Komatsu HD325-8E0 HD405-8E0 Dump Truck Operation & Maintenance Manual EENAM03790 – PDF DOWNLOAD

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Komatsu HD325-8E0 HD405-8E0 Dump Truck Operation & Maintenance Manual EENAM03790 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HD325-8E0 HD405-8E0 Dump Truck Operation & Maintenance Manual EENAM03790 – PDF DOWNLOAD

SERIAL NUMBERS
HD325-8E0 – 55001 and up
HD405-8E0 – 55001 and up

READ THIS MANUAL:

• This manual gives details of the operation and methods of inspection and maintenance for this machine that
  must be observed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
  safety rules for the operation and maintenance of machines.
• Read, understand and follow all precautions and warnings in this manual and on the machine before performing
  operation and maintenance. Failure to do so may result in serious injury or death.
• Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
• Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
• If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
  understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
  you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform improper
  operation and maintenance of the machine. It may cause serious injury or death.
• If you sell the machine, be sure to give this manual to the new owner together with the machine.
  Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
  read it at any time.

TABLE OF CONTENTS:

Komatsu HD325-8E0 HD405-8E0 Dump Truck Operation & Maintenance Manual EENAM03790 – PDF DOWNLOAD

FOREWORD 3
READ THIS MANUAL 4
KOMATSU MACHINE OPERATOR PRIVACY POLICY 5
SAFETY INFORMATION 8
NOISE 9
VIBRATION LEVELS 10
VIBRATION – OPERATING CONDITION 10
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE 10
INTRODUCTION 12
MAIN USE OF MACHINE 12
DIRECTIONS OF MACHINE 12
VISIBILITY FROM OPERATOR’S SEAT 12
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 14
PRODUCT INFORMATION 15
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 15
LOCATION OF ENGINE NUMBER PLATE 15
FLUORINATED GREENHOUSE GASES 16
SERVICE METER LOCATION 16
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 16
SERIAL PLATE 17
DECLARATION OF CONFORMITY 18
TABLE OF CONTENTS 19
SAFETY 23
SAFETY LABELS 24
LOCATION OF SAFETY LABELS 25
CONTENTS OF SAFETY LABELS 28
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 35
PRECAUTIONS BEFORE STARTING OPERATION 35
ENSURE SAFE OPERATION 35
UNDERSTAND THE MACHINE 35
PREPARATIONS FOR SAFE OPERATION 35
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT 35
INSPECT MACHINE 35
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 35
KEEP MACHINE CLEAN 35
PRECAUTIONS FOR INSIDE OPERATOR’S COMPARTMENT 36
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 36
IF ANY PROBLEM IS FOUND 36
PRECAUTIONS TO PREVENT FIRE 36
ACTIONS IF FIRE OCCURS 36
PREVENT FIRE 37
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 38
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 38
NO JUMPING ON OR OFF MACHINE 38
LIFTING OF PERSONNEL PROHIBITED 39
PEOPLE ON DUMP BODY 39
WHEN STANDING UP FROM OPERATOR’S SEAT 39
PRECAUTIONS WHEN LEAVING MACHINE 39
EMERGENCY EXIT FROM OPERATOR’S CAB 40
ELECTROMAGNETIC INTERFERENCE 40
DO NOT GET CAUGHT IN WORK EQUIPMENT 40
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 40
UNAUTHORIZED MODIFICATION 41
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 41
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 41
PRECAUTIONS FOR OPERATION 42
PRECAUTIONS FOR JOBSITE 42
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 42
PRECAUTIONS WHEN WORKING ON LOOSE GROUND 42
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 42
ENSURE GOOD VISIBILITY 43
CHECK SIGNS AND SIGNALMAN’S SIGNALS 43
BEWARE OF ASBESTOS DUST 43
START ENGINE 44
USE WARNING TAGS 44
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 44
PRECAUTIONS WHEN STARTING ENGINE 45
IN COLD AREAS 45
START ENGINE WITH JUMPER CABLES 45
PRECAUTIONS FOR OPERATION 45
CHECKS BEFORE OPERATION 45
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 46
WHEN TRAVELING 46
PRECAUTIONS WHEN TRAVELING ON SLOPES 47
PRECAUTIONS WHEN OPERATING MACHINE 47
WHEN LOADING ON DUMP BODY 47
WHEN DUMPING 47
WHEN OPERATING ON SNOW OR FROZEN SURFACES 47
WHEN PARKING MACHINE 48
TRANSPORTATION 48
PRECAUTIONS WHEN LOADING AND UNLOADING 49
TOWING AND BEING TOWED 49
PRECAUTIONS FOR TOWING AND BEING TOWED 49
PRECAUTIONS FOR MAINTENANCE 50
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 50
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 50
KEEP WORK PLACE CLEAN AND TIDY 50
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 50
ONLY AUTHORIZED PERSONNEL 50
APPOINT LEADER WHEN WORKING WITH OTHERS 50
STABILITY 50
GUARDS 51
END OF SERVICE LIFE 51
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 51
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 52
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS 52
PRECAUTIONS FOR WORKING AT HIGH PLACES 53
PRECAUTIONS WHEN WORKING ON MACHINE 53
PRECAUTIONS WHEN WORKING UNDER MACHINE 53
USE PROPER TOOLS 54
PRECAUTIONS FOR CHECK AND MAINTENANCE 54
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 54
PRECAUTIONS FOR WELDING 54
HANDLE BATTERY 54
WHEN USING HAMMER 55
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT 55
PRECAUTIONS FOR HIGH-TEMPERATURE OIL 56
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS 56
PRECAUTIONS FOR HIGH-PRESSURE OIL 56
PRECAUTIONS FOR HIGH-PRESSURE FUEL 56
HANDLE HIGH-PRESSURE HOSES AND PIPING 56
PRECAUTIONS FOR HIGH VOLTAGE 57
PRECAUTIONS FOR NOISE 57
HANDLE SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGS 57
PRECAUTIONS FOR COMPRESSED AIR 57
MAINTENANCE OF AIR CONDITIONER 57
CHEMICAL HAZARD 57
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 57
METHOD FOR SELECTING WINDOW WASHER FLUID 58
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 58
TIRES 58
HANDLE TIRES 58
PRECAUTIONS FOR STORING TIRES 59
PRECAUTIONS FOR DEF 60
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 60
PRECAUTIONS FOR ADDING 60
PRECAUTIONS FOR STORING 60
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 60
OTHER PRECAUTIONS 60
OPERATION 61
GENERAL VIEW 62
MACHINE EQUIPMENT NAME 62
CONTROLS AND GAUGES NAMES 63
MACHINE MONITOR EQUIPMENT NAME 65
OTHER EQUIPMENT NAME 68
EXPLANATION OF COMPONENTS 71
EXPLANATION OF MACHINE MONITOR EQUIPMENT 71
BASIC OPERATION OF MACHINE MONITOR 72
WARNING DISPLAY 77
ACTION LEVEL DISPLAY 78
ENGINE COOLANT TEMPERATURE CAUTION LAMP 81
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP 82
RETARDER OIL TEMPERATURE CAUTION LAMP 82
FUEL LEVEL CAUTION LAMP 82
BRAKE OIL PRESSURE CAUTION LAMP 82
DEF LEVEL CAUTION LAMP 83
SEATBELT CAUTION LAMP 83
STEERING SYSTEM CAUTION LAMP 83
STEERING OIL PRESSURE CAUTION LAMP 84
STEERING OIL TEMPERATURE CAUTION LAMP 84
SECONDARY STEERING SYSTEM CAUTION LAMP 84
SECONDARY STEERING MOTOR CAUTION LAMP 85
HOIST CONTROL SYSTEM CAUTION LAMP 85
BODY FLOAT CAUTION LAMP 85
INCLINATION CAUTION LAMP 86
SYSTEM CAUTION LAMP 86
KDPF SYSTEM CAUTION LAMP 86
KDPF SOOT ACCUMULATION CAUTION LAMP 87
DEF SYSTEM CAUTION LAMP 87
DEF SYSTEM HIGH TEMPERATURE STOP CAUTION LAMP 87
TRANSMISSION SYSTEM CAUTION LAMP 88
TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP 88
RETARDER SYSTEM CAUTION LAMP 88
ENGINE SYSTEM CAUTION LAMP 89
PARKING BRAKE SYSTEM CAUTION LAMP 89
KTCS SYSTEM CAUTION LAMP 89
ENGINE OIL PRESSURE CAUTION LAMP 90
ENGINE OIL LEVEL CAUTION LAMP 90
ENGINE OVERRUN CAUTION LAMP 90
RADIATOR COOLANT LEVEL CAUTION LAMP 91
CHARGE LEVEL CAUTION LAMP 91
AIR CLEANER CLOGGING CAUTION LAMP 91
FAN CONTROL SYSTEM CAUTION LAMP 91
FAN-REVERSE OPERATION CAUTION LAMP 92
AIR CONDITIONER SYSTEM CAUTION LAMP 92
ARSC SYSTEM CAUTION LAMP 92
ARSC OVERHEAT NOTICE CAUTION LAMP 92
PAYLOAD METER SYSTEM CAUTION LAMP 93
BRAKE COOLING OIL FILTER CLOGGING CAUTION LAMP 93
HYDRAULIC OIL FILTER CLOGGING CAUTION LAMP 93
AUTO SUSPENSION SYSTEM CAUTION LAMP 93
MAINTENANCE TIME CAUTION LAMP 94
CENTRALIZED WARNING LAMP 94
PILOT DISPLAY AND METER DISPLAY 96
110
USER MENU 113
SWITCHES 164
STARTING SWITCH 165
CIGARETTE LIGHTER 166
LAMP SWITCH 166
DIMMER SWITCH 167
TURN SIGNAL LEVER 167
WIPER, WINDOW WASHER SWITCH 167
HORN BUTTON 168
MONITOR BRIGHTNESS SELECTOR SWITCH 168
SWITCH FOR MIRROR WITH HEATED WIRE 168
HAZARD LAMP SWITCH 169
SECONDARY STEERING SWITCH 169
REARVIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH 169
AISS LOW SWITCH 169
FRONT BRAKE OFF SWITCH 170
ENGINE POWER MODE SELECTOR SWITCH 171
PARKING BRAKE SWITCH 171
FOG LAMP SWITCH 172
POWER WINDOW SWITCH 172
SIDE LAMP SWITCH 173
ROOM LAMP1 SWITCH 173
ROOM LAMP2 SWITCH 173
ENGINE SHUTDOWN SECONDARY SWITCH 174
STAIRCASE LIGHTING SWITCH 174
CONTROL LEVERS AND PEDALS 175
BRAKE PEDAL 176
SECONDARY BRAKE PEDAL 176
ACCELERATOR PEDAL 176
GEAR SHIFT LEVER 176
RETARDER CONTROL LEVER 178
ARSC TRAVEL SPEED SET LEVER 178
DUMP LEVER 179
DUMP LEVER LOCK KNOB 179
OTHER EQUIPMENT 180
CAB DOOR 180
DRINK BOX 181
LUNCH BOX TRAY 181
MAGAZINE BOX 181
CUP HOLDER 182
ASHTRAY 182
POWER SUPPLY OUTLET 182
FUSE 183
TOOL BOX 186
GREASE PUMP HOLDER 186
FIRE EXTINGUISHER 186
BATTERY DISCONNECT SWITCH 187
SYSTEM OPERATING LAMP 188
CIRCUIT BREAKER 188
DUST INDICATOR 189
BODY PIVOT PINS 189
HANDLE REAR VIEW MONITOR 190
HANDLE Komatsu Diesel Particulate Filter (KDPF) 193
Komatsu Closed Crankcase Ventilation (KCCV) 202
HANDLE UREA SCR SYSTEM WARNING 202
KOMTRAX 217
MACHINE OPERATIONS AND CONTROLS 218
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 218
METHOD FOR WALK-AROUND CHECK 218
METHOD FOR CHECKING BEFORE STARTING 221
ADJUST BEFORE OPERATION 236
METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE 249
METHOD FOR STARTING ENGINE 252
METHOD FOR MANUAL PREHEATING WHEN STARTING ENGINE 254
TURBOCHARGER PROTECTION FUNCTION 255
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE 256
METHOD FOR CANCELING TO HOLD DUMP BODY 256
METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF ENGINE 256
METHOD FOR CHECKING LOW-SPEED RUN AND ACCELERATION OF ENGINE 256
METHOD FOR RUNNING-IN THE NEW MACHINE 257
257
METHOD FOR WARM-UP OPERATION 257
METHOD FOR STOPPING ENGINE 258
METHOD FOR CHECKING AFTER STOPPING ENGINE 259
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE 259
METHOD FOR MOVING MACHINE 259
METHOD FOR TRAVELING REVERSE 261
METHOD FOR STOPPING MACHINE 262
METHOD FOR SHIFTING GEARS 265
METHOD FOR TRAVELING DOWNHILL 266
HANDLE Automatic Retarder Speed Control (ARSC) 269
BRAKE PERFORMANCE CURVE 272
METHOD FOR TURNING MACHINE 284
METHOD FOR LOADING 285
METHOD FOR DUMPING 285
PRECAUTIONS FOR OPERATION 287
PERMISSIBLE WATER DEPTH 288
METHOD FOR PARKING MACHINE 288
METHOD FOR CHECKING AFTER FINISHING WORK 289
LOCK 289
METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP 290
METHOD FOR OPENING AND CLOSING TRANSMISSION CASE FILLER CAP 291
METHOD FOR OPENING AND CLOSING OIL FILLER CAP OF STEERING AND HOIST OIL TANK 292
METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR 292
HANDLE TIRE 293
PRECAUTIONS WHEN HANDLING TIRES 293
T Km P H (Ton-Km-Hour-Rating) 294
TIRE T Km P H VALUE AND CONTINUOUS MAX TRAVEL SPEED 294
PRECAUTIONS FOR LONG DISTANCE TRAVEL 295
HANDLE AIR CONDITIONER 297
EXPLANATION OF AIR CONDITIONER EQUIPMENT 298
OFF SWITCH 298
FAN SWITCH 299
TEMPERATURE CONTROL SWITCH 299
VENT SELECTOR SWITCH 300
AUTO SWITCH 301
FRESH/RECIRC AIR SELECTOR SWITCH 301
AIR CONDITIONER DISPLAY 302
AIR CONDITIONER SWITCH 302
DEFROSTER SWITCH 303
METHOD FOR OPERATING AIR CONDITIONER 303
METHOD FOR AUTOMATIC OPERATION 303
METHOD FOR STOPPING AUTOMATIC OPERATION 304
METHOD FOR MANUAL OPERATION 304
METHOD FOR STOPPING MANUAL OPERATION 306
METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET 306
METHOD FOR OPERATING DEFROSTER 307
HANDLE RADIO 310
EXPLANATION OF RADIO EQUIPMENT 310
POWER BUTTON 310
BAND/AUX SELECTOR BUTTON 310
VOLUME CONTROL BUTTON 310
TUNING/TIME ADJUSTMENT BUTTON 310
PRESET BUTTON 311
DISPLAY SELECTOR BUTTON 311
SOUND CONTROL BUTTON 311
DISPLAY 311
AUX 311
METHOD FOR CONTROLLING RADIO 311
METHOD FOR ADJUSTING FREQUENCY 311
METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING) 312
METHOD FOR CALLING PRESET 312
METHOD FOR REGISTERING PRESET 312
METHOD FOR ADJUSTING SOUND BALANCE 313
METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE) 313
METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS) 313
METHOD FOR ADJUSTING CLOCK 313
DETERMINE AND MAINTAIN TRAVEL ROAD 315
TRANSPORTATION 316
PRECAUTIONS FOR TRANSPORTATION 316
SELECT TRANSPORTATION METHOD 316
METHOD FOR SECURING MACHINE 316
PRECAUTIONS FOR LIFTING MACHINE 316
PROCEDURE FOR LIFTING MACHINE 318
COLD WEATHER OPERATION 320
COLD WEATHER OPERATION INFORMATION 320
FUEL AND LUBRICANTS 320
COOLANT 320
DEF 320
BATTERY 320
RADIATOR CURTAIN 321
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 321
AFTER COLD WEATHER SEASON 321
PRECAUTIONS FOR LONG-TERM STORAGE 323
PREPARATION FOR LONG-TERM STORAGE 323
MAINTENANCE DURING LONG-TERM STORAGE 323
STARTING MACHINE AFTER LONG-TERM STORAGE 323
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE 324
TROUBLES AND ACTIONS 325
ACTIONS WHEN RUNNING OUT OF FUEL 325
ACTIONS IF TRANSMISSION HAS TROUBLE 325
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR 325
PRECAUTIONS FOR TOWING MACHINE 326
METHOD FOR RELEASING PARKING BRAKE 328
PRECAUTIONS FOR DISCHARGED BATTERY 330
PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY 330
PRECAUTIONS FOR CHARGING BATTERY 331
START ENGINE WITH JUMPER CABLES 332
OTHER TROUBLE 333
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM 333
PHENOMENA AND ACTIONS FOR CHASSIS 334
PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS 336
IF MACHINE MONITOR SHOWS WARNING DISPLAY 338
MAINTENANCE 339
PRECAUTIONS FOR MAINTENANCE 340
CHECK SERVICE METER READING 340
KOMATSU GENUINE REPLACEMENT PARTS 340
KOMATSU GENUINE LUBRICANTS 340
ALWAYS USE CLEAN WASHER FLUID 340
FRESH AND CLEAN LUBRICANTS 340
CHECK DRAINED OIL AND USED FILTER 340
PRECAUTIONS FOR REFILLING OIL OR FUEL 340
PRECAUTIONS FOR ADDING DEF 340
PRECAUTIONS FOR WELDING 340
DO NOT DROP THINGS INSIDE MACHINE 340
PRECAUTIONS FOR KDPF 341
PRECAUTIONS FOR SCR ASSEMBLY 341
DUSTY JOBSITES 341
AVOID MIXING OIL 341
LOCK INSPECTION COVERS 341
BLEED AIR FROM HYDRAULIC CIRCUIT 341
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 341
CHECKS AFTER INSPECTION AND MAINTENANCE 341
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 342
PRECAUTIONS FOR JACK-UP 342
OUTLINE OF MAINTENANCE 343
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 343
OIL 343
FUEL 344
COOLANT AND WATER FOR DILUTION 344
DEF 344
GREASE 345
PERFORM KOWA (Komatsu Oil Wear Analysis) 345
STORE OIL AND FUEL 346
STORE DEF 346
FILTER 346
HANDLE ELECTRICAL COMPONENTS 347
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 348
MAINTENANCE SCHEDULE 350
MAINTENANCE SCHEDULE TABLE 350
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED 351
MAINTENANCE PROCEDURE 353
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 353
WHEN REQUIRED 353
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER 353
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 357
METHOD FOR CLEANING RADIATOR FINS, AFTERCOOLER FINS, OIL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS 362
METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE 363
METHOD FOR ROTATING FAN IN REVERSE 363
METHOD FOR CLEANING FIN WITH COMPRESSED AIR 365
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID 366
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER 366
METHOD FOR CHECKING DUMP BODY 368
METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER 368
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 370
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT 371
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT 373
SELECT AND CHECK TIRES 374
METHOD FOR RELEASING PARKING BRAKE 376
CHECKS BEFORE STARTING 377
EVERY 250 HOURS MAINTENANCE 377
METHOD FOR LUBRICATING 377
METHOD FOR CHECKING AND ADDING OIL IN DIFFERENTIAL CASE 379
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL 379
METHOD FOR CHECKING DRIVE SHAFT 380
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 380
METHOD FOR CLEANING TRANSMISSION CASE AND BRAKE SUB-TANK BREATHER 382
METHOD FOR CLEANING STEERING AND HOIST OIL TANK BREATHER 383
METHOD FOR CHECKING FRAME 383
METHOD FOR CHECKING FOOT BRAKE PERFORMANCE 383
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE 384
METHOD FOR CHECKING PARKING BRAKE PERFORMANCE 385
METHOD FOR CHECKING AND CLEANING AUTOMATIC SUSPENSION 386
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR 387
EVERY 500 HOURS MAINTENANCE 388
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE 388
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 390
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT 391
METHOD FOR CHECKING WEAR OF FRONT DISC BRAKE PADS 392
METHOD FOR CHECKING ALTERNATOR AND AIR CONDITIONER COMPRESSOR DRIVE BELT 393
EVERY 1000 HOURS MAINTENANCE 394
METHOD FOR CHANGING OIL IN TRANSMISSION CASE AND BRAKE SUB-TANK, CLEANING STRAINER 394
METHOD FOR REPLACING TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT 397
METHOD FOR REPLACING BRAKE OIL FILTER ELEMENT 397
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE 398
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT 400
METHOD FOR LUBRICATING PARKING BRAKE 401
METHOD FOR LUBRICATING 402
METHOD FOR CHECKING REAR BRAKE DISC WEAR AMOUNT 403
METHOD FOR COLLECTING LEAKED OIL FROM FLOATING SEAL 403
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP 404
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT 404
METHOD FOR CHECKING AND LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF COMPRESSOR FOR ALTERNATOR AND AIR CONDITIONER 406
EVERY 2000 HOURS MAINTENANCE 407
METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT 407
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE 408
METHOD FOR CHANGING OIL IN DEFERENTIAL CASE 409
METHOD FOR CLEANING DIFFERENTIAL CASE BREATHER 409
METHOD FOR CLEANING HYDRAULIC TANK STRAINER 410
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE 410
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE 410
METHOD FOR REPLACING KCCV FILTER ELEMENT 410
METHOD FOR REPLACING DEF FILTER 413
METHOD FOR REPLACING DEF TANK FILLER PORT FILTER 416
EVERY 4000 HOURS MAINTENANCE 417
REPLACE DEFINED LIFE PARTS 417
METHOD FOR CHANGING OIL IN STEERING AND HOIST OIL TANK 418
METHOD FOR LUBRICATING DRIVE SHAFT 418
METHOD FOR CHECKING WATER PUMP 418
METHOD FOR CHECKING ALTERNATOR 419
METHOD FOR CHECKING STARTING MOTOR 419
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER 419
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 419
EVERY 4500 HOURS MAINTENANCE 420
METHOD FOR CLEANING KDPF 420
METHOD FOR CLEANING DEF TANK 420
METHOD FOR CLEANING FUEL DOSER 420
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING, HARDENING OF RUBBER 420
METHOD FOR CHECKING EXHAUST PIPE FIRE PREVENTION COVER 420
EVERY 8000 HOURS MAINTENANCE 421
METHOD FOR REPLACING ENGINE HIGH-PRESSURE PIPING CLAMP 421
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP 421
METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR 421
EVERY 9000 HOURS MAINTENANCE 422
METHOD FOR REPLACING DEF HOSE 422
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING 422
END OF SERVICE LIFE 422
EVERY 15000 HOURS MAINTENANCE 422
METHOD FOR CHECKING AND REPLACING STEERING-A ARM MOUNTING BOLT 422
SPECIFICATIONS 423
SPECIFICATIONS 424
SPECIFICATIONS: HD325-8E0 424
SPECIFICATIONS: HD405-8E0 425
ATTACHMENTS AND OPTIONS 427
HANDLING PAYLOAD METER 428
OUTLINE OF SYSTEM 428
PAYLOAD DISPLAY 429
EXTERNAL DISPLAY LAMP 430
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER 431
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD 432
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD IN CAB 432
METHOD FOR USING DOWNLOAD SOFTWARE 432
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES 434
DISPLAY FUEL CONSUMPTION RECORD 436
SETTING MACHINE ID AND OPEN ID 437
METHOD FOR PERFORMING CALIBRATION 438
BODY SELECTION 441
HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER 442
EXPLANATION OF COMPONENTS 442
POWER OUTLET FOR ENGINE HEATER 442
CONNECT EXTERNAL POWER SUPPLY 442
FUSIBLE LINK 442
ENGINE HEATER 443
INSTALLATION PROCEDURES FOR EXTERNAL POWER SUPPLY SYSTEM FOR EXTERNAL POWER SUPPLY ENGINE PREHEATER 443
FABRICATE EXTERNAL POWER SUPPLY CABLE 445
INSTALL EXTERNAL POWER SUPPLY SYSTEM 447
METHOD FOR OPERATING EXTERNAL POWER SUPPLY HEATER 448
CIRCUIT DIAGRAM OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 449
HANDLE EXTERNAL POWER SUPPLY CONNECTOR FOR STARTING MOTOR 451
HANDLE EXTERNAL ENGINE SHUTDOWN SECONDARY SWITCH 452
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) 453
OPERATION OF KTCS 453
METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND 453
HANDLE SPEED LIMIT FUNCTION 454
OPERATION OF SPEED LIMIT FUNCTION 454
OPERATION IF TROUBLES ON SYSTEM OCCUR 455
REPLACEMENT PARTS 457
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 458
DEFINED LIFE PARTS LIST 458
CONSUMABLE PARTS 459
CONSUMABLE PARTS LIST 459
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 460
LUBRICATION CHART 460
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 462
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 464
INDEX 465

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