Professional Documents
Culture Documents
Manual
CEAW004101
DUMP TRUCK
SERIAL NUMBERS
A30427 & UP
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 730E dump truck.
Variations of design required for specific truck orders may require some modification of the general procedures outlined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to front, rear, right, or left, are given in respect to the operator's normal seated position.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.
FAM0011
Introduction
ii
Introduction
FAM0011
TABLE OF CONTENTS
SUBJECT
PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAM0011
Introduction
iii
iv
Introduction
FAM0011
5. Inspect all lifting devices. Refer to the manufacturer's specifications for correct capacities and
safety procedures when lifting components.
6. Perform a daily inspection of all lifting cables
and chains. Replace any questionable items.
Use cables and chains that are properly rated
for the load to be lifted.
7. DO NOT stand beneath a suspended load. Use
of guy ropes are recommended for guiding and
positioning a suspended load.
8. Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
charged and in good working condition.
9. Cap screws and/or nuts being replaced must be
the same grade as originally supplied.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its components.
FAM0109
Page 1-1
sizes.
15. Heavy duty 3/4 in. & 1 in. square drive impact
wrench sets.
16. Impact sockets for 3/4 in. & 1 in. square drive
tools.
Page1-2
FAM0109
FAM0109
Page 1-3
Part
Number
Description
EB1759
Nitrogen
Charging Kit
Use
Suspension and
Accumulator
Nitrogen
Charging
1. T-Handle Valve
2. Charging Valve Adapter
Part Number
Description
Use
EC7852
Roll-Out
Assembly
Power Module
Remove and
Install
EG2298
Roller Assembly
MM0055
Cap Screw
M20 x 2.5 x 50
MM0465
Flat Washer
M20
Part Number
Description
Use
PB8326
Miscellaneous
and Cab
Mounting
Page1-4
FAM0109
Part Number
Description
Use
TZ2734
3/4 Torque
Adapter
Miscellaneous
Part Number
Description
Use
TZ2733
Tubular Handle
Use with
PB8326 and
TZ2734
FAM0109
Part Number
Description
Use
TY2150
Installation of
Front Wheel
Bearing Face
Seals
Part Number
Description
EC1741
EC1742
TZ0992
Sleeve
Alignment Tool
Use
Steering Linkage
and Tie Rod
Assembly. Refer
to Section G.
Page 1-5
Part Number
Description
Use
AK4720
Payload Data
Manger
EF9160
PLM Download
Harness
Payload Meter
Download. Refer
to Section D.
Part Number
Description
PB6039
Hydraulic
Coupling
Part Number
Description
TW9425
Special Wrench
Accumulator
Gland Nut
Use
Miscellaneous
PART NO.
PC2061
Part Number
Description
Use
TG1106
Eye Bolt
Miscellaneous
Lifting
Requirements
Page1-6
Use
DESCRIPTION
Belt Tension
Tester
USE
A/C Belt Tension
FAM0109
Part
Number
Description
Use
EL8868
TZ8968
Socket 3-1/2
Miscellaneous
TZ2726
Socket 1-1/8
Miscellaneous
TZ2729
Socket 1-1/4
Miscellaneous
TV7567
Socket 1-5/16
Miscellaneous
PB6825
Miscellaneous
TR0529
Socket 1-3/4
Miscellaneous
TZ2100
Socket 1-7/8
Miscellaneous
TZ2727
Socket 2-1/4
Miscellaneous
TZ2728
Socket 2-3/4
Miscellaneous
PB6824
Miscellaneous
TZ8968
Socket 3-1/2
Miscellaneous
TR0532
Square Drive
Extension 8
Miscellaneous
TR0533
Square Drive
Extension 17
Miscellaneous
TV1186
Extension 3-1/2
Miscellaneous
TR0546
Sliding T-Handle
Miscellaneous
TZ2730
Adapter 1 x 1-1/2
Miscellaneous
TZ2731
Adapter 3/4 x 1
Miscellaneous
PB6851
Miscellaneous
PB6852
Miscellaneous
FAM0109
PART NO.
DESCRIPTION
V-Belt Alignment Tool
USE
Aligning A/C
pulleys
Page 1-7
FAM0109
FAM0109
Page 1-9
NOTES
Page1-10
FAM0109
POWER STEERING
FAM0210
DYNAMIC RETARDING
Dynamic retarding is used to slow the truck during
normal operation or control the speed coming down a
grade. The dynamic retarding ability of the DC electric system is controlled by the operator through the
activation of the retarder pedal in the operators cab
and by setting the RSC (Retarder Speed Control).
Dynamic retarding is automatically activated if the
truck goes to a preset overspeed setting.
BRAKE SYSTEM
The wheel service brakes are caliper/dry disc brakes
applied by an all hydraulic actuation system.
Depressing the brake pedal actuates wheel-speed
single disc front brakes and armature-speed dual
disc rear brakes. The rear brakes can also be activated by operating a switch on the instrument panel.
All wheel brakes will be applied automatically if the
system pressure decreases below a preset minimum.
The parking brake is a caliper/disc type, mounted on
each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
protection (will not apply with the truck moving.)
SUSPENSION
HydrairII suspension cylinders, located at each
wheel, provide a smooth and comfortable ride for the
operator and dampens shock loads to the chassis
during loading and operation.
FAM2-1
FAM0210
SPECIFICATIONS
These specifications are for the standard 730E dump truck. Customer options may change this listing.
SERVICE CAPACITIES
ENGINE
Komatsu SSA16V159
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 16
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake HP. . 1491 kW (2000 HP) @ 1900 RPM
Flywheel HP . . . . 1388 kW (1860 HP) @ 1900 RPM
Weight (Wet) . . . . . . . . . . . . . . . 5294 kg (11,670 lbs)
Pumps:
DYNAMIC RETARDING
. . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Retarding
BATTERY ELECTRIC SYSTEM
STEERING
FAM0210
FAM2-3
These specifications are for the 730E dump truck without trolley assist. Specifications for trolley trucks will be different.
STANDARD DUMP BODY*
WEIGHT DISTRIBUTION
Capacity:
Empty Vehicle
Kilograms
(Pounds)
Front Axle . . . . . . . . . . . . 66,840 . . . .
(147,357)
Rear Axle . . . . . . . . . . . . 73,752 . . . . . . .(162,593)
Kilograms . . .
(Pounds)
TIRES
FAM2-4
FAM0210
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before
each use. Lifting equipment must be in good condition and rated for approximately two times the weight
being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result.
Optional equipment added onto the truck may cause an increase to the component weights listed in this
chapter. Contact your customer support manager for concerns or questions about lifting truck components.
NOTE: All component weights are dry weights. The additional weight of coolant, fuel, and oil that may be in the
components are not calculated into this list.
ITEM
KILOGRAMS
POUNDS
CHASSIS
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38,555 . . . . . . . . . . . . . . . . . . . . . 85,000
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,586 . . . . . . . . . . . . . . . . . . . . . . 5,700
Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,404 . . . . . . . . . . . . . . . . . . . . . . 5,300
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,990 . . . . . . . . . . . . . . . . . . . . . 11,000
FAM0310
Page 3-1
ITEM
KILOGRAMS
POUNDS
DRIVE SYSTEM
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214 . . . . . . . . . . . . . . . . . . . . . . . . 472
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,833 . . . . . . . . . . . . . . . . . . . . . . .8,450
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,678 . . . . . . . . . . . . . . . . . . . . . . .3,700
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10,569 . . . . . . . . . . . . . . . . . . . . . . 23,300
FLUID COMPONENTS
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .698 . . . . . . . . . . . . . . . . . . . . . . .1,539
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 . . . . . . . . . . . . . . . . . . . . . . . . 796
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,270 . . . . . . . . . . . . . . . . . . . . . . .2,800
Page 3-2
FAM0310
WELD PROCEDURES
Electric arc welding, either the semi-automatic MIG
(GMAW), Flux Core (FCAW), or Stick electrode
welding (SMAW), are approved processes for field
installation and maintenance welding. Welding of
highly stressed structural members such as castings,
torque tubes, top and bottom plates on the frame
rails, and the curved intersection points of frames
should be done with the specific detailed instructions
from Komatsu Product Service. See Annex A for
repair procedures. These repair procedures are
detailed instructions for most high stressed structural
members.
APPROVED CONSUMABLES
WELDER QUALIFICATION AND
TRAINING
The welding technique must be of the highest standard to produce the soundest weld possible. Only
welders who have been trained and qualified for
structural steel welding in all positions, in conformance with the American Welding Society (AWS) D1.1
or (AWS) D14.3 only, are allowed to perform the
welding. The welding instructions for field assembly
of Komatsu components are normally provided by
engineering drawings. Additional detailed welding
instructions for field repairs are provided in the field
repair manual SEB14001. A full understanding of the
AWS standard welding symbols is necessary to perform and inspect such field welds. Weld sizes specified on the drawings are intended to reflect minimum
requirements.
FAM0406
4-1
WELD INSPECTION
1. Air Movement - Avoid areas where air movement from wind, drafts, or blowers is prevalent.
This is particularly important when a shielding
gas is being used as part of the welding process.
1. Visual Inspection - This is the process of looking for potential defects such as undersized
welds that can be checked with weld gauges
for, surface cracks, surface porosity, craters,
and undercuts.
4-2
FAM0406
RECORDS
2. Dye Penetrant Inspection - This is an easily
applied process which indicates cracks or surface conditions. The process is relatively inexpensive, but does not produce a permanent
record except by normal photography.
3. Fluorescent Penetrant Inspection - Similar to
dye penetrant inspection. This process uses a
black (ultraviolet) light for increased efficiency
and accuracy.
4. Magnetic Particle Inspection - This process
requires special equipment that is usually more
costly than the dye penetrant inspections. This
process does not provide a permanent record
except by normal photography.
5. Ultrasonic Inspection - This is a popular method
of examining weld discontinuities. Specialized
equipment and operator certification is required.
With some equipment printed data is available
of the test providing a permanent record. Also,
operator records with equipment settings and
test results are normally recorded.
6. X-Ray Inspection - This process provides a
view of the weld and base materials but it is
highly specialized. This procedure provides a
permanent visual record, but is more expensive
than most other inspection techniques.
ANNEX A
The following are general repair procedures, which
must be followed for all repair and rework of major
load carrying members on Komatsu equipment.
FAM0406
4-3
4-4
9. All welds are to be made with approved consumables only. The SMAW (Stick) welding rod
must be used within four hours after being
removed from a new sealed container or from a
52C (125F) minimum drying oven. Any rod
that exceeds this exposure time must be dried
for one hour at 427C (800F) before being
used. Keep all weld starts and stops to a minimum.
10. When the weld is complete, immediately (before
the weldment cools) post heat the entire weld
area to 150C (300F). Even if the area is over
150C (300F) heat must be applied to maintain
this temperature for 15 minutes, and then allow
it to cool slowly. In some cases this might
require wrapping with insulation blankets.
11. Grind all butt-welded repairs smooth using 36 or
finer grit grinding material. All grinding marks
should be parallel to the direction of primary
stress if possible (and if known).
12. Hammer peen the toes of repair fillet welds as
detailed in Annex B, see attached.
13. Inspect repaired areas (for surface defects)
using magnetic particle or dye penetrant
inspection procedures.
14. If surface defects are found, remove all defects
by grinding to a maximum depth of 1.5 mm
(0.06 in.). Larger defects must be removed as
per the above mentioned procedures. All spot
welding also requires preheating and post heating.
FAM0406
ANNEX B
2.0 TOE GRINDING WITH A ROTARY BURR
Equipment:
3. Adequate lighting
Procedure
1. The toe of the weld should serve as a guide for
the peening tool resulting in the area of deformation being approximately equally divided
between the base material and the weld metal
face to the specified depth and not to exceed 5
mm (0.19 in.) in width. Refer to Figure 4-1.
Procedure
FAM0406
4-5
4-6
FAM0406
FAM0406
4-7
BIBLIOGRAPHY
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earthmoving and
Construction Equipment
Metals and How to Weld Them - James F. Lincoln
Arc Welding Foundation. Cleveland, Ohio
Procedure Handbook of Arc Welding - Lincoln Electric Company, Cleveland, Ohio
American Welding Society - Welding Handbook
British Standard BS5135 - Metal Arc Welding of Carbon and Carbon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The
Welding Institute, F. R. Coe, Author
4-8
FAM0406
1. Open the battery disconnect switches and disconnect the battery charging alternator lead
wire.
2. Disconnect all electrical harnesses from the
Engine Control System (ECS). The ECS is
located inside the electrical cabinet behind the
operator's cab. Disconnect the ground strap
from the ECS.
3. Fasten the welding machine ground (-) lead to
the piece being welded. The grounding clamp
must be attached as near as possible to the
weld area.
4. DO NOT weld on the rear of the control cabinet!
The metal panels on the back of the cabinet are
part of the capacitors and cannot be heated.
5. DO NOT weld on the retard grid exhaust louvers.
6. Some power cable panels throughout the truck
are made of aluminum or stainless steel. They
must be repaired with the same material or the
power cables may be damaged.
7. Power cables must be cleated in wood or other
non-ferrous materials. DO NOT repair cable
cleats by encircling the power cables with metal
clamps or hardware. Inspect power cable insulation prior to servicing the cables and prior to
returning the truck to service. Discard cables
with broken insulation.
8. Protect power cables and wiring harnesses
from weld spatter and heat.
9. DO NOT lay welding cables over or near the
vehicle electrical harnesses. Welding voltage
may be induced into the electrical harnesses
and cause damage to components.
10. DO NOT allow welding current to pass through
ball bearings, roller bearings, suspensions, or
hydraulic cylinders.
FAM0406
4-9
NOTES
4-10
FAM0406
4. Install support blocks under the rear axle housing. The support blocks must be approximately
30 cm (12 in.) high and spread out along the
axle. The support blocks must be a minimum of
51 mm (2 in.) away from the wheel motor
mounting face.
FAM0506
Page 5-1
ASSEMBLY LAYOUT
Page 5-2
FAM0506
CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines
varies. Photographs or illustrations used in the following procedures are provided as general guidelines only. Actual assembly may be different, but this
general procedure provides a basic outline for
assembly.
Items like the hydraulic tank and the accumulators
may have been removed for shipping and will have to
be locally installed.
Each shipment may be different, depending on the
truck configuration and destination.
8. Site cleanup
FAM0610
10/07
Chassis Assembly
Page 6-1
CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at other locations may be different. However, this outline will provide a general basis for assembly.
Follow all safety recommendations in this manual. Follow all local, state, and federal regulations.
In the procedures that follow, many very heavy components will be required to be lifted into place and
secured.
Page 6-2
Chassis Assembly
10/07 FAM0610
FAM0610
10/07
Chassis Assembly
Page 6-3
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
38,555 kg (85,000 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.
Page 6-4
Chassis Assembly
10/07 FAM0610
FIGURE 6-1.
FIGURE 6-2.
FAM0610
10/07
Chassis Assembly
Page 6-5
2. Clean the mating surfaces for the deck supports to prepare for installation.
Page 6-6
Chassis Assembly
10/07 FAM0610
FIGURE 6-3.
FIGURE 6-4.
FAM0610
10/07
Chassis Assembly
Page 6-7
3. Lift the LH deck support into position. The weight of the deck support is approximately 408 kg (900 lb).
a. Bolt the support into place.
b. Weld the support to the frame. 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. Follow the specifications shown
in Figure 6-7.
c. 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. Install and weld the RH deck support. The weight of the deck support is approximately 295 kg (650 lb).
Page 6-8
Chassis Assembly
10/07 FAM0610
FIGURE 6-5.
FIGURE 6-6.
FAM0610
10/07
Chassis Assembly
Page 6-9
FIGURE 6-7.
Page 6-10
Chassis Assembly
10/07 FAM0610
NOTES
FAM0610
10/07
Chassis Assembly
Page 6-11
5. Clean the mounting surfaces for the hydraulic tank and the fuel tank.
6. Lift the fuel tank into position on the cradles. The weight of the fuel tank is approximately 1270 kg (2800 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.
7. Connect the fuel supply and fuel return hoses to the ports on the fuel tank.
8. Install the filters to the rear of the tank and secure the wiring harness.
FIGURE 6-8.
Page 6-12
Chassis Assembly
10/07 FAM0610
FIGURE 6-9.
FIGURE 6-10.
FAM0610
10/07
Chassis Assembly
Page 6-13
FIGURE 6-11.
Page 6-14
Chassis Assembly
10/07 FAM0610
FIGURE 6-12.
FIGURE 6-13.
FAM0610
10/07
Chassis Assembly
Page 6-15
FIGURE 6-14.
FIGURE 6-15.
Page 6-16
Chassis Assembly
10/07 FAM0610
FIGURE 6-16.
FIGURE 6-17.
FAM0610
10/07
Chassis Assembly
Page 6-17
13. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assemblies installed is approximately 10,569 kg (23,300 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 6-23.
Alternately 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 6-18.
Page 6-18
Chassis Assembly
10/07 FAM0610
FIGURE 6-19.
FIGURE 6-20.
FAM0610
10/07
Chassis Assembly
Page 6-19
Page 6-20
Chassis Assembly
10/07 FAM0610
FIGURE 6-21.
FIGURE 6-22.
FAM0610
10/07
Chassis Assembly
Page 6-21
2. Cap Screw
17. The hardened flat washers use on the front suspensions are punched during the manufacturing
process. Assemble the cap screws and washers, and position the punch lip away from the
cap screw head to prevent damage. See Figure
6-23.
Page 6-22
Chassis Assembly
10/07 FAM0610
FAM0610
10/07
Chassis Assembly
Page 6-23
Page 6-24
Chassis Assembly
10/07 FAM0610
FIGURE 6-27.
FIGURE 6-28.
FAM0610
10/07
Chassis Assembly
Page 6-25
19. 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).
20. Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brake assembly is
approximately 3300 kg (7340 lb).
21. Lift the retainer plate into position under the spindle. The weight of the plate is approximately 30 kg (66 lb).
Install the twelve retainer plate cap screws. Alternately tighten the cap screws to 678 Nm (500 ft lb). Continue to tighten the cap screws in increments of 330 Nm (250 ft lb) until 2705 270 Nm (1,995 200 ft lb) is
reached.
Repeat the previous steps for the remaining wheel.
Page 6-26
Chassis Assembly
10/07 FAM0610
FIGURE 6-29.
FIGURE 6-30.
FAM0610
10/07
Chassis Assembly
Page 6-27
22. Clean and prepare the steering cylinder and tie rod mounting surfaces.
23. Move the steering cylinders into position in the steering arms bores. Lubricate the pin and pin bore surfaces
with multi purpose grease number 2 (5% molybdenum disulphide). Install the pin, spacers, bearing seals and
hardware to each joint. Tighten the pin retainer cap screws to standard torque. Refer to Standard Tables in
Section 10, Appendix.
NOTE: Use alignment sleeve (TY4576) to aid in assembly of the steering cylinder joints.
24. Lift the tie rod into position. The weight of the tie rod is approximately 136 kg (300 lb). Lubricate the pin and
pin bore surfaces with multi purpose grease number 2 (5% molybdenum disulphide). Install the pin, spacers,
bearing seals and hardware to each joint. Tighten the pin retainer cap screws to standard torque.
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 6-31.
Page 6-28
6. Bearing Seal
7. Spherical Bearing
8. Steering Arm
9. Cap Screw
10. Bearing Retainer
Chassis Assembly
10/07 FAM0610
FIGURE 6-32.
FAM0610
10/07
Chassis Assembly
Page 6-29
19. Lift the contactor box into position on the retarding grid. Install the mounting hardware and tighten to standard
torque. Refer to Standard Tables in Section 10, Appendix.
20. Lift the RH deck into position on the truck. The weight of the assembly is approximately 4600 kg (10,141 lb).
Loosely install the deck mounting hardware.
NOTE: Do not torque the hardware until after all decks are in place.
Page 6-30
Chassis Assembly
10/07 FAM0610
FIGURE 6-33.
FIGURE 6-34.
FAM0610
10/07
Chassis Assembly
Page 6-31
21. Install the handrails onto the LH deck and lift the deck into place. The weight of the LH deck with handrails is
approximately 635 kg (1400 lb). Loosely install the eight deck mounting cap screws.
NOTE: Do not torque the hardware until after all decks are in place.
Page 6-32
Chassis Assembly
10/07 FAM0610
FIGURE 6-35.
FIGURE 6-36.
FAM0610
10/07
Chassis Assembly
Page 6-33
22. Tap the cab mounting holes to remove any paint before cab installation.
23. Lift the operator cab into position. The weight of the cab is approximately 2449 kg (5400 lb).
Install and tighten the forty cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.
Page 6-34
Chassis Assembly
10/07 FAM0610
FIGURE 6-37.
FIGURE 6-38.
FAM0610
10/07
Chassis Assembly
Page 6-35
24. Lift the air intake tubes into place. The weight of the LH tube is approximately 15 kg (33 lb). The weight of the
RH tube is approximately 28 kg (62 lb). Secure the tubes in place with the hump hoses and clamps.
Page 6-36
Chassis Assembly
10/07 FAM0610
FIGURE 6-39.
FIGURE 6-40.
FAM0610
10/07
Chassis Assembly
Page 6-37
25. Lift the center deck into position on the truck. The weight of the deck is approximately 233 kg (514 lb). Install
the deck mounting cap screws and tighten to standard torque. Refer to Standard Tables in Section 10, Appendix.
26. Lift the diagonal ladder into position on the truck. The weight of the ladder is approximately 130 kg (287 lb).
Install the ladder mounting hardware and tighten to standard torque.
Page 6-38
Chassis Assembly
10/07 FAM0610
FIGURE 6-41.
FIGURE 6-42.
FAM0610
10/07
Chassis Assembly
Page 6-39
27. Tighten the cap screws that secure the diagonal ROPS beam and the decks. Tighten the cap screws to standard torque.Refer to Standard Tables in Section 10, Appendix.
28. Weld the uprights in place. Refer to Figure 6-45 for welding specifications.
Page 6-40
Chassis Assembly
10/07 FAM0610
FIGURE 6-43.
FIGURE 6-44.
FAM0610
10/07
Chassis Assembly
Page 6-41
FIGURE 6-45.
Page 6-42
Chassis Assembly
10/07 FAM0610
NOTES
FAM0610
10/07
Chassis Assembly
Page 6-43
29. Raise the front of the truck for front wheel installation.
NOTE: Clean the mating surfaces before installing
the wheels.
30. Using a tire handler, lift the front wheel into position on the wheel hub. Install the wheel retainer
lugs and lubricated nuts. Evenly tighten each
nut using the sequence shown in Figure 6-46 to
407 Nm (300 ft lbs).
31. Spin the wheel and check the rim run-out. Maximum run-out is 5 mm (0.20 in.). If run-out
exceeds specifications, loosen all nuts and retighten them in the proper sequence.
32. If run-out is within specifications, then tighten
each nut in the proper sequence to 746 Nm.
(550 ft lbs).
33. Connect the valve stem to the wheel hub.
34. After truck assembly operate the truck for one
load and retighten the wheel nuts, as specified.
Recheck the nut torque daily (each 24 hours of
operation) to ensure proper torque is maintained on each nut. Once torque is maintained,
daily checking is no longer required. Check
intermittently to ensure torque is maintained.
FIGURE 6-47.
Page 6-44
Chassis Assembly
10/07 FAM0610
39. Spin the wheel and check the rim run-out. Maximum run-out is 5 mm (0.20 in.). If the run-out
exceeds specifications, then loosen all the nuts
and re-tighten them evenly in the proper
sequence.
40. If run-out is within specifications, tighten each
nut in the proper sequence to 746 Nm (550 ft
lbs).
41. Secure the inner and outer dual tire inflation
lines to the bracket on the outer rim. Tighten the
cap screws to standard torque.
42. Install the wheel cover. Remove the blocks from
under the truck and lower the truck to the
ground.
43. After truck assembly is complete, operate the
truck for one load and retighten the wheel nuts
in the proper sequence. Recheck the nut torque
daily (each 24 hours of operation) to ensure
proper torque is maintained on each nut. Once
the torque is maintained, daily checking is no
longer required. Check intermittently to ensure
torque is maintained.
FAM0610
10/07
Chassis Assembly
Page 6-45
FIGURE 6-49.
FIGURE 6-50.
Page 6-46
Chassis Assembly
10/07 FAM0610
FIGURE 6-51.
FIGURE 6-52.
FAM0610
10/07
Chassis Assembly
Page 6-47
44. Complete the wiring for the control cabinet and retarding grid.
FIGURE 6-53.
Page 6-48
Chassis Assembly
10/07 FAM0610
FIGURE 6-54.
FIGURE 6-55.
FAM0610
10/07
Chassis Assembly
Page 6-49
FIGURE 6-56.
FIGURE 6-57.
Page 6-50
Chassis Assembly
10/07 FAM0610
FAM0610
10/07
Chassis Assembly
Page 6-51
46. Install the blower hose and clamps to the control cabinet and alternator.
47. LIft the air intake ductwork into position and install the mounting hardware. The weight of the inlet duct is
approximately 214 kg (472 lb). Tighten the cap screws to standard torque. Refer to Standard Tables in Section
10, Appendix.
FIGURE 6-58.
Page 6-52
Chassis Assembly
10/07 FAM0610
FIGURE 6-59.
FIGURE 6-60.
FAM0610
10/07
Chassis Assembly
Page 6-53
FIGURE 6-61.
FIGURE 6-62.
Page 6-54
Chassis Assembly
10/07 FAM0610
NOTES
FAM0610
10/07
Chassis Assembly
Page 6-55
Page 6-56
Chassis Assembly
10/07 FAM0610
FIGURE 6-63.
FIGURE 6-64.
FAM0610
10/07
Chassis Assembly
Page 6-57
49. Install and wire the battery boxes. Refer to the electrical schematic for reference.
Page 6-58
Chassis Assembly
10/07 FAM0610
FIGURE 6-65.
FIGURE 6-66.
FAM0610
10/07
Chassis Assembly
Page 6-59
50. Finish routing and connecting remaining hydraulic, electric, and lubrication connections. Install the clamping
for each component.
51. After the chassis assembly is complete, the body can be installed. Refer to Section 8 for more information.
FIGURE 6-67.
Page 6-60
Chassis Assembly
10/07 FAM0610
FIGURE 6-68.
FIGURE 6-69.
FAM0610
10/07
Chassis Assembly
Page 6-61
FIGURE 6-70.
FIGURE 6-71.
Page 6-62
Chassis Assembly
10/07 FAM0610
FAM0710
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
of the floor.
7-2
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
FAM0710
7-3
BODY WELDING
Follow the guidelines listed below when welding the
body:
Use dry weld rod or weld wire.
Weld surfaces must be dry and above 10C
(50F).
If stick electrode is used, use as large a diameter
rod as practical to weld the floor and front sheet
joints.
The following sequence must be followed for the
front sheet:
First Pass: Back step and skip weld in 10
increments along the entire length of the joint.
Refer to Figure 7-7.
Repeat the same procedure until the entire joint
is filled. DO NOT stop welding until entire joint is
complete.
The body floor V groove must also be welded
using the same procedure as the front sheet.
Weld from the front to the rear. Refer to Figure 77.
7-4
FAM0710
FIGURE 7-10.
FIGURE 7-8.
FIGURE 7-11.
FAM0710
7-5
FIGURE 7-12.
FIGURE 7-14.
FIGURE 7-15.
FIGURE 7-13.
FIGURE 7-16.
7-6
FAM0710
FIGURE 7-17.
FIGURE 7-19.
FIGURE 7-18.
FIGURE 7-20.
FAM0710
7-7
7. Install any optional equipment such as body liners and side boards.
8. Clean the weld joints and paint.
7-8
FAM0710
Before raising or lifting the body, ensure there is adequate clearance between the body and overhead
structures or electric power lines.
Body weight can vary substantially, depending on liner plate installation, etc. Ensure the lifting device is
rated for at least a 45 ton capacity.
1. Attach the lifting device to the dump body and lower over the truck frame. Align the body pivot and frame pivot
holes.
2. Install shims (3, Figure 8-3), as required, to center the body on the frame pivot.
NOTE: A minimum of one shim is required at the outside end of the frame pivot. DO NOT install shims at the
inside.
FIGURE 8-1.
FAM0809
Page 8-1
FIGURE 8-2.
Page 8-2
FAM0809
3. Align the pin retainer cap screw hole and push the pivot pin through the spacers and into the pivot bushings in
each side of the frame.
4. Install the cap screw through each pin and tighten the nuts to standard torque.
5. Align the hoist cylinder upper mounting eye with the body. Align the retaining cap screw hole and install the
pin.
6. Install the pin retaining cap screws and nuts and tighten to standard torque.
FAM0809
Page 8-3
FIGURE 8-4.
Page 8-4
3. Hoist Cylinder
4. Pin Retainer
FAM0809
BODY SLING
BODY PADS
Any time personnel are required to perform maintenance on the vehicle with the dump body in the
raised position, the body must be supported in
the raised position with the body sling cable.
FAM0809
Page 8-5
Adjustment
1. All pads, except the rear pad on each side, must contact the frame with approximately equal compression of
the rubber. 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. If the pad contact appears to be unequal, repeat the above procedure. The vehicle must be parked on a flat, level surface for inspection.
Proper body pad to frame contact is required to ensure maximum pad life.
FIGURE 8-7.
Page 8-6
FAM0809
BODY GUIDE
ROCK EJECTORS
3. Frame
4. Wear Plate
FAM0809
Page 8-7
BODY SWITCHES
Refer to Figure 8-10 to properly position the body
switches.
FINAL ASSEMBLY
Install the remaining items to the body and associated components including: lubrication lines, mud
flaps, decals, body position indicator, etc.
Page 8-8
FAM0809
FIGURE 8-10.
FAM0809
Page 8-9
NOTES
Page 8-10
FAM0809
FINAL CHECKOUT
Final checkout requires truck operation.
Place the operation and maintenance manual and
safety manuals in the operator cab, if not already there.
Any personnel involved in the final check-out of the
truck must read and understand all safety and operating instructions in the operation and maintenance manual.
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.
FAM1005
Appendix
Page 10-1
NOTES
Page 10-2
Appendix
FAM1005
LUBRICATION CHART
NOTES
EQUIPMENT LIST
Hydrair Charging Kit
Jacks and/or Overhead Crane
Support Blocks for:
Oiling Height Dimensions (Front and Rear)
All HydrairII suspensions are charged with compressed nitrogen gas with sufficient pressure to
cause injury and/or damage if improperly handled. Follow all safety instructions, cautions, and
warnings provided in the following procedures to
prevent any accidents during oiling and charging.
2. The suspension piston rod extension for nitrogen charging must be correct.
3. The nitrogen charge pressure must be correct.
FRONT SUSPENSION
All HydrairII suspensions are charged with compressed nitrogen gas with sufficient pressure to
cause injury and/or damage if improperly handled. Follow all the safety notes, cautions, and
warnings in these procedures to prevent accidents during servicing and charging.
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the
wheels.
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the protective covers from the charging valves.
OILING
HEIGHT
IN. (mm)
CHARGING
HEIGHT
IN. (mm)
CHARGING
PRESSURE
psi (kPa)
730E*
1.5 (38.1)
9.0 (229)
400 (2758)
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
6. Valve Body
7. O-Ring
8. Valve Stem
9. O-Ring
REAR SUSPENSION
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the
wheels.
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the protective covers from the charging valves and the
rubber covers from the suspension piston.
OILING
HEIGHT
IN. (mm)
CHARGING
HEIGHT
IN. (mm)
*CHARGING
PRESSURE
psi (kPa)
730E
2.9 (72.6)
10.9 (276)
206 (1420)
* Note: Charging pressures are for reference only and may vary depending on body
weights.
Part No.
Approved Sources
VJ3911
(need to add
6% of
AK3761)
Mobil 424
Mobil D.T.E. 15
Texaco TDH Oil
Amoco Ultimate Motor
Oil 5W-30
AK4063
5 Gallon container
AK4064
55 Gallon container
VJ5925
(need to add
6% of
AK3761)
AK4065
5 Gallon container
AK4066
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 19 Liter (5 gallon) cans.
FRICTION MODIFIER
Part No.
Suspension Oil
AK3761
(5 Gallon container of
100% friction modifier)
Property
Value
Nitrogen
99.9% minimum
Water
32 PPM maximum
Dew Point
Oxygen
0.1% maximum
NOTES
TOE-IN ADJUSTMENT
1. Move the truck to a flat, level surface. Align the
front wheels in a straight ahead position and
then turn the key switch to the OFF position.
Allow at least 90 seconds for the steering circuit
to depressurize. DO NOT turn the steering
wheel during this time. After 90 seconds, verify
that the circuit is depressurized by turning the
steering wheel. If the wheels do not turn, the
truck is safe to adjust. Chock the wheels to prevent truck movement.
2. Check the toe-in by measuring the distance
between the centers of the front tires. Refer to
Figure 3-1. Measure along the horizontal centerlines at the front and rear of the front tires.
3. For trucks equipped with radial tires, the measurements at the front and rear of the tires must
be equal. Equal measurements at the front and
rear result in 0 toe-in. If the measurements are
not equal, the tie rod must be adjusted. Proceed
to the next step.
The nominal front measurement for bias ply
tires is 1.9 0.6 (0.75 0.25 in) less than the
rear measurement. If the measurement is not
within this range, the tie rod must be applied.
Proceed to the next step.
4. Loosen the clamp locknuts on the tie rod and
rotate the tie rod as necessary to obtain the correct toe-in setting. Refer to Table 2 for additional information.
TOE-IN DATA
cm (in.)
349.2
(137.48)
349.6
(137.63)
2.0
(0.79)
G03027
G3-1
NOTES
G3-2
G03027
LUBRICANT PUMP
Grease requirements will depend on ambient temperatures encountered during truck operation:
NLGI
No.2
SYSTEM PRIMING
The system must be full of grease and free of air
pockets to function properly. After maintenance, if
the primary or secondary lubrication lines were
replaced, it will be necessary to prime the system to
eject all entrapped air.
SYSTEM CHECKOUT
To check system operation, not including the timer,
proceed as follows:
1. Start the engine.
2. Actuate the test switch at the reservoir/pump
assembly.
3. The motor and pump will operate until the system attains 20685 kPa (3000 psi).
4. Once the required pressure is achieved, the
pump motor will turn off and the system will vent.
5. Check for pump, hose, or injector damage or
leakage when the system is pressurized.
6. After checking the system, shut the engine off.
Observe normal precautions regarding high
voltage present in the propulsion system before
attempting to repair the lubrication system.
3. Timer Selector
3. Check all the grease hoses from the SL-1 injectors to the lubrication points.
5. System Checkout.
a. Remove all SL-1 injector cover caps to allow
visual inspection of the injector cycle indicator pins during system operation.
1. Change the oil after every 500 hours of operation. Use SAE 10W30 motor oil.
NOTES
NOTES:
NOTES:
NOTES:
tH
n.
R.
DATE
BY
DATE
J. McClone
6/26/95
MACHINE& HODEL
L EF5761
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I
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DATE
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Necessary Equipment
1. Check-out procedure and system schematic
2. Accumulator charging outfit with good gauges and either K type bottles of dry
nitrogen or T type bottles with a gas intensifier.
3. Clear plastic hose and bucket for bleeding brakes of air.
4. If truck is only partially assembled and this check-out is to be done without brakes
installed, brake simulators are required in order to simulate the brake volumes.
5. At least 3, calibrated gauges with quick-connect couplings, capable of measuring
up to 5000 psi.
Assumptions
1. All components used within the brake system are to specification.
2. Any parts that do not function as described will be replaced or adjusted. (Notify
Quality Control Department for problems or to obtain adjusting procedures for
individual components.)
3. The hydraulic source for the brake system (The Steering System is in proper
operation and the compensator has been adjusted.
Note: Refer to steering and hoist check-out group for procedures and
specifications.
Initial System Set-up
1. Install pressure measuring instruments at:
(a) Test Port BF (brake cabinet)
(b) Test Port BR (brake cabinet)
(c) Test Port LAP1 (brake manifold)
2. Open each brake accumulator bleed down valve and precharge both accumulators
to 1400 psi. Allow gas temperature to approach ambient temperature before
completing precharge process.
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KomatsuCHECK-OUT PROCEDURE
EF5761
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4. Start engine to fill accumulators with oil. Observe rising brake pressures as
system charges. Brake pressure should begin to fall when Auto Apply Valve
releases. The brake pressures when auto apply releases should be approximately
1750 psi front and 1700 psi rear. Record the brake pressures at auto apply release.
5. Partially depress brake pedal and bleed air from bleeders located at each brake or
brake simulators.
Parking Brake
Note: Move one of the pressure measuring instruments from the BF or BR
locations to port PK2 on the brake manifold.
*
6. Apply brake lock. Release parking brake with park brake switch. Verify that
park brake status light indicates parking brake is released. Record parking brake
release pressure. (pressure should be 2600 =t100 psi).
7. Ifparking brakes are on vehicle, then measure the lining to disc clearance with
feeler gauge and record the clearances.
8. Cycle park brake switch several times to assure crisp application and release of
pressure and proper function of status light.
9. Apply parking brake and release brake lock.
Note: Return the pressure measuring device to the BF or BR location.
Service Brakes
10. Very slowly depress brake pedal to check circuit tracking. Rear brake pressure
must begin to rise before front brake pressure. Rear brake pressure should be
between 45 and 205 psi when front brake pressure begins to rise. Force feedback
of pedal on foot should be smooth with no abnormal noise or mechanical
roughness.
*
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11. Slowly depress brake pedal and record the rear brake pressure at which the stop
671-2-3-97
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KomatsuCHECK-OUT PROCEDURE
EF5761
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12. Quickly and completely depress pedal and check to see that front brake pressure
is 2500 i: 100 psi and that rear brake pressure is 1700i: 75 psi within 1 second.
Holding pedal fully applied, both pressures should remain above their minimum
values for a minimum of 20 seconds.
13. Release peda1. Brake pressure should return to zero with a couple of seconds and
there should be no residual pressure trapped in brakes. If the vehicle is equipped
with rear brakes check to see if rear brake linings are retracted from brake discs
and are free and loose in brake calipers.
3 of 7
17. Cycle brake lock several times to assure crisp application of and release of
pressure and proper function of status light. Record rear brake pressure, which
should be 1500 i: 100 psi.
18. Allow engine to run until low brake accumulator pressure stabilizes at or above
2700 psi.
*
'
19. Shut engine down. Allow the steering accumulator to bleed completely down.
Disable steering pressure switch from the brake warning circuit by unplugging the
diode between circuits 33 and 33F. (This is diode 22 on diode board 1) Turn key
switch on. After 2 minutes record the low accumulator pressure. (LAP1 port) If
LAPI pressure is below 2100 psi, then leakage in the system is excessive and the
source of the leakage needs to be identified.
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EF5761
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20. Crack the front brake accumulator bleed down valve and observe LAP 1 pressure.
The low brake pressure lamp and buzzer must actuate at 1850::!::75 psi. Record
this value. Brake pressures should begin to rise (auto apply) when LAP 1 reaches
24. Record auto apply brake pressures. Enable the steering pressure switch by
plugging in the diode removed between circuits 33 and 33F.
Reapplications
25. Start engine to recharge hydraulic system. Allow engine to run until low brake
accumulator pressure stabilizes at or above 2700 psi.
*
26. Shut engine down. Do not allow steering accumulator to bleed down. Make
repeated slow, complete brake applications with pedal until auto apply comes on.
Record the number of brake applications prior to auto apply.
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671-2-3-97
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KomatsuCHECK-OUT PROCEDURE
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EF5761
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30. Very slowly depressthe brake pedal until the brake differential switch has
activated the low brake pressurelamp and the buzzer. Record the rear brake
pressure at the point this occurs. (The fault should occur @ 600 ~ 50 psi).
Release the pedal.
31. Shut engine down and turn key switch off. Open each brake accumulator bleed
down valve and bleed down entire brake system.
32. Outside the brake cabinet, reconnect the hose that connects the front brake
accumulator to the brake pedal in cab. Disconnect the hose that supplies oil from
the rear brake accumulator to the brake pedal in the cab for the rear brakes and
plug the tube end at the cabinet. Be sure to leave end of hose vented to
atmosphere.
33. Very slowly depress the brake pedal until the rear brake differential switch has
activated the low brake pressure lamp and the buzzer. Record the front brake
pressure at the point this occurs. (The fault should occur at 1O00::!::
75 psi).
34. Shut engine down and turn key switch off Open each brake accumulator bleed
down valve and bleed down the entire brake system. Outsidethe brake cabinet,
reconnect the hose that connects the rear brake accumulator to.the brake pedal in
cab. Remove all instrumentation and simulators. This concludes the brake
system check-out.
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KomatsuCHECK-OUT PROCEDURE
EF5761
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STEP 4
STEP 6
STEP 7
STEP 12
STEP 13
671-2-3-97
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KomatsuCHECK-OUT PROCEDURE
EF5761
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STEP 17
STEP 20
STEP 21
STEP 24
REAPPLICATIONS
STEP 26
STEP 33
MACHINE
UNIT NO.
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NOTES:
KOMATSU
CHECKOUT PROCEDURE
I
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NAME:
VHMS System Checkout Procedure
WRITTEN BY:
DATE:
07/17/04
CHECKED BY:
DATE:
APPROVED
G. Horst
DATE:
BY:
1
0
DASH
A SIZE
INTEGRATED
INTERFACEMODULECHECKOUT 8/18/04 \\\"'\4
NEWRELEASE
DATE
ECN
DESCRIPTION
OFCHANGE
MICROFILM
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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
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Page 2 of 15
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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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Page 3 of 15
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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~
;.."""""",,,~:.--
CLOSE
355: Eng_OilJemp
385:AmblenCair _temp
386: Blow_by-press
387: Eng_oil-press
388: Boost-press
389: Exh_gas_temp
500: FueUnjection
501: Ave_Min_ldle_On
502:Auto_Lube_Sw
503: BatC 12V_A
504: BatU 2V_B
505: BatU 2V- C
0
Delete
0
0
START/STOP
12s
Sampling
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- 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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KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
PaQe 5 of 15
KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
Paqe 6 of 15
Hydraulic Tank Temperature (RR Hydraulic Oil Temp on VHMS Watcher) - confirm as being
near ambient on a cold truck. (564)
Motor Temperature High - short wire 722L to ground at TB21E-B momentarily and confirm
state change (zero to one). (558)
Motor Blower Off - short wire 32B to ground at TB21E-E momentarily and confirm state
change (zero to one). (555)
Diode Fault - short wire 79VD to ground at TB21D-G momentarily and confirm state change
(zero to one). (551)
Electric Drive System Fault - short wire 79VS to ground at TB21D-E momentarily and
confirm state change (zero to one). (516)
Ground Fault - short wire 79VG to ground at TB21D-F momentarily and confirm state
change (zero to one). (557)
Park Brake Set Switch - with engine running, toggle Park Brake Switch and confirm state
change (zero to one).
2. Engine Speed 1M- with engine running observe reported speed.
3. Vehicle Speed - observe reported speed while testing the speedometer with the GE DID
panel. Set to 20 mph and observe 20mph on speedometer as well as within VHMS.
4. Battery 12V A - check with batteries fully charged or being charged. Voltage should be
about 12 volts.
5. Battery 12V B - check with batteries fully charged or being charged. Voltage should be
about 12 volts.
6. Battery 12V C - check with batteries fully charged or being charged. Voltage should be
about 12 volts.
Page 6 of 15
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~---~------
KOMATSU
~-
~--
-------
CHECKOUT PROCEDURE
I
EK8480-1
PaQe 7 of 15
2.
3.
4.
5.
6.
7.
8.
9.
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.
2.
3.
Dismount the sending unit only from the tank and position the gauge to a low level with a
screwdriver. The shaft of the screwdriver will turn this magnetically coupled sending unit
to any position you desire.
Set the gauge to empty. After 15 seconds, the Low Fuel Light should come on.
Return the gauge to the approximate position of the actual fuel in the tank before remounting
it.
The Park Brake Solenoid and Brake Apply output can be checked with the following procedure.
1. Turn parking brake off. Park brake valve should be energized and brake auto apply valve
should not. Energization of these valves can be determined by checking voltage across
the valves or check for magnetism in the valve with a screwdriver.
2. Use the GE DID panel to set the truck speed to some elevated value such as is used to
calibrate the speedometer. The park brake valve should continue to be energized. The
auto apply valve should continue to be off.
3. With the truck speed signal still high, turn the park brake on. The park brake valve should
m
continue to be energized, and the auto apply valve should stay off.
Page 7 of 15
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KOMATSU
CHECKOUT PROCEDURE
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EK8480-1
PaQe 8 of 15
4.
Now remove the high truck speed signal. The auto apply valve should pulse on for about 1.5
seconds, and the park brake valve should turn off after the auto apply valve has been on
for 1 second.
Page 8 of 15
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KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
Paqe 9 of 15
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Page 9 of 15
KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
PaQe 10 of 15
16.Select "Setup". (DO NOT select "Data Clear & Setup" this time.)
17.Hold down the "ALT" key and press "S". Set the service meter reading hours. (SMR). Record in
Item 10 on Form 3.
18.Select "Apply" and accept the confirmation prompts.
19.Configure the OrbComm settings. Select "EDIT" in the Communication Settings window.
20.Set the file transfer settings as follows and record in Item 11 on Form 3.
Item
Short Trend Analysis
Short Load Map
Send
ON
ON
Short FaultHistory
ShortPayloadmeter
ON
ON
Occurrence
Day
for PLM3
Short Brake Load Map
ON
SMR
Timer
SMR
SMR
Number
1
Interval
20 (SMR)
160 (SMR)
6
1
160
21. Set GCC (Ground Control Center) to the appropriate setting and record in item 12 on From 3
GCC code
1
120
121
122
123
130
Territory
(country)
USA
ITALY
MALAYSIA
KOREA
BRAZIL
JAPAN
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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- --
u_-
---
-- ---
KOMATSU
_u-
--
CHECKOUT PROCEDURE
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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KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
PaQe 12 of 15
To : VHMSlWebCARE
support
FAX: 81-3-5561-4766
WebCARE
machine
Ref. No.
Date
Name
team
registration
Fonn
request
( DB information]
1. Distributor name
2. Branch
3. Person
4. E-mail address
in Charge
"An
Name
5. DB code (GCPS)
[ Customer
information]
6. Customer
name
7. Site name
[ Machine information]
8. Model Name
9. Serial No.
.. Retro-klt
Installed on new machine 0
0
PM Clinic
KUC
[ Orbcomm
Activation]
12. Date of Orbcomm activation
[ Remark]
WebC.,ARE
.1
~
)
.
)
I-)
Page 12 of 15
KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
Paqe 13 of 15
Important
Terminal
Terminal Part Number
Terminal SIN
PIN:
(YY/MM/DD)
SIN:
I
Model-Type-S/N#
(Country-Area-number>
FAX Number
(Country. Area-number)
e-mail address
Name (please print)
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.
Page 13 of 15
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KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
Paqe 14 of 15
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
Mil:
D9sigaj
-+81-3-55614766
~CXl.jp
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Page 14 of 15
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KOMATSU
CHECKOUT PROCEDURE
I
EK8480-1
PaQe 15 of 15
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Page 15 of 15
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NOTES:
Grade 5
Cap
Screw
Thread
Size
kgm
1/4-20
1/4-28
5/16-18
TORQUE GRADE 5
ft lbs
. . A5-1
. . A5-2
. . A5-2
. . A5-3
. . A5-3
. . A5-3
. . A5-3
. . A5-4
. . A5-4
. . A5-4
. . A5-5
. . A5-5
. . A5-6
TORQUE GRADE 8
Cap
Screw
Thread
Size
Grade 8
TORQUE GRADE 5
TORQUE GRADE 8
Nm
ft lbs
kgm
Nm
ft lbs
kgm
Nm
ft lbs
kgm
Nm
0.97
9.5
10
1.38
13.6
1.11
10.8
11
1.52
14.9
3/4-16
235
32.5
319
335
46.3
454
7/8-9
350
48.4
475
500
69.2
15
2.07
20.3
21
2.90
28
678
7/8-14
375
51.9
508
530
73.3
719
5/16-24
16
2.21
22
22
3.04
3/8-16
25
3.46
34
35
4.84
30
1.0-8
525
72.6
712
750
103.7
1017
47
1.0-12
560
77.4
759
790
109.3
3/8-24
30
4.15
41
40
1071
5.5
54
1.0-14
570
78.8
773
800
110.6
1085
7/16-14
40
5.5
54
7/16-20
45
6.2
61
58
8.0
79
1 1/8-7
650
89.9
881
1050
145
1424
62
8.57
84
1 1/8-12
700
96.8
949
1140
158
1546
1/2-13
65
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
CAP SCREW
SIZE*
TORQUE
ft lbs
TORQUE
Nm
TORQUE
kgm
0.250 - 20
12
16
1.7
0.312 - 18
24
33
3.3
M6 x1
12
1.22
0.375 - 16
42
57
5.8
M8 x 1.25
30
22
3.06
CAP SCREW
SIZE*
TORQUE
Nm
TORQUE
ft lbs
TORQUE
kgm
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
15.81
0.562 - 12
150
203
20.7
M14 x 2
155
114
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
1.125 - 12
1330
1800
184
1.250 - 7
1715
2325
237
1.250 - 12
1840
2495
254
1.375 - 6
2270
3080
313
1.375 - 12
2475
3355
342
1.500 - 6
2980
4040
411
1.500 - 12
3225
4375
445
TABLE IV.
TORQUE CHART FOR JIC 37 SWIVEL NUTS
WITH OR WITHOUT O-RING SEALS
TABLE VI.
TORQUE CHART FOR
O-RING BOSS FITTINGS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
ft lbs
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
ft lbs
0.125
0.312 24
4 1
0.125
0.312 24
4 2
0.188
0.375 24
8 3
0.188
0.375 24
5 2
0.250
0.438 20
12 3
0.250
0.438 20
8 3
0.312
0.500 20
15 3
0.312
0.500 20
10 3
0.375
0.562 18
18 5
0.375
0.562 18
13 3
0.500
0.750 16
30 5
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.
TORQUE CHART FOR
PIPE THREAD FITTINGS
TABLE VII.
TORQUE CHART FOR
O-RING FACE SEAL FITTINGS
SIZE
CODE
PIPE
THREAD
SIZE
WITH
SEALANT
ft lbs
WITHOUT
SEALANT
ft lbs
0.125 27
15 3
20 5
0.250 18
20 5
25 5
0.375 18
25 5
35 5
0.500 14
35 5
45 5
12
0.750 14
45 5
55 5
16
1.000 11.50
55 5
65 5
20
1.250 11.50
70 5
80 5
24
1.500 11.50
80 5
95 10
32
2.000 11.50
95 10
120 10
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE ft
lbs
0.250
0.438 20
11 1
0.375
0.562 18
18 2
0.500
0.750 16
35 4
10
0.625
0.875 14
51 5
12
0.750
1.062 12
71 7
16
1.000
1.312 12
98 6
20
1.250
1.625 12
132 7
24
1.500
1.875 12
165 15
(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
(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
(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
10
20
30
40
50
60
70
80
90
(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
NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa).
1. Select Table X.
2. Go to psi row 90, column 7; read 668.8
97 psi = 668.8 kPa.
3. Multiply by 10:
970 psi = 6688 kPa.
4. Go to psi row 0, column 5; read 34.475
psi = 34.47 kPa. Add to step 3.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
TABLE XIII
COMMON CONVERSION MULTIPLIERS
Multiply
By
TO
Multiply
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
1.61
kilometer (km)
mile mi.
0.6210
mile mi.
kilometer (km)
To Convert From
2)
TO
in.2
0.1550
6.45
929
0.001
16.39
cu in in.3
0.061
liters (l)
0.016
liters (l)
cu in in.3
61.02
0.028
cu ft ft3
35.314
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)
0.0338
pound (mass)
kilogram (kg)
0.454
kilogram (kg)
pound (mass)
2.2046
Newton (N)
4.448
Newton (N)
0.2248
0.113
Newton-meters (Nm)
0.102
sq. in.
ft lbs (force)
1.356
Newton-meters (N.m)
ft lbs
0.7376
ft lbs (force)
0.138
kilogram-meters (kgm)
ft lbs
7.2329
psi (pressure)
kilopascals (kPa)
6.895
kilogram-meters (kgm)
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
psi
14.2231
kilopascals (kPa)
98.068
ton
0.0011
(kg/cm2)
ton (short)
kilogram (kg)
907.2
kilograms/cm
ton (short)
metric ton
0.0907
kilograms/cm2 (kg/cm2)
quart qt
liters (l)
0.946
kilogram (kg)
gallon gal
liters (l)
3.785
metric ton
HP (horsepower)
Watts
745.7
liters (l)
HP (horsepower)
kilowatts (kw)
0.745
liters (l)
ton
1.1023
quart qt
1.0567
gallon gal
0.2642
Watts
Horsepower HP
0.00134
kilowatts (kw)
Horsepower HP
1.3410
MACHINE MODEL
(Circle One)
MACHINE
SERIAL NUMBER
ENGINE MODEL
Date of Inspection
Wheel Motor
ENGINE
SERIAL NUMBER
CUSTOMER UNIT
NUMBER
730E 830E
830E-AC 930E-4
Service Meter Reading
Serial Numbers
Location of Machine at Inspection
LH
RH
Other
Distributors Name
Customers Name
Date
Customers Address
Inspectors Comments:
Inspectors Name
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.
CEAW003209
Page 1 of 5
Acceptance Procedures
Maintenance
Inspection Item
Accepted
No.
Parts
Hardware
Visual inspection of hydraulic hoses and electric cables to ensure they are securely
clamped and clear from sharp edges and not rubbing each other
Ground Straps
Verify all ground straps are secure (sub frame, anchor etc.)
Engine Fan
Oil level visible through the upper sight glass with body down
Hatch Door
(730E, 830E)
Verify adequate latch seal on the rear axle hatch door to prevent dust entry
Anchor Pin
Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and properly tightened hardware
10
Wheel Motors
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
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
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
Wheels
Verify front suspension mounting cap screws have been properly tightened per appropriate
service manual procedure using the turn-of-the-nut method
730E
Verify torque on front wheel nuts at 2326 136 Nm (1715 100 ft lbs)
Verify torque on rear inside wheel nuts at 2326 136 Nm (1715 100 ft lbs)
Verify torque on rear outside wheel nuts and adapter ring at 2326 136 Nm (1715 100 ft
lbs)
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)
Cab
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 mounting tightening procedure.
CEAW003209
Page 2 of 5
Acceptance Procedures
Maintenance
Inspection Item
Accepted
No.
Cab Compartment
1
Cab Doors
Verify doors open and close smoothly, latch works properly, O&M manual in door
Cab Windows
Door Locks
Verify left and right door locks work properly with key
Interior
Cab Seats
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
Passenger Seat
Steering Wheel
Wiper
Verify wiper works all speeds, & range does not extend beyond glass surface
Cigarette Lighter
10
Horn
11
Back Up Horn
12
Shift Tower
13
Gauges
14
Hydraulic Fittings
Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet
15
Hoist
Headlights
Verify the windshield washer works properly and washer fluid bottle is full
Lights
1
Instrument Panel
2a
Dimmer Switch
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
Hazard Flashers
Back Up Light
Brake Lights
1
Service Brake
Brake Lock
Emergency Brake
Parking Brake
Dome Light
Retarder Lights
CEAW003209
Page 3 of 5
Acceptance Procedures
Maintenance
Inspection Item
Accepted
No.
Service Inspection
1
Suspension
730E
Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear
Front charge height, 229 mm (9 in.) at 2758 kPa (400 psi)
Rear charge height, 276 mm (10.9 in. ) at 1420 kPa (206 psi)
830E, 830E-AC
(See Note below chart)
Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
Front charge height, 229 mm (9 in.) at 2689 kPa (390 psi)
Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)
930E-4
(See Note below chart)
Suspension oiling height at 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
Front charge height, 229 mm (9 in.) at 2930 kPa (425 psi)
Rear charge height, 190 mm (7.5 in.) at 1482 kPa (215 psi)
Accumulators
Verify nitrogen charge in accumulators is at 9653 kPa (1400 psi) for all models, for both
steering and brakes
Engine Prelube
Engine Starting
Engine Noise
Brake Lock
Verify when switch is ON, brakes are applied and light is illuminated
Parking Brake
Verify when switch is ON, brakes are applied and light is illuminated
Brake Pressure
730E
Verify with pedal depressed, front brake pressure is 17,236 689 kPa (2500 100 psi)
Verify with pedal depressed, rear brake pressure is 11,721 517 kPa (1700 75 psi)
Verify brake lock pressure is 10,342 689 kPa (1500 100 psi)
Verify parking brake pressure is 17,926 689 kPa (2600 100 psi)
830E, 830E-AC
Verify with pedal depressed, front brake pressure is 20,684 1034 kPa (3000 150 psi)
Verify with pedal depressed, rear brake pressure is 13,652 689 kPa (1980 100 psi)
Verify brake lock pressure is 10,342 689 kPa (1500 100 psi)
Verify parking brake pressure is 17,236 689 kPa (2500 100 psi)
930E-4
Verify with pedal depressed, front brake pressure (BF) is 17,236 517 kPa (2500 75 psi)
Verify with pedal depressed, rear brake pressure (BR) is 17,236 517 kPa (2500 75 psi)
Verify brake lock pressure is 13,790 689 kPa (2000 100 psi)
Verify parking brake release pressure is 18,616 689 kPa (2700 100 psi)
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.
CEAW003209
Page 4 of 5
11
730E
Acceptance Procedures
Maintenance
Inspection Item
Hoist Times
Accepted
No.
830E, 830E-AC
930E-4
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)
13
Ensure automatic lube system is operating properly and timer is set as desired
14
Error Codes
15
Machine
Record machine model-type, machine serial number and engine serial number
16
Dump Body
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__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CEAW003209
Page 5 of 5
NOTES:
MACHINE MODEL
(Circle One)
MACHINE
SERIAL NUMBER
ENGINE MODEL
Date of Inspection
Wheel Motor
ENGINE
SERIAL NUMBER
CUSTOMER UNIT
NUMBER
730E 830E
830E-AC 930E-4
Service Meter Reading
Serial Numbers
Location of Machine at Inspection
LH
RH
Other
Distributors Name
Customers Name
Date
Customers Address
Inspectors Comments:
Inspectors Name
Title
By:
Signature
Remark:
CEAW004201
Page 1 of 5
No.
Inspection Item
Acceptance Procedures
As Found
Condition
Corrective
Action
Parts
Hardware
Verify the oil level is visible through the upper sight glass
with the body down.
Anchor Pin
Wheel Motors
Verify the correct oil is being used and oil is at the proper
level.
Fuel Tank
Radiator
10
Steering Components
11
Hydraulic Components
12
Leakage
Hardware Torque
1
Steering Arm To
Suspension
Steering Cylinder To
Frame
Steering Cylinder To
Steering Arm
CEAW004201
Page 2 of 5
No.
Inspection Item
Acceptance Procedures
As Found
Condition
Corrective
Action
Cab Compartment
1
Horn
Back Up Horn
Gauges
Glass
Verify no cracks exist on cab windows. Ensure all windows are properly sealed.
Seat/Seat belts
Verify the cab seats and seat belts are in proper working
condition.
CEAW004201
Page 3 of 5
No.
Inspection Item
Acceptance Procedures
As Found
Condition
Corrective
Action
Service Inspection
1
Suspension
730E
830E, 830E-AC
(See Note below)
930E-4
(See Note below)
NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling
and charging instructions.
2
Accumulators
Steering
Lubrication
Hydraulic Filters
Tires
Pressure
Size
Manufacturer
GE Drive/Control
System
GE Rotating
Components
(Wheel Motors, MTA,
Grid Blower)
10
Measure and record sun pinion end play for both RH and
LH wheel motors
11
VHMS
CEAW004201
Page 4 of 5
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No.
Description of Modification
1
2
3
4
5
6
ADDITIONAL COMMENTS:______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CEAW004201
Page 5 of 5
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