Komatsu Galeo HM300-2 Articulated Dump Truck Maintenance Manual

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ARTICULATED DUMP TRUCK

HM300

PEN00101-04

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SERIAL NUMBERS

NOTICE

Komatsu has Operation & Maintenance Manuals written in some other languages. if a foreign language manual is necessary, contact your local distributor for availability.

2001

and up

WARNING

Unsafe Use of this machine may cause serious injury or

Death.Operators and maintenance personnel must read

this manual before operating or maintaining this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it .

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FOREWORD

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.

WARNING

Operators and maintenance personnel must always do as follows before beginning operation or maintenance.

Always be sure to read and understand this manual thoroughly before performing operation and maintenance.

Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.

Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu deliversmachines that comply with all applicable regulations and standards of the country towhich it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

Storage location for the Operation and Maintenance Manual: On inside of left door

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FOREWORD

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FOREWORD

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FOREWORD

SAFETY INFORMATION

To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This word is used also to alert against unsafe practices that may cause property damage.

Example of safety message using signal word

WARNING

When standing up from the operator's seat, always place the lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know.

This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine.

This word is used for information that is useful to know.

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SAFETY INFORMATION

Safety labels

Safety labels are affixed to the machine to informthe operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.

Example of safety label using words

FOREWORD

Safety labels using pictogram

Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it isyour responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributorfor the latest available information of your machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 J (1))

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FOREWORD

INTENDED USE

DIRECTIONS OF MACHINE

INTENDED USE

In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine.

(D)

(A) (B) (C)

FRONT REAR LEFT

RIGHT

(E)

OPERATOR'S SEAT

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LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

FOREWORD

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

This is at the rear right of the cab. The design of the nameplate differs according to the territory.

EPA REGULATIONS, ENGINE NUMBER PLATE

It is located on the upper left side of the engine cylinder block if you look from the fan side.

EPA: Environmental Protection Agency, U.S.A.

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FOREWORD

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

SERVICE METER POSITION

It is at the center bottom of the machine monitor.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Product identification number (PIN)

Distributor name

Address

Service Personnel

Phone/Fax

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FOREWORD

CONTENTS

FOREWORD 1- 1 FOREWORD 1- 2 SAFETY INFORMATION 1- 5 INTENDED USE 1- 7 DIRECTIONS OF MACHINE 1- 7 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8 EPA REGULATIONS, ENGINE NUMBER PLATE 1- 8 SERVICE METER POSITION 1- 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9 SAFETY 2- 1 SAFETY 2- 2 SAFETY LABELS 2- 4 POSITION FOR ATTACHING SAFETY LABELS 2- 5 SAFETY LABELS 2- 6 GENERAL PRECAUTIONS 2- 11 PRECAUTIONS DURING OPERATION 2- 20 STARTING ENGINE 2- 20 OPERATION 2- 22 TRANSPORTATION 2- 26 BATTERY 2- 27 TOWING 2- 29 PRECAUTIONS FOR MAINTENANCE 2- 30 PRECAUTIONS WITH TIRES 2- 37 OPERATION 3- 1 GENERAL VIEW 3- 2 GENERAL VIEW OF MACHINE 3- 2 GENERAL VIEW OF CONTROLS AND GAUGES 3- 3 EXPLANATION OF COMPONENTS 3- 5 MACHINE MONITOR 3- 5 OTHER FUNCTIONS OF MACHINE MONITOR 3- 26 SWITCHES 3- 30 CONTROL LEVERS AND PEDALS 3- 40 BODY PIVOT PIN 3- 45 ARTICULATE LOCK 3- 45 LOCATION OF FIRE EXTINGUISHER 3- 46 DUST INDICATOR 3- 46 CIRCUIT BREAKER 3- 46 FUSES 3- 47 CAR RADIO 3- 50 CAR STEREO 3- 56 AIR CONDITIONER 3- 64 OPERATION 3- 70 CHECK BEFORE STARTING ENGINE 3- 70 STARTING ENGINE 3- 85 OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 87 STOPPING ENGINE 3- 88 CHECKS AFTER STOPPING ENGINE 3- 88 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 89

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FOREWORD

SHIFTING GEAR 3- 94 TRAVELING DOWNHILL 3- 96 STEERING THE MACHINE 3-102 OPERATION USING DIFFERENTIAL LOCK 3-103 LOADING OPERATIONS 3-104 DUMP OPERATIONS 3-105 CAB TILT OPERATION 3-107 PRECAUTIONS FOR OPERATION 3-110 PARKING MACHINE 3-111 CHECKS AFTER COMPLETION OF WORK 3-112 LOCKING 3-112 HANDLING TIRES 3-113 DETERMINING AND MAINTAINING TRAVEL ROAD 3-114 DETERMINING TRAVEL ROAD 3-114 MAINTAINING TRAVEL ROAD 3-114 TRANSPORTATION 3-115 PRECAUTIONS WHEN TRANSPORTING 3-115 STEPS FOR TRANSPORTATION 3-115 METHOD OF SECURING MACHINE 3-116 METHOD OF LIFTING MACHINE 3-117 COLD WEATHER OPERATION 3-121 PRECAUTIONS FOR LOW TEMPERATURE 3-121 PRECAUTIONS AFTER COMPLETION OF WORK 3-122 AFTER COLD WEATHER 3-123 LONG-TERM STORAGE 3-124 BEFORE STORAGE 3-124 DURING STORAGE 3-124 AFTER STORAGE 3-124 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-124 TROUBLESHOOTING 3-125 AFTER RUNNING OUT OF FUEL 3-125 IF TRANSMISSION HAS TROUBLE 3-126 METHOD OF LOWERING DUMP BODY IN EMERGENCY 3-126 METHOD OF TOWING MACHINE 3-127 IF BATTERY IS DISCHARGED 3-131 OTHER TROUBLE 3-135 MAINTENANCE 4- 1 GUIDES TO MAINTENANCE 4- 2 OUTLINE OF SERVICE 4- 4 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4 OUTLINE OF ELECTRIC SYSTEM 4- 8 WEAR PARTS 4- 9 WEAR PARTS LIST 4- 9 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 11 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 13 TORQUE LIST 4- 13 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 15

CONTENTS

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CONTENTS

SAFETY CRITICAL PARTS 4- 16 MAINTENANCE SCHEDULE CHART 4- 17 MAINTENANCE SCHEDULE CHART 4- 17 SERVICE PROCEDURE 4- 19 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 19 WHEN REQUIRED 4- 20 CHECK BEFORE STARTING 4- 39 EVERY 50 HOURS SERVICE 4- 40 EVERY 250 HOURS SERVICE 4- 41 EVERY 500 HOURS SERVICE 4- 53 EVERY 1000 HOURS SERVICE 4- 60 EVERY 2000 HOURS SERVICE 4- 71 EVERY 4000 HOURS SERVICE 4- 77 EVERY 6000 HOURS SERVICE 4- 79 EVERY 8000 HOURS SERVICE 4- 80 SPECIFICATIONS 5- 1 SPECIFICATIONS 5- 2 ATTACHMENTS, OPTIONS 6- 1 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC) 6- 2 EXPLANATION OF COMPONENTS 6- 2 METHOD OF OPERATION 6- 3 USE OF REAR VIEW MONITOR 6- 4 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR 6- 4 SETTING OF REAR VIEW MONITOR 6- 7 CAUTIONS WHEN USING REAR VIEW MONITOR 6- 7 HANDLING DUMPING COUNTER 6- 8 HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 9 BASIC PRECAUTIONS 6- 9 INDEX 7- 1

FOREWORD

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SAFETY

SAFETY LABELS 2- 4 POSITION FOR ATTACHING SAFETY LABELS 2- 5 SAFETY LABELS 2- 6

GENERAL PRECAUTIONS 2- 11 SAFETY RULES 2- 11 IF ABNORMALITIES ARE FOUND 2- 11 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11 FIRE EXTINGUISHER AND FIRST AID KIT 2- 11 SAFETY FEATURES 2- 12 KEEP MACHINE CLEAN 2- 12 INSIDE OPERATOR'S COMPARTMENT 2- 12 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 12 HANDRAILS AND STEPS 2- 13 MOUNTING AND DISMOUNTING 2- 13 CRUSHING OR CUTTING PREVENTION 2- 13 PREVENTION OF BURNS 2- 14 FIRE PREVENTION 2- 15 ACTION IF FIRE OCCURS 2- 15 WINDOW WASHER LIQUID 2- 16 PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 16 PRECAUTIONS FOR ATTACHMENTS, OPTIONS 2- 16 UNAUTHORIZED MODIFICATION 2- 16 SAFETY AT WORKSITE 2- 16 WORKING ON LOOSE GROUND 2- 17 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 17 ENSURE GOOD VISIBILITY 2- 18 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS 2- 18 CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 18 EMERGENCY ESCAPE FROM OPERATOR'S CAB 2- 18 ASBESTOS DUST HAZARD PREVENTION 2- 19

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SAFETY

PRECAUTIONS DURING OPERATION 2- 20 STARTING ENGINE 2- 20 CHECKS BEFORE STARTING ENGINE, ADJUST 2- 20 PRECAUTIONS WHEN STARTING 2- 20 PRECAUTIONS IN COLD AREAS 2- 21 OPERATION 2- 22 CHECKS BEFORE STARTING OPERATION 2- 22 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22 PRECAUTIONS WHEN TRAVELING 2- 23 PRECAUTIONS WHEN TRAVELING ON SLOPES 2- 23 PRECAUTIONS WHEN OPERATING DUMP BODY 2- 24 PRECAUTIONS WHEN OPERATING 2- 24 PRECAUTIONS FOR ACCUMULATED SNOW, ICE 2- 24 PARKING MACHINE 2- 25 TRANSPORTATION 2- 26 LOADING AND UNLOADING 2- 26 SHIPPING 2- 26 BATTERY 2- 27 BATTERY HAZARD PREVENTION 2- 27 STARTING WITH BOOSTER CABLES 2- 28 TOWING 2- 29 WHEN TOWING 2- 29

SAFETY

PRECAUTIONS FOR MAINTENANCE 2- 30 WARNING TAG 2- 30 KEEP WORK PLACE CLEAN AND TIDY 2- 30 APPOINT LEADER WHEN WORKING WITH OTHERS 2- 30 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 31 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 32 PROPER TOOLS 2- 33 HANDLING SUSPENSION CYLINDER, ACCUMULATOR 2- 33 PERSONNEL 2- 33 WORK UNDER THE MACHINE 2- 33 NOISE 2- 33 PRECAUTIONS WHEN USING HAMMER 2- 34 REPAIR WELDING 2- 34 REMOVING BATTERY TERMINAL 2- 34 PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 34 PRECAUTIONS FOR HIGH-PRESSURE FUEL 2- 34 HANDLING HIGH-PRESSURE HOSES, PIPING 2- 35 PRECAUTIONS FOR HIGH VOLTAGE 2- 35 WASTE MATERIALS 2- 35 MAINTENANCE OF AIR CONDITIONER 2- 35 COMPRESSED AIR 2- 35 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS 2- 36

PRECAUTIONS WITH TIRES 2- 37 HANDLING TIRES 2- 37 PRECAUTIONS WHEN STORING TIRE 2- 37

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SAFETY LABELS

SAFETY

SAFETY LABELS

The following warning signs and safety labels are used on this machine.

Be sure that you fully understand the correct position and content of labels. To ensure that the content of labels can be read properly, be sure that they are in the correct place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to peel off. There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way. If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

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SAFETY

POSITION FOR ATTACHING SAFETY LABELS

SAFETY LABELS

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SAFETY LABELS

(1) Caution for modification of ROPS/FOPS (09620-A2000)

(2) Caution for checking engine room (09667-A0880)

SAFETY

(3) Caution when releasing radiator cap (09653-A0641)

(4) Caution when releasing hydraulic tank cap (09653-A0641)

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SAFETY

(5) Caution when handling suspension (09659-A0641)

(6) Caution for handling accumulator (09659-A057B)

SAFETY LABELS

(7) Warnings for electric wire

Warnings for crush hazard when inspection and maintenance (56B-93-12980)

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SAFETY LABELS

(8) Cautions before starting

Cautions when traveling in reverse (569-93-61720)

SAFETY

(9) Caution when handling battery cable (09808-A1681)

(10) Exhaust pipe is hot! (09817-A1103)

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SAFETY

(11) Prohibited to enter (09162-C0881)

(12) Cation for articulate lock (09161-C0881)

SAFETY LABELS

(13)Precautions when handling battery

(The battery manufacturer sticks this caution plate on the battery. )

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SAFETY LABELS

(14) Caution for parking brake

(This plate is fixed in position by the chamber maker)

(15) Prohibited to jump start (09842-A0481)

(This plate is fixed to the starting motor)

SAFETY

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SAFETY

GENERAL PRECAUTIONS

SAFETY RULES

Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger. When working with another operator or with the person on the worksite traffic duty, discuss the content of the operation beforehand and use the determined signals when carrying out the operation.

IF PROBLEMS ARE FOUND

If you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

Do not wear loose clothing and accessories. There is a hazard that they may catch on dump lever or other protruding parts. If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught. Always wear a hard hat and safety shoes. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the machine. Check that all protective equipment functions properly before using it.

FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.

Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies. Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used. Provide a first aid kit in the storage point. Carry out periodic checks and add to the contents if necessary.

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GENERAL PRECAUTIONS

SAFETY FEATURES

Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition.

KEEP MACHINE CLEAN

If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean.

SAFETY

INSIDE OPERATOR'S COMPARTMENT

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious accident. Do not leave parts or tools lying around the operator's compartment. Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire. Do not use cellular telephones inside the operator's compartment when driving or operating the machine. Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

Before adjusting or standing up from the operator's seat, always set shift lever (1) to the N position and parking brake switch (2) to the PARKING position, then stop the engine. If the gear shift lever or dump lever are touched by mistake, there is danger that the machinemay suddenly move and cause serious personal injury or damage. When leaving the machine, always place shift lever(1) at neutral and set parking brake switch (2) to the PARKING position. Lower the dump body, set the dump lever to the HOLD position, and lock with the dump lever lock knob. Apply all the locks and always remember to take the key with you and keep it in the fixed place.

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SAFETY

HANDRAILS AND STEPS

To prevent personal injury caused by slipping or falling off the machine, always do as follows.

Use the parts marked by arrows in the diagram when getting on or off the machine. A: For getting on or off machine using left door B: For getting on or off machine using right door

GENERAL PRECAUTIONS

To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself. Do not grip the dump lever when getting on or off the machine. Never climb on the engine hood or covers where there are no non-slip pads. Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts. Do not get on or off the machine while holding tools in your hand.

MOUNTING AND DISMOUNTING

Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.

CRUSHING OR CUTTING PREVENTION

If the clearance at the articulating portion changes, it will lead to serious personal injury. Do not allow anyone to come inside the articulation range. The clearance in the area around the dump body changes according to the movement of the dump body. If you are caught, you will suffer serious injury. Do not allow anyone near any of the rotating or telescoping parts.

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GENERAL PRECAUTIONS

PREVENTION OF BURNS Hot coolant

To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Hot oil

To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation. Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.

SAFETY

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SAFETY

FIRE PREVENTION

Fire caused by fuel or oil

Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following:

Do not smoke or use any flame near fuel or oil. Stop the engine before refueling. Do not leave the machine while adding fuel or oil. Tighten all fuel and oil caps securely. Do not spill fuel on overheated surfaces or on parts of the electrical system. Use well-ventilated areas for adding or storing oil and fuel. Keep oil and fuel in the determined place and do not allow unauthorized persons to enter. After adding fuel or oil, wipe up any spilled fuel or oil. When carrying out grinding or welding work on the chassis, move any flammable materials to a safe place before starting. When washing parts with oil, use a non-flammableoil. Diesel oil and gasoline may catch fire, so do not use them. Put greasy rags and other flammable materials into a safe container to maintain safety at the work place. Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

GENERAL PRECAUTIONS

Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.

Fire coming from electric wiring

Short circuits in the electrical system can cause fire.

Always keep electric wiring connections clean and securely tightened. Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.

Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause serious injury. When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.

ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.

Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine.

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GENERAL PRECAUTIONS

WINDOW WASHER LIQUID

Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)

The operator's cab has a ROPS structure. In addition to supporting of the load if the machine tips over, it also absorbs the impact energy and protects the operator. If the function of ROPS is reduced, it cannot protect the operator and he may be injured. Always do the following.

Do not weld, drill holes, or make any other modification to the operator's cab structure. Repair or replace the operator's cab if it is deformed by falling objects or when the machine tips over. For details of repair,

please consult your Komatsu distributor. Even when the ROPS isinstalled, ifyou donot fastenyour seatbelt securely, it cannot protect you properly. Always fasten your seat belt when operating the machine.

SAFETY

PRECAUTIONS FOR ATTACHMENTS, OPTIONS

When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore

contact your Komatsu distributor for advice.

Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized

attachments or parts will not be the responsibility of Komatsu.

Always read the instruction manual for the attachment.

UNAUTHORIZED MODIFICATION

If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility. Before making any modifications, please consult your Komatsu distributor. Komatsu cannot take any responsibility for accidents, failures, or damage caused by modifications not authorized by Komatsu.

SAFETY AT WORKSITE

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do

not operate where there is a hazard of landslides or falling rocks.

Take necessary measures to prevent any unauthorized person from entering the operating area.

When traveling or operating in shallow water or onsoft ground,check the shape and condition of the bedrock, and

the depth and speed of flow of the water before starting operations.

Always design and maintain the roads on the jobsite so that the machines can travel safely.

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SAFETY

WORKING ON LOOSE GROUND

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas. When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.

Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

GENERAL PRECAUTIONS

Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations. To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body. Use a signalman to give warning if the machine approaches too close to the electric cables. When carrying out operations near high voltage cables, do not let anyone near the machine. If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the machine.

Voltage of Cables Safety Distance

100 V - 200 V Over 2 m (7 ft)

6,600 V Over 2 m (7 ft)

22,000 V Over 3 m (10 ft)

66,000 V Over 4 m (14 ft)

154,000 V Over 5 m (17 ft)

187,000 V Over 6 m (20 ft)

275,000 V Over 7 m (23 ft)

500,000 V Over 11 m (36 ft)

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GENERAL PRECAUTIONS

ENSURE GOOD VISIBILITY

This machine is equipped with mirrors to improve the visibility, but even with mirrors, there are places, which cannot be seen from the operator's seat, so always be careful when operating. When operating or traveling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area aroundthe machine, there is danger that the machine may sufferdamage orthe operator may suffer serious personal injury. When operating or traveling in places with poor visibility, alwaysobserve the following items strictly.

If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful attention to the signs and follow the instructions of the flagman. The signals should be given only by one flagman. When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set up additional lighting in the area. Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms. Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility. In areas where it is impossible to confirm the area behind the machine and observation cameras have been set up, clean off any dirt from the lens and make sure that the camera gives a clear view of the rear.

SAFETY

PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS

The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or machine must be operated inside a building or under ground, where the ventilation is poor, take steps to ensure that the engine exhaust gas is removed and that ample fresh air is brought in.

CHECKING SIGNALMAN'S SIGNALS AND SIGNS

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if

necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

Only one signalman should give signals.

Make sure that all workers understand the meaning of all signals and signs before starting work.

EMERGENCY ESCAPE FROM OPERATOR'S CAB

The cab installed on this machine has doors on the left and right sides. If the door on one side does not open,

escape through the door on the other side.

2 - 18

SAFETY

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust in theair can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste. Always observe the following.

Spray water to keep down the dust when cleaning. Do not use compressed air for cleaning. If there is danger that there may be asbestos dust in the air, always operate the machine from an upwind position. All workers should use an approved respirator. Do not allow other persons to approach during the operation.

Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts.

GENERAL PRECAUTIONS

2 - 19

PRECAUTIONS DURING OPERATION

STARTING ENGINE

If there is a warning tag hanging from the shift lever, do not start the engine or touch the levers.

SAFETY

CHECKS BEFORE STARTING ENGINE, ADJUST

Carry out the following checks before starting the engine at the beginning of the day's work.

Remove all dirt from the surface of the window glass to ensure a good view. Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and check that they light up correctly. Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. Check that there is no mud ordust accumulatedaround the movable parts of the acceleratorpedal or brake pedal, and check that the pedals work properly. Adjust the operator'sseat to a position whereit is easy to carry out operations, and check that there is no damage or wear to the seat belt or mounting clamps. Check that the gauges and instruments work properly, check the angle of the mirror, and check that the gearshift lever is at neutral and the dump lever is at HOLD. Before starting the engine, make sure that the dump lever lock knob is in the LOCK position. Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. Refer to "WALK-AROUND CHECK (PAGE 3-70)". Check that there are no persons or obstacles above, below, or in the area around the machine. Check that the parking brake switch is in the PARKING position.

PRECAUTIONS WHEN STARTING

Start and operate the machine only while seated. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. When starting the engine, sound the horn as a warning. If another person is allowed on the machine, that person may sit only in the assistant's seat. For machines equipped with a backup alarm, check that the warning device works properly.

2 - 20

SAFETY

PRECAUTIONS IN COLD AREAS

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the gear shift

lever or dump lever are operated, the reaction of the machine will be slow or may change suddenly, and this may

cause an accident.

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.

There is a hazard that this will ignite the battery and cause the battery to explode.

Before charging or starting the engine with a different power source, melt the battery electrolyte and check that

there is no leakage of electrolyte before starting.

PRECAUTIONS DURING OPERATION

2 - 21

PRECAUTIONS DURING OPERATION

SAFETY

OPERATION

CHECKS BEFORE STARTING OPERATION

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine.

Always fasten your seat belt. Check the operation of the steering, travel, and brake systems. Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel. If any problem is found, carry out repairs immediately. Before traveling or carrying out operations, check that articulation lock (1) is securely at the FREE position.

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles. Before travelling, sound the horn to warn people in the area. Always operate the machine only when seated. If another person is allowed on the machine, that person may sit only in the assistant's seat. Check that the backup alarm (backup warning buzzer) works properly. Always close the door and the window of the operator's compartment and check that the door lock is applied. If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other

machines or people when turning or swinging the machine. Always be sure to carry out the above precautions even when the machine is equipped with mirrors.

2 - 22

SAFETY

PRECAUTIONS WHEN TRAVELING

Do not load the dump body above the maximum payload. The brakes will lose their effect. Never turn the starting switch to the OFF position. It is dangerous if the engine stops when the machine is traveling, because the steering becomes heavy. Lower the dump body, setting the dump lever at FLOAT position, then travel. Never transport anyoneriding on the body or carry out any other operation besides the main use for the machine. This is dangerous. When traveling on rough ground, travel at low speed and avoid sudden changes in direction to prevent the machine from turning over. When traveling or carrying out operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them. When passing over bridges or structures, check first that the structure is strong enough to support the weight of the machine. When operating in tunnels, inside buildings, or under bridges or electric wires, or other places where the height is limited, operate slowly and be extremely careful not to let the machine or dump body contact anything. Continuous long time traveling at high speed may cause tires to heat up, abnormally increasing the inflation pressure inside the tires, and to blow up. The explosion of the tire is very destructive, and it can lead to serious injury or death. Contact with your Komatsu distributor before doing long continuous traveling. Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a slope. Always place the transmission in gear before traveling.

If the transmission is in Neutral, the engine cannot provide any braking effect and the steering wheel will become heavier. In addition, there will be lack of cooling oil for the retarder, so there is danger that it will overheat or that the actuation of the brake will be poor. There may also be damage to the transmission or other parts of the power train, and there is danger of unexpected accidents.

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side, always do as follows.

When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly. Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that the machine may slip. If the engine should stop on a slope, apply the brakes fully and apply the parking brake also to stop the machine. Do not shift gear while traveling downhill or travel downhill with the transmission in neutral. It is dangerous if the engine has no braking effect. Always set the transmission to a lower gear before starting to travel downhill.

2 - 23

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN OPERATING DUMP BODY

Before starting the dumping operation, check to be sure there is no person or object behind the machine.

Stop the machine in the correct position, and check again that there is no person or object behind the machine.

Give the determined signal, then slowly operate the dump body.

If necessary, use blocks for the wheels or position a flagman.

Do not carry out dumping operations on slopes. The machine stability will become poor and there is the danger

that it could tip over.

Do not travel with the body raised.

Do not leave or return to the operator's seat during loading work.

When carrying out dumping operations, set the machine facing straight forward. If dumping operations are

carried out with the machinearticulated, the stability of the machine will be reduced and there is danger that it may

tip over.

When the dump body is raised, the center of gravityof the machine moves continuously. At this time, if the ground

is soft, the stability of the machine changes. Take care.

Take care particularly when dumping sticky material(wet clay, frozen material, etc.) on a soft ground. The stability

of the machine is reduced and there is danger that it may tip over.

PRECAUTIONS WHEN OPERATING

When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to the

dump body, do not exceed the performance or maximum load specified for the machine structure.

When operating in tunnels, or under bridges or electric wires, or in other places where the height is limited,

operate slowly and be extremely careful not to let the dump body contact anything.

To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for

operation, particular in confined spaces, indoors, and in places where there are other machines.

SAFETY

PRECAUTIONS FOR ACCUMULATED SNOW, ICE

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,

and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly

careful when working on slopes.

With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the

machine to tip over or make it impossible for the machine to escape.

If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful

not to leave the road shoulder or to get trapped in a snow drift.

When traveling on snow-covered roads, always fit tire chains.

When traveling on snow-covered roads, never use the foot brake to make sudden stops. Shift down to use the

engine brake and carry out double braking (depress the brake pedal several times) to stop the machine.

When the loaded materials in the dump body are frozen, do not dump. There is a danger that the machine could

tip over.

2 - 24

SAFETY

PARKING MACHINE

Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding.

When leaving the machine, always place shift lever(1) at neutral and set parking brake switch (2) to the PARKING position. Lower the dump body, set the dump lever to the HOLD position, lock with the dump lever lock knob, then stop the engine. Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place. If it is necessary to park the machine on a slope, set blocks under the wheels to prevent the machine from moving.

PRECAUTIONS DURING OPERATION

2 - 25

PRECAUTIONS DURING OPERATION

SAFETY

TRANSPORTATION

This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor.

LOADING AND UNLOADING

When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows.

Perform loading and unloading on firm, level ground only.

Maintain a safe distance from the edge of the road or cliff.

Always use ramps of adequate strength. Be sure that the ramps

are wide, long, and thick enough to provide a safe loading slope.

Take suitable steps to prevent the ramps from moving out of

position or coming off.

Be sure the ramp surface is clean and free of grease, oil, ice and

loose materials. Remove dirt from machine-tracks. On a rainy

day, in particular, be extremely careful since the ramp surface is

slippery.

Run the engine at low speed, drive the machine at low speed, and operate slowly.

Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the

ramps again.

When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and

grade.

After loading the machine, always lock the door. There is danger that the door may open during transportation.

For details, see "TRANSPORTATION (PAGE 3-115)".

SHIPPING

When shipping the machine on a trailer, do as follows.

The weight, transportation height, and overall length of the machine differ according to the attachment, so be sure

to confirm the dimensions.

When passing over bridges or structures on private land, check first that the structure is strong enough to support

the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their

instructions.

Lock the articulation lock to prevent the machine from articulating.

For details of the transportation procedure, see "TRANSPORTATION (PAGE 3-115)" in the Operation Section.

2 - 26

SAFETY

PRECAUTIONS DURING OPERATION

BATTERY

BATTERY HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.

Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line. When working with batteries, always wear safety glasses and rubber gloves. Never smoke or use any flame near the battery.

If you spill acid on your clothes or skin, immediately flush the area with large amount of water. If acid gets into your eyes, flush them immediately with large amount of water and seek medical attention.

Before working with batteries, turn the starting switch to the OFF position.

As there is a hazard that sparks will be generated, always do as follows.

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other metal objects lying around near the battery. Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the battery, connect the positive(+) terminalfirst, and connect the ground last. Tighten the battery terminalssecurely. Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it. Tighten the battery caps securely. Install the battery securely to the determined place.

2 - 27

PRECAUTIONS DURING OPERATION

STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows.

When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the operator's

seat and the other working with the battery).

When starting from another machine, do not allow the two

machines to touch.

When connecting the booster cables, turn the starting switch

OFF position for both the normal machine and problem

machine. There is a hazard that the machine will move when the

power is connected.

Be sure to connect the positive (+) cable first when installing the

booster cables. Disconnect the negative (-) cable (ground side)

first when removing them.

When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch the

machine.

Always wear safety glasses and rubbergloves whenstarting the

engine with booster cables.

When connecting a normal machine to a problem machine with

booster cables, always use a normal machine with the same

battery voltage as the problem machine.

For details of the starting procedure when using booster cables,

see "STARTING ENGINE WITH BOOSTER CABLE (PAGE

3-133)" in the OPERATION section.

SAFETY

2 - 28

SAFETY

PRECAUTIONS DURING OPERATION

TOWING

WHEN TOWING

When towing or being towed, mistakes in the method of selecting and inspecting the wire rope or drawbar, or in the method of towing may lead to serious personal injury. For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-127)"

Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed. Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing operation. Always wear leather gloves when handling wire rope. Never tow a machine on a slope. During the towing operation, never stand between the towing machine and the machine being towed.

2 - 29

PRECAUTIONS FOR MAINTENANCE

WARNING TAG

Attach the DO NOT OPERATE warning tag to shift lever in the

operator's cab during the inspection and maintenance. Attach

additional warning tags around the machine if necessary.

Warning tag Part No. 09963-03001

Keep the warning tag in the tool box when it is not used. If the

tool box is unavailable, keep it in the case for operation manual.

If any person other than the serviceman starts the engine, or

touches or operates the gear shift lever or dump lever while the

serviceman is carrying out service or maintenance of the

machine, it may lead to serious injury.

SAFETY

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. Always keep the work place clean and tidy to enable you to carry out operations safely.

If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.

APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the attachment, appoint a leader and follow his

instructions during the operation.

When working with others, misunderstandings between workers can lead to serious accidents.

2 - 30

SAFETY

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

Stop the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding.

Lower the dump body, set dump lever (1) to the HOLD position, lock with dump lever lock knob (2), then stop the engine.

PRECAUTIONS FOR MAINTENANCE

Set parking brake switch to the PARKING position and put blocks (3) under the tires to prevent the machine from moving.

2 - 31

PRECAUTIONS FOR MAINTENANCE

Lock with articulation lock (4) so that the machine that does not

articulate.

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent personal injury, do not carry out maintenance with the engine running. Ifmaintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.

One worker must always sit in the operator's seat and be ready

to stop the engine at any time. All workers must maintain

contact with the other workers.

Set dump lever (1) to the HOLD position, lock with dump lever

lock knob (2), then set parking brake switch (3) to the PARKING

position.

SAFETY

When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in

the parts, so be careful not to come close.

Do not touch the gear shift lever or dump lever. If the gear shift lever or dump lever must be operated, give a signal

to the other workers to warn them to move to a safe place.

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2 - 32

SAFETY

PROPER TOOLS

Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury.

HANDLING SUSPENSION CYLINDER, ACCUMULATOR

The suspension cylinders and accumulator are charged with high-pressure nitrogen gas. If any mistake is made in handling, it may cause serious personal injury. To prevent this, always follow the procedure below.

Do not remove or disassemble the cylinder. Do not bring it near flame or dispose of it in fire. Do not make holes in it, weld it, or use a cutting torch. Do not bear any shock by hammering, rolling or similar activity. Ask for your Komatsu distributor when sealing gas into the cylinder or releasing gas from it.

PRECAUTIONS FOR MAINTENANCE

PERSONNEL

Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.

WORK UNDER THE MACHINE

If it is necessary to go under the machine when it is raised in order to carry out service or maintenance, support the machine securely with blocks and stands strong enough to support the weight of the machine. When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the dump lever lock knob, then use the body pivot pin. For details of using the body pivot pin, see "BODY PIVOT PIN (PAGE 3-45)".

NOISE

When carrying out maintenance of the engine and you are exposedto noisefor longperiods of time, wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

2 - 33

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows.

If hard metal parts such as pins, and bearings are hit with a

hammer, there is danger that small pieces will fly off; this may

lead to seious injury. Wear protective glasses, hard hat, and

other protective equipment.

If pins are hit with a hammer, there is a hazard that the metal

particles may fly out and injure people in the surrounding area.

Always make sure that no-one is in the surrounding area before

using the hammer.

There is a hazard that the pin hit with strong force may fly out

and injure people in the surrounding area.

REPAIR WELDING

Welding operations must always be carriedout by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.

SAFETY

REMOVING BATTERY TERMINAL

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the battery to prevent the flow of current.

PRECAUTIONS WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious personal injury, so always do as follows.

For details of the method of releasing the pressure: see the section on "INSPECTION AND ADJUSTMENT". Do

not carry out any inspection or replacement operation before the pressure has been completely removed.

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping

and hoses and for swelling in the hoses.

When carry out inspection, wear safety glasses and leather gloves.

There is a hazard that high-pressure oil leaking from small holes

may penetrate your skin or cause blindness if it contacts your

eyes directly. If you are hit by a jet ofhigh-pressure oil and suffer

injury to your skin or eyes, wash the place with clean water, and

consult a doctor immediately for medical attention.

PRECAUTIONS FOR HIGH-PRESSURE FUEL

When the engine is running, high-pressure is generated in the engine fuel piping. When carrying out inspection or maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal pressure to go down before starting the operation.

2 - 34

SAFETY

HANDLING HIGH-PRESSURE HOSES, PIPING

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque.If anydamaged hoses are found, stop operations immediately and contact your Komatsu distributor.

Replace the hose if any of the following problems are found.

Damaged or leaking hydraulic fitting. Frayed or cut covering or exposed reinforcement wire layer. Covering swollen in places. Twisted or crushed movable portion. Foreign material embedded in covering.

PRECAUTIONS FOR HIGH VOLTAGE

When the engine is running or immediately after it has stopped, high voltage is generated at the injector terminal and inside the engine controller, so there is danger of electrocution. Never touch the injector terminal or the inside of the engine controller. If it is necessary to touch the injector terminal or the inside of the engine controller, please contact your Komatsu distributor.

PRECAUTIONS FOR MAINTENANCE

WASTE MATERIALS

To prevent pollution, pay careful attention to the method of disposing of waste materials.

Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.

MAINTENANCE OF AIR CONDITIONER

If air conditionerrefrigerant gets intoyour eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant.

COMPRESSED AIR

When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.

2 - 35

PRECAUTIONS FOR MAINTENANCE

PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS

In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service

and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship

to safety, such as hoses and seat belts, must be replaced at periodic intervals.

Replacement of safety-critical parts: See "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE

4-15)". The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval. Replace or repair safety-critical parts if any defect is found, even when they have not reached the specified replacement time.

SAFETY

2 - 36

SAFETY

PRECAUTIONS WITH TIRES

HANDLING TIRES

If tires or rims are handled mistakenly, there is danger that the tire may explode or be damaged, or that the rim may fly off and cause serious personal injury or death. To maintain safety, always do as follows.

Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations. Use only the specified tires and inflate them to the specified pressure. Suitable inflation pressure: see "SELECTION AND INSPECTION OF TIRES (PAGE 4-35)". When pumping up the tires, check that no other person is standing near the tire, and install an air chuck with a clip that can be secured to the air valve. To prevent the tire inflation pressure from becoming too high, measure the pressure from time to time with an air gauge while pumping up the tire. If the tire pressure goes down abnormally or the rim parts do not fit the tire, there is a problem with the tire or rim parts. Always contact your Komatsu distributor for repairs. If the rim parts are not fitted properly when the tire is being pumped up, there is danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand beside the tread when pumping up the tire. Do not adjust the tire inflation pressure immediately after traveling at high speed or carrying out operations under heavy load. Never carry out welding or light a fire near the tire.

PRECAUTIONS WHEN STORING TIRE

Tires for construction equipment are extremely heavy, so trying to hold the tire may lead to serious injury.

As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires must be stored outside, always erect a fence and put up "No Entry" signs. Stand the tire on level ground, and block it securely so that it cannot roll or fall over if any person should touch it. Do not lay the tire on its side. This will deform the tire and cause it to deteriorate. If the tire should fall over, do not attempt to stop it. Get out of the way quickly.

2 - 37

3 - 1

GENERAL VIEW

GENERAL VIEW OF MACHINE

OPERATION

Hydraulic tank

(1)

Dump body

(2)

Rear wheel

(3)

Hoist cylinder

(4)

Front wheel

(5)

3 - 2

Turn signal lamp

(6)

Head lamp

(7)

Air cleaner

(8)

Fuel tank

(9)

Fire extinguisher (if equipped)

(10)

OPERATION

GENERAL VIEW OF CONTROLS AND GAUGES

GENERAL VIEW

Dump lever

(1)

Lamp switch, Turn signal lever, Dimmer switch

(2)

Steering wheel

(3)

Machine monitor

(4)

Retarder control lever

(5)

Cigarette lighter

(6)

Shift lever

(7)

Parking brake switch

(8)

Accelerator pedal

(9)

Brake pedal

(10)

Dump lever lock knob

(11)

3 - 3

GENERAL VIEW

Enlargement of machine monitor

OPERATION

Machine monitor mode selector switch 2

(1)

Machine monitor mode selector switch 1

(2)

Fog lamp switch (if equipped)

(3)

Yellow rotating lamp switch (if equipped)

(4)

Side lamp switch (if equipped)

(5)

Switch for rear window glass with heated wire

(6)

Working lamp (front) switch

(7)

Night lighting dimmer switch

(8)

Hazard lamp switch

(9)

Emergency steering switch

(10)

Power mode selector switch

(11)

AISS LOW switch

(12)

Inter-axle differential lock switch

(13)

3 - 4

OPERATION

EXPLANATION OF COMPONENTS

The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays.

MACHINE MONITOR

Character display

Caution items

Emergency stop item

NOTICE When the engine starting switch is turned to the ON position before starting the engine, a system check is carried out for 3 seconds.

The central warning lamp lights up for 2 seconds, and then goes out. The alarm buzzer sounds for 2 seconds, and then stops. The monitor lamp lights up for 2 seconds and then goes out for 1 second. The shift indicator displays 88 for 2 seconds and then goes out for 1 second. After a 3-second system check, the meter starts to function. The character display shows "KOMATSU" for 3 seconds. If the lamps do not work, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection. When the starting switch is turned ON, if the shift lever is not at the neutral position, after completion of the system check, the shift lever position pilot lamp and the central warning lamp will light up, and the alarm buzzer will continue to sound intermittently. When this happens, if the shift lever is set at neutral, N is displayed, the central warning lamp goes out, and the buzzer stops.

D:E:Meter display portion

Central warning lamp

3 - 5

EXPLANATION OF COMPONENTS

OPERATION

Check central warning lamp, alarm buzzer, monitor lamps, and meters.

Before starting the engine, set the starting switch in the ON position and check that the machine monitor operates as follows.

The central warning lamp lights up for 2 seconds, then goes off. The alarm buzzer sounds for 2 seconds, then stops. The monitor lamps light up for 2 seconds, then go off for 1 second. The gearshift indicator displays "88" for 2 seconds, then goes off for 1 second. The meters start the operations after the system is checked for 3 seconds. The character display displays "KOMATSU" for 3 seconds.

If the machine monitor does not operate as explained above, there is probably a failure, so please contact your Komatsu distributor for inspection.

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OPERATION

CHARACTER DISPLAY

EXPLANATION OF COMPONENTS

The character display can display the following items.

(4)

Service meter

(1)

Odometer

(2)

Reverse travel odometer

(3)

Normally, the service meter/odometer is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action. When the time for replacing the filter or changing the oil is reached, after completion of the system check with the starting switch at the ON position, the maintenance monitor caution lamps flash or light up, and at the same time, the filter or oil to be replaced is displayed.

NOTICE Information regarding the failure of the machine or maintenance is displayed on the character display when the starting switch is at the ON position, check the display to confirm that there is no problem before starting to travel.

Action code display

(5)

Filter, oil replacement time display

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EXPLANATION OF COMPONENTS

SERVICE METER

This meter (1) shows the total time that the machine has been operating. While the engine is running, the servicemeter advanceseven if the machine is not moving. The meter advances by 1 for every hour of operation, regardless of the engine speed. Even if the starting switch is at the OFF position, the service meter will display as long as the top part () of machine monitor mode selector switch 1 is being pressed.

NOTICE When the starting switch is at the OFF position, if the service meter is displayed even though the top () of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection.

ODOMETER

This meter (2) indicates the total distance traveled in kilometers. Even when the starting switch is at the OFF position, while the top () of machine monitor mode selector switch 1 is being pressed, it indicates the total distance traveled.

OPERATION

NOTICE When the starting switch is at the OFF position, if the total distance is displayed even although the top () of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection.

REVERSE TRAVEL ODOMETER

This meter (3) indicates the total distance traveled in reverse in kilometers. For details of the method of displaying the total distance traveled in reverse, see "OTHER FUNCTIONS OF MACHINE MONITOR (PAGE 3-26)".

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OPERATION

ACTION CODE DISPLAY

EXPLANATION OF COMPONENTS

CAUTION

If action code E03 is displayed, stop themachine immediately. Then see"ACTION CODE(PAGE 3-140)" and contact yourKomatsu distributor for repairs.

If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed on this panel (4) to recommend suitable action. If more than one failure occurs at the same time, the most important action code is displayed. The order of importance, starting from the highest, is E03, E02, and E01. If failures of equal importance occur at the same time, the latest one is displayed. When action codes E02 or E03 occur, the alarm buzzer sounds intermittently and the central warning lamp lights up.

E03: When this code is displayed, stop the machine immediately,

check the failure code, and contact your Komatsu distributor for repairs.

REMARK

The top line of the character display displays "E03" and the bottom line displays "CHECK RIGHT NOW" and "CALL" in turn for 3 seconds each. The telephone number is displayed on the right of the "CALL" display. If the telephone number has not been set, there is a blank. For details of the method of setting the telephone number, see "INPUT METHOD FOR TELEPHONE NUMBER (PAGE 3-28)".

E02: If overrun related information is displayed, reduce the engine

speed and the speed of the machine while continuing operations. If the overheat related display is given, stop the machine and run the engine under no load at a mid-range speed. If an action code is still displayed after doing this, check the failure code and contact your Komatsu distributor for repairs.

REMARK

The top line of the character display displays "E02" and the bottom line displays the condition of the machine related to overrun or overheat.

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EXPLANATION OF COMPONENTS

E01: If maintenance location is displayed and the maintenance

caution lamp lights up, carry out inspection and maintenance of the displayed item after the completion of operations or when the shift changes. If "MAINTENANCE" is displayed together with E01, check the failure code and contact your Komatsu distributor for repairs.

REMARK

"E01" is displayed on the top line of the character display and "MAINTENANCE" or the part of the machine requiring inspection, filling of fluid, or replacement is displayed on the bottom line.

FILTER, OIL REPLACEMENT TIME DISPLAY

After completion of the system check, this display (5) shows for 30 seconds the filters and oil which are near the replacement interval. The maintenance caution lamp also flashes or lights up at the same time. After replacing the filter or changing the oil, reset the replacement interval. For details, see "RESET METHOD FOR FILTER, OIL REPLACEMENT TIME (PAGE 3-27)".

OPERATION

REMARK

The top line of the character display shows the name and ID number of the item needing replacement. The line at the bottom shows the remaining time until replacement and the total number of times the item has been replaced. After giving the display for 30 seconds, the display does not appear again until the starting switch is turned again to the ON position. If the action code is being displayed, the message in the diagram aboveis not displayed on the character display. If there two or more items to be displayed, they are displayed every three seconds. If there are more than 10 items to be displayed, all the items are displayed once each. The display is given when the time reaches 30 hours before the filter and oil replacement interval. When the replacement interval approaches, the maintenance caution lamp flashes, and if the replacement interval has passed, the lamp lights up.

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OPERATION

Items for display of filter, oil replacement time

EXPLANATION OF COMPONENTS

Item

Fuel prefilter 500 FUEL P FILT 41

Engine oil filter 500 ENG FILT 02

Engine oil 500 ENG OIL 01

Fuel main filter 1000 FUEL FILT 03

Corrosion resistor 1000 CORR RES 06

Transmission oil 1000 TM OIL 12

Transmission oil filter 1000 TM FILT 13

Brake oil filter 1000 BK OIL FILT 14

Brake cooling oil filter 1000 BK C FILT 16

Hydraulic filter 2000 HYD FILT 04

Differential case oil 2000 DIFF OIL 11

Final drive oil 2000 FNL OIL 08

Hydraulic oil 4000 HYD OIL 10

REMARK

See the section below for details of the procedure for replacing the filter and oil.

Fuel prefilter "REPLACE FUEL PREFILTER CARTRIDGE (PAGE 4-54)" Engine oil filter "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-53)" Engine oil "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-53)" Fuel main filter "REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-60)" Corrosion resistor "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-61)" Transmission oil "CHANGE OIL IN TRANSMISSION CASE (PAGE 4-63)" Transmission oil filter "REPLACE TRANSMISSION OIL FILTER ELEMENT - VALVE SIDE (PAGE 4-62)" Brake oil filter "CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT (PAGE 4-65)" Brake cooling oil filter "REPLACE TRANSMISSION OIL FILTER ELEMENT - BRAKE COOLING SIDE (PAGE 4-62)" Hydraulic filter "REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-73)" Differential case oil "CHANGE OIL IN DIFFERENTIAL CASE (PAGE 4-72)" Final drive oil "CHANGE OIL IN FINAL DRIVE CASE (PAGE 4-71)" Hydraulic oil "CHANGE OIL IN HYDRAULIC TANK (PAGE 4-77)"

Replacement

interval

Character display ID number

3 - 11

EXPLANATION OF COMPONENTS

CAUTION ITEMS

CAUTION

If the monitor lights up during travel, inspect the location of the problem quickly and take the necessary action.

OPERATION

Emergency steering pilot lamp

Seat belt caution lamp

(1)

Parking brake pilot lamp

(2)

Dump body pilot lamp

(3)

SEAT BELT CAUTION LAMP

This monitor (1) lights up if the seat belt is not fastened. There is danger when traveling, so always fasten your seat belt.

(4)

Fuel level caution lamp

(5)

Maintenance caution lamp

(6)

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OPERATION

PARKING BRAKE PILOT LAMP

This monitor (2) lights up when the parking brake is applied.

DUMP BODY PILOT LAMP

This monitor (3) lights up when the dump body is raised or the dump body lever is at any position other than "FLOAT".

After the starting switch has been turned to the ON position, the dump body is held in position regardless of the position of the dump lever, so when canceling, turn the lamp off (see "CANCELING DUMP BODY HOLD CONDITION (PAGE 3-88)" for details).

EXPLANATION OF COMPONENTS

EMERGENCY STEERING PILOT LAMP

This monitor (4) lights up when the emergency steering is actuated. If any abnormality should occur in the steering oil pressure circuit when the machine is traveling, the auto emergency steering is actuated and the related lamp lights up.

FUEL LEVEL CAUTION LAMP

This monitor (5) lights up when the level of the fuel remaining in the fuel tank goes below 57 liters (15.06 US gal). If it lights up, check the fuel level and add fuel.

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EXPLANATION OF COMPONENTS

MAINTENANCE CAUTION LAMP

This monitor (6) lights up if any of the the following are applicable. When it lights up, action code "E01" and the location needing maintenance are displayed on the character display at the same time, so carry out inspection, filling, or replacement.

Drop in engine oil level Clogged engine oil filter (if equipped) Drop in hydraulic oil level (if equipped) Clogged air cleaner Clogged hydraulic filter (if equipped) Clogged transmission oil filter Drop in engine cooling water level Clogged brake cooling oil filter (if equipped)

REMARK

In addition to the above, if the filter or oil replacement time is displayed on the character display, the lamp will flash or light up.

OPERATION

3 - 14

OPERATION

EXPLANATION OF COMPONENTS

EMERGENCY STOP ITEM

CAUTION

If the monitor lights up, stop operations immediately, then check the corresponding area and carry out the action.

If any problem is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor for the location of the problem and the central warning lamp will light up.

Brake oil pressure caution lamp

Engine water temperature caution lamp

(1)

Torque converter oil temperature caution lamp

(2)

Retarder oil temperature caution lamp

(3)

Battery charge circuit caution lamp

(4)

Steering oil temperature caution lamp

(5)

Engine oil pressure caution lamp

(6)

ENGINE WATER TEMPERATURE CAUTION LAMP

This monitor (1) warns the operator that the engine coolant temperature has risen. When it lights up, "E02 ENGINE OVERHEAT" is displayed on the character display at the same time, and the engine output is automatically limited. Run the engine under no load at a mid-range speed until the lamp goes out.

(7)

Tilt caution lamp

(8)

Machine monitor, option system caution lamp

(9)

Engine system caution lamp

(10)

Transmission system caution lamp

(11)

Retarder system caution lamp

(12)

3 - 15

EXPLANATION OF COMPONENTS

TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP

This monitor (2) warns the operator that the torque converter oil temperature has risen. When it lights up, "E02 TC OVERHEAT" is displayed on the character display at the same time, so stop the machine in a safe place, set the shift lever to the N position, and run the engine under no load at a mid-range speed until the lamp goes out.

RETARDER OIL TEMPERATURE CAUTION LAMP

This monitor (3) warns the operator that the brake oil temperature has risen. When it lights up, "E02 BRAKE OVERHEAT" is displayed on the character display at the same time , so stop the machine in a safe place, set the shift lever to the N position, and run the engine under no load at a mid-range speed until the lamp goes out.

OPERATION

BATTERY CHARGE CIRCUIT CAUTION LAMP

This monitor (4) lights up when the engine is running to warn the operator of a problem in the charging system. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and check the charging circuit.

STEERING OIL TEMPERATURE CAUTION LAMP

This monitor (5) lights up to warn the operator that the steering oil temperature has risen. When it lights up, "E02 STRG OVERHEAT" is displayed on the character display at the same time, so stop the machine in a safe place, set the shift lever to the N position, and run the engine under no load at a mid-range speed until the lamp goes out.

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OPERATION

ENGINE OIL PRESSURE CAUTION LAMP

This monitor (6) lights up to warn the operator that the engine lubricating oil pressure has dropped. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display, and the engine output is automatically limited. Stop the machine immediately at a safe place, thenstop theengine and carry out inspection.

The lamp lights up if the engine lubricating oil pressure goes below the specified value when the engine is running, If the engine is not running, the lamp does not light up.

BRAKE OIL PRESSURE CAUTION LAMP

This monitor (7) lights up to warn the operator that the brake oil pressure has dropped. The central warning lamp and alarm buzzer are not actuated when the engine is stopped. If the brake oil pressure is lower than the specified value 30 seconds after the engine has been started, "E03 CHECK RIGHT NOW" is displayed on the character display, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.

EXPLANATION OF COMPONENTS

TILT CAUTION LAMP

This monitor (8) lights up if the rear of the machine is tilted beyond the safety range to the left or right when the dump lever is at the RAISE position. Lower the body and move the machine to a safe place where the machine is stable.

MACHINE MONITOR, OPTION SYSTEM CAUTION LAMP

This monitor (9) lights up when a problem has been detected in the machine monitor or in the system for an installed option. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.

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EXPLANATION OF COMPONENTS

ENGINE SYSTEM CAUTION LAMP

This monitor (10) lights up when a problem has been detected in the system controlled by the engine controller. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.

TRANSMISSION SYSTEM CAUTION LAMP

This monitor (11) lights up when a problem has been detected in the system controlled by the transmission controller. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.

OPERATION

RETARDER SYSTEM CAUTION LAMP

This monitor (12) lights up when a problem has been detected in the system controlled by the retarder controller. When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, so stop the machine immediately at a safe place, then stop the engine and carry out inspection.

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OPERATION

EXPLANATION OF COMPONENTS

METER DISPLAY PORTION

PILOT DISPLAY PORTION

When the starting switch is ON, the pilot display lights up when the display items are functioning.

Head lamp high beam pilot lamp

Engine pre-heating pilot lamp

(1)

Retarder pilot lamp

(2)

Inter-axle differential lock pilot lamp

(3)

Lock-up pilot lamp

(4)

Shift hold pilot lamp

(5)

ENGINE PRE-HEATING PILOT LAMP

This monitor (1) lights up when the electrical heater for pre-heating the engine is being actuated. When the starting switch is turned to the ON position in cold weather, the monitor lights up. It goes out after 20 to 30 seconds to indicate that the pre-heating has been completed.

(6)

Turn signal pilot lamp

(7)

Shift indicator

(8)

Shift lever position pilot lamp

(9)

Power mode pilot lamp

(10)

3 - 19

EXPLANATION OF COMPONENTS

RETARDER PILOT LAMP

This monitor (2) lights up when the retarder control lever is pulled and the retarder is actuated.

INTER-AXLE DIFFERENTIAL LOCK PILOT LAMP

This monitor (3) lights up when the inter-axle differential lock is actuated.

OPERATION

LOCKUP PILOT LAMP

This pilot lamp (4) lights up when the torque converter lockup is engaged and the transmission is shifted to direct drive.

SHIFT HOLD PILOT LAMP

This monitor (5) lights up when the shift hold switch is actuated.

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OPERATION

HEAD LAMP HIGH BEAM PILOT LAMP

This monitor (6) lights up when the head lamps are set to high beam.

TURN SIGNAL PILOT LAMP

This pilot lamp (7) flashes at the same time as the turn signal lamp flashes.

EXPLANATION OF COMPONENTS

SHIFT INDICATOR

This monitor (8) shows the transmission shift range (speed range).

SHIFT LEVER POSITION PILOT LAMP

This monitor (9) displays the position of the shift lever. The letter or number for the speed range selected by the shift lever lights up.

3 - 21

EXPLANATION OF COMPONENTS

POWER MODE PILOT LAMP

This monitor (10) displays the power mode. When the mode is selected with the power mode selector switch, either High Power (P) or Economy (E) lights up.

OPERATION

3 - 22

OPERATION

METERS

EXPLANATION OF COMPONENTS

Engine water temperature gauge

Speedometer

(1)

Engine tachometer

(2)

Fuel gauge

(3)

SPEEDOMETER

This meter (1) indicates the travel speed of the machine.

ENGINE TACHOMETER

This meter (2) shows the engine speed. If the gauge indicator the red range during operations, the alarm buzzer will sound and the central warning lamp will light up at the same time, so reduce the engine speed and the machine travel speed.

(4)

Torque converter oil temperature gauge

(5)

Retarder oil temperature gauge

(6)

3 - 23

EXPLANATION OF COMPONENTS

FUEL GAUGE

This meter (3) shows the amount of fuel remaining in the fuel tank. When the fuel level caution lamp lights up, it indicates that there is less than 57 liters (15.06 US gal) of fuel remaining in the tank, so check and add fuel.

ENGINE WATER TEMPERATURE GAUGE

This meter (4) indicates the engine water temperature. It should be in the white range during operation. If it is in the red range during operation, the alarm buzzer will sound and the central warning lamp will light up at the same time. "E02 ENGINE OVERHEAT" is displayed on the character display, so run at the engine under no load at a mid-range speed and wait until the meter enters the white range. If it is in the red range, the engine output is automatically limited.

OPERATION

TORQUE CONVERTER OIL TEMPERATURE GAUGE

This meter (5) indicates the torque converter oil temperature. It should be in the white range during operation. If it is in the red range during operation, the alarm buzzer will sound and the central warning lamp will light up. "E02 TC OVERHEAT" is displayed on the character display, so run the engine under no load at a mid-range speed and wait until the meter enters the white range.

RETARDER OIL TEMPERATURE GAUGE

This meter (6) indicates the retarder oil temperature. It should be in the white range during operation. If it is in the red range during operation, the alarm buzzer will sound and the central warning lamp will light up at the same time. "E02 BRAKE OVERHEAT" is displayed on the character display, so stop the machine in a safe place, set the shift lever to the N position, run the engine under no load at a mid-range speed and wait until the lamp goes out.

3 - 24

OPERATION

CENTRAL WARNING LAMP

If the machine is in the following condition, this lamp will flash, and at the same time, the alarm buzzer will sound intermittently.

When a problem has occurred in any of "EMERGENCY STOP ITEM (PAGE 3-15)". When action code "E02" or "E03" is displayed on the character display. If the parking brake is applied, but the shift lever is not at the N position. When the dump lever is not at the FLOAT position or the dump body is raised and the shift lever is not at the N position. When the engine tachometer indicates the red range.

EXPLANATION OF COMPONENTS

3 - 25

EXPLANATION OF COMPONENTS

OPERATION

OTHER FUNCTIONS OF MACHINE MONITOR

DISPLAY METHOD FOR REVERSE TRAVEL ODOMETER

Use this when checking the total travel distance in reverse.

Check that the character display is showing the service meter/odometer, or the action code. If it is giving any

1. other display, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display to be given. Press the () of machine monitor mode selector switch 1. It

2. displays the overall distance traveled in reverse. When completing the operation, press () of machine monitor

3. mode selector switch 1 or turn the starting switch OFF.

3 - 26

OPERATION

EXPLANATION OF COMPONENTS

RESET METHOD FOR FILTER, OIL REPLACEMENT TIME

The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time.

1. Press the () of machine monitor mode selector switch 1, and display the reverse travel in odometer.

Press (>) or (<) of machine monitor mode selector switch 2 and

display "MAINTENANCE MONITOR".

Press the () of machine monitor mode selector switch 1. It

will change to the display in the diagram on the right. The bottom line shows two items: the replacement time on the left and the total number of times the item has been replaced on the right. Press (>) or (<) of machine monitor mode selector switch 2 and

display the item to be reset.

5. Press the () of machine monitor mode selector switch 1. It

will change to the display in the diagram on the right. The top line shows [Reset] and [Item to be reset] in turn.

6. When resetting the replacement time, press (>) or (<) of

machine monitor mode selector switch 2, align the cursor with "YES", then press () of machine monitor mode selector switch 1. It will reset and returned to the previous screen. To abandon, align the cursor with "NO", then press () of machine monitor mode selector switch 1.

When resetting the replacement time for another item, carry out the procedure from Step 4. After completing,

press () of machine monitor mode selector switch 1 twice or turn the starting switch OFF.

3 - 27

EXPLANATION OF COMPONENTS

INPUT METHOD FOR TELEPHONE NUMBER

When an error for action code "E03" occurs, it is possible to display the telephone number.

1. Press the () of machine monitor mode selector switch 1 and display the reverse travel odometer. Press (>) or (<) of machine monitor mode selector switch 2 and

2. display "TEL".

Press () of machine monitor mode selector switch 1. It will

3. change to the display in the diagram on the right.

Once the telephone number is input, the input number will be displayed next time.

OPERATION

Up to 12 digits can be displayed for the telephone number.

4. Input from the first digits. The cursor is displayed at the input position. Press (>) or (<) of machine monitor mode selector switch 2 and display "0 - 9 ". To leave a blank, select "*". When the input valueis decided, press () of machinemonitor mode selector switch 1. The cursor will move to the next position. Repeat the procedure in Step 4 until the last digit. At the last digit, press () of machine monitor mode selector

5. switch 1 to return to the previous screen. If there is a mistake in the input or the input is to be stopped, press () of machine monitor mode selector switch 1 to return to the previous screen. When completing the operation, press () of machine monitor mode selector switch 1 twice or turn the starting

6. switch OFF.

3 - 28

OPERATION

EXPLANATION OF COMPONENTS

METHOD FOR SELECTING LANGUAGE

Use this when switching the language displayed on the character display.

1. Press the () of machine monitor mode selector switch 1 and display the reverse travel odometer.

Press (>) or (<) of machine monitor mode selector switch 2 and

display "LANGUAGE".

Press the () of machine monitormode selector switch 1. The

presently selected language is displayed. Press (>) or (<) of machine monitor mode selector switch 2 and

select the language.

The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.

When the () of machine monitor mode selector switch 1 is pressed, the language is set and the screen returns

to the previous screen.

6. When completing the operation, press () of machine monitor mode selector switch 1 twice or turn the starting

switch OFF.

3 - 29

EXPLANATION OF COMPONENTS

SWITCHES

OPERATION

Starting switch

(1)

Lamp switch

(2)

Turn signal lever Dimmer switch Hazard lamp switch

(3)

Night lighting dimmer switch

(4)

Power mode selector switch

(5)

Emergency steering switch

(6)

Shift hold switch

(7)

Parking brake switch

(8)

AISS LOW switch

(9)

Inter-axle differential lock switch

(10)

Fog lamp switch (if equipped)

(11)

Side lamp switch (if equipped)

(12)

Working lamp (front) switch

(13)

Switch for rear window glass with heated wire

(14)

Yellow rotating lamp switch (if equipped)

(15)

Power window switch (right) (if equipped)

(16)

Power window switch (left)

(17)

Machine monitor mode selector switch 1, 2

(18)

Cigarette lighter

(19)

Horn button

(20)

Wiper, window washer switch

(21)

Room lamp switch

(22)

3 - 30

OPERATION

STARTING SWITCH

This switch (1) is used to start or stop the engine.

OFF position : At this position, the starting switch key can be inserted or removed. When the key is turned to this position, all the electric circuits are switched off and the engine stops.

ON position : In this position, electric current flows in the charging and lamp circuits. Keep the starting switch key at the ON position while the engine is running. When turning the starting switch ON or OFF, if the starting switch is held at a position between ON and OFF, the controller may detect this as a problem. If this happens, return the starting switch to the OFF position, then operate it as usual to the ON position.

EXPLANATION OF COMPONENTS

In cold weather, if the starting switch is turned to the ON position, pre-heating is automatically started and the engine pre-heating pilot lamp lights up. After the pre-heating is completed, the engine pre-heating pilot lamp goes out.

START position : This is theposition to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to the ON position when released.

LAMP SWITCH

This switch (2) lights up the head lamps, side clearance lamps, tail lamps, machine monitor lighting, and rear lamps. Position (a): OFF Position (b): Side clearance lamps, tail lamps, real lamps, and

machine monitor lighting light up Position (c): Front lamps light up in addition to lamps at position (b) The lamp switch can be operated regardless of the position of the lever.

TURN SIGNAL LEVER

This lever (2) operates the turn signal lamp. (a)Right turn: Push the lever forward (b)Left turn: Push the lever back When the lever is operated, the turn signal pilot lamp also flashes. The lever is automatically returned when the steering wheel is turned back. If the lever does not return, move it by hand.

3 - 31

EXPLANATION OF COMPONENTS

DIMMER SWITCH

This switch (2) is used to switch the head lamps between high beam and low beam. Each time switch (2) is moved up in direction (a), the head lamps switch between high beam and low beam. When the switch is released, it automatically returns to its original position (b). When the lamp switch is OFF, if the switch is operated in direction (a), the head lamps light up at the high beam position.

HAZARD LAMP SWITCH

This switch (3) is used to make the left and right turn signal indicators flash. (a): OFF (b): Turn signal lamp and turn signal pilot lamp flash

OPERATION

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

NIGHT LIGHTING DIMMER SWITCH

This switch (4) is used to adjust the brightnessof the lighting inside the machine monitor and the pilot lamp display. Turn it to the right to make the display brighter; turn it to the left to make the display dimmer.

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OPERATION

POWER MODE SELECTOR SWITCH

This switch (5) is used to switch the power mode. This makes it possible to travel economically in a way suited to the operating conditions. If portion (a) of the switch is pressed, high-power mode pilot lamp (P) lights up and the system is switched to the high-power mode. If portion (b) of the switch is pressed, economy mode pilot lamp (E) lights up and the system is switched to the economy mode.

(a): High power mode (general operations)

Normal standard operating conditions

(b): Economy mode (operations on flat ground)

Work with emphasis on fuel consumption, such as work on flat ground where the maximum power is not needed

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

EMERGENCY STEERING SWITCH

This switch (6) 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 and the pilot lamp on the machine monitor light up.

EXPLANATION OF COMPONENTS

The emergency steering pump can be used for a maximum of 90 seconds. When the emergency steering is beingused, keepthe travel speed to a maximum of 5 km/h (3.1 MPH). The emergency steering is actuated automatically in the following cases.

When the steering hydraulic pump fails When the engine has stopped during operation

When the emergency steering is actuated, stop the machine promptly and perform inspection.

If the starting switch is at the ON position and the parking brake switch is at the TRAVEL position when the machine is stopped, the automatic emergency steering is actuated after 1 second, so set the parking brake switch to the PARKING position.

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EXPLANATION OF COMPONENTS

SHIFT HOLD SWITCH

This switch (7) actuates the gearshift limiter. Activating the shift hold function will restrict the automatic shifting of the transmission to gear speeds below the gearshift lever gear shifting. The shift hold function can be canceled by [1] moving the gearshift lever or [2] activating the shift hold switch located on the gearshift lever. The shift hold pilot lamp located on the machine instrument panel will indicated the status of the shift hold function. Before starting either up or down a range, pre-select the transmission gear and maintain a machine travel speed which will give you full control under all the anticipated conditions.

When the machine is running, the transmission may cause hunting (a repetition of shifting up and shifting down in a short span of time), depending on the road condition, load condition and slope grade. In that case, press the shift hold switch and run, holding a low gear speed, in order to protect the transmission as well as to ensure operator's comfortability.

OPERATION

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OPERATION

PARKING BRAKE SWITCH

EXPLANATION OF COMPONENTS

WARNING

When parking or leaving the machine, always apply the parking brake.

This switch (8) is used to actuate and release the parking brake valve.

(a): Parking

The parking brake is applied.

(b): Travel

The parking brake is released.

When the switch is set to the PARKING position, the parking brake pilot lamp lights up. When the switch is set to the PARKING position, if the shift lever is at any position other than N, the central warning lamp will flash and the alarm buzzer will sound. If the pressuresaved in the accumulatordrops and goes below 5.4 MPa {55 kg/cm2, 781 PSI}, the brake and parking brake are automatically applied. For details of the method of releasing the brake, see "WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY (PAGE 3-130)".

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

REMARK

If the engine is stopped with the parking brake switch at TRAVEL, the parking brake will be applied automatically even though the parking brake switch is at TRAVEL. When starting the engine again, operate the parking brake switch to PARKING, and then move it back to TRAVEL to cancel the parking brake.

NOTICE During loading operations, do not apply the parking brake. Apply the retarder brake.

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EXPLANATION OF COMPONENTS

AISS LOW SWITCH

Using this switch (9), it is possible to switch the AISS freely between AUTO and LOW. Use each position as follows.

(a): AUTO position

For normal operations

(b): LOW position

When fine control of the machine is needed, such as when putting it into a garage.

If the switch is at AUTO position:

When stopping the machine, if the parking brake or retarder brake are operated, the idling is automatically adjusted to low speed; when starting the machine, if the parking brake is canceled, the idling is automatically adjusted to high-speed. The water temperature is detected, and when it is at low temperature, the idle is automatically adjusted to high speed to reduce the warming-up time.

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

OPERATION

INTER-AXLE DIFFERENTIAL LOCK SWITCH

This switch (10) can be used to switch the actuating conditions for the inter-axle differential lock. When this switch is pressed, the system is switched to MANUAL. When the switch is not pressed or is pressed to return it, the system is switched to AUTO.

AUTO: The slippage of the front axle is detected and the inter-axle

differential lock is automatically actuated.

MANUAL: When the shift lever is at the F3, F2, F1, N, R1, or R2

position, the inter-axle differential lock is actuated.

Regardless of the position of the switch, when the differential lock is actuated, the inter-axle differential lock pilot lamp lights up.

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

For details when using the differential lock, see "OPERATION USING DIFFERENTIAL LOCK (PAGE 3-103)".

FOG LAMP SWITCH

(If equipped) This switch (11) is used to switch on the fog lamp.

(a): Fog lamp goes out (b): Fog lamp lights up

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

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OPERATION

SIDE LAMP SWITCH

(If equipped) This switch (12) is used to switch on the side lamp.

(a): Side lamp goes out (b): Side lamp lights up

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

WORKING LAMP (FRONT) SWITCH

This switch (13) is used to switch on the working lamp (front).

(a): Working lamp goes out (b): Working lamp lights up

EXPLANATION OF COMPONENTS

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

SWITCH FOR REAR WINDOW GLASS WITH HEATED WIRE

Use this switch (14) to turn the heater for the rear glass ON/OFF. (a): Wire heater OFF (b): Wire heater ON

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

REMARK

The wire heater does not automatically turn OFF when it becomes hot, so when it is not needed, turn the switch manually to the OFF position.

YELLOW ROTATING LAMP SWITCH

(If equipped) This switch (15) is used to switch the yellow rotating lamp on and off. When the lamp is switched on, it lights up and rotates.

(a): Yellow rotating lamp goes out (b): Yellow rotating lamp lights up

When working at night, the symbol inside the switch lights up regardless of the selected position of the switch.

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EXPLANATION OF COMPONENTS

POWER WINDOW SWITCH (RIGHT) (LEFT)

(The right power window is optional.)

OPERATION

WARNING

When closing the window glass, be careful not to get anyone's hands or head caught. There is danger of serious injury if anyone is caught in the window glass.

CAUTION

After fully opening or fully closing the window glass, release the switch immediately. If the switch is kept operated, it may cause failure of the power window.

Switches (16) and (17) are used to open and close the window glass. The switches can only be used when the starting switch is at the ON position.

(A): Glass goes down (B): Glass goes up

When the glass reaches the top or bottom and stops, release the switch.

MACHINE MONITOR MODE SELECTOR SWITCH 1, 2

This switch (18) is used to operate the character display.

CIGARETTE LIGHTER

This switch (19) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, then pull it out and use it to light your cigarette.

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OPERATION

HORN BUTTON

When the horn button (20) in the center of the steering wheel is pressed, the horn will sound.

WIPER, WINDOW WASHER SWITCH

This switch (21) is used to operate the wiper for the front glass and rear glass. Using the wiper when the glass is dry will scratch the glass. Spray with window washer fluid before actuating the wiper. Front wiper Position (a) (OFF): Stopped Position (b) (INT): Wiper moves once every 4 to 7 seconds Position (c) (LOW): Wiper moves at low speed Position (d) (Hi): Wiper moves at high speed

EXPLANATION OF COMPONENTS

When the button at the tip of the switch is pressed, washer fluid is sprayed out. Do not keep the button pressed for more than 10 seconds.

Rear wiper Position (a): Washer fluid is sprayed out Position (b) (OFF): Stopped Position (c): Wiper is actuated Position (d): Wiper is actuated and washer fluid is sprayed out

ROOM LAMP SWITCH

The switch (22) is used to turn the room lamp ON and OFF. Position (a): OFF Position (b): Lights up when the door opens Position (c): Lights up

REMARK

The room lamp lights up even when the main switch is OFF, so when leaving the operator's seat, set the switch to position (a) or (b). When carrying out operations with the door fully opened, set the switch to position (a) (OFF).

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EXPLANATION OF COMPONENTS

CONTROL LEVERS AND PEDALS

OPERATION

Brake pedal

(1)

Accelerator pedal

(2)

Shift lever

(3)

BRAKE PEDAL

This pedal (1) is used to apply the wheel brakes.

Dump lever

(4)

Retarder control lever

(5)

Dump lever lock knob

(6)

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OPERATION

ACCELERATOR PEDAL

This pedal (2) is used to adjust the engine speed. It can be operated freely between the engine low idle position and the full throttle position.

GEAR SHIFT LEVER

The gear range can be selected with this lever (3) to match the travel conditions.

Position D: This is used when traveling normally. When this position is used, the transmission is set automatically between the 2nd torque converter drive and 6th gear according to the travel speed. While the dump body is raised, however, the transmission is fixed to the 2nd gear and is not changed. Keep the dump body lowered during travel. The maximum travel speed in this position is 58.6 km/h (36.4 MPH).

EXPLANATION OF COMPONENTS

REMARK

In conformity with the EU safety rule (EN474-6 5.1.3), the gear shift lever is restricted to the 2nd speed and cannot be shifted in the D position, when the machine is running while the dump body is not fully lowered to its seat.

Position R1: This is used when traveling in reverse. When this position is used, the transmission is fixed in R1 and the travel is carried out in torque converter drive or direct drive according to the travel speed. The maximum travel speed in this position is 7.6 km/h (4.7 MPH).

Position R2: This is used when traveling in reverse. When this position is used, the transmission is fixed in R2 and the travel is carried out in torque converter drive or direct drive according to the travel speed. The maximum travel speed in this position is 18.1 km/h (11.2 MPH). The machine cannot travel in reverse while the dump body is raised. Lower the dump body and set the dump lever in the "FLOAT" position, and then set it in the "R1" or "R2" position.

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EXPLANATION OF COMPONENTS

5 - 1 position: These positions are used in places where it is difficult to travel at high speed, or when traveling on soft ground, or when starting the machine off on a slope when it is loaded. They are also used when going downhill if it is needed to use the braking force of the engine. While the dump body is raised, the transmission is fixed to the 1st gear and is not changed. Keep the dump body lowered during travel.

REMARK

In conformity with the EU safety rule (EN474-6 5.1.3), the gear shift lever is restricted to the 1st speed and cannot be shifted if it is anywhere between 1 to 5 positions, when the machine is running while the dump body is not fully lowered to its seat.

The speed ranges for each position are as follows.

Position Speed range Max. speed [km/h (MPH)]

R2 R2nd torque converter - direct 18.1 (11.2)

R1 R1st torque converter - direct 7.6 (4.7)

D 2nd torque converter - 6th direct 58.6 (36.4)

5 1st torque converter - 5th direct 38.4 (23.9)

4 1st torque converter - 4th direct 25.5 (15.8)

3 1st torque converter - 3rd direct 16.2 (10.1)

2 1st torque converter - 2nd direct 10.7 (6.6)

1 1st torque converter - 1st direct 6.8 (4.2)

OPERATION

When operating the shift lever, be sure to set it in position securely. If the lever is not placed in position properly, the shift position display on the panel may go out and the Transmission system caution lamp may light up. Before shifting between forward and reverse, stop the machine completely and then run the engine at low idle. When starting the engine, if the shift lever is not at the N (neutral) position, the engine will not start. When the starting switch is at the ON position, if theshift lever is not at the N (neutral) position, theshift lever position pilot lamp will flash, the central warning lamp will light up, and the alarm buzzer will sound.

If the parking brake is applied or the shift lever is not at the N (neutral) position, the central warning lamp will light up and the alarm buzzer will sound.

If the shift lever is set to any position other than N (neutral) when the dump lever is at a position other than FLOAT or the body is still raised, the central warning lamp will light up and the alarm buzzer will sound.

The shift lever must not be returned to the N (neutral) position while traveling.

Release the accelerator pedal and run the engine at low idle when moving the shift lever from the N position to the forward or reverse position.

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OPERATION

When moving the shift lever from the N (neutral) position to the R1 (reverse) position or from the N position to the D position, press the lock button on the shift lever before operating it.

Activating the shift hold function will restrict the automatic shifting of the transmission to gear speeds below the gearshift lever gear shifting. The shift hold function can be canceled by [1] moving the gearshift lever or [2] activating the shift hold switch located on the gearshift lever. The shift hold pilot lamp located on the machine instrument panel will indicated the status of the shift hold function. Before starting either up or down a range, pre-select the transmission gear and maintain a machine travel speed which will give you full control under all the anticipated conditions.

EXPLANATION OF COMPONENTS

DUMP LEVER

CAUTION

To prevent damage to the dump body through vibration from the road surface, always lower the dump body before traveling.

This lever (4) is used to operate the dump body. (a) RAISE (b) HOLD: The dump body stops and is held in position. (c) FLOAT: The dump body moves freely under external force. (d) LOWER Always set to the FLOAT position when traveling.

It is impossible to travel in reverse if the dump body is raised. If the engine stops during the dump operation, the dump body is held in position, regardless of the position of the dump lever. Even when the engine starts again, the dump body is held in position. For details of the method of canceling the hold function, see "CANCELING DUMP BODY HOLD CONDITION (PAGE 3-88)".

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EXPLANATION OF COMPONENTS

RETARDER CONTROL LEVER

CAUTION

The retarder must not be used as a parking brake.

Use this lever (5) to operate the retarder when traveling downhill. The more the lever is pulled, the greater the braking force becomes. When the retarder is operated, the retarder operation lamp lights up.

When leaving the operator's seat, always apply the parking brake.

DUMP LEVER LOCK KNOB

WARNING

When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the dump lever lock knob, then use the body pivot pin.

OPERATION

This device (6) is used to lock the dump lever.

To set to the FREE position, pull the lock knob upuntil it stops, then turn it to lock it in position. To set to the LOCK position, pull the lock knob up, then turn it to release the lock. The knob will be pushed in by the force of the spring, and the lock will be applied. After doing this, check that the dump lever is locked.

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OPERATION

EXPLANATION OF COMPONENTS

BODY PIVOT PIN

WARNING

When carrying out inspection of the machine with the dump body raised, always set the dump lever to the HOLD position, lock with the dump lever lock knob, then use the body pivot pin.

This is a safety device for the dump body, and is used when carrying out inspection or maintenance with the dump body raised. Raise the dump body fully, insert body pivot pins (1). Always insert the body pivot pins on both sides.

STOWING BODY PIVOT PIN

Store the body pivot pin under the rear of the dump body. Insert body pivot pin (1), then insert lock pin (2) to stow the body pivot pin.

ARTICULATE LOCK

WARNING

If the machine is transported or raised without applying the articulation lock, the machine may suddenly articulate. This may cause serious injury to persons in the surrounding area.

When transporting or raising the machine, always apply the articulation lock. Apply the articulation lock if necessary when carrying out maintenance.

The articulation lock is a device to lock the front frame and rear frame to prevent the machine from articulating. LOCK position: Always set to this position when transporting or

raising the machine. Set to the LOCK position if necessary when carrying out maintenance.

FREE position: Always set to this position when traveling

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EXPLANATION OF COMPONENTS

LOCATION OF FIRE EXTINGUISHER

Fire extinguisher (1) is installed to the left front of the machine.

DUST INDICATOR

This device indicates clogging of the air cleaner. Depending on the degree of clogging of the element, red line (1) appears in the transparent portion. If red line (1) indicates 7.5 kPa (30 INCHES H2O) (0.076 kg/cm2, 1.1 PSI), clean the element immediately. After cleaning, press top portion (2) of the indicator to return red line (1) to its original position.

OPERATION

CIRCUIT BREAKER

After the circuit breaker operates, it can be reset by pushing in the reset button. If the reset button comes out soon after it is pushed in, there may be a short circuit in the electric circuit. In this case, ask your Komatsu distributor for repair.

(1) For primary power supply (30 A) (2) For primary power supply (Direct) and engine controller (30 A) (3) For secondary power supply (Accessory power) (80 A)

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OPERATION

FUSES

The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

NOTICE

When replacing any fuse, always turn the power off (turn the starting switch to OFF). When replacing the fuse, always use a fuse of the same capacity and type.

EXPLANATION OF COMPONENTS

FUSE CAPACITY AND CIRCUIT NAME

Fuse BOX I (BT1)

No. Capacity Name of circuit

(1) 20A Main lamp

(2) 10A Turn signal lamp

(3) 20A Head lamp (right)

(4) 20A Head lamp (left)

(5) 10A Side lamp (right)

(6) 10A Side lamp (left)

(7) 10A Stop lamp

(8) 20A Backup lamp, backup buzzer

(9) 20A Working lamp (front)

(10) 20A

–

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EXPLANATION OF COMPONENTS

Fuse box II (BT2)

No. Capacity Name of circuit

(11) 5A Engine controller

(12) 10A KOMTRAX

(13) 10A Machine monitor

(14) 10A Parking brake

(15) 10A Rear view monitor

(16) 20A Front wiper

(17) 20A Rear wiper

(18) 10A Machine monitor, KOMTRAX

(19) 10A Retarder controller

(20) 20A Terminal ‚a

(21) 10A Transmission controller

(22) 20A Hazard lamp

(23) 10A Emergency steering

(24) 10A Room lamp

(25) 20A Direct from battery (spare)

OPERATION

Fuse box III (BT3)

No. Capacity Name of circuit

(26) 20A Fog lamp (if equipped)

(27) 20A Air conditioner controller (if equipped)

(28) 10A Heater

(29) 10A Heater

(30) 10A Machine monitor

(31) 10A Retarder controller

(32) 10A Transmission controller

(33) 10A Emergency steering, Parking brake relay

(34) 20A Power window(right)

(35) 20A Power window(left)

(36) 20A

(37) 20A

(38) 20A

(39) 30A Rear heater

(40) 30A Engine controller

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OPERATION

Fuse box IV (BT4)

No. Capacity Name of circuit

(41) 10A Spot Light (if equipped), Room lamp 2

(42) 10A Radio

(43) 10A

(44) 20A Side lamp (if equipped)

(45) 10A Auto-preheater

(46) 10A Horn

(47) 10A Tachograph (if equipped)

(48) 10A Cigarette lighter

(49) 10A Air suspension seat

(50) 10A Air conditioner

Fuse box V

Yellow rotating lamp (if equipped) Step lamp (if equipped)

EXPLANATION OF COMPONENTS

No. Capacity Name of circuit

(51) 120A Power supply for electrical intake air heater

Precautions when adding electrical equipment

CAUTION

If the electrical equipment system is changed, problems may occur in the machine control. Do not make any changes to the electrical system.

If you want to make any change to the electrical system, please contact your Komatsu distributor.

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Komatsu Galeo HM300-2 Articulated Dump Truck Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

SAFETY INFORMATION

INTENDED USE

DIRECTIONS OF MACHINE

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

EPA REGULATIONS, ENGINE NUMBER PLATE

SERVICE METER POSITION

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

CONTENTS

SAFETY

SAFETY LABELS

POSITION FOR ATTACHING SAFETY LABELS

SAFETY LABELS

GENERAL PRECAUTIONS

SAFETY RULES

IF PROBLEMS ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

FIRE EXTINGUISHER AND FIRST AID KIT

SAFETY FEATURES

KEEP MACHINE CLEAN

INSIDE OPERATOR'S COMPARTMENT

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

HANDRAILS AND STEPS

MOUNTING AND DISMOUNTING

CRUSHING OR CUTTING PREVENTION

FIRE PREVENTION

ACTION IF FIRE OCCURS

WINDOW WASHER LIQUID

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)

PRECAUTIONS FOR ATTACHMENTS, OPTIONS

UNAUTHORIZED MODIFICATION

SAFETY AT WORKSITE

WORKING ON LOOSE GROUND

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

ENSURE GOOD VISIBILITY

PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS

CHECKING SIGNALMAN'S SIGNALS AND SIGNS

EMERGENCY ESCAPE FROM OPERATOR'S CAB

ASBESTOS DUST HAZARD PREVENTION

PRECAUTIONS DURING OPERATION

STARTING ENGINE

CHECKS BEFORE STARTING ENGINE, ADJUST

PRECAUTIONS WHEN STARTING

PRECAUTIONS IN COLD AREAS

OPERATION

CHECKS BEFORE STARTING OPERATION

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

PRECAUTIONS WHEN TRAVELING

PRECAUTIONS WHEN TRAVELING ON SLOPES

PRECAUTIONS WHEN OPERATING DUMP BODY

PRECAUTIONS WHEN OPERATING

PRECAUTIONS FOR ACCUMULATED SNOW, ICE

PARKING MACHINE

TRANSPORTATION

LOADING AND UNLOADING

SHIPPING

BATTERY

BATTERY HAZARD PREVENTION

STARTING WITH BOOSTER CABLES

TOWING

WHEN TOWING

PRECAUTIONS FOR MAINTENANCE

WARNING TAG

KEEP WORK PLACE CLEAN AND TIDY

APPOINT LEADER WHEN WORKING WITH OTHERS

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

PROPER TOOLS

HANDLING SUSPENSION CYLINDER, ACCUMULATOR

PERSONNEL

WORK UNDER THE MACHINE

NOISE

PRECAUTIONS WHEN USING HAMMER

REPAIR WELDING

REMOVING BATTERY TERMINAL