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Field Assembly

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

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 taken.

WARNING identifies a specific potential hazard


WHICH WILL RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

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.

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Introduction

FAM0011

TABLE OF CONTENTS

SUBJECT

PAGE NUMBER

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

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

MAJOR 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

DUMP BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

FAM0011

Introduction

iii

KOMATSU MODEL 730E DUMP TRUCK

iv

Introduction

FAM0011

SAFETY RULES, TOOLS & EQUIPMENT


SAFETY RULES
The following list of safety practices is intended for
use by personnel during field assembly of the truck.
This list of safety rules is not intended to replace local
safety rules or regulations and federal, state, or local
laws. The safety precautions recommended here are
general and must be used in conjunction with all prevailing local rules and regulations.
1. All personnel must be properly trained for the
assembly operation.
2. Wear safety equipment such as safety glasses,
hard toe shoes and hard hats at all times during
assembly.

11. When welding, connect the ground cable to the


part being welded. DO NOT allow welding current to pass through bearings, engine, etc.
12. DO NOT weld the transmission housing unless
it has been completely disassembled.
13. DO NOT weld the fuel tank or hydraulic tank
unless the tanks have been properly purged
and ventilated.
14. Use the proper tools for the job to be performed.
Never improvise wrenches, screw drivers, sockets, etc. unless specified.

3. Thoroughly inspect the assembly site. Remove


weeds, debris and other flammable material.

15. Lifting eyes and hooks must be fabricated from


the proper materials and rated to lift the
intended load.

4. Use only solid, hard wood for supports. When


using metal support stands, place wood blocks
between the support and the frame to prevent
metal to metal contact.

16. When the weight of any component(s) or any


assembly procedure is not known, contact your
customer support manager for further information.

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

Safety Rules, Tools, & Equipment

Page 1-1

TOOLS AND EQUIPMENT FOR


ASSEMBLY

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

The following equipment is recommended for field


assembly of the truck.

13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)


14. Set of standard master mechanics hand tools.

Thread taps and dies of both inch and metric


1. Equipment and tool storage trailer with a lockable door. Approximately 12 x 2.5 m (40 x 8 ft)
2. Cranes

sizes.

Metric sockets and open end wrenches, 6mm


to 36mm.

a. Two, 45 metric ton (50 ton) cranes to remove


the chassis from the freight trailer and place
on cribbing. These cranes can also be used
to lift the assembled body onto to the chassis.
b. One, 109-136 metric tons (120-150 ton)
crane. The crane is needed to turn the body
over after completion of the underside welding. A 45 metric ton (50 ton) crane is also
required for this task.

Inch sockets and open end wrenches up to 1


3/4 in.

Torque wrenches - 339 Nm (250 ft lb) with


18:1 multiplier. Torque wrenches - 339 Nm
(600 ft lb) with 4:1 multiplier. Hydrotorque - 1
1/2 in. drive with capability of 5559 Nm
(4100 ft lb) or greater.

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


with 12 inch extension to tighten ROPS cap
screws.

3. One fork lift - 6804 kg (15,000 lb) capacity, with


high lift capability.

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

4. Two, 300 amp portable welding units and an


oxy-acetylene cutting set.

2 5/8 in. (Snap-On P/N J15042) to tighten


front suspension hardware.

5. One, propane torches for weld preheating.


6. Portable air compressor - 3.5 cmm (125 cfm)
and 690 kPa (100 psi) capacity.
Two, 15 m (50 ft) air hoses.

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.

7. Metal stands and a sufficient amount of wood


cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm
(4 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15
cm (4 ft. x 6 in. x 6 in.) - such as railway cross
ties

17. Special tools (see list, following pages)

8. Tire handler - Wiggins/Iowa Mold Tooling.

20. Miscellaneous: i.e. grinders, containers, rags.

9. Miscellaneous air tools

21. Spreader bars for cab and decks.

10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft)


11. Chains, lifting cables, slings:

18. Two, hydraulic or pneumatic porta-power jacks,


4.5 and 9 metric ton (5 and 10 ton)
19. Various hooks and shackles

22. Two ratchet hoists of 2.7 metric ton (3 ton)


capacity.

Two, 4 point slings, 3 m (10 ft) in length

23. Pry bars

Two, 4 point slings, 2 m (6 ft) in length

24. Solvent - 38 liters (10 gal)

Two, 1 m (4 ft) and two, 2 m (6 ft)

25. Paint remover - 19 liters (5 gal)


26. Rust preventive grease

Two, 3 m (10 ft) nylon straps


Four lengths of 2.54 cm x 15 m (1 in. x 50 ft)
of rope

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Safety Rules, Tools, & Equipment

FAM0109

LIFTING SLING GENERAL


INFORMATION

FAM0109

Safety Rules, Tools, & Equipment

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

Offset Box End


Wrench,
1 7/16

Miscellaneous
and Cab
Mounting

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

NOTE: Arrangement of parts may vary from the


illustration shown, depending on the charging kit P/N

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Safety Rules, Tools, & Equipment

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

Seal Installation Tool

Installation of
Front Wheel
Bearing Face
Seals

Part Number

Description

EC1741
EC1742
TZ0992

Sleeve
Alignment Tool

Safety Rules, Tools, & Equipment

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

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Use

Safety Rules, Tools, & Equipment

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

Impact Socket 1-5/8

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

Impact Socket 3-1/8

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

Locking Steel Pin (for


use with 1-1/2
square drive
sockets)

Miscellaneous

PB6852

Locking Rubber Ring


(for use with 1-1/2
square drive
sockets)

Miscellaneous

FAM0109

PART NO.

Safety Rules, Tools, & Equipment

DESCRIPTION
V-Belt Alignment Tool

USE
Aligning A/C
pulleys

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ASSEMBLY SCHEDULE AND RESOURCE LAYOUT


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Safety Rules, Tools, & Equipment

FAM0109

FAM0109

Safety Rules, Tools, & Equipment

Page 1-9

NOTES

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Safety Rules, Tools, & Equipment

FAM0109

MAJOR COMPONENTS AND SPECIFICATIONS


The Komatsu model 730E dump truck is an electric drive, off-highway, rear dump truck. Standard 730E gross vehicle weight is 324,322 kg (715,000 lbs) rated for a nominal payload of 185 t (203 tons). Some Trolley versions may
have a higher GVW. Refer to the grade/speed chart in the operators cab for the appropriate GVW.
ENGINE

POWER STEERING

The Komatsu 730E dump truck is powered by a


Komatsu SSA16V159 engine rated at 2000 HP
(1492 kW).

The Komatsu 730E dump truck is equipped with a


full-time power steering system, which provides positive steering control with a minimum of effort by the
operator. The system includes nitrogen-charged
accumulators which automatically provide emergency power if the steering hydraulic pressure is
reduced below an established minimum.

ALTERNATOR (GE GTA-22)


The diesel engine drives an alternator mounted inline with the engine. The Alternating Current (AC)
output of the alternator is rectified to Direct Current
(DC) and sent to the DC drive wheel motors.
WHEEL MOTORS (GE 788)
The output of the alternator supplies electrical energy
to the two wheel motors attached to the rear axle
housing. The two wheel motors convert electrical
energy back to mechanical energy through built-in
gear trains within the wheel motor assembly. The
direction of the wheel motors is controlled by a forward or reverse hand selector switch located on a
console to the right side of the operator.
BLOWER
The blower supplies cooling air for the rectifiers, AC
alternator, and to both wheel motors, where it is then
exhausted to the atmosphere.
OPERATOR'S CAB
The operator's cab for the Komatsu 730E dump truck
has been engineered for operator comfort and to
allow for efficient and safe operation of the truck.
The cab provides for wide visibility, with an integral
four-post Rollover Protective Structure/Falling Object
Protective Structure (ROPS/FOPS), and an
advanced analog operator environment. It includes a
tinted safety-glass windshield and power-operated
side windows, a deluxe interior with a fully adjustable
seat with lumbar support, a fully adjustable/tilt steering wheel, controls mounted within easy reach of the
operator, and an analog instrument panel which provides the operator with all instruments and gauges,
which are necessary to control and/or monitor the
truck's operating systems.

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.

Major Components & Specifications

FAM2-1

730E MAJOR COMPONENTS


FAM2-2

Major Components & Specifications

FAM0210

SPECIFICATIONS
These specifications are for the standard 730E dump truck. Customer options may change this listing.
SERVICE CAPACITIES

ENGINE

Liters. . . U.S. Gallons

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)

Crankcase (includes lube oil filters)


Komatsu . . . . . . . . . . . . . . . . . 223. . . . . . . . . . . . .59
Cooling System . . . . . . . . . . . 409. . . . . . . . . . . .108
Fuel . . . . . . . . . . . . . . . . . . . 3217 . . . . . . . . . . .850
Hydraulic System . . . . . . . . . . 731 . . . . . . . . . . .193
Wheel Motor Gear Box. . . .40/Wheel . . .10.5/Wheel

ELECTRIC DRIVE SYSTEM


HYDRAULIC SYSTEM
STATEX III w/Fuelsaver . . . . . . . . . AC/DC Current

Pumps:

Alternator . . . . . . . . . . . . . General Electric GTA - 22

Hoist (gear-type). . . . . . . . . . .513 l/min (135.6 GPM)

Motorized Wheels . . . . . . . . . . General Electric 788*

. . . . . . . . . . . . at 17240 kPa (2500 psi) @ 1900 rpm

Standard Gear Ratio* . . . . . . . . . . . . . . . . . 26.825:1

Steering/Brake (vane-type). . . . . 235 l/min (62 GPM)

Maximum Speed . . . . . . . . . . . 34.6 mph (55.7 km/h)

. . . . . . . . . . . at 18960 kPa (2750 psi) @ 1900 RPM

*NOTE: Wheel motor application depends upon GVW, haul road


grade, haul road length, rolling resistance, and other parameters.
KOMATSU & G.E. must analyze each job condition to assure
proper application.

Relief Pressure-Hoist . . . . . . . .17240 kPa (2500 psi)

DYNAMIC RETARDING

Tank . . . . . . . Vertical - Cylindrical, Non-Pressurized

Electric Dynamic Retarding . . . . . . . . . . . . Standard

Service Capacity . . . . . . . . 731 Liters (193 U.S. Gal)

Maximum Retarding . . . . . . . . . 2759 kW (3700 HP)

Filtration . . . . . . . . . . . In-line Replaceable Elements

. . . . . . . . . . . . . With Continuous Rated Blown Grids

Suction . . . . . . . . . . . . . Single, Full Flow, 100 Mesh

. . Two-Speed Overspeed & Extended Range Retarding

Hoist and Steering High-Pressure Filters

. . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Retarding
BATTERY ELECTRIC SYSTEM

Relief Pressure-Steering . . . . .27580 kPa (4000 psi)


Hoist . . . . . . . . Two Three-Stage Hydraulic Cylinders

. . . . . . . . . . . . . . . . . Dual, Full Flow, Seven Micron


. . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 rating = 200
SERVICE BRAKES

Batteries . Bumper-Mounted in Polyethylene Boxes


. . . . . . . . . . Four 12-Volt Batteries in Series/Parallel
. . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity
. . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch

Actuation . . . . . . . All Hydraulic - Caliper/Disc


. . . . . . . . . . . . . . .(Front) . . . . . . . . . . . . . . . .(Rear)
Type . . . . . . . . . Single Disc. . . . . . . . . . . . Dual Disc
. . . . . . . . . . . . Wheel Speed . . . . . .Armature Speed

Alternator . . . . . . . . . . . 24-Volt, 220 Ampere Output


Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt

STEERING

Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt

Turning Circle (SAE). . . . . . . . . . . . . . . 28.0 m (92 ft)


Twin hydraulic cylinders with accumulator assist to
provide constant rate steering.
Emergency power steering automatically provided by
accumulators (meets SAE J1511).

FAM0210

Major Components & Specifications

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)

Struck . . . . . . . . . . . . . . . . 77 m . . . . . 101 yds


Heaped @ 2:1 (SAE) . . . . 111 m . . . . 145 yds
Width (inside) . . . . . . . . . . . . . . . 5.61 m (22 ft 6 in.)
Depth . . . . . . . . . . . . . . . . . . . . . 2.08 m (6 ft 10 in.)
Loading Height . . . . . . . . . . . . . . 5.61 m (18 ft 5 in.)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Total (100% fuel) . . . . . . 140,592. . . . . . .(309,950)


Standard Komatsu Body . 25,612. . . . . . . .(61,000)
Standard Tire Weight. . . . 18,371. . . . . . . .(40,500)
Loaded Vehicle

Kilograms . . .

(Pounds)

*Optional capacity dump bodies are available.

Front Axle . . . . . . . . . . 107,026. . . . . . . 235,950)


Rear Axle. . . . . . . . . . . . 217,296. . . . . . . 479,050)

TIRES

Total * . . . . . . . . . . . . . 324,322 . . . . . .(715,000)


Nominal Payload . . . . . 183,730. . . . . . .(405,050)

Radial Tires (standard) . . . . . . . . . . . . . . 37.00 R57


Rock Service, Deep Tread . . . . . . . . . . . . Tubeless
Rims . (Patented Phase II New Generation Rims)
Tires and Rims . . . . . . . . . . . . . . . Interchangeable

FAM2-4

*Nominal payload is defined by Komatsu America


Corporations payload policy documentation. In general, 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.

Major Components & Specifications

FAM0210

MAJOR COMPONENT WEIGHTS

The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before
each use. Lifting equipment must be in good condition and rated for approximately two times the weight
being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result.
Optional equipment added onto the truck may cause an increase to the component weights listed in this
chapter. Contact your customer support manager for concerns or questions about lifting truck components.

NOTE: All component weights are dry weights. The additional weight of coolant, fuel, and oil that may be in the
components are not calculated into this list.

ITEM

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

DECK AND DECK SUPPORT COMPONENTS


Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,449 . . . . . . . . . . . . . . . . . . . . . . 5,400
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 . . . . . . . . . . . . . . . . . . . . . . 1,596
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 . . . . . . . . . . . . . . . . . . . . . . 1,400
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 . . . . . . . . . . . . . . . . . . . . . . . .514
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 . . . . . . . . . . . . . . . . . . . . . . . .900
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 . . . . . . . . . . . . . . . . . . . . . . . .650
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 . . . . . . . . . . . . . . . . . . . . . . 1,700
RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907 . . . . . . . . . . . . . . . . . . . . . . 2,000
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 . . . . . . . . . . . . . . . . . . . . . . . .216
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 . . . . . . . . . . . . . . . . . . . . . . . .287

FAM0310

Major Component Weights

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

FRONT AXLE COMPONENTS


Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,330 . . . . . . . . . . . . . . . . . . . . . . .7,340
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 . . . . . . . . . . . . . . . . . . . . . . . . 423
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,964 . . . . . . . . . . . . . . . . . . . . . . .4,330
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 . . . . . . . . . . . . . . . . . . . . . . . . 300

Page 3-2

Major Component Weights

FAM0310

FIELD WELDING FOR ASSEMBLY OR REPAIR


When welding on Komatsu equipment, whether at
initial field assembly or during normal maintenance
repairs, special procedures must be followed.
Due to the continuous program of research and
development, periodic revisions may be made to this
publication. It is recommended that customers contact their distributors for information on the latest revision.
The welding information contained in this chapter is
general information that must be followed unless otherwise specified in a detailed repair procedure provided on an engineering drawing or a detailed
specific repair procedure. Additional specific information, or detailed instructions can be obtained through
your local Komatsu customer support manager.

WELD PROCEDURES
Electric arc welding, either the semi-automatic MIG
(GMAW), Flux Core (FCAW), or Stick electrode
welding (SMAW), are approved processes for field
installation and maintenance welding. Welding of
highly stressed structural members such as castings,
torque tubes, top and bottom plates on the frame
rails, and the curved intersection points of frames
should be done with the specific detailed instructions
from Komatsu Product Service. See Annex A for
repair procedures. These repair procedures are
detailed instructions for most high stressed structural
members.

APPROVED CONSUMABLES
WELDER QUALIFICATION AND
TRAINING

GMAW - LW102-15 or ER80S-D2

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.

SMAW - E7018-1, E8018-C1, or E8018-C3

FCAW - E70T-5, E71T-8, or E71T8-NI1

WELD QUALITY REQUIREMENTS


1. Each weld must be homogeneous with low
porosity, free from cracks, and slag inclusions.
2. Each weld must have complete fusion between
the base metal and weld metal added by the
electrode.
3. All welds must be reasonably smooth, without
excessive deformity, and all craters filled. No
cracks are permitted.
4. The toe of a weld to a stressed member must
have a smooth transition. Excessive convexity
in multi-pass fillet welds is not permitted. Excessive convexity produces high residual stress in
the throat of the weld, and is not permitted.
5. Undercut in excess of 0.8 mm (0.03 in.) on critical welds must be reworked by the application
of welding an additional cover pass. It is important that this pass is blended with the existing
weld.

FAM0406

Field Welding For Assembly Or Repair

4-1

6. When welding in the vertical position, always


weld using the vertical up technique. Large
wash weld weaves should not be used when
welding on truck frames. Properly applied multiple pass welding is the required procedure on
truck frames.

2. Low Ambient Temperature - DO NOT weld in


temperatures below 50F (10C). At low temperature conditions, preheating of all welding
joint work areas is required. See preheat and
post heating requirements as detailed in Annex
A.

7. Slag is to be removed from all weld beads, and


must be completely removed before each pass
in a multiple pass procedure. It is also required
that all slag is removed and tie in all areas.
Grind all welds where a weld crosses or intersects with another weld.

3. Weld Cooling - Protect the weld area from a


rapid cooling rate. Heat retardation may be
accomplished through the use of heat lamps,
torches, insulating blankets, etc.

MATERIALS, CONTROLS, AND


PRECAUTIONS
The steel used in the fabrication of all Komatsu
equipment is of high strength low alloy (HSLA) material of different grades. The standard dump body
main plates are made from abrasion resistant materials. These materials offer themselves very well to
welding during fabrication, and repair.
The welding consumables are often supplied by
Komatsu America Corp. with the new equipment as
part of the field welding / assembly package. For field
welding and repairs, the approved consumables as
detailed, should be procured from a local, reliable
supplier. Other highly specialized welding consumables are available but have limited use on Komatsu
structural components. Approval is required from
your Komatsu customer support manager.

4. Moisture - Any moisture on the steel surfaces to


be welded must be removed before welding.
Electrodes must be stored in sealed containers
until needed. Electrodes must be kept in a
warming oven at the work location until used to
prevent any moisture absorption which might
affect weld quality.
5. Foreign Materials - Any foreign substances
(dirt, paint, rust, scale, and carbon deposits
from cuttings) must be removed prior to welding. Clean all weld areas and surfaces with a
grinder to ensure that all foreign materials have
been removed.

WELD INSPECTION

Control of the welding area environment is essential


for producing proper and sound welds. Essentially,
five areas require attention and control.

All welding repairs are subject to inspection by a


Komatsu appointed inspector or laboratory to insure
quality. After the weld has been made it can be
inspected by a number of non-destructive evaluation
techniques. The inspections can include any of the
methods listed below. All assembly welds and weld
repairs that are deemed unacceptable by the inspector must be corrected at no additional cost to
Komatsu. All weld repairs are also subject to additional inspection.

1. 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

Field Welding For Assembly Or Repair

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.

Komatsu requires record keeping of all welding work.


This information is valuable when personnel or job
conditions change. The service and warranty departments of Komatsu must be provided with inspection
reports and photographs of the weld area before,
during, and after the repair. The photographs must
be clear and close enough to show the weld joint
preparation complete, with backer bars installed, etc.
just prior to welding. These photos easily identify if
the required preheating and post heating have been
done with a three inch circumference around the
weld repair area. Without this documentation,
Komatsu will not cover any weld repair claim made
under warranty. No exceptions will be made.

ANNEX A
The following are general repair procedures, which
must be followed for all repair and rework of major
load carrying members on Komatsu equipment.

1. The repair or rework area must be protected


from wind and moisture during the entire procedure. If the repair work is to done outside additional precautions must be taken to protect the
weld repair process from outside elements. All
welding should be done at an ambient temperature of 10C (50F) or above.
2. Clean and grind the entire repair area to
remove all rust, grease, oils, paint, and any
other foreign materials likely to contaminate the
weld.

FAM0406

Field Welding For Assembly Or Repair

4-3

3. Air arc the entire crack leaving a V-shape joint.


The depth of the V (or U shaped) joint will be
determined by the depth of the crack. The width
to depth ratio should be approximately 1.25:1
and never less than 1:1. All cracks through the
parent material will require a slightly wider root
opening than the original, usually 6 mm (0.25
in.) to allow the installation of a backup strip.
Backup strips are required for all cracks that
have gone through the parent material and cannot be welded from both sides. If a weld repair
allows access to both sides of the plate, no
backup strip is required as long as complete
weld penetration is achieved. If backup strips
are not used, the surface profile on both sides
must be ground smooth with no undercut. Documentation must support this repair. Photographs of surface condition are required by the
service and warranty departments of Komatsu.
4. Use dye penetrant to ensure the cracks are
completely removed.
5. After air arcing and inspections (Steps 3 & 4) all
areas cut by the air arc should be cleaned thoroughly with a grinder to remove all possible carbon deposits and dye penetrant.
6. Fill gouges with weld and grind all surfaces
smooth to avoid defects in the new weld.
7. Grind all surfaces to be welded so they are free
of slag, rust, and any other foreign materials.
8. Preheat the entire weld joint area until the surrounding surface area reaches 150C (300F)
at a distance of 76 mm (3 in.) from all areas to
be welded.

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.

Field Welding For Assembly Or Repair

FAM0406

ANNEX B
2.0 TOE GRINDING WITH A ROTARY BURR

1.0 TOE HAMMER PEENING


Equipment:

Equipment:

1. Hand held pneumatic hammer


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.)


diameter with 13 mm (0.50 in.) spherical tip

4. 6 mm (0.25 in.) diameter spherical tip bit


5. Protective clothing, gloves, includes eye, face,
and ear protection.

3. Adequate air supply


4. Adequate lighting
5. Protective clothing, gloves, includes eye, face,
and ear protection

Procedure
1. The toe of the weld should serve as a guide for
the 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

NOTE: Peening shall only be performed after weld


acceptance by visual inspection.

1. The toe of the weld should serve as a guide for


the burr tool resulting in the material removed
being approximately equally divided between
the base material and the weld metal face to the
specified depth and not exceed 8 mm (0.31 in.)
in width. Refer to Figure 4-2.

2. The weld must have a smooth profile and the


toe must have a good transition to the parent
material (no overlap) before the peening operation is performed. Grinding the weld face and
toe area is permitted to correct unacceptable
conditions. Visual inspection/acceptance is to
be done after peening with the appropriate
radius and depth gauge.

2. The weld must have a smooth profile and the


toe must have a good transition to the parent
material (no overlap) before the grinding operation is performed. Grinding the weld face and
toe area is permitted to correct unacceptable
conditions. Visual inspection/acceptance to be
done after grinding with the appropriate radius
and depth gauge.

3. Hold the hammer tool at approximately one half


the included angle between the weld face and
the parent material and perpendicular to the
direction of travel. This will normally require
approximately four passes of the peening tool
with the pressure of near full operator weight
being applied. The depth of the indentation
must be between 0.6 mm to 0.8 mm (0.02 to
0.03 in.).

3. The axis of the tool should be maintained at


about 45 to the parent plate and inclined at
about 45 to the direction of travel. The depth of
the grinding must be between 0.8 mm to 1.0
mm (0.030 to 0.040 in.). The final surface must
be clean, smooth and free of all traces of undercut or slag.

FAM0406

Field Welding For Assembly Or Repair

4-5

FIGURE 4-1. TOE HAMMER PEENING

4-6

Field Welding For Assembly Or Repair

FAM0406

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

FAM0406

Field Welding For Assembly Or Repair

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

SPECIAL PRECAUTIONS WHEN


SERVICING AN A/C DRIVE SYSTEM
TRUCK
Consult a qualified technician, specifically trained for
servicing the A/C drive system, before welding on the
truck.
The following procedures must be followed to ensure
the safety of maintenance personnel and to help prevent damage to the equipment.

British Standard BS5135 - Metal Arc Welding of Carbon 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 retarding grids, wheel motors, alternator, and power
cables connecting these devices are safe to
work on.

4-8

Field Welding For Assembly Or Repair

FAM0406

General Welding Guidelines


Locate the GF cut-out switch in the access
panel on the left side of the main control cabinet. Place the switch in the CUTOUT position.
This will prevent the alternator from re-energizing and creating system voltage until the switch
is returned to its former position.
After repairs, replace all covers and doors and
place the GF cutout switch and battery disconnect switches in their original positions. Reconnect all harnesses prior to starting the truck.
Leave the drive system in the rest mode until
the truck is to be moved.
4. If the red lights on the exterior of the control
cabinet and/or the back wall of the operator's
cab continue to be illuminated, a fault has
occurred.
Leave all cabinet doors in place. DO NOT touch
the retard grid elements. DO NOT disconnect
any power cables or use them as hand or foot
holds.

Notify your Komatsu customer service manager


immediately. Only qualified personnel, specifically trained for servicing the A/C drive system,
may perform this service.

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

Field Welding For Assembly Or Repair

4-9

NOTES

4-10

Field Welding For Assembly Or Repair

FAM0406

RECEIVING & ASSEMBLY PREPARATION


1. Inspect all components for possible shipping
damages. Note any damage found and report to
shipping agent.
2. Spread out all parts and organize per unit number. Check for missing parts. List the unit number of all major components. Verify the cab and
decks are with the correct chassis.
3. Install support blocks under the chassis. The
support blocks must be approximately 84 cm
(33 in.) high.

5. Clean all mounting surfaces on the chassis and


on the individual components.
6. Check all electrical connectors and verify they
are free of paint and/or corrosion. Clean any
connector with questionable electrical continuity.
7. Check all factory installed components for the
proper tightening torque.
8. Arrange the work site as shown on the following
page.

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

Receiving & Assembly Preparation

Page 5-1

ASSEMBLY LAYOUT
Page 5-2

Receiving & Assembly Preparation

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.

BASIC ASSEMBLY PROCEDURE


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

RECOMMENDED ASSEMBLY DATA

8. Site cleanup

1. Service Report (Pre-Delivery)


2. Acknowledgement of Receipt of Company Warranty
3. Assembly Blueprints & Schematics
4. Fluid Specifications (refer to the lubrication
chart in Section 10, Appendix)
5. Suspension Oiling & Charging Procedure
(available in Section 10, Appendix)
6. Fan Drive Adjustment Procedure (available in
the engine service manual)
7. Toe-In Adjustment Procedure (Section 10,
Appendix)
8. Hydraulic Checkout Procedure (Section 10,
Appendix)
9. Brake Checkout Procedure (Section 10, Appendix)
10. Propulsion System Checkout Procedure (available in Section 10 of this manual)
11. Filter List (available in parts book)
12. Lubrication & Service PM Forms (available in
the operation and maintenance manual)
13. Component Weights - for crane reference
(available in Section 3 of this manual)
14. Standard Torque Chart (available in Section 10
of this manual)
15. Field Assembly Inspection Report Form (available in Section 10 of this manual)

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.

Disconnect the battery cables before arc welding


on the truck. Failure to do so may seriously damage the batteries and electrical equipment. Disconnect the battery charging alternator lead wire
before welding on the frame or its components.
Fasten the welding machine ground cable to the
component being welded.
DO NOT allow welding current to pass through
bearings.
DO NOT lay welding cables over truck electrical
cables and harnesses. Welding voltages could be
induced into the truck wiring and cause damage
to components.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly cleaned and
ventilated.

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.

Maintain fire control equipment. Inspect fire


extinguishers regularly to ensure they are fully
charged and in good working condition.

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.

Mark cap screws and nuts with paint or ink after


tightening to the specified torque. This method
provides verification that the hardware has been
properly tightened.

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.

Page 6-2

Chassis Assembly

10/07 FAM0610

GENERAL PRECAUTIONS AND


INSTRUCTION
1. Clean and remove all foreign material from
component mounting surfaces.
2. DO NOT weld the front uprights until all upper
decks are installed.
3. Torque the deck mounting bolts before the
exhaust tubes, etc. are installed.
4. Verify all electrical connectors are free from
paint and/or corrosion. Clean any connector
that may be questionable.
5. Do not torque the diagonal ROPS beam until
after the operator cab & LH air intake tubes are
in place.
6. Before installing the cab, tap all threaded holes
to remove paint.
7. Verify all wiring is properly connected before
attempting to start the engine.

FAM0610

10/07

8. Recheck the torque on hardware installed at the


factory.
9. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.
10. Use the proper precautions when checking the
nitrogen pressure and oil level in the accumulators.
11. Verify the lube system is lubricated, purged and
all levels full prior to start up.
12. Purge air from the steering pump before truck
operation. Pressure will not build in the brake
and steering circuit if air is present. Air in the
system may damage the pump. Refer to the
Hydraulic Checkout Procedure in Section 10 of
this manual.
13. Use the battery disconnect switch when arc
welding. Connect the weld ground near the
weld area.

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

9. Clean the mating surfaces for the LH and RH uprights.


10. 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.
11. 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
771 kg (1,700 lb).
DO NOT weld the torque tubes on the uprights until the decks are installed.
12. Attach the upper radiator stabilizers rods to the uprights. After the decks are installed and the uprights welded,
adjust the stabilizers to vertically level the radiator.

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

14. Prepare the mounting surfaces for the LH diagonal tube.


Lift the tube into position. The weight of the diagonal tube is approximately 98 kg (216 lb).
Do not tighten the cap screws until the deck and the cab are in place.

Page 6-20

Chassis Assembly

10/07 FAM0610

FIGURE 6-21.

FIGURE 6-22.

FAM0610

10/07

Chassis Assembly

Page 6-21

15. Clean and dry the mounting surfaces on both


the suspension and the frame. Use a cleaning
agent that does not leave a film after evaporation, such as trichlorethylene, tetrachlorethylene, acetone or lacquer thinner.

16. Lubricate the cap screw threads, cap screw


head seats, washer faces, and nut seats with a
rust preventive compound.

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 6-23. INSTALLATION OF HARDENED


FLAT WASHER
1. Hardened Flat Washer

2. Cap Screw

The use of dry threads in this application is not


recommended. Due to the high tightening forces
required to load these cap screws, dry threads or
threads lubricated with anti-seize compounds
may result in damage. Only use the approved
lubricants listed below.

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.

American Anti-Rust Grease #3-X from Standard


Oil Division of American Oil Company

18. Lift the front suspension into position. The


weight of each front suspension cylinder is
approximately 2228 kg (4,912 lb). Install the
mounting hardware and tighten according to the
"turn-of-the-nut" method outlined on the following pages.

Rustolene D grease from Sinclair Oil Company


Gulf NoRust #3 from Gulf Oil Company
Rust Ban 326 from Humble Oil Company
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.

Page 6-22

Chassis Assembly

10/07 FAM0610

Turn-Of-The-Nut Tightening Procedure


a. Tighten all 14 cap screws (1, 6, 8, Figure 624) to 542 5 Nm (400 40 ft lb).
b. Maintain this torque on the top two corner
cap screws and the bottom, outer four cap
screws (without spacers).
c. Loosen the eight remaining cap screws and
then tighten again as follows:
d. Initially tighten the four cap screws (1) at the
upper mount to 95 Nm (70 ft lb). Then,
advance the cap screw heads 60 as outlined in Steps d-1 through d-3. Refer to Figure 6-25.

FIGURE 6-25. 60 DEGREE ADVANCE


FIGURE 6-24. SUSPENSION INSTALLATION
1. Cap Screws and
Washers
2. Nuts and Washers
3. Housing
4. Mounting Surface
5. Shear Bar

6. Cap Screws and


Washers
7. Piston
8. Cap Screws and
Washers
9. Spacer
10. Nuts and Washers

Initially tighten the bottom four cap screws


(6, Figure 6-24) to 203 Nm (150 ft lb).
Then, advance the cap screw heads 90 as
outlined in Steps d-1 through d-3. Refer to
Figure 6-26.

FIGURE 6-26. 90 DEGREE ADVANCE

FAM0610

10/07

Chassis Assembly

Page 6-23

1.) Mark a reference line on a corner of the


hexagonal cap screw head or nut and the
mounting surface opposite this corner, as
shown. Then mark the position located
60 or 90 clockwise relative to the first
reference line on the mounting surface.
Refer to Figures 6-28 and 6-29.
2.) Scribe a reference mark at the opposite
end of the turning member to ensure that
either the cap screw head or nut, remains
stationary.
3.) Each corner of a hexagon represents 60.
The turning member, either the cap screw
head or nut, is turned until the marked
corner is adjacent with the marked reference line. 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 6-24) and the bottom outer four cap
screws (8), (without spacers).
1.) Tighten the top two corner cap screws to
95 Nm (70 ft lb), then advance the cap
screw heads 60.
2.) Tighten the bottom, outer four cap screws
to 203 Nm (150 ft lb), then advance the
cap screw heads 90.
NOTE: If for any reason, these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 cap screws and
repeat the entire process. The hardware must be
cleaned and lubricated.

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.

Refer to the illustration on the following page.


1. Steering Cylinder
2. Tie Rod Assembly
3. Retainer
4. Locknut
5. Spacer

Page 6-28

6. Bearing Seal
7. Spherical Bearing
8. Steering Arm
9. Cap Screw
10. Bearing Retainer

11. Cap Screw


12. Lockwasher
13. Washer
14. Cap Screw
15. Pin

Chassis Assembly

16. Cap Screw


17. Retainer Plate
18. Flat Washer

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 6-46. FRONT WHEEL TIGHTENING


SEQUENCE

FIGURE 6-47.

Page 6-44

Chassis Assembly

10/07 FAM0610

35. Attach the tire handler (or lifting device) to the


inner dual and install the inner dual onto the
wheel motor hub. Do not damage the tire inflation extension line.
NOTE: During inner wheel installation, ensure the air
inflation line lays in the channel on the wheel hub
assembly.

36. Using a lifting device, install the rear wheel


spacer onto the wheel motor hub. Tap the
spacer up against the inner dual.
37. Attach the tire handler to the outer dual and
position onto the wheel motor hub.
NOTE: Position the outer dual wheel so that the tire
valve bracket aligns with the inner wheel inflation
line.

38. Install the wedges onto the studs and secure in


place with the lubricated wheel nuts. Evenly
tighten each nut in an alternating pattern, as
shown in Figure 6-48, to 407 Nm (300 ft lbs).

FIGURE 6-48. REAR WHEEL TIGHTENING


SEQUENCE

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

45. Install the exhaust system.

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

48. Install the hangers to the intake and exhaust tubes.

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

DUMP BODY ASSEMBLY


GENERAL INFORMATION

The total weight of the body is approximately


26,853 kg (59,201 lb). Use two cranes for assembling the body. A 45 metric ton (50 ton) crane and
a 109-136 metric tons (120-150 ton) crane are
required. The larger crane is needed to help turn
the body over after completion of the underside
welding.
Assembly of the body must be performed on flat terrain with an adequate area for welding machines and
for maneuvering lifting equipment.

If the body is being welded in a cold climate, it is


advisable to move the parts to be welded into an
enclosed shop area. Surfaces to be welded must be
dry and the temperature must be above 10C (50F).
If shop space is not available, it may be necessary to
provide a portable enclosure and pre-heat the parts
prior to welding.
In most instances, it is easier to assemble and weld
the body while the sections are upside down. After
the pivot, guide pin, and body pads are welded in
place, the body can be turned over and the remainder of the assembly can be completed.
All paint must be removed from surfaces to be
welded. Use a wire brush or paint removal equipment.
Refer to the assembly blueprints shipped with the
truck for specific welding details and the parts
required for assembly.

Body sections must be assembled as originally


manufactured. Match the shipping numbers stenciled on the body sections to mate the correct
parts. DO NOT mix components.

FIGURE 7-1. BODY PARTS NOMENCLATURE


7. LH Side Sheet
4. Lift Hole
1. Canopy
5. Floor
2. Front Sheet
6. Pivot
3. RH Side Sheet

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
of the floor.

FIGURE 7-2. DOMESTIC LAYOUT

7. Install cap screw (3) in the front sheet near the


floor. Attach a wedge or a clamp inside the
body as necessary to align the front sheet.
8. Use a wedge to align the front sheet and canopy. Install cap screws (4, 5 & 6).
9. Install cap screw (7) and the sleeve in the front
of the canopy.
10. Install cap screws (8 & 9).
11. Install the backer strips on the front sheet center
joint as shown on the assembly blueprint.

FIGURE 7-3. INTERNATIONAL LAYOUT

NOTE: The backer strips must be tack welded in a


location where the tack will be burned away on the
first pass.
12. Loosely install cap screws (10 & 11) in the floor.
13. Loosen cap screws (1 & 2).

2. Remove the paint from the weld areas.


3. Lift the RH body half and support the front
sheet, side sheets, and rear edge of the floor
with blocks. Refer to Figure 7-4.
4. Lift the LH body and support with blocks under
the front sheet and side sheet. Position a
hydraulic jack on blocks at the tail end to support the floor at the rear. Refer to Figure 7-5.

7-2

14. Attach appropriate lifting apparatus to the body


pivot. Insert the lifting apparatus through the
body pin bores. The weight of the pivot is
approximately 1492 kg (3289 lb). DO NOT damage the bores.
15. Lift the pivot over the body. Lower the pivot into
position against the rear of the body, as shown
in Figure 7-6. Align the pivot with the body sills.

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

FAM0710

Dump Body Assembly

7-3

16. If necessary, use a hydraulic jack or crane to


raise the center of the body to allow the pivot to
fit inside the bolsters. Loosely install the cap
screws in the pivot.
17. If assembling an international body (threepiece), lift the canopy into position at this time.
Install the canopy cap screws and tighten.
18. Tighten all floor, front sheet, and canopy cap
screws. Use a chalk line to align the front of the
canopy.
19. Tighten the pivot cap screws.
20. Install the filler plates and backer strips for the
pivot to body sill weld joints.
21. Check the alignment and fit of all components
22. Tack weld the joints.

BODY WELDING
Follow the guidelines listed below when welding the
body:
Use dry weld rod or weld wire.
Weld surfaces must be dry and above 10C
(50F).
If stick electrode is used, use as large a diameter
rod as practical to weld the floor and front sheet
joints.
The following sequence must be followed for the
front sheet:
First Pass: Back step and skip weld in 10
increments along the entire length of the joint.
Refer to Figure 7-7.
Repeat the same procedure until the entire joint
is filled. DO NOT stop welding until entire joint is
complete.
The body floor V groove must also be welded
using the same procedure as the front sheet.
Weld from the front to the rear. Refer to Figure 77.

FIGURE 7-7. FRONT SHEET & FLOOR JOINT


WELDING SEQUENCE

1. Complete the welds at the center seam, the


front sheet and the canopy. Refer to the assembly blueprints for welding requirements.
2. Remove the canopy alignment blocks.

7-4

Dump Body Assembly

FAM0710

3. Install the remaining gussets, the body guide


and the body pad mounts. Refer to Figures 7-8
through 7-11.

DO NOT install the heated body exhaust boxes


onto the body at this time. The exhaust boxes
must be installed after the body is installed onto
the truck.

FIGURE 7-10.

FIGURE 7-8.

FIGURE 7-11.

4. Once the body underside is completed, the


body can be turned over. Use two cranes to
invert the body, a 45 metric ton (50 ton) crane
and a 109-136 metric ton (120-150 ton) crane.
The following photographs show a typical
example of a body being inverted with two
cranes.
FIGURE 7-9.

FAM0710

Position the body onto support blocks as shown


in Figure 7-18.

Dump Body Assembly

7-5

FIGURE 7-12.
FIGURE 7-14.

FIGURE 7-15.
FIGURE 7-13.

FIGURE 7-16.

7-6

Dump Body Assembly

FAM0710

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.

6. Install the mud flap brackets, clearance light


housings (Figure 7-21), etc. as specified on the
installation blueprints.

FIGURE 7-18.

FIGURE 7-20.

FAM0710

Dump Body Assembly

7-7

7. Install any optional equipment such as body liners and side boards.
8. Clean the weld joints and paint.

7-8

Dump Body Assembly

FAM0710

DUMP BODY INSTALLATION


Installation

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

Dump Body Installation

Page 8-1

FIGURE 8-2.

FIGURE 8-3. DUMP BODY PIVOT PIN


(RH Side Shown)
1. Body
2. Bushing
3. Shim

Page 8-2

4. Pin Retainer Capscrew


5. Frame
6. Body Pivot Pin

Dump Body Installation

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

Dump Body Installation

Page 8-3

FIGURE 8-4.

FIGURE 8-5. HOIST CYLINDER MOUNT (UPPER)


1. Dump Body
2. Hoist Cylinder Pin

Page 8-4

3. Hoist Cylinder
4. Pin Retainer

Dump Body Installation

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.

NOTE: It is not necessary to remove the dump body


to replace the body pads. The pads must be
inspected during scheduled maintenance inspections
and replaced if worn excessively.

1. Raise the body to a height sufficient to allow


access to all pads.

Inspect the cable and mounting brackets for


signs of fatigue or wear before use.

1. To lock the dump body in the UP position, raise


the body to its maximum height.
2. Remove the pins storing the sling in the storage
position and place the cable clevis over the eye
below the rear suspension mount and eye on
the body. Reinsert the pins and retainers.
3. Slowly lower the body until the cable is tight.
4. After the work has been completed, raise the
body, unhook the cable, and reattach to its storage position.

Place the blocks between the body and frame.


Secure the blocks in place.
2. Place the pad and shims into position. Install
the mounting hardware and tighten to 34 Nm
(25 ft lbs). Repeat at each pad location.
3. Raise the body, remove the blocks supporting
the body, and lower the body onto the frame.

FIGURE 8-6. BODY PAD


4. Body Pad
1. Dump Body
5. Frame
2. Shim
3. Pad Mounting Hardware

FAM0809

Dump Body Installation

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

Dump Body Installation

FAM0809

BODY GUIDE

ROCK EJECTORS

The body guide is designed to ensure the body is


positioned properly on the frame to prevent excessive body pad and pivot pin bushing wear during
truck operation.

Rock ejectors are placed between the rear dual


wheels to keep rocks or other material from lodging
between the tires.

1. Body guide wear points must be inspected each


time a body pad inspection is performed. Refer
to Figure 8-8. The body guide must be centered
between wear plates (4), with a gap of 5.0 mm
(0.19 in.) at each side when new.
2. If the gap becomes excessive, wear plates (4)
must be replaced.

The rock ejectors must be inspected during tire


inspections. If the ejectors are bent or worn excessively, they must be repaired or replaced to prevent
possible tire damage.
Inspection
1. The ejectors must be positioned on the vertical
center line between the rear tires within 5.0 mm
(0.19 in.).
2. With the truck parked on a level surface, arm
(2, Figure 8-9) must be approximately 80 mm
(3.15 in.) from wheel spacer ring (3).
3. If arm (1) becomes bent, it must be removed
and straightened.
4. Wear plates (2) must be replaced if severely
worn.
5. Inspect the mounting brackets, pins, and stops
for wear and/or damage, and repair as necessary.

FIGURE 8-8. BODY GUIDE


1. Dump Body
2. Body Guide

3. Frame
4. Wear Plate

FIGURE 8-9. ROCK EJECTOR INSTALLATION


1. Rock Ejector Arm
2. Wear Plate

FAM0809

Dump Body Installation

3. Rear Wheel Spacer


Ring

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

Dump Body Installation

FAM0809

FIGURE 8-10.
FAM0809

Dump Body Installation

Page 8-9

NOTES

Page 8-10

Dump Body Installation

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.

1. Complete delivery and warranty forms.


2. Check all coolant and lubricants for proper levels
and specifications. The lubrication chart is shown
in Section 10, Appendix.
3. Verify the shut-off valves in the hydraulic cabinet
are open.

FAM0903

4. Purge any air from the pumps. Pressure will not


build if air is present. Operating the pumps with air
in the system will result in damage.
5. Perform a final check of all systems and prepare
for operation. Several checks and tasks are outlined in Section 10, Appendix.
6. Complete the checks listed in the Field Assembly
Inspection Report Form. A copy of the form is provided with the truck and is also available in Section 10, Appendix.
7. Operate the truck in a traffic-free area until safe
operation has been validated.
8. Release the truck for use after all checks have
been completed and all deficiencies corrected.

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
3. Toe In Adjustment
4. Automatic Lubrication System Checkout
5. Air Conditioning Checkout Procedure - EL4302
6. Air Conditioning Drive Belt Adjustment Procedure - EL9330
7. Hydraulic Checkout Procedure - EL2601
8. Brake Checkout Procedure - EF5761
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

FAM1005

Appendix

Page 10-1

NOTES

Page 10-2

Appendix

FAM1005

LUBRICATION CHART

NOTES

SUSPENSION OILING AND CHARGING


GENERAL
These procedures cover the oiling and charging of
HydrairII suspensions on Komatsu 730E dump
trucks.
Suspensions, which have been properly charged, will
provide improved handling and ride characteristics
while also extending the fatigue life of the truck frame
and improving tire wear.
NOTE: Inflation pressures and exposed piston
lengths are calculated for a normal truck gross
vehicle weight (GVW). Additions to truck weight by
adding body liners, tailgates, water tanks, etc. will be
considered part of the payload. Keeping the truck
GVW within the specification, shown on the Grade/
Speed Retard chart in the operator cab, will extend
the service life of the truck main frame and allow the
HydrairII suspensions to produce a comfortable ride.

For best results, charge Hydrair II suspensions in pairs


(fronts together and rears together). If rears are to be
charged, the fronts must be charged first.
NOTE: For longer life of the suspension components,
a friction modifier must be added to the suspension
oil. See Specifications chart, Figure 4-6, at the end of
this chapter.
NOTE: Set up dimensions specified in the charts
must be maintained during oiling and charging
procedures. However, after the truck has been
operated, these dimensions may vary.

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.

Charging Height Dimensions (Front Only)


Hydrair Oil (See Specifications Chart)
Friction Modifier (See Specifications Chart)
Dry Nitrogen (See Specifications Chart)

Proper charging of Hydrair II suspensions requires


that three basic conditions be established in the following order:
1. The oil level must be correct.

Hydrair Charging Kit


Assemble service kit, as shown in Figure 4-1, and
attach to container of pure dry nitrogen gas (8).

2. The suspension piston rod extension for nitrogen charging must be correct.
3. The nitrogen charge pressure must be correct.

Installation of Charging Kit


1. Remove protective covers and charging valve
caps from suspensions to be charged.
2. Turn T handle valve (1, Figure 4-1) of charging
valve adapters (2) completely counterclockwise.
3. Ensure manifold outlet valves (3) and inlet valve
(4) are closed (turned completely clockwise).

Suspension Oiling and Charging

4. Turn swivel nut (small hex) on charging valve


three full turns counterclockwise to unseat the
valve.
5. Attach charging valve adapters (2) to each suspension charging valve stem.
6. Turn T handle valve (1) clockwise. This will
depress the core of the charging valve and
open the gas chamber of the suspension.
7. Open both manifold outlet valves (3).
NOTE: By selective opening and closing of manifold
outlet valves (3) and inlet valve (4), suspensions may
be charged separately or together.

Removal of Charging Kit


1. Close both manifold outlet valves (3).
2. Turn T handle valve (1) counterclockwise to
release charging valve cores.
3. Remove charging valve adapters (2) from the
charging valves.
4. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 5.4 Nm (4 ft lbs).
5. If a new charging valve is being used, tighten
the swivel nut to 14.2 Nm (10.5 ft lbs). Loosen
and retighten swivel nut to 14.2 Nm (10.5 ft
lbs). Again loosen the swivel nut and retighten
to 5.4 Nm (4 ft lbs). Install valve cap (1) and
tighten to 3.3 Nm (2.5 ft lbs).
6. Install charging valve caps and protective covers on both suspensions.

Support Blocks For Oiling and Charging


Dimensions
Prior to starting the oiling and charging procedures,
supports must be fabricated which will maintain the
correct exposed piston rod extensions.

FIGURE 4-1. HYDRAIR CHARGING KIT


NOTE: The arrangement of parts may vary from
the illustration above, depending on the 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 4-6)

Nitrogen charging support blocks for the rear


suspension are not longer necessary. However,
oiling blocks are necessary to properly set the
oiling height.
Exposed piston rod extensions are specified for both
oil level and nitrogen charging for HydrairII suspensions. These dimensions are listed in the tables
below Figures 4-2 and 4-5. Measure the dimensions
from the face of the cylinder gland to the machined
surface on the spindle at the front suspension. At the
rear suspension, measure from the face of the cylinder gland to the piston flange.

Suspension Oiling and Charging

Support blocks may be made in various forms. Mild


steel materials are recommended. Square stock or
pipe segments [25 mm (1 in.) minimum] may be
used. Blocks must be capable of supporting the
weight of the truck during oiling and charging procedures while avoiding contact with plated surfaces
and seals on the suspension. Refer to Figure 4-2 for
front suspension support block placement and Figure
4-4 for rear support block placement.

FRONT SUSPENSION

All 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.

NOTE: For longer life of suspension components, a


friction modifier must be added to the suspension oil.
See the Oil and Nitrogen Specifications chart, Figure
4-6, at the end of this chapter.

1. Position and secure the 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 pistons or damage wiper seals in the lower bearing
retainer. Support blocks must seat on the spindle and the cylinder housing. The blocks must
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 the valve seal. DO
NOT turn the large hex. The charging valve
body has a bleeder groove in its mounting
threads, but for the 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 the
nitrogen pressure from the suspension. When
all nitrogen has been vented to the atmosphere,
the suspension will have collapsed slowly and
be seated solidly on the support blocks.
Remove the top fill plug next to the charging
valve (Figure 4-2).

Front Suspension Oiling

When the blocks are in place on a suspension,


they must be secured with a strap or other means
to avoid accidental discharge. An unsecured
block could fly loose as weight is applied, presenting the possibility of serious injury to nearby
personnel and/or damage to the equipment.
Overhead clearance may be reduced rapidly and
suddenly when nitrogen pressure is released!

Suspension Oiling and Charging

Front Suspension Nitrogen Charging

Lifting equipment (crane or hydraulic jacks) must


be of sufficient capacity to lift the weight of the
truck. Ensure that all personnel are clear of the
lift area before the lift is started. Clearances
under the truck may be suddenly reduced.

1. If removed, install the charging valve with new


O-ring (9, Figure 4-3). Lubricate the O-ring with
clean Hydrairoil.

FIGURE 4-2. FRONT SUSPENSION


FRONT SUSPENSION DIMENSIONS (EMPTY)
TRUCK MODEL
AND OPTIONS

OILING
HEIGHT
IN. (mm)

CHARGING
HEIGHT
IN. (mm)

CHARGING
PRESSURE
psi (kPa)

730E*

1.5 (38.1)

9.0 (229)

400 (2758)

* with standard rock body


Note: If truck starts to lift off blocks before charging pressure is
attained, stop charging.

FIGURE 4-3. CHARGING VALVE


4. Fill the suspension with clean Hydrair oil, with
6% friction modifier, until the cylinder is full to
the top of the fill plug bore. Drip pans must be
used and all spillage cleaned from outside of
the suspension. Allow the suspension to settle
for at least 15 minutes to clear any trapped
nitrogen and/or bubbles from the oil. Add more
suspension oil if necessary. Install a new fill
plug O-ring, and install the plug.

1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer

Suspension Oiling and Charging

6. Valve Body
7. O-Ring
8. Valve Stem
9. O-Ring

2. Tighten the valve body (large hex, 6) to 22.4


Nm (16.5 ft lbs). The valve swivel nut (small
hex, 4) must be unseated by turning counterclockwise three full turns.

10. Close inlet valve (4, Figure 4-1). Leave manifold


outlet valves (3) open for five minutes in order
to allow the pressures in the suspensions to
equalize.
11. Close manifold outlet valves (3) and remove
charging kit components. Refer to Removal of
Charging Kit.

Dry nitrogen is the only gas approved for use in


HydrairII suspensions. Charging of these components with oxygen or other gases may result in
an explosion which could cause fatalities, serious injuries, and/or major property damage. Use
only nitrogen gas meeting the specifications
shown in chart (Figure 4-6).
3. Install Hydrair charging kit and a bottle of pure
dry nitrogen. Refer to Installation of Charging
Kit in this chapter.
4. Charge the suspensions with nitrogen gas to
50.8 mm (2 in.) greater than the charging height
listed in Figure 4-2. Close inlet valve (4, Figure
4-1).
5. Remove the oiling blocks from the suspensions
and install the nitrogen charging blocks. Secure
the blocks to prevent accidental dislodging.
NOTE: Use caution to prevent damage to plated cylinder surfaces and oil seals when installing the
blocks.
6. Remove the center hose from manifold (6).
7. Open inlet valve (4) until the pressure has
dropped below the pressure listed in Figure 4-2,
and then close the valve.

12. If the charging valve is being reused, tighten


swivel nut (4, Figure 4-3) to 5.4 Nm (4 ft lbs).
13. If a new charging valve is being used, tighten
the swivel nut to 14.2 Nm (10.5 ft lbs). Loosen
and retighten the swivel nut to 14.2 Nm (10.5 ft
lbs). Again loosen the swivel nut and retighten
to 5.4 Nm (4 ft lbs). Install valve cap (1) and
tighten to 3.3 Nm (2.5 ft lbs).
14. Install a protective guard over the charging
valve.
15. Raise the truck body in order to extend the front
suspensions and allow for removal of the nitrogen charging blocks. Ensure that sufficient
overhead clearance exists before raising the
body. If the suspensions do not extend after
raising the body, turn the steering wheel from
stop to stop several times. If the suspensions
still do not extend enough to allow for removal
of the blocks, use a crane or floor jacks to raise
the truck and remove the blocks.
The front suspensions are now ready for operation. Visually check the extension with the truck
both empty and loaded. Record the extension
dimensions. Maximum downward travel is indicated by the dirt ring at the base of the piston.
Operator comments on steering response and
suspension rebound will also be noted.

8. Install the center hose to manifold (6).


9. Charge the suspensions to the pressure listed
in Figure 4-2. DO NOT use an overcharge of
nitrogen to lift the suspensions off of the charging blocks.

Suspension Oiling and Charging

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.

When oiling blocks are used, they must be


secured in place with a strap or some other
means. An unsecured block can fly loose as
weight is applied, presenting the possibility of
serious injury and/or damage.

Rear Suspension Oiling


NOTE: For longer life of suspension components, a
friction modifier must be added to the suspension oil.
See Specifications chart, Figure 4-6, at the end of
this chapter.
1. Position and secure the oiling blocks in place
(Figure 4-4) so the blocks are seated between
the frame and the rear axle housing. A block
must be used on both the left and right sides of
the truck.

Ensure all personnel are clear and support


blocks are secure before relieving nitrogen pressure 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 the valve seal. DO
NOT turn the large hex. The charging valve
body has a bleeder groove in its mounting
threads, but for safety of all personnel, the valve
body must not be loosened until all nitrogen
pressure has been vented from the suspension.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
nitrogen pressure has been vented to the atmosphere, loosen and remove the fill plug. The
suspension will have collapsed slowly as gas
pressure was released. The weight of the truck
is now supported by the support blocks.
NOTE: A plastic tube may be used to help bleed off
trapped air inside the piston.
4. Remove the vent plug, pressure sensor, and
charging valve. Refer to Figure 4-5. Use one of
the open ports to fill the suspension with clean
Hydrair oil, with 6% friction modifier. Fill until
clean oil seeps from the open ports. Drip pans
must be used, and all spillage cleaned from the
outside of the suspension.
5. Allow the suspension to settle for at least 15
minutes to clear any trapped nitrogen and/or air
bubbles from the oil. Add oil if necessary.
6. Install the vent plug and pressure sensor onto
the suspension.
7. Installation a new O-ring onto the charging
valve. Lubricate the O-ring with clean Hydrair
oil.
Install the charging valve onto the suspension
and tighten valve body (6, Figure 4-3) to 22.4
Nm (16.5 ft lbs).

Suspension Oiling and Charging

FIGURE 4-4. OILING BLOCK INSTALLATION


1. Main Frame
2. Oiling Support Block

3. Rear Axle Housing

FIGURE 4-5. REAR SUSPENSION

REAR SUSPENSION DIMENSIONS (EMPTY)


TRUCK MODEL
AND OPTIONS

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.

Suspension Oiling and Charging

Rear Suspension Nitrogen Charging


3. Install Hydrair charging kit and a bottle of pure
dry nitrogen. Refer to Installation of Charging
Kit.
Lifting equipment (overhead or mobile cranes, or
hydraulic jacks) must be of sufficient capacity to
lift the weight of the truck. Ensure that all personnel are clear of the lift area before the lift is
started. Clearances under the truck may be suddenly reduced.

Ensure the automatic apply circuit has not


applied the service brakes during truck maintenance. If the front brakes are applied during rear
suspension charging, the axle cannot pivot for
frame raising/lowering, and the rear suspension
may be unable to move up or down.
1. If removed, install charging valve with new Oring (9, Figure 4-3). Lubricate the O-ring with
clean Hydrairoil.
2. Tighten the valve body (large hex, 6) to 22.4
Nm (16.5 ft lbs). The valve swivel nut (small
hex, 4) must be unseated by turning counterclockwise three full turns.

Dry nitrogen is the only gas approved for use in


HydrairII suspensions. Charging of these components with oxygen or other gases may result in
an explosion, which could cause fatalities, serious injuries, and/or major property damage. Use
only nitrogen gas meeting the specifications
shown in chart (Figure 4-6).

4. Charge the suspensions with nitrogen gas to


50.8 mm (2 in.) greater than the charging height
listed in Figure 4-5.
5. Slowly release the gas until the suspensions
match the charging height listed in Figure 4-5.
6. Close inlet valve (4, Figure 4-1). Leave manifold
outlet valves (3) open for five minutes in order
to allow the pressures in the suspensions to
equalize.
7. Ensure both of the suspension cylinders are
extended the same distance 10 mm (0.39 in.).
If the difference in the extension from side to
side exceeds 10 mm, check the front suspensions for equal extension. Adjust the front as
necessary.
NOTE: A low left front suspension will cause the right
rear suspension to be high. A low right front
suspension will cause the left rear suspension to be
high.
8. Close manifold outlet valves (3) and remove the
charging kit components. Refer to Removal of
Charging Kit.
9. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 5.4 Nm (4 ft lbs).
10. If a new charging valve is being used, tighten
swivel nut to 14.2 Nm (10.5 ft lbs). Loosen and
retighten the swivel nut to 14.2 Nm (10.5 ft
lbs). Again, loosen the swivel nut and retighten
to 5.4 Nm (4 ft lbs). Replace valve cap (1) and
tighten to 3.3 Nm (2.5 ft lbs).
11. Install the protective guards over the charging
valves. Install the rubber covers over the piston
rods.
The rear suspensions are now ready for operation. Visually check piston extension both with
the truck loaded and empty. Record the extension dimensions. Maximum downward travel is
indicated by the dirt ring at the base of the piston rod. Operator comments on steering
response and suspension rebound will also be
noted.

Suspension Oiling and Charging

OIL AND NITROGEN SPECIFICATIONS CHART


HYDRAIR II OIL SPECIFICATIONS
Ambient Temperature
Range

-34.5C- and above


(30F and above)

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

Sunfleet TH Universal Tractor Fluid


Chevron Tractor Hydraulic FluidConoco Power Tran III Fluid Petro
Canada Duratran Fluid
Shell Canada Donax TDL

AK4063

Suspension Oil (premixed with


6% friction modifier)

5 Gallon container

AK4064

-48.5C and above


(-55F and above)

55 Gallon container

VJ5925
(need to add
6% of
AK3761)

Emery 2811, SG-CD,


5W-30
Mobil Delvac I, 5W-30

Petro Canada Super Arctic Motor


Oil, 0W-30
Conoco High Performance
Synthetic Motor Oil, 5W-30

AK4065

Suspension Oil (premixed with


6% friction modifier)

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

FRICTION MODIFIER Mixing Instructions


(94% Suspension Oil, 6% Friction Modifier)

Part No.

Suspension Oil

Amount of Friction Modifier to Add

AK3761
(5 Gallon container of
100% friction modifier)

1 gallon of suspension oil

add 7.7 oz.

5 gallons of suspension oil

add 38.4 oz.

55 gallons of suspension oil

add 3.3 gal.

NITROGEN GAS (N2)SPECIFICATIONS


Hydrair

Nitrogen gas used in


II
suspension cylinders must meet or
exceed CGA specification G-10.1 for
Type 1, Grade F nitrogen gas

Property

Value

Nitrogen

99.9% minimum

Water

32 PPM maximum

Dew Point

-55C (-68F) maximum

Oxygen

0.1% maximum

FIGURE 4-6. SPECIFICATIONS CHART

Suspension Oiling and Charging

NOTES

Suspension Oiling and Charging

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.)

Nominal tie-rod length, radial tires.


(Zero toe-in)

349.2
(137.48)

Nominal tie-rod length, bias ply


tires 1.9 mm (0.75 in. toe-in)

349.6
(137.63)

Change in toe-in dimension with


one full turn of tie rod

2.0
(0.79)

FIGURE 3-1 MEASURING TOE-IN

5. When the adjustment is complete, tighten the


clamp locknuts on the tie rod to 430 Nm (310 ft
lbs).
6. Remove the chocks from the rear wheels.

G03027

Front Wheel Hub and Spindle

G3-1

NOTES

G3-2

Front Wheel Hub and Spindle

G03027

AUTOMATIC LUBRICATION SYSTEM


LUBRICANT REQUIRED FOR SYSTEM

LUBRICANT PUMP

Grease requirements will depend on ambient temperatures encountered during truck operation:

Pump Housing Oil Level

-32 to 32C (-25 to 90F) - Use NLGI No. 1


multipurpose grease (MPG).

The pump housing must be filled to the proper level


with SAE 10W30 motor oil. Oil level must be checked
at 1000 hour intervals. To add oil, remove oil level
plug (4, Figure 3-1) and fill the housing to the bottom
of the plug hole.

Below -32C (-25F) - Refer to local supplier for


extreme cold weather lubricant requirements.

Pump Pressure Control

Above 32C (90F) - Use


multipurpose grease (MPG).

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.

High pressure hydraulic fluid from the truck steering


system is reduced to 2240 to 2413 kPa (325 to 350
psi) by the pressure reducing valve located on the
manifold on top of the pump motor. This pressure
can be read on the gauge installed on the manifold
and must be checked occasionally to verify pressure
is within the above limits.

1. Fill lubrication reservoir with lubricant, if necessary.


2. To purge air from the main supply line, remove
the main supply line at outlet port (6, Figure 3-1)
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 an external grease source, pump grease
until grease appears at the group of injectors
and re-install the pipe plug. Repeat for remaining injector groups.
5. Remove the caps from each injector and connect an external grease supply to the zerk on
the injector and pump until grease appears at
the far end of the individual grease hose or the
joint being greased.

FIGURE 3-1. PUMP CONTROLS


1. Pump Pressure
Control
2. Manifold
3. Pressure Gauge

Automatic Lubrication System

4. Oil Level Plug


5. Flow Control Valve
6. Outlet Port
7. Manual Override

INJECTORS (SL-1 Series H)


Injector Specifications
Each lubrication injector services only one
grease point. In case of pump malfunction, each
injector is equipped with a covered grease fitting
to allow the use of external lubricating
equipment.
Injector Output Volume:
Maximum Output =1.31 cc (0.08 in3)
Minimum Output = 0.13 cc (0.008 in3)
Operating Pressure:
Minimum - 12755 kPa (1850 psi)
Maximum- 24133 kPa (3500 psi)
Recommended - 17238 kPa (2500 psi)
Maximum Vent Pressure (Recharge):
4137 kPa (600 psi)
Injector Adjustment
The injectors may be adjusted to supply from 0.13 1.31 cc (0.008 - 0.08 in3) of lubricant per injection
cycle. The injector piston travel distance determines
the amount of lubricant supplied. This travel is controlled by an adjusting screw in the top of the injector
housing.
Turn adjusting screw (1, Figure 3-2) counterclockwise to increase lubricant amount delivered and
clockwise to decrease the lubricant amount.
When the injector is not pressurized, maximum injector delivery volume is attained by turning adjusting
screw (1) fully counterclockwise until piston assembly
(8) touches the adjusting screw. At the maximum
delivery point, about 9.7 mm (0.38 in.) adjusting screw
threads must be showing. Decrease the delivered
lubricant amount by turning the adjusting screw clockwise to limit injector piston travel. If only half the lubricant is needed, turn the adjusting screw to the point
where about 4.8 mm (0.19 in.) threads are showing.
The injector will be set at the minimum delivery point
with about 0.22 mm (0.009 in.) thread showing.
NOTE: The above information concerns adjustment
of injector delivery volume. The timer adjustment
must also be changed if overall lubricant delivery is
too little or too much. Injector output must not be
adjusted to less than one-fourth capacity.

FIGURE 3-2. TYPE SL-1 INJECTOR


1. Adjusting Screw
2. Locknut
3. Piston Stop Plug
4. Gasket
5. Washer
6. Viton O-Ring
7. Injector Body
Assembly
8. Piston Assembly
9. Fitting Assembly
10. Plunger Spring

11. Spring Seat


12. Plunger
13. Viton Packing
14. Inlet Disc
15. Viton Packing
16. Washer
17. Gasket
18. Adapter Bolt
19. Adapter
20. Viton Packing

NOTE: Piston assembly (8) has a visible indicator pin


at the top of the assembly to verify injector operation.
NOTE: Piston stop plug (3) must be tightened to 34-41
Nm (25-30 ft lbs). Adapter (19) must be tightened to
61-68 Nm (45-50 ft lbs).

Automatic Lubrication System

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.

Lubrication Cycle Timer Check


To check the solid-state timer operation without waiting for the normal timer setting, proceed as follows:
NOTE: The timer incorporates a liquid and dust-tight
cover which must be in place and secured at all times
during truck operation.
1. Remove the dust cover.
2. Adjust timer selector (3, Figure 3-4) to the five
minute interval setting.
3. The timer must cycle in five minutes if the truck
is operating.

FIGURE 3-3. LOCATION OF LUBRICATION CYCLE


TIMER
2. Lubrication Cycle
1. Cab Interface
Timer
Compartment Under
Passenger Seat
.

NOTE: If the timer check is being made on a cold


start, the first cycle will be approximately double the
nominal setting. All subsequent cycles must be within
the selected time tolerance.
4. Perform voltage checks at the timer if the above
checks do not identify the problem.
a. Ensure that the timer ground connection is
clean and tight.
b. With the key switch on, use a voltmeter to
read the voltage between the positive and
negative posts on the solid-state timer. A normal reading must be 18 to 26VDC, depending upon whether the engine is on or not.

FIGURE 3-4. LUBRICATION CYCLE TIMER


(SHOWN WITH COVER REMOVED)
1. Timer Enclosure
2. Red LED

Automatic Lubrication System

3. Timer Selector

Lubrication Cycle Timer Adjustment

100 Hour Inspection


1. Check the oil after every 100 hours of operation. The crankcase must be filled to the center
of the drain plug located on the back of the
crankcase.

The timer is set at the factory for a nominal 2.5


minute (off time) interval. Dwell time is approximately
75 seconds. A longer interval (off time) is obtained by
turning the timer selector to the desired position.
Set the timer by turning the timer selector to the 2.5
minute setting. Then turn the selector clockwise one
detent at a time to the desired setting, or until the
maximum limit of 80 minutes is reached.

250 Hour Inspection

NOTE: The timer is a sealed unit. DO NOT attempt to


disassemble it.

1. Check all grease hoses from the SL-1 injectors


to the lubrication points.
a. Repair or replace all worn and broken hoses.
b. Ensure all the air is purged and all new feed
line hoses are filled with grease before sending the truck back into service.

PREVENTIVE MAINTENANCE INSPECTION


Use the following maintenance procedures to ensure
proper system operation.
10 Hour Lubrication System Inspection
1. Check the grease reservoir level.
Inspect the grease level height after each shift
of operation. The grease usage must be consistent from day-to-day operations.
Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate
a broken supply line.
2. Check the filter bypass indicator when filling the
reservoir. Replace the element if bypassing.

2. Check all grease supply line hoses from the


pump to the SL-1 injectors.
a. Repair or replace all worn and broken supply
lines.
b. Ensure all air is purged and all new supply
line hoses are filled with grease before sending the truck back into service.
3. Check the grease reservoir level.
a. Fill the reservoir if low. Check the filter
bypass indicator when filling the reservoir.
Replace the element if bypassing.
b. Check the reservoir for contaminants. Clean,
if required.

3. Check all the grease hoses from the SL-1 injectors to the lubrication points.

c. Check that all filler plugs, covers, and


breather vents on the reservoir are intact and
free of contaminants.

a. Repair or replace all damaged feed line


hoses.

4. Inspect all bearing points for a bead of lubricant


around the bearing seal.

b. Ensure all air is purged and all new feed line


hoses are filled with grease before sending
the truck back into service.

It is good practice to manually lubricate each


bearing point at the grease fitting provided on
each Injector. This will indicate if there are any
frozen or plugged bearings, and will help flush
the bearings of contaminants.

4. Inspect the key lubrication points for a bead of


lubricant around the seal. If a lubrication point
appears dry, troubleshoot and repair the problem.

Automatic Lubrication System

500 Hour Inspection

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.

b. Start the truck engine.


c. Actuate manual override (7, Figure 3-1). The
hydraulic motor and grease pump should
operate.
d. With the system pressurized, check each
SL-1 injector assembly. The cycle indicator
pin will be retracted inside the injector body.

1000 Hour Inspection


1. Check the pump housing oil level. Refill to the
bottom of the level plug with SAE 10W30 motor
oil, if necessary.

e. When the system attains 20685 kPa (3000


psi), the pump will shut off and the pressure
in the system will drop to zero, venting back
to the grease reservoir.
f. With the system vented, check all of the SL-1
injector indicator pins. All of the pins must be
visible. Replace or repair the injectors, if
defective.
g. Reinstall all the injector cover caps.
h. Check the timer operation.

NOTE: With the engine on, the lubrication system will


activate within five minutes. System pressure will
build to 20685 kPa (3000 psi) within 25-40 seconds.

i. If the system is working properly, the


machine is ready for operation.
j. If the system is malfunctioning, refer to the
troubleshooting chart.

Automatic Lubrication System

NOTES

Automatic Lubrication System

NOTES:

NOTES:

NOTES:

KOMAtsu CHECK-OUT PROCEDURE


NAME
BRAKE SYSTEM CHECKOUT
WRITTEN BY
DATE
D. D. Smith
6/20/95
CHECKED

tH

n.

R.

DATE

BY

DATE

J. McClone

6/26/95

MACHINE& HODEL

L EF5761
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1 of 7

730E
I

4 PlIrkin2: Brk Note: P2:2 H 8 1 'OlHl 00 NS


14/ 10 l'
4
3 D-Ddate 1t14 tor Mt2:.
L ReVlsed14/
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Steps ::IU & jj
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teps 14. 17
1
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0 STR.ASY.,p U$[O ON
6
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A SIZE 1 MICROFILM
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DATE

II

[CN
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BY CK'D

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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Peoria Operations

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KomatsuCHECK-OUT PROCEDURE

EF5761
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Note: For best performance, charge accumulators in the ambient conditions in


which the machine will be operating.
3. Close both accumulator bleed down valves. Ifbrakes have not been assembled to
truck when check-out is performed, attach brake simulators to the brake
application lines.
*

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.
*

'"

......

11. Slowly depress brake pedal and record the rear brake pressure at which the stop

lights energize. (Thisshouldbe 75 =tpsi).

671-2-3-97

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Peoria Operations

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KomatsuCHECK-OUT PROCEDURE

EF5761

'au

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

Note: If step 13 is incorrect, perform deadband adjustment as follows: Insert a


'O.025"shimbetween valve and pedal return stop. Loosen jam nut. Adjust set
screw until pressure begins to rise in one or both circuits. Back set screw off 1/8
turn and lock set screw with jam nut. Remove the shim.
Brake Lock/Secondary
14. (A) Disconnect lead wire on brake lock solenoid, located on brake manifold in
hydraulic cabinet and to the immediate right of the PK2 port.
(B) Install jumper to connect delay timer wires together.
15. Apply brake lock. Brake lock pressure degradation switch should sound warning
buzzer. Depress brake pedal until warning stops and then very slowly release
pedal until warning resumes. Record BR pressure at which warning resumes.
16. Connect lead wire on brake lock solenoid and remove jumper from lead wires to
timer.
*

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.

Low Brake Pressure and Auto Apply


I

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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Peoria Operations

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KomatsuCHECK-OUT PROCEDURE
*

EF5761

'..e 4

of

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

1650::!:: 100psi. Recordthis value. Closefrontbrakeaccumulatorbleeddown


valve.
*

21. Record auto apply brake pressures.


22. Start engine to recharge hydraulic system. Allow e.qgineto run until low brake
accumulator pressure stabilizes at or above 2700 psi.
23. Shut engine down. Allow the steering accumulator to bleed completely down.
Turn key switch on. Crack the rear brake accumulator bleed down valve and
observe LAP 1 pressure. Verify that the low brake pressure lamp and buzzer, and
auto apply set points are within a 100 psi of those recorded in step 20. Close the
rear brake accumulator bleed down valve.

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.

Differential Pressure Switch


27. Open each brake accumulator bleed down valve and bleed down the entire brake
system.
28. Outside the brake cabinet, disconnect the hose that supplies oil from the front
brake accumulator to the brake pedalinthe cab for the front brakes and plug the
tube end at the cabinet. Be sure to leave end of hose vented to atmosphere.
29. Start engine. Allow the engine to run until LAP1 pressure stabilizes at or above
2700 psi.
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Komatsu Mining Sys~ems, Inc.


Peoria Operations

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KomatsuCHECK-OUT PROCEDURE
*

EF5761
'au

5 of 7

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).

Release the pedal. .

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.

*Asterisk denotes item to be recorded Data Sheet.

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Komatsu Mining Systems, Inc.


Peoria Operations

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5 of 7

KomatsuCHECK-OUT PROCEDURE

EF5761
Pau 6 of 7

HYDRAULIC BRAKE SYSTEM


CHECK-OUT DATA SHEET

STEP 4

Front brake pressure when Auto Apply releases.


Rear brake pressure when Auto Apply releases.

PARKING BRAKE SYSTEM

STEP 6

Parking brake release pressure.

STEP 7

Left outboard lining/disc gap.


Left inboard lining/disc gap.
Right outboard lining/disc gap.
Right inboard lining/disc gap.

SERVICE BRAKE SYSTEM


STEP 11

Rear brake pressure when stop lights energize.

STEP 12

Front brake pressure. (pedal applied)


Rear brake pressure (pedal applied)

STEP 13

Front brake pressure (pedal released)


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Rear brake pressure (pedal released)

671-2-3-97

Komatsu Mining Systems, Inc.


Peoria Operations

.po.
Pau

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KomatsuCHECK-OUT PROCEDURE

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P..e 7 of 7

BRAKE LOCK/SECONDARY SYSTEM


STEP 15

Rear brake pressure when brake lock degradation fault


occurs.

STEP 17

Rear brake pressure when brake lock is applied.

LOW BRAKE PRESSURE AND AUTO APPLY


STEP 19

LAP pressure after 2 minutes.

STEP 20

LAP pressure when low brake pressure fault occurs.


LAP pressure when auto apply occurs.

STEP 21

Front brake pressure after auto apply.


Rear brake pressure after auto apply.

STEP 24

Front brake pressure after auto apply.


Rear brake pressure after auto apply.

REAPPLICATIONS
STEP 26

Number of applications prior to auto apply.

DIFFERENTIAL PRESSURE SWITCH


STEP 30

Rear brake pressure at which the front differential fault


occurs.

STEP 33

Front brake pressure at which the rear differential fault


occurs.

MACHINE

UNIT NO.

SIN

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NAME OF MECHANIC OR INSPECTOR DOING CHECK-OUT

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671-2-3-97

Komatsu Mining Systems, Inc.


Peoria Operations

Pau

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NOTES:

KOMATSU

CHECKOUT PROCEDURE
I

EK8480-1
Paqe 1 of 15

NAME:
VHMS System Checkout Procedure
WRITTEN BY:

MACHINE & MODEL:


930E, 960E, 830E

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

I I I I I I I I I I I I I

I I I

GGH

SK

BY

CK'D

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.

Page 1 of 15

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KOMATSU

CHECKOUT PROCEDURE
I

EK8480-1
PaQe 2 of 15

INSTALL THE APPLICATION CODE


Before the Interface Module can be put to work, the application code must be installed.
Application code must match the truck model for Interface Module installation.
Use EJ9098-1 software for 930E trucks and EL0355-0 software for 830E trucks.
Go to the Interface Module web site www.kac-peoria.com/interfacemodule/ to get the
necessary files and instructions.

PLM3 NOTE
Use the Payload Data Manager software to verify the PLM3 installed software.
PLM3 software EJ0575-3 or later is required for the Interface Module to properly acquire
truck speed on model 830E and 930E trucks. Go to PLM3 web site,
www.kac-peoria.com navload'for software and instructions.

PART 1 - Installation

and wirin(:l verification

CHECK FOR FAULT CODES ASSOCIATED WITH THE INTERFACE


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

CHECK INPUT TO THE INTERFACE MODULE


Use the VHMS Watcher software.
1. Double click the shortcut VHMSWatcher on the Desktop screen. The program begins with a
blank window. On the menu bar, there are five items: File, VHMS, Settings, Interaction, Help.
Only use the VHMS pull down menu.
2. Click on VHMS on the menu bar. A small menu pops up, showing two items: Read Table
Data and Port Setting. Click Read Table Data.
3. Click VHMS on menu bar again, this time click Port Setting. A small window shows up to
allow selection of Port Setting. Select the appropriate port (COM1,COM2), and select the
baud rate to be 19.2K.
4. Click VHMS on menu bar again. Click Open Connection.
5. Click VHMS on menu bar again, click Start. A window will open as shown:
m

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_~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

EfiJl
Start I; : :iI ~ 6Jt) lJ

I~

~ Interface

Module

Re...1

J;J Can8anFF

:j
Untitled

- VhmsWatc...1

We must see 4 lines of message like shown above, if 2 or 3 lines then it did not work. If it does not
work, the problem is with serial communication (maybe the key switch is off, or the serial port is
wrong, or is assigned to other software).

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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

301: 2 s: En9-Speed: rpm


0

301: 2 s: Eng_Speed: rpm


354: 2 s: Cool_Temp: degC

354: 2 s: Cool_Temp: degC

355: Eng_OilJemp
385:AmblenCair _temp
386: Blow_by-press
387: Eng_oil-press
388: Boost-press
389: Exh_gas_temp
500: FueUnjection
501: Ave_Min_ldle_On
502:Auto_Lube_Sw
503: BatC 12V_A
504: BatU 2V_B
505: BatU 2V- C

0
Delete
0

0
START/STOP

12s

Sampling

:!I ~ [J t1 JJ

.:J

:J
I;NUM

For Help. press F1


I

~_."---J

ll

Rel!.dy

::Ell Start

r,~Interll!.ce Module

Reml

JJ CanBI!.nFF

j @ Document..

WordPl!.d

r~

Untitled

- VhmsW...

I~~;

2:10PM

That is the main screen of the Watcher program. On the table list on the right, click to highlight the
selected item we want to view the value, then click the "Add" bar. The selected item will show up in
the 6 slots on the left of the screen (so we can view up to 6 items at a time). The screen shows an
example when only two items are selected to view: Eng_Speed and CooL Temp. After finishing
selecting items to view, click on the START/STOP button, the values of the items will show up. This
button is like a toggle switch, click it a second time, then the data capture is disabled. When 6 items
are selected, to view another item, we have to remove one item by clicking the Delete button, then
repeat the process of Add a new item to view. Remember, before Delete, need to click the
START/STOP button, so that the data capture is disabled, after removing an item and replacing with
a new item by ADD, need to click the START/STOP button again to enable data capture.
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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
change (zero to one).
8. Propel System Temp Caution - short wire 34TW to ground at TB26-B momentarily and
confirm state change (zero to one).
9. Propel System Reduced Level - short wire 72LP to ground at TB25-W momentarily and
confirm state change (zero to one).
10. Reduced Retard - short wire 76LR to ground at TB25-T momentarily and confirm state
change (zero to one).
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For 830E trucks only:


1.
2.
3.
4.
5.
6.

Hydraulic Tank Temperature (RR Hydraulic Oil Temp on VHMS Watcher) - confirm as being
near ambient on a cold truck. (564)
Motor Temperature High - short wire 722L to ground at TB21E-B momentarily and confirm
state change (zero to one). (558)
Motor Blower Off - short wire 32B to ground at TB21E-E momentarily and confirm state
change (zero to one). (555)
Diode Fault - short wire 79VD to ground at TB21D-G momentarily and confirm state change
(zero to one). (551)
Electric Drive System Fault - short wire 79VS to ground at TB21D-E momentarily and
confirm state change (zero to one). (516)
Ground Fault - short wire 79VG to ground at TB21D-F momentarily and confirm state
change (zero to one). (557)

For 960E trucks only:


1.

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.

CHECK OUTPUTS FROM THE INTERFACE MODULE


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

For 930E and 960E:


1. Check the output of Brake Cooling RPM Advance 1, Brake Cooling RPM Advance 2, Brake
Oil Temperature Gauge (930E only), and High Brake Oil Temp Lamp by placing a 169
ohm resistor (a range of 1520 to 1860 should work) in place of any of the four input
temperature probes.

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EK8480-1
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2.
3.
4.
5.
6.
7.
8.
9.

Brake Cooling RPM Advance 1 should go to 24 volts (check at TB40-B).


Brake Cooling RPM Advance 2 should go to 24 volts (check at TB40-C).
The Brake Oil Temperature Gauge (930E only) should read near the middle of the red band.
The High Brake Oil Temp light should come on.
If the output functions do not turn on, read the value of the temperature for the selected input
in VHMS Watcher. It should be between 126 and 140 C.
If the temperature reading is low check wiring for high resistance between the probe and
Interface Module.
If the temperature reading is high check for shorts in the wiring.
It the temperature is in the right range but the output functions do not work, check the
Interface Module output circuit and wiring associated with any non-working function.

For 960E only:


Actuate and hold the lamp test switch in the operator's cab. The following lamps are driven by
the Interface Module and should come on (along with all the other lamps):
1. Park Brake Lamp
2. Low Fuel Lamp
3. Batt Charge Alt Failure Lamp
4. 1MWarning Lamp
5. High Brake Oil Temp Lamp

The functionality of the Fuel Level output can be confirmed by observing the needle position of the
gauge when the low fuel lamp comes on.
1.

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.

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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
m
typing 'TEST". The heading "TEST" should appear at the top of 10 screen.
"
15.Enter the Service 10field as in step 7 above.
QC)

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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
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

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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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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EK8480-1
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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.

10. Unit No.


11. Item to be registered in WebCARE.
VHMS

.. Retro-klt
Installed on new machine 0
0

PM Clinic

KUC

[ Orbcomm
Activation]
12. Date of Orbcomm activation

[ Remark]

WebC.,ARE

.1

VHMS/WebCARE Support team


TEL
81-3-5561-2765
FAX
81-3-5561-4766
E-mail
webcare@komatsu.co.jp

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EK8480-1
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TO: Customer support Gr.,Solution Div.,Komatsu Ltd.


(KOMTRAX Service Hotline)
Phone: +81-463-22-8780
Fax: +81-463-22-8448
Address: 3-25-1 Shinomiya, Hiratsuka-shi, kanagawa 2548555,Japan
E-mail: cs_kom@komatsu.co.jp

Important

Request for Orbcomm Terminal Activation


Please fill in the form below and fax or send by mail to Customer Support Gr., Kltd. to activate
Orbcomm terminal.

Terminal
Terminal Part Number

(Pleasefillin terminal PIN&S/Nor put on enclosedsticker here)

Terminal SIN

PIN:

Terminal Activation Date

(YY/MM/DD)

SIN:
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.

Page 13 of 15

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EK8480-1
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\+MS InstallationO1eck-out Sheet (Fam 3)


,Ii3ad befr;re installation

IXJn't stat

engine

befa"e

item

No. 1 t1'rcug116

ere COI1lJIeted.

J!ttI!rirBallalia1, fillco ttis sheet and sera back to Call aner I7i FAXa e-Mlil.
(W!bC'.PR:settirg wll be I11ICiI
aftB"Call Qner receives ttis sheet.)

~Call

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FAX

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-+81-3-55614766

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'vHvS 00x

Pm LID keep:;cn.ntirg up

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NOTES:

STANDARD TORQUE CHARTS AND CONVERSION TABLES


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

Grade 5

Cap
Screw
Thread
Size

kgm

1/4-20

1/4-28

5/16-18

The Komatsu engineering department does not


recommend the use of special friction-reducing
lubricants, such as Copper Coat, Never-Seez, and
other similar products, on the threads of standard
fasteners where standard torque values are applied.
The use of special friction-reducing lubricants will
significantly alter the clamping force being applied to
fasteners during the tightening process.
If special friction-reducing lubricants are used with the
standard torque values listed below in Table I,
excessive stress and possible breakage of the
fasteners may result.
Where the torque tables specify Lubricated Threads
for the standard torque values listed, these standard
torque values are to be used with simple lithium base
chassis grease (multi-purpose EP NLGI) or a rustpreventive grease (see list, page A5-2) on the threads
and seats unless specified otherwise.
NOTE: Ensure the threads of fasteners and tapped
holes are free of burrs and other imperfections before
assembling.

TABLE I. -STANDARD TORQUE CHART


SAE HEX HEAD CAP SCREW AND NUT ASSEMBLY
(LUBRICATED THREADS) - TOLERANCES 10%

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

EFFECT OF SPECIAL LUBRICANTS


On Fasteners and Standard Torque Values

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

1 ft lbs = 0.138 kgm = 1.356 Nm

STANDARD ASSEMBLY TORQUES


For 12-Point, Grade 9 Cap Screws (SAE)

STANDARD ASSEMBLY TORQUES


For Class 10.9 Cap screws & Class 10 Nuts

The following specifications apply to required assembly


torques for all 12-point, grade 9 (170,000 psi minimum
tensile) cap screws.

The following specifications apply to required assembly


torques for all metric Class 10.9 finished hexagon head
cap screws and Class 10 nuts.

Cap screw threads and seats shall be lubricated


when assembled.

Cap screw threads and seats shall not be


lubricated when assembled. These specifications
are based on all cap screws, nuts, and hardened
washers being phosphate and oil coated.

NOTE: Unless the instructions specifically recommend


otherwise, these standard torque values are to be used
with simple lithium base chassis grease (multi-purpose
EP NLGI) or a rust preventive grease (see list, this
page) on the threads.
Torques are calculated to give a clamping force of
approximately 75% of proof load.
The maximum torque tolerance shall be 10% of
the torque value shown.

NOTE: If zinc-plated hardware is used, each piece


must be lubricated with simple lithium base chassis
grease (multi-purpose EP NLGI) or a rust preventive
grease (see list, this page) to achieve the same
clamping forces provided below.
Torques are calculated to give a clamping force of
approximately 75% of proof load.
The maximum torque tolerance shall be within
10% of the torque value shown.

TABLE 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
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

* Shank Diameter (mm) - Threads per millimeter


This table represents standard values only. Do not use these
values to replace torque values which are specified in assembly
instructions.

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

* Shank Diameter (in.) - Threads per inch


This table represents standard values only. Do not use these
values to replace torque values which are specified in assembly
instructions.

Suggested* Sources for Rust Preventive Grease:


AMERICAN ANTI-RUST GREASE #3-X from
Standard Oil Company (also American Oil Co.)
GULF NORUST #3 from Gulf Oil Company.
MOBILARMA 355, Product No. 66705 from Mobil
Oil Corporation.
RUST BAN 326 from Humble Oil Company.
RUSTOLENE B GREASE from Sinclair Oil Co.
RUST PREVENTIVE GREASE - CODE 312 from
the Southwest Grease and Oil Company.
NOTE: This list represents the current engineering
approved sources for use in Komatsu manufacture. It is
not exclusive. Other products may meet the same
specifications of this list.

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

TABLE VIII. TORQUE CONVERSIONS


Foot Pounds (ft lbs) to Newton-meters (Nm)
ft lbs

(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

(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

See NOTE on page A5-5 regarding Table usage

TABLE X. PRESSURE CONVERSIONS


Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
psi

(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

See NOTE on page A5-5 regarding Table usage

TABLE XI. PRESSURE CONVERSIONS


Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
psi

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

See NOTE below regarding Table usage

NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa).
1. Select Table X.
2. Go to psi row 90, column 7; read 668.8
97 psi = 668.8 kPa.

3. Multiply by 10:
970 psi = 6688 kPa.
4. Go to psi row 0, column 5; read 34.475
psi = 34.47 kPa. Add to step 3.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.

TABLE XII. TEMPERATURE CONVERSIONS


Formula: F - 32 / 1.8 = C or C x 1.8 + 32 = F
FAHRENHEIT
CELSIUS
FAHRENHEIT
CELSIUS
FAHRENHEIT
CELSIUS
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


METRIC TO ENGLISH

COMMON CONVERSION MULTIPLIERS


ENGLISH TO METRIC
To Convert
From

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

sq. centimeters (cm )

6.45

sq. centimeters (cm

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

Newton (N)

4.448

Newton (N)

pound (force) lbs

0.2248

Newton meters (Nm)

0.113

Newton-meters (Nm)

kilogram meters (kgm)

0.102

sq. in. in.

pound (force) lbs


in. lbs. (force)

sq. in.

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

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

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
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

Dump Body Manufacturer


Komatsu

RH
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


Komatsu America Corp.
2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send Pink Reports to your KAC Regional Service Manager


Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.
Mark each item with the appropriate symbol as shown below.

CEAW003209

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 1 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Inspection Around Machine


1

Parts

Visual inspection of unit for loose parts and debris

Hardware

Visual inspection of unit for missing and/or loose mounting hardware

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

Ground Straps

Verify all ground straps are secure (sub frame, anchor etc.)

Engine Oil Level

Verify engine oil level is in operating range

Engine Fan

Inspect fan-to-shroud clearance and belt alignment

Hydraulic Oil Level

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

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

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 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
(See Note below chart)

Verify torque on front wheel nuts at 2326 136 Nm (1715 100 ft lbs)
Verify torque on rear inside wheel nuts at 2326 136 Nm (1715 100 ft lbs)
Verify torque on rear outside wheel nuts and adapter ring at 2326 136 Nm (1715 100 ft
lbs)

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

Verify torque on cab mounting cap screws at 949 Nm (700 ft lbs)

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

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

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

Verify windows can be opened and closed smoothly

Door Locks

Verify left and right door locks work properly with key

Interior

Visually inspect interior for completeness of assembly

Cab Seats

Inspect operators seat adjustments (slide lever, back rest operation,


seat inclination, seat height etc.)

Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.

Inspect seat belt for proper installation (and seat tethers)


6

Passenger Seat

Verify back rest operates without interference

Steering Wheel

Check tilt and telescoping functions

Wiper

Verify wiper works all speeds, & range does not extend beyond glass surface

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

Headlights

Verify all headlights working, high and low beams

Check adjustable lever can be locked securely

Verify the windshield washer works properly and washer fluid bottle is full

Lights
1

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

Hazard Flashers

Verify flasher operates properly

Back Up Light

Verify back up light operates properly when shifter is in R position

Manual Back Up Light

Verify switch and light work properly

Fog Light (optional)

Verify fog lights and indicator lights operating properly

Verify hazard indicator lights operating properly

Brake Lights
1

Service Brake

Verify service brake lights operating properly

Brake Lock

Verify brake lock light operating properly

Emergency Brake

Verify emergency brake light operating properly

Parking Brake

Verified parking brake light operating properly

Dome Light

Verify dome light is on when the switch is ON

Retarder Lights

Verify retard light operating properly

CEAW003209

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 3 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Service Inspection
1

Suspension

730E

(See Note below chart)

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

If equipped, ensure prelube is working prior to engine starting

Engine Starting

Ensure engine starts easily

Engine Noise

No abnormal noise from engine

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

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 4 of 5

11

730E

Acceptance Procedures

Maintenance

Inspection Item
Hoist Times

Accepted

No.

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


Power down - 15-17 seconds
Float down empty - 23-25 seconds

930E-4

Power up loaded - 21-23 seconds


Power down - 23-25 seconds
Float down empty - 24-26 seconds

All Trucks

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

Payload Meter Sys.

Calibrate and check payload meter operation per O&M manual

Ensure automatic lube system is operating properly and timer is set as desired

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__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________

CEAW003209

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 5 of 5

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
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

Dump Body Manufacturer


Komatsu

RH
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


Komatsu America Corp.
2300 N.E. Adams St., P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send canary reports to:

Manager of Field Assembly


Komatsu America Corp.
2300 N.E. Adams St., P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send pink reports to your KAC Regional Service Manager


Send gold reports to the Service Manager at the KAC Distributor who sold the truck

CEAW004201

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 1 of 5

No.

Inspection Item

Acceptance Procedures

As Found
Condition

Corrective
Action

Inspection Around Machine


1

Parts

Visually inspect the truck for loose parts and debris.

Hardware

Visually inspect the truck for missing and/or loose


mounting hardware.

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.

Engine Oil Level

Verify the engine oil level is at the proper operating


range.

Hydraulic Oil Level

Verify the oil level is visible through the upper sight glass
with the body down.

Anchor Pin

Visually inspect the anchor hitch pin and anti-sway bar


assembly for proper installation and properly tightened
hardware.

Wheel Motors

Verify the correct oil is being used and oil is at the proper
level.

Fuel Tank

Verify the fuel tank mounting is secure and there are no


fuel leaks.

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
Suspension

730E - Verify hardware torque Target: 2705 Nm (1995 ft lbs)


830E, 830E-AC- Verify hardware torque Target: 2705 Nm (1995 ft lbs)
930E-4 - Verify hardware torque Target: 2705 Nm (1995 ft lbs)

Steering Cylinder To
Frame

730E - Verify hardware torque Target: 464 Nm (342 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 712 Nm (525 ft lbs)
930E-4 - Verify hardware torque Target: 1017 Nm (750 ft lbs)

Steering Cylinder To
Steering Arm

730E - Verify hardware torque Target: 464 Nm (342 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 712 Nm (525 ft lbs)
930E-4 - Verify hardware torque Target: 1017 Nm (750 ft lbs)

CEAW004201

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 2 of 5

No.

Inspection Item

Acceptance Procedures

Tie Rod Pin Retainer

730E - Verify hardware torque -

As Found
Condition

Corrective
Action

Target: 464 Nm (342 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 712 Nm (525 ft lbs)
930E-4 - Verify hardware torque Target: 1017 Nm (750 ft lbs)
5

Front Brake Caliper


Mounting

730E - Verify hardware torque -

(Capscrew with Nut)

830E, 830E-AC - Verify hardware torque -

Target: 1085 Nm (800 ft lbs)


Target: 1085 Nm (800 ft lbs)

Front Brake Caliper


Mounting
(Capscrew Only)

730E - Verify hardware torque Target: 1166 Nm (860 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 1166 Nm (860 ft lbs)

Rear Service Brake


Caliper Mounting

730E - Verify hardware torque Target: 780 Nm (575 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 780 Nm (575 ft lbs)

Rear Brake Adapter


Mounting

730E - Verify hardware torque Target: 488 Nm (360 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 488 Nm (360 ft lbs)

Brake Disc To Adapter


Mounting

730E - Verify hardware torque Target: 278 Nm (205 ft lbs)


830E, 830E-AC - Verify hardware torque Target: 278 Nm (205 ft lbs)

Cab Compartment
1

Horn

Check for proper tone and volume. Ensure there is no


looseness in the horn button.

Back Up Horn

Check for proper tone, volume, and function.

Gauges

Verify all gauges are installed straight and are operating


correctly.

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

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 3 of 5

No.

Inspection Item

Acceptance Procedures

As Found
Condition

Corrective
Action

Service Inspection
1

Suspension

730E

(See Note below)

Suspension oiling height: 38.1 mm (1.5 in.) front and


72.6 mm (2.9 in.) rear
Front charge height: 229 mm (9 in.) at 2758 kPa (400
psi)
Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206
psi)

830E, 830E-AC
(See Note below)

Suspension oiling height: 25.4 mm (1 in.) front and 25.4


mm (1 in.) rear
Front charge height: 229 mm (9 in.) at 2689 kPa (390
psi)
Rear charge height: 241 mm (9.5 in.) at 1724 kPa (250
psi)

930E-4
(See Note below)

Suspension oiling height: 25.4 mm (1 in.) front and 25.4


mm (1 in.) rear
Front charge height: 229 mm (9 in.) at 2930 kPa (425
psi)
Rear charge height: 190 mm (7.5 in.) at 1482 kPa (215
psi)

NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling
and charging instructions.
2

Accumulators

Verify the nitrogen charge in the accumulators is at 9653


kPa (1400 psi) for all models, for both steering and
brakes.

Steering

Verify that steering system is operating smoothly while


turning from lock to lock.
Verify the steering system is free of noise and vibration.

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.

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.

Tires

Check and record the tire pressure/size/manufacturer for


future reference

Pressure
Size
Manufacturer

Payload Meter System

Calibrate and check payload meter operation per O&M


manual. Troubleshoot any error codes and delete after
repair.

GE Drive/Control
System

Check drive control system operation per O&M manual.


Troubleshoot, correct and delete any error codes.

GE Rotating

Visually inspect wheel motor armature condition - brush


wear, commutator color, etc.

Components
(Wheel Motors, MTA,
Grid Blower)

Inspect MTA slip rings and brushes.

10

Wheel Motor Sun Pinion


End Play

Measure and record sun pinion end play for both RH and
LH wheel motors

11

VHMS

Verify the VHMS system is functioning properly per O&M


manual. Troubleshoot and repair any problems.

CEAW004201

Inspect grid blower motor commutator condition, brush


wear, etc.

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 4 of 5

MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No.

Description of Modification

Reason For Installation

1
2
3
4
5
6

ADDITIONAL COMMENTS:______________________________________________________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CEAW004201

White - Komatsu, Manager of Technical Support


Canary - Komatsu, Manager of Field Assembly
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 5 of 5

www.komatsuamerica.com

Komatsu America Corp.


2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072

Copyright 2007 Komatsu


Printed in U.S.A.

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