW SWITCH Using the AISS LOW switch, it is possible to switch the AISS to AUTO or LOW as desired. The positions are used as follows. k position: LOW position Used when fine control movements are needed, such as when parking in confined spaces.
Page 67 11. EXPLANATION OF COMPONENTS 12. EMERGENCY STEERING SWITCH This switch is used to actuate the emergency steering pump. When the switch is pressed, the emergency pump is actuated to make it possible to operate the steering. When the switch is ON, the pilot lamp (red) inside the switch lights up.
Page 68 11. EXPLANATION OF COMPONENTS 15. PARKING BRAKE VALVE LEVER  WARNING PARKING ‡ When parking or leaving the machine, always apply the parking brake. TRAVEL ‡ During loading operations, do not apply the parking brake. Pull the retarder lever to apply the brake. AE61740B This lever is used to actuate the parking brake valve.
Page 69 11. EXPLANATION OF COMPONENTS 19. WIPER SWITCH This switch is used to operate the wiper. INT position: Wiper moves intermittently LOW position: Wiper moves at low speed HI position: Wiper moves at high speed When the switch is pressed, washer fluid is sprayed out. AE132810 20.
Page 70 11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS AND PEDALS 1. BRAKE PEDAL This is used to apply the wheel brakes. AE132830 2. ACCELERATOR PEDAL This is used to adjust the engine speed. It can be operated freely between the engine low idling position and the full throttle position.
Page 71 They are also used when going downhill if it is needed to use the braking force of the engine. HD465-5 HD605-5 Max. speed Max. speed Max.
Page 72 11. EXPLANATION OF COMPONENTS 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.
Page 73: Differential Lock Pedal
11. EXPLANATION OF COMPONENTS 6. RETARDER CONTROL LEVER  CAUTION The retarder must not be used as a parking brake. This lever is used to operate the retarder, which applies the rear brake when going downhill. The more the lever is pulled, the greater the braking force becomes.
Page 74 11. EXPLANATION OF COMPONENTS 11.4 MECHATRONICS EQUIPMENT CONTROLLER 1. SHIFT CONTROLLER A two-digit number followed by the action code is displayed in the inspection window to identify the location of the abnormality. When the condition is normal, “0.0” or “0.C” is displayed. 2.
Page 75 11. EXPLANATION OF COMPONENTS 11.6 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.
Page 76 APS controller Wiper motor, washer motor Air conditioner blower motor Air conditioner compressor Spare Spare Please contact your Komatsu distributor before using any spare fuse terminal. Fuse box IV Fuse capacity Circuit name Power source for fuse box Fuse box V...
Page 77 11. EXPLANATION OF COMPONENTS 11.8 LOCATION OF MANUAL BOX Manual box 1 is located on top of the rear cover in the cab. Always keep the operation and maintenance manual in this box for easy reading access. 2-32...
Page 78: Explanation Of Components
11. EXPLANATION OF COMPONENTS 11.9 CAR RADIO 11.9.1 EXPLANATION OF COMPONENTS PRESET STATION SW-VOLUME AUTO TONE TUNING DOWN UP PLL SYKTHESIZEO AK TUNER AM106540 1. Power switch/volume control knob (‡ SW-VOLUME) When this switch is depressed, the radio is turned on and the selected frequency appears on the display 6.
Page 79 11. EXPLANATION OF COMPONENTS 4. Auto tuning button (AUTO) In frequency selection, when this button is pressed, the fre- quency automatically moves to high frequency. SW-VOLUME SET STATION AUTO TONE TUNING DOWN PLL SYKTHESIZED AK TUNER AM106580 5. Preset button (1, 2, 3, 4, 5, 6) (PRESET STATION) If a desired station is preset using this button, the station can be selected by one-touch action.
Page 80 11. EXPLANATION OF COMPONENTS 11.9.2 SETTING METHOD Presetting 1. Press the power switch 1. A frequency will appear on the 1 RESET STATION SW-VOLUME AUTO TONE display 6. TUNING DOWN PLL SYKTHESIZED AK TUNER 2. Select a desired frequency using the auto-tuning button 4 or manual-tuning button 3.
Page 81: Precautions For Use
11. EXPLANATION OF COMPONENTS Antenna If the receiving wave is weak or generates noise, extend the antenna. If the wave is too strong, adjust the sensitivity by retracting the antenna. NOTICE When transporting the machine or parking it in a garape, always fully retract the antenna to avoid the possibility of breakage.
Page 82 11. EXPLANATION OF COMPONENTS 11.10 CAR STEREO 11.10.1 METHOD OF USE When listening to the cassette tape 1. POWER Turn the power switch clockwise to turn the power on. 2. INSERTING TAPE Insert the cassette tape vertically into the cassette player. The tape is set in position and the program indicator lights up.
Page 83 11. EXPLANATION OF COMPONENTS 6. FF (FAST FORWARD), REW (REWIND) If the FF or REW buttons are pressed, the button is locked and the tape can be fast forwarded or rewound. To release the lock ‡ Press the button for the other direction. ‡...
Page 84 11. EXPLANATION OF COMPONENTS WHEN LISTENING TO RADIO (AM/FM) 1. AM/FM SELECTION When the push button is pressed in, the radio receives FM (k), and when it is pressed again the radio receives AM (i). 2. PUSH BUTTON SELECTION If the push button is pressed, the radio is tuned in to the preset station.
Page 85 11. EXPLANATION OF COMPONENTS 11.11 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. 11.11.1 GENERAL LOCATIONS ON CONTROL PANEL 1.
Page 86 11. EXPLANATION OF COMPONENTS 4. EXTERNAL/INTERNAL AIR CHANGEOVER SWITCH Changes between internal air circulation and external air intake. When pressing the switch, the indicator lamp on the top of switch lights up. Internal air circulation This is used when wishing to quickly cool or warm the cab or when the air inside the cab is stale.
Page 87 11. EXPLANATION OF COMPONENTS 11.11.2 METHOD OF OPERATION Switch External/internal Air conditioner Temperature Vent mode Condition air changeover switch switch control switch selector switch of use switch Rapid All green RECIRC FACE Cooling More than Normal HI-LO FRESH FACE half are green More than Dehumidifying, heating HI-LO...
Page 88 Clean the air filter and check the refrigerant. For details, see WHEN REQUIRED. To allow the air conditioner to display its full ability and provide a pleasant environment, always contact your Komatsu distributor to carry out refilling of the refrigerant and other inspection and main- tenance.
Page 89 11. EXPLANATION OF COMPONENTS 11.12 CAR HEATER 11.12.1 GENERAL LOCATIONS ON CONTROL PANEL HEATER AE617410 1. HEATER SWITCH This switch is used for turning the heater ON/OFF and for adjusting the air flow. Stopped: OFF 1: Low 2: High AE134920 2.
Page 90 11. EXPLANATION OF COMPONENTS 11.12.3 PRECAUTIONS ON USING HEATER ‡ In winter season always use antifreeze fluid with the density suitable to outside air temperature. Do not use antifreeze fluid stored over a period longer than its recommended serviceable life. ‡...
Page 91: Check Before Starting Engine
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. 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 work equipment and hydraulic system.
Page 92 12. OPERATION 1. CHECK DUMP BODY, FRAME, TIRES, CYLINDERS, LINKAGE, HOSES FOR DAMAGE, WEAR, PLAY Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and carry out repairs if any abnormality is found. 2.
Page 93 12. OPERATION 9. CHECK REAR VIEW MIRROR, UNDER VIEW MIRROR Check for any damage to the mirrors, and if any damage is found, replace the mirror. Clean all dirt from the surface of the mirror and adjust the angle so that the view to the rear and below the machine can be seen from the operator’s seat.
Page 94 12. OPERATION 12.1.2 CHECK BEFORE STARTING Always carry out the checks in this section before starting the engine. CHECK COOLANT LEVEL, ADD WATER  WARNING Do not remove the cap while the radiator water is hot. Hot water may spurt out. When removing the cap, press the cap knob to release the internal pressure before removing the cap.
Page 95 12. OPERATION CHECK DUST INDICATOR 1. Check that the red piston has not appeared in the transparent portion of dust indicator 1. 2. If the red piston has appeared, clean or replace the element immediately. For details of the method of cleaning the element, see “24.2 WHEN REQUIRED”.
Page 96 12. OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Check the oil level with dipstick G. 2. Remove dipstick G, and wipe the oil off with a cloth. 3. Insert dipstick G fully in the oil filler pipe, then take it out again. 4.
Page 97 12. OPERATION CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL 1. After starting the engine, run the engine at low idling and check the oil level with sight gauge G 2. If the oil level is low, add engine oil through oil filler F. For details of the oil to use, see “20.
Page 98 12. OPERATION CHECK OIL LEVEL IN REAR BRAKE COOLING OIL TANK, ADD OIL  WARNING When the oil filler cap is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully. 1. Check with sight gauge G. 2.
Page 99 12. OPERATION CHECK FUEL LEVEL  WARNING When adding fuel, do not let the fuel overflow. This may cause fire. If any oil spills, wipe it up completely. 1. Check the fuel level with fuel gauge G installed to the fuel tank. 2.
Page 100 Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts). The proper inflation pressure is shown below. HD465-5 Tire size Inflation pressure 24.00-35-36PR (standard) 0.44 MPa (4.5 kgf/cm , 63.9 PSI)
Page 101 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, so please contact your Komatsu distributor for inspection. 2-56...
Page 102 12. OPERATION CHECK FOR NORMAL ACTUATION OF FOOT BRAKE Check when starting operations, and if the braking effect is poor, check and adjust. For details, see “24.5.3 CHECK WEAR OF FRONT DISC BRAKE PADS”. CHECK BRAKING CAPACITY OF FOOT BRAKE Check the braking capacity of the foot brake as follows.
Page 103 2. Turn emergency steering switch 1 ON, and check that the steering wheel can be operated for 20 seconds. If the steering wheel cannot be operated, please contact your Komatsu distributor. ‡ Checking auto emergency steering 3. Turn the starting switch key to the START position and start the engine.
Page 104 When carrying out walk-around checks or checks before starting, 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 the cause. CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR The water separator separates water mixed in the fuel.
Page 105 12. OPERATION 12.1.3 ADJUSTMENT BEFORE OPERATION ADJUSTING OPERATOR’S SEAT  WARNING ‡ Park the machine in a safe place and stop the engine when carrying out adjustment of the operator’s seat. ‡ Adjust the seat before starting operations or when changing operators.
Page 106 12. OPERATION ADJUST SEAT BELT  WARNING ‡ Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it. ‡ Always fasten the seat belt before starting operations. ‡...
Page 107 12. OPERATION ‡ Adjust belt length To make belt shorter: Pull the free end of the belt at the buckle end or tongue end. To make belt longer: Set the belt holding the buckle or tongue end at right angles to the buckle or tongue, and pull.
Page 108 12. OPERATION 12.1.4 OPERATIONS, CHECKS BEFORE STARTING ENGINE  WARNING If the shift lever is touched by mistake, the machine may suddenly move. Before standing up from the operator’s seat, place the gear shift lever at neutral, and set the parking brake lever to the PARKING position.
Page 109: Starting Engine
12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING  WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 110 12. OPERATION 12.2.2 STARTING IN COLD WEATHER (when using APS) When starting the engine in cold weather, do as follows.  WARNING If a starting aid fluid is used, there is danger of an explosion. Never use any starting aid fluid. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 111 12. OPERATION 6. Maintain the same condition and wait. After approx. 12 seconds, the preheating is completed and cold start pilot 4 changes to flashing. Keeping the hand on APS switch 3 causes flashing to continue. 7. Depress accelerator pedal 5 about half way. 8.
Page 112: Operations And Checks After Starting Engine
12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Avoid abrupt acceleration until the warming-up run is com- pleted. Do not run the engine at low idling or high idling for more than 20 minutes.
Page 113: Moving Machine Off
12. OPERATION 12.4 MOVING MACHINE OFF  WARNING When moving off, check that the area around the machine is safe, and sound the horn before moving. Do not allow anyone in the area around the machine. There is a blind spot behind the machine, so use extreme care when reversing the machine.
Page 114 12. OPERATION 5. Depress accelerator pedal 6 to move the machine off. 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. ‡...
Page 115: Shifting Gear
12. OPERATION 12.5 SHIFTING GEAR Shift gear as follows. This machine has an automatic transmission, so set 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 shift lever is locked to 2nd speed at the D position and 1st speed at the 5-L position.
Page 116: Traveling Downhill
Komatsu distributor for repairs. ‡ Operate the retarder slowly. If the brakes are applied sud- denly, there is danger that the tire will slip.
Page 117 12. OPERATION 1. Before starting to travel downhill, release accelerator pedal 1 and operate retarder lever 2 to slow the machine down. 2. Move the shift lever to a position (5, 4, 3, L) that matches the maximum permissible speed for the retarder brake performance. 3.
Page 118 12. OPERATION 12.6.1 BRAKE PERFORMANCE CURVE ‡ HD465-5 Method of using graph Example: Downhill distance: 1500 m (4921 ft) Travel resistance – 11% [grade resistance – 13%] [rolling resistance 2%] Load: 46 tons Obtain the maximum permissible speed and the speed range from the graph when traveling downhill under the above conditions.
Page 119 12. OPERATION 4. Take the point where it crosses the performance curve as C, and draw a perpendicular line down. Take the point where this line crosses the travel speed scale as D. 5. The following information can be obtained from this procedure. From point D : Maximum permissible speed = 29.5 km/h (18.3 MPH)
Page 120 12. OPERATION ‡ Brake performance [Downhill distance: 600 m (1968 ft)] (Standard tire 24.00-35) ‡ Brake performance [Downhill distance: 900 m (2952 ft)] (Standard tire 24.00-35) 2-75...
Page 121 12. OPERATION ‡ Brake performance [Downhill distance: 1500 m (4921 ft)] (Standard tire 24.00-35) ‡ Brake performance [Downhill distance: Continuous] (Standard tire 24.00-35) 2-76...
Page 122 12. OPERATION ‡ Brake performance [Downhill distance: 450 m (1476 ft)] (Small size tire 21.00-35) ‡ Brake performance [Downhill distance: 600 m (1968 ft)] (Small size tire 21.00-35) 2-77...
Page 123 12. OPERATION ‡ Brake performance [Downhill distance: 900 m (2952 ft)] (Small size tire 21.00-35) ‡ Brake performance [Downhill distance: 1500 m (4921 ft)] (Small size tire 21.00-35) 2-78...
Page 124 12. OPERATION ‡ Brake performance [Downhill distance: Continuous] (Small size tire 21.00-35) 2-79...
Page 125 12. OPERATION ‡ HD605-5 Method of using graph Example: Downhill distance: 1500 m (4921 ft) Travel resistance – 11% [grade resistance – 13%] [rolling resistance 2%] Load: 60 tons Obtain the maximum permissible speed and the speed range from the graph when traveling downhill under the above conditions. 1.
Page 126 12. OPERATION 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 = 29.5 km/h...
Page 127 12. OPERATION ‡ Brake performance [Downhill distance: 600 m (1968 ft)] (Standard tire 24.00R35ﬂﬂ) ‡ Brake performance [Downhill distance: 900 m (2952 ft)] (Standard tire 24.00R35ﬂﬂ) 2-82...
Page 128 12. OPERATION ‡ Brake performance [Downhill distance: 1500 m (4921 ft)] (Standard tire 24.00R35ﬂﬂ) ‡ Brake performance [Downhill distance: Continuous] (Standard tire 24.00R35ﬂﬂ) 2-83...
Page 129: Traveling In Reverse
12. OPERATION 12.7 TRAVELING IN REVERSE  WARNING ‡ When switching between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so use extreme care when reversing the machine. ‡...
Page 130: Steering The Machine
12. OPERATION 12.8 STEERING THE MACHINE  WARNING If the machine is turned at high speed or on a steep slope, there is danger that it will turn over, so do not operate the steering in such conditions.  CAUTION Do not continue to apply force to the steering wheel when it has been turned fully to the left or right.
Page 131: Stopping The Machine
12. OPERATION 12.9 STOPPING THE MACHINE  WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping ‡ 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.
Page 132 12. OPERATION 12.9.2 STOPPING IN EMERGENCY  WARNING ‡ When the machine stops, put blocks under the tires immedi- ately. ‡ 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.
Page 133: Operating Dump Body
12. OPERATION 12.10 OPERATING DUMP BODY  WARNING ‡ When dumping a load, always carry out the dumping opera- tion 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. ‡...
Page 134 Rocks of Mohs hardness of more than 4.5 ‡ Rocks with a weight of more than 300 kg (662 lb) ‡ When transporting steel ingots For details of the types of dump body and the procedure for selection, see “27. SELECTING DUMP BODY” (HD465-5 only). 2-89...
Page 135: Precautions For Operation
Take corrective action as follows after checking the action code. Action code 02 Park the machine on safe place and contact Komatsu’s service department. 04 Carry out safety stop. Stop the engine and contact Komatsu’s service department.
Page 136: Parking Machine
12. OPERATION 12.12 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.
Page 137: Checks After Completion Of Work
12. OPERATION 12.13 CHECKS AFTER COMPLETION OF WORK Use the machine monitor to check the engine water temperature, engine oil pressure, and fuel level. If the engine has overheated, do not stop the engine suddenly. Run it at a mid-range speed to cool it gradually before stopping. 12.14 STOPPING ENGINE NOTICE If the engine is suddenly stopped without allowing it to cool...
Page 138: Locking
12. OPERATION 12.16 LOCKING Always lock the following places. 1 Fuel cap of fuel tank 2 Cab doors (left and right) Lock the right side door manually from the inside (operator’s seat). REMARK The starting switch key is used for locking places 1 and 2. 2-93...
Page 139: Handling Tires
Bead wire Tires where there is abnormal deterioration, deformation, AE133860 and damage, and the tire cannot withstand use When replacing the tires, please contact your Komatsu distribu- tor. It is dangerous to jack up the machine without taking adequate precaution. 12.17.2 T.Km.P.H (Ton-Km-Per-Hour Rating)
Page 140 12. OPERATION 12.17.3 TIRE T.Km.P.H. AND MAXIMUM SPEED FOR CONTINUOUS TRAVEL (REFERENCE) ‡ HD465-5 Tire ton-km-per-hour Maximum continuous traveling speed (km/h) rating with ambient with ambient temperature temperature Tire 16°C 27°C 38°C 49°C 16°C 27°C 38°C 49°C Without load Size: 24.00-35-36PR...
Page 141 The T.Km.P.H. in the table may differ slightly according to the tire maker, so for operations which require travel near the travel speed given in the table, please contact your Komatsu distributor. 12.17.5 PRECAUTIONS FOR LONG DISTANCE TRAVEL If the machine travels continuously at high speed for a long distance, there will be a marked increase in the generation of heat in the tire.
Page 142: Determining And Maintaining Travel Road
13. DETERMINING AND MAINTAINING TRAVEL ROAD Determining and traveling the road in the jobsite is an extremely important factor both for reasons of safety and for reducing the cycle time. To ensure safety in operations, do as follows. 13.1 DETERMINING TRAVEL ROAD ‡...
Page 143: Maintaining Travel Road
13. DETERMINING AND MAINTAINING TRAVEL ROAD 13.2 MAINTAINING TRAVEL ROAD Carry out the necessary action according to the conditions to insure that the road can always be traveled in safety. ‡ Remove any unevenness in the travel surface, sloping to the left or right, or drooping of the road shoulder.
Page 144: Cold Weather Operation
14. COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “20.
Page 145 14. COLD WEATHER OPERATION 14.1.3 BATTERY  WARNING ‡ To avoid gas explosions, 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 large amounts of water, and consult a doctor.
Page 146: Precautions After Completion Of Work
14. COLD WEATHER OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. ‡ Mud and water on the machine body should be completely removed.
Page 147: Long-Term Storage
15. LONG-TERM STORAGE 15.1 BEFORE STORAGE When putting the machine in storage for a long time, do as follows. ‡ After every part is washed and dried, house the machine in a dry building. Never leave it outdoors. If the machine must be left outdoors, park it on well-drained concrete and cover it with canvas, etc.
Page 148: After Storage
15. LONG TERM STORAGE 15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. ‡...
Page 149: Troubleshooting
16. TROUBLESHOOTING 16.1 AFTER RUNNING OUT OF FUEL When starting the engine after it has run out of fuel, first fill with fuel, then fill the fuel filter cartridge with clean fuel and bleed the air from the fuel line before starting the engine. For details of the method of bleeding the air, see “24.6 EVERY 500 HOURS SERVICE”.
Page 150 16. TROUBLESHOOTING 16.2.2 WHEN ENGINE DOES NOT RUN NOTICE Towing the machine is for moving it to a place where inspection and maintenance can be carried out. It is not for towing the machine long distances. Do not tow the machine for long distances. ‡...
Page 151 16. TROUBLESHOOTING METHOD OF RELEASING PARKING BRAKE  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.
Page 152 16. TROUBLESHOOTING METHOD OF RELEASING EMERGENCY BRAKE  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. ‡...
Page 153: If Battery Is Discharged
16. TROUBLESHOOTING 16.3 IF BATTERY IS DISCHARGED  WARNING ‡ When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. ‡ Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.
Page 154 16. TROUBLESHOOTING 16.3.2 PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of “16.3 IF BATTERY DISCHARGED” and the instruction manual accompanying the charger, and do as follows.
Page 155 16. TROUBLESHOOTING 16.3.3 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE  WARNING INCORRECT ‡ When connecting the cables, never contact the positive + and negative . terminals. ‡...
Page 156 16. TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 157: Other Trouble
If action code “04” is displayed, check the service code and immediately stop the engine. 4. After checking the service code, contact your Komatsu distribu- tor for repairs. REMARK ‡...
Page 158 ‡ ( ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. ‡ If “02” or “04” is displayed, stop the machine at a safe place and apply the parking brake. After checking the service code, contact your Komatsu distributor for repairs.
Page 159 ‡ ( ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. ‡ If “02” or “04” is displayed, stop the machine at a safe place and apply the parking brake. After checking the service code, contact your Komatsu distributor for repairs.
Page 160 The engine speed varies depending on the load. After moving the machine to a safe place by operating the accelerator pedal, contact your Komatsu distributor for repairs.
Page 161 ‡ ( ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. ‡ If “02” or “04” is displayed, stop the machine at a safe place and apply the parking brake. After checking the service code, contact your Komatsu distributor for repairs.
Page 162 16. TROUBLESHOOTING ENGINE (continued) (16.4.4) Problem Main causes Remedy ‡ Crushed fuel tank breather tube (‡ Replace breather tube) Fuel stops from time to time ‡ Oil leakage (‡ Check, repair) Excessive oil consumption ‡ Excessive oil in oil pan ‡...
Page 163 16.4.5 APS (STARTING AID) SYSTEM ‡ ( ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes...
Page 164 16. TROUBLESHOOTING MECHATRONICS-RELATED UNITS If any abnormality occurs, stop the machine, apply the parking brake and check the service code, then contact your Komatsu distributor for repairs. ‡ Electronic display panel ELECTRONIC DISPLAY PANEL SERVICE CODE LIST SERVICE ACTION MECHATRONIC...
Page 165 16. TROUBLESHOOTING TRANSMISSION CONTROLLER SERVICE CODE LIST SERVICE ACTION TRANSMISSION ITEM CODE CODE CAUTION BATTERY VOLTAGE LOW b001 SOLENOID VOLTAGE FAILURE b002 N SAFETY ON b003 – ROM SUM CHECK FAULT b004 CLUTCH ENGAGED DOUBLE b005 T/M CUT RELAY FAILURE b006 BATTERY VOLTAGE LOW (12V) b007...
Page 166 16. TROUBLESHOOTING TRANSMISSION CONTROLLER SERVICE CODE LIST (continued) SERVICE ACTION TRANSMISSION ITEM CODE CODE CAUTION R CLUTCH ECMV FAILURE 3 b058 ENG. SPEED SENSOR FAILURE b060 T/M IN SPEED SENSOR FAILURE b061 T/M MID. SPEED SENSOR FAILURE b062 T/M OUT SPEED SENSOR FAILURE b063 L/U CLUTCH SLNOID FAILED HIGH b071...
Page 167 16. TROUBLESHOOTING TRANSMISSION CONTROLLER SERVICE CODE LIST (continued) SERVICE ACTION TRANSMISSION ITEM CODE CODE CAUTION ** LOW BR. AIR PRESS b0E9 ENG. OIL PRESS. ABNORMAL b0F5 R BRAKE CHAMBER STROKE END b0F6 ‡ Engine controller (If equipped electronic governor) ENG. CONTROLLER SERVICE CODE LIST SERVICE ACTION ENGINE...
Page 168 16. TROUBLESHOOTING ‡ Suspension controller SUSPENSION CONTROLLER SERVICE CODE LIST SERVICE ACTION MECHATRONIC ITEM CODE CODE CAUTION BATTERY VOLTAGE ABNORMAL d001 – – CONTROLLER ABNORMAL d002 – – SUS. PRESS. SNSR FR FAILURE d011 SUS. PRESS. SNSR FL FAILURE d012 T/M OUTPUT SPEED SIGNAL LOST d015 STRG.
Page 169 16. TROUBLESHOOTING ‡ Payload meter (if equipped) Order of priority Display Content Internal CPU stopped (CPU reset) – –8 (Controller power source, etc. is normal) E–31 Sensor power source (18V) abnormal E–32 Relay short circuit E–33 Drop in voltage of backup battery E–01 Rear right wheel ‡...
Page 170 16. TROUBLESHOOTING ‡ Payload meter (cord type, if equipped) Priority of Description Service code External display lamp display Dump lever not at FLOAT b-FL lights up. All lamps flash (except dozing) b-FL lights up. – Memory card not inserted. Cd flashes. –...
Page 171 16. TROUBLESHOOTING Priority of Description Service code External display lamp display Related lamp: External display lamp No.1 relay F-41 flashes. Lights up when parking. short circuit Lights off when traveling. External display lamp No.2 relay F-42 flashes. Other lamps: short circuit Normally operates when External display lamp No.3 relay F-43 flashes.
Page 172 16. TROUBLESHOOTING Symbols (*1) and (*2) in abnormality/warning chart Warning display (*1) in “memory FULL” (1) Cycle data 1 If the data of 2600 cycles or more are stored in the memory (remaining data under 3000 cycles), the screen repeats the cycle as follows. L:FULL flashes 7 times.
Page 173 16. TROUBLESHOOTING (5) For releasing “data FULL” described in (1) to (3) , see the separate manual for PLM II (Card-type payload meter) of “8.3 OPERATOR CHECK MODE, 8. OPERATION OF SWITCH”. Once “data FULL” in (4) is displayed, it can not be cleared until automatically cleared to zero. Always clear data before “data FULL”...
Page 174 MAINTENANCE...
Page 175 Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 176 Do not allow water to get on any electrical component. Controller: The controller for the machine monitor may be mistakenly actuated by interference from external electric waves> For this reason, when installing a radio or other such device, please consult your Komatsu distributor.
Page 177 17. GUIDES TO MAINTENANCE Pre-and post-work checks: Before starting work in mud, rain, snow or at the seashore, check plugs and valves for tightness. Wash the machine immediately after the work to protect components from rusting. Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.
Page 178 When changing the oil, always replace the related filters at the same time. ‡ We recommend you to 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. 18.1.2 FUEL ‡...
Page 179 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. ‡ Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 180 Make sure that the oil is well mixed before sampling. • Carry out sampling regularly at fixed intervals. • Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu dis- tributor.
Page 181 Never remove or disassemble any electric components installed in the machine. ‡ Never install any electric components other than those specified by Komatsu. ‡ Be careful to keep the electric system free of water when washing the machine or when it rains.
Page 182 The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.
Page 183 20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY KIND OF RESERVOIR FLUID –22 –4 104122˚F Specified Refill –30 –20 –10 40 5 0 ˚ C SAE 30 SAE 10W 61¬...
Page 184 ‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping.
Page 185 (The 15W40 oil SAE80, 90, 140 NLGI No. 2 Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT (Winter, one EO15-40CD season type) Diesel sigma S Super dieselmulti- AGIP Rotra MP GR MU/EP –...
Page 186 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Coolant SAE10W, 30, 40 Gear Oil Grease Supplier [Ethylene Glycol 10W30, 15W40 [GL-4 or GL-5] [Lithium-Base] Base] (The 15W40 oil SAE80, 90, 140 NLGI No.
Page 187 Disc gauge ass’y 561-98-61120 Calliper disc gauge 566-98-41410 If any of the above tools are broken, please order them from your Komatsu distributor. 21.1.1 PLACE FOR STORING TOOLS Store the tools at position 1 inside the battery box. AE135040 3-14...
Page 188 The tightening torque is determined by the width across the flats b of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 189 If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. 3-16...
Page 190 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Replacement Safety parts for periodic replacement Q’ty Remarks interval Fuel hose (Fuel tank – priming hose) Fuel hose (Priming hose – injection pump) Fuel hose (Injection pump – fuel filter) Fuel hose (Fuel filter –...
Page 191 23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge 3-23 Replace transmission filter element 3-23 Change oil in transmission case, clean transmission case strainer 3-23 Replace steering, hoist oil tank and rear brake cooling oil tank filter element 3-23...
Page 192 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE CHECK BEFORE STARTING (continued) Drain water from air tank 3-39 Check oil level in engine oil pan, add oil 3-40 Check oil level in transmission case, add oil 3-41 Check oil level in steering and hoist oil tank, add oil 3-41 Check oil level in rear brake cooling oil tank, add oil 3-42...
Page 193 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 250 HOURS SERVICE Change oil in engine oil pan, replace engine oil filter (full-flow and bypass) cartridge 3-49 Check oil level in differential case, add oil 3-51 Check oil level in final drive case, add oil 3-51 Lubrication 3-52...
Page 194 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 1000 HOURS SERVICE Replace corrosion resistor cartridge 3-64 Change oil in transmission case, clean transmission case strainer 3-65 Replace steering, hoist oil tank and rear brake cooling oil tank filter element 3-66 Lubrication 3-67 ‡...
Page 195 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 4000 HOURS SERVICE Replace injection pump screen filter 3-75 Clean injection pump oil inlet strainer 3-75 Check water pump 3-75 Replace critical parts for periodical replacement from service kit 3-75 Check, adjust air compressor 3-75 Check fan pulley and tension pulley 3-75...
Page 196 24. SERVICE PROCEDURE 24.1 INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. ‡ REPLACE FUEL FILTER CARTRIDGE ‡ REPLACE TRANSMISSION FILTER ELEMENT ‡ CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER ‡ REPLACE STEERING, HOIST OIL TANK AND REAR BRAKE COOL- ING OIL TANK FILTER ELEMENT ‡...
Page 197 24. SERVICE PROCEDURE 24.2 WHEN REQUIRED 24.2.1 CLEAN INSIDE OF COOLING SYSTEM  WARNING ‡ Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water. ‡ Since cleaning is performed while the engine is running, it is very dangerous to go under the machine as the machine may suddenly start moving.
Page 198 Antifreeze is flammable, so keep it away from any flame. ‡ Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. ‡ We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 199 24. SERVICE PROCEDURE 1. Stop the engine and tighten corrosion resistor valve 1(2 places). 2. Turn radiator cap 2 slowly, and remove it. 3. Open drain valve 3 at the bottom of the radiator, drain plug 4 at the side of the cylinder block, and drain the water. 4.
Page 200 24. SERVICE PROCEDURE 11. Replace the corrosion resistor, and open valve 1 (2 places). For details of the procedure for replacing the corrosion resistor, see 24.6 EVERY 1000 HOURS SERVICE. 12. Supply the antifreeze and city water until it overflows from the water filler.
Page 201 24. SERVICE PROCEDURE 24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER  WARNING ‡ Never clean or replace the air cleaner with the engine run- ning. ‡ When using compressed air to clean the element, there is danger that dust will fly and get into your eyes, so always wear safety glasses.
Page 202 24. SERVICE PROCEDURE 4. After cleaning, put a light bulb inside the element, and if small holes or thinner parts are found, replace the element. NOTICE When cleaning the element, do not hit it or beat it against anything. Do not use any element if the element folds or gasket or seal are damaged.
Page 203 REMARK Run the engine at idling and set the air conditioner to cooling. If bubbles can be seen in the sight glass, the refrigerant level is low, so contact your Komatsu distributor to have the system re filled. 3-30...
Page 204 1. Clean the dump body to make it easier to check. 2. Check all parts of the dump body for damage. If any cracks or abnormal wear are found, carry out repairs. Contact your Komatsu distributor for details of the repair proce- dure. 24.2.7 CHECK ELECTRIC INTAKE AIR HEATER...
Page 205 24. SERVICE PROCEDURE 24.2.8 BLEED AIR FROM REAR BRAKE  WARNING Stop the machine on level ground and put blocks under the wheels before bleeding the air. 1. Pull the retarder brake lever, loosen air bleed plug 1 to bleed the air from the circuit, then tighten plug 1 and release the retarder brake lever.
Page 206 Measure the thickness of the pad, and if it is less than 1.5 mm AE134060 (0.06 in), contact your Komatsu distributor to have it replaced. When making the first adjustment after replacing the pad, turn bolt 1one turn (6 clicks) in the counterclockwise direction.
Page 207 When carrying out the inspection, check that the engine fan is not rotating. If the result of the measurement shows that it is greater than the standard value, please contact your Komatsu distributor for disas- sembly and inspection. 3-34...
Page 208 13°C). If the engine cooling water temperature is above 13°C, please ask your Komatsu distributor to carry out the inspection. 1. Open fuel valve 1 of the starting aid and remove hose 2 at the nozzle intake port end.
Page 209 Select the tires according to the conditions of use and attach- ments of the machine. Use the following table. Since the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires. HD465-5...
Page 210 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. HD465-5 Tire size Inflation pressure 24.00-35-36PR (standard)
Page 211 24. SERVICE PROCEDURE 24.3 CHECK BEFORE STARTING Always carry out the checks in this section before starting the engine. 24.3.1 CHECK COOLANT LEVEL, ADD WATER  WARNING Do not remove the cap while the radiator water is hot. Hot water may spurt out. When removing the cap, press the cap knob to release the internal pressure before removing the cap.
Page 212 24. SERVICE PROCEDURE 24.3.3 CHECK DUST INDICATOR 1. Check that the red piston has not appeared in the transparent portion of dust indicator 1. 2. If the red piston has appeared, clean or replace the element immediately. For details of the method of cleaning the element, see “24.2 WHEN REQUIRED”.
Page 213 24. SERVICE PROCEDURE 24.3.5 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Check the oil level with dipstick G. 2. Remove dipstick G, and wipe the oil off with a cloth. 3. Insert dipstick G fully in the oil filler pipe, then take it out again. 4.
Page 214 24. SERVICE PROCEDURE 24.3.6 CHECK OIL LEVEL IN TRANSMISSION CASE, ADD 1. After starting the engine, run the engine at low idling and check the oil level with sight gauge G 2. If the oil level is low, add engine oil through oil filler F. For details of the oil to use, see “20.
Page 215 24. SERVICE PROCEDURE 24.3.8 CHECK OIL LEVEL IN REAR BRAKE COOLING OIL TANK, ADD OIL  WARNING When the oil filler cap is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully. 1.
Page 216 24. SERVICE PROCEDURE 24.3.10 CHECK FUEL LEVEL  WARNING When adding fuel, do not let the fuel overflow. This may cause fire. If any oil spills, wipe it up completely. 1. Check the fuel level with fuel gauge G installed to the fuel tank. 2.
Page 217 Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts). The proper inflation pressure is shown below. HD465-5 Tire size Inflation pressure 24.00-35-36PR (standard) 0.44 MPa (4.5 kgf/cm , 63.9 PSI)
Page 218 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, so please contact your Komatsu distributor for inspection. 3-45...
Page 219 24. SERVICE PROCEDURE 24.3.15 CHECK FOR NORMAL ACTUATION OF FOOT BRAKE Check when starting operations, and if the braking effect is poor, check and adjust. For details, see “24.5.3 CHECK WEAR OF FRONT DISC BRAKE PADS”. 24.3.16 CHECK BRAKING CAPACITY OF FOOT BRAKE Check the braking capacity of the foot brake as follows.
Page 220 2. Turn emergency steering switch 1 ON, and check that the steering wheel can be operated for 20 seconds. If the steering wheel cannot be operated, please contact your Komatsu distributor. ‡ Checking auto emergency steering 3. Turn the starting switch key to the START position and start the engine.
Page 221 When carrying out walk-around checks or checks before starting, 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 the cause. 24.3.30 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR The water separator separates water mixed in the fuel.
Page 222 AE134090 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 plug 2: 68.6 ± 9.81 N•m (7 ±...
Page 223 24. SERVICE PROCEDURE 6. Clean the filter holder, fill the new filter cartridge with clean engine oil, coat the packing face and thread with engine oil (or coat thinly with grease), then install the filter cartridge. 7. When installing the filter cartridge, tighten until the packing face is in contact with the filter holder, then tighten a further 3/4 –...
Page 224 24. SERVICE PROCEDURE 24.4.2 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD  WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. 1. Remove plug G and check that the oil level is near the bottom of the plug hole.
Page 225 24. SERVICE PROCEDURE 24.4.4 LUBRICATION 1. Stop the engine. 2. Use the grease pump to pump in grease through the grease fitting marked by the arrow. 3. After greasing, wipe off all the old grease that is pushed out. Carry out the greasing operation every day when operating in places where the grease flows out easily, such as when traveling through mud or water.
Page 226 24. SERVICE PROCEDURE 5. Front suspension (left and right: 1 point each) AE134160 6. Steering cylinder pin (left and right: 2 points each) 7. Steering link pin (5 points) AE134170 8. Steering linkage (left and right: 3 points each) AE134180 9.
Page 227 If distilled water is added to above the U.L line, use a pipette 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. 3-54...
Page 228 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. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTRO-...
Page 229 24. SERVICE PROCEDURE 24.4.6 CHECK ALTERNATOR BELT, ADJUST 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. AE134210 Adjusting 1.
Page 230 24. SERVICE PROCEDURE 24.4.7 CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT, ADJUST Checking The belt should normally deflect by above 10 mm (0.39 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.
Page 231 2. Check all parts of the frame for damage. In particular, check the colored portions in the diagram and if any cracks or damage are found, repair the damage. Please contact your Komatsu distributor for details of the repair procedure. AE134310 3-58...
Page 232 AE134320 When the dump lever is at any position other than FLOAT: hard. If any abnormality is found, please contact your Komatsu dis- tributor for inspection and adjustment. If operations are carried out on muddy or wet ground, mud will stick to the link, and the movement may become slow, so check and clean.
Page 233 24. SERVICE PROCEDURE 24.5 EVERY 500 HOURS SERVICE Carry out maintenance for EVERY 250 HOURS SERVICE at the same time. 24.5.1 REPLACE FUEL FILTER CARTRIDGE  WARNING ‡ The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations.
Page 234 24. SERVICE PROCEDURE 9. Tighten air bleed plug 3, then push in knob 4 of the priming pump, and tighten it. 10. After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter seal surface. If there is any leakage of fuel, check the tightening of the filter cartridge.
Page 235 Gauge Gauge If the result of the inspection shows that the pad must be Caliper replaced, please contact your Komatsu distributor for replacement. Near wear Wear limit limit replace pads The pad wear is not necessarily the same for the left and right AE134380 wheels, so always check the pads on both the left and right.
Page 236 24. SERVICE PROCEDURE 24.5.4 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS 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.
Page 237 24. SERVICE PROCEDURE 24.6 EVERY 1000 HOURS SERVICE Carry out maintenance for EVERY 250 HOURS and EVERY 500 HOURS SERVICE at the same time. 24.6.1 REPLACE CORROSION RESISTOR CARTRIDGE  WARNING The oil is at high temperature after the engine has been oper- ated, so never replace the cartridge immediately after finishing operations.
Page 238 24. SERVICE PROCEDURE 24.6.2 CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER  WARNING The oil is at high temperature after the engine has been oper- ated, so never change the oil immediately after finishing opera- tions. Wait for the oil to cool down before starting the operation. ‡...
Page 239 24. SERVICE PROCEDURE 24.6.3 REPLACE STEERING, HOIST OIL TANK AND REAR BRAKE COOLING OIL TANK FILTER ELEMENT  WARNING When removing the oil filler cap, turn it slowly to release the internal pressure before removing it. 1. Turn the cap of oil filler F slowly to release the internal pressure, then remove the cap.
Page 240 24. SERVICE PROCEDURE 24.6.4 LUBRICATION 1. Using a grease pump, pump in grease through grease fittings marked by arrows. 2. After greasing, wipe off all the old grease that is pushed out. 1. Transmission mount (1 point) AE134470 2. Automatic suspension link (left and right: 1 point each) AE134480 3.
Page 241 6. If mark A of the 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.
Page 242 24. SERVICE PROCEDURE 24.6.6 CHECK TIGHTENING OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions checked. 24.6.7 CHECK PLAY OF TURBOCHARGER ROTOR Please contact your Komatsu distributor for inspection of the rotor play. 3-69...
Page 243 24. SERVICE PROCEDURE 24.7 EVERY 2000 HOURS SERVICE Carry out maintenance for EVERY 250 HOURS, EVERY 500 HOURS and EVERY 1000 HOURS SERVICE at the same time. 24.7.1 CHANGE OIL IN STEERING, HOIST OIL TANK  WARNING The oil is at high temperature after the engine has been oper- ated, so never change the oil immediately after finishing opera- tions.
Page 244 24. SERVICE PROCEDURE 24.7.2 CHANGE OIL IN REAR BRAKE COOLING OIL TANK  WARNING The oil is at high temperature after the engine has been oper- ated, so never change the oil immediately after finishing opera- tions. Wait for the oil to cool down before starting the operation. When removing the oil filler cap, turn it slowly to release ‡...
Page 245 24. SERVICE PROCEDURE 24.7.3 CHANGE OIL IN FINAL DRIVE CASE  WARNING The oil is at high temperature after the engine has been oper- ated, so never change the oil immediately after finishing opera- tions. Wait for the oil to cool down before starting the operation. ‡...
Page 246 24. SERVICE PROCEDURE 24.7.5 CLEAN DIFFERENTIAL CASE BREATHER Remove the mud and dirt from around the breather, then re- move the breather and wash out the dirt from inside with clean diesel oil or flushing oil. AE134580 24.7.6 CLEAN ENGINE BREATHER ELEMENT 1.
Page 247 24. SERVICE PROCEDURE 24.7.8 CLEAN EMERGENCY RELAY VALVE Please contact your Komatsu distributor to have the valve disas- sembled and cleaned. 24.7.9 CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or there may be no grease on the bearing, so please contact your Komatsu distributor for inspection and repair.
Page 248 24.8.4 REPLACE CRITICAL PARTS FOR PERIODICAL REPLACEMENT FROM SERVICE KIT For details, see “22. PERIODIC REPLACEMENT OF SAFETY CRITI- CAL PARTS”. Please contact your Komatsu distributor for replacement of critical parts. 24.8.5 CHECK, ADJUST AIR COMPRESSOR Ask your Komatsu distributor to carry out this work.
Page 249 24. SERVICE PROCEDURE 24.9 EVERY 3 YEARS SERVICE 24.9.1 REPLACE SEAT BELT Replace the seat belt once every 3 years. 3-76...
Page 250 SPECIFICATIONS...
Page 251 ‡ Min. ground clearance (bottom of rear axle) 645 (2 ft 1 in) 555 mm (1 ft 10 in) Engine ‡ Type Komatsu SAA6D170E-2 diesel engine ‡ Flywheel horsepower 551.63 kw (740 HP) 2000 rpm ‡ Max. torque 3010 N•m (307 kgf•m, 2220 lbft)/1400 rpm ‡...
Page 252 25. SPECIFICATIONS...
Page 253 8500 mm (27 ft 11 in) ‡ Min. ground clearance (bottom of rear axle) 645 (2 ft 1 in) Engine ‡ Type Komatsu SAA6D170E-2 diesel engine ‡ Flywheel horsepower 551.63 kW (740 HP) 2000 rpm ‡ Max. torque 3030 N•m (309 kgf•m, 2235 lbft)/1400 rpm ‡...
Page 254 25. SPECIFICATIONS...
Page 255 OPTIONS, ATTACHMENTS...
Page 256 9. External display lamps 26.2 EXTERNAL DISPLAY LAMPS ‡ HD465-5 When the actual load is displayed, the lamps light up as follows. Lamp 1 (green): Displays load between 14 tons and 21 tons Lamp 2 (green): Displays load between 21 tons and 41 tons...
Page 257 The prediction display for the load level and the actual load display are shown at the same time. Example: HD465-5 1st bucket: 10 tons 2nd bucket: 12 tons (22 tons) 3rd bucket: 12 tons (34 tons) 4th bucket: 11 tons (45 tons) If the load changes as above, the external display lamps will give the display in the table below.
Page 258 26. HANDLING PAYLOAD METER Example: HD605-5 1st bucket: 12 tons 2nd bucket: 11 tons (23 tons) 3rd bucket: 12 tons (35 tons) 4th bucket: 12 tons (47 tons) 5th bucket: 13 tons (60 tons) If the load changes as above, the external display lamps will give the display in the table below.
Page 259 26. HANDLING PAYLOAD METER 26.3 OPERATING PAYLOAD METER Resetting power (the power can be reset by turning the power ON.) ‡ The display for the first 3 seconds is 88:88, and after that, the time is displayed for 7 seconds. ‡...
Page 260 26. HANDLING PAYLOAD METER 26.3.2 OPERATION OF SWITCHES WHEN CARRYING OUT CALIBRATION Carry out calibration at the following times. ‡ When the machine is delivered, and once every month after that. ‡ When the gas pressure and oil have been adjusted in the suspension cylinder.
Page 261 26. HANDLING PAYLOAD METER CARRYING OUT SENSOR CHECK 1. Drive the machine unloaded on flat ground. 2. Set the shift lever to N and press calibration switch 1 for at least 2 seconds, then press calibration switch 1 again for at least 2 seconds.
Page 262 26. HANDLING PAYLOAD METER RESETTING TIME  WARNING Never try to reset the time when traveling. 1. When time set adjustment switch 1 is pressed for at least 2 seconds, the minute display will flash. Press time adjustment increase switch 3 to set the minute display correctly. 2.
Page 263 Press the FEED switch to feed out the remaining paper. Never try to pull the paper out forcibly. Always use Komatsu genuine printer paper (7818-27-2910). 1. Open the roll of printer paper, fold the paper at a point approx. 3 cm (1.2 in) from the end of the paper, then cut the paper straight along the fold.
Page 264 26. HANDLING PAYLOAD METER METHOD OF CUTTING PRINTER PAPER 1. Press the FEED switch to feed the paper out to the necessary position. 2. Put the paper in contact with the cutter on the lid, then pull up to cut the paper from one side to the other. Do not pull the paper out and cut it without using the paper AE134800 cutter.
Page 265 26. HANDLING PAYLOAD METER 3. Remove the screws (M6 x 4) holding the payload meter, then pull the payload meter out to the front. 4. Remove the connectors, remove the screws (top: M4 x 8, rear: M4X8 M4 x 3) of top cover 1 of the payload meter, then remove top cover 1.
Page 266 26. HANDLING PAYLOAD METER 10. Install the payload meter to its original position on the panel. After replacing the battery, do as follows. 1) Turn the starting switch to the ON position. 2) Press the memory data clear switch twice to delete the data from memory.
Page 267 26. HANDLING PAYLOAD METER 3. Remove the connectors, remove the screws (top: M4 x 8, rear: M4X8 M4 x 3) of top cover 1 of the payload meter, then remove top cover 1. M4X3 AE134820 4. Use tweezers to remove the paper caught between printer head 2 and guide 3.
Page 268 27. SELECTING DUMP BODY Select the dump body from the following table. (HD465-5 only) Purpose Body type Features Body shape ª Transporting rocks Rock body ‡ A liner is installed to the whole inside surface of the dump body to allow the loading of crushed rock, coal, or timber.
Page 269 (Card-type payload meter) For operation, see the separate manual for PLM (Card-type payload meter). ‡ Spare rim ‡ Spare time ‡ Body extension (HD465-5 only) ‡ Fog lamp Please contact your Komatsu distributor for details. 5-15...
Page 270 29. TACHOGRAPH (TCO 15-6) 29.1 EXPLANATION OF COMPONENTS 1. INSTRUMENT LOCK This can be used for the instrument lock key when replacing the charts, or for operator change identification keys 1 and 2. 2. CLOCK DIAL One line indicates one minute. 3.
Page 271 29. TACHOGRAPH (TCO 15-6) 7. SPEED INDICATION CONFIRMATION LAMP This is interconnected with the speedometer and is used to confirm the speed indication. When using the confirmation switch to light up the confirmation lamp during checks before starting, always check for any disconnection in the three indication confirmation lamps.
Page 272 29. TACHOGRAPH (TCO 15-6) 18. CUTTING KNIFE This knife cuts the tape connecting the charts. 19. INSTRUMENT LIGHTING LAMP 20. NAME PLATE This indicates the type and model. 21. VOLTAGE INDICATION LABEL 29.2 METHOD OF USING KEY There are three types of key. Key 1 with no mark is used for opening and locking the instrument.
Page 273 29. TACHOGRAPH (TCO 15-6) 29.3 METHOD OF USE 1. Checking operation of clock Watch through clock operation confirmation aperture 1 to con- firm that the clock is working. The clock is electric, so there is no need to wind it up. 2.
Page 274 If the size of the hole changes, it may cause an error in the recording. Stop the engine completely before inserting the new charts. Use Komatsu genuine charts (P/N: YZ762929-980) for 90 km/h (55.9 MPH) 7 days. 7. Closing the cover Lift up the cover to close it, then turn the instrument lock key 90°...
Page 275 30. REVO TACHOGRAPH (TCO 15-7) 30.1 EXPLANATION OF COMPONENTS 1. INSTRUMENT LOCK This can be used for the key to open when replacing the chart. 2. CLOCK DIAL One line indicates one minute. 3. SPEED SCALE This is the scale for the machine travel speed. 4.
Page 276 30. REVO TACHOGRAPH (TCO 15-7) 7. ODOMETER This displays the total distance (km) traveled by the machine. 8. PERIOD INDICATING LABEL This indicates that it is for 7 days. 9. RPM SCALE This is the scale for the momentary speed in revolutions per minute (rpm).
Page 277 30. REVO TACHOGRAPH (TCO 15-7) 21. VOLTAGE INDICATION LABEL 22. RPM RECORDING STYLUS This records the momentary engine speed on the chart. 23. ADJUSTMENT SCREW FOR RPM WARNING LAMP The speed at which the lamp gives a warning can be set as desired.
Page 278 30. REVO TACHOGRAPH (TCO 15-7) 30.2 METHOD OF USE 1. Opening the cover Insert the instrument lock key in hole 1, 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.
Page 279 If the size of the hole changes, it may cause an error in the recording. Stop the engine completely before inserting the new charts. Use Komatsu genuine charts (P/N: YZ762929-730) for 90 km/h (55.9 MPH) 7 days. 6. Closing the cover Lift up the cover to close it, then turn the instrument lock key 90°...
Page 280 31. USING DIFFERENTIAL LOCK 31.1 DIFFERENTIAL LOCK PEDAL The differential lock is used on snow-covered or muddy areas where the tires are likely to slip. The left and right wheels on the rear axle are locked together to prevent slipping and to provide a powerful drive force.
Page 281 31. USING DIFFERENTIAL LOCK 31.2 PRECAUTIONS AND METHOD OF USE ‡ Depress the differential lock pedal to actuate the differential lock 5 – 10 m before entering the area where the tires may slip. 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.
Page 282 32. OPERATION OF ABS AND ABS/ASR ABS (ANTI-SKID BRAKE SYSTEM) When the truck is braked suddenly or braked on a slippery snow- covered road, etc., this system works to prevent the tires from locking and skidding. Accordingly, the truck is kept in a normal attitude and good steering performance is secured.
Page 283 32. OPERATION OF ABS AND ABS/ASR 4. TROUBLESHOOTING SWITCH Used for troubleshooting. 32.2 OPERATION METHOD 32.2.1 ABS OPERATION  WARNING Always stop the truck before turning on the ABS/ASR main switch 3. If it is turned on while the truck is running, the ABS/ ASR may not function normally.
Page 284 32. OPERATION OF ABS AND ABS/ASR 32.3 PRECAUTIONS FOR USE  WARNING ‡ If the ABS functions while traveling on a slippery road, the braking distance may be slightly lengthened. Even if the ABS is turned on, the tires may lock when the truck is braked when running at a very low speed.
Page 285: Troubleshooting
If the ABS/ASR system malfunctions while being used, the warning lamp (Red) will light up. In this case, stop the truck at a safe place immediately, then ask your Komatsu distributor to carry out. The positions of each switch and the statuses of the correspond- ing warning lamps are as follows.
Page 286 33. HANDLING AUTO-GREASING SYSTEM With this system, the electric pump is connected to the divider valve, and a lubricating controller with built-in micro computer controls the electric pump and automatically supplies the grease. 33.1 METHOD OF OPERATING AUTO-GREASING SYSTEM 1. Turn the starting switch ON and start the electric pump. REMARK Immediately after the power is turned on, all display lamps on the lubrication controller inside the console box will light up for...
Page 287 33. HANDLING AUTO-GREASING SYSTEM LUBRICATION CONTROLLER DISPLAY TABLE The condition of the lubricating system can be seen from the 7-segment LED and the LED display on the controller panel. Type Item Symptom LED display 7-segment display Counting When normal Power source LED flashes or lights up numeral flashes...
Page 288 33. HANDLING AUTO-GREASING SYSTEM 33.1.1 ACTUATION OF AUTO-GREASING When engine starting switch 1 is turned one stage, the auto- greasing system is automatically set to the actuation condition. Do not press start button 3 of lubrication controller 2. REMARK Operating when desired It is possible to start the system and carry out one cycle of greasing regardless of the time count.
Page 289 If the machine is used in ambient temperatures below –20°C, set the greasing time to 20 minutes (code No. 7). In addition, use lithium-based grease No. 0. For details of setting the time, see “33.1.3 METHOD OF SET- TING”. When changing the set value, please contact your Komatsu distributor. 5-35...
Page 290 33. HANDLING AUTO-GREASING SYSTEM 33.1.3 METHOD OF SETTING When setting the various items, the value is not input directly. Select the code number from the set code table below, and set as follows. Setting code table Code no. Greasing interval (Hr) 1 1.5 2 Greasing time (min) 10 15 20 25...
Page 291 33. HANDLING AUTO-GREASING SYSTEM 5. When the code number that is to be set flashes, press the SET key to carry out the setting. 6. Repeat Steps 3 to 5 to set all of the items a, b, and c. After completing the setting, press the ESC key to leave the setting mode.
Page 292 33. HANDLING AUTO-GREASING SYSTEM 3. When grease is supplied for the first time, there is usually some air under the follower plate 2. If grease is supplied to the upper limit, however, the air is bled through the small hole on the side of the tank.
Page 293 33. HANDLING AUTO-GREASING SYSTEM 33.1.5 METHOD FOR BLEEDING AIR 1. When there is air in piston portion of pump 1. Remove the air bleed screw (hexagon head socket plug 1/8) from the side of the pump. 2. Turn the power on, press the SET/START key, and run the pump. 3.
Page 294 33. HANDLING AUTO-GREASING SYSTEM 33.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM ‡ Basically, the power source input to the lubrication controller should be DC24V, but use a maximum limit of 30V. ‡ The grease nipple installed to the service port used for initial charging of the divider valve has a ball check structure, so it may leak if dirt gets stuck in it.
Page 295: Specifications
33. HANDLING AUTO-GREASING SYSTEM 33.3 TROUBLESHOOTING If any abnormality occurs in the greasing system, the error codes will flash alternately to display the type of abnormality. Error code Item Cause Remedy E © a Defective pressurizing Air in main piping Run pump as necessary and of pump release grease from end of...
Page 296: Arsc (Automatic Retard Speed Control)
34. ARSC (AUTOMATIC RETARD SPEED CONTROL) When traveling downhill, if the switch is pressed at the speed that is to be maintained, the retarder is automatically actuated to prevent the travel speed from exceeding the set speed, so this makes retarder operations easy.
Page 297 34. ARSC (AUTOMATIC RETARD SPEED CONTROL) 1. SYSTEM SWITCH This is used to turn the ARSC system ON/OFF. 2. ARSC SET LEVER This lever is used in the following cases: When setting the travel speed When making fine adjustments to the set speed (tap up/tap down) When canceling the speed setting When setting the travel speed, check the display on the set travel speed display.
Page 298: Method Of Operation
34. ARSC (AUTOMATIC RETARD SPEED CONTROL) 34.2 METHOD OF OPERATION 34.2.1 ACTUATION OF ARSC SYSTEM The ARSC system is actuated when the system switch is ON. If the set switch on the ARSC set lever is pressed, the travel speed at that moment is set as the downhill travel speed.
Page 299 34. ARSC (AUTOMATIC RETARD SPEED CONTROL) 34.2.5 METHOD OF DECREASING SET SPEED If it is desired to decrease the set speed, operate the retarder control lever to reduce speed, and when the desired set travel speed is reached, press the set switch on the ARSC set lever. The set travel speed will be changed to the new speed.
Page 300 34. ARSC (AUTOMATIC RETARD SPEED CONTROL) 34.3 TROUBLESHOOTING 34.3.1 WHEN A PROBELM OCCURS IN THE SYSTEM This system is equipped with a self-diagnostic function. If any problem occurs, a failure code is displayed by the controller LED under the assistant’s seat. Failure Remedy No.
Page 301 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.
Page 302 34. ARSC (AUTOMATIC RETARD SPEED CONTROL) 34.3.3 METHOD OF MODEL SELECTION, TIRE LARGE DIAMETER/SMALL DIAMETER, REFERENCE FOR FAILURE CODE When the machine starting switch is turned ON, the codes below are automatically displayed in the following order on the controller LED. 1.
Page 303: Engine Oil Pan Heater, Coolant Heater
35. ENGINE OIL PAN HEATER, COOLANT HEATER To keep the engine warm and make it easy to start again when the engine has been stopped in cold areas, an electric heater for the coolant and lubrication oil is available as an option. 1 Power supply : Prepare an AC, 3-phase, 230 V power supply with a capacity of at least 6 kW.
Page 304: Method Of Use
35. ENGINE OIL PAN HEATER, COOLANT HEATER 35.1 METHOD OF USE In seasons when the ambient temperature when starting the engine is less than –20°C (for SAE30 engine oil, the season when the temperature is less than +4°C), start the heater immediately after stopping the engine on the previous day to prevent the temperature of the engine water and lubricating oil from going down.
Page 305 35. ENGINE OIL PAN HEATER, COOLANT HEATER Graph A Relationship between ambient temperature and time that machine can be left (when machine temperature has been maintained) 5-51...
Page 306: Precautions When Using
35. ENGINE OIL PAN HEATER, COOLANT HEATER 35.2 PRECAUTIONS WHEN USING 1. This heater is used for maintaining the temperature. If the engine has cooled completely, it will take an extremely long time to warm up the engine. In such cases, do as follows. If the machine has cooled to the ambient temperature, it is necessary to use the electric heater (engine) and a fan heater (to warm the inside of the engine room) before starting the engine.
Page 307 35. ENGINE OIL PAN HEATER, COOLANT HEATER Graph B Relationship between ambient temperature and warming-up time (when machine has cooled to ambient temperature) 5-53...

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