Komatsu 730E Manual

CEAM011001
Operation & Maintenance
Manual
DUMP TRUCK
SERIAL NUMBERS A30212 - A30259
®

CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. Wash hands after handling.
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.
This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or
disclosed 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
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 Komatsu distributor for information on the latest revision.
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.

NOTES

OM1032.1 02/03 Introduction - Section 1
Page 1-1
FOREWORD
This manual is written for use by the operator and/or the service technician and is designed to help these persons
to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
All operators and maintenance personnel should read and understand the materials in this manual before operat-
ing the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and
cautions should be understood and followed when operating or accomplishing repairs on the truck.
The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of inter-
est. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction
of what is found on the truck.
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 G.V.W. (Gross Vehicle
Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 730E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system;
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 man-
ufacturing 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 compo-
nents. 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 & 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.

Introduction - Section 1 OM1032.1 02/03
Page 1-2
Alerts
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 oper-
ating 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.

OM1032.1 02/03 Introduction - Section 1
Page 1-3
TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ALERTS Page - a description of the DANGER, WARNING, and CAUTION symbols used in this manual. . . 1-2
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Truck Model Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
STANDARD CHARTS and TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority. These safety rules are provided as a guide for the Komatsu truck operator. However, local
conditions and regulations may add many more to this list.
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Before Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Before Carrying Out Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
WARNING, CAUTION, and Instruction Plates / Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3
This portion of the manual covers Identification, location, and operation of the controls, switches, and indicators in
the Operator's Cab and use / function of these controls, switches, and indicators.
OPERATING INSTRUCTIONS
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
At The Truck - Ground Level Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Introduction - Section 1 OM1032.1 02/03
Page 1-4
TABLE OF CONTENTS (Continued)
SUBJECT....................................................................................................... SECTION / PAGE
OPERATION (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 3
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
DELAYED ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
OPERATOR CAB and CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
STEERING WHEEL AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
SERVICE BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
DYNAMIC RETARDER PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
THROTTLE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
HEATER / AIR CONDITIONER VENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
OVER HEAD PANEL AND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
INSTRUMENT PANEL AND INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
INSTRUMENT PANEL (Figure 3-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
PANEL GAUGES, INDICATORS, AND CONTROLS (Discussion of items 1 - 28, Figure 3-6) . . . . . . . . . . . .3-24
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL (Figure 3-7) . . . . . . . . . . . . . . . . . . . . . . . .3-30
INDICATOR LIGHT SYMBOLS - Refer to Figure 3-7 by rows (A-E) and columns (1 - 8). . . . . . . . . . . . . . . .3-31
Hazard Warning Lights (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
Lamp Test Switch / Centry™ Diagnostic Test Switch (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
CENTRY™ FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
DETERMINING "FAULT" CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
EXITING THE DIAGNOSTICS MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 4
This portion of the manual pertains mainly to the periodic Lubrication and Service required to keep the truck oper-
ating at its design potential. Routine lubrication and maintenance procedures are provided in this section. For
major repairs, refer to the appropriate section in the Truck Service Manual. Refer to the engine manufacturer's ser-
vice manual when servicing the engine.
Lubrication and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Service Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Hydraulic Tank Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Radiator Filling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Cooling System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
10 HOUR (SHIFT) Lubrication And Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
50 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

OM1032.1 02/03 Introduction - Section 1
Page 1-5
TABLE OF CONTENTS (Continued)
SUBJECT ....................................................................................................... SECTION / PAGE
MAINTENANCE (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4
100 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
250 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
500 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
1000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
5000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Lincoln Automatic Lubrication System (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Lubricant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Filter and Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
24 VDC Solid State Timer Checkout & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Pump Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Preventative Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5
This portion of the manual covers major component descriptions and truck specifications.
Major Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 & 7
This portion of the manual covers operation/maintenance of OPTIONAL EQUIPMENT.
PAYLOAD METER III (Refer to separate PAYLOAD METER III Index) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
RADIO, AM/FM STEREO CASSETTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Introduction - Section 1 OM1032.1 02/03
Page 1-6
KOMATSU MODEL 730E DUMP TRUCK

OM1032.1 02/03 Introduction - Section 1
Page 1-7
About This Manual
This Manual is written for use by the operator and/or the service technician and is designed to help these persons
to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All
operators and maintenance personnel should 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 cau-
tions should be understood and followed when operating or accomplishing repairs on the truck.
The front cover of this manual includes a Form Number. This Form No. should be referenced when ordering addi-
tional copies of this manual, or for any other correspondence regarding the coverage in this manual.
Direct all inquiries to:
Komatsu America Corp.
DataKom, Peoria Technical Publications
P.O. Box 240
Peoria, IL 61650-0240
FAX - [phone]
This first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of inter-
est. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
When searching for a specific area of interest, go first to the Table of Contents to locate the Section in which the
subject might generally be included. Then, go to that Section of the Table of Contents to find a Subject description
that most closely describes the specific area of interest to find a page number and go to that page. Section Num-
bers and Page Numbers are located at the top, outside corner of the page.
At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the infor-
mation in a particular Section, refer to the document (module) number, the manual Form No., and use the address
shown above to correspond. If there is a date (month/year) behind the document (module) number, that indicates
the latest revision date of that page.
The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction
of what is found on the truck.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “Right”, “Left”,
“Front”, or “Rear” are made with respect to the operator's normal seated position, unless specifically stated other-
wise.
When assembly instructions are provided without references to torque values, standard torque values should be
assumed. Standard torque requirements are shown in torque charts on the following pages of this section, and in
the General Information section of the truck service manual. Individual torques when provided in the text are in bold
face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise
specified.

Introduction - Section 1 OM1032.1 02/03
Page 1-8
NOTES

OM1032.2 Introduction - Section 1
Standard Charts and Tables Page 1-9
STANDARD CHARTS AND TABLES
This manual provides dual dimensioning for most spec-
ifications. U.S. standard units are specified first, with
metric (SI) units in parentheses. References through-
out the manual to standard torques or other standard
values will be to one of the following Charts or Tables.
For values not shown in any of the charts or tables,
standard conversion factors for most commonly used
measurements are provided in TABLE XIII, page 1-14.
INDEX OF TABLES
TABLE I . . . . . . . Standard Torque Chart (SAE) . . . 1-9
TABLE II . Standard Torque, 12-Point, Grade 9 . . 1-10
TABLE III . . Standard Metric Assembly Torque . . 1-10
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . 1-11
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . 1-11
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . 1-11
TABLEVII . . . . O-Ring Face Seal Torque Chart . . 1-11
TABLE VIII . Torque Conversions (ft.lbs. - N.m) . . 1-12
TABLE IX . . Torque Conversions (ft.lbs. - kg.m) . . 1-12
TABLE X . . . Pressure Conversions (psi - kPa) . . 1-12
TABLE XI . . Pressure Conversions (psi - MPa) . . 1-12
TABLE XII . . . . . . . .Temperature Conversions . . 1-13
TABLE XIII . . . Common Conversion Multipliers . . 1-14
EFFECT OF SPECIAL LUBRICANTS
On Fasteners and Standard Torque Values
KOMATSU engineering department does NOT recom-
mend the use of special “friction-reducing” lubricants
such as, “Copper Coat”, “Never Seize”, and other simi-
lar products on the threads of standard fasteners
where “standard torque” values are applied.
The use of special “friction-reducing” lubricants will sig-
nificantly alter the clamping force being applied to fas-
teners during the tightening process.
If special “friction-reducing” lubricants are used with the
“Standard Torque” values listed below in Table I (and in
Komatsu shop manuals), excessive stress and possi-
ble breakage of the fasteners may result.
Where Torque Tables specify “Lubricated Threads” for
the Standard Torque values listed, these standard
torque values are to be used with simple lithium
base chassis grease (multi-purpose EP NLGI) or a
rust- preventive grease (see list, page 1-10) on the
threads and seats, unless specified otherwise.
NOTE: Always be sure threads of fasteners and tapped
holes are free of burrs and other imperfections before
assembling.
Standard torque values are not to be used when
“Turn-of-the-Nut” tightening procedures are rec-
ommended.
TABLE I. -STANDARD TORQUE CHART
SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS)
TOLERANCES ±10%
Cap-
screw
Thread
Size
TORQUE -
GRADE 5
TORQUE -
GRADE 8
Cap-
screw
Thread
Size
TORQUE -
GRADE 5
TORQUE -
GRADE 8
ft. lbs. kg.m N.m ft. lbs. kg.m N.m ft. lbs. kg.m N.m ft. lbs. kg.m N.m
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft. lbs. = 0.138 kg.m = 1.356 N.m
Grade 5 Grade 8

Introduction - Section 1 OM1032.2
Page 1-10 Standard Charts and Tables
Standard Assembly Torques For 12-Point, Grade 9,
Capscrews (SAE)
The following specifications apply to required assembly
torques for all 12-Point, Grade 9 (170,000 psi minimum
tensile), Capscrews.
• Capscrew threads and seats SHALL be lubricated
when assembled.
Unless instructions specifically recommend otherwise,
these standard torque values are to be used with
simple lithium base chassis grease (multi-purpose EP
NLGI) or a rust- preventive grease (see list, this page)
on the threads.
• Torques are calculated to give a clamping force of
approximately 75% of proof load.
• The maximum torque tolerance shall be ±10% of
the torque value shown.
Standard Metric Assembly Torque For Class 10.9
Capscrews & Class 10 Nuts
The following specifications apply to required assembly
torques for all metric Class 10.9 finished hexagon head
capscrews and Class 10 nuts.
• Capscrew threads and seats SHALL NOT be lubri-
cated when assembled. These specifications are
based on all capscrews, nuts, and hardened
washers being phosphate and oil coated.
NOTE: If zinc-plated hardware is used, each piece
must be lubricated with a Rust Preventive Grease or
Lithium-base grease to achieve the same clamping
forces provided below.
• Torques are calculated to give a clamping force of
approximately 75% of proof load.
• The maximum torque tolerance shall be within
±10% of the torque value shown.
Suggested* Sources for Rust Preventive Grease:
• AMERICAN ANTI-RUST GREASE #3-X from
Standard Oil Company (also American Oil Co.)
• GULF NORUST #3 from Gulf Oil Company.
• MOBILARMA 355, Product No. 66705 from Mobil
Oil Corporation.
• RUST BAN 326 from Humble Oil Company.
• RUSTOLENE B GREASE from Sinclair Oil Co.
• RUST PREVENTIVE GREASE - CODE 312 from
the Southwest Grease and Oil Company.
NOTE: This list represents the current Engineering
approved sources for use in Komatsu manufacture. It is
not exclusive. Other products may meet the same
specifications of this list.
TABLE II. - STANDARD ASSEMBLY TORQUE
for 12-Point, Grade 9 Capscrews
CAPSCREW
SIZE*
TORQUE
ft. lbs.
TORQUE
N.m
TORQUE
kg.m
0.250 - 20 12 16 1.7
0.312 - 18 24 33 3.3
0.375 - 16 42 57 5.8
0.438 -14 70 95 9.7
0.500 -13 105 142 14.5
0.562 - 12 150 203 20.7
0.625 - 11 205 278 28.3
0.750 - 10 360 488 49.7
0.875 - 9 575 780 79.4
1.000 - 8 860 1166 119
1.000 - 12 915 1240 126
1.125 - 7 1230 1670 170
1.125 - 12 1330 1800 184
1.250 - 7 1715 2325 237
1.250 - 12 1840 2495 254
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
1.500 - 12 3225 4375 445
* Shank Diameter (in.) - Threads per inch
This table represents standard values only. Do not use these val-
ues to replace torque values which are specified in assembly
instructions.
TABLE III. - STANDARD METRIC ASSEMBLY TORQUE
CAPSCREW
SIZE*
TORQUE
N.m
TORQUE
ft.lbs.
TORQUE
kg.m
M6 x1 12 9 1.22
M8 x 1.25 30 22 3.06
M10 x 1.5 55 40 5.61
M12 x 1.75 95 70 9.69
M14 x 2 155 114 15.81
M16 x 2 240 177 24.48
M20 x 2.25 465 343 47.43
M24 x 3 800 590 81.6
M30 x 3.5 1600 1180 163.2
M36 x 4 2750 2028 280.5
* Shank Diameter (mm) - Threads per millimeter
This table represents standard values only. Do not use these val-
ues to replace torque values which are specified in assembly
instructions.

OM1032.2 Introduction - Section 1
Standard Charts and Tables Page 1-11
TABLE IV.
TORQUE CHART FOR JIC 37° SWIVEL NUTS
WITH OR WITHOUT O-RING SEALS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
– 2 0.125 0.312 – 24 4 ±1
– 3 0.188 0.375 – 24 8 ±3
– 4 0.250 0.438 – 20 12 ±3
– 5 0.312 0.500 – 20 15 ±3
– 6 0.375 0.562 – 18 18 ±5
– 8 0.500 0.750 – 16 30 ±5
– 10 0.625 0.875 – 14 40 ±5
– 12 0.750 1.062 – 12 55 ±5
– 14 0.875 1.188 – 12 65 ±5
– 16 1.000 1.312 – 12 80 ±5
– 20 1.250 1.625 – 12 100 ±10
– 24 1.500 1.875 – 12 120 ±10
– 32 2.000 2.500 – 12 230 ±20
TABLE VI.
TORQUE CHART FOR
O-RING BOSS FITTINGS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
– 2 0.125 0.312 – 24 4 ±2
– 3 0.188 0.375 – 24 5 ±2
– 4 0.250 0.438 – 20 8 ±3
– 5 0.312 0.500 – 20 10 ±3
– 6 0.375 0.562 – 18 13 ±3
– 8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 96 ±10
TABLE V.
TORQUE CHART FOR
PIPE THREAD FITTINGS
SIZE
CODE
PIPE
THREAD
SIZE
WITH
SEALANT
FT. LBS.
WITHOUT
SEALANT
FT. LBS.
– 2 0.125 – 27 15 ±3 20 ±5
– 4 0.250 – 18 20 ±5 25 ±5
– 6 0.375 – 18 25 ±5 35 ±5
– 8 0.500 – 14 35 ±5 45 ±5
– 12 0.750 – 14 45 ±5 55 ±5
– 16 1.000 – 11.50 55 ±5 65 ±5
– 20 1.250 – 11.50 70 ±5 80 ±5
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10
TABLE VII.
TORQUE CHART FOR
O-RING FACE SEAL FITTINGS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
– 4 0.250 0.438 – 20 11 ±1
– 6 0.375 0.562 – 18 18 ±2
– 8 0.500 0.750 – 16 35 ±4
– 10 0.625 0.875 – 14 51 ±5
– 12 0.750 1.062 – 12 71 ±7
– 16 1.000 1.312 – 12 98 ±6
– 20 1.250 1.625 – 12 132 ±7
– 24 1.500 1.875 – 12 165 ±15

Introduction - Section 1 OM1032.2
Page 1-12 Standard Charts and Tables
TABLE X. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
PSI0123456789
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page 1 -13 regarding Table usage
TABLE VIII. TORQUE CONVERSIONS
Foot Pounds – ft. lbs. To Newton-meters (N.m)
FT.LBS.0123456789
0(N.m)1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page 1 -13 regarding Table usage
TABLE IX. TORQUE CONVERSIONS
Foot Pounds – ft. lbs. To kilogram-meters (kg.m)
FT.LBS.0123456789
0(kg.m)0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page 1 -13 regarding Table usage

OM1032.2 Introduction - Section 1
Standard Charts and Tables Page 1-13
TABLE XII. TEMPERATURE CONVERSIONS
Formula: F° - 32 ÷1.8 = C° or C° x 1.8 + 32 = F°
CELSIUS
C°
FAHRENHEIT
F°
CELSIUS
C°
FAHRENHEIT
F°
CELSIUS
C°
FAHRENHEIT
F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 – 1 30 86
113 235 455 54 130 266 – 4 25 77
110 230 446 52 125 257 – 7 20 68
107 225 437 49 120 248 – 9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 – 5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 – 4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
TABLE XI. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
PSI0 102030405060708090
0(MPa)0.0690.140.210.280.340.410.480.550.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa).
1. Select Table X.
2. Go to PSI row 90, column 7; read 668.8
97 psi = 668.8 kPa.
3. Multiply by 10:
970 psi = 6688 kPa.
4. Go to PSI row 0, column 5; read 34.475
psi = 34.47 kPa. Add to step 3.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.

Introduction - Section 1 OM1032.2
Page 1-14 Standard Charts and Tables
COMMON CONVERSION MULTIPLIERS
ENGLISH To METRIC
To Convert
From TO
Multiply
By
inch – in. millimeter (mm) 25.40
inch – in. centimeter (cm) 2.54
foot – ft. meter (m) 0.3048
yard – yd. meter (m) 0.914
mile – mi. kilometer (km) 1.61
sq. in. – in.2sq. centimeters (cm2)6.45
sq. ft. – ft.2sq. centimeters (cm2)929
cu. in. – in.3cu. centimeters (cm3)16.39
cu. in. – in.3liters (l) 0.016
cu. ft. – ft.3cu. meters (m3)0.028
cu. ft. – ft.3liters (l) 28.3
ounce – oz. kilogram (kg) 0.028
fluid ounce – fl. oz. milliliter (ml) 29.573
pound (mass) kilogram (kg) 0.454
pound (force) – lbs. Newton (N) 4.448
in. lbs. (force) Newton.meters (N.m) 0.113
ft. lbs. (force) Newton.meters (N.m) 1.356
ft. lbs. (force) kilogram.meters (kg.m) 0.138
kilogram.meters
(kg.m) Newton.meters (N.m) 9.807
psi (pressure) kilopascals (kPa) 6.895
psi (pressure) megapascals (MPa) 0.007
psi (pressure) kilograms/cm2(kg/cm2)0.0704
ton (short) kilogram (kg) 907.2
ton (short) metric ton 0.0907
quart – qt. liters (l) 0.946
gallon – gal. liters (l) 3.785
HP (horsepower) Watts 745.7
HP (horsepower) kilowatts (kw) 0.745
COMMON CONVERSION MULTIPLIERS
METRIC To ENGLISH
To Convert From TO
Multiply
By
millimeter (mm) inch – in. 0.0394
centimeter (cm) inch – in. 0.3937
meter (m) foot – ft. 3.2808
meter (m) yard – yd. 1.0936
kilometer (km) mile – mi. 0.6210
sq. centimeters (cm2) sq. in. – in.20.1550
sq. centimeters (cm2) sq. ft. – ft.20.001
cu. centimeters (cm3) cu. in. – in.30.061
liters (l) cu. in. – in.361.02
cu. meters (m3) cu. ft. – ft.335.314
liters (l) cu. ft. – ft.30.0353
grams (g) ounce – oz. 0.0353
milliliter (ml) fluid ounce – fl. oz. 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pound (force) – lbs. 0.2248
Newton.meters (N.m) kilogram.meters (kg.m) 0.102
Newton.meters (N.m) ft. lbs. (force) 0.7376
kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters (kg.m) Newton.meters (N.m) 9.807
Kilopascals (kPa) psi (pressure) 0.1450
megapascals (MPa) psi (pressure) 145.038
kilograms/cm2(kg/cm2)psi (pressure) 14.2231
kilograms/cm2(kg/cm2)kilopascals (kPa) 98.068
kilogram (kg) ton (short) 0.0011
metric ton ton (short) 1.1023
liters (l) quart – qt. 1.0567
liters (l) gallon – gal. 0.2642
Watts HP (horsepower) 0.00134
kilowatts (kw) HP (horsepower) 1.3410
TABLE XIII COMMON CONVERSION MULTIPLIERS

OM2026.1 Safety - Section 2
General Safety Page 2-1
GENERAL SAFETY
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. 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 regulations may
add many more to this list.
Read and follow all safety precautions.
Failure to do so may result in serious injury or death.
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, be sure all personnel understand all
hand signals that are to be used.
SAFETY FEATURES
• Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.
(See Walk-Around Inspection, Operating Instructions - Section 3)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• NEVER remove any safety features. ALWAYS keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
• Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or
in moving parts and cause serious injury or death. Also, do not wear oily clothes
because they are flammable.
• Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating
or maintaining the machine. Always wear safety goggles, hard hat and heavy
gloves if your job involves scattering metal chips or minute materials-this is so
particularly when driving pins with a hammer and when cleaning the air cleaner
element with compressed air. Check also that there is no one near the machine.
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 injury
or damage caused by any unauthorized modification.

Safety - Section 2 OM2026.1
Page 2-2 General Safety
STANDING UP FROM THE SEAT
• To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the
following before standing up from the operator's seat.
• Place the gear shift lever at neutral and set the parking lever to the PARKING position.
• Lower the dump body, set the dump lever to the FLOAT position.
• Stop the engine. When leaving the machine, always lock everything. Always remember to take the key with
you. If the machine should suddenly move or move in an unexpected way, this may result in serious bodily
injury or death.
MOUNTING AND DISMOUNTING
• NEVER jump on or off the machine. NEVER get on or off a moving machine.
• When getting on or off the machine, face the machine and use the handhold and steps.
• Never hold any control levers when getting on or off the machine.
• Always maintain three-point contact with the handholds and steps to ensure that you support yourself.
• When bringing tools to the operator's compartment, always pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
• Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
A: For use when getting on or off the machine from the left door.
B: For use when getting on or off the machine from the engine hood or right door.
FIRE PREVENTION FOR FUEL AND OIL
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
• Keep flame away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil tank caps securely.
• Refueling and oiling should be made in well ventilated areas.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

OM2026.1 Safety - Section 2
General Safety Page 2-3
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
• Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature
and are under pressure. If the cap is removed, or the oil or water is drained, or the filters are replaced, there is
danger of serious burns. Always wait for the temperature to cool down, and carry out the operation according
to the specified procedure.
• To prevent hot water from spurting out:
1) Stop the engine.
2) Wait for the water temperature to cool down.
3) Turn the cap slowly to release the pressure before removing the cap.
• To prevent hot engine oil from spurting out:
1) Stop the engine.
2) Wait for the oil temperature to cool down.
3) Turn the cap slowly to release the pressure before removing the cap.
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.If you handle
materials containing asbestos fibers, follow these guidelines as given below:
• NEVER use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Operate the machine with the wind to your back, whenever possible.
• Use an approved respirator if necessary.
PREVENTION OF INJURY BY WORK EQUIPMENT
• Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead
to serious bodily injury or death.
FIRE EXTINGUISHER AND FIRST AID KIT
• Be sure fire extinguishers have been provided and know how to use them.
• Provide a first aid kit at the storage point.
• Know what to do in the event of a fire.
• Be sure you know the phone numbers of persons you should contact in case of
an emergency.