930E-4 Field Assembly PDF

Field Assembly Manual
CEAW004600
DUMP TRUCK
SERIAL NUMBERS
A30462 & UP
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-4 dump truck. Variations of design required for specific truck orders may require some modification of the general procedures outlined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the truck. General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the current production truck model. This manual lists metric (SI) and U.S. standard dimensions throughout. All location references to front, rear, right, or left, are given in respect to the operator's normal seated position. It is recommended that all maintenance personnel read and understand the materials in the service manual before performing maintenance and/or operational checks on the assembled truck.
FAM0013
Introduction
This alert symbol is used with the signal words, CAUTION, DANGER, and WARNING in this manual to alert the reader to hazards arising from improper operating and maintenance practices.
DANGER Identifies a specific potential hazard which will result in either injury or death if proper precautions are not used.
WARNING identifies a specific potential hazard which may result in either injury or death if proper precautions are not used.
CAUTION is used for general reminders of proper safety practices or to direct the readers attention to avoid unsafe or improper practices which may result in damage to the equipment.
ii
Introduction
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TABLE OF CONTENTS
SUBJECT
PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 TRUCK COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
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Introduction
iii
NOTES
iv
Introduction
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SAFETY RULES, TOOLS & EQUIPMENT

SAFETY RULES
The following list of safety practices is intended for use by personnel during field assembly of the truck. This list of safety rules is not intended to replace local safety rules or regulations and federal, state, or local laws. The safety precautions recommended here are general and must be used in conjunction with all prevailing local rules and regulations. 1. All personnel must be properly trained for the assembly process. 2. Wear safety equipment such as safety glasses, hard toe shoes and hard hats at all times during assembly. 3. Thoroughly inspect the assembly site. Remove weeds, debris and other flammable material. 4. Use only solid, hard wood for supports. When using metal support stands, place wood blocks between the support and the frame to prevent metal to metal contact. 5. Inspect all lifting devices. Refer to the manufacturer's specifications for correct capacities and safety procedures when lifting components. 6. Perform a daily inspection of all lifting cables and chains. Replace any questionable items. Use cables and chains that are properly rated for the load to be lifted. 7. DO NOT stand beneath a suspended load. Use of guy ropes are recommended for guiding and positioning a suspended load. 8. Maintain fire control equipment. Inspect fire extinguishers regularly to ensure they are fully charged and in good working condition. 9. Cap screws and/or nuts being replaced must be the same grade as originally supplied.
Before welding, refer to Special Precautions When Servicing A 930E Truck, in Section 4. 10. Disconnect the battery charging alternator lead wire before welding on the frame or its components. 11. When welding, connect the ground cable to the part being welded. DO NOT allow welding current to pass through bearings, engine, etc. 12. DO NOT weld the fuel tank or hydraulic tank unless the tanks have been properly purged and ventilated. 13. Use the proper tools for the job to be performed. Never improvise wrenches, screw drivers, sockets, etc. unless specified. 14. Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load. 15. When the weight of any component(s) or any assembly procedure is not known, contact your customer support manager for further information.
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Safety Rules, Tools, & Equipment
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TOOLS AND EQUIPMENT FOR ASSEMBLY

The following equipment is recommended for field assembly of the truck. 12. Two, ratchet pullers - 2.7 metric ton (3 ton) 1. Equipment and tool storage trailer with a lockable door. Approximately 12 x 2.5 m (40 x 8 ft) 2. Cranes a. Two, 45 metric ton (50 ton) cranes to remove the chassis from the freight trailer and place on cribbing. These cranes can also be used to lift the assembled body onto to the chassis. b. One, 109-136 metric tons (120-150 ton) crane. The crane is needed to turn the body over after completion of the underside welding. A 45 metric ton (50 ton) crane is also required for this task. 3. One fork lift - 6804 kg (15,000 lb) capacity, with high lift capability. 4. Two, 300 amp portable welding units and an oxyacetylene cutting set. 5. One, propane torches for weld preheating. 6. Portable air compressor - 3.5 cmm (125 cfm) and 690 kPa (100 psi) capacity. Two, 15 m (50 ft) air hoses. 7. Metal stands and a sufficient amount of wood cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm (14 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm (4 ft. x 6 in. x 6 in.) - such as railway cross ties 8. Tire handler - Wiggins/Iowa Mold Tooling. 9. Miscellaneous air tools 10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft) 11. Chains, lifting cables, slings: 13. Two, ratchet pullers - 1.4 metric ton (1.5 ton) 14. Set of standard master mechanics hand tools.
Thread taps and dies of both inch and metric

sizes.
Metric sockets and open end wrenches, 6mm to

36mm.
Inch sockets and open end wrenches up to 1 3/

4 in.
Torque wrenches - 339 Nm (250 ft lb) with 18:1

multiplier. Torque wrenches - 339 Nm (600 ft lb) with 4:1 multiplier. Hydrotorque - 1 1/2 in. drive with capability of 5559 Nm (4100 ft lb) or greater.
Box wrench 1 3/8 in. (Snap-On p/n X440B) with

12 inch extension to tighten ROPS cap screws.
Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2

5/8 in. (Snap-On P/N J15042) to tighten front suspension hardware. 15. Heavy duty 3/4 in. & 1 in. square drive impact wrench sets. 16. Impact sockets for 3/4 in. & 1 in. square drive tools. 17. Special tools (see list, following pages) 18. Two, hydraulic or pneumatic porta-power jacks, 4.5 and 9 metric ton (5 and 10 ton) 19. Various hooks and shackles 20. Miscellaneous: i.e. grinders, containers, rags. 21. Spreader bars for cab and decks. 22. Two ratchet hoists of 2.7 metric ton (3 ton) capacity. 23. Pry bars 24. Solvent - 38 liters (10 gal) 25. Paint remover - 19 liters (5 gal) 26. Rust preventive grease
Two, 4 point slings, 3 m (10 ft) in length Two, 4 point slings, 2 m (6 ft) in length Two, 1 m (4 ft) and two, 2 m (6 ft) Two, 3 m (10 ft) nylon straps Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of rope
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LIFTING SLING GENERAL INFORMATION
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Page 1-3
Part Number EB1759
Description Nitrogen Charging Kit
Use Suspension & Accumulator Nitrogen Charging
1. T Handle Valve 2. Charging Valve Adapter 3. Manifold Outlet Valves (from gauge) 4. Inlet Valve (from regulator) 5. Regulator Valve (Nitrogen Pressure) 6. Manifold 7. Charging Pressure Gauge (Suspensions) 8. Dry Nitrogen Gas
Part Number EJ2626 (No longer available as complete unit) EJ2271 PC0706 TH9449
Description Roller Assy.
Use Power Module Remove & Install
Roller Mount Bearing Bearing Retainer Ring Roller Retainer Ring Cap screw 0.75 -10 NC x 2 1/4 in. Lockwasher 0.75 in. Roller Ring
TG1680
C1645
C1542 EH8686
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Part Number PB8326
Description Offset Box End Wrench, 1, 7/16 in.
Use Miscellaneous
Part Number TZ2734
Description 3/4 in. Torque Adapter
Use Miscellaneous
Part Number TZ2733
Description Tubular Handle
Use Use with PB8326 & TZ2734
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Part Number BF4117
Description Seal Installation Tool
Use Front & Rear Disc Brake Floating Ring Seal Installation Rear Axle/Hub Adaptor Floating Ring Seal Installation
ED3347
Seal Installation Tool
Part Number EH4638
Description Sleeve Alignment Tool
Use Steering Linkage and Tie Rod
Part Number EF9302 EB1723 EF9301 WA0010 TL3995 EB4813 SV9812
Description Wear Indicator Cap, Indicator Pin Indicator O-ring, Indicator Pin O-ring, Indicator Cap Housing, Indicator O-ring, housing
Use Brake Disc Wear
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Part Number EF9160
Description Harness
Use Payload Meter Download
Part Number EH7817
Description Alignment Tool
Use Upper Hoist Pin
Part Number PB4684
Description Hydraulic Coupling
Use Miscellaneous
Part Number PB9067
Description Bulkhead Connector
Use Battery Jumper
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Part Number TZ2100 TZ2727 TZ2729
Description Socket (1 7/8 in.) Socket (2 1/4 in.) Socket (1 1/4 in.)
Use Misc.
Part Number TZ2730 TZ2731
Description Adapter (1-1 1/2 in.) Adapter (3/4-1 in.)
Use Socket adapter
Part Number WA4826
Description Lifting Eye Bolt
Use Miscellaneous
Part Number PC0370
Description Sling
Use Body Retention
Part Number PC0367
Description Shackle
Use Miscellaneous
Part Number TR0532 TR0533
Description Extension (8 in.) Extension (17 in.)
Use Miscellaneous
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TRUCK COMPONENTS AND SPECIFICATIONS

Truck And Engine
The 930E-4 dump truck is an off-highway, rear dump truck with A/C electric drive. The gross vehicle weight is 1,106,000 lbs. (501 673 kg). The engine is a Komatsu SSDA16V160 rated @ 2700 HP (2014 kW).
Operator's Cab
The operator cab has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab provides wide visibility, with an integral 4-post ROPS/FOPS, and an advanced analog operator environment. It includes a tinted safetyglass 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 provides the operator with all instruments and gauges which are necessary to control and/or monitor the truck's operating systems.
Alternator (GE-GTA41)
The diesel engine drives an in-line alternator at engine speed. The alternator produces A/C current which is rectified to DC within the main control cabinet. The rectified DC power is converted back to A/C 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 solidstate switch referred to as a "gate turn-off thyristor" (GTO). The GTO cycles on and off at varying frequencies to create an A/C power signal from the DC supply. The A/C power signal produced by each inverter is a variable-voltage, variable-frequency signal (VVVF). Frequency and voltage are changed to suit the operating conditions. Cooling air for the control / power group and wheel motors, as well as the alternator itself, is provided by dual fans mounted on the alternator shaft.
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 nitrogen-charged accumulators which automatically provide 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 activation 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 Retarding is automatically activated, if the truck speed goes to a preset overspeed setting.
A/C 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 A/C induction motors with full-wave A/C 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 the center console.
Brake System
Service brakes at each wheel are oil-cooled multiple disc brakes applied by an all-hydraulic actuation system. Depressing the brake pedal actuates both front and rear brakes, after first applying 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 springapplied/hydraulically-released with wheel speed application protection (will not apply with truck moving).
Suspension
HydrairII 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.
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Truck Components And Specifications
Page 2-1
930E-3 MAJOR COMPONENTS

Page 2-2 Truck Components And Specifications FAM0212
SPECIFICATIONS
These specifications are for the standard Komatsu 930E Truck. Customer Options may change this listing.
ENGINE
Komatsu SSDA16V160 No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rpm High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . 1910 rpm Rated Full Load . . . . . . . . . . . . . . . . . . . . . 1900 rpm Rated Brake HP. . . 2700 HP (2014 kW) @ 1900 rpm Flywheel HP . . . . . 2550 HP (1902 kW) @ 1900 rpm Weight* (Wet) . . . . . . . . 21,182 pounds (9608 kg)
* Weight does not include Radiator, Sub-frame, or Alternator
SERVICE CAPACITIES
. . . . . . . . . . . . . . . . . . U.S. Gallons . . . . . . . Liters Crankcase * . . . . . . . . . . . . . . . . 74 . . . . . . . . . .280 * Includes Lube Oil Filters Cooling System . . . . . . . . . . . . . 157 . . . . . . . . . .594 Fuel . . . . . . . . . . . . . . . . . . . . . 1200 . . . . . . . . .4542 Hydraulic System . . . . . . . . . . . . 350 . . . . . . . . 1325 Wheel Motor Gear Box. . . 25/Wheel . . . . . 95/Wheel
HYDRAULIC SYSTEMS
Hoist & Brake Cooling Pump:. . . . . . . . Tandem Gear Rated @ . . . . . . 270 GPM (1022 l/min.) @ 1900 rpm . . . . . . . . . . . . . . . . . . . . .and 2500 psi (17 237 kPa) Steering/Brake Pump:Pressure Compensated Piston Rated @ . . . . . . . 65 GPM (246 l/min.) @ 1900 rpm . . . . . . . . . . . . . . . . . . . . .and 2750 psi (18 961 kPa) Relief Pressure-Hoist . . . . . . . 2500 psi (17 237 KPa) Relief Pressure-Steering . . . . 4000 psi (27 579 KPa) Hoist Cylinders (2) . . . . . . . . . . . . 3-Stage Hydraulic Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized Tank Capacity . . . . . . . . 250 US 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
A/C ELECTRIC DRIVE SYSTEM

(AC/DC Current) Alternator . . . . . . . . . . . . . General Electric GTA - 41 Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 cfm (340 m/ min) Motorized Wheels . . GDY106 A/C Induction Traction Standard Gear Ratio*. . . . . . . . . . . . . . . . . 32.62:1 Maximum Speed . . . . . . . . . . 40 mph (64.5 km/h)
*NOTE: Wheel motor application depends upon GVW, haul road grade and 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 Rating . . . . . . . . . . . . 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.
SERVICE BRAKES
All Hydraulic Actuation . . . . . . . with Traction System . . . . . . . . . . . . . . . . . . . . . Wheel Slip / Slide Control Front and Rear Oil-Cooled Multiple Discs-each wheel Total Friction Area / Brake . . 15,038 in (97 025 cm) Maximum Apply Pressure . . . 2500 psi (17 238 kPa)
BATTERY ELECTRIC SYSTEM

Batteries 4 x 8D 1450CCA, 12 volt, in series/parallel, . . . . and 2x30H 800CCA, 220-ampre-hour batteries, . . . . . . . . . . bumper mounted with disconnect switch Alternator . . . . . . . . . . . 24 Volt, 260 Ampere Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt Cranking Motors (2). . . . . . . . . . . . . . . . . . . . 24 Volt
STEERING
Turning Circle (SAE). . . . . . . . . . .97 ft. 7 in. (29.7 m) Twin hydraulic cylinders with accumulator assist to provide constant rate steering.
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STANDARD DUMP BODY CAPACITIES AND DIMENSIONS

Capacity, Heaped @ 2:1 (SAE) . . . . . . . . .276 yd3 (211 m3) Struck . . . . . . . . . . . . . . . . . . . . .224 yd3 (171 m3) Width (Inside) . . . . . . . . . . . . . . . 26 ft. 9 in. (8.15 m) Depth . . . . . . . . . . . . . . . . . . . . . . 10 ft. 7 in. (3.2 m) Loading Height . . . . . . . . . . . . . . 23 ft. 2in. (7.06 m) Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45 *OPTIONAL capacity dump bodies are available.
WEIGHT DISTRIBUTION
Empty Vehicle . . . . . . . . Pounds . . . . (Kilograms) Front Axle (49.3%) . . . . . 227,738 . . . . . . . 103 301 Rear Axle (50.7%) . . . . . . 237,034 . . . . . . . 107 518 Total (50% Fuel) . . . . . . 464,772 . . . . . . . 210 819 Standard Komatsu body . . 66,936 . . . . . . . . 30,362 Standard tire weight. . . . . . 57,600 . . . . . . . . 26,127 Loaded Vehicle . . . . . . . Pounds Kilograms
TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . 53/80 R63 Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless Rims . . . .(patented Phase I New Generation rims)
Front Axle (33.9%) . . . . . 363,000 164 656 Rear Axle (66.1%) . . . . . . 737 000 . . . . . . . 334 301 Total * . . . . . . . . . . . . . 1,106,000 . . . . . . . 501 673 Nominal Payload* . . . . . . 641,228 . . . . . . . 290,859 * Nominal payload is as defined within Komatsu America Corporations payload policy documentation. Nominal 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 custom/optional extras fitted to the truck which are not stated within the Standard Features list of the applicable specification sheet.
OVERALL TRUCK DIMENSIONS
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MAJOR COMPONENT WEIGHTS
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before each use. Lifting equipment must be in good condition and rated for approximately two times the weight being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result. Optional equipment added onto the truck may cause an increase to the component weights listed in this chapter. Contact your customer support manager for concerns or questions about lifting truck components. NOTE: All component weights are dry weights. The additional weight of coolant, fuel, and oil that may be in the components are not calculated into this list.
ITEM CHASSIS
KILOGRAMS
POUNDS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,813 . . . . . . . . . . . . . . . . . . . . . . 6,202 Tire 53/80 R63 (148" OD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500 Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,122 . . . . . . . . . . . . . . . . . . . . . 15,702 Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21,866 . . . . . . . . . . . . . . . . . . . . . 48,206 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,711 . . . . . . . . . . . . . . . . . . . . . . 3,772
DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,725 . . . . . . . . . . . . . . . . . . . . . . 6,008 RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937 . . . . . . . . . . . . . . . . . . . . . . 2,066 LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 . . . . . . . . . . . . . . . . . . . . . . 1,455 Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . .551 Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654 . . . . . . . . . . . . . . . . . . . . . . 1,442 Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 . . . . . . . . . . . . . . . . . . . . . . . .602 LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 . . . . . . . . . . . . . . . . . . . . . . 1,601 RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578 . . . . . . . . . . . . . . . . . . . . . . 1,274 LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 . . . . . . . . . . . . . . . . . . . . . . . .298 RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . .150 Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 . . . . . . . . . . . . . . . . . . . . . . . .397 Diagonal Ladder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . . . . . . . . . . . . 119
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Major Component Weights
Page 3-1
ITEM POWER MODULE
KILOGRAMS
POUNDS
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 . . . . . . . . . . . . . . . . . . . . . . . . 613 Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891 . . . . . . . . . . . . . . . . . . . . . . .1,964 Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340 Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,082 . . . . . . . . . . . . . . . . . . . . . . .6,795 Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,176 . . . . . . . . . . . . . . . . . . . . . . .7,002 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,993 . . . . . . . . . . . . . . . . . . . . . . .8,803 Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9305 . . . . . . . . . . . . . . . . . . . . . . 20,514 Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1996 . . . . . . . . . . . . . . . . . . . . . . .4,400
HYDRAULIC COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . . . . . . . . . . . . . . . 379 Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .932 . . . . . . . . . . . . . . . . . . . . . . .2,055 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . . . . . . . . . . . . . . . . . . . . . . . 322 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731 . . . . . . . . . . . . . . . . . . . . . . .1,612
FRONT AXLE COMPONENTS

Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,496 . . . . . . . . . . . . . . . . . . . . . . .3,298 Spindle, Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,803 . . . . . . . . . . . . . . . . . . . . . . 10,589 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331 . . . . . . . . . . . . . . . . . . . . . . . . 730 Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,790 . . . . . . . . . . . . . . . . . . . . . . .6,151
REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,242 . . . . . . . . . . . . . . . . . . . . . . .4,943 Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 . . . . . . . . . . . . . . . . . . . . . . . . 351 Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371 . . . . . . . . . . . . . . . . . . . . . . . . 818 Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,568 . . . . . . . . . . . . . . . . . . . . . . 14,480 Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 . . . . . . . . . . . . . . . . . . . . . . . . 324 Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 . . . . . . . . . . . . . . . . . . . . . . 39,683 Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 . . . . . . . . . . . . . . . . . . . . . . . . 675
Page 3-2
Major Component Weights
FAM0312
FIELD WELDING FOR ASSEMBLY OR REPAIR

When welding on Komatsu equipment, whether at initial field assembly or during normal maintenance repairs, special procedures must be followed. Due to the continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributors for information on the latest revision. The welding information contained in this chapter is general information that must be followed unless otherwise specified in a detailed repair procedure provided on an engineering drawing or a detailed specific repair procedure. Additional specific information, or detailed instructions can be obtained through your local Komatsu customer support manager.
WELD PROCEDURES
Electric arc welding, either the semi-automatic MIG (GMAW), Flux Core (FCAW), or Stick electrode welding (SMAW), are approved processes for field installation and maintenance welding. Welding of highly stressed structural members such as castings, torque tubes, top and bottom plates on the frame rails, and the curved intersection points of frames should be done with the specific detailed instructions from Komatsu Product Service. See Annex A for repair procedures. These repair procedures are detailed instructions for most high stressed structural members.
APPROVED CONSUMABLES WELDER QUALIFICATION AND TRAINING

The welding technique must be of the highest standard to produce the soundest weld possible. Only welders who have been trained and qualified for structural steel welding in all positions, in conformance with the American Welding Society (AWS) D1.1 or (AWS) D14.3 only, are allowed to perform the welding. The welding instructions for field assembly of Komatsu components are normally provided by engineering drawings. Additional detailed welding instructions for field repairs are provided in the field repair manual SEB14001. A full understanding of the AWS standard welding symbols is necessary to perform and inspect such field welds. Weld sizes specified on the drawings are intended to reflect minimum requirements. GMAW - LW102-15 or ER80S-D2 FCAW - E70T-5, E71T-8, or E71T8-NI1 SMAW - E7018-1, E8018-C1, or E8018-C3
WELD QUALITY REQUIREMENTS

1. Each weld must be homogeneous with low porosity, free from cracks, and slag inclusions. 2. Each weld must have complete fusion between the base metal and weld metal added by the electrode. 3. All welds must be reasonably smooth, without excessive deformity, and all craters filled. No cracks are permitted. 4. The toe of a weld to a stressed member must have a smooth transition. Excessive convexity in multi-pass fillet welds is not permitted. Excessive convexity produces high residual stress in the throat of the weld, and is not permitted. 5. Undercut in excess of 0.8 mm (0.03 in.) on critical welds must be reworked by the application of welding an additional cover pass. It is important that this pass is blended with the existing weld.
FAM0403
Field Welding For Assembly Or Repair
4-1
6. When welding in the vertical position, always weld using the vertical up technique. Large wash weld weaves should not be used when welding on truck frames. Properly applied multiple pass welding is the required procedure on truck frames. 7. Slag is to be removed from all weld beads, and must be completely removed before each pass in a multiple pass procedure. It is also required that all slag is removed and tie in all areas. Grind all welds where a weld crosses or intersects with another weld.
2. Low Ambient Temperature - DO NOT weld in temperatures below 50F (10C). At low temperature conditions, preheating of all welding joint work areas is required. See preheat and post heating requirements as detailed in Annex A. 3. Weld Cooling - Protect the weld area from a rapid cooling rate. Heat retardation may be accomplished through the use of heat lamps, torches, insulating blankets, etc. 4. Moisture - Any moisture on the steel surfaces to be welded must be removed before welding. Electrodes must be stored in sealed containers until needed. Electrodes must be kept in a warming oven at the work location until used to prevent any moisture absorption which might affect weld quality. 5. Foreign Materials - Any foreign substances (dirt, paint, rust, scale, and carbon deposits from cuttings) must be removed prior to welding. Clean all weld areas and surfaces with a grinder to ensure that all foreign materials have been removed.
MATERIALS, CONTROLS, AND PRECAUTIONS

The steel used in the fabrication of all Komatsu equipment is of high strength low alloy (HSLA) material of different grades. The standard dump body main plates are made from abrasion resistant materials. These materials offer themselves very well to welding during fabrication, and repair. The welding consumables are often supplied by Komatsu America Corp. with the new equipment as part of the field welding / assembly package. For field welding and repairs, the approved consumables as detailed, should be procured from a local, reliable supplier. Other highly specialized welding consumables are available but have limited use on Komatsu structural components. Approval is required from your Komatsu customer support manager. Control of the welding area environment is essential for producing proper and sound welds. Essentially, five areas require attention and control. 1. Air Movement - Avoid areas where air movement from wind, drafts, or blowers is prevalent. This is particularly important when a shielding gas is being used as part of the welding process.
WELD INSPECTION
All welding repairs are subject to inspection by a Komatsu appointed inspector or laboratory to insure quality. After the weld has been made it can be inspected by a number of non-destructive evaluation techniques. The inspections can include any of the methods listed below. All assembly welds and weld repairs that are deemed unacceptable by the inspector must be corrected at no additional cost to Komatsu. All weld repairs are also subject to additional inspection. 1. Visual Inspection - This is the process of looking for potential defects such as undersized welds that can be checked with weld gauges for, surface cracks, surface porosity, craters, and undercuts.
4-2
FAM0403
RECORDS
2. Dye Penetrant Inspection - This is an easily applied process which indicates cracks or surface conditions. The process is relatively inexpensive, but does not produce a permanent record except by normal photography. 3. Fluorescent Penetrant Inspection - Similar to dye penetrant inspection. This process uses a black (ultraviolet) light for increased efficiency and accuracy. 4. Magnetic Particle Inspection - This process requires special equipment that is usually more costly than the dye penetrant inspections. This process does not provide a permanent record except by normal photography. 5. Ultrasonic Inspection - This is a popular method of examining weld discontinuities. Specialized equipment and operator certification is required. With some equipment printed data is available of the test providing a permanent record. Also, operator records with equipment settings and test results are normally recorded. 6. X-Ray Inspection - This process provides a view of the weld and base materials but it is highly specialized. This procedure provides a permanent visual record, but is more expensive than most other inspection techniques. Komatsu requires record keeping of all welding work. This information is valuable when personnel or job conditions change. The service and warranty departments of Komatsu must be provided with inspection reports and photographs of the weld area before, during, and after the repair. The photographs must be clear and close enough to show the weld joint preparation complete, with backer bars installed, etc. just prior to welding. These photos easily identify if the required preheating and post heating have been done with a three inch circumference around the weld repair area. Without this documentation, Komatsu will not cover any weld repair claim made under warranty. No exceptions will be made.
ANNEX A
The following are general repair procedures, which must be followed for all repair and rework of major load carrying members on Komatsu equipment. 1. The repair or rework area must be protected from wind and moisture during the entire procedure. If the repair work is to done outside additional precautions must be taken to protect the weld repair process from outside elements. All welding should be done at an ambient temperature of 10C (50F) or above. 2. Clean and grind the entire repair area to remove all rust, grease, oils, paint, and any other foreign materials likely to contaminate the weld.
FAM0403
4-3
3. Air arc the entire crack leaving a V-shape joint. The depth of the V (or U shaped) joint will be determined by the depth of the crack. The width to depth ratio should be approximately 1.25:1 and never less than 1:1. All cracks through the parent material will require a slightly wider root opening than the original, usually 6 mm (0.25 in.) to allow the installation of a backup strip. Backup strips are required for all cracks that have gone through the parent material and cannot be welded from both sides. If a weld repair allows access to both sides of the plate, no backup strip is required as long as complete weld penetration is achieved. If backup strips are not used, the surface profile on both sides must be ground smooth with no undercut. Documentation must support this repair. Photographs of surface condition are required by the service and warranty departments of Komatsu. 4. Use dye penetrant to ensure the cracks are completely removed. 5. After air arcing and inspections (Steps 3 & 4) all areas cut by the air arc should be cleaned thoroughly with a grinder to remove all possible carbon deposits and dye penetrant. 6. Fill gouges with weld and grind all surfaces smooth to avoid defects in the new weld. 7. Grind all surfaces to be welded so they are free of slag, rust, and any other foreign materials. 8. Preheat the entire weld joint area until the surrounding surface area reaches 150C (300F) at a distance of 76 mm (3 in.) from all areas to be welded.
9. All welds are to be made with approved consumables only. The SMAW (Stick) welding rod must be used within four hours after being removed from a new sealed container or from a 52C (125F) minimum drying oven. Any rod that exceeds this exposure time must be dried for one hour at 427C (800F) before being used. Keep all weld starts and stops to a minimum. 10. When the weld is complete, immediately (before the weldment cools) post heat the entire weld area to 150C (300F). Even if the area is over 150C (300F) heat must be applied to maintain this temperature for 15 minutes, and then allow it to cool slowly. In some cases this might require wrapping with insulation blankets. 11. Grind all butt-welded repairs smooth using 36 or finer grit grinding material. All grinding marks should be parallel to the direction of primary stress if possible (and if known). 12. Hammer peen the toes of repair fillet welds as detailed in Annex B, see attached. 13. Inspect repaired areas (for surface defects) using magnetic particle or dye penetrant inspection procedures. 14. If surface defects are found, remove all defects by grinding to a maximum depth of 1.5 mm (0.06 in.). Larger defects must be removed as per the above mentioned procedures. All spot welding also requires preheating and post heating.
4-4
FAM0403
ANNEX B
1.0 TOE HAMMER PEENING
Equipment: 1. Hand held pneumatic hammer 2. Adequate air supply 3. Adequate lighting 4. 6 mm (0.25 in.) diameter spherical tip bit 5. Protective clothing, gloves, includes eye, face, and ear protection. Procedure 1. The toe of the weld should serve as a guide for the peening tool resulting in the area of deformation being approximately equally divided between the base material and the weld metal face to the specified depth and not to exceed 5 mm (0.19 in.) in width. Refer to Figure 4-1. NOTE: Peening shall only be performed after weld acceptance by visual inspection. 2. The weld must have a smooth profile and the toe must have a good transition to the parent material (no overlap) before the peening operation is performed. Grinding the weld face and toe area is permitted to correct unacceptable conditions. Visual inspection/acceptance is to be done after peening with the appropriate radius and depth gauge. 3. Hold the hammer tool at approximately one half the included angle between the weld face and the parent material and perpendicular to the direction of travel. This will normally require approximately four passes of the peening tool with the pressure of near full operator weight being applied. The depth of the indentation must be between 0.6 mm to 0.8 mm (0.02 to 0.03 in.). Equipment: 1. High speed rotary air tool (15,000-20,000 rpm) 2. Tungsten carbide rotary burr 13 mm (0.50 in.) diameter with 13 mm (0.50 in.) spherical tip 3. Adequate air supply 4. Adequate lighting 5. Protective clothing, gloves, includes eye, face, and ear protection Procedure 1. The toe of the weld should serve as a guide for the burr tool resulting in the material removed being approximately equally divided between the base material and the weld metal face to the specified depth and not exceed 8 mm (0.31 in.) in width. Refer to Figure 4-2. 2. The weld must have a smooth profile and the toe must have a good transition to the parent material (no overlap) before the grinding operation is performed. Grinding the weld face and toe area is permitted to correct unacceptable conditions. Visual inspection/acceptance to be done after grinding with the appropriate radius and depth gauge. 3. The axis of the tool should be maintained at about 45 to the parent plate and inclined at about 45 to the direction of travel. The depth of the grinding must be between 0.8 mm to 1.0 mm (0.030 to 0.040 in.). The final surface must be clean, smooth and free of all traces of undercut or slag.
2.0 TOE GRINDING WITH A ROTARY BURR
FAM0403
4-5
FIGURE 4-1. TOE HAMMER PEENING
4-6
FAM0403
FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR
FAM0403
4-7
BIBLIOGRAPHY
American Welding Society Bulletin No. D14.3-94/ D1.1 - Specification for Welding Earthmoving and Construction Equipment Metals and How to Weld Them - James F. Lincoln Arc Welding Foundation. Cleveland, Ohio Procedure Handbook of Arc Welding - Lincoln Electric Company, Cleveland, Ohio American Welding Society - Welding Handbook British Standard BS5135 - Metal Arc Welding of Carbon and Carbon-Manganese Steels Welding Steels Without Hydrogen Cracking - The Welding Institute, F. R. Coe, Author
SPECIAL PRECAUTIONS WHEN SERVICING AN A/C DRIVE SYSTEM TRUCK

Consult a qualified technician, specifically trained for servicing the A/C drive system, before welding on the truck. The following procedures must be followed to ensure the safety of maintenance personnel and to help prevent damage to the equipment.
Anytime the engine is on: Do not open any of the cabinet doors or remove any covers. Do not use power cables for hand holds or foot steps. Do not touch retarder grid elements. Before opening any cabinets or touching a grid element or a power cable, the engine and all warning lights must be off.
Engine Stop Procedure Prior To Maintenance Perform the following procedure prior to maintenance to ensure that no hazardous voltages are present in the A/C drive system. 1. Before turning off the engine, verify the status of all the drive system warning lights on the overhead display panel. Use the lamp test switch to verify that all lamps are functioning properly. 2. If all red drive system warning lights are off, turn the engine off. 3. After the engine has been off for at least five minutes, inspect the link voltage lights. The lights are located on the exterior of the main control cabinet and back wall of the operator's cab (DID panel). If all lights are off, the retarding grids, wheel motors, alternator, and power cables connecting these devices are safe to work on.
4-8
FAM0403
Locate the GF cut-out switch in the access panel on the left side of the main control cabinet. Place the switch in the CUTOUT position. This will prevent the alternator from re-energizing and creating system voltage until the switch is returned to its former position. After repairs, replace all covers and doors and place the GF cutout switch and battery disconnect switches in their original positions. Reconnect all harnesses prior to starting the truck. Leave the drive system in the rest mode until the truck is to be moved. 4. If the red lights on the exterior of the control cabinet and/or the back wall of the operator's cab continue to be illuminated, a fault has occurred. Leave all cabinet doors in place. DO NOT touch the retard grid elements. DO NOT disconnect any power cables or use them as hand or foot holds.
General Welding Guidelines 1. Open the battery disconnect switches and disconnect the battery charging alternator lead wire. 2. Disconnect all electrical harnesses from the Engine Control System (ECS). The ECS is located inside the electrical cabinet behind the operator's cab. Disconnect the ground strap from the ECS. 3. Fasten the welding machine ground (-) lead to the piece being welded. The grounding clamp must be attached as near as possible to the weld area. 4. DO NOT weld on the rear of the control cabinet! The metal panels on the back of the cabinet are part of the capacitors and cannot be heated. 5. DO NOT weld on the retard grid exhaust louvers. 6. Some power cable panels throughout the truck are made of aluminum or stainless steel. They must be repaired with the same material or the power cables may be damaged. 7. Power cables must be cleated in wood or other non-ferrous materials. DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Inspect power cable insulation prior to servicing the cables and prior to returning the truck to service. Discard cables with broken insulation. 8. Protect power cables and wiring harnesses from weld spatter and heat. 9. DO NOT lay welding cables over or near the vehicle electrical harnesses. Welding voltage may be induced into the electrical harnesses and cause damage to components. 10. DO NOT allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders.
Notify your Komatsu customer service manager immediately. Only qualified personnel, specifically trained for servicing the A/C drive system, may perform this service.
FAM0403
4-9
NOTES
4-10
FAM0403
RECEIVING & ASSEMBLY PREPARATION

1. Inspect all components for possible shipping damages. Note any damage found and report to shipping agent. 2. Spread out all parts and organize per unit number. Check for missing parts. List the unit number of all major components. Verify the cab and decks are with the correct chassis. 3. Install support blocks under the chassis. The support blocks must be approximately 84 cm (33 in.) high. 4. Install support blocks under the rear axle housing. The support blocks must be approximately 30 cm (12 in.) high and spread out along the axle. The support blocks must be a minimum of 51 mm (2 in.) away from the wheel motor mounting face. 5. Clean all mounting surfaces on the chassis and on the individual components. 6. Check all electrical connectors and verify they are free of paint and/or corrosion. Clean any connector with questionable electrical continuity. 7. Check all factory installed components for the proper tightening torque. 8. Arrange the work site as shown on the following page.
FAM0503
Receiving & Assembly Preparation
Page 5-1
Page 5-2
Receiving & Assembly Preparation
FAM0503
ASSEMBLY LAYOUT
CHASSIS ASSEMBLY
Due to differences in machine configurations and shipping restrictions/requirements throughout the world, the shipping and packaging of large machines varies. Photographs or illustrations used in the following procedures are provided as general guidelines only. Actual assembly may be different, but this general procedure provides a basic outline for assembly. Items like the hydraulic tank and the accumulators may have been removed for shipping and will have to be locally installed. Each shipment may be different, depending on the truck configuration and destination.
BASIC ASSEMBLY PROCEDURE

1. Site preparation 2. Unload truck components 3. Assemble the chassis 4. Weld the body NOTE: Chassis assembly and body welding may be done in either order, or simultaneously. The most logical order depends on available resources such as cranes, welders, assemblers, etc. 5. Static checkout (electrical & mechanical) 6. Install the body 7. Dynamic checkout (electrical & mechanical) 8. Site cleanup
RECOMMENDED ASSEMBLY DATA

1. Service Report (Pre-Delivery) 2. Acknowledgement of Receipt of Company Warranty 3. Assembly Blueprints & Schematics 4. Fluid Specifications (refer to the lubrication chart in Section 10, Appendix) 5. Suspension Oiling & Charging Procedure (available in Section 10, Appendix) 6. Fan Drive Adjustment Procedure (available in the engine service manual) 7. Toe-In Adjustment Procedure (Section 10, Appendix) 8. Hydraulic Checkout Procedure (Section 10, Appendix) 9. Brake Checkout Procedure (Section 10, Appendix) 10. Propulsion System Checkout Procedure (available in Section 10 of this manual) 11. Filter List (available in parts book) 12. Lubrication & Service PM Forms (available in the operation and maintenance manual) 13. Component Weights - for crane reference (available in Section 3 of this manual) 14. Standard Torque Chart (available in Section 10 of this manual) 15. Field Assembly Inspection Report Form (available in Section 10 of this manual)
FAM0612
Chassis Assembly
Page 6-1
ORDER OF ASSEMBLY
The assembly procedure is organized in levels. Generally, the tasks to be done at a given level may be performed in any convenient order or simultaneously. However, all tasks in that level must be completed before proceeding to the next higher level. Each level depends on the installation of components from the previous level. NOTE: As stated earlier, shipping and packaging of large machines will vary. Some of these steps may change due to different shipping configurations and/ or truck options.
LEVEL 3
1. Spindles/Hubs 2. Steering Cylinders 3. Tie Rod
LEVEL 4
1. LH Deck 2. RH Deck/Grid Box 3. Operator Cab
LEVEL 5 LEVEL 1
1. Chassis - Unload and crib for assembly. 2. Auxiliary Control Cabinet (temporary) 3. Deck Support (on horsecollar over suspension). NOTE: It is easier to install and weld the deck supports before the front suspensions are installed. However, do not install the deck supports first, unless there is a suitable means of installing the suspension with the deck support in place. 4. Rear Suspension 5. Hydraulic Tank 6. Fuel Tank 7. Front Suspensions 8. Diagonal Ladder 9. Uprights/Air Cleaners 10. Diagonal Support Beams (leave loose until left deck is bolted in place) NOTE: Do not weld the air cleaner / uprights until all decks and the operator cab are installed. Ratchet hoists may be required to help tie all the structures together for a proper fit. 1. Exhaust Pipes 2. Weld Uprights 3. Blower - Air Intake Ductwork 4. Wheel Motors
LEVEL 6
1. Front Tires 2. Rear Tires 3. Hoist Cylinders
LEVEL 7
1. Clearance Lights 2. Body Pads/Shims/Guides 3. Front Mud Flaps
LEVEL 8
1. Dump Body Installation
LEVEL 9
1. Hoist Cylinders 2. Rock Ejectors 3. Rear Mud Flaps
LEVEL 2
1. Air Cleaner Piping 2. Center Deck 3. Control Cabinet 4. Auxiliary Control Cabinet
Page 6-2
Chassis Assembly
FAM0612
CHASSIS ASSEMBLY
LEVEL 10
1. Clean the Truck 2. Decals 3. Lighting Wiring 4. Charge Suspensions 5. Charge Accumulators 6. Add Fluids 7. Charge the Air Conditioning System NOTE: Prior to starting the engine, verify that the steering pump case is full of oil. Follow all safety recommendations in this manual. Follow all local, state, and federal regulations. In the procedures that follow, many very heavy components will be required to be lifted into place and secured. The photographs referenced in this procedure depict an actual truck assembly. Assembly at another location may be different. However, this outline will provide a general basis for assembly.
LEVEL 11
1. System Checkouts 2. Exhaust Blankets 3. Clean Assembly Rear 4. Touch Up Paint 5. Train Operators 6. Optional - Install Fire Suppression System
Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected daily for serviceable condition. Refer to the manufacturers guidelines for correct capacities and safety procedures when lifting components. Replace any questionable items. Slings, chains and cables used for lifting must be rated for approximately two times the intended load. When in doubt as to the weight of components or any assembly procedure, contact your customer support manager for further information. Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load. Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a suspended load. Before lifting, ensure there is adequate clearance from overhead structures or electric power lines.
FAM0612
Chassis Assembly
Page 6-3
GENERAL PRECAUTIONS AND INSTRUCTION

1. Clean and remove all foreign material from component mounting surfaces. Disconnect the battery cables before welding on the truck. Failure to do so may seriously damage the batteries and electrical equipment. Disconnect the battery charging alternator lead wire before welding on the frame or its components. Fasten the welding machine ground cable to the component being welded. DO NOT allow welding current to pass through bearings. DO NOT lay welding cables over truck electrical cables and harnesses. Welding voltages could be induced into the truck wiring and cause damage to components. DO NOT weld on the fuel tank or the hydraulic tank unless they have been properly purged and ventilated. Maintain fire control equipment. Inspect fire extinguishers regularly to ensure they are fully charged and in good working condition. 2. Mount the front suspensions first so that deck substructures can be installed while other components are installed. 3. DO NOT weld the front uprights until all upper decks are installed. 4. Install the fuel return hose on the rearward most fitting on the fuel tank. 5. Torque the deck mounting bolts before the exhaust tubes, etc. are installed. 6. Verify all electrical connectors are free from paint and/or corrosion. Clean any connector that may be questionable. 7. Do not torque the diagonal ROPS beam until after the operator cab & LH air intake tubes are in place. 8. Before installing the cab to the substructure, tap all threaded holes to remove paint. 9. Verify all wiring is properly connected before attempting to start the engine. 10. Recheck the torque on hardware installed at the factory. 11. Use blocks for charging the suspension (oil & nitrogen). Follow the procedures outlined in Section 10, Appendix. 12. Steering accumulators are normally not charged with nitrogen when shipped from the factory. Use proper precautions when checking the nitrogen pressure and oil level in the cylinder. 13. Brake accumulators are normally charged with nitrogen when shipped from the factory. Use proper precautions when checking pressures. 14. Verify the lube system is lubricated, purged and all levels full prior to start up. 15. Purge air from the steering pump before truck operation. Pressure will not build in the brake and steering circuit if air is present. Air in the system may damage the pump. Refer to the Hydraulic Checkout Procedure in Section 10 of this manual. 16. Use the battery disconnect switch when arc welding. Connect the weld ground near the weld area.
Mark cap screws and nuts with paint or ink after tightening to the specified torque. This method provides verification that the hardware has been properly tightened.
Page 6-4
Chassis Assembly
FAM0612
NOTES
FAM0612
Chassis Assembly
Page 6-5
1. Lift the chassis off the truck/trailer (Figure 6-1) or rail car using two cranes with a minimum capacity of 50 tons each. Place the chassis on adequate support blocks in a level position. The weight of the chassis, as shipped, is approximately 60,382 kg (133,000 lb). The support blocks must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm (12 in.) high under the rear axle housing (Figure 6-2). Placement of the chassis at this height will allow easy installation of truck components. Thoroughly clean the chassis.
Page 6-6
Chassis Assembly
FAM0612
FIGURE 6-1.
FIGURE 6-2.
FAM0612
Chassis Assembly
Page 6-7
2. Lift the LH deck support into position. The weight of the deck support is approximately 654 kg (1442 lb). a. Bolt the support into place. b. Tack weld the support. c. The four tapped pads on each support and the corresponding blocks on the horsecollar must be removed to allow for a complete weld around the joint. d. Remove the plate and backer strip from the back of the LH deck support (see inset in Figure 6-7). Install the backer strip at the end of the deck support. Install the plate at the end of the deck support. e. Weld completely around the support without leaving any gaps. Finish welding around the plate. f. Grind all areas, and clean. Paint after welding is complete.
If the tapped pads are not removed, a complete weld around the support can not be achieved. The gaps in the weld around the support may result in premature frame cracking in this area.
Refer to Figures 6-3 thru 6-8. Repeat for the RH deck support. The weight of the deck support is approximately 273 kg (602 lb).
Page 6-8
Chassis Assembly
FAM0612
FIGURE 6-3.
FIGURE 6-4.
FAM0612
Chassis Assembly
Page 6-9
FIGURE 6-5.
FIGURE 6-6.
Page 6-10
Chassis Assembly
FAM0612
FIGURE 6-7.
FIGURE 6-8.
FAM0612
Chassis Assembly
Page 6-11
3. Position the top rear suspension eye between the ears on the frame, as shown in Figure 6-9. 4. Lubricate pin (1). Align the retaining cap screw hole with the hole in the mounting bore, and partially push the pin in until secure. 5. Insert spacer (4) and continue to push the pin in through the spherical bearing. Insert the remaining spacer and continue to install the pin in until the retaining cap screw hole is aligned with the hole in the pin. NOTE: Note the proper orientation of the spacers as shown in Figure 6-9. 6. Install cap screw (2) and locknut (3). Tighten to 465 Nm (343 ft lb).
Page 6-12
Chassis Assembly
FAM0612
FIGURE 6-9. REAR SUSPENSION MOUNTING PIN (Typical, Top and Bottom) 1. Pin 2. Retainer Cap Screw 3. Locknut 4. Bearing Spacer 5. Retainer Ring 6. Bearing 7. Cap Screw 8. Washer 9. Sleeve
FAM0612
Chassis Assembly
Page 6-13
7. Clean the mounts for the hydraulic tank. 8. Lift the tank into position. (Figure 6-10). The weight of the hydraulic tank is approximately 731 kg (1612 lb). Tighten the four mounting cap screws near the top of the tank to 622 62 Nm (459 46 ft lb). Tighten the two mounting cap screws near the bottom of the tank to 800 80 Nm (590 59 ft lb).
10. Clean the mounts for the fuel tank and lift the tank into position. (Figure 6-11) The weight of the fuel tank is approximately 1690 kg (3725 lb). Tighten the four mounting cap screws near the top of the tank to 712 71 Nm (525 52 ft lb). Tighten the four mounting cap screws near the bottom of the tank to 298 30 Nm (220 22 ft lb).
Page 6-14
Chassis Assembly
FAM0612
FIGURE 6-10.
FIGURE 6-11.
FAM0612
Chassis Assembly
Page 6-15
10. Connect the piping to the hydraulic tank and properly tighten all fittings. Refer to Figures 6-12 and 6-13.
NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened. The valves are open when the handles are parallel with the hoses.
Page 6-16
Chassis Assembly
FAM0612
FIGURE 6-12.
FIGURE 6-13.
FAM0612
Chassis Assembly
Page 6-17
11. Install the two hoist filters onto the bracket at the inner side of the fuel tank. Connect the fuel supply and return lines to the fuel tank. Refer to Figure 6-14.
12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil. Refer to Figure 6-15.
Page 6-18
Chassis Assembly
FAM0612
FIGURE 6-14.
FIGURE 6-15.
FAM0612
Chassis Assembly
Page 6-19
13. Lift the front suspension into position. Refer to Figure 6-18. The weight of each front suspension cylinder is approximately 2790 kg (6150 lb). Lubricate the cap screw threads, cap screw head seats and nut seats with rust preventive grease. The hardware for the front suspension must be tightened according to the "turn-ofthe-nut" method as described below.
"Turn-Of-The-Nut" Tightening Procedure a. Tighten all 14 cap screws (1, 6, 8, Figure 619) to 542 5 Nm (400 40 ft lb). b. Maintain this torque on the top two corner cap screws and the bottom, outer four cap screws (without spacers). c. Loosen the eight remaining cap screws and then tighten again as follows: d. For the four cap screws (1, Figure 6-19) at the upper mount, initially tighten the cap screws to 95 Nm (70 ft lb), then advance the cap screw head 60 as outlined in Steps d-1 through d-3. Refer to Figure 6-16. 1.) Mark a reference line on a corner of the hexagonal cap screw head or nut and the mounting surface opposite this corner, as shown. Then mark the position located 60 or 120 clockwise relative to the first reference line on the mounting surface. Refer to Figures 6-16 and 6-17. 2.) Scribe a reference mark at the opposite end of the turning member to ensure that either the cap screw head or nut, remains stationary. 3.) Each corner of a hexagon represents 60. The turning member, either the cap screw head or nut, is turned until the marked corner is adjacent with the marked reference line. Ensure that the opposite end of the turning member has NOT turned during the tightening procedure. NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench during the tightening procedure. e. Loosen the top two corner cap screws (1) and the bottom outer four cap screws (8), (without spacers). FIGURE 6-16. 60 DEGREE ADVANCE 1.) Tighten the top two corner cap screws to 95 Nm (70 ft lb), then advance the cap screw heads 60. 2.) Tighten the bottom, outer four cap screws to 271 Nm (200 ft lb), then advance the cap screw heads 120. NOTE: If for any reason, these fasteners need to be checked for tightness after completing this procedure, loosen and inspect all 14 cap screws and repeat the entire process. The hardware must be cleaned and lubricated.
For the bottom four cap screws (6, Figure 6-19), initially tighten the cap screws to 136 Nm (100 ft lb), then advance the cap screw head 120 as outlined in Steps d-1 through d-3. Refer to Figure 6-17.
FIGURE 6-17. 120 DEGREE ADVANCE
Page 6-20
Chassis Assembly
FAM0612
FIGURE 6-19. SUSPENSION INSTALLATION 1. Cap Screws, Washers 2. Nuts, Washers 3. Housing 4. Mounting Surface 5. Shear Bar 6. Cap Screws, Washers 7. Piston 8. Cap Screws, Washers 9. Spacer 10. Nuts, Washers
FIGURE 6-18.
FAM0612
Chassis Assembly
Page 6-21
14. Install the diagonal ladder. The weight of the diagonal ladder is approximately 180 kg (397 lb). Refer to Figure 6-20. Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.
Page 6-22
Chassis Assembly
FAM0612
FIGURE 6-20.
FAM0612
Chassis Assembly
Page 6-23
15. Lift LH & RH uprights into position and install the four cap screws for each upright. Tighten to 465 47 Nm (343 34 ft lb). The weight of the LH upright is approximately 726 kg (1601 lb). The weight of the RH upright is approximately 578 kg (1274 lb). Refer to Figures 6-21 and 6-22. NOTE: DO NOT weld the torque tubes on the uprights until the decks are installed.
Page 6-24
Chassis Assembly
FAM0612
FIGURE 6-21.
FIGURE 6-22.
FAM0612
Chassis Assembly
Page 6-25
16. If installed (some trucks are shipped with the center deck not installed), remove the center deck to enable easy installation of the air intake tubing and the two diagonal cross tubes. The weight of the center deck is approximately 250 kg (550 lb). Refer to Figure 6-23.
17. Lift the LH diagonal tube into position (Figure 6-24). The weight of the tube is approximately 135 kg (298 lb). Do not tighten the cap screws until the deck and the cab are in place.
Page 6-26
Chassis Assembly
FAM0612
FIGURE 6-23.
FIGURE 6-24.
FAM0612
Chassis Assembly
Page 6-27
18. Lift the RH diagonal tube into position (Figure 6-25). The weight of the tube is 68 kg (150 lb). Do not tighten the cap screws until the decks are in place.
19. Lift the six air intake tubes and hump hoses into place. Install and tighten the clamps that secure the hoses. Refer to Figure 6-26.
Page 6-28
Chassis Assembly
FAM0612
FIGURE 6-25.
FIGURE 6-26.
FAM0612
Chassis Assembly
Page 6-29
20. Lift the center deck into position. (Figure 6-27). Tighten the four cap screws to 465 47 Nm (343 34 ft lb).
Page 6-30
Chassis Assembly
FAM0612
FIGURE 6-27.
FAM0612
Chassis Assembly
Page 6-31
21. Lift the electrical control cabinet into position. The weight of the cabinet is approximately 3045 kg (6714 lb). Install the mounting hardware and shims. Tighten the 10 cap screws to 1600 160 Nm (1180 118 ft lb). Refer to Figure 6-28.
Page 6-32
Chassis Assembly
FAM0612
FIGURE 6-28.
FAM0612
Chassis Assembly
Page 6-33
22. Clean the tapered portion of the suspension rod and the bore of the spindle. Lubricate the two surfaces with multi purpose grease number 2 (5% molybdenum disulphide). Lift the spindle/brake assembly into position. The weight of each spindle/brake assembly is approximately 5393 kg (11,890 lb). Refer to Figures 6-29 thru 6-33. A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the assembly for easier mounting to the suspension. Lift the retainer plates to the bottom of each suspension using blocks and a hydraulic jack. Install the fourteen cap screws. Evenly tighten the cap screws to 678 Nm (500 ft lb). Continue to tighten the cap screws in increments of 330 Nm (250 ft lb) until 2705 270 Nm (1,995 200 ft lb) is reached. After installation is complete, connect the brake piping to each brake.
Page 6-34
Chassis Assembly
FAM0612
FIGURE 6-29.
FAM0612
Chassis Assembly
Page 6-35
FIGURE 6-30.
FIGURE 6-34
FIGURE 6-31.
Page 6-36
Chassis Assembly
FAM0612
FIGURE 6-32.
FIGURE 6-33.
FAM0612
Chassis Assembly
Page 6-37
23. Connect the steering cylinders and the tie rod to the steering arms. The tie rod toe-in must be adjusted once the tires and the body are installed. The toe-in adjustment procedure is located in Section 10, Appendix. Refer to Figure 6-34.
Page 6-38
Chassis Assembly
FAM0612
FIGURE 6-34.
FAM0612
Chassis Assembly
Page 6-39
24. Install the handrails and lift the LH deck into place (Figure 6-35). The weight of the LH deck with handrails is approximately 720 kg (1587 lb). Loosely install the eight cap screws. After all decking is in place, tighten the cap screws on each deck to 465 47 Nm (343 34 ft lb).
25. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 3082 kg (6795 lb). Tighten the eight cap screws to 800 80 Nm (590 59 ft lb). 26. Install the handrails on the RH deck. 27. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approximately 4100 kg (9039 lb). Refer to Figure 6-36.
Page 6-40
Chassis Assembly
FAM0612
FIGURE 6-35.
FIGURE 6-36.
FAM0612
Chassis Assembly
Page 6-41
28. Lift the operator cab into position. The weight of the cab is approximately 2725 kg (6008 lb). Refer to Figures 6-37 and 6-38. Remove any paint from the cab mounting holes. Determine if shims are required at each mounting pad. The gap between the cab and the ROPS support must not exceed 1 mm (0.039 in.). Install shims at each mounting pad as required. Install and tighten the thirty two cap screws to 800 80 Nm (590 59 ft lb). 29. Tighten the hardware for the diagnonal tubes. For the RH tube, tighten the 12 cap screws to 240 24 Nm (177 17 ft lb). For the LH tube, tighten the 16 cap screws to 800 80 Nm (590 59 ft lb).
Page 6-42
Chassis Assembly
FAM0612
FIGURE 6-37.
FIGURE 6-38.
FAM0612
Chassis Assembly
Page 6-43
30. Weld the LH & RH uprights to the front frame tube. Refer to Figure 6-39.
31. Lift the two bumper extensions into place. Refer to Figure 6-40. Tighten the cap screws to standard torque.
Page 6-44
Chassis Assembly
FAM0612
FIGURE 6-39.
FIGURE 6-40.
FAM0612
Chassis Assembly
Page 6-45
32. Install any remaining handrails. Tighten the cap screws to standard torque.
Page 6-46
Chassis Assembly
FAM0612
FIGURE 6-41.
FAM0612
Chassis Assembly
Page 6-47
33. Connect the wiring for the electrical control cabinet, auxiliary control cabinet, and grid box. 34. Install the air intake ductwork and tighten the connecting hardware. The weight of the inlet duct is approximately 278 kg (613 lb). Refer to Figures 6-42- 6-48.
Page 6-48
Chassis Assembly
FAM0612
FIGURE 6-42.
FAM0612
Chassis Assembly
Page 6-49
FIGURE 6-43.
FIGURE 6-44.
Page 6-50
Chassis Assembly
FAM0612
FIGURE 6-45.
FIGURE 6-46.
FAM0612
Chassis Assembly
Page 6-51
FIGURE 6-47.
Page 6-52
Chassis Assembly
FAM0612
FIGURE 6-48.
FAM0612
Chassis Assembly
Page 6-53
35. Attach a lifting device to the parking brake assembly and lift into position. Refer to Figure 6-49. Use a port-apower to release spring pressure and allow the alignment of the brake discs during installation. 36. Seat the parking brake assembly against the housing and install the eight cap screws and washers. Tighten to standard torque.
Page 6-54
Chassis Assembly
FAM0612
FIGURE 6-49.
FIGURE 6-50.
FAM0612
Chassis Assembly
Page 6-55
The wheel motors must be properly aligned before installing onto the axle housing. The wheel motor has markings which help determine installation orientation. Two sets of dimples are located at the 3 oclock and 9 oclock positions. A centerline symbol marks the 12 oclock position of the wheel motor. Refer to Figure 6-51. The axle housing also contains dimples at the 3 oclock and 9 oclock positions next to the wheel motor mounting rings. Refer to Figure 6-52. When installing the wheel motors, ensure the markings on both components line up. The top cap screw hole on the axle housing may also be determined by counting the holes in between the two sets of punch marks. The top hole on the axle housing should line up with the CL stamping on the wheel motor.
Page 6-56
Chassis Assembly
FAM0612
FIGURE 6-51.
FIGURE 6-52.
FAM0612
Chassis Assembly
Page 6-57
37. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assemblies installed is approximately 18,000 kg (39,683 lb). Refer to Figure 6-53. The hardened flat washers used in this application are punched during the manufacturing process. Therefore, the washers must be installed with the punched lip away from the head of the mounting cap screws to prevent damage to the fillet between the cap screw head and the shank. Refer to Figure 6-54. Tighten the 70 mounting cap screws for each wheel motor to 2007 201 Nm (1480 148 ft lb). NOTE: When lifting the wheel motors, do not lift under the brake assembly. (Shipping fasteners installed in the outboard rim bolt circle must remain in place during lifting and installation of wheel motors.)
Page 6-58
Chassis Assembly
FAM0612
FIGURE 6-53.
FIGURE 6-54. 1. Washer 2. Cap Screw
FAM0612
Chassis Assembly
Page 6-59
38. Connect the power cables and the speed sensors to each of the wheel motors. Connect the apply lines, brake cooling supply lines, and return lines to each wheel. Refer to Figures 6-55 thru 6-58.
Page 6-60
Chassis Assembly
FAM0612
FIGURE 6-55.
FIGURE 6-56.
FAM0612
Chassis Assembly
Page 6-61
NOTES
Page 6-62
Chassis Assembly
FAM0612
FIGURE 6-57.
FIGURE 6-58.
FAM0612
Chassis Assembly
Page 6-63
Front Wheel Installation NOTE: Remove all dirt and rust from mating parts before installing the tire and rim assembly. 39. Grip the tire and rim assembly with the tire handler. Align the tire inflation hose and the wheel hub. Position the rim onto the wheel hub studs. 40. Lubricate all stud threads and nut seating flanges with lithium base grease. Install and tighten the nuts in the following sequence: a. Install 6 nuts at the 12 O'clock and 6 nuts at the 6 O'clock positions. Tighten each nut to 2326 136 Nm (1715 100 ft lb). b. Install 3 nuts directly below the 3 O'clock and 3 nuts directly above the 9 O'clock positions. Tighten the nuts to 2326 136 Nm (1715 100 ft lb). c. Install 3 nuts directly above the 3 O'clock and 3 nuts directly below the 9 O'clock positions. Tighten these nuts to 2326 136 Nm (1715 100 ft lb). d. Install the remaining nuts and tighten in a clockwise pattern to 2326 136 Nm (1715 100 ft lb). e. Retighten all nuts in a clockwise pattern to the required 2326 136 Nm (1715 100 ft lb). Refer to Figure 6-59 & 6-60.
After the truck has been assembled and is operational, the truck must be operated for a short period of time, and the torque on the wheels re-checked. Tighten the wheels to the specified torque.
Page 6-64
Chassis Assembly
FAM0612
FIGURE 6-59.
FIGURE 6-60.
FAM0612
Chassis Assembly
Page 6-65
Rear Wheel Installation
FIGURE 6-61. REAR WHEEL ASSEMBLY 1. Wheel Motor Mounting Flange 2. Inner Wheel Rim 3. Disc Brake Assembly 4. Extension 5. Wheel Hub 6. Flanged Nut 7. Inner Extension 8. Clamps 9. Adapter Ring 10. Flanged Nut 11. Flanged Nut 12. Wheel Motor Transmission 13. Extension 14. Bracket 15. Outer Wheel Rim
NOTE: Clean all mating surfaces and check the stud threads before installing the wheels. 41. Bleed the disc brakes before installing the rear tires. Refer to Section J of the service manual for brake bleeding procedures. 42. Grip the inner tire and rim with the tire handler and lift onto wheel hub (5, Figure 6-61). Align extension (4) for mating with inner extension (7). 43. Lubricate all stud threads and nut seating flanges with a lithium base grease. Install and tighten the nuts in the following sequence: a. Install 6 nuts at the12 O'clock position and 6 nuts at the 6 O'clock position. Tighten to 2326 136 Nm (1715 100 ft lb). b. Install 3 nuts directly below the 3 O'clock position and 3 nuts directly above the 9 O'clock position. Tighten to 2326 136 Nm (1715 100 ft lb). c. Install 3 nuts directly above the 3 O'clock position and 3 nuts directly below the 9 O'clock position. Tighten to 2326 136 Nm (1715 100 ft lb). d. Install the remaining nuts in a clockwise pattern. Tighten to 2326 136 Nm (1715 100 ft lb). e. Retighten all nuts in a clockwise pattern to the required 2326 136 Nm (1715 100 ft lb).
44. Install inner extension (7, Figure 6-61) and clamps (8) before installing the outer tires.
Page 6-66
Chassis Assembly
FAM0612
FIGURE 6-62.
FIGURE 6-63.
FAM0612
Chassis Assembly
Page 6-67
DO NOT move the truck without the rear, outer tires installed. Serious mechanical damage to the wheel motor hub and torque tube may result. The adapter rings and outer dual tires must be installed. The mounting cap screws must be tightened to 2325 Nm (1715 ft lb).
45. Position the rim adaptors into place on each outer rim. Install the fifty flanged nuts and tighten the nuts to 2325 136 Nm (1715 100 ft lb). Refer to Rear Wheel Installation for the correct tightening sequence. Install the outer tires and tighten the fifty nuts to 2325 136 Nm (1715 100 ft lb). Refer to Rear Wheel Installation for the correct tightening sequence. Refer to Figure 6-64.
After the truck has been assembled and is operational, the truck must be operated for a short period of time, and the torque on the wheels re-checked. Tighten the wheels to the torque specified above.
46. Connect the electrical harnesses and hydraulic hoses below the operators cab. Refer to Figure 6-65.
Page 6-68
Chassis Assembly
FAM0612
FIGURE 6-64.
FIGURE 6-65.
FAM0612
Chassis Assembly
Page 6-69
47. Install the front LH & RH mud-flaps on the underside of each deck. 48. Weld both rear LH & RH mud-flap brackets into place on the backside of the deck supports. Install the mudflaps. Refer to Figures 6-66 and 6-67.
Page 6-70
Chassis Assembly
FAM0612
FIGURE 6-66.
FIGURE 6-67.
FAM0612
Chassis Assembly
Page 6-71
49. Raise the hoist cylinder into position over the pivot point on the frame. The weight of each hoist cylinder is approximately 932 kg (2055 lb). Position the cylinder with the air bleed vent plug on top, and facing the front of the truck. Install spacer (6, Figure 6-69). Align the bearing eye with the pivot point and push the cylinder into place. Install retaining plate (3), locking plate (2),and the cap screws. Tighten the cap screws to 298 Nm (220 ft lb). Bend the locking plate tabs over the cap screw flats.
The truck is now ready for body installation.
Page 6-72
Chassis Assembly
FAM0612
FIGURE 6-68.
FIGURE 6-69. 1. Cap Screw 2. Lock Plate 3. Retainer 4. Retainer Ring 5. Bearing 6. Spacer
FAM0612
Chassis Assembly
Page 6-73
NOTES
Page 6-74
Chassis Assembly
FAM0612
DUMP BODY ASSEMBLY

GENERAL INFORMATION
If the body is being welded in a cold climate, it is advisable to move the parts to be welded into an enclosed shop area. Surfaces to be welded must be dry and the temperature must be above 10C (50F). If shop space is not available, it may be necessary to provide a portable enclosure and pre-heat the parts prior to welding. In most instances, it is easier to assemble and weld the body while the sections are upside down. After the pivot, guide pin, and body pads are welded in place, the body can be turned over and the remainder of the assembly can be completed. All paint must be removed from surfaces to be welded. Use a wire brush or paint removal equipment. Refer to the assembly blueprints shipped with the truck for specific welding details and the parts required for assembly.
The total weight of the body is approximately 30,362 kg (66,937 lb). Use two cranes for assembling the body. A 45 metric ton (50 ton) crane and a 109-136 metric tons (120-150 ton) crane are required. The larger crane is needed to help turn the body over after completion of the underside welding. Assembly of the body must be performed on flat terrain with an adequate area for welding machines and for maneuvering lifting equipment.
Body sections must be assembled as originally manufactured. Match the shipping numbers stenciled on the body sections to mate the correct parts. DO NOT mix components.
FIGURE 7-1. BODY PARTS NOMENCLATURE 1. Canopy 4. Lift Hole 7. LH Side Sheet 2. Front Sheet 5. Floor 3. RH Side Sheet 6. Pivot
FAM0703
Dump Body Assembly
7-1
BODY ASSEMBLY
NOTE: References to LH and RH in the following procedures assume the body is in its' normal, upright position, as shown in Figure 7-1. 1. Organize the body sections in a large, flat, open space. Position the sections side by side and upside down. Arrange the sections so they are properly oriented for assembly. Refer to Figure 7-2 for domestic configuration, and 7-3 for international configuration.
FIGURE 7-4. 5. Use the hydraulic jack to align the body halves at the rear. Install cap screw (1, Figure 7-5) and the sleeve. NOTE: Figure 7-5 shows the hardware numbered in installation sequence. Cap screws (1, 2 & 7) are marked with an asterisk (*). These cap screws are installed with sleeves. The remainder of the cap screws do not have sleeves. FIGURE 7-2. DOMESTIC LAYOUT 6. Install cap screw (2) and the sleeve at the front of the floor. 7. Install cap screw (3) in the front sheet near the floor. Attach a wedge or a clamp inside the body as necessary to align the front sheet. 8. Use a wedge to align the front sheet and canopy. Install cap screws (4, 5 & 6). 9. Install cap screw (7) and the sleeve in the front of the canopy. 10. Install cap screws (8 & 9). 11. Install the backer strips on the front sheet center joint as shown on the assembly blueprint. NOTE: The backer strips must be tack welded in a location where the tack will be burned away on the first pass. 12. Loosely install cap screws (10 & 11) in the floor. 13. Loosen cap screws (1 & 2). 2. Remove the paint from the weld areas. 3. Lift the RH body half and support the front sheet, side sheets, and rear edge of the floor with blocks. Refer to Figure 7-4. 4. Lift the LH body and support with blocks under the front sheet and side sheet. Position a hydraulic jack on blocks at the tail end to support the floor at the rear. Refer to Figure 7-5. 14. Attach appropriate lifting apparatus to the body pivot. Insert the lifting apparatus through the body pin bores. The weight of the pivot is approximately 1492 kg (3289 lb). DO NOT damage the bores. 15. Lift the pivot over the body. Lower the pivot into position against the rear of the body, as shown in Figure 7-6. Align the pivot with the body sills.
FIGURE 7-3. INTERNATIONAL LAYOUT
7-2
Dump Body Assembly
FAM0703
NOTE: Figures 7-5 & 7-6 illustrate a domestic configuration with the canopy attached to the body halves. The canopy for international bodies is shipped as a separate piece. Do not attach the international canopy at this time
FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE
FIGURE 7-6. BODY PIVOT INSTALLATION
FAM0703
Dump Body Assembly
7-3
16. If necessary, use a hydraulic jack or crane to raise the center of the body to allow the pivot to fit inside the bolsters. Loosely install the cap screws in the pivot. 17. If assembling an international body (threepiece), lift the canopy into position at this time. Install the canopy cap screws and tighten. 18. Tighten all floor, front sheet, and canopy cap screws. Use a chalk line to align the front of the canopy. 19. Tighten the pivot cap screws. 20. Install the filler plates and backer strips for the pivot to body sill weld joints. 21. Check the alignment and fit of all components 22. Tack weld the joints.
BODY WELDING
Follow the guidelines listed below when welding the body: Use dry weld rod or weld wire. Weld surfaces must be dry and above 10C (50F). If stick electrode is used, use as large a diameter rod as practical to weld the floor and front sheet joints. The following sequence must be followed for the front sheet: First Pass: Back step and skip weld in 10 increments along the entire length of the joint. Refer to Figure 7-7. Repeat the same procedure until the entire joint is filled. DO NOT stop welding until entire joint is complete. The body floor V groove must also be welded using the same procedure as the front sheet. Weld from the front to the rear. Refer to Figure 77.
FIGURE 7-7. FRONT SHEET & FLOOR JOINT WELDING SEQUENCE
1. Complete the welds at the center seam, the front sheet and the canopy. Refer to the assembly blueprints for welding requirements. 2. Remove the canopy alignment blocks.
7-4
Dump Body Assembly
FAM0703
3. Install the remaining gussets, the body guide and the body pad mounts. Refer to Figures 7-8 through 7-11.
DO NOT install the heated body exhaust boxes onto the body at this time. The exhaust boxes must be installed after the body is installed onto the truck.
FIGURE 7-10.
FIGURE 7-8.
FIGURE 7-11.
4. Once the body underside is completed, the body can be turned over. Use two cranes to invert the body, a 45 metric ton (50 ton) crane and a 109-136 metric ton (120-150 ton) crane. The following photographs show a typical example of a body being inverted with two cranes. FIGURE 7-9. Position the body onto support blocks as shown in Figure 7-18.
FAM0703
Dump Body Assembly
7-5
FIGURE 7-12. FIGURE 7-14.
FIGURE 7-15. FIGURE 7-13.
FIGURE 7-16.
7-6
Dump Body Assembly
FAM0703
5. Refer to Figure 7-7 and the body assembly print to complete the welds on the inside of the body.
FIGURE 7-17.
FIGURE 7-19.
FIGURE 7-18.
FIGURE 7-20.
FAM0703
Dump Body Assembly
7-7
6. Install the mud flap brackets, clearance light housings (Figure 7-21), etc. as specified on the installation blueprints.
7. Install any optional equipment such as body liners and side boards (Figure 7-22).
FIGURE 7-21.
FIGURE 7-22.
8. Clean the weld joints and paint.
7-8
Dump Body Assembly
FAM0703
FINAL ASSEMBLY
Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected daily for serviceable condition. Refer to the manufacturers guidelines for correct capacities and safety procedures when lifting components. Replace any questionable items. Slings, chains and cables used for lifting must be rated for approximately two times the intended load. When in doubt as to the weight of components or any assembly procedure, contact your customer support manager for further information. Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load. Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a suspended load. Before lifting the body, ensure there is adequate clearance between the body and overhead structures or electric power lines.
FAM0811
Final Assembly
Page 8-1
1. Body welding and chassis assembly must be completed before proceeding. Before the body is lifted off the ground, tie guy ropes to each of the four corners of the body for aiding in installation. There are two methods of installing the body depending on the cranes available. a. If the truck is operational and can be driven, two 50 ton cranes can be used, one positioned at either side of the body. The body can then be lifted high enough to allow the truck to be reverse propelled under the body (Figures 8-1, 8-2 & 8-3). b. If a large crane of approximately 150 ton is available, the body can be lifted over the chassis and installed in a similar fashion to that in Step a.
Page 8-2
Final Assembly
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FIGURE 8-1.
FIGURE 8-2.
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Final Assembly
Page 8-3
NOTES
Page 8-4
Final Assembly
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FIGURE 8-3.
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Final Assembly
Page 8-5
2. With the body in position, install shims (6, Figure 8-5) in both body pivots. Install enough shims to fill the outboard gaps and to center the body on the frame pivot. DO NOT install shims at the inside. A minimum of one shim is required at the outboard end of both frame pivots. 3. Align the hole in pivot pin (3) with the cap screw hole in body ear (4). Push the pivot pin through shims (6), frame pivot (7), and into pivot bushings (5 & 9). 4. Install cap screw (1) through the pin and tighten nut (2) to 407 Nm (300 ft lbs). Use washers, as necessary on the nut side only, to provide proper thread contact. 5. Install the pivot pin at the opposite side of the body.
Page 8-6
Final Assembly
FAM0811
FIGURE 8-4.
FIGURE 8-5. DUMP BODY PIVOT PIN 1. Cap Screw 2. Lock Nut 3. Body Pivot Pin 4. Body Ear 5. Body Pivot Bushing 6. Shim 7. Frame Pivot 8. Pivot Bushing 9. Body Pivot Bushing
FAM0811
Final Assembly
Page 8-7
6. Align the hoist cylinder upper bushings with the body. Refer to Figure 8-6. Align the retaining cap screw hole and install pin (2, Figure 8-7). Install the pin retaining cap screws and nuts. Tighten to to 407 Nm (300 ft lbs).
Page 8-8
Final Assembly
FAM0811
FIGURE 8-6.
FIGURE 8-7. HOIST CYLINDER UPPER MOUNT 1. Dump Body 3. Hoist Cylinder 2. Hoist Cylinder Pin 4. Pin Retainer
FAM0811
Final Assembly
Page 8-9
7. Shim the body pads as required. All pads, except the two rear pads, should contact the frame with approximately equal compression of the rubber. Refer to Figures 8-8 and 8-9. A gap of approximately 1.5 mm (0.06 in.) is required at each rear pad. This can be accomplished by using one less shim at each rear pad. 8. Inspect pad contact. If pad contact appears to be unequal, correct as necessary.
Proper body pad to frame contact is required for maximum pad life.
Page 8-10
Final Assembly
FAM0811
FIGURE 8-8.
FIGURE 8-9. BODY PAD INSTALLATION 3. Dump Body 5. Frame 7. Shim 4. Pad Mounting Hardware 6. Body Pad 8. Mounting Pad
FAM0811
Final Assembly
Page 8-11
9. Tack weld rock ejector mounting brackets into position on the underside of the body (Figure 8-11). The ejectors must be positioned on the center line between the rear tires within 6.0 mm (0.25 in.). Before welding, drop a plumb line to check rock ejector clearance. Position the rock ejector a distance of 455 mm (17.9 in.) from the wheel housing. Refer to Figure 8-12. NOTE: With rock ejector arm (1) hanging vertical as shown in Figure 8-12, there must be no gap at stop block (3, Figure 8-11).
If the rock ejector arms are bent during operation, they must be removed and straightened. Inspect mounting brackets (4, Figure 8-11), pins (2) and stops (3) at each shift change for wear and/or damage. Repair as necessary.
Page 8-12
Final Assembly
FAM0811
FIGURE 8-10.
FIGURE 8-11. ROCK EJECTOR MOUNTING 1. Rock Ejector Arm 2. Pin 3. Stop Block 4. Mounting Bracket
FIGURE 8-12. ROCK EJECTOR INSTALLATION 1. Rock Ejector Arm 2. Wheel Housing
FAM0811
Final Assembly
Page 8-13
10. IInstall the remaining axle housing air ducts and hatch cover. Refer to Figures 8-13 through 8-15.
Page 8-14
Final Assembly
FAM0811
FIGURE 8-13.
FIGURE 8-14.
FAM0811
Final Assembly
Page 8-15
NOTES
Page 8-16
Final Assembly
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FIGURE 8-15.
FAM0811
Final Assembly
Page 8-17
11. Install the mud flaps onto the body and chassis (Figures 8-16 & 8-17).
Page 8-18
Final Assembly
FAM0811
FIGURE 8-16.
FIGURE 8-17.
FAM0811
Final Assembly
Page 8-19
12. Install both body guide brackets loosely into place (Figure 8-19). Once in position, slowly lower the body and mark the position in which the brackets are to be welded. The body guides must be centered between wear plates (3), with a maximum gap of 4.8 mm (0.19 in.) at each side.
13. With the body in its lowered position on the frame rail, the position of the body up limit switch actuator arm (Figure 8-20) can be marked on the underside of the body. Refer to the assembly prints for precise positioning specifications. Raise the body enough to be able to weld the mounting pad to the underside of the body.
Before welding, install support blocks between the body and the frame.
14. Raise the body and attach the body retention cable. Remove the support blocks. 15. Weld the body guide brackets into place. Refer to Figures 8-19 & 8-20.
Page 8-20
Final Assembly
FAM0811
FIGURE 8-18.
FIGURE 8-19. BODY GUIDE 1. Dump Body 2. Body Guide 3. Body Guide Wear Plates
FIGURE 8-20. BODY-UP SWITCH ADJUSTMENT 1. Switch Mounting Bracket 2. Adjustment Cap Screws 3. Proximity Switch 4. Actuator Arm 5. Adjustment Screws
FAM0811
Final Assembly
Page 8-21
16. If the truck is to be equipped with a heated body, install the exhaust box at the pivot and tighten the hardware (Figures 8-21 & 8-22).
Page 8-22
Final Assembly
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FIGURE 8-21.
FIGURE 8-22.
FAM0811
Final Assembly
Page 8-23
17. If the truck is to be equipped with mufflers, install at this time. Refer to Figure 8-24.
Page 8-24
Final Assembly
FAM0811
FIGURE 8-23.
FAM0811
Final Assembly
Page 8-25
18. With the body in the raised position, set the body hoist limit switch and weld the target into position (Figure 824). The switch should activate 152 mm (6 in.) before maximum cylinder stroke. Refer to the assembly prints for precise specifications.
19. With the body in the raised position, install the grease lines for the hoist cylinders and clamp along the inside of the body (Figure 8-25).
Page 8-26
Final Assembly
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FIGURE 8-24.
FIGURE 8-25.
FAM0811
Final Assembly
Page 8-27
20. Install the exhaust tubing blankets (Figure 8-26).
21. Install the LH & RH engine inspection lights (Figure 8-27).
Page 8-28
Final Assembly
FAM0811
FIGURE 8-26.
FIGURE 8-27.
FAM0811
Final Assembly
Page 8-29
22. Install add-on components such as the lubrication sytem and the oil reserve system. Verify that all electrical and hydraulic connections are correct. Refer to Figure 8-28 & 8-29.
Page 8-30
Final Assembly
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FIGURE 8-28.
FIGURE 8-29.
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Final Assembly
Page 8-31
23. Install the fire system. Refer to Figures 8-30, 8-31, 8-32. This installation is normally performed by the fire system distributor.
Page 8-32
Final Assembly
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FIGURE 8-30.
FIGURE 8-31.
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Final Assembly
Page 8-33
NOTES
Page 8-34
Final Assembly
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FIGURE 8-32.
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Final Assembly
Page 8-35
24. Paint the truck as needed. 25. Install the anti-skid strips at the designated areas on the decks (Figure 8-33).
26. Install all decals on their designated areas (Figure 8-34).
Page 8-36
Final Assembly
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FIGURE 8-33.
FIGURE 8-34.
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Final Assembly
Page 8-37
27. After completing the assembly of the truck, verify that all cap screw heads or nuts are marked with paint, indicating they have been properly tightened. Check all hydraulic lines and electrical connections for secure installation. Notify qualified maintenance personnel that the truck is ready for final static and dynamic systems checkout.
Page 8-38
Final Assembly
FAM0811
FINAL CHECKOUT
Final checkout requires truck operation. Place the operation and maintenance manual and safety manuals in the operator cab, if not already there. Any personnel involved in the final check-out of the truck must read and understand all safety and operating instructions in the operation and maintenance manual. 1. Complete delivery and warranty forms. 2. Check all coolant and lubricants for proper levels and specifications. The lubrication chart is shown in Section 10, Appendix. 3. Verify the shut-off valves in the hydraulic cabinet are open. 4. Purge any air from the pumps. Pressure will not build if air is present. Operating the pumps with air in the system will result in damage. 5. Perform a final check of all systems. Several checks are outlined in Section 10, Appendix. 6. Complete the checks listed in the Field Assembly Inspection Report Form. A copy of the form is provided with the truck and is also available in Section 10, Appendix. 7. Operate the truck in a traffic-free area until safe operation has been validated. 8. Release the truck for use after all checks have been completed and all deficiencies corrected.
FAM0903
Final Checkout
Page 9-1
NOTES
Page 9-2
Final Checkout
FAM0903
APPENDIX
This chapter contains additional information and procedures for aiding in field assembly of the truck. Refer to the list below for contents of this chapter. Refer to the latest service manual for additional information on servicing the truck. 1. Lubrication Chart - WB2790 2. Suspension Oiling And Charging Procedure 3. Toe In Adjustment Procedure 4. Automatic Lubrication System Checkout Procedure 5. Air Conditioning Checkout Procedure - EL4302 6. Air Conditioning Drive Belt Adjustment Procedure - EL9330 7. Hydraulic Checkout Procedure - EL2605 8. Brake Checkout Procedure - EJ1732 9. VHMS Checkout Procedure - EK8480 10. Payload Meter III Checkout Procedure - EJ3061 11. Electrical Checkout Procedure - EF9650 12. Standard Torque Charts and CoversionTables 13. Field Assembly Inspection Report 14. 50 Hour Post-Commissioning Checksheet
FAM1008
Appendix
Page 10-1
NOTES
Page 10-2
Appendix
FAM1008
LUBRICATION CHART
NOTES
SUSPENSION OILING AND CHARGING PROCEDURE

GENERAL
These procedures cover the oiling and charging of Hydrair II suspensions on Komatsu 930E dump trucks. Suspensions which have been properly charged will provide improved handling and ride characteristics while also extending the fatigue life of the truck frame and improving tire wear. NOTE: Inflation pressures and exposed piston lengths are calculated for a normal truck gross vehicle weight (GVW). Additions to truck weight by adding body liners, tailgates, water tanks, etc. should be considered part of the payload. Keeping the truck GVW within the specification shown on the Grade/ Speed Retard chart in the operator cab will extend the service life of the truck main frame and allow the Hydrair II suspensions to produce a comfortable ride.
EQUIPMENT LIST
Hydrair Charging Kit Jacks and/or Overhead Crane Support Blocks for: Oiling Height Dimensions (Front and Rear) Charging Height Dimensions (Front Only) Hydrair Oil (See Specifications Chart) Friction Modifier (See Specifications Chart) Dry Nitrogen (See Specifications Chart)
Installation of Charging Kit Assemble the charging kit as shown in Figure 4-1 and attach it to a container of pure dry nitrogen (8). 1. Remove the protective covers and charging valve caps from the suspensions. 2. Turn "T" handles (1, Figure 4-1) of adapters (2) completely counterclockwise.
All Hydrair II suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury and/or damage if improperly handled. Follow all safety instructions, cautions, and warnings provided in the following procedures to prevent any accidents during oiling and charging. Proper charging of Hydrair II suspensions requires that three basic conditions be established in the following order: 1. Oil level must be correct. 2. Suspension piston rod extension for nitrogen charging must be correct. 3. Nitrogen charge pressure must be correct. For best results, Hydrair II suspensions should be charged in pairs (fronts together and rears together). If rear suspensions are to be charged, the front suspensions should be charged first. NOTE: For longer life of suspension components, a friction modifier should be added to the suspension oil. See the Specifications Charts at the end of this section. NOTE: Setup dimensions in the Specifications Charts must be maintained during oiling and charging procedures. However, after the truck has been operated, these dimensions may vary. FIGURE 4-1. HYDRAIR CHARGING KIT NOTE: The arrangement of parts may vary from the illustration depending on the kit part number. 1. T Handle Valve 2. Charging Valve Adapter 3. Manifold Outlet Valves (from gauge) 4. Inlet Valve (from regulator) 5. Regulator Valve (Nitrogen Pressure) 6. Manifold 7. Charging Pressure Gauge (Suspensions) 8. Dry Nitrogen Gas Container
3. Ensure outlet valves (3) and inlet valve (4) are closed (turned completely clockwise). 4. Turn swivel nut (small hex) on the charging valve three full turns counterclockwise to unseat the valve. 5. Attach charging valve adapters (2) to each suspension charging valve stem. 6. Turn "T" handles (1) clockwise. This will depress core of charging valve and open the gas chamber of the suspension. 7. Open both outlet valves (3). NOTE: By selective opening and closing of outlet valves (3), and inlet valve (4), suspensions may be charged separately or together. Removal of Charging Kit 1. Close both outlet valves (3). 2. Turn "T" handles (1) counterclockwise to release the charging valve cores. 3. Remove charging valve adapters (2) from the charging valves. 4. Tighten the swivel nut (small hex) on the charging valve. If a new charging valve is being used, tighten the swivel nut to 15 Nm (11 ft lb), then loosen and retighten the swivel nut to 15 Nm (11 ft lb). Loosen the swivel nut again and retighten to 6 Nm (50 in. lb). Install the valve cap finger-tight. 5. Install the charging valve caps and protective covers on both suspensions.
Support Blocks For Oiling And Charging Dimensions Before starting the oiling and charging procedures, supports should be fabricated to maintain the correct exposed piston rod extensions.
Nitrogen charging support blocks for the rear suspension are no longer necessary. However, oiling blocks are necessary to properly set the oiling height. Exposed piston rod extensions are specified for both oil level and nitrogen charging for Hydrair II suspensions. These dimensions are listed in the tables below Figures 4-2 and 4-5. Measure the dimensions from the face of the cylinder gland to the machined surface on the spindle at the front suspension. At the rear suspension, measure from the face of the cylinder gland to the piston flange. Support blocks may be made in various forms. Mild steel materials are recommended. Square stock or pipe segments at least 25 mm (1 in.) may be used. Blocks must be capable of supporting the weight of the truck during oiling and charging procedures while avoiding contact with plated surfaces and seals on the suspension. Refer to Figure 4-2 for front suspension support block placement and Figure 4-4 for rear support block placement.
FRONT SUSPENSION
All Hydrair II suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury and/or damage if improperly handled. Follow all the safety notes, cautions and warnings in these procedures to prevent accidents during servicing and charging. 1. Park the unloaded truck on a hard, level surface. Apply the parking brake and chock the wheels. 2. Thoroughly clean the area around the charging valve on the suspensions. Remove the protective covers from the charging valves. Front Suspension Oiling
2. Remove the charging valve cap. Turn the charging valve swivel nut (small hex) counterclockwise three full turns to unseat the valve seal. DO NOT turn the large hex. The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body must not be loosened until all nitrogen pressure has been released from the suspension. 3. Depress the charging valve core to release nitrogen pressure from the suspension. When all nitrogen has been released, the suspension should have collapsed slowly and be seated solidly on the support blocks. Remove the top fill plug next to the charging valve (Figure 4-2).
When blocks are in place on a suspension, they must be secured with a strap or other means to avoid accidental discharge. An unsecured block could fly loose as weight is applied, presenting the possibility of serious injury to nearby personnel and/or damage to the equipment. Overhead clearance may be reduced rapidly and suddenly when nitrogen pressure is released.
Make certain all personnel are clear and support blocks are secure before relieving nitrogen pressure from the suspension. Wear a face mask or goggles while relieving nitrogen pressure. NOTE: For longer life of suspension components, a friction modifier should be added to the suspension oil. See the Specifications Charts at the end of this section. 1. Position and secure oiling height dimension blocks in place (Figure 4-2). The blocks should be positioned 180 degrees apart to provide stability. When nitrogen pressure is released, the suspensions will lower and rest on the blocks. Ensure that the blocks do not mar or scratch the plated surfaces of the pistons or damage wiper seals in the lower bearing retainer. Support blocks must seat on the spindle and the cylinder housing. FIGURE 4-2. FRONT SUSPENSION
FRONT SUSPENSION DIMENSIONS (EMPTY)

OILING HEIGHT CHARGING HEIGHT *CHARGING PRESSURE
25.4 mm (1.0 in.)
299 mm (9.0 in.)
2930 kPa (425 psi)
* with standard Rock Body Note: If the truck starts to lift off the blocks before charging pressure is attained, STOP CHARGING.
4. Fill the suspension with clean Hydrair oil (with 6% friction modifier) until the cylinder is full to the top of the fill plug bore. Use drip pans and clean all spillage from the outside of the suspension. Allow the suspension to settle for at least 15 minutes to clear any trapped nitrogen and bubbles from the oil. Add more suspension oil if necessary. Install a new O-ring on the fill plug and install the plug. Front Suspension Nitrogen Charging
Dry nitrogen is the only gas approved for use in Hydrair II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in the Specifications Chart at the end of this section. 3. Install the Hydrair charging kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit in this section. 4. Charge the suspensions with nitrogen gas to 50.8 mm (2 in.) greater than the charging height listed in Figure 4-2. Close inlet valve (4, Figure 4-1). 5. Remove the oiling blocks from the suspensions and install the nitrogen charging blocks. Secure the blocks to prevent accidental dislodging. NOTE: Use caution to prevent damage to plated cylinder surfaces and oil seals when installing the blocks. 6. Remove the center hose from manifold (6). 7. Open inlet valve (4) until the pressure drops below the pressure listed in Figure 4-2, then close the valve. 8. Install the center hose to manifold (6). 9. Charge the suspensions to the pressure listed in Figure 4-2. DO NOT use an overcharge of nitrogen to lift the suspensions off the charging blocks. 10. Close inlet valve (4, Figure 4-1). Leave outlet valves (3) open for five minutes to allow the pressures in the suspensions to equalize. 11. Close outlet valves (3). Remove the charging kit components. Refer to Removal of Charging Kit in this section. 12. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 6 Nm (50 in. lb).
Lifting equipment (crane or hydraulic jacks) must be of sufficient capacity to lift the truck weight. Be certain that all personnel are clear of the lift area before the lift is started. Clearances under the truck may be suddenly reduced. 1. If removed, install the charging valve with new O-ring (9, Figure 4-3). Lubricate the O-ring with clean Hydrair oil. 2. Tighten valve body (6) (large hex) to 23 Nm (17 ft lb). Swivel nut (4) (small hex) must be unseated by turning it counterclockwise three full turns.
FIGURE 4-3. CHARGING VALVE 1. Valve Cap 2. Seal 3. Valve Core 4. Swivel Nut 5. Rubber Washer 6. Valve Body 7. O-Ring 8. Valve Stem 9. O-Ring
13. If a new charging valve is being used, tighten the swivel nut to 15 Nm (11 ft lb)), then loosen and retighten the swivel nut to 15 Nm (11 ft lb)). Loosen the swivel nut again and retighten to 6 Nm (50 in. lb). Install the valve cap fingertight. 14. Install the protective guard over the charging valve.
15. Raise the truck body in order to extend the front suspensions, allowing for removal of the nitrogen charging blocks. Ensure that sufficient overhead clearance exists before raising the body. If the suspensions do not extend after raising the body, turn the steering wheel from stop to stop several times. If the suspensions still do not extend enough to allow for removal of the blocks, use a crane or floor jacks to raise the truck and remove the blocks. The front Hydrair suspensions are now ready for operation. Visually check piston extension with the truck both empty and loaded. Record the extension dimensions. Maximum downward travel is indicated by the dirt ring at the base of the piston. Operator comments on steering response and suspension rebound should also be noted.
NOTE: For longer life of suspension components, a friction modifier should be added to the suspension oil. See the Specifications Charts at the end of this section. 1. Position and secure the oiling blocks in place so the blocks are seated between the frame and the rear axle housing (Figure 4-4). A block should be used on both the left and right sides of the truck.
REAR SUSPENSION
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the wheels. 2. Thoroughly clean the area around the charging valve on the suspensions. Remove the protective covers from the charging valves and the rubber covers from the suspension piston. Rear Suspension Oiling FIGURE 4-4. OILING BLOCK INSTALLATION 1. Main Frame 2. Oiling Support Block 3. Rear Axle Housing
When blocks are in place on a suspension, they must be secured with a strap or other means to avoid accidental discharge. An unsecured block could fly loose as weight is applied, presenting the possibility of serious injury to nearby personnel and/or damage to the equipment. Overhead clearance may be reduced rapidly and suddenly when nitrogen pressure is released.
2. Remove charging valve cap. Turn the charging valve swivel nut (small hex) counterclockwise three full turns to unseat the valve seal. DO NOT turn the large hex. The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body must not be loosened until all nitrogen pressure has been released from the suspension.
Make certain all personnel are clear and support blocks are secure before relieving nitrogen pressure from the suspension. Wear a face mask or goggles while relieving nitrogen pressure.
3. Depress the charging valve core to release nitrogen pressure from the suspension. When all nitrogen pressure has been released, loosen and remove the fill plug. The suspension should have collapsed slowly as gas pressure was released. The weight of the truck is now supported by the support blocks. NOTE: A plastic tube can be used to help bleed off trapped air inside the piston. 4. Remove the vent plug, pressure sensor, and charging valve (Figure 4-5). Use one of the open ports to fill the suspension with clean Hydrair oil (with 6% friction modifier). Fill until clean oil seaps from the open ports. Use drip pans and clean all spillage from the outside of the suspension. Allow the suspension to settle for at least 15 minutes to clear any trapped nitrogen and bubbles from the oil. Add more suspension oil if necessary. 5. Install the vent plug and pressure sensor onto the suspension. 6. Install a new O-ring onto the charging valve. Lubricate the O-ring with clean Hydrair oil. 7. Install the charging valve onto the suspension. Tighten valve body (6, Figure 4-3) to 23 Nm (17 ft lb).
FIGURE 4-5. REAR SUSPENSION 1. Main Frame 2. Charging Valve 3. Rear Axle Housing
REAR SUSPENSION DIMENSIONS (EMPTY)

OILING HEIGHT CHARGING HEIGHT *CHARGING PRESSURE
53 mm (2.1 in.)
218 mm (8.6 in.)
1296 kPa (188 psi)
* Note: Charging pressures are for reference only and may vary depending on body weights.
Rear Suspension Nitrogen Charging
Lifting equipment (overhead or mobile cranes, or hydraulic jacks) must be of sufficient capacity to lift the truck weight. Ensure that all personnel are clear of lift area before lifting is started. Clearances under the truck may be suddenly reduced.
7. Ensure that both of the suspension cylinders are extended the same distance 10 mm (0.39 in.). If the difference in the extension from side to side exceeds this amount, check the front suspensions for equal extension. Adjust the front suspensions as necessary. NOTE: A low left front suspension will cause the right rear suspension to be high. A low right front suspension will cause the left rear suspension to be high. 8. Close outlet valves (3). Remove the charging kit components. Refer to Removal of Charging Kit in this section. 9. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 6 Nm (50 in. lb). 10. If a new charging valve is being used, tighten the swivel nut to 15 Nm (11 ft lb), then loosen and retighten the swivel nut to 15 Nm (11 ft lb). Loosen the swivel nut again and retighten to 6 Nm (50 in. lb). Install the valve cap finger-tight. 11. Install the protective guards over the charging valves. Install the rubber covers over the piston rods. The rear Hydrair suspensions are now ready for operation. Visually check piston extension with the truck both empty and loaded. Record the extension dimensions. Maximum downward travel is indicated by the dirt ring at the base of the piston. Operator comments on steering response and suspension rebound should also be noted.
Ensure that the automatic apply circuit has not applied the service brakes during truck maintenance. If the front brakes are applied during rear suspension charging, the axle cannot pivot for frame raising/lowering, and the rear suspension may be unable to move up or down. 1. If removed, install charging valve with new Oring (9, Figure 4-3). Lubricate the O-ring with clean Hydrair oil. 2. Tighten valve body (6) (large hex) to 23 Nm (17 ft lb). Swivel nut (4) (small hex) must be unseated by turning it counterclockwise three full turns.
Dry nitrogen is the only gas approved for use in Hydrair II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in the Specifications Chart at the end of this section. 3. Install Hydrair charging kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit in this section. 4. Charge the suspensions with nitrogen gas to 38 mm (1.5 in.) greater than the charging height listed in Figure 4-5. 5. Slowly release gas until the suspensions match the charging height listed in Figure 4-5. 6. Close inlet valve (4, Figure 4-1). Leave outlet valves (3) open for five minutes to allow the pressures in the suspensions to equalize.
OIL AND NITROGEN SPECIFICATIONS CHARTS

HYDRAIR II OIL SPECIFICATIONS Ambient Temperature Range Part No. VJ3911 (need to add 6% of AK3761) AK4063 AK4064 VJ5925 (need to add 6% of AK3761) AK4065 AK4066 Approved Sources Sunfleet TH Universal Tractor Fluid Mobil 424 Chevron Tractor Hydraulic Fluid Mobil D.T.E. 15 Conoco Power Tran III Fluid Petro Texaco TDH Oil Canada Duratran Fluid AMOCO ULTIMATE Motor Oil Shell Canada Donax TDL 5W-30 Suspension Oil (premixed with 6% Friction Modifier) Emery 2811, SG-CD, 5W-30 Mobil Delvac I, 5W-30 Suspension Oil (premixed with 6% Friction Modifier) 5 Gallon container 55 Gallon container Petro Canada Super Arctic Motor Oil, 0W-30 Conoco High Performance Synthetic Motor Oil, 5W-30 5 Gallon container 55 Gallon container
-30F & above (-34.5C & above)
-55F & above (-48.5C & above)
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and VJ5925 oils are supplied in 5 gallon (19 Liter) cans.
FRICTION MODIFIER Part Number AK3761 (5 Gallon container of 100% Friction Modifier)
FRICTION MODIFIER Mixing Instructions (94% Suspension Oil, 6% Friction Modifier) Suspension Oil 1 gallon of suspension oil 5 gallons of suspension oil 55 gallons of suspension oil NITROGEN GAS (N2) SPECIFICATIONS Property Value 99.9% Minimum 32 PPM Maximum -68F (-55C) Maximum 0.1% Maximum Amount of Friction Modifier to add add 7.7 oz. add 38.4 oz. add 3.3 gal.
Nitrogen gas used in II Suspension Cylinders must meet or exceed CGA specification G-10.1 for Type 1, Grade F Nitrogen Gas
HYDRAIR
Nitrogen Water Dew Point Oxygen
TOE-IN ADJUSTMENT
1. The steering system must first be centered in the straight ahead position. Turn the key switch OFF. Allow at least 90 seconds for the accumulators to depressurize. DO NOT turn the steering wheel during this time. 2. Block the front and back of the rear wheels. 3. Check the toe-in by measuring the distance between the centers of the front tires. Obtain the measurements on the horizontal centerline at the front and rear of the tires. Refer to Figure 3-1. Radial tires must have equal measurements at the front and the rear of the tires. Equal measurements results in zero toe-in. 4. Loosen the clamp locknuts on the tie rod. Rotate the tie rod as necessary to obtain the correct toe-in setting of zero toe-in.. 5. When the adjustment is complete, tighten the locknuts on the tie rod to 420 42 Nm (310 31 ft lbs). 6. Remove the blocks from the rear wheels. 930E TOE-IN DATA Nominal tie-rod length, radial tires to achieve zero toe-in 3667 mm (144.37 in.)
FIGURE 3-1. MEASURING TOE-IN
NOTES
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE

GREASE REQUIREMENTS
Grease requirements will depend on ambient temperatures encountered during truck operation: Above 32C (90F) - Use multipurpose grease (MPG). NLGI No.2
-32 to 32C (-25 to 90F) - Use NLGI No. 1 multipurpose grease (MPG). Below -32C (-25F) - Refer to local supplier for extreme cold weather lubricant requirements.
PUMP HOUSING OIL

The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level every 1000 hours. To add oil, remove oil level plug (4, Figure 3-2) and fill the housing to the bottom of the plug hole.
SYSTEM PRIMING
The system must be full of grease and free of air pockets to function properly. After maintenance, if the primary or secondary lubrication lines were replaced, it will be necessary to prime the system to eject all entrapped air. 1. Fill lube reservoir with lubricant, if necessary. 2. To purge air from the main supply line, remove the main supply line at the canister and connect an external grease supply to the line. 3. Remove plugs from each injector group in sequence (right front, left front, and rear axle). 4. Using the external grease source, pump grease until grease appears at the group of injectors and re-install the pipe plug. Repeat for remaining injector groups. 5. Remove the caps from each injector and connect an external grease supply to the zerk on the injector and pump until grease appears at the far end of the individual grease hose or the joint being greased.
FIGURE 3-1. PUMP/RESERVOIR COMPONENTS 1. Hose from Filter 2. Outlet to Injectors 3. Hydraulic Motor 4. Pressure Reducing Valve 5. Solenoid Valve 6. Manual Override Switch 7. Vent Valve 8. Pressure Gauge 9. Pump Assembly 10. Flow Control Valve 11. Pressure Switch 12. Grease Reservoir 13. Vent Hose
PRESSURE AND FLOW CONTROL

High pressure hydraulic fluid from the truck steering system is reduced to 2 240 to 2 413 kPa (325 to 350 psi) by pressure reducing valve (4, Figure 3-1) located on the manifold on top of the pump motor. This pressure can be observed on the gauge installed on the manifold. Occasionally check to verify that pressure is within the above limits. The pressure reducing valve is factory adjusted. DO NOT tamper with this setting. Flow control valve (5) controls oil flow through the pump. The valve is factory adjusted to 2.5 gpm (9.5 L/min.). DO NOT tamper with this setting.
SYSTEM CHECKOUT
To check system operation (not including timer), proceed as follows: 1. Turn key switch ON and start the engine. 2. Actuate the lube system test switch at the reservoir/pump assembly on the front bumper. 3. The motor and pump should operate until the system attains 2500 psi (17 237 kPa). 4. Once the required pressure is reached, the pump motor should turn off and the system should vent. 5. Check for pump, hose or injector damage or leakage with the system pressurized. FIGURE 3-2. PUMP CONTROLS 1. Pressure Reducing Valve 4. Oil Level Plug 2. Manual Override Switch 5. Flow Control Valve (Test) 3. Pressure Gauge 6. After checking the system, shut off the engine. Repair the lube system as necessary.
PREVENTATIVE MAINTENANCE PROCEDURES

The following maintenance procedures should be used to insure proper system operation. Daily Lubrication System Inspection 1. Check grease reservoir level. Inspect grease level height after each shift of operation. Grease usage should be consistent from day-today operations. Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate a broken supply line. 2. Check filter bypass indicator when filling reservoir. Replace element if bypassing. 3. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points. a. Repair or replace all damaged feed line hoses. b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service. 4. Inspect key lubrication points for a bead of lubricant around seal. If a lubrication point appears dry, troubleshoot and repair problem. 250 Hour Inspection 1. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points (see, Figure 31). a. Repair or replace all worn / broken feed line hoses. b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service. 2. Check all grease supply line hoses from the pump to the SL-1 injectors. a. Repair or replace all worn / broken supply lines. b. Make sure that all air is purged and all new supply line hoses are filled with grease before sending the truck back into service. 3. Check grease reservoir level. a. Fill reservoir if low. b. Check reservoir for contaminants. Clean, if required.
c. Check that all filler plugs, covers and breather vents on the reservoir are intact and free of contaminants. 4. Inspect all bearing points for a bead of lubricant around the bearing seal. It is good practice to manually lube each bearing point at the grease fitting provided on each Injector. This will indicate if there are any frozen or plugged bearings, and will help flush the bearings of contaminants. 5. System Checkout a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation. b. Start truck engine. c. Actuate the manual override switch (6, Figure 3-1). The hydraulic motor and grease pump should operate. d. With the grease under pressure, check each SL-1 injector assembly. The cycle indicator pin should be retracted inside the injector body. e. When the system attains 17,237 kPa (2500 psi), the pump should shut off and the pressure in the system should drop to zero, venting back to the grease reservoir. f. With the system vented, check all of the SL-1 injector indicator pins; all of the pins should be visible. Replace or repair injectors, if defective. g. Reinstall all injector cover caps. h. Check timer operation. NOTE: With engine running, lube system should activate within 5 minutes. The system should build 13,790 to17,237 kPa (2000 to 2500 psi) within 25-40 seconds. i. If the system is working properly, the truck is ready for operation. j. If the system is malfunctioning, refer to the troubleshooting chart.
1000 Hour Inspection 1. Check pump housing oil level and correct if necessary.
NOTES
NOTES:
NOTES:
NOTES:
NOTES:
KOMATSU
NAME: VHMS System Checkout Procedure WRITTEN BY: DATE:
CHECKOUT PROCEDURE
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MACHINE & MODEL: 930E, 960E, 830E
07/17/04
CHECKED BY: APPROVED G. Horst BY: DATE: DATE: 1 0 DASH A SIZE INTEGRATED INTERFACE MODULE CHECKOUT 8/18/04 \\\"'\4 NEWRELEASE DATE ECN DESCRIPTION OFCHANGE MICROFILM GGH BY SK CK'D
I I I I I I I I I I I I I
I I I
I I I I
Structure and purpose: This procedure is in two parts. The first part verifies the installation of the VHMScontroller,The Interface module, the OrbComm communicator, the sensors, and all associated wiring. The second part ofthe procedure setsup VHMSfor time of day, time zone, fault,trendand payloaddata transmission, and OrbCommcommunication settings.
Preliminarv procedures (can be done before ac~nstallationt 1. WebCARE Machine registration must be completed. Fill out the "WebCARE Machine registration request" (a copy is attached to this document) and FAX to the VHMSlWebCARE support team (FAX number is on the form). 2. The "Orbcomm activation request" must be completed (a copy is also attached to this document). If this is a field installation, one of the serial number stickers should be placed on the form (be sure to place the other on the Orbcomm modem itself). When complete, FAX the form to the KOMTRAX Service Hotline (FAX number is on the form). It will take a week or two to complete this activation. Necessarv Eauipment: 1. Checkout procedure and system schematic. 2. Laptop computer with VHMS PC software installed (VHMS Technical Analysis Toolbox), and VHMS Watcher software. 3. RS232 serial cable with a male DB9 connector on one end and a female connector on the other end. 4. You will need the correct CGCDatcsv file for use with the specific truck model you are checking out This .csv file is used with the VHMS Watcher software to identify by name the input signals that the Interface Module (1M)sends to VHMS. Installina the CGCDat.csv File: 1. The file names take this form: CGCDat930E.csv, CGCDat830E.csv, etc. They will be found in the same file folder as the VhmsWatcher.exe program. 2. The active file is always named CGCDatcsv. If you have the wrong file active, you must rename it (OLDCGCDatcsv). Then make a copy of the correct file and change the copy's name to CGCDatcsv.
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CHECKOUT PROCEDURE
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INSTALL THE APPLICATION CODE

Before the Interface Module can be put to work, the application code must be installed. Application code must match the truck model for Interface Module installation. Use EJ9098-1 software for 930E trucks and EL0355-0 software for 830E trucks. Go to the Interface Module web site www.kac-peoria.com/interfacemodule/ to get the necessary files and instructions.
PLM3 NOTE
Use the Payload Data Manager software to verify the PLM3 installed software. PLM3 software EJ0575-3 or later is required for the Interface Module to properly acquire truck speed on model 830E and 930E trucks. Go to PLM3 web site, www.kac-peoria.com navload'for software and instructions.
PART 1 - Installation
and wirin(:l verification
CHECK FOR FAULT CODES ASSOCIATED WITH THE INTERFACE MODULE

Look at a recent download (with the VHMS Technical Analysis Toolbox) and view fault history. Confirm that there are no fault codes associated with the Interface Module. If any are found, these circuits should be analyzed to determine the cause of the fault and should be repaired.
CHECK INPUT TO THE INTERFACE MODULE

Use the VHMS Watcher software. 1. Double click the shortcut VHMSWatcher on the Desktop screen. The program begins with a blank window. On the menu bar, there are five items: File, VHMS, Settings, Interaction, Help. Only use the VHMS pull down menu. 2. Click on VHMS on the menu bar. A small menu pops up, showing two items: Read Table Data and Port Setting. Click Read Table Data. 3. Click VHMS on menu bar again, this time click Port Setting. A small window shows up to allow selection of Port Setting. Select the appropriate port (COM1,COM2), and select the baud rate to be 19.2K. 4. Click VHMS on menu bar again. Click Open Connection. 5. Click VHMS on menu bar again, click Start. A window will open as shown: m
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KOMATSU
::;:'2 ..HMS !:ielp ; If !
CHECKOUT PROCEDURE
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_~r012~:::~~~i~~{~~"'.:~-':::~"":=:~~"~"-"~'~~'~-
:t:s'$~~1::!:7~='~'"'
IDOxc120: Seq# Ox2:Args Hello sent (rpc_senUnspector) IDOxfffe: Seq# Ox2: acked by receiver (rpc_ack_inspector)
ID Oxfffd: Seq# OxO: sentto COM.dll (rpc_tx_inspector) kind.930E: Cold Start!
ID Oxc121: Seq#OxO: Ver.11030100181
Ready
EfiJl Start I; : :iI ~ 6J t) lJ
I~
~ Interface
Module
Re...1
J;J Can8anFF
:j
Untitled
- VhmsWatc...1
We must see 4 lines of message like shown above, if 2 or 3 lines then it did not work. If it does not work, the problem is with serial communication (maybe the key switch is off, or the serial port is wrong, or is assigned to other software).
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CHECKOUT PROCEDURE
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6. Next, click VHMS item on menu bar again, when the menu pops up, this time click Regist&Display, then a screen like this will show up:
Iii BtaSelectMenu"
301: 2 s: En9-Speed: rpm 0 354: 2 s: Cool_Temp: degC 0
., ,,';":-'.;:.';'
-;;:~;<i,-::'<:',:'",~"'~'Hl~
;.."""""",,,~:.--
CLOSE 301: 2 s: Eng_Speed: rpm 354: 2 s: Cool_Temp: degC 355: Eng_OilJemp 385:AmblenCair _temp 386: Blow_by-press 387: Eng_oil-press 388: Boost-press 389: Exh_gas_temp 500: FueUnjection 501: Ave_Min_ldle_On 502:Auto_Lube_Sw 503: BatC 12V_A 504: BatU 2V_B 505: BatU 2V- C Sampling
0 Delete 0
~
.:J
0
START/STOP
12s
ll
~_."---J
Rel!.dy
:J
I;NUM
.
For Help. press F1 ::Ell Start

I
:!I ~ [J t1 JJ
r,~Interll!.ce Module
Reml
JJ CanBI!.nFF
j @ Document..
WordPl!.d
r~
Untitled
- VhmsW...
I~~;
2:10PM
That is the main screen of the Watcher program. On the table list on the right, click to highlight the selected item we want to view the value, then click the "Add" bar. The selected item will show up in the 6 slots on the left of the screen (so we can view up to 6 items at a time). The screen shows an example when only two items are selected to view: Eng_Speed and CooL Temp. After finishing selecting items to view, click on the START/STOP button, the values of the items will show up. This button is like a toggle switch, click it a second time, then the data capture is disabled. When 6 items are selected, to view another item, we have to remove one item by clicking the Delete button, then repeat the process of Add a new item to view. Remember, before Delete, need to click the START/STOP button, so that the data capture is disabled, after removing an item and replacing with a new item by ADD, need to click the START/STOP button again to enable data capture.
m
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For all trucks:
CHECKOUT PROCEDURE
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1. Ambient Air Temperature - should read close to actual ambient. (Ambient air temp 385) 2. Steering Pressure - Insert 1330 :t20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Steer Press 574) 3. BrakePressure- Insert1330:t20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Brake_Press 515) 4. HoistPressure1 - Insert1330:t20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Hoist_Press_1 529) 5. Hoist Pressure 2 - Insert 1330 :1:20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Hoist_Press_2 530) 6. Pump Filter Switches - short wire 39 to ground at the switches for 3 seconds and confirm state change (zero to one). (Pump_Filter_Sw 559) 7. Low Steering Precharge - short wire 51A to ground at the switches and confirm state change (zero to one). The warning state should be sustained until the key switch is turned off and back on. (Low_Str_Precharg_Sw 538) 8. Hydraulic Tank Level- disconnect wire 34L from tank probe and confirm state change (zero to one). (Hydraulic_Level 532) 9. Auto Lube Switch - short wire 68LLP1 to ground at RB6 (830E models) or RB7 (930E models) or at the Lincoln Lube Timer (960E models) for and confirm state change (zero to one). The warning state should be sustained until the key switch is turned off and back on. (Auto_Lube 502) For 930E and 960E GE trucks, but not 830E trucks: 1. Brake Oil Temperature RR - confirm as being near ambient on a cold truck. (564) 2. Brake Oil Temperature LR - confirm as being near ambient on a cold truck. (536) 3. Brake Oil Temperature RF - confirm as being near ambient on a cold truck. (563) 4. Brake Oil Temperature LF - confirm as being near ambient on a cold truck. (535) 5. No Propel/Retard - short wire 75-6P to ground at TB26-C momentarily and confirm state change (zero to one). 6. No Propel - short wire 75NP to ground at TB25-P momentarily and confirm state change (zero to one). 7. Propel System Caution - short wire 79W to ground at TB26-D momentarily and confirm state change (zero to one). 8. Propel System Temp Caution - short wire 34TW to ground at TB26-B momentarily and confirm state change (zero to one). 9. Propel System Reduced Level - short wire 72LP to ground at TB25-W momentarily and confirm state change (zero to one). 10. Reduced Retard - short wire 76LR to ground at TB25-T momentarily and confirm state change (zero to one). m ,;: CO ~ CO Q I ~
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KOMATSU
For 830E trucks only:
1. 2. 3. 4. 5. 6.
CHECKOUT PROCEDURE
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Hydraulic Tank Temperature (RR Hydraulic Oil Temp on VHMS Watcher) - confirm as being near ambient on a cold truck. (564) Motor Temperature High - short wire 722L to ground at TB21E-B momentarily and confirm state change (zero to one). (558) Motor Blower Off - short wire 32B to ground at TB21E-E momentarily and confirm state change (zero to one). (555) Diode Fault - short wire 79VD to ground at TB21D-G momentarily and confirm state change (zero to one). (551) Electric Drive System Fault - short wire 79VS to ground at TB21D-E momentarily and confirm state change (zero to one). (516) Ground Fault - short wire 79VG to ground at TB21D-F momentarily and confirm state change (zero to one). (557)
For 960E trucks only:

Park Brake Set Switch - with engine running, toggle Park Brake Switch and confirm state change (zero to one). 2. Engine Speed 1M- with engine running observe reported speed. 3. Vehicle Speed - observe reported speed while testing the speedometer with the GE DID panel. Set to 20 mph and observe 20mph on speedometer as well as within VHMS. 4. Battery 12V A - check with batteries fully charged or being charged. Voltage should be about 12 volts. 5. Battery 12V B - check with batteries fully charged or being charged. Voltage should be about 12 volts. 6. Battery 12V C - check with batteries fully charged or being charged. Voltage should be about 12 volts. 1.
CHECK OUTPUTS FROM THE INTERFACE MODULE

For 830E only:
1. Check the High Hydraulic Temperature Lamp by pressing the lamp test rocker switch. The lamp should light.
For 930E and 960E:

1. Check the output of Brake Cooling RPM Advance 1, Brake Cooling RPM Advance 2, Brake Oil Temperature Gauge (930E only), and High Brake Oil Temp Lamp by placing a 169 ohm resistor (a range of 1520 to 1860 should work) in place of any of the four input
temperature probes.
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~-
~--
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KOMATSU
2. 3. 4. 5. 6. 7. 8. 9.
CHECKOUT PROCEDURE
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Brake Cooling RPM Advance 1 should go to 24 volts (check at TB40-B). Brake Cooling RPM Advance 2 should go to 24 volts (check at TB40-C). The Brake Oil Temperature Gauge (930E only) should read near the middle of the red band. The High Brake Oil Temp light should come on. If the output functions do not turn on, read the value of the temperature for the selected input in VHMS Watcher. It should be between 126 and 140 C. If the temperature reading is low check wiring for high resistance between the probe and Interface Module. If the temperature reading is high check for shorts in the wiring. It the temperature is in the right range but the output functions do not work, check the Interface Module output circuit and wiring associated with any non-working function.
For 960E only:

Actuate and hold the lamp test switch in the operator's cab. The following lamps are driven by the Interface Module and should come on (along with all the other lamps): 1. Park Brake Lamp 2. Low Fuel Lamp 3. Batt Charge Alt Failure Lamp 4. 1MWarning Lamp 5. High Brake Oil Temp Lamp
The functionality of the Fuel Level output can be confirmed by observing the needle position of the gauge when the low fuel lamp comes on. 1. Dismount the sending unit only from the tank and position the gauge to a low level with a screwdriver. The shaft of the screwdriver will turn this magnetically coupled sending unit to any position you desire. Set the gauge to empty. After 15 seconds, the Low Fuel Light should come on. Return the gauge to the approximate position of the actual fuel in the tank before remounting it.
2. 3.
The Park Brake Solenoid and Brake Apply output can be checked with the following procedure. 1. Turn parking brake off. Park brake valve should be energized and brake auto apply valve should not. Energization of these valves can be determined by checking voltage across the valves or check for magnetism in the valve with a screwdriver. 2. Use the GE DID panel to set the truck speed to some elevated value such as is used to calibrate the speedometer. The park brake valve should continue to be energized. The auto apply valve should continue to be off. 3. With the truck speed signal still high, turn the park brake on. The park brake valve should m continue to be energized, and the auto apply valve should stay off.
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4.
CHECKOUT PROCEDURE
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Now remove the high truck speed signal. The auto apply valve should pulse on for about 1.5 seconds, and the park brake valve should turn off after the auto apply valve has been on for 1 second.
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KOMATSU
PART 2 - VHMS setup
CHECKOUT PROCEDURE
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VHMSCheckout and WebCARE ReQistration

1. It is vitally important that each item in the checkout procedure be checked-off before continuing on to the next. 2. The information recorded in form 3 at the back of this procedure will be needed for full registration and commission of VHMS. After completion of the form 3, Fax to the number indicated on the form. 3. Email thefilescreatedbyperformingaVHMSdownloadtowebcare@komatsu.co.jp
BeQin VHMS Checkout and Setup Key Switch off

1. Record the the following on Form 3: a. Truck serial number (item 2). b. VHMS box serial number (item 3). c. OrbComm box serial number (item 4). 2. Verify the seven segment LED display on the VHMS controller are off. 3. Disconnect the OrbComm antenna. (WebCARE must be ready to receive data before connecting the antenna.)
Key Switch on. DO NOT START Engine.

4. Watch the seven segment red LED display on the VHMS box. After a short time the display should start counting up. Verify and record (item 5) on Form 3. 5. Connect a lap top PC to the VHMS RS232 serial port. 6. Start the VHMS Setting Tool software. 7. Type the VHMS part number into the "Service 10"field. (If VHMS has test software installed enter "0". 8. Select "Data Clear & Setup" 9. Select EDIT and set the VHMS time of day clock. a. Fill in all entries in item 6 on Form 3. b. Enter the correct time zone. (the UTC or GMT setting) c. Select DST (Daylight Savings Time) if appropriate) 10.Set the truck model, type, variation, and serial number. Fill in all entries in item 7 on Form 3. 11.Set the engine serial number and record in item 8 on Form 3. 12.Select "Apply", accept the confirmation prompts, select no to the download data question and then select "Exit". Completely exit the Setting Tool program. Check YES to reboot the controller. 13.Restart the Setting Tool program. 14.Before entering the Service 10,activate the TEST mode by holding down the "ALT" key and m typing 'TEST". The heading "TEST" should appear at the top of 10 screen. " 15.Enter the Service 10field as in step 7 above. QC) ~
~ QC) Q I
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KOMATSU
CHECKOUT PROCEDURE
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16.Select "Setup". (DO NOT select "Data Clear & Setup" this time.) 17.Hold down the "ALT" key and press "S". Set the service meter reading hours. (SMR). Record in Item 10 on Form 3. 18.Select "Apply" and accept the confirmation prompts. 19.Configure the OrbComm settings. Select "EDIT" in the Communication Settings window. 20.Set the file transfer settings as follows and record in Item 11 on Form 3. Item Short Trend Analysis Short Load Map Send ON ON Timer SMR SMR Number 1 Interval 20 (SMR) 160 (SMR)
Short FaultHistory ShortPayloadmeter

for PLM3 Short Brake Load Map
ON ON
ON
Occurrence Day
SMR
6 1
160
21. Set GCC (Ground Control Center) to the appropriate setting and record in item 12 on From 3 GCC code 1 120 121 122 123 130 Territory (country) USA ITALY MALAYSIA KOREA BRAZIL JAPAN
22.Check address boxes 1, 2 and 3 and record in item 12 on Form 3. 23.Select "Apply" and exit the Setting Tool program. Answer "YES" when prompted to reset the controller. 24.Start the Payload Data Manager program and select connect to the Payload Meter. (This can be done with the serial cable still connected to the VHMS data port.) 25.Set the PLM3 time of day and date to be the same as VHMS date and time. (:t2 minutes) Record item13 on From 3. 26. Exit the Payload Data Manager program.
Key Switch on. START Engine. Wait 30 seconds. Record item 14 on Form 3.
27. Press and hold the GE data store switch (this will trigger a VHMS Manual Snapshot) for 3 seconds, and then release. (The GE DataStore switch is located on the bottom rear of the console to the right of the driver's seat.) The white "Data Store in Progress" LED should light solid and bright. The LED may glow dim (not completely off) before the GE DatStore switch is pushed. The white LED will begin a slow flash after 5 minutes, then flash rapidly for 30 secorJOSm ~ co
~
co
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u_-
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-- ---
_u-
--
KOMATSU
CHECKOUT PROCEDURE
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beginning at 7 minutes. Record proper operation of the manual data store in item 15 on Form 3 28.Wait until the Data Store in Progress LED has finished flashing. Wait another minute, then turn the key switch off and stop the engine. Record item 17 on Form 3. Key Switch on. DO NOT START Engine. Record item 18 on Form 3.
29. Start the VHMS Technical Analysis Tool Box program. (user name = 'usr' and password = '1') 30.Select the Download icon and select the correct comm port when prompted, usually COM1. 31.Select "Connection" 32.Verify that the date & time displayed on the download screen are correct for the current local date/time and that the displayed Service Meter hours are equal to the value entered previously. Record in item 19 Form 3. 33.Verify that a Manual Snapshot (MFAO)has been recorded. The display should show an item named 'Snapshot' with code MFAOand text "Manual Trigger". Record in item 20 on Form 3. 34.Select the 'Select All' option (from the bottom right of window) and perform a download. Record in item 21 on Form 3. 35.Verify that the 'Download Completed' message is displayed. Click on "exit". Record item 22 on Form 3. 36. From the Technical Analysis Tool Box launch the View program. 37. Find the data from the download performed in step 31. The data can be identified by the file name which has the date in which it was created. Select the correct file and click "OK". 38.Verify that a Manual Snapshot (MFAO)was recorded by selecting "Fault History" on the upper left corner of the screen. The MFAOfault should be recorded with the time of the manual snapshot and SMR hours entered previously. 39. Select the MACHINE HISTORY option from the list on the left side of the screen. 40.Verify that the Key ON/OFF and Engine ON/OFF records are recorded correctly. 41. Exit the VHMS Technical Analysis Toolbox software. Record in item 23 on Form 3. 42. Start the Setting Tool program. Enter the Service ID field as in step 7 above. 43. Select the radio button labeled 'Setup and Clear'. 44.Accept all the current settings, then Apply and Exit. Record in item 24 on Form 3. 45. Record remaining items on Form 3 and Fax a copy of Form 3 to VHMS/WebCARE support center FAX: 81-3-5561-4766. 46. Email a copy of the download files to VHMSlWebCARE supoort center webcare@komatsu.co.jp. The files are found in folder C:\VHMS_DATA\930E\(truck serial number)\(date of download)\CHKOO01 47.Wait 24 hours. Reconnect the antenna.
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To : VHMSlWebCARE support FAX: 81-3-5561-4766
CHECKOUT PROCEDURE
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team
Ref. No. Date Name
WebCARE
machine
registration
request
Fonn
"An
( DB information] 1. Distributor name 3. Person in Charge
2. Branch
Name
4. E-mail address
5. DB code (GCPS)
[ Customer 6. Customer
information] name 7. Site name
[ Machine information] 8. Model Name 10. Unit No. 11. Item to be registered in WebCARE. VHMS
9. Serial No.
. Installed on new machine 0 . Retro-klt 0
PM Clinic
KUC
[ Orbcomm Activation] 12. Date of Orbcomm activation
[ Remark]
WebC.,ARE
VHMS/WebCARE Support team TEL 81-3-5561-2765 FAX 81-3-5561-4766 E-mail webcare@komatsu.co.jp Page 12 of 15
1 .
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KOMATSU
CHECKOUT PROCEDURE
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TO: Customer support Gr.,Solution Div.,Komatsu Ltd. (KOMTRAX Service Hotline) Phone: +81-463-22-8780 Fax: +81-463-22-8448 Address: 3-25-1 Shinomiya, Hiratsuka-shi, kanagawa 2548555,Japan E-mail: cs_kom@komatsu.co.jp
Important
Request for Orbcomm Terminal Activation

Please fill in the form below and fax or send by mail to Customer Support Gr., Kltd. to activate Orbcomm terminal.
Terminal Terminal Part Number Terminal SIN Terminal Activation Date Country where used Machine Information Customer's Contact Address Company (or Plant) Phone Number FAX Number
e-mail address Name (please print) Signature
First Middle Family
(Pleasefillin terminal PIN&S/N or put on enclosedsticker here)
PIN: (YY/MM/DD) I
SIN: I
Model-Type-S/N#
(Country-Area-number> (Country. Area-number)
Note: It will take one or two weeks to activate after being received this sheet. Orbcomm terminal is unable to communicate before activation being completed.
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\+MS InstallationO1eck-out Sheet (Fam 3)
, Ii3ad befr;re installation
CHECKOUT PROCEDURE
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IXJn't stat
engine
befa"e
item
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STANDARD TORQUE CHARTS AND CONVERSION TABLES

This manual provides dual dimensioning for most specifications. U.S. standard units are specified first, with metric (SI) units in parentheses. References throughout the manual to standard torques or other standard values will be to one of the following charts or tables. For values not shown in these charts or tables, standard conversion factors for most commonly used measurements are provided in TABLE XIII, page A5-6. Standard torque values are not to be used when turnof-the-nut tightening procedures are recommended. INDEX OF TABLES TABLE I . . . . . . . Standard Torque Chart (SAE) TABLE II . Standard Torque, 12-Point, Grade 9 TABLE III . . Standard Metric Assembly Torque TABLE IV . . . . . . JIC Swivel Nuts Torque Chart TABLE V . . . . . . . . .Pipe Thread Torque Chart TABLE VI . . . . . . . . O-Ring Boss Torque Chart TABLEVII . . . . O-Ring Face Seal Torque Chart TABLE VIII . Torque Conversions (ft lbs to Nm) TABLE IX . Torque Conversions (ft lbs to kgm) TABLE X . . Pressure Conversions (psi to kPa) TABLE XI . Pressure Conversions (psi to MPa) TABLE XII . . . . . . . .Temperature Conversions TABLE XIII . . . Common Conversion Multipliers
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values

The Komatsu engineering department does not recommend the use of special friction-reducing lubricants, such as Copper Coat, Never-Seez, and other similar products, on the threads of standard fasteners where standard torque values are applied. The use of special friction-reducing lubricants will significantly alter the clamping force being applied to fasteners during the tightening process. If special friction-reducing lubricants are used with the standard torque values listed below in Table I, excessive stress and possible breakage of the fasteners may result. Where the 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 rustpreventive grease (see list, page A5-2) on the threads and seats unless specified otherwise. NOTE: Ensure the threads of fasteners and tapped holes are free of burrs and other imperfections before assembling.
. . A5-1 . . A5-2 . . A5-2 . . A5-3 . . A5-3 . . A5-3 . . A5-3 . . A5-4 . . A5-4 . . A5-4 . . A5-5 . . A5-5 . . A5-6
Grade 5
TABLE I. -STANDARD TORQUE CHART SAE HEX HEAD CAP SCREW AND NUT ASSEMBLY (LUBRICATED THREADS) - TOLERANCES 10%
TORQUE GRADE 8 Nm 9.5 10.8 20.3 22 34 41 54 61 88 95 122 129 169 183 298 ft lbs 10 11 21 22 35 40 58 62 90 95 125 135 175 190 310 kgm 1.38 1.52 2.90 3.04 4.84 5.5 8.0 8.57 12.4 13.1 17.3 18.7 24.2 26.2 42.8 Nm 13.6 14.9 28 30 47 54 79 84 122 129 169 183 237 258 420 Cap Screw Thread Size 3/4-16 7/8-9 7/8-14 1.0-8 1.0-12 1.0-14 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 1 1/2-6 1 1/2-12 TORQUE GRADE 5 ft lbs 235 350 375 525 560 570 650 700 910 975 1200 1310 1580 1700 kgm 32.5 48.4 51.9 72.6 77.4 78.8 89.9 96.8 125.9 134.8 166 181 219 235 Nm 319 475 508 712 759 773 881 949 1234 1322 1627 1776 2142 2305
Grade 8
TORQUE GRADE 8 ft lbs 335 500 530 750 790 800 1050 1140 1480 1580 1940 2120 2560 2770 kgm 46.3 69.2 73.3 103.7 109.3 110.6 145 158 205 219 268 293 354 383 Nm 454 678 719 1017 1071 1085 1424 1546 2007 2142 2630 2874 3471 3756
Cap Screw Thread Size 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10
TORQUE GRADE 5 ft lbs 7 8 15 16 25 30 40 45 65 70 90 95 125 135 220 kgm 0.97 1.11 2.07 2.21 3.46 4.15 5.5 6.2 9 9.7 12.4 13.1 17.3 18.7 30.4
1 ft lbs = 0.138 kgm = 1.356 Nm
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap Screws (SAE)

The following specifications apply to required assembly torques for all 12-point, grade 9 (170,000 psi minimum tensile) cap screws. Cap screw threads and seats shall be lubricated when assembled. NOTE: Unless the 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.
TABLE II. STANDARD ASSEMBLY TORQUE for 12-Point, Grade 9 Cap screws CAP SCREW SIZE* 0.250 - 20 0.312 - 18 0.375 - 16 0.438 -14 0.500 -13 0.562 - 12 0.625 - 11 0.750 - 10 0.875 - 9 1.000 - 8 1.000 - 12 1.125 - 7 1.125 - 12 1.250 - 7 1.250 - 12 1.375 - 6 1.375 - 12 1.500 - 6 1.500 - 12 TORQUE ft lbs 12 24 42 70 105 150 205 360 575 860 915 1230 1330 1715 1840 2270 2475 2980 3225 TORQUE Nm 16 33 57 95 142 203 278 488 780 1166 1240 1670 1800 2325 2495 3080 3355 4040 4375 TORQUE kgm 1.7 3.3 5.8 9.7 14.5 20.7 28.3 49.7 79.4 119 126 170 184 237 254 313 342 411 445
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts
The following specifications apply to required assembly torques for all metric Class 10.9 finished hexagon head cap screws and Class 10 nuts. Cap screw threads and seats shall not be lubricated when assembled. These specifications are based on all cap screws, nuts, and hardened washers being phosphate and oil coated. NOTE: If zinc-plated hardware is used, each piece must be lubricated with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust preventive grease (see list, this page) 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.
TABLE III. STANDARD ASSEMBLY TORQUE for Metric Class 10.9 Cap screws & Class 10 Nuts CAP SCREW SIZE* M6 x1 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M20 x 2.25 M24 x 3 M30 x 3.5 M36 x 4 TORQUE Nm 12 30 55 95 155 240 465 800 1600 2750 TORQUE ft lbs 9 22 40 70 114 177 343 590 1180 2028 TORQUE kgm 1.22 3.06 5.61 9.69 15.81 24.48 47.43 81.6 163.2 280.5
* Shank Diameter (mm) - Threads per millimeter This table represents standard values only. Do not use these values to replace torque values which are specified in assembly instructions.
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.
* Shank Diameter (in.) - Threads per inch This table represents standard values only. Do not use these values to replace torque values which are specified in assembly instructions.
TABLE IV. TORQUE CHART FOR JIC 37 SWIVEL NUTS WITH OR WITHOUT O-RING SEALS SIZE CODE 2 3 4 5 6 8 10 12 14 16 20 24 32 TUBE SIZE (O.D.) 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 0.875 1.000 1.250 1.500 2.000 THREADS UNF-2B 0.312 24 0.375 24 0.438 20 0.500 20 0.562 18 0.750 16 0.875 14 1.062 12 1.188 12 1.312 12 1.625 12 1.875 12 2.500 12 TORQUE ft lbs 4 1 8 3 12 3 15 3 18 5 30 5 40 5 55 5 65 5 80 5 100 10 120 10 230 20 SIZE CODE 2 3 4 5 6 8 10 12 14 16 20 24 32
TABLE VI. TORQUE CHART FOR O-RING BOSS FITTINGS TUBE SIZE (O.D.) 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 0.875 1.000 1.250 1.500 2.000 THREADS UNF-2B 0.312 24 0.375 24 0.438 20 0.500 20 0.562 18 0.750 16 0.875 14 1.062 12 1.188 12 1.312 12 1.625 12 1.875 12 2.500 12 TORQUE ft lbs 4 2 5 2 8 3 10 3 13 3 24 5 32 5 48 5 54 5 72 5 80 5 80 5 96 10
TABLE V. TORQUE CHART FOR PIPE THREAD FITTINGS PIPE THREAD SIZE 0.125 27 0.250 18 0.375 18 0.500 14 0.750 14 1.000 11.50 1.250 11.50 1.500 11.50 2.000 11.50 WITH SEALANT ft lbs 15 3 20 5 25 5 35 5 45 5 55 5 70 5 80 5 95 10 WITHOUT SEALANT ft lbs 20 5 25 5 35 5 45 5 55 5 65 5 80 5 95 10 120 10 SIZE CODE 4 6 8 10 12 16 20 24
TABLE VII. TORQUE CHART FOR O-RING FACE SEAL FITTINGS TUBE SIZE (O.D.) 0.250 0.375 0.500 0.625 0.750 1.000 1.250 1.500 THREADS UNF-2B 0.438 20 0.562 18 0.750 16 0.875 14 1.062 12 1.312 12 1.625 12 1.875 12 TORQUE ft lbs 11 1 18 2 35 4 51 5 71 7 98 6 132 7 165 15
SIZE CODE 2 4 6 8 12 16 20 24 32
TABLE VIII. TORQUE CONVERSIONS Foot Pounds (ft lbs) to Newton-meters (Nm) ft lbs 0 10 20 30 40 50 60 70 80 90 0 (N.m) 13.56 27.12 40.67 54.23 67.79 81.35 94.91 108.47 122.03 1 1.36 14.91 28.47 42.03 55.59 69.15 82.70 96.26 109.82 123.38 2 2.71 16.27 29.83 43.39 56.94 70.50 84.06 97.62 111.18 124.74 3 4.07 17.63 31.18 44.74 58.30 71.86 85.42 98.97 112.53 126.09 4 5.42 18.98 32.54 46.10 59.66 73.21 86.77 100.33 113.89 127.45 5 6.78 20.34 33.90 47.45 60.01 74.57 88.13 101.69 115.24 128.80 6 8.14 21.69 35.25 48.81 62.37 75.93 89.48 103.04 116.60 130.16 7 9.49 23.05 36.61 50.17 63.72 77.28 90.84 104.40 117.96 131.51 8 10.85 24.40 37.96 51.52 65.08 78.64 92.20 105.75 119.31 132.87 9 12.20 25.76 39.32 52.87 66.44 80.00 93.55 107.11 120.67 134.23
See NOTE on page A5-5 regarding Table usage
TABLE IX. TORQUE CONVERSIONS Foot Pounds (ft lbs) to kilogram-meters (kgm) ft lbs 0 10 20 30 40 50 60 70 80 90 0 (kg.m) 1.38 2.77 4.15 5.53 6.92 8.30 9.68 11.06 12.45 1 0.138 1.52 2.90 4.29 5.67 7.05 8.44 9.82 11.20 12.59 2 0.277 1.66 3.04 4.43 5.81 7.19 8.57 9.96 11.34 12.72 3 0.415 1.80 3.18 4.56 5.95 7.33 8.71 10.10 11.48 12.86 4 0.553 1.94 3.32 4.70 6.09 7.47 8.85 10.23 11.62 13.00 5 0.692 2.07 3.46 4.84 6.22 7.61 8.99 10.37 11.76 13.14 6 0.830 2.21 3.60 4.98 6.36 7.74 9.13 10.51 11.89 13.28 7 0.968 2.35 3.73 5.12 6.50 7.88 9.27 10.65 12.03 13.42 8 1.106 2.49 3.87 5.26 6.64 8.02 9.40 10.79 12.17 13.55 9 1.245 2.63 4.01 5.39 6.78 8.16 9.54 10.93 12.30 13.69
TABLE X. PRESSURE CONVERSIONS Pounds/square inch (psi) To Kilopascals (kPa) Formula: psi x 6.895 = kPa psi 0 10 20 30 40 50 60 70 80 90 0 (kPa) 68.95 137.9 206.8 275.8 344.7 413.7 482.6 551.6 620.5 1 6.895 75.84 144.8 213.7 282.7 351.6 420.6 489.5 558.5 627.4 2 13.79 82.74 151.7 220.6 289.6 358.5 427.5 496.4 565.4 634.3 3 20.68 89.63 158.6 227.5 296.5 365.4 434.4 503.3 572.3 641.2 4 27.58 96.53 165.5 234.4 303.4 372.3 441.3 510.2 579.2 648.1 5 34.47 103.42 172.4 241.3 310.3 379.2 448.2 517.1 586.1 655.0 6 41.37 110.32 179.3 248.2 317.2 386.1 455.1 524.0 593.0 661.9 7 48.26 117.21 186.2 255.1 324.1 393.0 462.0 530.9 599.9 668.8 8 55.16 124.1 193.1 262.0 331.0 399.9 468.9 537.8 606.8 675.7 9 62.05 131.0 200.0 268.9 337.9 406.8 475.8 544.7 613.7 682.6
TABLE XI. PRESSURE CONVERSIONS Pounds/square inch (psi) To Megapascals (MPa) Formula: psi x 0.0069 = MPa psi 0 100 200 300 400 500 600 700 800 900 0 (MPa) 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.52 6.21 10 0.069 0.76 1.45 2.14 2.83 3.52 4.21 4.90 5.58 6.27 20 0.14 0.83 1.52 2.21 2.90 3.59 4.27 4.96 5.65 6.34 30 0.21 0.90 1.59 2.28 2.96 3.65 4.34 5.03 5.72 6.41 40 0.28 0.97 1.65 2.34 3.03 3.72 4.41 5.10 5.79 6.48 50 0.34 1.03 1.72 2.41 3.10 3.79 4.48 5.17 5.86 6.55 60 0.41 1.10 1.79 2.48 3.17 3.86 4.55 5.24 5.93 6.62 70 0.48 1.17 1.86 2.55 3.24 3.93 4.62 5.31 6.00 6.69 80 0.55 1.24 1.93 2.62 3.31 4.00 4.69 5.38 6.07 6.76 90 0.62 1.31 2.00 2.69 3.38 4.07 4.76 5.45 6.14 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.
TABLE XII. TEMPERATURE CONVERSIONS Formula: F - 32 / 1.8 = C or C x 1.8 + 32 = F CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT C F C F C 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 XIII COMMON CONVERSION MULTIPLIERS
COMMON CONVERSION MULTIPLIERS ENGLISH TO METRIC To Convert From inch in. inch in. foot ft yard yd mile mi. sq. in. in. sq. ft. ft2 cu. in. in.3 cu. in. in.3 cu. ft. ft3 cu. ft. ft3 ounce oz fluid ounce fl oz pound (mass) pound (force) lbs in. lbs. (force) ft lbs (force) ft lbs (force) psi (pressure) psi (pressure) psi (pressure) ton (short) ton (short) quart qt gallon gal HP (horsepower) HP (horsepower)
2
COMMON CONVERSION MULTIPLIERS METRIC TO ENGLISH Multiply By 25.40 2.54 0.3048 0.914 1.61 To Convert From millimeter (mm) centimeter (cm) meter (m) meter (m) kilometer (km) sq. centimeters (cm
2)
TO millimeter (mm) centimeter (cm) meter (m) meter (m) kilometer (km) sq. centimeters (cm ) sq. centimeters (cm2) cu. centimeters (cm3) liters (l) cu. meters (m3) liters (l) kilogram (kg) milliliter (ml) kilogram (kg) Newton (N) Newton meters (Nm) Newton meters (Nm) kilogram meters (kgm) kilopascals (kPa) megapascals (MPa) kilograms/cm2 (kg/cm2) kilogram (kg) metric ton liters (l) liters (l) Watts kilowatts (kw)
2
TO inch in. inch in. foot ft yard yd mile mi. sq. in. in.2
Multiply By 0.0394 0.3937 3.2808 1.0936 0.6210 0.1550 0.001 0.061 61.02 35.314 0.0353 0.0353 0.0338 2.2046 0.2248 0.102 0.7376 7.2329 9.807 0.1450 145.038 14.2231 98.068 0.0011 1.1023 1.0567 0.2642 0.00134 1.3410
6.45 929 16.39 0.016 0.028 28.3 0.028 29.573 0.454 4.448 0.113 1.356 0.138 6.895 0.007 0.0704 907.2 0.0907 0.946 3.785 745.7 0.745
sq. centimeters (cm2) cu. centimeters (cm3) liters (l) cu. meters (m3) liters (l) grams (g) milliliter (ml) kilogram (kg) Newton (N) Newton-meters (Nm) Newton-meters (N.m) kilogram-meters (kgm) kilogram-meters (kgm) kilopascals (kPa) megapascals (MPa) kilograms/cm
2
sq. ft. ft2 cu in in.3 cu in in.3 cu ft ft3 cu ft ft3 ounce oz. fluid ounce fl oz. pound (mass) pound (force) lbs kilogram meters (kgm) ft lbs ft lbs Newton meters (Nm) psi psi psi kilopascals (kPa) ton ton quart qt gallon gal Horsepower HP Horsepower HP
(kg/cm2)
kilograms/cm2 (kg/cm2) kilogram (kg) metric ton liters (l) liters (l) Watts kilowatts (kw)
FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
MACHINE MODEL
(Circle One) 730E 830E 830E-AC 930E-4 Service Meter Reading Date of Inspection Wheel Motor Serial Numbers Location of Machine at Inspection Distributors Name Customers Name Customers Address Dump Body Manufacturer Komatsu Dump Body Style KAC Area Service Manager Signature Date LH Other RH
MACHINE SERIAL NUMBER
ENGINE MODEL
ENGINE SERIAL NUMBER
CUSTOMER UNIT NUMBER
Inspectors Comments:
Inspectors Name Title Signature
KOMATSU USE ONLY: Sheet receiving Date: By: Remark:
Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation. All four copies are to be distributed as shown below.
Send White Reports to
Manager of Technical Support Komatsu America Corp. 2300 N.E. Adams St, P.O. Box 240 Peoria, IL 61650-0240 U.S.A. Manager of Field Assembly Komatsu America Corp. 2300 N.E. Adams St, P.O. Box 240 Peoria, IL 61650-0240 U.S.A.
Send Canary Reports to
Send Pink Reports to your KAC Regional Service Manager Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.
Mark each item with the appropriate symbol as shown below.
CEAW003209
White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Page 1 of 5
No.
1 2 3 4 5 6 7 8 9 10 11 12 13
Inspection Item
Parts Hardware Hoses and Cables Ground Straps Engine Oil Level Engine Fan Hydraulic Oil Level Hatch Door (730E, 830E) Anchor Pin Wheel Motors Fuel Tank Radiator Decks and Ladders
Acceptance Procedures
Visual inspection of unit for loose parts and debris Visual inspection of unit for missing and/or loose mounting hardware Visual inspection of hydraulic hoses and electric cables to ensure they are securely clamped and clear from sharp edges and not rubbing each other Verify all ground straps are secure (sub frame, anchor etc.) Verify engine oil level is in operating range Inspect fan-to-shroud clearance and belt alignment Oil level visible through the upper sight glass with body down Verify adequate latch seal on the rear axle hatch door to prevent dust entry Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and properly tightened hardware Inspect oil specification and proper oil level Verify fuel tank mounting is secure and there are no fuel leaks Inspect coolant fill level, cold temperature protection, and DCA additive Inspect all ladders and handrails are secure and hardware is tight Visual inspection of installation of grid blower, rectifier assembly and control box for correct assembly of components and proper clamping, no loose contacts, no damaged or poorly crimped cables
Inspection Around Machine
14
Battery
Inspect all wiring and connections in battery box - no rubbing or chafing Verify battery mounting hardware is secure Verify electrolyte at proper level and caps are securely installed Verify all battery terminals are secure
15
Frame
Visually inspect installation of steering cylinders, tie rod, and accumulators per print Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations (all hardware secure, no leaks)
Hardware Torque 1 2 Suspension Wheels 730E 830E, 830E-AC (See Note below chart) 930E-4 (See Note below chart) Verify torque on front wheel nuts at 2326 136 Nm (1715 100 ft lbs) Verify torque on rear inside wheel nuts at 2326 136 Nm (1715 100 ft lbs) Verify torque on rear outside wheel nuts and adapter ring at 2326 136 Nm (1715 100 ft lbs) 3 4 5 Rops Cab Wheel Motor Verify torque on left rops beam cap screws at 949 Nm (700 ft lbs) Verify torque on right cross beam cap screws at 240 Nm (177 ft lbs) Verify torque on cab mounting cap screws at 949 Nm (700 ft lbs) Verify torque on wheel motor mounting cap screws at 2007 Nm (1480 ft lbs) Verify front suspension mounting cap screws have been properly tightened per appropriate service manual procedure using the turn-of-the-nut method Verify torque on all wedge nuts at 746 Nm (550 ft lbs) Verify torque on all wedge nuts at 746 Nm (550 ft lbs)
(See Note below chart)
NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mounting tightening procedure.
CEAW003209
Page 2 of 5
Accepted
Maintenance
No.
1 2 3 4 5
Inspection Item
Cab Doors Cab Windows Door Locks Interior Cab Seats
Verify doors open and close smoothly, latch works properly, O&M manual in door Verify windows can be opened and closed smoothly Verify left and right door locks work properly with key Visually inspect interior for completeness of assembly Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc. Inspect operators seat adjustments (slide lever, back rest operation, seat inclination, seat height etc.) Inspect seat belt for proper installation (and seat tethers) Verify back rest operates without interference Check tilt and telescoping functions Check adjustable lever can be locked securely Verify wiper works all speeds, & range does not extend beyond glass surface Verify the windshield washer works properly and washer fluid bottle is full Check lighter operation, should pop up after 10 seconds and be hot Check for proper sound, no looseness in horn button Check for proper sound, and function Check for proper function, no binding or looseness Verify gauges are installed straight and operating correctly Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet Check operation of the hoist lever in all four positions Verify all headlights working, high and low beams Verify high beam indicators are functional Verify lights at proper angle
Cab Compartment
6 7 8 9 10 11 12 13 14 15 Lights 1
Passenger Seat Steering Wheel Wiper Cigarette Lighter Horn Back Up Horn Shift Tower Gauges Hydraulic Fittings Hoist Headlights
2 2a 2b
Instrument Panel Dimmer Switch Turn Signal
Check switch depresses and all lights function Verify dimmer operates properly Visually inspect front and rear turn signal operation on left and right sides Directional indicators operate properly Switch turns off after turn is completed
3 4 5 6 1 2 3 4 5 6
Hazard Flashers Back Up Light Manual Back Up Light Fog Light (optional) Service Brake Brake Lock Emergency Brake Parking Brake Dome Light Retarder Lights
Verify flasher operates properly Verify hazard indicator lights operating properly Verify back up light operates properly when shifter is in R position Verify switch and light work properly Verify fog lights and indicator lights operating properly Verify service brake lights operating properly Verify brake lock light operating properly Verify emergency brake light operating properly Verified parking brake light operating properly Verify dome light is on when the switch is ON Verify retard light operating properly
Brake Lights
CEAW003209
Page 3 of 5
Accepted
Maintenance
No.
1
Inspection Item
Suspension 730E
Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear Front charge height, 229 mm (9 in.) at 2758 kPa (400 psi) Rear charge height, 276 mm (10.9 in. ) at 1420 kPa (206 psi) Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear Front charge height, 229 mm (9 in.) at 2689 kPa (390 psi) Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi) Suspension oiling height at 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear Front charge height, 229 mm (9 in.) at 2930 kPa (425 psi) Rear charge height, 190 mm (7.5 in.) at 1482 kPa (215 psi) Verify nitrogen charge in accumulators is at 9653 kPa (1400 psi) for all models, for both steering and brakes If equipped, ensure prelube is working prior to engine starting Ensure engine starts easily No abnormal noise from engine Verify when switch is ON, brakes are applied and light is illuminated Verify when switch is ON, brakes are applied and light is illuminated
Service Inspection (See Note below chart)
830E, 830E-AC (See Note below chart)
930E-4 (See Note below chart)
2 3 4 5 6 7 8
Accumulators Engine Prelube Engine Starting Engine Noise Brake Lock Parking Brake Brake Pressure 730E
Verify with pedal depressed, front brake pressure is 17,236 689 kPa (2500 100 psi) Verify with pedal depressed, rear brake pressure is 11,721 517 kPa (1700 75 psi) Verify brake lock pressure is 10,342 689 kPa (1500 100 psi) Verify parking brake pressure is 17,926 689 kPa (2600 100 psi)
830E, 830E-AC
Verify with pedal depressed, front brake pressure is 20,684 1034 kPa (3000 150 psi) Verify with pedal depressed, rear brake pressure is 13,652 689 kPa (1980 100 psi) Verify brake lock pressure is 10,342 689 kPa (1500 100 psi) Verify parking brake pressure is 17,236 689 kPa (2500 100 psi)
930E-4
Verify with pedal depressed, front brake pressure (BF) is 17,236 517 kPa (2500 75 psi) Verify with pedal depressed, rear brake pressure (BR) is 17,236 517 kPa (2500 75 psi) Verify brake lock pressure is 13,790 689 kPa (2000 100 psi) Verify parking brake release pressure is 18,616 689 kPa (2700 100 psi)
9 10
Steering Hoist
Verify that steering system is operating smoothly, turning from lock to lock Verify steering system is free of noise and vibration Verify hoist pressure is 17,236 kPa (2500 psi) power up, and 10,342 kPa (1500 psi) power down Verify hoist limit switch is operational and is set correctly (measure on the hoist cylinder - 3rd stage), cylinder should stop 6 inches before full extension Verify that the hoist hold position operates properly Verify that there is no heavy shock when the body returns to the frame in float
NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling and charging instructions.
CEAW003209
Page 4 of 5
Accepted
Maintenance
No.
11
Inspection Item
Hoist Times 730E Power down - 15-17 seconds
Power up loaded - 21-23 seconds Float down empty - 22-24 seconds
830E, 830E-AC
Power up loaded - 25-27 seconds Power down - 15-17 seconds Float down empty - 23-25 seconds
930E-4
Power up loaded - 21-23 seconds Power down - 23-25 seconds Float down empty - 24-26 seconds
All Trucks 12 13 14 15 16 17 18 Lubrication Payload Meter Sys. Error Codes Machine Dump Body Electrical Checks Truck Programming
Ensure body up switch activates the body up alarm and light in the cab Ensure automatic lube system is serviced and full (and air bled from system) Ensure automatic lube system is operating properly and timer is set as desired Calibrate and check payload meter operation per O&M manual Troubleshoot any error codes and delete Record machine model-type, machine serial number and engine serial number Ensure the dump body is shimmed correctly prior to truck release Ensure the electrical checkout procedure has been completed and signed off on, including megger testing (see appropriate shop manual for procedure) Ensure the truck is programed with its own unique configuration file and a copy of the file saved
ADDITIONAL COMMENTS__________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
CEAW003209
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Accepted
Maintenance
NOTES:
50 HOUR POST-COMMISSIONING CHECKSHEET

Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.
MACHINE MODEL
(Circle One) 730E 830E 830E-AC 930E-4 Service Meter Reading Date of Inspection Wheel Motor Serial Numbers Location of Machine at Inspection Distributors Name Customers Name Customers Address LH Other RH Dump Body Manufacturer Komatsu Dump Body Style KAC Area Service Manager Signature Date
MACHINE SERIAL NUMBER
ENGINE MODEL
ENGINE SERIAL NUMBER
CUSTOMER UNIT NUMBER
Inspectors Comments:
Inspectors Name Title Signature
KOMATSU USE ONLY: Sheet receiving Date: By: Remark:
Send white reports to:
Manager of Technical Support Komatsu America Corp. 2300 N.E. Adams St., P.O. Box 240 Peoria, IL 61650-0240 U.S.A. Manager of Field Assembly Komatsu America Corp. 2300 N.E. Adams St., P.O. Box 240 Peoria, IL 61650-0240 U.S.A.
Send canary reports to:
Send pink reports to your KAC Regional Service Manager Send gold reports to the Service Manager at the KAC Distributor who sold the truck
CEAW004201
Page 1 of 5
No.
Inspection Item
As Found Condition
Corrective Action
Inspection Around Machine 1 2 3 Parts Hardware Hoses and Cables Visually inspect the truck for loose parts and debris. Visually inspect the truck for missing and/or loose mounting hardware. Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped and clear of sharp edges and other objects that may cause chaffing. Verify the engine oil level is at the proper operating range. Verify the oil level is visible through the upper sight glass with the body down. Visually inspect the anchor hitch pin and anti-sway bar assembly for proper installation and properly tightened hardware. Verify the correct oil is being used and oil is at the proper level. Verify the fuel tank mounting is secure and there are no fuel leaks. Inspect the coolant fill level, cold temperature protection, and DCA additive. Verify proper installation of the steering cylinders, tie rod, and accumulators. Visually inspect the hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations. All hardware must be secure, and no leaks evident. Visually inspect the entire machine for leaks.
4 5 6
Engine Oil Level Hydraulic Oil Level Anchor Pin
7 8 9 10 11
Wheel Motors Fuel Tank Radiator Steering Components Hydraulic Components
12
Leakage
Hardware Torque 1 Steering Arm To Suspension 730E - Verify hardware torque Target: 2705 Nm (1995 ft lbs) 830E, 830E-AC- Verify hardware torque Target: 2705 Nm (1995 ft lbs) 930E-4 - Verify hardware torque Target: 2705 Nm (1995 ft lbs) 2 Steering Cylinder To Frame 730E - Verify hardware torque Target: 464 Nm (342 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 712 Nm (525 ft lbs) 930E-4 - Verify hardware torque Target: 1017 Nm (750 ft lbs) 3 Steering Cylinder To Steering Arm 730E - Verify hardware torque Target: 464 Nm (342 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 712 Nm (525 ft lbs) 930E-4 - Verify hardware torque Target: 1017 Nm (750 ft lbs)
CEAW004201
Page 2 of 5
No.
4
Inspection Item
Tie Rod Pin Retainer
730E - Verify hardware torque Target: 464 Nm (342 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 712 Nm (525 ft lbs) 930E-4 - Verify hardware torque Target: 1017 Nm (750 ft lbs)
As Found Condition
Corrective Action
Front Brake Caliper Mounting (Capscrew with Nut)
730E - Verify hardware torque Target: 1085 Nm (800 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 1085 Nm (800 ft lbs) 730E - Verify hardware torque Target: 1166 Nm (860 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 1166 Nm (860 ft lbs) 730E - Verify hardware torque Target: 780 Nm (575 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 780 Nm (575 ft lbs)
Front Brake Caliper Mounting (Capscrew Only)
Rear Service Brake Caliper Mounting
Rear Brake Adapter Mounting
730E - Verify hardware torque Target: 488 Nm (360 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 488 Nm (360 ft lbs)
Brake Disc To Adapter Mounting
730E - Verify hardware torque Target: 278 Nm (205 ft lbs) 830E, 830E-AC - Verify hardware torque Target: 278 Nm (205 ft lbs)
Cab Compartment 1 2 3 4 5 Horn Back Up Horn Gauges Glass Seat/Seat belts Check for proper tone and volume. Ensure there is no looseness in the horn button. Check for proper tone, volume, and function. Verify all gauges are installed straight and are operating correctly. Verify no cracks exist on cab windows. Ensure all windows are properly sealed. Verify the cab seats and seat belts are in proper working condition.
CEAW004201
Page 3 of 5
No.
Inspection Item
As Found Condition
Corrective Action
Service Inspection 1 Suspension 730E (See Note below) Suspension oiling height: 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear Front charge height: 229 mm (9 in.) at 2758 kPa (400 psi) Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206 psi) 830E, 830E-AC (See Note below) Suspension oiling height: 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear Front charge height: 229 mm (9 in.) at 2689 kPa (390 psi) Rear charge height: 241 mm (9.5 in.) at 1724 kPa (250 psi) 930E-4 (See Note below) Suspension oiling height: 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear Front charge height: 229 mm (9 in.) at 2930 kPa (425 psi) Rear charge height: 190 mm (7.5 in.) at 1482 kPa (215 psi) NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling and charging instructions. 2 Accumulators Verify the nitrogen charge in the accumulators is at 9653 kPa (1400 psi) for all models, for both steering and brakes. Verify that steering system is operating smoothly while turning from lock to lock. Verify the steering system is free of noise and vibration. 4 Lubrication Ensure the automatic lube system contains no air and is filled to the proper level. Ensure the automatic lube system is operating properly and the timer is set as desired. 5 Hydraulic Filters Verify the 50 hour change of all hydraulic filters has been completed. NOTE: Elements are supplied from the factory in the parts crate. 6 Tires Check and record the tire pressure/size/manufacturer for future reference Pressure Size Manufacturer 7 Payload Meter System Calibrate and check payload meter operation per O&M manual. Troubleshoot any error codes and delete after repair. Check drive control system operation per O&M manual. Troubleshoot, correct and delete any error codes. Visually inspect wheel motor armature condition - brush wear, commutator color, etc. Inspect MTA slip rings and brushes. Inspect grid blower motor commutator condition, brush wear, etc. Measure and record sun pinion end play for both RH and LH wheel motors Verify the VHMS system is functioning properly per O&M manual. Troubleshoot and repair any problems.
Steering
8 9
GE Drive/Control System GE Rotating Components (Wheel Motors, MTA, Grid Blower)
10 11
Wheel Motor Sun Pinion End Play VHMS
CEAW004201
Page 4 of 5
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No. 1 2 3 4 5 6 Description of Modification Reason For Installation
ADDITIONAL COMMENTS:______________________________________________________________
__________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW004201
White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager Page 5 of 5
www.komatsuamerica.com
Komatsu America Corp. 2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072
Copyright 2006 Komatsu Printed in U.S.A.

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Field Assembly Manual

SAFETY RULES, TOOLS & EQUIPMENT

Safety Rules, Tools, & Equipment

TOOLS AND EQUIPMENT FOR ASSEMBLY

Thread taps and dies of both inch and metric

Metric sockets and open end wrenches, 6mm to

Inch sockets and open end wrenches up to 1 3/

Torque wrenches - 339 Nm (250 ft lb) with 18:1

Box wrench 1 3/8 in. (Snap-On p/n X440B) with

Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2

Safety Rules, Tools, & Equipment

LIFTING SLING GENERAL INFORMATION

Safety Rules, Tools, & Equipment

Part Number EB1759

Description Nitrogen Charging Kit

Use Suspension & Accumulator Nitrogen Charging

Description Roller Assy.

Use Power Module Remove & Install

Safety Rules, Tools, & Equipment

Part Number PB8326

Description Offset Box End Wrench, 1, 7/16 in.

Part Number TZ2734

Description 3/4 in. Torque Adapter

Part Number TZ2733

Description Tubular Handle

Use Use with PB8326 & TZ2734

Safety Rules, Tools, & Equipment

Part Number BF4117

Description Seal Installation Tool

Seal Installation Tool

Part Number EH4638

Description Sleeve Alignment Tool

Use Steering Linkage and Tie Rod

Part Number EF9302 EB1723 EF9301 WA0010 TL3995 EB4813 SV9812

Use Brake Disc Wear

Safety Rules, Tools, & Equipment

Part Number EF9160

Use Payload Meter Download

Part Number EH7817

Description Alignment Tool

Use Upper Hoist Pin

Part Number PB4684

Description Hydraulic Coupling

Part Number PB9067

Description Bulkhead Connector

Use Battery Jumper

Safety Rules, Tools, & Equipment

Part Number TZ2100 TZ2727 TZ2729

Part Number TZ2730 TZ2731

Description Adapter (1-1 1/2 in.) Adapter (3/4-1 in.)

Use Socket adapter

Part Number WA4826

Description Lifting Eye Bolt

Part Number PC0370

Use Body Retention

Part Number PC0367

Part Number TR0532 TR0533

Description Extension (8 in.) Extension (17 in.)

Safety Rules, Tools, & Equipment

Safety Rules, Tools, & Equipment

Safety Rules, Tools, & Equipment

TRUCK COMPONENTS AND SPECIFICATIONS