Komatsu HM400-5 Manual

HM400-5
SERIAL NUMBERS
HM400-5 - 10001 and up
ARTICULATED DUMP TRUCK
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 inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
Operation &
Maintenance Manual
EENAM03380
WARNING
ORIGINAL INSTRUCTIONS

FOREWORD
Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).
1-1

BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
read it at any time.
Keep the Operation and Maintenance Manual inside of the left
door.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.
BEFORE READING THIS MANUAL FOREWORD
1-2

SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
kk
DANGER
This signal word indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
kk
WARNING
This signal word indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
kk
CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against unsafe
practices that may cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
NOTICE If precautions described are not observed, the machine may be damaged or the service life may
be reduced.
REMARK This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
1-3

NOISE
Two labels indicating the machine noise level are affixed on the machine.
• Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator’s position is 2.5dB, in accordance with
ISO 11201
• Sound power level emitted by the machine, measured ac-
cording to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 4.0 dB.
NOISE FOREWORD
1-4

VIBRATION LEVELS
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper-
ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with
ISO 7096.
FOR HM400-5 WITH STANDARD TIRES :
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.58 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.16
m/s2 according to EN12096:1997.
FOR HM400-5 WITH WIDE TIRES :
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.59 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.24
m/s2 according to EN12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
VIBRATION - OPERATING CONDITION
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading and
travelling without load)
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
• Tire pressures (for wheeled machines), tension of crawler (for crawler machines)
• Brake and steering systems
• Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling in good condition
• Remove any large rocks or obstacles
• Fill any ditches and holes
• Site manager should provide machine operators with machine and schedule time to maintain terrain
conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
• Adjust the seat and suspension for the weight and size of the operator
• Wear seat belt
• Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
• When pushing with bucket or blade, avoid sudden loading; load gradually
• Drive around obstacles and rough terrain conditions
• Slow down when it is necessary to go over rough terrain
• Make the curve radius of travelling path as large as possible
• Travel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance travelling
FOREWORD VIBRATION LEVELS
1-5

• Reduce speed to prevent bounce
• Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
• Operate the machine only when you are in good health
• Provide breaks to reduce long periods of sitting in the same posture
• Do not jump down from the cab or machine
• Do not repeatedly handle and lift loads
VIBRATION LEVELS FOREWORD
1-6

INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Traveling with a load
DIRECTIONS OF MACHINE
(A) Front
(B) Rear
(C) Left
(D) Right
(E) Operator's seat
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.
VISIBILITY FROM OPERATOR'S SEAT
This machine complies with the visibility standard (ISO 5006).
This machine maintains a proximity visibility of a height of 1.5 m at a point 1 m away from the outside surface of
the machine, and a visibility for a circumference of 12 m.
FOREWORD INTRODUCTION
1-7

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS
EMISSION
About Engine Technology
This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION FOREWORD
1-8

PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-
AL NO. PLATE
This is on the rear left side of the operator's cab.
The design of the nameplate differs according to the district.
LOCATION OF ENGINE NUMBER PLATE
The is on the engine cylinder head.
FOREWORD PRODUCT INFORMATION
1-9

SERVICE METER LOCATION
In the initial state, it is on the left bottom of the machine moni-
tor.
See “METER DISPLAY SELECTION (3-78)” if the screen is
not displayed.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number
(PIN)
Manufacturers name:
Address: KOMATSU LTD. 2-3-6 Akasaka
Minato-ku, Tokyo 107-8414
Japan
Authorised representative:
Address: KOMATSU EUROPE INT. Mechelsesteenweg 586
B-1800 Vilvoorde
Belgium
Distributor name
Address
Service personnel
Phone/Fax
PRODUCT INFORMATION FOREWORD
1-10

SERIAL PLATE
C
E
A
B
D
F
G
H
EI000001
A MACHINE DESIGNATION/TYPE E ENGINE POWER
B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
D OPERATING MASS H AUTHORISED REPRESENTATIVE
FOREWORD SERIAL PLATE
1-11

DECLARATION OF CONFORMITY
The manufacturer/Authorised representative
The manufacturer Authorised representative
KOMATSU LTD.
2-3-6 Akasaka
Minato-ku, Tokyo 107-8414
Japan
KOMATSU EUROPE INT.
Mechelsesteenweg 586
B-1800 Vilvoorde
Belgium
Declares that this machine:
HM400-5
Fulfils all the relevant provisions of following EC Directives:
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Outdoor Noise Directive 2001/14/EC amended by 2005/88/EC
DECLARATION OF CONFORMITY FOREWORD
1-12

TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
BEFORE READING THIS MANUAL ......................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-3
NOISE....................................................................................................................................................... 1-4
VIBRATION LEVELS ................................................................................................................................ 1-5
VIBRATION - OPERATING CONDITION ........................................................................................... 1-5
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ................................................................ 1-5
INTRODUCTION ...................................................................................................................................... 1-7
MAIN USE OF MACHINE .................................................................................................................. 1-7
DIRECTIONS OF MACHINE.............................................................................................................. 1-7
VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-7
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION..................................................... 1-8
PRODUCT INFORMATION....................................................................................................................... 1-9
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........ 1-9
LOCATION OF ENGINE NUMBER PLATE ........................................................................................ 1-9
SERVICE METER LOCATION ......................................................................................................... 1-10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................................ 1-10
SERIAL PLATE ........................................................................................................................................1-11
DECLARATION OF CONFORMITY ........................................................................................................ 1-12
SAFETY........................................................................................................................................................... 2-1
SAFETY.................................................................................................................................................... 2-2
SAFETY LABELS ..................................................................................................................................... 2-4
LOCATION OF SAFETY LABELS...................................................................................................... 2-5
CONTENTS OF SAFETY LABELS .................................................................................................... 2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-15
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-15
PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-18
DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-20
UNAUTHORIZED MODIFICATION .................................................................................................. 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING..................................................... 2-21
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-22
PRECAUTIONS FOR JOBSITE....................................................................................................... 2-22
START ENGINE............................................................................................................................... 2-24
PRECAUTIONS FOR OPERATION ................................................................................................. 2-26
TRANSPORTATION......................................................................................................................... 2-29
TOWING AND BEING TOWED........................................................................................................ 2-30
PRECAUTIONS FOR MAINTENANCE................................................................................................... 2-31
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-31
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-35
TIRES .............................................................................................................................................. 2-39
PRECAUTIONS FOR DEF...................................................................................................................... 2-41
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING .................................................. 2-41
PRECAUTIONS FOR ADDING........................................................................................................ 2-41
PRECAUTIONS FOR STORING...................................................................................................... 2-41
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE .................................................................... 2-41
OTHER PRECAUTIONS.................................................................................................................. 2-41
OPERATION.................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES................................................................................................. 3-3
OTHER EQUIPMENT NAME............................................................................................................. 3-7
EXPLANATION OF COMPONENTS....................................................................................................... 3-10
FOREWORD TABLE OF CONTENTS
1-13

EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................. 3-10
SWITCHES...................................................................................................................................... 3-93
CONTROL LEVERS AND PEDALS............................................................................................... 3-104
OTHER EQUIPMENT .................................................................................................................... 3-107
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-150
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-150
METHOD FOR STARTING ENGINE.............................................................................................. 3-177
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-181
METHOD FOR STOPPING ENGINE ............................................................................................. 3-183
METHOD FOR CHECKING AFTER STOPPING ENGINE............................................................. 3-183
START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MACHINE........................ 3-184
METHOD FOR SHIFTING GEARS................................................................................................ 3-188
METHOD FOR TRAVELING DOWNHILL ...................................................................................... 3-190
METHOD FOR TURNING MACHINE ............................................................................................ 3-195
OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK ................................................................. 3-196
HANDLE AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC) ................................... 3-197
OPERATION OF ARAC SYSTEM.................................................................................................. 3-198
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)..................................................... 3-199
OPERATION OF KTCS SYSTEM .................................................................................................. 3-200
OPERATION IF TROUBLES ON SYSTEM OCCUR ...................................................................... 3-200
OPERATION IF TIRES ARE STUCK IN GROUND ........................................................................ 3-201
METHOD FOR LOADING.............................................................................................................. 3-201
METHOD FOR DUMPING ............................................................................................................. 3-202
METHOD FOR OPERATING CAB TILT ......................................................................................... 3-204
PRECAUTIONS FOR OPERATION ............................................................................................... 3-207
METHOD FOR PARKING MACHINE............................................................................................. 3-208
METHOD FOR CHECKING AFTER FINISHING WORK................................................................ 3-209
LOCK............................................................................................................................................. 3-209
HANDLE TIRE ............................................................................................................................... 3-218
HANDLE AIR CONDITIONER............................................................................................................... 3-219
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-220
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-225
HANDLE RADIO ................................................................................................................................... 3-232
EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-232
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-234
DUMP BODY HEATING SPECIFICATIONS.......................................................................................... 3-237
DETERMINE AND MAINTAIN TRAVEL ROAD ..................................................................................... 3-238
TRANSPORTATION.............................................................................................................................. 3-239
PRECAUTIONS FOR TRANSPORTATION.................................................................................... 3-239
PRECAUTIONS FOR TRANSPORTING MACHINE ...................................................................... 3-239
SELECT TRANSPORTATION METHOD........................................................................................ 3-239
METHOD FOR SECURING MACHINE.......................................................................................... 3-239
PRECAUTIONS FOR LIFTING MACHINE..................................................................................... 3-240
COLD WEATHER OPERATION............................................................................................................ 3-244
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-244
PRECAUTIONS AFTER DAILY WORK COMPLETION ................................................................. 3-245
AFTER COLD WEATHER SEASON .............................................................................................. 3-245
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-246
PREPARATION FOR LONG-TERM STORAGE............................................................................. 3-246
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-246
STARTING MACHINE AFTER LONG-TERM STORAGE............................................................... 3-246
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE..................................... 3-247
TROUBLES AND ACTIONS ................................................................................................................. 3-248
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-248
ACTIONS IF TRANSMISSION HAS TROUBLE............................................................................. 3-248
METHOD FOR LOWERING DUMP BODY IN EMERGENCY........................................................ 3-249
PRECAUTIONS FOR TOWING MACHINE.................................................................................... 3-250
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-253
TABLE OF CONTENTS FOREWORD
1-14

OTHER TROUBLE......................................................................................................................... 3-256
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR ADDING DEF ................................................................................................. 4-2
PRECAUTIONS FOR WELDING ....................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-2
PRECAUTIONS FOR SCR ASSEMBLY ............................................................................................ 4-3
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.............................................................. 4-10
MAINTENANCE SCHEDULE.................................................................................................................. 4-12
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-12
MAINTENANCE PROCEDURE .............................................................................................................. 4-14
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-14
WHEN REQUIRED .......................................................................................................................... 4-14
CHECKS BEFORE STARTING........................................................................................................ 4-35
EVERY 50 HOURS MAINTENANCE ............................................................................................... 4-36
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-37
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-48
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-56
EVERY 2000 HOURS MAINTENANCE ........................................................................................... 4-70
EVERY 4000 HOURS MAINTENANCE ........................................................................................... 4-80
EVERY 4500 HOURS MAINTENANCE ........................................................................................... 4-84
EVERY 6000 HOURS MAINTENANCE ........................................................................................... 4-84
EVERY 8000 HOURS MAINTENANCE ........................................................................................... 4-86
EVERY 9000 HOURS MAINTENANCE ........................................................................................... 4-86
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
HANDLE CAB POWER TILT..................................................................................................................... 6-2
HANDLING PAYLOAD METER................................................................................................................. 6-6
OUTLINE OF SYSTEM...................................................................................................................... 6-6
NORMAL OPERATION DISPLAY ...................................................................................................... 6-7
EXTERNAL DISPLAY LAMP.............................................................................................................. 6-8
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER ................................................... 6-9
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD............................ 6-9
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES ............................................................... 6-12
DISPLAY FUEL CONSUMPTION RECORD .................................................................................... 6-13
SETTING MACHINE ID AND OPEN ID............................................................................................ 6-14
METHOD FOR PERFORMING CALIBRATION................................................................................ 6-15
REPLACEMENT PARTS.................................................................................................................................. 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2
FOREWORD TABLE OF CONTENTS
1-15

DEFINED LIFE PARTS LIST.............................................................................................................. 7-2
CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS LIST............................................................................................................. 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-4
LUBRICATION CHART...................................................................................................................... 7-4
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-6
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-8
INDEX.............................................................................................................................................................. 8-1
TABLE OF CONTENTS FOREWORD
1-16

SAFETY
Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.
2-1

SAFETY
SAFETY LABELS ............................................................................................................................................ 2-4
LOCATION OF SAFETY LABELS............................................................................................................. 2-5
CONTENTS OF SAFETY LABELS ........................................................................................................... 2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-15
ENSURE SAFE OPERATION .......................................................................................................... 2-15
UNDERSTAND THE MACHINE....................................................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION ............................................................................................ 2-15
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ................................................................. 2-15
INSPECT MACHINE........................................................................................................................ 2-15
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT............................................. 2-15
KEEP MACHINE CLEAN ................................................................................................................. 2-15
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT ...................................................... 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ................................................................... 2-16
IF ANY PROBLEM IS FOUND ......................................................................................................... 2-16
PRECAUTIONS TO PREVENT FIRE...................................................................................................... 2-16
ACTIONS IF FIRE OCCURS ........................................................................................................... 2-16
PREVENT FIRE............................................................................................................................... 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.................................................................... 2-18
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE..................................... 2-18
NO JUMPING ON OR OFF MACHINE............................................................................................. 2-19
PEOPLE ON DUMP BODY.............................................................................................................. 2-19
WHEN STANDING UP FROM OPERATOR'S SEAT ........................................................................ 2-19
PRECAUTIONS WHEN LEAVING MACHINE.................................................................................. 2-19
EMERGENCY EXIT FROM OPERATOR'S CAB.............................................................................. 2-20
DO NOT GET CAUGHT IN WORK EQUIPMENT ................................................................................... 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-20
UNAUTHORIZED MODIFICATION ......................................................................................................... 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ........................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING............................................................ 2-21
PRECAUTIONS FOR OPERATION ............................................................................................................... 2-22
PRECAUTIONS FOR JOBSITE.............................................................................................................. 2-22
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS................................................................. 2-22
PRECAUTIONS WHEN WORKING ON LOOSE GROUND............................................................. 2-22
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................................ 2-22
ENSURE GOOD VISIBILITY............................................................................................................ 2-23
CHECK SIGNS AND SIGNALMAN'S SIGNALS............................................................................... 2-23
BEWARE OF ASBESTOS DUST..................................................................................................... 2-23
START ENGINE...................................................................................................................................... 2-24
USE WARNING TAGS ..................................................................................................................... 2-24
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ........................................................ 2-24
WHEN STARTING ENGINE............................................................................................................. 2-25
IN COLD AREAS ............................................................................................................................. 2-25
START ENGINE WITH JUMPER CABLES ...................................................................................... 2-25
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-26
CHECKS BEFORE OPERATION..................................................................................................... 2-26
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE............................................... 2-26
WHEN TRAVELING......................................................................................................................... 2-27
WHEN TRAVELING ON SLOPES.................................................................................................... 2-27
PRECAUTIONS WHEN OPERATING MACHINE............................................................................. 2-27
WHEN LOADING ON DUMP BODY ................................................................................................ 2-28
WHEN DUMPING ............................................................................................................................ 2-28
WHEN OPERATING ON SNOW OR FROZEN SURFACES ............................................................ 2-28
WHEN PARKING MACHINE............................................................................................................ 2-28
TRANSPORTATION................................................................................................................................ 2-29
PRECAUTIONS WHEN LOADING AND UNLOADING.................................................................... 2-29
SAFETY SAFETY
2-2