Komatsu 730E Install guide

CEBM024401
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS
A30603, A30610 - A30616,
A30621, A30628, A30629, &
A30632
®

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CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead com-
pounds, chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm. Wash hands after handling.
Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-
sonnel 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 America Corp (KAC), and is not to be reproduced, used, or dis-
closed except in accordance with written authorization from KAC.
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 obli-
gation 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 Komatsu distributor for information on the latest revision.
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NON-OEM PARTS IN CRITICAL SYSTEMS
For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.
Replacement parts manufactured and supplied by unauthorized sources may not be
designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.
Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the Kom-
atsu product on the supplier and user. Komatsu will not in any case accept responsi-
bility for the failure or performance of non-OEM parts in its products, including any
damages or personal injury resulting from such use.
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A00044 Introduction A-1
FOREWORD
This manual is written for use by the service technician. It is designed to help these persons to become fully knowl-
edgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and main-
tenance personnel must read and understand the materials in this manual before operating the truck or performing
maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be under-
stood and followed when operating or repairing the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other gen-
eral information. The major portion of the manual pertains to disassembly, service, and reassembly. Each major
serviceable component has a section in the shop manual. Disassembly of any component should only be done as
far as necessary to accomplish needed repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict
a specific model.
This manual shows dimensioning in metric units and in U.S. English units. All references to Right, Left, Front, or
Rear are made with respect to the operator's normal seated position, unless specifically stated otherwise.
Standard torque requirements for common fasteners are shown in torque charts in the general information section.
Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque
specifications have ±10% tolerance unless otherwise specified.
A product identification plate is 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 GVW (Gross Vehicle Weight)
rating.
The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter E, when present, designates an electrical wheel motor drive system.
The product identification number (vehicle serial number) contains information which will identify the original manu-
facturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The 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). GVW is total weight:
the empty vehicle weight + the fuel and lubricants + the payload.
To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the truck and record this
value. Subtract it from the GVW to determine the allowable payload.
NOTE: Accumulations of mud, frozen material, etc., become part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations must be removed as often as
practical.
Exceeding the allowable payload will reduce the expected life of truck components.
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A-2 Introduction A00044
This ALERT symbol is used in this manual, along with
the signal words CAUTION, DANGER, and WARNING, to
alert the reader to hazards arising from improper operat-
ing 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 WILL 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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A00044 Introduction A-3
TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE, FUEL, COOLING AND AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
ELECTRIC PROPULSION AND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
DRIVE AXLE, SPINDLES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
SUSPENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M
OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
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A-4 Introduction A00044
KOMATSU MODEL 730E DUMP TRUCK
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A01001 8/10 Index A1-1
SECTION A
GENERAL INFORMATION
INDEX
MAJOR COMPONENTS & SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
SAFETY AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
TORQUE TABLES AND CONVERSION CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
STORAGE AND IDLE MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
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A1-2 Index 8/10 A01001
NOTES
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A02086 Major Component Description A2-1
MAJOR COMPONENT DESCRIPTION
The Komatsu model 730E standard dump truck is an electric drive, off-highway, rear dump truck with a gross vehi-
cle weight of 324 319 kg (715,000 lbs) that is rated for a nominal payload of 185 t (203 tons). Some Trolley ver-
sions may have a higher GVW. Refer to the grade/speed chart in the operator’s cab for the appropriate GVW.
ENGINE
The Komatsu 730E dump truck is powered by a
Komatsu SSA16V159 engine rated at 1 492 kW
(2,000 HP).
ALTERNATOR (GE GTA-22)
The diesel engine drives an alternator mounted in-
line with the engine. The Alternating Current (AC)
output of the alternator is rectified to Direct Current
(DC) and sent to the DC drive wheel motors.
WHEEL MOTORS (GE 788)
The output of the alternator supplies electrical energy
to the two wheel motors attached to the rear axle
housing. The two wheel motors convert electrical
energy back to mechanical energy through built-in
gear trains within the wheel motor assembly. The
direction of the wheel motors is controlled by a for-
ward or reverse hand selector switch located on a
console to the right side of the operator.
BLOWER
The blower supplies cooling air for the rectifiers, AC
alternator, and to both wheel motors, where it is then
exhausted to the atmosphere.
OPERATOR'S CAB
The operator's cab for the Komatsu 730E dump truck
has been engineered for operator comfort and to
allow for efficient and safe operation of the truck.
The cab provides for wide visibility, with an integral
four-post Rollover Protective Structure/Falling Object
Protective Structure (ROPS/FOPS), and an
advanced analog operator environment. It includes a
tinted safety-glass windshield and power-operated
side windows, a deluxe interior with a fully adjustable
seat with lumbar support, a fully adjustable/tilt steer-
ing wheel, controls mounted within easy reach of the
operator, and an analog instrument panel which pro-
vides the operator with all instruments and gauges,
which are necessary to control and/or monitor the
truck's operating systems.
POWER STEERING
The Komatsu 730E dump truck is equipped with a
full-time power steering system, which provides posi-
tive steering control with a minimum of effort by the
operator. The system includes nitrogen-charged
accumulators which automatically provide emer-
gency power if the steering hydraulic pressure is
reduced below an established minimum.
DYNAMIC RETARDING
Dynamic retarding is used to slow the truck during
normal operation or control the speed coming down a
grade. The dynamic retarding ability of the DC elec-
tric system is controlled by the operator through the
activation of the retarder pedal in the operator’s cab
and by setting the RSC (Retarder Speed Control).
Dynamic retarding is automatically activated if the
truck goes to a preset overspeed setting.
BRAKE SYSTEM
The wheel service brakes are caliper/dry disc brakes
applied by an all hydraulic actuation system.
Depressing the brake pedal actuates wheel-speed
single disc front brakes and armature-speed dual
disc rear brakes. The rear brakes can also be acti-
vated by operating a switch on the instrument panel.
All wheel brakes will be applied automatically if the
system pressure decreases below a preset mini-
mum.
The parking brake is a caliper/disc type, mounted on
each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
protection (will not apply with the truck moving.)
SUSPENSION
Hydrair®II suspension cylinders, located at each
wheel, provide a smooth and comfortable ride for the
operator and dampens shock loads to the chassis
during loading and operation.

A2-2 Major Component Description A02086
1. Cab
2. Radiator
3. Reserve Oil
4. Auto Lube
5. Engine
6. Front Hydrair II® Suspension
7. Traction Alternator
8. Cooling Blower
9. Cooling Duct
10.Steering Circuit Filter
11.Hoist Circuit Filter
12.Fuel Tank
13.Hoist Cylinders
14.Rear Axle Housing
15.Drive Motors
16.Rear Hydrair II® Suspension
17.Tires
18.Hydraulic Tank
19.SteeringandBrakeCircuitPump
20.Hoist Circuit Pump
21.Accumulators
730E MAJOR COMPONENTS

A02086 Major Component Description A2-3
SPECIFICATIONS
These specifications are for the standard 730E dump truck. Customer options may change this listing.
ENGINE
Komatsu SSA16V159
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 16
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake HP 1 491 kW (2,000 HP) @ 1,900 RPM
Flywheel HP . . 1 388 kW (1,860 HP) @ 1,900 RPM
Weight (Wet) . . . . . . . . . . . . . . 5 294 kg (11,670 lbs)
ELECTRIC DRIVE SYSTEM
STATEX III w/Fuelsaver . . . . . . . . . AC/DC Current
Alternator. . . . . . . . . . . . . General Electric GTA - 22
Motorized Wheels . . . . . . . . . . General Electric 788*
Standard Gear Ratio* . . . . . . . . . . . . . . . . . 26.825:1
Maximum Speed . . . . . . . . . . . 34.6 mph (55.7 km/h)
*NOTE: Wheel motor application depends upon GVW, haul road
grade, haul road length, rolling resistance, and other parameters.
KOMATSU & G.E. must analyze each job condition to assure
proper application.
DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . Standard
Maximum Retarding . . . . . . . . 2 759 kW (3,700 HP)
. . . . . . . . . . . . . With Continuous Rated Blown Grids
Two-Speed Overspeed & Extended Range Retarding
. . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Retarding
BATTERY ELECTRIC SYSTEM
Batteries . Bumper-Mounted in Polyethylene Boxes
. . . . . . . . . . Four 12-Volt Batteries in Series/Parallel
. . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity
. . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch
Alternator. . . . . . . . . . . 24-Volt, 140 Ampere Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt
Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt
SERVICE CAPACITIES
. . . . . . . . . . . . . . . . . . . . . . Liters. . . U.S. Gallons
Crankcase (includes lube oil filters)
Komatsu . . . . . . . . . . . . . . . . . 223. . . . . . . . . . . . .59
Cooling System . . . . . . . . . . . 409. . . . . . . . . . . .108
Fuel . . . . . . . . . . . . . . . . . . . 3217. . . . . . . . . . .850
Hydraulic System . . . . . . . . . . 731 . . . . . . . . . . .193
Wheel Motor Gear Box. . . .40/Wheel . . .10.5/Wheel
HYDRAULIC SYSTEM
Pumps:
Hoist (gear-type). . . . . . . . . . .513 l/min (135.6 GPM)
. . . . . . . . . . at 17 240 kPa (2,500 psi) @ 1,900 rpm
Steering/Brake (vane-type). . . . . 235 l/min (62 GPM)
. . . . . . . . . .at 18 960 kPa (2,750 psi) @ 1,900 RPM
Relief Pressure-Hoist . . . . . . .17 240 kPa (2,500 psi)
Relief Pressure-Steering . . . .27 580 kPa (4,000 psi)
Hoist . . . . . . . . Two Three-Stage Hydraulic Cylinders
Tank . . . . . . . Vertical - Cylindrical, Non-Pressurized
Service Capacity . . . . . . . . 731 Liters (193 U.S. Gal)
Filtration . . . . . . . . . . . In-line Replaceable Elements
Suction . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
Hoist and Steering High-Pressure Filters
. . . . . . . . . . . . . . . . . Dual, Full Flow, Seven Micron
. . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 rating = 200
SERVICE BRAKES
Actuation . . . . . . . All Hydraulic - Caliper/Disc
. . . . . . . . . . . . . . .(Front) . . . . . . . . . . . . . . . .(Rear)
Type . . . . . . . . . Single Disc. . . . . . . . . . . . Dual Disc
. . . . . . . . . . . . Wheel Speed . . . . . .Armature Speed
STEERING
Turning Circle (SAE). . . . . . . . . . . . . . . 28.0 m (92 ft)
Twin hydraulic cylinders with accumulator assist to
provide constant rate steering.
Emergency power steering automatically provided by
accumulators (meets SAE J1511).

A2-4 Major Component Description A02086
These specifications are for the 730E dump truck
without trolley assist. Specifications for trolley trucks
will be different.
STANDARD DUMP BODY*
Capacity:
Struck . . . . . . . . . . . . . . . . 77 m³. . . . . 101 yds³
Heaped @ 2:1 (SAE) . . . . 111 m³ . . . . 145 yds³
Width (inside) . . . . . . . . . . . . . . . 6.86 m (22 ft 5 in.)
Depth . . . . . . . . . . . . . . . . . . . . . . 2.26 m (7 ft 4 in.)
Loading Height . . . . . . . . . . . . . . 5.61 m (18 ft 5 in.)
Dumping Angle. . . . . . . . . . . . . . . . . . . . . . . . . . 45°
*Optional capacity dump bodies are available.
TIRES
Radial Tires (standard) . . . . . . . . . . . . . . 37.00 R57
Rock Service, Deep Tread . . . . . . . . . . . . Tubeless
Rims . (Patented Phase II New Generation™ Rims)
Tires and Rims . . . . . . . . . . . . . . . Interchangeable
WEIGHT DISTRIBUTION
Empty Vehicle Kilograms (Pounds)
Front Axle . . . . . . . . . . . . 69 966 . . . . (154,249)
Rear Axle . . . . . . . . . . . .73 670 . . . . . . .(162,415)
Total (100% fuel) . . . . . .143 636. . . . . . .(316,664)
Standard Komatsu Body .25 612. . . . . . . .(56,464)
Standard Tire Weight. . . .18 371. . . . . . . .(40,500)
Loaded Vehicle Kilograms (Pounds)
Front Axle . . . . . . . . . . 115 655. . . . . . .(254,975)
Rear Axle. . . . . . . . . . . .231 343. . . . . . .(510,025)
Total * . . . . . . . . . . . . . .346 998 . . . . . .(765,000)
Nominal Payload . . . . . .206 408. . . . . . .(455,050)
*Nominal payload is as defined within Komatsu
America Corp. payload policy documentation. Nomi-
nal payload must be adjusted should the weight of
any customized body or tires fitted vary from that of
the standard Komatsu body and tires as shown
above. Nominal payload must also be adjusted to
take into account the additional weight of any cus-
tomized/optional extras fitted to the truck which are
not stated within the Standard Features list of this
specification sheet.

A03048 General Safety & Operation A3-1
SECTION A3
GENERAL SAFETY AND OPERATION
INDEX
GENERAL SAFETY AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Truck Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Fire Extinguishers And First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
ROPS Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Preventing Injury From Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Precautions For Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Precautions When Starting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
PRECAUTIONS FOR TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Safety At The Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Ventilation For Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
In The Operator’s Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling In The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Precautions When Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Ensuring Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Operating On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10

A3-2 General Safety & Operation A03048
Avoid Damage To The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Driving Near High-Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
When Loading The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
Battery Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
Jump-Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Jump Starting With Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Stopping The Engine Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Keeping The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Rules To Follow When Adding Fuel Or Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Handling High-Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Precautions With High-Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Maintenance Near High Temperatures And High Pressures . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Rotating Fan And Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
Handling Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
Storing Tires After Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19

A03048 General Safety & Operation A3-3
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
SAFETY IS THINKING AHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
WALK AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
ENGINE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
EMERGENCY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Pre-Operation Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Additional Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
To Raise The Dump Body: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
To Lower The Dump Body: (When dumping over a berm or into a crusher): . . . . . . . . . . . . A3-30
To Lower The Dump Body (When dumping on flat ground): . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
DELAYED ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
SUDDEN LOSS OF POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33

A3-4 General Safety & Operation A03048
GENERAL SAFETY AND OPERATION
Safety records of most organizations will show that
the greatest percentage of accidents are caused by
unsafe behavior. The remainder are caused by
unsafe mechanical or physical conditions. Report all
unsafe conditions to the proper authority.
The following safety rules are provided as a guide for
the operator. However, local conditions and regula-
tions may add many more to this list.
Read and follow all safety precautions. Failure to
do so may result in serious injury or death.
PERSONAL SAFETY
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.
• When working with another operator, or a person
on work site traffic duty, ensure all personnel
understand all hand signals that are to be used.
Truck Safety Features
• Ensure all guards and covers are in their proper
position. Repair any damaged guards and
covers. (See Walk-Around Inspection, later in this
section.)
• Learn the proper use of safety features, such as
safety locks, safety pins, and seat belts. Use
these safety features properly.
• DO NOT remove any safety features. Keep
safety features in good operating condition.
• Improper use of safety features may result in
serious bodily injury or death.
Clothing And Personal Items
•
Avoid wearing loose
clothing, jewelry, and
loose long hair. They
can catch on controls
or in moving parts
and cause serious
injury or death.
Additionally, DO
NOT wear oily
clothes as they are
flammable.
• Wear a hard hat, safety glasses, safety shoes,
mask, and gloves when operating or maintaining
a machine. Wear safety goggles, a hard hat, and
heavy gloves if your job involves scattering metal
chips or very small materials--particularly when
driving pins with a hammer, or when cleaning air
cleaner elements with compressed air. Also,
ensure that the work area is free of other
personnel during such tasks.
Unauthorized Modification
• Any modification made to this vehicle, without
authorization from Komatsu America Corp., can
possibly create hazards.
• Before making any modification, consult your
authorized regional Komatsu America Corp.
distributor. Komatsu will not be responsible for
any injury or damage caused by any
unauthorized modification.
Leaving The Operator’s Seat
• When leaving the operator's seat, DO NOT touch
any controls. To prevent accidents from
occurring, perform the following:
Move the selector switch to NEUTRAL, and apply
the parking brake.
Lower the dump body, and move the hoist control
lever to the FLOAT position.
Stop the engine. When exiting the machine, lock
compartments, and take the keys with you to
prevent entry from unauthorized persons.

A03048 General Safety & Operation A3-5
Mounting And Dismounting
• DO NOT jump on or off the machine. DO NOT
climb on or off a machine while it is moving.
• When climbing on or off a machine, face the
machine and use the handhold and steps.
• DO NOT hold any control levers when getting on
or off a machine.
• Maintain three-point contact with the handholds
and steps to ensure that you support yourself.
• When bringing tools up to the operating deck,
pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the
handholds or steps, wipe them clean
immediately. Keep these components clean.
Repair any damage, and tighten any loose bolts.
Use the handrails and steps marked by arrows
in the diagram below when climbing on or off
the machine.
Fire Extinguishers And First Aid Kits
• Ensure fire extinguishers
are accessible and
proper usage techniques
are known.
• Provide a first aid kit at
the storage point.
• Know what to do in the
event of a fire.
• Keep the phone numbers of persons you must
contact in case of an emergency.
Precautions For High Temperature Fluids
• Immediately after operating the
truck, engine coolant, engine
oil, and hydraulic oil are at high
temperatures and are
pressurized. If the cap is
removed, the fluids drained, the
filters are replaced, etc., there is
danger of serious burns. Allow heat and pressure
to dissipate before performing such tasks, and
follow proper procedures, as outlined in the
service manual.
• To prevent hot coolant from spraying:
1. Stop the engine, and wait for the coolant tem-
perature to decrease.
2. Depress the pressure relief button on the radiator
cap.
3. Turn the radiator cap slowly to allow pressure to
dissipate.
• To prevent hot engine oil spray:
1. Stop the engine.
2. Wait for the oil temperature to cool.
3. Turn the cap slowly to allow pressure to dissipate.

A3-6 General Safety & Operation A03048
Asbestos Dust Hazard Prevention
Asbestos dust is hazardous to
your health when inhaled. If you
handle materials containing
asbestos fibers, follow the
guidelines below:
• DO NOT use compressed
air for cleaning.
• Use water for cleaning and to control dust.
• Operate the machine or perform tasks with the
wind to your back, whenever possible.
• Use an approved respirator, when necessary.
Fire Prevention For Fuel And Oil
• Fuel, oil, and antifreeze can be ignited by a
flame. These fluids are extremely flammable and
hazardous.
• Keep flames away from flammable fluids.
• Stop the engine while refueling.
• DO NOT smoke while refueling.
• Tighten all fuel and oil tank caps securely.
• Refuel and maintain oil in well-ventilated areas.
• Keep oil and fuel in a designated location. DO
NOT allow unauthorized persons to enter.
ROPS Precautions
• The Rollover Protection Structure (ROPS) must
be properly installed before using the truck.
• The ROPS is intended to protect the operator if
the machine rolls over. It is designed not only to
support the load of the machine, but also to
absorb the energy of the impact.
• ROPS structures, installed on equipment
manufactured and designed by Komatsu America
Corp., fulfills all of the regulations and standards
for all countries. If it is modified or repaired
without authorization from Komatsu, or is
damaged when the machine rolls over, the
strength of the structure will be compromised and
will not be able to fulfill its intended purpose.
Optimum strength of the structure can only be
achieved if it is repaired or modified, as specified
by Komatsu.
• When modifying or repairing the ROPS, consult
your nearest Komatsu distributor.
• Even with the ROPS installed, the operator must
use the seat belt when operating the machine.
Preventing Injury From Work Equipment
• DO NOT position any part of your body between
movable parts, such as the dump body, chassis,
or cylinders. If the work equipment is operated,
clearances will change and may cause serious
bodily injury or death.
Precautions For Optional Attachments
• When installing and using optional equipment,
read the instruction manual for the attachment
and the information related to attachments in this
manual.
• DO NOT use attachments that are not authorized
by Komatsu America Corp., or the authorized
regional Komatsu distributor. Use of unauthorized
attachments could create a safety problem and
adversely affect the proper operation and useful
life of the machine.
• Any injuries, accidents, and product failures
resulting from the use of unauthorized
attachments, will not be the responsibility of
Komatsu America Corp., or the authorized
regional Komatsu distributor.