CEAW004001 Field Assy Manual

CEAW004001
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS A30318 & UP
®
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-3SE 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 posi-
tion.
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.
FAM0010 Introduction i
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 reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
ii Introduction FAM0010
TABLE OF CONTENTS
SUBJECT PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TRUCK COMPONENT 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
FAM0010 Introduction iii

KOMATSU 930E-3SE
iv Introduction FAM0010
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 Before welding, refer to Special Precautions When
general and must be used in conjunction with all pre- Servicing A 930E Truck, in Section 4.
vailing local rules and regulations.
1. All personnel must be properly trained for the
10. Disconnect the battery charging alternator lead
assembly process.
wire before welding on the frame or its compo-
2. Wear safety equipment such as safety glasses, nents.
hard toe shoes and hard hats at all times during
assembly. 11. When welding, connect the ground cable to the
part being welded. DO NOT allow welding current
3. Thoroughly inspect the assembly site. Remove to pass through bearings, engine, etc.
weeds, debris and other flammable material.
12. DO NOT weld the fuel tank or hydraulic tank
4. Use only solid, hard wood for supports. When
unless the tanks have been properly purged and
using metal support stands, place wood blocks
ventilated.
between the support and the frame to prevent
metal to metal contact. 13. Use the proper tools for the job to be performed.
5. Inspect all lifting devices. Refer to the manufac- Never improvise wrenches, screw drivers, sock-
turer's specifications for correct capacities and ets, etc. unless specified.
safety procedures when lifting components. 14. Lifting eyes and hooks must be fabricated from
6. Perform a daily inspection of all lifting cables and the proper materials and rated to lift the intended
chains. Replace any questionable items. Use load.
cables and chains that are properly rated for the 15. When the weight of any component(s) or any
load to be lifted. assembly procedure is not known, contact your
7. DO NOT stand beneath a suspended load. Use of customer support manager for further information.
guy ropes are recommended for guiding and posi-
tioning a suspended load.
8. Maintain fire control equipment. Inspect fire extin-
guishers 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.
FAM0108 Safety Rules, Tools, & Equipment Page 1-1

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 13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)
door. Approximately 12 x 2.5 m (40 x 8 ft)
14. Set of standard master mechanics hand tools.
2. Cranes
a. Two, 45 metric ton (50 ton) cranes to remove
• Thread taps and dies of both inch and metric
the chassis from the freight trailer and place on sizes.
cribbing. These cranes can also be used to lift • Metric sockets and open end wrenches, 6mm to
the assembled body onto to the chassis. 36mm.
b. One, 109-136 metric tons (120-150 ton) crane. • Inch sockets and open end wrenches up to 1 3/
The crane is needed to turn the body over after 4 in.
completion of the underside welding. A 45 met-
ric ton (50 ton) crane is also required for this • Torque wrenches - 339 N·m (250 ft lb) with 18:1
task. multiplier. Torque wrenches - 339 N·m (600 ft
lb) with 4:1 multiplier. Hydrotorque - 1 1/2 in.
3. One fork lift - 6804 kg (15,000 lb) capacity, with
drive with capability of 5559 N·m (4100 ft lb) or
high lift capability.
greater.
4. Two, 300 amp portable welding units and an oxy-
acetylene cutting set. • Box wrench 1 3/8 in. (Snap-On p/n X440B) with
12 inch extension to tighten ROPS cap screws.
5. One, propane torches for weld preheating.
6. Portable air compressor - 3.5 cmm (125 cfm) and • Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2
690 kPa (100 psi) capacity. 5/8 in. (Snap-On P/N J15042) to tighten front
suspension hardware.
Two, 15 m (50 ft) air hoses.
15. Heavy duty 3/4 in. & 1 in. square drive impact
7. Metal stands and a sufficient amount of wood wrench sets.
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 16. Impact sockets for 3/4 in. & 1 in. square drive
(4 ft. x 6 in. x 6 in.) - such as railway cross ties tools.
8. Tire handler - Wiggins/Iowa Mold Tooling. 17. Special tools (see list, following pages)
9. Miscellaneous air tools 18. Two, hydraulic or pneumatic porta-power jacks,
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft) 4.5 and 9 metric ton (5 and 10 ton)
11. Chains, lifting cables, slings: 19. Various hooks and shackles
• Two, 4 point slings, 3 m (10 ft) in length 20. Miscellaneous: i.e. grinders, containers, rags.
21. Spreader bars for cab and decks.
• Two, 4 point slings, 2 m (6 ft) in length
22. Two ratchet hoists of 2.7 metric ton (3 ton) capac-
• Two, 1 m (4 ft) and two, 2 m (6 ft)
ity.
• Two, 3 m (10 ft) nylon straps 23. Pry bars
• Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of 24. Solvent - 38 liters (10 gal)
rope
25. Paint remover - 19 liters (5 gal)
26. Rust preventive grease
Page1-2 Safety Rules, Tools, & Equipment FAM0108

LIFTING SLING GENERAL INFORMATION

Part Number Description Use
EB1759 Nitrogen Suspension &
Charging Kit 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

EJ2626 Roller Assy. Power Module
(No longer Remove & Install
available as
complete unit)
EJ2271 Roller Mount
PC0706 Bearing
TH9449 Bearing
Retainer
Ring
TG1680 Roller
Retainer
Ring
C1645 Cap screw
0.75 -10 NC
x 2 1/4 in.
C1542 Lockwasher
0.75 in.
EH8686 Roller Ring

PB8326 Offset Box End Miscellaneous
Wrench,
1, 7/16 in.

TZ2734 3/4 in. Torque Miscellaneous
Adapter

TZ2733 Tubular Handle Use with
PB8326 &
TZ2734

BF4117 Seal Installation Front & Rear
Tool Disc Brake
Floating Ring
Seal Installation
ED3347 Seal Installation Rear Axle/Hub
Tool Adaptor Float-
ing Ring Seal
Installation

EH4638 Sleeve Steering Link-
Alignment Tool age and Tie Rod

EF9302 Wear Indicator Brake Disc
Wear
EB1723 Cap, Indicator
EF9301 Pin Indicator
WA0010 O-ring, Indica-
tor Pin
TL3995 O-ring, Indica-
tor Cap
EB4813 Housing, Indi-
cator
SV9812 O-ring, housing

EF9160 Harness Payload Meter
Download

EH7817 Alignment Tool Upper Hoist Pin

PB4684 Hydraulic Miscellaneous
Coupling

PB9067 Bulkhead Battery Jumper
Connector

TZ2100 Socket (1 7/8 in.) Misc.
TZ2727 Socket (2 1/4 in.)
TZ2729 Socket (1 1/4 in.)

TZ2730 Adapter (1-1 1/2 in.) Socket adapter
TZ2731 Adapter (3/4-1 in.)

WA4826 Lifting Eye Bolt Miscellaneous

PC0370 Sling Body Retention

PC0367 Shackle Miscellaneous

TR0532 Extension (8 in.) Miscellaneous
TR0533 Extension (17 in.)

TRUCK COMPONENTS AND SPECIFICATIONS
Truck And Engine Operator's Cab
The 930E-3SE dump truck is an off-highway, rear The operator's cab has been engineered for operator
dump truck with AC electric drive. The gross vehicle comfort and to allow for efficient and safe operation of
weight is 1,112,000 lbs. (504 400 kg). The engine is a the truck. The cab provides for wide visibility, with an
Komatsu SSDA18V170 rated @ 3500 HP (2611 kW). integral 4-post ROPS/FOPS structure, and an
advanced analog operator environment. It includes a
Alternator (GE-GTA39) tinted safety-glass windshield, power-operated side
windows, a deluxe interior with a fully adjustable seat
The diesel engine drives an in-line alternator at engine and lumbar support, a fully adjustable tilt/telescope
speed. The alternator produces AC current which is steering wheel, controls mounted within easy reach of
rectified to DC within the main control cabinet. The rec- the operator, and an analog instrument panel which
tified DC power is converted back to AC by groups of provides the operator with all instruments and gauges
devices called “inverters”, also within the main control which are necessary to control and/or monitor the
cabinet. Each inverter consists of six “phase modules” truck's operating systems.
under the control of a “gate drive unit” (GDU). The
GDU controls the operation of each phase module. Power Steering
Each phase module contains an air-cooled solid-state The truck is equipped with a full time power steering
switch referred to as a “gate turn-off thyristor” (GTO). system which provides positive steering control with
The GTO cycles on and off at varying frequencies to minimum operator effort. The system includes nitro-
create an AC power signal from the DC supply. gen-charged accumulators which automatically provide
emergency power if the steering hydraulic pressure is
The AC power signal produced by each inverter is a reduced below an established minimum.
variable-voltage, variable-frequency signal (VVVF).
Frequency and voltage are changed to suit the operat- Dynamic Retarding
ing conditions.
The dynamic retarding is used to slow the truck during
Cooling air for the control / power group and wheel normal operation or control speed coming down a
motors, as well as the alternator itself, is provided by grade. The dynamic retarding ability of the electric sys-
dual fans mounted on the alternator shaft. tem is controlled by the operator through the activation
of the retarder pedal (or by operating a lever on the
AC Induction Traction Motorized Wheels steering column) in the operators cab and by setting
the RSC (Retarder Speed Control). Dynamic retarding
The alternator output supplies electrical energy to the
is automatically activated, if the truck speed goes to a
two wheel motors attached to the rear axle housing.
preset overspeed setting.
The motorized wheels use three-phase AC induction
motors with full-wave AC power.
Brake System
The two wheel motors convert electrical energy back to
Service brakes at each wheel are oil-cooled multiple
mechanical energy through built-in geartrains within
disc brakes applied by an all-hydraulic actuation sys-
the wheel motor assembly. The direction of the wheel
tem. Depressing the brake pedal actuates both front
motors is controlled by a forward or reverse hand
and rear brakes, after first applying the retarder. All
selector switch located on a console to the right side of
wheel brakes will be applied automatically, if system
the operator.
pressure decreases below a preset minimum.
Suspension The parking brake is a dry disc type, mounted inboard
on each rear wheel motor, and is spring-applied and
Hydrair®II suspension cylinders located at each wheel
hydraulically-released with wheel speed application
provide a smooth and comfortable ride for the operator
protection (will not apply with truck moving).
and dampens shock loads to the chassis during load-
ing and operation.
FAM0209 Truck Components And Specifications Page 2-1

930E-3 MAJOR COMPONENTS
Page 2-2 Truck Components And Specifications FAM0209

SPECIFICATIONS
These specifications are for the standard 930E-3SE. Customer options may change this listing.
ENGINE SERVICE CAPACITIES

Komatsu SSDA18V170 . . . . . . . . . . . . . . . . . . . . . . . . U.S. Gallons . . . . Liters
Number of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 18 Crankcase (Includes lube oil filters)
Operating Cycle . . . . . . . . . . . . . . . . . . . . . . 4-Stroke SSDA18V170 . . . . . . . . . . . . . 90 . . . . . . . . . . . .341
Rated Brake HP . . . . 3500HP (2611kW)@1900RPM Cooling System . . . . . . . . . . . . 190. . . . . . . . . . . .719
Flywheel HP . . . . . . . . . . . . . . . . 3429HP (2558 kW) Fuel . . . . . . . . . . . . . . . . . . . . 1200 . . . . . . . . . .4542
Weight (Wet)* . . . . . . . . . . . . . 22,266 lbs (10 100 kg) Hydraulic System . . . . . . . . . . 350 . . . . . . . . . .1325
* Weight does not include Radiator, Sub-frame, or Alternator Wheel Motor Gear Box . . . .25/Wheel . . . . 95/Wheel
AC ELECTRIC DRIVE SYSTEM HYDRAULIC SYSTEM

AC/DC Current Hoist & Brake Cooling Pump . . . . . . . . Tandem Gear
Alternator . . . . . . . . . . . . . General Electric GTA - 39 Rated at . . . . . . . . . . . . . . . . . 246 GPM (1022 l/min)
Dual impeller, In-line Blower 16,000 cfm (453 m³/min) . . . . . . . . . . . @ 1900 RPM & 2500 psi (17. 2 MPa)
Motorized Wheels . . . . AC Induction Traction Motors Steering/Brake Pump Pressure Compensated Piston
. . . . . . . . . . . . . . . . . . . . . Wheel Slip/Slide Control Rated at . . . . . . . . 66 GPM (250 l/min) @ 1900 RPM

. . . . . . . . . . . . . . . . . . . . . . & 2750 psi (18. 9 MPa)
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . 32.62:1
Relief Pressure - Hoist . . . . . . . 2500 psi (17.2 MPa)
Maximum Speed . . . . . . . . . . . 40 MPH (64.5 km/h)
Relief Pressure-Steering & Brake Pump
*NOTE: Wheel motor application depends upon GVW, haul road grade, haul
road length, rolling resistance, and other parameters. Komatsu & G.E. must . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.6 MPa)
analyze each job condition to assure proper application.
Hoist Cylinders (2) . . . . . . . . . . . . 3-Stage Hydraulic
Tank - Vertical / Cylindrical . . . . . . . Non-Pressurized
DYNAMIC RETARDING
Tank Capacity . . . . . . . . . 250 US Gal. (947 Liters)
Electric Dynamic Retarding. . . . . . . . . . . . . Standard
Filtration . . . . . . . . . . . In-line Replaceable Elements
Maximum Retarding . . . . . . . . . . 5400 HP (4026 kW)
Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Continuous . . . . . . . . . . . . . . . . . 3900 HP (2909 kW)
Hoist & Steering Filters . . . . . Beta 12 Rating = 200
Continuously Rated High-density Blown Grids with
Retard at Engine Idle & Retard in Reverse Propul- . . . . . . . . . . . . . . . . . . Dual, In-Line, High Pressure
sion.
SERVICE BRAKES
BATTERY ELECTRIC SYSTEM All Hydraulic Actuation . . . . . . . with Traction System
Batteries . . . . . . . . . . . . . . . . . . . . bumper-mounted . . . . . . . . . . . . . . . . . . . . . Wheel Slip/Slide Control
4, 8D & 2, 30H 12 Volt Batteries (Series/Parallel) Front & Rear Oil-Cooled Multiple Discs each wheel.
. . . . . . . . . . . .220 Ampere-Hour Capacity batteries Total Friction Area /Brake . . . 15,038 in² (97 019 cm²)
. . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch Maximum Apply Pressure . . . . 2500 psi (17 238 kPa)
Alternator . . . . . . . . . . . 24 Volt, 260 Ampere Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
Cranking Motors (2) . . . . . . . . . . . . . . . . . . . . 24 Volt

STEERING WEIGHT DISTRIBUTION
Turning Circle (SAE) . 97 ft. 7 in. (29.7 m) EMPTY. . . . . . . . . . . . . . . Pounds . . . . . Kilograms
Twin hydraulic cylinders with accumulator assist to Front Axle (49.3%) . . . . . . . . 234,314 . . . . . .106 284
provide constant rate steering. Emergency power
Rear Axle (50.7%) . . . . . . . . 235,253 . . . . . .106 710
steering automatically provided by accumulators.
Total (50% Fuel) . . . . . . . . . . 469,567 . . . . . .212 994
STANDARD DUMP BODY* LOADED

Front Axle (33.0%) . . . . . . . . 366,280 . . . . . .166 143
Capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle (67.0%) . . . . . . . . 745,720 . . . . . .338 257
Struck . . . . . . . . . . . . . . . . . .224 yds³ . . . . . . .171 m³
Total . . . . . . . . . . . . . . . . . . 1,112,000. . . . . .504 400
Heaped @ 2:1 (SAE) . . . . . .276 yds³ . . . . . . . 211 m³
Width (Inside). . . . . . . . . . . 26 ft. 9 in. . . . . . .(8.15 m) Not to exceed 1,112,000 lbs. (504 400 kg), including
options, fuel, and payload. Weights in excess of this
Depth . . . . . . . . . . . . . . . . . 10 ft. 7 in. . . . . . . .(3.2 m)
amount require factory approval.
Loading Height. . . . . . . . . . 23 ft. 2 in.. . . . . .(7.06 m)
Dumping Angle . . . . . . . . . . . 45°
* OPTIONAL capacity dump bodies are available.
TIRES
Radial Tires (standard). . . . 53/80 R63
Rock Service, Deep Tread . Tubeless
Rims. . . . . . . (patented Phase I New Generation™
rims)

OVERALL TRUCK DIMENSIONS

NOTES

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 compo-
nents.
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 KILOGRAMS POUNDS
CHASSIS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,630 . . . . . . . . . . . . . . . . . . . . . . 5,800
Tire 53/80 R63 (148" OD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6,939 . . . . . . . . . . . . . . . . . . . . . 15,300
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24,578 . . . . . . . . . . . . . . . . . . . . . 54,185
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,690 . . . . . . . . . . . . . . . . . . . . . . 3,725
DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,684 . . . . . . . . . . . . . . . . . . . . . . 3,713
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,008 . . . . . . . . . . . . . . . . . . . . . . 2,222
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 . . . . . . . . . . . . . . . . . . . . . . .1410
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . .550
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636 . . . . . . . . . . . . . . . . . . . . . . 1,402
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 . . . . . . . . . . . . . . . . . . . . . . . .604
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776 . . . . . . . . . . . . . . . . . . . . . . 1,710
RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653 . . . . . . . . . . . . . . . . . . . . . . 1,440
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 . . . . . . . . . . . . . . . . . . . . . . . .344
RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . .150
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 . . . . . . . . . . . . . . . . . . . . . . . .395
Vertical Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 . . . . . . . . . . . . . . . . . . . . . . . .125
FAM0309 Major Component Weights Page 3-1

POWER MODULE
RH Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 . . . . . . . . . . . . . . . . . . . . . . . . 370
LH Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264 . . . . . . . . . . . . . . . . . . . . . . . . 582
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955 . . . . . . . . . . . . . . . . . . . . . . .2,105
Engine Sub-Module (less Grille). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,200 . . . . . . . . . . . . . . . . . . . . . . 42,329
Air Cleaner Assembly (Single) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 . . . . . . . . . . . . . . . . . . . . . . . . 170
Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,742 . . . . . . . . . . . . . . . . . . . . . . .6,045
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,045 . . . . . . . . . . . . . . . . . . . . . . .6,713
Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 . . . . . . . . . . . . . . . . . . . . . . . . 445
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,710 . . . . . . . . . . . . . . . . . . . . . . 10,384
Engine (Komatsu SSDA18V170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,342 . . . . . . . . . . . . . . . . . . . . . . 22,800
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,091 . . . . . . . . . . . . . . . . . . . . . . .4,609
HYDRAULIC COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . . . . . . . . . . . . . . . 380
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .962 . . . . . . . . . . . . . . . . . . . . . . .2,120
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 . . . . . . . . . . . . . . . . . . . . . . . . 320
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .684 . . . . . . . . . . . . . . . . . . . . . . .1,508
FRONT AXLE COMPONENTS

Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,496 . . . . . . . . . . . . . . . . . . . . . . .3,300
Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,393 . . . . . . . . . . . . . . . . . . . . . . 11,890
LH Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333 . . . . . . . . . . . . . . . . . . . . . . . . 734
RH Steering Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333 . . . . . . . . . . . . . . . . . . . . . . . . 734
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,790 . . . . . . . . . . . . . . . . . . . . . . .6,150
Page 3-2 Major Component Weights FAM0309

REAR AXLE COMPONENTS

Rear Suspension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,120 . . . . . . . . . . . . . . . . . . . . . . 2,470
Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 . . . . . . . . . . . . . . . . . . . . . . . .350
Wheel Motor Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . . . . . . . . . . . . . . . . . . . . .174
Pivot Eye Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 . . . . . . . . . . . . . . . . . . . . . . . .763
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6,600 . . . . . . . . . . . . . . . . . . . . . 14,550
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 . . . . . . . . . . . . . . . . . . . . . . . .330
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . .19,900 . . . . . . . . . . . . . . . . . . . . . 43,872
Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 . . . . . . . . . . . . . . . . . . . . . . . .940
FAM0309 Major Component Weights Page 3-3

NOTES
Page 3-4 Major Component Weights FAM0309

FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at WELD PROCEDURES
initial field assembly or during normal maintenance
repairs, special procedures must be followed. Electric arc welding, either the semi-automatic “MIG”
(GMAW), Flux Core (FCAW), or “Stick” electrode
Due to the continuous program of research and welding (SMAW), are approved processes for field
development, periodic revisions may be made to this installation and maintenance welding. Welding of
publication. It is recommended that customers con- highly stressed structural members such as castings,
tact their distributors for information on the latest revi- torque tubes, top and bottom plates on the frame
sion. rails, and the curved intersection points of frames
The welding information contained in this chapter is should be done with the specific detailed instructions
general information that must be followed unless oth- from Komatsu Product Service. See Annex A for
erwise specified in a detailed repair procedure pro- repair procedures. These repair procedures are
vided on an engineering drawing or a detailed detailed instructions for most high stressed structural
specific repair procedure. Additional specific informa- members.
tion, or detailed instructions can be obtained through
your local Komatsu customer support manager.
APPROVED CONSUMABLES
GMAW - LW102-15 or ER80S-D2
WELDER QUALIFICATION AND
TRAINING FCAW - E70T-5, E71T-8, or E71T8-NI1
The welding technique must be of the highest stan- SMAW - E7018-1, E8018-C1, or E8018-C3
dard to produce the soundest weld possible. Only
welders who have been trained and qualified for
structural steel welding in all positions, in conform-
ance with the American Welding Society (AWS) D1.1
WELD QUALITY REQUIREMENTS
or (AWS) D14.3 only, are allowed to perform the 1. Each weld must be homogeneous with low
welding. The welding instructions for field assembly porosity, free from cracks, and slag inclusions.
of Komatsu components are normally provided by 2. Each weld must have complete fusion between
engineering drawings. Additional detailed welding the base metal and weld metal added by the
instructions for field repairs are provided in the field electrode.
repair manual SEB14001. A full understanding of the
3. All welds must be reasonably smooth, without
AWS standard welding symbols is necessary to per-
excessive deformity, and all craters filled. No
form and inspect such field welds. Weld sizes speci-
cracks are permitted.
fied on the drawings are intended to reflect minimum
requirements. 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. Exces-
sive 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 criti-
cal welds must be reworked by the application
of welding an additional cover pass. It is impor-
tant that this pass is blended with the existing
weld.
FAM0403 Field Welding Procedures 4-1

6. When welding in the vertical position, always 2. Low Ambient Temperature - DO NOT weld in
weld using the vertical up technique. Large temperatures below 50°F (10°C). At low tem-
wash weld weaves should not be used when perature conditions, preheating of all welding
welding on truck frames. Properly applied multi- joint work areas is required. See preheat and
ple pass welding is the required procedure on post heating requirements as detailed in Annex
truck frames. A.
7. Slag is to be removed from all weld beads, and 3. Weld Cooling - Protect the weld area from a
must be completely removed before each pass rapid cooling rate. Heat retardation may be
in a multiple pass procedure. It is also required accomplished through the use of heat lamps,
that all slag is removed and tie in all areas. torches, insulating blankets, etc.
Grind all welds where a weld crosses or inter- 4. Moisture - Any moisture on the steel surfaces to
sects with another weld. 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
MATERIALS, CONTROLS, AND affect weld quality.
PRECAUTIONS 5. Foreign Materials - Any foreign substances
The steel used in the fabrication of all Komatsu (dirt, paint, rust, scale, and carbon deposits
equipment is of high strength low alloy (HSLA) mate- from cuttings) must be removed prior to weld-
rial of different grades. The standard dump body ing. Clean all weld areas and surfaces with a
main plates are made from abrasion resistant materi- grinder to ensure that all foreign materials have
als. These materials offer themselves very well to been removed.
welding during fabrication, and repair.
The welding consumables are often supplied by
Komatsu America Corp. with the new equipment as WELD INSPECTION
part of the field welding / assembly package. For field All welding repairs are subject to inspection by a
welding and repairs, the approved consumables as Komatsu appointed inspector or laboratory to insure
detailed, should be procured from a local, reliable quality. After the weld has been made it can be
supplier. Other highly specialized welding consum- inspected by a number of non-destructive evaluation
ables are available but have limited use on Komatsu techniques. The inspections can include any of the
structural components. Approval is required from methods listed below. All assembly welds and weld
your Komatsu customer support manager. repairs that are deemed unacceptable by the inspec-
Control of the welding area environment is essential tor must be corrected at no additional cost to
for producing proper and sound welds. Essentially, Komatsu. All weld repairs are also subject to addi-
five areas require attention and control. tional inspection.
1. Air Movement - Avoid areas where air move- 1. Visual Inspection - This is the process of look-
ment from wind, drafts, or blowers is prevalent. ing for potential defects such as undersized
This is particularly important when a shielding welds that can be checked with weld gauges
gas is being used as part of the welding pro- for, surface cracks, surface porosity, craters,
cess. and undercuts.
4-2 Field Welding Procedures FAM0403

RECORDS
2. Dye Penetrant Inspection - This is an easily
Komatsu requires record keeping of all welding work.
applied process which indicates cracks or sur-
This information is valuable when personnel or job
face conditions. The process is relatively inex-
conditions change. The service and warranty depart-
pensive, but does not produce a permanent
ments of Komatsu must be provided with inspection
record except by normal photography.
reports and photographs of the weld area before,
3. Fluorescent Penetrant Inspection - Similar to during, and after the repair. The photographs must
dye penetrant inspection. This process uses a be clear and close enough to show the weld joint
black (ultraviolet) light for increased efficiency preparation complete, with backer bars installed, etc.
and accuracy. just prior to welding. These photos easily identify if
4. Magnetic Particle Inspection - This process the required preheating and post heating have been
requires special equipment that is usually more done with a three inch circumference around the
costly than the dye penetrant inspections. This weld repair area. Without this documentation,
process does not provide a permanent record Komatsu will not cover any weld repair claim made
except by normal photography. under warranty. No exceptions will be made.
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, ANNEX A
operator records with equipment settings and The following are general repair procedures, which
test results are normally recorded. must be followed for all repair and rework of major
6. X-Ray Inspection - This process provides a load carrying members on Komatsu equipment.
view of the weld and base materials but it is
highly specialized. This procedure provides a
permanent visual record, but is more expensive 1. The repair or rework area must be protected
than most other inspection techniques. from wind and moisture during the entire proce-
dure. If the repair work is to done outside addi-
tional precautions must be taken to protect the
weld repair process from outside elements. All
welding should be done at an ambient tempera-
ture of 10°C (50°F) 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.

3. Air arc the entire crack leaving a V-shape joint. 9. All welds are to be made with approved con-
The depth of the V (or U shaped) joint will be sumables only. The SMAW (Stick) welding rod
determined by the depth of the crack. The width must be used within four hours after being
to depth ratio should be approximately 1.25:1 removed from a new sealed container or from a
and never less than 1:1. All cracks through the 52°C (125°F) minimum drying oven. Any rod
parent material will require a slightly wider root that exceeds this exposure time must be dried
opening than the original, usually 6 mm (0.25 for one hour at 427°C (800°F) before being
in.) to allow the installation of a backup strip. used. Keep all weld starts and stops to a mini-
Backup strips are required for all cracks that mum.
have gone through the parent material and can- 10. When the weld is complete, immediately (before
not be welded from both sides. If a weld repair the weldment cools) post heat the entire weld
allows access to both sides of the plate, no area to 150°C (300°F). Even if the area is over
backup strip is required as long as complete 150°C (300°F) heat must be applied to maintain
weld penetration is achieved. If backup strips this temperature for 15 minutes, and then allow
are not used, the surface profile on both sides it to cool slowly. In some cases this might
must be ground smooth with no undercut. Doc- require wrapping with insulation blankets.
umentation must support this repair. Photo-
graphs of surface condition are required by the 11. Grind all butt-welded repairs smooth using 36 or
service and warranty departments of Komatsu. finer grit grinding material. All grinding marks
should be parallel to the direction of primary
4. Use dye penetrant to ensure the cracks are
stress if possible (and if known).
completely removed.
5. After air arcing and inspections (Steps 3 & 4) all 12. Hammer peen the toes of repair fillet welds as
areas cut by the air arc should be cleaned thor- detailed in Annex B, see attached.
oughly with a grinder to remove all possible car- 13. Inspect repaired areas (for surface defects)
bon deposits and dye penetrant. using magnetic particle or dye penetrant
6. Fill gouges with weld and grind all surfaces inspection procedures.
smooth to avoid defects in the new weld. 14. If surface defects are found, remove all defects
7. Grind all surfaces to be welded so they are free by grinding to a maximum depth of 1.5 mm
of slag, rust, and any other foreign materials. (0.06 in.). Larger defects must be removed as
8. Preheat the entire weld joint area until the sur- per the above mentioned procedures. All spot
rounding surface area reaches 150°C (300°F) welding also requires preheating and post heat-
at a distance of 76 mm (3 in.) from all areas to ing.
be welded.

ANNEX B
1.0 TOE HAMMER PEENING 2.0 TOE GRINDING WITH A ROTARY BURR
Equipment:
1. Hand held pneumatic hammer Equipment:
2. Adequate air supply 1. High speed rotary air tool (15,000-20,000 rpm)
3. Adequate lighting 2. Tungsten carbide rotary burr 13 mm (0.50 in.)
4. 6 mm (0.25 in.) diameter spherical tip bit diameter with 13 mm (0.50 in.) spherical tip
5. Protective clothing, gloves, includes eye, face, 3. Adequate air supply
and ear protection. 4. Adequate lighting
5. Protective clothing, gloves, includes eye, face,
Procedure
and ear protection
1. The toe of the weld should serve as a guide for
the peening tool resulting in the area of defor- Procedure
mation being approximately equally divided 1. The toe of the weld should serve as a guide for
between the base material and the weld metal the burr tool resulting in the material removed
face to the specified depth and not to exceed 5 being approximately equally divided between
mm (0.19 in.) in width. Refer to Figure 4-1. the base material and the weld metal face to the
NOTE: Peening shall only be performed after weld specified depth and not exceed 8 mm (0.31 in.)
acceptance by visual inspection. in width. Refer to Figure 4-2.
2. The weld must have a smooth profile and the 2. The weld must have a smooth profile and the
toe must have a good transition to the parent toe must have a good transition to the parent
material (no overlap) before the peening opera- material (no overlap) before the grinding opera-
tion is performed. Grinding the weld face and tion is performed. Grinding the weld face and
toe area is permitted to correct unacceptable toe area is permitted to correct unacceptable
conditions. Visual inspection/acceptance is to conditions. Visual inspection/acceptance to be
be done after peening with the appropriate done after grinding with the appropriate radius
radius and depth gauge. and depth gauge.
3. Hold the hammer tool at approximately one half 3. The axis of the tool should be maintained at
the included angle between the weld face and about 45° to the parent plate and inclined at
the parent material and perpendicular to the about 45° to the direction of travel. The depth of
direction of travel. This will normally require the grinding must be between 0.8 mm to 1.0
approximately four passes of the peening tool mm (0.030 to 0.040 in.). The final surface must
with the pressure of near full operator weight be clean, smooth and free of all traces of under-
being applied. The depth of the indentation cut or slag.
must be between 0.6 mm to 0.8 mm (0.02 to
0.03 in.).

FIGURE 4-1. TOE HAMMER PEENING

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

BIBLIOGRAPHY SPECIAL PRECAUTIONS WHEN
SERVICING A 930E TRUCK
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earthmoving and Consult a qualified technician, specifically trained for
Construction Equipment servicing the A/C drive system, before welding on the
Metals and How to Weld Them - James F. Lincoln truck.
Arc Welding Foundation. Cleveland, Ohio
The following procedures must be followed to ensure
Procedure Handbook of Arc Welding - Lincoln Elec- the safety of maintenance personnel and to help pre-
tric Company, Cleveland, Ohio vent damage to the equipment.
American Welding Society - Welding Handbook
British Standard BS5135 - Metal Arc Welding of Car-
bon and Carbon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The Anytime the engine is on:
Welding Institute, F. R. Coe, Author
• 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 retard-
ing grids, wheel motors, alternator, and power
cables connecting these devices are safe to
work on.

Locate the GF cut-out switch in the access General Welding Guidelines
panel on the left side of the main control cabi- 1. Open the battery disconnect switches and dis-
net. Place the switch in the CUTOUT position. connect the battery charging alternator lead
This will prevent the alternator from re-energiz- wire.
ing and creating system voltage until the switch
is returned to its former position. 2. Disconnect all electrical harnesses from the
Engine Control System (ECS). The ECS is
After repairs, replace all covers and doors and located inside the electrical cabinet behind the
place the GF cutout switch and battery discon- operator's cab. Disconnect the ground strap
nect switches in their original positions. Recon- from the ECS.
nect all harnesses prior to starting the truck. 3. Fasten the welding machine ground (-) lead to
Leave the drive system in the rest mode until the piece being welded. The grounding clamp
the truck is to be moved. must be attached as near as possible to the
4. If the red lights on the exterior of the control weld area.
cabinet and/or the back wall of the operator's 4. DO NOT weld on the rear of the control cabinet!
cab continue to be illuminated, a fault has The metal panels on the back of the cabinet are
occurred. part of the capacitors and cannot be heated.
Leave all cabinet doors in place. DO NOT touch 5. DO NOT weld on the retard grid exhaust lou-
the retard grid elements. DO NOT disconnect vers.
any power cables or use them as hand or foot 6. Some power cable panels throughout the truck
holds. 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
Notify your Komatsu customer service manager
clamps or hardware. Inspect power cable insu-
immediately. Only qualified personnel, specifi-
lation prior to servicing the cables and prior to
cally trained for servicing the A/C drive system,
returning the truck to service. Discard cables
may perform this service.
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.

NOTES

RECEIVING & ASSEMBLY PREPARATION
1. Inspect all components for possible shipping 5. Clean all mounting surfaces on the chassis and
damages. Note any damage found and report to on the individual components.
shipping agent. 6. Check all electrical connectors and verify they
2. Spread out all parts and organize per unit num- are free of paint and/or corrosion. Clean any
ber. Check for missing parts. List the unit num- connector with questionable electrical continu-
ber of all major components. Verify the cab and ity.
decks are with the correct chassis. 7. Check all factory installed components for the
3. Install support blocks under the chassis. The proper tightening torque.
support blocks must be approximately 84 cm 8. Arrange the work site as shown on the following
(33 in.) high. page.
4. Install support blocks under the rear axle hous-
ing. 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.
FAM0503 Receiving & Assembly Preparation Page 5-1

ASSEMBLY LAYOUT
Page 5-2 Receiving & Assembly Preparation FAM0503

CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines BASIC ASSEMBLY PROCEDURE
varies. Photographs or illustrations used in the fol-
lowing procedures are provided as general guide- 1. Site preparation
lines only. Actual assembly may be different, but this 2. Unload truck components
general procedure provides a basic outline for 3. Assemble the chassis
assembly. 4. Weld the body
Items like the hydraulic tank and the accumulators NOTE: Chassis assembly and body welding may be
may have been removed for shipping and will have to done in either order, or simultaneously. The most
be locally installed. logical order depends on available resources such as
Each shipment may be different, depending on the cranes, welders, assemblers, etc.
truck configuration and destination. 5. Static checkout (electrical & mechanical)
6. Install the body
7. Dynamic checkout (electrical & mechanical)
RECOMMENDED ASSEMBLY DATA 8. Site cleanup
1. Service Report (Pre-Delivery)
2. Acknowledgement of Receipt of Company War-
ranty
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, Appen-
dix)
10. Propulsion System Checkout Procedure (avail-
able 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 (avail-
able in Section 10 of this manual)
FAM0609 Chassis Assembly Page 6-1

ORDER OF ASSEMBLY
The assembly procedure is organized in levels. Gen- LEVEL 3
erally, the tasks to be done at a given level may be
1. Spindles/Hubs
performed in any convenient order or simultaneously.
However, all tasks in that level must be completed 2. Steering Cylinders
before proceeding to the next higher level. Each level 3. Tie Rod
depends on the installation of components from the
previous level. LEVEL 4
NOTE: As stated earlier, shipping and packaging of 1. LH Deck
large machines will vary. Some of these steps may 2. RH Deck/Grid Box
change due to different shipping configurations and/
3. Operator Cab
or truck options.
LEVEL 5
1. Exhaust Pipes
LEVEL 1 2. Weld Uprights
1. Chassis - Unload and crib for assembly. 3. Blower - Air Intake Ductwork
2. Auxiliary Control Cabinet (temporary) 4. Wheel Motors
3. Deck Support (on horsecollar over suspension).
NOTE: It is easier to install and weld the deck LEVEL 6
supports before the front suspensions are installed. 1. Front Tires
However, do not install the deck supports first, unless 2. Rear Tires
there is a suitable means of installing the suspension
3. Hoist Cylinders
with the deck support in place.
4. Rear Suspension LEVEL 7
5. Hydraulic Tank
1. Clearance Lights
6. Fuel Tank
2. Body Pads/Shims/Guides
7. Front Suspensions
3. Front Mud Flaps
8. Diagonal Ladder
9. Uprights/Air Cleaners LEVEL 8
10. Diagonal Support Beams (leave loose until left 1. Dump Body Installation
deck is bolted in place)
LEVEL 9
NOTE: Do not weld the air cleaner / uprights until all 1. Hoist Cylinders
decks and the operator cab are installed. Ratchet
2. Rock Ejectors
hoists may be required to help tie all the structures
together for a proper fit. 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 FAM0609

CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
LEVEL 10
an actual truck assembly. Assembly at another loca-
1. Clean the Truck tion may be different. However, this outline will pro-
2. Decals vide a general basis for assembly.
3. Lighting Wiring
4. Charge Suspensions
5. Charge Accumulators
6. Add Fluids
7. Charge the Air Conditioning System Follow all safety recommendations in this man-
ual. Follow all local, state, and federal regula-
NOTE: Prior to starting the engine, verify that the tions.
steering pump case is full of oil.
LEVEL 11 In the procedures that follow, many very heavy com-

ponents will be required to be lifted into place and
1. System Checkouts secured.
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 manufacturer’s 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.

GENERAL PRECAUTIONS AND
INSTRUCTION
1. Clean and remove all foreign material from
component mounting surfaces.
Disconnect the battery cables before welding on 2. Mount the front suspensions first so that deck
the truck. Failure to do so may seriously damage substructures can be installed while other com-
the batteries and electrical equipment. Discon- ponents are installed.
nect the battery charging alternator lead wire 3. DO NOT weld the front uprights until all upper
before welding on the frame or its components. decks are installed.
Fasten the welding machine ground cable to the 4. Install the fuel return hose on the rearward most
component being welded. fitting on the fuel tank.
DO NOT allow welding current to pass through 5. Torque the deck mounting bolts before the
bearings. exhaust tubes, etc. are installed.
DO NOT lay welding cables over truck electrical 6. Verify all electrical connectors are free from
cables and harnesses. Welding voltages could be paint and/or corrosion. Clean any connector
induced into the truck wiring and cause damage that may be questionable.
to components. 7. Do not torque the diagonal ROPS beam until
after the operator cab & LH air intake tubes are
DO NOT weld on the fuel tank or the hydraulic
in place.
tank unless they have been properly purged and
ventilated. 8. Before installing the cab to the substructure, tap
all threaded holes to remove paint.
Maintain fire control equipment. Inspect fire
9. Verify all wiring is properly connected before
extinguishers regularly to ensure they are fully
attempting to start the engine.
charged and in good working condition.
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
Mark cap screws and nuts with paint or ink after nitrogen pressure and oil level in the cylinder.
tightening to the specified torque. This method 13. Brake accumulators are normally charged with
provides verification that the hardware has been nitrogen when shipped from the factory. Use
properly tightened. 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 weld-
ing. Connect the weld ground near the weld
area.

NOTES

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 installa-
tion of truck components.
Thoroughly clean the chassis.

FIGURE 6-1.
FIGURE 6-2.

2. Remove the auxiliary control cabinet (Figure 6-3) from the LH frame rail where it is supported and tack welded
for shipment. The weight of the auxiliary control cabinet is approximately 202 kg (445 lb).
The electrical wiring for the auxiliary control cabinet has already been connected to the truck and cannot eas-
ily be disconnected. Temporarily place the auxiliary cabinet on the control cabinet support to allow the LH
deck support to be placed into position and welded to the horsecollar (Figure 6-4).

FIGURE 6-3.
FIGURE 6-4.

3. Lift the LH deck support into position. The weight of the deck support is approximately 636 kg (1402 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 6-5 thru 6-10.
Repeat for the RH deck support. The weight of the deck support is approximately 274 kg (604 lb).

FIGURE 6-5.
FIGURE 6-6.

FIGURE 6-7.
FIGURE 6-8.

FIGURE 6-9.
FIGURE 6-10.

4. Position the top rear suspension eye between the ears on the frame, as shown in Figure 6-11.
5. Lubricate pin (1). Align the retaining cap screw hole with the hole in the mounting bore, and partially push the
pin in until secure.
6. 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 6-11.
7. Install cap screw (2) and locknut (3). Tighten to 465 N·m (343 ft lb).

FIGURE 6-11. REAR SUSPENSION MOUNTING PIN
(Typical, Top and Bottom)
1. Pin 6. Bearing
2. Retainer Cap Screw 7. Cap Screw
3. Locknut 8. Washer
4. Bearing Spacer 9. Sleeve
5. Retainer Ring

8. Clean the mounts for the hydraulic tank.
9. Lift the tank into position. (Figure 6-12). The weight of the hydraulic tank is approximately 684 kg (1508 lb).
Tighten the four mounting cap screws near the top of the tank to 712 ± 71 N·m (525 ± 52 ft lb).
Tighten the two mounting cap screws near the bottom of the tank to 800 ± 80 N·m (590 ± 59 ft lb).
10. Clean the mounts for the fuel tank and lift the tank into position. (Figure 6-13) 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 N·m (525 ± 52 ft lb).
Tighten the four mounting cap screws near the bottom of the tank to 420 ± 42 N·m (310 ± 31 ft lb).

FIGURE 6-12.
FIGURE 6-13.

10. Connect the piping to the hydraulic tank and properly tighten all fittings.
Refer to Figures 6-14 and 6-15.
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.

FIGURE 6-14.
FIGURE 6-15.

11. Install the filters onto the brackets on the back side of the fuel tank. Connect the fuel supply and return lines to
the fuel tank.
Refer to Figure 6-16.
12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.

FIGURE 6-16.
FIGURE 6-17.

13. Lift the front suspension into position. Refer to Figure 6-20. 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-of-
the-nut" method as described below.
"Turn-Of-The-Nut" Tightening Procedure

a. Tighten all 14 cap screws (1, 6, 8, Figure 6- 1.) Mark a reference line on a corner of the
21) to 542 ± 5 N·m (400 ± 40 ft lb). hexagonal cap screw head or nut and the
mounting surface opposite this corner, as
b. Maintain this torque on the top two corner shown. Then mark the position located
cap screws and the bottom, outer four cap 60° or 120° clockwise relative to the first
screws (without spacers). reference line on the mounting surface.
c. Loosen the eight remaining cap screws and Refer to Figures 6-18 and 6-19.
then tighten again as follows: 2.) Scribe a reference mark at the opposite
d. For the four cap screws (1, Figure 6-21) at end of the turning member to ensure that
the upper mount, initially tighten the cap either the cap screw head or nut, remains
screws to 95 N·m (70 ft lb), then advance stationary.
the cap screw head 60° as outlined in Steps 3.) Each corner of a hexagon represents 60°.
d-1 through d-3. Refer to Figure 6-18. The turning member, either the cap screw
head or nut, is turned until the marked
corner is adjacent with the marked refer-
ence line. Ensure that the opposite end of
the turning member has NOT turned dur-
ing 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 6-18. 60 DEGREE ADVANCE 1.) Tighten the top two corner cap screws to
95 N·m (70 ft lb), then advance the cap
screw heads 60°.
For the bottom four cap screws (6, Figure 2.) Tighten the bottom, outer four cap screws
6-21), initially tighten the cap screws to 136 to 271 N·m (200 ft lb), then advance the
N·m (100 ft lb), then advance the cap cap screw heads 120°.
screw head 120° as outlined in Steps d-1 NOTE: If for any reason, these fasteners need to be
through d-3. Refer to Figure 6-19. 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.
FIGURE 6-19. 120 DEGREE ADVANCE

FIGURE 6-21. SUSPENSION INSTALLATION
1. Cap Screws, Washers 6. Cap Screws, Washers

2. Nuts, Washers 7. Piston
FIGURE 6-20.
3. Housing 8. Cap Screws, Washers
4. Mounting Surface 9. Spacer
5. Shear Bar 10. Nuts, Washers

14. Install the diagonal ladder.
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-22.

15. Lift LH & RH uprights into position and install the four cap screws for each upright. Tighten to 465 ± 47 N·m
(343 ± 34 ft lb). The weight of the LH upright is approximately 776 kg (1710 lb). The weight of the RH upright
is approximately 653 kg (1440 lb).
NOTE: DO NOT weld the torque tubes on the uprights until the decks are installed.

FIGURE 6-23.
FIGURE 6-24.

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).
17. Lift the LH diagonal tube into position (Figure 6-26). The weight of the tube is approximately 156 kg (344 lb).
Do not tighten the cap screws until the deck and the cab are in place.

FIGURE 6-25.
FIGURE 6-26.

18. Lift the RH diagonal tube into position (Figure 6-27). 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.

FIGURE 6-27.
FIGURE 6-28.

20. Lift the center deck into position. (Figure 6-29). Tighten the four cap screws to 465 ± 47 N·m (343 ± 34 ft lb.).

FIGURE 6-29.

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 N·m (1180 ± 118 ft lb).

FIGURE 6-30.
FIGURE 6-31.

22. Apply strip seal to the outer edges of the auxiliary control cabinet mounting surface (top & back side). Use
adhesive to secure the strip seal in place. Lift the auxiliary control cabinet into position on the LH side of the
main electrical control cabinet. Refer to Figure 6-32. The weight of the auxiliary control box is approximately
202 kg (445 lb).
Install the six cap screws to the cabinet and tighten the cap screws to 88 ± 8 N·m (65 ± 6 ft lb).
23. 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 6-33 thru 6-37.
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 N·m (500 ft lb). Continue to tighten the cap screws in increments of 330
N·m (250 ft lb) until 2705 ± 270 N·m (1,995 ± 200 ft lb) is reached.
After installation is complete, connect the brake piping to each brake.

FIGURE 6-32.
FIGURE 6-33.

FIGURE 6-34.
FIGURE 6-34
FIGURE 6-35.

FIGURE 6-36.
FIGURE 6-37.

24. 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 Figures 6-38 & 6-39.

FIGURE 6-38.
FIGURE 6-39.

25. Install the handrails and lift the LH deck into place (Figure 6-40). The weight of the LH deck with handrails is
approximately 640 kg (1410 lb). Loosely install the eight cap screws.
After all decking is in place, tighten the cap screws on each deck to 550 ± 55 N·m (405 ± 40 ft lb).
26. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 2742 kg (6045 lb).
Tighten the eight cap screws to 800 ± 80 N·m (590 ± 59 ft lb).
27. Install the handrails on the RH deck.
28. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approxi-
mately 3750 kg (8267 lb). Refer to Figure 6-41.

FIGURE 6-40.
FIGURE 6-41.

29. Lift the operator cab into position. The weight of the cab is approximately 1684 kg (3713 lb). Refer to Figures
6-42 and 6-43.
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 N·m (590 ± 59 ft lb).
30. Tighten the hardware for the diagnonal tubes. For the RH tube, tighten the 12 cap screws to 240 ± 24 N·m
(177 ± 17 ft lb). For the LH tube, tighten the 16 cap screws to 800 ± 80 N·m (590 ± 59 ft lb).

FIGURE 6-42.
FIGURE 6-43.

31. Weld the LH & RH uprights to the front frame tube. Refer to Figure 6-44.
32. Lift the two bumper extensions into place. Refer to Figure 6-45.
Tighten the cap screws to standard torque.

FIGURE 6-44.
FIGURE 6-45.

33. Install any remaining handrails. Tighten the cap screws to standard torque.

FIGURE 6-46.

34. Connect the wiring for the electrical control cabinet, auxiliary control cabinet, operators cab and grid box.
35. Connect the hydraulic piping from the operator’s cab to the hydraulic cabinet.
36. Install the air intake ductwork and tighten the connecting hardware.

FIGURE 6-47.
FIGURE 6-48.

FIGURE 6-49.
FIGURE 6-50.

FIGURE 6-51.
FIGURE 6-52.

37. Install the retainer plate, cap screw and washer onto the parking brake gear. Tighten the cap screw to 595 to
670 N·m (440 to 495 ft lb). Refer to Figure 6-53.
38. Attach a lifting device to the parking brake assembly and lift into position. Refer to Figure 6-54. Use a port-a-
power to release spring pressure and allow the alignment of the brake discs during installation.
39. Seat the parking brake assembly against the housing and install the eight cap screws and washers. Tighten to
standard torque.

FIGURE 6-53.
FIGURE 6-54.

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 o’clock
and 9 o’clock positions. A centerline symbol marks the 12 o’clock position of the wheel motor. Refer to
Figure 6-55.
The axle housing also contains dimples at the 3 o’clock and 9 o’clock positions next to the wheel motor
mounting rings. Refer to Figure 6-56.
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.

FIGURE 6-55.
DIMPLES AT
3 O’CLOCK AND
9 O’CLOCK POSITIONS.
FIGURE 6-56.

40. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assem-
blies installed is approximately 19 900 kg (43,872 lb). Refer to Figure 6-57.
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 6-58.
Tighten the 70 mounting cap screws for each wheel motor to 2007 ± 201 N·m (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.)

FIGURE 6-57.
FIGURE 6-58.
1. Washer 2. Cap Screw

41. 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.

FIGURE 6-59.
FIGURE 6-60.

NOTES

FIGURE 6-61.
FIGURE 6-62.

Front Wheel Installation
NOTE: Remove all dirt and rust from mating parts before installing the tire and rim assembly.
42. 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.
43. 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 N·m
(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 N·m (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 N·m (1715 ± 100 ft lb).
d. Install the remaining nuts and tighten in a clockwise pattern to 2326 ± 136 N·m (1715 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2326 ± 136 N·m (1715 ± 100 ft lb).
Refer to Figure 6-63 & 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 specified torque.

FIGURE 6-63.
FIGURE 6-64.

Rear Wheel Installation
FIGURE 6-65. REAR WHEEL ASSEMBLY

1. Wheel Motor 4. Extension 8. Clamps 12. Wheel Motor
Mounting Flange 5. Wheel Hub 9. Adapter Ring Transmission
2. Inner Wheel Rim 6. Flanged Nut 10. Flanged Nut 13. Extension
3. Disc Brake Assembly 7. Inner Extension 11. Flanged Nut 14. Bracket
15. Outer Wheel Rim
NOTE: Clean all mating surfaces and check the stud threads before installing the wheels.
44. Bleed the disc brakes before installing the rear tires. Refer to Section J of the service manual for brake bleed-
ing procedures.
45. Grip the inner tire and rim with the tire handler and lift onto wheel hub (5, Figure 6-65). Align extension (4) for
mating with inner extension (7).
46. 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 N·m
(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 N·m (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 N·m (1715 ± 100 ft lb).
d. Install the remaining nuts in a clockwise pattern. Tighten to 2326 ± 136 N·m (1715 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2326 ± 136 N·m (1715 ± 100 ft lb).
Refer to Figure 6-66 and 6-67.
47. Install inner extension (7, Figure 6-65) and clamps (8) before installing the outer tires.

FIGURE 6-66.
FIGURE 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 N·m (1715 ft lb).
48. Position the rim adaptors into place on each outer rim. Install the fifty flanged nuts and tighten the nuts to
2325 ± 136 N·m (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 N·m (1715 ± 100 ft lb). Refer to Rear Wheel
Installation for the correct tightening sequence.
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.
49. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-69.

FIGURE 6-68.
FIGURE 6-69.

50. Install the front LH & RH mud-flaps on the underside of each deck.
51. Weld both rear LH & RH mud-flap brackets into place on the backside of the deck supports. Install the mud-
flaps.

FIGURE 6-70.
FIGURE 6-71.

52. Raise the hoist cylinder into position over the pivot point on the frame. The weight of each hoist cylinder is
approximately 962 kg (2,120 lb). Position the cylinder with the air bleed vent plug on top, and facing the front
of the truck. Install spacer (6, Figure 6-71). 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 N·m (220 ft lb).
Bend the locking plate tabs over the cap screw flats.
The truck is now ready for body installation.

FIGURE 6-73.
1. Cap Screw 4. Retainer Ring

2. Lock Plate 5. Bearing
3. Retainer 6. Spacer
FIGURE 6-72.

NOTES

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 10°C (50°F).
If shop space is not available, it may be necessary to
provide a portable enclosure and pre-heat the parts
The total weight of the body is approximately prior to welding.
30,362 kg (66,937 lb). Use two cranes for assem- In most instances, it is easier to assemble and weld
bling the body. A 45 metric ton (50 ton) crane and the body while the sections are upside down. After
a 109-136 metric tons (120-150 ton) crane are the pivot, guide pin, and body pads are welded in
required. The larger crane is needed to help turn place, the body can be turned over and the remain-
the body over after completion of the underside der of the assembly can be completed.
welding.
All paint must be removed from surfaces to be
Assembly of the body must be performed on flat ter- welded. Use a wire brush or paint removal equip-
rain with an adequate area for welding machines and ment.
for maneuvering lifting equipment. Refer to the assembly blueprints shipped with the
truck for specific welding details and the parts
required for assembly.
Body sections must be assembled as originally

manufactured. Match the shipping numbers sten-
ciled 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.
6. Install cap screw (2) and the sleeve at the front
FIGURE 7-2. DOMESTIC LAYOUT 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 can-
opy. 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
FIGURE 7-3. INTERNATIONAL LAYOUT 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. 14. Attach appropriate lifting apparatus to the body
3. Lift the RH body half and support the front pivot. Insert the lifting apparatus through the
sheet, side sheets, and rear edge of the floor body pin bores. The weight of the pivot is
with blocks. Refer to Figure 7-4. approximately 1492 kg (3289 lb). DO NOT dam-
4. Lift the LH body and support with blocks under age the bores.
the front sheet and side sheet. Position a 15. Lift the pivot over the body. Lower the pivot into
hydraulic jack on blocks at the tail end to sup- position against the rear of the body, as shown
port the floor at the rear. Refer to Figure 7-5. in Figure 7-6. Align the pivot with the body sills.
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

16. If necessary, use a hydraulic jack or crane to BODY WELDING
raise the center of the body to allow the pivot to
fit inside the bolsters. Loosely install the cap Follow the guidelines listed below when welding the
screws in the pivot. body:
17. If assembling an international body (three- • Use dry weld rod or weld wire.
piece), lift the canopy into position at this time.
• Weld surfaces must be dry and above 10°C
Install the canopy cap screws and tighten.
(50°F).
18. Tighten all floor, front sheet, and canopy cap
• If stick electrode is used, use as large a diameter
screws. Use a chalk line to align the front of the rod as practical to weld the floor and front sheet
canopy. joints.
19. Tighten the pivot cap screws. • The following sequence must be followed for the
20. Install the filler plates and backer strips for the front sheet:
pivot to body sill weld joints. First Pass: Back step and skip weld in 10
21. Check the alignment and fit of all components increments along the entire length of the joint.
22. Tack weld the joints.
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 7-
7.
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 assem-
bly blueprints for welding requirements.
2. Remove the canopy alignment blocks.

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.
Position the body onto support blocks as shown
FIGURE 7-9. in Figure 7-18.

FIGURE 7-12.
FIGURE 7-14.
FIGURE 7-15.
FIGURE 7-13.
FIGURE 7-16.

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.

6. Install the mud flap brackets, clearance light 7. Install any optional equipment such as body lin-
housings (Figure 7-21), etc. as specified on the ers and side boards (Figure 7-22).
installation blueprints.
FIGURE 7-21. FIGURE 7-22.
8. Clean the weld joints and paint.

FINAL ASSEMBLY
• Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected
daily for serviceable condition. Refer to the manufacturer’s 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.
FAM0808 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 instal-
lation.
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 FAM0808

FIGURE 8-1.
FIGURE 8-2.

NOTES

FIGURE 8-3.

2. With the body in position, install shims (6, Figure 8-5) in both body pivots. Install enough shims to fill the out-
board 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 N·m (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.

FIGURE 8-4.
FIGURE 8-5. DUMP BODY PIVOT PIN
1. Cap Screw 6. Shim

2. Lock Nut 7. Frame Pivot
3. Body Pivot Pin 8. Pivot Bushing
4. Body Ear 9. Body Pivot Bushing
5. Body Pivot Bushing

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 N·m (300 ft lbs).

FIGURE 8-6.
FIGURE 8-7. HOIST CYLINDER UPPER MOUNT

1. Dump Body 3. Hoist Cylinder
2. Hoist Cylinder Pin 4. Pin Retainer

7. Shim the body pads as required. All pads, except the two rear pads, should contact the frame with approxi-
mately 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.

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

9. Tack weld rock ejector mounting brackets into position on the underside of the body (Figure 8-11). The ejec-
tors 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 mount-
ing brackets (4, Figure 8-11), pins (2) and stops (3) at each shift change for wear and/or damage. Repair as
necessary.

FIGURE 8-10.
FIGURE 8-11. ROCK EJECTOR MOUNTING
1. Rock Ejector Arm 3. Stop Block

2. Pin 4. Mounting Bracket
FIGURE 8-12. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 2. Wheel Housing

10. IInstall the remaining axle box air ducts. Refer to Figures 8-13 through 8-16.

FIGURE 8-13.
FIGURE 8-14.

NOTES

FIGURE 8-15.
FIGURE 8-16.

11. Install the mud flaps onto the body and chassis (Figures 8-17 & 8-18).

FIGURE 8-17.
FIGURE 8-18.

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 8-21) can be marked on the underside of the body. Refer to the assembly prints for precise position-
ing 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.

FIGURE 8-19.
FIGURE 8-21. BODY-UP SWITCH ADJUSTMENT

FIGURE 8-20. BODY GUIDE
1. Dump Body 3. Body Guide Wear 1. Switch Mounting Bracket 3. Proximity Switch
2. Body Guide Plates 2. Adjustment Cap Screws 4. Actuator Arm
5. Adjustment Screws

16. If the truck is to be equipped with a heated body, install the exhaust box at the pivot and tighten the hardware
(Figures 8-22 & 8-23).

FIGURE 8-22.
FIGURE 8-23.

17. If the truck is to be equipped with mufflers, install at this time.

FIGURE 8-24.

18. With the body in the raised position, set the body hoist limit switch and weld the target into position (Figure 8-
25). 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 8-26).

FIGURE 8-25.
FIGURE 8-26.

20. Install the exhaust tubing blankets (Figure 8-27).
21. Install the LH & RH engine inspection lights (Figure 8-28).

FIGURE 8-27.
FIGURE 8-28.

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 8-29.

FIGURE 8-29.

23. Install the fire system. Refer to Figures 8-30, 8-31, 8-32.
This installation is normally performed by the fire system distributor.

FIGURE 8-30.
FIGURE 8-31.

NOTES

FIGURE 8-32.

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).

FIGURE 8-33.
FIGURE 8-34.

27. After completing the assembly of the truck, verify that all cap screw heads or nuts are marked with paint, indi-
cating 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.

FIGURE 8-35.
FIGURE 8-36.

NOTES

FINAL CHECKOUT
Final checkout requires truck operation.
Place the operation and maintenance manual and 4. Purge any air from the pumps. Pressure will not
safety manuals in the operator cab, if not already there. build if air is present. Operating the pumps with air
in the system will result in damage.
Any personnel involved in the final check-out of the
5. Perform a final check of all systems. Several
truck must read and understand all safety and operat-
checks are outlined in Section 10, Appendix.
ing instructions in the operation and maintenance man-
ual. 6. Complete the checks listed in the Field Assembly
Inspection Report Form. A copy of the form is pro-
vided with the truck and is also available in Sec-
1. Complete delivery and warranty forms. tion 10, Appendix.
2. Check all coolant and lubricants for proper levels 7. Operate the truck in a traffic-free area until safe
and specifications. The lubrication chart is shown operation has been validated.
in Section 10, Appendix. 8. Release the truck for use after all checks have
3. Verify the shut-off valves in the hydraulic cabinet been completed and all deficiencies corrected.
are open.
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
FAM1003 Appendix Page 10-1

NOTES
Page 10-2 Appendix FAM1003

LUBRICATION CHART
NOTES
SUSPENSION OILING AND CHARGING PROCEDURE
GENERAL EQUIPMENT LIST
These procedures cover the oiling and charging of • Hydrair Charging Kit
Hydrair® II suspensions on Komatsu 930E dump • Jacks and/or Overhead Crane
trucks.
• Support Blocks for:
Suspensions which have been properly charged will Oiling Height Dimensions (Front and Rear)
provide improved handling and ride characteristics Charging Height Dimensions (Front Only)
while also extending the fatigue life of the truck frame
• Hydrair Oil (See Specifications Chart)
and improving tire wear.
• Friction Modifier (See Specifications Chart)
NOTE: Inflation pressures and exposed piston
lengths are calculated for a normal truck gross • Dry Nitrogen (See Specifications Chart)
vehicle weight (GVW). Additions to truck weight by
adding body liners, tailgates, water tanks, etc. should Installation of Charging Kit
be considered part of the payload. Keeping the truck Assemble the charging kit as shown in Figure 4-1
GVW within the specification shown on the Grade/ and attach it to a container of pure dry nitrogen (8).
Speed Retard chart in the operator cab will extend
1. Remove the protective covers and charging
the service life of the truck main frame and allow the
valve caps from the suspensions.
Hydrair II suspensions to produce a comfortable ride.
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
FIGURE 4-1. HYDRAIR CHARGING KIT
charged in pairs (fronts together and rears together).
If rear suspensions are to be charged, the front NOTE: The arrangement of parts may vary from
suspensions should be charged first. the illustration depending on the kit part number.
NOTE: For longer life of suspension components, a
1. “T” Handle Valve
friction modifier should be added to the suspension
2. Charging Valve Adapter
oil. See the Specifications Charts at the end of this
3. Manifold Outlet Valves (from gauge)
section.
4. Inlet Valve (from regulator)
NOTE: Setup dimensions in the Specifications 5. Regulator Valve (Nitrogen Pressure)
Charts must be maintained during oiling and 6. Manifold
charging procedures. However, after the truck has 7. Charging Pressure Gauge (Suspensions)
been operated, these dimensions may vary. 8. Dry Nitrogen Gas Container
3. Ensure outlet valves (3) and inlet valve (4) are Support Blocks For Oiling And Charging
closed (turned completely clockwise). Dimensions
4. Turn swivel nut (small hex) on the charging Before starting the oiling and charging procedures,
valve three full turns counterclockwise to unseat supports should be fabricated to maintain the correct
the valve. exposed piston rod extensions.
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. Nitrogen charging support blocks for the rear
7. Open both outlet valves (3). suspension are no longer necessary. However,
oiling blocks are necessary to properly set the
NOTE: By selective opening and closing of outlet
oiling height.
valves (3), and inlet valve (4), suspensions may be
charged separately or together. Exposed piston rod extensions are specified for both
oil level and nitrogen charging for Hydrair II
Removal of Charging Kit suspensions. These dimensions are listed in the
1. Close both outlet valves (3). tables below Figures 4-2 and 4-5. Measure the
dimensions from the face of the cylinder gland to the
2. Turn "T" handles (1) counterclockwise to
machined surface on the spindle at the front
release the charging valve cores.
suspension. At the rear suspension, measure from
3. Remove charging valve adapters (2) from the the face of the cylinder gland to the piston flange.
charging valves.
Support blocks may be made in various forms. Mild
4. Tighten the swivel nut (small hex) on the
steel materials are recommended. Square stock or
charging valve. If a new charging valve is being
pipe segments at least 25 mm (1 in.) may be used.
used, tighten the swivel nut to 15 N•m (11 ft.
Blocks must be capable of supporting the weight of
lbs.), then loosen and retighten the swivel nut
the truck during oiling and charging procedures while
to 15 N•m (11 ft. lbs.). Loosen the swivel nut
avoiding contact with plated surfaces and seals on
again and retighten to 6 N•m (50 in. lbs.).
the suspension. Refer to Figure 4-2 for front
Install the valve cap finger-tight.
suspension support block placement and Figure 4-4
5. Install the charging valve caps and protective for rear support block placement.
covers on both suspensions.
FRONT SUSPENSION 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
All Hydrair II suspensions are charged with
personnel, the valve body must not be loosened
compressed nitrogen gas with sufficient
until all nitrogen pressure has been released
pressure to cause injury and/or damage if
from the suspension.
improperly handled. Follow all the safety notes,
cautions and warnings in these procedures to 3. Depress the charging valve core to release
prevent accidents during servicing and charging. nitrogen pressure from the suspension. When
all nitrogen has been released, the suspension
1. Park the unloaded truck on a hard, level should have collapsed slowly and be seated
surface. Apply the parking brake and chock the solidly on the support blocks. Remove the top
wheels. fill plug next to the charging valve (Figure 4-2).
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the
protective covers from the charging valves.
Front Suspension Oiling
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 FIGURE 4-2. FRONT 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 FRONT SUSPENSION DIMENSIONS (EMPTY)
be positioned 180 degrees apart to provide
OILING HEIGHT CHARGING HEIGHT *CHARGING PRESSURE
stability. When nitrogen pressure is released,
the suspensions will lower and rest on the 25.4 mm 299 mm 2930 kPa
blocks. Ensure that the blocks do not mar or (1.0 in.) (9.0 in.) (425 psi)
scratch the plated surfaces of the pistons or * with standard Rock Body
damage wiper seals in the lower bearing Note: If the truck starts to lift off the blocks before charging
pressure is attained, STOP CHARGING.
retainer. Support blocks must seat on the
spindle and the cylinder housing.
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
Dry nitrogen is the only gas approved for use in
at least 15 minutes to clear any trapped
Hydrair II suspensions. Charging of these
nitrogen and bubbles from the oil. Add more
components with oxygen or other gases may
suspension oil if necessary. Install a new O-ring
result in an explosion which could cause
on the fill plug and install the plug.
fatalities, serious injuries and/or major property
Front Suspension Nitrogen Charging 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.
Lifting equipment (crane or hydraulic jacks) must
be of sufficient capacity to lift the truck weight. 4. Charge the suspensions with nitrogen gas to
Be certain that all personnel are clear of the lift 50.8 mm (2 in.) greater than the charging height
area before the lift is started. Clearances under listed in Figure 4-2. Close inlet valve (4, Figure
the truck may be suddenly reduced. 4-1).
5. Remove the oiling blocks from the suspensions
1. If removed, install the charging valve with new
and install the nitrogen charging blocks. Secure
O-ring (9, Figure 4-3). Lubricate the O-ring with
the blocks to prevent accidental dislodging.
clean Hydrair oil.
2. Tighten valve body (6) (large hex) to 23 N•m NOTE: Use caution to prevent damage to plated
(17 ft. lbs.). Swivel nut (4) (small hex) must be cylinder surfaces and oil seals when installing the
unseated by turning it counterclockwise three blocks.
full turns. 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 N•m (50 in. lbs.).
FIGURE 4-3. CHARGING VALVE 13. If a new charging valve is being used, tighten
the swivel nut to 15 N•m (11 ft. lbs.), then
1. Valve Cap 6. Valve Body loosen and retighten the swivel nut to 15 N•m
2. Seal 7. O-Ring (11 ft. lbs.). Loosen the swivel nut again and
3. Valve Core 8. Valve Stem retighten to 6 N•m (50 in. lbs.). Install the valve
4. Swivel Nut 9. O-Ring cap finger-tight.
5. Rubber Washer 14. Install the protective guard over the charging
valve.
15. Raise the truck body in order to extend the front NOTE: For longer life of suspension components, a
suspensions, allowing for removal of the friction modifier should be added to the suspension
nitrogen charging blocks. Ensure that sufficient oil. See the Specifications Charts at the end of this
overhead clearance exists before raising the section.
body. If the suspensions do not extend after 1. Position and secure the oiling blocks in place
raising the body, turn the steering wheel from so the blocks are seated between the frame
stop to stop several times. If the suspensions and the rear axle housing (Figure 4-4). A block
still do not extend enough to allow for removal should be used on both the left and right sides
of the blocks, use a crane or floor jacks to raise of the truck.
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.
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 3. Rear Axle Housing

When blocks are in place on a suspension, they 2. Oiling Support Block
must be secured with a strap or other means to
avoid accidental discharge. An unsecured block
could fly loose as weight is applied, presenting 2. Remove charging valve cap. Turn the charging
the possibility of serious injury to nearby valve swivel nut (small hex) counterclockwise
personnel and/or damage to the equipment. three full turns to unseat the valve seal. DO
Overhead clearance may be reduced rapidly and NOT turn the large hex. The charging valve
suddenly when nitrogen pressure is released. 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 N•m
(17 ft. lbs.).
FIGURE 4-5. REAR SUSPENSION

1. Main Frame 3. Rear Axle
2. Charging Valve Housing
REAR SUSPENSION DIMENSIONS (EMPTY)

OILING HEIGHT CHARGING HEIGHT *CHARGING PRESSURE
53 mm 218 mm 1296 kPa

(2.1 in.) (8.6 in.) (188 psi)
* Note: Charging pressures are for reference only and may vary depending on
body weights.
Rear Suspension Nitrogen Charging 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.
Lifting equipment (overhead or mobile cranes, or
hydraulic jacks) must be of sufficient capacity to NOTE: A low left front suspension will cause the right
lift the truck weight. Ensure that all personnel are rear suspension to be high. A low right front
clear of lift area before lifting is started. suspension will cause the left rear suspension to be
Clearances under the truck may be suddenly high.
reduced. 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 N•m (50 in. lbs.).
Ensure that the automatic apply circuit has not
applied the service brakes during truck 10. If a new charging valve is being used, tighten
maintenance. If the front brakes are applied the swivel nut to 15 N•m (11 ft. lbs.), then
during rear suspension charging, the axle cannot loosen and retighten the swivel nut to 15 N•m
pivot for frame raising/lowering, and the rear (11 ft. lbs.). Loosen the swivel nut again and
suspension may be unable to move up or down. retighten to 6 N•m (50 in. lbs.). Install the valve
cap finger-tight.
1. If removed, install charging valve with new O-
ring (9, Figure 4-3). Lubricate the O-ring with 11. Install the protective guards over the charging
clean Hydrair oil. valves. Install the rubber covers over the piston
rods.
2. Tighten valve body (6) (large hex) to 23 N•m
(17 ft. lbs.). Swivel nut (4) (small hex) must be The rear Hydrair suspensions are now ready for
unseated by turning it counterclockwise three operation. Visually check piston extension with the
full turns. 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.
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 Part No. Approved Sources
Range
VJ3911 Mobil 424 Sunfleet TH Universal Tractor Fluid
(need to add Mobil D.T.E. 15 Chevron Tractor Hydraulic Fluid
6% of Texaco TDH Oil Conoco Power Tran III Fluid Petro
-30°F & above AK3761) AMOCO ULTIMATE Motor Oil Canada Duratran Fluid
(-34.5°C & above) 5W-30 Shell Canada Donax TDL
AK4063 Suspension Oil (premixed with 5 Gallon container
AK4064 6% Friction Modifier) 55 Gallon container
VJ5925 Emery 2811, SG-CD, Petro Canada Super Arctic Motor
(need to add 5W-30 Oil, 0W-30
6% of Mobil Delvac I, 5W-30 Conoco High Performance
-55°F & above AK3761) Synthetic Motor Oil, 5W-30
(-48.5°C & above) AK4065 Suspension Oil (premixed with 5 Gallon container
AK4066 6% Friction Modifier) 55 Gallon container
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 FRICTION MODIFIER Mixing Instructions

(94% Suspension Oil, 6% Friction Modifier)
Part Number Suspension Oil Amount of Friction Modifier to add
AK3761 1 gallon of suspension oil add 7.7 oz.
(5 Gallon container of 5 gallons of suspension oil add 38.4 oz.
100% Friction Modifier)
55 gallons of suspension oil add 3.3 gal.
NITROGEN GAS (N2) SPECIFICATIONS

Property Value
Nitrogen gas used inHYDRAIR® II Nitrogen 99.9% Minimum
Suspension Cylinders must meet or
Water 32 PPM Maximum
exceed CGA specification G-10.1 for
Type 1, Grade F Nitrogen Gas Dew Point -68°F (-55°C) Maximum
Oxygen 0.1% Maximum
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 accumu-
lators to depressurize. DO NOT turn the steer-
ing 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 mea-
surements 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 N•m (310 ±
31 ft lbs).
6. Remove the blocks from the rear wheels.
930E TOE-IN DATA

Nominal tie-rod length, radial tires 3667 mm
to achieve zero toe-in (144.37 in.)
FIGURE 3-1. MEASURING TOE-IN

NOTES
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
GREASE REQUIREMENTS
Grease requirements will depend on ambient tem-
peratures encountered during truck operation:
• Above 32°C (90°F) - Use NLGI No.2
multipurpose grease (MPG).
• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1
multipurpose grease (MPG).
• Below -32°C (-25°F) - 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, Fig-
ure 3-2) and fill the housing to the bottom of the plug
hole.
SYSTEM PRIMING FIGURE 3-1. PUMP/RESERVOIR COMPONENTS

The system must be full of grease and free of air
1. Hose from Filter 7. Vent Valve
pockets to function properly. After maintenance, if
2. Outlet to Injectors 8. Pressure Gauge
the primary or secondary lubrication lines were
3. Hydraulic Motor 9. Pump Assembly
replaced, it will be necessary to prime the system to
4. Pressure Reducing 10. Flow Control Valve
eject all entrapped air.
Valve 11. Pressure Switch
1. Fill lube reservoir with lubricant, if necessary. 5. Solenoid Valve 12. Grease Reservoir
2. To purge air from the main supply line, remove 6. Manual Override Switch 13. Vent Hose
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 PRESSURE AND FLOW CONTROL
until grease appears at the group of injectors High pressure hydraulic fluid from the truck steering
and re-install the pipe plug. Repeat for remain- system is reduced to 2 240 to 2 413 kPa (325 to 350
ing injector groups. psi) by pressure reducing valve (4, Figure 3-1)
5. Remove the caps from each injector and con- located on the manifold on top of the pump motor.
nect an external grease supply to the zerk on This pressure can be observed on the gauge
the injector and pump until grease appears at installed on the manifold. Occasionally check to ver-
the far end of the individual grease hose or the ify that pressure is within the above limits. The pres-
joint being greased. sure 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), pro-
ceed as follows:
1. Turn key switch ON and start the engine.
2. Actuate the lube system test switch at the reser-
voir/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.
6. After checking the system, shut off the engine.
Repair the lube system as necessary.
FIGURE 3-2. PUMP CONTROLS
1. Pressure Reducing 3. Pressure Gauge

Valve 4. Oil Level Plug
2. Manual Override Switch 5. Flow Control Valve
(Test)
PREVENTATIVE MAINTENANCE c. Check that all filler plugs, covers and
PROCEDURES breather vents on the reservoir are intact and
free of contaminants.
The following maintenance procedures should be 4. Inspect all bearing points for a bead of lubricant
used to insure proper system operation. around the bearing seal.
Daily Lubrication System Inspection It is good practice to manually lube each bearing
1. Check grease reservoir level. point at the grease fitting provided on each Injector.
This will indicate if there are any frozen or plugged
Inspect grease level height after each shift of opera- bearings, and will help flush the bearings of contami-
tion. Grease usage should be consistent from day-to- nants.
day operations. 5. System Checkout
• Lack of lubricant usage would indicate an a. Remove all SL-1 injector cover caps to allow
inoperative system. Excessive usage would visual inspection of the injector cycle indica-
indicate a broken supply line.
tor pins during system operation.
2. Check filter bypass indicator when filling reser-
voir. Replace element if bypassing. b. Start truck engine.
3. Check all grease feed line hoses from the SL-1 c. Actuate the manual override switch (6, Fig-
Injectors to the lubrication points. ure 3-1). The hydraulic motor and grease
pump should operate.
a. Repair or replace all damaged feed line
hoses. d. With the grease under pressure, check each
SL-1 injector assembly. The cycle indicator
b. Make sure that all air is purged and all new
pin should be retracted inside the injector
feed line hoses are filled with grease before
body.
sending the truck back into service.
4. Inspect key lubrication points for a bead of lubri- e. When the system attains 17,237 kPa (2500
cant around seal. If a lubrication point appears psi), the pump should shut off and the pres-
dry, troubleshoot and repair problem. sure in the system should drop to zero, vent-
ing back to the grease reservoir.
250 Hour Inspection f. With the system vented, check all of the SL-1
1. Check all grease feed line hoses from the SL-1 injector indicator pins; all of the pins should
Injectors to the lubrication points (see, Figure 3- be visible. Replace or repair injectors, if
1). defective.
a. Repair or replace all worn / broken feed line g. Reinstall all injector cover caps.
hoses. h. Check timer operation.
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. NOTE: With engine running, lube system should
activate within 5 minutes. The system should build
2. Check all grease supply line hoses from the
13,790 to17,237 kPa (2000 to 2500 psi) within 25-40
pump to the SL-1 injectors.
seconds.
a. Repair or replace all worn / broken supply
lines.
b. Make sure that all air is purged and all new i. If the system is working properly, the truck is
supply line hoses are filled with grease ready for operation.
before sending the truck back into service. j. If the system is malfunctioning, refer to the
3. Check grease reservoir level. troubleshooting chart.
a. Fill reservoir if low.
b. Check reservoir for contaminants. Clean, if 1000 Hour Inspection
required.
1. Check pump housing oil level and correct if nec-
essary.
NOTES
) I
KOMATSU CHECKOUT PROCEDURE

IEL4302-1
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NAME: MACHINE & MODEL:

AlC CHECKOUT PROCEDURE ALL TRUCKS
WRITTEN BY: DATE:
Bill Anderson 9/7/04

CHECKED BY: DATE:
Mike McMullen 9/17/04 1 Item 2 (b) chanQed aDDroved oil - was 2356151 4/13/05 \\'-ILL. BA 'bAt
APPROVED BY: DATE: 112074
DASH DESCRIPTION OF CHANGE DATE ECN BY CK'D
A SIZE MICROFILM
T. Heller 9-17-04 I I
T T I I I I I I I I I I 1T T 1 I I
1. Keep AlC Components sealed until prepared to charge system. The PAG oil in compressor and desiccant in receiver-
drier both attract moisture leaving system open for contamination.
2. At field erection the following steps need to be taken to make A-C system operational.
a. Remove compressor and drain oil.

b. Add 7 oz. of new GM PAG oil to compressor sump (thru drain hole) and reinstall. Use approved oil GM
12378526.
c. Add 7 oz. of new GM PAG oil to inlet side of accumulator or receiver-drier.
d. Connect all hoses and components for A-C system. Note: Lubricate oil rings before assembly.
e. Evacuatesystem down to minimum of 29.00" Hg for a minimum of 45 minutes.
f. Shut off vacuum pump and observe gauges, system should hold a minimum vacuum of 28.00" Hg for 15
minutes. If vacuum does not hold, fmd and repair leak, then evacuate system again.
g. Charge system with 7.4# of 134a refrigerant.
h. Observe pressures and check for leaks.
i. Observe cab vent outlet temperatures, fan on low and temperature setting on maximum.
j. Check evaporator condensation drain line to see if open.
3. Refer to Service Manual for recommended pressures, temperatures and trouble shooting guide.
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NAME: MACHINE & MODEL:

VHMS System Checkout Procedure 930E, 960E, 830E
WRITTEN BY: DATE:
07/17/04
CHECKED BY: DATE:

1 INTEGRATEDINTERFACEMODULECHECKOUT 8/18/04 \\\"'\4 GGH SK
APPROVED BY: DATE: 0 NEWRELEASE
G. Horst DASH DESCRIPTIONOFCHANGE DATE ECN BY CK'D
A SIZE MICROFILM
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 OrbCommcommunicationsettings.
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. m
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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:
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_~r012~:::~~~i~~{~~"'.:~-':::~"":=:~~"~"-"~'~~'~- :t:s'$~~1::!:7~='~'"'
::;:'2 ..HMS !:ielp
; If !
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)

ID Oxc121: Seq#OxO: Ver.11030100181 kind.930E: Cold Start!
Ready
:j
Start I; : :iI ~ 6Jt) lJ
EfiJl 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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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" ., ,,';":-'.;:.';' -;;:~;<i,-::'<:',:'",~"'~'Hl~ ;.."""""",,,~:.--
301: 2 s: En9-Speed: rpm CLOSE I
0 301: 2 s: Eng_Speed: rpm

354: 2 s: Cool_Temp: degC
354: 2 s: Cool_Temp: degC 355: Eng_OilJemp
0 385:AmblenCair _temp
386: Blow_by-press
387: Eng_oil-press
388: Boost-press
0 389: Exh_gas_temp
500: FueUnjection
Delete 501: Ave_Min_ldle_On
502:Auto_Lube_Sw
0 503: BatC 12V_A
504: BatU 2V_B
505: BatU 2V- C ~
0
START/STOP Sampling 12s .:J
0
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Rel!.dy :J
For Help. press F1 I;NUM
::Ell Start I :!I ~ [J t1 JJ . r,~Interll!.ce Module Reml JJ CanBI!.nFF j @ Document.. WordPl!.d I 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.
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For all trucks:
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 :1:20ohm 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
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
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For 830E trucks only:
1. Hydraulic Tank Temperature (RR Hydraulic Oil Temp on VHMS Watcher) - confirm as being
near ambient on a cold truck. (564)
2. Motor Temperature High - short wire 722L to ground at TB21E-B momentarily and confirm
state change (zero to one). (558)
3. Motor Blower Off - short wire 32B to ground at TB21E-E momentarily and confirm state
change (zero to one). (555)
4. Diode Fault - short wire 79VD to ground at TB21D-G momentarily and confirm state change
(zero to one). (551)
5. Electric Drive System Fault - short wire 79VS to ground at TB21D-E momentarily and
confirm state change (zero to one). (516)
6. Ground Fault - short wire 79VG to ground at TB21D-F momentarily and confirm state
change (zero to one). (557)
For 960E trucks only:
1. Park Brake Set Switch - with engine running, toggle Park Brake Switch and confirm state
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.
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. I
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2. Brake Cooling RPM Advance 1 should go to 24 volts (check at TB40-B).

3. Brake Cooling RPM Advance 2 should go to 24 volts (check at TB40-C).
4. The Brake Oil Temperature Gauge (930E only) should read near the middle of the red band.
5. The High Brake Oil Temp light should come on.
6. 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.
7. If the temperature reading is low check wiring for high resistance between the probe and
Interface Module.
8. If the temperature reading is high check for shorts in the wiring.
9. 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.
2. Set the gauge to empty. After 15 seconds, the Low Fuel Light should come on.
3. Return the gauge to the approximate position of the actual fuel in the tank before remounting
it.
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
continue to be energized, and the auto apply valve should stay off. m
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I EK8480-1
PaQe 8 of 15
4. 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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I EK8480-1
Paqe 9 of 15
PART 2 - VHMS setup

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
typing 'TEST". The heading "TEST" should appear at the top of 10 screen. m
15.Enter the Service 10field as in step 7 above. "
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Page 9 of 15
KOMATSU CHECKOUT PROCEDURE I EK8480-1
PaQe 10 of 15
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 Send Timer Number Interval

Short Trend Analysis ON SMR 1 20 (SMR)
Short Load Map ON SMR - 160 (SMR)
Short FaultHistory ON Occurrence 6 -
ShortPayloadmeter ON Day 1 -
for PLM3
Short Brake Load Map ON SMR 160
21. Set GCC (Ground Control Center) to the appropriate setting and record in item 12 on From 3
GCC code Territory

(country)
1 USA
120 ITALY
121 MALAYSIA
122 KOREA
123 BRAZIL
130 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
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Page 10 of 15
- -- u_- --- -- --- - _u- - - --

I EK8480-1
Paqe 11 of 15
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 Toolboxsoftware. 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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I EK8480-1
PaQe 12 of 15
To : VHMSlWebCARE support team Ref. No.

FAX: 81-3-5561-4766 Date
Name
WebCARE machine registration request Fonn "An
( DB information]
1. Distributor name 2. Branch Name
3. Person in Charge 4. E-mail address
5. DB code (GCPS)
[ Customer information]
6. Customer name 7. Site name
[ Machine information]
8. Model Name 9. Serial No.
10. Unit No.
11. Item to be registered in WebCARE.

VHMS PM Clinic D KUC D
.. Retro-klt
Installed on new machine 0
0
[ Orbcomm Activation]
12. Date of Orbcomm activation
[ Remark]
WebC.,ARE VHMS/WebCARE Support team

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TEL 81-3-5561-2765 )
FAX 81-3-5561-4766 .
E-mail webcare@komatsu.co.jp
)
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Page 12 of 15
I EK8480-1
Paqe 13 of 15
TO: Customer support Gr.,Solution Div.,Komatsu Ltd.

(KOMTRAX Service Hotline)
Phone: +81-463-22-8780
I Important
Fax: +81-463-22-8448
Address: 3-25-1 Shinomiya, Hiratsuka-shi, kanagawa 254-
8555,Japan
E-mail: cs_kom@komatsu.co.jp
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 (Pleasefillin terminal PIN&S/Nor put on enclosedsticker here)
Terminal SIN PIN: SIN:
Terminal Activation Date (YY/MM/DD) I I
Country where used

Machine Information Model-Type-S/N#
Customer's Contact Address
Company (or Plant)

Phone Number (Country-Area-number>
FAX Number (Country. Area-number)
e-mail address
Name (please print) First Middle Family
Signature
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. m
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I EK8480-1
Paqe 14 of 15
\+MS InstallationO1eck-out Sheet (Fam 3)

,Ii3ad befr;re installation IXJn't stat engine befa"e item No. 1 t1'rcug116 ere COI1lJIeted.
J!ttI!rirBallalia1, fillco ttis sheet and sera back to Call aner I7i FAXa e-Mlil.
(W!bC'.PR:settirg wll be I11ICiI aftB"Call Qner receives ttis sheet.)
~Call Qner Phone-+81-3-5561-2765
FAX -+81-3-55614766
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I EK8480-1
PaQe 15 of 15
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STANDARD TORQUE CHARTS AND CONVERSION TABLES
This manual provides dual dimensioning for most EFFECT OF SPECIAL LUBRICANTS
specifications. U.S. standard units are specified first, On Fasteners and Standard Torque Values
with metric (SI) units in parentheses.
The Komatsu engineering department does not
References throughout the manual to standard torques recommend the use of special friction-reducing
or other standard values will be to one of the following lubricants, such as Copper Coat, Never-Seez®, and
charts or tables. For values not shown in these charts other similar products, on the threads of standard
or tables, standard conversion factors for most fasteners where standard torque values are applied.
commonly used measurements are provided in TABLE The use of special friction-reducing lubricants will
XIII, page A5-6. significantly alter the clamping force being applied to
Standard torque values are not to be used when “turn- fasteners during the tightening process.
of-the-nut” tightening procedures are recommended. If special friction-reducing lubricants are used with the
standard torque values listed below in Table I,
INDEX OF TABLES excessive stress and possible breakage of the
TABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1 fasteners may result.
TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2
Where the torque tables specify “Lubricated Threads”
TABLE III . . Standard Metric Assembly Torque . . A5-2
for the standard torque values listed, these standard
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . A5-3
torque values are to be used with simple lithium base
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3
chassis grease (multi-purpose EP NLGI) or a rust-
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3
preventive grease (see list, page A5-2) on the threads
TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3
and seats unless specified otherwise.
TABLE VIII . Torque Conversions (ft lbs to N•m) . . A5-4
TABLE IX . Torque Conversions (ft lbs to kg•m) . . A5-4 NOTE: Ensure the threads of fasteners and tapped
TABLE X . . Pressure Conversions (psi to kPa) . . A5-4 holes are free of burrs and other imperfections before
TABLE XI . Pressure Conversions (psi to MPa) . . A5-5 assembling.
TABLE XII . . . . . . . .Temperature Conversions . . A5-5
TABLE XIII . . . Common Conversion Multipliers . . A5-6
Grade 5 TABLE I. -STANDARD TORQUE CHART

Grade 8
SAE HEX HEAD CAP SCREW AND NUT ASSEMBLY
(LUBRICATED THREADS) - TOLERANCES ±10%
Cap TORQUE - TORQUE - Cap TORQUE - TORQUE -
Screw GRADE 5 GRADE 8 Screw GRADE 5 GRADE 8
Thread Thread
ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m
Size Size
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lbs = 0.138 kg•m = 1.356 N•m
STANDARD ASSEMBLY TORQUES STANDARD ASSEMBLY TORQUES
For 12-Point, Grade 9 Cap Screws (SAE) For Class 10.9 Cap screws & Class 10 Nuts
The following specifications apply to required assembly The following specifications apply to required assembly
torques for all 12-point, grade 9 (170,000 psi minimum torques for all metric Class 10.9 finished hexagon head
tensile) cap screws. cap screws and Class 10 nuts.
• Cap screw threads and seats shall be lubricated • Cap screw threads and seats shall not be
when assembled. lubricated when assembled. These specifications
are based on all cap screws, nuts, and hardened
NOTE: Unless the instructions specifically recommend washers being phosphate and oil coated.
otherwise, these standard torque values are to be used
with simple lithium base chassis grease (multi-purpose NOTE: If zinc-plated hardware is used, each piece
EP NLGI) or a rust preventive grease (see list, this must be lubricated with simple lithium base chassis
page) on the threads. grease (multi-purpose EP NLGI) or a rust preventive
grease (see list, this page) to achieve the same
• Torques are calculated to give a clamping force of clamping forces provided below.
approximately 75% of proof load.
• Torques are calculated to give a clamping force of
• The maximum torque tolerance shall be ±10% of
approximately 75% of proof load.
the torque value shown.
• The maximum torque tolerance shall be within
±10% of the torque value shown.
TABLE II. STANDARD ASSEMBLY TORQUE
for 12-Point, Grade 9 Cap screws TABLE III. STANDARD ASSEMBLY TORQUE
for Metric Class 10.9 Cap screws & Class 10 Nuts
CAP SCREW TORQUE TORQUE TORQUE
SIZE* ft lbs N•m kg•m CAP SCREW TORQUE TORQUE TORQUE
0.250 - 20 12 16 1.7 SIZE* N•m ft lbs kg•m
0.312 - 18 24 33 3.3 M6 x1 12 9 1.22
0.375 - 16 42 57 5.8 M8 x 1.25 30 22 3.06
0.438 -14 70 95 9.7 M10 x 1.5 55 40 5.61
0.500 -13 105 142 14.5 M12 x 1.75 95 70 9.69
0.562 - 12 150 203 20.7 M14 x 2 155 114 15.81
0.625 - 11 205 278 28.3 M16 x 2 240 177 24.48
0.750 - 10 360 488 49.7 M20 x 2.25 465 343 47.43
0.875 - 9 575 780 79.4 M24 x 3 800 590 81.6
1.000 - 8 860 1166 119 M30 x 3.5 1600 1180 163.2
1.000 - 12 915 1240 126 M36 x 4 2750 2028 280.5
1.125 - 7 1230 1670 170 * Shank Diameter (mm) - Threads per millimeter
1.125 - 12 1330 1800 184 This table represents standard values only. Do not use these
1.250 - 7 1715 2325 237 values to replace torque values which are specified in assembly
1.250 - 12 1840 2495 254 instructions.
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342 Suggested* Sources for Rust Preventive Grease:
1.500 - 6 2980 4040 411 • AMERICAN ANTI-RUST GREASE #3-X from
1.500 - 12 3225 4375 445 Standard Oil Company (also American Oil Co.)
* Shank Diameter (in.) - Threads per inch • GULF NORUST #3 from Gulf Oil Company.
This table represents standard values only. Do not use these
values to replace torque values which are specified in assembly
• MOBILARMA 355, Product No. 66705 from Mobil
instructions. Oil Corporation.
• RUST BAN 326 from Humble Oil Company.
• RUSTOLENE B GREASE from Sinclair Oil Co.
• RUST PREVENTIVE GREASE - CODE 312 from
the Southwest Grease and Oil Company.
NOTE: This list represents the current engineering
approved sources for use in Komatsu manufacture. It is
not exclusive. Other products may meet the same
specifications of this list.
TABLE IV. TABLE VI.
TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR
WITH OR WITHOUT O-RING SEALS O-RING BOSS FITTINGS
SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B ft lbs CODE (O.D.) UNF-2B ft lbs
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
TABLE V. TABLE VII.

TORQUE CHART FOR TORQUE CHART FOR
PIPE THREAD FITTINGS O-RING FACE SEAL FITTINGS
PIPE WITH WITHOUT SIZE TUBE SIZE THREADS TORQUE ft

SIZE THREAD SEALANT SEALANT CODE (O.D.) UNF-2B lbs
CODE SIZE ft lbs ft lbs
–4 0.250 0.438 – 20 11 ±1
–2 0.125 – 27 15 ±3 20 ±5
–6 0.375 0.562 – 18 18 ±2
–4 0.250 – 18 20 ±5 25 ±5
–8 0.500 0.750 – 16 35 ±4
–6 0.375 – 18 25 ±5 35 ±5
– 10 0.625 0.875 – 14 51 ±5
–8 0.500 – 14 35 ±5 45 ±5
– 12 0.750 1.062 – 12 71 ±7
– 12 0.750 – 14 45 ±5 55 ±5
– 16 1.000 1.312 – 12 98 ±6
– 16 1.000 – 11.50 55 ±5 65 ±5
– 20 1.250 1.625 – 12 132 ±7
– 20 1.250 – 11.50 70 ±5 80 ±5
– 24 1.500 1.875 – 12 165 ±15
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10
TABLE VIII. TORQUE CONVERSIONS
Foot Pounds (ft lbs) to Newton-meters (N•m)
ft lbs 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage
TABLE IX. TORQUE CONVERSIONS

Foot Pounds (ft lbs) to kilogram-meters (kg•m)
ft lbs 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
TABLE X. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
psi 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
TABLE XI. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
psi 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa). 3. Multiply by 10:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to psi row 0, column 5; read 34.475
2. Go to psi row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
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 COMMON CONVERSION MULTIPLIERS

ENGLISH TO METRIC METRIC TO ENGLISH
To Convert Multiply Multiply

From TO By To Convert From TO By
inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394
inch – in. centimeter (cm) 2.54 centimeter (cm) inch – in. 0.3937
foot – ft meter (m) 0.3048 meter (m) foot – ft 3.2808
yard – yd meter (m) 0.914 meter (m) yard – yd 1.0936
mile – mi. kilometer (km) 1.61 kilometer (km) mile – mi. 0.6210
sq. in. – in. 2

sq. centimeters (cm ) 2 6.45 sq. centimeters (cm 2) sq. in. – in.2 0.1550
sq. ft. – ft2 sq. centimeters (cm2) 929 sq. centimeters (cm2) sq. ft. – ft2 0.001
cu. in. – in.3 cu. centimeters (cm3) 16.39 cu. centimeters (cm3) cu in – in.3 0.061
cu. in. – in.3 liters (l) 0.016 liters (l) cu in – in.3 61.02
cu. ft. – ft3 cu. meters (m3) 0.028 cu. meters (m3) cu ft – ft3 35.314
cu. ft. – ft3 liters (l) 28.3 liters (l) cu ft – ft3 0.0353
ounce – oz kilogram (kg) 0.028 grams (g) ounce – oz. 0.0353

fluid ounce – fl oz milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl oz. 0.0338
pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046
pound (force) – lbs Newton (N) 4.448 Newton (N) pound (force) – lbs 0.2248
in. lbs. (force) Newton meters (N•m) 0.113 Newton-meters (N•m) kilogram meters (kg•m) 0.102
ft lbs (force) Newton meters (N•m) 1.356 Newton-meters (N.m) ft lbs 0.7376
ft lbs (force) kilogram meters (kg•m) 0.138 kilogram-meters (kg•m) ft lbs 7.2329
psi (pressure) kilopascals (kPa) 6.895 kilogram-meters (kg•m) Newton meters (N•m) 9.807
psi (pressure) megapascals (MPa) 0.007 kilopascals (kPa) psi 0.1450
psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 megapascals (MPa) psi 145.038
ton (short) kilogram (kg) 907.2 kilograms/cm 2 (kg/cm2) psi 14.2231
ton (short) metric ton 0.0907 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
quart – qt liters (l) 0.946 kilogram (kg) ton 0.0011
gallon – gal liters (l) 3.785 metric ton ton 1.1023
HP (horsepower) Watts 745.7 liters (l) quart – qt 1.0567
HP (horsepower) kilowatts (kw) 0.745 liters (l) gallon – gal 0.2642
Watts Horsepower HP 0.00134
kilowatts (kw) Horsepower HP 1.3410
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 MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

(Circle One) SERIAL NUMBER SERIAL NUMBER NUMBER
730E 830E 930E-3

Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:
Signature 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.
Send Canary Reports to Manager of Field Assembly

Komatsu America Corp.
2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.
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.
CEAW003208 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visual inspection of unit for loose parts and debris
2 Hardware Visual inspection of unit for missing and/or loose mounting hardware
3 Hoses and Cables Visual inspection of hydraulic hoses and electric cables to ensure they are securely
clamped and clear from sharp edges and not rubbing each other
4 Ground Straps Verify all ground straps are secure (sub frame, anchor etc.)
5 Engine Oil Level Verify engine oil level is in operating range
6 Engine Fan Inspect fan-to-shroud clearance and belt alignment
7 Hydraulic Oil Level Oil level visible through the upper sight glass with body down
8 Hatch Door Verify adequate latch seal on the rear axle hatch door to prevent dust entry
(730E, 830E)
9 Anchor Pin Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and prop-
erly tightened hardware
10 Wheel Motors Inspect oil specification and proper oil level
11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks
12 Radiator Inspect coolant fill level, cold temperature protection, and DCA additive
13 Decks and Ladders 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
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 Suspension Verify front suspension mounting cap screws have been properly tightened per appropriate
service manual procedure using the “turn-of-the-nut” method
2 Wheels 730E Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
830E Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
930E-3 Verify torque on front wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs)
(See Note below chart) Verify torque on rear inside wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs)
Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft
lbs)
3 Rops Verify torque on left rops beam cap screws at 949 N·m (700 ft lbs)
Verify torque on right cross beam cap screws at 240 N·m (177 ft lbs)
4 Cab Verify torque on cab mounting cap screws at 949 N·m (700 ft lbs)
5 Wheel Motor Verify torque on wheel motor mounting cap screws at 2007 N·m (1480 ft lbs)
NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mount-
ing tightening procedure.
Maintenance
Accepted
Cab Compartment
1 Cab Doors Verify doors open and close smoothly, latch works properly, O&M manual in door
2 Cab Windows Verify windows can be opened and closed smoothly
3 Door Locks Verify left and right door locks work properly with key
4 Interior Visually inspect interior for completeness of assembly
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
5 Cab Seats Inspect operators seat adjustments (slide lever, back rest operation,
seat inclination, seat height etc.)
Inspect seat belt for proper installation (and seat tethers)
6 Passenger Seat Verify back rest operates without interference
7 Steering Wheel Check tilt and telescoping functions
Check adjustable lever can be locked securely
8 Wiper Verify wiper works all speeds, & range does not extend beyond glass surface
Verify the windshield washer works properly and washer fluid bottle is full
9 Cigarette Lighter Check lighter operation, should pop up after 10 seconds and be hot
10 Horn Check for proper sound, no looseness in horn button
11 Back Up Horn Check for proper sound, and function
12 Shift Tower Check for proper function, no binding or looseness
13 Gauges Verify gauges are installed straight and operating correctly
14 Hydraulic Fittings Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet
15 Hoist Check operation of the hoist lever in all four positions
Lights
1 Headlights Verify all headlights working, high and low beams
Verify high beam indicators are functional
Verify lights at proper angle
2 Instrument Panel Check switch depresses and all lights function
2a Dimmer Switch Verify dimmer operates properly
2b Turn Signal 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 Hazard Flashers Verify flasher operates properly
Verify hazard indicator lights operating properly
4 Back Up Light Verify back up light operates properly when shifter is in R position
5 Manual Back Up Light Verify switch and light work properly
6 Fog Light (optional) Verify fog lights and indicator lights operating properly
Brake Lights
1 Service Brake Verify service brake lights operating properly
2 Brake Lock Verify brake lock light operating properly
3 Emergency Brake Verify emergency brake light operating properly
4 Parking Brake Verified parking brake light operating properly
5 Dome Light Verify dome light is on when the switch is ON
6 Retarder Lights Verify retard light operating properly
Maintenance
Accepted
Service Inspection
1 Suspension 730E Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear
(See Note below chart) 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 Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)
930E-3 Suspension oiling height at 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
Rear charge height, 190 mm (7.5 in.) at 1482 kPa (215 psi)
2 Accumulators Verify nitrogen charge in accumulators is at 9653 kPa (1400 psi) for all models, for both
steering and brakes
3 Engine Prelube If equipped, ensure prelube is working prior to engine starting
4 Engine Starting Ensure engine starts easily
5 Engine Noise No abnormal noise from engine
6 Brake Lock Verify when switch is ON, brakes are applied and light is illuminated
7 Parking Brake Verify when switch is ON, brakes are applied and light is illuminated
8 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 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 parking brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)
930E-3 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 parking brake release pressure is 18,616 ± 689 kPa (2700 ± 100 psi)
9 Steering Verify that steering system is operating smoothly, turning from lock to lock
Verify steering system is free of noise and vibration
10 Hoist 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.
Maintenance
Accepted
11 Hoist Times 730E Power up loaded - 21-23 seconds
Power down - 15-17 seconds
Float down empty - 22-24 seconds
830E Power up loaded - 25-27 seconds
930E-3 Power up loaded - 21-23 seconds
ALL Trucks Ensure body up switch activates the body up alarm and light in the cab
12 Lubrication 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
13 Payload Meter Sys. Calibrate and check payload meter operation per O&M manual
14 Error Codes Troubleshoot any error codes and delete
15 Machine Record machine model-type, machine serial number and engine serial number
16 Dump Body Ensure the dump body is shimmed correctly prior to truck release
17 Electrical Checks Ensure the electrical checkout procedure has been completed and signed off on, including
megger testing (see appropriate shop manual for procedure)
18 Truck Programming Ensure the truck is programed with it’s own unique configuration file and a copy of the file
saved
ADDITIONAL COMMENTS__________________________________________________________
__________________________________________________________________________________
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__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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__________________________________________________________________________________
__________________________________________________________________________________
®
www.komatsuamerica.com
Komatsu America Corp. Copyright 2006 Komatsu

2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072 Printed in U.S.A.

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CEAW004001

SERIAL NUMBERS A30318 & UP

DANGER Identifies a specific potential hazard

WARNING identifies a specific potential hazard

CAUTION is used for general reminders

SUBJECT PAGE NUMBER

SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

TRUCK COMPONENT 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

FAM0010 Introduction iii

FAM0108 Safety Rules, Tools, & Equipment Page 1-1

12. Two, ratchet pullers - 2.7 metric ton (3 ton)

Page1-2 Safety Rules, Tools, & Equipment FAM0108

FAM0108 Safety Rules, Tools, & Equipment Page 1-3

1. “T” Handle Valve

Part Number Description Use

Page1-4 Safety Rules, Tools, & Equipment FAM0108

Part Number Description Use

Part Number Description Use

FAM0108 Safety Rules, Tools, & Equipment Page 1-5

Part Number Description Use

Part Number Description Use

Page1-6 Safety Rules, Tools, & Equipment FAM0108

Part Number Description Use

Part Number Description Use

Part Number Description Use

FAM0108 Safety Rules, Tools, & Equipment Page 1-7

Part Number Description Use

Part Number Description Use

Part Number Description Use

Part Number Description Use

Part Number Description Use

Page1-8 Safety Rules, Tools, & Equipment FAM0108

FAM0209 Truck Components And Specifications Page 2-1

Page 2-2 Truck Components And Specifications FAM0209

ENGINE SERVICE CAPACITIES

AC ELECTRIC DRIVE SYSTEM HYDRAULIC SYSTEM

Alternator . . . . . . . . . . . . . General Electric GTA - 39 Rated at . . . . . . . . . . . . . . . . . 246 GPM (1022 l/min)

. . . . . . . . . . . . . . . . . . . . . Wheel Slip/Slide Control Rated at . . . . . . . . 66 GPM (250 l/min) @ 1900 RPM

FAM0209 Truck Components And Specifications Page 2-3

STANDARD DUMP BODY* LOADED

* OPTIONAL capacity dump bodies are available.

Page 2-4 Truck Components And Specifications FAM0209

FAM0209 Truck Components And Specifications Page 2-5

Page 2-6 Truck Components And Specifications FAM0209

ITEM KILOGRAMS POUNDS

DECK AND DECK SUPPORT COMPONENTS

FAM0309 Major Component Weights Page 3-1

FRONT AXLE COMPONENTS

Page 3-2 Major Component Weights FAM0309

REAR AXLE COMPONENTS

FAM0309 Major Component Weights Page 3-3

Page 3-4 Major Component Weights FAM0309

FAM0403 Field Welding Procedures 4-1