Komatsu HAULPAK DUMP TRUCK Manual (EN)

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Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read and understand this manual before operating or maintaining this machine. This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it. This material is proprietary to Komatsu Mining Systems, Inc. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Systems, Inc. It is the policy of the Company to improve products whenever it is possible and practical to do so.

The Company reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Because of continuous research and development, periodic revisions may be made to this publication. Customers should contact their local distributor for information on the latest revision. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

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FOREWORD This handbook is intended to provide the HAULPAK ® operator with the necessary information to allow for safe and efficient truck operation. The HAULPAK ® operator should be a qualified individual who has had proper training to achieve full production with the truck. An efficient, qualified operator can help insure long production life of the truck and avoid costly down time due to misuse of the unit and its systems. Training for both operators and maintenance personnel is recommended and is available upon request. Operator training is accomplished at the job site by qualified operator instructors. Maintenance training is provided both in the factory setting and in field schools.

All requests for operator and/or maintenance training should be forwarded to the local HAULPAK ® Distributor for action. This handbook shows dimensioning of U.S. standard and metric (SI) units, and all references to "Right", "Left", "Front", or "Rear" are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Illustrations used in this handbook are typically representative and may not necessarily depict a specific model. A Product Identification plate is normally located on the frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.

(Gross Vehicle Weight) rating. The HAULPAK ® Model designation consists of three numbers and one letter (i.e. 210M). The three numbers represent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.

The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight : the Empty Vehicle Weight + the fuel/lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload.

To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often as practical . Exceeding the allowable payload will reduce expected life of truck components. HB0010 7/95 Introduction HB-1

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HB-2 Introduction HB0010 7/95 This "ALERT" symbol is used with the signal words, "CAUTION", "DANGER", and "WARNING" in this manual to alert the reader to hazards arising from improper operating and maintenance practices. "DANGER" identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken. "WARNING" identifies a specific potential hazard WHICH MAY RESULT in either INJURY OR DEATH if proper precautions are not taken. "CAUTION" is used for general reminders of proper safety practices OR to direct the reader’s attention to avoid unsafe or improper practices which may result in damage to the equipment.

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TABLE OF CONTENTS

TABLE OF CONTENTS SUBJECT PAGE MAJOR COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . HB1-1 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB2-1 WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3-1 OPERATOR CONTROLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . HB4-1 INSTRUMENTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . HB5-1 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . HB6-1 LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . HB7-1 HB0010 7/95 Introduction HB-3

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