830E Field Assembly CEAW004701

CEAW004701
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS A30816 & UP

FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 830E dump truck. Varia-
tions 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.
FAM0012 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 readers attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
ii Introduction FAM0012
TABLE OF CONTENTS
SUBJECT PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TRUCK COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAM0012 Introduction iii

KOMATSU 830E
iv Introduction FAM0012
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES
The following list of safety practices is intended for use 10. Disconnect the battery charging alternator lead
by personnel during field assembly of the truck. wire before welding on the frame or its compo-
nents.
This list of safety rules is not intended to replace local
safety rules or regulations and federal, state, or local 11. When welding, connect the ground cable to the
laws. The safety precautions recommended here are part being welded. DO NOT allow welding current
general and must be used in conjunction with all pre- to pass through bearings, engine, etc.
vailing local rules and regulations. 12. DO NOT weld the fuel tank or hydraulic tank
1. All personnel must be properly trained for the unless the tanks have been properly purged and
assembly process. ventilated.
2. Wear safety equipment such as safety glasses, 13. Use the proper tools for the job to be performed.
hard toe shoes and hard hats at all times during Never improvise wrenches, screw drivers, sock-
assembly. ets, etc. unless specified.
3. Thoroughly inspect the assembly site. Remove 14. Lifting eyes and hooks must be fabricated from
weeds, debris and other flammable material. the proper materials and rated to lift the intended
4. Use only solid, hard wood for supports. When load.
using metal support stands, place wood blocks 15. When the weight of any component(s) or any
between the support and the frame to prevent assembly procedure is not known, contact your
metal to metal contact. customer support manager for further information.
5. Inspect all lifting devices. Refer to the manufac-
turer's specifications for correct capacities and
safety procedures when lifting components.
6. Perform a daily inspection of all lifting cables and
chains. Replace any questionable items. Use
cables and chains that are properly rated for the
load to be lifted.
7. DO NOT stand beneath a suspended load. Use of
guy ropes are recommended for guiding and 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.
FAM0101 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 Nm (250 ft lb) with 18:1
task. multiplier. Torque wrenches - 339 Nm (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 Nm (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 FAM0101

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

EJ2627 Roller Assy. Power Module
(No longer Remove & Install
available as
complete unit)
EJ2629 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

TZ3535 Offset Box End Miscellaneous
Wrench,
1, 1/2 in.

TZ2734 3/4 in. Torque Miscellaneous
Adapter

TZ2733 Tubular Handle Use with TZ2734
& TZ3535

TY2150 Seal Installation Front Face
Tool Seals

TY4576 Sleeve Steering Link-
Alignment Tool age and Tie Rod
TZ0992 Sleeve Rear Suspen-
Alignment Tool sion & Anti-
Sway Bar

PB6039 Hydraulic Miscellaneous
Coupling

PC2061 Belt Tension Tester A/C Belt Ten-
sion

EL8868 V-Belt Align- Aligning A/C
ment Tool pulleys

EF9160 Harness Payload Meter
Download
AK4720 Software Payload Meter
Data Manager

EH7817 Alignment Tool Upper Hoist Pin

TZ2100 Socket (1 7/8 in.)
TZ2728 Socket (2 3/4 in.) Miscellaneous
TV7567 Socket (1 5/16 in.)
PB6825 Impact Socket
(1 5/8 in.)

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

WA4826 Lifting Eye Bolt Miscellaneous
TG1106

TV1186 Extension (3 1/2 in.) Miscellaneous
TR0532 Extension (8 in.)
TR0533 Extension (17 in.)

TRUCK COMPONENT DESCRIPTION
The Komatsu 830E truck is an electric drive, off-high-
way, rear dump truck. The gross vehicle weight is
385 852 kg (850,650 lb) (246 ton nominal payload).
OPERATORS CAB
The operator cab has been engineered for operator
ENGINE comfort and to allow for efficient and safe operation
This 830E is powered by a Komatsu SDA16V160 of the truck. The cab contains an integrated Roll
diesel engine rated at 1865 kW (2500 hp) @ 1900 Over Protection Structure (ROPS) and is fully insu-
rpm. The radiator, engine, alternator, and blower are lated to reduce noise and vibration. The tinted safety-
mounted on a separate subframe to provide fast, glass windshield and side windows provide excellent
easy removal and installation of the power module. visibility. The seat is a comfortable, adjustable sus-
pension seat, the steering wheel provides tilt and
telescoping adjustments and controls are mounted
ALTERNATOR (G.E. GTA-26) within easy reach of the operator. The instrument
The alternator is mounted in-line with the engine. The panel provides the operator with instruments and
alternating current (AC) output of the alternator is gauges that are necessary to control and monitor the
rectified to direct current (DC) and sent to the wheel trucks operating systems and is marked with interna-
mounted DC drive traction motors. tional symbols for easy identification of functions.
BLOWER DYNAMIC RETARDING

The dual impeller, in-line blower supplies cooling air Dynamic retarding is used to slow the truck during
for the alternator, rectifiers, and both traction motors. normal operation or control speed coming down a
The air is exhausted to atmosphere through the grade. The dynamic retarding ability of the DC elec-
wheel motors. tric system is controlled by the operator by depress-
ing the foot operated retarder pedal and/or setting
the RSC (Retarder Speed Control) on the instrument
WHEEL MOTORS panel. Dynamic retarding is automatically activated if
Traction motors located within each rear wheel struc- truck exceeds the overspeed setting.
ture receive electrical energy from the alternator. The
two traction motors convert electrical energy back to
BRAKE SYSTEM
mechanical energy through built-in gear trains within
the wheel structure. The direction of the drive motors The braking system consists of an all hydraulic actu-
is controlled by a forward or reverse hand selector ation system. Depressing the brake pedal actuates
switch located on a console in the cab to the right wheel-speed single disc front brakes and armature-
side of the operator. speed dual disc rear brakes. The brakes can also be
activated by operating a switch on the instrument
panel. The brakes will be applied automatically if sys-
POWER STEERING tem pressure decreases below a preset minimum.
The truck is equipped with a full time power steering
system which provides positive steering control with
SUSPENSION
a minimum of effort by the operator. The system
includes a nitrogen-charged accumulator which auto- Hydrair II suspension cylinders located at each
matically provides emergency power if the steering wheel provide a smooth and comfortable ride for the
hydraulic pressure is reduced below an established operator and dampens shock loads to the chassis
minimum. during loading.
FAM0201 Truck Components And Specifications Page 2-1

Page 2-2 Truck Components And Specifications FAM0201
SPECIFICATIONS
These specifications are for a standard Komatsu 830E 24 VDC ELECTRIC SYSTEM
truck. Customer options may change this listing. Batteries . . . Four 12 Volt Batteries in Series/Parallel
. . . .220 Ampere-Hour Capacity w/Disconnect Switch
ENGINE Alternator . . . . . . . . . . . . 24 Volt, 260 Ampere Output
Komatsu SDA16V160 (optional SSDA16V160) Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cranking Motors . . . . . . . . . . . . . . . . . . . . . (2) 24 Volt
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . .4-Stroke
Rated Brake HP. . . 1865 kW (2500 HP) @ 1900 rpm
Flywheel HP . . . . . 1761 kW (2360 HP) @ 1900 rpm SERVICE CAPACITIES
Weight* (Wet) . . . . . . . . . . . 9 608 kg (21,182 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters . (US Gal)
Crankcase * . . . . . . . . . . . . . . . . . 280.0 . . . . (74.0)
* Weight does not include radiator, sub-frame, or alter- * Includes Lube Oil Filters
nator Cooling System . . . . . . . . . . . . . . . . 568 . . . . .(150)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542 . . . .(1200)
Hydraulic System . . . . . . . . . . . . . . . 946 . . . . (250)
ELECTRIC DRIVE SYSTEM - STATEX III Hydraulic Tank . . . . . . . . . . . . . . . . . 901 . . . . .(238)
(AC/DC Current) Wheel Motor Gear Box (each) . . . . .39.7 . . . . (10.5)
Alternator . . . . . . . . . . . . . General Electric GTA - 26
Dual Impeller, In-Line Blower. 255 m3/min (9000 cfm)
HYDRAULIC SYSTEMS*
Motorized Wheels . . . . . . . . . . . General Electric 787
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1 Pumps
Maximum Speed* . . . . . . . . 48.8 km/h (30.3 MPH) Hoist . . . . . . . . . . . . . . . . . . . . . Tandem Gear Pump
(*w/40.00-57 Tires and 31.875:1 gear train) . . . . . . . . . . .851 lpm (225 GPM) @ 1900 RPM and
. . . . . . . . . . . . . . . . . . . . . . . 17 240 kPa (2,500 psi)
Steering & Brake . . Piston, Pressure Compensating
. . . . . . . . . . . 246 lpm (65 GPM) @ 1900 RPM and
DYNAMIC RETARDING . . . . . . . . . . . . . . . . . . . . . . . 18 961 kPa (2,750 psi)
Extended range retarding with fully blown 14-resistor
System Relief Pressures
grids and reverse retarding standard equipment.
Hoist . . . . . . . . . . . . . . . . . . . 17 240 kPa (2,500 psi)
Maximum Rating . . . . . . . . . . . 2983 kW (4000 HP)
Steering/Brakes . . . . . . . . . . 27 580 kPa (4,000 psi)
Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . 3-Stage
Tank (Vertical/Cylindrical) . . . . . . . Non-Pressurized
TIRES
Filtration Remote-mounted, Replaceable, Elements
Rock Service, Deep Tread. . . . . . . . . (E-4) Tubeless Suction . . . . . . . . . . . Single, Full Flow, 100 Mesh
Standard Tire . . . . . . . . . 40.00 - R57, 68 Ply Rating Hoist & Steering . . . . . . . . . . . . . . . . . . . . . . . . . .
(w/787 Wheelmotor) . . . . . . . . . . . . . . . . . . . . . . . Full Flow, Dual In-Line,
Standard 5 piece patented Phase II New Genera- . . . . . . . . . . . . . High Pressure Beta 12 Rating =200
tion Rims * *With Quick Disconnects for powering disabled truck
* Rims are interchangeable with different positions on and system diagnostics.
the truck, but due to improved design for greater load
support, rims are not interchangeable with other man-
ufacturers rims. SERVICE BRAKES
Rim Size: Actuation . . . . . . . . . . . . . . . . . . . . . . . All Hydraulic
737 mm (29 in.) X 1448 mm (57 in.) X 152 mm (6 in.) Front . . . . . . . . . . . . . . . Wheel Speed, Single Disc
Inboard Mounted . . . . . . . . . . . . . . . . 3 Calipers
Disc Diameter, O.D. . . . . . . 1213 mm (47.75 in.)
Rear . . . . . . . . . . . . . . . Armature Speed, Dual Disc
STEERING (w / Accumulators)
Disc Diameter, O.D. . . . . . . . 635 mm (25.00 in.)
Turning Circle - Front Wheel Track . . 28.4 m (93 ft.) Emergency Brake- Automatically Applied (Standard)
Full Time Power Steering. . . . . . . . . . Twin Cylinders Brake Lock . . . . . . . . . . . . Manual Switch on Panel
Automatic Emergency Steering . . . . . . . .Standard . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping)
FAM0201 Truck Components And Specifications Page 2-3

DISC PARKING BRAKE WEIGHT DISTRIBUTION
Each Rear Wheel . . . . . . . . . . . . . . . . Dual Caliper Empty Vehicle . . . . . . . . Kilograms (Pounds)
. . . . . . . . . . Spring Applied, Hydraulically Released Front Axle . . . . . . . . . . . . . . . .81 823 . . . (180,387)
Rear Axle. . . . . . . . . . . . . . . . .80 682 . . . (177,872)
Total (100% Fuel) . . . . . . . . 162 505 . . . (358,259)
DUMP BODY CAPACITIES AND DIMENSIONS Loaded Vehicle . . . . . . . . Kilograms . . . (Pounds)

Standard, Heaped @ 2:1 (SAE) . 147 m3 (193 yd3) Front Axle . . . . . . . . . . . . . . . 127 330 . . . (280,715)
Struck . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd3) Rear Axle. . . . . . . . . . . . . . . . 258 522 . . . (569,935)
Loading Height Empty . . . . . . . 6.61 m (21 ft. 8 in.) Total . . . . . . . . . . . . . . . . . . . 385 852 . . . (850,650)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nominal Payload *. . . . . . . . . 223 347 . . . (492,391)
Non-heated Body w/Exhaust Mufflers . . . Standard . . . . . . . . . . . . . . . . . . (246 U.S. Ton)
*Nominal payload is defined by Komatsu America
Corporations payload policy documentation. In gen-
eral, the nominal payload must be adjusted for the
specific vehicle configuration and site application.
The figures above are provided for basic product
description purposes. Please contact your Komatsu
distributor for specific application requirements.
OVERALL TRUCK DIMENSIONS

(Empty with Standard Body)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 m (47 ft. 3 in.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32 m (24 ft. 0 in.)
Height with Canopy . . . . . . . . . . . . . . . . 6.96 m (22 ft. 10 in.)
Height with Dump Body Up . . . . . . . . . . 13.52 m (44 ft. 4 in.)
Turning Circle (on front track) . . . . . . . . 28.4 m (93 ft. 0 in.)
Page 2-4 Truck Components And Specifications FAM0201

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
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48,988 . . . . . . . . . . . . . . . . . . . . 108,000
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18,288 . . . . . . . . . . . . . . . . . . . . . 40,318
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 971 . . . . . . . . . . . . . . . . . . . . . . 2,140
Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5,380 . . . . . . . . . . . . . . . . . . . . . 11,640
DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,177 . . . . . . . . . . . . . . . . . . . . . . 4,800
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 . . . . . . . . . . . . . . . . . . . . . . 1,583
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,315 . . . . . . . . . . . . . . . . . . . . . . 2,900
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 . . . . . . . . . . . . . . . . . . . . . . . .485
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 . . . . . . . . . . . . . . . . . . . . . . 1,080
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 . . . . . . . . . . . . . . . . . . . . . . . .489
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,225 . . . . . . . . . . . . . . . . . . . . . . 2,700
RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907 . . . . . . . . . . . . . . . . . . . . . . 2,000
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 . . . . . . . . . . . . . . . . . . . . . . . .265
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 . . . . . . . . . . . . . . . . . . . . . . . .388
Vertical Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . .77
LH Bumper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 . . . . . . . . . . . . . . . . . . . . . . . .400
RH Bumper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 . . . . . . . . . . . . . . . . . . . . . . . .400
FAM0301 Major Component Weights Page 3-1

ITEM KILOGRAMS POUNDS
POWER MODULE
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 . . . . . . . . . . . . . . . . . . . . . . . . 646
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .763 . . . . . . . . . . . . . . . . . . . . . . .1,682
Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,720 . . . . . . . . . . . . . . . . . . . . . . .8,200
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .907 . . . . . . . . . . . . . . . . . . . . . . .2,000
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,741 . . . . . . . . . . . . . . . . . . . . . . .8,248
Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,558 . . . . . . . . . . . . . . . . . . . . . . 18,867
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,905 . . . . . . . . . . . . . . . . . . . . . . .4,200
FLUID COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 . . . . . . . . . . . . . . . . . . . . . . . . 309
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .796 . . . . . . . . . . . . . . . . . . . . . . .1,755
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 . . . . . . . . . . . . . . . . . . . . . . . . 278
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 . . . . . . . . . . . . . . . . . . . . . . . . 717
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,711 . . . . . . . . . . . . . . . . . . . . . . .3,772
FRONT AXLE COMPONENTS

Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,900 . . . . . . . . . . . . . . . . . . . . . . .8,600
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 . . . . . . . . . . . . . . . . . . . . . . . . 496
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,336 . . . . . . . . . . . . . . . . . . . . . . .5,150
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272 . . . . . . . . . . . . . . . . . . . . . . . . 600
REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,146 . . . . . . . . . . . . . . . . . . . . . . .2,527
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373 . . . . . . . . . . . . . . . . . . . . . . . . 822
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,086 . . . . . . . . . . . . . . . . . . . . . . 11,213
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 . . . . . . . . . . . . . . . . . . . . . . . . 342
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12,201 . . . . . . . . . . . . . . . . . . . . . . 26,899
Page 3-2 Major Component Weights FAM0301

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 For Assembly Or Repair 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 50F (10C). 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 For Assembly Or Repair 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 10C (50F) or above.
2. Clean and grind the entire repair area to
remove all rust, grease, oils, paint, and any
other foreign materials likely to contaminate the
weld.

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 52C (125F) 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 427C (800F) 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 150C (300F). Even if the area is over
backup strip is required as long as complete 150C (300F) 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 inspec-
6. Fill gouges with weld and grind all surfaces tion 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 150C (300F) 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 AN A/C DRIVE SYSTEM
American Welding Society Bulletin No. D14.3-94/ TRUCK
D1.1 - Specification for Welding Earthmoving and
Construction Equipment Consult a qualified technician, specifically trained for
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
Procedure Handbook of Arc Welding - Lincoln Elec- The following procedures must be followed to ensure
tric Company, Cleveland, Ohio the safety of maintenance personnel and to help pre-
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
Welding Institute, F. R. Coe, Author Anytime the engine is on:
Do not open any of the cabinet doors or
remove any covers.
Do not use power cables for hand holds or
foot steps.
Do not touch retarder grid elements.
Before opening any cabinets or touching a grid

element or a power cable, the engine and all
warning lights must be off.
Engine Stop Procedure Prior To Maintenance
Perform the following procedure prior to maintenance

to ensure that no hazardous voltages are present in
the A/C drive system.
1. Before turning off the engine, verify the status
of all the drive system warning lights on the
overhead display panel. Use the lamp test
switch to verify that all lamps are functioning
properly.
2. If all red drive system warning lights are off,
turn the engine off.
3. After the engine has been off for at least five
minutes, inspect the link voltage lights. The
lights are located on the exterior of the main
control cabinet and back wall of the operator's
cab (DID panel). If all lights are off, the 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)
FAM0613 10/07 Chassis Assembly Page 6-1

ORDER OF ASSEMBLY LEVEL 5
The assembly procedure is organized in levels. Gen- 1. Operator Cab
erally, the tasks to be done at a given level may be 2. Blower Inlet Duct
performed in any convenient order or simultaneously. 3. Front Tires
However, all tasks in that level must be completed
4. Rear Tires
before proceeding to the next higher level. Each level
depends on the installation of components from the
previous level. LEVEL 6
1. Weld Uprights
NOTE: As stated earlier, shipping and packaging of
large machines will vary. Some of these steps may
change due to different shipping configurations and/ LEVEL 8
or truck options. 1. Dump Body Installation
LEVEL 7
1. Hoist Cylinders
LEVEL 1
2. Rock Ejectors
1. Chassis - Unload and crib for assembly.
3. Mud Flaps
2. Deck Supports
4. Clearance Lights
NOTE: It is easier to install and weld the deck
5. Body Pads/Shims/Guides
supports before the front suspensions are installed.
However, do not install the deck supports first, unless 6. Exhaust Blankets
there is a suitable means of installing the suspension
with the deck support in place. LEVEL 8
3. Hydraulic Tank 1. Clean the Truck
4. Fuel Tank 2. Lighting Wiring
5. Front Suspensions 3. Charge Suspensions
6. Uprights/Air Cleaners 4. Charge Accumulators
7. Diagonal Support Beam 5. Add Fluids
6. Charge the Air Conditioning System
NOTE: Do not weld the air cleaner / uprights until all
decks and the operator cab are installed. Ratchet NOTE: Prior to starting the engine, verify that the
hoists may be required to help tie all the structures steering pump case is full of oil.
together for a proper fit.
LEVEL 2 LEVEL 9
1. Air Cleaner Piping 1. System Checkouts
2. Spindles/Hubs 2. Decals
3. Diagonal Ladder 3. Touch Up Paint
4. Train Operators
LEVEL 3 5. Optional - Install Fire Suppression System
1. Control Cabinet
2. Center Deck
3. Steering Cylinders
4. Tie Rod
5. LH Deck
6. RH Deck/Grid Box
7. Wheel Motors
Page 6-2 Chassis Assembly 10/07 FAM0613

CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at other loca-
tions may be different. However, this outline will pro-
vide a general basis for assembly.
Disconnect the battery cables before arc welding
on the truck. Failure to do so may seriously dam-
age the batteries and electrical equipment. Dis-
connect the battery charging alternator lead wire
before welding on the frame or its components.
Follow all safety recommendations in this man- Fasten the welding machine ground cable to the
ual. Follow all local, state, and federal regula- component being welded.
tions. DO NOT allow welding current to pass through
bearings.
DO NOT lay welding cables over truck electrical
In the procedures that follow, many very heavy com-
cables and harnesses. Welding voltages could be
ponents will be required to be lifted into place and
induced into the truck wiring and cause damage
secured.
to components.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly cleaned and
ventilated.
Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
Inspect all lifting devices. Slings, chains, and charged and in good working condition.
cables used for lifting components must be
inspected daily for serviceable condition.
Refer to the manufacturers guidelines for
correct capacities and safety procedures
when lifting components. Replace any
questionable items.
Slings, chains and cables used for lifting
must be rated for approximately two times the
intended load.
When in doubt as to the weight of Mark cap screws and nuts with paint or ink after
components or any assembly procedure, tightening to the specified torque. This method
contact your customer support manager for provides verification that the hardware has been
further information. properly tightened.
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 8. Recheck the torque on hardware installed at the
factory.
1. Clean and remove all foreign material from
component mounting surfaces. 9. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
2. DO NOT weld the front uprights until all upper
Section 10, Appendix.
decks are installed.
3. Torque the deck mounting bolts before the 10. Use the proper precautions when checking the
exhaust tubes, etc. are installed. nitrogen pressure and oil level in the accumula-
tors.
4. Verify all electrical connectors are free from
paint and/or corrosion. Clean any connector 11. Verify the lube system is lubricated, purged and
that may be questionable. all levels full prior to start up.
5. Do not torque the diagonal ROPS beam until 12. Purge air from the steering pump before truck
after the operator cab & LH air intake tubes are operation. Pressure will not build in the brake
in place. and steering circuit if air is present. Air in the
6. Before installing the cab, tap all threaded holes system may damage the pump. Refer to the
to remove paint. Hydraulic Checkout Procedure in Section 10 of
this manual.
7. Verify all wiring is properly connected before
attempting to start the engine. 13. Use the battery disconnect switch when arc
welding. Connect the weld ground near the
weld area.

NOTES

1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each. Lift
the chassis onto adequate support blocks or stands. The weight of the chassis, as shipped, is approximately
48,988 kg (108,000 lb).
The support blocks/stands must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm
(12 in.) high under the rear axle housing. Placement of the chassis at this height will allow easy installation of
truck components.
Thoroughly clean the chassis.

FIGURE 6-1.

2. Clean the mating surfaces for the deck supports to prepare for installation.

FIGURE 6-2.
FIGURE 6-3.

3. Lift the LH deck support into position. The weight of the deck support is approximately 490 kg (1080 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. 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. Gaps in the
weld around the support may result in premature frame cracking in this area.
4. Repeat for the RH deck support. The weight of the deck support is approximately 222 kg (489 lb).

FIGURE 6-4.
FIGURE 6-5.

10. Prepare the hydraulic filters for mounting on the fuel tank. Ensure all filter hardware is properly tightened.
11. Clean the mounts for the hydraulic tank and the fuel tank.

FIGURE 6-6.
FIGURE 6-7.

12. Lift the hydraulic tank into position on the cradles. The weight of the hydraulic tank is approximately 325 kg
(717 lb).
Install the four cap screws and the cradle caps at the top of the tank. Tighten to 616 61 Nm (454 45 ft lb).
Install the rubber dampeners and mounting hardware at the rear of the tank. Tighten the two cap screws to
standard torque. Refer to Standard Tables in Section 10, Appendix.
13. Lift the fuel tank into position on the cradles. The weight of the fuel tank is approximately 1711 kg (3772 lb).
Install the four cap screws and the cradle caps at the top of the tank. Tighten to standard torque. Refer to
Standard Tables in Section 10, Appendix.
Install the rubber dampeners and mounting hardware at the rear of the tank. Tighten the four cap screws to
standard torque.

FIGURE 6-8.
FIGURE 6-9.

10. Connect the piping to the hydraulic tank and properly tighten all fittings.
.
NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened.
11. Install the hydraulic filters onto the bracket at the rear of the fuel tank.
Connect the fuel supply line to the fitting at the rear of the tank, and connect the return line to the fitting at the
top of the tank.

FIGURE 6-10.
FIGURE 6-11.

12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.

FIGURE 6-12.
FIGURE 6-13.

13. Clean and dry the mounting surfaces on both 14. Lubricate the cap screw threads, cap screw
the suspension and the frame. Use a cleaning head seats, washer faces, and nut seats with a
agent that does not leave a film after evapora- rust preventive compound.
tion, such as trichlorethylene, tetrachlorethyl-
ene, acetone or lacquer thinner.
High tightening torque is required to load the

front suspension mounting cap screws.
Repeated tightening will result in cap screw
fatigue and damage. DO NOT reuse mounting
cap screws, washers and nuts. Replace the
hardware after each use.
Suspension mounting cap screws are specially
hardened to meet or exceed grade 8
specifications. Replace only with cap screws of
correct hardness. Refer to the appropriate parts
book for the correct part numbers. FIGURE 6-14. INSTALLATION OF HARDENED
. FLAT WASHER
1. Hardened Flat Washer 2. Cap Screw
The use of dry threads in this application is not 15. The hardened flat washers use on the front sus-
recommended. Due to the high tightening forces pensions are punched during the manufacturing
required to load these cap screws, dry threads or process. Assemble the cap screws and wash-
threads lubricated with anti-seize compounds ers, and position the punch lip away from the
may result in damage. Only use the approved cap screw head to prevent damage. See Figure
lubricants listed below. 6-14.
American Anti-Rust Grease #3-X from Standard 16. Lift the front suspension into position. Refer to
Oil Division of American Oil Company Figure 6-15. The weight of each front suspen-
Rustolene D grease from Sinclair Oil Company sion cylinder is approximately 2,336 kg (5,150
lb). Install the mounting hardware and tighten
Gulf NoRust #3 from Gulf Oil Company
according to the "turn-of-the-nut" method out-
Rust Ban 326 from Humble Oil Company lined on the following pages.
1973 Rustproof from the Texas Company
Rust Preventive Grease-Code 312 from the
Southwest Grease and Oil Company
NOTE: If none of the rust preventive greases listed
above are available for field assembly, use one of the
following lubricants:
SAE 30 weight oil
5% Molybdenum - Disulphide Grease
DO NOT use anti-seize compounds.

FIGURE 6-15.

"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
18) to 542 5 Nm (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 90 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 6-16 and 6-17.
then tighten again as follows:
2.) Scribe a reference mark at the opposite
d. Initially tighten the four cap screws (1) at the end of the turning member to ensure that
upper mount to 95 Nm (70 ft lb). Then, either the cap screw head or nut, remains
advance the cap screw heads 60 as out- stationary.
lined in Steps d-1 through d-3. Refer to Fig-
3.) Each corner of a hexagon represents 60.
ure 6-16.
The turning member, either the cap screw
head or nut, is turned until the marked
corner is adjacent with the marked refer-
ence line. Prevent the opposite end of the
turning member from turning during the
tightening procedure.
NOTE: Do not exceed 4 rpm tightening
speed. Do not hammer or jerk the wrench
during the tightening procedure.
e. Loosen the top two corner cap screws (1,
Figure 6-18) and the bottom outer four cap
screws (8), (without spacers).
FIGURE 6-16. 60 DEGREE ADVANCE 1.) Tighten the top two corner cap screws to
95 Nm (70 ft lb), then advance the cap
screw heads 60.
Initially tighten the bottom four cap screws 2.) Tighten the bottom, outer four cap screws
(6, Figure 6-18) to 136 Nm (100 ft lb). to 203 Nm (150 ft lb), then advance the
Then, advance the cap screw heads 90 cap screw heads 90.
as outlined in Steps d-1 through d-3. Refer
NOTE: If for any reason, these fasteners need to be
to Figure 6-17.
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 6-17. 90 DEGREE ADVANCE

FIGURE 6-18. SUSPENSION INSTALLATION
1. Cap Screws, Washers 6. Cap Screws, Washers

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

17. Remove the center deck to enable easy installation of the air intake tubing and the diagonal cross tube (Fig-
ure 6-19). The weight of the center deck is approximately 220 kg (485 lb).
Do not discard the hardware at the rear of the deck. This hardware is to be used for installation.

FIGURE 6-19.

18. Prepare the upright mating surfaces for installation. Refer to Figure 6-20.
19. Attach either upright to a crane using adequate lifting apparatus. Attach a ratchet hoist to the lifting apparatus
to enable the upright to pivot for proper alignment. Refer to Figure 6-21.

FIGURE 6-20.
FIGURE 6-21.

20. Lift the LH & RH uprights into position and install the four cap screws for each upright. Tighten to standard
torque. Refer to Standard Tables in Section 10, Appendix. The weight of the RH upright is approximately 907
kg (2000 lb). The weight of the LH upright is approximately 1,225 kg (2,700 lb).
Refer to Figure 6-22.
DO NOT weld the torque tubes on the uprights until the decks are installed.
21. Attach the upper radiator stabilizers rods to the uprights. Refer to Figure 6-23. After the decks are installed
and the uprights welded, adjust the stabilizers to vertically level the radiator.

FIGURE 6-22.
FIGURE 6-23.

22. Prepare the mounting surfaces for the LH diagonal tube (Figure 6-24).
23. Lift the tube into position (Figure 6-25). The weight of the diagonal tube is approximately 120 kg (265 lb).
Do not tighten the cap screws until the deck and the cab are in place.

FIGURE 6-24.
FIGURE 6-25.

24. Install the hanger brackets for the intake tubes. Refer to Figure 6-26.
25. Lift the air intake tubes into place. Install and tighten the clamps that secure the hoses.
Refer to Figure 6-27 - 6-29. The intake tubes are assembled and adjusted for installation on the truck. DO
NOT loosen any of the connections during installation.

FIGURE 6-26.
FIGURE 6-27.

FIGURE 6-28.

FIGURE 6-29.

26. Lift the center deck into position. Install the mounting hardware and tighten to standard torque. Refer to Stan-
dard Tables in Section 10, Appendix.
27. 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).

FIGURE 6-30.
FIGURE 6-31.

28. Lift the retainer plate into position under the spindle. The weight of the plate is approximately 48 kg (106 lb).
Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brake assembly is
approximately 3900 kg (8600 lb).
29. Install the twelve retainer plate cap screws. Alternately tighten the cap screws to 678 Nm (500 ft lb). Con-
tinue to tighten the cap screws in increments of 330 Nm (250 ft lb) until 2705 270 Nm (1,995 200 ft lb) is
reached.
30. Repeat the previous steps for the remaining wheel.

FIGURE 6-32.
FIGURE 6-33.

31. Prepare the steering cylinder and tie rod mounting surfaces.

FIGURE 6-34.

32. Move the steering cylinder rod eye into position on the steering arm. Lubricate the mounting pin with grease.
Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 71 Nm (525 53 ft
lb).
NOTE: Use alignment sleeve (TY4576) to aid in assembly of the steering cylinder joints.
33. Lift the tie rod into position on the steering arms. The weight of the tie rod is 272 kg (600 lb). Lubricate the
mounting pins with grease. Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to
712 71 Nm (525 53 ft lb).
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.
NOTE: Use alignment sleeve (TY4576) to aid in assembly of the tie rod joints.

FIGURE 6-35.
FIGURE 6-36.

34. Install the handrails onto the LH deck and lift the deck into place. The weight of the LH deck with handrails is
approximately 1315 kg (2900 lb). Loosely install the eight deck mounting cap screws.
NOTE: After each deck is in place, tighten the cap screws to standard torque. Refer to Standard Tables in Section
10, Appendix.
35. Lift the operator cab into position. The weight of the cab is approximately 2177 kg (4800 lb).
Tap the cab mounting holes to remove any paint.
Install and tighten the forty cap screws to standard torque.
36. Tighten the hardware for the LH diagonals tube to standard torque. Refer to Standard Tables in Section 10,
Appendix.

FIGURE 6-37.
FIGURE 6-38.

37. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 3720 kg (8200 lb).
Install the mounting cap screws and tighten to standard torque. Refer to Standard Tables in Section 10,
Appendix.
NOTE: On domestic trucks, the retarding grids are already installed on the deck.
38. Install the handrails on the RH deck.
39. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approxi-
mately 4500 kg (9920 lb).
40. Weld the LH & RH uprights to the front frame tube.

FIGURE 6-39.
FIGURE 6-40.

41. Lift the two bumper extensions into place. The weight of each bumper extension is approximately 181 kg (400
lb).
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-41.
FIGURE 6-42.

42. Lift the control cabinet into position. The weight of the cabinet is approximately 907 kg (2000 lb). Install the
mounting hardware. Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10,
Appendix.
43. Connect the wiring for the control cabinet and the retarder grid. Refer to Figures 6-44 - 6-47.

FIGURE 6-43.

FIGURE 6-44.
FIGURE 6-45.

FIGURE 6-46.
FIGURE 6-47.

44. Install the blower hose and clamps to the control cabinet and transition duct.
45. LIft the air intake ductwork into position and install the mounting hardware. The weight of the inlet duct is
approximately 293 kg (646 lb). Tighten the cap screws to standard torque. Refer to Standard Tables in Section
10, Appendix. Refer to 6-48 - 6-51.

FIGURE 6-48.

FIGURE 6-49.
FIGURE 6-50.

FIGURE 6-51.

46. Lift the rear center deck into position behind the inlet duct. The weight of the deck is approximately 92 kg (203
lb). Install the mounting hardware and tighten to standard torque. Refer to Standard Tables in Section 10,
Appendix.

FIGURE 6-52.
1. Rear Center Deck 2. Inlet Duct

47. Install the diagonal ladder. The weight of the diagonal ladder is approximately 176 kg (388 lb).
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-53.

48. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assem-
blies installed is approximately 12,201 kg (26,899 lb).
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 6-57.
Tighten the wheel motor mounting cap screws to 2007 201 Nm (1480 148 ft lb).
NOTE: When lifting the wheel motors, do not lift under the brake assembly. Shipping fasteners installed in the
outboard rim bolt circle must remain in place during lifting and installation of wheel motors.
FIGURE 6-54.
FIGURE 6-55.

FIGURE 6-56.
FIGURE 6-57.
1. Washer 2. Cap Screw

49. Connect the power cables and hydraulic hoses to each of the wheel motors.

FIGURE 6-58.

FIGURE 6-59. FRONT WHEEL ASSEMBLY
1. Valve Assembly 6. Lock Ring 11. Lockwasher 16. Lockwasher

2. Bead Seat Band 7. Wheel Retainer Lug 12. Nut 17. Bent Plate
3. Rim 8. Nut 13. Clamp 18. Hub
4. O-Ring 9. Capscrew 14. Capscrew
5. Side Flange 10. Flat Washer 15. Flatwasher
50. Use a tire handler to lift the front wheel into position
on the wheel hub. Install wheel retainer lugs (7, Fig-
ure 6-59 and lubricated nuts (8). Evenly tighten each
nut to 407 Nm (300 ft lb). Tighten the nuts in the
sequence shown in Figure 6-60.
51. Spin the wheel and check rim run-out. Maximum run-
out is 5mm (0.20 in.). If run-out exceeds specifica-
tions, loosen all nuts and tighten again.
If run-out is within specifications, tighten each nut to
746 Nm (550 ft lb).Tighten the nuts in the sequence
shown in Figure 6-60.
After the truck has been assembled and is operational, FIGURE 6-60. TIGHTENING SEQUENCE
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. Recheck the torque on
a daily basis until the torque is maintained. Check the
torque at regular intervals, thereafter.

FIGURE 6-61.
FIGURE 6-62.

FIGURE 6-63. REAR WHEEL ASSEMBLY
1. Side Flange 5. Lock Ring 9. Clamp 13. Inner Wheel Rim

2. Outer Wheel Rim 6. Spacer 10. Nut
3. Bead Seat Band 7. Valve Cap 11. Wheel Retainer Wedge
4. O-Ring 8. Core 12. Valve Extension Tube
52. Use a tire handler to lift the inner dual wheel onto the wheel motor hub. Use caution when positioning. DO
NOT damage the tire inflation extension.
53. Use a lifting device to install spacer (6, Figure 6-63) onto wheel motor hub. The weight of the spacer is
approximately 88 kg (194 lb). Tap the spacer against the inner dual.
54. Lift the outer dual into position on the wheel motor hub.
Due to its size and weight, keep personnel away from the wheel assembly during installation.
NOTE: Position the outer dual wheel so that tire valve bracket aligns with the inner wheel inflation hose.

55. Install the wedges onto the studs and secure in place
with the lubricated wheel nuts. Evenly tighten each nut
in an alternating (criss-cross) pattern as shown in Fig-
ure 6-64. Tighten the nuts to 407 Nm (300 ft lb).
56. Spin the wheel and check rim run-out. Maximum run-
out is 5 mm (0.20 in.). If run-out exceeds specifica-
tions, loosen all of the nuts. Again, tighten the nuts as
specified in the previous step.
57. If run-out is within specifications, tighten each nut in
sequence to 746 Nm (550 ft lb).
After the truck has been assembled and is operational,

the truck must be operated for a short period of time, FIGURE 6-64. TIGHTENING SEQUENCE
and the torque on the wheels re-checked. Tighten the
wheels to the torque specified above.Recheck the
torque on a daily basis until the torque is maintained.
Check the torque at regular intervals, thereafter.
58. Secure the inner and outer dual tire inflation lines to the bracket on the outer rim. Tighten the cap screws to
standard torque.
FIGURE 6-65.

59. Attach a lifting device to the radiator surge tank. Lift the tank into position on the radiator. Install the mounting
hardware to the surge tank.
Install the hoses to the radiator and the surge tank.

FIGURE 6-66.
FIGURE 6-67.

60. Lift the surge tank cover into position and install the mounting hardware. The weight of the cover is approxi-
mately 98 kg (216 lb).

FIGURE 6-68.

61. Connect the electrical harnesses and hydraulic hoses below the operators cab.
62. Connect the hydraulic piping from the operators cab to the hydraulic cabinet and route the hoses appropri-
ately.
FIGURE 6-69.
FIGURE 6-70.

FIGURE 6-71.
FIGURE 6-72.

63. Install the mud-flaps and mud guards.
64. Install any remaining handrails. Tighten the cap screws to standard torque. Refer to Standard Tables in Sec-
tion 10, Appendix.
65. The truck is now ready for body installation.

DUMP BODY ASSEMBLY
GENERAL INFORMATION If the body is being welded in a cold climate, it is

advisable to move the parts to be welded into an
enclosed shop area. Surfaces to be welded must be
dry and the temperature must be above 10C (50F).
If shop space is not available, it may be necessary to
provide a portable enclosure and pre-heat the parts
The total weight of the body is approximately prior to welding.
26,853 kg (59,201 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
FAM0710 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 FAM0710

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 10C
Install the canopy cap screws and tighten.
(50F).
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.
Refer to Figure 7-7.
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.
8. Clean the weld joints and paint.
FIGURE 7-21.

FINAL ASSEMBLY
Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected
daily for serviceable condition. Refer to the manufacturers guidelines for correct capacities and safety
procedures when lifting components. Replace any questionable items.
Slings, chains and cables used for lifting must be rated for approximately two times the intended load.
When in doubt as to the weight of components or any assembly procedure, contact your customer
support manager for further information.
Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load.
Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a
suspended load.
Before lifting the body, ensure there is adequate clearance between the body and overhead structures
or electric power lines.
FAM0812 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 (Figure 8-1).
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.
2. With the body in position, install shims (6, Figure 8-4) 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 Nm (300 ft lb). Use washers, as necessary on
the nut side only, to provide proper thread contact.
5. Install the pivot pin at the opposite side of the body.
Page 8-2 Final Assembly FAM0812

FIGURE 8-1.
FIGURE 8-2.

FIGURE 8-3.

FIGURE 8-4. 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 8-5. Align the retaining cap screw hole
and install pin (2, Figure 8-6).
Install the pin retaining cap screws and nuts. Tighten to 407 Nm (300 ft lbs).

FIGURE 8-5.
FIGURE 8-6. 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 Figure 8-7.
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 8-7. BODY PAD INSTALLATION
3. Dump Body 5. Frame 7. Shim
4. Pad Mounting Hardware 6. Body Pad 8. Mounting Pad

9. Tack weld the rock ejector mounting brackets into position on the underside of the body. The ejectors must be
positioned on the center line between the rear tires within 6.0 mm (0.25 in.). Before welding, drop a plumb line
to check rock ejector clearance. Position the rock ejector a distance of 88 mm (3.5 in.) from the wheel hous-
ing. Refer to Figure 8-10.
NOTE: With rock ejector arm (1) hanging vertical as shown in Figure 8-9, there must be no gap at stop block (3).
If the rock ejector arms are bent during operation, they must be removed and straightened. Inspect the
mounting brackets, pins and stops at each shift change for wear and/or damage. Repair as necessary.

FIGURE 8-8.
FIGURE 8-9. ROCK EJECTOR MOUNTING
1. Rock Ejector Arm 3. Stop Block

2. Pin 4. Mounting Bracket
FIGURE 8-10. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 3. Wheel Spacer
2. Wear Sleeve

10. Install any remaining mud guards or flaps (Figures 8-11 & 8-12).

FIGURE 8-11.
FIGURE 8-12.

11. Install both body guide brackets loosely into place (Figure 8-13).
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.

FIGURE 8-13. BODY GUIDE
1. Dump Body 3. Body Guide Wear

2. Body Guide Plates

12. Adjust the body up limit switch.
Adjust the switch bracket to maintain an air gap between the sensing area and target of 12.7 mm (0.50 in.) to
15.7 mm (0.62 in.). Adjust the switch to cover the bottom 53.8 mm (2.12 in.) of the target. Secure the compo-
nents in place.
13. Raise the body and attach the body retention cable. Remove the support blocks. Weld the body guide brack-
ets into place.

FIGURE 8-14. BODY-UP SWITCH ADJUSTMENT

14. Install the exhaust system piping and hangers. The deck mounted muffler exhaust is shown Figure 8-15.
Refer to the installation prints for other optional exhaust systems.

FIGURE 8-15.

15. With the body in the raised position, adjust the body hoist limit switch. Position the target so that it covers the
entire switch sensing area. Adjust the gap between the target and the switch to 12.7 - 14.7 mm (0.50 - 0.58
in.). Secure the target into position.
The switch should activate 152 mm (6 in.) before maximum cylinder stroke.
16. Install the LH & RH engine inspection lights (Figure 8-17).

FIGURE 8-16.
FIGURE 8-17.

17. Install add-on components such as the lubrication system. Verify that all electrical and hydraulic connections
are correct. Refer to Figure 8-19.
FIGURE 8-18.

FIGURE 8-19.
1. L.H. Suspension, Bottom Bearing 13. R.H. Anti-Sway Bar Bearing

2. L.H. Hoist Cylinder, Top Bearing 14. R.H. Suspension, Top Bearing
3. L.H. Hoist Cylinder, Bottom Bearing 15. Truck Frame
4. L.H. Anti-Sway Bar Bearing 16. Vent Hose
5. L.H. Suspension, Top Bearing 17. Pipe Plug (Oil Level)
6. L.H. Body Pivot Pin 18. Pressure Switch, N.O., 17 237 kPa (2500 psi)
7. R.H. Body Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. R.H. Suspension, Bottom Bearing 21. Filter
10. R.H. Hoist Cylinder, Top Bearing 22. Grease Supply to Injectors
11. R.H. Hoist Cylinder, Bottom Bearing 23. Injectors
12. Rear Axle Pivot Pin 24. Pressure Switch, N.O., 13 790 kPa (2000 psi)

18. Install the fire system. Refer to Figures 8-20 & 8-21.
This installation is normally performed by the fire system distributor.

FIGURE 8-20.
FIGURE 8-21.

19. Paint the truck as needed.
20. Install the anti-skid strips at the designated areas on the decks (Figure 8-22).
21. Install all decals on their designated areas (Figure 8-23).

FIGURE 8-22.
FIGURE 8-23.

22. 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 8-24.

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 - EL2603
8. Brake Checkout Procedure - EG4938
9. VHMS Checkout Procedure - EK8480
10. Payload Meter III Checkout Procedure - EJ3061
11. Electrical Checkout Procedure - EK8477
12. Standard Torque Charts and Conversion Tables
13. Field Assembly Inspection Report
14. 50 Hour Post Commissioning Checksheet
FAM1001 10/07 Appendix Page 10-1

NOTES
Page 10-2 Appendix 10/07 FAM1001

LUBRICATION CHART
NOTES
SUSPENSION OILING AND CHARGING PROCEDURE
GENERAL For best results, HYDRAIR II suspensions should
These procedures cover the Oiling and Charging of be charged in pairs (fronts together and rears
together). If rears are to be charged, the fronts
HYDRAIRII suspensions on Komatsu Electric Drive
should be charged first.
Dump Trucks.
NOTE: For longer life of suspension components, a
Suspensions which have been properly charged will
Friction Modifier should be added to the suspension
provide improved handling and ride characteristics
oil. See Specifications Chart, Figure 4-5 at the end of
while also extending the fatigue life of the truck frame
this chapter.
and improving tire wear.
NOTE: Set up dimensions specified in the charts
NOTE: Inflation pressures and exposed piston
must be maintained during oiling and charging
lengths are calculated for a normal truck gross
procedures. However, after the truck has been
vehicle weight (GVW). Additions to truck weight by
operated, these dimensions may vary.
adding body liners, tailgates, water tanks, etc. should
be considered part of the payload. Keeping the truck
GVW within the specification shown on the Grade/
EQUIPMENT LIST
Speed Retard chart in the operator cab will extend HYDRAIR Charging Kit
the service life of the truck main frame and allow the
Jacks and/or Overhead Crane
HYDRAIRII suspensions to produce a comfortable
ride. Support Blocks (Front and Rear) for:
Oiling Height Dimensions
Nitrogen Charging Height Dimensions
HYDRAIR Oil (See Specifications Chart)

All HYDRAIR II suspensions are charged with Friction Modifier (See Specifications Chart)
compressed nitrogen gas with sufficient pres-
Dry Nitrogen (See Specifications Chart)
sure to cause injury and/or damage if improperly
handled. Follow all safety instructions, cautions,
and warnings provided in the following proce-
dures to prevent any accidents during Oiling and
Charging.
Proper charging of HYDRAIRII 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.
HYDRAIR CHARGING KIT 5. Attach charging valve adapters (2) to each sus-
pension charging valve stem.
Assemble service kit as shown in Figure 4-1 and
6. Turn "T" handles (1) clockwise (this will depress
attach to container of pure dry nitrogen (8).
core of charging valve and open the gas cham-
Installation of Charging Kit ber of the suspension).
7. Open both outlet valves (3).
1. Remove protective covers and charging valve
caps from suspensions to be charged. NOTE: By selective opening and closing of outlet
2. Turn "T" handles (1, Figure 4-1) of adapters (2) valves (3), and inlet valve (4), suspensions may be
completely counterclockwise. charged separately or together.
3. Ensure outlet valves (3) and inlet valve (4) are
closed (turned completely clockwise).
4. Turn swivel nut (small hex) on charging valve Removal of Charging Kit
three full turns counterclockwise to unseat the 1. Close both outlet valves (3).
valve. 2. Turn "T" handles (1) counterclockwise to
release charging valve cores.
3. Remove charging valve adapters (2) from
charging valves.
4. Tighten swivel nut (small hex) on charging
valve. If a new charging valve is being used,
tighten swivel nut to 14.2 Nm (10.5 ft lbs)
torque, then loosen and retighten swivel nut to
14.2 Nm (10.5 ft lbs) torque. Again loosen
swivel nut and retighten to 5.4 Nm (4 ft lbs)
torque. Replace valve cap (1) and tighten to 3.3
Nm (2.5 ft lbs) torque (finger tight).
5. Install charging valve caps and protective cov-
ers on both suspensions.
FIGURE 4-1. HYDRAIR CHARGING KIT

NOTE: Arrangement of parts may vary from
illustration above, depending on Charging Kit P/N.
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 (Specifications Figure 4-5)
SUPPORT BLOCKS FOR OILING AND FRONT SUSPENSION
CHARGING DIMENSIONS 1. Park the unloaded truck on a hard, level sur-
face. Place the directional control lever in
PARK. Place chock in front and behind two sets
Prior to starting oiling and charging procedures, sup-
of wheels to prevent roll away.
ports should be fabricated which will maintain the
correct exposed piston rod extensions. 2. Thoroughly clean area around the charging
valve on the suspensions. Remove the protec-
tive covers from the charging valves.
Rear support blocks for nitrogen charging are no

longer necessary. Rear suspensions still require All HYDRAIRII suspensions are charged with
support blocks for oil charging. compressed nitrogen gas with sufficient pres-
Exposed piston rod extensions are specified for both sure to cause injury and/or damage if improperly
handled. Follow all the safety notes, cautions and
oil level and nitrogen charging for HYDRAIRII sus- warnings in these procedures to prevent acci-
pensions. These dimensions are listed in the Tables dents during servicing and charging.
below Figures 4-2 and 4-4. Measure dimensions
from the face of the cylinder gland to the machined
surface on the spindle at the front suspension. Mea- Front Suspension Oiling
sure from the face of the cylinder gland to the piston
flange at the rear suspension.
Support blocks may be made in various forms. Mild

steel materials are recommended. Square stock or When blocks are in place on a suspension, they
pipe segments [1 in. (25 mm) minimum] may be must be secured with a strap or other means to
used. Blocks must be capable of supporting the avoid accidental discharge. An unsecured block
weight of the truck during oiling and charging proce- could fly loose as weight is applied, presenting
dures while avoiding contact with plated surfaces the possibility of serious injury to nearby person-
and seals on the suspension. Refer to Figure 4-2 for nel and/or damage to the equipment. Overhead
front suspension support block placement and Figure clearance may be reduced rapidly and suddenly
4-4 for rear support block placement. when nitrogen pressure is released!
Friction Modifier should be added to the suspension
this chapter.
1. Position and secure oiling height dimension
blocks in place (Figure 4-2). When nitrogen
pressure is released, suspensions will lower to
rest on the blocks. Ensure the blocks do not
mar or scratch the plated surfaces of the pis-
tons or damage wiper seals in the lower bearing
retainer. Support blocks must seat on the spin-
dle and the cylinder housing. The blocks should
be positioned 180 apart to provide stability.
Wear a face mask or goggles while relieving

nitrogen pressure.
2. Remove charging valve cap. Turn the charging
valve swivel nut (small hex) counterclockwise
three full turns to unseat valve seal. DO NOT
TURN LARGE HEX. The charging valve body
has a bleeder groove in its mounting threads
but for safety of all personnel the valve body
MUST NOT be loosened until ALL nitrogen
pressure has been vented from the suspension.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
all nitrogen has been vented to the atmosphere,
the suspension should have collapsed slowly
and be seated solidly on the support blocks. FIGURE 4-2. FRONT SUSPENSION
4. Remove top fill plug next to the charging valve
(Figure 4-2).
5. Fill the suspension with clean HYDRAIR oil FRONT SUSPENSION DIMENSIONS (EMPTY)
(with 6% friction modifier) until the cylinder is full
TRUCK MODEL & OILING CHARGING CHARGING
to the top of the fill plug bore. Drip pans should OPTIONS HEIGHT HEIGHT PRESSURE
be used and all spillage cleaned from outside of mm (IN.) mm (IN.) kPa (psi)
the suspension. Allow the suspension to stand 830E* 25.4 (1.0) 229 (9.0) 2689 (390)
for at least 15 minutes to clear any trapped
830E** 25.4 (1.0) 229 (9.0) 2827 (410)
nitrogen and/or bubbles from the oil. Add more
* with standard Rock Body
suspension oil if necessary. Install a new fill ** with Combination Body / Tailgate
plug O-ring, and install the plug. Note: If truck starts to lift off blocks before charging pressure is
attained, STOP CHARGING.
Front Suspension Nitrogen Charging 2. Tighten valve body (large hex, 6) to 16.5 ft lbs
(22.4 Nm) torque. The valve swivel nut (small
hex, 4) must be unseated by turning counter-
clockwise three full turns.
Lifting equipment (crane or hydraulic jacks) must

be of sufficient capacity to lift the truck weight.
Be certain that all personnel are clear of lift area
before lift is started. Clearances under the truck
Dry nitrogen is the only gas approved for use in
may be suddenly reduced.
HYDRAIRII suspensions.Charging of these
1. If removed, install the charging valve with new components with oxygen or other gases may
O-ring (9, Figure 4-3). Lubricate the O-ring with result in an explosion which could cause fatali-
clean HYDRAIRoil. ties, serious injuries and/or major property dam-
age. Use only nitrogen gas meeting the
specifications shown in chart (Figure 4-5).
3. Install HYDRAIR Charging Kit and a bottle of

pure dry nitrogen. Refer to Installation of Charg-
ing Kit.
4. Charge the suspensions with nitrogen gas to
50.8 mm (2 in.) greater than the charging height
listed in Figure 4-2. Close inlet valve (4, Figure
4-1).
5. Remove the oiling blocks from the suspensions
and install the nitrogen charging blocks. Secure
the blocks to prevent accidental dislodging.
NOTE: Use caution to prevent damage to plated cyl-
inder surfaces and oil seals when installing the
blocks.
FIGURE 4-3. CHARGING VALVE 6. Remove the center hose from manifold (6).
7. Open inlet valve (4) until the pressure has
1. Valve Cap 6. Valve Body dropped below the pressure listed in Figure 4-2,
2. Seal 7. O-Ring and then close the valve.
3. Valve Core 8. Valve Stem 8. Install the center hose to manifold (6).
4. Swivel Nut 9. O-Ring
5. Rubber Washer 9. Charge the suspensions to the pressure listed
in Figure 4-2. DO NOT use an overcharge of
nitrogen to lift the suspensions off of the charg-
ing blocks.
10. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes in order to allow
the pressures in the suspensions to equalize.
11. Close outlet valves (3) and remove charging kit REAR SUSPENSION
components. Refer to Removal of Charging Kit. 1. Park the unloaded truck on a hard, level sur-
12. If charging valve is being reused, tighten swivel face. Apply the parking brake, and chock the
nut (4, Figure 4-3) to 5.4 Nm (4 ft lbs) torque. wheels.
13. If a new charging valve is being used, tighten 2. Thoroughly clean the area around the charging
swivel nut to 14.2 Nm (10.5 ft lbs) torque, then valve on the suspensions. Remove the protec-
loosen and retighten swivel nut to 14.2 Nm tive covers from the charging valves and the
(10.5 ft lbs) torque. Again loosen swivel nut and metal covers from the suspension piston.
retighten to 5.4 Nm (4 ft lbs) torque. Replace
valve cap (1) and tighten to 3.3 Nm (2.5 ft lbs)
torque (finger tight).
14. Install protective guard over charging valve. When the blocks are in place on a suspension,
15. Raise the truck body in order to extend the front they must be secured in place with a strap or
suspensions and allow for removal of the nitro- other means to insure the blocks staying in place
gen charging blocks. Ensure that sufficient while being used. An unsecured block could fly
overhead clearance exists before raising the loose as weight is applied, presenting the possi-
body. If the suspensions do not extend after bility of serious injury and/or damage.
raising the body, turn the steering wheel from
stop to stop several times. If the suspensions
Friction Modifier must be added to the suspension
still do not extend enough to allow for removal
of the blocks, use a crane or floor jacks to raise
this chapter.
the truck and remove the blocks.
Any time the suspensions are recharged, the calibra-
tion of the Payload Meter system is affected. Refer to Rear Suspension Oiling
the Payload Meter III section and perform a
Clean Truck Tare. This will ensure accurate payload 1. If the suspensions are extended, position and
records. secure oiling height dimension blocks (sup-
ports) in place (See Figure 4-4) so the blocks
The front HYDRAIR suspensions are now ready for are seated between the piston flange and the
operation. Visually check the extension with the truck cylinder housing. Ensure the blocks do not mar
both empty and loaded. Record the extension dimen- or scratch the plated surfaces on the piston or
sions. Maximum downward travel is indicated by the damage the wiper seals in the cylinder barrel.
dirt ring at the base of the piston. Operator com- Support blocks must seat on the piston flange
ments on steering response and suspension rebound and the cylinder housing. The blocks should be
should also be noted. positioned 180 apart to provide stability.
Make certain all personnel are clear and support

blocks are secure before relieving nitrogen pres-
sure from the suspension. Use a face mask or
goggles when venting nitrogen.
2. Remove charging valve cap. Turn the charging
valve swivel nut (small hex) counterclockwise
three full turns to unseat valve seal. DO NOT
TURN LARGE HEX. The charging valve body
has a bleeder groove in its mounting threads,
but for safety of all personnel, the valve body
MUST NOT be loosened until ALL nitrogen
pressure has been vented from the suspension.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
nitrogen pressure has been vented to atmo-
sphere, loosen and remove the fill plug. The
suspension should have collapsed slowly as
gas pressure was released. Truck weight is now
supported by the support blocks.
4. Use a plastic tube to help bleed off trapped air
inside the piston. Remove vent plugs and the
bleeder screw. Service the suspension with
clean HYDRAIR Oil (with 6% friction modifier)
until clean oil comes out of the port where the
bleeder screw and plug were removed from the
side of the housing. Drip pans should be used FIGURE 4-4. REAR SUSPENSION
and all spillage cleaned from the outside of the
suspension. Install the bleeder and vent plugs.
Continue to fill the oil until it reaches the fill port.
Allow the suspension to stand for at least 15
minutes to clear any trapped nitrogen and/or air Rear Suspension Nitrogen Charging
bubbles from the oil. Add oil if necessary, and
install the fill plug.
REAR SUSPENSION DIMENSIONS (EMPTY) Lifting equipment (overhead or mobile cranes, or

TRUCK MODEL & OILING CHARGING *CHARGING hydraulic jacks) must be of sufficient capacity to
OPTIONS HEIGHT HEIGHT PRESSURE lift the truck weight. Be certain that all personnel
mm (IN.) mm (IN.) kPa (psi)
are clear of lift area before lift is started. Clear-
830E 25.4 (1.0) 241 (9.5) 1724 (250) ances under the truck may be suddenly reduced.
830E 25.4 (1.0) 241 (9.5) 2172 (315)
* Note: Charging pressures are for reference only and may vary depending on body
weights.
Ensure the automatic apply circuit has not

applied the service brakes during truck mainte-
nance. If the front brakes are applied during rear
suspension charging, the axle cannot pivot for
frame raising / lowering, and the rear suspension
may be unable to move up or down.
1. If removed, install charging valve with new O- NOTE: A low left front suspension will cause the right
ring (9, Figure 4-3). Lubricate the O-ring with rear suspension to be high. A low right front
clean HYDRAIRoil. suspension will cause the left rear suspension to be
high.
2. Tighten valve body (large hex, 6) to 22.4 Nm
(16.5 ft lbs) torque. The valve swivel nut (small 8. Close outlet valves (3) and remove charging kit
hex, 4) must be unseated by turning counter- components. Refer to Removal of Charging Kit.
clockwise three full turns. 9. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 5.4 Nm (4 ft lbs)
torque.
10. If a new charging valve is being used, tighten
swivel nut to 14.2 Nm (10.5 ft lbs) torque, then
Dry nitrogen is the only gas approved for use in loosen and retighten the swivel nut to 14.2 Nm
HYDRAIRII suspensions. Charging of these (10.5 ft lbs) torque. Again, loosen the swivel nut
components with oxygen or other gases may and retighten to 5.4 Nm (4 ft lbs) torque.
result in an explosion which could cause fatali- Replace valve cap (1) and tighten to 3.3 Nm
ties, serious injuries and/or major property dam- (2.5 ft lbs) torque (finger tight).
age. Use only nitrogen gas meeting the
11. Install the protective guards over the charging
specifications shown in chart (Figure 4-5).
valves and install the metal covers over the pis-
ton rods.
3. Install HYDRAIR Charging Kit and a bottle of
Any time the suspensions are recharged, the calibra-
pure dry nitrogen. Refer to Installation of Charg-
tion of the Payload Meter system is affected. Refer to
ing Kit.
the Payload Meter III section and perform a
4. Charge the suspensions with nitrogen gas to Clean Truck Tare. This will ensure accurate payload
50.8 mm (2 in.) greater than the charging height records.
listed in Figure 4-4.
5. Slowly release gas until the suspensions match The rear HYDRAIR suspensions are now ready for
the charging height listed in Figure 4-4. operation. Visually check piston extension both with
the truck loaded and empty. Record the extension
6. Close inlet valve (4, Figure 4-1). Leave outlet
dimensions. Maximum downward travel is indicated
valves (3) open for five minutes in order to allow
by the dirt ring at the base of the piston rod. Operator
the pressures in the suspensions to equalize.
comments on steering response and suspension
7. Ensure both of the suspension cylinders are rebound should also be noted.
extended the same distance 10 mm (0.39 in.).
If the difference in the extension from side to
side exceeds 10 mm (0.39 in.), check the front
suspensions for equal extension. Adjust the
front as necessary.
OIL AND NITROGEN SPECIFICATIONS CHART
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
-30F & above AK3761) AMOCO ULTIMATE Motor Oil Petro Canada Duratran Fluid
(-34.5C & 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
-55F & above AK3761) Synthetic Motor Oil, 5W-30
(-48.5C & 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 -68F (-55C) Maximum
Oxygen 0.1% Maximum
FIGURE 4-5. SPECIFICATIONS CHART

NOTES
TOE-IN ADJUSTMENT
1. Center the front wheels by straightening the
steering wheel. Turn the key switch OFF. Allow
at least 90 seconds for the accumulators to
depressurize. DO NOT turn the steering wheel
during this time.
2. Chock the front and back of the rear wheels.
3. Check the toe-in by measuring the distance
between the centers of the front tires. Measure
on the horizontal centerline at both the front and
the 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 0 toe-in.
830E TOE-IN DATA

Nominal tie-rod length, radial tires 3658 mm
to achieve: 0 toe-in (144.0 in.)
4. If the measurements are not equal, adjust the

tie rod. Loosen the clamp locknuts on the tie
rod. Rotate the tie rod as necessary to obtain
the correct toe-in setting of 0.
5. When the adjustment is complete, tighten the
locknuts on the tie rod to 420 42 Nm (310 FIGURE 3-1. MEASURING TOE-IN
31 ft lb).
6. Remove the wheel chocks from the rear
wheels.
NOTES
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
GREASE REQUIREMENTS
Grease requirements will depend on ambient tem-
peratures encountered during truck operation:
Above 32C (90F) - Use NLGI No.2
multipurpose grease (MPG).
-32 to 32C (-25 to 90F) - Use NLGI No. 1
multipurpose grease (MPG).
Below -32C (-25F) - Refer to local supplier for
extreme cold weather lubricant requirements.
PUMP HOUSING OIL

The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Check the oil level every
1000 hours. To add oil, remove oil level plug (4, 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 the
2. Outlet to Injectors 8. Pressure Gauge
primary or secondary lubrication lines were replaced,
3. Hydraulic Motor 9. Pump Assembly
it will be necessary to prime the system to eject all
4. Pressure Reducing 10. Flow Control Valve
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 Valve 4. Oil Level Plug

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

breather vents on the reservoir are intact and
free of contaminants.
NOTES
KOMATSU CHECKOUT PROCEDURE
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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
ll ~_."---J
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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I EK8480-1
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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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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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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
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KOMATSU CHECKOUT PROCEDURE I EK8480-1
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16.Select "Setup". (DO NOT select "Data Clear & Setup" this time.)
17.Hold down the "ALT" key and press "S". Set the service meter reading hours. (SMR). Record in
Item 10 on Form 3.
18.Select "Apply" and accept the confirmation prompts.
19.Configure the OrbComm settings. Select "EDIT" in the Communication Settings window.
20.Set the file transfer settings as follows and record in Item 11 on Form 3.
Item 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.
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(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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Page 15 of 15
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 Nm) . . A5-4
TABLE IX . Torque Conversions (ft lbs to kgm) . . 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 kgm Nm ft lbs kgm Nm ft lbs kgm Nm ft lbs kgm Nm
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 kgm = 1.356 Nm
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 Nm kgm CAP SCREW TORQUE TORQUE TORQUE
0.250 - 20 12 16 1.7 SIZE* Nm ft lbs kgm
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 (Nm)
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 (kgm)
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 (Nm) 0.113 Newton-meters (Nm) kilogram meters (kgm) 0.102
ft lbs (force) Newton meters (Nm) 1.356 Newton-meters (N.m) ft lbs 0.7376
ft lbs (force) kilogram meters (kgm) 0.138 kilogram-meters (kgm) ft lbs 7.2329
psi (pressure) kilopascals (kPa) 6.895 kilogram-meters (kgm) Newton meters (Nm) 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
(Circle One) MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT
SERIAL NUMBER SERIAL NUMBER NUMBER
730E 830E
830E-AC 930E-4
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributors Name Dump Body Style
Customers Name KAC Area Service Manager Signature Date
Customers Address
Inspectors Comments:
Inspectors 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

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.
CEAW003209 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 Nm (550 ft lbs)
(See Note below chart)
830E, 830E-AC Verify torque on all wedge nuts at 746 Nm (550 ft lbs)
(See Note below chart)
930E-4 Verify torque on front wheel nuts at 2326 136 Nm (1715 100 ft lbs)
(See Note below chart) Verify torque on rear inside wheel nuts at 2326 136 Nm (1715 100 ft lbs)
Verify torque on rear outside wheel nuts and adapter ring at 2326 136 Nm (1715 100 ft
lbs)
3 Rops Verify torque on left rops beam cap screws at 949 Nm (700 ft lbs)
Verify torque on right cross beam cap screws at 240 Nm (177 ft lbs)
4 Cab Verify torque on cab mounting cap screws at 949 Nm (700 ft lbs)
5 Wheel Motor Verify torque on wheel motor mounting cap screws at 2007 Nm (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, 830E-AC 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-4 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, 830E-AC Verify with pedal depressed, front brake pressure is 20,684 1034 kPa (3000 150 psi)
Verify with pedal depressed, rear brake pressure is 13,652 689 kPa (1980 100 psi)
Verify parking brake pressure is 17,236 689 kPa (2500 100 psi)
930E-4 Verify with pedal depressed, front brake pressure (BF) is 17,236 517 kPa (2500 75 psi)
Verify with pedal depressed, rear brake pressure (BR) is 17,236 517 kPa (2500 75 psi)
Verify 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, 830E-AC Power up loaded - 25-27 seconds
930E-4 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 its own unique configuration file and a copy of the file
saved
ADDITIONAL COMMENTS__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
NOTES:
50 HOUR POST-COMMISSIONING CHECKSHEET
Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.
MACHINE MODEL
(Circle One) MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT
SERIAL NUMBER SERIAL NUMBER NUMBER
730E 830E
830E-AC 930E-4
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributors Name Dump Body Style
Customers Name KAC Area Service Manager Signature Date
Customers Address
Inspectors Comments:
Inspectors Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:
Signature Remark:
Send white reports to: Manager of Technical Support

2300 N.E. Adams St., P.O. Box 240
Peoria, IL 61650-0240 U.S.A.
Send canary reports to: Manager of Field Assembly

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
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
Inspection Around Machine
1 Parts Visually inspect the truck for loose parts and debris.
2 Hardware Visually inspect the truck for missing and/or loose

mounting hardware.
3 Hoses and Cables Visually inspect hydraulic hoses and electric cables to
ensure they are securely clamped and clear of sharp
edges and other objects that may cause chaffing.
4 Engine Oil Level Verify the engine oil level is at the proper operating
range.
5 Hydraulic Oil Level Verify the oil level is visible through the upper sight glass
with the body down.
6 Anchor Pin Visually inspect the anchor hitch pin and anti-sway bar
assembly for proper installation and properly tightened
hardware.
7 Wheel Motors Verify the correct oil is being used and oil is at the proper
level.
8 Fuel Tank Verify the fuel tank mounting is secure and there are no
fuel leaks.
9 Radiator Inspect the coolant fill level, cold temperature protection,

and DCA additive.
10 Steering Components Verify proper installation of the steering cylinders, tie rod,
and accumulators.
11 Hydraulic Components Visually inspect the hoist valve, pumps, filters, hydraulic
tank and hoist cylinder installations. All hardware must
be secure, and no leaks evident.
12 Leakage Visually inspect the entire machine for leaks.
Hardware Torque
1 Steering Arm To 730E - Verify hardware torque -
Suspension Target: 2705 Nm (1995 ft lbs)
830E, 830E-AC- Verify hardware torque -
Target: 2705 Nm (1995 ft lbs)
930E-4 - Verify hardware torque -
2 Steering Cylinder To 730E - Verify hardware torque -
Frame Target: 464 Nm (342 ft lbs)
830E, 830E-AC - Verify hardware torque -
3 Steering Cylinder To 730E - Verify hardware torque -
Steering Arm Target: 464 Nm (342 ft lbs)
Condition Action
4 Tie Rod Pin Retainer 730E - Verify hardware torque -
5 Front Brake Caliper 730E - Verify hardware torque -
Mounting Target: 1085 Nm (800 ft lbs)
(Capscrew with Nut) 830E, 830E-AC - Verify hardware torque -
6 Front Brake Caliper 730E - Verify hardware torque -
(Capscrew Only)
7 Rear Service Brake 730E - Verify hardware torque -
Caliper Mounting Target: 780 Nm (575 ft lbs)
8 Rear Brake Adapter 730E - Verify hardware torque -
9 Brake Disc To Adapter 730E - Verify hardware torque -
Cab Compartment
1 Horn Check for proper tone and volume. Ensure there is no
looseness in the horn button.
2 Back Up Horn Check for proper tone, volume, and function.
3 Gauges Verify all gauges are installed straight and are operating
correctly.
4 Glass Verify no cracks exist on cab windows. Ensure all win-
dows are properly sealed.
5 Seat/Seat belts Verify the cab seats and seat belts are in proper working
condition.
Condition Action
Service Inspection
1 Suspension 730E Suspension oiling height: 38.1 mm (1.5 in.) front and
(See Note below) 72.6 mm (2.9 in.) rear
Front charge height: 229 mm (9 in.) at 2758 kPa (400
psi)
Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206
psi)
830E, 830E-AC Suspension oiling height: 25.4 mm (1 in.) front and 25.4
(See Note below) mm (1 in.) rear
psi)
psi)
930E-4 Suspension oiling height: 25.4 mm (1 in.) front and 25.4
(See Note below) mm (1 in.) rear
psi)
psi)
NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling
and charging instructions.
2 Accumulators Verify the nitrogen charge in the accumulators is at 9653
kPa (1400 psi) for all models, for both steering and
brakes.
3 Steering Verify that steering system is operating smoothly while
turning from lock to lock.
Verify the steering system is free of noise and vibration.
4 Lubrication Ensure the automatic lube system contains no air and is
filled to the proper level.
Ensure the automatic lube system is operating properly
and the timer is set as desired.
5 Hydraulic Filters Verify the 50 hour change of all hydraulic filters has been
completed.
NOTE: Elements are supplied from the factory in the
parts crate.
6 Tires Check and record the tire pressure/size/manufacturer for Pressure
future reference
Size
Manufacturer
7 Payload Meter System Calibrate and check payload meter operation per O&M
manual. Troubleshoot any error codes and delete after
repair.
8 GE Drive/Control Check drive control system operation per O&M manual.
System Troubleshoot, correct and delete any error codes.
9 GE Rotating Visually inspect wheel motor armature condition - brush
Components wear, commutator color, etc.
(Wheel Motors, MTA, Inspect MTA slip rings and brushes.
Grid Blower) Inspect grid blower motor commutator condition, brush
wear, etc.
10 Wheel Motor Sun Pinion Measure and record sun pinion end play for both RH and
End Play LH wheel motors
11 VHMS Verify the VHMS system is functioning properly per O&M
manual. Troubleshoot and repair any problems.
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No. Description of Modification Reason For Installation

1
ADDITIONAL COMMENTS:______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________

www.komatsuamerica.com
Komatsu America Corp. Copyright 2007 Komatsu

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

830E Field Assembly CEAW004701

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SERIAL NUMBERS A30816 & 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 COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

FAM0012 Introduction iii

FAM0101 Safety Rules, Tools, & Equipment Page 1-1

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

Page1-2 Safety Rules, Tools, & Equipment FAM0101

FAM0101 Safety Rules, Tools, & Equipment Page 1-3

Part Number Description Use

Page1-4 Safety Rules, Tools, & Equipment FAM0101

Part Number Description Use

Part Number Description Use

FAM0101 Safety Rules, Tools, & Equipment Page 1-5

Part Number Description Use

Part Number Description Use

Part Number Description Use

Page1-6 Safety Rules, Tools, & Equipment FAM0101

Part Number Description Use

Part Number Description Use

FAM0101 Safety Rules, Tools, & Equipment Page 1-7

Part Number Description Use

Part Number Description Use

Part Number Description Use

Page1-8 Safety Rules, Tools, & Equipment FAM0101

BLOWER DYNAMIC RETARDING

FAM0201 Truck Components And Specifications Page 2-1

FAM0201 Truck Components And Specifications Page 2-3

DUMP BODY CAPACITIES AND DIMENSIONS Loaded Vehicle . . . . . . . . Kilograms . . . (Pounds)

OVERALL TRUCK DIMENSIONS

Page 2-4 Truck Components And Specifications FAM0201

ITEM KILOGRAMS POUNDS

DECK AND DECK SUPPORT COMPONENTS

FAM0301 Major Component Weights Page 3-1

FRONT AXLE COMPONENTS

REAR AXLE COMPONENTS

Page 3-2 Major Component Weights FAM0301

FAM0403 Field Welding For Assembly Or Repair 4-1

4-2 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-3

4-4 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-5

4-6 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-7

Before opening any cabinets or touching a grid

Engine Stop Procedure Prior To Maintenance

Perform the following procedure prior to maintenance

4-8 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-9

4-10 Field Welding For Assembly Or Repair FAM0403

FAM0503 Receiving & Assembly Preparation Page 5-1

Page 5-2 Receiving & Assembly Preparation FAM0503

FAM0613 10/07 Chassis Assembly Page 6-1