Komatsu 930E-2 Install guide

ThismaterialisproprietarytoKomatsuMiningSystems,Inc.andisnottobereproduced,used,ordisclosedexcept
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.
Becauseof continuousresearch anddevelopment, periodicrevisions maybe madeto thispublication. Customers
should contact their local distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of
Californiatocausecancer,birthdefectsorotherreproductiveharm.
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.
Thismanualshouldbekeptin ornearthemachine forreference,andperiodically
reviewed by all personnel who will come into contact with it.
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.

NOTES:

FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician
become fully knowledgeable of the truck and all its systems in order to keep it running and in
production. All maintenance personnel should read and understand the materials in this manual
before performing maintenance and/or operational checks on the truck. All safety notices, warnings
and cautions should be understood and followed when accomplishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well
as other general information. The major portion of the manual pertains to disassembly, service and
reassembly. Each major serviceable area is dealt with individually. For example: The disassembly,
service and reassembly of the radiator group is discussed as a unit. The same is true of the engine
and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly
should be carried only 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 of U.S. standard and metric (SI) units throughout and 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 are shown in torque charts in the general information section and
individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All
torque specifications have ± 10% tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck 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. 930E). 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. Thevehicle design and application guidelines aresensitiveto thetotalmaximumGross
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 ofmud,frozen material,etc. becomea partofthe GVWand reduces allowable
payload. To maximize payload and to keep from exceeding the GVWrating, these accumulations
should be removed as often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
A00017 03/01 Introduction A-1

“DANGER” identifies a specific potential hazard
WHICH WILL RESULT
in either INJURYOR DEATH
if proper precautions are not taken.
“WARNING” identifies a specific potential hazard
WHICH MAYRESULT
in either INJURYOR 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.
This “ALERT” symbol is used with the signal words,
“CAUTION”, “DANGER”, and “WARNING” in this man-
ual to alert the reader to hazards arising from
improper operating and maintenance practices.
A-2 Introduction A00017 03/01

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
HYDRAIR®II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
A00017 03/01 Introduction A-3

KOMATSU MODEL 930E Dump Truck
A-4 Introduction A00017 03/01

SECTION A
GENERAL INFORMATION
INDEX
TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . A2-1
GENERAL SAFETY AND TRUCKOPERATION . . . . . . . . . . . . . . . . . . . . . . . . . A3-1
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1
CHARTS AND TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1
STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-1
A01001 2/94 Index A1-1

NOTES
A1-2 Index A01001 2/94

MAJOR COMPONENT DESCRIPTION
Truck And Engine
The 930E Dump Truck is an off-highway, rear dump
truck with AC Electric Drive. The gross vehicle weight
is 1,100,000 lbs. (498 957 kg). The engine is a Cum-
mins QSK60C rated @ 2700 HP (2014 kW).
Alternator (GE-GTA34)
The diesel engine drives an in-line alternator at engine
speed. The alternator produces AC current which is
rectified to DC within the main control cabinet. The
rectified DC power is converted back to AC by groups
of devices called “inverters”, also within the main
control cabinet. Each inverter consists of six “phase
modules” under the control of a “gate drive unit”
(GDU). The GDU controls the operation of each phase
module.
Each phase module contains an air-cooled solid-state
switch referred to as a “gate turn-off thyristor” (GTO).
The GTO cycles on and off at varying frequencies to
create an AC power signal from the DC supply.
The AC power signal produced by each inverter is a
variable-voltage, variable-frequency signal (VVVF).
Frequency and voltage are changed to suit the oper-
ating conditions.
AC Induction Traction Motorized Wheels
The alternator output supplies electrical energy to the
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction
motors with full-wave AC power.
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 forward or reverse hand
selector switch located on a console to the right side
of the operator.
Blower
Both the inverters and the wheel motors produce heat
while in operation and must be cooled. Cooling air is
provided by a separate AC drive blower using rectified
DC as its power source. Cooling air flow volume is
modulated based on thermal requirements.
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.
Operator’s Cab
The Operator’s Cab 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 4-post ROPS/FOPS stucture, and an ad-
vanced analog operator envirnment. 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 steering
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 truck is equipped with a full time power steering
system which provides positive steering control with
minimum operator effort. The system includes nitro-
gen-charged accumulators which automatically pro-
vide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
Dynamic Retarding
The dynamic retarding is used to slow the truck during
normal operation or control speed coming down a
grade. The dynamic retarding ability of the electric
system is controlled by the operator through the acti-
vation of the retarder pedal (or by operating a lever on
the steering wheel) in the operators cab and by setting
the RSC (Retarder Speed Control). Dynamic Retard-
ing is automatically activated, if the truck speed goes
to a preset overspeed setting.
Brake System
Service brakes at each wheel are oil-cooled multiple
disc brakes applied by an all-hydraulic actuation sys-
tem. Depressing the brake pedal actuates both front
and rear brakes, after first appling the retarder. All
wheel brakes will be applied automatically, if system
pressure decreases below a preset minimum.
The parking brake is a dry disc type, mounted inboard
on each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
protection (will not apply with truck moving).
A02055 Major Component Description A2-1

930E MAJOR COMPONENTS
A2-2 Major Component Description A02055

SPECIFICATIONS
These specifications are for the standard 930E Truck. Customer Options may change this listing.
ENGINE
Cummins QSK60
Number of Cylinders . . . . . . . . . . . . . . 16
Operating Cycle . . . . . . . . . . . . . 4-Stroke
Rated Brake HP 2700HP (2014 kW) @ 1900 RPM
Flywheel HP . . . . . . . . . 2550HP (1879 kW)
Weight (Dry)* . . . . . . . . 19,515 lbs. (8852 kg)
* Weight does not include Radiator, Sub-frame, or Alternator
AC ELECTRIC DRIVE SYSTEM
AC/DC Current
Alternator . . . . . . . General Electric GTA - 34
Integral Cooling Fan . . . 2500 cfm (71 m3/min)
AC Thermally Mod. Dual Fan
. . . . . . . . . . . . . 12,000 cfm (340 m3/min)
Motorized Wheels . AC Induction Traction Motors
. . . . . . . . . . . . . . Wheel Slip/Slide Control
Standard Gear Ratio* . . . . . . . . . . 31.50:1
Maximum Speed . . . . . 40 MPH (64.5 km/h)
*NOTE: Wheelmotor application depends upon GVW, haul
road grade, haul road length, rolling resistance, and other pa-
rameters.
Komatsu & G.E. must analyze each job condition to assure
proper application.
DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . Standard
Maximum Retarding . . . . . 5400 HP (4026 kW)
Continuous . . . . . . . . . 3300 HP (2460 kW)
Continuously Rated High-density Blown Grids
with Retard at Engine Idle and Retard in Reverse
Propulsion.
BATTERY ELECTRIC SYSTEM
Batteries - . . . . . . . . . . . bumper-mounted
..........................................................................................................................................................................................................................4 x 8D & 2 x 30H 12 Volt Batteries in Series/Parallel
. . . . . . . . . . . . 220 Ampere-Hour Capacity
. . . . . . . . . . . . . . With Disconnect Switch
Alternator . . . . . . 24 Volt, 240 Ampere Output
Lighting . . . . . . . . . . . . . . . . . . 24 Volt
Starters (2) . . . . . . . . . . . . . . . . . 24 Volt
SERVICE CAPACITIES
. . . . . . . . . . U.S. Gallons . . . . . Liters
Crankcase (Includes lube oil filters)
QSK60-C . . . . . . . . . . . 74 . . . . . . 280
Cooling System . . . . . . . 157 . . . . . . 594
Fuel . . . . . . . . . . . . 1200 . . . . . 4542
Hydraulic System . . . . . . 350 . . . . . 1325
Wheel Motor Gear Box 20/Wheel . . . 76/Wheel
HYDRAULIC SYSTEM
Hoist & Brake Cooling Pump: . . . . Tandem Gear
Output . . . 270 GPM (1022 l/min) @ 1900 RPM
. . . . . . . . . . . . and 2500 psi (17 237 kPa)
Steering/Brake Pump: Press. Compensated Piston
Output . . . . 65 GPM (246 l/min) @ 1900 RPM
. . . . . . . . . . . and 2750 psi (18 961 kPa)
Relief Pressure- Hoist . . . . 2500 psi (17.2 MPa)
Relief Press.- Steering/Brake 2750 psi (22.4 MPa)
Hoist . . . . . . . Two 3-Stage Hydraulic Cylinders
Tank . . . . Vertical - Cylindrical, Non-Pressurized
Tank Capacity . . . . 250 U.S. Gal. (947 Liters)
Filtration . . . . . . . In-line replaceable elements
Suction . . . . . . Single, Full Flow, 100 Mesh
Hoist & Steering Filters . . Beta 12 rating = 200
. . . . . . . . . . Dual, In-Line, High Pressure
SERVICE BRAKES
All Hydraulic Actuation . . . with Traction System
. . . . . . . . . . . . . Wheel Slip/Slide Control
Front & Rear Oil-Cooled Multiple Discs
. . . . . . . . . . . . . . . . . . at Each Wheel.
Total Friction Area /Brake 15,038 in2(97 019 cm2)
Maximum Apply Pressure . 2500 psi (17 238 kPa)
STEERING
Turning Circle (SAE) . . . . 97 ft. 4 in. (29.67 m)
Twin hydraulic cylinders with accumulator assist to
provide constant rate steering.
Emergency Power Steering automatically provided by
Accumulators
A02055 Major Component Description A2-3

STANDARD DUMP BODY*
Capacity:
Struck . . . . . . . . . 224 yds3. . . . 171 m3
Heaped @ 2:1 (SAE) 276 yds3. . . . 211 m3
Width (Inside) . . . . . . . . . 26 ft. 9 in. (8.15 m)
Depth . . . . . . . . . . . . . 10 ft. 3 in. (3.1 m)
Loading Height . . . . . . . . . . 23 ft. (7.01 m)
Dumping Angle . . . . . . . . . . . . . . . . 45o
* OPTIONAL Capacity Dump Bodies are available.
TIRES
Radial Tires (standard) . . . . . . . . 53/80 R63
Rock Service, Deep Tread . . . . . . . Tubeless
Rims . (patented Phase II New Generationrims)
WEIGHT DISTRIBUTION
EMPTY . . . . . . . . . Pounds . . Kilograms
Front Axle (49.3%) . . . 219,913 . . . . 99 751
Rear Axle (50.7%) . . . 226,121 . . . 102 567
Total (50% Fuel) . . . . 446,034 . . . 202 318
LOADED
Front Axle (33.9%) . . . 372,727 . . . 169 069
Rear Axle (66.1%) . . . 727,273 . . . 329 891
Total . . . . . . . . . 1,100,000 . . . 498 960
Not to exceed 1,100,000 lbs. (498 957 kg), including
options, fuel, and payload. Weights in excess of this
amount require factory approval.
OVERALL TRUCK DIMENSIONS
A2-4 Major Component Description A02055

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.
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 worksite 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 to this vehichle without authorization from Komatsu Mining Systems, Inc. can possibly
create hazards.
•Before making any modification, consult the authorized regional Komatsu Mining Systems, Inc. distributor.
Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.
Readandfollowall safetyprecautions.Failuretodoso mayresult
in serious injury or death.
A03017 General Safety and Operating Instructions A3-1

LEAVING THE OPERATOR’S SEAT
•When preparing to leave the operator’s seat, do not touch any control lever that is not locked.
To prevent accidental operations from occurring , always carry out the following:
•Move the shift control lever to the Neutral position (N) and set the parking lever/switch 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.
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.
A3-2 General Safety and Operating Instructions A03017

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, orthe 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.
A03017 General Safety and Operating Instructions A3-3

PRECAUTIONS WHEN USING ROPS
•If ROPS is installed, the ROPS must never be removed when operating the machine.
•The ROPS is installed to protect the operator if the machine should roll over. It is designed not only to support
the load if the machine should roll over, but also to absorb the impact energy.
•The ROPS installed on equipment manufactured and designed by Komatsu MiningSystems, Inc. fulfills all of the
regulations and standards for all countries, but if it is modified or repaired without authorization from Komatsu
Mining Systems, Inc., or is damaged when the machine rolls over, the strength will drop and it will not be able to
fulfill its function properly. It can only display its performance if it is repaired or modified in the specified way.
•When modifying or repairing the ROPS, always consult the authorized regional Komatsu Mining Systems, Inc.
distributor.
•Even if the ROPS is installed, it cannot show its full effect if the operator does not fasten the seat belt properly.
Always fasten the seat belt when operating.
PRECAUTIONS FOR ATTACHMENTS
•When installing and using optional equipment, read the instructionmanual for the attachment and the information
related to attachments in this manual.
•Do not use attachments that are not authorized by Komatsu Mining Systems, Inc., or the authorized regional
Komatsu Mining Systems, Inc. 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 Mining Systems, Inc., or the authorized regional Komatsu Mining Systems, Inc.
distributor.
A3-4 General Safety and Operating Instructions A03017

PRECAUTIONS DURING OPERATION
SAFETY IS THINKING AHEAD
Prevention is the best safety program. Prevent a potential accident by knowing the employer’s safety requirements
and all necessary job site regulations. In addition, know the proper use and care of all the safety equipment on the
truck. Only qualified operators or technicians should attempt to operate or maintain the Komatsu Truck.
Safe practices start before the operator gets to the equipment!
SAFETY AT WORKSITE
•When walking to and from the truck, maintain a safe distance from all machines even if the operator is visible.
•Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
•Examine the road surface in the jobsite and determine the best and safest method of operation.
•Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
•If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty
or by installing fences around the worksite.
•Theoperatormustcheckpersonallytheworkposition,roadstobeused,andexistenceofobstaclesbeforestarting
operations.
•Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines
to travel.
•If travel through wet areas is necessary, check the depth and flow of water before crossing the shallow parts.
NEVER be in water which is in excess of the permissible water depth.
FIRE PREVENTION
•Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compart-
ment. These could cause a fire.
•Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks
repaired.
Wipe up any excess oil, fuel or other flammable fluids.
•Be sure a fire extinguisher is present and working.
•Do not operate the machine near any flame.
PREPARING FOR OPERATION
•Always mount and dismount facing the truck. Never attempt to mount or dismount the truck while it is in motion.
Always use handrails and ladder when mounting or dismounting from the truck.
•Check the deck areas for debris, loose hardware or tools. Check for people and objects that might be in the way.
•Become familiar with and use all protective equipment devices on the truck and insure that these items (anti-skid
material, grab bars, seat belts, etc.) are securely in place.
VENTILATION FOR ENCLOSED AREAS
•If it is necessary to start the engine within an enclosed area, provide adequate ventilation.
Exhaust fumes from the engine can KILL.
A03017 General Safety and Operating Instructions A3-5

IN OPERATOR’S CAB - BEFORE STARTING ENGINE
•Do not leave tools or spare parts lying around in the operator’s compartment or allow trash to accumulate in cab
of truck. Keep all unauthorized reading material out of truck cab.
•Keep the cab floor, controls, steps, and handrails free of oil, grease, snow, and excess dirt.
•Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use
seat belts when operating your machine.
•Read and understand the contents of this manual. Read the Section 3 pertaining to safety and operating
instructions with special attention. Become thoroughly acquainted with all gauges, instruments and controls
before attempting operation of the truck.
•Read and understand the WARNING and CAUTION decals in the operator’s cab.
•Insure steering wheel, horn, controls and pedals are free of any oil, grease or mud.
•Check operation of windshield wiper, condition of wiper blades, and check washer reservoir for fluid level.
•Befamiliarwithallsteeringandbrakesystemcontrolsandwarningdevices,roadspeedsandloadingcapabilities,
before operating the truck.
KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN
•Remove any dirt from the surface of the windshield and all cab windows and lights. Good visibility may prevent
an accident.
•Adjust the rear view mirror to a position where the operator can see best from the operator’s seat, and keep the
surface of the mirror clean. If any glass or light should break, replace it with a new part.
•Insure headlights, worklights and taillights are in proper working order. Check that the machine is equipped with
the head lamps and working lamps needed for the operating conditions.
OPERATING THE MACHINE
WHEN STARTING ENGINE
•NEVER start the engine if a warning tag has been attached to the control.
•When starting the engine, sound the horn as an alert.
•Start and operate the machine only while seated.
•Donotallow anypersonotherthantheoperator in theoperator’scompartmentoranyotherplace onthe machine.
Truck Operation - General
•WEAR SEAT BELTS AT ALL TIMES.
•Only authorized persons are allowed to ride in truck. Riders should be in cab only and belted in passenger seat.
•Do not allow anyone to ride on decks or steps of truck.
•Do not allow anyone to get on or off truck while it is in motion.
•Do not move truck into or out of a building without a signal person present.
•Know and obey the hand signal communications between operator and spotter. When other machines and
personnel are present, the operator should move in andout of buildings, loading areas and through traffic, under
the direction of a signal person. Courtesy at all times is a safety precaution!
•Report immediately to supervisor any conditions on haul road, pit or dump area that may cause an operating
hazard.
A3-6 General Safety and Operating Instructions A03017