Manual Armado 930E-4SE Serial Numbers A30769 & UP CEAW006203

CEAW006203
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS A30769 & UP
®
FOREWORD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-4SE dump truck.
Variations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.
FAM0015 Introduction i
This alert symbol is used with the signal words, CAUTION, DANGER, and
WARNING in this manual to alert the reader to hazards arising from improper
operating and maintenance practices.
DANGER Identifies a specific potential hazard

which will result
in either injury or death
if proper precautions are not used.
WARNING identifies a specific potential hazard

which may result
in either injury or death
if proper precautions are not used.
CAUTION is used for general reminders

of proper safety practices
or
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
ii Introduction FAM0015
TABLE OF CONTENTS
SUBJECT PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TRUCK COMPONENT AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAM0015 Introduction iii

KOMATSU 930E-4SE
iv Introduction FAM0015
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES
The following list of safety practices is intended for use
by personnel during field assembly of the truck.
This list of safety rules is not intended to replace local
safety rules or regulations and federal, state, or local
laws. The safety precautions recommended here are Before welding, refer to Special Precautions When
general and must be used in conjunction with all pre- Servicing An AC Drive System Truck in Section 4.
vailing local rules and regulations.
1. All personnel must be properly trained for the
10. Disconnect the battery charging alternator lead
assembly process.
wire before welding on the frame or its compo-
2. Wear safety equipment such as safety glasses, nents.
hard toe shoes and hard hats at all times during
assembly. 11. When welding, connect the ground cable to the
part being welded. DO NOT allow welding current
3. Thoroughly inspect the assembly site. Remove to pass through bearings, engine, etc.
weeds, debris and other flammable material.
12. DO NOT weld the fuel tank or hydraulic tank
4. Use only solid, hard wood for supports. When
unless the tanks have been properly purged and
using metal support stands, place wood blocks
ventilated.
between the support and the frame to prevent
metal to metal contact. 13. Use the proper tools for the job to be performed.
5. Inspect all lifting devices. Refer to the manufac- Never improvise wrenches, screw drivers, sock-
turer's specifications for correct capacities and ets, etc. unless specified.
safety procedures when lifting components. 14. Lifting eyes and hooks must be fabricated from
6. Perform a daily inspection of all lifting cables and the proper materials and rated to lift the intended
chains. Replace any questionable items. Use load.
cables and chains that are properly rated for the 15. When the weight of any component(s) or any
load to be lifted. assembly procedure is not known, contact your
7. DO NOT stand beneath a suspended load. Use of customer support manager for further information.
guy ropes are recommended for guiding and posi-
tioning a suspended load.
8. Maintain fire control equipment. Inspect fire extin-
guishers regularly to ensure they are fully charged
and in good working condition.
9. Cap screws and/or nuts being replaced must be
the same grade as originally supplied.
FAM0108 5/10 Safety Rules, Tools, & Equipment Page 1-1

TOOLS AND EQUIPMENT FOR ASSEMBLY
The following equipment is recommended for field
assembly of the truck.
12. Two, ratchet pullers - 2.7 metric ton (3 ton)

1. Equipment and tool storage trailer with a lockable 13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)
door. Approximately 12 x 2.5 m (40 x 8 ft)
14. Set of standard master mechanics hand tools
2. Cranes
a. Two, 45 metric ton (50 ton) cranes to remove
• Thread taps and dies of both inch and metric
the chassis from the freight trailer and place on sizes
cribbing. These cranes can also be used to lift • Metric sockets and open end wrenches, 6mm to
the assembled body onto to the chassis. 36mm
b. One, 109-136 metric tons (120-150 ton) crane. • Inch sockets and open end wrenches
The crane is needed to turn the body over after up to 1 3/4 in.
completion of the underside welding. A 45 met-
ric ton (50 ton) crane is also required for this • Torque wrenches - 339 N·m (250 ft lb) with 18:1
task. multiplier. Torque wrenches - 339 N·m (600 ft lb)
with 4:1 multiplier. Hydrotorque - 1 1/2 in. drive
3. One fork lift - 6804 kg (15,000 lb) capacity, with
with capability of 5559 N·m (4100 ft lb) or
high lift capability
greater
4. Two, 300 amp portable welding units and an oxy-
acetylene cutting set • Box wrench 1 3/8 in. (Snap-On p/n X440B) with
12 inch extension to tighten ROPS cap screws
5. One, propane torches for weld preheating
6. Portable air compressor - 3.5 cmm (125 cfm) and • Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2
690 kPa (100 psi) capacity. 5/8 in. (Snap-On P/N J15042) to tighten front
suspension hardware
Two, 15 m (50 ft) air hoses.
15. Heavy duty 3/4 in. & 1 in. square drive impact
7. Metal stands and a sufficient amount of wood wrench sets
cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm
(14 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm 16. Impact sockets for 3/4 in. & 1 in. square drive
(4 ft. x 6 in. x 6 in.) - such as railway cross ties tools
8. Tire handler - Wiggins/Iowa Mold Tooling 17. Special tools (see list, following pages)
9. Miscellaneous air tools 18. Two, hydraulic or pneumatic porta-power jacks,
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft) 4.5 and 9 metric ton (5 and 10 ton)
11. Chains, lifting cables, slings: 19. Various hooks and shackles
• Two, 4 point slings, 3 m (10 ft) in length 20. Miscellaneous (i.e. grinders, containers, rags)
21. Spreader bars for cab and decks
• Two, 4 point slings, 2 m (6 ft) in length
22. Two ratchet hoists - 2.7 metric ton (3 ton) capacity
• Two, 1 m (4 ft) and two, 2 m (6 ft)
23. Pry bars
• Two, 3 m (10 ft) nylon straps
24. Solvent - 38 liters (10 gal)
• Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of
rope 25. Paint remover - 19 liters (5 gal)
26. Rust preventive grease
27. 22 mm Allen wrench socket - 3/4 in. drive
Page1-2 Safety Rules, Tools, & Equipment 5/10 FAM0108

LIFTING SLING GENERAL INFORMATION

Part Number Description Use
EB1759 Nitrogen Suspension &
Charging Kit Accumulator
Nitrogen
Charging
1. “T” Handle Valve

2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas

EJ2626 Roller 930E-4
Assembly
EH8687 930E-4SE
(No longer Power Module
available as Removal &
complete unit)
Installation
EJ2271 Roller Mount 930E standard
EH8681 Roller Mount 930E SE
PC0706 Bearing
TH9449 Bearing
Retainer Ring
TG1680 Roller
Retainer Ring
C1645 Capscrew -
3/4” - 10NC x
2 1/4”
C1542 Lockwasher -
3/4”
EH8686 Roller Ring

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

TZ2734 3/4 in. Torque Miscellaneous
Adapter

TZ2733 Tubular Handle Use with
PB8326 &
TZ2734

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

EH4638 Sleeve Steering Linkage
Alignment Tool and Tie Rod

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

PC2525 Harness Payload Meter
Download

EH7817 Alignment Tool Upper Hoist Pin

PB4684 Hydraulic Miscellaneous
Coupling

PB9067 Bulkhead Battery Jumper
Connector

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

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

WA4826 Lifting Eye Bolt Miscellaneous

PC0370 Sling Body Retention

PC0367 Shackle Miscellaneous

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

MAJOR COMPONENTS & SPECIFICATIONS
Truck And Engine Operator's Cab
The 930E-4SE Dump Truck is an off-highway, rear The operator cab has been engineered for operator
dump truck with AC Electric Drive. The gross vehicle comfort and to allow for efficient and safe operation
weight is 1,114,670 lbs. (505,611 kg). The engine is a of the truck. The cab provides wide visibility with an
Komatsu SSDA18V170 rated @ 3500 HP (2611 kW). integral 4-post ROPS/FOPS structure and an
advanced analog operator environment. It includes a
Main Alternator tinted safety-glass windshield and power-operated
side windows, a deluxe interior with a fully adjustable
The diesel engine drives an in-line alternator at seat with lumbar support, a fully adjustable/tilt steer-
engine speed. The alternator produces AC current ing wheel, controls mounted within easy reach of the
which is rectified to DC within the main control cabi- operator, and an analog instrument panel which pro-
net. The rectified DC power is converted back to AC vides the operator with all instruments and gauges
by groups of devices called "inverters", which are which are necessary to control and/or monitor the
also within the main control cabinet. Each inverter truck's operating systems.
consists of six phase modules under the control of a
gate driver power converter (GDPC). The two
GDPCs control the operation of each phase module.
Power Steering
The truck is equipped with a full time power steering
Each phase module contains paired positive and
system which provides positive steering control with
negative semiconductor switches referred to as insu-
minimum operator effort. The system includes nitro-
lated gate bipolar transistors (IGBT). The IGBTs
gen-charged accumulators which automatically pro-
cycle on and off at varying frequencies to create an
vide emergency power if the steering hydraulic
AC power signal from the DC supply.
pressure is reduced below an established minimum.
The AC power signal produced by each inverter is a
variable-voltage, variable-frequency (VVVF) signal. Dynamic Retarding
Frequency and voltage are changed to suit the oper-
The dynamic retarding is used to slow the truck dur-
ating conditions.
ing normal operation or control speed coming down a
Cooling air for the control/power group and wheel grade. The dynamic retarding ability of the electric
motors, as well as the alternator itself, is provided by system is controlled by the operator through the acti-
dual fans mounted on the alternator shaft. vation of the retarder pedal (or by operating a lever
on the steering wheel) in the operators cab and by
AC Induction Traction Motorized Wheels setting the RSC (Retarder Speed Control). Dynamic
retarding is automatically activated, if the truck speed
The alternator output supplies electrical energy to the
goes to a preset overspeed setting.
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction
motors with full-wave AC power. Brake System
Service brakes at each wheel are oil-cooled multiple
The two wheel motors convert electrical energy back
disc brakes applied by an all-hydraulic actuation sys-
to mechanical energy through built-in gear trains
tem. Depressing the brake pedal actuates both front
within the wheel motor assembly. The direction of the
and rear brakes after first applying the retarder. All
wheel motors is controlled by a directional control
wheel brakes will be applied automatically if the
lever located on the center console.
brake system pressure decreases below a preset
minimum.
Suspension The parking brake is a dry disc type, mounted
inboard on each rear wheel motor, and is spring-
Hydrair II® suspension cylinders located at each applied and hydraulically-released with wheel speed
wheel provide a smooth and comfortable ride for the application protection (will not apply with truck mov-
operator and dampens shock loads to the chassis ing).
during loading and operation.
FAM0215 9/09 Truck Components And Specifications Page 2-1

930E-4SE MAJOR COMPONENTS
Page 2-2 Truck Components And Specifications 9/09 FAM0215

SPECIFICATIONS
These specifications are for the standard Komatsu 930E-4SE Dump Truck. Customer options may change this
listing.
ENGINE
Komatsu SSDA18V170
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3500 HP (2611 kW) @ 1900 RPM
Flywheel HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3429 HP (2558 kW) @ 1900 RPM
Weight (Wet)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 kg (22,266 lbs)
* Weight does not include Radiator, Sub-frame, or Alternator.
AC ELECTRIC DRIVE SYSTEM
(AC/DC Current)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Electric GTA-39
Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453 m³/ min (16,000 cfm)
Motorized Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GDY106 AC Induction Traction Motors
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.62:1
Maximum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5 km/h (40 mph)
* Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.
Komatsu and GE must analyze each job condition to ensure proper application.
DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard
Maximum Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5400 HP (4026 kW)
Continuous* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3900 HP (2909 kW)
* Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.
BATTERY ELECTRIC SYSTEM

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four 8D, 12 volt wet batteries with disconnect switch
Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 CCA
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 140 Amp Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Cranking Motors (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
SERVICE CAPACITIES
Crankcase (including lube oil filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 liters (90 gallons)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .799 liters (211 gallons)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5300 liters (1400 gallons)
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325 liters (350 gallons)
Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 liters (25 gallons) per wheel

HYDRAULIC SYSTEMS
Hoist and Brake Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931 L/min (246 gpm) @ 1900 RPM and 17,237 kPa (2500 psi)
Steering/Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 18,961 kPa (2750 psi)
Relief Pressure - Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17,237 kPa (2500 psi)
Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27,579 kPa (4000 psi)
Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947 liters (250 gallons)
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 Rating =200
SERVICE BRAKES
All Hydraulic Actuation with Traction System Wheel Slip/Slide Control
Front and Rear Oil-Cooled Multiple Discs on each wheel
Total Friction Area / Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97,019 cm² (15,038 in²)
Maximum Apply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17,238 kPa (2500 psi)
STEERING
Twin hydraulic cylinders with accumulator assist to provide constant rate steering
Emergency power steering automatically provided by accumulators
Turning Circle (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.7 m (97 ft. 7 in.)
TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53/80 R63
Rock Service, Deep Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless
Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . patented Phase I New Generation™ rims
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS

Capacity
Heaped @ 2:1 (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211 m3 (276 yd3)
Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171 m3 (224 yd3)
Width (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 m (26 ft. 9 in.)
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 m (10 ft. 7 in.)
Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.06 m (23 ft. 2 in.)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
NOTE: Optional capacity dump bodies are available.

WEIGHT DISTRIBUTION
Empty Vehicle Loaded Vehicle
Front Axle (48.5%). . . . . . . 104,460 kg (230,293 lbs) Front Axle (32.8%) . . . . . . 165,958 kg (365,871 lbs)
Rear Axle (51.5%) . . . . . . . 110,848 kg (244,377 lbs)
Rear Axle (67.2%) . . . . . . . 339,653 kg 748,799 lbs)
Total (with 50% Fuel) . . . . 215,308 kg (474,670 lbs)
Total . . . . . . . . . . . . . . . . 505,611 kg (1,114,670 lbs)
Standard Komatsu body . . . . 30,362 kg (66,936 lbs)
Standard tire weight. . . . . . . . 26,127 kg (57,600 lbs)
Nominal Payload*. . . . . . . 290,302 kg (640,000 lbs)
* Nominal payload is defined within Komatsu
America Corporation’s payload policy
documentation. Nominal payload must be adjusted if
the weight of any customized body or tires vary from
that of the standard Komatsu body and tires. Nominal
payload must also be adjusted to take into account
the additional weight of any custom/optional extras
fitted to the truck which are not stated within the
Standard Features list of the applicable specification
sheet.
OVERALL TRUCK DIMENSIONS

NOTES

MAJOR COMPONENT WEIGHTS
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before
each use. Lifting equipment must be in good condition and rated for approximately two times the weight
being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result.
Optional equipment added onto the truck may cause an increase to the component weights listed in this
chapter. Contact your customer support manager for concerns or questions about lifting truck compo-
nents.
NOTE: All component weights are dry weights. The additional weight of coolant, fuel, and oil that may be in the
components are not calculated into this list.
ITEM KILOGRAMS POUNDS
CHASSIS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,813 . . . . . . . . . . . . . . . . . . . . . . 6,202
Tire 53/80 R63 (148" OD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,122 . . . . . . . . . . . . . . . . . . . . . 15,702
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21,874 . . . . . . . . . . . . . . . . . . . . . 48,224
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,056 . . . . . . . . . . . . . . . . . . . . . . 4,533
DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,725 . . . . . . . . . . . . . . . . . . . . . . 6,008
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937 . . . . . . . . . . . . . . . . . . . . . . 2,066
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 . . . . . . . . . . . . . . . . . . . . . . 1,455
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . .551
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654 . . . . . . . . . . . . . . . . . . . . . . 1,442
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 . . . . . . . . . . . . . . . . . . . . . . . .602
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 . . . . . . . . . . . . . . . . . . . . . . 1,601
RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578 . . . . . . . . . . . . . . . . . . . . . . 1,274
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 . . . . . . . . . . . . . . . . . . . . . . . .298
RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . .150
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 . . . . . . . . . . . . . . . . . . . . . . . .397
Diagonal Ladder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . . . . . . . . . . . . 119
FAM0314 Major Component Weights Page 3-1

ITEM KILOGRAMS POUNDS
POWER MODULE
Air Intake Ducts
Wheel Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337 . . . . . . . . . . . . . . . . . . . . . . . . 743
Alternator Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 . . . . . . . . . . . . . . . . . . . . . . . . 441
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955 . . . . . . . . . . . . . . . . . . . . . . .2,105
Air Cleaner Assembly
Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 . . . . . . . . . . . . . . . . . . . . . . . . 193
Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Retarding Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,082 . . . . . . . . . . . . . . . . . . . . . . .6,795
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,176 . . . . . . . . . . . . . . . . . . . . . . .7,002
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,710 . . . . . . . . . . . . . . . . . . . . . . 10,381
Engine (Komatsu SSDA18V170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,300 . . . . . . . . . . . . . . . . . . . . . . 22,707
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,100 . . . . . . . . . . . . . . . . . . . . . . .4,630
HYDRAULIC COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . . . . . . . . . . . . . . . 379
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .932 . . . . . . . . . . . . . . . . . . . . . . .2,055
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . . . . . . . . . . . . . . . . . . . . . . . 322
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731 . . . . . . . . . . . . . . . . . . . . . . .1,612
FRONT AXLE COMPONENTS

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

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,242 . . . . . . . . . . . . . . . . . . . . . . .4,943
Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 . . . . . . . . . . . . . . . . . . . . . . . . 351
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371 . . . . . . . . . . . . . . . . . . . . . . . . 818
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,568 . . . . . . . . . . . . . . . . . . . . . . 14,480
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 . . . . . . . . . . . . . . . . . . . . . . . . 324
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 . . . . . . . . . . . . . . . . . . . . . . 39,683
Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 . . . . . . . . . . . . . . . . . . . . . . . . 675
Page 3-2 Major Component Weights FAM0314

FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at WELD PROCEDURES
initial field assembly or during normal maintenance
repairs, special procedures must be followed. Electric arc welding, either the semi-automatic “MIG”
(GMAW), Flux Core (FCAW), or “Stick” electrode
Due to the continuous program of research and welding (SMAW), are approved processes for field
development, periodic revisions may be made to this installation and maintenance welding. Welding of
publication. It is recommended that customers con- highly stressed structural members such as castings,
tact their distributors for information on the latest revi- torque tubes, top and bottom plates on the frame
sion. rails, and the curved intersection points of frames
The welding information contained in this chapter is should be done with the specific detailed instructions
general information that must be followed unless oth- from Komatsu Product Service. See Annex A for
erwise specified in a detailed repair procedure pro- repair procedures. These repair procedures are
vided on an engineering drawing or a detailed detailed instructions for most high stressed structural
specific repair procedure. Additional specific informa- members.
tion, or detailed instructions can be obtained through
your local Komatsu customer support manager.
APPROVED CONSUMABLES
GMAW - LW102-15 or ER80S-D2
WELDER QUALIFICATION AND
TRAINING FCAW - E70T-5, E71T-8, or E71T8-NI1
The welding technique must be of the highest stan- SMAW - E7018-1, E8018-C1, or E8018-C3
dard to produce the soundest weld possible. Only
welders who have been trained and qualified for
structural steel welding in all positions, in conform-
ance with the American Welding Society (AWS) D1.1
WELD QUALITY REQUIREMENTS
or (AWS) D14.3 only, are allowed to perform the 1. Each weld must be homogeneous with low
welding. The welding instructions for field assembly porosity, free from cracks, and slag inclusions.
of Komatsu components are normally provided by 2. Each weld must have complete fusion between
engineering drawings. Additional detailed welding the base metal and weld metal added by the
instructions for field repairs are provided in the field electrode.
repair manual SEB14001. A full understanding of the
3. All welds must be reasonably smooth, without
AWS standard welding symbols is necessary to per-
excessive deformity, and all craters filled. No
form and inspect such field welds. Weld sizes speci-
cracks are permitted.
fied on the drawings are intended to reflect minimum
requirements. 4. The toe of a weld to a stressed member must
have a smooth transition. Excessive convexity
in multi-pass fillet welds is not permitted. Exces-
sive convexity produces high residual stress in
the throat of the weld, and is not permitted.
5. Undercut in excess of 0.8 mm (0.03 in.) on criti-
cal welds must be reworked by the application
of welding an additional cover pass. It is impor-
tant that this pass is blended with the existing
weld.
FAM0403 Field Welding For Assembly Or Repair 4-1

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

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

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

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

FIGURE 4-1. TOE HAMMER PEENING

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

BIBLIOGRAPHY SPECIAL PRECAUTIONS WHEN
SERVICING AN AC DRIVE SYSTEM TRUCK
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earthmoving and Consult a qualified technician, specifically trained for
Construction Equipment servicing the AC drive system, before welding on the
Metals and How to Weld Them - James F. Lincoln truck.
Arc Welding Foundation. Cleveland, Ohio
The following procedures must be followed to ensure
Procedure Handbook of Arc Welding - Lincoln Elec- the safety of maintenance personnel and to help pre-
tric Company, Cleveland, Ohio vent damage to the equipment.
American Welding Society - Welding Handbook
British Standard BS5135 - Metal Arc Welding of Car-
bon and Carbon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The Anytime the engine is on:
Welding Institute, F. R. Coe, Author
• Do not open any of the cabinet doors or
remove any covers.
• Do not use power cables for hand holds or
foot steps.
• Do not touch retarder grid elements.
Before opening any cabinets or touching a grid

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

to ensure that no hazardous voltages are present in
the AC drive system.
1. Before turning off the engine, verify the status
of all the drive system warning lights on the
overhead display panel. Use the lamp test
switch to verify that all lamps are functioning
properly.
2. If all red drive system warning lights are off,
turn the engine off.
3. After the engine has been off for at least five
minutes, inspect the link voltage lights. The
lights are located on the exterior of the main
control cabinet and back wall of the operator's
cab (DID panel). If all lights are off, the retard-
ing grids, wheel motors, alternator, and power
cables connecting these devices are safe to
work on.

Locate the GF cut-out switch in the access General Welding Guidelines
panel on the left side of the main control cabi- 1. Open the battery disconnect switches and dis-
net. Place the switch in the CUTOUT position. connect the battery charging alternator lead
This will prevent the alternator from re-energiz- wire.
ing and creating system voltage until the switch
is returned to its former position. 2. Disconnect all electrical harnesses from the
Engine Control System (ECS). The ECS is
After repairs, replace all covers and doors and located inside the electrical cabinet behind the
place the GF cutout switch and battery discon- operator's cab. Disconnect the ground strap
nect switches in their original positions. Recon- from the ECS.
nect all harnesses prior to starting the truck. 3. Fasten the welding machine ground (-) lead to
Leave the drive system in the rest mode until the piece being welded. The grounding clamp
the truck is to be moved. must be attached as near as possible to the
4. If the red lights on the exterior of the control weld area.
cabinet and/or the back wall of the operator's 4. DO NOT weld on the rear of the control cabinet!
cab continue to be illuminated, a fault has The metal panels on the back of the cabinet are
occurred. part of the capacitors and cannot be heated.
Leave all cabinet doors in place. DO NOT touch 5. DO NOT weld on the retard grid exhaust lou-
the retard grid elements. DO NOT disconnect vers.
any power cables or use them as hand or foot 6. Some power cable panels throughout the truck
holds. are made of aluminum or stainless steel. They
must be repaired with the same material or the
power cables may be damaged.
7. Power cables must be cleated in wood or other
non-ferrous materials. DO NOT repair cable
cleats by encircling the power cables with metal
Notify your Komatsu customer service manager
clamps or hardware. Inspect power cable insu-
immediately. Only qualified personnel, specifi-
lation prior to servicing the cables and prior to
cally trained for servicing the AC drive system,
returning the truck to service. Discard cables
may perform this service.
with broken insulation.
8. Protect power cables and wiring harnesses
from weld spatter and heat.
9. DO NOT lay welding cables over or near the
vehicle electrical harnesses. Welding voltage
may be induced into the electrical harnesses
and cause damage to components.
10. DO NOT allow welding current to pass through
ball bearings, roller bearings, suspensions, or
hydraulic cylinders.

NOTES

RECEIVING & ASSEMBLY PREPARATION
1. Inspect all components for possible shipping 5. Clean all mounting surfaces on the chassis and
damages. Note any damage found and report to on the individual components.
shipping agent. 6. Check all electrical connectors and verify they
2. Spread out all parts and organize per unit num- are free of paint and/or corrosion. Clean any
ber. Check for missing parts. List the unit num- connector with questionable electrical continu-
ber of all major components. Verify the cab and ity.
decks are with the correct chassis. 7. Check all factory installed components for the
3. Install support blocks under the chassis. The proper tightening torque.
support blocks must be approximately 84 cm 8. Arrange the work site as shown on the following
(33 in.) high. page.
4. Install support blocks under the rear axle hous-
ing. The support blocks must be approximately
30 cm (12 in.) high and spread out along the
axle. The support blocks must be a minimum of
51 mm (2 in.) away from the wheel motor
mounting face.
FAM0503 Receiving & Assembly Preparation Page 5-1

ASSEMBLY LAYOUT
Page 5-2 Receiving & Assembly Preparation FAM0503

CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines BASIC ASSEMBLY PROCEDURE
varies. Photographs or illustrations used in the fol-
lowing procedures are provided only as a general 1. Site preparation
guideline. Actual assembly may be different, but this 2. Unload truck components
general procedure provides a basic outline for 3. Assemble the chassis
assembly. 4. Weld the body
NOTE: The hydraulic tank and accumulators may NOTE: Chassis assembly and body welding may be
have been removed for shipping purposes and may done in either order, or simultaneously. The most
require local installation. logical order depends on available resources such as
Each shipment may be different, depending on the cranes, welders, assemblers, etc.
truck configuration and destination. 5. Static checkout (electrical & mechanical)
6. Install the body
7. Dynamic checkout (electrical & mechanical)
RECOMMENDED ASSEMBLY DATA 8. Site cleanup
1. Service Report (Pre-Delivery)
2. Acknowledgement of Receipt of Company War-
ranty
3. Assembly Blueprints & Schematics
4. Fluid Specifications (refer to the lubrication
chart in Section 10, Appendix)
5. Suspension Oiling & Charging Procedure
(available in Section 10, Appendix)
6. Fan Drive Adjustment Procedure (available in
the engine service manual)
7. Toe-In Adjustment Procedure (Section 10,
Appendix)
8. Hydraulic Checkout Procedure (Section 10,
Appendix)
9. Brake Checkout Procedure (Section 10, Appen-
dix)
10. Propulsion System Checkout Procedure (avail-
able in Section 10 of this manual)
11. Filter List (available in parts book)
12. Lubrication & Service PM Forms (available in
the operation and maintenance manual)
13. Component Weights - for crane reference
(available in Section 3 of this manual)
14. Standard Torque Chart (available in Section 10
of this manual)
15. Field Assembly Inspection Report Form (avail-
able in Section 10 of this manual)
FAM0615 7/10 Chassis Assembly Page 6-1

ORDER OF ASSEMBLY
The assembly procedure is organized in levels. Gen- LEVEL 3
erally, the tasks to be done at a given level may be 1. Spindles/Hubs
performed in any convenient order or simultaneously.
2. Steering Cylinders
However, all tasks in that level must be completed
before proceeding to the next higher level. Each level 3. Tie Rod
depends on the installation of components from the
previous level. LEVEL 4
NOTE: As stated earlier, shipping and packaging of 1. LH Deck
large machines will vary. Some of these steps may 2. RH Deck/Grid Box
change due to different shipping configurations and/ 3. Operator Cab
or truck options.
LEVEL 5
1. Exhaust Pipes
LEVEL 1 2. Weld Uprights
1. Chassis - Unload and crib for assembly. 3. Blower - Air Intake Ductwork
2. Auxiliary Control Cabinet (temporary) 4. Wheel Motors
3. Deck Support (on horsecollar over suspension).
LEVEL 6
NOTE: It is easier to install and weld the deck
supports before the front suspensions are installed. 1. Front Tires
However, do not install the deck supports first, unless 2. Rear Tires
there is a suitable means of installing the suspension 3. Hoist Cylinders
with the deck support in place.
4. Rear Suspension LEVEL 7
5. Hydraulic Tank 1. Clearance Lights
6. Fuel Tank 2. Body Pads/Shims/Guides
7. Front Suspensions 3. Front Mud Flaps
8. Diagonal Ladder
9. Uprights/Air Cleaners LEVEL 8
10. Diagonal Support Beams (leave loose until left 1. Dump Body Installation
deck is bolted in place)
LEVEL 9
NOTE: Do not weld the air cleaner / uprights until all 1. Hoist Cylinders
decks and the operator cab are installed. Ratchet 2. Rock Ejectors
hoists may be required to help tie all the structures
3. Rear Mud Flaps
together for a proper fit.
LEVEL 2
1. Air Cleaner Piping
2. Center Deck
3. Control Cabinet
4. Auxiliary Control Cabinet
Page 6-2 Chassis Assembly 7/10 FAM0615

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

ponents will be required to be lifted into place and
1. System Checkouts secured.
2. Exhaust Blankets
3. Clean Assembly Rear
4. Touch Up Paint
5. Train Operators
6. Optional - Install Fire Suppression System
• Inspect all lifting devices. Slings, chains, and
cables used for lifting components must be
inspected daily for serviceable condition.
Refer to the manufacturer’s guidelines for
correct capacities and safety procedures
when lifting components. Replace any
questionable items.
• Slings, chains and cables used for lifting
must be rated for approximately two times the
intended load.
• When in doubt as to the weight of
components or any assembly procedure,
contact your customer support manager for
further information.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the
intended load.
• Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
positioning a suspended load.
• Before lifting, ensure there is adequate
clearance from overhead structures or
electric power lines.

GENERAL PRECAUTIONS AND
INSTRUCTION
1. Clean and remove all foreign material from
component mounting surfaces.
Disconnect the battery cables before welding on 2. Mount the front suspensions first so that deck
the truck. Failure to do so may seriously damage substructures can be installed while other com-
the batteries and electrical equipment. Discon- ponents are installed.
nect the battery charging alternator lead wire 3. DO NOT weld the front uprights until all upper
before welding on the frame or its components. decks are installed.
Fasten the welding machine ground cable to the 4. Install the fuel return hose on the rearward most
component being welded. fitting on the fuel tank.
DO NOT allow welding current to pass through 5. Torque the deck mounting bolts before the
bearings. exhaust tubes, etc. are installed.
DO NOT lay welding cables over truck electrical 6. Verify all electrical connectors are free from
cables and harnesses. Welding voltages could be paint and/or corrosion. Clean any connector
induced into the truck wiring and cause damage that may be questionable.
to components. 7. Do not torque the diagonal ROPS beam until
after the operator cab and LH air intake tubes
DO NOT weld on the fuel tank or the hydraulic
are in place.
tank unless they have been properly purged and
ventilated. 8. Before installing the cab to the substructure, tap
all threaded holes to remove paint.
Maintain fire control equipment. Inspect fire
9. Verify all wiring is properly connected before
extinguishers regularly to ensure they are fully
attempting to start the engine.
charged and in good working condition.
10. Recheck the torque on hardware installed at the
factory.
HARDWARE TIGHTENING METHOD 11. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.
12. Steering accumulators are normally not charged
with nitrogen when shipped from the factory.
Use proper precautions when checking the
Mark cap screws and nuts with paint or ink nitrogen pressure and oil level in the cylinder.
before tightening to the specified torque. This
13. Brake accumulators are normally charged with
method provides verification that the hardware
nitrogen when shipped from the factory. Use
has been properly tightened.
proper precautions when checking pressures.
14. Verify the lube system is lubricated, purged and
1. Snug down all of the hardware with an impact all levels full prior to start up.
wrench or appropriate ratchet.
15. Purge air from the steering pump before truck
2. Apply a paint mark down the side of the hard- operation. Pressure will not build in the brake
ware and onto the component surface. Make and steering circuit if air is present. Air in the
sure that all of the hardware that is being tight- system may damage the pump. Refer to the
ened is marked. Hydraulic Checkout Procedure in Section 10 of
3. Apply the specified torque to all of the marked this manual.
hardware. 16. Use the battery disconnect switch when arc
All of the marks should now be offset, showing welding. Connect the weld ground near the
that the hardware has been properly tightened. weld area.

Hydraulic fluid escaping under pressure can
To help prevent contamination that may lead to
have sufficient force to enter a person's body by
premature pump failures, flush the hydraulic sys-
penetrating the skin and cause serious injury,
tem before the initial truck start-up.
and possibly death, if proper medical treatment
by a physician familiar with this type of injury is
17. Before the truck is started for the first time, the not received immediately.
hydraulic system must be flushed. Refer to the
following hydraulic system flushing procedure. Before disconnecting pressure lines, removing
fittings or replacing components in the hydraulic
circuits, or installing test gauges, ALWAYS bleed
down the steering and brake accumulators.
HYDRAULIC SYSTEM FLUSHING
PROCEDURE NOTE: The hoist cylinder bypass blocks should be
saved for possible use later in case the hydraulic
When a new truck is assembled and the engine is system needs to be flushed after a component
started for the very first time, the hydraulic system failure.
must be flushed immediately to remove contamina-
1. If the tires are installed on the truck, chock the
tion that may have been introduced during the field
left and right rear wheels securely on both sides
assembly process. DO NOT start the engine unless
to prevent truck movement. If the truck is sitting
all flushing equipment is installed and ready for use.
on cribbing, ensure it is secure enough to allow
The flushing procedure will help eliminate harmful
safe operation of the engine and clearance for
contamination that may lead to premature pump or
turning the front spindles lock to lock without
valve failures. Starting the engine just one time with-
risk of collapsing the cribbing.
out performing the flushing procedure may contami-
nate the hydraulic system. 2. Inspect all hydraulic hoses to ensure that they
are properly routed and securely connected.
Special hydraulic system flushing tools for the 930E
3. Connect a laptop PC to the interface module.
truck have been released. Hoist system bypass
Start the Interface Realtime Data Monitor pro-
blocks (PC3074) and steering system flushing hose
gram.
(XB5777) must be on-site before or during field
assembly, so when the truck is started for the first 4. Ensure that both brake accumulators and both
time, the hydraulic system can be flushed and any steering accumulators are properly precharged
debris can be removed from the hydraulic system. with nitrogen to 9 650 kPa (1,400 psi). Refer to
Fitting assembly (XB7075) shown as (3, Figure 6-7) the shop manual for the accumulator charging
will also be required. procedure.
5. Confirm that the steering pressure is released
All flushing hoses must be rated to withstand 27 580
by turning the steering wheel. No steering
kPa (4,000 psi) pressure. The hoses must be 1 inch
movement should occur.
inside diameter and meet SAE 100R12 specifica-
tions. 6. If any fault codes are displayed, troubleshoot
the system and repair the problem before pro-
ceeding.
Table 1: XB5777 HOSE ASSEMBLY
Part
Number Qty Description
HA2185 1 Hose
WB0546 1 Fitting, Elbow - 45 Deg
WB0599 1 Fitting, Straight Adapter

7. Install accurate pressure gauges at the follow-
ing locations:
• Pressure test port “TP3” (4, Figure 6-1) on the
bleed down manifold - 35 000 kPa (5,000 psi).
• Pressure test port (1, Figure 6-2) for the front
brake cooling circuit - 3 450 kPa (500 psi).
• Pressure test ports (2, Figure 6-2) on both high
pressure hoist filters - 24 000 kPa (3,500 psi).
• Pressure test port (1, Figure 6-3) for the rear
brake cooling circuits - 3 450 kPa (500 psi).
• Pressure test port “GPA” (2, Figure 6-4) located
on the steering pump - 35 000 kPa (5,000 psi).
If any hydraulic pressure is detected on the pres-

sure gauge installed at TP3, there is residual oil
pressure in the system. Do not loosen or remove
any hydraulic hoses, fittings or components. The
steering accumulators have not been properly
depressurized. Locate and correct the depressur-
ization problem. Always relieve all hydraulic
pressure before disconnecting any hydraulic
lines or fittings. Always tighten all connections
securely before applying pressure. Confirm that
the steering pressure is released by turning the
steering wheel. No steering movement should
occur.
FIGURE 6-1. BLEED DOWN MANIFOLD
1. Plug - QD Supply Port 4. Test Port (TP3)
8. Ensure pressure gauge connected at "TP3" 2. Plug - QD Return Port 5. Test Port (TP2)
reads 0 kPa (0 psi) before removing plugs (1 & 3. Bleed Down Manifold
2, Figure 6-1). Remove plugs (1 & 2) from the
bleed down manifold. Connect jumper hose
assembly (XB5777) between "QD supply" port
and the "QD return" port on the bleed down
manifold. Tighten all connections securely
before applying pressure.
9. Connect the four hoist cylinder hoses (3, Figure
6-2) together as shown using bypass blocks (4).
The hardware for connecting the hoses to the
blocks is the same hardware for connecting the
hoses to the hoist cylinders. Ensure that all of
the connections are secure. Cover all open
ports to prevent contamination.

10. At the rear axle housing, connect brake cooling
lines (1, 2 & 3, Figure 6-5) together using fitting
assembly (3, Figure 6-6). Cap the three open
fittings on the axle housing with clean caps.
Several hose clamps may have to be removed
to connect the three hoses to the fitting assem-
bly.
11. At the left front brake assembly, connect cooling
hoses (1 & 3, Figure 6-7) together using
adapter (2). Cap the open fittings on the brake
assembly. At the right front brake assembly,
connect the two cooling hoses together using
another adapter. Cap the open fittings on the
brake assembly.
NOTE: The adapters are installed on the truck when
it is shipped from the factory.
FIGURE 6-3. BRAKE COOLING MANIFOLD

1. Test Port (Rear Brake Cooling Pressure)
2. Test Port (Front Brake Supply Pressure)
3. Test Port (Front Brake Return Pressure)
4. Test Port (Hoist Return Pressure)
5. Test Port (Rear Brake Return Pressure)
FIGURE 6-2. TEST PORT LOCATIONS AND

HOIST FLUSHING HOOKUP
1. Test Port (Front Brake Cooling Circuit)

2. Test Port (Hoist Filters)
3. Hoist Cylinder Hoses
4. Bypass Blocks (PC3074)

12. The steering pump case must be filled with oil
before startup to avoid pump damage. Discon-
nect the hose that is connected to fitting (1, Fig-
ure 6-4). Then remove fitting (1). Fill the
steering pump case with clean type C-4 hydrau-
lic oil through the case drain port. It may require
up to 2.9 liters (3 quarts) of oil. Re-install fitting
(1) and reconnect the hose.
NOTE: Filling the steering pump case with oil does
not eliminate the need to bleed air from the pump
suction line.
FIGURE 6-5. REAR AXLE BRAKE LINES

1. BS - Left & Right Brake Cooling Oil Supply
2. LBR - Left Brake Cooling Return Line
3. RBR - Right Brake Cooling Return Line
FIGURE 6-4. STEERING PUMP & HOIST SYSTEM

QUICK DISCONNECTS
1. Fitting (Pump Case Drain)
2. Test Port (GPA) FIGURE 6-6. FITTING ASSEMBLY
1. 90° Swivel Elbow (PC3062)

2. T-Fitting (WB0426)
3. Fitting Assembly (XB7075)

Do not apply the brakes or turn the steering
wheel at any time during this procedure until
Step 33.
17. Ensure both brake accumulator bleed down
valves (1, Figure 6-8) are open.
18. Move the hoist control lever to the FLOAT posi-
tion.
19. Turn the key switch ON but do not start the
engine. Verify that the low steering accumulator
FIGURE 6-7. FRONT WHEEL BRAKE LINES precharge warning is not displayed. If the warn-
1. Cooling Hose 3. Cooling Hose ing is displayed, correct the problem before pro-
2. Adapter (EG1794) 4. Brake Apply Hose ceeding.
13. Fully open all hydraulic shutoff valves in the

pump suction lines. The valves are fully open
when the valve handle is in-line with the hose.
Serious pump damage will occur if any shutoff

valve is not fully open when the engine is started.
FIGURE 6-8. BRAKE MANIFOLD
14. Fill the hydraulic tank with clean type C-4
hydraulic oil. Ensure that the oil level is visible in 1. Accumulator Bleed Down Valves
the center of the upper sight glass. 2. Brake Manifold
15. To bleed trapped air from inside the pump suc-
tion hoses, loosen the cap screws where the
three suction hoses attach to the inlet of each
pump. Ensure that the O-ring does not fall out of
the groove. After oil appears, retighten the cap
screws to the standard torque.
16. Check the hydraulic tank oil level. If necessary,
add oil.

20. Start the engine and operate at low idle. Within 22. If all pump pressures and brake cooling oil sup-
30 seconds after starting the engine, check the ply pressures are correct as stated in Steps 20
two oil pressures listed below. If the oil pressure and 21, increase engine speed to 1500 rpm and
readings are not correct, stop the engine. flush the system for 20 minutes. During this
Locate and repair the problem before proceed- time, move the hoist control lever to the
ing. If the pressure readings are correct, pro- POWER UP position for 30 seconds, and then
ceed to the next step. Do not turn the steering move it to the POWER DOWN position for 30
wheel or apply the brakes at this time. seconds. Repeat this hoist control cycle five
times. This process will carry any system con-
• With the engine at low idle, and the oil temp at
taminants to the hydraulic filters.
21° C (70° F), oil pressure at the hoist filters
should be approximately 552 kPa (80 psi) or less. Monitor the pressure gauges at the front and
• Oil pressure at steering pump test port "GPA" rear brake cooling test ports during this step.
should be approximately 690 kPa (100 psi). The pressure readings should always be 0 kPa
(0 psi) when the hoist valve is in the POWER
UP or POWER DOWN positions, and approxi-
mately 345 kPa (50 psi) while in the HOLD or
FLOAT positions.
23. When the 20 minute flushing process is com-
Do not operate the engine at low idle for more
plete, turn the key switch to the OFF position
than 30 seconds. The steering pump pressure at
and allow at least two minutes after the engine
test port "GPA" must be at or above 1 725 kPa
has stopped for the steering accumulators to
(250 psi) during the flushing process to provide
completely depressurize.
adequate internal pump lubrication. Steering
pump damage will result if the pressure is below 24. Remove the adapters from both front wheel
1 725 kPa (250 psi) for more than 30 seconds. brake cooling hoses and re-connect the cooling
hoses to the front brake assemblies.
21. If the oil pressure readings in Step 20 are cor- 25. Remove the tee fitting assembly from the three
rect, increase the engine speed to obtain oil rear brake cooling hoses. Re-connect the three
pressure at test port "GPA" of 1 725 kPa (250 rear brake cooling hoses to the axle housing.
psi). Move the hoist control lever to the POWER 26. Check the pressure gauge connected to the
UP or to the POWER DOWN position. The "TP3" port on the bleed down manifold. If any
pressure readings at the front brake cooling port pressure is still in the system, the bleed down
(1, Figure 6-2) and rear brake cooling test port process did not complete. Locate and repair the
(1, Figure 6-3) should be 0 kPa (0 psi). If the problem. If the pressure is 0 kPa (0 psi), remove
pressure is not 0 kPa (0 psi), the hoist valve pip- the jumper hose and fittings installed in the
ing (or pilot lines) may be connected incorrectly, bleed down manifold. Install the two plugs (1 &
or the hoist valve could be defective. Correct 2, Figure 6-1) previously removed back into the
the plumbing problem or replace the hoist valve bleed down manifold.
and repeat this step.
add oil.
28. Close both brake accumulator bleed down
valves (1, Figure 6-8).

NOTE: Do not combine Step 29 with any other steps. 31. If Step 30-b results are satisfactory, open both
Do not apply the brakes or steer the truck during brake accumulator bleed down valves (1, Fig-
Step 29. ure 6-8) on the brake manifold to completely
depressurize the brake accumulators. After all
29. To flush the accumulators, start the engine and
hydraulic pressure has been released, close
operate the engine until the pressure at the
both accumulator bleed down valves. Repeat
"TP3" port on the bleed down manifold is
Steps 29 - 31 five times.
approximately 21 200 kPa (3,075 psi). This is
the pressure where the steering pump unloader 32. To flush the steering system, start the engine.
valve shifts and unloads the pump. Allow the accumulators to fully charge and the
steering pump to unload.
• If the accumulator pressure exceeds 21 546 kPa
(3,125 psi), immediately turn the engine off and 33. Turn the steering wheel full left and then full
open the brake accumulator bleed down valves. right ten times.
Refer to Steering pump pressure control
adjustments in the shop manual, then repeat 34. Turn the key switch to the OFF position. Allow at
Step 29. least two minutes after the engine has stopped
for the steering accumulators to completely
• If the accumulator pressure does not reach depressurize. The pressure gauge at the bleed
20 856 kPa (3,025 psi), check for faults on the down manifold pressure test port "TP3" will be
Interface Realtime Data Monitor program. If there
103 kPa (15 psi) or less after a successful bleed
is a bleed down fault active, locate and correct
the problem. If no faults are active, refer to down.
Steering pump pressure control adjustments in 35. The hydraulic system flushing procedure has
the shop manual, then repeat Step 29. been completed. All hydraulic system high pres-
30. When the pressure gauge connected to "TP3" sure filter elements must be replaced.
reads approximately 21 200 kPa (3,075 psi): a. Close both hoist pump suction line shutoff
a. For the first time only through this step: valves and the steering pump suction line
shutoff valve.
• Leave the key switch in the ON position,
and use the engine shut down switch on b. Remove the hoist and steering hydraulic fil-
the center console to stop the engine. ter elements. Clean the housings and install
new filter elements.
• After the engine has stopped, confirm that
steering accumulator bleed down does not c. Open both hoist pump suction line shutoff
occur, and that no bleed down faults or valves and the steering pump suction line
any other faults are displayed on the shutoff valve.
Interface Realtime Data Monitor.
36. Remove all pressure gauges and re-install the
b. The second and subsequent times through
dust caps on all quick disconnect fittings.
this step:
• Turn the key switch to the OFF position. add oil.
Confirm that after the engine has stopped
that the steering accumulator bleed down 38. Proceed to the steering and brake system
process begins. checkout procedures in the Field Assembly
Manual.
• Confirm that accumulator bleed down
completes within two minutes. Also 39. After the steering and brake system checkout
confirm that bleed down fault A236 procedures are completed, remove hoist cylin-
"Steering bleed fault" or any other bleed der bypass blocks (4, Figure 6-2) and connect
down fault does not become active. The the hoist cylinder hoses to the hoist cylinders.
pressure gauge at the bleed down Ensure the hoses and ports are clean to pre-
manifold pressure test port "TP3" will be
vent contamination.
103 kPa (15 psi) or less after a successful
bleed down. NOTE: Do not to extend the hoist cylinders until the
body is installed.

FIGURE 6-9.
1. Lift the chassis off the truck/trailer (Figure 6-9) or rail car using two cranes with a minimum capacity of 50 tons
each.
FIGURE 6-10.
2. Place the chassis on adequate support blocks in a level position. The weight of the chassis, as shipped, is
approximately 60 382 kg (133,000 lbs).The support blocks must be approximately 84 cm (33 in.) high at the
front, and approximately 30 cm (12 in.) high under the rear axle housing (Figure 6-10). Placement of the chas-
sis at this height will allow easy installation of the truck components.
3. Thoroughly clean the chassis.

DO NOT mix components from different trucks. Components such as deck supports are marked with the
serial number of the corresponding truck unit. Only use components of the unit number that is being
assembled.
FIGURE 6-11.
4. Lift the LH deck support into position. The weight of the LH deck support is approximately 654 kg (1442 lbs).
Bolt the support into place. Do not weld the support at this time.
Refer to Figure 6-11.

FIGURE 6-12.
5. Lift the LH upright into position and install the four cap screws. Tighten to 465 ± 47 N·m (343 ± 34 ft lb). The
weight of the LH upright with air cleaners is approximately 930 kg (2,050 lb).
NOTE: DO NOT weld the torque tubes on the uprights until the decks are installed.

FIGURE 6-13.
6. Lift the LH diagonal beam into position and install the capscrews loosely. The weight of the beam is approxi-
mately 135 kg (298 lb).
NOTE: Do not tighten the cap screws until the deck and the cab are in place.

FIGURE 6-14. DETERMINING CAB FIT
1. Cab 3. LH Diagonal Beam

2. Deck Support 4. Left Upright
7. Lift the cab onto the deck supports and install the mounting hardware. Verify no gaps exist between the
mounting pads of the cab. If gaps are present, the upright and/or deck support may need to be repositioned.
8. Tighten the cap screws that secure the LH diagonal beam.

FIGURE 6-15.
9. Tack weld the LH deck support.
If the tapped pads are not removed, a complete weld around the support can not be achieved. The gaps in
the weld around the support may result in premature frame cracking in this area.
10. Remove the four tapped pads on each support and the corresponding blocks on the horsecollar to allow for a
complete weld around the joint.
11. Remove the plate and backer strip from the back of the LH deck support (see inset in Figure 6-16). Install the
backer strip at the end of the deck support. Install the plate at the end of the deck support.
12. Weld completely around the support without leaving any gaps. Finish welding around the plate.
13. Grind all areas, and clean. Paint after welding is complete.
Refer to Figures 6-16 through 6-19.
14. Lift the RH deck support into position. The weight of the RH deck support is approximately 273 kg (602 lb).
Bolt the support into place.
15. Repeat Steps 9 through 13 for the RH deck support.

FIGURE 6-16.
FIGURE 6-17.

FIGURE 6-18.
FIGURE 6-19.

FIGURE 6-20.
16. Weld the LH upright to the front frame tube according to the drawing specifications provided with the truck.
17. Remove the cab after welding is complete. Continue with the assembly process.

Rear Suspension Installation
18. Secure rear suspension assembly (1, Figure 6-21) to a fork lift and raise it into position. The suspension
assembly should be retracted as far as possible before installation.
19. Position the top suspension eye between the ears on the frame. Orient the cylinder so that the charging valve
faces the opposite suspension cylinder.
20. Lubricate all pin-to-bearing and pin-to-sleeve contact surfaces with anti-seize compound. Lubricating the pin
surfaces aids in removal and installation, as well as prevention of rust and corrosion.
21. Align the hole in pin (5) with the hole in the mounting bore. Drive in the pin far enough so that the pin does not
fall out.
22. Insert bearing spacer (7) over the pin. Continue to drive the pin through spherical bearing (9). When the pin
emerges, insert the remaining bearing spacer over the pin on the opposite side and continue to drive the pin
until the hole in the axle housing is aligned with the hole in the pin.
23. Install shoulder bolt (2), then install washer (3) and nut (4). If further alignment of the holes is necessary,
install a pin removal tool onto the pin. Use the tool and a large pipe wrench or other suitable device to align
the holes. Tighten the nut to 68 N·m (50 ft lb).
24. Adjust the piston rod height until the lower suspension eye is aligned with the bore in the rear axle housing.
Repeat the above procedure to install the bottom pin. Mounting components in the top and bottom joints are
identical.
FIGURE 6-21. REAR SUSPENSION CYLINDER PIN INSTALLATION

1. Suspension Cylinder 5. Pin 9. Bearing
2. Shoulder Bolt 6. Sleeve 10.Capscrew
3. Flat Washer 7. Spacer 11.Lockwasher
4. Locknut 8. Retaining Ring

FIGURE 6-22.
25. Clean the mounts for the fuel tank.
26. Lift the tank into position (Figure 6-22). The weight of the fuel tank is approximately 2 056 kg (4,533 lb).
a. Install the mounting caps, washers and cap screws at the top of the fuel tank. Do not tighten the cap
screws at this time.
b. Install the rubber dampeners, flat washers and cap screws in the lower mounts at the rear of the fuel tank.
Tighten the cap screws to 420 ± 42 N·m (310 ± 31 ft lb).
c. Tighten the cap screws at the top of the fuel tank to 711 ± 72 N·m (525 ± 53 ft lb).

FIGURE 6-23.
27. Clean the mounts for the hydraulic tank.
28. Lift the tank into position. Refer to Figure 6-23. The weight of the hydraulic tank is approximately 590 kg
(1,300 lb).
a. Install the four mounting cap screws near the top of the tank. Tighten to 622 ± 62 N·m (459 ± 46 ft lb).
b. Install the two mounting cap screws near the bottom of the tank. Tighten to 800 ± 80 N·m (590 ± 59 ft lb).

FIGURE 6-24.
29. Connect the piping to the hydraulic tank and properly tighten all fittings. Refer to Figure 6-24.
FIGURE 6-25.
30. Install the fuel tank quick fill box at the bottom of the hydraulic tank. Refer to Figure 6-25
NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened. The valves
are open when the handles are parallel with the hoses.

FIGURE 6-26.
31. Install the two hoist filters onto the bracket at the inner side of the fuel tank. Connect the fuel supply and return
lines to the fuel tank.

32. Raise the hoist cylinder into position over the pivot point on the frame. The weight of each hoist cylinder is
approximately 969 kg (2,137 lb). Position the cylinder with the air bleed vent plug on top, and facing the front
of the truck. Refer to Figure 6-27.
33. Install spacer (6, Figure 6-28). Align the bearing eye with the pivot point and push the cylinder into place.
34. Install retaining plate (3), locking plate (2), and cap screws (1). Tighten the cap screws to 298 N·m (220 ft lb).
Bend the locking plate tabs over the cap screw flats.
FIGURE 6-27.
FIGURE 6-28.
1. Cap Screw 4. Retainer Ring

2. Locking Plate 5. Bearing
3. Retaining Plate 6. Spacer

Front Suspension Installation
FIGURE 6-29.
FIGURE 6-30.
35. Remove all paint, rust, dirt and foreign debris from the suspension mounting surfaces. Refer to Figures 6-29
and 6-30.
36. 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 isopropyl alcohol, acetone or lacquer thinner.
37. Inspect the suspension and frame mounting surfaces for damage or wear. Check for the following criteria:
Flatness of each surface must be within 0.25 mm (0.010 in.).
Surface finish must not exceed 0.635 µm (250 µ in.) roughness average (RA), medium tool cut.
If measurements are not within specifications, contact your Komatsu customer service manager for further
instructions.
38. Clean and dry all suspension mounting hardware. Use the same cleaning agent that was used to clean the
mounting surfaces.

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.
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 dam-
age. Only use the approved lubricant specified below.
39. Lubricate the cap screw threads, cap screw head seats, washer faces and nut seats with 5% molybdenum-
disulphide grease.
40. Identify and separate the hardware according to location on the suspension. Refer to Figure 6-31.
FIGURE 6-31.
1. Cap Screw - 1 1/2" - 6NC x 6 1/2" (G8)

2. Flat Washer - 1 1/2" (G8)
3. Nut - 1 1/2" - 6NC (G8)
4. Cap Screw - 1 3/4" - 5NC x 14 1/2" (G8)
5. Flat Washer - 1 3/4" (G8)
6. Nut - 1 3/4" - 5NC (G8)
7. Spacer
8. Shear Key
9. Part Of Frame

41. Lift the front suspension into position on the frame.
The weight of each front suspension cylinder is
approximately 2795 kg (6162 lb). Refer to Figure 6-
32.
FIGURE 6-32.

42. Install the mounting hardware and the shear key.
Install the shear key flush with the side face of the
suspension. Refer to Figure 6-33.
a. Install one washer under each cap screw head

and one washer under each nut (where applica-
ble).
b. Initially tighten the hardware to 1356 ± 136 N·m

(1000 ± 100 lb ft) in the sequence shown in Fig-
ure 6-34. Use a properly calibrated torque
wrench to ensure accuracy.
NOTE: Do not exceed 4 rpm tightening speed. Do not
hammer or jerk the wrench while tightening.
FIGURE 6-33.
c. The mounting cap screws will now need to be

loosened and then tightened using angle-
advance. The first set of cap screws to be
adjusted will be at the upper mounting joint. The
cap screws must be loosened one at time and
then tightened by advancing a specified rotational
degree. Use the map shown in Figure 6-34 for
proper tightening sequence.
FIGURE 6-34.

Upper Mounting Joint - 60° Advance
The proper sequence for the upper mounting joint is 1-2-3-4-9-10. Refer to Figure 6-34.
43. Loosen the first cap screw. All other cap screws must be maintained at 1356 ± 136 N·m (1000 ± 100 lb ft).
44. Tighten the cap screw to 95 N·m (70 lb ft).
NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening.
45. Mark a corner of the cap screw head with a paint

marker as shown in Figure 6-35. Draw a reference
line on the suspension surface next to the marked
corner on the cap screw. Draw a reference line on the
suspension 60 degrees in advance of the marked
corner on the cap screw.
46. Advance the cap screw to the 60° advance mark.

Hold the nut at the rear of the joint stationary while
tightening.
FIGURE 6-35.
47. Make new reference lines along the cap screw, nut
and frame at the rear of the joint as shown in Figure
6-36. These reference lines will be used to verify the
cap screws have maintained their torque.
48. Repeat this process in sequence for the remaining

cap screws in the upper mounting joint.
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, again, must be cleaned and
lubricated before repeating.
FIGURE 6-36.

Lower Mounting Joint - 120° Advance
The proper sequence for the lower mounting joint is 5-6-7-8-11-12-13-14. Refer to Figure 6-34.
49. Loosen the first cap screw. All other cap screws must remain tightened.
50. Tighten the cap screw to the specified torque:

Cap screws 5-6-7-8 . . . . . . 136 N·m (100 lb ft)
Cap screws 11-12-13-1 . . . 4271 N·m (200 lb ft)
NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening.
51. Mark a corner of the cap screw head with a paint

marker as shown in Figure 6-37. Draw a reference
line on the suspension surface (or frame) next to the
marked corner on the cap screw. Draw a reference
line on the suspension surface (or frame) 120 degrees
in advance of the marked corner on the cap screw.
52. Advance the cap screw to the 120° advance mark.

Hold the nut at the rear of the joint (where applicable)
stationary while tightening. FIGURE 6-37.
53. Make new reference lines along the cap screw, nut
and frame at the rear of the joint as shown in Figure
6-36. For the four cap screws with spacers, refer to
Figure 6-38. These reference lines will be used to ver-
ify the cap screws have maintained their torque.
54. Repeat this process in sequence for the remaining

cap screws in the lower mounting joint.
NOTE: If for any reason these fasteners need to be FIGURE 6-38.

checked for tightness after completing this procedure,
loosen and inspect all 14 cap screws and repeat the entire
process. The hardware, again, must be cleaned and
lubricated before repeating.

FIGURE 6-39.
55. 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).
56. Lift the spindle/brake assembly into position. The weight of each spindle/brake assembly is approximately
4 803 kg (10,589 lb). Refer to Figure 6-39.
NOTE: A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the
assembly for easier mounting to the suspension.

FIGURE 6-40.
57. Lift the retainer plates to the bottom of each suspension using blocks and a hydraulic jack. Refer to Figure 6-
40.

FIGURE 6-41.
58. Lubricate the 14 cap screws on the threads and seats with lithium based chassis grease (multi-purpose, EP
NLGI).
59. Install the cap screws. Evenly tighten the cap screws to 678 N·m (500 ft lb). Continue to tighten the cap
screws in increments of 339 N·m (250 ft lb) until the final torque of 2 705 ± 135 N·m (1,995 ± 100 ft lb) is
reached. Refer to Figure 6-41.
60. After installation is complete, connect the brake piping to each brake.

FIGURE 6-42.
61. Connect the steering cylinders and the tie rod to the steering arms. Refer to Figure 6-42.
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.

FIGURE 6-43.
62. Install the diagonal ladder. The weight of the diagonal ladder is approximately 180 kg (397 lb). Refer to Figure
6-43.
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-44.
63. Lift the RH upright into position and install the four cap screws. Tighten to 465 ± 47 N·m (343 ± 34 ft lb). The
weight of the RH upright with air cleaners is approximately 810 kg (1,785 lb). Refer to Figure 6-44.
NOTE: DO NOT weld the torque tubes on the uprights until the decks are installed.

FIGURE 6-45.
64. If installed, remove the center deck to enable easier installation of the air intake tubing and the two diagonal
beams. The weight of the center deck is approximately 250 kg (551 lb).
65. Lift the RH diagonal beam into position. The weight of the beam is 68 kg (150 lb). Refer to Figure 6-45.
NOTE: Do not tighten the cap screws until the decks are in place.

FIGURE 6-46.
66. Lift the air intake tubes and hump hoses into place. Install and tighten the clamps that secure the hoses. Refer
to Figure 6-46.

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

FIGURE 6-48.
68. Install the handrails and lift the LH deck into place. The weight of the LH deck with handrails is approximately
720 kg (1587 lb). Loosely install the eight cap screws. Refer to Figure 6-48.

FIGURE 6-49.
69. Lift the retarding grid into place on the RH deck. The weight of the grid is approximately 2 742 kg (6,045 lb).
Tighten the eight cap screws to the standard torque.
70. Install the handrails on the RH deck. Lift the RH deck into position and loosely install the six cap screws. The
weight of the deck/retarding grid assembly is approximately 3 830 kg (8,444 lb). Refer to Figure 6-49.
71. After all decking is in place, tighten the cap screws on each deck to 465 ± 47 N·m (343 ± 34 ft lb).

FIGURE 6-50.
72. Lift the operator cab into position. The weight of the cab is approximately 2 725 kg (6,008 lb). Refer to Figure
6-50.
73. Remove any paint from the cab mounting holes.
74. Determine if shims are required at each mounting pad. The gap between the cab and the ROPS support must
not exceed 1 mm (0.04 in.). Install shims at each mounting pad as required.

FIGURE 6-51.
75. Install and tighten the 32 cap screws to 800 ± 80 N·m (590 ± 59 ft lb). Refer to Figure 6-51.

FIGURE 6-52.
76. Lift the electrical control cabinet into position. The weight of the cabinet is approximately 3 175 kg (7,000 lb).
Install the mounting hardware and shims. Tighten the 10 cap screws to 1 600 ± 160 N·m (1,180 ± 118 ft lb).
77. Tighten the hardware for the diagnonal beams. For the RH beam, tighten the 12 cap screws to 240 ± 24 N·m
(177 ± 17 ft lb). For the LH beam, tighten the 16 cap screws to 800 ± 80 N·m (590 ± 59 ft lb). Refer to Figures
6-13 and 6-45.

FIGURE 6-53.
78. Weld the RH upright to the front frame tube. Refer to Figure 6-53.

FIGURE 6-54.
79. Lift the two bumper extensions into place. Tighten the cap screws to standard torque. Refer to Figure 6-55.

FIGURE 6-55.
80. Install any remaining handrails. Tighten the cap screws to standard torque.

81. Connect the wiring for the electrical control cabinet, auxiliary control cabinet, and retarding grid box.
NOTE: The auxiliary control cabinet may be shipped with the external wiring already connected.
82. Install the air intake ductwork and tighten the connecting hardware. Refer to Figures 6-56 through 6-62.
The weight of the alternator blower inlet duct

is approximately 337 kg (743 lb).
The weight of the alternator blower inlet duct

is approximately 200 kg (441 lb).
FIGURE 6-56.
FIGURE 6-57.

FIGURE 6-58.
FIGURE 6-59.

FIGURE 6-60.
FIGURE 6-61.

FIGURE 6-62.

FIGURE 6-63.
83. Install the parking brake adapter, retainer plate, hardened flat washer and capscrew. Tighten the capscrew to
595 - 670 N·m (400 - 495 ft lb). Refer to Figure 6-63.

FIGURE 6-64.
84. Attach a lifting device to the parking brake assembly and lift into position. Refer to Figure 6-64.
85. Use a port-a-power to release spring pressure and allow the alignment of the brake discs during installation.
86. Seat the parking brake assembly against the housing and install the eight cap screws and washers. Tighten to
standard torque.

Wheel Motor Installation
87. Thoroughly clean the cap screw holes and the mounting faces of the rear axle housing and wheel motor.
88. Inspect the cap screw holes in the rear axle housing for damage. Re-tap any holes that have damaged
threads. Thoroughly clean any cap screw holes that have been re-tapped.
89. Check the mounting faces of the rear axle housing and the wheel motor for surface defects (nicks, scratches,
etc). Repair any defects before installing the wheel motor.
90. Check the flatness of both mounting faces of the rear axle housing. Check the flatness at four equally spaced
intervals (for example, 0°, 45°, 90° and 135°).
The maximum allowable variation in flatness is 2.29 mm (0.09 in.). Do not use a rear axle housing that does
not meet this specification.
91. Apply a lithium based grease to the threaded cap screw holes in the rear axle housing.
92. Install two guide pins 180° apart (3 o’clock and 9 o’clock positions) in the rear axle housing.
Each complete wheel motor assembly weighs approximately 18 132 kg (39,975 lb). Ensure that the lifting
devices are capable of handling the load safely.
93. Lift the wheel motor into position on the rear axle housing. Ensure that all cables and hoses are clear before
installation. Refer to Figure 6-65.
If the brake system hoses are installed, guide them through the spindle holes during installation.
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 6-65.

The wheel motors must be properly aligned before installing them onto the rear axle housing. The wheel
motor has markings which help determine installation orientation. Two sets of dimples are located at the 3
o’clock and 9 o’clock positions. A centerline symbol marks the 12 o’clock position of the wheel motor.
The axle housing also contains dimples at the 3 o’clock and 9 o’clock positions next to the wheel motor
mounting rings. Refer to Figure 6-67.
When installing the wheel motors, make sure that the markings on both components line up. The top cap
screw hole on the rear axle housing may also be determined by counting the holes in between the two sets
of punch marks. The top hole on the rear axle housing should line up with the “CL” stamping on the wheel
motor.

FIGURE 6-66. WHEEL MOTOR DIMPLE MARKINGS
Punch Marks
FIGURE 6-67. REAR AXLE HOUSING DIMPLE MARKINGS

High tightening force is required to install the cap screws that secure the wheel motors to the rear axle
housing. Repeated tightening will result in cap screw fatigue and damage.
Do not reuse any wheel motor mounting hardware (cap screws and hardened washers). Replace the
hardware after one use.
Do not retighten any wheel motor mounting cap screw that has loosened after the truck has been placed
into operation. If any wheel motor mounting cap screw has loosened during truck operation, all of the cap
screws and hardened washers must be replaced with new hardware.
The cap screws that are used to secure the wheel motors to the rear axle housing are specially hardened
to meet or exceed Grade 8 specifications. Replace these cap screws with only new cap screws of the
correct hardness. Refer to the appropriate parts book for the correct part number.
The use of dry threads in this application is not recommended. Due to the high tightening force that is
required to install the wheel motor mounting cap screws, dry threads may cause damage to tools, cap
screws or the rear axle housing.
Komatsu does not recommend the use of special friction-reducing lubricants, such as Copper Coat,
Never-Seez® or 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 during
the tightening process. If a special friction-reducing lubricant is used, excessive stress and possible
breakage of the fasteners may result.
94. Select the hardware to be installed in Group 1 of the tightening sequence. Refer to Figure 6-69.
95. Inspect each cap screw for rust, corrosion and surface defects on any seat or thread. Do not use any cap
screw if a defect is suspected.
96. Lubricate the cap screw threads, cap screw head seats and washer faces with a lithium based grease con-
taining 5% molybdenum-disulphide.
NOTE: The special hardened washers that are used in this

application may have a punch lip on one side due to the
manufacturing process. When placing this washer under
the cap screw head, the washers must be installed with the
punch lip facing away from the cap screw head to prevent
damage to the fillet between the cap screw head and the
shank. Refer to Figure 6-68.
FIGURE 6-68. INSTALLATION OF HARDENED

WASHER
1. Washer 2. Cap Screw

97. Install the hardware for Group 1. Tighten each cap screw to 542 N•m (400 ft lb).
98. Repeat steps 94 - 96 for each remaining group in the tightening sequence. Refer to Figure 6-69.
Install and tighten all of the hardware in a group before proceeding to the next group in the tightening
sequence. Remove the guide pins that were installed in step 92 when installing the hardware for Groups 3
and 4.
99. After all of the hardware in all of the groups has been installed and tightened to 542 N•m (400 ft lb), move
back to Group 1. Increase the torque on each cap screw in Group 1 to 2 006 N•m (1,480 ft lb). Repeat this
step for each remaining group in the tightening sequence. Refer to Figure 6-69.
FIGURE 6-69. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

100. Connect the power cables and the speed sensors to each of the wheel motors. Connect the brake apply
lines, brake cooling supply lines and return lines to each wheel. Refer to Figures 6-70 through 6-73.
FIGURE 6-70.
FIGURE 6-71.

FIGURE 6-72.
FIGURE 6-73.

Front Wheel Installation
NOTE: Remove all dirt and rust from mating parts before installing the tire and rim assembly.
101. Grip the tire and rim assembly with the tire handler. Align the tire inflation hose and the wheel hub. Position
the rim onto the wheel hub studs. Refer to Figure 6-74.
102. Lubricate all stud threads and nut seating flanges with lithium base grease. Refer to Figure 6-75. Install and
tighten the nuts in the following sequence:
a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten each nut to 2 326 ±
136 N·m (1,715 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.
Tighten the nuts to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
c. Install three nuts directly above the 3 o'clock position and three nuts directly below the 9 o'clock position.
Tighten these nuts to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
d. Install the remaining nuts and tighten in a clockwise pattern to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2 326 ± 136 N·m (1,715 ± 100 ft lb).
After the truck has been assembled and is operational, the truck must be operated for a short period of
time, and the torque on the wheels re-checked. Tighten the wheels to the specified torque.

FIGURE 6-74.
FIGURE 6-75.

Rear Wheel Installation
FIGURE 6-76. REAR WHEEL ASSEMBLY

1. Wheel Motor 5. Wheel Hub 10. Flanged Nut 14. Bracket
Mounting Flange 6. Flanged Nut 11. Flanged Nut 15. Outer Wheel Rim
2. Inner Wheel Rim 7. Inner Extension 12. Wheel Motor
3. Disc Brake Assembly 8. Clamps Transmission
4. Extension 9. Adapter Ring 13. Extension
NOTE: Clean all mating surfaces and check the stud threads before installing the wheels.
103. Bleed the disc brakes before installing the rear tires. Refer to Section J of the shop manual for brake bleed-
ing procedures.
104. Grip the inner tire and rim with the tire handler and lift the wheel onto the wheel hub. Refer to Figures 6-77
and 6-78. Align extension (4, Figure 6-76) for mating with inner extension (7).
105. Lubricate all stud threads and nut seating flanges with a lithium base grease. Install and tighten the nuts in
the following sequence:
a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten to 2 326 ± 136 N·m
(1,715 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.
Tighten to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
c. Install three nuts directly above the 3 o'clock position and three nuts directly below the 9 o'clock position.
Tighten to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
d. Install the remaining nuts in a clockwise pattern. Tighten to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2 326 ± 136 N·m (1,715 ± 100 ft lb).
106. Install inner extension (7, Figure 6-76) and clamps (8) before installing the outer tires.

FIGURE 6-77.
FIGURE 6-78.

DO NOT move the truck without the rear, outer tires installed. Serious mechanical damage to the wheel
motor hub and torque tube may result. The adapter rings and outer dual tires must be installed. The
mounting cap screws must be tightened to 2 325 N·m (1,715 ft lb).
107. Position the rim adaptors into place on each outer rim. Install the fifty flanged nuts and tighten the nuts to
2 325 ± 136 N·m (1,715 ± 100 ft lb). Refer to Rear Wheel Installation for the correct tightening sequence.
Install the outer tires and tighten the fifty nuts to 2 325 ± 136 N·m (1,715 ± 100 ft lb). Refer to Rear Wheel
Installation for the correct tightening sequence. Refer to Figure 6-79.
After the truck has been assembled and is operational, the truck must be operated for a short period of
time, and the torque on the wheels re-checked. Tighten the wheels to the torque specified above.
108. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-80.

FIGURE 6-79.
FIGURE 6-80.

109. Install the front LH and RH mud flaps on the underside of each deck.
110. Weld both rear LH and RH mud flap brackets into place on the backside of the deck supports.
Install the mud flaps.
Refer to Figures 6-81 and 6-82.
The truck is now ready for body installation.

FIGURE 6-81.
FIGURE 6-82.

NOTES

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

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

manufactured. Match the shipping numbers sten-
ciled on the body sections to mate the correct
parts. DO NOT mix components.
FIGURE 7-1. BODY PARTS NOMENCLATURE

1. Canopy 4. Lift Hole 7. LH Side Sheet
2. Front Sheet 5. Floor
3. RH Side Sheet 6. Pivot
FAM0703 Dump Body Assembly 7-1

BODY ASSEMBLY
NOTE: References to LH and RH in the following

procedures assume the body is in its' normal, upright
position, as shown in Figure 7-1.
1. Organize the body sections in a large, flat,
open space. Position the sections side by side
and upside down. Arrange the sections so they
are properly oriented for assembly. Refer to
Figure 7-2 for domestic configuration, and 7-3
for international configuration.
FIGURE 7-4.
5. Use the hydraulic jack to align the body halves
at the rear. Install cap screw (1, Figure 7-5) and
the sleeve.
NOTE: Figure 7-5 shows the hardware numbered in
installation sequence. Cap screws (1, 2 & 7) are
marked with an asterisk (*). These cap screws are
installed with sleeves. The remainder of the cap
screws do not have sleeves.
6. Install cap screw (2) and the sleeve at the front
FIGURE 7-2. DOMESTIC LAYOUT of the floor.
7. Install cap screw (3) in the front sheet near the
floor. Attach a wedge or a clamp inside the
body as necessary to align the front sheet.
8. Use a wedge to align the front sheet and can-
opy. Install cap screws (4, 5 & 6).
9. Install cap screw (7) and the sleeve in the front
of the canopy.
10. Install cap screws (8 & 9).
11. Install the backer strips on the front sheet center
joint as shown on the assembly drawing.
NOTE: The backer strips must be tack welded in a
location where the tack will be burned away on the
FIGURE 7-3. INTERNATIONAL LAYOUT first pass.
12. Loosely install cap screws (10 & 11) in the floor.
13. Loosen cap screws (1 & 2).
2. Remove the paint from the weld areas. 14. Attach appropriate lifting apparatus to the body
3. Lift the RH body half and support the front pivot. Insert the lifting apparatus through the
sheet, side sheets, and rear edge of the floor body pin bores. The weight of the pivot is
with blocks. Refer to Figure 7-4. approximately 1492 kg (3289 lb). DO NOT dam-
4. Lift the LH body and support with blocks under age the bores.
the front sheet and side sheet. Position a 15. Lift the pivot over the body. Lower the pivot into
hydraulic jack on blocks at the tail end to sup- position against the rear of the body, as shown
port the floor at the rear. Refer to Figure 7-5. in Figure 7-6. Align the pivot with the body sills.
7-2 Dump Body Assembly FAM0703

NOTE: Figures 7-5 & 7-6 illustrate a domestic configuration with the canopy attached to the body halves. The
canopy for international bodies is shipped as a separate piece. Do not attach the international canopy at this
time
FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE
FIGURE 7-6. BODY PIVOT INSTALLATION

16. If necessary, use a hydraulic jack or crane to BODY WELDING
raise the center of the body to allow the pivot to
fit inside the bolsters. Loosely install the cap Follow the guidelines listed below when welding the
screws in the pivot. body:
17. If assembling an international body (three- • Use dry weld rod or weld wire.
piece), lift the canopy into position at this time.
• Weld surfaces must be dry and above 10°C
Install the canopy cap screws and tighten.
(50°F).
18. Tighten all floor, front sheet, and canopy cap
• If stick electrode is used, use as large a diameter
screws. Use a chalk line to align the front of the rod as practical to weld the floor and front sheet
canopy. joints.
19. Tighten the pivot cap screws. • The following sequence must be followed for the
20. Install the filler plates and backer strips for the front sheet:
pivot to body sill weld joints. First Pass: Back step and skip weld in 10
21. Check the alignment and fit of all components increments along the entire length of the joint.
22. Tack weld the joints.
Repeat the same procedure until the entire joint
is filled. DO NOT stop welding until entire joint is
complete.
• The body floor “V” groove must also be welded
using the same procedure as the front sheet.
Weld from the front to the rear. Refer to Figure 7-
7.
FIGURE 7-7. FRONT SHEET & FLOOR JOINT

WELDING SEQUENCE
1. Complete the welds at the center seam, the

front sheet and the canopy. Refer to the assem-
bly drawings for welding requirements.
2. Remove the canopy alignment blocks.

3. Install the remaining gussets, the body guide
and the body pad mounts. Refer to Figures 7-8
through 7-11.
DO NOT install the heated body exhaust boxes

onto the body at this time. The exhaust boxes
must be installed after the body is installed onto
the truck.
FIGURE 7-10.
FIGURE 7-8.
FIGURE 7-11.
4. Once the body underside is completed, the

body can be turned over. Use two cranes to
invert the body, a 45 metric ton (50 ton) crane
and a 109-136 metric ton (120-150 ton) crane.
The following photographs show a typical
example of a body being inverted with two
cranes.
Position the body onto support blocks as shown
FIGURE 7-9. in Figure 7-18.

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

5. Refer to Figure 7-7 and the body assembly
print to complete the welds on the inside of the
body.
FIGURE 7-17.
FIGURE 7-19.
FIGURE 7-18.
FIGURE 7-20.

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

FINAL ASSEMBLY
• Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected
daily for serviceable condition. Refer to the manufacturer’s guidelines for correct capacities and safety
procedures when lifting components. Replace any questionable items.
• Slings, chains and cables used for lifting must be rated for approximately two times the intended load.
• When in doubt as to the weight of components or any assembly procedure, contact your customer
support manager for further information.
• Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load.
• Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a
suspended load.
• Before lifting the body, ensure there is adequate clearance between the body and overhead structures
or electric power lines.
FAM0811 6/10 Final Assembly Page 8-1

FIGURE 8-1.
1. Body welding and chassis assembly must be completed before proceeding.

Before the body is lifted off the ground, tie guy ropes to each of the four corners of the body for aiding in instal-
lation.
There are two methods of installing the body depending on the cranes available.
a. If the truck is operational and can be driven, two 50 ton cranes can be used, one positioned at either side
of the body. The body can then be lifted high enough to allow the truck to be reverse propelled under the
body. Refer to Figures 8-1, 8-2 and 8-3.
b. If a large crane of approximately 150 ton is available, the body can be lifted over the chassis and installed
in a similar fashion to that in Step a.
Page 8-2 Final Assembly 6/10 FAM0811

FIGURE 8-2.
FIGURE 8-3.

2. Install shims (8, Figure 8-5) in both body pivots, as required, to fill the outside gaps and center the body on the
frame pivot.
NOTE: Do not install shims on the inside. A minimum of one shim is required at the outside end of both frame
pivots.
3. Align the hole in body pivot pin (4) with the bolt hole in the pin retainer on the outer body pivot ear. Push the
body pivot pin through the outer body pivot ear, the frame pivot, and the inner body pivot ear.
4. Install shoulder bolt (1) through the body pivot pin. Install flat washer (2) and nut (2). Tighten the nut to 339
N•m (250 ft lb).

FIGURE 8-4.
FIGURE 8-5. DUMP BODY PIVOT PIN

1. Shoulder Bolt 4. Body Pivot Pin 7. Pivot Bushing
2. Flat Washer 5. Pivot Bushing 8. Shim
3. Nut 6. Body Pivot Ear 9. Body Pivot Bushing

5. Align the hoist cylinder bearing eye with the bore of hoist cylinder upper mounting bracket (1, Figure 8-7).
6. Align the bolt hole in pivot pin (3) with the bolt hole in mounting bracket (1). Install the pivot pin through the
first spacer (2), then align the second spacer with the bore on the other side of hoist cylinder bearing eye.
Finish installing the pin through second spacer (2).
7. Install shoulder bolt (4) through each pin.

NOTE: Do not use a flat washer under the head of the shoulder bolt. This will ensure that the shoulder bolt does
not run out of threads when tightening.
8. Install flat washer (5) and nut (6) onto the threaded end of each shoulder bolt. Tighten the nuts to 339 N·m
(250 ft lb).

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

1. Mounting Bracket 3. Pivot Pin 5. Flat Washer
2. Spacer 4. Shoulder Bolt 6. Nut

FIGURE 8-8.
10. Shim the body pads as required. All pads, except the two rear pads, should contact the frame with approxi-
mately equal compression of the rubber. Refer to Figures 8-8 and 8-9.
A gap of approximately 1.5 mm (0.06 in.) is required at each rear pad. This can be accomplished by using one
less shim at each rear pad.
11. Inspect pad contact. If pad contact appears to be unequal, correct as necessary.
NOTE: Proper body pad to frame contact is required for maximum pad life.

FIGURE 8-9. BODY PAD INSTALLATION
1. Dump Body 3. Shim
2. Body Pad 4. Mounting Hardware

FIGURE 8-10.
10. Tack weld rock ejector mounting brackets into position on the underside of the body. Refer to Figure 8-11.
The ejectors must be positioned on the center line between the rear tires within 6.0 mm (0.25 in.). Before
welding, drop a plumb line to check rock ejector clearance. Position the rock ejector a distance of 455 mm
(17.9 in.) from the wheel housing. Refer to Figure 8-12.
NOTE: With rock ejector arm (1) hanging vertical as shown in Figure 8-12, there must be no gap at stop block (3,
Figure 8-11).
If the rock ejector arms are bent during operation, they must be removed and straightened. Inspect mount-
ing brackets (4, Figure 8-11), pins (2) and stops (3) at each shift change for wear and/or damage. Repair as
necessary.

FIGURE 8-11. ROCK EJECTOR MOUNTING
1. Rock Ejector Arm 3. Stop Block
2. Pin 4. Mounting Bracket
FIGURE 8-12. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 2. Wheel Housing

FIGURE 8-13.
FIGURE 8-14.

FIGURE 8-15.
11. Install the remaining axle housing air ducts and hatch cover. Refer to Figures 8-13, 8-14 and 8-15.

FIGURE 8-16.
FIGURE 8-17.
12. Install the mud flaps onto the body and chassis. Refer to Figures 8-16 and 8-17.

NOTES

FIGURE 8-18.
13. Install both body guide brackets loosely into place. Refer to Figure 8-18.
Once in position, slowly lower the body and mark the position in which the brackets are to be welded. The
body guides must be centered between wear plates (3, Figure 8-19), with a maximum gap of 4.8 mm (0.19
in.) at each side.
14. With the body in its lowered position on the frame rail, the position of body up limit switch actuator arm (4, Fig-
ure 8-20) can be marked on the underside of the body. Refer to the assembly prints for precise positioning
specifications.
Raise the body enough to be able to weld the mounting pad to the underside of the body.
Before welding, install support blocks between the body and the frame.
15. Raise the body and install the body up sling. Remove the support blocks.
16. Weld the body guide brackets into place. Refer to Figures 8-18 and 8-19.

FIGURE 8-19. BODY GUIDE FIGURE 8-20. BODY-UP SWITCH INSTALLATION
1. Dump Body 3. Body Guide Wear 1. Switch Mounting Bracket 4. Actuator Arm
2. Body Guide Plates 2. Adjustment Cap Screws 5. Adjustment Screws
3. Proximity Switch

FIGURE 8-21.
FIGURE 8-22.
17. If the truck is to be equipped with a heated body, install the exhaust box at the pivot and tighten the hardware
(Refer to Figures 8-21 and 8-22.

FIGURE 8-23.
18. If the truck is to be equipped with mufflers, install them at this time. Refer to Figure 8-23.

FIGURE 8-24.
19. With the body in the raised position, set the body hoist limit switch and weld the target into position. Refer to
Figure 8-24.
The switch should activate 152 mm (6 in.) before maximum cylinder stroke. Refer to the assembly prints for
specifications.

FIGURE 8-25.
20. With the body in the raised position, install the grease lines for the hoist cylinders and clamp along the inside
of the body. Refer to Figure 8-25.

FIGURE 8-26.
21. Install the exhaust tubing blankets. Refer to Figure 8-26.

FIGURE 8-27.
22. Install the LH and RH engine bay lights. Refer to Figure 8-27.

FIGURE 8-28.
23. Install add-on components such as the lubrication system and the oil reserve system. Verify that all electrical
and hydraulic connections are correct. Refer to Figure 8-28 and 8-29.

FIGURE 8-29.

FIGURE 8-30.
FIGURE 8-31.

FIGURE 8-32.
24. Install the fire suppression system. Refer to Figures 8-30, 8-31 and 8-32.
NOTE: This installation is normally performed by the fire system distributor.
25. Paint the truck as needed.

FIGURE 8-33.
26. Install the anti-skid strips at the designated areas on the decks. Refer to Figure 8-33.

FIGURE 8-34.
27. Install all decals on their designated areas. Refer to the installation drawing for all decal locations.
28. After completing the assembly of the truck:

a. Verify that all cap screw heads or nuts are marked with paint, indicating they have been properly tightened.
b. Check all hydraulic lines and electrical connections for secure installation.
c. Notify qualified maintenance personnel that the truck is ready for final static and dynamic systems check-
out.

FIGURE 8-35.
FIGURE 8-36.

FINAL CHECKOUT
Final checkout requires truck operation. 5. Perform a final check of all systems and prepare
for operation. Several checks and tasks are out-
Place the operation and maintenance manual and
lined in Section 10, Appendix.
safety manuals in the operator cab, if not already there.
6. Complete the checks listed in the Field Assembly
Any personnel involved in the final check-out of the Inspection Report Form. A copy of the form is pro-
truck must read and understand all safety and operat- vided with the truck and is also available in Sec-
ing instructions in the operation and maintenance man- tion 10, Appendix.
ual.
7. Operate the truck in a traffic-free area until safe
operation has been validated.
1. Complete delivery and warranty forms. 8. Release the truck for use after all checks have
been completed and all deficiencies corrected.
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 on the hydraulic tank
suction lines are open.
4. Purge any air from the pumps and suction lines.
Pressure will not build if air is present. Operating
the pumps with air in the system will result in dam-
age. Refer to the truck assembly section for more
information on how to bleed the air from the
pumps and suction lines.
FAM0903 3/09 Final Checkout Page 9-1

NOTES
Page 9-2 Final Checkout 3/09 FAM0903

APPENDIX
This chapter contains additional information and procedures for aiding in field assembly of the truck. Refer to the
list below for contents of this chapter. Refer to the latest service manual for additional information on servicing the
truck.
1. Lubrication Chart - WB2790
2. Suspension Oiling And Charging Procedure
3. Toe-In Adjustment Procedure
4. Automatic Lubrication System Checkout Procedure - EJ4060
5. Air Conditioning Checkout Procedure - EL4302
6. Air Conditioning Drive Belt Adjustment Procedure - EL9330
7. Hydraulic Checkout Procedure - EM7604
8. Brake Checkout Procedure - EM7346
9. VHMS Checkout Procedure - EM2129
10. Payload Meter III Checkout Procedure - EJ3061
11. Electrical Checkout Procedure - EF9650
12. Amendments To Electrical Checkout Procedure - EM8300
13. Standard Torque Charts and Coversion Tables
14. Field Assembly Inspection Report
15. 50 Hour Post-Commissioning Checksheet
FAM1015 7/10 Appendix Page 10-1

NOTES
Page 10-2 Appendix 7/10 FAM1015

LUBRICATION CHART
NOTES
SUSPENSION OILING AND CHARGING PROCEDURE
GENERAL EQUIPMENT LIST
These procedures cover the oiling and charging of • Hydrair Charging Kit
Hydrair® II suspensions on Komatsu 930E dump • Jacks and/or Overhead Crane
trucks.
• Support Blocks for:
Suspensions which have been properly charged will Oiling Height Dimensions (Front and Rear)
provide improved handling and ride characteristics Charging Height Dimensions (Front Only)
while also extending the fatigue life of the truck frame
• Hydrair Oil (See Specifications Chart)
and improving tire wear.
• Friction Modifier (See Specifications Chart)
NOTE: Inflation pressures and exposed piston
lengths are calculated for a normal truck gross • Dry Nitrogen (See Specifications Chart)
vehicle weight (GVW). Additions to truck weight by
adding body liners, tailgates, water tanks, etc. should Installation of Charging Kit
be considered part of the payload. Keeping the truck Assemble the charging kit as shown in Figure 4-1
GVW within the specification shown on the Grade/ and attach it to a container of pure dry nitrogen (8).
Speed Retard chart in the operator cab will extend
1. Remove the protective covers and charging
the service life of the truck main frame and allow the
valve caps from the suspensions.
Hydrair II suspensions to produce a comfortable ride.
2. Turn "T" handles (1, Figure 4-1) of adapters (2)
completely counterclockwise.
All Hydrair II suspensions are charged with

compressed nitrogen gas with sufficient
pressure to cause injury and/or damage if
improperly handled. Follow all safety
instructions, cautions, and warnings provided in
the following procedures to prevent any
accidents during oiling and charging.
Proper charging of Hydrair II suspensions requires

that three basic conditions be established in the
following order:
1. Oil level must be correct.
2. Suspension piston rod extension for nitrogen
charging must be correct.
3. Nitrogen charge pressure must be correct.
For best results, Hydrair II suspensions should be
FIGURE 4-1. HYDRAIR CHARGING KIT
charged in pairs (fronts together and rears together).
If rear suspensions are to be charged, the front NOTE: The arrangement of parts may vary from
suspensions should be charged first. the illustration depending on the kit part number.
NOTE: For longer life of suspension components, a
1. “T” Handle Valve
friction modifier should be added to the suspension
2. Charging Valve Adapter
oil. See the Specifications Charts at the end of this
3. Manifold Outlet Valves (from gauge)
section.
4. Inlet Valve (from regulator)
NOTE: Setup dimensions in the Specifications 5. Regulator Valve (Nitrogen Pressure)
Charts must be maintained during oiling and 6. Manifold
charging procedures. However, after the truck has 7. Charging Pressure Gauge (Suspensions)
been operated, these dimensions may vary. 8. Dry Nitrogen Gas Container
3. Ensure outlet valves (3) and inlet valve (4) are Support Blocks For Oiling And Charging
closed (turned completely clockwise). Dimensions
4. Turn swivel nut (small hex) on the charging Before starting the oiling and charging procedures,
valve three full turns counterclockwise to unseat supports should be fabricated to maintain the correct
the valve. exposed piston rod extensions.
5. Attach charging valve adapters (2) to each
suspension charging valve stem.
6. Turn "T" handles (1) clockwise. This will
depress core of charging valve and open the
gas chamber of the suspension. Nitrogen charging support blocks for the rear
7. Open both outlet valves (3). suspension are no longer necessary. However,
oiling blocks are necessary to properly set the
NOTE: By selective opening and closing of outlet
oiling height.
valves (3), and inlet valve (4), suspensions may be
charged separately or together. Exposed piston rod extensions are specified for both
oil level and nitrogen charging for Hydrair II
Removal of Charging Kit suspensions. These dimensions are listed in the
1. Close both outlet valves (3). tables below Figures 4-2 and 4-5. Measure the
dimensions from the face of the cylinder gland to the
2. Turn "T" handles (1) counterclockwise to
machined surface on the spindle at the front
release the charging valve cores.
suspension. At the rear suspension, measure from
3. Remove charging valve adapters (2) from the the face of the cylinder gland to the piston flange.
charging valves.
Support blocks may be made in various forms. Mild
4. Tighten the swivel nut (small hex) on the
steel materials are recommended. Square stock or
charging valve. If a new charging valve is being
pipe segments at least 25 mm (1 in.) may be used.
used, tighten the swivel nut to 15 N·m (11 ft lb),
Blocks must be capable of supporting the weight of
then loosen and retighten the swivel nut to 15
the truck during oiling and charging procedures while
N·m (11 ft lb). Loosen the swivel nut again and
avoiding contact with plated surfaces and seals on
retighten to 6 N·m (50 in. lb). Install the valve
the suspension. Refer to Figure 4-2 for front
cap finger-tight.
suspension support block placement and Figure 4-4
5. Install the charging valve caps and protective for rear support block placement.
covers on both suspensions.
FRONT SUSPENSION 2. Remove the charging valve cap. Turn the
charging valve swivel nut (small hex)
counterclockwise three full turns to unseat the
valve seal. DO NOT turn the large hex. The
charging valve body has a bleeder groove in its
mounting threads, but for safety of all
All Hydrair II suspensions are charged with
personnel, the valve body must not be loosened
compressed nitrogen gas with sufficient
until all nitrogen pressure has been released
pressure to cause injury and/or damage if
from the suspension.
improperly handled. Follow all the safety notes,
cautions and warnings in these procedures to 3. Depress the charging valve core to release
prevent accidents during servicing and charging. nitrogen pressure from the suspension. When
all nitrogen has been released, the suspension
1. Park the unloaded truck on a hard, level should have collapsed slowly and be seated
surface. Apply the parking brake and chock the solidly on the support blocks. Remove the top
wheels. fill plug next to the charging valve (Figure 4-2).
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the
protective covers from the charging valves.
Front Suspension Oiling
When blocks are in place on a suspension, they

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

blocks are secure before relieving nitrogen
pressure from the suspension. Wear a face mask
or goggles while relieving nitrogen pressure.
NOTE: For longer life of suspension components, a
friction modifier should be added to the suspension FIGURE 4-2. FRONT SUSPENSION
oil. See the Specifications Charts at the end of this
section.
1. Position and secure oiling height dimension
blocks in place (Figure 4-2). The blocks should FRONT SUSPENSION DIMENSIONS (EMPTY)
be positioned 180 degrees apart to provide
OILING HEIGHT CHARGING HEIGHT *CHARGING PRESSURE
stability. When nitrogen pressure is released,
the suspensions will lower and rest on the 25.4 mm 299 mm 2930 kPa
blocks. Ensure that the blocks do not mar or (1.0 in.) (9.0 in.) (425 psi)
scratch the plated surfaces of the pistons or * with standard Rock Body
damage wiper seals in the lower bearing Note: If the truck starts to lift off the blocks before charging
pressure is attained, STOP CHARGING.
retainer. Support blocks must seat on the
spindle and the cylinder housing.
4. Fill the suspension with clean Hydrair oil (with
6% friction modifier) until the cylinder is full to
the top of the fill plug bore. Use drip pans and
clean all spillage from the outside of the
suspension. Allow the suspension to settle for
Dry nitrogen is the only gas approved for use in
at least 15 minutes to clear any trapped
Hydrair II suspensions. Charging of these
nitrogen and bubbles from the oil. Add more
components with oxygen or other gases may
suspension oil if necessary. Install a new O-ring
result in an explosion which could cause
on the fill plug and install the plug.
fatalities, serious injuries and/or major property
Front Suspension Nitrogen Charging damage. Use only nitrogen gas meeting the
specifications shown in the Specifications Chart
at the end of this section.
3. Install the Hydrair charging kit and a bottle of
pure dry nitrogen. Refer to Installation of
Charging Kit in this section.
Lifting equipment (crane or hydraulic jacks) must
be of sufficient capacity to lift the truck weight. 4. Charge the suspensions with nitrogen gas to
Be certain that all personnel are clear of the lift 50.8 mm (2 in.) greater than the charging height
area before the lift is started. Clearances under listed in Figure 4-2. Close inlet valve (4, Figure
the truck may be suddenly reduced. 4-1).
5. Remove the oiling blocks from the suspensions
1. If removed, install the charging valve with new
and install the nitrogen charging blocks. Secure
O-ring (9, Figure 4-3). Lubricate the O-ring with
the blocks to prevent accidental dislodging.
clean Hydrair oil.
2. Tighten valve body (6) (large hex) to 23 N·m (17 NOTE: Use caution to prevent damage to plated
ft lb). Swivel nut (4) (small hex) must be cylinder surfaces and oil seals when installing the
unseated by turning it counterclockwise three blocks.
full turns. 6. Remove the center hose from manifold (6).
7. Open inlet valve (4) until the pressure drops
below the pressure listed in Figure 4-2, then
close the valve.
8. Install the center hose to manifold (6).
9. Charge the suspensions to the pressure listed
in Figure 4-2. DO NOT use an overcharge of
nitrogen to lift the suspensions off the charging
blocks.
10. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes to allow the
pressures in the suspensions to equalize.
11. Close outlet valves (3). Remove the charging kit
components. Refer to Removal of Charging Kit
in this section.
12. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 6 N·m (50 in. lb).
FIGURE 4-3. CHARGING VALVE 13. If a new charging valve is being used, tighten
the swivel nut to 15 N·m (11 ft lb)), then loosen
1. Valve Cap 6. Valve Body and retighten the swivel nut to 15 N·m (11 ft
2. Seal 7. O-Ring lb)). Loosen the swivel nut again and retighten
3. Valve Core 8. Valve Stem to 6 N·m (50 in. lb). Install the valve cap finger-
4. Swivel Nut 9. O-Ring tight.
5. Rubber Washer 14. Install the protective guard over the charging
valve.
15. Raise the truck body in order to extend the front NOTE: For longer life of suspension components, a
suspensions, allowing for removal of the friction modifier should be added to the suspension
nitrogen charging blocks. Ensure that sufficient oil. See the Specifications Charts at the end of this
overhead clearance exists before raising the section.
body. If the suspensions do not extend after 1. Position and secure the oiling blocks in place
raising the body, turn the steering wheel from so the blocks are seated between the frame
stop to stop several times. If the suspensions and the rear axle housing (Figure 4-4). A block
still do not extend enough to allow for removal should be used on both the left and right sides
of the blocks, use a crane or floor jacks to raise of the truck.
the truck and remove the blocks.
The front Hydrair suspensions are now ready for
operation. Visually check piston extension with the
truck both empty and loaded. Record the extension
dimensions. Maximum downward travel is indicated
by the dirt ring at the base of the piston. Operator
comments on steering response and suspension
rebound should also be noted.
REAR SUSPENSION
1. Park the unloaded truck on a hard, level
surface. Apply the parking brake, and chock the
wheels.
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the
protective covers from the charging valves and
the rubber covers from the suspension piston.
Rear Suspension Oiling
FIGURE 4-4. OILING BLOCK INSTALLATION
1. Main Frame 3. Rear Axle Housing

When blocks are in place on a suspension, they 2. Oiling Support Block
must be secured with a strap or other means to
avoid accidental discharge. An unsecured block
could fly loose as weight is applied, presenting 2. Remove charging valve cap. Turn the charging
the possibility of serious injury to nearby valve swivel nut (small hex) counterclockwise
personnel and/or damage to the equipment. three full turns to unseat the valve seal. DO
Overhead clearance may be reduced rapidly and NOT turn the large hex. The charging valve
suddenly when nitrogen pressure is released. body has a bleeder groove in its mounting
threads, but for safety of all personnel, the valve
body must not be loosened until all nitrogen
pressure has been released from the
suspension.
Make certain all personnel are clear and support

blocks are secure before relieving nitrogen
pressure from the suspension. Wear a face mask
or goggles while relieving nitrogen pressure.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
all nitrogen pressure has been released, loosen
and remove the fill plug. The suspension should
have collapsed slowly as gas pressure was
released. The weight of the truck is now
supported by the support blocks.
NOTE: A plastic tube can be used to help bleed off
trapped air inside the piston.
4. Remove the vent plug, pressure sensor, and
charging valve (Figure 4-5). Use one of the
open ports to fill the suspension with clean
Hydrair oil (with 6% friction modifier). Fill until
clean oil seaps from the open ports. Use drip
pans and clean all spillage from the outside of
the suspension. Allow the suspension to settle
for at least 15 minutes to clear any trapped
nitrogen and bubbles from the oil. Add more
suspension oil if necessary.
5. Install the vent plug and pressure sensor onto
the suspension.
6. Install a new O-ring onto the charging valve.
Lubricate the O-ring with clean Hydrair oil.
7. Install the charging valve onto the suspension.
Tighten valve body (6, Figure 4-3) to 23 N·m
(17 ft lb).
FIGURE 4-5. REAR SUSPENSION

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

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

(2.1 in.) (8.6 in.) (188 psi)
* Note: Charging pressures are for reference only and may vary depending on
body weights.
Rear Suspension Nitrogen Charging 7. Ensure that both of the suspension cylinders
are extended the same distance ± 10 mm (0.39
in.). If the difference in the extension from side
to side exceeds this amount, check the front
suspensions for equal extension. Adjust the
front suspensions as necessary.
Lifting equipment (overhead or mobile cranes, or
hydraulic jacks) must be of sufficient capacity to NOTE: A low left front suspension will cause the right
lift the truck weight. Ensure that all personnel are rear suspension to be high. A low right front
clear of lift area before lifting is started. suspension will cause the left rear suspension to be
Clearances under the truck may be suddenly high.
reduced. 8. Close outlet valves (3). Remove the charging kit
components. Refer to Removal of Charging Kit
in this section.
9. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 6 N·m (50 in. lb).
Ensure that the automatic apply circuit has not
applied the service brakes during truck 10. If a new charging valve is being used, tighten
maintenance. If the front brakes are applied the swivel nut to 15 N·m (11 ft lb), then loosen
during rear suspension charging, the axle cannot and retighten the swivel nut to 15 N·m (11 ft lb).
pivot for frame raising/lowering, and the rear Loosen the swivel nut again and retighten to 6
suspension may be unable to move up or down. N·m (50 in. lb). Install the valve cap finger-tight.
1. If removed, install charging valve with new O- 11. Install the protective guards over the charging
ring (9, Figure 4-3). Lubricate the O-ring with valves. Install the rubber covers over the piston
clean Hydrair oil. rods.
2. Tighten valve body (6) (large hex) to 23 N·m (17 The rear Hydrair suspensions are now ready for
ft lb). Swivel nut (4) (small hex) must be operation. Visually check piston extension with the
unseated by turning it counterclockwise three truck both empty and loaded. Record the extension
full turns. dimensions. Maximum downward travel is indicated
by the dirt ring at the base of the piston. Operator
comments on steering response and suspension
rebound should also be noted.
Dry nitrogen is the only gas approved for use in

Hydrair II suspensions. Charging of these
components with oxygen or other gases may
result in an explosion which could cause
fatalities, serious injuries and/or major property
damage. Use only nitrogen gas meeting the
specifications shown in the Specifications Chart
at the end of this section.
3. Install Hydrair charging kit and a bottle of pure
dry nitrogen. Refer to Installation of Charging
Kit in this section.
4. Charge the suspensions with nitrogen gas to 38
mm (1.5 in.) greater than the charging height
listed in Figure 4-5.
5. Slowly release gas until the suspensions match
the charging height listed in Figure 4-5.
6. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes to allow the
pressures in the suspensions to equalize.
OIL AND NITROGEN SPECIFICATIONS CHARTS
HYDRAIR® II OIL SPECIFICATIONS

Ambient Temperature Part No. Approved Sources
Range
VJ3911 Mobil 424 Sunfleet TH Universal Tractor Fluid
(need to add Mobil D.T.E. 15 Chevron Tractor Hydraulic Fluid
6% of Texaco TDH Oil Conoco Power Tran III Fluid Petro
-30°F & above AK3761) AMOCO ULTIMATE Motor Oil Canada Duratran Fluid
(-34.5°C & above) 5W-30 Shell Canada Donax TDL
AK4063 Suspension Oil (premixed with 5 Gallon container
AK4064 6% Friction Modifier) 55 Gallon container
VJ5925 Emery 2811, SG-CD, Petro Canada Super Arctic Motor
(need to add 5W-30 Oil, 0W-30
6% of Mobil Delvac I, 5W-30 Conoco High Performance
-55°F & above AK3761) Synthetic Motor Oil, 5W-30
(-48.5°C & above) AK4065 Suspension Oil (premixed with 5 Gallon container
AK4066 6% Friction Modifier) 55 Gallon container
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and VJ5925
oils are supplied in 5 gallon (19 Liter) cans.
FRICTION MODIFIER FRICTION MODIFIER Mixing Instructions

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

Property Value
Nitrogen gas used inHYDRAIR® II Nitrogen 99.9% Minimum
Suspension Cylinders must meet or
Water 32 PPM Maximum
exceed CGA specification G-10.1 for
Type 1, Grade F Nitrogen Gas Dew Point -68°F (-55°C) Maximum
Oxygen 0.1% Maximum
TOE-IN ADJUSTMENT
1. The steering system must first be centered in
the straight ahead position. Turn the key switch
OFF. Allow at least 90 seconds for the accumu-
lators to depressurize. DO NOT turn the steer-
ing wheel during this time.
2. Block the front and back of the rear wheels.
3. Check the toe-in by measuring the distance
between the centers of the front tires. Obtain
the measurements on the horizontal centerline
at the front and rear of the tires. Refer to Figure
3-1.
Radial tires must have equal measurements at
the front and the rear of the tires. Equal mea-
surements results in zero toe-in.
4. Loosen the clamp locknuts on the tie rod.
Rotate the tie rod as necessary to obtain the
correct toe-in setting of zero toe-in..
5. When the adjustment is complete, tighten the
locknuts on the tie rod to 420 ± 42 N•m (310 ±
31 ft lbs).
6. Remove the blocks from the rear wheels.
930E TOE-IN DATA

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

NOTES
KOMATSU CHECKOUT PROCEDURE
IEJ4060-2
Page 1 of 2
NAME: MACHINE & MODEL:

Auto Lube Grease Procedure Electric Trucks
WRITTEN BY: DATE:
B. Anderson 7-4-00
CHECKED BY: DATE:
2 Change Note -nt 9/16/04 1\<...014- BA 114M
1 'Note some pumps, etc. 3/24/04 111518 BA MM
M. McMullen 7-7-00
APPROVED BY: DATE: 0
DASH DESCRIPTION OF CHANGE DATE ECN BY CK'D
ASIZE MICROFILM
I I I I I I I I I I I I I I I I I I I I
THE FOllOWING PROCEDURE MUST BE DONE ON INITIAL START-UP FOR THE LINCOLN
INDUSTRIAL ROTARY HYDRAULIC GREASE PUMP WITH ADJUSTABLE CONTROLS.
1. Check adjustment of pressure regular valve which should be set at 325 to 350 psi. (note this valve is parallel to pump motor and is suppose
to be factory set @ 350 psi).
2. Flow control valve should be set so a cycle would take 18 seconds to complete. (note this valve is perpendicular to pump motor).
LINCOLN INDUSTRIAL ROTARY HYDRAULIC GREASE PUMP WITH FIXED PUMP

CONTROLS NO ADJUSTMENT CAN BE MADE.
I. Observe gauge during cycle 325 psi minimum pressure should be obtained.
2. Flow control valve should be set so a cycle would take 16 to 20 secondsto complete.
THE FOllOWING PROCEDURES MUST BE DONE IN ORDER TO REMOVE ANY TRAPPED AIR THAT
IS IN THE lUBE SYSTEMS AND PROPERLY lUBE THE SPHERICAL BEARINGS.
1. On initial start up of the system.
2. When any parts or hoses are replaced or removed.
3. During the factory build of the truck (before the truck ships). This includes ship loose parts.
4. Prior to delivery of new units after field erection.
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EJ4060-2.doc Page 1 of2

KOMATSU CHECKOUT PROCEDURE
IEJ4060-2
PaQe 2 of 2
PROCEDURE: AUTO LUBE SYSTEMS
1. To purge the air from the main supply line, remove the main supply line at the Lincoln Lube canister and connect the shop grease pump to
the supply line. (Some adaptation may be required to connect the shop grease pump to the supply line).
2. Remove the pipe plugs from each injector group in sequence, (right front, left front and rear axle). Using the shop grease pump, pump the
grease, until grease appears at the group of injectors and re-install the pipe plug. Repeat for the other 2 groups of injectors.
3. Remove the shop grease pump from the main supply line and reconnect the main supply line to the grease canister.
4. Remove the injector caps from each injector and connect the shop grease pump to the zerk fitting on the injector and pump grease until
grease appears at the far end of the individual grease hose or at the joint that is being greased.
5. Repeat Step 4 for all injectors on the truck.
PROCEDURE: STANDARD LUBE SYSTEMS
1. Connect the shop grease pump to each zerk fitting on the truck and pump grease until grease comes out of the far end of the individual
grease hose or the joint that is being greased.
PROCEDURE: FOR GREASING SPHERICAL BEARINGS (FACTORY ASSEMBLY)
Greasing the spherical bearings can be done by one or more of the following:
. Using the shop grease gun, pump the spherical bearing full of grease until grease is visible from both sides of the bearing. This is to be
done on all spherical bearings.
. On sub-assemblies not installed and not subject to final assembly inspection - install a zerk fitting into the port where the grease hose will
be connected or use a tapered rubber adapter to push against the grease port.
. On sub-assemblies where spherical bearings are installed and subject to final assembly inspection
Lincoln Lube System already installed and purged.
- use the standard grease system or the
PROCEDURE: DRIVE SHAFTS
Grease all universal joints and slipjoints until grease appears.
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EJ4060-2.doc Page 2 of2

STANDARD TORQUE CHARTS AND CONVERSION TABLES
This manual provides dual dimensioning for most EFFECT OF SPECIAL LUBRICANTS
specifications. U.S. standard units are specified first, On Fasteners and Standard Torque Values
with metric (SI) units in parentheses.
The Komatsu engineering department does not
References throughout the manual to standard torques recommend the use of special friction-reducing
or other standard values will be to one of the following lubricants, such as Copper Coat, Never-Seez®, and
charts or tables. For values not shown in these charts other similar products, on the threads of standard
or tables, standard conversion factors for most fasteners where standard torque values are applied.
commonly used measurements are provided in TABLE The use of special friction-reducing lubricants will
XIII, page A5-6. significantly alter the clamping force being applied to
Standard torque values are not to be used when “turn- fasteners during the tightening process.
of-the-nut” tightening procedures are recommended. If special friction-reducing lubricants are used with the
standard torque values listed below in Table I,
INDEX OF TABLES excessive stress and possible breakage of the
TABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1 fasteners may result.
TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2
Where the torque tables specify “Lubricated Threads”
TABLE III . . Standard Metric Assembly Torque . . A5-2
for the standard torque values listed, these standard
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . A5-3
torque values are to be used with simple lithium base
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3
chassis grease (multi-purpose EP NLGI) or a rust-
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3
preventive grease (see list, page A5-2) on the threads
TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3
and seats unless specified otherwise.
TABLE VIII . Torque Conversions (ft lbs to N•m) . . A5-4
TABLE IX . Torque Conversions (ft lbs to kg•m) . . A5-4 NOTE: Ensure the threads of fasteners and tapped
TABLE X . . Pressure Conversions (psi to kPa) . . A5-4 holes are free of burrs and other imperfections before
TABLE XI . Pressure Conversions (psi to MPa) . . A5-5 assembling.
TABLE XII . . . . . . . .Temperature Conversions . . A5-5
TABLE XIII . . . Common Conversion Multipliers . . A5-6
Grade 5 TABLE I. -STANDARD TORQUE CHART

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

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

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

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

Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
psi 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
TABLE XI. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
psi 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa). 3. Multiply by 10:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to psi row 0, column 5; read 34.475
2. Go to psi row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
TABLE XII. TEMPERATURE CONVERSIONS

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

C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
TABLE XIII
COMMON CONVERSION MULTIPLIERS
COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS

ENGLISH TO METRIC METRIC TO ENGLISH
To Convert Multiply Multiply

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

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

fluid ounce – fl oz milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl oz. 0.0338
pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046
pound (force) – lbs Newton (N) 4.448 Newton (N) pound (force) – lbs 0.2248
in. lbs. (force) Newton meters (N•m) 0.113 Newton-meters (N•m) kilogram meters (kg•m) 0.102
ft lbs (force) Newton meters (N•m) 1.356 Newton-meters (N.m) ft lbs 0.7376
ft lbs (force) kilogram meters (kg•m) 0.138 kilogram-meters (kg•m) ft lbs 7.2329
psi (pressure) kilopascals (kPa) 6.895 kilogram-meters (kg•m) Newton meters (N•m) 9.807
psi (pressure) megapascals (MPa) 0.007 kilopascals (kPa) psi 0.1450
psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 megapascals (MPa) psi 145.038
ton (short) kilogram (kg) 907.2 kilograms/cm 2 (kg/cm2) psi 14.2231
ton (short) metric ton 0.0907 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
quart – qt liters (l) 0.946 kilogram (kg) ton 0.0011
gallon – gal liters (l) 3.785 metric ton ton 1.1023
HP (horsepower) Watts 745.7 liters (l) quart – qt 1.0567
HP (horsepower) kilowatts (kw) 0.745 liters (l) gallon – gal 0.2642
Watts Horsepower HP 0.00134
kilowatts (kw) Horsepower HP 1.3410
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
MACHINE MODEL
(Circle One) MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT
730E SERIAL NUMBER SERIAL NUMBER NUMBER
830E 830E-1AC
930E-4 930E-4SE
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:
Signature Remark:
Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation.
All four copies are to be distributed as shown below.
Send White Reports to Manager of Technical Support

Komatsu America Corp.
2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.
Send Canary Reports to Manager of Field Assembly

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.
CEAW003212 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visual inspection of unit for loose parts and debris
2 Hardware Visual inspection of unit for missing and/or loose mounting hardware
3 Hoses and Cables Visual inspection of hydraulic hoses and electric cables to ensure they are securely
clamped and clear from sharp edges and not rubbing each other
4 Ground Straps Verify all ground straps are secure (sub frame, anchor etc.)
5 Engine Oil Level Verify engine oil level is in operating range
6 Engine Fan Inspect fan-to-shroud clearance and belt alignment
7 Hydraulic Oil Level Oil level visible through the upper sight glass with body down
8 Hatch Door Verify adequate latch seal on the rear axle hatch door to prevent dust entry
(730E, 830E, 830E-1AC)
9 Anchor Pin Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and prop-
erly tightened hardware
10 Wheel Motors Inspect oil specification and proper oil level
11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks
12 Radiator Inspect coolant fill level, cold temperature protection, and DCA additive
13 Decks and Ladders Inspect all ladders and handrails are secure and hardware is tight
Visual inspection of installation of grid blower, rectifier assembly and control box for correct
assembly of components and proper clamping, no loose contacts, no damaged or poorly
crimped cables
14 Battery Inspect all wiring and connections in battery box - no rubbing or chafing
Verify battery mounting hardware is secure
Verify electrolyte at proper level and caps are securely installed
Verify all battery terminals are secure
15 Frame Visually inspect installation of steering cylinders, tie rod, and accumulators per print
Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder
installations (all hardware secure, no leaks)
Hardware Torque
1 Suspension Verify front suspension mounting cap screws have been properly tightened per appropriate
service manual procedure using the “turn-of-the-nut” method
2 Wheels 730E Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
830E, 830E-1AC Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
930E-4, 930E-4SE Verify torque on front wheel nuts at 2 326 ± 136 N·m (1715 ± 100 ft lbs)
(See Note below chart) Verify torque on rear inside wheel nuts at 2 326 ± 136 N·m (1715 ± 100 ft lbs)
Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft
lbs)
3 Rops Verify torque on left rops beam cap screws at 949 N·m (700 ft lbs)
Verify torque on right cross beam cap screws at 240 N·m (177 ft lbs)
4 Cab Verify torque on cab mounting cap screws at 949 N·m (700 ft lbs)
5 Wheel Motor Verify torque on wheel motor mounting cap screws at 2 007 N·m (1480 ft lbs)
NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mount-
ing tightening procedure.
Maintenance
Accepted
Cab Compartment
1 Cab Doors Verify doors open and close smoothly, latch works properly, O&M manual in door
2 Cab Windows Verify windows can be opened and closed smoothly
3 Door Locks Verify left and right door locks work properly with key
4 Interior Visually inspect interior for completeness of assembly
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
5 Cab Seats Inspect operators seat adjustments (slide lever, back rest operation,
seat inclination, seat height etc.)
Inspect seat belt for proper installation (and seat tethers)
6 Passenger Seat Verify back rest operates without interference
7 Steering Wheel Check tilt and telescoping functions
Check adjustable lever can be locked securely
8 Wiper Verify wiper works all speeds, & range does not extend beyond glass surface
Verify the windshield washer works properly and washer fluid bottle is full
9 Cigarette Lighter Check lighter operation, should pop up after 10 seconds and be hot (730E,830E only)
10 Horn Check for proper sound, no looseness in horn button
11 Back Up Horn Check for proper sound, and function
12 Shift Tower Check for proper function, no binding or looseness
13 Gauges Verify gauges are installed straight and operating correctly
14 Hydraulic Fittings Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet
15 Hoist Check operation of the hoist lever in all four positions
Lights
1 Headlights Verify all headlights working, high and low beams
Verify high beam indicators are functional
Verify lights at proper angle
2 Instrument Panel Check switch depresses and all lights function
2a Dimmer Switch Verify dimmer operates properly
2b Turn Signal Visually inspect front and rear turn signal operation on left and right sides
Directional indicators operate properly
Switch turns off after turn is completed
3 Hazard Flashers Verify flasher operates properly
Verify hazard indicator lights operating properly
4 Back Up Light Verify back up light operates properly when shifter is in R position
5 Manual Back Up Light Verify switch and light work properly
6 Fog Light (optional) Verify fog lights and indicator lights operating properly
Brake Lights
1 Service Brake Verify service brake lights operating properly
2 Brake Lock Verify brake lock light operating properly
3 Emergency Brake Verify emergency brake light operating properly
4 Parking Brake Verified parking brake light operating properly
5 Dome Light Verify dome light is on when the switch is ON
6 Retarder Lights Verify retard light operating properly
Maintenance
Accepted
Service Inspection
1 Suspension 730E Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear
(See Note below chart) Front charge height, 229 mm (9 in.) at 2758 kPa (400 psi)
Rear charge height, 276 mm (10.9 in. ) at 1420 kPa (206 psi)
830E, 830E-1AC Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)
930E-4, 930E-4SE Suspension oiling height at 25.4 mm (1 in.) front and 53.0 mm (2.1 in.) rear
Rear charge height, 218 mm (8.6 in.) at 1482 kPa (215 psi)
2 Accumulators Verify nitrogen charge in accumulators is at 9 653 kPa (1400 psi) for all models, for both
steering and brakes (charge pressure will vary with ambient temperature, refer to chart in SM)
3 Engine Prelube If equipped, ensure prelube is working prior to engine starting
4 Engine Starting Ensure engine starts easily
5 Engine Noise No abnormal noise from engine
6 Brake Lock Verify when switch is ON, brakes are applied and light is illuminated. Must be in Neutral.
7a Parking Brake Verify when switch is ON, brakes are applied and light is illuminated
730E, 830E
7b 830E-1AC, 930E-4, Verify when directional control lever is in PARK, brakes are applied and light is illuminated
930E-4SE
8 Brake Pressure 730E Verify with pedal depressed, front brake pressure is 17 236 ± 689 kPa (2500 ± 100 psi)
Verify with pedal depressed, rear brake pressure is 11 721 ± 517 kPa (1700 ± 75 psi)
Verify brake lock pressure is 10 342 ± 689 kPa (1500 ± 100 psi)
Verify parking brake pressure is 17 926 ± 689 kPa (2600 ± 100 psi)
830E, 830E-1AC 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) (830E)
or 10 894 ± 517 kPa (1580 ± 75 psi) (830E-1AC)
Verify parking brake pressure is 17 236 ± 689 kPa (2500 ± 100 psi)
930E-4, 930E-4SE Verify with pedal depressed, front brake pressure (BF) is 17 236 ± 517 kPa (2500 ± 75 psi)
Verify with pedal depressed, rear brake pressure (BR) is 17 236 ± 517 kPa (2500 ± 75 psi)
Verify parking brake release pressure is 18 616 ± 689 kPa (2700 ± 100 psi)
9 Steering Verify that steering system is operating smoothly, turning from lock to lock
Verify steering system is free of noise and vibration
10 Hoist Verify hoist pressure is 17 236 kPa (2500 psi) power up, and 10 342 kPa (1500 psi) power
down
Verify hoist limit switch is operational and is set correctly (measure on the hoist cylinder - 3rd
stage), cylinder should stop 6 inches before full extension
Verify that the hoist hold position operates properly
Verify that there is no heavy shock when the body returns to the frame in float
NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete
suspension oiling and charging instructions.
Maintenance
Accepted
11 Hoist Times 730E Power up loaded - 21-23 seconds
Power down - 15-17 seconds
Float down empty - 22-24 seconds
830E, 830E-1AC Power up loaded - 25-27 seconds
930E-4, 930E-4SE Power up loaded - 21-23 seconds
All Trucks Ensure body up switch activates the body up alarm and light in the cab
12 Lubrication Ensure automatic lube system is serviced and full (and air bled from system)
Ensure automatic lube system is operating properly and timer is set as desired
13 Payload Meter Sys. Calibrate and check payload meter operation per O&M manual
14 Error Codes Troubleshoot any error codes and delete
15 Machine Record machine model-type, machine serial number and engine serial number
16 Dump Body Ensure the dump body is shimmed correctly prior to truck release
17 Electrical Checks Ensure the electrical checkout procedure has been completed and signed off on, including
megger testing (see appropriate Field Assembly Manual or Shop Manual for procedure)
18 Truck Programming Ensure the truck is programed with it’s own unique configuration file and a copy of the file
saved
ADDITIONAL COMMENTS__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
50 HOUR POST-COMMISSIONING CHECKSHEET
Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.
MACHINE MODEL
(Circle One) MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT
730E SERIAL NUMBER SERIAL NUMBER NUMBER
830E 830E1-AC
930E-4 930E-4SE
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

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

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

2300 N.E. Adams St., P.O. Box 240
Peoria, IL 61650-0240 U.S.A.
Send pink reports to your KAC Regional Service Manager
Send gold reports to the Service Manager at the KAC Distributor who sold the truck
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
Inspection Around Machine
1 Parts Visually inspect the truck for loose parts and debris.
2 Hardware Visually inspect the truck for missing and/or loose

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

and DCA additive.
10 Steering Components Verify proper installation of the steering cylinders, tie rod,
and accumulators.
11 Hydraulic Components Visually inspect the hoist valve, pumps, filters, hydraulic
tank and hoist cylinder installations. All hardware must
be secure, and no leaks evident.
12 Leakage Visually inspect the entire machine for leaks.
Hardware Torque
1 Steering Arm To 730E - Verify hardware torque -
Suspension Target: 2705 N·m (1995 ft lbs)
830E, 830E-1AC- Verify hardware torque -
Target: 2705 N·m (1995 ft lbs)
930E-4, 930E-4SE - Verify hardware torque -
2 Steering Cylinder To 730E - Verify hardware torque -
Frame Target: 464 N·m (342 ft lbs)
830E, 830E-1AC - Verify hardware torque -
3 Steering Cylinder To 730E - Verify hardware torque -
Steering Arm Target: 464 N·m (342 ft lbs)
Condition Action
4 Tie Rod Pin Retainer 730E - Verify hardware torque -
5 Front Brake Caliper 730E - Verify hardware torque -
Mounting Target: 1085 N·m (800 ft lbs)
(Capscrew with Nut) 830E, 830E-1AC - Verify hardware torque -
6 Front Brake Caliper 730E - Verify hardware torque -
(Capscrew Only)
7 Rear Service Brake 730E - Verify hardware torque -
Caliper Mounting Target: 780 N·m (575 ft lbs)
8 Rear Brake Adapter 730E - Verify hardware torque -
9 Brake Disc To Adapter 730E - Verify hardware torque -
Cab Compartment
1 Horn Check for proper tone and volume. Ensure there is no
looseness in the horn button.
2 Back Up Horn Check for proper tone, volume, and function.
3 Gauges Verify all gauges are installed straight and are operating
correctly.
4 Glass Verify no cracks exist on cab windows. Ensure all win-
dows are properly sealed.
5 Seat/Seat belts Verify the cab seats and seat belts are in proper working
condition.
Condition Action
Service Inspection
1 Suspension 730E Suspension oiling height: 38.1 mm (1.5 in.) front and
(See Note below) 72.6 mm (2.9 in.) rear
Front charge height: 229 mm (9 in.) at 2758 kPa (400
psi)
Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206
psi)
830E, 830E-1AC Suspension oiling height: 25.4 mm (1 in.) front and 25.4
(See Note below) mm (1 in.) rear
psi)
psi)
930E-4, 930E-4SE Suspension oiling height: 25.4 mm (1 in.) front and 53.0
(See Note below) mm (2.1 in.) rear
psi)
psi)
NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling
and charging instructions.
2 Accumulators Verify the nitrogen charge in the accumulators is at 9653
kPa (1400 psi) for all models, for both steering and
brakes. (Charge pressure will vary with ambient temper-
ature, refer to chart in SM)
3 Steering Verify that steering system is operating smoothly while
turning from lock to lock.
Verify the steering system is free of noise and vibration.
4 Lubrication Ensure the automatic lube system contains no air and is
filled to the proper level.
Ensure the automatic lube system is operating properly
and the timer is set as desired.
5 Hydraulic Filters Verify the 50 hour change of all hydraulic filters has been
completed.
NOTE: Elements are supplied from the factory in the
parts crate.
6 Tires Check and record the tire pressure/size/manufacturer for Pressure
future reference Size
Manufacturer
7 Payload Meter System Calibrate and check payload meter operation per O&M
manual. Troubleshoot any error codes and delete after
repair.
8 GE Drive/Control Check drive control system operation per O&M manual.
System Troubleshoot, correct and delete any error codes.
9 GE Rotating Visually inspect wheel motor armature condition - brush
Components wear, commutator color, etc.
(Wheel Motors, MTA, Inspect MTA slip rings and brushes.
Grid Blower) Inspect grid blower motor commutator condition, brush
wear, etc.
10 Wheel Motor Sun Pinion Measure and record sun pinion end play for both RH and
End Play LH wheel motors
11 VHMS Verify the VHMS system is functioning properly per O&M
manual. Troubleshoot and repair any problems.
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No. Description of Modification Reason For Installation

1
ADDITIONAL COMMENTS:______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
®
www.komatsuamerica.com
Komatsu America Corp. Copyright 2010 Komatsu

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

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SERIAL NUMBERS A30769 & UP

DANGER Identifies a specific potential hazard

WARNING identifies a specific potential hazard

CAUTION is used for general reminders

SUBJECT PAGE NUMBER

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

TRUCK COMPONENT AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

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

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

FAM0015 Introduction iii

FAM0108 5/10 Safety Rules, Tools, & Equipment Page 1-1

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

Page1-2 Safety Rules, Tools, & Equipment 5/10 FAM0108

FAM0108 5/10 Safety Rules, Tools, & Equipment Page 1-3

1. “T” Handle Valve

Part Number Description Use

Page1-4 Safety Rules, Tools, & Equipment 5/10 FAM0108

Part Number Description Use

Part Number Description Use

FAM0108 5/10 Safety Rules, Tools, & Equipment Page 1-5

Part Number Description Use

Part Number Description Use

Page1-6 Safety Rules, Tools, & Equipment 5/10 FAM0108

Part Number Description Use

Part Number Description Use

Part Number Description Use

FAM0108 5/10 Safety Rules, Tools, & Equipment Page 1-7

Part Number Description Use

Part Number Description Use

Part Number Description Use

Part Number Description Use

Part Number Description Use

Page1-8 Safety Rules, Tools, & Equipment 5/10 FAM0108

FAM0215 9/09 Truck Components And Specifications Page 2-1

Page 2-2 Truck Components And Specifications 9/09 FAM0215

AC ELECTRIC DRIVE SYSTEM

BATTERY ELECTRIC SYSTEM

FAM0215 9/09 Truck Components And Specifications Page 2-3

STANDARD DUMP BODY CAPACITIES AND DIMENSIONS

NOTE: Optional capacity dump bodies are available.

Page 2-4 Truck Components And Specifications 9/09 FAM0215

OVERALL TRUCK DIMENSIONS

FAM0215 9/09 Truck Components And Specifications Page 2-5

Page 2-6 Truck Components And Specifications 9/09 FAM0215

ITEM KILOGRAMS POUNDS

DECK AND DECK SUPPORT COMPONENTS

FAM0314 Major Component Weights Page 3-1

FRONT AXLE COMPONENTS

REAR AXLE COMPONENTS

Page 3-2 Major Component Weights FAM0314

FAM0403 Field Welding For Assembly Or Repair 4-1

4-2 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-3

Manual Armado 930E-4SE Serial Numbers A30769 & UP CEAW006203

Manual Armado 930E-4SE Serial Numbers A30769 & UP CEAW006203

Manual Armado 930E-4SE Serial Numbers A30769 & UP CEAW006203