Komatsu HD325, HD405 Operator Manual

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BEFORE READING THIS MANUAL

FOREWORD
BEFORE READING THIS MANUAL
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.
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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.
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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.
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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.
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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
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FOREWORD

CONTENTS

CONTENTS
FOREWORD 1- 1 BEFORE READING THIS MANUAL 1- 2 SAFETY INFORMATION 1- 3 INTENDED USE 1- 4 USE OF MACHINE 1- 4 DIRECTIONS OF MACHINE 1- 4 VISIBILITY FROM OPERATOR'S SEAT 1- 4 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 5 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 5 ENGINE SERIAL NO. PLATE 1- 5 SERVICE METER POSITION 1- 6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 6 SAFETY 2- 1 SAFETY 2- 2 SAFETY LABELS 2- 5 POSITION FOR ATTACHING SAFETY LABELS 2- 6 SAFETY LABELS 2- 7 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11 PRECAUTIONS BEFORE STARTING OPERATION 2- 11 PREPARATIONS FOR SAFE OPERATION 2- 11 FIRE PREVENTION 2- 13 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14 DO NOT GET CAUGHT IN DUMP BODY 2- 16 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 16 UNAUTHORIZED MODIFICATION 2- 16 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 17 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 17 PRECAUTIONS FOR OPERATION 2- 18 PRECAUTIONS FOR JOBSITE 2- 18 STARTING ENGINE 2- 20 OPERATION 2- 22 TRANSPORTATION 2- 26 TOWING 2- 27 PRECAUTIONS FOR MAINTENANCE 2- 28 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 28 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 32 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- 39 BODY PIVOT PIN 3- 44 LOCATION OF FIRE EXTINGUISHER 3- 44 DUST INDICATOR 3- 45
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CONTENTS
FUSES 3- 46 CAR RADIO 3- 49 CAR STEREO 3- 55 AIR CONDITIONER 3- 64 OPERATION 3- 70 CHECK BEFORE STARTING ENGINE 3- 70 STARTING ENGINE 3- 89 OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 91 STOPPING ENGINE 3- 92 CHECKS AFTER STOPPING ENGINE 3- 92 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 93 SHIFTING GEAR 3- 98 TRAVELING DOWNHILL 3-100 STEERING THE MACHINE 3-109 LOADING OPERATIONS 3-109 DUMP OPERATIONS 3-110 PRECAUTIONS FOR OPERATION 3-111 PARKING MACHINE 3-112 CHECKS AFTER COMPLETION OF WORK 3-113 LOCKING 3-113 HANDLING TIRES 3-114 DETERMINING AND MAINTAINING TRAVEL ROAD 3-117 DETERMINING TRAVEL ROAD 3-117 MAINTAINING TRAVEL ROAD 3-117 TRANSPORTATION 3-118 PRECAUTIONS WHEN TRANSPORTING 3-118 STEPS FOR TRANSPORTATION 3-118 METHOD OF SECURING MACHINE 3-118 METHOD OF LIFTING MACHINE 3-119 COLD WEATHER OPERATION 3-122 PRECAUTIONS FOR LOW TEMPERATURE 3-122 PRECAUTIONS AFTER COMPLETION OF WORK 3-123 AFTER COLD WEATHER 3-124 LONG-TERM STORAGE 3-125 BEFORE STORAGE 3-125 DURING STORAGE 3-125 AFTER STORAGE 3-125 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-125 TROUBLESHOOTING 3-126 AFTER RUNNING OUT OF FUEL 3-126 IF TRANSMISSION HAS TROUBLE 3-126 METHOD OF LOWERING DUMP BODY IN EMERGENCY 3-127 METHOD OF TOWING MACHINE 3-129 IF BATTERY IS DISCHARGED 3-133 OTHER TROUBLE 3-137 MAINTENANCE 4- 1 GUIDES TO MAINTENANCE 4- 2 OUTLINE OF SERVICE 4- 5 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5 OUTLINE OF ELECTRIC SYSTEM 4- 9
FOREWORD
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FOREWORD
WEAR PARTS 4- 10 WEAR PARTS LIST 4- 10 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 11 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 12 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 14 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15 TORQUE LIST 4- 15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 16 SAFETY CRITICAL PARTS 4- 17 MAINTENANCE SCHEDULE CHART 4- 18 MAINTENANCE SCHEDULE CHART 4- 18 SERVICE PROCEDURE 4- 21 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 21 WHEN REQUIRED 4- 22 CHECK BEFORE STARTING 4- 48 EVERY 250 HOURS SERVICE 4- 49 EVERY 500 HOURS SERVICE 4- 61 EVERY 1000 HOURS SERVICE 4- 67 EVERY 2000 HOURS SERVICE 4- 79 EVERY 4000 HOURS SERVICE 4- 82 EVERY 8000 HOURS SERVICE 4- 84 EVERY 15000 HOURS SERVICE 4- 85 SPECIFICATIONS 5- 1 SPECIFICATIONS 5- 2 ATTACHMENTS, OPTIONS 6- 1 SELECTING DUMP BODY 6- 2 HANDLING AIR SUSPENSION SEAT 6- 3 SEAT ADJUSTMENT 6- 3 REMOVAL AND INSTALLATION OF HEADREST 6- 5 HANDLING AUTOMATIC SPIN REGULATOR (ASR) 6- 6 EXPLANATION OF COMPONENTS 6- 6 ACTUATION OF ASR SYSTEM 6- 7 PRECAUTIONS WHEN USING 6- 7 BLEEDING AIR FROM ASR CIRCUIT 6- 8 HANDLING ABS 6- 9 EXPLANATION OF COMPONENTS 6- 9 ABS SYSTEM CHECK AFTER STARTING ENGINE 6- 11 OPERATION OF ABS 6- 11 PRECAUTIONS WHEN USING 6- 12 HANDLING PAYLOAD METER II (CARD TYPE) 6- 13 METHOD OF USING ACCURATELY 6- 14 GENERAL LOCATIONS 6- 15 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS) 6- 20 EXTERNAL DISPLAY LAMPS 6- 24 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER 6- 26 OPERATION OF SWITCHES 6- 31 PROBLEM AND WARNING DISPLAY (ERROR CODE) 6- 53 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY) 6- 60
CONTENTS
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CONTENTS
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED 6- 63 ARSC (AUTOMATIC RETARDER SPEED CONTROL) 6- 66 EXPLANATION OF COMPONENTS 6- 67 METHOD OF OPERATION 6- 70 USE OF REAR VIEW MONITOR 6- 73 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR 6- 73 SETTING OF REAR VIEW MONITOR 6- 76 CAUTIONS WHEN USING REAR VIEW MONITOR 6- 76 HANDLING DUMPING COUNTER 6- 77 HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 78 BASIC PRECAUTIONS 6- 78 INDEX 7- 1
FOREWORD
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SAFETY

SAFETY
SAFETY
SAFETY LABELS 2- 5 POSITION FOR ATTACHING SAFETY LABELS 2- 6 SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11 PRECAUTIONS BEFORE STARTING OPERATION 2- 11 ENSURING SAFE OPERATION 2- 11 UNDERSTANDING THE MACHINE 2- 11 PREPARATIONS FOR SAFE OPERATION 2- 11 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 11 INSPECTING MACHINE 2- 11 WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2- 11 KEEP MACHINE CLEAN 2- 12 PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT 2- 12 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2- 12 IF ANY PROBLEM IS FOUND 2- 12 FIRE PREVENTION 2- 13 ACTION IF FIRE OCCURS 2- 13 PRECAUTIONS TO PREVENT FIRE 2- 13 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 2- 14 NO JUMPING ON OR OFF MACHINE 2- 14 NO PEOPLE ON DUMP BODY 2- 14 PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT 2- 15 PRECAUTIONS WHEN LEAVING MACHINE 2- 15 EMERGENCY EXIT FROM OPERATOR'S CAB 2- 15 DO NOT GET CAUGHT IN DUMP BODY 2- 16 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 16 UNAUTHORIZED MODIFICATION 2- 16 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 17 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 17
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SAFETY
PRECAUTIONS FOR OPERATION 2- 18 PRECAUTIONS FOR JOBSITE 2- 18 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 18 WORKING ON LOOSE GROUND 2- 18 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 18 ENSURE GOOD VISIBILITY 2- 19 CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 19 BEWARE OF ASBESTOS DUST 2- 19 STARTING ENGINE 2- 20 USE WARNING TAGS 2- 20 CHECKS BEFORE STARTING ENGINE 2- 20 PRECAUTIONS WHEN STARTING ENGINE 2- 21 PRECAUTIONS IN COLD AREAS 2- 21 STARTING WITH BOOSTER CABLES 2- 21 OPERATION 2- 22 CHECKS BEFORE OPERATION 2- 22 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22 PRECAUTIONS WHEN TRAVELING 2- 23 TRAVELING ON SLOPES 2- 23 PRECAUTIONS WHEN OPERATING 2- 23 PRECAUTIONS WHEN LOADING DUMP BODY 2- 24 PRECAUTIONS WHEN OPERATING DUMP BODY 2- 24 TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 2- 24 PARKING MACHINE 2- 25 TRANSPORTATION 2- 26 LOADING AND UNLOADING 2- 26 TOWING 2- 27 WHEN TOWING 2- 27
SAFETY
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SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 28 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 28 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 28 KEEP WORKPLACE CLEAN AND TIDY 2- 28 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 28 ONLY AUTHORIZED PERSONNEL 2- 28 APPOINT LEADER WHEN WORKING WITH OTHERS 2- 28 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 29 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 30 INSTALLING, REMOVING, OR STORING ATTACHMENTS 2- 31 PRECAUTIONS WHEN WORKING AT HIGH PLACES 2- 31 PRECAUTIONS WHEN WORKING UNDER MACHINE 2- 31 PROPER TOOLS 2- 31 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 32 PRECAUTIONS WHEN WELDING 2- 32 HANDLING BATTERY 2- 32 PRECAUTIONS WHEN USING HAMMER 2- 33 PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2- 33 PRECAUTIONS WITH HIGH-TEMPERATURE OIL 2- 33 PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 34 PRECAUTIONS WITH HIGH-PRESSURE FUEL 2- 34 HANDLING HIGH-PRESSURE HOSES AND PIPING 2- 34 NOISE 2- 34 HANDLING SUSPENSION CYLINDER, ACCUMULATOR, GAS SPRING 2- 35 PRECAUTIONS WITH COMPRESSED AIR 2- 35 MAINTENANCE OF AIR CONDITIONER 2- 35 DISPOSING OF WASTE MATERIALS 2- 35 METHOD OF SELECTING WINDOW WASHER FLUID 2- 35 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 36 TIRES 2- 37 HANDLING TIRES 2- 37 PRECAUTIONS WHEN STORING TIRES 2- 38
SAFETY
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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.
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SAFETY LABELS
SAFETY

POSITION FOR ATTACHING SAFETY LABELS

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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)
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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)
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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)
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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.
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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.
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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.
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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.
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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.
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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 the ROLL-OVER PROTECTIVE STRUCTURE (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 Cables Safety 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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