This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamentalsafety
rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance
of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the
location shown on the right so that all relevant personnel can read
it at any time.
Storage location for the Operation and Maintenance Manual:
On inside of left door
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor,see "TABLE TO ENTER SERIAL
NO. AND DISTRIBUTOR (PAGE 1-6)".
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has
been shipped. If this machine has been purchased in another country, 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.
1 - 2
.
FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.
This word is used for information that is useful to know.
1 - 3
.
INTENDED USE
FOREWORD
INTENDED USE
USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Traveling with a load
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
(D)
(A)
(B)
(C)
FRONT
REAR
LEFT
RIGHT
(E)
OPERATOR'S SEAT
VISIBILITY FROM OPERATOR'S SEAT
This machine complies with the visibility standard (ISO 5006).
This machine maintains a close visibility of a height of 1.5 m at a point 1 m away from the outside surface of the
machine, and a visibility for a circumference of 12 m.
1 - 4
.
FOREWORD
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
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
It is located on the left front end of the frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE
On the top of the engine cylinder head cover.
1 - 5
.
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
FOREWORD
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
1 - 6
.
FOREWORD
CONTENTS
CONTENTS
FOREWORD1-1
BEFORE READING THIS MANUAL1-2
SAFETY INFORMATION1-3
INTENDED USE1-4
USE OF MACHINE1-4
DIRECTIONS OF MACHINE1-4
VISIBILITY FROM OPERATOR'S SEAT1-4
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR1-5
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE1-5
ENGINE SERIAL NO. PLATE1-5
SERVICE METER POSITION1-6
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR1-6
SAFETY2-1
SAFETY2-2
SAFETY LABELS2-5
POSITION FOR ATTACHING SAFETY LABELS2-6
SAFETY LABELS2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE2- 11
PRECAUTIONS BEFORE STARTING OPERATION2- 11
PREPARATIONS FOR SAFE OPERATION2- 11
FIRE PREVENTION2- 13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE2- 14
DO NOT GET CAUGHT IN DUMP BODY2- 16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES2- 16
UNAUTHORIZED MODIFICATION2- 16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS2- 17
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING2- 17
PRECAUTIONS FOR OPERATION2- 18
PRECAUTIONS FOR JOBSITE2- 18
STARTING ENGINE2- 20
OPERATION2- 22
TRANSPORTATION2- 26
TOWING2- 27
PRECAUTIONS FOR MAINTENANCE2- 28
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE2- 28
PRECAUTIONS FOR INSPECTION AND MAINTENANCE2- 32
TIRES2- 37
OPERATION3-1
GENERAL VIEW3-2
GENERAL VIEW OF MACHINE3-2
GENERAL VIEW OF CONTROLS AND GAUGES3-3
EXPLANATION OF COMPONENTS3-5
MACHINE MONITOR3-5
OTHER FUNCTIONS OF MACHINE MONITOR3- 26
SWITCHES3- 30
CONTROL LEVERS AND PEDALS3- 39
BODY PIVOT PIN3- 44
LOCATION OF FIRE EXTINGUISHER3- 44
DUST INDICATOR3- 45
1 - 7
.
CONTENTS
FUSES3- 46
CAR RADIO3- 49
CAR STEREO3- 55
AIR CONDITIONER3- 64
OPERATION3- 70
CHECK BEFORE STARTING ENGINE3- 70
STARTING ENGINE3- 89
OPERATIONS, CHECKS AFTER STARTING ENGINE3- 91
STOPPING ENGINE3- 92
CHECKS AFTER STOPPING ENGINE3- 92
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING3- 93
SHIFTING GEAR3- 98
TRAVELING DOWNHILL3-100
STEERING THE MACHINE3-109
LOADING OPERATIONS3-109
DUMP OPERATIONS3-110
PRECAUTIONS FOR OPERATION3-111
PARKING MACHINE3-112
CHECKS AFTER COMPLETION OF WORK3-113
LOCKING3-113
HANDLING TIRES3-114
DETERMINING AND MAINTAINING TRAVEL ROAD3-117
DETERMINING TRAVEL ROAD3-117
MAINTAINING TRAVEL ROAD3-117
TRANSPORTATION3-118
PRECAUTIONS WHEN TRANSPORTING3-118
STEPS FOR TRANSPORTATION3-118
METHOD OF SECURING MACHINE3-118
METHOD OF LIFTING MACHINE3-119
COLD WEATHER OPERATION3-122
PRECAUTIONS FOR LOW TEMPERATURE3-122
PRECAUTIONS AFTER COMPLETION OF WORK3-123
AFTER COLD WEATHER3-124
LONG-TERM STORAGE3-125
BEFORE STORAGE3-125
DURING STORAGE3-125
AFTER STORAGE3-125
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE3-125
TROUBLESHOOTING3-126
AFTER RUNNING OUT OF FUEL3-126
IF TRANSMISSION HAS TROUBLE3-126
METHOD OF LOWERING DUMP BODY IN EMERGENCY3-127
METHOD OF TOWING MACHINE3-129
IF BATTERY IS DISCHARGED3-133
OTHER TROUBLE3-137
MAINTENANCE4-1
GUIDES TO MAINTENANCE4-2
OUTLINE OF SERVICE4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC4-5
OUTLINE OF ELECTRIC SYSTEM4-9
FOREWORD
1 - 8
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FOREWORD
WEAR PARTS4- 10
WEAR PARTS LIST4- 10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT4- 11
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE4- 12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL4- 14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS4- 15
TORQUE LIST4- 15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS4- 16
SAFETY CRITICAL PARTS4- 17
MAINTENANCE SCHEDULE CHART4- 18
MAINTENANCE SCHEDULE CHART4- 18
SERVICE PROCEDURE4- 21
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)4- 21
WHEN REQUIRED4- 22
CHECK BEFORE STARTING4- 48
EVERY 250 HOURS SERVICE4- 49
EVERY 500 HOURS SERVICE4- 61
EVERY 1000 HOURS SERVICE4- 67
EVERY 2000 HOURS SERVICE4- 79
EVERY 4000 HOURS SERVICE4- 82
EVERY 8000 HOURS SERVICE4- 84
EVERY 15000 HOURS SERVICE4- 85
SPECIFICATIONS5-1
SPECIFICATIONS5-2
ATTACHMENTS, OPTIONS6-1
SELECTING DUMP BODY6-2
HANDLING AIR SUSPENSION SEAT6-3
SEAT ADJUSTMENT6-3
REMOVAL AND INSTALLATION OF HEADREST6-5
HANDLING AUTOMATIC SPIN REGULATOR (ASR)6-6
EXPLANATION OF COMPONENTS6-6
ACTUATION OF ASR SYSTEM6-7
PRECAUTIONS WHEN USING6-7
BLEEDING AIR FROM ASR CIRCUIT6-8
HANDLING ABS6-9
EXPLANATION OF COMPONENTS6-9
ABS SYSTEM CHECK AFTER STARTING ENGINE6- 11
OPERATION OF ABS6- 11
PRECAUTIONS WHEN USING6- 12
HANDLING PAYLOAD METER II (CARD TYPE)6- 13
METHOD OF USING ACCURATELY6- 14
GENERAL LOCATIONS6- 15
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)6- 20
EXTERNAL DISPLAY LAMPS6- 24
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER6- 26
OPERATION OF SWITCHES6- 31
PROBLEM AND WARNING DISPLAY (ERROR CODE)6- 53
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)6- 60
CONTENTS
1 - 9
.
CONTENTS
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN
REPLACED6- 63
ARSC (AUTOMATIC RETARDER SPEED CONTROL)6- 66
EXPLANATION OF COMPONENTS6- 67
METHOD OF OPERATION6- 70
USE OF REAR VIEW MONITOR6- 73
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR6- 73
SETTING OF REAR VIEW MONITOR6- 76
CAUTIONS WHEN USING REAR VIEW MONITOR6- 76
HANDLING DUMPING COUNTER6- 77
HANDLING MACHINES EQUIPPED WITH KOMTRAX6- 78
BASIC PRECAUTIONS6- 78
INDEX7-1
FOREWORD
1 - 10
.
2 - 1
.
SAFETY
SAFETY
SAFETY
SAFETY LABELS2-5
POSITION FOR ATTACHING SAFETY LABELS2-6
SAFETY LABELS2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE2- 11
PRECAUTIONS BEFORE STARTING OPERATION2- 11
ENSURING SAFE OPERATION2- 11
UNDERSTANDING THE MACHINE2- 11
PREPARATIONS FOR SAFE OPERATION2- 11
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT2- 11
INSPECTING MACHINE2- 11
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT2- 11
KEEP MACHINE CLEAN2- 12
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT2- 12
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT2- 12
IF ANY PROBLEM IS FOUND2- 12
FIRE PREVENTION2- 13
ACTION IF FIRE OCCURS2- 13
PRECAUTIONS TO PREVENT FIRE2- 13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE2- 14
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE2- 14
NO JUMPING ON OR OFF MACHINE2- 14
NO PEOPLE ON DUMP BODY2- 14
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT2- 15
PRECAUTIONS WHEN LEAVING MACHINE2- 15
EMERGENCY EXIT FROM OPERATOR'S CAB2- 15
DO NOT GET CAUGHT IN DUMP BODY2- 16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES2- 16
UNAUTHORIZED MODIFICATION2- 16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS2- 17
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING2- 17
2 - 2
.
SAFETY
PRECAUTIONS FOR OPERATION2- 18
PRECAUTIONS FOR JOBSITE2- 18
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS2- 18
WORKING ON LOOSE GROUND2- 18
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES2- 18
ENSURE GOOD VISIBILITY2- 19
CHECKING SIGNS AND SIGNALMAN'S SIGNALS2- 19
BEWARE OF ASBESTOS DUST2- 19
STARTING ENGINE2- 20
USE WARNING TAGS2- 20
CHECKS BEFORE STARTING ENGINE2- 20
PRECAUTIONS WHEN STARTING ENGINE2- 21
PRECAUTIONS IN COLD AREAS2- 21
STARTING WITH BOOSTER CABLES2- 21
OPERATION2- 22
CHECKS BEFORE OPERATION2- 22
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE2- 22
PRECAUTIONS WHEN TRAVELING2- 23
TRAVELING ON SLOPES2- 23
PRECAUTIONS WHEN OPERATING2- 23
PRECAUTIONS WHEN LOADING DUMP BODY2- 24
PRECAUTIONS WHEN OPERATING DUMP BODY2- 24
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES2- 24
PARKING MACHINE2- 25
TRANSPORTATION2- 26
LOADING AND UNLOADING2- 26
TOWING2- 27
WHEN TOWING2- 27
SAFETY
2 - 3
.
SAFETY
PRECAUTIONS FOR MAINTENANCE2- 28
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE2- 28
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE2- 28
KEEP WORKPLACE CLEAN AND TIDY2- 28
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE2- 28
ONLY AUTHORIZED PERSONNEL2- 28
APPOINT LEADER WHEN WORKING WITH OTHERS2- 28
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE2- 29
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING2- 30
INSTALLING, REMOVING, OR STORING ATTACHMENTS2- 31
PRECAUTIONS WHEN WORKING AT HIGH PLACES2- 31
PRECAUTIONS WHEN WORKING UNDER MACHINE2- 31
PROPER TOOLS2- 31
PRECAUTIONS FOR INSPECTION AND MAINTENANCE2- 32
PRECAUTIONS WHEN WELDING2- 32
HANDLING BATTERY2- 32
PRECAUTIONS WHEN USING HAMMER2- 33
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT2- 33
PRECAUTIONS WITH HIGH-TEMPERATURE OIL2- 33
PRECAUTIONS WITH HIGH-PRESSURE OIL2- 34
PRECAUTIONS WITH HIGH-PRESSURE FUEL2- 34
HANDLING HIGH-PRESSURE HOSES AND PIPING2- 34
NOISE2- 34
HANDLING SUSPENSION CYLINDER, ACCUMULATOR, GAS SPRING2- 35
PRECAUTIONS WITH COMPRESSED AIR2- 35
MAINTENANCE OF AIR CONDITIONER2- 35
DISPOSING OF WASTE MATERIALS2- 35
METHOD OF SELECTING WINDOW WASHER FLUID2- 35
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS2- 36
TIRES2- 37
HANDLING TIRES2- 37
PRECAUTIONS WHEN STORING TIRES2- 38
SAFETY
2 - 4
.
SAFETY
SAFETY LABELS
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.
2 - 5
.
SAFETY LABELS
SAFETY
POSITION FOR ATTACHING SAFETY LABELS
2 - 6
.
SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Precaution about modifying ROPS (09620-B2000)
(2) Caution for rotation of engine fan, fan belt
(09667-A0880)
(3) Caution for opening radiator cap (09653-A0641)
(4) Caution for opening hydraulic tank cap (09653-A0641)
2 - 7
.
SAFETY
SAFETY LABELS
SAFETY LABELS
(5) Warning for handling suspension (09659-A0881)
SAFETY
(6) Warnings for electric wire
Warnings for crush hazard when inspection and maintenance
(569-93-82450)
2 - 8
.
SAFETY
(7) Caution before starting
Caution when traveling in reverse
(569-93-81720)
SAFETY LABELS
(8) Caution when handling battery cable (09808-A1681)
(9) Exhaust pipe is hot! (09817-A1103)
2 - 9
.
SAFETY
SAFETY LABELS
SAFETY LABELS
(10) Caution for avoiding falling down (09805-C0881)
SAFETY
(11) Precautions for handling accumulator (09659-A057B)
(12) Caution when gandling battery
This safety label is provided by the battery manufacturer.
(13) Jump start prohibited (09842-A0481)
This safety label is fixed to the engine starting motor.
2 - 10
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SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
GENERAL PRECAUTIONS COMMON TO OPERATION AND
MAINTENANCE
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying
out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully
and obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION
ENSURING SAFE OPERATION
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety, precautions, and instructions in this manual when operating or performing inspection or
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.
UNDERSTANDING THE MACHINE
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
PREPARATIONS FOR SAFE OPERATION
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT
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.
INSPECTING MACHINE
Check the machine before starting operations. If any abnormalityis found, do not operate the machine until repairs
of the problem location have been completed.
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT
Do not wear loose clothes or any accessories. If these catch on
the control levers or protruding parts, there is danger that it may
cause the machine to move unexpectedly.
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.
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.
Check that all protective equipment functions properly before
using it.
2 - 11
.
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
KEEP MACHINE CLEAN
If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or
oil, there is a hazard that you will slip and fall. Wipeoff any mud or oil from the machine. Always keep the machine
clean.
If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. If there is any
misoperation, there is danger that the machine may move
unexpectedly and cause serious personal injury or death. When
washing the machine with water or steam, do not allow the water
or steam to come into direct contact with electrical components.
SAFETY
PRECAUTIONS 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 tools or a machine parts lying around inside the operator's compartment. If tools or parts get into the
control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in serious
personal injury or death.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could cause serious personal injury or death.
Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT
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.
IF ANY PROBLEM IS 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.
2 - 12
.
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
FIRE PREVENTION
ACTION IF FIRE OCCURS
Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.
Do not jump off the machine. There is the danger of falling and suffering serious injury.
PRECAUTIONS TO PREVENT FIRE
Fire caused by fuel, oil, antifreeze, or window washer fluid
Do not bring any flame or fire close to flammable substances
such as fuel, oil, antifreeze, or window washer fluid. There is
danger that they may catch fire. To prevent fire, always observe
the following:
Do not smoke or use any flame near fuel or other flammable
substances.
Stop the engine before adding fuel.
Do not leave the machine when adding fuel or oil.
Tighten all fuel and oil caps securely.
Be careful not to spill fuel on overheated surfaces or on parts
of the electrical system.
After adding fuel or oil, wipe up any spilled fuel or oil.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
When washing parts with oil,use a non-flammableoil. Do not
use diesel oil or gasoline. There is danger that they may
catch fire.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Determine well-ventilated areas for storing oil and fuel. Keep
the oil and fuel in the determined place and do not allow
unauthorized persons to enter.
When carrying out grinding or welding work on the machine,
move any flammable materials to a safe place before
starting.
Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, coal 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. To prevent fire, always observe the following.
Keep all 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 piping
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrateduring operation and rub against other parts. There is dangerthat this may lead
to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or death.
2 - 13
.
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications.
SAFETY
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the handrails and steps marked by arrows in the diagram on
the right when getting on or off the machine.
Always face the machine and maintain at least three-point
contact (both feet and one hand, or both hands and one foot)
with the handrail and steps to ensure that you support yourself.
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 grip the control levers when getting on or off the machine.
Never climb on the engine hood or covers where there are no non-slip pads.
Do not get on or off the machine while holding tools in your hand.
NO JUMPING ON OR OFF MACHINE
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.
NO PEOPLE ON DUMP BODY
Never let anyone ride in the dump body. There is danger of falling and suffering serious personal injury.
2 - 14
.
SAFETY
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT
Before standing up from the operator's seat to adjust the operator's
seat, always lower the dump body completely, lock with dump
lever lock knob (1), set gear shift lever (2) to the N position, set
parking brake switch (3) to the PARKING position, then stop the
engine.
If this is not done and the control levers are touched by mistake,
there is danger that the machine may suddenly move and cause
serious personal injury or death.
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
PRECAUTIONS WHEN LEAVING MACHINE
If the proper procedures are not taken when parking the machine, the machine may suddenly move off by itself, and
this may lead to serious personal injury or death. Always do the following.
When leaving the machine, always lower the dump body
completely, lock with dump lever lock knob (1), set gear shift
lever (2) to the N position, set parking brake switch (3) to the
PARKING position, then stop the engine.
Lock all places and always take the key with you and leave it in
the specified location.
EMERGENCY EXIT FROM OPERATOR'S CAB
Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open,
escape from the door on the other side.
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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
SAFETY
DO NOT GET CAUGHT IN DUMP BODY
The clearance in the area around the dump body changes
according to the movement of the dump body. If you are caught,
there is danger that you will suffer serious injury or death.
Do not allow anyone near any of the rotating or telescopic parts.
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
The operator's compartment is equipped with a structure (ROPS,
FOPS) to protect the operator by absorbing the impact energy. If
the machine weight (mass) exceeds the certified value (shown on
theROLL-OVERPROTECTIVESTRUCTURE(ROPS)
CERTIFICATION plate), ROPS will not be able to fulfill its function.
Do not increase machine weight beyond the certified value by
modifying the machine or by installing attachments to the machine.
Also, if the function of the protective equipment is impeded, the
protective equipment will not be able to protect the operator, and
the operator may suffer injury or death. Always observe the
following.
If the machine is equipped with a protective structure, do not remove the protective structure and carry out
operations without it.
If the protective structure is welded, or holes are drilled in it, or it is modified in any other way, its strength may
drop. Consult your Komatsu distributor before carrying out any modifications.
If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced
and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu distributor for
advice on the method of repair.
Even if the protective structure is installed, always fasten your seat belt properly when operating the machine.
If you do not fasten your seatbelt properly, it cannot display its effect.
UNAUTHORIZED MODIFICATION
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Do not try to increase the capacity of the dump body or make any other modifications. Such modifications will
cause a drop in the braking efficiency, the balance of the machine will become poor, and this may lead to an
unexpected accident.
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.
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
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.
When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
contact your Komatsu distributor for advice.
When installing and using optional attachments, read the instruction manual for the attachment, and the general
information related to attachments in this manual.
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
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.
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.
PRECAUTIONS FOR OPERATION
SAFETY
PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR JOBSITE
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting
operations, always check the following to confirm that there is no danger on the jobsite.
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 water or on soft ground, check the water depth, speed of the current, bedrock, and
shape of the ground beforehand and avoid any place that will obstruct travel.
Maintain the travel path on the jobsite so that there is no obstruction to travel operations.
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.
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 CablesSafety Distance
100V - 200V Over 2 m (7 ft)
6,600V Over 2 m (7 ft)
22,000V Over 3 m (10 ft)
66,000V Over 4 m (14 ft)
154,000V Over 5 m (17 ft)
187,000V Over 6 m (20 ft)
275,000V Over 7 m (23 ft)
500,000V Over 11 m (36 ft)
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SAFETY
ENSURE GOOD VISIBILITY
This machine is equipped with mirrors to ensure good visibility, but even then there are places that cannot be seen
from the operator's seat, so be careful when operating.
When traveling or carrying out operations in places with poor visibility, it is impossible to check for obstacles in the
area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury
or death. When traveling or carrying out operations in places with poor visibility, always observe the following.
Position a signalman if there are areas where the visibility is not good.
Only one signalman should give signals.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to ensure
good visibility.
If the machine is equipped with cameras, clean off any dirt from the lens and make sure that the camera gives
a clear view.
PRECAUTIONS FOR OPERATION
CHECKING SIGNS AND SIGNALMAN'S SIGNALS
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.
BEWARE OF ASBESTOS DUST
Asbestos dust in the air 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.
Do not use compressed air.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position, and make
sure that all workers operate on the upwind side.
All workers should use anti-dust masks.
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.
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