Komatsu HD785 Operator Manual

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PEN00042-03

DUMP TRUCK

HD785

SERIAL NUMBERS

-5

4254

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.

NOTICE

Komatsu has Operation & Mai ntenance Manuals written in some other languages. if a foreign langu age manual is necessary, contact your local distr ibutor for availability.

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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 to which 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.

Place to Keep the Manual It is located behind the operator's seat.

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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 safety 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 inform the 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 is your 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 distributor for 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 -> (1))

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FOREWORD

INTENDED USE

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.

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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

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 POSITION

The engine serial number plate is on the upperright side of (viewed from the fan) the cylinder block (on the intake manifold cover).

SERVICE METER POSITION

It is located on the right side of the meter section.

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FOREWORD

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

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 ENGINE SERIAL NO. PLATE POSITION 1- 8 SERVICE METER POSITION 1- 8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9 SAFETY 2- 1 SAFETY INFORMATION 2- 2 SAFETY LABELS 2- 4 POSITION FOR ATTACHING SAFETY LABELS 2- 5 SAFETY LABELS 2- 6 GENERAL PRECAUTIONS 2- 10 PRECAUTIONS DURING OPERATION 2- 18 BEFORE STARTING ENGINE 2- 18 AFTER STARTING ENGINE 2- 20 BATTERY 2- 23 TOWING 2- 25 PRECAUTIONS FOR MAINTENANCE 2- 26 PRECAUTIONS WITH TIRES 2- 32 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 SWITCHES 3- 22 CONTROL LEVERS AND PEDALS 3- 30 MECHATRONICS EQUIPMENT CONTROLLER 3- 34 SAFETY PIN 3- 35 DUST INDICATOR 3- 35 FUSES 3- 36 CAR STEREO 3- 38 AIR CONDITIONER 3- 47 CAR HEATER 3- 52 LOCATION OF FIRE EXTINGUISHER 3- 53 LOCATION OF FIRST AID KIT 3- 53 OPERATION 3- 54 CHECK BEFORE STARTING ENGINE 3- 54 STARTING ENGINE 3- 70 OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 73 STOPPING ENGINE 3- 74 CHECKS AFTER STOPPING ENGINE 3- 74 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 75 SHIFTING GEAR 3- 80 TRAVELING DOWNHILL 3- 81

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FOREWORD

STEERING THE MACHINE 3- 87 LOADING OPERATIONS 3- 87 DUMP OPERATIONS 3- 88 PRECAUTIONS FOR OPERATION 3- 89 PARKING MACHINE 3- 90 CHECKS AFTER COMPLETION OF WORK 3- 91 DRAIN WATER FROM AIR TANK 3- 91 LOCKING 3- 92 HANDLING TIRES 3- 93 DETERMINING AND MAINTAINING TRAVEL ROAD 3- 95 DETERMINING TRAVEL ROAD 3- 95 MAINTAINING TRAVEL ROAD 3- 95 TRANSPORTATION 3- 96 PRECAUTIONS WHEN TRANSPORTING 3- 96 STEPS FOR TRANSPORTATION 3- 96 METHOD OF SECURING MACHINE 3- 97 METHOD OF LIFTING MACHINE 3- 98 COLD WEATHER OPERATION 3-100 PRECAUTIONS FOR LOW TEMPERATURE 3-100 PRECAUTIONS AFTER COMPLETION OF WORK 3-101 AFTER COLD WEATHER 3-102 LONG-TERM STORAGE 3-103 BEFORE STORAGE 3-103 DURING STORAGE 3-103 AFTER STORAGE 3-103 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-103 TROUBLESHOOTING 3-104 AFTER RUNNING OUT OF FUEL 3-104 METHOD OF TOWING MACHINE 3-104 IF BATTERY IS DISCHARGED 3-109 OTHER TROUBLE 3-113 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- 7 WEAR PARTS 4- 8 WEAR PARTS LIST 4- 8 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12 TORQUE LIST 4- 12 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13 SAFETY CRITICAL PARTS 4- 14 MAINTENANCE SCHEDULE CHART 4- 15 MAINTENANCE SCHEDULE CHART 4- 15 SERVICE PROCEDURE 4- 18 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 18

CONTENTS

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CONTENTS

WHEN REQUIRED 4- 19 CHECK BEFORE STARTING 4- 36 EVERY 100 HOURS SERVICE 4- 37 EVERY 250 HOURS SERVICE 4- 38 EVERY 500 HOURS SERVICE 4- 53 EVERY 1000 HOURS SERVICE 4- 58 EVERY 2000 HOURS SERVICE 4- 63 EVERY 4000 HOURS SERVICE 4- 69 EVERY 15000 HOURS SERVICE 4- 71 SPECIFICATIONS 5- 1 SPECIFICATIONS 5- 2 ATTACHMENTS, OPTIONS 6- 1 HANDLING PAYLOAD METER 6- 2 NAME OF PARTS 6- 2 EXTERNAL DISPLAY LAMPS 6- 3 OPERATING PAYLOAD METER 6- 5 TACHOGRAPH (TCO 15-6) 6- 13 EXPLANATION OF COMPONENTS 6- 13 METHOD OF USING KEY 6- 15 METHOD OF USE 6- 15 REVO TACHOGRAPH (TCO 15-7) 6- 17 EXPLANATION OF COMPONENTS 6- 17 METHOD OF USE 6- 19 USING DIFFERENTIAL LOCK 6- 21 DIFFERENTIAL LOCK PEDAL 6- 21 PRECAUTIONS AND METHOD OF USE 6- 22 OPERATION OF ABS AND ABS/ASR 6- 23 EXPLANATION OF COMPONENTS 6- 23 OPERATION METHOD 6- 25 PRECAUTIONS FOR USE 6- 26 TROUBLESHOOTING 6- 26 ARSC (AUTOMATIC RETARDER SPEED CONTROL) 6- 27 EXPLANATION OF COMPONENTS 6- 28 METHOD OF OPERATION 6- 30 TROUBLESHOOTING 6- 32 PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE) 6- 35 CHECK BEFORE STARTING 6- 35 ABNORMALITY DISPLAYED DURING OPERATION 6- 35 HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS 6- 35 MESSAGE FOR OPERATION AND MAINTENANCE (MOM) 6- 36 ASR-II (AUTOMATIC SPIN REGULATOR II) 6- 41 EXPLANATION OF COMPONENTS 6- 41 ACTUATION OF ASR-II SYSTEM 6- 42 PRECAUTIONS WHEN USING 6- 42 TROUBLESHOOTING 6- 43 HANDLING AUTO-GREASING SYSTEM 6- 45 OUTLINE OF AUTO-GREASING SYSTEM 6- 45 SETTING GREASE CAN 6- 46 INITIAL SETTING OF AUTO-GREASING SYSTEM 6- 47

FOREWORD

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FOREWORD

METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 47 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM 6- 48 POSITION OF EACH INJECTOR 6- 52 GREASING POINTS FOR EACH INJECTOR 6- 56 HIGH ALTITUDE SPECIFICATIONS 7- 1 EXPLANATION OF COMPONENTS 7- 2 SERVICE PROCEDURE 7- 3 CHECK BEFORE STARTING 7- 3 EVERY 2000 HOURS SERVICE 7- 4 INDEX 8- 1

CONTENTS

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SAFETY INFORMATION

SAFETY

SAFETY INFORMATION

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

GENERAL PRECAUTIONS 2- 10 SAFETY RULES 2- 10 IF ABNORMALITIES ARE FOUND 2- 10 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 10 FIRE EXTINGUISHER AND FIRST AID KIT 2- 10 SAFETY FEATURES 2- 10 KEEP MACHINE CLEAN 2- 11 INSIDE OPERATOR'S COMPARTMENT 2- 11 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 11 HANDRAILS AND STEPS 2- 12 MOUNTING AND DISMOUNTIN 2- 12 PREVENTION OF BURNS 2- 13 FIRE PREVENTION 2- 13 ACTION IF FIRE OCCURS 2- 14 WINDOW WASHER LIQUID 2- 14 PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 15 PRECAUTIONS FOR ATTACHMENTS 2- 15 UNAUTHORIZED MODIFICATION 2- 15 SAFETY AT WORKSITE 2- 15 WORKING ON LOOSE GROUND 2- 16 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 16 ENSURE GOOD VISIBILITY 2- 16 PRECAUTIONS ON INDOOR VENTILATION 2- 17 CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 17 ASBESTOS DUST HAZARD PREVENTION 2- 17

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SAFETY

PRECAUTIONS DURING OPERATION 2- 18 BEFORE STARTING ENGINE 2- 18 CHECKS BEFORE STARTING ENGINE, ADJUST 2- 18 PRECAUTIONS WHEN STARTING ENGINE 2- 18 PRECAUTIONS IN COLD AREAS 2- 19 AFTER STARTING ENGINE 2- 20 CHECK AFTER STARTING ENGINE 2- 20 PRECAUTIONS WHEN TRAVELING FORWARD OR REVERSE 2- 20 PRECAUTIONS DURING OPERATION 2- 21 PRECAUTIONS WHEN TRAVELING ON THE SLOPES 2- 21 PRECAUTIONS WHEN OPERATING DUMP BODY 2- 21 PRECAUTIONS FOR OPERATION 2- 21 METHOD OF USING BRAKES 2- 21 PRECAUTIONS UNDER THE SNOWING AND FREEZING CONDITION 2- 22 PRECAUTIONS FOR PARKING 2- 22 BATTERY 2- 23 BATTERY HAZARD PREVENTION 2- 23 STARTING WITH BOOSTER CABLES 2- 24 TOWING 2- 25 WHEN TOWING 2- 25

SAFETY INFORMATION

PRECAUTIONS FOR MAINTENANCE 2- 26 WARNING TAG 2- 26 KEEP WORK PLACE CLEAN AND TIDY 2- 26 APPOINT LEADER WHEN WORKING WITH OTHERS 2- 26 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 27 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 28 PROPER TOOLS 2- 28 HANDLING SUSPENTION CYLINDER 2- 29 PERSONNEL 2- 29 WORK UNDER THE MACHINE 2- 29 NOISE 2- 29 PRECAUTIONS WHEN USIN HAMMER 2- 29 REPAIR WELDING 2- 29 REMOVING BATTERY TERMINAL 2- 30 PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 30 HANDLING HIGH-PRESSURE HOSES, PIPING 2- 30 WASTE MATERIALS 2- 30 MAINTENANCE OF AIR CONDITIONER 2- 30 COMPRESSED AIR 2- 31 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS 2- 31

PRECAUTIONS WITH TIRES 2- 32 HANDLING TIRES 2- 32 PRECAUTIONS WHEN STORING TIRE 2- 32

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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

SAFETY LABELS

POSITION FOR ATTACHING SAFETY LABELS

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SAFETY LABELS

SAFETY

SAFETY LABELS

(1) Roll-over protective structure (ROPS) (09620-30202)

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

(3) Caution for opening hydraulic tank cap

Caution for opening radiator cap (09653-A0641)

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SAFETY

(4) Warning for handling suspension cylinder

(09659-A0881)

(5) Warnings for electric wire

Warnings for crush hazard when inspection and maintenance Warnings for inspection of emergency steering system, emergency brake system Warning for leaving operator's seat, stopping engine Warning for retarder oil temperature (569-93-61730)

SAFETY LABELS

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SAFETY LABELS

(6) Cautions before starting

Cautions when traveling in reverse Cautions for operating hoist control lever (dump lever) (569-93-61720)

SAFETY

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

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

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SAFETY

(9) Caution for avoiding falling down (09805-C0881)

SAFETY LABELS

(10) Caution when handling battery

(This plate is stick on the machine by the battery maker.)

(11) Jump start prohibited (09842-A0481)

(This plate is stick on the starting motor.)

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GENERAL PRECAUTIONS

SAFETY

GENERAL PRECAUTIONS

SAFETY RULES

Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger. When working with another operator or with a person on worksite traffic duty, be sure that all personnel understand all hand signals that are to be used.

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 control levers 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.

SAFETY FEATURES

Be sure that all guards and covers 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.

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SAFETY

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.

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.

GENERAL PRECAUTIONS

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

Before adjusting or standing up from the operator's seat, always set the gear shift lever to the N position and the parking brake valve lever to the PARKING position, then stop the engine. If you touch or bump the control levers unintentionally, the machine could suddenly move, and cause an accident that might result in bodily harm. Place gear shift lever (1) at neutral and set parking brake valve lever (2) to the PARKING position. Lower the dump body, set the dump lever to the HOLD position, then apply the lock. Stop the engine. Apply all the lock and always remember to take the key with you and keep where it should be.

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GENERAL PRECAUTIONS

HANDRAILS AND STEPS

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 below when getting on or off the machine. A: For use whengetting on or off the operator's seat fromthe left

door

B: For use when getting on or off the operator's seat from the

engine hood or right door

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.

SAFETY

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.

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SAFETY

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.

GENERAL PRECAUTIONS

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.

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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.

SAFETY

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.

WINDOW WASHER LIQUID

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

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SAFETY

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)

Install ROPS when working in places where there is danger of falling rocks, such as in mines and quarries, or in places where there is danger of rolling over.

If ROPS is installed, do not remove it when operating the machine. ROPS is installed to protect the operator when machine rolls over. When machine rolls over, ROPS supports its weight and absorbs its impact energy. If ROPS is modified, its strength may be reduced. When modifying, consult your Komatsu distributor. If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be maintained. In this case, besure to ask your Komatsu distributor about repair

method. Even when the ROPS isinstalled, if you do notfasten yourseat belt securely, it cannot protect you properly. Always fasten your seat belt when operating the machine.

GENERAL PRECAUTIONS

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, or product failures resulting from the use of unauthorized attachments or parts will not be

the responsibility of Komatsu.

When installing and using optional attachments, read the instruction manual for the attachment, and the general

information related to attachments in this manual.

UNAUTHORIZED MODIFICATION

Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor.

Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting

from modifications made without authorization from 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 on soft 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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GENERAL PRECAUTIONS

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 injury or property damage. 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

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)

SAFETY

ENSURE GOOD VISIBILITY

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely. Always do as follows.

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.

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SAFETY

PRECAUTIONS ON INDOOR VENTILATION

Exhaust fumes from the engine can kill.

If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

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.

GENERAL PRECAUTIONS

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.

2 - 17

PRECAUTIONS DURING OPERATION

SAFETY

PRECAUTIONS DURING OPERATION

BEFORE STARTING ENGINE

If there is a warning tag hanging from gear shift lever (1), do not start the engine or touch the levers.

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 accelerator pedal or brake pedal, and check that the pedals work properly. Adjust the operator'sseat to a position where it is easy to carry out operations, and check that there is no damage or wear to the seat belt or mounting clamps. Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position. Before starting the engine, make sure that the safety lock lever 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 3-54)". Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTING ENGINE

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.

2 - 18

SAFETY

PRECAUTIONS IN COLD AREAS

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

levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.

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.

Drain water in the air tank.

If there is no sound of the air being released when the service brake or parking brake are operated, check the air

tank pressure and remove any snow or ice from around the brake valve.

PRECAUTIONS DURING OPERATION

2 - 19

PRECAUTIONS DURING OPERATION

SAFETY

AFTER STARTING ENGINE

CHECKS AFTER STARTING ENGINE

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 travel, steering and brake systems, and dump body control system. 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.

PRECAUTIONS WHEN TRAVELING 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. Always fasten your seat belt. 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. Always be sure to carry out the above precautions even when the machine is equipped with mirrors.

2 - 20

SAFETY

PRECAUTIONS DURING OPERATION

Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal immediately to stop the machine. Lower the dump body, setting the dump lever at FLOAT position, then travel. To prevent the machine from rolling over when traveling on rough ground, travel at low speed and avoid sudden changes in direction. 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.

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN TRAVELING ON THE 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 the gear while traveling downhill or travel downhill with the transmission in neutral. If this is neglected, the engine does not work as a brake, and that is dangerous. Be sure to set the transmission in one of the lower gear speeds. In addition, apply the brake and use the engine as a brake, if necessary.

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.

PRECAUTIONS FOR OPERATION

Do not load the dump body above the maximum payload. The brakes will lose their effect. 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.

METHOD OF USING BRAKES

Do not rest your foot on the brake pedal unless it is necessary. Do not depress the brake pedal repeatedly if not necessary. When traveling downhill, use the braking force of the engine, and always use the retardar at the same time.

2 - 21

PRECAUTIONS DURING OPERATION

RECAUTIONS UNDER THE SNOWING AND FREEZING CONDITION

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.

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 slopes, never apply the foot brake suddenly. Reduce the speed and use the

engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times). If

necessary, lower the bucket to the ground 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.

SAFETY

PRECAUTIONS FOR PARKING

Park the machine on firm, level ground.

Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.

When leaving the machine, place the gear shift lever (1) at

neutral and set the parking valve lever (2) to the PARKING

position. 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.

2 - 22

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 terminals securely. 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 - 23

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 movewhen 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

3-111)" in the OPERATION section.

SAFETY

2 - 24

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 3-104)"

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 - 25

PRECAUTIONS FOR MAINTENANCE

SAFETY

PRECAUTIONS FOR MAINTENANCE

WARNING TAG

Attach the DO NOT OPERATE warning tag to gear shift lever (1)

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.

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 - 26

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 falling rocks or landslides, or of flooding if the land is low.

Lower the dump body and stop the engine. Set parking brake valve lever to the PARKING position and put blocks (1) under the tires to prevent the machine from moving.

PRECAUTIONS FOR MAINTENANCE

2 - 27

PRECAUTIONS FOR MAINTENANCE

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine running. If maintenance 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.

Lock the dump lever in HOLD position to prevent the operation

cab from moving. Also, set parking brake valve lever to the

PARKING position to prevent the machine from moving.

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 any control levers. If any control 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.

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.

2 - 28

SAFETY

HANDLING SUSPENSION CYLINDER

The suspension cylinder is charged with high-pressure nitrogen gas. If any mistake is made in handling, it may lead to serious injury. To prevent this, always do as follows.

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.

PERSONNEL

Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer.

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 with the dump body raised, always set the dump lever to the HOLD position, and lock it in position, then insert the safety pin securely. Whenyou use safety pin, see "SAFETY PIN (PAGE 3-35)".

PRECAUTIONS FOR MAINTENANCE

NOISE

When carrying out maintenance of the engine and you are exposed to 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.

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 hummer. 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 carried out 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.

2 - 29

PRECAUTIONS FOR MAINTENANCE

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 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 leakingfrom small holes

may penetrate your skin or cause blindness if it contacts your

eyes directly. If you are hit by a jet of high-pressureoil and suffer

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

consult a doctor immediately for medical attention.

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 thespecified torque. If any damaged 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.

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 into your eyes, it may cause blindness;if it touches your skin, it may cause frostbite. Never touch refrigerant.

2 - 30

SAFETY

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.

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

4-13)". The material of these components naturally changes over time, and repeateduse 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 time specified interval.

PRECAUTIONS FOR MAINTENANCE

2 - 31

PRECAUTIONS WITH TIRES

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 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 4-34)". 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 operationsunder 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 - 32

3 - 1

GENERAL VIEW

OPERATION

GENERAL VIEW

GENERAL VIEW OF MACHINE

(1) (2) (3)

Dump body Rear wheel Front wheel

(4)

Turn signal light

(5)

Head lamp

3 - 2

OPERATION

GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES

Safety lock

(1)

Dump lever

(2)

Lamp switch, Turn signal lever, Dimmer switch

(3)

Steering wheel

(4)

Machine monitor

(5)

Retarder control lever

(6)

Cigarette lighter

(7)

Shift lever

(8)

Parking brake valve lever

(9)

Shift limiter switch

(10)

Power mode selector switch (if equipped)

(11)

Emergency brake lever

(12)

Emergency steering switch

(13)

Message display for PMC (if equipped)

(14)

Engine emergency stop switch

(15)

Accelerator pedal

(16)

Brake pedal

(17)

Differential lock pedal (if equipped)

(18)

3 - 3

GENERAL VIEW

Enlargement of machine monitor

OPERATION

Caution/pilot lamp bulb check switch

(1)

Starting switch

(2)

Preheating switch

(3)

AISS LOW switch

(4)

Panel dimmer switch

(5)

Hazard lamp switch

(6)

Front brake cut-off switch

(7)

Exhaust brake switch

(8)

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

Meter display portion

User code display

Caution items

Emergency stop item

NOTICE When the starting switch is turned to the ON position before the engine is started, all the monitors, gauges, and the central warning lamp will light up for approx. 3 seconds, and the alarm buzzer will sound for approx. one second. When this happens, the speedometer will display 88. If no monitor lamp lights up, then there is probably a failure or disconnection in that circuit, therefore contact your Komatsu distributor to have the circuit checked. When the starting switch is at the ON position, if the shift lever is not at the neutral position, then the transmission shift lever position pilot lamp (1) and the central warning lamp will flash and the alarm buzzer will continue to sound intermittently. At this time, when the lever is placed in neutral, letter N is displayed, the central warning lamp goes out and the buzzer stops.

Checking for blown caution lamp or pilot lamp bulbs Turn the starting switch to the ON position before starting the engine, press bulb check switch (2) and check that no caution lamp or pilot lamp bulbs are blown. If any lamp does not light up, the bulb is probably blown, so replace the bulb. If the lamp does not light up even when the bulb is replaced, there is probably a failure or disconnection, so please contact your Komatsu distributor to have the circuit checked.

Mechatronic caution lamp portion

Central warning lamp

3 - 5

EXPLANATION OF COMPONENTS

USER CODE DISPLAY

If any failure occurred on the machine or if the operation needs to be changed or if checks and maintenance are required, the user code display (1) shows the user code indicating appropriate corrective action. At this time, the monitor related to the abnormal area lights up or flashes, and the central warning light flashes.

OPERATION

(1) User code display

WARNING

If user code 02 or 04 is displayed, stop the machine immediately. See "SERVICE CODE (PAGE 3-118)", and check the service code number. Contact Komatsu distributor, telling them the service code number, for repair.

If letter "E-" and any user code of "01 to 07" is displayed in turn at the upper right of the liquid crystal display on the monitor panel, stop the machine once. Then, take the corrective action as follows after checking user code (1). User code 02: Park the machine at a safe location and contact your Komatsu distributor. 04: Carry out an emergency stop. Stop the engine and contact your Komatsu distributor. 01: Carry out checks and maintenance according to the Operation and Maintenance Manual. 03: Operate the machine keeping the engine at low revolution and low travel speed. 05: Stop the machine. Run the engine at a mid-range speed under no load. 06: Restart the engine. Idle the engine for a while. 07: Do not raise the dump body.

If the user code is displayed again even after taking the corrective action shown above when the user code 01, 03, 05, 06, or 07 is displayed, check the sevice code.

3 - 6

OPERATION

CAUTION ITEMS

EXPLANATION OF COMPONENTS

CAUTION

If any of the warning monitors lights up, carry out the inspection and maintenance of the appropriate item as soon as possible. If it is left without the inspection and maintenance, it will lead to the trouble or failure.

If there is any abnormallity for the caution items, the monitor for the corresponding abnormal area lights up.

Transmission filter clogging

Battery charge

(1)

Emergency steering

(2)

Parking brake

(3)

Dump body actuation caution

(4)

BATTERY CHARGE

This (1) notifies the operator of any abnormality in the charging system when the engine is running. If it lights up and simultaneously displays user code 01, check the charging circuit.

(5)

Fuel level

(6)

Maintenance caution lamp (if equipped)

(7)

3 - 7

EXPLANATION OF COMPONENTS

EMERGENCY STEERING

This (2) 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.

PARKING BRAKE

This (3) lights up when the parking brake is applied. It goes on and out respectively responding to the parking brake lever shifting of PARK/TRAVEL.

OPERATION

DUMP BODY ACTUATION CAUTION

This monitor (4) lights up when the dump body control lever is at any position other than FLOAT or when the body is lifted. Always set the lever to the FLOAT position and lower the body during traveling.

TRANSMISSION FILTER CLOGGING

This monitor (5) notifies the operator that the transmission filter is clogged. If it lights up anddisplays action code01 at the same time, replace the transmission filter.

3 - 8

OPERATION

FUEL LEVEL

This monitor (6) flashes when the level of the fuel in the fuel tank goes below 170 liters (44.88 US gal). If it flashes, check the fuel level and add fuel.

MAINTENANCE CAUTION LAMP

(If equipped) If the machine is in any of the following conditions, this lamp will light up. If it lights up and displays user code 01 at the same time, carry out check, replenishment or replacement.

EXPLANATION OF COMPONENTS

Insufficient oil in the front brake oil tank Insufficient oil in the transmission case Insufficient oil in the hydraulic oil tank Clogging of the transmission filter (on the tank side) Clogging of the full flow filter (the engine oil filter) Clogging of the hydraulic oil filter Wear of the rear brake disc (right hand) Wear of the rear brake disc (left hand) Drop of the battery electrolyte level Insufficient oil in the engine oil pan Clogging of the air cleaner

3 - 9

EXPLANATION OF COMPONENTS

EMERGENCY STOP ITEM

OPERATION

CAUTION

If any of these monitor lights up or flashes, stop the engine immediately or put the engine in low idling, then check the corresponding area and carry out the action.

If the abonormaliy is found in the emergency items, the waring buzzer sounds and the monitor corresponds to the abnormal section lights up or flashes, and the central warning light flashes.

Engine oil pressure

Air pressure

(1)

Engine water temperature

(2)

Torque converter oil temperature

(3)

Retarder oil temperature

(4)

Radiator water level

(5)

AIR PRESSURE

This monitor (1) warns the operator that the air pressure inside the air tank has dropped. If it flashes and displays the user code "05" at the same time, stop the machine, run the engine under no load at a mid-range speed, and wait until the lamp goes out.

(6)

Angle warning

(7)

Rear brake caution lamp

(8)

Steering oil temperature

(9)

3 - 10

OPERATION

ENGINE WATER TEMPERATURE

This (2) warns the operator that the engine cooling water temperature has risen. For the machine equipped with an electronic governor (if equipped), the engine output is automatically limited. If it flashes and displays user code 05 at the same time, stop the machine and run the engine under no load at a mid-range speed until the engine water temperature gauge enters the green range.

TORQUE CONVERTER OIL TEMPERATURE

This monitor (3) warns the operator that the torque converter oil temperature has risen. If it flashes and displays user code "05" at the same time, stop the machine and run the engine under no load at a mid-range speed until the torque converter oil temperature gauges enters the green range.

EXPLANATION OF COMPONENTS

RETARDER OIL TEMPERATURE

This monitor (4) warns the operator that the retarder oil temperature has risen. If it flashes and displays user code "05" at the same time, stop the machine, place the shift lever at the N (neutral) position, then run the engine under no load at a mid-range speed until the warning lamp goes out.

RADIATOR WATER LEVEL

This (5) warns the operator that the radiator water level has dropped. If it lights up and displays user code 01 at the same time, stop the engine, check the level of the cooling water in the radiator, and add the water.

3 - 11

EXPLANATION OF COMPONENTS

ENGINE OIL PRESSURE

This (6) warns the operator that the engine lubricating oil pressure has dropped. If it lights up and displays user code 04 at the same time, stop the machine safely. Then, stop the engine 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.

ANGLE WARNING

When the dump body is raised, this monitor (7) warns the operator that the machine has tilted beyond the safety range to the left or right. If it lights up and displays action code "07" at the same time, lower the body and move the machine to a safe, stable place.

OPERATION

REAR BRAKE CAUTION LAMP

This monitor (8) lights up if the brake oil pressure drops under the normal value. If it lights up and display user code "04" at the same time, immediately check the rear brake system. After checking and repairing, depress the rod for the overstroke sensor on the brake chamber. If depressing is not carried out, the rear brake caution lamp will continue to light up.

STEERING OIL TEMPERATURE

This monitor (9) warns the operator that the steering oil temperature has risen. If it lights up and displays user code "05" at the same time, stop the machine, place the shift lever at the N (neutral) position, then run the engine under no load at a mid-range speed until the warning lamp goes out.

3 - 12

OPERATION

METER DISPLAY PORTION

PILOT DISPLAY PORTION

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

EXPLANATION OF COMPONENTS

High beam

Preheating monitor

(1)

Exhaust brake pilot

(2)

Rear brake pilot (retarder)

(3)

Differential lock pilot (if equipped)

(4)

Lockup pilot lamp

(5)

Shift limiter pilot lamp

(6)

PREHEATING MONITOR

This lamp lights up when the electrical heater for preheating the engine is being actuated.

(7)

Turn signal pilot lamp

(8)

Shift indicator (with lockup display)

(9)

Transmission shift lever position pilot lamp

(10)

Auto suspension mode display lamp

(11)

Power mode display lamp (if equipped)

(12)

3 - 13

EXPLANATION OF COMPONENTS

EXHAUST BRAKE PILOT

This pilot lamp (2) lights up when the exhaust brake is actuated.

REAR BRAKE PILOT (Retarder)

This pilot lamp (3) lights up when the foot brake is depressed or the retarder control lever is pulled, and the rear brake is applied.

OPERATION

DIFFERENTIAL LOCK PILOT

(If equipped) This pilot lamp (4) lights up when the differential lock pedal (if equipped) is depressed and the differential lock is actuated.

LOCKUP PILOT LAMP

This pilot lamp (5) lights up when the torque converter lockup is engaged and the transmission is shifted to direct drive.

3 - 14

OPERATION

SHIFT LIMITER PILOT LAMP

This pilot lamp (6)lights up when the shift limiter switch is actuated.

HIGH BEAM

This monitor (7) lights up when the head lamps are set to high beam.

EXPLANATION OF COMPONENTS

TURN SIGNAL PILOT LAMP

This pilot lamp (8) flashes at the same time as the turn signal lamp flashes.

SHIFT INDICATOR

This monitor (9) displays the transmission shift range (speed range). When the key was turned ON, if the shift lever is operated, it will display "2" at the lever position "D", "1" at the "5" - "L" position, and "R" at the R position even if the engine is stopped.

3 - 15

EXPLANATION OF COMPONENTS

TRANSMISSION SHIFT LEVER POSITION PILOT LAMP

This monitor (10) indicates the position of the transmission shift lever.

AUTO SUSPENSION MODE DISPLAY LAMP

This monitor (11) displays the suspension mode, when the machine is equipped with the suspension controller. An automatic suspension system is mounted which automatically switches the damping characteristics of the suspension according to the size of the load, use of the brake, operation of the steering, and operation of the dump control. Normally it is set to the soft mode when the dump truck is traveling empty and to the medium mode when it is traveling loaded. When the foot brake is operated or the machine is suddenly turned,or the dump control is operated, the suspension mode is switched to insure the stability of the machine to the front and rear, and left and right.

OPERATION

H : Hard mode M : Medium mode S : Soft mode

POWER MODE DISPLAY LAMP

(If equipped) This monitor (12) displays the power mode. Select the mode with the power mode switch.

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OPERATION

METERS

EXPLANATION OF COMPONENTS

Speedometer

(1)

Engine tachometer

(2)

Service meter

(3)

Odometer

(4)

Fuel gauge

(5)

SPEEDOMETER

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

Air pressure gauge

(6)

Engine water temperature gauge

(7)

Torque converter oil temperature gauge

(8)

Retarder oil temperature gauge

(9)

3 - 17

EXPLANATION OF COMPONENTS

ENGINE TACHOMETER

This meter (2) indicates the speed of the engine. While operating the machine, if the red range lights up, simultaneously the warning buzzer sounds and the central warning lamp flashes, then operate the machine while lowering the engine speed and the traveling speed.

SERVICE METER

This meter (3) shows the total hours of operation of the machine. If the engine is running, the service meter will advance even if the machine is not moving. The meter advances by 1 for every one hour of operation, regardless of the engine speed.

OPERATION

ODOMETER

This (4) indicates the distance traveled in kilometers.

FUEL GAUGE

This gauge (5) indicates the amount of fuel in the fuel tank. The green range should be lighted up during operation. If only the red range remains lighted during operation, it indicates that there is less than 120 liters (31.68 US gal) of fuel remaining in the tank, so check and add fuel.

3 - 18

OPERATION

AIR PRESSURE GAUGE

This gauge (6) indicates the air pressure inside the air tank. The green range should be lit up during operation. If the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, and the air pressure monitor lamp will also flash at the same time. If this happens, stop the machine, raise the enginespeed, and wait until the green range lights up.

REMARK

If the air pressure drops further, the parking brake is automatically applied.

ENGINE WATER TEMPERATURE GAUGE

This gauge (7) indicates the engine cooling water temperature. The green range should be lighted up during operation. If the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, and the engine water temperature monitor lamp will flash at the same time. If this happens, stop the machine, run the engine under no load at a mid-range speed, and wait until the green range lights up. If the red range lights up, the engine output of the machine equipped with an electronic governor is automatically limited.

EXPLANATION OF COMPONENTS

TORQUE CONVERTER OIL TEMPERATURE GAUGE

This gauge (8) indicates the torque converter oil temperature. The green range should be lit up during operation. If the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, andthe torque converter oil temperature monitor lamp will flash at the same time. If this happens, stop the machine, run the engine under no load at a mid-range speed, and wait until the green range lights up.

RETARDER OIL TEMPERATURE GAUGE

This gauge (9) indicates the retarder cooling oil temperature. The green range should be lit up during operation. If the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, and the retarder oil temperature monitor lamp will flash at the same time. If this happens, stop the machine, run the engine under no load at a mid-range speed, and wait until the green range lights up.

3 - 19

EXPLANATION OF COMPONENTS

MECHATRONIC CAUTION LAMP PORTION

If an abnormality is detected in the mechatronics-related parts of the control system, the monitor lamp and the central warning lamp light up and the alarm buzzer sounds intermittently. Stop the machine, then take appropriate corrective action according to the user code.

OPERATION

(1)

Engine (Mechatronics-related)

(2)

Automatic transmission (Mechatronics-related)

ENGINE

(Mechatronics-related) If an abnormality is detected in the mechatronics-related parts of the engine control system, this lamp (1) flashes to warn of the abnormality.

(3) Mechatronics-related parts

(Excluding 1. and 2. above)

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OPERATION

AUTOMATIC TRANSMISSION

(Mechatronics-related) If an abnormality is detected in the mechatronics- related parts of the transmission control system, this lamp (2) flashes to warn of the abnormality.

MECHATRONICS-RELATED PARTS

(Excluding 1. and 2. above) If an abnormality is detected in the mechatronics-related parts of the control system other than those of the engine and transmission, this lamp (3) flashes to warn of the abnormality.

EXPLANATION OF COMPONENTS

CENTRAL WARNING LAMP

If the machine is in the following condition, this lamp will flash.

When an abnormality has occurred in any of B caution items. When the abnormalities has occurred refered to "CAUTION ITEMS (PAGE 3-7)".

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

When an abnormality has occurred in any of "EMERGENCY STOP ITEM (PAGE 3-10)". When "MECHATRONIC CAUTION LAMP PORTION (PAGE 3-20)" flashes. If the parking brake is applied, but the shift lever is not at neutral. When the dump lever is not at the FLOAT position and the shift lever is not at neutral. When engine tachometer red range lights up.

3 - 21

EXPLANATION OF COMPONENTS

OPERATION

SWITCHES

Starting switch

(1)

Lamp switch

(2)

Turn signal lever Dimmer switch Caution/pilot lamp bulb check switch

(3)

Exhaust brake switch

(4)

Front brake cut-off switch

(5)

Hazard lamp switch

(6)

Night lighting dimmer switch

(7)

AISS LOW switch

(8)

Preheating switch

(9)

Power mode selector switch

(10)

Emergency steering switch

(11)

Emergency brake lever

(12)

Shift limiter switch

(13)

Parking brake valve lever

(14)

Engine emergency stop switch

(15)

Cigarette lighter

(16)

Horn button

(17)

Wiper switch

(18)

Room lamp switch

(19)

3 - 22

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

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

monitor lighting light up

(b) position 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 - 23

EXPLANATION OF COMPONENTS

DIMMER SWITCH

This (2) is used to switch the head lamps between high beam and low beam. (a) Low beam (b) High beam

CAUTION/PILOT LAMP BULB CHECK SWITCH

Press this switch (3) when the starting switch is at the ON position to check for any blown bulbs.

OPERATION

EXHAUST BRAKE SWITCH

This switch (4)shows the operating condition of the exhaust brake. If it is pushed once, it lights up; and it goes off when it is pushed again. OFF position (Light is off): The exhaust brake is actuated when the brake pedal is depressed or the retarder control lever is operated if the torque converter is in the lockup condition. ON position (Light is on): The exhaust brake is actuated when the accelerator pedal is released if the torque converter is in the lockup condition.

3 - 24

OPERATION

FRONT BRAKE CUT-OFF SWITCH

EXPLANATION OF COMPONENTS

WARNING

When traveling on icy roads, on snow, or on other slippery road surfaces, set the front brake cut-off switch to the ON position and travel slowly at a safe speed. If the front brake cut-off switch is set to the OFF position, it becomes dangerously difficult to control the steering when traveling under the abovementioned conditions.

This switch (5) switches the braking method according to the road surface conditions. If the switch is pressed, the lamp lights up, the front brake cut function is actuated, and the brakes are not applied to the front wheels. If the switch is pressed again, the lamp goes out and the front brake cut function is canceled.

OFF position (Light is off.): When the brake pedal is depressed, the brakes are applied to both the front and rear wheels. ON position (Light is on.): When the brake pedal is depressed, the front brakes are not applied. The brakes are applied only to the rear wheels.

When traveling at high speed, on a road surface that has been properly watered, set the front brake cut-off switch to OFF position (lamp off), and normally use the retarder control lever to control the travel speed (retarder braking is applied only to the rear wheels). To control the machine whenever emergencyaction is needed, such as when the machine slips to the side or when the machine has to be stopped suddenly, use the brake pedal to operate the brakeson the front wheels to give extra braking force.

HAZARD LAMP SWITCH

This switch (6) flashes the left- and right-hand turn signal lamps. When the switch is turned on, the turn signal pilot lamp flashes at the same time. If the starting switch is OFF, the turn signal pilot lamp does not flash.

3 - 25

EXPLANATION OF COMPONENTS

NIGHT LIGHTING DIMMER SWITCH

This switch (7) is used to adjust the brightness of the monitor panel lighting and pilot lamps. Turn to the right to make the lighting brighter and turn it to the left to make the lighting dimmer.

AISS LOW SWITCH

AUTO and LOW speed can be freely switched to each other with AISS LOW switch (8). Use each position as follows. If the switch is depressed, it lights up, and if it is depressed once again, the light goes off. OFF position (Light is off): AUTO position

At normal operation

ON position (Light is on): Low speed position

When the delicate start and operation is needed like putting the machine into garage

OPERATION

If the switch is at AUTO position:

When stopping the machine, by setting either parking brake or retarder brake at ON position, idling is set at low

1. speed. When starting, by setting the parking brake at OFF position, idling is set at high speed.

2. Detecting the water temperature, idle is set at high speed automatically under the low temperature condition, and the warm-up time is shortened.

PREHEATING SWITCH

This switch (9) operate an electric heater to heat the intake air for the engine. If it is pushed, it lights up and perform preheating. If it is released, it returns to the original position.

OFF position (Light is off): If the ambient temperature is below

approx. - 5°C (23°F), preheating is carried out automatically according to the ambient temperature.

ON position (Light is on): Preheating is carried out.

Press this switch if the engine does not start when only automatic preheating is carried out or when post-heating is required after the engine is started. When the switch is released, it will return automatically to the automatic preheating position.

3 - 26

OPERATION

POWER MODE SELECTOR SWITCH

The power mode switch (10) can be switched to allow the machine to travel economically in a way suited to the operating conditions. If depressed once, it lights up; if depressed once again, the light goes off. OFF position: High power (general operations)

This is used for general operating conditions.

ON position: economy (traveling in flat areas)

This position is used when the emphasis is on reducing fuel consumption, such as when traveling on flat ground where maximum output is not needed.

EMERGENCY STEERING SWITCH

This switch (11) is used to actuate the emergency steering pump. When the switch is pressed, the emergency pump is actuated to make it possible to operate the steering. When the switch is ON, the pilot lamp (red) inside the switch lights up. The emergency steering pump can be used for a maximum of 90 seconds. When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH). When the emergency steering is actuated, it is possible to use the dump lever to raise the dump body.

EXPLANATION OF COMPONENTS

Automatic emergency steering will be actuated automatically in the following cases:

When hydraulic pump for steering has trouble When engine has stopped during operation

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

If the key switch is turned ON when the machine is stopped and the parking brake switch is OFF, the auto emergency steering is actuated after 1 second, so turn the parking brake switch to the ON (PARKING) position.

EMERGENCY BRAKE LEVER

This lever (12) is used to actuate the emergency brake. ON (applied): Emergency brake actuated TRAVEL: Emergency brake released

If the pressure in the air tank drops below 0.22 MPa (2.2 kgf/cm2,

31.24 PSI), the emergency brake is automatically applied. If the emergency brake is applied because of a failure in the air system, the central warning lamp flashes and the alarm buzzer sounds. For details of releasing the brake when the emergency brake has been applied because of a failure in the air system, see "RELEASE METHOD WHEN PARKING BRAKE AND EMERGENCY BRAKE HAVE BEEN ACTUATED IN EMERGENCY (PAGE 3-107)"

3 - 27

EXPLANATION OF COMPONENTS

SHIFT LIMITER SWITCH

This switch (13) is used to limit the maximum speed range when the transmission shift lever is in the D or L range. If the switch is depressed, it lights up, and the shifit limiter function get actuated; consequently the maximum speed for D range is limited to F6, and the speed for L range is limited to F1 only. If the switch is depressed again, the light goes away. Light-off position: D range F2 - F7

L range F1 - F2

Light-on position: D range F2 - F6

L range F1

PARKING BRAKE VALVE LEVER

OPERATION

WARNING

When parking or leaving the machine, always apply the parking brake. During loading operations, do not apply the parking brake. Pull the retarder lever to apply the brake.

This lever (14) is used to actuate the parking brake valve. PARKING: Parking brake actuated TRAVEL: Parking brake is released. When the lever is set to the PARKING position, the parking brake pilot lamp lights up. When the lever is set to the PARKING position, if the gear shift lever is at any position other than N, the central warning lamp will flash and the alarm buzzer will sound.

If the air pressure drops and goes below 0.22MPa(2.2kgf/cm2, 31.24PSI), the emergency brake and parking brake are automatically applied. For details of releasing the brakewhen the emergencybrake has beenapplied because of a failure in the air system, see "RELEASE METHOD WHEN PARKING BRAKE AND EMERGENCY BRAKE HAVE BEEN ACTUATED IN EMERGENCY (PAGE 3-107)"

ENGINE EMERGENCY STOP SWITCH NOTICE This switch must not be used for stopping the engine under normal conditions. When the engine has completely stopped, return the switch to the ON (TRAVEL) position.

Use this switch (15) if the engine will not stop even when the starting switch is turned to the OFF position.

3 - 28

OPERATION

CIGARETTE LIGHTER

This (16) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, so pull it out and use it to light your cigarette.

HORN BUTTON

When the horn button (17) in the center of the steering wheel is pressed, the horn will sound.

EXPLANATION OF COMPONENTS

WIPER SWITCH

This switch (18) is used to operate the wiper. INT position: Wiper moves intermittently OFF LOW position: Wiper moves at low speed HI position: Wiper moves at high speed When the switch is pressed, washer fluid is sprayed out.

ROOM LAMP SWITCH

This (19) is used to switch the room lamp on or off. (a) OFF (b) ON

3 - 29

EXPLANATION OF COMPONENTS

OPERATION

CONTROL LEVERS AND PEDALS

Brake pedal

(1)

Accelerator pedal

(2)

Shift lever

(3)

Safety lock

(4)

BRAKE PEDAL

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

Dump lever

(5)

Retarder control lever

(6)

Differential lock pedal (if equipped)

(7)

3 - 30

OPERATION

ACCELERATOR PEDAL

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

GEAR SHIFT LEVER

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

EXPLANATION OF COMPONENTS

D position: This is used for normal travel. If the lever is placed in this position, the transmission is shifted automatically from 2nd (torque converter drive) to 7th (direct drive) to match the travel speed of the machine. If the dump body is raised, the speed rangeis fixed at 2nd when the shift lever is at D position. Always lower the dump body when traveling. The maximum speed in D position is 65 km/h (40.4 MPH).

R position: This is used when traveling in reverse. This position uses the torque converter drive. The machine cannot travel in reverse if the dump lever is not at the FLOAT position. Set the dump lever to the FLOAT position before moving the shift lever to the R position.

5 - L 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.

The speed ranges for each position are as follows.

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

5 1st torque converter - 5th direct 36 (22.4)

4 1st torque converter - 4th direct 27 (16.8)

3 1st torque converter - 3rd direct 20 (12.4)

L 1st torque converter - 2nd direct 15 (9.3)

If the dump body is raised, it is impossible to shift up from 1st. Always lower the dump body when traveling.

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 warning monitor lamp may light up.

3 - 31

EXPLANATION OF COMPONENTS

Before shifting between forward and reverse, stop the machine completely and then run the engine at low idle. When starting the engine, if the gear shift lever is not at the N position, the engine will not start. When the starting switch is turned to the ON position, if the shift lever is not at the N (neutral) position, the transmission shift lever position pilot lamp and the central warning lamp will flash and the alarm buzzer will sound.

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

When the dump lever is not at the FLOAT position and when the dump body has risen, if the shift lever is not at the N (neutral) position, the central warning lamp will flash 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 (neutral) position to the forward or reverse position.

OPERATION

When moving the gear shift lever from the N (neutral) position to the R (reverse) position or from the D positions to position 5 (or other lower position), press the lock button on the gear shift lever before moving it.

SAFETY LOCK

WARNING

When raising the dump body to inspect the machine, always place the dump lever at the HOLD position, apply the lock, and then use the safety pins.

This device (4) is used to lock the dump lever.

3 - 32

OPERATION

DUMP LEVER

EXPLANATION OF COMPONENTS

WARNING

To prevent damage to the dump body through vibration from the road surface, always lower the dump body and set at FLOAT position before traveling.

This lever (5) 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 For details, see "DUMP OPERATIONS (PAGE 3-88)".

RETARDER CONTROL LEVER

CAUTION

The retarder must not be used as a parking brake.

This lever (6) is used to operate the retarder, which applies the rear wheel brake when going downhill. The more the lever is pulled, the greater the braking force becomes. When the retarder is actuated, the rear brake pilot lamp lights up.

For details, see "TRAVELING DOWNHILL (PAGE 3-81)". When leaving the operator's seat, always apply the parking brake.

DIFFERENTIAL LOCK PEDAL

(If equipped) This pedal (7) is used to actuate the differential lock control. When the pedal is depressed, the differential lock is actuated, and when it is released, the differential lock is canceled. See "USING DIFFERENTIAL LOCK (PAGE 6-21)" for the details.

3 - 33

EXPLANATION OF COMPONENTS

OPERATION

MECHATRONICS EQUIPMENT CONTROLLER

(1)

Transmission controller

(2)

Engine controller

(3) Suspension controller

TRANSMISSION CONTROLLER

A two-digit number followed by the service code is displayed in the inspection window of this controller (1) to identify the location of the abnormality. When the condition is normal, "0.0" or "0.C" is displayed.

For the mothod of checking the service code when an abnormality occurs, see "TRANSMISSION CONTROLLER (PAGE 3-119)".

ENGINE CONTROLLER

For this controller (2), the last two-digit number of the service code is displayed in the inspection window to identify the location of the abnormality. When the condition is normal, "0.0" is displayed. For the method to check the service code when the abnormality occurs, see "SERVICE CODE (PAGE 3-118)".

SUSPENSION CONTROLLER

For this controller (3), the last two-digit number of the service code is displayed in the inspection window to identify the location of the abnormality. When the condition is normal, "0.0" is displayed. For the method to check the service code when the abnormality occurs, see "SERVICE CODE (PAGE 3-118)".

3 - 34

OPERATION

EXPLANATION OF COMPONENTS

SAFETY PIN

WARNING

When raising the dump body to inspect the machine, always place the dump lever at the HOLD position, apply the lock, and then use the safety pins.

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 safety pins (1). Always insert the safety pins on both sides.

STOWING SAFETY PIN

Safety pins (1) are stowed in the towing bracket of the rear axle housing.

DUST INDICATOR

This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent part of this indicator, the element is clogged. Immediately clean the element. After cleaning, push indicator button (2) to return the red piston to the original position.

3 - 35

EXPLANATION OF COMPONENTS

OPERATION

FUSES

WARNING

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.

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.

FUSE CAPACITY AND CIRCUIT NAME

Fuse box I

Fuse

No.

capacity

1 10A Car radio, car stereo

2 10A Horn switch

3 10A Cigarette lighter

4 20A Turn signal indicator lamp, fog lamp (if equipped)

5 10A Engine start relay, neutral relay

6 20A Head lamp (low beam), stop lamp, room lamp

720A

8 10A Backup lamp, backup buzzer

910A

10 10A

Head lamp (high beam), side clearance lamp, tail lamp, night lighting

Ribon heater relay, front brake cut-off solenoid, BCV relay solenoid

Overrun prevention solenoid, transmission controller, exhaust brake solenoid

Circuit name

3 - 36

OPERATION

Fuse box II

Fuse

No.

capacity

11 10A Engine controller, governor cut relay

Electronic display panel, caution pilot lamp,

12 10A

13 5A

14 5A

15 20A Payload external display lamp (if equipped)

16 5A PMC (if equipped)

17 10A

18 10A

19 10A Emergency steering

20 10A Direct from battery (spare)

central warning lamp, buzzer, PMC (if equipped), MOM( if equipped)

Suspension control solenoid, suspension controller

Payload meter (if equipped), payload relay (if equipped)

Start switch, radio back-up, emergency engine stop solenoid (if equipped electronic governor), engine stop motor

T/M controller, engine controller (if equipped), PMC (if equipped)

Circuit name

EXPLANATION OF COMPONENTS

Fuse box III

Fuse

No.

capacity

21 10A AISS motor

22 20A Wiper motor, washer motor

23 20A Air conditioner blower motor

24 10A Air conditioner compressor

25 10A Spare

26 10A Spare

Circuit name

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EXPLANATION OF COMPONENTS

OPERATION

CAR STEREO

(If equipped)

EXPLANATION OF COMPONENTS

Power switch/Volume

(1)

Auto-store/Preset scan button

(2)

Bass control knob

(3)

Treble control knob

(4)

Loudness button

(5)

Time/Radio display selector button

(6)

Tape eject button

(7)

Band display

(A)

Metal tape display

(B)

FM stereo reception display

(C)

Loudness display

(D)

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Cassette door

(8)

Fast forward, rewind buttons

(9)

Preset buttons

(10)

Metal tape button

(11)

Manual tuning buttons

(12)

Seek tuning buttons

(13)

Band selector button

(14)

Tape direction display

(E)

Preset channel display

(F)

Time/Frequency display

(G)

OPERATION

POWER SWITCH/VOLUME

Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume.

AUTO-STORE/PRESET SCAN BUTTON

Use this button (2) to actuate the preset scan and auto-store functions.

Auto-store Each time this button is pressed for more than 2 seconds while in radio reception, this auto-store function automatically starts to search for the desired station within a receivable band, and memorize the frequency in the preset memory. During this scanning process, the frequency shown in the right side of display continues to change. This indicates that each frequency is memorized in the auto-store.

EXPLANATION OF COMPONENTS

REMARK

The auto-store function cannot be used when the channel display is flashing. When the display is flashing, the preset scan function is being used.

Preset scan If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations in the same band will be broadcast one after another for 5 seconds each, starting from No. 1 through No. 6 stations consecutively. When the desired station is found, press the button again. This stopsthe presetscan tuningprocess and switches to ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.

BASS CONTROL KNOB

Turn this button (3) to the left to reduce the low tones; turn it to the right to emphasize the low tones. Direction (a): Low tone reduced Direction (b): Low tone emphasized

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EXPLANATION OF COMPONENTS

TREBLE CONTROL KNOB

Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized

LOUDNESS BUTTON

This button (5) is used when playing at low volume. It makes it possible to hear more easily by emphasizing the low tone when the low tones are weak. Push button: Actuated (ON) Push button again: Canceled (OFF)

OPERATION

TIME/RADIO DISPLAY SELECTOR BUTTON

This button (6) is used to switch between the "Radio/tape display" and the "Time display".

Correcting the time Press the button to set the time display. (A) Correcting hour:

Keep the DISP button pressed and press the bottom (H) of the TUNING button to correct the hour.

(B) Correcting minute:

Keep the DISP button pressed and press the top (M) of the TUNING button to correct the minute.

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OPERATION

TAPE EJECT BUTTON

This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays.

CASSETTE DOOR

Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).

EXPLANATION OF COMPONENTS

FAST FORWARD, REWIND BUTTONS

These buttons (9) are used to fast-forward or rewind the tape.

Fast-forward/rewind If you press the button pointing in the same direction as the lighted arrow indicating the direction of play, the tape will be fast-forwarded; if you press the button pointing in the opposite direction, the tape will rewind. To stop the tape, lightly press the button that is not locked. The fast-forward or rewind operation will be canceled. If the fast forward and rewind buttons are pressed at the same time, the tape will change sides.

PRESET BUTTONS

These buttons (10) are used to call up the broadcast station frequencies preset in memory for each of buttons No. 1 to No. 6. It is possible to preset 18 stations (FM: 12; AM: 6) with these buttons.

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EXPLANATION OF COMPONENTS

METAL TAPE BUTTON

(used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, "MTL" appears on the display.

MANUAL TUNING BUTTONS

These buttons (12) are used for manual tuning. When "TUN ∧" button is pressed, the frequency goes up 9 kHz for AM or 0.1 MHz for FM; when "TUN ∨" button is pressed, the frequency goes down 9 kHz for AM or 0.1 MHz for FM. If the button is pressed down and held, the frequency will change continuously.

OPERATION

SEEK TUNING BUTTONS

These buttons (13) are used to seek tuning. When the "SEEK UP" button is pressed, the search automatically goes up; when the "SEEK DOWN" button is pressed, the search automatically goes down. When the next station that can be received is found, it automatically stops.

BAND SELECTOR BUTTON

When this button (14) is pressed, the band is switched between FM1, FM2, and MW (AM). The band is shown on the display.

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OPERATION

METHOD OF OPERATION

METHOD OF SETTING PRESET BUTTONS

To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).

1. If you are playinga cassette, press the tape eject button to stop

the tape. Select the station to be preset.

Use band selector button (1) to select MW (AM), FM1, or FM2, then use the manual tuning button to select the frequency of the broadcasting station.

3. Press manual memory button (2) or seek tuning button (3).

Press preset button (4) of the number to be preset for 2

seconds while the frequency display is being shown on the display. (The preset channel and frequency are displayed and the presetting is completed). Repeat Steps 2 to 4 to preset other stations.

EXPLANATION OF COMPONENTS

REMARK

Use Steps 2 to 4 also when changing the setting of a preset switch to another station. When the power is disconnected, such as when the battery is replaced, all the settings are deleted, so preset the stations again.

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EXPLANATION OF COMPONENTS

MANUAL MEMORY BUTTON

Select the station to be preset with manual tuning button (1) or seek tuning button (2), then keep button No.1 to button No.6 of button (3) pressed for 2 seconds while the frequency is being displayed to preset the station.

OPERATION

LISTENING TO RADIO

Turn the starting switch ON, then turn power switch (1) ON.

2. Set band selector button (2) to AM or FM. Select the station with the preset buttons or manual tuning

3. button (3).

4. Adjust the volume, balance, and tone as desired. When turning the radio OFF, turn power switch (1) to the left

5. until it clicks.

REMARK

To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape. If you insert a cassette when listening to the radio, the tape will start to play.

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OPERATION

LISTENING TO CASSETTE TAPE

Turn the starting switch ON, then turn power switch (1) ON.

Set the cassette with the exposed portion of the tape on the

right side and push it past the cassette door. The tape will automatically start playing. If the arrow indicating the direction of play is pointing to the right, the top side is being played; if the arrow is pointing to the left, the bottom side is being played. When the tape reaches the end, it is automatically reversed and the other side starts to play. When finished with the tape, press the cassette eject button to

eject the tape and automatically switch to the radio.

EXPLANATION OF COMPONENTS

REVERSING TAPE

When listening to the tape, press both FAST FORWARD, REWIND buttons (A) and (B) at the same time lightly. When this is done, the tape direction display will be reversed.

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EXPLANATION OF COMPONENTS

PRECAUTIONS FOR USE

Stow the antenna when traveling in places with low overhead clearance. To ensure safety during operations, keep the volume at a level where it is possible to hear other machines. If water gets inside the speaker case or radio (auto tuning), it may cause a serious problem, take care not to let water get in these items. Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a cloth soaked in alcohol if the equipment is extremely dirty.

NOTICE Handling cassette tape

Clean the tape head approx. once a month with a commercially available head cleaning tape. Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place where there is a magnetic field. Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the machine. If the tape is slack, it easily gets caught up inside the machine. Use a pencil to wind in the tape to remove any slack. Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to get the tape out of the machine.

OPERATION

3 - 46

OPERATION

EXPLANATION OF COMPONENTS

AIR CONDITIONER

By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites.

GENERAL LOCATIONS ON CONTROL PANEL

(4)

Fan switch

(1)

Air conditioner switch

(2)

Mode selector switch

(3)

RECIRC/FRESH selector switch

(5)

Temperature control switch

FAN SWITCH

This switch (1) can be used to adjust the air flow to 4 stages. This switch also acts as the main switch for the air conditioner. When the switch is pressed, the indicator lamp above the switch lights up to indicate the air flow.

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EXPLANATION OF COMPONENTS

AIR CONDITIONER SWITCH

This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.

MODE SELECTOR SWITCH

This switch (3) is used to select the vents. The following five vent modes are available: FACE, FACE/FOOT, FOOT, FOOT/DEF, DEF. When the switch is pressed, the indicator lamp above the switch lights up to display the vent mode.

OPERATION

RECIRC/FRESH SELECTOR SWITCH

This switch (4) changes between recirculation of the internal air (RECIRC) or intake of external air (FRESH). When pressing the switch, the indicator lamp on the top of switch lights up.

RECIRC This switch (4) is used when wishing to quickly cool or warm the cab or when the air inside the cab is stale.

FRESH This switch (4) is used to cool or warm the cab with the fresh. Also, it is used for fresh air intake or to remove condensation on windows.

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OPERATION

TEMPERATURE CONTROL SWITCH

The temperature can be adjusted with this switch (5) steplessly from low temperature to high temperature.

The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the green lamps light up, the lower the temperature is.

The color of the indicator lamp changes while the switch is being pressed. When the temperature reaches the desired level, release the switch to set the temperature.

The settings for each mode are retained in memory even when the starting switch is turned OFF. However, in the following cases, the settings must be made again.

When the machine has been out of use for more than 7 days When the battery voltage is extremely low When there has been abnormal interference from outside When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)

EXPLANATION OF COMPONENTS

If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent the entry of dust. The higher the position of the fan switch, the more effective the pressurizing becomes.

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EXPLANATION OF COMPONENTS

METHOD OF OPERATION

OPERATION

Switch

Fan switch

Condition of use

Rapid HI ON All green RECIRC FACE

Cooling

Dehumidifying,

Heating

Vetilation or

pressurizing

When carrying out the defrosting, if the temperature control switch is set so that all lamps are red, this will improve the performance for defrosting and demisting. With the FACE vents, it is possible to adjust the direction of the air flow and to turn it on or off. However, do not set to the FACE mode with the vents closed.

WHEN NOT USING THE AIR CONDITIONER REGURARLY To lubricate each part of the compressor, operate cooling, dehumidifying and heating for 3 to 5 minutes once a month at low idle. Also, check the amount of cooling gas twice a year.

Normal HI - LO ON

heating

Rapid HI OFF All red RECIRC FOOT

Normal HI - LO OFF

Defroster HI ON

HI - LO ON

HI - LO OFF All green FRESH FACE

Air conditioner

switch

Temperature

control switch

More than half

are green

More than half

are red

More than half

are red

More than half

are red

RECIRC/FRESH

selector switch

FRESH FACE

FRESH FOOT

FRESH DEF

Mode selector

switch

REMARK

If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recirculated air to warm up the inside of the cab, then turn the air conditioner switch on. The air conditioner will be run.

PRECAUTIONS WHEN USING AIR CONDITIONER

Carry out ventilation from time to time when using the cooling.

If you smoke when using the cooling, your eyes may start to sting, so in such a case, carry out ventilation and cooling for a short time to remove the smoke. When using the air conditioner for a long period of time, carry out ventilation process at least once every hour.

Be careful not to cool the cab too much.

When using the air conditioner, it is recommended for health reasons, that it should only feel slightly cooler (5 or 6 °C (9 or 10.8°F) lower than the outside temperature) when you enter the cab. Therefore, adjust the temperature to a suitable level.

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OPERATION

INSPECTION AND MAINTENANCE

Even when not using the air conditioner, run the compressor at low speed for several minutes once a week to prevent the loss of the oil film at various parts of the compressor. (Run the engine at low speed and set the temperature control lever to the central position.)

Clean the air filter and check the refrigerant. For details, see "CLEAN AIR CONDITIONER AIR FILTER (PAGE 4-24)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-25)".

To enable the air conditioner to perform to the full and to maintain a pleasant working environment, always contact your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks.

EXPLANATION OF COMPONENTS

3 - 51

EXPLANATION OF COMPONENTS

OPERATION

CAR HEATER

GENERAL LOCATIONS ON CONTROL PANEL

(1) Heater switch (2) Vent selector knob

HEATER SWITCH

This switch is used for turning the heater ON/OFF and for adjusting the air flow. Stopped:OFF (1) Low (2) High

VENT SELECTOR KNOB

This is used to select the vent. (1) Foot (2) Defroster

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OPERATION

PRECAUTIONS WHEN HANDLING

When using the car heater, open valve (1) installed to the

engine thermostat housing.

2. When the season for using the car heaterends, close valve(1).

PRECAUTIONS ON USING HEATER

In winter season always use antifreeze fluid with the density suitable to outside air temperature. Do not use antifreeze fluid stored over a period longer than its recommended serviceable life. If you don't use antifreeze fluid in winter season for your car, drain the coolant from the radiator after at the end of each day. Be sure to change the water hose every two years. DAILY INSPECTION If malfunctions are found as follows, go to the car dealer for repair.

Scratch cracks or swelling of hose. Water leaks from the joint of water hose. Removal of protection cover for the water hose. Broken heater unit bracket or loosening of heater unit installation bolts.

Since this heater warms the cab by using hot water from the engine, it functions only while the engine coolant is hot.

EXPLANATION OF COMPONENTS

LOCATION OF FIRE EXTINGUISHER

Fire extinguisher (1) is located on top of the air piping cover at the right outside rear.

LOCATION OF FIRST AID KIT

First aid box (1) is located on top of the rear cover in the cab.

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OPERATION

CHECK BEFORE STARTING ENGINE

WALK-AROUND CHECK

Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil, fuel, or coolant, and check the condition of the hydraulic system. Check also for loose wiring, play, and accumulation of dust in places that get very hot and are exposed to extremely high temperatures.

WARNING

Be sure to attach the warning sign on the operaation lever of the machine. Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.

Always carry out the following items before starting the engine each day.

1. Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play.

Check the dump body, frame, tires, cylinders, linkage, and hoses for cracks or excessive wear or play, and carry out repairs if any problem is found.

Remove dirt from around engine, battery, radiator, and aftercooler.

Check that there is no dirt or dust accumulated around the engine, radiator or aftercooler. Check also that there is no flammable material (dry leaves, twigs, etc.) accumulated around the battery, or engine, muffler, turbocharger, or other high temperature parts of the engine. Remove any dirt or flammable materials that are found.

3. Check for leakage of water or oil around engine

Check that there is no oil leakage from the engine or coolant leakage from the cooling system. If any problem is found, repair it.

Check for oil leakage from transmission case, differential case, final drive case, brake oil tank, hydraulic tank,

4. hose, joint

Check that there is no oil leakage. If any problem is found, repair the place where the oil is leaking. Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.

5. Check for loose air cleaner mounting bolts.

Check for the loose bolts. If loose, tighten them.

6. Check dump body mount rubber

Check for any cracks, embedded foreign objects, or loose bolts.

7. Check for damage to handrail, loose bolts

Repair any damage and tighten any loose bolts.

3 - 54

Komatsu HD785 Operator 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

ENGINE SERIAL NO. PLATE POSITION

SERVICE METER POSITION

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

CONTENTS

SAFETY INFORMATION

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

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 ON INDOOR VENTILATION

CHECKING SIGNALMAN'S SIGNALS AND SIGNS

ASBESTOS DUST HAZARD PREVENTION

PRECAUTIONS DURING OPERATION

BEFORE STARTING ENGINE

CHECKS BEFORE STARTING ENGINE, ADJUST

PRECAUTIONS WHEN STARTING ENGINE

PRECAUTIONS IN COLD AREAS

AFTER STARTING ENGINE

CHECKS AFTER STARTING ENGINE

PRECAUTIONS WHEN TRAVELING FORWARD OR REVERSE

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN TRAVELING ON THE SLOPES

PRECAUTIONS WHEN OPERATING DUMP BODY

PRECAUTIONS FOR OPERATION

METHOD OF USING BRAKES

RECAUTIONS UNDER THE SNOWING AND FREEZING CONDITION

PRECAUTIONS FOR PARKING

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

PERSONNEL

WORK UNDER THE MACHINE

NOISE

PRECAUTIONS WHEN USING HAMMER

REPAIR WELDING

REMOVING BATTERY TERMINAL

PRECAUTIONS WITH HIGH-PRESSURE OIL

HANDLING HIGH-PRESSURE HOSES, PIPING

WASTE MATERIALS

MAINTENANCE OF AIR CONDITIONER