Field Assembly Manual: Dump Truck

CEAW009000
Field Assembly
Manual
930E-5
DUMP TRUCK
SERIAL NUMBERS 930E-5 A40004 and up
ENGINE 16V160
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2018 Komatsu

Printed in U.S.A.
Komatsu America Corp.
October 2018
READ AND UNDERSTAND THE OPERATION
& MAINTENANCE MANUAL BEFORE OPERATING
THIS VEHICLE OR PERFORMING ANY
MAINTENANCE.
Unsafe use of this machine may cause serious injury or death.

Operators and maintenance personnel must read this manual, must
be trained and authorized by the employer, before operating or
maintaining this machine. This manual should be kept in or near the
machine for reference and periodically reviewed by all personnel
who come in contact with the machine.
WARNING: Breathing diesel engine exhaust exposes you to

chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
WARNING: This product can expose you to chemicals including

lead, which is known to the State of California to cause cancer and
birth defects or other reproductive harm.
For more information go to www.P65warnings.ca.gov
FOREWORD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-5 dump truck. Vari-
ations 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.
FAM0037 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 FAM0037
TABLE OF CONTENTS
SUBJECT PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TRUCK COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAM0037 Introduction iii

KOMATSU 930E-5
iv Introduction FAM0037
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES 11. When welding, connect the ground cable to the
part being welded. DO NOT allow welding current
The following list of safety practices is intended for use
to pass through bearings, engine, etc.
by personnel during field assembly of the truck.
12. DO NOT weld the fuel tank or hydraulic tank
This list of safety rules is not intended to replace local
unless the tanks have been properly purged and
safety rules or regulations and federal, state, or local
ventilated.
laws. The safety precautions recommended here are
general and must be used in conjunction with all pre- 13. Use the proper tools for the job to be performed.
vailing local rules and regulations. Never improvise wrenches, screw drivers, sock-
ets, etc. unless specified.
1. All personnel must be properly trained for the
assembly process. 14. Lifting eyes and hooks must be fabricated from
2. Wear safety equipment such as safety glasses, the proper materials and rated to lift the intended
hard toe shoes and hard hats at all times during load.
assembly. 15. When the weight of any component(s) or any
3. Thoroughly inspect the assembly site. Remove assembly procedure is not known, contact your
weeds, debris and other flammable material. customer support manager for further information.
4. Use only solid, hard wood for supports. When
using metal support stands, place wood blocks
between the support and the frame to prevent Use of Tie-Off Anchor During Maintenance and
metal to metal contact. Repair
5. Inspect all lifting devices. Refer to the manufac- While working at heights
turer's specifications for correct capacities and during assembly, mainte-
safety procedures when lifting components. nance or repair of the haul
6. Perform a daily inspection of all lifting cables and truck, workers should wear
chains. Replace any questionable items. Use an appropriate fall protec-
cables and chains that are properly rated for the tion harness and attach it
load to be lifted. to a tie-off anchor or tie-off
7. DO NOT stand beneath a suspended load. Use of point.
guy ropes are recommended for guiding and posi- Komatsu anchor (58B-98-75190) is available for use
tioning a suspended load. with fall protection harnesses. Carefully read and
8. Maintain fire control equipment. Inspect fire extin- understand the harness maker’s instructions before
guishers regularly to ensure they are fully charged using any fall protection harness.
and in good working condition. The load carrying capacity of anchor (58B-97-75190) is
9. capscrews and/or nuts being replaced must be 2 270 kg (5,000 lb).
the same grade as originally supplied.
NOTE: The anchor must not be used for lifting.
Before welding, refer to Special Precautions When

Servicing An AC Drive System Truck in Section 4.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its compo-
nents.
FAM0131 Safety Rules, Tools, & Equipment Page 1-1

TOOLS AND EQUIPMENT FOR ASSEMBLY 12. Two, ratchet pullers - 2.7 metric ton (3 ton)
The following equipment is recommended for field 13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)
assembly of the truck. 14. Set of standard master mechanics hand tools
• Thread taps and dies of both inch and metric
1. Equipment and tool storage trailer with a lockable sizes
door. Approximately 12 x 2.5 m (40 x 8 ft) • Metric sockets and open end wrenches, 6mm to
2. Cranes 36mm
a. Two, 45 metric ton (50 ton) cranes to remove • Inch sockets and open end wrenches
the chassis from the freight trailer and place on up to 1 3/4 in.
cribbing. These cranes can also be used to lift
the assembled body onto to the chassis. • Torque wrenches - 339 N·m (250 ft lb) with 18:1
multiplier. Torque wrenches - 339 N·m (600 ft
b. One, 109-136 metric tons (120-150 ton) crane. lb) with 4:1 multiplier. Hydrotorque - 1 1/2 in.
The crane is needed to turn the body over after drive with capability of 5559 N·m (4100 ft lb) or
completion of the underside welding. A 45 met- greater
ric ton (50 ton) crane is also required for this
task. • Box wrench 1 3/8 in. (Snap-On p/n X440B) with
12 inch extension to tighten ROPS capscrews
3. One fork lift - 6804 kg (15,000 lb) capacity, with
high lift capability • Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2
4. Two, 300 amp portable welding units and an oxy- 5/8 in. (Snap-On P/N J15042) to tighten front
acetylene cutting set suspension hardware
5. One, propane torches for weld preheating 15. Heavy duty 3/4 in. & 1 in. square drive impact
6. Portable air compressor - 3.5 cmm (125 cfm) and wrench sets
690 kPa (100 psi) capacity. 16. Impact sockets for 3/4 in. & 1 in. square drive
tools
Two, 15 m (50 ft) air hoses.
7. Metal stands and a sufficient amount of wood 17. Special tools (see list, following pages)
cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm 18. Two, hydraulic or pneumatic porta-power jacks,
(14 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm 4.5 and 9 metric ton (5 and 10 ton)
(4 ft. x 6 in. x 6 in.) - such as railway cross ties
19. Various hooks and shackles
8. Tire handler - Wiggins/Iowa Mold Tooling
20. Miscellaneous (i.e. grinders, containers, rags)
9. Miscellaneous air tools
21. Spreader bars for cab and decks
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft)
22. Two ratchet hoists - 2.7 metric ton (3 ton) capacity
11. Chains, lifting cables, slings:
23. Pry bars
• Two, 4 point slings, 3 m (10 ft) in length
24. Solvent - 38 liters (10 gal)
• Two, 4 point slings, 2 m (6 ft) in length
25. Paint remover - 19 liters (5 gal)
• Two, 1 m (4 ft) and two, 2 m (6 ft)
26. Rust preventive grease
• Two, 3 m (10 ft) nylon straps
27. 22 mm Allen wrench socket - 3/4 in. drive
• Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of
rope
Page 1-2 Safety Rules, Tools, & Equipment FAM0131

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

TZ2734 3/4 in. Torque Miscellaneous
Adapter

TZ2733 Tubular Handle Use with
PB8326 &
TZ2734

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
III Download

EH7817 Alignment Tool Upper Hoist Pin

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 Socket
TZ2731 in.) adapter
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.)

KOMVISION® CALIBRATION TOOLS
58E-98-00600 Tripod Stand Radar
Calibration

XB0841 Reflector Radar
Calibration

58E-98-00910 Front Grid Camera
Sheet Calibration
58E-98-00920 Side Grid Sheet Camera
Calibration
58E-98-00930 Rear Grid Camera
Sheet Calibration

HIGH VOLTAGE TOOLS
0-2000 VDC CUSTOM METER KIT (58B-06-00800)

Item Number Part Number Description Use
1 58B-06-00700 2000 V Meter & Probe Servicing control cabinet
2 58B-06-00730 Handle Extension Servicing control cabinet
3 58B-06-00740 Hand Guard Servicing control cabinet
4 58B-06-00720 Handle Servicing control cabinet
5 58B-06-00710 RCDC Lead Servicing control cabinet
6 58B-06-00750 Probe Tip Servicing control cabinet
7 58B-06-00770 Power Supply (Tester) Servicing control cabinet
8 58B-06-00780 Capacitor Discharge Sticks Servicing control cabinet
9 58B-06-00760 Box w/Foam Servicing control cabinet
10 58B-06-00790 Gloves Servicing control cabinet
0-2000 VDC CUSTOM METER KIT (58B-06-00800)

BODY PAD SPACER TOOL
XC2293 Spacer Body Pad
Shimming
15.9
40.0
20.0
* NOTE INCH EQUIVALENT MATERIAL

TYP
3.0
R
2.00" PLATE
387.5
355.6
TYP
50.8
REF
8.0
R
XC2293 SPACER BLOCK DIMENSION

NOTES

TRUCK COMPONENTS AND SPECIFICATIONS
Truck and Engine Operator’s Cab
The 930E-5 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 522 406 kg (1,151,707 lbs). The engine is a of the truck. The cab provides wide visibility with an
Komatsu SSDA16V160 rated @ 2,700 HP (2014 integral 4-post ROPS/FOPS structure and an
kW). advanced analog operator environment. It includes a
tinted safety-glass windshield and power-operated
Main Alternator side windows, a deluxe interior with a fully adjustable
seat with lumbar support, a fully adjustable/tilt
The diesel engine drives an in-line alternator at
steering wheel, controls mounted within easy reach
engine speed. The alternator produces AC current
of the operator, and an analog instrument panel
which is rectified to DC within the main control
which provides the operator with all instruments and
cabinet. The rectified DC power is converted back to
gauges which are necessary to control and/or
AC by groups of devices called "inverters", which are
monitor the truck's operating systems.
also within the main control cabinet. Each inverter
consists of six phase modules under the control of a
gate driver power converter (GDPC). The two
Power Steering
GDPCs control the operation of each phase module. 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 minimum operator effort. The system includes
insulated gate bipolar transistors (IGBT). The IGBTs nitrogen-charged accumulators which automatically
cycle on and off at varying frequencies to create an provide 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

Dynamic Retarding
variable-voltage, variable-frequency (VVVF) signal.
Frequency and voltage are changed to suit the The dynamic retarding is used to slow the truck
operating conditions. during normal operation or control speed coming
Cooling air for the control/power group and wheel down a grade. The dynamic retarding ability of the
motors, as well as the alternator itself, is provided by electric system is controlled by the operator through
dual fans mounted on the alternator shaft. the activation of the retarder pedal (or by operating a
lever on the steering wheel) in the operators cab and
AC Induction Traction Motorize Wheels by setting the RSC (Retarder Speed Control).
Dynamic retarding is automatically activated, if the
The alternator output supplies electrical energy to the truck speed goes to a preset overspeed setting.
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction Brake System
motors with full-wave AC power.
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
to mechanical energy through built-in gear trains system. Depressing the brake pedal actuates both
within the wheel motor assembly. The direction of the front and rear brakes after first applying the retarder.
wheel motors is controlled by a directional control All 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
Hydrair II® suspension cylinders located at each inboard on each rear wheel motor, and is spring-
wheel provide a smooth and comfortable ride for the applied and hydraulically-released with wheel speed
operator and dampens shock loads to the chassis application protection (will not apply with truck
during loading and operation. moving).
FAM0237 Truck Components And Specifications Page 2-1

Selective Catalytic Reduction (SCR) Diesel Exhaust Fluid (DEF)
The truck is equipped with an SCR system to reduce The truck is equipped with an DEF dosing system
the levels of oxides of nitrogen emitted from the which is the reactant necessary for the functionality
engine, that are harmful to our health and the of the SCR system. The DEF tank is attached to the
environment. SCR is the aftertreatment technology fuel tank.
that treats exhaust gas downstream of the engine.
Small quantities of diesel exhaust fluid (DEF) are
injected into the exhaust upstream of a catalyst,
where it vaporizes and decomposes to form
ammonia and carbon dioxide. The ammonia is the
desired product which in conjunction to the SCR
catalyst, converts the oxides of nitrogen to harmless
nitrogen and water.
Page 2-2 Truck Components And Specifications FAM0237

FIGURE 2-1. TRUCK COMPONENTS
1. Operator Cab 9. Fuel Tank 16. Wet Disc Brake 22. Steering and Brake
2. Auto Lubrication 10. DEF Tank and Pumps 17. Tires Circuit Pump
3. Engine 11. DEF Filter 18. Rear Suspension 23. Hydraulic Tank
4. Front Suspension 12. Pump Filter 19. Dosing Modules 24. Hoist Circuit Pump
5. Wet Disc Brakes 13. Steering Circuit Filter 20. Selective Catalytic 25. Cooling Duct
6. Accumulator 14. Hoist Cylinders Reduction (SCR)
7. Auxiliary Blowers 15. AC Induction Traction System
8. Hoist Circuit Filters Motor 21. Rear Axle Housing

SPECIFICATIONS
These specifications are for the standard Komatsu HYDRAULIC SYSTEMS
930E-5 Truck. Customer options may change this Pumps
listing. Hoist and Brake Cooling . . . . . . Tandem Gear Pump
Rating @ . . . 931 L/min (246 gpm) @ 1900 RPM and
ENGINE 17,237 kPa (2,500 psi)
Komatsu SDA16V160 Steering/Brake Pump Pressure Compensated Piston
(Optional SSDA16V160) Rating @ . . . 246 L/min (65 gpm) @ 1900 RPM and
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . .16 18,961 kPa (2750 psi)
Operating Cycle . . . . . . . . . . . . . . . . . . . . . . 4-Stroke Relief Pressure - Hoist . . . . . 17,237 kPa (2,500 psi)
Rated Brake HP . 2014 kW (2,700 HP) @ 1900 RPM Relief Pressure - Steering/Brake
Flywheel HP . . . . 1902 kW (2,550 HP) @ 1900 RPM . . . . . . . . . . . . . . . . . . . . . . . 27,579 kPa (4,000 psi)
Weight (Wet)* . . . . . . . . . . . . . . 8 841 kg (19,491 lbs) Hoist Cylinders (2). . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized
* Weight does not include Radiator, Sub-frame, or Tank Capacity. . . . . . . . . . . 947 liters (250 gallons)
Alternator. Filtration. . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
AC ELECTRIC DRIVE SYSTEM Hoist and Steering Filters (Dual In-Line, High
(AC/DC Current) Pressure). . . . . . . . . . . . . . . . . . Beta 12 Rating =200
Alternator . . . . . . . . . . . . . . General Electric GTA-41
Dual Impeller, In-Line Blower SERVICE BRAKES
. . . . . . . . . . . . . . . . . . . . . .411 m³/ min (14,520 cfm) All Hydraulic Actuation with Traction System Wheel
Motorized Wheels Slip/Slide Control
GDY106 AC Induction Traction . . . . . . . . . . . Motors Front and Rear Oil-Cooled Multiple Discs on each
Standard Gear Ratio* . . . . . . . . . . . . . . . .32.62:1 wheel
Maximum Speed . . . . . . . . . . 64.5 km/h (40 mph) Total Friction Area / Brake . . 97 019 cm² (15,038 in²)
Maximum Apply Pressure . . . 17 238 kPa (2,500 psi)
* Wheel motor application depends upon GVW, haul
road grade and length, rolling resistance, and other STEERING
parameters. Komatsu must analyze each job condi-
Twin hydraulic cylinders with accumulator assist to
tion to ensure proper application.
provide constant rate steering. Emergency power
DYNAMIC RETARDING steering automatically provided by accumulators
Electric Dynamic Retarding . . . . . . . . . . . . Standard Turning Circle (SAE) . . . . . . . . . . 29.7 m (97 ft. 7 in.)
Maximum Rating . . . . . . . . . . . . 4026 kW (5400 HP)
Continuous* . . . . . . . . . . . . . . . . 2460 kW (3300 HP) TIRES
* Continuously rated high-density blown grids with Radial Tires (standard) . . . . . . . . . . . . . . . 56/80 R63
retard at engine idle and retard in reverse propulsion. Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless
Rims . . . . . . . . . . . . . . . . Rated to 827 kPa (120 psi)
BATTERY ELECTRIC SYSTEM
Batteries . .4 x 8D,12 volt, in series/parallel, bumper STANDARD DUMP BODY CAPACITIES AND
mounted with isolation station DIMENSIONS
Cold Cranking Amps . . . . . . . . . . . . . . 1400 CCA Capacity
Alternator . . . . . . . . . . .24 Volts, 140 Ampere Output Heaped @ 2:1 (SAE)202 m3 (264 yd3)
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts Struck . . . . . . . . . . . . . . . . . . . . .151 m3 (197 yd3)
Cranking Motors (2) . . . . . . . . . . . . . . . . . . . 24 Volts Width (Inside) . . . . . . . . . . . . . . . . 8.4 m (27 ft. 8 in.)
Depth. . . . . . . . . . . . . . . . . . . . . . . . 2.8 m (9 ft. 2 in.)
SERVICE CAPACITIES
Loading Height . . . . . . . . . . . . . . 6.78 m (22 ft. 3 in.)
Crankcase (including lube oil filters). 363 liters (95.8
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
gallons)
Cooling System . . . . . . . . . . 594 liters (157 gallons) NOTE: Optional capacity dump bodies are available.
Fuel . . . . . . . . . . . . . . . . 4 542 liters (1,200 gallons)
Hydraulic System . . . . . . . . 1 325 liters (350 gallons)
Wheel Motor Gear Box
. . . . . . . . . . . . . . . . . 95 liters (25 gallons) per wheel

WEIGHT DISTRIBUTION * Nominal payload is defined within Komatsu
America Corporation’s payload policy
Empty Vehicle Kilograms (Pounds) documentation. Nominal payload must be adjusted if
Front Axle (49.3%). . 105 125 kg. . . . . .(231,763 lbs) the weight of any customized body or tires vary from
Rear Axle (50.7 %) . 113 886 kg . . . . . .(251,076 lbs) that of the standard Komatsu body and tires. Nominal
Total (with 50% fuel) 219 012 kg . . . . . .(482,839 lbs) payload must also be adjusted to take into account
Standard Komatsu body 36,228 kg . . . . (79,869 lbs) the additional weight of any custom/optional extras
Standard tire weight 26,127 kg . . . . . . .(57,600 lbs) fitted to the truck which are not stated within the
Loaded Vehicle Standard Features list of the applicable specification
Front Axle (33.0%). . 168,565 kg . . . . . .(371,622 lbs) sheet.
Rear Axle (67.0%) . . 342,237 kg . . . . . .(754,504 lbs)
Total . . . . . . . . . . . . . 510,802 kg. . . . (1,126,126 lbs)
Nominal Payload* . . 291,790 kg. . . . . .(643,287 lbs)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 306 . . . . . . . . . . . . . . . . . . . . . . 2,879
Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 615 . . . . . . . . . . . . . . . . . . . . . 12,379
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 540 . . . . . . . . . . . . . . . . . . . . . 54,101
DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 619 . . . . . . . . . . . . . . . . . . . . . . 5,773
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 194. . . . . . . . . . . . . . . . . . . . . . . 2,633
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 899 . . . . . . . . . . . . . . . . . . . . . . 1,983
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 092 . . . . . . . . . . . . . . . . . . . . . . 2,407
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 . . . . . . . . . . . . . . . . . . . . . . 1,764
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 . . . . . . . . . . . . . . . . . . . . . . . .606
LH Upright with Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 237 . . . . . . . . . . . . . . . . . . . . . . 2,726
RH Upright with Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 989 . . . . . . . . . . . . . . . . . . . . . . 2,180
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 . . . . . . . . . . . . . . . . . . . . . . . .306
RH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 . . . . . . . . . . . . . . . . . . . . . . . .165
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 . . . . . . . . . . . . . . . . . . . . . . . .420
Vertical Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 . . . . . . . . . . . . . . . . . . . . . . . .129
FAM0327 Major Component Weights Page 3-1

ITEM KILOGRAMS POUNDS
POWER MODULE
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 . . . . . . . . . . . . . . . . . . . . . . . . 176
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .806 . . . . . . . . . . . . . . . . . . . . . . .1,777
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 703 . . . . . . . . . . . . . . . . . . . . . . .5,960
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 506 . . . . . . . . . . . . . . . . . . . . . . .5,524
Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387 . . . . . . . . . . . . . . . . . . . . . . . . 854
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 993 . . . . . . . . . . . . . . . . . . . . . . .8,803
Engine (Komatsu SDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 558 . . . . . . . . . . . . . . . . . . . . . . 18,867
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 651 . . . . . . . . . . . . . . . . . . . . . . .3,640
DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203 . . . . . . . . . . . . . . . . . . . . . . . . 447
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356 . . . . . . . . . . . . . . . . . . . . . . . . 785
Auxiliary Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303 . . . . . . . . . . . . . . . . . . . . . . . . 668
FLUID COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 . . . . . . . . . . . . . . . . . . . . . . . . 479
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .941 . . . . . . . . . . . . . . . . . . . . . . .2,075
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 . . . . . . . . . . . . . . . . . . . . . . . . 278
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .639 . . . . . . . . . . . . . . . . . . . . . . .1,408
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 671 . . . . . . . . . . . . . . . . . . . . . . .3,684
FRONT AXLE COMPONENTS

Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 520 . . . . . . . . . . . . . . . . . . . . . . 12,169
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 . . . . . . . . . . . . . . . . . . . . . . . . 496
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 423 . . . . . . . . . . . . . . . . . . . . . . .3,137
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 . . . . . . . . . . . . . . . . . . . . . . . . 550
REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909 . . . . . . . . . . . . . . . . . . . . . . .2,005
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 . . . . . . . . . . . . . . . . . . . . . . . . 763
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 967 . . . . . . . . . . . . . . . . . . . . . . 15,359
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 . . . . . . . . . . . . . . . . . . . . . . . . 330
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12 200 . . . . . . . . . . . . . . . . . . . . . . 26,900
Page 3-2 Major Component Weights FAM0327

FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at WELD PROCEDURES
initial field assembly or during normal maintenance
Electric arc welding, either the semi-automatic “MIG”
repairs, special procedures must be followed.
(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
should be done with the specific detailed instructions
The welding information contained in this chapter is
from Komatsu Product Service. See Annex A for
general information that must be followed unless oth-
repair procedures. These repair procedures are
erwise specified in a detailed repair procedure pro-
detailed instructions for most high stressed structural
vided on an engineering drawing or a detailed
members.
specific repair procedure. Additional specific informa-
tion, or detailed instructions can be obtained through
APPROVED CONSUMABLES
your local Komatsu customer support manager.
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
WELD QUALITY REQUIREMENTS
structural steel welding in all positions, in confor-
mance with the American Welding Society (AWS) 1. Each weld must be homogeneous with low
D1.1 or (AWS) D14.3 only, are allowed to perform the porosity, free from cracks, and slag inclusions.
welding. The welding instructions for field assembly 2. Each weld must have complete fusion between
of Komatsu components are normally provided by the base metal and weld metal added by the
engineering drawings. Additional detailed welding electrode.
instructions for field repairs are provided in Welding 3. All welds must be reasonably smooth, without
Manual I (SEBF14001), and Welding Manual II excessive deformity, and all craters filled. No
(SEBF15002). A full understanding of the AWS stan- cracks are permitted.
dard welding symbols is necessary to perform and
4. The toe of a weld to a stressed member must
inspect such field welds. Weld sizes specified on the
have a smooth transition. Excessive convexity
drawings are intended to reflect minimum require-
in multi-pass fillet welds is not permitted. Exces-
ments.
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 import-
ant that this pass is blended with the existing
weld.
6. When welding in the vertical position, always
weld using the vertical up technique. Large
wash weld weaves should not be used when
welding on truck frames. Properly applied multi-
ple pass welding is the required procedure on
truck frames.
FAM0403 5/13 Field Welding For Assembly Or Repair Page 4-1

7. Slag is to be removed from all weld beads, and 5. Foreign Materials - Any foreign substances
must be completely removed before each pass (dirt, paint, rust, scale, and carbon deposits
in a multiple pass procedure. It is also required from cuttings) must be removed prior to weld-
that all slag is removed and tie in all areas. ing. Clean all weld areas and surfaces with a
Grind all welds where a weld crosses or inter- grinder to ensure that all foreign materials have
sects with another weld. been removed.
MATERIALS, CONTROLS, AND WELD INSPECTION

PRECAUTIONS All welding repairs are subject to inspection by a
The steel used in the fabrication of all Komatsu Komatsu appointed inspector or laboratory to insure
equipment is of high strength low alloy (HSLA) mate- quality. After the weld has been made it can be
rial of different grades. The standard dump body inspected by a number of non-destructive evaluation
main plates are made from abrasion resistant materi- techniques. The inspections can include any of the
als. These materials offer themselves very well to methods listed below. All assembly welds and weld
welding during fabrication, and repair. repairs that are deemed unacceptable by the inspec-
tor must be corrected at no additional cost to
The welding consumables are often supplied by
Komatsu. All weld repairs are also subject to addi-
Komatsu America Corp. with the new equipment as
tional inspection.
part of the field welding / assembly package. For field
welding and repairs, the approved consumables as 1. Visual Inspection - This is the process of look-
detailed, should be procured from a local, reliable ing for potential defects such as undersized
supplier. Other highly specialized welding consum- welds that can be checked with weld gauges
ables are available but have limited use on Komatsu for, surface cracks, surface porosity, craters,
structural components. Approval is required from and undercuts.
your Komatsu customer support manager. 2. Dye Penetrant Inspection - This is an easily
Control of the welding area environment is essential applied process which indicates cracks or sur-
for producing proper and sound welds. Essentially, face conditions. The process is relatively inex-
five areas require attention and control. pensive, but does not produce a permanent
record except by normal photography.
1. Air Movement - Avoid areas where air move-
3. Fluorescent Penetrant Inspection - Similar to
ment from wind, drafts, or blowers is prevalent.
dye penetrant inspection. This process uses a
This is particularly important when a shielding
black (ultraviolet) light for increased efficiency
gas is being used as part of the welding pro-
and accuracy.
cess.
4. Magnetic Particle Inspection - This process
2. Low Ambient Temperature - DO NOT weld in
requires special equipment that is usually more
temperatures below 50°F (10°C). At low tem-
costly than the dye penetrant inspections. This
perature conditions, preheating of all welding
process does not provide a permanent record
joint work areas is required. See preheat and
except by normal photography.
post heating requirements as detailed in Annex
A. 5. Ultrasonic Inspection - This is a popular method
of examining weld discontinuities. Specialized
3. Weld Cooling - Protect the weld area from a
equipment and operator certification is required.
rapid cooling rate. Heat retardation may be
With some equipment printed data is available
accomplished through the use of heat lamps,
of the test providing a permanent record. Also,
torches, insulating blankets, etc.
operator records with equipment settings and
4. Moisture - Any moisture on the steel surfaces to test results are normally recorded.
be welded must be removed before welding.
6. X-Ray Inspection - This process provides a
Electrodes must be stored in sealed containers
view of the weld and base materials but it is
until needed. Electrodes must be kept in a
highly specialized. This procedure provides a
warming oven at the work location until used to
permanent visual record, but is more expensive
prevent any moisture absorption which might
than most other inspection techniques.
affect weld quality.
Page 4-2 Field Welding For Assembly Or Repair 5/13 FAM0403

RECORDS 5. After air arcing and inspections (Steps 3 & 4) all
areas cut by the air arc should be cleaned thor-
Komatsu requires record keeping of all welding work.
oughly with a grinder to remove all possible car-
This information is valuable when personnel or job
bon deposits and dye penetrant.
conditions change. The service and warranty depart-
ments of Komatsu must be provided with inspection 6. Fill gouges with weld and grind all surfaces
reports and photographs of the weld area before, smooth to avoid defects in the new weld.
during, and after the repair. The photographs must 7. Grind all surfaces to be welded so they are free
be clear and close enough to show the weld joint of slag, rust, and any other foreign materials.
preparation complete, with backer bars installed, etc. 8. Preheat the entire weld joint area until the sur-
just prior to welding. These photos easily identify if rounding surface area reaches 150°C (300°F)
the required preheating and post heating have been at a distance of 76 mm (3 in) from all areas to
done with a three inch circumference around the be welded.
weld repair area. Without this documentation,
9. All welds are to be made with approved con-
Komatsu will not cover any weld repair claim made
sumables only. The SMAW (Stick) welding rod
under warranty. No exceptions will be made.
must be used within four hours after being
removed from a new sealed container or from a
ANNEX A
52°C (125°F) minimum drying oven. Any rod
The following are general repair procedures, which that exceeds this exposure time must be dried
must be followed for all repair and rework of major for one hour at 427°C (800°F) before being
load carrying members on Komatsu equipment. used. Keep all weld starts and stops to a mini-
1. The repair or rework area must be protected mum.
from wind and moisture during the entire proce- 10. When the weld is complete, immediately (before
dure. If the repair work is to done outside addi- the weldment cools) post heat the entire weld
tional precautions must be taken to protect the area to 150°C (300°F). Even if the area is over
weld repair process from outside elements. All 150°C (300°F) heat must be applied to maintain
welding should be done at an ambient tempera- this temperature for 15 minutes, and then allow
ture of 10°C (50°F) or above. it to cool slowly. In some cases this might
2. Clean and grind the entire repair area to require wrapping with insulation blankets.
remove all rust, grease, oils, paint, and any 11. Grind all butt-welded repairs smooth using 36 or
other foreign materials likely to contaminate the finer grit grinding material. All grinding marks
weld. should be parallel to the direction of primary
3. Air arc the entire crack leaving a V-shaped joint. stress if possible (and if known).
The depth of the V- or U-shaped joint will be
12. Hammer peen the toes of repair fillet welds as
determined by the depth of the crack. The width
detailed in Annex B, see attached.
to depth ratio should be approximately 1.25:1
and never less than 1:1. All cracks through the 13. Inspect repaired areas (for surface defects)
parent material will require a slightly wider root using magnetic particle or dye penetrant inspec-
opening than the original, usually 6 mm (0.25 tion procedures.
in) to allow the installation of a backup strip. 14. If surface defects are found, remove all defects
Backup strips are required for all cracks that by grinding to a maximum depth of 1.5 mm
have gone through the parent material and can- (0.06 in). Larger defects must be removed as
not be welded from both sides. If a weld repair per the above mentioned procedures. All spot
allows access to both sides of the plate, no welding also requires preheating and post heat-
backup strip is required as long as complete ing.
weld penetration is achieved. If backup strips
are not used, the surface profile on both sides
must be ground smooth with no undercut. Doc-
umentation must support this repair. Photo-
graphs of surface condition are required by the
service and warranty departments of Komatsu.
4. Use dye penetrant to ensure the cracks are
completely removed.

ANNEX B 2.0 TOE GRINDING WITH A ROTARY BURR
1.0 TOE HAMMER PEENING Equipment:
Equipment: 1. High speed rotary air tool (15,000-20,000 rpm)

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

FIGURE 4-1. TOE HAMMER PEENING

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

BIBLIOGRAPHY
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earth Moving and
Construction Equipment
Metals and How to Weld Them - James F. Lincoln Before opening any cabinets or touching a
Arc Welding Foundation. Cleveland, Ohio retarding grid element or a power cable, the
engine must be shutdown and the red drive
Procedure Handbook of Arc Welding - Lincoln Elec- system warning lights must not be illuminated.
tric Company, Cleveland, Ohio
American Welding Society - Welding Handbook Engine Shutdown Procedure before Welding or
Performing Maintenance
British Standard BS5135 - Metal Arc Welding of Car-
bon and Carbon-Manganese Steels Normal operation of the drive system at shutdown
leaves the system safe to maintain. However, in the
Welding Steels Without Hydrogen Cracking - The event of a system failure, performing the following
Welding Institute, F. R. Coe, Author procedure prior to any maintenance activities will
ensure that no hazardous voltages are present in the
SPECIAL PRECAUTIONS WHEN AC drive system.
SERVICING AN AC DRIVE SYSTEM TRUCK
1. Before shutting down the engine, verify the
Prior to welding and/or repairing an AC dump truck, status of all the drive system warnings.
maintenance personnel must attempt to notify a
Komatsu service representative. Only qualified If any of the red drive system warning lights
personnel, specifically trained for servicing the AC remain on, do not attempt to open any cabinets,
drive system, must perform this service. disconnect any cables, or reach inside the
retarder grid cabinet without a trained drive
If it is necessary to perform welding or repair to the system technician present, even if engine is off.
truck without the field engineer present, the following Only qualified personnel, specifically trained for
procedures must be followed to ensure that the truck servicing the AC drive system, may perform
is safe for maintenance personnel to work on and to this service.
reduce the chance for damage to equipment.
2. If all red drive system warning lights are off,
follow all of the instructions for “Parking The
Machine.”
3. After the engine has been off for at least five
minutes, inspect the link voltage lights on the
exterior of the main control cabinet and rear of
Anytime the engine is running do not open any of the center console. If all lights are off, the retard
the cabinet doors or remove any covers. Do not grids, wheel motors, alternator, and related
use any of the power cables for hand holds or power cables are safe to work on.
foot steps. DO NOT touch the retarding grid
4. Locate GF cutout switch (2, Figure 4-3) in the
elements.
front access panel on the left side of the main
control cabinet. Place the switch in the
CUTOUT position. This will prevent the
alternator from reenergizing and creating
system voltage until the switch is returned to the
previous position.
5. Ensure both battery disconnect switches are in
the OFF position. Verify that the battery
disconnects are functioning.
6. Before doing any welding on the truck, always
disconnect the battery charging alternator lead
wire.
7. Do not weld on the rear of the control cabinet!
The metal panels on the back of the cabinet are
part of capacitors and cannot be heated.

8. Do not weld on the retard grid exhaust louvers - 11. If the red lights on the exterior of the control cab-
they are made of stainless steel. Some power inet continue to be illuminated after following
cable panels throughout the truck are also the above procedure, a fault has occurred.
made of aluminum or stainless steel. They must
Leave all cabinet doors in place; Do not touch
be repaired with the same material or the power
the retard grid elements; do not disconnect any
cables may be damaged.
power cables, or use them as hand or foot
9. Power cables must be cleated in wood or other holds.
non-ferrous materials. Do not repair cable
cleats by encircling the power cables with metal 12. Replace all covers and doors and place the GF
clamps or hardware. Always inspect power cutout switch and battery disconnect switches
cable insulation prior to servicing the cables and in their original positions. Reconnect all har-
prior to returning the truck to service. Discard nesses prior to starting the truck.
cables with broken insulation. Leave the drive system in the rest mode until
10. Power cables and wiring harnesses must be the truck is to be moved.
protected from weld spatter and heat. Always
fasten the welding machine ground (-) lead to
the piece being welded; the grounding clamp
must be attached as near as possible to the
weld area.
Always avoid laying welding cables over or
near the vehicle electrical harnesses. Welding
voltage could be induced into the electrical
harness and cause damage to components. FIGURE 4-3. INFORMATION DISPLAY PANEL
Never allow welding current to pass through
1. Control Power Switch
ball bearings, roller bearings, suspensions, or
2. GF Cutout Switch
hydraulic cylinders.
3. Capacitor Charge Light

RECEIVING & ASSEMBLY PREPARATION
Preparation Coded Boxes
A parts check list will be included in each shipping
Inspection, Cleaning, Setup
crate that is shipped with the truck. The list consists
1. Inspect all components for possible shipping of tables that represent a portion of the assembly
damages. Note any damage found and report to process. The parts listed in each table will be packed
shipping agent. in waterproof corrugated PVC boxes.
2. Spread out all parts and organize per unit num- The boxes will be packed into shipping crates and
ber. Check for missing parts. List the unit num- shipped with the truck. Refer to Figure 5-1, through
ber of all major components. Verify the cab and Figure 5-3. Assembly technicians can then locate the
decks are with the correct chassis. boxes that match the operation (table) being per-
3. Install support blocks under the chassis. The formed. The boxes will be packed into the crate in
support blocks must be approximately 84 cm chronological order. Parts needed early in the
(33 in.) high. assembly process will be located near the top of the
4. Install support blocks under the rear axle hous- crates.
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.
5. Clean all mounting surfaces on the chassis and
on the individual components.
6. Clean and tap all mounting capscrew holes.
7. Check all electrical connectors and verify they
are free of paint and/or corrosion. Clean any
connector with questionable electrical continu-
ity.
8. Check all factory installed components for the
proper tightening torque.
9. Arrange the work site as shown on the following
page.
FIGURE 5-1.
FAM0515 Receiving & Assembly Preparation 5-1

FIGURE 5-2. FIGURE 5-3.
5-2 Receiving & Assembly Preparation FAM0515

ASSEMBLY LAYOUT
FAM0515 Receiving & Assembly Preparation 5-3

NOTES
5-4 Receiving & Assembly Preparation FAM0515

CHASSIS ASSEMBLY
Due to differences in machine configurations and BASIC ASSEMBLY PROCEDURE
shipping restrictions/requirements throughout the
1. Site Preparation
world, the shipping and packaging of large machines
varies. Photographs or illustrations used in the fol- 2. Unload Truck Components
lowing procedures are provided as general guide- 3. Assemble the Chassis
lines only. Actual assembly may be different, but this 4. Weld the Body
general procedure provides a basic outline for
assembly. NOTE: Chassis assembly and body welding may be
done in either order, or simultaneously. The most
Items like the hydraulic tank and the accumulators logical order depends on available resources such as
may have been removed for shipping and will have to cranes, welders, assemblers, etc.
be locally installed.
5. Static Checkout (electrical and mechanical)
Each shipment may be different, depending on the 6. Hydraulic Flushing
truck configuration and destination.
7. Install the Body
RECOMMENDED ASSEMBLY DATA 8. Dynamic Checkout (electrical and mechanical)
9. Site Cleanup
1. Acknowledgment of Receipt of Company War-
ranty
2. Assembly Blueprints and Schematics, if appli-
cable
FAM0647 Chassis Assembly Page 6-1

ORDER OF ASSEMBLY 4. LH Deck
5. RH Deck/Grid Box
The assembly procedure is organized in levels. Gen-
erally, the tasks to be done at a given level may be 6. Weld Uprights
performed in any convenient order or simultaneously. 7. Adjust Radiator Stabilizers
However, all tasks in that level must be completed 8. Operator Cab (Mounting)
before proceeding to the next higher level. Each level
depends on the installation of components from the LEVEL 4
previous level.
1. Control Cabinet
NOTE: As stated earlier, shipping and packaging of 2. Transformer
large machines will vary. Some of these steps may
3. Blower Inlet Duct
change due to different shipping configurations and/
or truck options. 4. Diagonal Ladder
5. Control Group Blowers
LEVEL 1 6. Wheel Motor
1. Chassis - Unload and crib for assembly 7. Wheel Motor Blowers
2. Deck Supports 8. Front Tires
NOTE: It is easier to install and weld the deck 9. Rear Tires
supports before the front suspensions are installed.
However, do not install the deck supports first, unless LEVEL 5
there is a suitable means of installing the suspension 1. Exhaust Blankets
with the deck support in place.
3. Uprights/Air Cleaners LEVEL 6
NOTE: Do not weld the uprights / air cleaners until all 1. Dump Body Installation
decks and the operator cab are installed. Ratchet
hoists may be required to help tie all the structures LEVEL 7
together for a proper fit. 1. Hoist Cylinders (Upper Mount)
4. Diagonal Beams (ROPS) 2. Body Pads/Shims/Guides
5. Suspensions - should they not have a install 3. Rock Ejectors (If applicable)
stand 4. Mud Flaps
6. Operator Cab (Verify Fit) 5. Clearance Lights
7. Weld Deck Supports
8. Hydraulic Tank LEVEL 8
9. Hoist Cylinder Install 1. Clean the Truck
10. Fuel Tank 2. Lighting Wiring
3. Charge Suspensions
LEVEL 2 4. Charge Accumulators
1. Air Cleaner Piping 5. Add Fluids
2. Headache Rack Installation
NOTE: Prior to starting the engine, verify that the
3. Spindles/Hubs steering pump case is full of oil.
LEVEL 3 6. Hydraulic System Flushing

1. Steering Cylinders
LEVEL 9
2. Tie Rod
1. System Checkouts
3. Center Deck
2. Decals
3. Touch Up Paint
4. Install Optional Equipment
Page 6-2 Chassis Assembly FAM0647

CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at other loca-
tions may be different. However, this outline will pro-
vide a general basis for assembly.
Disconnect the battery cables before arc welding
on the truck. Failure to do so may seriously dam-
age the batteries and electrical equipment. Dis-
connect the battery charging alternator lead wire
before welding on the frame or its components.
Follow all safety recommendations in this man- Fasten the welding machine ground cable to the
ual. Follow all local, state, and federal regula- component being welded.
tions. DO NOT allow welding current to pass through
bearings.
In the procedures that follow, many very heavy com-
ponents will be required to be lifted into place and DO NOT lay welding cables over truck electrical
secured. cables and harnesses. Welding voltages could be
induced into the truck wiring and cause damage
to components.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly cleaned and
ventilated.
• Inspect all lifting devices. Slings, chains, and Maintain fire control equipment. Inspect fire
cables used for lifting components must be extinguishers regularly to ensure they are fully
inspected daily for serviceable condition. charged and in good working 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. Mark capscrews and nuts with paint or ink before
tightening to the specified torque. This method
• When in doubt as to the weight of
components or any assembly procedure, provides verification that the hardware has been
contact your customer support manager for properly tightened.
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 10. Use the proper precautions when checking the
INSTRUCTION nitrogen pressure and oil level in the accumula-
tors.
1. Clean and remove all foreign material from
component mounting surfaces. 11. Verify the lube system is lubricated, purged and
all levels full prior to start up.
2. DO NOT weld the front uprights to the bumper
until cab and all upper decks are installed. 12. Purge air from the steering pump before truck
3. Tighten the deck mounting capscrews before operation. Pressure will not build in the brake
the exhaust tubes, etc. are installed. and steering circuit if air is present. Air in the
system may damage the pump. Refer to the
4. Verify all electrical connectors are free from Hydraulic Checkout Procedure in Section 10 of
paint and/or corrosion. Clean any connector this manual.
that may be questionable.
13. Use the battery disconnect switch when arc
5. Do not tighten the diagonal beam (ROPS) cap-
welding. Connect the weld ground near the
screws until after the operator cab and LH air
weld area.
intake tubes are in place.
6. Before installing the cab to the substructure, tap 14. Before the truck is started for the first time, the
all threaded holes to remove paint. hydraulic system must be flushed. Refer to the
hydraulic system flushing procedure in the
7. Verify all wiring is properly connected before
Appendix.
attempting to start the engine.
8. Recheck the torque on hardware installed at the
factory.
9. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.

CHASSIS AND COMPONENT SERIAL These include the uprights, diagonal beam(s), deck
NUMBER (SN) IDENTIFICATION supports and cab.
During assembly it is important that each component Cylinders, suspensions, spindles, retarding grid and
be installed on the correct chassis. wheel motors will be stamped with the components
individual part number (PN) and SN not the chassis
Failure to install the correct components on the cor- SN. The shipping documentation of the chassis will
rect chassis can result in weld fitments, hydraulic and have the component PN and SN identified on it for
electrical connection issues. proper installation.
Structural components will be stamped with at least The following chart lists the chassis components
the last two digits of the chassis serial number (SN). along with a brief description and a graphic of where
the SN stamp is located.
CHASSIS STAMPED LOCATION OF COMPONENT GRAPHIC INDICATING SN

COMPONENT SERIAL NUMBER (SN) LOCATION
Upright Edge of Upright Tube
Mounting Plate Edge of Mounting Plate

Deck Support Locator Block on Deck
Support
Operator Cab Mounting Pad on Cab
Control Cabinet Upper LH side of Control

Cabinet

Front Suspension Next to the Keyway
Spindle Top of the Spindle Edge
Hoist Cylinder On the Barrel

Rear Suspension Below Warning Decal
Wheel Motor Edge of Flange

ASSEMBLY PROCEDURAL STEPS The support blocks/stands must be approximately 84
1. Lift the chassis off the truck/trailer or rail car cm (33 in.) high at the front, and approximately 30 cm
(see Figure 6-1 and Figure 6-2) using a crane (12 in.) high under the rear axle housing. Refer to
with minimum capacity of 100 tons or two Figure 6-3. Placement of the chassis at this height
cranes with a minimum capacity of 50 tons will allow easy installation of truck components. Thor-
each. Lift the chassis onto adequate support oughly clean the chassis.
blocks or stands. The weight of the chassis, as
shipped, is approximately 48,943 kg (107,900
lb).
FIGURE 6-1.

FIGURE 6-2.
FIGURE 6-3.

2. Clean the mating surfaces for the deck supports
and the frame to prepare for installation. The
surfaces must be free of paint, rust, dirt, grease
and oil.
FIGURE 6-5.
FIGURE 6-4.

3. Install LH deck support into position. Bolt the
support into place. Do not weld the support at
this time. Refer to Figure 6-8 through Figure 6-
11.
NOTE: If more than one truck is being assembled at
one time, ensure the uprights, deck supports and
diagonal braces are installed on the correct chassis.
These parts are marked with the truck serial number
to ensure proper assembly. Refer to Chassis and
Component Serial Number (SN) Identification chart
found earlier in this section.
FIGURE 6-6.
FIGURE 6-8.
FIGURE 6-7.



4. Install RH deck support into position. Bolt the
support into place. Do not weld the support at
this time. Refer to Figure 6-12 through Figure 6-
16.
NOTE: If more than one truck is being assembled at
one time, ensure the uprights, deck supports and
diagonal braces are installed on the correct chassis.
These parts are marked with the truck serial number
to ensure proper assembly. Refer to Chassis and
Component Serial Number (SN) Identification chart
found earlier in this section.
FIGURE 6-13.
FIGURE 6-12.
FIGURE 6-14.

FIGURE 6-15.
FIGURE 6-16.

5. Prepare the upright mating surfaces and the
frame for installation. The surfaces must be free
of paint, rust, dirt, grease and oil. Refer to Fig-
ure 6-17.
FIGURE 6-17.

6. Attach each uprights to a crane using adequate
lifting apparatus. Attach a ratchet hoist to the
lifting apparatus (on the front side) to enable the
upright to pivot for proper alignment during
installation (see to Figure 6-18). Install the four
capscrews to mount the upright.
NOTE: Do not weld the torque tubes on the uprights
at this time.
7. Lift each upright into their position (see Figure
6-19 and Figure 6-20) and install the four cap-
screws to mount the upright. Tighten to stan-
dard torque. Refer to Standard Tables in
Section 10, Appendix. Tighten to 465 ± 47 N·m
(343 ± 34 ft lb). The weight of the uprights with
air cleaner attached is approximately 822 kg
(1,812 lb).
NOTE: Do not weld the torque tubes on the uprights
at this time.
FIGURE 6-18.


8. Attach the upper radiator stabilizer rods to the
uprights. Refer to Figure 6-21 through Figure 6-
23. Do not tighten at this time. Adjustment will
be performed after the decks and uprights are
fully installed.
FIGURE 6-22.
FIGURE 6-21.

9. Lift the LH and RH diagonal beam (ROPS) into
position. Refer to Figure 6-24 through Figure 6-
29. The weight of the LH diagonal beam
(ROPS) is approximately 139 kg (306 lb). The
weight of the RH diagonal beam (ROPS) is
approximately 75 kg (165 lb).
The surfaces must be free of paint, rust, dirt,
grease and oil. Leave the capscrews loose.
NOTE: Do not tighten the capscrews until the deck
and the cab are in place.
FIGURE 6-23.
FIGURE 6-24.


FIGURE 6-28.
FIGURE 6-27.
FIGURE 6-29.

10. Clean the front suspension mounting surfaces.
The surfaces must be free of paint, rust, dirt,
grease and oil. Refer to Figure 6-30 and Figure
6-31.
11. Clean and dry the mounting surfaces on both
the suspension and the frame. Use a cleaning
agent that does not leave a film after evapora-
tion, such as trichlorethylene, tetrachloreth-
ylene, acetone or lacquer thinner.
FIGURE 6-31.
FIGURE 6-30.

High tightening torque is required to load the
front suspension mounting capscrews. Repeated
tightening will result in capscrew fatigue and
damage. Do not reuse mounting capscrews,
washers and nuts. Replace the hardware after
each use.
Suspension mounting capscrews are specially
hardened to meet or exceed grade 8
specifications. Replace only with capscrews of
correct hardness. Refer to the appropriate parts
book for the correct part numbers.
. FIGURE 6-32. INSTALLATION OF HARDENED
FLAT WASHER
1. Hardened Flat Washer 2. Capscrew
The use of dry threads in this application is not

recommended. Due to the high tightening forces 14. Lift the front suspension into position. The
required to load these capscrews, dry threads or weight of each front suspension cylinder is
threads lubricated with anti-seize compounds approximately 2 228 kg (4,912 lb). Install the
may result in damage. Only use a lithium based mounting hardware and tighten according to the
chassis grease (multi-purpose, EP, NLGI #2, with "angle advance" method outlined on the follow-
a maximum moly content of 5%). ing pages. Refer to Figure 6-33 through Figure
12. Lubricate the capscrew threads, capscrew head 6-41.
seats, washer faces, and nut seats with a lith-
ium based chassis grease (multi-purpose, EP,
NLGI #2, with a maximum moly content of 5%).
13. The hardened flat washers used on the front
suspensions may be punched during the manu-
facturing process. If there is a punch lip on the
flat washer, install the flat washer to position the
punch lip away from the capscrew head to pre-
vent damage. See Figure 6-32.
FIGURE 6-33.

FIGURE 6-34.
FIGURE 6-35. SUSPENSION INSTALLATION

Angle Advance" Tightening Procedure
a. Initially tighten the hardware to 1 356 ± 136
N·m (1,000 ± 100 lb ft) in the sequence Upper Mounting Joint - 60° Advance
shown in Figure 6-35. Use a properly cali-
The proper sequence for the upper mounting joint is
brated torque wrench to ensure accuracy.
1-2-3-4-9-10. Refer to Figure 6-35.
NOTE: Do not exceed 4 rpm tightening speed. Do
b. Loosen only the first capscrew. All other cap-
not hammer or jerk the wrench while tightening.
screws must be maintained at 1 356 ± 136
The mounting capscrews will now need to be loos- N·m (1,000 ± 100 lb ft).
ened and then tightened using angle advance c. Tighten the capscrew to 95 N·m (70 lb ft).
method. The first set of capscrews to be adjusted will
be at the upper mounting joint. The capscrews must d. Mark a corner of the capscrew head with a
be loosened one at time and then tightened by paint marker as shown in Figure 6-36. Draw
advancing a specified rotational degree. Use the a reference line on the suspension surface
map shown in Figure 6-35 for proper tightening next to the marked corner on the capscrew.
sequence. Draw a second reference line on the suspen-
sion 60 degrees in advance of the marked
corner on the capscrew.

Lower Mounting Joint - 90° Advance
The proper sequence for the lower mounting joint is
5-6-7-8-11-12-13-14. Refer to Figure 6-35.
h. Loosen the first capscrew. All other cap-
screws must remain tight.
i. Tighten the capscrew to 203 N·m (150 lb ft).
NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.
j. Mark a corner of the capscrew head with a
FIGURE 6-36. 60 DEGREE ADVANCE
paint marker as shown in Figure 6-38. Draw
a reference line on the suspension surface
e. Hold the nut at the rear of the joint stationary (or frame) next to the marked corner on the
while tightening. Advance the capscrew to capscrew. Draw a second reference line on
the 60° advance mark. the suspension surface (or frame) 90
degrees in advance of the marked corner on
f. Make new reference lines along the cap- the capscrew.
screw, nut and frame at the rear of the joint
as shown in Figure 6-37. These reference
lines will be used to verify the capscrews
have maintained their torque.
g. Repeat this process in sequence for the
remaining five capscrews 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 capscrews and
repeat the entire process. The hardware, again, must FIGURE 6-38. 90 DEGREE ADVANCE
be cleaned and lubricated before repeating.
FIGURE 6-37. MAKING REFERENCE LINES

k. Hold the nut stationary at the rear of the joint
(where applicable) while tightening. Then
advance the capscrew to the 90° advance
mark.
l. Make new reference lines along the cap-
screw, nut and frame at the rear of the joint
as shown in Figure 6-37. For the four cap-
screws with spacers, refer to Figure 6-39.
These reference lines will be used to verify
the capscrews have maintained their torque.
FIGURE 6-40.
FIGURE 6-39. 90 DEGREE ADVANCE
m.Repeat this process in sequence for the

remaining capscrews in the lower mounting
joint.
NOTE: If for any reason these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 capscrews and
repeat the entire process. The hardware, again, must
be cleaned and lubricated before repeating.
Inspection
Visual inspections of the bolted joints are necessary
after the truck has been released for use. Inspect the
joints at each front suspension at the following inter-
vals: 8 hours, 50 hours, 250 hours, and 500 hours.
If the reference lines on the hardware (Figure 6-37
and Figure 6-39) have remained in alignment, the
truck may remain in use.
If at least one of the capscrews has shown signs of
movement, the truck must be taken out of service.
The suspension mounting capscrews must be
removed, cleaned, and inspected. If any capscrews
have any signs of damage, replace all capscrews.
Install the capscrews again, according to this installa- FIGURE 6-41.
tion procedure.

15. Tap the cab mounting holes to remove any paint 16. Tighten all of the hardware for the left hand
from the threads. Tap size is 1.00 x MM36. Lift diagonal tube to standard torque.
the cab onto the deck supports (see Figure 6-
17. Securely tack weld the left upright and the left
42) and install 1/2 of the mounting hardware.
deck support in place.
Verify no gaps exist between the mounting pads
of the cab. If gaps are present, the upright and/ NOTE: Refer to Field Welding For Assembly or
or deck support may need to be repositioned. Repair in this manual for additional warning, cautions
Tighten the cab mounting hardware to standard or steps when welding.
torque. Refer to Standard Tables in Section 10,
Appendix.
FIGURE 6-42. DETERMINING CAB FIT
1. Left Upright 3. LH Deck Support

2. Cab 4. LH Diagonal Beam
18. Remove the cab mounting hardware and

remove the cab.

NOTE: Refer to Field Welding For Assembly or
Repair in this manual for additional warning, cautions
or steps when welding.
a. The four tapped pads on the left deck sup-
port and the corresponding blocks on the
If the tapped pads are not removed, a complete horsecollar must be removed to allow for a
weld around the support can not be achieved. complete weld around the joint.
Gaps in the weld around the support may result
b. Completely weld all around the left deck sup-
in premature frame cracking in this area.
port as described on the assembly drawing
19. Completely weld the left hand deck support in provided with the truck.
place. Refer to Figure 6-43 and Figure 6-44.
c. Grind all areas smooth and clean. Paint the
weld and surrounding area.
FIGURE 6-43.

FIGURE 6-44.

20. Completely weld the left hand upright to the welding the uprights in place as instructed per
front frame tube. Refer to Figure 6-45 and Fig- the assembly drawing provided with the truck.
ure 6-46. After the upright is securely tack
NOTE: Refer to Field Welding For Assembly or
welded in place, remove the capscrews. Also
Repair in this manual for additional warning, cautions
cut the capscrew blocks off of the frame. Finish
or steps when welding.
FIGURE 6-45.
FIGURE 6-46.

21. Lift the hoist cylinder into position over the pivot
point on the frame. The weight of each hoist cyl-
inder is approximately 969 kg (2,137 lb). Posi-
tion the cylinder with the air bleed vent plug on
top, and facing the front of the truck. Refer to
Figure 6-47
FIGURE 6-48.
1. Capscrew 4. Retainer Ring

2. Locking Plate 5. Bearing
FIGURE 6-47. FUEL HOSE INSTALLATION 3. Retaining Plate 6. Spacer
22. Install spacer (6, Figure 6-48). Align the bearing

eye with the pivot point and push the cylinder
into place.
23. Install retaining plate (3), locking plate (2), and
capscrews (1). Tighten the capscrews to 465 ±
47 N·m (343 ± 34 ft lb). Bend the locking plate
tabs over the capscrew flats.
NOTE: DONOT connect the hoist hydraulic hoses at
this time. The cylinders are not shipped on the
chassis.

24. Remove all paint from the mounts for the
hydraulic tank and the fuel tank. Refer to Figure
6-49.
FIGURE 6-49.
25. Lift the hydraulic tank into position on the cra-

dles. Refer to Figure 6-50 through Figure 6-53.
The weight of the hydraulic tank is approxi-
mately 700 kg (1,545 lb).
Install the four capscrews with special flat wash-
ers and the cradle caps at the top of the tank.
Tighten the capscrews to 622 ± 61 N·m (459 ±
45 ft lb). FIGURE 6-50.
Install the rubber dampeners and mounting
hardware at the rear of the tank. Tighten the two
capscrews to standard torque. Refer to Stan-
dard Tables in Section 10, Appendix.
FIGURE 6-55.

FIGURE 6-52.
FIGURE 6-53.

26. Lift the fuel tank with DEF tank already installed Tighten to standard torque. Refer to Standard
into position on the cradles (Figure 6-54). The Tables in Section 10, Appendix.
weight of the fuel tank is approximately 1 711 kg
Install the rubber dampeners and mounting
(3,772 lb).
hardware at the rear of the tank. Tighten the
Install the four capscrews with special flat wash- four capscrews to standard torque.
ers and the cradle caps at the top of the tank.
FIGURE 6-54.
1. Fuel Tank 2. DEF Tank

27. Prepare the hydraulic filters for mounting on the
fuel tank. Ensure that all filter hardware is prop-
erly tightened. Refer to Figure 6-55.
FIGURE 6-55.

28. Connect the piping to the hydraulic tank and 29. Install the hydraulic filters onto the bracket at
properly tighten all fittings. Refer to Figure 6-56. the rear of the fuel tank. Refer to Figure 6-57.
NOTE: When the machine is ready for operation, the Connect the fuel supply line to the fitting at the
hydraulic tank shut-off valves must be opened. rear of the tank, and connect the return line to
the fitting at the top of the tank.

30. Lift the LH air intake plenum into place. Refer to
Figure 6-58 through Figure 6-60.
FIGURE 6-59.
FIGURE 6-58.

31. Lift the LH air intake tubes into place. Install and
tighten the clamps that secure the hoses.
Refer to Figure 6-61 through Figure 6-63. The
intake tubes are assembled and adjusted for
installation on the truck.
NOTE: DO NOT loosen any of the connections
during installation.
FIGURE 6-60.
FIGURE 6-61.


32. Lift the RH air intake plenum into place. Refer to
Figure 6-64 and Figure 6-65.
FIGURE 6-65.
FIGURE 6-64.

33. Lift the RH air intake tubes into place. Install and
tighten the clamps that secure the hoses.
Refer to Figure 6-66 through Figure 6-68. The
intake tubes are assembled and adjusted for
installation on the truck.
NOTE: DO NOT loosen any of the connections
FIGURE 6-67.
FIGURE 6-66.
FIGURE 6-68.
34. Install Headache Rack. Refer to Figure 6-69

through Figure 6-71.
35. Clean the mating surfaces for the headache
rack and the frame to prepare for installation.

FIGURE 6-69.
FIGURE 6-70.

36. Clean mating surface. Install and tighten eight
M20 capscrews to 465 N·m (343 ft lb).
FIGURE 6-71.

37. Clean the tapered portion of the suspension rod NOTE: Never use any lubricants on the spindle bore
and the bore of the spindle. Clean and check containing copper, such as many “anti’-seize”
the tapped holes in bottom of Hydrair® piston compounds. Products containing copper will
for damaged threads. Retap holes, if necessary, contribute to corrosion in this area.
with 1.250 in. - 12NF tap. Lubricate spindle bore
and suspension rod taper with a lithium based
chassis grease (multi-purpose, EP, NLGI #2).
Refer to Figure 6-72.
FIGURE 6-72.

38. Lift the retainer plate into position under the NOTE: The use of dry threads in this application is
spindle. The weight of the retainer plate is not recommended. Due to the high tightening forces
approximately 48 kg (106 lb). Lift the spindle/ required to load these capscrews, dry threads may
brake assembly and retainer plate into position. cause damage to tools.
The weight of each spindle/brake assembly is
approximately 3 216 kg (7,090 lb). Refer to Fig-
ure 6-73.
FIGURE 6-73.

39. Lubricate capscrew threads, capscrew head 40. Repeat the previous steps for the remaining
seats and washer face with lithium based chas- wheel.
sis grease (multi-purpose, EP, NLGI #2, with a
41. Check the capscrew torque on the steering arm
maximum moly content of 5%). Install the
capscrews. Capscrew torque should be 2 705 ±
twelve retainer plate capscrews. Refer to Figure
271 N·m (1,995 ± 200 ft lb).
6-74. Tighten capscrews using the following
procedure: NOTE: If the steering arms have to be installed,
lubricate capscrew threads, capscrew head seats
a. Tighten capscrews uniformly to 678 N·m
and washers with a lithium based chassis grease
(500 ft lb) torque.
(multi-purpose EP, NLGI #2).
b. Continue to uniformly tighten the capscrews
in increments of 339 N·m (250 ft lb) to obtain
a final torque of 2 495 ± 251 N·m (1,840 ±
185 ft lb).
FIGURE 6-74.

42. Prepare the steering cylinder and tie rod mount- The tie rod toe-in must be adjusted once the
ing surfaces. Refer to Figure 6-75. tires and the body are installed. The toe-in
adjustment procedure is located in Section 10,
Appendix. Ensure the clamping capscrews on
tie rod are tight after adjusting toe-in.
NOTE: Use alignment sleeve (TY4576) to aid in
assembly of the tie rod joints.
FIGURE 6-75.
43. Move the steering cylinder rod eye into position

on the steering arm. Lubricate the mounting pin
with grease. Install the spacers, the mounting
pin, and hardware. Tighten the pin capscrew to
1 017 ± 102 N·m (750 ± 75 ft lb). Refer to Fig- FIGURE 6-76.
ure 6-76 and Figure 6-77.
NOTE: Use alignment sleeve (TY4576) to aid in
assembly of the steering cylinder joints.
44. Lift the tie rod into position on the steering arms.
Ensure the anti-rotation tabs on the tie rod ends
are on the bottom side of the tie rod when
installed. The weight of the tie rod is 250 kg
(550 lb). Lubricate the mounting pins with
grease. Install the spacers, the mounting pin,
and hardware. Tighten the pin capscrew to 1
017 ± 102 N·m (750 ± 75 ft lb).
FIGURE 6-77.

45. Lift the center deck into position (Figure 6-78).
Tighten the four capscrews to 465 ± 47 N·m
(343 ± 34 ft lb). Refer to Standard Tables in Sec-
tion 10, Appendix.
FIGURE 6-78.

46. Install the handrails onto the LH deck and lift the NOTE: DO NOT attach lifting chains to the handrails.
deck into place (Figure 6-79). The weight of the Install eye bolts and lifting chains at designated lifting
LH deck with handrails is approximately 802 kg points on the deck only.
(1,768 lb). Loosely install the eight deck mount-
After the deck is in place, tighten the capscrews to
ing capscrews.
standard torque. Refer to Standard Tables in Section
10, Appendix.
FIGURE 6-79.

47. Install the handrails on the RH deck. NOTE: On domestic trucks, the retarding grid is
48. Lift the RH deck into position and install the six already installed on the deck. DO NOT attach lifting
capscrews. The weight of the RH deck is chains to the handrails or retarding grid lifting eyes.
approximately 725 kg (1,598 lb). Tighten the Install eye bolts and lifting chains at designated lifting
mounting capscrews to standard torque. Refer points on the deck only. The retarding grid may need
to Figure 6-80. to be removed from the deck and installed separately
after RH deck installation.
FIGURE 6-80.
49. Lift the retarding grid into place on the RH deck.

The weight of the retarding grid is approxi- FIGURE 6-81.
mately 2 364 kg (5,212 lb). Refer to Figure 6-81.
Install the grid mounting hardware and tighten
the eight capscrews to standard torque. Refer
to Standard Tables in Section 10, Appendix.

50. After the right deck is bolted in place, weld the screws. Also cut the capscrew blocks off of the
RH upright to the front frame tube. Refer to Fig- frame. Finish welding the uprights in place as
ure 6-82 and Figure 6-83. After the upright is instructed per the assembly drawing provided
securely tack welded in place, remove the cap- with the truck.
FIGURE 6-82.
FIGURE 6-83.

51. After both LH and RH decks are installed and The truck is now ready for body installation.
both uprights welded, adjust the upper radiator
stabilizers.
a. Loosen all hardware for the lower radiator
stabilizers (Figure 6-86).
b. Adjust the upper radiator stabilizers, located
between the radiator and the uprights at
each top corner of the radiator (Figure 6-84).
The radiator must be perpendicular to the
subframe within 3.0 mm (0.12 in.). When the
position is established, tighten the upper FIGURE 6-84. UPPER RADIATOR STABILIZER
radiator stabilizer locknuts and recheck the
perpendicularity of the radiator.
c. Adjust the radiator shroud bumpers, located
below each deck, on each side of the radia-
tor shroud (Figure 6-85). Adjust the bumpers
so that they just contact the shroud with no
pre-load.
d. If the lower radiator stabilizer has a fixed
mount at the subframe, tighten all hardware.
If the lower radiator stabilizers have a rubber

mount (Figure 6-86), adjust the stabilizers so
that the stabilizer bar is free from assembly
stress. Tighten the hardware. FIGURE 6-85. RADIATOR SHROUD BUMPER
Hydraulic system contamination can cause pre-

mature failure of hydraulic system components.
To guard against premature hydraulic system
component failure, perform the hydraulic system
flushing procedure.
52. Before the engine is started the first time, the
hydraulic system should be set up to perform
the flushing procedure. Refer to the Hydraulic
System Flushing Procedure in the Appendix.
The purpose of hydraulic system flushing is to
eliminate contaminants that could have been
introduced into the hydraulic system during
truck assembly. Performing the flushing proce- FIGURE 6-86. LOWER RADIATOR STABILIZER
dure will remove these contaminants from the
hydraulic system and minimize the potential for 1. Capscrews 2. Nuts
hydraulic system component damage at
startup.

53. Cab Mounting c. Check for any gaps between cab mounting
a. Tap the cab mounting holes to remove any plates and the frame mounting plates. Use
paint from the threads. Tap size is 1.00 x shims EL1949 (front) or EL1950 (rear) as
8NC. required to reduce the gap to less than 1.0
mm (0.04 in.).
b. Lift the operator cab into position (Figure 6-
d. Install and tighten the 28 cab mounting cap-
87). The weight of the cab with brake cabinet
screws to 2 750 N·m (2,028 ft lb).
is approximately 2 177 kg (4,800 lb).
FIGURE 6-87.

54. Lift the two bumper extensions into place. The tion system. Ensure that all wires are out of the
weight of each bumper extension is approxi- way before installation.
mately 123 kg (271 lb). Refer to Figure 6-88 and
Tighten the capscrews to standard torque.
Figure 6-89. The LH bumper extension supports
Refer to Standard Tables in Section 10, Appen-
the isolation station and reserve oil system and
dix.
the RH bumper extension supports the lubrica-
FIGURE 6-88.
FIGURE 6-89.

55. Lift the control cabinet into position. The weight Install the mounting hardware. Tighten the cap-
of the control cabinet is approximately 3 400 kg screws to standard torque. Refer to Standard
(7,500 lb). Tables in Section 10, Appendix.
Refer to Figure 6-90 through Figure 6-94. NOTE: Install one front right and two back left bolts
from the bottom up. Refer to Figure 6-92.
FIGURE 6-90.

FIGURE 6-91.
FIGURE 6-92.

FIGURE 6-93.

56. Connect the wiring for the electrical control cab- Tighten each cable connection per torque
inet, auxiliary control cabinet, and retarding grid. Table 6-1: Torque Table for OEM Interfaces
Refer to Figure 6-94 and Figure 6-95. below.
Table 6-1: Torque Table for OEM Interfaces
Description Torque (N m) Torques (ft lb)

Tertiary and Field Cable Connections 64 47
Retarding Contactor Cable Connections 64 47
Chopper Cable Connections 64 47
Grid Blower Insulators 26 19
DC Link Bus Bar 64 47
WM Cable Connections 64 47
Rectifier AC Link Connections 64 47
FIGURE 6-94.

FIGURE 6-95. AUXILIARY CONTROL CABINET EXTERNAL WIRING
1. Aux. Cabinet Cab Center Console 7. Power Cable (Red) 13. Auxiliary Cabinet OP Controls Har-
Harness 8. Power Cable (Black) ness
2. Right Front Frame Rail Harness 9. Front Wheel Speed Sensor 14. Auxiliary Cabinet Cab Dash Har-
3. Left Front Frame Rail Harness Harness ness
4. Aux. Cabinet Basic Cab Harness 10. Rear Wheel Speed Harness 15. Left Rear Frame Rail Harness
5. Aux. Cabinet Engine Harness 11. Ethernet Harness
6. Aux. Cabinet Hydraulic Harness 12. Right Rear Frame Rail Harness

FIGURE 6-96. AUXILIARY CONTROL CABINET EXTERNAL WIRING
1. Cable – F2 8. Cable – TM1-TB 15. Cable – GMB2 MC 21. Cable – 4DCP6
2. Cable – F1 9. Cable – TM1-TA 16. Cable – WMB Main 22. Cable – CVBA5
3. Cable – T19 10. Cable – TM1-TC Phase 23. Cable – CVBC5
4. Cable - T20 11. Cable – TM2-TC 17. Cable – CGB Main Phase 24. Cable – CVBB5
5. Cable – T2 12. Cable – TM2 – TA 18. Cable – 7DCP6 25. Cable – CVBD5
6. Cable – T1 13. Cable – TM2-TB 19. Cable – 6DCP6
7. Cable – T3 14. Cable – GMB1 MC 20. Cable – 5DCP6

57. Lift the transformer into place. The weight of the
transformer is approximately 356 kg (785 lbs).
Refer to Figure 6-97 through Figure 6-101.
Ensure that all wires are out of the way before
installation.
dix.
FIGURE 6-98.
FIGURE 6-97.


58. Lift the transition duct into place on the alterna-
tor and install the mounting hardware. Install the
flexible duct to connect the transition duct to the
alternator.
NOTE: To help prevent damage to the flexible duct,
ensure that all capscrews are installed so that the
shank end is facing away from the flexible duct.
FIGURE 6-101.

59. Install the LH and RH blowers. Refer to Figure
6-102 through Figure 6-104.
FIGURE 6-103.
FIGURE 6-102.

60. Install the transition and blower hose with
clamps.
61. Lift the air intake ductwork (Figure 6-105
through Figure 6-107) into position and install
the mounting hardware. The weight of the inlet
duct is approximately 191 kg (421 lb). Tighten
the capscrews to standard torque. Refer to
Standard Tables in Section 10, Appendix.
NOTE: Install gasket that is not pictured.
FIGURE 6-104.
FIGURE 6-105.

FIGURE 6-106.

FIGURE 6-107.

62. Install the flexible duct (1, Figure 6-108) with NOTE: To help prevent damage to the flexible duct,
capscrews (2), flat washers (3) and lockwash- ensure that all capscrews are installed so that the
ers (4). shank end is facing away from the flexible duct.
FIGURE 6-108.
1. Blower Flexible Duct 3. Flat Washers
2. Capscrews 4. Lockwashers

FIGURE 6-109.
1. LH Blower Assembly 4. Alternator Duct 7. Rigid Duct Assembly
2. RH Blower Assembly 5. Alternator Flexible Duct 8. Flex Hose Duct
3. Transformer 6. Flex Hose Duct 9. Duct Structure

63. Install the diagonal ladder. The weight of the
diagonal ladder is approximately 179 kg (395
lb).
Refer to Figure 6-110 and Figure 6-111.
dix.
NOTE: The diagonal ladder may not always be
installed in the orientation shown in Figure 6-110.
Diagonal ladders are available in both LH and RH
configurations.
FIGURE 6-111.
FIGURE 6-110.

64. Install center deck handrail. Refer to Figure 6- 65. Install the engine access ladders, handrails and
112. platforms (if equipped) on the truck frame.
Tighten mounting hardware to standard torque.
FIGURE 6-114.

Parking Brake Installation 67. Install the parking brake adapter, retainer plate,
66. Use a cleaner containing organic-based sol- hardened flat washer and capscrew. Tighten the
vents, such as acetone, methanol or ethanol, to capscrew to 712 ± 72 N·m (525 ± 53 ft lb).
clean the rust preventive coating from the park- Refer to Figure 6-115.
ing brake adapter teeth. Water-based cleaners,
such as mild soaps and detergents, do not ade-
quately remove the rust preventive coating.
FIGURE 6-115.

68. Attach a lifting device to the parking brake 70. Seat the parking brake assembly against the
assembly and lift into position. Refer to Figure housing and install the eight capscrews and
6-116. washers. Tighten the capscrews to 298 ± 30
69. Use a port-a-power to release spring pressure N·m (220 ± 22 ft lb).
and allow the alignment of the brake discs
FIGURE 6-116.

Wheel Motor Installation 74. Check the flatness of both mounting faces of
71. Thoroughly clean the capscrew holes and the rear axle housing. Flatness should be
mounting faces of the rear axle housing and checked in four equally spaced intervals (i.e. 0,
wheel motor. Refer to Figure 6-117. 45, 90, and 135).
72. Inspect rear axle housing capscrew holes for The maximum variation in flatness allowed is
damage re-tap any holes with damaged 0.090 inch (2.29 mm).
threads. 75. Apply LW025-27 multi-purpose grease to each
73. Check the mounting faces of the rear axle hous- wheel motor mounting capscrew hole of the
ing for surface defects (i.e. nicks, scratches and rear axle structure.
other damage). The mounting faces must be 76. Install two guide pins 180° apart in the rear
free of surface defects. housing
FIGURE 6-117.

Each complete wheel motor assembly weighs
approximately 12 200 kg (26,900 lb). Ensure that
the lifting devices are capable of handling the
load safely and that the area is clear of all
personnel when lifting.
When lifting the wheel motor assembly, do not

place straps/cables on, or lift from the inner
wheel rim adapter ring. Lifting straps, or cables,
should be placed so that the weight of the wheel
motor assembly is supported by the wheel motor
mounting flange and the machined hub surface.
Shipping fasteners installed in the outer wheel
rim adapter ring must remain in place during lift-
ing and installation of wheel motors.
77. 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-
118 through Figure 6-122.
FIGURE 6-118.



78. Select the hardware to be installed in Group 1 of
the tightening sequence. Refer to Figure 6-124.
Inspect each capscrew for rust, corrosion and
surface defects on any seat or thread. Do not
use any capscrew if a defect is suspected.
79. Lubricate the capscrew threads, capscrew head
seats and washer faces with a lithium based
chassis grease (multi-purpose, EP NLGI #2,
with a maximum of 5% molybdenum).
NOTE: The hardened flat washers used in this
application may have a punch lip on one side due to
the manufacturing process. Therefore, the washers
must be installed with the punched lip away from the
head of the mounting capscrews to prevent damage
to the fillet between the capscrew head and the FIGURE 6-123. FLAT WASHER
shank. Refer to Figure 6-123. 1. Washer 2. Capscrew
80. Install the hardware for Group 1. Tighten each
capscrew to 542 N·m (400 ft lb). 81. Repeat Steps 81 - 83 for each remaining group
in the tightening sequence. Refer to Figure 6-
124.
NOTE: 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 76 when installing the
hardware for Group 3.

82. After all of the hardware in all of the groups has (1,480 ft lb). Repeat this step for each remain-
been installed and tightened to 542 N·m (400 ft ing group in the tightening sequence. Refer to
lb), move back to Group 1. Increase the torque Figure 6-124.
on each capscrew in Group 1 to 2 007 N·m
.
FIGURE 6-124. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

83. Connect the power cables and the speed sen- 84. Connect the brake supply lines, brake cooling
sors to each of the wheel motors. supply lines and return lines to each wheel.
FIGURE 6-125.

Front Wheel Installation b. Install three nuts directly below the 3 o'clock
85. Grip the tire and rim assembly with the tire han- position and three nuts directly above the 9
dler. Align the tire inflation hose and the wheel o'clock position. Tighten the nuts to 1 315 ±
hub. Position the rim onto the wheel hub studs. 136 N·m (970 ± 100 ft lb).
Refer to Figure 6-126. c. Install three nuts directly above the 3 o'clock
position and three nuts directly below the 9
NOTE: Remove all dirt and rust from mating parts
o'clock position. Tighten these nuts to 1 315
before installing the tire and rim assembly.
± 136 N·m (970 ± 100 ft lb).
86. Lubricate all stud threads and nut seating
d. Install the remaining nuts and tighten in a
flanges with lithium base grease. Refer to Fig-
clockwise pattern to 1 315 ± 136 N·m (970 ±
ure 6-127. Install and tighten the nuts in the fol-
100 ft lb).
lowing sequence:
e. Retighten all nuts in a clockwise pattern to
a. Install six nuts at the 12 o'clock position and
the required 2 325 ± 136 N·m (1,715 ± 100 ft
six nuts at the 6 o'clock position. Tighten
lb).
each nut to 1 315 ± 136 N·m (970 ± 100 ft
lb).
FIGURE 6-126.

FIGURE 6-127.

Rear Wheel Installation b. Install three nuts directly below the three
87. Grip the inner tire and rim with the tire handler o'clock position and three nuts directly above
and lift the wheel onto the wheel hub. Refer to the 9 o'clock position. Tighten to 2 326 ± 136
Figure 6-129 and Figure 6-130. Align extension N·m (1,715 ± 100 ft lb). Install three nuts
(4, Figure 6-128) for mating with inner extension directly above the three o'clock position and
(7). three nuts directly below the nine o'clock
position. Tighten to 2 326 ± 136 N·m (1,715
NOTE: Clean all mating surfaces and check the stud ± 100 ft lb).
threads before installing the wheels.
c. Install the remaining nuts in a clockwise pat-
88. Lubricate all stud threads and nut seating tern. Tighten to 2 326 ± 136 N·m (1,715 ±
flanges with lithium base grease. Install and 100 ft lb).
tighten the nuts in the following sequence:
d. Retighten all nuts in a clockwise pattern to
a. Install six nuts at the 12 o'clock position and the required 2 326 ± 136 N·m (1,715 ± 100 ft
six nuts at the six o'clock position. Tighten to lb).
1 315 ± 136 N·m (970 ± 100 ft lb).
89. Install inner extension (7, Figure 6-128) and
clamps (8) before installing the outer tires.
FIGURE 6-128. 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

FIGURE 6-129.
FIGURE 6-130.

91. Install the outer tires and tighten the fifty nuts to
2 326 ± 136 N·m (1,715 ± 100 ft lb). Refer to
Rear Wheel Installation for the correct tighten-
ing sequence. Refer to Figure 6-131.
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 capscrews must be tight-
ened to 2 326 ± 136 N·m (1,715 ± 100 ft lb).
90. Position the rim adaptors into place on each
outer rim. Install the fifty flanged nuts and
tighten the nuts to 2 326 ± 136 N·m (1,715 ±
100 ft lb). Refer to Rear Wheel Installation for
the correct tightening sequence.
FIGURE 6-131.

Rear Suspension Installation 96. Insert bearing spacer (7) over the pin. Continue
92. Secure rear suspension assembly (1, Figure 6- to drive the pin through spherical bearing (9).
132) to a fork lift and raise it into position. The When the pin emerges, insert the remaining
suspension assembly should be retracted as far bearing spacer over the pin on the opposite
as possible before installation. side and continue to drive the pin until the hole
in the axle housing is aligned with the hole in
93. Position the top suspension eye between the the pin.
ears on the frame. Orient the cylinder so that
97. Install shoulder bolt (2), then install washer (3)
the charging valve faces the opposite suspen-
and nut (4). If further alignment of the holes is
sion cylinder.
necessary, install a pin removal tool onto the
94. Lubricate all pin-to-bearing and pin-to-sleeve pin. Use the tool and a large pipe wrench or
contact surfaces with anti-seize compound. other suitable device to align the holes. Tighten
Lubricating the pin surfaces aids in removal and the nut to 68 N·m (50 ft lb).
installation, as well as prevention of rust and
corrosion. 98. Adjust the piston rod height until the lower sus-
pension eye is aligned with the bore in the rear
95. Align the hole in pin (5) with the hole in the axle housing. Repeat the above procedure to
mounting bore. Drive in the pin far enough so install the bottom pin. Mounting components in
that the pin does not fall out. the top and bottom joints are identical.
FIGURE 6-132. 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

After the truck has been assembled and is opera-
tional, 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 speci-
fied above.
99. Connect the electrical harnesses and hydraulic
hoses below the operator’s cab. Install the
cover plate for the hydraulic hoses. Tighten the
connecting hardware to the standard torque.
Refer to Figure 6-133 through Figure 6-135.
FIGURE 6-134.
FIGURE 6-133.

100. Install exhaust blankets (6, 7, 8, 9 & 11, Figure
6-136). Then install blankets (5) and (10). Blan-
kets should have 50 mm (2 in.) overlap on the
ends.
101. Install the remaining exhaust blankets.
FIGURE 6-135.

FIGURE 6-136. EXHAUST BLANKETS
1. Exhaust Blanket 8. Exhaust Blanket 15. Exhaust Blanket
22. Exhaust Blanket

Before Starting the Engine
Alternator Rotor Lock
Be careful not to damage fiberglass housing on

alternator.
Follow the steps listed below to prepare the alterna-
tor rotor lock for operation. Refer to Figure 6-137
102. Remove warning tags from rotor lock tool (Fig-
ure 6-137). Place a protective sheet in the alter-
nator housing to protect the fiberglass housing
from damage.
103. Loosen jam nuts and collapse the rotor lock tool
enough to allow it to be removed. Unscrew cap-
screws to remove mount.
104. Remove rotor lock tool then remove bracket.
FIGURE 6-138. ALTERNATOR ROTOR LOCK

105. Position drive shaft (Figure 6-140) between
alternator shaft (Figure 6-141) and hydraulic
pump flange (Figure 6-142).
a. Attach the drive shaft to the alternator shaft
using capscrews then torque capscrews to
54 N·m (40 ft lb).
b. Attach the drive shaft to the hydraulic pump
flange using capscrews and nuts, then
torque capscrews and nuts to 47 N·m (35 ft
lb).
c. Install drive shaft cover. Refer to Figure 6-
143.
d. Remove the protective sheet from the alter-
nator housing, then remove the warning tag
from the steering wheel.
FIGURE 6-141. DRIVE SHAFT ATTACHED TO

ALTERNATOR SHAFT
FIGURE 6-140. DRIVE SHAFT

FIGURE 6-142. DRIVE SHAFT ATTACHED TO FIGURE 6-143. DRIVE SHAFT INSTALLED
HYDRAULIC PUMP FLANGE

106. Install any remaining handrails. Tighten the cap- 107. Do not start the engine unless the hydraulic sys-
screws to standard torque. Refer to Standard tem flushing tools are installed and ready to per-
Tables in Section 10, Appendix. form the flushing procedure. Refer to the
appendix for the hydraulic system flushing pro-
cedure.
108. The parking brake must be flushed before oper-
ating the truck. Refer to the appendix for the
parking brake flushing procedure.
Before the engine is started the first time, the 109. Check the oil level in each wheel motor. Rotate
hydraulic system should be set up to perform the one of the eight plugs to the six o’clock position
flushing procedure. Refer to the hydraulic and remove the plug. The oil level should be
system flushing procedure in the Appendix. The even with the bottom of the plug opening. Fill
purpose of hydraulic system flushing is to the wheel motor with the recommended oil as
eliminate contaminants that could have been necessary.
introduced into the hydraulic system during
truck assembly. Performing the flushing 110. Check the hydraulic tank oil level and check for
procedure will remove these contaminants from leaks before and after engine start-up. Service
the hydraulic system and minimize the potential the hydraulic tank oil as necessary.
for hydraulic system component damage at 111. The truck is now ready for dump body installa-
startup. tion.

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 4/16 Dump Body Assembly Page 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
Figure 7-3 for international configuration.
FIGURE 7-4.
5. Use the hydraulic jack to align the body halves
at the rear. Install capscrew (1, Figure 7-5) and
the sleeve.
NOTE: Figure 7-5 shows the hardware numbered in
installation sequence. capscrews (1, 2 & 7) are
marked with an asterisk (*). These capscrews are
installed with sleeves. The remainder of the
capscrews do not have sleeves.
6. Install capscrew (2) and the sleeve at the front
FIGURE 7-2. DOMESTIC LAYOUT of the floor.
7. Install capscrew (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 capscrews (4, 5 & 6).
9. Install capscrew (7) and the sleeve in the front
of the canopy.
10. Install capscrews (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 capscrews (10 & 11) in the floor.
13. Loosen capscrews (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.
Page 7-2 Dump Body Assembly 4/16 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
raise the center of the body to allow the pivot to
fit inside the bolsters. Loosely install the cap-
screws in the pivot.
17. If assembling an international body (three-
piece), lift the canopy into position at this time.
Install the canopy capscrews and tighten.
18. Tighten all floor, front sheet, and canopy cap-
screws. Use a chalk line to align the front of the
canopy.
19. Tighten the pivot capscrews. FIGURE 7-7. FRONT SHEET & FLOOR JOINT
WELDING SEQUENCE
20. Install the filler plates and backer strips for the
pivot to body sill weld joints.
21. Check the alignment and fit of all components
1. Complete the welds at the center seam, the
22. Tack weld the joints. front sheet and the canopy. Refer to the assem-
bly drawings for welding requirements.
BODY WELDING 2. Remove the canopy alignment blocks.
Follow the guidelines listed below when welding the 3. Install the remaining gussets, the body guide
body: and the body pad mounts. Refer to Figure 7-8
• Use dry weld rod or weld wire.
• Weld surfaces must be dry and above 10°C
(50°F).
• If stick electrode is used, use as large a diameter
rod as practical to weld the floor and front sheet
joints. DO NOT install the heated body exhaust boxes
• The following sequence must be followed for the onto the body at this time. The exhaust boxes
front sheet: must be installed after the body is installed onto
the truck.
First Pass: Back step and skip weld in 10
increments along the entire length of the joint.
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 7-8.

FIGURE 7-11.
FIGURE 7-9. 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
in Figure 7-18.
FIGURE 7-10.
FIGURE 7-12.

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

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.
84652
8. Clean and paint the weld joints.

FINAL ASSEMBLY
• Inspect all lifting devices. Slings, chains, and • Before lifting the body, ensure there is
cables used for lifting components must be adequate clearance between the body and
inspected daily for serviceable condition. overhead structures or electric power lines.
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 Before the engine is started the first time, the
intended load.
hydraulic system should be set up to perform the
• When in doubt as to the weight of flushing procedure. Refer to the hydraulic sys-
components or any assembly procedure, tem flushing procedure in the appendix. The pur-
contact your customer support manager for pose of hydraulic system flushing is to eliminate
further information. contaminants that could have been introduced
• Lifting eyes and hooks must be fabricated into the hydraulic system during truck assembly.
from the proper materials and rated to lift the Performing the flushing procedure will remove
intended load. these contaminants from the hydraulic system
• Never stand beneath a suspended load. Guy and minimize the potential for hydraulic system
ropes are recommended for guiding and component damage at startup.
positioning a suspended load.
FAM0827 Final Assembly Page 8-1

1. Body welding and chassis assembly must be a. If the truck is operational and can be driven,
completed before proceeding. two 50 ton cranes can be used, one posi-
tioned at either side of the body. The body
Before the body is lifted off the ground, tie guy
can then be lifted high enough to allow the
ropes to each of the four corners of the body for
truck to be reverse propelled under the body.
aiding in installation.
Refer to Figure 8-1, Figure 8-2 and Figure 8-
There are two methods of installing the body 3.
depending on the cranes available.
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.
FIGURE 8-1.
Page 8-2 Final Assembly FAM0827

FIGURE 8-2.
FIGURE 8-3.

2. Install shims (8, Figure 8-5) in both body pivots, 3. Align the hole in body pivot pin (4) with the bolt
as required, to fill the outside gaps and center hole in the pin retainer on the outer body pivot
the body on the frame pivot. ear. Push the body pivot pin through the outer
body pivot ear, the frame pivot, and the inner
NOTE: Do not install shims on the inside. A
body pivot ear.
minimum of one shim is required at the outside end
of both frame pivots. 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 7. Install shoulder bolt (4) through each pin.
bore of hoist cylinder upper mounting bracket
NOTE: Do not use a flat washer under the head of
(1, Figure 8-7).
the shoulder bolt. This will ensure that the shoulder
6. Align the bolt hole in pivot pin (3) with the bolt bolt does not run out of threads when tightening.
hole in mounting bracket (1). Install the pivot pin
8. Install flat washer (5) and nut (6) onto the
through the first spacer (2), then align the
threaded end of each shoulder bolt. Tighten the
second spacer with the bore on the other side of
nuts to 339 N·m (250 ft lb).
hoist cylinder bearing eye. Finish installing the
pin through second spacer (2).

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

10. Shim the body pads as required. All pads, plished by using one less shim at each rear
except the two rear pads, should contact the pad.
frame with approximately equal compression of
If pad contact appears to be unequal, refer to
the rubber. Refer to Figure 8-8.
“Body Pad Shimming Procedure”.
A gap of approximately 1.5 mm (0.06 in.) is
required at each rear pad. This can be accom-
FIGURE 8-8. BODY PAD INSTALLATION
1. Dump Body 3. Shim

2. Body Pad 4. Mounting Hardware

Body Pad Shimming Procedure
Proper contact between the body pad and frame is
required to ensure maximum pad life. All pads
(except the rear pad on each side) should contact the
frame with approximately equal compression of the
rubber. A gap of approximately 1.9 mm (0.075 in.) is
required at each rear pad. This can be accomplished
by using one less shim at each rear pad.
If pad contact appears to be unequal, perform the
following shimming procedure.
1. Park the truck on a flat, level surface.
2. Raise the unloaded dump body to a height that
is sufficient to allow access to all of the body
pads.
To avoid serious personal injury or death, the FIGURE 8-9. MEASUREMENT DETAILS
body retention sling must be installed anytime 1. Shims 2. Body Pad
personnel are required to perform maintenance
on the truck with the dump body in the raised 9. Subtract the body pad thickness of 39.7 mm
position. (1.56 in.) from each measurement that was
3. Install the body retention sling. Refer to “Secur- recorded in Step 8. There will be a total of eight
ing The Body” in Section 20 of the Operation & measurements “B” per side. Refer to Figure 8-9.
Maintenance Manual for the body retention
sling installation procedure. “A” - 39.7 mm (1.56 in.) = “B”
4. Remove all of the body pads and shims. 10. Divide each measurement “B” by the single
shim thickness of 1.5 mm (0.06 in.) to deter-
5. Bolt one spacer block (XC2293) to each side of
mine the number of shims required for each
the body. Use the pad mounting holes closest to
mounting location.
the front of the dump body.
6. Remove the body retention sling. Lower the “B” / 1.5 mm (0.06 in.) = number of shims
dump body onto the spacer blocks. 11. Remove one shim from the calculation for the
7. Check the dump body’s position and fit on the most rearward body pad on both sides.
truck. If there is any interference when the body
NOTE: Using half shims is allowed if necessary. Half
is on the spacer blocks, contact your local
shims must be installed at the top of the stack.
Komatsu distributor to resolve the issue.
8. With the body lowered, measure the distance NOTE: The frame rail and the body bolster do not
from the frame rail to each pair of bolt holes at have to be parallel.
the dump body’s pad mounting locations. There
will be a total of eight measurements “A” per
side. Refer to Figure 8-9.

FIGURE 8-11. ROCK EJECTOR MOUNTING
1. Rock Ejector Arm 3. Stop Block
2. Pin 4. Mounting Bracket
FIGURE 8-10.
If the rock ejector arms are bent during opera-

tion, they must be removed and straightened.
Inspect mounting brackets (4, Figure 8-11), pins
(2) and stops (3) at each shift change for wear
and/or damage. Repair as necessary.
12. 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).
FIGURE 8-12. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 2. Wheel Housing

13. Install the mud flaps onto the body and chassis.
FIGURE 8-13.
FIGURE 8-14.

14. Install both body guide brackets loosely into 15. With the body lowered onto the frame rail, mark
place. Refer to Figure 8-15. the position of body up limit switch bracket (5,
Figure 8-18) on the underside of the body.
Once in position, slowly lower the body and
Refer to the assembly prints for specifications.
mark the position in which the brackets are to
be welded. The body guides must be centered 16. Raise the body enough to be able to weld the
between wear plates (3, Figure 8-16), with a mounting pad for switch mounting bracket (1) to
maximum gap of 4.8 mm (0.19 in.) at each side. the underside of the body.
FIGURE 8-15.

Before welding, install support blocks between
the body and the frame.
17. Fully raise the body and install the body reten-
tion sling. Remove the support blocks.
Refer to “Securing The Body” in the Operation
& Maintenance Manual for information about
properly securing the body using the body
retention sling.
18. Weld the body guide brackets into place. Refer
to (2, Figure 8-16).
FIGURE 8-17.
19. Weld the tapped pad to the frame (Figure 8-17)
once the Proximity Switch (3, Figure 8-18) is
located in the proper position. It comes from the
factory tack welded.
FIGURE 8-18. BODY-UP SWITCH INSTALLATION
1. Switch Mounting Bracket 4. Magnet Assembly

2. Adjustment Capscrews 5. Bracket
3. Proximity Switch
FIGURE 8-16. BODY GUIDE

1. Dump Body 3. Body Guide Wear
2. Body Guide Plates

20. If the truck is to be equipped with a heated body, the hardware Refer to Figure 8-19 and
install the exhaust box at the pivot and tighten Figure 8-20.
FIGURE 8-19.
FIGURE 8-20.

21. If equipped with deck mounted mufflers, install
the mufflers. Refer to Figure 8-21 and Figure 8-
22.
FIGURE 8-24.
FIGURE 8-25.

22. Adjust the hoist limit switch. switch is required. This is due to the fact that
a. Prior to adjustment, the dump body must be magnetic fields are not crisp 90 degree boxed fields
raised to 152 mm (6 in.) of the maximum but are instead curved about the shape of the
hoist cylinder extension and supported in magnet. Refer to Figure 8-25. The sensing field
that location. boundary limit takes on the same curved sensing
area shape of the magnet field. The curved sensing
b. Loosen proximity switch adjustment cap- area results in the actuation of the switch
screws (4, Figure 8-23). Slide switch (1) up approximately 30 mm (1.18 in.) prior to reaching the
or down to position the top of the switch 30 edge of the magnet. Therefore, it is crucial that the
mm (1.18 in.) (Dimension B) away from the 30 mm (1.18 in.) is observed when setting the hoist
lower edge of magnet (2). Tighten the cap- limit switch.
screws when adjusted properly. If necessary,
c. Weld the tapped pad to the frame (Figure 8-
capscrews (3) could also be loosened to
24) once the Proximity Switch (1, Figure 8-
move the magnet to obtain the 30 mm (1.18
23) is located in the proper position. It comes
in) gap.
from the factory tack welded.
NOTE: Since a magnetic target is used to activate
the switch, a larger initial distance in setting the
FIGURE 8-23. HOIST LIMIT SWITCH (REAR VIEW)
1. Proximity Switch 4. Capscrews

2. Magnet 5. Dump Body
3. Capscrews

FIGURE 8-25. HOIST LIMIT SWITCH OPTIMUM
SETTING ADJUSTMENT
FIGURE 8-24.
d. Loosen capscrews (2, Figure 8-23) securing

proximity switch (3) to the mounting bracket.
Slide the switch to the left or right until the
passing distance between the two targets is
45 mm (1.77 in.) (Dimension A). Tighten the
capscrews after adjusting. Refer to Figure 8-
25 for an illustration of optimum setting of the
switch.
e. Lower the body onto the frame.
f. Check the operation of the proximity switch
to verify that the hoist cylinders stop before
reaching maximum cylinder stroke. If the cyl-
inders extend to full stroke, adjust the prox-
imity switch as necessary to prevent full
cylinder extension.

23. With the body in the raised position, install the along the inside of the body. Refer to Figure 8-
grease lines for the hoist cylinders and clamp 26.
FIGURE 8-26.

24. Install the exhaust tubing blankets. Refer to
Figure 8-27.
FIGURE 8-27.

Miscellaneous Installations a. Connect the lubrication system to the LH
25. Install the lubrication system: bumper and tighten the bolt to standard
torque. Refer to Figure 8-28.
FIGURE 8-28. LUBRICATION SYSTEM
FIGURE 8-29.
1. Injector Indicator 4. Injector Grease Zerk

2. Injector Grease Zerk Cap
3. Injector Cover 5. Injector Manifold Plug

b. Remove the pipe plug (17, Figure 8-30) from f. At each injector bank, remove cap (4, Figure
each injector bank, one at a time. 8-29) on each injector. Pump grease into the
c. Disconnect hose (22) and connect it to a Zerk (2) until grease appears the far end of
grease supply source. Pump grease into the he individual grease line or the joint that is
hose until grease appears at the injector being greased. Install cap and repeat pro-
bank where the pipe plug was removed. cess on each injector on the truck.
Install pipe plug. g. Verify that all electrical and hydraulic con-
nections are correct. Refer to Figure 8-30.
d. At another injector bank, remove pipe plug,
and pump grease into hose (22) until grease h. Install the service center under the bumper
appears at the open port at the injector bank. platform. Tighten the mounting hardware to
Install plug. standard torque. Refer to Figure 8-28. The
e. Remove the plug at injector bank on the rear service center can be on the LH or optionally
axle housing. Pump grease into hose (22) on the RH side, or on both sides.
until grease appears at the open port at the
injector bank. Install plug.

FIGURE 8-30. LUBRICATION SYSTEM
1. LH Suspension, Bottom Bearing 13. RH Anti-Sway Bar Bearing

2. LH Hoist Cylinder, Top Bearing 14. RH Suspension, Top Bearing
3. LH Hoist Cylinder, Bottom Bearing 15. Grease Reservoir
4. LH Anti-Sway Bar Bearing 16. Vent Hose
5. LH Suspension, Top Bearing 17. Pipe Plug (Oil Level)
6. LH Body Pivot Pin 18. Not Used In This Application
7. RH Body Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. RH Suspension, Bottom Bearing 21. Filter
10. RH Hoist Cylinder, Top Bearing 22. Grease Supply to Injectors
11. RH Hoist Cylinder, Bottom Bearing 23. Injectors
12. Rear Axle Pivot Pin 24. Pressure Switch, N.O. - 13 790 kPa (2,000 psi)

26. Install the isolation box on the LH bumper and
tighten the bolts to standard torque. Refer to
Figure 8-31.
FIGURE 8-31. ISOLATION STATION

27. If equipped, install the optional Scoreboard(s).
85178
FIGURE 8-32. LH SCOREBOARD INSTALLATION
1. Load Lights
2. Payload Meter Scoreboard (Optional)
28. Install the LH and RH engine bay lights. Refer to

Figure 8-33.
1 2
85195
FIGURE 8-33. ENGINE BAY LIGHTS
1. LH Bay Lights 2. RH Bay Lights

29. If equipped with the KomVision® camera sys- 30. Mount Radar 2 (4, Figure 8-34), Radar 1 (5),
tem, mount the RH Front Camera (1, Figure 8- Radar 8 (6), Radar 7 (7), Radar 3 (3, Figure 8-
34), LH Front Camera (2), LH Rear (3) and RH 35) and Radar 4 (4) in the shown locations in
Rear (2, Figure 8-35). figures.
31. Mount the Rear Camera (1, Figure 8-36) and
Radar 5 (2), Radar 6 (3).
FIGURE 8-34. CAMERA AND RADAR LOCATIONS
1. RH Front Camera 5. Radar 1

2. LH Front Camera 6. Radar 8
3. LH Rear Camera 7. Radar 7
4. Radar 2

1. RH Front Camera 3. Radar 3

2. RH Rear Camera 4. Radar 4

1
3 2
85183

1. Rear Camera 3. Radar 6
2. Radar 5
32. Paint the truck as needed. 34. Install the fire suppression system. Refer to Fig-
ure 8-37.
33. Install all decals at their designated areas. Refer
to the installation drawing for all decal locations. NOTE: This installation is normally performed by the
fire system distributor.

FIGURE 8-37.
35. After completing the assembly of the truck: b. Check all hydraulic lines and electrical con-
a. Verify that all capscrew heads or nuts are nections for secure installation.
marked with paint, indicating they have been c. Notify qualified maintenance personnel that
properly tightened. the truck is ready for final static and dynamic
systems checkout.

85198
FIGURE 8-38.
85199
FIGURE 8-39.

NOTES

FINAL CHECKOUT
Final checkout requires truck operation. 5. Perform a final check of all systems and prepare
for operation, including the pre-shift brake test.
Place the operation and maintenance manual and
Several checks and tasks are outlined in Section
safety manuals in the operator cab, if they are not
10, Appendix.
already there.
6. Complete the checks listed in the Field Assembly
Personnel involved in the final check-out of the truck Inspection Report Form. A copy of the form is pro-
must read and understand all safety and operating vided with the truck and is also available in Sec-
instructions in the operation and maintenance manual. tion 10, Appendix.
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
2. Check all coolant and lubricants for proper levels
been completed and all deficiencies corrected.
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 air from the pumps and suction lines. Pres-
sure will not build if air is present. Operating the
pumps with air in the system will result in damage.
Refer to the truck assembly section for more infor-
mation on how to bleed the air from the pumps
and suction lines.
FAM0903 5/13 Final Checkout Page 9-1

NOTES
Page 9-2 Final Checkout 5/13 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 - FAM1105
2. Seat Belts And Tethers Checkout Procedure - SM2700
3. Electric Checkout Procedure - 58F-06-03870
4. Interface Module Checkout Procedure - 58F-06-03861
5. Hydraulic System Checkout Procedure - 58F-60-40932
6. Brake System Checkout Procedure - 58F-60-40941
7. Retractable Ladder System Checkout Procedure - 58E-00-10490
8. Additional Electrical Checkout for Trucks with IM Controls - EM7279
9. Suspension Oiling And Charging Procedure - 58E-60-02200
10. Oil And Nitrogen Specifications Chart - FAM1204
11. Pre-Shift Brake Test - Test Procedure - 58E-06-09750
12. Toe In Adjustment Procedure - FAM1307
13. Automatic Lubrication System Checkout Procedure - 58F-90-00300
14. Automatic Lubrication System - FAM1405
15. Parts & Service News - AA18054
16. Air Conditioning System Checkout Procedure - EM4003
17. Payload Meter IV Checkout Procedure - 58B-06-02400
18. Komtrax Plus Shop Setup Procedure - 58F-06-05240
19. Komtrax Plus Site Setup Procedure - 58F-06-05250
20. KomVision® Checkout Procedure - 58E-43-10000-00
21. KomVision Manual (? being provided by engineer/Neil)
22. Wireless Bridge Checkout Procedure - 58F-06-05340
FAM1047 Appendix Page 10-1

23. Field Assembly Inspection Report - CEAW009400
24. 50 Hour Post-Commissioning Checksheet - CEAW009200
25. Standard Torque Charts and Conversion Tables - FAM1502
26. Rear Axle Cooling Air Pressure Switch Adjustment and Test - EL6021
Page 10-2 Appendix FAM1047

LUBRICATION CHART
FAM1105 Lubrication Chart F11-1

NOTES
F11-2 Lubrication Chart FAM1105

SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
GENERAL DESCRIPTION 4. The other end of the tether belt should be
attached to the appropriate mounting point on
This checkout procedure describes installation,
the operator seat, along with the correct half of
adjustment, and inspection procedures for operator
the seat belt set. The correct point to mount the
seat belts, passenger seat belts, operator seat tether
seat belt and tether belt to the seat varies with
belts, and passenger seat tether belts where
different suppliers of seats. Basically you bolt
applicable.
the tether directly to the same mounting hole
On all 530M / HD1500-5, HD1500-7, 730E, 860E, that the seat belt anchor uses. This ensures
930E, 960E and on 830E trucks effective with unit that the tether and seat belt are connected.
544 (and including all 830E's which were previously
KAC PEORIA purchases all seats with seat
equipped with the 'HMS' system) and any new
belts and tethers already installed. Individual
models that are introduced; our seats have been
seat manufacturers may mount their tether and
purchased with seat belts and tethers belts already
seat belts differently than stated here. They
installed. This document should be provided in part in
have independently tested their seats to be in
the Parts and Service news for use when belts and
compliance with the applicable SAE or ISO
tethers are changed out due to wear and tear.
testing standards.
Tether belts must be properly installed on all 5. After installing both the tether belts and the seat
equipment and properly adjusted. If the seat itself belts, the tether belts must be adjusted. Where
does contain internal tethers, it must also have the tether is secured to the floor of the cab or
ADJUSTABLE external tethers installed. the deck structure, it must be bolted directly to
1. The tether belts are to be anchored to the floor that surface without the floor mat material
of the operator cab using the eye bolt supplied between it and the floor. Securely tighten the
with the tether belt set. The tether belts on the bolt anchoring the tether and seat belt to the
2-PT operator seat of the 530M / HD1500-5, seat inter-connection point.
730E, 830E and 930E trucks do not have sister On the 530M /HD1500-5, HD1500-7, 730E,
hooks, they have a tab style anchor. See 830E, 860E, 930E, and 960E trucks, the tether
illustration in your parts book for each specific belt is located outboard of the seat belt sub-
model. assembly. On other trucks, the tether may be on
2. The eye bolt should be securely installed into either inboard or outboard the seat belt when
the tapped hole provided. The eye bolt should bolted to the ICP bar (inter-connecting point).
be installed as far as possible, with the securing Some of the older mechanical seats have
nut in place, and backed off just enough to align internal tethers and have been tested for
it with the direction of pull of the seat on the compliance in that configuration.
tethers, and then locked in place using the nut 6. To properly adjust the tether belts the seat must
provided. be lifted and supported in its highest position of
3. The tether belt should be secured to the eye upward rebound with the seat in its furthest
bolt using the sister hook end of the tether and forward position. If the seat has a mechanical
the cotter pin provided. vertical adjustment, to compensate for short
versus long waisted operators, then this
adjustment must be at its highest point. With the
seat in this position, adjust the tether belts so
they just have slack and are not tight. This
allows for a slight extension when the rebound
bumper internal to the seat deflects under a
rebounding load.
SM2700-2 Seat Belts and Tethers Checkout Procedure 1

7. See accompanying sketches for correct 9. It is a must that all seat belts and tether belts be
location of the tether belt / seat belt connection inspected daily by each operator at the
point. beginning of the shift to ensure that they are still
8. Older model truck passenger seats usually intact and contain no damage which would
have a very long seat belt which bolts directly to lessen their ability to provide maximum safety
the floor in the tapped holes provided in the as designed. They must be replaced if worn, cut
floor or cab structure. These are usually 7/16" or damaged.
UNF bolts.
On early models of the 530M / HD1500-5,
730E, 830E and 930E passenger seat did have
tethers, but the free end is attached to
components base structure itself using sister
hooks and eye bolts. The later versions of these
trucks mount the seat belt to the eye bolts,
which were mounting into the components base
structure. See illustration in your parts book for
each specific model.
Initials / Date
 Seat belts are installed on operator seat. _____________________
 Tethers are installed on operator seat. _____________________
 Tethers are correctly mounted to the floor. _____________________
 Tethers are correctly adjusted. _____________________
 Seat belts are installed on passenger seat. _____________________
 Tethers are installed on passenger seat. _____________________
 Tethers are correctly mounted to the floor. _____________________
 Tethers are correctly adjusted. _____________________
Signature_________________________________ Date________________ Unit No.________________
2 Seat Belts and Tethers Checkout Procedure SM2700-2

FIGURE 1.PASSENGER SEAT INSTALLATION
530M / HD1500-5, 730E, 830E and 930E
FIGURE 3.OPERATOR SEAT INSTALLATION
EARLIER MODELS
530M / HD1500-5, 730E, 830E and 930E
1. Tether Belt 3. Components Base BOTH MECHANICAL AND INTERNAL
2. Seat Belt COMPRESSOR STYLE
FIGURE 4.TYPICAL SEAT INSTALLATION WITH

FIGURE 2.TYPICAL TETHER/SEAT BELT INTEGRAL TETHER
INSTALLATION - OPERATOR SEAT ON TRUCKS EARLY MECHANICAL SEAT WITHOUT
WITH OR WITHOUT AIR EXTERNAL TETHERS
1. Tether Belt 2. Seat Belt 1. Tether Cable 2. Seat Belt
SM2700-2 Seat Belts and Tethers Checkout Procedure 3

FIGURE 5.TYPICAL PASSENGER SEAT / BELT FIGURE 7.INSTALLATION OF TETHER-LESS
INSTALLATION SEAT BELT ON PASSENGER SEAT MOUNTED
HD1500-7, EARLIER 830E AND SMALLER TO COMPONENTS BASE ASSEMBLY
MODELS TRUCKS EARLIER MODELS 530M / HD1500-5, 730E, 830E and 930E
1. Rigid Support 2. Seat Belt
FIGURE 8.TYPICAL 2PT SEAT / BELT

PASSENGER SEAT INSTALLATION -
FIGURE 6.TYPICAL 3PT SEAT / BELT CURRENT MODELS
INSTALLATION - CURRENT MODELS 730E-8, 830E, 860E, 930E and 960E
HD1500-7, 730E, 830E, 860E, 930E and 960E
4 Seat Belts and Tethers Checkout Procedure SM2700-2

ELECTRIC CHECKOUT PROCEDURE
Scope This checkout procedure should be performed by
qualified trained personnel that have knowledge of
This checkout procedure is designed for 930E-5 with
the operation of the truck and the stored energy
operator electronic dash panel and GE Invertex II. It
systems on it. Personnel should observe all
is to be used along with the GE Vehicle Test
precautions established by Komatsu America Corp
Instructions, GE Events & Fault Lists, Interface
(KAC) and at other locations where the checkout is
Module Checkout Procedure, Payload Meter IV
being performed. All potentially store energy within
Checkout Procedure, and the Hydraulic System
the truck should be released before performing any
Checkout found in the Truck Checkout Group
troubleshooting.
Procedures.
Electrical Hazard
General Description
This checkout procedure prescribes the tests and
procedures to check out the function and operation of
the 24 volt control & lighting systems. The Checkout
Procedures must be completed to provide a
permanent record of the various systems testing for While the AC Drive System Truck is running
each unit. (engine on), none of the cabinet doors or covers
should be open or removed or none of the power
The main GE drive control cabinet consists of the
cables should be touched.
following electrical components: Auxiliary three-
The system (link hot) is not dependent on selec-
phase air cooled rectifier, phase inverters and
tor switch position or accelerator pedal being
chopper modules, Micro-Processed Control unit,
pushed, If the GF cutoff switch is in the normal
alternator field regulator, and retard contactors. The
position (ON), the Rest Switch is turned OFF, and
Auxiliary Control Cabinet contains the GE Drive
the engine is running, the drive system link is
System interface wiring, truck Interface Module (IM),
"hot" with dangerous voltage.
Payload Meter Module, Diagnostic and CAN
communications, truck control wiring connection Normal operation of the drive system at shutdown
points, and the 24 volt power distribution and fuse should leave the system safe to operate. In the event
protection. The Komtrax Plus (VHMS) Module and of a system failure, performing the following
ORBCOMM Module are located in the back wall of procedure will insure that hazardous voltages are not
the operator cab. present in the drive system.
1. Before shutting down the engine, verify the
General Precautions status of the drive system warning lights in the
operator dash display. If any of the red drive
system link warning lights are on, do not
attempt to open any cabinets, disconnect any
cables, or reach inside the retard grid cabinet
without a trained drive system technician
Before starting the engine, always sound the present - even after shutting down the engine.
horn once prior to cranking. 2. Verify all drive system warning alarms are off,
set the selector switch in the park position, then
Block wheels of the truck to prevent possible roll shut down the engine and chock the wheels.
away before performing this procedure.
58F-06-03870 Electric Checkout Procedure 1

3. After the engine has been off for at least five (5) Drive System Control Group (Invertex II) contains the
minutes, inspect the Link Voltage light on the following.
front of the main control cabinet and verify that
1. Control Group:
the link voltage has been discharged. Only if the
link voltage is discharged, then the retard grids, a. Integrated Control Panel II- ICP2
wheel motors, alternator and power cables b. Drive System Controller DSC
connecting these devices are secure to work
on. c. Power Rectifier Panel
4. Power cables must be clamped with wood or d. Rectifier Inverter and Chopper Modules
other non-ferrous material clamps. Do not repair 2. A/C Power Alternator
cable cleats by encircling the power cables with 3. Retard Grid Assembly
metal clamps or hardware. Always inspect
4. A/C Propulsion Wheel Motors
power cable insulation prior to servicing the
cables. Replace any cables with damaged
insulation.
Test equipment needed to fully test AC
system
Normal shutdown procedure 1. Portable Test Unit (PTU) system consisting of;
IBM compatible Laptop Computer, RS232 serial
1. Truck stopped, put selector switch in the park
cable with male DB9 connector, and Ethernet
position (this applies to the park brake).
cable
2. Apply the HVDC Power-Off (REST) Switch.
2. Vehicle wiring schematic
(Retard Contactors are engaged and high
voltage link energy is diffused through the grid). 3. GE Drive System Electrical schematic and GE
Vehicle Test Instructions
3. The (RED) Link Energized light should be
“OFF” to indicate “0” voltage on the low voltage 4. Megger 0 - 1500 volt (0 - 2000 megohms)
section of the control cabinet (located on the 5. Several jumper wires
door on the front of the control cabinet, closest 6. One Multi-Meter 1000V meter
to the operator cab).
4. Turn the key switch to the “OFF” position. The Portable Test Unit (PTU) is used to test,
preferred and normal way to stop the engine of download and record system parameters.
the truck is by use of the key switch (when the 1. The PTU can be plugged into the DB9 port -
key is turned off, the steering hydraulic system "Diag.6", or the Ethernet port located in the
pressure should also bleed down after 90 back of the center console in the operator cab.
seconds).
2. The PTU can also be plugged into the DB9 port
5. To insure that the link will not be re-energized, , or the Ethernet port on the front side of the
turn the GF Cutoff Switch to the OFF position of Invertex II inside the GE control cabinet, upper
the switch. Verify Link Voltage has discharged section, door closest to the operator cab.
by looking at Link Energized light (RED) on the
outside of the low voltage control compartment. Visual Inspection
1. Before carrying out this checkout procedure,
AC Drive System Description
preform a visual inspection of the truck and
1. For complete AC Drive System Description verify all electrical connections (power cables
read through the GE Vehicle Test Instructions. and harnesses) are connected except the
(See GE VTI Procedure from the Checkout battery cable connections to the 24V batteries
Group Procedure). and circuit 21PT to both engine starter relays
located inside battery box.
2. At Battery Isolation Station, verify both the
Starter Disconnect Switch and the Main battery
disconnect are turned to OFF position and the
battery cables are connected correctly.
3. Check that all fluids are their correct levels -
engine oil, engine coolant, transmission,
hydraulic oil.
2 Electric Checkout Procedure 58F-06-03870

Resistance Check Preparation Voltage Check
Check to be sure link voltage is drained down Check to be sure link voltage is drained down
before performing test. before performing test.
1. Inside battery box, verify both the short jumper
Key Switch OFF Checks
battery cables are removed which connect the
positive and ground between the two batteries 1. Verify that the key switch is in the off position.
that make up 24vdc. 2. Verify the GE cut off switch is in cut off position,
2. Inside battery box, verify the 21PT circuit wires and that the GE link is de-energized.
which connect to both engine starter relays (1 & 3. Verify that circuit 21PT is disconnected and
2) are disconnected and insulated to prevent insulated from both engine start relays located
the engine from cranking. in the battery control box on the front platform.
3. Place the operator key switch to “OFF” position. 4. Make sure the engine emergency shutdown
4. Turn all cab operator switches to the “OFF” switch in the Operator cab is in the “Run”
position. position (switch pushed down) and the ground
level shutdown switch is pulled out.
Resistance Check 5. Inside the Battery Box, re-connect both battery
1. Inside the Auxiliary Cabinet, check the cables jumper between the two sets of battery
resistance with a multi-meter from ground buss to provide truck 24vdc.
circuit 0 to the following points. All points should 6. Check battery voltage to ground, circuit 11,
measure resistance values from a few ohms to inside the battery box. A battery charger may
infinity. need to be installed if battery voltage is low.
NOTE: All circuits should show resistance from a few 7. At Battery Isolation Station, turn the Main
ohms to infinity. STOP and troubleshoot any direct battery disconnect Switch to ON position
shorts (0 ohms) to ground. leaving the Starter Disconnect Switch to OFF
position.
Table 1: Auxiliary Cabinet Resistance 8. Check for battery voltage to ground, circuit 11,
inside the Auxiliary Cabinet on the 24vdc-Buss.
CIRCUIT CONNECTION
11 24V buss
12V VEC91-S7
71CK TB24-N
10V TB31-N
+15VDI TB21-TN
-15VDI TB21-W
5VDI TB21-U
5VIM P710-2 (RH REAR BRAKE
TEMP SENSOR)
24VIM TB32-H
18CIM SPS-1, HPS1-1, and HPS2-1
2. Restore all circuits to original form.

9. Inside the Auxiliary Cabinet, check the following Key Switch ON Check
circuits for the appropriate battery voltage to
1. In the operator turn the key to ON or first
ground.
position turning the key to the right of OFF.
a. Check circuit 11B1 (TB24) to ground (0) for 2. Inside the Auxiliary Cabinet, check the following
12VDC. circuits inside the auxiliary cabinet for the
b. Check the following circuits for 24VDC to appropriate voltage to ground (0).
ground (0):
Table 3: Auxiliary Cabinet Voltage to Ground
Table 2: Auxiliary Cabinet Battery Voltage
CIRCUIT CONNECTION VOLTAGE REQUIRED
CIRCUIT CONNECTION DESCRIPTION 11D TB22-A 24VDC
11A TB35-A 712 TB24-K 24VDC
11E1 TB27-A 71CK TB24-N 24VDC
11E2 TB27-B 71LS TB23-M 24VDC
11E3 TB27-C 71VHM TB28-B 24VDC
11E4 TB27-D 24VIM TB32-H 24VDC
11L TB22-C 5VIM TB30-K 5VDC
11SL TB24-A 12V VEC91-S7 12VDC
39G TB34-T 18VIM TB24-W 18VDC
11LL Relay HLMR-88 Lo-beam Headlight
Low Mtg Relay GE Control Switch ON Check
11LR Relay HHMR- Lo-beam Headlight 1. In the GE Control Cabinet turn the ON the
88 High Mtg Relay Control Power Switch.
11HL Relay HBHR-88 Hi-beam Headlight 2. Verify the LED power indicators are illuminated
Relay on the face of GE Invertex II Control system.
47B Relay BULR-88 Back Up Light Relay 3. Continue checking the following circuits inside
85 TB28-C the auxiliary cabinet for the appropriate voltage
to ground (0).
4. Check circuit for other voltages to ground (0);
Table 4: GE Control Cabinet Voltage to Ground
CIRCUIT CONNECTION VOLTAGE REQUIRED

71GE TB24-G 24VDC
10V TB31-N 10 to 12VDC
15SRW TB33-M 15VDC
15SLW TB33-S 15VDC
77P TB29-A 15VDC
714P TB29-H 15VDC
15VDI TB21-T 15VDC
-15VDI TB21-W - 15VDC
5VDI TB21-U 5VDC

Truck Function Check Verify the following switches are illuminated.
If any of the following functions fail to operate power a. Center console directional selector switch
down the truck and release all stored energy. Using b. Engine Shutdown Switch
the electrical wiring diagram, troubleshoot the circuits
within the associated truck function which failed to c. Body Override / Reset Switch
operate. With the clearance lights ON, verify the panel
light dimmer can adjust the back light on the
Key Switch OFF
electronic display panel brightness.
1. Operator Cab Dome Light - Verify operation of 3. Dash Lights -With the headlight switch in the
the Cab dome light by turning ON and OFF the OFF position and the Selector switch in the
of the dome light switch. “Park” position, Verify the bottom green
2. Front Vehicle Horn - Check the front vehicle indicator in the following operator switches are
horn for proper operation. illuminated.
3. Ladder Light Switch - Operate the ladder light a. Headlight Switch
switches from OFF to ON, inside the operator
cab and at ground level near the ladder b. Ladder Light Switch
entrance. The two platform lights, diagonal c. Hazard Light Switch
ladder light and the deck light, should illuminate. 4. Headlights - Turn the Headlight switch to the
4. Hazard Signals - Operate the Hazard Switch to headlight position (last/top position). The Low
verify the front and rear hazard lights flash. beam head lights in the lower and upper grill
5. Hydraulic Brake Cabinet - Verify the dome lights should turn ON.
operation in the hydraulic brake cabinet. Move the “Combo switch” on the steering
6. Isolation Station - In the battery isolation station, column to the High beam position.
verify the indicator (ON / OFF) lights for each of
The Low beam headlights should remain on
the disconnect switches function properly when
and the Hi-beam headlights should come on.
are toggled ON and OFF.
7. Engine Service Lights - At the left & right front NOTE: The Hi-beam-On indicator in dash should be
frame rail, turn On and OFF the engine service illuminated.
lights. The engine service lights can be turned 5. Fog Lights - If equipped, with optional fog
on or off from either side. lamps, verify operation by turning ON and OFF
the fog light switch.
Key Switch ON
6. Electric Windows - Run the operator cab and
1. Operator Switch Indicators - With the key switch passenger windows up and down with the
in the ON position, verify the following operator window switches on the Selector switch console
switch indicators are illuminated; to verify operation.
• Actia Display Mode 1 & 2 7. Backup Horn and Lights - Move the direction
Selector switch to the reverse position and
• Manual Backup
verify the following:
• Grid Dry
a. The back-up horns sounds.
• Heated Mirrors
b. The backup lights operate.
• If equipped with Fog lights
Move the Selector switch to Neutral or Forward
• Rotating Beacon position and verify the following:
• Camera Select a. The backup horn turns off.
2. Clearance Lights - Turn the headlight switch to
b. Backup lights turn off.
the clearance light position (first position).
8. Manual Backup Lights - Turn the Manual
Verify that the following Instrument Panel lights Backup switch on and verify the following:
are illuminated.
a. The rear backup lights operate.
a. Front left/right clearance lights
b. The deck mounted backup lights (if
b. Rear tail lights equipped) operate.

9. Turn Signals - Turn the “Combo” switch lever to 15. Operator HVAC System - Verify operation of the
the Right and Left turning on the signals and HVAC with engine running by operating the AC
verify the following lights flash in the proper and the Heater selector switch. Check all
direction: blower speed positions.
a. The Clearance lights on the decks 16. Auxiliary Cabinet Dome Lights - Verify the dome
lights operation the auxiliary cabinet.
b. Dump body lights
c. Instrument panel lights 17. Hydraulic Pump Access Light - If equipped,
verify the hydraulic pump module access light
10. Windshield wiper - Operate the windshield functions correctly by operating the switch
wipers in the following speeds to verify located on the air duct behind the cab.
operation:
Interface Module (IM) System
a. Low speed
b. High speed See IM Procedure from the Check-out Group
Procedures.
c. Intermittent speed
1. Connect the PTU (laptop computer) to the
11. Windshield Washer pump - Press the Operator Cab - IM diagnostic port (DIAG 5).
windshield washer button to verify that the
2. Load or verify that the latest software
washer pump runs and the wiper run
configuration has been loaded into the Interface
monetarily.
Module (IM).
12. Heated Mirrors - Verify the both left and right 3. Review the IM system error code report and
hand heated mirrors function when the heated resolve all reported faults.
mirror switch is turned ON.
4. Complete the checkout procedure for “IM
13. Entertainment Radio - Verify operation of the Checkout Procedure”.
entertainment radio. Check both front and rear
speakers. Komtrax Plus (VHMS) Checkout
14. Operator Cab Air Seats - Check both the driver See VHMS Procedure from the Check-out Group
and passenger air seats by raising and lowering Procedures.
the seat to verify operation.
1. Perform the VHMS Setup Procedure.
2. Perform the VHMS Checkout Procedure.
Payload Meter Checkout

See PLM Procedure from the Check-out Group
Procedures
1. In the operator cab connect a laptop computer
to PC Ethernet port. Load or verify that the
latest software configuration has been loaded
into the Payload Meter IV.
2. Complete the Checkout Procedure for the PLM
per the vehicle specific procedure.

GE Vehicle Test Instructions (VTI) 2. Megger Test Procedure
Using the GE Vehicle Test Instructions (VTI), perform 3. Truck Configuration
the procedures and checkouts in the following 4. Installing DSC Software
sections of the VTI. See GE VTI Procedure from the 5. Digital / Analog Checks and Calibrations
Check-out Group Procedures.
• Using the GE VTI complete the Digital & Analog
The GE Vehicle Test Instructions should be read checks and calibrations.
completely and understood before performing the
• Use the GE w/PTU software, to check the
following checkouts:
following inputs & outputs to GE:
1. Truck Initial Checkout Procedure
Table 5: Digital I/O to GE
Digital I/O to GE
GE PTU Name Function Description Criteria
KEYSW Key SW on Operator Key Switch ON/ OFF
CPSFB Control Power Relay Output for GE Control Power (71GE) ON/OFF
PKBP Park Brake Input Park Brake Applied Pressure Switch ON/OFF
BRAKON Service Brakes ON Service Brake Applied Pressure Switch
WHEELOCK Wheel Brake Lock SW Brake Lock Switch Dash ON/OFF
BRAKTSREQ PreShift Brake Test Pre-Shift Park Brake Test Switch ON/OFF
AXLEP Axle Blower PSI SW Traction Motor Pressure Switch ON/OFF
CNTRLP Control Cabinet PSI SW GE Control Cabinet Blower Pressure Switch (RPM
950- 1150)
RSC Retard Spd Control SW Retard Speed Control Switch ON/OFF
SPINDIS Slip Slide Dis Slip Slide Feature Disabled
FORREQ Forward Direction Directional Shift Selector - Reverse Position
REVREQ Reverse Direction Directional Shift Selector - Forward Position
REST-DO Bodyup Reset Bodyup Override / Rest Reset Switch ON/OFF
DATST Data Store Data Store Switch ON/OFF
GFNCO Generator Field Coil SW Control Cabinet DC Field Cut Switch
PROPLO Propel Lockout Isolation Box & GE Cabinet Propel Lockout Switch
ON/OFF
OEMACCIN OEM Accel Inhibit Optional Hyd Access Ladder Down Limit Switch
ENGSTRREQ Eng Start Request Engine Starter Request Key Switch Start
ENGKILL Engine Kill SW Engine Secondary Shutdown Cab & Ground ON/
OFF
ENGWARN Engine Warning Engine Warning Signal (J1939 CAN)
WARMUP Grid Dry SW Grid Dry / Engine Warm Switch ON/OFF
FULPAYLD Full PayLoad Full Payload Signal (RPC CAN)
OVERPAYLD Over Load Over Load Payload Signal (RPC CAN)
BODYDWN Body Down SW Body-up Proximity Switch ON/OFF
OVERPAYLD Over Load Over Load Payload Signal (RPC CAN)
AUTON Autonomous Mode AHT Option - Auto / MAN Signal (RPC CAN)

Table 6: Analog I/O to GE Body Hoist Limit
1. Turn the key with to the ON position.
Analog I/O to GE
2. Place a piece of metal in front of the body up
Function Description Criteria switch located at the rear of the truck.
Power Supply Operating value verified 3. In the brake cabinet measure the voltage at the
Retard Pedal Operation range verified and hoist limit solenoid, circuit 53H to ground.
Calibrated With the metal in front of the body up switch,
Accelerator Pedal Operation range verified and battery voltage should be read.
Calibrated 4. Remove the metal from the rear of the truck.
10V Pot Reference Operating value verified
Voltage should read zero volts when the metal
RSC Pot / Retard Operation range verified and is removed.
Speed SW Calibrated
• The following digital circuits to GE are not used

as these signals are now communicated over
RPC CAN or not needed.
Circuit NO Description GE Connector

77 Truck Speed Freq P303-R
Signal
77A Truck Speed Freq P303-F
Signal
Shield Truck Speed Freq P303-Y
Shield
• Checks prior to Self-load test (Load Box)

• Engine Running Tests (Self-load Test)
Engine Shutdown Smart Timer Check

1. Use a Multi-Meter to monitor the voltage on
circuit 21NSL (TB27) to ground.
2. Start and run the engine at an elevated RPM
approximately 1700 RPM until engine coolant
becomes hot (180degF).
Circuit 21NSL will go from 0 to 24vdc.
3. Let the engine return to idle for approximately
one minute and turn the key switch to OFF
position.
The engine should continue to operate at idle
speed for approximately three minutes or less
and then shutdown.

Checkout Completion Report
TRUCK SERIAL NUMBER ____________________________________
Function Description Criteria Result

(OK/Fail)
Operator Cab Dome Light Cab dome light functions
Front Vehicle Horn Vehicle Horn functions
Ladder Light Switch All Ladder and Deck light operate
Hazard Signals Hazard Lights operate
Electric Windows Driver and passenger windows operate up and down
Hyd Brake Cab Dome Light Hyd Brake Cab Dome Light functions
Hyd Pump Access Light If Equipped- Hyd Pump Access Light operates
Isolation Station Engine Service Lights All Indicator light operate correctly with corresponding dis-
connect switch
Rear Axle Service Light Rear Axle Service Light
Operator Switch Indicators All Dash Switch indicator lights function correctly
Clearance Lights Deck and Axle clearance light function
Headlights Low and Hi-Beam headlights operate
Fog Lights If Equipped - Fog Light operate
Backup Horn and Lights Backup Lights and Horn work in Reverse
Manual Backup Lights Backup Light s function with Manual backup switch
Turn Signals Dash indicators, Front and Rear Turn signal operate left
and right
Service Brake Lights Brake light operate with service brake
Windshield wiper Wipers operate in Low and High Speed
Windshield Washer pump Washer pump operates
Heated Mirrors If equipped - heated mirrors operate
Entertainment Radio Radio operate
Operator Cab Air Seats Driver and Passenger air seats operate
Operator HVAC System HVAC System operate
Auxiliary Cabinet Dome Lights Aux Box Dome lights function
Body Hoist Limit Body Hoist Limit function
Control Power Relay GE I/O - Output for GE Control Power (71GE) ON/OFF
Park Brake Input GE I/O - Park Brake Applied Pressure Switch ON/OFF
Service Brakes ON GE I/O - Service Brake Applied Pressure Switch
Wheel Brake Lock SW GE I/O - Brake Lock Switch Dash ON/OFF (RPC CAN)
PreShift Brake Test GE I/O - Pre-Shift Park Brake Test Switch ON/OFF
Axle Blower PSI SW GE I/O - Traction Motor Pressure Switch ON/OFF
Control Cabinet PSI SW GE Control Cabinet Blower Pressure Switch
(RPM 950- 1150)
Retard Speed Control SW GE I/O - Retard Speed Control Switch ON/OFF
Slip Slide Dis GE I/O - Slip Slide Feature Disabled
Forward Direction GE I/O - Directional Shift Selector - Reverse Position

Function Description Criteria Result
(OK/Fail)
Reverse Direction GE I/O - Directional Shift Selector - Forward Position
Rest Switch GE I/O - DC Power Rest Switch ON/OFF
Body up Reset GE I/O - Body up Override / Rest Reset Switch ON/OFF
Data Store GE I/O - Data Store Switch ON/OFF
Generator Field Coil SW GE I/O - Control Cabinet DC Field Cut Switch
Propel Lockout GE I/O - Isolation Box & GE Cabinet Propel Lockout
Switch ON/OFF
OEM Accel Inhibit GE I/O - Optional Hyd Access Ladder Down Limit Switch
Eng Start Request GE I/O - Engine Starter Request Key Switch Start
Engine Kill SW GE I/O - Engine Secondary Shutdown Cab & Ground ON/
OFF
Engine Warning GE I/O - Engine Warning Signal (J1939 CAN)
Grid Dry SW GE I/O - Grid Dry / Engine Warm Switch ON/OFF
Full Pay Load GE I/O - Full Payload Signal (RPC CAN)
Over Load GE I/O - Over Load Payload Signal (RPC CAN)
Body Down SW GE I/O - Body-up Proximity Switch ON/OFF
Retard Pedal GE I/O - Signal From Retarder Pedal
Accel Pedal GE I/O - Signal from Accelerator Pedal
10V Pot Reference GE I/O - Conditioned Potentiometer Voltage for GE +15v
out
RSC Pot GE I/O - Retard Speed Control Switch & Ad RSC Potenti-
ometer

INTERFACE MODULE CHECKOUT PROCEDURE
Purpose How to Use the IM Realtime Data Monitor
This procedure is used to checkout the IM
Software
installation. Connect a DB9 straight through cable from the serial
port on the laptop to the IM Diagnostic connector in
the cab or auxiliary cabinet. The IM must be powered
to communicate with the laptop.
Necessary Equipment
1. This checkout procedure and vehicle wiring Double click the shortcut to IM Realtime Monitor on
schematic. the Desktop screen. After the program runs, a blank
window shows up. On the menu select “Select Serial
2. Laptop computer with GE's wPTU software
Port” to pick the serial port used and then select
installed.
“Start/Stop” to view the data.
3. Laptop computer with IM Realtime Data Monitor
Software installed. This software can be found Check for Fault Codes Associated With the
on the Komatsu America Extranet: Interface Module
https://www.komatsuamerica.net/northamerica/ Key on then run the IM Realtime Data Monitor
Software and confirm that there are no fault codes
associated with the Interface Module. If any are
4. RS232 serial cable with a male DB9 connector found, these circuits should be analyzed to
on one end and a female connector on the other determine the cause of the fault and they should be
end. repaired or if required the IM should be replaced.
5. 3/8 inch nut driver, voltmeter, 3 inch (or longer)
jumper wire.
6. Connector back - probes.
7. Small flat screw driver. Use the screw driver to
gently push in the orange wire release buttons
when removing a wire from a terminal board.
Install the Application Code

Before the Interface Module can be put to work, the
application code must be installed. Application code
must be matched to the truck model that the
Interface Module is installed on.
To get the necessary files and instructions, go to the

Komatsu America Extranet:
https://www.komatsuamerica.net/northamerica/
Validate the correct IM software is installed by using
the IM Realtime Data Monitoring software to locate
the CRC number of installed IM software. Compare
the CRC number on the IM Realtime Data Monitoring
software to the CRC number on the text document
inside of the software zip file found on the extranet.
Confirm these numbers are the same.
58F-06-03861 Interface Module Checkout Procedure 1

Interface Module I/O 9. Crank Sense (IM3-U) - Open the Start Battery
Disconnect switch so that there is no battery
Use the IM Realtime Data Monitor software to
voltage to the starters. Momentarily short TB28
confirm the functionality of all IM inputs and serial
- J to 24V and confirm state change (zero to
connections. The key switch must be on for all tests
one). After removing 24V short from TB28 - J,
below.
close the Start Battery Disconnect switch.
Check Digital Inputs to the Interface Module 10. Selector Switch (Park) (IM3-T) - Place shifter
1. Hydraulic Tank Level (IM2-k) Disconnect into park position and confirm 1 state then shift
connector CN712 at Hydraulic Tank Level into neutral and confirm 0 state. Return shifter
Sensor. Short pin C to ground momentarily and to park position.
confirm state change (one to zero). Reconnect 11. Selector Switch (FNR) (IM2-N) - Place shifter
CN712. into park position and confirm 0 state then shift
2. Low Steering Precharge (IM2-W) - This step into neutral, forward, and reverse and confirm 1
requires properly pre-charged steering state for each of these positions. Return shifter
accumulators. Disconnect one of the Low to park position.
Accumulator Precharge Switches momentarily 12. Strg Bleed Pressure Sw (IM2-Z) - Disconnect
and confirm state change (zero to one). connector SABS at the Steering Bleed Pressure
Reconnect switch. Switch and confirm state change (zero to one).
3. Pump Filter Switches (IM2-Y) - Disconnect Reconnect SABS.
connector CN730 at Steering Filter Pressure
13. Brake Lock Switch Power Supply (IM3-L) -
Switch momentarily and confirm state change
Ensure that shifter is in park position. Use GE's
(zero to one). Reconnect CN730.
wPTU software to turn on FWD True output
4. Park Brake Released (IM2-M) - Short wire 73S signal. Confirm state change (zero to one).
to ground at TB33-C momentarily and confirm Leave GE FWD True signal on until completion
state change (one to zero). of step 20.
5. Park Brake Request (IM3-V) - Short the engine 14. Brake Lock (IM2 - i) - Actuate brake lock switch
oil pressure switch wire circuit 36 on TB28-A to and confirm state change (zero to one). Turn off
ground. Move shift lever from neutral to park GE FWD True signal. Confirm input state
position and confirm state change (one to zero). remains at one. Turn off brake lock switch.
Remove the ground from TB28-A. Confirm input state returns to zero. (The Brake
6. GE Batt + (IM3-M) - confirm this is a one. Lock Switch Power Supply test, item 19, must
7. Starter Motor 1 Energized (IM3-R) - Disconnect be completed before this test can be
wire 11 SM1 from cranking motor to TB28 - F at successfully completed). Turn off GE FWD True
TB28 - F. Momentarily short TB28 - F to 24V signal.
and confirm state change (zero to one). 15. Service Brake Set sw (IM3 - C) - Short wire 44R
Reconnect disconnected wire. at TB35 - F to 24 volts momentarily and confirm
8. Starter Motor 2 Energized (IM3-S) - Disconnect state change (zero to one).
wire 11 SM2 from cranking motor to TB28 - G at
16. Cummins Shutdown Delay (1M3-F)- Disconnect
TB28 - G. Momentarily short TB28 - G to 24V
wire 21 NSL from the Engine ECM at TB27 - E
and confirm state change (zero to one).
leaving wire 21 NSL to IM connected at TB27 -
Reconnect disconnected wire.
E. Momentarily short TB27 - E to 24V and
confirm state change (zero to one). Reconnect
disconnected wire.
2 Interface Module Checkout Procedure 58F-06-03861

17. Secondary Engine Shutdown sw (1M3-E) - 29. Brake Lock Degrade sw (IM2 - V) - Short wire
Actuate the Secondary Engine Shutdown 33T to ground at TB32 - F momentarily and
switch and confirm state change (one to zero). confirm state change (one to zero).
18. Keyswitch (1M3-G) - confirm state is a one. 30. Keyswitch Direct (IM2 - P) - Confirm state is a
19. Mode sw1 (IM3-H) - Actuate the “left arrow” one. Turn keyswitch off for 1 second and then
LCD screen navigation switch and confirm state back on. Confirm state changes to zero and
change (one to zero). then back to one.
20. Mode sw2 (IM3-J) - Actuate the “OK” LCD 31. Auto Lube Level (IM3-W) - Disconnect
screen navigation switch and confirm state connector CN511 at the Auto Lube Low Level
change (one to zero). Switch, short pin C to ground momentarily and
confirm state change (one to zero). Reconnect
21. Mode sw3 (IM3-K) - Actuate the “down arrow” connector CN511.
LCD screen navigation switch and confirm state
change (one to zero) 32. Auto Lube Press sw (IM3-Y) - Short wire 68P to
ground at TB60-B momentarily and confirm
22. Mode sw4 (IM2-q) - Actuate the “up arrow” LCD state change (one to zero).
screen navigation switch and confirm state
change (one to zero). 33. Body Up sw (IM2 - R) - For trucks without a
body installed yet, place washer on body
23. Crank Request (IM2 - j) - Open the Starter proximity sensor, confirm state change, them
Disconnect switch so that there is no battery remove washer and confirm state change
voltage to the starters. Momentarily turn again. For truck with body installed, make sure
keyswitch to the crank position and confirm that the body is lowered down all the way, and
state change (zero to one). then momentarily disconnect wire 71 F at TB35
24. Park Brake Set (IM2-f) - Momentarily disconnect - S and confirm state change (one to zero).
Park Brake Pressure switch, identified by circuit Reconnect disconnected wire.
33, and confirm state change (zero to one). 34. Dynamic Retard (IM3 - Z) - Momentarily short
25. Seat Belt sw (1M2-g) - Buckle seat belt. Then wire 74ZA to ground at TB21 - D and confirm
unbuckle seat belt and confirm state change state change (one to zero).
(zero to one). 35. No Propel/Retard (GE CPU Running) (IM2-n) -
26. Snapshot In - Progress (IM2-L) - Actuate the Confirm state is a zero. Turn off the GE
Data Store Switch. Confirm state change (one keyswitch. Confirm state changes to a one.
to zero). Turn GE keyswitch back on. Confirm state
changes to a zero once GE is booted back up
27. Low Steering Pressure sw1 (IM2-S) - Using a (see DID panel), which can take up to 45
back - probe, short wire 33F to ground at seconds.
connector CN14 pin 6 momentarily and confirm
state change (one to zero). Remove back - 36. Accessory Drive Pump Filter Switch (IM3-X) -
probe. Disconnect Connector HAFSW. Short wire
39HP1 to ground momentarily at connector
28. Brake Accum Pressure sw (IM2-U) - HAFSW pin A and confirm state change (one to
Momentarily short wire 33BP to ground at TB32 zero). Reconnect connector HAFSW.
- E. Confirm state change (one to zero).

Check Analog Inputs To The Interface Module 8. Left Rear Brake Oil Temp [C] (IM3-i) -
Disconnect left rear brake oil temp sensor and
Verify that the used analog inputs are in the range of
confirm fault A166, Hydraulic Oil Temp - Left
the values listed below.
Rear Sensor Low, is active. Reconnect sensor.
1. Truck Speed [kph] (IM1-gh) - Use GE DID to 9. Right Front Brake Oil Temp [C] (IM3-r) -
simulate vehicle speed and confirm reported Disconnect right front brake oil temp sensor and
speed matches vehicle speed set using GE confirm fault A169, Hydraulic Oil Temp - Right
DID+/ - 2 kph. Front Sensor Low, is active. Reconnect sensor.
2. Steering Pressure [kPa] (1M3 - d) - Disconnect
10. Left Front Brake Oil Temp [C] (IM3-t) -
steering pressure sensor, identified by circuit
Disconnect left front brake oil temp sensor and
33SP, and confirm fault A204, Steering
confirm fault A168, Hydraulic Oil Temp - Left
Pressure Sensor Low, is active. Reconnect
Front Sensor Low is active. Reconnect
sensor.
sensor.Hoist Pressure 2 [kPa] (IM3-q) - Short
3. Ambient Air Temp [C] (1M3-e) - confirm wire 33HP2 to ground at TB28-K momentarily
reported temperature matches ambient and confirm fault A203, Hoist Pressure 2
temperature within 3°C (5.4°F). Sensor Low, is active.
4. Fuel Level [%] (1M3-g) - confirm reported %
11. Hoist Pressure 1 [kPa] (IM3-s) Short wire
level matches actual fuel level in tank +/ - 5%.
33HP1 to ground at TB30 - N momentarily and
5. 12V Converter [V] (1M3 - h) - confirm reported confirm fault A202, Hoist Pressure 1 Sensor
voltage is 13.5V +/ - 0.5V. (24V Battery voltage Low, is active.
must be greater than 18 volts.)
12. Battery Voltage 24V [V] (IMint) confirm reported
6. Brake Pressure [kPa] (IM3-p) - Disconnect voltage is +/ - 1 volt of actual measured battery
service brake pressure sensor located in brake voltage.
cabinet, identified by circuit 33BPS, and confirm
fault A205, Brake Pressure Sensor Low, is
active. Reconnect sensor.
7. Right Rear Brake Oil Temp [C] (IM3-m) -
Disconnect right rear brake oil temp sensor and
confirm fault A167, Hydraulic Oil Temp - Right
Rear Sensor Low, is active. Reconnect sensor.

Check Serial Interfaces to the Interface Module 2. Start Enable output (1M1-B). Disconnect all
circuit 21 PL wires from pre - lube timer prior to
Proper operation of the serial interfaces to the IM is
performing this step. Place shifter in park and
assured if faults A184, A233, A237, and A257 are not
confirm that circuit 21PS on TB28 - H is 24 volts
active.
while cranking. Place shifter in neutral and
Check Outputs from the Interface Module confirm that circuit 21PS on TB28 - H is 0 volts
while cranking. Reconnect all circuit 21PL wires
NOTE: Before performing these next steps, the key to pre - lube timer.
switch must be turned off for at least 7 minutes to
3. IM On Signal (IM1-K). With keyswitch on,
allow the IM to completely shutdown. Confirm that
confirm voltage on circuit 110NS at TB35-T is
the IM has shutdown by verifying that the green LED
approximately 0 volts.
on the IM controller has stopped flashing. While
performing the following IM output checks, ensure 4. Red Warn output (IM1-G), Sonalert output (1M
that no output short circuit fault codes are reported 1-M). Disconnect the IM from the CAN/RPC
by the IM Realtime Data Monitor software. network by unplugging its T - connection to the
network then confirm the following on the dash
1. Park Brake Solenoid output (IM1-E), Brake panel:
Auto Apply output (IM1-R). Short the engine oil
pressure switch wire circuit 36 to ground on a. All status panel indicators flash on/off.
TB28 - A. Key on and shift into neutral. Confirm b. The red warning indicator flashes on/off.
that park brake solenoid is energized by
c. Two separate audible alarms can be heard
verifying that coil is magnetized. Use the GE
sounding on/off.
DID panel to set the truck speed to a speed
above 1 kph. Shift into park. Confirm that the d. A loss of communications message is
park brake solenoid remains energized. Reduce displayed on the speedometer .
the truck speed to 0 kph. Confirm that the brake e. The needles in all of the gauges are moving
lock solenoid energizes and after one second through their entire range of motion.
confirm that the park brake solenoid de-
energizes and after one half second confirm Reconnect the IM to the CAN/RPC network.
that the brake lock solenoid de-energizes. 5. Steering Bleed Down Solenoid output (IM1-P).
Remove the ground from TB28-A. Confirm steering bleed down solenoid is de -
energized. Turn key switch off and confirm that
steering bleed down solenoid is energized by
verifying that coil is magnetized.

S/N ___________________
IM Installation Checkout Checklist
Function Description Expected Result Result (OK/Fail) Comments

DIGITAL INPUT CHECKS:
1 - Hydraulic Tank Level 1 to 0
input
2 - Low Steering Precharge 0 to 1
input
3 - Pump Filter Switches 1 to 0
input
4 - Park Brake Released 1 to 0
input
5 - Park Brake Request 1 to 0
input
6 - GE Batt+ input 1
7- Starter Motor 1 0 to 1
Energized input
8 - Starter Motor 2 0 to 1
Energized input
9 - Crank Sense input 0 to 1
10 - Selector Switch (Park) 1 to 0
11 - Selector Switch (FNR) 0 in Park, 1 in Forward,
Neutral, and Reverse
12 - Steering Bleed 0 to 1
Pressure input
13 - Brake Lock Switch 0 to 1
Power Supply input
14 - Brake Lock input 0 to 1
15 - Service Brake Set input 0 to 1
16 - Cummins Shutdown 0 to 1
Delay input
17 - Secondary Engine 1 to 0
Shutdown input
18 - Keyswitch input 1
19 - Mode switch 1 input 1 to 0
23 - Crank Request input 0 to 1
24 - Park Brake Set input 0 to 1
25 - Seat Belt switch 0 to 1
26 - Snapshot input 1 to 0

27 - Low Steering Pressure 1 to 0
switch input
28 - Brake Accumulator 1 to 0
Pressure switch input
29 - Brake Lock Degrade 1 to 0
switch input
30 - Keyswitch Direct input 1 to 0 to 1
31 - Auto Lube Level switch 1 to 0 to 1
input
32 - Auto Lube Pressure 1 to 0
switch input
33 - Body Up switch input w/o body 0 to 1 to 0 with body
1 to 0
34- Dynamic Retard input 1 to 0

35 - No Propel/Retard input 0 to 1 to 0
(GE CPU Running)
36 - Accessory Drive Pump 1 to 0
Filter Switch
ANALOG INPUT CHECKS:
1 - Truck Speed set speed+/ - 2 kph
2 - Steering Pressure fault A204
3 - Ambient Air Temp ambient temp+/ - 3C
4 - Fuel Level tank level+/ - 5%
5 - Converter Voltage 13.5 +/ - 0.5V (12V)
6 - Brake Pressure fault A205
7 - Right Rear Brake Oil fault A167
Temp
8 - Left Rear Brake Oil fault A166 Temp
9 - Right Front Brake Oil fault A169
Temp
10 - Left Front Brake Oil fault A168
Temp
11 - Hoist Pressure 2 fault A203
12 - Hoist Pressure 1 fault A202
13 - Battery Voltage 24V measured battery voltage
+/- 1V
SERIAL COMM CHECKS:
1 - CAN/11939, Drive no fault A184, A233, A237,
System CAN/RPC, Display A257
CAN/RPC, Payload
CAN/RPC
OUTPUT CHECKS:
1a - Park Brake Solenoid energized/de-energized

1b - Brake Lock Solenoid energized/de-energized in
park brake setting sequence
2 - Start Enable output 24 V, OV
3 - IM On Signal output OV
4 - Electronic Dash Panel Items 4a-e function as
check described
5 - Steering Bleed Solenoid Solenoid de-energized then
output energized
Completed By: _________________________________________ Date: _______________________

HYDRAULIC CHECKOUT PROCEDURE
Scope The solenoid will remain energized until the Interface
Module shuts down. Battery disconnect switch must
This manual is intended for factory checkout and field
be in ON position during entire steering accumulator
commissioning of new trucks. Where applicable,
bleed down operation.
notes for verifying both partially and completely
assembled systems are included. Once the steering bleeddown solenoid is energized,
fault A235, Steering Bleed in Process, will be
Data to be Recorded generated and the warning buzzer will sound. The
Steps in this document requiring recording of data fault will remain active until either the steering bleed
are indicated with an asterisk (*). A consolidated form pressure switch indicates that the pressure has been
for recording data is located in the Checkout Data bled or 90 seconds have elapsed.
Sheet section at the end of this document. If steering bleed down successfully reduces the
NOTE: Refer to Hydraulic System Schematic when pressure below 1 758 ± 103 kPa (255 ± 15 psi) within
performing this Checkout Procedure. 90 seconds and the parking brake has applied, as
indicated by the park brake pressure switch, then the
NOTE: Be sure accumulators are bled down before Interface Module will shut down. Steering pressure at
loosening any hydraulic fitting. bleeddown manifold test port T3 will be 103 kPa (15
NOTE: Carefully disconnect all hoses, tubing, psi) or less after successful bleed down.
gauges, and plugs in case hydraulic pressure is Fault A236, Steering Bleed Fault, will appear on the
trapped. operator cab display if 90 seconds elapse before the
steering bleeddown pressure switch indicates a
Required Software successful bleeddown. The Interface Module will
1. Interface Module Realtime Data Monitor keep the steering bleeddown solenoid energized and
software is required to view faults and system will not shut down while the fault is active. The
status at several steps of this manual. The Interface Module Warning indicator will illuminate
current version of the software may be and the warning buzzer will sound.
downloaded from
komtraxvhmsplm/vhmsplm/usefulinformation/
software/
Pre-checkout Items If Interface Module Warning Indicator is illumi-

nated, buzzer sounding, do not attempt to
The following four Pre-checkout Items must be
remove any hydraulic hose, fitting, plug or
reviewed and understood before performing this
switch. As hydraulic pressure may be trapped.
Checkout Procedure:
1. Interface Module Checkout Procedure must be Refer to Interface Module Checkout Procedure for
successfully completed before engine is additional information about Fault A236. Battery
started. Failure to do so may prevent detection disconnect switch must be in ON position during
of improper/incomplete steering accumulator entire steering accumulator bleed down operation
bleed down function if problems existing with and remain in ON position until no fault is active or
wiring, switches, etc. in accumulator bleed until active faults are diagnosed.
down circuit. 3. Brake and auxiliary accumulators are not bled
2. The steering accumulator bleed down solenoid down through the steering accumulator
is energized, which allows bleed down of the bleeddown circuit. Brake accumulators are bled
accumulators two seconds after the following down by means of needle valves located in the
three conditions are met: hydraulic brake cabinet. The auxiliary
accumulator is bled down by means of a needle
a.The key switch is turned OFF. valve located on the accumulator tap and
b.The truck is stopped, 0 kph. distribution manifold.
c. The engine is not running, 0 rpm.
58F-60-40932 Hydraulic Checkout Procedure 1

NOTE: The auxiliary accumulator referenced in this
manual is a component of some auxiliary systems,
e.g. retractable ladder. These systems are optional
and may not be present on the truck being checked.
References to the auxiliary accumulator may be
disregarded if none is present. The following procedure does not remove high
pressure hydraulic oil from the hoist system. The
Bleeding Down Hydraulic Auxiliary, Brake body must be resting on the truck frame rails or
and Steering Accumulators supported by another means to remove the pres-
sure from the hoist system.
Each time the key switch is turned OFF with the truck
stopped, the steering accumulator bleeddown 1. Park the empty truck on flat, level ground.
solenoid is energized. When the solenoid is 2. Place the hoist lever into the FLOAT position
energized, all hydraulic steering pressure, including and verify that the body is resting on the frame.
the steering accumulators, is bled back to the 3. Stop the truck engine by turning the key switch
hydraulic tank. Brake pressure, however, will not to the OFF position. Wait two minutes for the
bleed down due to check valves that have been steering accumulators to bleed down via the
incorporated into the brake and steering bleeddown steering bleeddown valve.
manifolds
NOTE: The steering bleeddown valve is located in
In the event that a malfunction occurs with the the steering bleeddown manifold and is automatically
steering bleeddown system, it is possible that the energized for two minutes after the key switch is
steering accumulators may not fully depressurize. turned to the OFF position and the engine has
Should such a malfunction occur, the following stopped.
procedure is to be used to insure that all hydraulic
steering system pressure, including that stored by
the steering accumulators, is bled back to the
hydraulic tank.
It is important to verify that the hydraulic system
pressure has been removed from all the steering and The electrical system must remain powered for
brakes accumulators before disconnecting or the bleeddown valve to function properly.
replacing any hydraulic line, component, or installing 4. Chock the rear tires.
test gauges and hardware for diagnosing and
troubleshooting the systems. The following 5. Check the area around the front tires to make
procedure should be followed to insure that system sure all personnel and equipment are clear of
pressure has been removed. the tires.
Ensure no one is near the front tires when per-

Hydraulic fluid escaping under pressure can
forming the next step. All personnel are to be
have sufficient force to enter a person's body by
warned that clearances change when the steer-
penetrating the skin and cause serious injury and
ing wheel is turned and this could cause serious
possibly death if proper medical treatment by a
injury.
physician familiar with this type of injury is not
received immediately. Before disconnecting
pressure lines, removing fittings, replacing com-
ponents in the hydraulic circuits, or installing
test gauges, ALWAYS bleed down the steering DO NOT open the brake accumulator bleeddown
and brake accumulators. valves before moving the steering wheel to bleed
down the steering accumulators. If the brake
accumulators are bled down before the steering
accumulators are bled down pressure may
remain trapped in the steering circuit and could
cause serious injury.
2 Hydraulic Checkout Procedure 58F-60-40932

6. Turn the steering wheel back and forth until the Accumulator Precharge Procedure (Step 1)
wheel becomes stiff and can no longer be 1. Precharge all steering and brake accumulators
turned manually. If the wheel remains limber, as follows:
locate and correct the problem before
proceeding. NOTE: Permanent damage to bladder/piston
7. Open the (2) brake system manual bleed accumulators will result if the engine is started
valves, NV1 and NV2, located in the brake without all accumulators properly precharged.
manifold by turning the knobs fully NOTE: Use only dry Nitrogen to precharge
counterclockwise. The manifold is located in the accumulators.
cabinet behind the operator cab.
NOTE: Precharging rates of all bladder/piston
8. Depress the brake treadle pedal. The service accumulators must follow details in step d or
brakes should not apply; the brake light should permanent damage to accumulator bladders/piston
not illuminate. If the lights illuminate, locate and will result.
correct the problem before proceeding.
a.Carefully follow bleeddown procedure
9. Install a pressure gauge in test ports BR and BL
outlined in this document to fully bleed down
in the brake cabinet. With the brake pedal
the auxiliary, brake and steering
depressed, the pressure at each test port
accumulators. Leave the auxiliary (B/D) and
should remain at 103 kPa (15 psi) or less after
both brake (NV1 and NV2) needle valves
the brake system has successfully bled down.
fully open until precharging is complete.
10. Open the auxiliary systems manual bleeddown
b.Carefully remove plug/fitting in bleeddown
(B/D) valve, located in the accumulator tap and
manifold port TP3. All hydraulic pressure
distribution manifold, by turning the knob fully
should have been removed if step 1a was
counterclockwise. The manifold is located on
followed, but careful attention should still be
the frame rail, behind the right front suspension
paid when removing the plug. Removing the
strut.
plug will vent the oil side of the steering
11. Manually operate the lubrication pump valve. accumulators to atmosphere, allowing
The pump should not cycle. Should the pump proper bladder expansion or piston
cycle, locate and correct the problem before positioning during precharging if the 690 kPa
proceeding. (100 psi) vendor-supplied storage precharge
12. Install a pressure gauge at accumulator tap and is not present. All other accumulators are
distribution manifold test port GA. The pressure adequately vented for precharging when the
should be 15 psi or less after the auxiliary needle valves are open. Retain the plug for
systems accumulator has successfully bled reuse after precharging is complete.
down. c.All accumulators are to be precharged only
13. Install a pressure gauge in test port TP3 of the with dry nitrogen as follows:
bleeddown manifold. The pressure should be i.Check Nitrogen precharge pressure in each
103 kPa (15 psi) or less after the steering accumulator, and then follow steps d and e
system has successfully bled down. below for each accumulator.
14. The auxiliary, brake and steering systems are ii.If precharge pressure is below 690 kPa
now hydraulically bled down. (100 psi), set pressure regulator 172 kPa
15. Perform the desired work operations per the (25 psi) above measured pressure. Add
associated work instructions. nitrogen to raise the precharge pressure in
no less than the following times:
16. Upon completion of all work, tighten all
connections loosened during bleed down and • Auxiliary and Brake accumulators - three minutes
work operations. Close both brake system to initially raise pressure by 172 kPa (25 psi).
manual bleed valves opened in step 7. Close • Steering accumulators - four minutes to initially
auxiliary systems bleeddown (B/D) valve raise pressure by 172 kPa (25 psi).
opened in step 10.

Table 1: Recommended Accumulator
Precharge
Failure to observe the above charging limits will Ambient Precharge Pressure
result in permanent damage to accumulator blad- Temperature ±10 psi (±70 kPa)
der or piston. 120° F (49° C) 1,529 psi (10 542 kPa)
If precharge pressure is still below 690 kPa 110° F (43° C) 1,503 psi (10 363 kPa)
(100 psi) after adding Nitrogen at the rates 100° F (38° C) 1,477 psi (10 184 kPa)
listed above, slowly raise precharge
90° F (32° C) 1,452 psi (10 011 kPa)
pressure until 690 kPa (100 psi) is reached.
After 690 kPa (100 psi) or above is 80° F (27° C) 1,426 psi (9 832 kPa)
reached, follow step iii below. 70° F (21° C) 1,400 psi (9 653 kPa)
iii.If precharge pressure is 690 kPa (100 psi) 60° F (16° C) 1,374 psi (9 473 kPa)
or above, accumulator bladder is fully
50° F (10° C) 1,348 psi (9 294 kPa)
expanded or piston bottomed. Precharging
rate can then be safely increased until 9 40° F (4° C) 1,323 psi (9 122 kPa)
653 kPa (1,400 psi) is reached. Allow the 30° F (-1° C) 1,271 psi (8 763 kPa)
precharge to set for 15 minutes so the 20° F (-7° C) 1,245 psi (8 584 kPa)
nitrogen temperature may equalize. Adjust
precharge pressure to 9 653 kPa (1,400 10° F (-12° C) 1,220 psi (8 412 kPa)
psi) as necessary. Precharge pressure for 0° F (-18° C) and 1,194 psi (8 232 kPa)
all accumulators is 9 653 ± 69 (1,400 ± 10 below
psi) at 70 degrees Fahrenheit. Refer to
Table 1 for equivalent precharge Example:
requirements at other accumulator
temperatures. For an accumulator at temperature 50°F (10°C),
Correct precharge pressure is 1338 - 1358 psi (9 224
NOTE: Temperatures within an accumulator will - 9 364 kPa).
affect its precharge pressure. The precharge
pressure will rise as the accumulator internal NOTE: Precharge pressures below 8 232 kPa (1,194
temperature increases. Conversely, the pressure will psi) will cause low precharge warnings and are
fall as the internal temperature decreases. To ensure therefore, not recommended.
accurate measurement of accumulator precharge d.Reinstall and properly torque the bleeddown
pressures, the internal temperature must also be manifold plug removed from port TP3 in step
measured. The ambient air temperature may be 1b
used to approximate the accumulator internal
temperature after the truck has been shut down for e.Close manual bleeddown valves in the brake
one hour. The accumulator should be located out of cabinet and auxiliary tap and distribution
direct sunlight. See Table 1 for the recommended manifold.
precharge pressures at various ambient Record each steering, brake and auxiliary
temperatures. accumulator precharge pressure and temperature.

Pressure Gauge Installation (Steps 2 and The hose material can be 1/4" dia. SAE 100R2,
3) which has a 34 474 kPa (5,000 psi) rating. A
2. Install calibrated multiple range pressure needle valve will allow simple opening/closing,
gauges in the following locations: and must be rated for 27 579 kPa (4,000 psi) or
above. The hose assembly can consist of two
a.Pressure test port at each hoist filter. 14" dia. hoses connected to a needle valve. The
Gauges must read up to 24 132 kPa (3,500 opposite ends of the hoses can be connected
psi). as described below. The length of the hoses is
b.Steering pump test port GPA, located on the not critical and can be selected to provide the
same side of the pump as the suction port. best accessibility to the needle valve.
Gauge must read up to 34 474 kPa (5,000 a.Be certain both steering, both brake and the
psi). auxiliary accumulators are bled down.
c. Bleeddown manifold test port T3. Gauge b.Remove plug (SAE #10 O-ring boss port)
must read up to 34 474 kPa (5,000 psi). located near bleeddown manifold port TP3
3. Install calibrated pressure gauges in the (2, Figure 1-1). This port does not have an
following locations: identification stamping. Port TP3 is shown
a.Both test ports (right turn and left turn) of for reference. This port has the same
steering cylinder manifold. Gauges must pressure as bleeddown manifold ports
read up to 34 474 kPa (5,000 psi). Steering Supply and ACC2 (downstream
steering accumulator), and will allow both
b.Over center manifold test port marked TPD. steering accumulators to bleed down when
Gauge must read up to 24 580 kPa (3,500 the needle valve is opened. Retain the plug
psi). for reuse.
c. Bleed down manifold test port marked T2.
Gauge must read up to 34 474 kPa (5,000
psi).
d.Test port for front brake cooling, located in
block bolted on hoist valve outlet, and upper
left test port on brake/hoist return manifold
for rear brake cooling. Use low pressure
gauges, preferably with 517 kPa to 690 kPa
(75 psi to 100 psi) range.
Initial Start-Up and Flushing (Steps 4 - 19)

4. On the bleeddown manifold, use a jumper hose
to connect ports QD Supply and QD Return.
The hose must be rated to withstand 24 580
kPa (3,500 psi) in the event it becomes fully
pressurized. (1" diameter. SAE 100R12 hose is
rated for 27 580 kPa (4,000 psi). During flushing
however, the pressure within the hose normally
remains below 3 448 kPa (500 psi).
5. Join piston end and rod end hoist cylinder
hoses using the two supplied flushing blocks
PC3074, if not already assembled. FIGURE 1-1. BLEED DOWN MANIFOLD
6. (Optional) A hose/valve assembly may be 1. Plug (Remove)
installed for manually bleeding down steering 2. TP3
accumulators. This hose/needle valve
assembly is only for convenience and not c.Connect one end of hose/needle valve
required to execute the steps of this manual. It assembly to #10 SAE boss port of step b.
provides a means to manually bleeddown both
steering accumulators any time during the
checkout.

d.Remove plug in brake manifold port marked 7. if brakes are not installed, connect brake
T3 (1, Figure 1-2) SAE #6 O-ring boss port cooling supply and return hoses together for
located in brake cabinet. This port will return this entire checkout procedure. Service brake
oil bled from the steering accumulators to the and park brake hoses are to be fitted with steel
hydraulic tank. plugs (rated for 4427 579 kPa (4,000 psi) or
higher) during this checkout procedure.
8. Disconnect or disable all auxiliary hydraulic
systems including, but not limited to, automatic
lubrication, retractable ladder and radiator
shutters. These systems are optional and may
not be present on the truck being checked.
9. Fill piston pump case through case drain port
with clean hydraulic oil. An alternate method to
filling pump case with oil is by leaving case
drain hose connected and removing small plug
near case drain port, on same side of pump as
case drain port. Replace and torque small plug
when oil appears.
NOTE: Filling the pump case with oil does not
eliminate the need for bleeding air from the pump
suction line (as described in step 11). Both must be
done.
10. Fill hydraulic tank with hydraulic oil to upper
sight glass.
FIGURE 1-2. BRAKE MANIFOLD 11. Bleed air from all pump suction lines by
loosening each suction hose at pump inlet. Be
1. T3 sure O-ring does not fall out of groove. When oil
appears, re-torque bolts.
e.Connect hose/needle valve assembly to #6
O-ring boss port of step d. NOTE: Bleeding the piston pump suction line does
not eliminate the need for filling the piston pump case
f. Retain plugs removed from manifolds for with oil (as described in step 9). Both must be done.
replacement when hose/needle valve
assembly is removed. 12. Check the hydraulic tank oil level in tank is still
visible in upper sight glass. If necessary, add oil.
NOTE: Use of optional bleeddown hose/needle valve
assembly does not substitute for the use of jumper 13. Place hoist control in FLOAT position.
hose installed in step 4. 14. *Turn key switch ON but do not start engine.
Verify that the Low Steering Precharge fault
The hose/needle valve assembly is recommended to
A115 is not displayed. If fault is displayed,
remain installed throughout the entire checkout for
correct the problem before starting engine.
use whenever desired or necessary.
Auxiliary and brake accumulators do not have
pressure switches to warn of low precharge, but
must still be precharged to 9 653 kPa (1,400
psi) before starting engine. Do not start engine
without being certain that all steering, all brake
This hose/valve assembly cannot be connected and auxiliary accumulators are precharged to 9
or disconnected if the steering accumulators are 653 kPa (1,400 psi).
pressurized. Record if low precharge fault A115 is displayed
The hose/needle valve assembly and the associated before startup.
fittings must be removed when the Checkout Open auxiliary bleeddown valve. Start engine
Procedure is completed. The original plugs must be and operate at low idle for no more than 30
replaced in the manifold ports and properly torqued. seconds (see note below about steering pump
pressure). At low idle with 70 deg. F oil,

pressure at hoist filters should be approximately installed in step 6, leave it installed. Reconnect
552 kPa (80 psi); pressure at steering pump test all original plumbing. Check that oil is visible in
port GPA should be approximately 690 kPa upper sight glass on hydraulic tank. Add oil if
(100 psi); and pressure at front and rear brake necessary. Close auxiliary bleed down valve.
cooling test ports should be approximately 172
NOTE: Leave brake cooling supply and return hoses
kPa (25 psi).
connected together during this entire checkout if the
NOTE: Do not operate at low idle for more than 30 brakes are not installed.
seconds. Steering pump pressure at test port GPA
18. * Flush steering accumulators by starting and
needs to be at or above 1 724 kPa (250 psi) during
operating the engine until steering accumulator
the flushing process to provide adequate pump
pressure rises to approximately 21 201 kPa
internal lubrication. Steering pump damage will result
(3,075 psi), when the unloader valve shifts and
if pressure is below 1 724 kPa (250 psi). This applies
unloads the steering pump.
to all of steps 15, 16, 17 and 19 in this checkout
manual. If pressure will not reach 21 201 kPa (3,075 psi)
refer to pump adjustment procedure in step 25.
NOTE: Do not turn steering wheel until step 20.
If pressure reaches 21 201 kPa (3,075 psi):
NOTE: Do not apply brakes during any step of this
checkout manual. a.The first time through this step:
15. * With the engine at a speed fast enough to i.* Stop engine by leaving key switch on and
provide at least 1 724 kPa (250 psi) at steering using Engine Shutdown Switch on the cab
pump test port GPA move hoist control to center console. Confirm steering
POWER UP or POWER DOWN. Read brake accumulator bleeddown does not occur and
cooling oil supply pressures, which should be 0 that no bleeddown faults are generated.
psi when hoist control is in POWER UP or Refer to step 14.
POWER DOWN, confirming hoist valve is Confirm that steering accumulator does not bleed
functioning properly. If pressures do not go to 0 down by recording pressure at bleeddown manifold
kPa (0 psi), hoist valve may be plumbed test port TP3 and any bleeddown faults that were
incorrectly. Stop check out procedure and check generated.
all plumbing, including all pilot lines. If plumbing
error is found, correct and repeat this step. If no ii.*Turn key switch OFF and confirm that
plumbing error is found or if pressures still do steering bleeddown begins. Confirm that
not go to 0 kPa (0 psi), replace hoist valve and bleeddown completes normally within 90
repeat this step again. seconds and that bleeddown fault A236,
Steering Bleed Fault, (seen on Interface
Record left and right brake cooling pressures in hoist Realtime Data Monitor) is not active.
Power Up and Power Down. Steering pressure at bleeddown manifold
16. If all pump pressures and brake cooling oil test port TP3 will be 103 kPa (15 psi) or
supply pressures are as stated in steps 15 and less after successful bleeddown. Refer to
16, increase engine to 1500 rpm and flush step 14.
system for 20 minutes. During this time, move Record steering accumulator pressure at bleeddown
hoist control to POWER UP for 30 seconds. manifold test port TP3 and any bleeddown faults that
Then move hoist control to POWER DOWN for were generated.
30 seconds. Continue monitoring brake cooling
oil supply pressures. Oil supply pressure should Continue to step c.
be approximately 345 kPa (50 psi) with the hoist b.* For the second and all other times through
control in HOLD or FLOAT and drop near 0 kPa this step, turn the key switch OFF and allow
(0 psi) when hoist control is in POWER UP or steering accumulators to bleed down.
POWER DOWN. Steering pressure at bleeddown manifold
Repeat hoist control cycling five times. test port TP3 will be 103 kPa (15 psi) or less
after successful bleed down. Refer to step
17. After flushing is complete, stop engine and 14.
allow steering accumulators to completely
discharge. Remove special flushing plumbing. If Record steering accumulator pressure at bleeddown
optional steering accumulator bleed hose was manifold test port TP3 and any bleeddown faults that
were generated.

c. Open needle valves in hydraulic brake then steer into a stop and continue to turn the
cabinet and allow brake accumulators to fully steering wheel. One gauge on steering cylinder
discharge. Open needle valves on auxiliary manifold should read 21 374 (-0/+2 068) kPa
manifold and allow auxiliary accumulator to (3,100 (-0/+300) psi). Steer into opposite stop.
discharge. Close needle valves. The other gauge on steering cylinder manifold
d.Repeat this step (18) five times. should read 21 374 (-0/+2 068) kPa (3,100 (-0/
+300) psi).
NOTE: This step cannot be combined with the
flushing done in steps 14, 15, and 16. This flushing Record left and right shock valve settings.
procedure must be performed after step 17 is 23. *After checking steering shock valves, lower the
completed. steering relief valve pressure to 18 960 ± 483
kPa (2,750 ± 70 psi). To do this, steer full left or
NOTE: Do not steer or apply the brakes at any time
right into stop and adjust steering pressure at
during the accumulator flushing procedure. Steering
flow amplifier while slowly turning the steering
flushing is done in the following step.
wheel. Pressure is to be read on gauge
19. After completing the flushing of all connected to steering cylinder manifold. After
accumulators, the steering system must be setting relief valve pressure, reinstall the
flushed. Start the engine, and allow adjustment access plug.
accumulators to fully charge and pump to
Record final relief valve setting.
unload. Steer lock-to-lock at least 10 times.
Stop the engine and bleed down the steering
accumulators completely. Add oil if necessary.
Steering Pump Unloader Valve Adjustment
(Step 24)
Component Checkouts and Adjustments 24. *Steering pump unloader valve should unload
(Steps 20 - 39) the pump at 21 201 kPa (3,075 psi) (nominal)
and reload accumulators when their pressure
Steering Flow Amplifier Adjustment (Steps falls to 19 133 ± 172 kPa (2,775 ± 25 psi), as
20 - 23) measured at bleeddown manifold port TP2. The
20. Before checking steering shock valves, reload pressure is the critical pressure to adjust
temporarily raise steering relief valve pressure to. If the pump operates as described, proceed
setting. First remove the external access plug to the end of this step to record pressures and
on flow amplifier, then turn adjustment on to step 25. To adjust the pump unloader
clockwise to gently bottom out the valve. Retain valve proceed as follows:
the plug for reuse. Location of adjustment:
21. In preparation for steering shock valve Unloader valve adjustment screw is located on
checkout, adjust unloader valve on steering bottom side of pump as installed on truck.
pump by turning unloader adjustment clockwise
until a minimum reload pressure of 22 925 ± NOTE: Be sure accumulators are bled down before
172 kPa (3,325 ± 25 psi) is measured at loosening any hydraulic fitting.
bleeddown manifold port TP2. The unload a.Install calibrated multiple range pressure
pressure will be approximately (3,625 psi). gauge capable of 34 474 kPa (5,000 psi) at
NOTE: Unloader valve adjustment screw is located steering pump test port GPA.
on bottom side of pump as installed on truck. b.Install calibrated pressure gauge capable of
Steer to verify that at least 22 753 kPa (3,300 psi) is 34 474 kPa (5,000 psi) in the SAE #4 port of
maintained. The higher pressure developed during bleeddown manifold test port TP2.
this check is acceptable and will not affect pump c.Remove the adjustment cap and back out
performance. unloader valve adjustment screw completely.
NOTE: The pump adjustment in this step is to be d.Start truck and allow pump to unload. Pump
used only for checking the steering shock valves. It is in unloaded condition can be verified by the
not intended for normal truck operations. Use step 25 pressure gauge at steering pump test port
when adjusting the pump for normal truck operations. GPA reading 1 379 - 2 758 kPa (200 - 400
22. *To check steering shock valve pressure psi).
settings, steer away from the cylinder stops,

e.Adjust unloader valve to reload b.*Start the engine and operate at low idle until
accumulators when pressure at bleeddown the steering pump unloads. Continue engine
manifold port TP2 falls to 19 133 ± 172 kPa operation for a minimum of three minutes to
(2,775 ± 25 psi). Unload pressure will be allow accumulator temperatures to stabilize.
approximately 21 201 kPa (3,075 psi), but The steering (bleeddown manifold test ports
the reload pressure is the critical pressure to TP2 and TP3) and auxiliary (port GA)
obtain. If adjusting from step 18, do not turn accumulators should each pressurize to at
steering wheel to make accumulator least 19 995 kPa (2,900 psi).
pressure fall. The needle valves in the brake
Record the pressure at manifold ports TP2 and TP3
cabinet may be partially opened to slowly
and tap manifold port GA.
lower the accumulator pressure and cause
the pump to cycle every 20-30 seconds while c.Stop the engine using the engine shutdown
the unloader valve is adjusted. switch. No accumulator should bleed down.
f. Tighten the valve adjustment cap and verify d.Crack open the auxiliary accumulator
pressures remain as adjusted. If reload bleeddown (B/D) valve on the accumulator
pressure is 18 960 - 19 305 kPa (2,750 - tap & distribution manifold.
2,800 psi) as pump is cycling, valve is e.*Observe the pressure at bleeddown
properly adjusted. Close needle valves in manifold port TP2 (front steering
brake cabinet. accumulator) when supply valve SV closes
g.If pump is being adjusted from step 18, and the auxiliary accumulator pressure
return to step 18 now and flush accumulators (accumulator tap manifold test port GA)
without turning the steering wheel. continues to fall whileTP2 stabilizes at 17 82
(+690 / -345) kPa (2,550 (+100 / -50) psi). If
Record pump reloading and unloading pressures.
outside this range, locate and correct the
problem, and repeat steps b - e.
Auxiliary Accumulator Checkout (Step 25)
25. The auxiliary accumulator is filled from the front NOTE: Accumulator tap manifold test port GP1 is
steering accumulator through a supply valve connected directly to bleeddown manifold test port
(SV) located in the accumulator tap and TP2.
distribution manifold. The maximum pressure is Record front steering accumulator pressure TP2
equal to the steering pump unload pressure and when supply valve SV closes.
is not independently adjustable. The supply
f. *With the auxiliary accumulator bleeddown
valve closing pressure is the critical pressure to
(B/D) valve open, confirm the front and rear
verify. Verify the auxiliary accumulator pressure
steering accumulator pressures, TP2 and
as follows:
TP3, remain above 16 548 kPa (2,400 psi)
Location of controls: for a minimum of five minutes after the
auxiliary accumulator is bled down to 103
The accumulator tap manifold is located in
kPa (15 psi) or less.
behind the right front suspension strut,
beneath the auxiliary accumulator. Supply Record the steering accumulator pressures TP2 and
valve SV is controlled by a nonadjustable TP3 and auxiliary accumulator pressure GA 5
pressure switch located in the steering minutes after the auxiliary accumulator is bled down.
bleeddown manifold.
If either steering accumulator pressure falls
a.Install calibrated pressure gauges capable of below the limit or the auxiliary accumulator
34 474 kPa (5,000 psi) at tap and distribution pressure rises, locate and correct the
manifold test ports GA and (for convenience) problem, then repeat steps b - f.
GP1.
g.Close the auxiliary accumulator bleeddown
(B/D) valve.

System Diagnostics and Verification 28. *This step is for troubleshooting and may be
(Steps 26 - 31) omitted if excessive leakage in the bleeddown
26. *Start truck and allow the steering accumulators manifold is not suspected.
to charge to at least 18 960 kPa (2,750 psi), as With the steering hoses still disconnected as in
measured at bleeddown manifold port TP2, step 27, disconnect the tank return hose at the
before stopping engine using the engine bleeddown manifold flange port TANK.
shutdown switch (ESS) on center console. Key Disconnect hoist pilot valve return hose at
should be left to ON position for this step. bleeddown manifold port HOIST PILOT
NOTE: Do not bleed down rear steering accumulator RETURN and plug the manifold fitting. Plug the
with bleeddown solenoid valve on bleeddown return to tank hose. Vent the hoist pilot valve
manifold. return hose to the tank. DO NOT plug the hoist
pilot valve return hose.
Connect the Real-time Monitor and observe the
state of input IM2S. Open needle valves in Install a manual steering accumulator
brake cabinet to bleed front steering and brake bleeddown valve using either of the following
accumulators. Note the pressure triggering the methods:
IM2S change in state from 0 to 1. The activation Method 1: Refer to step 6, optional manual
range must be 15 858 ± 421 kPa (2,300 ± 61 bleeddown hose.
psi) falling. If outside this pressure range, locate
and correct the problem before repeating this Method 2: Connect a hose/needle valve
step. assembly between bleeddown manifold port
TP3 and hydraulic tank filler tube. This hose/
Record pressure when input IM2S changed state valve assembly cannot be connected or
from 0 to 1. disconnected if the accumulators are
27. *This step is for troubleshooting and may be pressurized. The opposite end of the hose
omitted if excessive leakage in steering system can be connected to a fitting which screws
is not suspected. into the hydraulic tank filler tube in place of
the filler cap. Both accumulators will be bled
Disconnect the flow amplifier return hose at the down when port TP3 is opened to tank,
bleeddown manifold, and cap the manifold port. reducing the possibility of either accumulator
Disconnect steering unit return hose at flow being accidentally left pressurized. The hose
amplifier and plug flow amplifier fitting. Start can be 1/4" SAE 100R2, rated for 34 474 kPa
engine and allow accumulators to fully charge (5,000 psi), or 3/8" SAE 100R2, rated for 27
and pump to unload. 579 kPa (4,000 psi). Needle valves are
NOTE: Do not turn the steering wheel when return suggested to allow simple opening/closing,
hoses are disconnected. but must be rated for 27 579 kPa (4,000 psi)
or above.
After the flow from the flow amplifier return hose
stabilizes, measure the volume of oil discharged Start the engine and wait until the pump
over a period of 1 minute. Leakage from flow unloads. After flow stabilizes measure the
amplifier is not to exceed 50 cubic inches (28 leakage from bleeddown manifold port TANK for
fluid ounces, 820 ml.) per minute. Replace flow a period of one minute. Maximum allowable
amplifier if leakage is excessive. leakage is 33 cubic inches (18 fluid ounces, 541
ml.) per minute (which is the total leakage from
After the flow from the steering unit return hose the bleeddown solenoid valve, steering relief
stabilizes, measure the volume of oil discharged valve and pilot-to-open check valves).
over a period of one minute. Leakage from
steering unit is not to exceed 10 cubic inches Record whether bleeddown manifold leakage was
(5.5 fluid ounces, 164 ml.) per minute. Replace checked. If checked, record the volume and
steering unit if leakage is excessive. measurement time.
Record whether steering system leakage was 29. Stop the engine using only the ESS. Using the
checked. If checked, record final amount measured Key Switch will engage the steering bleeddown
from flow amplifier and steering unit. solenoid.
Stop the engine using the key switch.

NOTE: Do not allow accumulators to bleed down e.*After pausing 20 minutes re-record each
using the bleeddown solenoid valve or all oil within accumulator pressure, noting any changes
the accumulators will flow out the open tank port! (rises or decays). Each brake accumulator
(AF3 and AR3) pressure decay must be less
Use the manual steering accumulator
than 2 275 kPa (330 psi) (6 895 kPa (1,000
bleeddown valve installed in step 28 to bleed
psi) loss per hour). The auxiliary accumulator
down both the front and rear steering
(GA) pressure decay must be less than 69
accumulators with the return hoses/plumbing
kPa (10 psi) (207 kPa (30 psi) loss per hour).
disconnected.
Record each brake (AF3 and AR3) and auxiliary
NOTE: Brake cabinet needle valves will bleed only
(GA) accumulator pressure 20 minutes after the
the front steering accumulator. The rear steering
steering accumulators are bled down.
accumulator will not be bled down.
f. Remove the pressure gauges installed in
30. Remove plugs and reconnect all steering and
step a.
bleeddown manifold hoses disconnected in
steps 27 and 28. If a hose/needle valve
Hoist System Checkout and Adjustment
assembly was installed in step 28 (method 2),
(Steps 32 - 34)
remove it.
32. If hoist cylinders are connected during shop
31. *This step is for troubleshooting and may be assembly, all four hoses must be disconnected
omitted if excessive leakage in braking or and capped for 18 960 kPa (2,750 psi)
auxiliary accumulator system is not suspected. (minimum) service in steps 32 through 34.
Record whether brake and auxiliary system leakage 33. *Start the engine and operate at high idle. Place
was checked. hoist control in POWER UP position. Pressure
a.Install a pressure gauge at brake manifold at hoist filters should be 18 960 ± 690 kPa
ports AF3 and AR3 and at auxiliary tap and (2,700 ± 100psi).
distribution manifold test port GA. NOTE: The main relief valves in the hoist valve are
b.Start the engine and operate at low idle until pre-adjusted and are not externally adjustable.
the steering pump unloads. Continue engine
Record Power Up pressure at hoist filter.
operation for a minimum of three minutes to
allow accumulator temperatures to stabilize. 34. *Place hoist control in POWER DOWN position.
Pressure at overcenter manifold test port TPD
c. Do not operate the service brakes during this should be 10 342 ± 690 kPa (1,500 ± 100 psi).
step. Adjust hoist pilot power down relief valve if out
d.* With the steering accumulators charged to of range.
at least 22 063 kPa (3,200 psi), stop the
Record Power Down pressure at overcenter manifold
engine using the key switch and allow the
test port TPD.
steering accumulators to bleed down. The
brake and auxiliary accumulators should
Hoist Counterbalance Valve Adjustment
each remain above 20 684 kPa (3,000 psi),
(Step 35)
as measured at brake manifold ports AF3
and AR3 and at auxiliary tap and distribution 35. *Note whether the body is present.
port GA. Record if body is fully installed.
Record each brake (AF3 and AR3) and auxiliary a.Skip the remainder of this step if the body is
(GA) accumulator pressure after the steering not installed.
accumulators are bled down.
NOTE: Counterbalance valve is located in the
overcenter manifold on pump/valve module.
NOTE: This adjustment requires the body to be
installed, empty and with hoist cylinders connected.
b.With the body resting on the frame and hoist
valve in FLOAT position, or with the body
secured up with proper restraints and hoist
valve in FLOAT position, stop the engine.

c. Loosen locknut on adjustment stem of f.ii.4If 20 684 kPa (3,000 psi) was not read
needle valve NV in the overcenter manifold. at high idle, counterbalance valve
Turn the adjustment stem fully in. This will adjustment is needed. Do step b, then
block the hoist cylinder head pressure from go to step g.
the counterbalance valve pilot.
g.Loosen locknut on adjustment stem of
d.Remove plug from port PILOT VENT on counterbalance valve (CBV on manifold).
manifold. Retain the plug for reuse. This will Turn adjustment stem fully clockwise to start
vent the counterbalance valve pilot to adjustment procedure so counterbalance
atmosphere. Do not allow any dirt or foreign valve pressure is as low as possible.
material to enter the opened port, as this is
NOTE: Turning the adjustment stem in (clockwise)
likely when body is moved. A clean SAE #4
decreases the pressure, turning the adjustment stem
(1/4") hydraulic hose is recommended to be
out (counterclockwise) increases the pressure.
installed, pointed downwards, and vented to
atmosphere to prevent dirt entry. h.Start the engine. If body was secured up,
disconnect restraints. Adjust counterbalance
e.Install calibrated 34 474 kPa (5,000 psi)
valve as needed to obtain 20 684 kPa (3,000
pressure gauge at the test port TR on
psi) on pressure gauge connected to port TR
overcenter manifold. This gauge will
when in POWER UP at high idle in the third
measure the hoist cylinder rod end pressure,
stage. Make all adjustments to
which is the pressure controlled by the
counterbalance valve carefully to avoid
counterbalance valve.
raising the pressure above 20 684 kPa
f. Use this step only if counterbalance valve (3,000 psi). Complete valve adjustment
setting is to be verified and no adjustment is range is 3 turns. After adjusting, secure
anticipated. Otherwise, go to step g. locknut on adjustment stem.
i.Start engine. If body was secured up, i. Reposition as in step b.
disconnect restraints.
Record final pressure measured at overcenter
ii.At low idle, raise body in the third stage manifold test port TR.
and read pressure on gauge connected to
port TR. All counterbalance valve j. Reinstall plug in port PILOT VENT.
pressures are read/adjusted while in the k.Turn needle valve adjustment stem fully out
third stage. and secure locknut. Needle valve must be
fully open for normal operation.
f.i.1If pressure is 20 684 kPa (3,000 psi) or
above, stop hoisting immediately. l. Remove pressure gauge from port TR.
Pressure is adjusted too high and must
be lowered. Do step b, then go to step g Auxiliary System(s) Checkout and
and continue. Adjustment (steps 36 and 37)
f.ii.2If pressure is below 20 684 kPa (3,000 36. Reconnect or enable auxiliary hydraulic
psi), increase engine speed by systems disabled in step 8.
approximately 300 rpm and do step (f.ii) 37. Perform associated auxiliary system checkouts,
above, and then follow either step as detailed in their respective checkout
(f.ii.1) or this step (f.ii.2) as appropriate. manuals. These systems are optional
Continue this process until engine is at equipment that may vary between individual
high idle or 20 684 kPa (3,000 psi) is trucks.
reached. Counterbalance valve
38. If optional steering accumulator bleed hose/
pressure is to be 20 684 kPa (3,000 psi)
needle valve assembly was installed in step 6,
when in POWER UP at high idle in the
bleed down all auxiliary, brake and steering
third stage.
accumulators and remove hose/needle valve
f.ii.3If 20 684 kPa (3,000 psi) was read at assembly and associated fittings. Reinstall and
high idle in the third stage, pressure is properly torque the original plugs.
adjusted correctly. Do step i, then go to 39. Remove gauges installed in steps 2, 3 and 25a.
step j.

Oil Cleanliness Check (Steps 40 and 41) c.Take particle count readings for at least 20
40. After completion of steps 1 through 39, the minutes without changing the engine speed.
hydraulic system cleanliness must be checked d.When the particle count level is at or below
before the truck is shipped from the factory or ISO 21/18/15 and showing a trend of
commissioned. improving cleanliness or maintaining ISO 21/
18/15 or lower, the hydraulic system meets
Oil sampling location on truck:
the acceptable cleanliness criteria.
Sample point is the test port on either hoist filter.
e.*If a particle count level of ISO 21/18/15 is
This port has a quick disconnect test coupling
not achieved, continue to operate truck at
installed. Do not use the steering filter test port.
high idle until the conditions of step d are
No jumper hoses used for system flushing can
achieved.
be installed.
Record final particle count level or attach printout
Oil sampling process and cleanliness criteria:
from particle counter.
a.Conduct this test only after the hydraulic
41. *After successfully completing steps 1 through
checkout procedure has been completed.
40, all hydraulic filter elements must be
(This allows a worst case condition since the
changed before the truck is shipped from the
hydraulic system is as fully connected as
factory or released to the customer.
possible in assembly and contaminants have
had the likelihood of being flushed out into Record the service (hour) meter reading (SMR) when
the oil stream.) each hydraulic hoist and steering hydraulic filter
element was changed.
b.Operate truck for at least 10 minutes at high
idle before taking readings. Do not operate
the steering, hoist, brakes or any other
hydraulic function during this entire step (40).

Hydraulic System Checkout Data Sheet
Acceptable values for each measurement are shown in parentheses, ().
Step 1. Accumulator precharge pressures:
Front Steering, ACC1 (9 653 ± 69 kPa (1,400 ± 10 psi) @ 70° F)
________ @ _____
Rear Steering, ACC2 (9 653 ± 69 kPa (1,400 ± 10 psi) @ 70° F)
________ @ _____
Front Brake, AF1 (9 653 ± 69 kPa (1,400 ± 10 psi) @ 70° F)
________ @ _____
Rear Brake, AR1 (9 653 ± 69 kPa (1,400 ± 10 psi) @ 70° F)
________ @ _____
Auxiliary, A6 (9 653 ± 69 kPa (1,400 ± 10 psi) @ 70° F)
________ @ _____
Initial Startup and Flushing
Step 14. Low precharge warning fault A115 displayed before startup?
(No) Yes No
Step 15. Left brake cooling pressure (0 kPa (0 psi)) _______
Right brake cooling pressure (0 kPa (0 psi)) ________
Step 18. Pressure at bleeddown manifold test port T3
a.i Does bleed down occur when stopping with Engine

Shutdown Switch on center console? (No) Yes No
Pressure at port T3 (approximately 21 201 kPa (3,075 psi) _________

Faults (none)__________
a.ii and b. Record pressures at TP3 and faults after each bleeddown cycle:
Cycle 1 Pressure after bleeddown (103 kPa (15 psi)) ________

Faults (none) ________

Faults (none) ________

Faults (none) _________


Steering Flow Amplifier Adjustment
Step 22. Flow amplifier settings:
Left Shock relief valve (21 374 -0/+2 068 kPa (3,100 -0/+300 psi)) _______
Right shock relief valve (21 374 -0/+2 068 kPa (3,100 -0/+300 psi)) _______
Step 23. steering relief valve (18 960 ± 483 kPa (2,750 ± 70 psi))________
Steering Pump Unloader Valve Adjustment
Step 24. Pump reload pressure (18 960 - 19 305 kPa (2,750 - 2,800 psi))________
Pump unload pressure (approximately 21 201 kPa (3,075 psi))________
Auxiliary Accumulator Checkout
Step 25.b Front steering accumulator pressure, T2 above (19 995 kPa (2,900 psi))
Rear steering accumulator pressure, T3 above (19 995 kPa (2,900 psi)) ______
Auxiliary accumulator pressure, GA (19 995 kPa (2,900 psi)) ______
e.Aux. accumulator supply valve closing pressure
(17 582 -690/+345 kPa) (2,550 +100/-50 psi) _______
System Diagnostics and Verification
Step 26. Pressure when input IM2S changes from zero (0) to one (1)
15 858 kPa (2,300 ± 61 psi) falling) ________
Step 27. Was the steering system leakage checked? (circle one) (Yes) Yes No
Flow amplifier leakage (820 ml [50 cu.in] or less per minute) _______
Steering unit leakage (164 ml [10 cu.in] or less per minute) ______

Step 28. Was the bleeddown manifold leakage checked? (circle one) (Yes) Yes No
Bleeddown manifold leakage( 541 ml [33.0 cu.in] or less per minute) ______
Step 31. Was brake or auxiliary system leakage checked? (circle one) (Yes) Yes No
d.After steering accumulator bleeddown:
Front brake accumulator pressure, AF3
(20 684 kPa (3,000 psi) or greater) ______
Rear brake accumulator pressure, AR3
Auxiliary accumulator pressure, GA
e.Twenty minutes after steering accumulator bleeddown:
Front brake accumulator pressure, AF3
(2 275 kPa (330 psi) or less below 32d) ______
Rear brake accumulator pressure, AR3
(2 275 kPa (330 psi) or less below 32d) ______
Auxiliary accumulator pressure, GA
(69 kPa (10 psi) or less below 32d) ______
Hoist System Checkout and Adjustment
Step 33. Power up pressure at the hoist filter
(17 237 ± 689 kPa (2,500 ± 100 psi)) _______
Step 34. Power down pressure at over-center manifold port TPD
(10 342 ± 689 kPa (1,500 ± 100 psi) _______
Hoist Counterbalance Valve Adjustment
Step 35. Was truck body installed?(circle one) (Yes) Yes No
i. Body counterbalance valve setting, TR
(20 684 kPa ± 689 kPa (3,000 ± 100 psi) ______

Oil Cleanliness Check
Step 40.e Hydraulic fluid cleanliness level, following 10 minutes at high idle
(ISO 21/18/15 or lower) ________
Particle counter printout attached to these sheets? (circle one) (Yes) Yes No
Step 41 Service meter reading (SMR) when filter elements were replaced:
Front hoist filter (hours) _______
Rear hoist filter (hours) _______
Steering filter (hours) _______

_________________________________________________
Signature of inspector or mechanic performing checkout
_________________________________________________
Name & badge no. (printed)
Date & shift checkout completed: ________________
Machine: ____________ Unit No.: ____________ Serial No.: ____________

BRAKE SYSTEM CHECKOUT PROCEDURE
Scope of Checkout Procedure a. In the factory, contact Quality Control if
problems are identified while performing this
The Brake Checkout Procedure will check the
procedure or to obtain procedures for
hydraulic, electrical and software control subsystems
adjusting individual components.
of the brake system for manual mode operation.
b. In the field, refer to the truck Shop Manual.
Purpose of Checkout Procedure: 3. The steering and brake Hydraulic Checkout
This Brake Checkout Procedure will verify the Procedure must be completed prior to
operation of the brake system by: performing the steps in this document. Included
in the procedure are:
1. Checking the pressure settings of brake
components. a. The brake (and steering) system hydraulic
source settings for normal operating
2. Checking the functionality of brake system.
conditions, including the pump reload valve
3. Checking the functionality of brake fault adjustment. Refer to the steering and hoist
detection. Hydraulic Checkout Procedure for details.
NOTE: This procedure does not verify brake b. All steering accumulators and all brake
performance. accumulators are properly pre-charged.
NOTE: This procedure does not verify the system Refer to 930E-5 Hydraulic Checkout
controls for autonomous mode operation. Procedure for the proper Accumulator Pre-
charging Procedure. Truck must not be
Necessary Equipment: started without all accumulators being
properly pre-charged.
1. 930E-5 Hydraulic System Checkout Manual,
Steering and Hoist Hydraulic Diagram, Brake 4. Interface Module Checkout Procedure must be
Hydraulic Diagram and this checkout manual successfully completed before this checkout
procedure is performed. Failure to do so may
2. Accumulator charging system with calibrated result in improper brake system operation and/
gauges and cylinders of dry nitrogen with, or or brake fault detection.
without, a gas intensifier.
5. Electrical system checkout must be
3. Brake simulators, if the truck is only partially successfully completed before performing this
assembled and all brakes are not installed. checkout procedure.
Simulator volumes must equal or exceed that of
the brakes that are absent. 6. All accumulators must be bled down before
loosening any hydraulic fitting. Refer to
4. Clear plastic hose and bucket for bleeding air Accumulator Bleeddown Procedure in steering
from service brakes and park brakes, or brake and hoist Hydraulic Checkout Procedure.
simulators.
7. Exercise caution when disconnecting hoses,
5. At least four calibrated pressure gauges with tubing, gauges, plugs, etc. in case hydraulic
quick-disconnect couplings, capable of pressure is trapped.
measuring up to 24 132 kPa (3,500 psi).
6. Interface Module Real-time Data Monitor
software.
Pre-Checkout Items
The following Pre-checkout Items must be reviewed,
understood, and completed prior to conducting the
Brake System Checkout Procedure:
1. All components used within the brake system
must be to factory specification.
2. Any parts that do not function as described
must be replaced or adjusted.
58F-60-40941 Brake System Checkout Procedure 1

2. Connect brake simulators to the brake
application lines where a brake is absent when
this checkout procedure is being performed.
3. *Open each brake accumulator bleeddown
If truck wheels are installed, wheels must be valve and verify pre-charge of each brake
properly chocked to prevent a possible roll away accumulator. Allow gas temperature to
throughout this procedure. approach ambient temperature before
completing the pre-charge process. Refer to the
8. This checkout procedure may be performed Steering and Hoist Hydraulic System Checkout
without truck wheels being installed. If wheels Procedure for details.
are installed, the above warning must be
followed. Record the pre-charge pressure of each brake
accumulator.
Software Operation and Configuration 4. Close both bleeddown valves that were opened
The latest version of Interface Module Realtime Data in step 3.
Monitor software shall be used. Copies may be
downloaded from
komtraxvhmsplm/vhmsplm/usefulinformation/
software/
Do not start the engine until all accumulators
Interface Module Realtime Data Monitor software have been properly pre-charged. Permanent
shall be used during this checkout procedure to view damage to bladder/piston will result if the engine
all faults, system status, and wheel speed signals. is started without all accumulators properly pre-
Confirm all information displayed on the instrument charged.
panel. 5. *Start engine and allow the accumulators to fill
with oil. Observe the rise in brake pressures as
GE Vehicle Information Display (VID) Panel the system charges. Front and rear brake
Configure GE VID Panel to metric (ie. kph for ground pressures, BF and BR, will begin to fall when
speed). Remain at 0 kph ground speed until the Auto Apply valve releases the brake pedal.
otherwise noted. This should occur at 11 376 ± 1 379 kPa (1,650
± 200 psi) (rising) for both the front and rear.
Truck Starting Procedure: NOTE: The Auto Apply valve setting is 11 376 ± 690
a. Shift lever must be in Park to start truck. kPa (1,650 ± 100 psi) (falling) for both front and rear.
This is checked in steps 24 and 25. The 1650 ± 200
NOTE: Shift lever must remain in Park unless
psi (rising) in this step considers the non-adjustable
otherwise noted.
differential and is not to be used for adjustment
b. Confirm GE VID Panel is set to zero (0) KPH purposes.
ground speed after starting the engine.
Record the front (BF) and rear (BR) brake pressures
Data to Record when Auto Apply begins to release.
6. Bleed the air from each service brake or service
Steps in this procedure that require recording of data
brake simulator as follows:
are indicated with an asterisk (*). A consolidated
form for recording data is located in the Checkout a. Attach clear plastic tubing to the air bleed
Data Sheet section at the end of this document. valves of each service brake assembly.
b. Slowly open each bleed valve.
Initial System Set Up:
c. Partially depress the brake pedal and bleed
1. Install pressure measuring instruments at the
air from each service brake until a clear
following ports in the hydraulic brake cabinet:
stream of oil flows.
a. Test port BF (sensor manifold)
d. Close bleed valves and remove clear plastic
b. Test port BR (sensor manifold) tubing when bleeding is complete.
c. Test port LAP1 (valve manifold)
2 Brake System Checkout Procedure 58F-60-40941

7. Bleed the air from each parking brake or Brake Lock (Secondary Brake) Check
parking brake simulator as follows: 14. With the engine running and the shift lever in
a. Attach clear plastic tubing to the air bleed Neutral, disconnect the electrical connector at
valves of each parking brake assembly the Brake Lock solenoid valve. The valve is
located on the valve manifold in the hydraulic
b. Slowly open each bleed valve.
cabinet, to the right of port PK2.
c. Shift into NEUTRAL and allow air to bleed
15. *Apply the Brake Lock using the Brake Lock
from each parking brake until a clear stream
switch. Brake Lock degradation pressure switch
of oil flows.
should actuate service brake degradation fault
d. Return shift lever to PARK. A118 and the warning buzzer. It will also cause
e. Close bleed valves and remove the clear bit IM-2V to change state from 1-0. Depress the
plastic tubing when bleeding is complete. brake pedal until the fault clears. Very slowly
release the pedal until bit IM-2V changes state.
8. Slowly depress the brake pedal. The pedal
The bit should change state at 6 895 ± 172 kPa
movement should be smooth, with no abnormal
(1,000 ± 25 psi) (falling). Fault A118 should
noise or mechanical roughness.
display and buzzer should sound approximately
9. *Slowly depress the brake pedal. Rear brake two seconds later. Service brake failure fault
pilot pressure (BR) should begin to rise before A265 will also display during this step.
front brake pilot pressure (BF). Rear brake pilot
pressure (BR) should be between 310 and 1 Record the rear brake pressure (BR) when the brake
413 kPa (45 and 205 psi) when front brake pilot degradation Bit IM-2V changes state.
pressure (BF) begins to rise. Verify fault A118 displays.
10. *Slowly depress the brake pedal and observe 16. Reconnect the electrical connector removed in
the rear brake pressure (BR) when the stop step 14.
lights illuminate. The pressure should be 517
±34 kPa (75 ± 5 psi). 17. *Cycle the Brake Lock switch several times to
assure the crisp application and release of
Record the rear brake pressure (BR) when the stop pressure and proper function of the service
lights illuminate. brake status light. The rear brake pressure (BR)
11. *Quickly and completely depress the brake should be 7 237 ± 690 kPa (2,500 ± 100 psi)
pedal. Verify that the front brake pressure is 17 with the Brake Lock ON.
237 ± 517 kPa (2,500 ± 75 psi) (BF) and the Record the rear brake pressure (BR) with the brake
rear brake pressure is 7 237 ± 517 kPa (2,500 ± lock ON.
75 psi) (BR) within one second.
Record the front (BF) and rear (BR) brake pressures Low Brake Pressure and Auto(matic)
one second after the pedal is applied. Brake Apply Check
18. Start the engine and allow the accumulators to
12. *Quickly depress and hold the brake pedal to
fully charge. The low brake accumulator
fully apply the brakes. Both pressures should
pressure, LAP1, will stabilize at or above 18 960
remain above the minimum values of step 10 a
kPa (2,750 psi).
minimum of 20 seconds.
19. Place the shift lever in Neutral and stop the
Record the front (BF) and rear (BR) brake pressures
engine by turning the key switch to OFF. The
20 seconds after the pedal is applied.
steering accumulators will bleed down.
13. *Release the brake pedal. Verify that both front
20. *Turn the key switch to ON, but do not start the
and rear brake pressures, BF and BR, return to
engine. sing port LAP1, observe the lowest
0 psi within two seconds.
accumulator pressure for a period of two
Record the front (BF) and rear (BR) brake pressures minutes. If the pressure is less than 14 478 kPa
two seconds after the pedal is released. (2,100 psi), there is excessive leakage in the
brake system. Locate and correct the leakage
before continuing this checkout procedure.

Record the lowest accumulator pressure (LAP1) 2 25. *Confirm service brake actuation after auto
minutes after the steering accumulators have bled apply is activated.
down.
LAP1 should be 1 376 ± 861 690 kPa (1,650 ±
21. Start the engine and allow the pressure at LAP1 125 psi).
to increase to 18 960 kPa (2,750 psi) or above.
Turn Key Switch to OFF to stop the engine and BF pressure should be 9 997- 12 266 kPa
allow the steering accumulators to completely (1,450 - 1,750 psi).
bleed down. BR pressure should be 17 237 ± 517 kPa
22. Turn the key switch to ON but DO NOT start the (2,500 ± 75 psi).
engine. Place the shift lever in Neutral.Use the Record pressures at LAP1, BF and BR with auto
GE VID panel to set the speed signal to 2.5 kph. apply active.
NOTE: The Speed signal must exceed 2 KPH to NOTE: Adjustment of auto apply sequence valve will
perform the following steps. Fault A260 will be be necessary if auto apply pressures of 1 376 ± 861
displayed 1.5 seconds after the speed signal is 690 kPa (1,650 ± 125 psi) are not obtained. Repeat
generated steps 18 through 25 if valve adjustment is performed.
23. *Crack the front brake accumulator bleed down 26. Close the front brake accumulator bleeddown
valve (valve to the right on brake manifold) and valve. Use the GE VID panel to reset the speed
observe LAP1 pressure. The low brake signal to zero (0 kph). Place shift lever in Park
pressure Fault A261 should be generated at 12 and start the engine, allowing the pressure at
7550 ± 345 kPa (1,850 ± 50 psi) when the Low LAP1 to increase to 2750 psi or above. Stop the
Brake Pressure Switch in port LAP2 trips. engine with the key switch and allow steering
LAP1 should be 12 7550 ± 345 kPa (1,850 ± 50 accumulators to completely bleed down. Faults
psi). A260 and A261 should clear.
BF pressure should be 0 kPa (0 psi). 27. Turn key switch On, but do not start the engine.
Place shift lever in Neutral. Use the GE VID
BR pressure should be 0 kPa (0 psi). panel to set the speed signal to 2.5 kph. Park
Record pressures at LAP1, PS1, BF and BR when brake fault A260 will display 1.5 seconds later.
the low brake pressure fault A261 displays. 28. *Crack the rear brake accumulator bleeddown
valve and observe LAP1 pressure. The low
Record if Fault A260 is displayed.
brake pressure fault A261 should generate.
NOTE: The 930E-5 is equipped with an Auto Apply
LAP1 should be within 690 kPa (100 psi) of that
System that will warn operators when the lowest
observed in step 23.
pressure in either the front or rear accumulator drops
below the Low Brake Pressure Switch setting 12 BF pressure should be 0 kPa (0 psi).
7550 ± 345 kPa (1,850 ± 50 psi). The Auto Apply
BR pressure should be 0 kPa (0 psi).
Sequence valve will activate and automatically apply
the front and rear brakes when the highest pressure Record pressures at LAP1, BF and BR when fault
in either the front or rear brake accumulator drops A261 displays.
below 11 376 ± 690 kPa (1,650 ± 100 psi).
Record if fault A260 is displayed.
24. With the front brake accumulator bleeddown
29. *With the rear brake accumulator bleed down
valve still cracked open, allow the pressure at
valve still cracked open, allow the pressure at
LAP1 to continue to drop. Brake pressure at
LAP1 to continue to drop to zero (0) psi. Brake
test port BR should begin to rise when the auto
pressures at test ports BF and BR should not
apply sequence valve shifts to actuate the
begin to rise due to Auto Apply.
service brake system.
LAP1 should be within 690 kPa (100 psi) of that
LAP1 should be 1 376 ± 690 kPa (1,650 ± 100
observed in step 23.
psi).
Record pressures at LAP1when BR starts to rise.

30. *Confirm service brake actuation after auto Each pressure should remain above the
apply is activated. minimum value for a minimum of 20 seconds.
LAP1 should be 690 kPa (100 psi) of that Record left (B1) and right (B2) front brake pressures
observed in step 25. one second after the pedal is applied.
BF pressure should be 17 237 ± 517 kPa (2,500 Record left (B1) and right (B2) front brake pressures
± 75 psi). 20 seconds after the pedal is applied.
BR pressure should be 9 997 - 12 266 kPa 38. *Release the brake pedal. The brake pressure
(1,450 - 1,750 psi). should return to zero within two seconds. There
should be no residual pressure trapped within
Record pressures at LAP1, BF and BR with auto
either brake.
apply active.
Record left (B1) and right (B2) front brake pressures
31. Close front brake accumulator bleeddown
two seconds after the pedal is released.
valve. Remove speed signal from GE VID panel
and reset to zero (0 kph). Park brake fault A260
Parking Brake Check
will clear.
The parking brakes are spring applied, hydraulic
Service (Primary) Brake Check pressure release type.
32. Relocate two pressure gauges from ports BR NOTE: When the parking brakes are applied, the
and BF to ports LBP and RBP in the rear axle parking brake solenoid is de-energized and the
hose junction plate. hydraulic lines vented. When the parking brakes are
33. Start the engine and allow the accumulators to to release, the parking brake solenoid is energized to
recharge to a minimum of 18 960 kPa (2,750 supply pressurized hydraulic oil to the parking
psi), as measured at port LAP1. The engine brakes.
may then be turned off using the engine 39. Install a pressure gauge to either parking brake
shutdown switch. test port PK3 on the brake manifold in the
34. *Quickly and completely depress the brake hydraulic cabinet or one of the two parking
pedal. Both left and right rear brake pressures brakes or parking brake simulators located on
should be 16 548 ± 483 kPa (2,400 ± 70 psi) the rear axle.
within one second. Hold the pedal fully applied. 40. Start the engine and allow the brake
Both pressures should remain above their accumulators to recharge to a minimum of 18
minimum values a minimum of 20 seconds. 960 kPa (2,750 psi), as measured at port LAP1.
Record left (LBP) and right (RBP) rear brake Operate the engine at idle for steps 41 and 42.
pressures 1 second after the pedal is applied. 41. *Release the parking brake by moving the shift
lever out of Park. Verify that the parking brake
Record left (LBP) and right (RBP) rear brake
status light indicates the parking brake is
pressures 20 seconds after the pedal is applied.
released. The parking brake release pressure
35. *Release the brake pedal. Each brake pressure should be 18 960 to 21 374 (2,750 to 3,100 psi)
should return to zero within two seconds. There and equal to LAP1.
should be no residual pressure trapped in either
brake. Record parking brake release pressure (PK3) when
the brakes are released.
Record left (LBP) and right (RBP) rear brake
42. *Cycle the shift lever in and out of Park several
pressures two seconds after the pedal is released.
times to assure the crisp application and
36. Relocate the pressure gauges from ports LBP release of the parking brake release pressure
and RBP to the left and right test ports B1 and and proper function of the parking brake status
B2 of the front spindles or front brake light. The parking brake release pressure
simulators. should be 0 - 34 kPa (0 - 5 psi) within two
37. *Quickly and completely depress the brake seconds of moving the lever to PARK.
pedal. Both left and right front brake pressure Record parking brake release pressure (PK3) 2
should be 16 548 ± 483 kPa (2,400 ± 70 psi) seconds after the shift lever is moved to Park.
within one second. Hold the pedal fully applied.

Control Logic Checks Application Sequence,” on page 6. Applications
should occur only after the vehicle speed has been
Parking Brake Control Logic Checks reduced to 0.8 kph or less. Key switch power (engine
To preserve pad service life, parking brake on) is required for the application sequence to occur.
applications should follow the 1.5 second application No sequence is used for parking brake release.
sequence detailed in Table 1, “Parking Brake Table 1: Parking Brake Application Sequence
Parking Brake Protection using Brake Lock
Time Elapsed Brake Lock Parking Brake

since parking Brake Apply Pressure Brake Release Pressure
brake apply State Solenoid Valve PP3 State Solenoid Valve PK3
0.0 - 1.0 Applied Energized 17 237 Released Energized 18 960 kPa
(2,500 psi) (2,750 psi)
1.0 - 1.5 Applied Energized 17 237 Applied De-energized 0 kPa (0 psi)
(2,500 psi)
after 1.5 Released De-energized 0 kPa (0 psi) Applied De-energized 0 kPa (0 psi)
NOTE: Energizing the parking brake solenoid valve shutdown switch on the center console. Confirm
pressurizes and releases the park brakes; de- that the park brake applies and that the park
energizing vents and applies the parking brakes. brake status light indicates that the park brake
is applied. Also, confirm that no park brake
43. Stop the engine, bleed down the accumulators
faults are generated. Pressure at PK3 should
and locate a pressure gauge at the following 4
be 18 960 to 21 374 kPa (2,750 to 3,100 psi)
ports in the hydraulic brake cabinet: front brake
and then fall to 0 kPa (0 psi). Pressure at PP3
pilot (BF), rear brake pilot (BR), parking brake
should begin at 0 kPa (0 psi) then rise to 17 237
(PK3) and brake lock (PP3).
± 690 (2,500 ± 100 psi) and finally fall back to 0
44. Start engine and allow the accumulators to fully psi. Pressure at BF should remain at 0 kPa (0
charge. The low brake accumulator pressure, psi) throughout. Pressure at BR should begin at
LAP1, will stabilize at or above 18 960 kPa 0 kPa (0 psi) then rise to 17 237 ± 690 (2,500 ±
(2,750 psi). 100 psi) and finally fall back to 0 kPa (0 psi).
45. Leave the engine running. Ensure the brake Record highest pressures observed at PK3, PP3, BF
lock switch is OFF. and BR during the first 1.5 seconds of actuating the
46. *Place the shift lever in Neutral. Apply park engine shutdown switch OFF.
brake by placing shift lever in Park. Confirm Record final pressures at PK3, PP3, BF and BR.
proper operation of the parking brake, the
status light, and that no faults are generated. 48. *Place the shift lever in Park, start the engine
Pressure at PK3 should be 18 960 to 21 374 and allow LAP1 to charge above 18 960 kPa
kPa (2,750 to 3,100 psi) and then fall to 0 kPa (2,750 psi). Turn the key switch OFF. Confirm
(0 psi). Pressure at PP3 should begin at 0 psi that the park brake remains applied. Pressure
then rise to 17 237 ± 690 (2,500 ± 100 psi) and at PK3, PP3, BF and BR remain at 18 960 kPa
finally fall back to 0 psi. Pressure at BF should (2,750 psi).
remain at 0 kPa (0 psi) throughout. Pressure at Record highest pressures observed at PK3, PP3, BF
BR should begin at 0 kPa (0 psi) then rise to 17 and BR while the engine stops.
237 ± 690 (2,500 ± 100 psi) and finally fall back
to 0 kPa (0 psi). 49. *Restart the engine and allow the accumulators
to fully charge to 18 960 kPa (2,750 psi) or
Record highest pressures observed at PK3, PP3, BF above, as measured at LAP1. Move the shift
and BR during the first 1.5 seconds of moving the lever to Neutral and turn the key switch Off.
shift lever to Park. Confirm that the park brake applies. Pressure at
Record final pressures at PK3, PP3, BF and BR. PK3 should be 18 960 to 21 374 kPa (2,750 to
3,100 psi) and then fall to 0 kPa (0 psi), PP3,
47. *Release the park brake by placing the shift BF, and BR should remain at 0 kPa (0 psi).
lever in Neutral. Stop engine using the engine

NOTE: Since key switch is off, brake lock sequencing NOTE: Faults A272 and A274 should not display.
with park brake will not occur. Fault A272 will be generated if the brake lock switch
has power to apply the brake lock when it should not.
Record highest pressures observed at PK3, PP3, BF
Fault A274 will be generated if brake lock application
and BR during the first 1.5 seconds of turning the key
and park brake application occur at the same time.
switch OFF.
Record pressures PK3, PP3, BF and BR with the
Record final pressures at PK3, PP3, BF and BR.
brake lock switch ON.
50. *This step verifies the parking brake will not
apply if it is requested while the truck is moving Record if faults A272 and A274 are displayed.
a. With the engine running and LAP1 pressure Toggle the brake lock switch OFF. No change in
above 18 960 kPa (2,750 psi), move the shift pressures, faults or status lights should occur.
lever to Neutral. 53. *Place the shift lever in Neutral. Attempt to
b. Place a jumper wire between TB28-A (circuit apply the brake lock by actuating the Brake
36) and GND to simulate engine running. Lock switch. Confirm proper operation of the
brake lock and the brake lock status light and
c. Stop engine using Engine Shutdown Switch. that no faults are generated. Pressure at PK3
Do not turn the key switch OFF. should remain at 18 960 to 21 374 kPa (2,750
d. Set the GE VID panel speed signal to 1.0 to 3,100 psi), PP3 and BR should rise to 17 237
kph. ± 690 (2,500 ± 100 psi). BF should remain at 0
kPa (0 psi). The brake lock status light should
e. Move the shift lever to Park.
illuminate.
f. *Confirm that the parking brake does not
Record pressures at PK3, PP3, BF and BR.
apply.
Record the brake lock status light state.
PK3 pressure should be 18 960 to 21 374
kPa (2,750 to 3,100 psi) 54. *With the shift lever in Neutral and the brake
lock switch ON, move the shift lever to Park.
PP3, BF and BR pressures should be 0
Confirm that the park brake applies, the brake
kPa (0 psi)
lock releases and the status lights indicate
Record the pressures at PK3, PP3, BF and BR while properly. Pressure at PK3 should be 18 960 to
the engine stops. 21 374 kPa (2,750 to 3,100 psi) and then fall to
0 psi. PP3 and BR should be 17 237 ± 690
g. *Fault A230 (park brake request while
(2,500 ± 100 psi) and then fall to 0 kPa (0 psi).
moving) will be displayed if pressure switch
BF should remain at 0 kPa (0 psi).
is installed while performing this step.
Record highest pressures observed at PK3, PP3, BF
NOTE: Fault A230 can also be created by
and BR during the first 1.5 seconds of moving the
unplugging pressure switch
shift lever to Park.
Record if fault A230 is displayed.
Record final pressures at PK3, PP3, BF and BR.
h. Remove jumper wire from circuit 36.
Record the park brake and brake lock status light
i. Reset the GE VID panel speed signal to 0 final states.
kph.
55. *With the brake lock switch ON, move the shift
lever to Neutral. Confirm the park brake
Brake Lock Control Logic Checks
releases, the brake lock sets and the status
51. Start engine and allow the accumulators to fully lights indicate properly without delay. Pressure
charge. The low brake accumulator pressure, at PK3 should rise to 18 960 to 21 374 kPa
LAP1, will stabilize at or above 18 960 kPa (2,750 to 3,100 psi). PP3 and BR should rise to
(2,750 psi). Leave the engine running. 17 237 ± 690 (2,500 ± 100 psi). BF should
52. *Attempt to apply the brake lock by toggling the remain at 0 kPa (0 psi).
brake lock switch ON. Confirm the brake lock Record pressures at PK3, PP3, BF and BR.
does not apply and the brake lock status light
does not illuminate. Pressure at PK3, PP3, BF Record the park brake and brake lock status light
and BR should remain at 0 kPa (0 psi). states.

56. *With the shift lever in Neutral, the brake lock NOTE: Interface Module status bit IM3F (Cummins
switch On, actuate the Engine Shutdown Shutdown Delay) will display one (1) during Smart
Switch. Confirm that the brake lock releases Time Shutdown.
and the park brake applies and that the status
e. With the Smart Timer active, reduce the
lights indicate properly. Pressure at PK3 should
engine speed to idle for approximately one
be 18 960 to 21 374 kPa (2,750 to 3,100 psi)
minute before turning the key switch OFF.
and then fall to 0 kPa (0 psi). PP3 and BR
The engine should continue to operate at
should be 17 237 ± 690 (2,500 ± 100 psi) and
idle for approximately three minutes before
then fall to 0 kPa (0 psi). BF should remain at 0
shutting down.
kPa (0 psi).
f. *Turn the brake lock switch ON after the key
Record highest pressures observed at PK3, PP3, BF switch has been turned off, while the engine
and BR during the first 1.5 seconds of actuating the continues to idle. No brake pressure or
engine shutdown switch. status light should change state. Park brake
Record the final pressures at PK3, PP3, BF and BR. release pressure PK3 and pressures PP3,
BF and BR should remain at 0 kPa (0 psi).
57. Reset (turn on) the engine shutdown switch,
The park brake status light should remain
place the shift lever in Park and restart the
illuminated. Brake lock status lights should
engine. Allow the brake system pressure at
remain out.
LAP1 to rise above 18 960 kPa (2,750 psi).
Record pressures PK3, PP3, BF and BR with brake
58. Verify brake lock will not apply during Smart
lock On during engine Smart Timed Shutdown.
Timed Shutdown as follows:
a. Connect a voltmeter between TB27-E (circuit Record the brake lock and park brake status light
21NSL) and GND. The meter should display states.
0 vdc, normal engine operating conditions. g. *No brake pressure or status light should
change state when the engine stops. The
NOTE: For this step Interface Module status bit IM3F
park brake status light should remain
(Cummins Shutdown Delay) may be monitored in
illuminated. Park brake release pressure
place of the voltmeter.
PK3 and pressures PP3, BF and BR should
b. With the engine running, shift lever in Park remain at 0 kPa (0 psi). The brake lock
and the brake system pressure LAP1 above status light should remain out.
18 960 kPa (2,750 psi), turn the brake lock
switch OFF. Record pressures PK3, PP3, BF and BR with brake
lock ON and shift lever in Park following engine
NOTE: The shift lever must remain in Park during Smart Timed Shutdown.
Smart Time Shutdown.
Record the brake lock and park brake status light
c. *Only the park brakes should apply. The park states.
brake status light should be illuminated. Park
brake release pressure PK3 should be 0 h. Remove the voltmeter from circuit 21NSL.
(+103/-0) kPa (0 (+15/-0) psi). Pressures NOTE: This step (58) cannot be combined with step
PP3, BF and BR should be 0 (+103/-0) kPa 53, as each verifies independent control circuitry.
(0 (+15/-0) psi). The brake lock status light
59. This step verifies that the brake lock function
should be out.
will activate if applied while the truck is moving.
Record pressures PK3, PP3, BF and BR with brake
a. Move the shift lever to Park, toggle the brake
lock Off during normal engine operation.
lock switch OFF and restart the engine.
Record the brake lock and park brake status light Allow the accumulators to fully charge to 18
states. 960 kPa (2,750 psi) or above, as measured
at LAP1.
d. Using the cab accelerator pedal, increase
the engine speed above 1500 rpm to raise b. Move the shift lever to Neutral.
the engine temperature. Circuit 21NSL will c. Using GE w/PTU software, set the FWD
indicate 24 vdc when the high engine True bit to ON.
temperature activates the Smart Timer.
d. Stop the engine using the Engine Shutdown
Switch. Do not turn the key switch OFF.

e. Set the GE VID panel speed signal to 1.0 61. Place the shift lever in Neutral and stop the
kph. engine using the Engine Shutdown Switch. The
f. Place a jumper wire between TB28-A (circuit key switch must remain ON. The steering
36) and GND to simulate engine running. accumulators should remain charged.
62. Use the GE VID panel to set the speed signal
g. Apply brake lock using Brake Lock switch.
above 1.0 kph.
h. *Confirm brake lock is active.
63. *Using the brake pedal, make repeated full,
PK3 pressure should be 18 960 to 21 374 slow brake applications until the low steering
kPa (2,750 to 3,100 psi) system pressure fault A261 displays. A
PP3 and BR pressures should be 17 237 ± minimum of six applications must be completed
690 (2,500 ± 100 psi) before the fault appears. Auto apply must not
actuate before the fault appears.
BF pressure should be 0 kPa (0 psi)
Record number of brake applications completed
Record pressures at PK3, PP3, BF and BR. before fault A261 displays.
The following verify that the brake lock function 64. Reset the speed signal to 0 kph with the GE VID
remains active after the truck stops. panel.
i. Move the shift lever to Park. 65. Turn the key switch to OFF. The steering
accumulators will bleed down.
j. Reset the GE VID panel speed to 0 kph.
k. *Confirm brake lock remains active. 66. Reset (turn on) the engine shutdown switch.
67. Open the front and rear brake accumulator
PK3 and BF pressures should be 0 kPa (0
bleeddown valves in the hydraulic cabinet.
psi)
68. Remove brake simulators (if used). Plug all
PP3 and BR pressures should remain 17
open lines.
237 ± 690 (2,500 ± 100 psi)
69. Remove all checkout pressure gauges. Cap all
Record pressures at PK3, PP3, BF and BR. quick disconnects.
l. *Confirm brake lock circuit not off fault A272 70. Close both valves opened in step 67.
and brake malfunction fault A274 become
active after the speed signal is reset to 0 kph.
Record if fault A272 and fault A274 are active when
speed is 0 kph.
m.Turn brake lock switch OFF.
n. *Confirm that brake lock releases. Pressures
BF, BR, PK3 and PP3 should be 0 kPa (0
psi). Faults A272 and A274 should clear.
Record pressures at PK3, PP3, BF and BR.
o. Using GE w/PTU software, set the FWD
True bit to OFF.
p. Remove the circuit 36 jumper wire.
Service Brake Reapplication (Stored

Energy) Check
60. Start engine and allow the accumulators to fully
charge. The low brake accumulator pressure
LAP1 will stabilize at or above 18 960 kPa
(2,750 psi).

Brake System Checkout Data Sheet
NOTE: The acceptance range of each measurement is listed within parentheses, ().
Initial startup and Service Brake Checks:
3. Brake accumulator gas precharge pressures with 0 psi oil:
Front brake accumulator AF1 (1400 psi @ 70º F) ___________ @ ______

Rear brake accumulator AR1 (1400 psi @ 70º F) ___________ @ ______
5. Brake pressures when auto apply begins to releases:
Front brake pilot BF 9 997 - 12 755 kPa (1,450 - 1,850 psi) _________
Rear brake pilot BR 9 997 - 12 755 kPa (1,450 - 1,850 psi) _________
9. Rear brake pilot pressure BR when BF begins to rise
310 - 1 413 kPa (45 - 205 psi) _________
10. Rear brake pilot pressure BR when BF begins to rise
310 - 1 413 kPa (45 - 205 psi) _________
11. Brake pressures, one second after brake pedal was applied:
Front brake BF 16 720 - 17 754 kPa (2,425 - 2,575 psi) _________
Rear brake BR 16 720 - 17 754 kPa (2,425 - 2,575 psi) _________
12. Brake pressures, 20 seconds after brake pedal was applied:
Front brake BF 16 720 kPa (2,425 psi or greater) _________
Rear brake BR 16 720 kPa (2,425 psi or greater) _________
13. Brake pressures, two seconds after brake pedal was released:
Front brake BF 0 - 103 kPa (0 - 15 psi) _________
Rear brake BR 0 - 103 kPa (0 - 15 psi) _________
Brake Lock (Secondary Brake) Check
15. Rear brake pressure BR when brake lock degradation bit IM-2V changes state
6 722 - 7 067 kPa (975 - 1,025 psi) _________
Fault A118 displayed? (Yes) Yes No
17. Rear brake pressure BR with brake lock switch ON
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________

Low Brake Pressure Warning and Auto(matic) Brake Apply Check
20. Low brake accumulator pressure LAP1 after two minutes
above 14 479 kPa (2,100 psi) _________
23. Pressures when fault A261 occurs.
Low brake accumulator LAP1 12 755 ± 345 kPa (1,850 ± 50 psi) _________
Front brake BF 0 kPa (0 psi) _________
Rear brake BR 0 kPa (0 psi) _________
24. Pressures when BR starts to rise.
25. Pressures when auto apply completes.
Front brake BF 9 997 - 12 066 kPa (1,450 - 1,750 psi) _________
Rear brake BR 17 237 ± 517 kPa (2,500 ± 75 psi) _________
28. Pressures when fault A261 occurs.
Low brake accumulator LAP1 step 23 result ± 690 kPa (± 100 psi) _________
Front brake BF 0 kPa (0 psi) _________
Rear brake BR 0 kPa (0 psi) _________
29. Pressures when BR starts to rise.
30. Pressures when auto apply completes.
Front brake BF 17 237 ± 517 kPa (2,500 ± 75 psi) _________
Rear brake BR 9 997 - 12 066 kPa (1,450 - 1,750 psi) _________
Service (Primary) Brake Check
34. One second after brake pedal was applied:
Left rear brakes LBP 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
Right rear brakes RBP 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________

After brake pedal was applied for 20 seconds:
Left rear brakes LBP 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
Right rear brakes RBP 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
35. After brake pedal was released for two seconds:
Left rear brakes LBP 0 - 103 kPa (0 - 15 psi) _________

Right rear brakes RBP 0 - 103 kPa (0 - 15 psi) _________
37. One second after brake pedal was applied:
Left front brake pressure B1 ( 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
Right front brake pressure B2 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
After brake pedal was applied for 20 seconds:
Left rear brakes B1 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
Right rear brakes B2 16 065 - 17 030 kPa (2,330 - 2,470 psi) _________
38. After brake pedal was released for two seconds:
Left front brake pressure B1 0 - 103 kPa (0 - 15 psi) _________

Right front brake pressure B2 0 - 103 kPa (0 - 15 psi) _________
Parking Brake Check
41. Parking brake pressure PK3 with shift lever out of Park
18 960 - 21 374 kPa (2,750 - 3,100 psi)_________
42. Parking brake pressure PK3 2 seconds after shift lever was moved to Park
0 - 35 kPa (0- 5 psi) _________
Parking Brake Control Logic Checks
46. Maximum pressures during 1.5 sec park brake application sequence:
Park brake pilot pressure (PK3) 18 960 - 21 374 kPa (2,750 - 3,100 psi)_________
Brake lock pressure (PP3) 16 548 - 17 926 kPa (2,400 - 2,600 psi) _________
Front service brakes relay valve pilot pressure (BF) 0 kPa (0 psi) _________
Rear service brakes relay valve pilot pressure (BR)
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________

Pressures at completion of this step:
Park brake pilot pressure (PK3) 0 kPa (0 psi) _________

Brake lock pressure (PP3) 0 kPa (0 psi) _________
Rear service brakes relay valve pilot pressure (BR) 0 kPa (0 psi) _________
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________

48. Maximum pressures during this step:



50. Pressures at completion of this step:
Brake Lock Control Logic Checks
52. Pressures with shift lever in Park, brake lock ON:

Fault A272 displayed? (No) Yes No
Fault A274 displayed? (No) Yes No
53. Pressures with shift lever in Neutral, brake lock ON:
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________
Brake lock status light illuminated? (Yes) Yes No
54. Maximum pressures during this step:
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________

Brake lock status light illuminated? (No) Yes No

Park brake status light illuminated? (Yes) Yes No
55. Pressures with shift lever in Neutral, brake lock ON:
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________
Park brake status light illuminated? (No) Yes No
56. Maximum pressures after engine stops:
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________

58c. With brake lock switch OFF, shift lever in Park, engine running in normal operating mode:


58f. With brake lock switch ON, shift lever in Park, engine running in normal operating mode:

58g. With brake lock switch ON, shift lever in Park, engine stopped
following Smart Timed Shutdown:

59h. Pressures at completion of this step:
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________
59k. Pressures at completion of this step:
16 548 - 17 926 kPa (2,400 - 2,600 psi) _________
59l. Faults at completion of this step:


59n. Pressures at completion of this step:

Service Brake Reapplication (Stored Energy) Check
63. Number of brake pedal applications before fault A261 displays
(6 minimum) _________

_________________________________________________
Signature of inspector or mechanic performing checkout
_________________________________________________
Name & badge no. (printed)
Date & shift checkout completed: ________________
Machine: ____________ Unit No.: ____________ Serial No.: ____________

RETRACTABLE LADDER SYSTEM CHECKOUT PROCEDURE
Scope of Checkout Procedure The following items must be reviewed and under-
stood before performing the Retractable Ladder Sys-
This checkout procedure will setup and verify the
tem (RLS) Checkout Procedure:
operation of the Retractable Ladder System (RLS).
• Electrical System Checkout Manual
• Interface Module Checkout Procedure
Necessary Equipment
• Hydraulic Checkout Manual
1. Auxiliary Hydraulic System Checkout
Procedure and Schematic (if equipped). • Brake Checkout Manual
2. (4) 0 - 34 474 kPa (0 - 5,000 psi) calibrated • Auxiliary Hydraulic Systems Checkout Manual
gauges with quick-disconnect couplings.
All accumulators (steering, brake and auxiliary) must
be properly pre-charged before using this checkout
Required Software
manual.
Interface Module Realtime Data Monitor software is
recommended for trucks equipped with an electronic
display panel. The latest version may be downloaded
from the Komatsu America Extranet, https://
www.komatsuamerica.net/northamerica/.
The truck is not to be started without the Steer-
Data to Record ing, Brake and Auxiliary System (if equipped)
Steps in this document requiring recording of data accumulators being properly pre-charged. Low
are indicated with an asterisk (*). A consolidated accumulator pre-charge could cause damage to
form for recording data is located in the Checkout the accumulators.
Data Sheet section at the end of this document.
NOTE: Refer to Auxiliary Systems Hydraulic Diagram
Procedure Steps
when performing the steps of this checkout manual. 1. Verify the following:
NOTE: Be sure accumulators are bled down before a. The engine keyswitch is OFF.
loosening any hydraulic fitting. For bleeddown details b. Upper deck manual lowering valve knob is
refer to OUT (manual position).
Factory installations: Hydraulic Checkout c. Ground level lowering switch button is OUT
Manual (normal operating position).
Field installations: Auxiliary Hydraulic Systems d. Ladder is in the full DOWN position.
Checkout Manual
e. Auxiliary accumulator bleeddown valve (Fig-
NOTE: Carefully disconnect all hoses, tubing, ure 1-1) is open.
gauges and plugs in case hydraulic pressure is 2. Connect a 0 - 34 474 kPa (0 - 5,000 psi)
trapped within. pressure gauge at accumulator tap and
distribution manifold port GA and ladder
Precheckout Items manifold ports GDOWN, GP and GUP. Each
gauge should display less than 103 kPa (15
psi).
a. Close the auxiliary accumulator manual
bleeddown valve (Figure 1-1) after verifying
the pressure at port GA is as specified.
Wheels (if installed) must be properly blocked
before performing this procedure to prevent a b. If pressure is present at port GDOWN, GP or
possible roll away. GUP, slowly cycle the cab ladder momentary
switch (Figure 1-2), UP - DOWN, until the
pressure is relieved.
58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 1

FIGURE 1-3. LADDER MANIFOLD
1. Ladder Down Relief 3. Ladder Solenoid

Valve Valve
2. Ladder UP Relief 4. Ladder Pressure
Valve Reducing Valve
FIGURE 1-1. AUXILIARY ACCUMULATOR 5. Loosen both the ladder up and ladder down
MANUAL BLEEDDOWN VALVE relief valve adjustment locknuts (Figure 1-3)
and turn the adjustments clockwise (in) until
1. Ladder Down Relief Valve each is lightly bottomed. Do not use excessive
force.
6. *Turn the cab keyswitch ON, but do not start
the engine. Verify the ladder down indicator light
in the cab indicator/warning panel (Figure 1-4 or
Figure 1-5) illuminates.
1
Record the response of the ladder down
2 indicator light.
85644
FIGURE 1-2. LADDER MOMENTARY SWITCH

(LOCATED IN CAB)
1. UP 2. DOWN
3. Press the cab ladder momentary switch (Figure

1-2) to the DOWN position. If active, the cab
alarm or fault A337 (Hyd Ladder Fault) on the
cab display panel (if equipped), should silence
and clear.
4. Loosen the ladder pressure reducing valve
adjustment locknut (Figure 1-3) and turn the
adjustment fully counterclockwise (out). Do not
use excessive force. Do not remove or
disassemble the valve.
2 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

1 85645
FIGURE 1-4. CAB DASH INDICATOR PANEL (TYPICAL) TRUCKS WITH

ELECTRONIC DISPLAY PANEL (EDP)
1. Ladder Down Indicator Light
FIGURE 1-5. CAB DASH INDICATOR PANEL (TYPICAL)

TRUCKS WITHOUT EDP
1. Ladder Down Indicator Light
7. Move the directional control lever to PARK and Record the ladder system supply pressure at
start engine. Allow engine to idle for five manifold port GA.
minutes to allow pressures to stabilize. 9. *Turn the ladder pressure reducing valve
8. *Port GA gauge should read greater than 18 adjustment clockwise (in) and count the number
0615 kPa (2,700 psi). All other gauges should of turns required to increase the ladder system
read less than 103 kPa (15 psi). operating pressure at port GP to 9 997 ± 1 034
kPa (1,450 ± 150 psi). The ladder should not
move.

Record the number of turns required to increase i) Port GUP gauge displays more than 3 447
port GP ladder system operating pressure to 9 kPa (500 psi).
997 kPa (1,450 psi).
ii) Port GDOWN gauge displays less than
NOTE: The pressure adjustment in this step 103 kPa (15 psi).
establishes a reference position for future steps of
b. After an additional 15 seconds,
this checkout manual. Use step 26 to set the
pressure reducing valve for normal operation. c. Port GUP gauge returns to less than 103
kPa (15 psi).
10. Continue to turn the ladder pressure reducing
valve adjustment clockwise (in) until the port GP Port GDOWN pressure returns to more than
gauge displays 11 721 (+/-345) kPa (1,700 (+/- 3 447 kPa (500 psi).
50) psi). DO Not adjust the ladder pressure d. The ground level alarm sounds for approxi-
reducing valve above the maximum limit of the mately 20 seconds.
specified range. Port GDOWN gauge should
display the same pressure as GP. Port GUP 15. Press the cab ladder momentary switch to the
gauge should display 103 kPa (15 psi) or less. DOWN position.
NOTE: This pressure adjustment in this step is only 16. Start the engine and operate at low idle for five
to verify the ladder relief valve settings. Use step 26 minutes to allow pressures to stabilize.
to set the pressure reducing valve for normal 17. Stop the engine using the keyswitch in the cab.
operation.
18. Adjust the ladder up relief valve during a 15 sec-
11. Stop the engine using the keyswitch in the cab. ond valve actuation period, as detailed in this
12. While observing the port GDOWN and port GP step. The ladder should not move any time
gauges, slowly turn the ladder down relief valve during this step.
adjustment counterclockwise (out) until the a. Press the cab ladder momentary switch to
valve begins to open. the UP position.
NOTE: Relief valve opening is indicated when the b. Allow five seconds for the ladder solenoid
GDOWN pressure begins to fall or pulsate with an valve to actuate.
incremental turn of the adjustment. The opening may
c. Within the following 15 seconds, observe the
be accompanied by an audible hydraulic hiss.
port GP and port GUP gauges and slowly
a. Tighten the ladder down relief valve adjust- turn the ladder up relief valve adjustment
ment locknut. counterclockwise (out) until the valve begins
b. *Verify the ladder down relief valve begins to to open.
open at 11 721 (+/- 1 172) kPa (1,700 (+/- NOTE: Relief valve opening is indicated when the
170) psi). GUP pressure begins to fall or pulsate with an
Record port GDOWN pressure when the down incremental turn of the adjustment. The opening may
relief valve begins to open. be accompanied by an audible hydraulic hiss.
13. Allow the ladder down relief valve to close and d. If adjustment is not completed within the 15
the pressures at ports GDOWN and port GP to second valve actuation period,
stabilize. Valve closing can be expedited by i) Tighten the ladder up relief valve
momentarily opening the auxiliary accumulator adjustment locknut.
bleeddown valve (Figure 1-1). Do not vent the
accumulator below 10 342 kPa (1,500 psi), as ii) *Verify the ladder up relief valve begins to
displayed on the port GA gauge. If vented open at 11 721 (+/- 1 172) kPa (1,700 (+/-
below 10 342 kPa (1,500 psi), briefly restart the 170) psi).
engine to raise the accumulator pressure. Record the pressure at port GUP when the up
14. Press the cab ladder momentary switch (Figure relief valve begins to open.
1-2) to the UP position. The ladder should not iii) Continue to step 19.
move. Verify the following:
e. If adjustment is not completed within the 15
a. After five seconds have lapsed second valve actuation period,

i) Reset the ladder valve timer by pressing iii)Ladder down indicator light (Figure 1-4 or
the cab ladder momentary switch to the 1-5) turns off when the ladder is full UP.
DOWN position.
iv)Fault A333 does not appear on the cab
ii) Return to step 18a. display panel (if equipped).
19. Open the auxiliary accumulator manual bleed- v) Cab alarm remains silent.
down valve (Figure 1-1). Port GA gauge should
display less than 103 kPa (15 psi). vi)Ground level alarm sounds for 20 seconds
or until the ladder is UP.
20. Press the cab ladder momentary switch to the
DOWN position. Record the response of the ladder, indicator
light, display and alarms.
21. Turn the ladder pressure reducing valve adjust-
ment fully counterclockwise (out). Note: The Record the pressures at the ports GDOWN, GP
port GP and GDOWN gauges may display pres- and GUP when the ladder is fully UP.
sure due to oil trapped within the ladder cylin- b. *Pressing the cab ladder momentary switch
der. This is acceptable. (Figure 2) to the DOWN position results in
22. Using the number of turns recorded in step 8, the following:
turn the ladder pressure reducing valve adjust- i) Ladder lowers smoothly five seconds after
ment clockwise (in). the switch is depressed.
23. Turn the ladder pressure reducing valve adjust- ii) Ladder down indicator light (Figure 1-4 or
ment counterclockwise (out) 1.5 turns. 1-5) illuminates during lowering.
24. Close the auxiliary accumulator manual bleed-
iii)Ladder down indicator light remains
down valve.
illuminated when ladder is DOWN.
25. Start the engine and allow it to operate at low
iv)Fault A333 does not appear on the cab
idle for five minutes. The ladder should not
display panel (if equipped).
move.
v) Cab alarm remains silent.
26. *Using the gauge in port GP, increase the lad-
der system pressure to 9 997 ± 1 000 kPa vi)Ground level alarm sounds for 15 seconds
(1,450 ± 145 psi) by turning the ladder pressure or until the ladder is DOWN.
reducing valve adjustment clockwise (in).
Record the response of the ladder, indicator
Tighten the valve adjustment locknut.
Record the pressure ladder system pressure at
Record the pressures at the ports GDOWN, GP
port GP.
and GUP when the ladder is fully DOWN.
27. Push the upper deck manual lowering valve
knob IN (normal operating position). The ladder 30. *With the ladder in the DOWN position, apply
should not move. the service brakes and move the directional
control lever to NEUTRAL. Verify the following
28. Use the cab ladder momentary switch to raise (during ladder motion):
and lower the ladder several times. Final ladder
a. Ladder begins raising without delay.
movement should be smooth and full. Maximum
pressures should remain at or below the limits b. Ladder down indicator light in the cab dash
specified in steps 12, 18 and 26. indicator panel flashes.
29. Verify normal ladder operation: c. Fault A333 (Hyd Ladder Fault) appears on
a. *Pressing the cab ladder momentary switch the cab display panel (if the truck cab is
(Figure 1-2) to the UP position results in the equipped with an electronic display panel).
following: d. Both cab and ground level alarms sound.
i) Ladder raises smoothly 5 seconds after Record the response of the ladder, indicator
the switch is depressed. light, display and each alarm.
ii) Ladder down indicator light remains 31. When the ladder reaches the full UP position,
illuminated during raising. verify the following:
a. Ladder down indicator light turns off.

b. Fault A333 clears from the cab display panel 36. *Pull the ground level lowering switch OUT (nor-
(if equipped). mal operating position). Verify the following:
c. Both cab and ground level alarms become a. Ladder does not move.
silent.
b. Cab ladder down indicator light continues to
Record the response of the indicator light, flash.
display and alarms. c. Fault A333 remains on the cab display panel
32. *Move the directional control lever to PARK. (if equipped).
Verify the ladder does not move and no alarm d. Cab alarm continues to sound.
sounds.
e. Ground level alarm remains silent.
Record the response of the ladder and alarms.
33. *Have an assistant push the ground level low- light, display and alarms.
ering switch button IN (manual position). Verify
the following: 37. *With the ground level lowering switch OUT,
press the cab ladder momentary switch to the
a. Ladder lowers without delay. DOWN position. Verify the following:
b. Cab ladder down indicator light flashes. a. Ladder does not move.
c. Fault A333 (Hyd Ladder Fault) appears on b. Cab ladder down indicator light illuminates.
the cab display panel (if equipped).
c. Fault A333 clears from the cab display panel
d. Cab alarm sounds without delay. It does not (if equipped).
silence when DOWN is reached.
d. Both alarms are silent.
Record the response of the ladder, indicator light, display and alarms.
light, display and each alarm.
38. Use the cab ladder switch to raise the ladder.
34. *With the ground level lowering switch IN, press
the cab ladder momentary switch to the DOWN 39. *Pull the upper deck manual lowering valve
position. Verify the following: knob OUT (manual position). The ladder should
slowly lower to the DOWN position. A mild out-
a. Cab ladder down indicator light illuminates ward push to the ladder may be required to start
without flashing. the lowering. This is acceptable. Verify the fol-
b. Fault A333 clears from the cab display panel lowing:
(if equipped). a. Cab ladder down indicator light flashes when
c. Both cab and ground level alarms are silent. the ladder leaves the UP position.
Record the response of the indicator light, b. Fault A333 (Hyd Ladder Fault) appears on
display and alarms. the cab display panel (if equipped).
35. *With the ground level lowering switch IN, press c. Cab alarm sounds. It does not silence when
the cab ladder momentary switch to the UP the DOWN position is reached.
position. Verify the following: d. Ground level alarm remains silent.
a. Ladder does not move. Record the response of the ladder, indicator
b. Without delay, the ground level alarm sounds light, display and alarms.
for 20 seconds. 40. *With the upper deck manual lowering valve
c. After a 15 second delay: knob OUT, press the cab ladder momentary
switch to the DOWN position. Verify the follow-
i) Cab ladder down indicator light flashes.
ing:
ii) Fault A333 (Hyd Ladder Fault) appears on a. Ladder does not move.
the display panel (if equipped).
b. Cab ladder down indicator light illuminates.
iii)Cab alarm sounds.
Record the response of the ladder, indicator (if equipped).

d. Both alarms are silent. 44. Use the cab ladder switch to raise the ladder.
Record the response of the ladder, indicator 45. Allow the engine to operate at low idle for five
light, display and alarms. minutes.
41. *With the upper deck manual lowering valve 46. Stop the engine using the cab keyswitch.
knob OUT, press the cab ladder momentary 47. *Using the cab ladder momentary switch, fully
switch to the UP position. Verify the following: lower and then fully raise the ladder. Repeat
a. Ladder does not move. until the ladder no longer lowers or raises. A
minimum of 3.5 complete lower & raise cycles
b. Without delay, the ground level alarm sounds
(4 lower strokes, 3 raise strokes) should be
for 20 seconds.
obtained.
c. After a 15 second delay:
Record the number of complete lower and raise
i) Cab ladder down indicator light flashes. strokes obtained.
ii) Fault A333 (Hyd Ladder Fault) appears on 48. Pull the upper deck manual lowering valve knob
the display panel (if equipped). OUT and fully lower the ladder.
iii)Cab alarm sounds. 49. Open the auxiliary accumulator bleeddown
valve. Port GA gauge should display less than
15 psi.
50. Disconnect the gauges installed in step 2.
42. *Push the upper deck manual lowering valve
knob IN (normal operating position). Verify the 51. Push the upper deck manual lowering valve
following: knob IN (normal operating position).
a. Ladder does not move.
b. Cab ladder down indicator light continues to
flash.
c. Fault A333 remains on the cab display panel
(if equipped).
d. Cab alarm continues to sound.
43. *With the upper deck manual lowering valve
knob IN, press the cab ladder momentary
switch to the DOWN position. Verify the follow-
ing:
a. Ladder does not move.
b. Cab ladder down indicator light illuminates.
(if equipped).
d. Both alarms are silent.

Retractable Ladder System Checkout Data Sheet
Acceptable values of each measurement are shown in parenthesis, ().
6. Ladder down indicator light illuminates when the ladder is DOWN? (yes) _________
8. Ladder system supply pressure (GA) >18 615 kPa (>2,700 psi) _________
9. Number of adjustment turns to increase ladder system operating pressure to 1450 psi
(no specification) _________
12. Ladder down relief pressure (GDOWN) 11 721 ± 1 172 kPa (1,700 ± 170 psi) _________
18. Ladder up relief pressure (GUP) 11 721 ± 1 172 kPa (1,700 ± 170 psi) _________
26. Ladder system pressure (GP) 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
29a. When the cab switch UP is pressed with the ground lowering switch OUT and the upper deck lowering knob
IN (normal positions), do the following occur:
- ladder raises smoothly after a five second delay? (yes) _________
- ladder down indicator light remains illuminated during raising? (yes) _________
- ladder down indicator light turns off when ladder is full UP? (yes) _________
- Fault A333 appears? (n/a if truck cab is not display equipped) (no) _________
- cab alarm sounds? (no) _________
- ground level alarm sounds for 20 seconds or until ladder is UP? (yes) _________
- pressures with ladder fully UP:
- GDOWN: ladder cylinder (0 +25/-0 psi) _________
- GP: ladder system supply 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
- GUP: ladder cylinder 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
29b. When the cab switch DOWN is pressed with the ground lowering switch OUT and the upper deck lowering
knob IN (normal positions), do the following occur:
- ladder lowers smoothly after a five second delay? (yes) _________
- ladder down indicator light illuminates during lowering? (yes) _________
- ladder down indicator light illuminates when ladder is full DOWN? (yes) _________
- Fault A333 appears? (if equipped) (no) _________
- cab alarm sounds? (no) _________
- ground level alarm sounds for 15 seconds or until ladder is DOWN? (yes) _________

- pressures with ladder fully DOWN:
- GDOWN: ladder cylinder 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
- GP: ladder system supply 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
- GUP: ladder cylinder 0 +172/ kPa (0 +25/-0 psi) _________
30. When NEUTRAL is selected, do the following occur (during motion):

- ladder begins raising without delay? (yes) _________
- ladder down indicator light flashes? (yes) _________
- Fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (yes) _________
31. When the ladder is fully UP, do the following occur:

- ladder down indicator light flashes or illuminates? (no) _________
- Fault A333 displays? (if equipped) (no) _________
- an alarm sounds? (no) _________
32. When PARK is selected, do the following occur:

- ladder moves from fully UP? (no) _________
33. When the ground lowering switch is pushed IN, do the following occur:
- ladder lowers without delay? (yes) _________
- ground level alarm sounds? (no) _________
34. When the cab switch DOWN is pressed with the ground lowering switch IN, do the following occur:
- ladder down indicator light illuminates without flashing (yes) _________
35. When the cab switch UP is pressed with the ground lowering switch IN, do the following occur:
- ladder moves from full DOWN? (no) _________
- ground alarm sounds for 20 seconds then silences? (yes) _________
- ladder down indicator light flashes after 15 seconds? (yes) _________
- Fault A333 appears after 15 seconds? (if equipped) (yes) _________
- cab alarm sounds after 15 seconds? (yes) _________

36. When the ground lowering switch is pulled OUT, do the following occur:
37. When the cab switch DOWN is pressed with the ground lowering switch OUT, do the following occur:
- ladder down indicator light illuminates without flashing? (yes) _________
39. When the upper lowering valve knob is OUT, do the following occur:
- ladder moves smoothly to full DOWN position? (yes) _________
- ladder down indicator light flashes when ladder is not fully UP? (yes) _________
- cab alarm sounds during lowering and at ladder full DOWN? (yes) _________
40. When the cab switch DOWN is pressed with the upper lowering valve knob OUT, do the following occur:
- ladder down indicator light illuminates? (yes) _________
41. When the cab switch UP is pressed with the upper lowering valve knob OUT, do the following occur:
- ground alarm sounds for 20 seconds then silences? (yes) _________
- ladder down indicator light flashes after 15 seconds? (yes) _________
- Fault A333 appears after 15 seconds? (if equipped) (yes) _________
- cab alarm sounds after 15 seconds? (yes) _________
42. When the upper lowering valve knob is IN, do the following occur:

43. When the cab switch DOWN is pressed with the upper lowering valve knob IN, do the following occur:
- ladder down indicator light illuminates without flashing? (yes) _________
47. Number of full ladder raise strokes down and up with the engine off.
(3.5 lower & raise cycles minimum) strokes down (4 minimum) _________
strokes up (3 minimum) _________
________________________________________________________________________
Name of Mechanic or Inspector performing Checkout
__________________________________
Date & Shift Checkout completed:
Machine: ___________________ Unit No. _________________ S/N ________________

NOTES

ADDITIONAL ELECTRICAL CHECKOUT FOR TRUCKS WITH IM CONTROLS
Purpose Park Brake
A PC running the IM Realtime Data Monitor software Perform the following tests to confirm the proper
connected to the IM diagnostic serial port is required operation of the Parking Brake and Brake Lock
to complete these tests. Investigate the cause of any circuits. If a test does not produce the expected
faults that are being reported by the IM Realtime results then troubleshoot the electrical circuits, the
Data Monitor during this checkout procedure. hydraulic circuits, or the braking components effected
Contact your local Komatsu distributor to obtain the by the test to locate the problem.
IM Realtime Data Monitor software.
Starter Lockout
Block wheels of truck to prevent a possible roll
away BEFORE performing this procedure.
Assumptions
Always sound the horn once before cranking the a. All components used within the brake
engine! system are to specification.
Shift to neutral and attempt to crank. Confirm that b. Any parts that do not function as described,
cranking is inhibited. Repeat for forward and reverse will be replaced or adjusted.
positions. c. The hydraulic source for the brake system is
in proper operation and the compensator has
been adjusted.
Smart Engine Shutdown Refer to steering and hoist for check-out procedures
Start engine and Load Box it sufficiently to cause and specifications.
these three conditions to occur concurrently: 1. With the engine running, release and apply the
a. coolant temp. to exceed 180 F park brake by shifting in and out of the park
position. Confirm that the Park Brake status
b. engine speed to exceed 1650 rpm
light indicates the correct state of the park
c. fuel rate to exceed 390 mm3/s brake. The light should be on when the shifter is
in the park position and off when it is not in the
1. Confirm that the Timed Shutdown indicator
lamp is off. park position.
2. When these three conditions are true and while

the parking brake is applied and after the
engine has been running for at least five
minutes, turn off the key switch. Confirm that
the engine continues to run for approximately
three minutes after one or more of the An energized Park Brake status light should
conditions a, b, or c above is no longer true. occur whenever the Park Brake switch is applied
Confirm that the Timed Shutdown indicator to confirm that the electrical and hydraulic sys-
lamp is on during this time. tems that control the parking brake are function-
ing correctly. It does not provide positive
confirmation that the parking brake itself is in
proper working order. This must be confirmed by
testing the application force of the parking brake.
2. With the engine running and the park brake
released, turn the key switch off. Confirm that
the Park Brake status light turns on to indicate
that the parking brake has applied. (The light
will eventually turn off as the IM shuts down.)
EM7279-1 4/16 Additional Electrical Checkout for Trucks with IM Controls 1

3. With the engine running and the park brake 3. With the engine running, release the park brake
applied, turn the Key switch off. Confirm that the and apply the brake lock. The Service Brake
Park Brake status light stays on to indicate that status light should be energized and the Park
the parking brake remains applied. (The light Brake status light should be de-energized.
will eventually turn off as the IM shuts down.) Apply the park brake. Confirm that the Park
4. With the engine running and the park brake Brake status light is energized and the Service
released, kill the engine using the Engine Stop Brake status light is de-energized.
switch. Confirm that the Park Brake status light 4. With the engine running, apply the brake lock
turns on to indicate that the parking brake has and release the park brake. Actuate the Engine
applied. Shutdown switch. Confirm that the Park Brake
status light is energized and the Service Brake
Brake Lock status light is de-energized.
5. Energize the Smart Timed Shutdown relay
RB7-K8 by grounding circuit 712M on TB28-X.
Ignore any faults that are generated because of
this temporary grounding. Attempt to apply the
brake lock using the Brake Lock switch. Confirm
The Brake Lock function only applies pressure to that the Service Brake status light (is de-
the rear service brakes. The Service Brake status energized. Remove ground connection from
light should illuminate whenever the Brake Lock TB28-X.
switch is applied to confirm that the electrical 6. Kill the engine using the Engine Shutdown
and hydraulic systems that control the brake lock Switch. With the park brake applied and GE's
system are functioning correctly. It does not pro- “Fwd True” output turned on using GE's wPTU
vide positive confirmation that the rear service pc software, apply the Brake Lock switch.
brakes are in proper working order. This must be Confirm that the Service Brake status light is
confirmed by testing the application force of the energized. Turn off the GE “Fwd True” output.
service brakes. Confirm that the Service Brake status light
1. With the engine running, release the park remains energized. Release the brake lock
brake. Apply and release the brake lock by using the Brake Lock switch. Confirm that the
actuating the Brake Lock switch. Confirm that Service Brake status light is de-energized.
the Service Brake status light indicates the
correct state of the brake lock. The light should Final Check
be on when the brake lock switch is in the Key on and confirm no active faults for 1 minute.
applied position and off when it is in the Start engine, let run for three minutes and confirm no
released position. active faults. Key off and confirm no active faults for 2
2. With the engine running, apply the park brake. minutes.
Attempt to apply the brake lock by actuating the
Brake Lock switch. Confirm that the Service
Brake status light does not energize and that
the Park Brake status light remains energized.
2 Additional Electrical Checkout for Trucks with IM Controls 4/16 EM7279-1

S/N ___________________
IM Installation Checkout Checklist

A. Starter Cranking is inhibited.
B1. Timed Engine Shutdown Lamp is off.
B2. Timed Engine Shutdown Lamp is on.
C1. Park Brake Park Brake status lamp indicates
correct state of parking brake.
C2. Park Brake Park Brake status lamp turns on.
C3. Park Brake Park Brake status lamp remains
on.
C4. Park Brake Park Brake status lamp turns on.
D1. Brake Lock Brake status lamp indicates cor-
rect state of brake lock.
D2. Brake Lock Brake status lamp off.
D3. Brake Lock Brake status lamp on and Park
Brake status lamp off.
Brake status lamp off and Park
Brake status lamp on.
D4. Brake Lock Brake status lamp off and Park
Brake status lamp on.
D5. Brake Lock Brake status lamp is off.
D6. Brake Lock Brake status lamp turns on.
Brake status lamp remains on.
Brake status lamp turns off.
E. Final Check No active faults.
Completed By: _________________________________________ Date: _______________________
EM7279-1 4/16 Additional Electrical Checkout for Trucks with IM Controls 3

NOTES
4 Additional Electrical Checkout for Trucks with IM Controls 4/16 EM7279-1

SUSPENSION OILING AND CHARGING PROCEDURE
GENERAL NOTE: Anytime the suspensions are charged, the
calibration of the Payload Meter System is affected,
refer to the Payload Meter Section in the Shop
Manual and perform a clean truck tare. This will
ensure accurate payload records.
All suspensions are charged with compressed Front Suspension

nitrogen gas with sufficient pressure to cause 1. Park the unloaded truck on a hard, level sur-
injury and/or damage if improperly handled. Fol- face. Place the directional control lever in
low all safety instructions, cautions, and warn- PARK.
ings provided in the following procedures to 2. Place wheel chocks in front and behind both
prevent any accidents during Servicing and sets of rear tires to prevent roll away.
Charging. 3. Throughly clean charging valve area, remove
covers.
Before starting oiling and charging procedures,

support blocks should be fabricated to maintain
the correct exposed piston rod extension. See When blocks are in place on a suspension, they
Shop Manual for further details. must be secured with a strap or other means to
avoid accidental discharge. An unsecured block
These procedures cover the Suspension Oiling and
could fly loose as weight is applied, presenting
Charging of suspensions on Komatsu Electric Drive
the possibility of serious injury to nearby person-
Dump Trucks.
nel and/or damage to the equipment. Overhead
NOTE: Suspensions which have been properly clearance may be reduced rapidly and suddenly
charged will provide improved handling and ride when nitrogen pressure is released!
characteristics while also extending the fatigue life of 4. Position and secure oiling blocks.
the truck frame and improving tire wear.
NOTE: Inflation pressures and exposed piston
lengths are calculated for a normal truck gross
vehicle weight (GVW). Additions to truck weight by
adding body liners, tailgates, water tanks, etc. should
be considered part of the payload. Wear a face mask or goggles while relieving
NOTE: For best results, suspensions should be nitrogen pressure. Make sure that all personnel
charged in pairs (fronts together and rears together). are clear and support blocks are secure before
If rears are to be charged, the fronts should be relieving nitrogen pressure from the suspension.
charged first. If truck lifts off of blocks before charging Causing serious injury to nearby personnel and/
is complete stop charging. If Both front and rear are or damage to the equipment. Overhead clearance
serviced, DO NOT remove the front suspension may be reduced rapidly and suddenly when nitro-
nitrogen charging blocks until after the rear gen is released.
suspensions have been completely serviced.
NOTE: For installing and removing the charging kit Be aware when relieving nitrogen gas, the truck
see Shop Manual. may drop suddenly onto the charging blocks.
5. Release the nitrogen pressure.
NOTE: For full instructions on front and rear
suspension oiling and charging nitrogen charging 6. Remove the charging valve cap (Figure 1-1)
refer to the Shop Manual. and turn counterclockwise three full turns. DO
NOT turn the large hex.
58E-60-02200 3/18 Suspension Oiling and Charging Procedures 1

7. Depress charging valve to release nitrogen
pressure. CHARGING FILL PLUG
VALVE
8. Remove the top fill plug next to the charging
valve.
9. Fill the suspension cylinder with clean oil until
the oil is even with the top of the fill plug bore.
10. Allow suspension to settle for at least 15 min-
utes.
11. Add more suspension oil if necessary. Install
new O-ring on fill plug and install plug.
12. Install charging kit.
13. Charge the suspension with enough nitrogen to
install the nitrogen charging blocks.
14. Remove the oiling blocks and install the nitro-
gen charging blocks.
15. Remove center hose from charging valve mani-
fold.
PISTON ROD
SPINDLE
MEASURE HERE
Lifting equipment (crane or hydraulic jacks) must

be of sufficient capacity to lift the truck weight.
Be certain that all personnel are clear of lift area
before lift is started. Clearances under the truck
may be suddenly reduced.
DRAIN 85632
16. Lower the truck onto the nitrogen charging
blocks. FIGURE 1-1. FRONT SUSPENSION
17. Re-install the center hose to the charging valve
manifold.
18. Charge the suspension to pressure listed in
Table 1.
19. Allow the pressures in the suspension to equal-
ize and close all valves and reinstall guards.
20. Raise truck in order to remove the nitrogen
charging blocks.
2 Suspension Oiling and Charging Procedures 3/18 58E-60-02200

Table 1: Front Suspension Oiling and Charging Height Dimensions
Front Suspension
Oiling Height Charging Height Gas Pressure
730E-7
2758kPa (400psi)
730E-7T 38.1mm (1.50in)
730E-8 2772kPa (402psi)
830E-1AC
830E-1AT 2696kPa (391psi)
830E-5
228.6mm (9.00in)
860E-1K
3365kPa (488psi)
860E-1KT
930E-4
930E-4SE 25.4mm (1.00in)
2930kPa (425psi)
930E-4AT
930E-5
960E-2K
219.1mm (8.63in) 3282kPa (476psi)
960E-2KT
980E-4 228.6mm (9.00in)
3047kPa (442psi)
980E-4 Oil Sands 165.1mm (6.50in)
Charging pressures are for reference only and may vary depending on body weights.

Rear Suspension 8. Use one of the open ports to fill the suspension
1. Park the unloaded truck on a hard, level sur- with clean oil.
face. Place the directional control lever in 9. Fill until oil sweeps from the open ports.
PARK. 10. Allow suspension to settle for at least 15 min-
2. Place wheel chocks in front and behind both utes. Add suspension oil if necessary.
sets of rear tires to prevent roll away.
11. Reinstall the vent plug and pressure sensor
3. Thoroughly clean port areas, remove covers. back into the suspension cylinder.
12. Install a new O-ring onto the charging valve and
re-install onto the suspension cylinder.
13. Install the charging kit.
14. Charge the suspension with enough nitrogen to
install the nitrogen charging blocks and remove
When blocks are in place on a suspension, they the oiling blocks.
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 person-
nel and/or damage to the equipment. Overhead
clearance may be reduced rapidly and suddenly
when nitrogen pressure is released!
Be aware when relieving nitrogen gas, the truck
4. Position and secure oiling blocks. may drop suddenly onto the charging blocks.
5. Remove the charging valve cap and turn coun- 15. Slowly release gas until the suspension pres-
terclockwise three full turns. DO NOT turn the sures match those reflected in the rear suspen-
large hex. sion gas pressure table. (Refer to Table 2)
6. Depress charging valve (Figure 1-2) to release
16. Allow the pressures in the suspension to equal-
nitrogen pressure.
ize and close all valves and reinstall guards if
7. Remove the vent plug, pressure sensor and necessary.
charging valve.
17. Remove the charging blocks.

PRESSURE SENSOR/
FILL PORT CHARGING VALVE/
VENT PLUG/FILL PORT FILL PORT
MEASURE HERE
85633
FIGURE 1-2. REAR SUPENSION

Table 2: Rear Suspension Oiling and Charging Height Dimensions
Rear Suspension
Oiling Height Charging Height Gas Pressure
730E-7
72.6mm (2.86in) 275.8mm (10.86in) 1420kPa (206psi)
730E-7T
730E-8 78.6mm (3.09in) 281.8mm (11.09in) 1544kPa (224psi)
830E-1AC
830E-1AT 1186kPa (172psi)
830E-5 270.1mm (10.63in)
860E-1K
1469kPa (213psi)
860E-1KT 54.2mm (2.13in)
930E-4
930E-4SE
219.3mm (8.63in) 1296kPa (188psi)
930E-4AT
930E-5
960E-2K
53.7mm (2.1in) 218.8mm (8.61in) 1351kPa (196psi)
960E-2KT
980E-4
47.2mm (1.86in) 212.3mm (8.36in) 1455kPa (211psi)
980E-4 Oil Sands
Charging pressures are for reference only and may vary depending on body weights.

OIL AND NITROGEN SPECIFICATIONS CHART
HYDRAIR® II OIL SPECIFICATIONS

Ambient Temperature Part No. Approved Sources
Range
VJ3911 Mobilfluid 424 Sunfleet TH Universal Tractor Fluid
(need to add Mobil DTE 15M Chevron Tractor Hydraulic Fluid-
6% of Texaco TDH Oil Conoco Power Tran III Fluid
-30°F and above AK3761) AMOCO ULTIMATE Motor Oil Petro Canada Duratran Fluid
(-34.5°C and 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-40 Conoco High Performance
-55°F and above AK3761) Synthetic Motor Oil, 5W-30
(-48.5°C and 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
FAM1204 Oil and Nitrogen Specifications Chart 12-1

NOTES
12-2 Oil and Nitrogen Specifications Chart FAM1204

PRE-SHIFT BRAKE TEST - TEST PROCEDURE
Purpose NOTE: Whether to log the events shall also be an
OEM option. Some mines may not want to fill the TCI
This procedure allows the operator to check the
log with these types of events.
functionality of Service Brake, Parking Brake, Drive
Brake (Hill start Assist (HSA)- If HSA is enabled) and
retarder prior to each shift.
Events Requiring PSBT:
534-1 - Hill Start Assist Disabled - Drive Brake Test
Pre-Shift Brake Check: needed
The static brake test allows the operator to check NOTE: While 534-1 event is logged the Hill start
and verify the service brake, parking brake, drive assist feature is inhibited. Drive brake portion of
Brake and the dynamic retarder at the time they are PSBT must be run to un-inhibit the feature.
tested.
NOTE: Komatsu recommends that operators perform
Operation
static brake tests to verify that the braking systems The static brake test utilizes a momentary switch and
are adequate at the beginning of each shift before a check light. The amber light at the top of the switch
operating the truck. acts as the check light.
After performing each test, it is the operator's NOTE: Whether to log the events shall also be an
responsibility to determine if the truck passed each OEM option. Some mines may not want to fill the TCI
test and if the truck is safe for operation. log with these types of events.
The order of performing the brake tests, (service
Brake Test Switch
brake, parking brake, Drive brake or retard system)
does not matter. Each brake test is a separate test, The brake test switch (Figure 1-1) is used to initiate a
where one brake system or all can be tested at any brake test. Press on the momentary switch to enter
time. the brake test mode. If certain conditions are met, the
operator can enter a brake test sequence.
If an operator has questions during brake testing,
refer to the drive system Vehicle Information Display
(VID) panel, located on the back wall of the cab for
guidance.
If the truck fails any brake test, notify mainte-

nance personnel immediately. DO NOT resume
operation unless the truck passes all brake tests.
Events
The following events have been added to the drive
system software to support the brake test feature.
• 645-1 Service Brake Test Performed FIGURE 1-1.
• 645-2 Parking Brake Test Performed
• 645-3 Retard Test Performed
• 645-4 Retard Test Failed
• 645-5 Brake Test Switch stuck closed
• 645-6 Drive Brake Test Performed
58E-06-09750 Pre-Shift Brake Test - Test Procedure 1

Brake Check Light For example, if the engine is off:
The amber light at the top of the switch is used to ERROR Entering Brake Test
indicate when the truck is in the brake test mode.
Engine not running
When illuminated, a brake test is ready. When
flashing, the brake test is at the validation point, or If the truck is loaded:
the retard system test is finished.
ERROR Entering Brake Test
Truck is NOT empty
If all the conditions are correct, except the brakes are
not set correctly, an error message will be displayed.
For example, if the service brake and parking brake
are both applied together:
ERROR Entering Brake Test
Set Brakes for Test
Brake Test Exit Criteria

Numerous conditions can occur which may interrupt
FIGURE 1-2. a brake test, including the following:
• Any of the setup conditions becoming false
Description • System Fault which restricts the LINK or Propel
The operator can choose which brake test to perform mode
and will set the truck controls based on the settings in • Truck Speed > 2.0 mph in Service Brake test
Table 1, “BRAKE TEST SETTINGS,” on page 3. The
• One rotation of motor rotor in Park brake or Drive
drive system will detect the position of the directional brake tests
control lever, and will prepare for the appropriate test.
The operator will then press the brake test switch. • Truck at torque level for more then 30 seconds
If the brake check light is illuminated solid after • Test requested, (button), but not initiated (pedal)
pressing the brake test switch, the system is in brake for 60 secs.
test mode and is ready to begin the test. The
operator then has 60 seconds to choose and initiate
PERFORMING THE BRAKE TESTS
the test to be performed. After testing, the operator Setup
will then determine if the truck passed the brake
tests, and if it is safe for operation. Before performing any brake test, the following
conditions must be met:
If the brake check light does not illuminate
immediately after pressing the brake test switch, • Dump body empty
there is most likely a problem with the setup. Refer to NOTE: The drive system will not enter any brake test
the setup conditions and take action to prepare the if the truck is loaded.
truck for a brake test.
• Truck located outside on a flat area, where truck
If there is a problem with the truck setup, the VID movement is allowed.
panel will display the problem.
2 Pre-Shift Brake Test - Test Procedure 58E-06-09750

Before performing any brake test, the truck must be
in the following state:
Engine running (low idle)
Link charged (Ready Mode)
Ensure the area around the truck is free of per-
sonnel and objects. Some truck movement could Dump body down
occur during brake testing. Not in LIMP mode (Both Inverters Cut-in and OK)
The drive system is unable to determine if the
truck is on a hill or in a parking ditch. Testing Zero ground speed
during these conditions will affect test results.
Table 1: BRAKE TEST SETTINGS
BRAKE TEST SETTINGS

Test Type Wheel Brake Service Brake Directional
Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF OFF/RELEASED PARK
Drive Brake ON OFF/RELEASED NEUTRAL
(HSA enabled)
Retard Test OFF OFF/RELEASED PARK
Service Brake Test 6. With the service brake pedal still fully applied,
fully depress the accelerator pedal. The drive
system controller will enter propel mode and
generate torque up to the service brake limit.
Maintain full service brake pressure during the
test.
If the truck fails the service brake test, notify NOTE: The drive system can only detect if the
maintenance personnel immediately. Do not service brakes are applied. It can not detect the
resume operation unless the truck passes all percentage of application. It is up to the operator to
brake tests. press hard enough on the service brake pedal to
1. Firmly depress the service brake pedal. On the achieve a full brake application.
retard/service brake one pedal system, push
the pedal fully to engage service brake
completely.
2. Place the directional control lever in the
NEUTRAL position. Ensure the wheel brake
lock switch is OFF.
3. Press the brake test switch and wait for the
brake check light to be on solid.
4. Fully depress the service brake pedal. Ensure
full brake application is reached. Failure to
reach full brake application will affect the
service brake test results.
5. The VID panel will display:
Service Brake Test READY
Press Accel Pedal to Start

7. The VID panel will display: Parking Brake Test
Service Brake Test ACTIVE
Check Truck Movement when Light Flashes
8. Once torque has reached the limit for the
service brake test, the brake check light will
begin to flash. This is the indication for the
operator to make a determination as to the If the truck fails the parking brake test, notify
status of the service brake system. maintenance personnel immediately. Do not
resume operation unless the truck passes all
• If the truck did not move: brake tests.
The service brake system passed the test. 1. Place the directional control lever in the PARK
• If the truck moved during the test: position.
2. Press the brake test switch and wait for the
The service brake system failed the test.
brake check light to be on solid.
9. Release the accelerator pedal and the torque
will be reduced, the test will stop and the brake 3. The VID panel will display:
check light will turn off. Parking Brake or Retard Test READY
10. Place the directional control lever in the PARK Press Accel or Retard Pedal to Start
position. Release the service brake pedal.
4. Fully depress the accelerator pedal. The drive
11. If the truck failed the service brake test, notify system controller will enter propel mode and
maintenance personnel immediately. generate torque up to the park brake limit.
If the test exits abnormally, or if the operator simply 5. The VID panel will display:
does not press the accelerator pedal far enough to Park Brake Test ACTIVE
achieve the torque level for the service brake test,
the VID panel will display: Check Truck Movement when Light Flashes
6. Once the torque has reached the limit for the
Brake Test ERROR
parking brake test, the brake check light will
Test did NOT Complete begin to flash. This is the indication for the
NOTE: If the operator partially or fully releases the operator to make a determination as to the
accelerator pedal during the test, torque will be status of the parking brake system.
reduced and the brake check light will go back on • If the truck did not move:
solid when torque falls below the test set point. The
operator can re-apply the accelerator pedal to The park brake system passed the test.
increase torque and the brake check light will again • If the truck moved during the test:
flash when the torque is at the test limit. 7. When the operator releases the accelerator
pedal, torque will be reduced, the test will stop
and the brake check light will turn off.

Retard System Test: Drive Brake System Test:
If the truck fails the retard system test, notify If the truck fails the parking brake test, notify
maintenance personnel immediately. Do not maintenance personnel immediately. Do not
resume operation unless the truck passes all resume operation unless the truck passes all
brake tests. brake tests.
1. Place the directional control lever in the PARK 1. Place the directional control lever in the
position. NEUTRAL position.
2. Press the brake test switch and wait for the 2. Press the brake test switch and wait for Hill start
brake check light to be on solid. assist inhibit light to flash
3. The VID panel will display: 3. Remove Brake lock switch (Pre-shift brake test
should illuminate to indicate test has entered)
Parking Brake or Retard Test READY
4. Fully depress the accelerator pedal till the Pre-
Press Accel or Retard Pedal to Start shift Brake test light flashes
4. Fully depress the retard pedal. (On trucks with 5. Once the torque has reached the limit for the
one pedal for service brakes and retard, push test, the brake check light will begin to flash.
pedal to engage retard but not far enough to This is the indication for the operator to make a
engage service brakes.) (Pushing the retard / determination as to the status of the parking
brake pedal far enough to engage service brake system.
brakes will cancel retarder test.) The drive
system controller will ramp up the engine • If the truck did not move:
speed, turn on CM1 through CM4 individually at The Drive Brake system passed the test.
50% and test the retarding system. The system
will verify current flow through each grid leg and • If the truck moved during the test:
the LINK1 and GRID1 sensors. The test has failed. Release the accelerator
5. The VID panel will display the current status of pedal. If the truck starts to roll, apply the service
brakes to hold the truck stationary. Notify
the test.
maintenance personnel immediately.
Retard System Test ACTIVE
CM1, CM2, CM3, CM4
(Elements are added as the test progresses.)
6. Upon successful completion of the test, the light
will flash for 10 seconds indicating a successful
test. The VID panel will display:
Retard System Test PASSED
Or
Retard System Test FAILED or Incomplete
NOTE: If the brake check light never flashes, but
turns off, the test has failed.
7. When the operator releases the retard pedal,
the test will stop and the brake check light will
turn off.
8. If the retard system failed the test, notify
maintenance personnel immediately. Do not
resume operation unless the truck passes all
brake tests.

NOTES

TOE-IN ADJUSTMENT
1. Center the front wheels by straightening the
steering wheel. Turn the key switch OFF. Allow
at least 90 seconds for the accumulators to de-
pressurize. DO NOT turn the steering wheel
during this time.
2. Chock the front and back of the rear wheels.
3. Check the toe-in by measuring the distance
between the centers of the front tires. Measure
on the horizontal centerline at both the front and
the rear of the tires. Refer to Figure 13-1.
Radial tires must have equal measurements at
the front and the rear of the tires. Equal mea-
surements results in 0 toe-in.
NOTE: The dimensions in the table are for reference
only. Do not use the dimensions to set the toe-in
830E TOE-IN DATA

Nominal tie-rod length, radial tires 3658 mm
to achieve: 0 toe-in (144.0 in.)
Change in toe-in dimension with 2.0
one full turn of tie rod (0.79)
4. If the measurements are not equal, adjust the

tie rod. Loosen the clamp locknuts on the tie
rod. Rotate the tie rod as necessary to obtain
the correct toe-in setting of 0.
FIGURE 13-1. MEASURING TOE-IN
5. When the adjustment is complete, tighten the
tie rod clamp capscrews and locknuts to 1017
N·m (750 ft lb). Reapply torque to each cap-
screw and locknut until the specified torque is
maintained.
6. Remove the wheel chocks from the rear
wheels.
FAM1307 Toe-In Adjustment F13-1

NOTES
F13-2 Toe-In Adjustment FAM1307

AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
Lincoln Flow Master Phase 1 Auto Lube 4. Hoses to bearings now must be purged of air.
System With Fixed Hydraulic Controls Using lube pump, manually operate cycles until
grease appears at each bearing or use an
external lube pump to force grease into each
line at grease Zerk on injector.
Adjust Injector Settings

Do not connect electrical harness at lube pump 1. Injectors Should Be Adjusted To "Half Injector"
until reservoir has been filled, (pump, lines, and Stroke For Initial Adjustment.
injectors purged of air), and system ready to
2. Individual Settings Should Be Made Per
operate. damage to lube pump can occur if pump
Specific Mine Application Needs.
is "run dry".
Lube Pump Start-up / Purging Procedure Timer

1. Fill reservoir with appropriate grease through Trucks with digital display/interface modules are fac-
provided filter. tory set and not field adjustable. Trucks with lubrica-
tion timers have field adjustment for some functions.
2. Remove grease pump discharge hose and Pump run time is fixed at 2.00 minutes; with off time
connect a short clean temporary hose. Route adjustable from 30 seconds to 30 minutes by dip
temporary hose back into the reservoir or waste switches in timer. Initial adjustment is suggested to
container. be 15 minutes. Mine should adjust for their particular
3. With truck running, start the manual override application.
valve to let the pump run. Watching the
discharge hose for grease flow. Warning System
4. Once full grease flow is achieved, stop pump. 1. Operate truck observing auto lube warning light
Grease flow should appear within two minutes. and bearings to see if they are receiving
if longer time is taken investigate the problem. grease.
5. Once pump is primed, reconnect original 2. If bearings are receiving grease and no auto
discharge hose to system. lube warnings are recorded, system is
operating as expected and no further testing is
Truck Lube System Purging Procedure required.
The main hoses to injector banks must be purged of 3. If auto lube warnings are recorded or bearings
air after the lube pump has been primed with grease. are not receiving grease, further testing is
1. Using truck lube pump or external pump, force required. refer to service manual for specific
grease into main line at lube pump. test procedures.
2. Remove plug on one front injector bank. then
pump grease into main line at lube pump until
full grease flow exits in port.
3. Repeat procedure for other front injector bank
and then follow with rear injector bank.
58F-90-00300 Automatic Lubrication System Checkout Procedure 1

NOTES
2 Automatic Lubrication System Checkout Procedure 58F-90-00300

AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION During the down stroke, the pump cylinder is
extended into the grease. Through the combination
The automatic lubrication system is a pressurized
of shovel action and vacuum generated in the pump
lubricant delivery system which delivers a controlled
cylinder chamber, the grease is forced into the pump
amount of lubricant to designated lube points. The
cylinder. Simultaneously, grease is discharged
system is controlled by an electronic timer which
through the outlet of the pump. The volume of grease
signals a solenoid valve to operate a hydraulic motor
during intake is twice the amount of grease output
powered grease pump. Hydraulic oil for pump
during one cycle. During the upstroke, the inlet check
operation is supplied by the truck steering circuit.
valve closes. One half of the grease taken in during
Grease output is proportional to the hydraulic motor the previous stroke is transferred through the outlet
input flow. A pump control manifold, mounted on top check and discharged to the outlet port.
of the hydraulic motor, controls input flow and
pressure. A 24VDC solenoid mounted on the
manifold turns the pump on and off.
The pump is driven by the rotary motion of the Over-pressurizing the system, modifying parts,
hydraulic motor, which is then converted to using incompatible chemicals and fluids, or
reciprocating motion through an eccentric crank using worn or damaged parts may result in
mechanism. The reciprocating action causes the equipment damage and/or serious personal
pump cylinder to move up and down. The pump is a injury.
positive displacement, double-acting type as grease
output occurs on both the up and the down stroke.
• DO not exceed the stated maximum
working pressure of the pump or the
lowest rated component in the system.
• Do not alter or modify any part of this
system unless approved by the factory.
• Do not attempt to repair or disassemble
the equipment while the system is
pressurized.
• Make sure that all fluid connections are
securely tightened before using this
equipment.
• Always read and follow the fluid
manufacturer's recommendations
regarding fluid compatibility and the use
of protective clothing and equipment.
• Check all equipment regularly. Repair or
replace worn or damaged parts
immediately.
This equipment generates very high grease
pressure. Extreme caution must be used when
operating this equipment as material leaks from
loose or ruptured components can inject fluid
FIGURE 1-1. PUMP & RESERVOIR COMPONENTS through the skin and into the body causing
1. Hose From Filter 8. Pipe Plug serious bodily injury including possible need for
2. Filter 9. Dip Stick amputation. Adequate protection is
3. Hydraulic Motor 10. Flow Control Valve recommended to prevent splashing of material
4. Pressure Reducing 11. Pressure Cut Off onto skin or into the eyes.
Valve Switch If any fluid appears to penetrate the skin, get
5. Solenoid Valve 12. Grease Reservoir emergency medical care immediately! Do not
6. Override Switch 13. Vent Hose treat as a simple cut. Tell attending physician
7. Vent Valve exactly what fluid was injected.
FAM1405 8/18 Automatic Lubrication System F14-1

FIGURE 1-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION
1. LH Suspension, Bottom Bearing 13. RH Anti-Sway Bar Bearing

2. LH Hoist Cylinder, Top Bearing 14. RH Suspension, Top Bearing
3. LH Hoist Cylinder, Bottom Bearing 15. Grease Reservoir
4. LH Anti-Sway Bar Bearing 16. Vent Hose
5. LH Suspension, Top Bearing 17. Pipe Plug (Oil Level)
6. LH Body Pivot Pin 18. Not used this application
7. RH Body Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. RH Suspension, Bottom Bearing 21. Filter
10. RH Hoist Cylinder, Top Bearing 22. Grease Supply to Injectors
11. RH Hoist Cylinder, Bottom Bearing 23. Injectors
12. Rear Axle Pivot Pin 24. Pressure Switch, N.O. - 13 790 kPa (2,000 psi)
F14-2 Automatic Lubrication System 8/18 FAM1405

SYSTEM COMPONENTS Flow Control Valve
Filter Flow control valve (10), mounted on the manifold,

controls the amount of oil flow to the hydraulic motor.
Filter assembly (21, Figure 1-2), mounted on the The flow control valve has been factory adjusted
grease reservoir, filters the grease prior to refilling the and the setting should not be disturbed.
reservoir from the shop supply. A bypass indicator
alerts service personnel when the filter requires Solenoid Valve
replacement.
Solenoid valve (5), when energized, allows oil to flow
Hydraulic Motor and Pump to the hydraulic motor.
Rotary hydraulic pump (3, Figure 1-1) is a fully Vent Valve

hydraulically operated grease pump. An integrated
With vent valve (7) closed, the pump continues to
pump control manifold is incorporated with the motor
operate until maximum grease pressure is achieved.
to control input flow and pressure.
As this occurs, the vent valve opens and allows the
NOTE: The pump crankcase oil level must be grease pressure to drop to zero, so the injectors can
maintained to the level marked on dipstick (9, recharge for their next output cycle.
Figure 1-1). If necessary, add 10W-30 motor oil.
Over Pressure Cut Off Switch
Pressure switch (18, Figure 1-2) is a normally open
switch set at 20 684 kPa (3,000 psi). This switch de-
energizes the pump solenoid relay if the grease line
pressure reaches the switch pressure setting, turning
Hydraulic oil supply inlet pressure must not off the motor and pump.
exceed 24 132 kPa (3500 psi). Exceeding the
rated pressure may result in damage to the Grease Pressure Failure Switch
system components and personal injury. Pressure switch (24) is a normally open switch set at
13 789 kPa (2,000 psi). If the appropriate grease
Grease Reservoir
pressure is not achieved during the normal pump
Grease reservoir (12) has an approximate capacity of cycle, the warning system will be activated,
41 kg (90 lb) of grease. When the grease supply is illuminating the warning lamp in the overhead display
replenished by filling the system at the service to notify the operator a problem exists in the lube
center, the grease is passed through the filter to system.
remove contaminants before it flows into the
reservoir. Injectors
Each injector (23) delivers a controlled amount of
Pressure Reducing Valve
pressurized lubricant to a designated lube point.
Pressure reducing valve (4), located on the manifold, Refer to Figure 1-2 for locations.
reduces the hydraulic supply pressure (from the truck
steering circuit) to a suitable operating pressure for Interface Module
the hydraulic motor used to drive the lubricant pump. The interface module provides a 24 VDC timed-
The pressure control valve has been factory interval signal to energize the solenoid valve,
adjusted and the setting should not be disturbed providing oil flow to operate the grease pump motor.
unless grease output pressure is outside the This interface module is mounted in the auxiliary
recommendations. control cabinet.
A pressure gauge can be installed where pipe plug
(8) is located. The pressure gauge will indicate Relief Valve (unloader valve)
hydraulic oil pressure to the inlet of the hydraulic Relief valve (14, Figure 1-3) protects the pump from
motor. Normal pressure is 2 241 - 2 413 kPa (325 - high pressures. This relief valve is set at 27 580 kPa
350 psi). (4,000 psi).

SYSTEM OPERATION 6. When grease pressure reaches pressure switch
(18, Figure 1-2) setting, the switch contacts will
Normal Operation close and energize the relay RB7-K5, removing
1. During truck operation, the lubrication cycle power from the hydraulic motor/pump solenoid
timer will energize the system at a preset time and the pump will stop. The relay will remain
interval. energized until grease pressure drops
(pressure switch opens again) and the timer
2. The interface module provides 24VDC to
turns off.
energize the pump solenoid valve (3), allowing
hydraulic oil provided by the truck steering 7. After the pump solenoid valve is de-energized,
pump circuit to flow to the pump motor and hydraulic pressure in the manifold drops and
initiate a pumping cycle. vent valve (11, Figure 1-3) will open, releasing
grease pressure in the lines to the injector
3. The hydraulic oil from the steering circuit is
banks. When this occurs, the injectors are then
directed through the pressure reducing valve
able to recharge for the next lubrication cycle.
(4) and flow control valve (6) before entering the
motor. Pump pressure can be read on optional 8. The system will remain at rest until the
pressure gauge (5) mounted on the manifold. lubrication cycle timer turns on and initiates a
new grease cycle.
4. With oil flowing into the hydraulic motor, the
grease pump will operate, pumping grease from 9. During the normal lubrication cycle, if grease
the reservoir to the injectors (13), through a pressure fails to reach 13 790 kPa (2,000 psi)
check valve (10) and to the vent valve (11). within 120 seconds at the pressure switch
located on the rear axle housing, an amber
5. During this period, the injectors will meter the
indicator light will illuminate on the overhead
appropriate amount of grease to each
panel.
lubrication point.
FIGURE 1-3. HYDRAULIC SCHEMATIC

1. Hydraulic Oil Return 6. Flow Control Valve 11. Vent Valve
2. Hydraulic Oil Supply 7. Hydraulic Motor 12. Orifice
3. Pump Solenoid Valve 8. Grease Pump 13. Injector Bank
4. Pressure Reducing Valve 9. Pressure Switch (N.O.) 14. Relief Valve
5. Motor Pressure Gauge 10. Check Valve

GENERAL INSTRUCTIONS
Lubricant Required For System
Grease requirements will depend on ambient
temperatures encountered during truck operation:
• Above 32°C (90°F) - Use NLGI No. 2
multipurpose grease (MPG).
• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1
multipurpose grease (MPG).
• Below -32°C (-25°F) - Refer to local
supplier for extreme cold weather
lubricant requirements.
Filter Assembly
Filter element (5, Figure 1-4) must be replaced if
bypass indicator (2) shows excessive element
restriction.
FIGURE 1-4. FILTER ASSEMBLY

1. Housing 6. Spring
2. Bypass Indicator 7. Bowl
3. O-Ring 8. O-Ring
4. Backup Ring 9. Plug
5. Element

LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Check the oil level at at
the 1000 hour maintenance interval. To add oil,
remove dipstick (4, Figure 1-5) on top of the pump
housing and fill the housing to the proper level
marked on the dipstick.
NOTE: If the pump is not equipped with dipstick (4),
remove oil level plug (5) and fill the housing to the
bottom of the plug hole.
Pump Pressure Control

High pressure hydraulic fluid from the truck steering
system is reduced by the pressure reducing valve
located on the manifold on top of the pump motor.
This pressure can be read if pipe plug (3) is removed,
and a gauge is installed on the manifold.
FIGURE 1-5. AUTO LUBE PUMP CONTROLS
1. Pump Pressure Control 4. Dipstick
2. Override Switch 5. Oil Level Plug
3. Pipe Plug (Gauge Port) 6. Flow Control Valve

SYSTEM CHECKOUT
To check system operation proceed as follows: Main Level Screens
Screen 1
1. Remove the dust covers from the injectors. Load = 240 t OK
LC = 25 TT = 6000 t
2. Start the engine. 2100 rpm SC = 20 mph <

3. Actuate the manual override button at the pump
assembly and observe pin movement at each ˇ Switch 1 Switch 2
Screen 2
ˆ
Load = 240 t
injector.
LC = 25 TT = 6000 t
4. Check for pump, hose or injector damage or 10,000 m SC = 20 mph
leakage with the system under pressure.

ˇ
5. After checking system, stop the engine. Screen 3
ˆ
Load = 240 t
Observing normal precautions regarding high LC = 25 TT = 6000 t
voltage present in the propulsion system before 3560.9 h SC = 20 mph
attempting to repair lube system.

ˆ ˇ
6. Re-install the injector dust covers.
Screen 4
1 Active Warnings
Lubrication Cycle Operation Press < to View
<
The time between lube events is determined by the Advance to screen 1 if moving and no
setting selected in the dash panel. Refer to Figure 1- Advance to screen 4 .

ˇ realtime data.
6 for lubrication menu screens. With the key switch ˆ

Screen 5
ON, scroll through the display menu screens and Realtime Data
select either 8, 15, 24 or 30 minutes between lube OK to View
(future development)
cycles. The default setting is 15 minutes. Advance to screen 1 if moving.
Advance to screen 5 OR
ˇ
NOTE: Turning the key switch to the ON position will
screen 4 OR screen 3.
Screen 6
ˆ
not initiate a lube cycle. To initiate a lube cycle while Payload Data
OK to View
the truck is stationary, select manual lube using the
dash display panel, or use the switch on the ˇ
lubrication pump. The truck must be moving before Screen 7
ˆ
the lube system will initiate lube cycles based on the 1 Repair Item
OK to View
time interval selected.
ˇ
Screen 8
ˆ
2 Maintenance Items
OK to View
ˇ
Screen 9
ˆ
Manual Lube
OK
System Controls
Press OK to View
Press OK to Start
Screen 9,
ˆ Screen 9,
subscreen 0
subscreen max.
Screen 10
English
Español
Français
OK Portuguese
ˇ
Screen 11
ˆ
Lube Interval
OK
Configure System 8 15 24 30
Press OK to Edit
Press OK to Edit
ˆ
Screen 11,
Screen 11,
subscreen 0
subscreen max.
80414
FIGURE 1-6. LUBRICATION MENU

SYSTEM TROUBLESHOOTING CHART
If the following procedures do not correct the problem, contact a factory authorized service center.
TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

Lube system is not grounded. Correct grounding connections to pump
assembly and truck chassis.
Electrical power loss. Locate cause of power loss and repair. 24
VDC power required. Ensure key switch is
ON.
Pump Does Not Operate Solenoid valve malfunction. Replace the solenoid valve assembly.
Relay malfunction. Replace relay.
Motor or pump malfunction. Repair or replace motor and/or pump
assembly. (Refer to shop manual for
rebuild instructions.)
Low lubricant supply Dirt in reservoir, pump inlet clogged, filter
Pump Will Not Prime clogged.
Trapped air in lubricant supply line. Prime system to remove trapped air.
Lubricant supply line is leaking. Check lines and connections to repair
Pump Will Not Build leakage.
Pressure Vent valve is leaking. Clean or replace vent valve.
Pump is worn or scored. Repair or replace pump assembly. (Refer
to shop manual for rebuild instructions.)
NOTE: Normally, during operation, the injector indicator stem will move into the
body of the injector when pressure builds properly. When the system vents
(pressure release) the indicator stem will again move out into the adjusting yoke.
Malfunctioning injector - Usually Replace individual injector assembly.
Injector Indicator Stem indicated by the pump building
Does Not Operate pressure and then venting.
All injectors inoperative - Service and/or replace pump assembly.
Pump build up not sufficient to cycle (Refer to shop manual for rebuild instruc-
injectors. tions.)
No system pressure to pump motor. Check hydraulic hose from steering
system.
Pressure Gauge Does Not No 24 VDC signal at pump sole- Determine problem in 24 VDC electric
Register Pressure noid. system.
(pressure gauge not
Pressure reducing valve setting is Refer to “Pressure Control Valve
included with pump)
too low. Adjustment”.
24V Relay may be defective. Replace relay.

TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
Pump Pressure Builds No signal at solenoid. Check interface module.

Very Slowly Or Not At All
Bearing Points Injector output adjustment setting is Readjust to lower setting.

Excessively Lubricated too high.
Timer/controller cycle time setting is Set to longer cycle time or reevaluate lube
too low. requirements.
Injector output adjustment setting is Readjust injector output setting.

too low.
Bearing Points Are Not

Sufficiently Lubricated
Timer/controller cycle time setting Set to shorter cycle time or reevaluate
does not deliver lubricant often lube requirements.
enough.
System is too large for pump output. Calculate system requirements per
planning manual.

NOTES

COMPONENT CODE 88
PARTS & SERVICE REF NO. AA18054

DATE July 24, 2018
NEWS Page 1 of 4
SUBJECT: FAULT CODE-BASED TROUBLESHOOTING GUIDE FOR AUTOMATIC

LUBRICATION SYSTEM WITH INTERFACE MODULE CONTROL
PURPOSE: To provide the field with a troubleshooting guide for automatic lubrication sys-
tems with interface module (IM) control based on fault codes.
APPLICATION: Komatsu Electric Drive Dump Trucks:
730E-8: A40018 & Up;
830E-1AC: A40939 & Up;
830E-1AT: A40988 & Up;
830E-5: A50005 & Up;
860E-1KT: A30087 & Up;
860E-1K: A30101 & Up;
930E-4: A31832 & Up;
930E-4AT: A31884 & Up;
930E-4SE: A31875 & Up;
930E-5: A40004 & Up;
960E-2: A30084 & Up;
960E-2KT: A50074 & Up;
980E-4: A40003 & Up;
980E-4AT: A40083 & Up
FAILURE CODE: 8800MA
DESCRIPTION:
The following is a troubleshooting guide for the automatic lubrication system based on possible fault
codes. See AA17027 for troubleshooting information on previous trucks.
AA18054
Page 2 of 4
TABLE 1: AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING

Fault Code Description Possible Condition Possible Cause Corrective Action
Repair electrical fault and
No power to check fuse.
solenoid valve
Refer to electrical schematic.
Check hydraulic supply for
proper pressure and flow and
repair as necessary.
Hydraulic supply pressure may

Auto lube control has
be checked at steering
detected an incomplete
No or insufficient manifold as grease pump is fed
lube cycle
hydraulic fluid flow from hydraulic steering circuit.
or pressure If accompanied by low
Code occurs when lube
Grease pump does not pressure steering fault,
A190 cycle is terminated by
run. troubleshooting steering
timeout rather than
system.
pressure. Resets when a
lube cycle is properly Check return line for
terminated by pressure obstructions and clear if
rather than timeout. necessary.
Faulty solenoid
Replace solenoid valve.
valve
Grease pump is
stalled due to grease Check vent valve.
back pressure.
Dismantle pump and repair
Grease pump is
defective or seized component
seized or damaged.
or replace pump.
AA18054
Page 3 of 4
Follow Auto Lube Checkout
Low or empty
procedure to fill reservoir and
grease reservoir
purge system of air.
Check hydraulic supply for
proper pressure and flow and
repair as necessary.
Hydraulic supply pressure may

be checked at steering
Insufficient manifold as grease pump is fed
hydraulic fluid flow from hydraulic steering circuit.
or pressure If accompanied by low
pressure steering fault,
troubleshoot steering system.
Check return line for
obstructions and clear if
necessary.
Follow Auto Lube Checkout
Air trapped in
Grease pump runs but procedure to purge system of
grease system
does not build pressure air.
to 18 615-24 132 kPa Leak at grease
(2700-3500 psi). Identify leaky components and
pump, supply lines,
repair or replace.
or injectors
A190 Grease vent valve is

not staying closed Clean or replace orifice fitting
due to insufficient at pump manifold.
pressure.
Grease vent valve
Repair vent valve or remove
damage or
contamination.
contamination
Grease pump tube
malfunction
Grease pump Service grease pump assembly.
pistons or checks
are worn.
Faulty inlet or
discharge check
Replace faulty components.
valve in grease
pump
Replace grease pressure
switch.
Pump runs and builds Grease pressure Repair electrical fault and
grease line pressure to switch circuit faulty check fuse.
18 615-24 132 kPa
(2700-3500 psi). Refer to electrical schematic.
Grease line Check grease lines and clear
obstruction any obstruction.
AA18054
Page 4 of 4
Low auto lube grease level
is detected.
Code occurs when input

switch indicates low
grease level for 3 seconds. If this fault code is present, an aftermarket low grease level sensing system has
A304 Resets when input switch been installed. Refer to the aftermarket system supplier for troubleshooting
indicates normal grease information.
level for 3 seconds.
NOTE: A low auto lube

grease level switch is not
available from Komatsu.
Replace grease pressure
switch.
Grease pump runs Grease pressure Repair electrical fault and
during an IM initiated switch circuit faulty check fuse.
Auto lube circuit is lube event and shuts
defective. down when it is Refer to electrical schematic.
terminated by IM. Grease pump does
Code occurs when not unload grease Check vent valve.
solenoid sense occurs with circuit pressure.
lube output off, or does not Faulty solenoid Check valve function and
occur with lube output on,
Grease pump continues valve replace if necessary.
or pressure switch stays
A305 to run after lube event Hydraulic inlet Install hydraulic inlet orifice
on, or circuit is open or
is terminated by IM. orifice disc not disc (Refer to AA17114 for
short to ground, any of
those for 5 seconds with installed further instruction)
control power on, or if Repair electrical fault and
Grease pump runs
grease line pressure Faulty solenoid check fuse.
when not initiated by
persists for 30 seconds circuit
IM.
after output off. Resets at Refer to electrical schematic.
power down. Replace solenoid valve.
Grease pump does not Faulty solenoid Repair electrical fault and
run. circuit check fuse.
Refer to electrical schematic.

Overload on output 1T Remove valves and flush pump
Stuck solenoid
manifold. If fault persists,
valve
Code occurs when IM replace solenoid valve.
detects over current or Grease pump does not
A361 Auto lube circuit Repair electrical fault and
over temp on output 1T. run.
Output is turned off when short to ground, check fuse.
overload is detected. overload, or open
Resets at power down. load Refer to electrical schematic.
AA18054
AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
1. Keep A/C components sealed until prepared to e. Charge system with 3.5 kg (7.4 lbs) of 134a
charge system. The RPAG oil in compressor refrigerant.
and desiccant in receiver-drier both attract
f. Observe pressures and check for leaks.
moisture. Leaving components open will
contaminate the system. g. Set the fan on low speed and temperature
2. At field erection the following steps need to be setting on maximum. Observe cab vent
taken to make A/C system operational. outlet temperatures.
h. Check evaporator condensation drain line to
a. Add 250 ml (8.3 oz) of PC2279 PAG
see if water is draining properly.
lubricant to intle side of accumulator.
3. Refer to Shop Manual for recommended
b. Connect all hoses and components for A/C
pressures, temperatures and troubleshooting
system.
guide.
NOTE: Lubricate O-rings before assembly with 4. If checking or refilling of compressor oil is
mineral oil. required, drain and refill with 300 ml (10.1 oz) of
c. Evacuate system down to minimum of 737 PC2279 PAG oil.
mm (29 in) Hg for a minimum of 45 minutes.
d. Shut off vacuum pump and observe gauges.
System should hold a minimum vacuum of
711 mm (28 in) Hg for 15 minutes. If vacuum
does not hold, find and repair leak. Repeat
Step c.
EM4003-2 Air Conditioning System Checkout Procedure 1

NOTES
2 Air Conditioning System Checkout Procedure EM4003-2

PAYLOAD METER IV CHECKOUT PROCEDURE
This procedure is used to checkout the Payload 5. In the auxiliary cabinet, check the controller
Meter IV (PLM IV) installation. input voltage between circuit 39G and 0
(ground). This voltage should nominally be
Necessary Equipment: 24VDC from the batteries.
1. Vehicle Electrical Wiring Diagram 6. Turn ON the Key Switch. Verify Payload screen
2. 58B-06-03100 - 3.0kΩ, ±1%, 1W resistor available on the Electronic Dash Display (EDD).
The payload meter defaults to 730E. Verify
structures (Qty. 4)
truck type by connecting to PLM IV Home Page,
3. Laptop computer refer Appendix A.
4. Cat5e Ethernet cable 7. In the auxiliary cabinet, check the sensor supply
5. Empty USB 2.0 Flash Drive (1 GB to 4 GB) voltage between circuit 39F and 0 (ground). The
6. 58B-06-0260X - Latest PLM IV application voltage should be 18VDC ±1VDC.
code, where 'X' is the latest version 8. Return to the cab and check the Electronic
7. Voltmeter Dash Display (EDD) main screen. With the 58B-
06-03100 resistors attached at the sensor
Install the Application Code: locations, the payload should be 0.
Before the payload meter can be checked, the latest NOTE: For trucks with Electronic Dash Displays,
application code must be installed. To download the values can be viewed on the Electronic Dash Display
latest application code, go to the Komatsu America "PAYLOAD DATA" screen.
Extranet:https://www.komatsuamerica.net/
NOTE: Payload units on EDD could be configured by
northamerica/.
navigating "CONFIGURE SYSTEM" screen. Refer to
To configure the laptop computer for communication "Digital Display Operation” section of truck operator
with PLM IV, please refer to Appendix A - Guide to manual for details.
Connect to Payload Meter IV. For details on the 9. IMPORTANT NOTE: Configuring PLM IV on a
application code, refer to Appendix B - Installing truck with Komatsu Electronic Dash Display
Payload Meter IV Software via USB. then continue to below step. Else if configuring
PLM IV on truck with analog speedometer or
General Instructions:
non-Electronic Dash Display then refer
1. Attach one 58B-06-03100 Resistor Structure in Appendix C before continuing below step.
place of the left-front suspension pressure
10. With the Ethernet cable connecting a laptop to
sensor. 58B-06-03100 acts as a suspension
the payload meter, log into the PLM IV home
pressure test load between circuit 39F and
page. Please refer to "Appendix A - Guide to
circuit 39FD.
connect to PLM IV" for more details to complete
2. Attach one 58B-06-03100 Resistor Structure in this step.
place of the right-front suspension pressure
sensor. 58B-06-03100 acts as a suspension • Real Time Data display
pressure test load between circuit 39F and • Configuration Options
circuit 39FC.
• Payload Data View
3. Attach one 58B-06-03100 Resistor Structure in
place of the left-rear suspension pressure • Payload Data Download
sensor. 58B-06-03100 acts as a suspension • Alarm Data View
• Alarm Data Download
circuit 39FB.
4. Attach one 58B-06-03100 Resistor Structure in
place of the right-rear suspension pressure
sensor. 58B-06-03100 acts as a suspension
circuit 39FA.
58B-06-02400 3/17 Payload Meter IV Checkout Procedure 1

11. Click on the "System Configurations" link to edit c. Operator Display Unit
the truck model, inclinometer position, units,
• Short Tons: Payload is displayed in short tons,
date and time, and other configurations. These
distance and speed are displayed in miles.
configurations are permanently saved. There
are eight configuration parameters on this page. • Metric Tons: Payload is displayed in metric tons,
Each critical configuration requires a password, distance and speed are displayed in kilometers
"Kac2300", in order to save the setting. For • Long Tons: Payload is displayed in long tons,
each of the following configurations, save the distance and speed are displayed in miles
appropriate option according to the truck d. Web page Pressure Units
installation:
Suspension pressure sensor values
a. Truck Model
displayed on Real Time Data Service screen
There are more than 20 different truck are only for observation. Selecting kg/cm2
models available for selection. The correct sets the pressure values in metric units.
truck model must be selected for the payload Selecting psi will set the pressure values in
meter to accurately estimate payloads. pound per square inch. (1 kg/cm2 = 14.22
psi)
b. PLM IV Mounting Orientation (For onboard
Inclinometers) e. Date and Time
It is important to configure the payload meter The current payload meter time is shown on
according its mounting position in the the Real Time Data Service page. It is
auxiliary control cabinet. Refer to the image important to set correct Date and Time
below for configuring the positions inside the information if the truck does not have a
auxiliary cabinet. Match the wall that the Komtrax Plus. If the truck is equipped with a
payload meter is mounted to the number of Komtrax Plus, it will automatically update the
the wall in the image. payload meter date and time when powered
on. The payload meter will hold a date and
time for approximately 30 days without
power. If the date and time is lost, set the
current information and keep the system
powered on to recharge the clock power
supply.
f. Payload Load Light Test
This setting is used to test the payload load
lamps and their wiring. Refer "Validating
Payload Lights" instructions test case.
g. Payload Gain Factor
85702
FIGURE 1-1. PLM IV MOUNTING ORIENTATION

1. Position (1) 3. Position (3)
2. Position (2) 4. Position (4)
DO NOT modify unless required. Default payload
gain factor is 100%, but the setting is adjustable
between 90% and 110%. It is highly advised NOT
to change the default payload gain value, as this
change will affect all payload calculations.
2 Payload Meter IV Checkout Procedure 3/17 58B-06-02400

h. Truck Tare Default b. Customer Unit Number - Most mining
operations assign a number to each piece of
equipment for quick identification. This
number or name can be entered in the
Customer Unit Number field. It is important to
enter the customer unit number. This number
DO NOT modify unless required. This option is one of the key fields used in off-truck
forces the payload meter to reset the Truck Tare databases. The field will hold up to 20 alpha-
to its default value. DO NOT use this function numeric characters. If no unique customer
UNLESS the payload meter state machine is number has been specified, enter the frame
locked up or has calculated an unusually low tare serial number.
value. Check the system for a SENSOR LOW c. Distributor - This field can hold the name of
PRESSURE alarm. the distributor that helped install the system.
12. In order to validate the Payload Load Lights, Komatsu also assigns a distributor number
make sure the brake lock is ON. The load lights to each distributor. This number is used on
can be set ON/OFF for five minutes in the all warranty claims. This distributor number
"System Configurations" webpage. After five can also be entered into this field. This
minutes, the lights will return to their default number is one of the key fields used in off-
state. Test the following scenarios: truck databases. The field will hold up to 20
alpha-numeric characters. If the distributor is
a. Green Light ON, Amber Light OFF, Red Light not known, enter "UNKNOWN".
OFF. Confirm that only the green payload
lights on the truck are illuminated. d. Customer Name - This field can hold the
name of the mine or operation where the
b. Green Light OFF, Amber Light ON, Red Light truck is in service. Komatsu also assigns a
OFF. Confirm that only the amber payload customer number to each customer. This
lights on the truck are illuminated. number is used on all warranty claims. This
c. Green Light OFF, Amber Light OFF, Red customer number can also be entered into
Light ON. Confirm that only the red payload this field. This number is one of the key fields
lights on the truck are illuminated. used in off-truck databases. The field will
hold up to 20 alpha-numeric characters. If
d. Green Light OFF, Amber Light OFF, Red
the customer is not known, enter
Light OFF. Confirm that all payload lights on
"UNKNOWN".
the truck are off.
e. Enter the password "Kac2300" to allow
13. Return to the PLM IV home page.
saving of the inputted data.
14. Click on the "Truck Data Configuration" link to
f. Click "SaveTruckData" button to save the
set the frame serial number, customer unit
information permanently.
number, distributor, and customer. In addition,
the Software Version Number can be verified. 15. On the "Truck Data Configuration" page, record
Enter all of the following information, then save the current PLM software version. This
them by entering the password "Kac2300" information should match the installed
application.
a. Frame Serial Number - The frame serial
number is located on a plate mounted to the 16. Return to the PLM IV home page.
truck frame. The plate is outboard on the
lower right rail facing the right front tire. It is
important to enter the correct frame serial
number as this number is a key field in off-
truck databases. The field will hold up to 20
alpha-numeric characters.

17. Click on the "Real Time Data Service" link. This 18. On the PC, return to PLM IV home screen.
web page displays the current PLM IV I/O
19. Remove the Resistor Structure (58B-06-03100)
status. This data is refreshed once a second.
from the left front suspension pressure sensor
a. The weight shown on the real time data location.
screen is the sprung weight and includes the
20. Wait at least one minute then remove the 58B-
weight of the truck. Given the suspension
06-03100 Resistor Structure from the left-rear
pressure dummy loads, the nominal value
suspension pressure sensor location.
shown should be 113 metric tons (125 short
tons). 21. Wait at least one minute then remove the 58B-
06-03100 Resistor Structure from the right-rear
b. Confirm that all suspension pressures are
suspension pressure sensor location.
within range. The nominal value should be
25.6 kg/cm2 (364 psi). Values between 19.2 22. Wait at least one minute then remove the 58B-
and 32 kg/cm2 (273 psi and 455 psi) are 06-03100 Resistor Structure from the right-front
acceptable. Record the values displayed. suspension pressure sensor location.
c. Confirm that the inclinometer is within range 23. Wait at least one minute.
and record the value. 24. From PLM IV home screen, select the "View
d. Confirm that the Body Up input is working Alarms" link to view alarms list.
correctly. Place a steel washer on the body 25. All 'Active Alarms' will be saved within five
up switch. The real time data screen should seconds. Confirm that the four alarms displayed
indicate "OFF". Remove the washer and the occurred in the proper order:
real time data screen should indicate "ON".
• Left-front suspension low
e. Confirm that the Brake Lock input is working
correctly. Turn the Brake Lock ON using the • Left-rear suspension low
switch on the dashboard. The real time data • Right-rear suspension low
screen should indicate "ON". Turn the Brake
• Right-front suspension low
Lock OFF. The real time data screen should
indicate "OFF". 26. Turn the key switch OFF, close all screens, and
disconnect the laptop from the payload meter
f. Simulate a 25 MPH (40.2 km/h) speed
system.
signal. Confirm that this value is displayed by
Electronic Dash Display and the web page
real time data screen. The value can be ±1
MPH (±2 km/h). The brake lock must be off
for the PLM IV to recognize speed input.

Appendix A 1. Right Click on the Wired Connection icon in the
bottom right corner.
Guide to Connect to Payload Meter IV
2. Click on "Open Network and Sharing Center."
PLM IV can be connected to a PC via a Cat5e cable 3. On the Network and Sharing Center window,
connection to the Ethernet port on the payload meter click on "Change adapter settings" on the left
communication board or at the Ethernet PC port in hand bar.
the cab. However, this Ethernet port can be
4. On the computer's Wired Connection Device,
connected to a wireless radio on the truck if a
right click on "Local Area Connection".
wireless option connection is available.
a. If using wireless, right click on "Wireless
Once connected, any web browser such as Internet Network Connection".
Explorer, Google Chrome, etc. can be used to
access the webserver. The PC's IP address MUST 5. Click on "Properties"
be configured within the same network range as the 6. Click on "Internet Protocol Version 4 (TCP/IPv4)
payload meter. to highlight the option.
1. Set PC's IP Address to a static IP (See Steps 7. Click on "Properties."
Below: "Configuring a PC's Static IP Address"). 8. Select the dot for "Use the following IP
2. Open Internet Explorer on PC. address:"
3. Enter the IP Address of PLM IV into the Internet 9. Fill in the following network settings within
Explorer address bar - Enter 192.168.0.128 range of the PLM IV's IP address:
4. At the PLM IV login screen, enter username • IP Address: 192.168.3.123
"plm" and password "pass". • Subnet Mask: 255.255.255.0
5. Click "Connect".
10. Click "OK".
Configuring a PC's Static IP Address 11. Click "OK".
For a wired or wireless connection, a static IP NOTE: To return the PC's network card to normal
address of the PC is required to allow connectivity. To operation, follow steps 1 through 7, but select
do this, follow the steps below and refer to Figure A “Obtain an IP address automatically”.
for help. These instructions were created using
Figure 1-2, “CONFIGURING A PC'S STATIC IP
Windows 7, but the process is similar for other
ADDRESS page 6 numbers correspond to steps on
operating systems.
Appendix A.

FIGURE 1-2. CONFIGURING A PC'S STATIC IP ADDRESS

Appendix B 6. On the home page, click the "Start Flash
Program" link.
Installing Payload Meter IV Truck Application
7. On the next webpage, click "Program Now".
Software via USB
This will start installing the application code.
1. Insert an empty USB flash drive into your laptop This process may up to 10 minutes to complete.
computer. Format the USB drive to FAT32 by
right clicking on the mounted drive and
selecting "Format".
2. Copy the released software image to the USB
drive. The file name should follow the format
58B-06-0260X.S19, where 'X' represents the During this process, DO NOT TURN OFF OR DIS-
latest revision. The released software image CONNECT POWER
should be the only file on the drive. 8. The webpage will periodically update with a
3. Insert the USB flash drive with the software completion percentage such as 5%, 10% 15%,
image into either of the two USB ports on the etc. These completion percentages may not
PLM IV communication board inside the always be visible. The software update is
auxiliary cabinet. Refer to Figure B for complete when you see "Flash Program
assistance locating. Progress 100%: Reboot PLM IV".
4. Turn the truck's Key Switch ON. 9. After observing "Reboot PLM IV" message,
5. Make sure your laptop is properly set up to reboot PLM IV by turning the Key Switch OFF,
communicate to the payload meter. If not yet waiting 10 seconds, and turning key switch
completed, follow the steps in Appendix A. Log back ON. The latest software installation is
into the PLM IV's home page. complete.
FIGURE 1-3. PLM IV COMMUNICATION MODULE

1. 10/100 Mbps Ethernet RJ45 Connector
2. LEDs
3. USB 2.0 Type A Connectors

Appendix C NOTE: The inclinometer displays whole degrees of
incline. Positive incline is truck nose up.
Configuring PLM IV on truck with analog speed-
ometer or Trucks with no Electronic Dash Dis- NOTE: The gauge will quickly display the type of
play. information being displayed every one minute. For
example, if the left-front pressure is being displayed,
1. Turn ON the Key Switch. The analog "Lf=" will quickly display every minute. Only the
speedometer/display gauge on the dashboard payload display, "pl=" does not display this
will scroll the truck type across the lower information.
display. The payload meter defaults to 730E.
4. Press and hold the 'SELECT' button on the
2. In the auxiliary control cabinet, check the dashboard. "id=" will be displayed. Release the
sensor supply voltage between circuit 39F and button and the operator id will be displayed.
0 (ground). This voltage should be 18VDC This value should be 0.
±1VDC.
3. Return to the cab and check the speedometer/ dashboard. "tl=" will be displayed. Release the
display gauge. The gauge will display the button and the total tons will be displayed. This
current payload. With the 58B-06-03100 value should be 0.
resistors attached at the sensor locations, the
payload should be 0.
dashboard. "l(" will be displayed. Release the
NOTE: For trucks with the analog speedometer button and the number of loads will be
gauge, the display can be used to quickly show the displayed. This value should be 0.
current readings from the four suspension pressure 7. Press and hold the 'SELECT' button on the
sensors and the inclinometer. This can be used dashboard. "lf=" will be displayed. Release the
during regularly scheduled service periods to check button and the left-front pressure will be
the state of the suspensions. These displays are live displayed. This value should be in metric units.
and will update as the values change. The nominal value should be 25.6 kg/cm2 (364
a. The display is changed by pressing the psi). Values between 19.2 and 32 kg/cm2 (273
'SELECT' button on the dashboard. The psi and 455 psi) are acceptable.
sequence of displays is: 8. Press and hold the 'SELECT' button on the
b. Pl= Payload dashboard. "rf=" will be displayed. Release the
button and the right-front pressure will be
c. id= Operator ID displayed. This value should be in metric units.
d. tl= Total Shift Tons The nominal value should be 25.6 kg/cm2 (364
psi). Values between 19.2 and 32 kg/cm2 (273
e. l(= Shift Load Counter
psi and 455 psi) are acceptable.
f. lF= Left Front Suspension Pressure 9. Press and hold the 'SELECT' button on the
g. rF= Right Front Suspension Pressure dashboard. "lr=" will be displayed. Release the
button and the left-rear pressure will be
h. lrr= Left Rear Suspension Pressure
displayed. This value should be in metric units.
i. rr= Right Rear Suspension Pressure The nominal value should be 25.6 kg/cm2 (364
j. in= Inclinometer psi). Values between 19.2 and 32 kg/cm2 (273
psi and 455 psi) are acceptable.
NOTE: The live displays cannot be cleared and the
SET button will have no effect.
dashboard. "rr=" will be displayed. Release the
NOTE: The units for the display are controlled by the button and the right-rear pressure will be
configuration of the payload meter. The payload displayed. This value should be in metric units.
meter defaults to display metric units, the pressures The nominal value should be 25.6 kg/cm2 (364
will be displayed in tenths of kg/cm2. For example, if psi). Values between 19.2 and 32 kg/cm2 (273
the display shows "202" the actual value is 20.2 kg/ psi and 455 psi) are acceptable.
cm2. If the payload meter is set to display short tons,
the pressures will be displayed in psi (lbs/in2). To
dashboard. "pl=" will be displayed. Release the
convert from kg/cm2 to psi, multiply by 14.2233.
button and the current payload will be
14.2233 psi (lbs/in2) = 1 kg/cm2.
displayed.

dashboard. "in=" will be displayed. Release the
button and the inclinometer value will be
displayed. This value is in degrees. The incline
will depend on how the truck is set during
assembly. Values between ±3° are acceptable.
Return back to step accessing PLM IV dynamic
webserver Home Page using CAT5e Ethernet Cable.

Payload Meter IV Checkout Procedure Confirmation
Value Initial
PLM Software Version: _______________ ___________
User switch and display works properly (Non-EDD truck) ___________
Electronic Dash Display Payload Screen works (EDD truck) ___________
Left-Front Pressure: _________________ ___________
Right-Front Pressure: ________________ ___________
Left-Rear Pressure: _________________ ___________
Right-Rear Pressure: ________________ ___________
Inclinometer: ______________________ ___________
Green light works properly ___________
Amber light works properly ___________
Red light works properly ___________
Brake Lock input works properly ___________
Body Up input works properly ___________
Speed input works properly ___________
Date: _______________________
Truck: ________________________
By: ______________________________________

KOMTRAX PLUS 2 SHOP SETUP PROCEDURE
Purpose Ethernet connection to Komtrax Plus 2
This procedure is used to setup the KOMTRAX Plus
Controller:
2 System with optional Iridium communication. The steps in this section need to be completed each
time a PC tool is used to setup, administrate, or
Necessary Equipment download a Komtrax Plus 2 controller.
1. Laptop with Komtrax Plus 2 PC tools installed. 1. Open Network and Sharing center on laptop,
2. Ethernet cable disable windows firewall or ask IT department to
add a permanent exception for all Komtrax Plus
Steps to Complete: 2 PC tools.
1. Establish Ethernet connection to Komtrax Plus 2. Disconnect laptop from all other network
2 controller. connections including Wi-Fi.
2. Komtrax Plus 2 configuration 3. Key on truck. Wait three minutes for the
3. Iridium Satellite system modem check (if truck Komtrax Plus 2 to boot.
is equipped) 4. Connect one end of Ethernet cable to laptop
4. Data Download (optional but recommended) and the other to the PC Ethernet port located on
the back wall of the cab. Komtrax Plus 2 uses
DHCP so the laptop is automatically assigned
an IP address.
FIGURE 1-1.
58F-06-05240 KOMTRAX Plus 2 Site Setup Procedure 1

5. <Optional> Open a command prompt to ping unsuccessful trouble shooting ethernet
192.168.3.20. A successful ping verifies that the connection.
laptop can communicate with Komtrax Plus 2,
continue with setup or administration. If ping is
FIGURE 1-2.
Komtrax Plus 2:
The purpose of this section is to populate required
parameters as well as confirm that the controller is
functioning properly prior to shipping.
1. Key on truck and wait for three minutes.
2. Open Initial Configuration PC tool.
3. Click "Plant Configuration" on the main menu.
FIGURE 1-3.
2 KOMTRAX Plus 2 Shop Setup Procedure 58F-06-05240

4. Click "KOMTRAX Plus Configuration" on plant 5. After clicking "KOMTRAX Plus Configuration", a
configuration menu. dialog box will open as the PC tool searches for
Komtrax Plus 2 controllers on the local area
network. When complete, available controller
will be shown. Double click target controller.
"Komtrax Plus configuration" page will open. If
no controller is found see previous section
"Ethernet connection to Komtrax Plus 2
controller".
FIGURE 1-4.

FIGURE 1-5.
6. Populate the "Machine1" tab.

• Software
• Machine model as shown on nameplate (ex:
830E-5)
• Machine serial number
7. Select the "Machine2" tab.
• Engine serial number
• Component serial number (usually blank)
FIGURE 1-6.

8. Click "Apply". Status window will be displayed, 10. Click "Back" to complete factory portion of initial
changes will take three minutes. configuration.
Iridium Modem Connection Test:

The purpose of this section is to verify that Komtrax
Plus 2 can communicate with the Iridium satellite
system over the J1939 CAN network. Iridium is
standard with the option to remove, it will not be
present on all trucks.
1. Verify that Iridium modem is installed. Skip this
section if customer has elected to remove
Iridium system.
2. Establish ethernet connection to Komtrax Plus
2.
4. Click "Plant Configuration" on the main menu.
FIGURE 1-8.
9. Click "Next" to review changes.

5. Click "KOMTRAX Configuration" on plant 6. After clicking "KOMTRAX Configuration", a
"Komtrax Configuration" menu will open. If no
controller is found see above section "Ethernet
connection to Komtrax Plus 2 controller".

FIGURE 1-12.

7. Click "Check" to begin modem test.
FIGURE 1-13.
8. One of two screens will be displayed. Example

of success shown on left. Failure shown on
right. In the event of failure, problem must be
corrected before the truck leaves the factory.
FIGURE 1-14.

Data Download Over Ethernet Connection: 3. Tool will automatically download if more than 12
hours has passed since the previous download.
Downloading data from the Komtrax Plus 2 controller
Click "Download" button to force a download.
immediately after setup can help identify
configuration problems and assist with 4. Click "View Files" for a link to the location where
troubleshooting. It is recommended but not required. the download is stored.
1. Establish ethernet connection to Komtrax Plus 5. Open Data Conversion PC Tool.
2. 6. Select folder with data from the download tool.
2. Open Data Collection PC Tool. Plus_Binary contains the files to be converted.
FIGURE 1-15.

7. Select binary files from target machine. They
will have the *.K extension.
FIGURE 1-16.
8. Click "Convert". Success dialog box will appear. 9. Click "View Files". Data is organized by truck
Click "OK". model and serial number and date.
FIGURE 1-17.
10. After conversion files are available for analysis.

Please use the files in the
Rate_Calendar_Alignment folder for human
readable date and time stamps.

KOMTRAX PLUS 2 SITE SETUP PROCEDURE
Purpose Ethernet connection to Komtrax Plus 2
This procedure is used to check the KOMTRAX Plus
controller
2 System with optional Iridium communication. The steps in this section need to be completed each
time a PC tool is used to setup, administrate, or
Necessary Equipment download a Komtrax Plus 2 controller.
1. Laptop with Komtrax Plus 2 PC tools installed. 1. Open Network and Sharing center on laptop,
2. Ethernet cable disable windows firewall or ask IT department to
add a permanent exception for all Komtrax Plus
Steps to Complete 2 PC tools.
1. Establish Ethernet connection to Komtrax Plus 2. Disconnect laptop from all other network
2 controller. connections including Wi-Fi.
2. Komtrax Plus 2 configuration 3. Key on truck. Wait three minutes for the
3. Global Positioning System (GPS) test Komtrax Plus 2 to boot.
4. Iridium Satellite system modem check (if truck 4. Connect one end of Ethernet cable to laptop
is equipped) and the other to the PC Ethernet port located on
the back wall of the cab. Komtrax Plus 2 uses
5. Data Download (optional but recommended) DHCP so the laptop is automatically assigned
6. 6.Refer to KWB setup and check out document an IP address.
if installing wireless connectivity. Prior steps are
a prerequisite to wireless setup.
FIGURE 1-1.

5. <Optional> Open a command prompt to ping unsuccessful trouble shooting ethernet
192.168.3.20. A successful ping verifies that the connection.
laptop can communicate with Komtrax Plus 2,
continue with setup or administration. If ping is
FIGURE 1-2.
Komtrax Plus 2 Configuration

This section of the setup is intended to be completed
when the truck is checked out at the customer's site.
The purpose is to populate site specific information.
1. Key on truck and wait for three minutes.
3. Click "Destination Configuration" on the main
menu.
FIGURE 1-3.
2 KOMTRAX Plus 2 Site Setup Procedure 58F-06-05250

4. Click "KOMTRAX Plus Configuration" on plant 5. After clicking "KOMTRAX Plus Configuration", a
"Komtrax Plus configuration" page will open. If
no controller is found, see previous section
"Ethernet connection to Komtrax Plus 2
controller".
FIGURE 1-4.

FIGURE 1-5.
6. Select the "Calendar" tab.

• Set time zone.
• Click daylight saving time if currently being
observed.
FIGURE 1-6.

7. Select "Unit Number" tab and enter unit 9. Click "Next" to review changes.
number. This is the customer assigned
designation for the truck.
FIGURE 1-9.
FIGURE 1-7. 10. Click "Back" to complete site portion of initial

configuration.
8. Click "Apply". Status window will be displayed,
changes will take three minutes. GPS Test
This test must be completed outside with an
unobstructed view of the sky. The purpose is to verify
the GPS system is working properly.
1. Park truck away from buildings or anything that
obstructs a clear view of the sky. Key on truck
and wait five minutes for Komtrax Plus 2 to
acquire GPS satellites.
2. Establish ethernet connection between laptop
and Komtrax Plus 2.
4. Click "Destination Configuration" on the main
menu.
5. Click "GPS Test".
6. After clicking "GPS Test", a dialog box will open
as the PC tool searches for Komtrax Plus 2
controllers on the local area network. When
complete, available controller will be shown.
Double click target controller. GPS test screen
will open. If no controller is found see above
FIGURE 1-8.
section "Ethernet connection to Komtrax Plus 2
controller".

FIGURE 1-10.
7. The dialog box on the left below is an example

of successfully receiving GPS signal. The box
on the right is a failed attempt. In the event of a
failure, click back, check connections and
antenna, then retest. If successful click back to
complete the test.

FIGURE 1-11.
Iridium Satellite System Opening 2. Park truck away from buildings or anything that
obstructs a clear view of the sky. Key on truck
This procedure must be completed outside with an
and wait five minutes for Komtrax Plus 2 to
unobstructed view of the sky. The purpose is to verify
acquire GPS and Iridium satellites.
the Iridium system is working properly and start
communication. 3. Establish ethernet connection between laptop
and Komtrax Plus 2.
1. Verify that Iridium modem is installed. Skip this
section if customer has elected to remove 4. Open Initial Configuration PC tool.
Iridium system. 5. Click "Destination Configuration" on the main
menu.

6. Click "KOMTRAX Configuration" on plant 10. Click "Ok". Return to the "Opening tab" Click
configuration menu. "Start" for the opening procedure.
7. Select "Opening" tab.
FIGURE 1-15.
FIGURE 1-13.
11. “Datum and Time Zone" menu will appear. Make
8. Make sure "with KOMTRAX Modem" radio changes if needed. Click "Start".
button is selected. Click "Start".
9. The following screen will appear. It may take
five to 10 minutes to complete. Any failure must
be investigated and corrected before moving on
to the next step.

12. The following menu will appear. Click "OK" to
complete Iridium satellite system setup.
FIGURE 1-16.
FIGURE 1-17.

Data Download Over Ethernet Connection 3. Tool will automatically download if more than 12
for Komtrax Plus 2 initialization hours has passed since the previous download.
Downloading data from the Komtrax Plus 2 controller Click "Download" button to force a download.
immediately after setup can help identify 4. Click "View Files" for a link to the location where
configuration problems and is required for the download is stored.
initialization. 5. Open Data Conversion PC Tool.
1. Establish ethernet connection to Komtrax Plus 6. Select folder with data from the download tool.
2. Plus_Binary contains the files to be converted.
2. Open Data Collection PC Tool.
FIGURE 1-18.

7. Select binary files from target machine. They
will have the *.K extension.
FIGURE 1-19.
8. Click "Convert". Success dialog box will appear. 9. Click "View Files". Data is organized by truck
Click "OK". model and serial number and date.
FIGURE 1-20.
10. After conversion files are available for analysis. 11. <Important> Send binary file (*.K) from step 7,
Please use the files in the to komtrax@komatsuna.com to complete the
Rate_Calendar_Alignment folder for human Komtrax Plus initialization process.
readable date and time stamps.

NOTES

KOMVISION® CHECKOUT PROCEDURE
Necessary Equipment NOTE: After the System boots up the screen will
1. Truck is operable for forward and reverse change from the logo screen to a system running
movements to 10 mph with space to do so. screen. The standby indicator should be blinking on /
off with a dimly lit green color icon. This illumination
2. Level space area adequate for calibration tarps intensity is intended for dark conditions and may be
layout and procedure. The calibration tarps difficult to see in bright ambient light. Shade if
layout consumes 18 meters x 25 meters of area necessary to view blinking icon.
with the truck in the interior area.
2. Record the blinking icon exist during boot up
Recommended area would be about 30 meters
and the time in seconds it takes for the logo
x 35 meters of level area.
screen to change to the running screen.
3. Drawings for installation.
3. Enable maintenance mode by simultaneously
4. Shop manual. pushing the Monitor Display Mode Switch (6,
5. Calibration tarps from tool kit. Figure 1-2), Reference Line Display Switch (7)
and Lower Body Display Switch (8) for 3
STEP 1 - Settings seconds.
1. Turn key switch to "RUN" position. The Startup The password entry screen mode opens
Logo Screen (Figure 1-1) should display (Figure 1-3).
immediately. Record whether or not the logo
displays.
FIGURE 1-1.STARTUP LOGO SCREEN
58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 1

FIGURE 1-2.MONITOR PANEL
1. Monitor Display 6. Monitor Display Mode Switch

2. Brightness Switches 7. Reference Line Display Switch
3. System Power Status Indicator 8. Lower Body Display Switch
4. Force Display Switch 9. Object Clear Switch
5. Camera Switches
4. Enter Password “6491” and select “OK” to The first two lines of text on the main menu are the
access the maintenance mode system. part number (1) and the application version number
(2).
The system enters maintenance mode and the
main menu (Figure 1-4) opens. 5. Record the Program part number and
Application number..
2 1
85119
FIGURE 1-3.PASSWORD MODE ENTRY FIGURE 1-4.MAIN MENU PROGRAM

1. Program Part Number
2. Application Number
2 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

6. Use the diagonal down right key (5,Figure 1-2)
to tab to the “MAIN SETTING” button. Use the
object clear switch (9) to select it.
The main setting input screen opens.(Figure 1-
5)
FIGURE 1-6.CAMERA POSITIONS
12. Set the following positions for camera 1 and

record the values (Figure 1-6) as needed:
a. Offset X
FIGURE 1-5.MAIN SETTING SCREEN b. Offset Y
c. Offset Z
7. Set the truck model using the diagonal down
right arrow (5, Figure 1-2) to move cursor d. Roll
location and the object clear switch (9) to select e. Pitch
entry.
f. Yaw
8. Tab to "SAVE" and select it.
When save is selected the defaults values for record the values as needed:
that truck model are saved.
a. Offset X
9. Tab to the Back button (Figure 1-5) and select
it. Verify the correct model is saved on the Main b. Offset Y
Menu. (Figure 1-4). c. Offset Z
10. Record the Machine Code Setting and all d. Roll
remaining data inputs (Figure 1-5).
e. Pitch
11. From the Main Menu select Camera Setting
(Figure 1-4). f. Yaw
The camera position page opens.(Figure 1-6) record the values as needed:
a. Offset X
b. Offset Y
c. Offset Z
d. Roll
e. Pitch
f. Yaw

15. Set the following positions for camera 4 and 18. Tab to 'SAVE' and select it.
record the values (Figure 1-6) as needed:
19. Return to the main menu (Figure 1-4) and then
a. Offset X back to camera positions window (Figure 1-6)
to confirm camera setting values where saved
b. Offset Y
correctly.
c. Offset Z
NOTE: See shop manual for value adjustments in
d. Roll case of non-standard adjusted relocations.
e. Pitch 20. From the Main Menu (Figure 1-4) tab to Radar
f. Yaw setting and select it.
16. Set the following positions for camera 5 and The Radar Setting screen opens.
record the values as needed:
a. Offset X
b. Offset Y
c. Offset Z
d. Roll
e. Pitch
f. Yaw
record the values as needed.
a. Offset X
b. Offset Y
FIGURE 1-7.RADAR AREA SCREEN
c. Offset Z
d. Roll 21. Record the following radar area screen settings
e. Pitch (Figure 1-7).
f. Yaw a. Outside Front value.
b. Outside Side value.

c. Offset Z
d. Roll
e. Pitch
f. Yaw
24. Set the following positions for Radar All
Positions 2 and record the values (Figure 1-8)
as needed:
a. Offset X
b. Offset Y
c. Offset Z
d. Roll
FIGURE 1-8.RADAR THRESHOLD SCREEN
e. Pitch
22. Record the following radar threshold screen f. Yaw
settings (Figure 1-8): 25. Set the following positions for Radar All
a. Radar 1 Power Setting. Positions 3 and record the values (Figure 1-8)
as needed:
b. Radar 2 Power Setting.
a. Offset X
c. Radar 3 Power Setting.
b. Offset Y
d. Radar 4 Power Setting.
c. Offset Z
e. Radar 5 Power Setting.
d. Roll
f. Radar 6 Power Setting.
e. Pitch
g. Radar 7 Power Setting.
f. Yaw
h. Radar 8 Power Setting.
as needed:
a. Offset X
b. Offset Y
c. Offset Z
d. Roll
e. Pitch
f. Yaw
as needed:
FIGURE 1-9.RADAR ALL POSITIONS SCREEN
a. Offset X
23. Set the following positions for Radar All position b. Offset Y
1 and record the values (Figure 1-8) as needed: c. Offset Z
a. Offset X d. Roll
b. Offset Y e. Pitch
f. Yaw

28. Set the following positions for Radar All NOTE: This requires the calibration mats to be laid
Positions 6 and record the values (Figure 1-8) accordingly around the machine on level ground. The
as needed: quickest is auto calibration which if successful will
a. Offset X complete automatically in several minutes.
However, the auto calibration is very sensitive to
b. Offset Y lighting conditions and surroundings. If the auto
c. Offset Z calibration fails the manual calibration will have to be
done. The manual calibration may take upwards to
d. Roll an hour.
e. Pitch 34. Record the calibration used.
f. Yaw a. Auto Calibration.
29. Set the following positions for Radar All b. Manual Calibration.
as needed: NOTE: After the successful calibration the Runtime
Screen should show with no errors. Troubleshoot and
a. Offset X
correct any errors per shop manual before
b. Offset Y continuing.
c. Offset Z 35. Verify all keys are illuminated by green lighting.
d. Roll 36. Verify all keys are illuminated by amber lighting
e. Pitch when in the depressed state.
f. Yaw 37. Verify radar function by having a person walk

around the machine in a 1 meter path of the
30. Set the following positions for Radar All calibration tarps. Confirm that the located target
Positions 8 and record the values (Figure 1-8) circle tracks properly and is consistent with
as needed: location. Record the following.
a. Offset X a. Radar target id follows person correctly.
b. Offset Y b. Smooth transition of the bird eye view.
c. Offset Z 38. Verify camera select by depressing the arrow
d. Roll keys (5, Figure 1-2) for each camera which
should in turn display the respective camera for
e. Pitch
that sector of the truck. Record the camera
f. Yaw select function for each camera.
31. Tab to 'SAVE' and select it. 39. Verify the following buttons function correctly:
32. Return to the main menu (Figure 1-4) and then a. Grid line
back to Radar position All window (Figure 1-9)
b. Body rear hide
to confirm Radar setting values where saved
correctly. c. Display mode
NOTE: See shop manual for value adjustments in 40. Verify the following buttons display mode bright
case of non-standard adjusted values required. and dim (2, Figure 1-2) function correctly:
33. Perform camera calibration per shop manual a. Grid line
procedures. b. body rear hide
c. display mode

41. Verify that when shift selector is placed in 47. Place the shift selector in the reverse position
reverse (“R”), the display changes to the rear (“R”). Get vehicle speed slightly above 15 mph.
camera view. Record findings. Record the following.
42. Place a target or have a person stand in the a. The speed traveling when the standby
front target zone of the truck. Place the shift screen is activated.
selector in the forward position (“F”) and verify
b. The screen goes back to active mode when
audible alarm sounds.
truck is coming to a stop.
43. Verify the alarm turns off when the shift selector
NOTE: If the Reverse vehicle speed was changed
is placed in the park (“P”) position.
from the default speed of 15mph in step 7.(Figure 1-
NOTE: Camera views should always be visible. 5) Speed slightly above setting will need to be
44. Place a target or have a person stand in the rear reached to activate the standby screen.
target zone of the truck. Place the shift selector 48. Verify no system errors exist. Record any
in the reverse position (“R”) and verify audible errors.
alarm sounds.
NOTE: System errors are displayed with a red icon
45. Verify the alarm turns off when the shift selector and alarm. Refer to shop manual fault log to clear
is placed in the neutral (“N”) position. any errors.
NOTE: Camera views should always be visible. 49. Perform the pre-shift KomVision® check
46. Place the shift selector in the forward position procedure per shop manual.
(“F”). Get vehicle speed slightly above 15 mph. 50. Record the following truck Information.
Record the following.
a. Truck Model Number.
a. Verify the speed traveling when the standby
screen is activated. b. Truck Serial Number.
b. Verify the screen goes back to active mode c. Person Name.

when truck is coming to a stop. d. Date completed.
NOTE: If the Forward vehicle speed was changed
from the default speed of 15mph in step 7.(Figure 1-
5) Speed slightly above setting will need to be
reached to activate the standby screen.

Settings
1 ________ (yes/no) Logo Screen displayed immediately.
2 ________ (yes/no) Blinking icon exists.
________ (seconds) Time it took for logo screen to change to running screen.
5 ________ Program part number.
________ Application number.

Main settings
10 ________ Setting for Machine code.
________ Setting for Offset.
________ Setting for Body Width.
________ Setting for Forward Option.
________ Setting for Rear wheel to end.
________ (yes/no) Diagonal Ladder LH.
________ (yes/no) Diagonal Ladder RH.
________ Forward Low-High speed
________ Reverse Low-High speed
________ Hysteresis.
________ Image Magnification Bird View.
________ (yes/no) Radar less option on box.

All Camera Positions
12 a _______ Camera 1 Offset X.
b. ______ Camera 1 Offset Y.
c. ______ Camera 1 Offset Z.
d. ______ Camera 1 Roll.
e. ______ Camera 1 Pitch.
f. ______ Camera 1 Yaw.

f. _______ Camera 4 Yaw.

Radar Area
21 a _______ Outside Front value.
b. ______ Outside Side value.

Radar Threshold
22 a. ______ Radar 1 Power Setting.
b. ______ Radar 2 Power Setting.
c._______ Radar 3 Power Setting.
d. ______ Radar 4 Power Setting.
e. ______ Radar 5 Power Setting.
f. ______ Radar 6 Power Setting.
g. ______ Radar 7 Power Setting.
h. ______ Radar 8 Power Setting.

Radar All Positions
23 a. ______ Position 1 Offset X.
b. ______ Position 1 Offset Y.
c._______ Position 1 Offset Z.
d. ______ Position 1 Roll.
e. ______ Position 1 Pitch.
f. ______ Position 1 Yaw.

b. _______ Position 3 Offset Y.
c. _______ Position 3 Offset Z.
f. _______ Position 3 Yaw.

34 a _______ Auto Calibration.
b _______ Manual Calibration.
35 ________ (yes/no) Verify all keys are Illuminated by green lighting.
36 ________ (yes/no) Verify all keys are Illuminated by amber lighting when
depressed.
37 a _______ (yes/no) Radar target id follows person correctly.
b _______ (yes/no) Smooth transition of the bird eye view.
38 a _______ (yes/no) Camera 1 select displays.
b _______ (yes/no) Camera 2 select displays.
c _______ (yes/no) Camera 3 select displays.
d _______ (yes/no) Camera 4 select displays.
e _______ (yes/no) Camera 5 select displays.
f _______ (yes/no) Camera 6 select displays.

39 a _______ (yes/no) Button function Grid line.
b. ______ (yes/no) Button function body rear hide.
c. ______ (yes/no) Button function display mode.
40 a _______ (yes/no) Display mode bright and dim Button function Grid line.
b. ______ (yes/no) Display mode bright and dim Button function body rear hide.
c. ______ (yes/no) Display mode bright and dim Button function display mode.
41 ________ (yes/no) The display changes to the rear camera view.
42 ________ (yes/no) audible alarm sounds.
43 ________ (yes/no) audible alarm turns off.
44 ________ (yes/no) audible alarm sounds.
45 ________ (yes/no) audible alarm turns off.
46 a _______ (Mph) The speed traveling when the standby screen is activated.
b _______ (yes/no) The screen goes back to active mode when truck is coming to
a stop.
47 a _______ (Mph) The speed traveling when the standby screen is activated.
b _______ (yes/no) The screen goes back to active mode when truck is coming to
a stop.
48 ________ (yes/no) System errors exist.
49 ________ (yes/no) The pre-shift KomVision® check completed.
51 a _______ Truck Model Number.
b _______ Truck Serial Number.
c _______ Person Name.
d _______ Date completed.

WIRELESS BRIDGE CHECKOUT PROCEDURE
Purpose Manufacturer: Ubiquiti Networks
This procedure is used to setup and check out Device: NanoStation M2
wireless communication to Komtrax Plus II and Part Number: NSM2
devices on the onboard local area network. It only QTY: At least one (1) per site
applies to EDTs with Komtrax Plus II, EDTs with
The Bullet and NanoStation devices are
Komtrax Plus 1/ VHMS require a different procedure.
commercially available and not limited to the
distributors above.
Concept
Komatsu Wireless Bridge (KWB) is a system that Download Configuration Files from
uses commercially available wireless technology to Komatsu Extranet:
allow communication that normally requires a wired The configuration files contain the settings to
connection and technician on board. Communication automatically configure the wireless radio and
requires an access point, often located in a pickup access point.
truck, or fueling area, and haul trucks equipped with
1. Navigate to https://www.komatsuamerica.net/
a Bullet wireless radio, associated hardware, and
authfiles/login.aspx
cables. A laptop running the Komtrax Plus PC tools
connected to the access point can automatically col- 2. Provide credentials and log in.
lect Komtrax Plus downloads when the truck comes 3. Select KOMTRAX / KOMTRAXplus / PLM
in range. If setup in fueling area downloads can con-
veniently be collected automatically each time truck
stops for fuel. The PC tools also provide links to
devices on the truck LAN such as Payload Meter
(PLM) IV and the drive system real-time data
screens. Haul cycle records can also be downloaded
from the PLM IV web page.
Necessary Equipment
1. Laptop computer
2. Bullet Titanium wireless radio (purchased
locally)
3. Two (2) Ethernet cables
4. Latest config file from Komatsu extranet
Purchase wireless radios

The wireless radios are governed by regulatory
agencies. The only way to ensure that proper
approvals are granted is to order locally so that the
certifications are applied when imported.
1. Navigate to http://www.ubnt.com/distributors/
2. Select distributor and order the following:
Manufacturer: Ubiquiti Networks

FIGURE 1-1.
Device: Bullet Titanium
Part Number: BM2-TI
QTY: One (1) per truck
58F-06-05340 Wireless Bridge Checkout Procedure 1

4. Select KOMTRAX Plus / PLM 5. Select PMO Software
6. KWB config files can be found on this page.

The part number is 58F-06-7042x.zip.
7. Download to PC for use in the next section.
2 Wireless Bridge Checkout Procedure 58F-06-05340

Configure Bullet wireless radio: Komatsu equipment such as loaders and mechanical
drive trucks.
The configuration file contains the settings required
to configure the bullet radio for communication with 1. Unpack the Bullet radio, power cable and POE
the 0002KPLUS wireless network. The file is generic, adapter.
so it can be used on each radio with no specific 2. Make connections as seen in the image below.
changes per truck. For convenience, 002KPLUS is
the same wireless network used by other Tier 4
FIGURE 1-4.
3. Change the laptop’s wired LAN settings to the 5. Proceed to the website regardless of any
following: (Refer to “APPENDIX A: CHANGING security messages.
A LAPTOP’S IP ADDRESS” on page 12) 6. Log in using the following default settings.
a. IP address: 192.168.1.100 a. Username: ubnt
b. Net mask: 255.255.0.0 b. Password: ubnt
4. Open an internet browser, chrome is 7. Navigate to the “System” tab.
recommended, and type 192.168.1.20 into the
address bar and then press the return key.

FIGURE 1-5.

8. Set time zone. 10. Click “Change”, next Click “Apply” on the blue
9. Click the magnifying glass icon next to the ribbon that appears toward the top of the
administrator user name. Enter the default screen. Record password in a safe place.
password and choose a new password.
FIGURE 1-6.
11. Under Configuration Management click 13. Wait ~30 seconds, click “Main”, verify the
“Choose File” select the configuration file you information matches the fields below. If not, a
downloaded from the extranet site for the Bullet problem has occurred and steps 11 and 12
radio, “58F-06-7042x_0002Kplus_bullet.cfg”. should be repeated. This check only works
12. Click “Upload”, next click “Apply” on the blue when the bullet is not in range of a powered
ribbon that appears toward the top of the 0002Kplus access point. If the access point
screen. cannot be powered off this step should be
skipped.
FIGURE 1-7.

Install Bullet radio on truck: mounted to the antenna station on the front handrail
on the left side of the truck.
Trucks equipped with KWB come with the required
cables and hardware. The Bullet radio will be
FIGURE 1-8.
1. Antenna 2. Hydrosorb Clamp
1. Antenna should be installed on bracket from 3. Install rubber washer on cable gland body if not
installation of GPS and KWB group. Connect already completed.
Bullet radio to antenna.
2. Install bolted half of hydrosorb clamp around
the Bullet and tighten bolts.

FIGURE 1-10.
5. Plug in the ethernet cable to the Bullet radio (2).

6. Thread the cable gland body into the Bullet
radio and tighten.
7. Split compression seal (6) at the precut location
and slide over ethernet cable. Push
compression seal into back side of cable gland
body.
8. Thread compression nut onto cable gland body.
Tighten to compress seal and waterproof the
connection.
9. Installation complete.
NOTE: Failure to complete this section correctly may
leave the bullet radio unprotected from water ingress
resulting in failure.
NOTE: Use cation not to twist ethernet cable or
connector.
Configure access point (if not already

completed):
Each mine site needs at least one access point
because KWB operates in infrastructure wireless
FIGURE 1-9. mode.
1. Unpackage the Nanostation M2 device, power
1. Ethernet Port 5. Cable Gland Body cable and POE adapter.
2. Bullet Titanium Radio 6. Compression Seal 2. Make connections as seen in the image below.
3. N-Type Connector 7. Compression Nut
4. Rubber Washer
4. Slide compression nut (7, Figure 1-9) and cable

gland body (5) over the ethernet cable paying
attention to the correct orientation.

FIGURE 1-11.
1. LAN Ethernet Port 2. reset Button
3. Change the laptop’s wired LAN settings to the 5. Proceed to the website regardless of any
following: (Refer to “APPENDIX A: CHANGING security messages.
A LAPTOP’S IP ADDRESS” on page 12) 6. Log in using the following default settings.
a. IP address: 192.168.1.100 a. Username: ubnt
b. Net mask: 255.255.0.0 b. Password: ubnt
4. Open an internet browser, chrome is 7. Navigate to the “System” tab.
recommended, and type 192.168.1.20 into the
address bar and then press the enter key.

FIGURE 1-12.
8. Set time zone. 10. Click “Change”, next Click “Apply” on the blue
9. Click the magnifying glass icon next to the ribbon that appears toward the top of the
administrator user name. Enter the default screen. Record password in a safe place.
password and choose a new password.

FIGURE 1-13.
11. Under Configuration Management click “Choose 13. Wait ~30 seconds, click “Main”, verify the
File”, select “58F-06- information matches the fields below. If not, a
7042x_0002Kplus_access_point.cfg” from the problem has occurred and steps 11 and 12
zip file downloaded from the extranet. should be attempted again.
12. Click “Upload”, next click “Apply” on the blue
ribbon that appears toward the top of the
screen.
FIGURE 1-14.
Test Connection: 3. Tool will automatically discover truck and

1. Power Nanostation and connect laptop to download if more than 12 hours has passed
0002KPLUS wireless network. since the previous download. Clicking
“Download” will force a download immediately.
2. Ensure that a haul truck with KWB and Komtrax
Plus II is nearby. Open Data Collection PC tool. 4. Open Komtrax Plus Discovery Tool.

5. All trucks in wireless range will show up in the

“Discovered Komtrax Plus Machines” box.
6. Click on a truck to see links to devices
connected to the onboard local area network.

APPENDIX A: CHANGING A LAPTOP’S IP
ADDRESS
The following instructions are for Windows 7.
1. Click Start > Control Panel
2. Open the Network and Sharing Center
a. If settings are displayed by icons click
“Network and Sharing Center”.
b. If settings are displayed by category click
“View network status and tasks”.
3. Click “Change Adapter settings” in the left-hand
pane.
4. Right click on the adapter that needs to be
configured.
a. For WIRED LAN CONNECTIONS use Local
Area Connection.
b. For WIRELESS CONNECTIONS use
Wireless Network Connection.
5. Click “Properties”
6. Select “Internet Protocol Version 4 (TCP/IPV4)”
(See Figure 1-17)
7. Click “Properties” (See Figure 1-17)
FIGURE 1-17.

8. For A static IP Address (See Figure 1-18): f. Click OK/Close
a. Select “Use the following IP Address:” radio 9. For Automatic IP Settings (See Figure 1-18):
button a. Select “Obtain an IP address automatically”
b. Enter into IP address field: use the IP radio button
address given in the section that calls out b. Select “Obtain DNS server address
this Appendix automatically” radio button
c. Subnet mask: use the Subnet Mask given in c. Click OK
the section that calls out this Appendix
d. Click OK/Close
d. Other fields: Leave blank
e. Click OK
FIGURE 1-18.

NOTES

FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
MACHINE MODEL MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
930E-5
Service Meter Reading Date of Inspection Wheel Motor

Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
(circle one) 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

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.
CEAW009400 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 Visually inspect unit for loose parts and debris
2 Hardware Visually inspect unit for missing and/or loose mounting hardware
Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped
3 Hoses and Cables
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
Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and
9 Anchor Pin
properly tightened hardware
10 Wheel Motors Inspect oil specification and proper oil level
11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks
12 Radiator Inspect coolant fill level, cold temperature protection, and DCA additive
Inspect all ladders and handrails are secure and hardware is tight
13 Decks and Ladders 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
Inspect all wiring and connections in battery box - no rubbing or chafing
14 Battery Verify battery mounting hardware is secure
Verify all battery terminals are secure
15 Steering Components Visually inspect installation of steering cylinders, tie rod, and accumulators
Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder
16 Hydraulic Components
installations (all hardware secure, no leaks)
Hardware Torque
Verify front suspension mounting capscrews have been properly tightened per appropriate
1 Suspension
shop manual procedure using the “angle advance” method
Verify torque on wheel motor mounting capscrews at 2007 N·m (1480 ft lb)
2 NOTE: Refer to the appropriate shop manual for the complete wheel motor
Wheel Motor
installation procedure.
Verify torque on all wheel nuts
NOTE: Refer to the appropriate shop manual for the complete wheel installation procedure.
3 Wheels Front wheels: 2325 ± 135 N·m (1715 ± 100 ft lb)

Rear inner wheels: 2325 ± 135 N·m (1715 ± 100 ft lb)
Rear outer wheels: 2325 ± 135 N·m (1715 ± 100 ft lb)
Verify torque on left ROPS beam capscrews at 800 N·m (590 ft lb)
4 ROPS
Verify torque on right ROPS beam capscrews at 240 N·m (177 ft lb)
5 Cab Verify torque on cab mounting capscrews at 2750 N·m (2028 ft lb)
6 Tie Rod Clamp Nuts Verify torque tie rod clamp nuts at 1017 ± 102 N·m (750 ± 75 ft lb)
Maintenance
Accepted
Cab Compartment
1 Cab Doors Verify doors open and close smoothly, latch works properly
2 Cab Windows Verify windows can be opened and closed smoothly
3 Door Locks Verify left and right door locks work properly with key
Visually inspect interior for completeness of assembly

4 Interior
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
Check operator seat adjustments (slide lever, back rest operation,
5 Cab Seats seat inclination, seat height etc.)
Inspect seat belt for proper installation (and seat tethers)
6 Passenger Seat Verify backrest operates without interference
Check tilt and telescoping functions

7 Steering Wheel
Check that adjustable lever can be locked securely
Verify wipers work at all speed settings and range do not extend beyond glass surface
8 Wipers
Verify windshield washer works properly and washer fluid reservoir is full
9 Document Holder Verify the OMM and Safety manuals are present
10 Horn Check for proper sound, no looseness in horn button
11 Back Up Horn Check for proper sound and function
12 Shift Lever 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
Verify all headlights are operating (high and low beams)
1 Headlights Verify high beam indicators are functional
Verify lights are at proper angle
2 Fog Lights Verify fog lights and indicator lights are operating properly
3 Instrument Panel Check that switch depresses and all lights function
4 Dome Light Verify dome light is on when the switch is ON
Visually inspect front and rear turn signal operation on left and right sides
5 Turn Signal Verify directional indicators are operating properly
Verify switch turns off after turn is completed
Verify flasher is operating properly
6 Hazard Flashers
Verify hazard indicator lights are operating properly
7 Back Up Light Verify mirror mounted back up lights are operating properly when shift lever is in R position
8 Manual Back Up Light Verify switch and light are operating properly (rear axle)
Verify service brake light is operating properly (top of cab)
9 Service Brake Lights
Verify service brake lights are operating properly (rear axle)
Verify retarder light is operating properly (top of cab)
10 Retarder Lights
Verify retarder lights are operating properly (rear axle)
Maintenance
Accepted
Service Inspection
1 Hydraulic System Perform flushing procedure at initial startup
Verify oiling height and charging height of all four suspensions
NOTE: Refer to the appropriate shop manual for the complete oiling and charging procedures.
Front suspension oiling height: 25.4 mm (1.00 in.)
2 Suspensions
Rear suspension oiling height: 54.2 mm (2.13 in.)
Front charging height: 228.6 mm (9 in.) at 2930 kPa (425 psi)
Rear charging height: 219.3 mm (8.63 in.) at 1296 kPa (188 psi)
Verify nitrogen charge in all accumulators
NOTE: Charging pressure will vary with ambient temperature. Refer to chart in shop manual.
3 Accumulators Steering accumulators: 9653 kPa (1400 psi)

Brake accumulators: 9653 kPa (1400 psi)
Auxiliary system accumulator: 9653 kPa (1400 psi)
4 Engine Prelube Ensure prelube is working prior to engine starting
5 Engine Starting Ensure engine starts easily
6 Engine Noise No abnormal noise from engine
Verify when switch is ON and shift lever is in NEUTRAL, brakes are applied and light is
7 Brake Lock
illuminated
8 Parking Brake Verify when shift lever is in PARK, parking brakes are applied and light is illuminated
Verify the following brake system pressures:
Front brakes (pedal depressed): 17237 ± 517 kPa (2500 ± 75 psi)
9 Brakes Rear brakes (pedal depressed): 17237 ± 517 kPa (2500 ± 75 psi)
Brake lock (engine running, shift lever NEUTRAL): 17237 ± 689 kPa (2500 ± 100 psi)
Parking brake (engine running, shift lever NEUTRAL): 20167 ± 1207 kPa (2925 ± 175 psi)
Verify that steering system is operating smoothly, turning from lock to lock
10 Steering
Verify steering system is free of noise and vibration
Verify hoist pressure at high idle
Power up: 18961 ± 689 kPa (2750 ± 100 psi)
Power down: 10342 ± 689 kPa (1500 ± 100 psi)
11 Hoist Verify hoist limit switch is operational and set correctly (measure on hoist cylinder - 3rd stage)
Cylinder should stop 152 mm (6 in.) before full extension
Verify the hoist HOLD position operates properly
Verify there is no heavy shock when the dump body returns to the frame in float
Power up loaded: 21-23 seconds
Power down: 23-25 seconds
12 Hoist Times
Float down empty: 24-26 seconds
Verify body up switch activates alarm and light in cab
Verify automatic lubrication system is functional, grease tank is full, and air is bled from system
13 Lubrication
Ensure automatic lubrication system is operating properly and timer is set as desired
Maintenance
Accepted
16 Machine Record machine model-type, machine serial number and engine serial number
17 Dump Body Verify dump body is shimmed correctly prior to truck release
18 Covers & Guards Verify all covers and guards are securely in place
19 Decals Verify all decals are installed in correct locations
20 Paint Touch up paint as needed
21 Optional Equipment Verify any optional equipment is installed and functioning properly
Ensure the electrical checkout procedure has been completed and signed off on, including
22 Electrical Checks
Megger testing (see appropriate Field Assembly Manual or Shop Manual for procedure)
Ensure the truck is programed with its own unique configuration file and a copy of the file
23 Truck Programming
saved
ADDITIONAL COMMENTS__________________________________________________________
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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 MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
930E-5
Service Meter Reading Date of Inspection Wheel Motor

Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
(circle one) 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

Peoria, IL 61650-0240 U.S.A.
Send Canary Reports to Manager of Field Assembly

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.
As Found Corrective
Condition Action
Inspection Around Machine
1 Parts Visually inspect the truck for loose parts and debris.
Visually inspect the truck for missing and/or loose

2 Hardware mounting hardware.
Visually inspect hydraulic hoses and electric cables to

3 Hoses and Cables ensure they are securely clamped and clear of sharp
edges and other objects that may cause chaffing.
Verify the engine oil level is at the proper operating range.
4 Engine Oil Level
Verify the oil level is visible through the upper sight glass
5 Hydraulic Oil Level with the body down.
Visually inspect the anchor hitch pin and anti-sway bar

6 Anchor Pin assembly for proper installation and properly tightened
hardware.
Verify the correct oil is being used and oil is at the proper
7 Wheel Motors level.
Verify the fuel tank mounting is secure and there are no

8 Fuel Tank fuel leaks.
9 Radiator Inspect the coolant fill level.
Verify proper installation of the steering cylinders, tie rod,

10 Steering Components and accumulators.
Visually inspect the hoist valve, pumps, filters, hydraulic

11 Hydraulic Components 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
Steering Arm To
1 Spindle Verify hardware torque: 2705 ± 271 N·m (1995 ± 200 ft lb)
Front Suspension
2 Retainer Plate Verify hardware torque: 2705 ± 271 N·m (1995 ± 200 ft lb)
Steering Cylinder To
3 Frame Verify hardware torque: 1017 ± 102 N·m (750 ± 75 ft lb)
Steering Cylinder To
4 Steering Arm Verify hardware torque: 1017 ± 102 N·m (750 ± 75 ft lb)
As Found Corrective
Condition Action
5 Tie Rod To Steering Arm Verify hardware torque: 1017 ± 102 N·m (750 ± 75 ft lb)
6 Tie Rod Clamp Nuts Verify hardware torque: 1017 ± 102 N·m (750 ± 75 ft lb)
Verify torque on front wheel nuts:

2325 ± 135 N·m (1715 ± 100 ft lb)
Verify torque on rear inner wheel nuts:

Wheels 2325 ± 135 N·m (1715 ± 100 ft lb)
7
Verify torque on rear outer wheel nuts:

2325 ± 135 N·m (1715 ± 100 ft lb)
NOTE: Refer to the appropriate shop manual for the complete wheel installation procedure.
Cab Compartment
1 Horn Check for proper sound, no looseness in horn button.
2 Back Up Horn Check for proper sound and function.
3 Gauges Verify gauges are installed straight and operating correctly.
Verify the cab windows have no cracks. Ensure all

windows are properly sealed. Verify windows can be
4 Cab Windows
opened and closed smoothly.
Verify the cab seats and seat belts are in proper working
5 Cab Seats & Seat Belts condition.
Verify that steering system is operating smoothly while

turning from stop to stop and is free of noise and
6 Steering
vibrations.
As Found Corrective
Condition Action
Service Inspection
Verify the front suspension oiling height:

25.4 mm (1.00 in.)
Verify the rear suspension oiling height:

54.2 mm (2.13 in.)
Suspensions
1 Verify the front charging height:
228.6 mm (9 in.) at 2930 kPa (425 psi)
Verify the rear charging height:

219.3 mm (8.63 in.) at 1296 kPa (188 psi)
NOTE: Refer to the appropriate shop manual for the complete oiling and charging procedures.
Verify the steering accumulator nitrogen charge:
9653 kPa (1400 psi)
Verify the brake accumulator nitrogen charge:

Accumulators 9653 kPa (1400 psi)
2
Verify the auxiliary system accumulator nitrogen charge:

9653 kPa (1400 psi)
NOTE: Charging pressure will vary with ambient temperature. Refer to chart in shop manual.
Verify automatic lubrication system is functional, grease
tank is full, and air is bled from system.
3 Lubrication
Ensure automatic lubrication system is operating properly
and timer is set as desired.
Verify the 50 hour change of all hydraulic filters has been

4 Hydraulic Filters completed.
Pressure:
Check and record the tire pressure/size/manufacturer for Size:

5 Tires
future reference.
Manufacturer:
Calibrate and check payload meter operation.

6 Payload Meter Troubleshoot any error codes and delete after repair.
Check drive control system operation. Troubleshoot,

7 Drive/Control System correct and delete any fault codes.
Inspect traction alternator slip rings and brushes.

Drive System Rotating
8 Inspect grid blower motor commutator, brush wear, etc.
Components
Verify the Komtrax system is functioning properly.

9 Komtrax Troubleshoot and repair any problems.
CEAW009200
LUBRICATION CHART OPTIONAL
LUBRICATION SPECIFICATIONS
22 3 18
LUBE KEY TYPE LUBRICANT 14
2
A ENGINE OIL ----- SEE ENGINE MANUAL
B HYDRAULIC OIL ----- SAE 10W C-4 AUXILIARY HEATERS REQUIRED BELOW -10° F (-23° C) 5
C HEAVY-DUTY SYNTHETIC GEAR OIL ----- SEE DRIVE SYSTEM MANUAL
D MULTI-PURPOSE EXTREME PRESSURE GREASE ----- NLGI NO. 2 (5% MIN. MOLY-DISULFIDE) 1 4
E TRANSMISSION OIL ----- SAE50

17
F POLYUREA GREASE NGLI NO. 2 ----- SEE DRIVE SYSTEM MANUAL 15
LUBE 19
SYM DESCRIPTION PTS 10 HR 50 HR 100 HR 250 HR 500 HR 1000 HR 2000 HR 2500 HR
KEY
23
1 CRANKCASE OIL LEVEL 1 A CHECK
2 ENGINE LUBE OIL FILTERS 16
16
3 FUEL FILTERS SEE ENGINE MANUAL
4 FUEL SEPARATOR 9 13 11
5 COOLANT FILTERS
DRAIN H2O 7
6 FUEL TANK 8
1 & SEDIMENT
White - Komatsu, Manager of Technical Support

CHANGE & 6
7 FUEL TANK BREATHER 1 10
DRAIN
8 HYDRAULIC OIL LEVEL 1 B CHECK *CHANGE
9 HYDRAULIC STRAINER 2 CLEAN
10 HYDRAULIC TANK BREATHER 2 CHANGE 12
11 HYDRAULIC FILTERS **** 3 ** ** ** ** CHANGE
12 MOTORIZED WHEEL OIL LEVEL 2 C SEE DRIVE SYSTEM MANUAL
13 HYD. PUMP DRIVE SHAFT 2 D GREASE
14 CHASSIS LUBE LEVEL 1 D CHECK 12
15 SEAT SLIDES 4 D GREASE
25 24 21 20
16 COOLING BLOWERS *** 4 F SEE DRIVE SYSTEM MANUAL
17 FRONT WHEEL BEARINGS 2 E CHECK CHANGE OPTIONAL
18 FRONT TRUNNION 1 D GREASE
MAGNETIC PLUG 2
19 CHECK
FRONT WHL COVER
20 DEF PUMP FILTER 2 SEE ENGINE MANUAL
21 DEF TANK FILTER 2 CHANGE
22 RETRACTABLE LADDER 4 D GREASE
23 GRID BLOWERS 4 F SEE DRIVE SYSTEM MANUAL
24 DEF TANK BREATHER 1 CLEAN
25 REAR AXLE BREATHER 1 CHANGE
Canary - Komatsu, Manager of Field Assembly

* 1000 HR INTERVAL CAN BE EXTENDED TO 2500 HR PROVIDED OIL SAMPLING AND ANALYSIS IS CONDUCTED EVERY 250 HR.
** ONE TIME CHANGE AT 50, 100, 250 AND 500 HR.
*** NOT APPLICABLE FOR 980E
**** 980E HAS 4 HYDRAULIC FILTERS / AUTONOMOUS TRUCKS HAVE 5 HYDRAULIC FILTERS
Page 5 of 6
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
Description of Modification Reason For Installation
ADDITIONAL COMMENTS__________________________________________________________
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STANDARD TORQUE CHARTS AND CONVERSION TABLES
This manual provides dual dimensioning for many

specifications. Metric units are specified first, with
U.S. standard units in parentheses. When torque val-
ues are not specified in the assembly instructions References throughout the manual to standard
contained in this manual, use the standard torque torques or other standard values will be to one of
value for the hardware being used. Standard value the following tables. Do not use standard values
torque tables are contained in this chapter for metric to replace specific torque values in assembly
and SAE hardware. instructions.
NOTE: This truck is assembled with both metric and
SAE (U.S.) hardware. Reference the correct table
when determining the proper torque value. For values not shown in any of the charts or tables,
standard conversion factors for most commonly used
measurements are provided in the following tables.
INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
TABLE 1 Standard Tightening Torque For Metric Capscrews and Nuts. . . . . . . . . . . . . . . . . . . . . . FAM15-2
TABLE 2 Standard Tightening Torque For SAE Grade 5 & 8 Capscrews and Nuts . . . . . . . . . . . . . FAM15-3
TABLE 3 Standard Tightening Torque 12-Pt, Grade 9, Capscrews (SAE) . . . . . . . . . . . . . . . . . . . . FAM15-4
TABLE 4 Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-5
TABLE 5 Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . FAM15-5
TABLE 6 Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-5
TABLE 7 JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-6
TABLE 8 Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-6
TABLE 9 O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-7
TABLE 10 O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-7
TABLE 11 Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-8
TABLE 12 Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-9
TABLE 13 Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-10
FAM1502 Standard Torque Charts and Conversion Tables F15-1

EFFECT OF SPECIAL LUBRICANTS STANDARD TIGHTENING TORQUES
On Fasteners and Standard Torque Values For Class 10.9 Capscrews & Class 10 Nuts
The Komatsu engineering department does not The following specifications apply to required
recommend the use of special friction-reducing assembly torques for all metric class 10.9 finished
lubricants, such as Copper Coat, Never-Seez®, and hexagon head capscrews and class 10 nuts.
other similar products, on the threads of standard
• Capscrew threads and seats shall not be
fasteners where standard torque values are applied.
lubricated when assembled. These specifications
The use of special friction-reducing lubricants will are based on all capscrews, nuts, and hardened
significantly alter the clamping force being applied to washers being phosphate and oil coated.
fasteners during the tightening process.
If zinc-plated hardware is used, each piece must
If special friction-reducing lubricants are used with be lubricated with simple lithium base chassis
the standard torque values listed in this chapter, grease (multi-purpose EP NLGI) or a rust
excessive stress and possible breakage of the preventive grease (see list, this page) to achieve
fasteners may result. the same clamping forces provided below.
Where the torque tables specify “Lubricated • Torques are calculated to give a clamping force
Threads” for the standard torque values listed, these of approximately 75% of proof load.
standard torque values are to be used with simple • The maximum torque tolerance shall be within
lithium base chassis grease (multi-purpose EP NLGI) ±10% of the torque value shown.
or a rust-preventive grease (see below) on the
• In the following table under “Capscrew Size”, the
threads and seats unless specified otherwise. first number represents the shank diameter
NOTE: Ensure the threads of fasteners and tapped (mm). The second number represents threads
holes are free of burrs and other imperfections before per millimeter.
assembling. Example: M20 x 2.25
M20 = shank diameter (20 mm)
Suggested* Sources for Rust Preventive Grease:
• American Anti-Rust Grease #3-X from Standard 2.25 = threads per millimeter
Oil Company (also American Oil Co.)
• Gulf NoRust #3 from Gulf Oil Company.
• Mobilarma 355, Product No. 66705 from Mobil
Oil Corporation.
• Rust Ban 326 from Humble Oil Company.
TABLE 1.
• Rustolene B Grease from Sinclair Oil Co. Standard Tightening Torque
for Metric Class 10.9 Capscrews & Class 10 Nuts
• Rust Preventive Grease - Code 312 from the
Southwest Grease and Oil Company. Capscrew Torque Torque Torque
Size N•m ft lb kg•m
NOTE: This list represents the current engineering M6 x1 12 9 1.22
approved sources for use in Komatsu manufacture. It
M8 x 1.25 30 22 3.06
is not exclusive. Other products may meet the same
specifications of this list. M10 x 1.5 55 40 5.61
M12 x 1.75 95 70 9.69
M14 x 2 155 114 15.81
M16 x 2 240 177 24.48
M20 x 2.25 465 343 47.43
M24 x 3 800 590 81.6
M30 x 3.5 1600 1180 163.2
M36 x 4 2750 2028 280.5
F15-2 Standard Torque Charts and Conversion Tables FAM1502

STANDARD TIGHTENING TORQUES
For SAE Grade 5 and Grade 8 Capscrews
The following specifications apply to required assem-
• The maximum torque tolerance shall be ±10% of
bly torques for all grade 5 and grade 8 capscrews.
the torque value shown.
• Capscrew threads and seats shall be lubricated
when assembled. • In the following table under Capscrew Size, the
first number represents the shank diameter (in.).
Unless instructions specifically recommend The second number represents threads per inch.
otherwise, these standard torque values are to be
used with simple lithium base chassis grease Example: 7/16 - 20
(multi-purpose EP NLGI) or a rust-preventive 7/16 = shank diameter (7/16 inch (0.438 inch))
grease (see list, previous page) on the threads.
20 = threads per inch
• Torques are calculated to give a clamping force
of approximately 75% of proof load.
TABLE 2.
Standard Tightening Torque
for SAE Hex Head Cap Screw And Nut Assembly
Cap Torque - Torque - Cap Torque - Torque -
screw Grade 5 Grade 8 Screw Grade 5 Grade 8
Size N·m ft lb kg·m N·m ft lb kg·m Size N·m ft lb kg·m N·m ft lb kg·m
1/4-20 9.5 7 0.97 13.6 10 1.38 3/4-16 319 235 32.5 454 335 46.3
1/4-28 10.8 8 1.11 14.9 11 1.52 7/8-9 475 350 48.4 678 500 69.2
5/16-18 20.3 15 2.07 28 21 2.90 7/8-14 508 375 51.9 719 530 73.3
5/16-24 22 16 2.21 30 22 3.04 1.0-8 712 525 72.6 1017 750 103.7
3/8-16 34 25 3.46 47 35 4.84 1.0-12 759 560 77.4 1071 790 109.3
3/8-24 41 30 4.15 54 40 5.5 1.0-14 773 570 78.8 1085 800 110.6
7/16-14 54 40 5.5 79 58 8.0 1 1/8-7 881 650 89.9 1424 1050 145
7/16-20 61 45 6.2 84 62 8.57 1 1/8-12 949 700 96.8 1546 1140 158
1/2-13 88 65 9 122 90 12.4 1 1/4-7 1234 910 125.9 2007 1480 205
1/2-20 95 70 9.7 129 95 13.1 1 1/4-12 1322 975 134.8 2142 1580 219
9/16-12 122 90 12.4 169 125 17.3 1 3/8-6 1627 1200 166 2630 1940 268
9/16-18 129 95 13.1 183 135 18.7 1 3/8-12 1776 1310 181 2874 2120 293
5/8-11 169 125 17.3 237 175 24.2 1 1/2-6 2142 1580 219 3471 2560 354
5/8-18 183 135 18.7 258 190 26.2 1 1/2-12 2305 1700 235 3756 2770 383
3/4-10 298 220 30.4 420 310 42.8
1 ft lb. = 0.138 kg·m = 1.356 N.m

STANDARD TIGHTENING TORQUES
For SAE Grade 9 Capscrews
The following specifications apply to required assem-
bly torques for SAE Hex Head and 12-point, grade 9
(170,000 psi minimum tensile), capscrews.
NOTE: Capscrew threads and seats shall be
lubricated when assembled. Unless instructions
specifically recommend otherwise, these standard
torque values are to be used with simple lithium base
chassis grease (multi-purpose EP NLGI) or a rust-
preventive grease (see list, this page) on the threads.
NOTE: Torques are calculated to give a clamping
force of approximately 75% of proof load. The
maximum torque tolerance shall be within ±10% of
the torque value shown.
TABLE 3.
Standard Tightening Torque for SAE Hex
Head and 12-Point, Grade 9 Capscrews
Torque Torque Torque

Capscrew Size*
N·m ft lb kg·m
0.250 - 20 16 12 1.7
0.312 - 18 33 24 3.3
0.375 - 16 57 42 5.8
0.438 -14 95 70 9.7
0.500 -13 142 105 14.5
0.562 - 12 203 150 20.7
0.625 - 11 278 205 28.3
0.750 - 10 488 360 49.7
0.875 - 9 780 575 79.4
1.000 - 8 1166 860 119
1.000 - 12 1240 915 126
1.125 - 7 1670 1230 170
1.125 - 12 1800 1330 184
1.250 - 7 2325 1715 237
1.250 - 12 2495 1840 254
1.375 - 6 3080 2270 313
1.375 - 12 3355 2475 342
1.500 - 6 4040 2980 411
1.500 - 12 4375 3225 445
* Shank Diameter (in) - Threads per inch

TABLE 4.
Tightening Torque For
T-Bolt Type Hose Clamp (SAE J1508 Type TB)
Newton meters Inch Pounds
Thread Size Band Width
(N·m) (in lb)
0.25-28 UNF 19.05 mm (0.75 in) 8.5 ± 0.6 N·m 75 ± 5 in lb
TABLE 5.
Split Flange Clamp Bolts
Cap Screw Thread Width Newton meters Foot Pounds Kilogram meters
Diameter Across Flat (N·m) (ft lb) (kg·m)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
10 14 66 48 6.7
12 17 112 83 11.5
16 22 279 206 28.5
TABLE 6.
Flared Tube And Hose Fittings
Thread Width Newton meters Foot Pounds Kilogram meters
Diameter of Nut Across Flat (N·m) (ft lb) (kg·m)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
14 19 25 18 2.5
18 24 50 36 5
22 27 80 58 8
24 32 140 101 14
30 36 175 130 18
33 41 195 145 20
36 46 245 180 25
42 55 295 215 30

TABLE 7.
Torque Chart For JIC 37° Swivel NutS
With Or Without O-ring Seals
Size Tube Size Threads UNF-2B Newton meters Foot Pounds
Code (OD) (N·m) (ft lb)
–2 0.125 0.312 – 24 5±1 4±1
–3 0.188 0.375 – 24 11 ± 4 8±3
–4 0.250 0.438 – 20 16 ± 4 12 ± 3
–5 0.312 0.500 – 20 20 ± 4 15 ± 3
–6 0.375 0.562 – 18 24 ± 7 18 ± 5
–8 0.500 0.750 – 16 40 ± 7 30 ± 5
– 10 0.625 0.875 – 14 54 ± 7 40 ± 5
– 12 0.750 1.062 – 12 75 ± 7 55 ± 5
– 14 0.875 1.188 – 12 88 ± 7 65 ± 5
– 16 1.000 1.312 – 12 108 ± 7 80 ± 5
– 20 1.250 1.625 – 12 136 ± 14 100 ± 10
– 24 1.500 1.875 – 12 163 ± 14 120 ± 10
– 32 2.000 2.500 – 12 312 ± 27 230 ± 20
TABLE 8.
Torque Chart For
Pipe Thread Fittings
Size Pipe Thread With Sealant With Sealant Without Sealant Without Sealant
Code Size N·m ft lb N·m ft lb
–2 0.125 – 27 20 ± 4 15 ±3 27 ± 7 20 ± 5
–4 0.250 – 18 27 ± 7 20 ±5 34 ± 7 25 ± 5
–6 0.375 – 18 34 ± 7 25 ±5 48 ± 7 35 ± 5
–8 0.500 – 14 48 ± 7 35 ±5 61 ± 7 45 ± 5
– 12 0.750 – 14 61 ± 7 45 ±5 75 ± 7 55 ± 5
– 16 1.000 – 11.50 75 ± 7 55 ±5 88 ± 7 65 ± 5
– 20 1.250 – 11.50 95 ± 7 70 ±5 108 ± 7 80 ± 5
– 24 1.500 – 11.50 108 ± 7 80 ±5 129 ± 14 95 ± 10
– 32 2.000 – 11.50 129 ± 14 95 ±10 163 ± 14 120 ± 10

TABLE 9.
Torque Chart For
O-ring Boss Fittings
Size Newton meters Foot Pounds

Tube Size (OD) Threads UNF-2B (N·m) (ft lb)
Code
–2 0.125 0.312 – 24 4±3 4±2
–3 0.188 0.375 – 24 7±3 5±2
–4 0.250 0.438 – 20 11 ± 4 8±3
–5 0.312 0.500 – 20 14 ± 4 10 ± 3
–6 0.375 0.562 – 18 18 ± 4 13 ± 3
–8 0.500 0.750 – 16 33 ± 7 24 ± 5
– 10 0.625 0.875 – 14 43 ± 7 32 ± 5
– 12 0.750 1.062 – 12 65 ± 7 48 ± 5
– 14 0.875 1.188 – 12 73 ± 7 54 ± 5
– 16 1.000 1.312 – 12 98 ± 7 72 ± 5
– 20 1.250 1.625 – 12 109 ± 7 80 ± 5
– 24 1.500 1.875 – 12 109 ± 7 80 ± 5
– 32 2.000 2.500 – 12 130 ± 14 96 ± 10
TABLE 10.
Torque Chart For
O-ring Face Seal Fittings
Size Tube Size Newton meters Foot Pounds

Threads UNF-2B (N·m) (ft lb)
CodeE (O.D.)
–4 0.250 0.438 – 20 15 ± 1 11 ± 1
–6 0.375 0.562 – 18 24 ± 3 18 ± 2
–8 0.500 0.750 – 16 48 ± 5 35 ± 4
– 10 0.625 0.875 – 14 69 ± 7 51 ± 5
– 12 0.750 1.062 – 12 96 ± 10 71 ± 7
– 16 1.000 1.312 – 12 133 ± 8 98 ± 6
– 20 1.250 1.625 – 12 179 ± 10 132 ± 7
– 24 1.500 1.875 – 12 224 ± 20 165 ± 15

TABLE11.
Common Conversion Multipliers
Metric To English
Multiply
To Convert From To
By
millimeter (mm) inch (in) 0.0394
centimeter (cm) inch (in) 0.3937
meter (m) foot (ft) 3.2808
meter (m) yard (yd) 1.0936
kilometer (km) mile (mi) 0.6210
square centimeters (cm2) square inch (in2) 0.1550
square centimeters (cm2) square feet (ft2) 0.001
cubic centimeters (cm3) cubic inch (in3) 0.061
liters (l) cubic inch (in3) 61.02
cubic meters (m3) cubic feet (ft3) 35.314
liters (l) cubic feet (ft3) 0.0353
grams (g) ounce (oz) 0.0353

milliliter (ml) fluid ounce (fl oz) 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pounds (lb) 0.2248
Newton meters (N·m) kilogram meters (kg·m) 0.102
Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram meters (kg·m) foot pounds (ft lb) 7.2329
kilogram meters (kg·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038
kilograms/cm 2 (kg/cm2) pounds/square inch (psi) 14.2231
kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
kilogram (kg) short ton (tn) 0.0011

metric ton short ton (tn) 1.1023
liters (l) quart (qt) 1.0567
liters (l) gallon (gal) 0.2642
Watts (W) horsepower (hp) 0.00134
kilowatts (kW) horsepower (hp) 1.3410

TABLE 12.
Common Conversion Multipliers
English to Metric
To Convert Multiply
To
From By
inch (in) millimeter (mm) 25.40
inch (in) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61
square inch (in2) square centimeters (cm2) 6.45
square feet (ft2) square centimeters (cm2) 929
cubic inches (in3) cubic centimeters (cm3) 16.39
cubic inches (in3) liters (l) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft3) liters (l) 28.3
ounce (oz) kilogram (kg) 0.028

fluid ounce (fl oz) milliliter (ml) 29.573
pound (lb) kilogram (kg) 0.454
pound (lb) Newton (N) 4.448
inch pounds (in lb) Newton meters (N·m) 0.113
foot pounds (ft lb) Newton meters (N·m) 1.356
foot pounds (ft lb) kilogram meters (kg·m) 0.138
kilogram meters (kg·m) Newton meters (N·m) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
pounds/square inch (psi) kilograms/square centimeter 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (l) 0.946
gallon (gal) liters (l) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745

TABLE 13.
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.

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CEAW009000

Copyright 2018 Komatsu

Unsafe use of this machine may cause serious injury or death.

WARNING: Breathing diesel engine exhaust exposes you to

WARNING: This product can expose you to chemicals including

DANGER Identifies a specific potential hazard

WARNING identifies a specific potential hazard

CAUTION is used for general reminders

SUBJECT PAGE NUMBER

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

TRUCK COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

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

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

FAM0037 Introduction iii

Before welding, refer to Special Precautions When

FAM0131 Safety Rules, Tools, & Equipment Page 1-1

Page 1-2 Safety Rules, Tools, & Equipment FAM0131

FAM0131 Safety Rules, Tools, & Equipment Page 1-3

1. “T” Handle Valve

Part Number Description Use

Page 1-4 Safety Rules, Tools, & Equipment FAM0131

Part Number Description Use

Part Number Description Use

FAM0131 Safety Rules, Tools, & Equipment Page 1-5

Part Number Description Use

Part Number Description Use

Page 1-6 Safety Rules, Tools, & Equipment FAM0131

Part Number Description Use

Part Number Description Use

Part Number Description Use

FAM0131 Safety Rules, Tools, & Equipment Page 1-7

Part Number Description Use

Part Number Description Use

Page 1-8 Safety Rules, Tools, & Equipment FAM0131

Part Number Description Use

Part Number Description Use

FAM0131 Safety Rules, Tools, & Equipment Page 1-9

0-2000 VDC CUSTOM METER KIT (58B-06-00800)

0-2000 VDC CUSTOM METER KIT (58B-06-00800)

Page 1-10 Safety Rules, Tools, & Equipment FAM0131

* NOTE INCH EQUIVALENT MATERIAL

XC2293 SPACER BLOCK DIMENSION

FAM0131 Safety Rules, Tools, & Equipment Page 1-11

Page 1-14 Safety Rules, Tools, & Equipment FAM0131

The AC power signal produced by each inverter is a

FAM0237 Truck Components And Specifications Page 2-1

Page 2-2 Truck Components And Specifications FAM0237

FAM0237 Truck Components And Specifications Page 2-3

Page 2-4 Truck Components And Specifications FAM0237

FAM0237 Truck Components And Specifications Page 2-5

Page 2-6 Truck Components And Specifications FAM0237

ITEM KILOGRAMS POUNDS

DECK AND DECK SUPPORT COMPONENTS

FAM0327 Major Component Weights Page 3-1

FRONT AXLE COMPONENTS

REAR AXLE COMPONENTS

Page 3-2 Major Component Weights FAM0327

FAM0403 5/13 Field Welding For Assembly Or Repair Page 4-1