Field Assembly Manual: Dump Truck

CEAW003001
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS A30039 & UP
®
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu HD1500-5 dump truck.
Variations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.
FAM0007 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 FAM0007
TABLE OF CONTENTS
SUBJECT PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
DUMP BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAM0007 Introduction iii

KOMATSU HD1500-5 DUMP TRUCK
iv Introduction FAM0007
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES
The following list of safety practices is intended for
use by personnel during field assembly of the
11. When welding, connect the ground cable to the
HD1500-5 Komatsu truck.
part being welded. DO NOT allow welding cur-
This list of safety rules is not intended to replace local rent to pass through bearings, engine, etc.
safety rules or regulations and federal, state, or local 12. DO NOT weld the transmission housing unless
laws. The safety precautions recommended here are it has been completely disassembled.
general and must be used in conjunction with all pre-
vailing local rules and regulations. 13. DO NOT weld the fuel tank or hydraulic tank
unless the tanks have been properly purged
1. All personnel must be properly trained for the and ventilated.
assembly operation.
14. Use the proper tools for the job to be performed.
2. Wear safety equipment such as safety glasses,
Never improvise wrenches, screw drivers, sock-
hard toe shoes and hard hats at all times during
ets, etc. unless specified.
assembly.
3. Thoroughly inspect the assembly site. Remove 15. Lifting eyes and hooks must be fabricated from
weeds, debris and other flammable material. the proper materials and rated to lift the
intended load.
4. Use only solid, hard wood for supports. When
using metal support stands, place wood blocks 16. When the weight of any component(s) or any
between the support and the frame to prevent assembly procedure is not known, contact your
metal to metal contact. customer support manager for further informa-
5. Inspect all lifting devices. Refer to the manufac- tion.
turer's specifications for correct capacities and
safety procedures when lifting components.
6. Perform a daily inspection of all lifting cables
and chains. Replace any questionable items.
Use cables and chains that are properly rated
for the load to be lifted.
7. DO NOT stand beneath a suspended load. Use
of guy ropes are recommended for guiding and
positioning a suspended load.
8. Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
charged and in good working condition.
9. Cap screws and/or nuts being replaced must be
the same grade as originally supplied.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its compo-
nents.
FAM0106 Safety Rules, Tools, & Equipment Page 1-1

TOOLS AND EQUIPMENT FOR
ASSEMBLY
The following equipment is recommended for field
assembly of the HD1500-5 truck.
12. Two, ratchet pullers - 2.7 metric ton (3 ton)
13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)
1. Equipment and tool storage trailer with a lock-
able door. Approximately 12 x 2.5 m (40 x 8 ft) 14. Set of standard master mechanics hand tools.
2. Cranes • Thread taps and dies of both inch and metric
sizes.
a. Two, 45 metric ton (50 ton) cranes to remove
the chassis from the freight trailer and place • Metric sockets and open end wrenches, 6mm
on cribbing. These cranes can also be used to 36mm.
to lift the assembled body onto to the chas-
• Inch sockets and open end wrenches up to 1
sis.
3/4 in.
b. One, 109-136 metric tons (120-150 ton)
crane. The crane is needed to turn the body
• Torque wrenches - 339 N·m (250 ft lb) with
over after completion of the underside weld- 18:1 multiplier. Torque wrenches - 339 N·m
ing. A 45 metric ton (50 ton) crane is also (600 ft lb) with 4:1 multiplier. Hydrotorque - 1
required for this task. 1/2 in. drive with capability of 5559 N·m
(4100 ft lb) or greater.
3. One fork lift - 6804 kg (15,000 lb) capacity, with
high lift capability. • Box wrench 1 3/8 in. (Snap-On p/n X440B)
4. Two, 300 amp portable welding units and an with 12 inch extension to tighten ROPS cap
oxy-acetylene cutting set. screws.
5. One, propane torches for weld preheating. • Sockets: 2 1/4 in. (Snap-On P/N J15036) and
6. Portable air compressor - 3.5 cmm (125 cfm) 2 5/8 in. (Snap-On P/N J15042) to tighten
and 690 kPa (100 psi) capacity. front suspension hardware.
15. Heavy duty 3/4 in. & 1 in. square drive impact
Two, 15 m (50 ft) air hoses.
wrench sets.
7. Metal stands and a sufficient amount of wood
cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm 16. Impact sockets for 3/4 in. & 1 in. square drive
(4 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 tools.
cm (4 ft. x 6 in. x 6 in.) - such as railway cross 17. Special tools (see list, following pages)
ties
18. Two, hydraulic or pneumatic porta-power jacks,
8. Tire handler - Wiggins/Iowa Mold Tooling. 4.5 and 9 metric ton (5 and 10 ton)
9. Miscellaneous air tools
19. Various hooks and shackles
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft)
20. Miscellaneous: i.e. grinders, containers, rags.
11. Chains, lifting cables, slings:
21. Spreader bars for cab and decks.
• Two, 4 point slings, 3 m (10 ft) in length 22. Two ratchet hoists of 2.7 metric ton (3 ton)
• Two, 4 point slings, 2 m (6 ft) in length capacity.
• Two, 1 m (4 ft) and two, 2 m (6 ft) 23. Pry bars
• Two, 3 m (10 ft) nylon straps 24. Solvent - 38 liters (10 gal)
• Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) 25. Paint remover - 19 liters (5 gal)
of rope 26. Rust preventive grease
Page1-2 Safety Rules, Tools, & Equipment FAM0106

LIFTING SLING GENERAL
INFORMATION

PART NO. DESCRIPTION USE
NItrogen Suspension &
EC3331 Charging Kit accumulator
nitrogen charging
NOTE: Not included with all trucks.

EG7805 Removal Tool Wheel Rim
EG7806 Threaded Rod Retainer
Removal

Electrical Computer (DAD)
EF9160 Harness hookup to PMC
Connector.

562-98-31301 Disc Gauge Brake Disc Wear
Tool
During Retard Control & Monitor (RCM) trouble-

shooting for codes such as J004 (Rear Left Brake
Pressure Low) and J005 (Rear Right Brake Pressure PART NO. DESCRIPTION USE
Low), the switching of harness connectors between
the right and left PPC valves may be necessary. EJ9233 Right Hand PPC Circuit
Switching of the connectors can help determine Harness Diagnosis
where in the electrical circuit the problem lies, or
whether the problem is hydraulic.
The left PPC and right PPC circuits were wired with
different connectors in order to prevent the acciden- PART NO. DESCRIPTION USE
tal crossing of connectors. Because of the differing EJ9234 Left Hand PPC Circuit
connectors, two harnesses have been developed to Harness Diagnosis
allow crossing from one circuit to the other for trou-
bleshooting purposes. The two harnesses are listed
in the tables to the right.

ASSEMBLY SCHEDULE AND RESOURCE LAYOUT

MAJOR COMPONENTS AND SPECIFICATIONS
Engine Power Steering
The Komatsu HD1500-5 dump truck is powered by a The truck is equipped with a full time power steering
Komatsu SDA12V160 diesel engine. system which provides positive steering control with
a minimum of effort by the operator. The system
includes nitrogen-charged accumulators which auto-
matically provide emergency power if the steering
hydraulic pressure is reduced below an established
Transmission minimum.
The Torqflow transmission consists of a 3-element,
single-stage, two-phase torque converter and a plan-
etary gear, multiple disc clutch transmission which is
hydraulically actuated and force-lubricated for opti-
Brake System
mum heat dissipation.
Depressing the brake pedal, or operating the retarder
The Torqflow transmission is capable of seven for-
lever on the RH side of the steering wheel, actuates
ward speeds and one reverse gear. Automatic shift-
the hydraulic front and rear service brakes. Both front
ing is controlled by an electronic shift control system
and rear service brakes are oil-cooled, multiple-disc
with automatic clutch modulation in all gears. A
brakes. These brakes are automatically activated
lockup system consisting of a wet, double-disc
when the engine speed exceeds the rated revolu-
clutch, is activated in F1-F7 gears for increased fuel
tions of the shift position. The system includes two
savings.
nitrogen-charged accumulators for quick response,
and to provide emergency braking if a problem
occurs in the primary braking circuit.
Final Drive Assembly

Retarder
The final drive consists of a plug-in differential with
planetary wheel drive. The operator can manually apply both the front and
rear oil-cooled, multiple-disc brakes by moving the
retarder control lever which is mounted on the steer-
ing column, or by using the foot-operated brake
pedal.
Operator’s Cab
The operator's cab has been engineered for operator
comfort and to allow for efficient and safe operation
of the truck.
Suspension
The cab provides for wide visibility, with an integral 4-
Hydro-pneumatic suspension cylinders are used at
post ROPS/FOPS structure, and an advanced ana-
each wheel to reduce shock and provide riding com-
log operator environment. It includes a tinted safety-
fort for the operator and machine stability.
glass windshield and power-operated side windows,
a deluxe interior with a fully adjustable seat with lum-
bar support, a fully adjustable/tilt steering wheel, con-
trols mounted within easy reach of the operator, and
an electronic display/monitoring panel to keep the
operator informed of the truck's operating circuits.
Audible alarms and indicator lights warn the operator
of system malfunctions.
FAM0206 Major Components and Specifications 2-1

HD1500-5 MAJOR COMPONENTS
2-2 Major Components and Specifications FAM0206

SPECIFICATIONS
Engine Service Capacities
Komatsu . . . . . . . . . . . . . . . . . . . . . . . . SDA12V160 . . . . . . . . . . . . . . . . . . . . . . . .Liters . . U.S Gallons
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 12 Engine . . . . . . . . . . . . . . . . . . 193 . . . . . . (51)
Operating Cycle (diesel) . . . . . . . . . . . . . . . 4-Stroke (Includes Lube Oil Filters)
Rated . 1108 kW (1486 SAE Brake HP) @ 1900 rpm Cooling System . . . . . . . . . . . 532 . . . . . (140.6)
Flywheel . . . 1048 kW (1406 SAE HP) @ 1900 rpm Fuel Tank . . . . . . . . . . . . . . . . 2120 . . . . (560.0)
Weight (dry) . . . . . . . . . . . . . . . . .5813 kg (12,815 lb) Transmission . . . . . . . . . . . . . 153 . . . . . . (40.5)
And Torque Converter
TRANSMISSION Hydraulic System . . . . . . . . . 900 . . . . . . (238)
Automatic Electronic Shift Control with Automatic (Includes Retarder Cooling)
Clutch Modulation In All Gears. Differential . . . . . . . . . . . . . . . 300 . . . . . . (79.0)
Torque Converter. . . . . . . . 3-Element, Single-stage, Final Drive (each planetary) . 120 . . . . . . (31.7)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-phase
Hydraulic System
Lockup Clutch . . . . . . . . . . . . . . . Wet, Double-disc,
Hydraulic Pumps (3)
. . . . . . . . . . . . . . . . . . . . . . Activated in F1-F7 gears.
Hoist (Tandem Gear)
Transmission . . . . . . . 7 Forward Speeds, 1 Reverse . . . . 805 l/min. (213 gpm) @ 18 960 kPa (2,750 psi)
. . . . . . . . . . . . .Planetary Gear, Multiple Disc Clutch,
Steering (Piston Pump)
. . . . . . . . . . Hydraulically Actuated, Force-lubricated
. . . 221 l/min. (58.5 gpm) @ 18 960 kPa (2,750 psi)
Gear . . . . . . . . . . . . . . . . . . . . . kph . . . . . . . . mph Brakes (Tandem Gear) . . . . 1512 l/min. (400 gpm)
1 . . . . . . . . . . . . . . . . . . . . . . 11.0 . . . . . . . . . 6.8 Hoist Control Valve . . . . . . . . . . . . . . . . . Spool Type
2 . . . . . . . . . . . . . . . . . . . . . . 14.6 . . . . . . . . . 9.1 Positions. . . . . . . . . . Raise, Hold, Float, and Lower
3 . . . . . . . . . . . . . . . . . . . . . . 19.5 . . . . . . . . 12.1 Hydraulic Cylinders
4 . . . . . . . . . . . . . . . . . . . . . . 24.5 . . . . . . . . 15.2 Hoist . . . . . . . . . . . . . 3-Stage Telescoping Piston
5 . . . . . . . . . . . . . . . . . . . . . . 32.6 . . . . . . . . 20.3 Steering . . . . . . . . . . . Twin - Double Acting Piston
6 . . . . . . . . . . . . . . . . . . . . . . 44.2 . . . . . . . . 27.5 Relief Valve Setting . . . . . . . .18 960 kPa (2,750 psi)
7 . . . . . . . . . . . . . . . . . . . . . . 58.0 . . . . . . . . 36.0 Filtration . . . . . . . . . . . In-line Replaceable Elements
Rev . . . . . . . . . . . . . . . . . . . . . 10.6 . . . . . . . . . 6.6 Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Hoist & Steering . . . . . . . . . Dual, Full Flow, In-line
Final Drive Assembly . . . . . . . . . . . . High Pressure. Beta 12 Rating = 200
Final Drive . . . . . . . . . . . . . . . . . Plug-in Differential Transmission . . . . . . . . . . . . . . .Dual, High Pressure
. . . . . . . . . . . . . . . . . . . . with Planetary Wheel Drive
Reduction Ratios: Service Brakes
Bevel Set . . . . . . . . . . . . . . . . . . . . . . . . . 2.647:1 Actuation: . . . . . . . . . . . . . . . . . . . . . . . All-Hydraulic
Planetary Final Drive . . . . . . . . . . . . . . . . . 7.235:1 Front . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Total Reduction . . . . . . . . . . . . . . . . . . . 19.151:1 Rear . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
. . . . Both Act as both Service and Retarder Brakes
Electric System
Retarder Brakes:
Batteries (series-parallel). . 4 x 12V / 220 Amp-Hour Normally Applied . . . . . . . . Manually By Operator.
Alternator . . . . . . . . . . . 24 Volt, 240 Ampere Output Automatically Actuated . . . . . . . . . . . . . . . . . . . . . .
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt when engine speed exceeds the rated revolutions
Cranking Motors . . . . . . . . . . . Two - 24 Volt Electric of the shift position for the transmission.
Parking Brake: . . . . . . Spring-Applied, Oil Released
Steering
. . . . Dry Caliper Disc Actuates On Rear Drive Shaft
Turning Circle Diameter (SAE) . . . . . . 24.4 m (80 ft) Emergency Brakes:
Automatic Emergency Steering . . . .2 Accumulators An emergency brake valve actuates the brakes
automatically, if hydraulic pressure drops below a
pre-set value. Manual operation is also possible.
FAM0206 Major Components and Specifications 2-3

Tires Weight Distribution
Rock Service (E-3) . . . . . . . . . . . . . . . . . . . Tubeless Based on SAE 2:1 Heaped . . . . . .78 m3 (102 yds3)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 33.00 R51 (w/Komatsu Engine; and . . . . . . . . . 33.00 R51 Tires)
Rim Size . . . . . 61x 12.95 x 12.7 cm (24 x 51 x 5 in.)
Phase II Generation™ . . . . . . . Separable Tire Rims Empty . . . . . . . . . . . . . . . Kilograms . . . . .Pounds
Front Axle . . . . . . . . . . . . . . 49 025 . . . . . 108,082
Rear Axle . . . . . . . . . . . . . . 51 437 . . . . . . . 113,399
Dump Body Capacity (Standard) Total . . . . . . . . . . . . . . . . . . 100 462 . . . . . 221,481
Struck . . . . . . . . . . . . . . . . . . . . . . . 54 m3 (71 yds3) Loaded (100 Ton Payload)
Heaped @ 2:1 (SAE) . . . . . . . . . . 78 m3 (102 yds3) . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . .Pounds
Front Axle . . . . . . . . . . . . . . 82 327 . . . . . . .181,500
Rear Axle . . . . . . . . . . . . . . 167 149 . . . . . .368,500
Overall Truck Dimensions Total * . . . . . . . . . . . . . . . . . 249 475 . . . . . .550,000
Loading Height . . . . . . . . . . . . . . . . 4.965 m (16' 3") *Not to Exceed 249 475 kg (550,000 lb).
Minimum Clearance Height . . . . . . . . 5.85 m (19' 2") Including Options, Fuel & Payload
Overall Length . . . . . . . . . . . . . . . . . 11.37 m (37' 4")
Maximum Width . . . . . . . . . . . . . . . . . 6.62 m (21' 9")
2-4 Major Components and Specifications FAM0206

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 AND CAB

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32,660 . . . . . . . . . . . . . . . . . . . . . 72,000
Wheel Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003 . . . . . . . . . . . . . . . . . . . . . . . 2211
Tire 33R51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2177 . . . . . . . . . . . . . . . . . . . . . . .4800
Wheel & Tire Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3180 . . . . . . . . . . . . . . . . . . . . . . . 7011
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,211 . . . . . . . . . . . . . . . . . . . . . 24,716
Center Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 . . . . . . . . . . . . . . . . . . . . . . . .527
Left Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 . . . . . . . . . . . . . . . . . . . . . . . .816
Right Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 . . . . . . . . . . . . . . . . . . . . . . . .952
RH Deck Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 . . . . . . . . . . . . . . . . . . . . . . . .163
LH ROPS Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 . . . . . . . . . . . . . . . . . . . . . . . 1160
RH Upright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 . . . . . . . . . . . . . . . . . . . . . . .1000
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 . . . . . . . . . . . . . . . . . . . . . . . .825
Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2064 . . . . . . . . . . . . . . . . . . . . . . .4550
RH/LH Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 . . . . . . . . . . . . . . . . . . . . . . . .130
FAM0306 Major Component Weights 3-1

ITEM KILOGRAMS POUNDS
ENGINE, TRANSMISSION AND RELATED COMPONENTS

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6125 . . . . . . . . . . . . . . . . . . . . . . 13,503
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1191 . . . . . . . . . . . . . . . . . . . . . . . 2626
Upper Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 . . . . . . . . . . . . . . . . . . . . . . . . . 66
Lower Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 . . . . . . . . . . . . . . . . . . . . . . . . . 51
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3268 . . . . . . . . . . . . . . . . . . . . . . . 7205
Battery Box with batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363 . . . . . . . . . . . . . . . . . . . . . . . . 850
FRONT AXLE COMPONENTS

Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 . . . . . . . . . . . . . . . . . . . . . . . 2646
Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .509 . . . . . . . . . . . . . . . . . . . . . . . 1122
Wheel Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .960 . . . . . . . . . . . . . . . . . . . . . . . 2116
A-arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 . . . . . . . . . . . . . . . . . . . . . . . . 664
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 . . . . . . . . . . . . . . . . . . . . . . . . 289
FLUID COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 . . . . . . . . . . . . . . . . . . . . . . . . 399
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 . . . . . . . . . . . . . . . . . . . . . . . 1543
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .937 . . . . . . . . . . . . . . . . . . . . . . . 2066
Hydraulic Brake Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 . . . . . . . . . . . . . . . . . . . . . . . . 992
REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455 . . . . . . . . . . . . . . . . . . . . . . . 1003
Rear Axle Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 . . . . . . . . . . . . . . . . . . . . . . . . 243
Anti-Sway Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 . . . . . . . . . . . . . . . . . . . . . . . . 201
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,360 . . . . . . . . . . . . . . . . . . . . . . 29,454
3-2 Major Component Weights FAM0306

FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at WELD PROCEDURES
initial field assembly or during normal maintenance
repairs, special procedures must be followed. Electric arc welding, either the semi-automatic “MIG”
(GMAW), Flux Core (FCAW), or “Stick” electrode
Due to the continuous program of research and welding (SMAW), are approved processes for field
development, periodic revisions may be made to this installation and maintenance welding. Welding of
publication. It is recommended that customers con- highly stressed structural members such as castings,
tact their distributors for information on the latest revi- torque tubes, top and bottom plates on the frame
sion. rails, and the curved intersection points of frames
The welding information contained in this chapter is should be done with the specific detailed instructions
general information that must be followed unless oth- from Komatsu Product Service. See Annex A for
erwise specified in a detailed repair procedure pro- repair procedures. These repair procedures are
vided on an engineering drawing or a detailed detailed instructions for most high stressed structural
specific repair procedure. Additional specific informa- members.
tion, or detailed instructions can be obtained through
your local Komatsu customer support manager.
APPROVED CONSUMABLES
GMAW - LW102-15 or ER80S-D2
WELDER QUALIFICATION AND
TRAINING FCAW - E70T-5, E71T-8, or E71T8-NI1
The welding technique must be of the highest stan- SMAW - E7018-1, E8018-C1, or E8018-C3
dard to produce the soundest weld possible. Only
welders who have been trained and qualified for
structural steel welding in all positions, in conform-
ance with the American Welding Society (AWS) D1.1
WELD QUALITY REQUIREMENTS
or (AWS) D14.3 only, are allowed to perform the 1. Each weld must be homogeneous with low
welding. The welding instructions for field assembly porosity, free from cracks, and slag inclusions.
of Komatsu components are normally provided by 2. Each weld must have complete fusion between
engineering drawings. Additional detailed welding the base metal and weld metal added by the
instructions for field repairs are provided in the field electrode.
repair manual SEB14001. A full understanding of the
3. All welds must be reasonably smooth, without
AWS standard welding symbols is necessary to per-
excessive deformity, and all craters filled. No
form and inspect such field welds. Weld sizes speci-
cracks are permitted.
fied on the drawings are intended to reflect minimum
requirements. 4. The toe of a weld to a stressed member must
have a smooth transition. Excessive convexity
in multi-pass fillet welds is not permitted. Exces-
sive convexity produces high residual stress in
the throat of the weld, and is not permitted.
5. Undercut in excess of 0.8 mm (0.03 in.) on criti-
cal welds must be reworked by the application
of welding an additional cover pass. It is impor-
tant that this pass is blended with the existing
weld.
FAM0404 Field Welding Procedures 4-1

6. When welding in the vertical position, always 2. Low Ambient Temperature - DO NOT weld in
weld using the vertical up technique. Large temperatures below 50°F (10°C). At low tem-
wash weld weaves should not be used when perature conditions, preheating of all welding
welding on truck frames. Properly applied multi- joint work areas is required. See preheat and
ple pass welding is the required procedure on post heating requirements as detailed in Annex
truck frames. A.
7. Slag is to be removed from all weld beads, and 3. Weld Cooling - Protect the weld area from a
must be completely removed before each pass rapid cooling rate. Heat retardation may be
in a multiple pass procedure. It is also required accomplished through the use of heat lamps,
that all slag is removed and tie in all areas. torches, insulating blankets, etc.
Grind all welds where a weld crosses or inter- 4. Moisture - Any moisture on the steel surfaces to
sects with another weld. be welded must be removed before welding.
Electrodes must be stored in sealed containers
until needed. Electrodes must be kept in a
warming oven at the work location until used to
prevent any moisture absorption which might
MATERIALS, CONTROLS, AND affect weld quality.
PRECAUTIONS 5. Foreign Materials - Any foreign substances
The steel used in the fabrication of all Komatsu (dirt, paint, rust, scale, and carbon deposits
equipment is of high strength low alloy (HSLA) mate- from cuttings) must be removed prior to weld-
rial of different grades. The standard dump body ing. Clean all weld areas and surfaces with a
main plates are made from abrasion resistant materi- grinder to ensure that all foreign materials have
als. These materials offer themselves very well to been removed.
welding during fabrication, and repair.
The welding consumables are often supplied by
Komatsu America Corp. with the new equipment as WELD INSPECTION
part of the field welding / assembly package. For field All welding repairs are subject to inspection by a
welding and repairs, the approved consumables as Komatsu appointed inspector or laboratory to insure
detailed, should be procured from a local, reliable quality. After the weld has been made it can be
supplier. Other highly specialized welding consum- inspected by a number of non-destructive evaluation
ables are available but have limited use on Komatsu techniques. The inspections can include any of the
structural components. Approval is required from methods listed below. All assembly welds and weld
your Komatsu customer support manager. repairs that are deemed unacceptable by the inspec-
Control of the welding area environment is essential tor must be corrected at no additional cost to
for producing proper and sound welds. Essentially, Komatsu. All weld repairs are also subject to addi-
five areas require attention and control. tional inspection.
1. Air Movement - Avoid areas where air move- 1. Visual Inspection - This is the process of look-
ment from wind, drafts, or blowers is prevalent. ing for potential defects such as undersized
This is particularly important when a shielding welds that can be checked with weld gauges
gas is being used as part of the welding pro- for, surface cracks, surface porosity, craters,
cess. and undercuts.
4-2 Field Welding Procedures FAM0404

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

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

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

FIGURE 4-1. TOE HAMMER PEENING

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

BIBLIOGRAPHY
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earthmoving and
Construction Equipment
Metals and How to Weld Them - James F. Lincoln
Arc Welding Foundation. Cleveland, Ohio
Procedure Handbook of Arc Welding - Lincoln Elec-
tric Company, Cleveland, Ohio
American Welding Society - Welding Handbook
British Standard BS5135 - Metal Arc Welding of Car-
bon and Carbon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The
Welding Institute, F. R. Coe, Author

RECEIVING & ASSEMBLY PREPARATION
1. Inspect all components for possible shipping 5. Clean all mounting surfaces on the chassis and
damages. Note any damage found and report to on the individual components.
shipping agent. 6. Check all electrical connectors and verify they
2. Spread out all parts and organize per unit num- are free of paint and/or corrosion. Clean any
ber. Check for missing parts. List the unit num- connector with questionable electrical continu-
ber of all major components. Verify the cab and ity.
decks are with the correct chassis. 7. Check all factory installed components for the
3. Inspect rear suspension spherical bearings to proper tightening torque.
ensure proper pin fit and movement. 8. Arrange the work site as shown on the following
4. Install support blocks under the frame at the page.
hoist cylinder mounts. The support blocks must
be approximately 76 cm (30 in.) high.
FAM0504 Receiving & Assembly Preparation 5-1

ASSEMBLY LAYOUT
5-2 Receiving & Assembly Preparation FAM0504

CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines BASIC ASSEMBLY PROCEDURE
varies. Photographs or illustrations used in the fol-
lowing procedures are provided as general guide- 1. Site preparation
lines only. Actual assembly may be different, but this 2. Unload truck components
general procedure provides a basic outline for 3. Assemble the chassis
assembly. 4. Weld the body
Items like the hydraulic tank and the accumulators NOTE: Chassis assembly and body welding may be
may have been removed for shipping and will have to done in either order, or simultaneously. The most
be locally installed. logical order depends on available resources such as
Each shipment may be different, depending on the cranes, welders, assemblers, etc.
truck configuration and destination. 5. Static checkout (electrical & mechanical)
6. Install the body
7. Dynamic checkout (electrical & mechanical)
RECOMMENDED ASSEMBLY DATA 8. Site cleanup
1. Service Report (Pre-Delivery)
2. Acknowledgement of Receipt of Company War-
ranty
3. Assembly Blueprints & Schematics
4. Fluid Specifications (refer to the lubrication
chart in Section 10, Appendix)
5. Suspension Oiling & Charging Procedure
(available in Section 10, Appendix)
6. Fan Drive Adjustment Procedure (available in
the engine service manual)
7. Toe-In Adjustment Procedure (Section 10,
Appendix)
8. Hydraulic Checkout Procedure (Section 10,
Appendix)
9. Hydraulic Brake Checkout Procedure (Section
10, Appendix)
10. Filter List (available in parts book)
11. Lubrication & Service PM Forms (available in
the operation and maintenance manual)
12. Component Weights - for crane reference
(available in Section 3 of this manual)
13. Standard Torque Chart (available in Section 10
of this manual)
FAM0606 Chassis Assembly 6-1

ORDER OF ASSEMBLY
The following list outlines a general assembly order 14. Center deck
for building the truck. It is possible for some of these 15. Weld both uprights
tasks to be performed out of order depending on fac-
16. Ladders, air cleaner piping, remaining hand-
tors such as manpower and location on the truck.
rails, mirrors, etc.
Before changing the order of assembly, however,
consider the impact on subsequent tasks. 17. Wheels and tires
NOTE: As stated earlier, shipping and packaging of 18. Install the dump body
large machines will vary. Some of these steps may 19. Connect hoist cylinders
change due to different shipping configurations and/
or truck options. 20. Install body accessories - mud flaps, body posi-
tion switches, etc.
21. Clean the truck
1. Chassis - Unload and place on support blocks
22. Install decals
2. Connect the rear axle.
23. Install lighting wiring
3. Front suspension, wheel and brake assembly
4. Fuel tank 24. Check and adjust suspension oiling and charg-
ing
5. Fit LH deck/ROPS support
6. Fit RH deck support 25. Charge steering accumulators
7. Fit LH upright 26. Add fluids
8. Weld deck supports
9. Fit RH upright NOTE: Prior to starting the engine, ensure the
steering pump case is full of oil.
27. Perform system check-outs
28. Clean the assembly area
29. Touch up paint
Do not weld the air cleaner and uprights until all 30. Operator training
decks and the operator cab are installed. Ratchet 31. Install fire suppression system, if applicable
pullers may be required to help align the struc-
tures for a proper fit.
10. RH deck, handrail and mirrors

11. Hydraulic brake cabinet
12. LH deck and handrails
13. Operator cab
6-2 Chassis Assembly FAM0606

HD1500 Chassis Assembly
Procedure
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at another loca-
tion may be different. However, this outline will pro- Disconnect the battery cables before welding on
vide a general basis for assembly. the truck. Failure to do so may seriously damage
the batteries and electrical equipment. Discon-
nect the battery charging alternator lead wire
before welding on the frame or its components.
Fasten the welding machine ground cable to the
component being welded.
Follow all safety recommendations in this man-
ual. Follow all local, state, and federal regula- DO NOT allow welding current to pass through
tions. bearings.
DO NOT lay welding cables over truck electrical
cables and harnesses. Welding voltages could be
In the procedures that follow, many very heavy com- induced into the truck wiring and cause damage
ponents will be required to be lifted into place and to components.
secured.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly purged and
ventilated.
Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
charged and in good working condition.
• Inspect all lifting devices. Slings, chains, and
cables used for lifting components must be
inspected daily for serviceable condition. Mark cap screws and nuts with paint or ink after tight-
Refer to the manufacturer’s guidelines for
ening to the specified torque. This method provides
correct capacities and safety procedures
when lifting components. Replace any verification that the hardware has been properly
questionable items. tightened.
• Slings, chains and cables used for lifting

must be rated for approximately two times the
intended load.
• When in doubt as to the weight of
components or any assembly procedure,
contact your customer support manager for
further information.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the
intended load.
• Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
• Before lifting, ensure there is adequate
clearance from overhead structures or
electric power lines.

GENERAL PRECAUTIONS AND
INSTRUCTION 13. Brake accumulators are normally charged with
1. Clean and remove all foreign material from nitrogen when shipped from the factory. Use
component mounting surfaces. proper precautions when checking pressures.
2. Mount the front suspensions first so that deck 14. Verify the lube system is lubricated, purged and
substructures can be installed while other com- all levels full prior to start up.
ponents are installed. 15. Purge air from the steering pump before truck
3. DO NOT weld the front uprights until all upper operation. Pressure will not build in the brake
decks are installed. and steering circuit if air is present. Air in the
4. Install the fuel return hose on the rearward most system may damage the pump. Refer to the
fitting on the fuel tank. Hydraulic Checkout Procedure in Section 10 of
this manual.
5. Torque the deck mounting bolts before the
exhaust tubes, etc. are installed. 16. Use the battery disconnect switch when weld-
6. Verify all electrical connectors are free from ing. Connect the weld ground near the weld
paint and/or corrosion. Clean any connector area.
that may be questionable.
7. Do not torque the diagonal ROPS beam until
after the operator cab & LH air intake tubes are
in place.
8. Before installing the cab to the substructure, tap
all threaded holes to remove paint.
9. Verify all wiring is properly connected before
attempting to start the engine.
10. Recheck the torque on hardware installed at the
factory.
11. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.
12. Steering accumulators are normally not charged
with nitrogen when shipped from the factory.
Use proper precautions when checking the
nitrogen pressure and oil level in the cylinder.

NOTES

1. The weight of the chassis, as shipped, is approximately 32,660 kg (72,000 lb). Lift the chassis off the trans-
port using two cranes. The cranes must be a minimum 45 metric ton (50 ton) capacity. Install support blocks
under the frame at the hoist cylinder mounts to raise the chassis for rear axle installation. The support blocks
must be approximately 76 cm (30 in.) high. Refer to Figures 6-1, 6 -2, & 6-3.
Thoroughly clean all mating surfaces if not done prior.

FIGURE 6-1.
FIGURE 6-3.
FIGURE 6-2.

2. The weight of the rear axle, as shipped, is approximately 13 360 kg (29,454 lb). Refer to Figure 6-4. Install the
rear axle under the frame. Connect the upper and lower links and the anti-sway bar. Install all pins and keep-
ers. Install the lower suspension mounting pins and keepers. Install the rear drive shaft and tighten the eight
cap screws to 382 ± 38 N·m (282 ± 28 ft lb).
The normal shipping arrangement for the chassis will include the three final drive attachment links (1
upper center, two lower sides) already installed to the main frame end. However, if for some reason these
are shipped separately, then they must be identified by part number and length to be certain that they are
installed correctly.
• The length of the center, upper link is 1460 mm (57.5 in.).
• The length of the lower links is 1490 mm (59 in.).
Misalignment of the rear drive shaft and final drive housing will occur if these parts are not installed cor-
rectly.
3. Attach two lifting slings and a hoist to the rear drive shaft. The weight of the drive shaft is approximately 220
kg (485 lb).
4. Lift the rear drive shaft into position between the transmission and the rear axle. Align the yokes on the drive
shaft. The yokes must be positioned in the same phase angle.
5. Apply Three Bond TB1741™ to cap screws (2). Install the eight cap screws and tighten to 382 ± 38 N·m (282
± 28 ft lbs).
6. Install the drive shaft guard. Refer to Figure 6-31.

FIGURE 6-4.

7. Install the front suspension/axle assemblies to each side of the truck. Each assembly weighs approximately
3,629 kg (8,000 lb). Refer to Figures 6-5 and 6-6.

FIGURE 6-5.
FIGURE 6-6.

8. Thoroughly clean the fuel tank saddle blocks. Lift the fuel tank into place as shown in Figure 6-7. The weight
of the fuel tank is approximately 937 kg (2,066 lb). Tighten the saddle block mounting cap screws.
10. Lift the ROPS support into place. This support weighs approximately 526 kg (1,160 lb). Secure the support
with the mounting cap screws. Weld the support according to the specifications outlined on the assembly
print. Refer to Figure 6-8.

FIGURE 6-7.
FIGURE 6-8.

11. Lift the right rear deck support into place. The support weighs approximately 74 kg (163 lb). Secure the sup-
port with the mounting cap screws. Weld the support according to the specifications outlined on the assembly
print. Refer to Figure 6-9.
12. Lift the left upright into position. This upright weighs approximately 374 kg (825 lb). Secure the upright with the
mounting cap screws. Refer to Figures 6-10, 6-11, & 6-12. DO NOT weld the upright at this time.

FIGURE 6-9.
FIGURE 6-10.

13. Weld both deck supports according to blueprint specifications. Refer to Figures 6-11 & 6-12.

FIGURE 6-11.
FIGURE 6-12.

14. Lift the RH upright into position. The upright weighs approximately 454 kg (1,000 lb). Secure the upright with
the mounting cap screws. Refer to Figure 6-13. DO NOT weld the upright at this time.

FIGURE 6-13.

10. Lift the RH deck into position. The weight of the deck is approximately 432 kg (952 lb). Install the mounting
hardware to secure the deck.
Install the handrails and mirrors onto the deck. These may be installed prior to deck installation. Refer to Fig-
ure 6-14.

FIGURE 6-14.

11. Lift the hydraulic brake cabinet into position. Refer to Figure 6-15. The weight of the cabinet is approximately
450 kg (992 lb).
12. Lift the LH deck into position. The weight of the deck is approximately 370 kg (816 lb). Install the mounting
hardware to secure the deck. Refer to Figures 6-16 and 6-17.
Install the handrails and mirrors onto the deck. These may be installed prior to deck installation.

FIGURE 6-15.
FIGURE 6-16.

13. Lift the operator cab into position on the left deck. The weight of the cab is approximately 2064 kg (4,550 lb).
Install the cab mounting hardware and tighten to 949 N·m (700 ft lb). Refer to Figure 6-17.

FIGURE 6-17.
FIGURE 6-18.

14. Lift the center deck into position on the truck. The deck weighs approximately 239 kg (527 lb). Install the
mounting hardware to the deck.
15. After installation of the decks and the cab, the welding process can be completed. Weld the uprights into
place.
16. Complete all hydraulic piping and electrical connections to the cab and the hydraulic cabinet. Refer to Figures
6-18 and 6-19.

FIGURE 6-19.
FIGURE 6-20.

17. Install the ladders. Refer to Figure 6-20.
18. Install the air cleaner piping and hangers.
19. Finish the installation of all handrails and mirrors. Refer to Figure 6-21.

FIGURE 6-21.
FIGURE 6-22.

20. Remove all dirt, debris and rust from mating parts before installing the wheel.
21. Grasp the wheel with the tire handler and position the wheel on the wheel hub. The weight of the wheels is
approximately 3180 kg (7011 lb). Align the notch in the wheel hub with the rim stopper. Refer to Figure 6-22.
22. Install wheel clamps and nuts. Moderately tighten the clamp nuts in the sequence specified in Figure 6-25.
Rotate the wheel, then check that the lateral runout of the rim is within 5 mm (0.20 in.). Adjust the wheel as
necessary.
23. Continue tightening the nuts to 2210 ± 245 N·m (1630 ± 181 ft lb) following the proper sequence.
24. Adjust the tire inflation to the tire manufacturer's recommended pressure.
25. After the truck is operational, drive the truck for one load and tighten the wheel nuts again. Use the same
torque specifications as previously outlined.
26. Check the torque daily until the specified torque value listed above is maintained on each nut. Check the
torque intermittently, thereafter.

FIGURE 6-23.
FIGURE 6-25.
FIGURE 6-24.

27. Complete all hydraulic piping, electrical wiring, mechanical connections, and clamping. Refer to reference
photographs, Figures 6-26 through 6-32.

FIGURE 6-26. BATTERY DISCONNECT
FIGURE 6-27. FRONT WHEEL / BRAKE

FIGURE 6-28. FRONT BRAKE
FIGURE 6-29. FRONT WHEEL LINKAGE

FIGURE 6-30. REAR AXLE
FIGURE 6-31. REAR DRIVE SHAFT

FIGURE 6-32. LUBRICATION INJECTORS AND FILTER PIPING
28. Install the dump body. Refer to Sections 7 & 8 for dump body installation.

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

advisable to move the parts to be welded into an
enclosed shop area. Surfaces to be welded must be
dry and the temperature must be above 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.
20,000 kg (44,082 lb). Use two cranes for assem- In most instances, it is easier to assemble and weld
bling the body. A 45 metric ton (50 ton) crane and the body while the sections are upside down. After
a 109-136 metric tons (120-150 ton) crane are the pivot, guide pin, and body pads are welded in
required. The larger crane is needed to help turn place, the body can be turned over and the remain-
the body over after completion of the underside der of the assembly can be completed.
welding.
All paint must be removed from surfaces to be
Assembly of the body must be performed on flat ter- welded. Use a wire brush or paint removal equip-
rain with an adequate area for welding machines and ment.
for maneuvering lifting equipment. Refer to the assembly blueprints shipped with the
truck for specific welding details and the parts
required for assembly.
Body sections must be assembled as originally

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

1. Canopy 4. Lift Hole 7. LH Side Sheet
2. Front Sheet 5. Floor
3. RH Side Sheet 6. Pivot
FAM0704 Dump Body Assembly 7-1

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

procedures assume the body is in its' normal, upright
position, as shown in Figure 7-1.
1. Organize the body sections in a large, flat,
open space. Position the sections side by side
and upside down. Arrange the sections so they
are properly oriented for assembly. Refer to
Figure 7-2 for domestic configuration, and 7-3
for international configuration.
FIGURE 7-4.
5. Use the hydraulic jack to align the body halves
at the rear. Install cap screw (1, Figure 7-5) and
the sleeve.
NOTE: Figure 7-5 shows the hardware numbered in
installation sequence. Cap screws (1, 2 & 7) are
marked with an asterisk (*). These cap screws are
installed with sleeves. The remainder of the cap
screws do not have sleeves.
6. Install cap screw (2) and the sleeve at the front
FIGURE 7-2. DOMESTIC LAYOUT of the floor.
7. Install cap screw (3) in the front sheet near the
floor. Attach a wedge or a clamp inside the
body as necessary to align the front sheet.
8. Use a wedge to align the front sheet and can-
opy. Install cap screws (4, 5 & 6).
9. Install cap screw (7) and the sleeve in the front
of the canopy.
10. Install cap screws (8 & 9).
11. Install the backer strips on the front sheet center
joint as shown on the assembly blueprint.
NOTE: The backer strips must be tack welded in a
location where the tack will be burned away on the
FIGURE 7-3. INTERNATIONAL LAYOUT first pass.
12. Loosely install cap screws (10 & 11) in the floor.
13. Loosen cap screws (1 & 2).
2. Remove the paint from the weld areas. 14. Attach appropriate lifting apparatus to the body
3. Lift the RH body half and support the front pivot. Insert the lifting apparatus through the
sheet, side sheets, and rear edge of the floor body pin bores. The weight of the pivot is
with blocks. Refer to Figure 7-4. approximately 1317 kg (2904 lb). DO NOT dam-
4. Lift the LH body and support with blocks under age the bores.
the front sheet and side sheet. Position a 15. Lift the pivot over the body. Lower the pivot into
hydraulic jack on blocks at the tail end to sup- position against the rear of the body, as shown
port the floor at the rear. Refer to Figure 7-5. in Figure 7-6. Align the pivot with the body sills.
7-2 Dump Body Assembly FAM0704

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

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

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

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

3. Install the remaining gussets, the body guide
and the body pad mounts.
DO NOT install the heated body exhaust boxes

onto the body at this time. The exhaust boxes
must be installed after the body is installed onto
the truck.
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.
Position the body onto support blocks as shown
in Figure 7-14.
FIGURE 7-9.
The following photographs show a typical exam-

ple of a body being inverted with two cranes. The
pictures were taken from a different model truck
and are only used as a reference.
FIGURE 7-10.
FIGURE 7-8.

FIGURE 7-11. FIGURE 7-13.
FIGURE 7-12.
FIGURE 7-14.

5. Refer to Figure 7-7 and the body assembly 6. Install any remaining components as specified
print to complete the welds on the inside of the on the installation blueprints.
body.
7. Install any optional equipment such as body lin-
ers and side boards.
8. Clean the weld joints and paint.
FIGURE 7-15.
FIGURE 7-16.

NOTES

DUMP BODY INSTALLATION
• Inspect all lifting devices. Slings, chains, and 1. Attach appropriate lifting cables and a hoist of
cables used for lifting components must be to the dump body. A typical body, as shown in
inspected daily for serviceable condition. Figure 8-1, weighs approximately 20,000 kg
Refer to the manufacturer’s guidelines for (44,082 lb). Lift the body and lower into position
correct capacities and safety procedures over the truck frame. Align the body pivot and
when lifting components. Replace any frame pivot holes.
questionable items.
2. Install shims (2 & 3, Figure 8-2) in both body
• Slings, chains and cables used for lifting pivots as required to fill the gaps. Center the
must be rated for approximately two times the body on the frame pivot. A minimum of one
intended load.
shim is required at the outside end of both
• When in doubt as to the weight of frame pivots.
components or any assembly procedure,
contact your customer support manager for
further information.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the
intended load.
• Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
• Before lifting the body, ensure there is
adequate clearance between the body and
overhead structures or electric power lines.
• Use a lifting device that is rated for at least a
25 ton capacity.
FIGURE 8-2. DUMP BODY PIVOT PIN

(Section B-B, Figure 8-4)
1. Body Pivot Pin 4. Pivot Bushing

2. Shim/Spacer 5. Cap Screw
3. Shim/Spacer 6. Lock Nut
3. Lift the pivot pin into position and align the pin
retainer cap screw hole. The weight of the pin is
approximatelly 49 kg (108 lb). Push pivot pin (1)
through the shim(s) and into the pivot bushings
in each side of the frame.
4. Install cap screw (5) through each pin. Install
FIGURE 8-1. DUMP BODY REMOVAL nut (6) and tighten.
1. Lifting Cables 2. Guide Rope
FAM0806 Dump Body Installation 8-1

7. Remove the shipping plates from the hoist cyl-
inder ports, and reinstall the hoses onto the
ports. New hardware is provided to install the
hoses without the plates.
Failure to remove the shipping plates from the

hoist cylinder hose ports may result in hose fail-
ure, personal injury, or death. Remove the plates
and reinstall the hoses before operating the
dump body.
FIGURE 8-3. HOIST CYLINDER UPPER MOUNT

1. Retainer 4. Retainer Ring
2. Cap screw & Washer 5. Bearing
3. Pin 6. Hoist Cylinder
5. Align the hoist cylinder upper mounting eye

between the mounting ears. Align the retainer
slot in pin (3, Figure 8-3) with retainer (1). Install
the pin.
6. Install pin retainer (1) and cap screws (2). Posi-
tion the retainer to obtain 0.5 mm (0.020 in)
clearance between the retainer and the bottom FIGURE 8-4. SHIPPING PLATE REMOVAL
of the slot in body pin (3). Tighten the cap
screws to standard torque. Repeat for the 1. Shipping Plate 2. Hoses
remaining cylinder.
8. Install the mud flaps, electrical cables and lubri-

cation hoses.
9. Install the rock ejectors. Refer to Rock Ejectors
in this chapter for installation information.
8-2 Dump Body Installation FAM0806

FIGURE 8-5. BODY COMPONENT LOCATIONS
1. Dump Body View A-A. Rock Ejector (See Figure 8-7)
2. Body-Up Retention (Safety) Cable View B-B. Body Pivot Pin (See Figure 8-2)
View C-C. Body Guide (See Figure 8-6)
View D-D. Body Pads (See Figure 8-5)
BODY PADS
Inspect the body pads during scheduled mainte-
nance inspections. Replace if damaged or worn,
excessively.
1. Raise the body to a height sufficient to allow
access to all body pad mounts.
Place blocks between the body and the frame.

Secure the blocks in place.
2. Remove the hardware attaching the pads to the
dump body. Refer to Figure 8-5.
3. Install the body pads and shims, noting the
quantity of shims required at each pad. The rear
pads have one less shim than the other pads. FIGURE 8-6. BODY PAD INSTALLATION
4. Install the mounting hardware and tighten. 1. Nut 6. Mounting Pad
5. Remove the blocks from between the body and 2. Lock Washer 7. Shims (as required)
the frame. Lower the body onto the frame. 3. Cap Screw 8. Body Pad
4. Flat Washer 9. Main Frame
5. Dump Body

Body Pad Adjustment BODY GUIDES
NOTE: The truck must be parked on a flat, level Install the body guides as shown in Figure 8-6.
surface for this adjustment. Inspect body guide wear plugs (2, Figure 8-6) each
1. All pads, except the rear pads, should contact time a body pad inspection is performed. If the gap
the frame with approximately equal compres- becomes excessive, replacement parts must be
sion of the rubber. installed.
2. A gap of approximately 1.5 mm (0.06 in.) is
required at each rear pad. This can be obtained
by using one less shim at each rear pad.
3. If pad contact appears to be unequal, repeat the
above procedure.
Proper body pad to frame contact is required to

ensure maximum pad life.
FIGURE 8-7. BODY GUIDE

1. Body Guide 3. Body Rail
2. Body Guide Wear Plug 4. Main Frame

BODY-UP RETENTION CABLE ROCK EJECTORS
Rock ejectors are placed between the rear dual
wheels to keep rocks and other material from lodging
between the tires. Failure to maintain the rock ejec-
tors could result in a build up of debris between the
dual wheels. Debris build up may lead to tire dam-
When performing maintenance on the vehicle age.
with the dump body raised, the body-up retention
cable must be installed. Inspection
1. The ejectors must be positioned on the center
line between the rear tires within 5 mm (0.20
To install the cable: in.).
1. Raise the body to it's maximum height. Refer to 2. With the truck parked on a level surface, the
Figure 8-4. arm (refer to Figure 8-7) must be approximately
2. Remove cable (2) from its stored position on the 109 mm (4.3 in.) from the wheel spacer ring.
body. Connect the cable between dump body NOTE: With rock ejector arm (1, Figure 8-7) hanging
(1) and the axle housing ear. vertical as shown in Figure 8-7, there must not be
3. Secure the cable clevis pins with cotter pins. any gap between the arm and the stop on bracket
4. Allow the body to lower until supported by the (2).
cable. 3. If arm (1) is bent, remove the arm and
5. After maintenance is complete, reverse the straighten.
above procedure to remove the cable assembly 4. Replace wear plates that are severely worn.
and place it in the storage position. 5. Inspect brackets (2) and pins (3) at each shift
change for wear and damage. Repair as neces-
sary.
FIGURE 8-8. ROCK EJECTORS

1. Rock Ejector Arm 4. Washer
2. Rock Ejector Bracket 5. Cotter Pin
3. Pin

HEATED BODY EXHAUST BOX
The standard body on HD1500 trucks utilizes a
heated body design. Engine exhaust flows through
the exhaust piping and enters dump body (1, Figure
8-8) through exhaust coupling (3). From the box,
exhaust flows into the front sheet to warm the body
and its contents. Exhaust exits the body through the
side panels. When the body is raised, the connection
to the body is broken. Exhaust is vented to the atmo-
sphere at exhaust tube (4).
The exhaust coupling is mounted on exhaust box (2).
The adjustment of the exhaust coupling is extremely
important in ensuring that no exhaust leakage occurs
at the coupling-to-exhaust tube joint. The coupling
contains a spring mechanism that maintains suffi-
cient force to create a seal between the tubing and
the exhaust coupling when the body is lowered. If the
exhaust box or the coupling is not properly installed,
exhaust leakage will occur.
FIGURE 8-9. BODY HEATED EXHAUST COUPLING
Because of the many tolerances in the body assem-
1. Dump Body 3. Exhaust Coupling
bly and installation, it is not possible to attach the
2. Exhaust Box 4. Exhaust Tube
exhaust box to the body before installing the body
onto the chassis. The dump body, body guides, and
body pads must be properly installed and adjusted
before welding the exhaust box to the body.
The details and specifications for installing the
exhaust box are located on the installation prints sup-
plied at machine shipment. Follow the exact instruc-
tions on the prints to ensure proper installation,
operation, and component durability.

BODY POSITION SWITCHES
Two magnetically activated proximity switches sense Inside the body limit switch, there are two magnets of
the position of the truck dump body. The body-up slightly varying strengths in line with one another.
switch (5, Figure 8-11) is located inside the left frame The magnets are located on separate ends of a
rail, forward of the body pivot. This switch provides a rocker lever assembly which contains the functional
"body seated" signal to the transmission controller switch contacts. In the non-actuated or rest state, in
when the body is resting on the frame. When the which there is no disturbance in the internal switch
body is raised above the frame rail (magnetic field natural magnetic fields, the stronger magnet domi-
removed from the switch sensing area), the switch nates the rocker into the “normal” position. Refer to
sends a "body float" signal to the transmission con- Figure 8-9.
troller. A warning lamp on the instrument panel left When the field of the dominate magnet becomes dis-
pod illuminates to inform the operator. tracted by a target, (a ferrous plate, or an opposite
NOTE: The body float lamp will also illuminate if the polarity magnet field (south pole)), the weaker mag-
hoist control is not in the FLOAT position or if there is net in the switch will then become more dominate
an open circuit between the switch and the and move the rocker lever. The switch is then consid-
transmission controller. ered to be actuated or in the “sensed” position.
Hoist limit switch (9) is located on the left frame rail
just behind the pivot. The hoist limit switch sends a
signal to the hoist limit solenoid (in the hydraulic cab-
inet), which activates and blocks oil flow from the
hoist pilot valve to the hoist valve. The “power up” oil
supply is blocked to prevent full hoist cylinder exten-
sion, and possible damage to the cylinders. Proper
switch adjustment insures the hoist cylinder travel
stops slightly before full extension.
If either the body up switch or the hoist limit switch do
not function as described above, adjust the switches
according to the procedure on the following pages.
Proximity Switch Operation

The body position switches on these trucks are mag-
netic field change operation switches. The switches
can sense a ferrous material target, as well as a spe-
cific pole (south pole) magnet field. When a switch is
activated by ferrous material, the maximum sensing
distance is approximately 13 mm (0.5 in.). When a
magnet is used instead of ferrous material, maximum
sensing distance is approximately 95 mm (3.75 in.).
Therefore, use of a magnet target allows the switch
to activate at greater sensing distances.
FIGURE 8-10. SWITCH CONTACTS - NORMAL

AND SENSED POSITIONS

Body-Up Switch Adjustment
Figure 8-11 shows two views of the body-up switch
(5) and the magnet used to activate the switch.
If switch adjustment is necessary, follow the proce-
dure below:
1. Verify proper pin orientation as shown in Figure
8-10.
1. With the body resting completely on the frame,
loosen the switch mounting cap screws (6) and/
or the magnet adjustment cap screws (3).
2. Position the lower edge of the magnet near the
upper edge of proximity switch (5) as shown in
view A-A.
FIGURE 8-11. PROXIMITY SWITCH PIN 3. Adjust the proximity switch so the passing dis-
IDENTIFICATION tance between the two targets is 15 mm (0.59
in). Tighten cap screws (6) and recheck vertical
A. Blue - Normally Open C. Green - Ground adjustment. If necessary, readjust and tighten
B. Red - Normally Closed D. Black - Common cap screws (3).

FIGURE 8-12. BODY-UP AND HOIST LIMIT SWITCHES
1. Body - Raised Position 6. Switch Mounting Cap Screws
2. Body - Resting on Frame 7. Mounting Bracket (On Frame)
3. Magnet Adjustment Cap Screws 8. Switch Mounting Cap Screws
4. Magnet 9. Proximity Switch (Body Limit)
5. Proximity Switch (Body-Up) 10. Magnet (Body Limit Switch)

Hoist Limit Switch Adjustment
Prior to adjustment, the body must be raised to maxi-
mum hoist cylinder extension and supported.
1. Verify proper pin orientation as shown in Figure
8-10.
2. With the body fully raised, loosen the proximity
switch adjustment cap screws (8), and slide the
switch up or down to position the top of the
switch 25 mm (1 in.) away from the lower edge
of magnet (10). Tighten the cap screws when
adjusted properly.
NOTE: Since a magnetic target is used to activate
the switch, a larger initial distance in setting the
switch is required. This is due to the fact that
magnetic fields are not crisp 90 degree boxed fields
but are instead curved about the shape of the
magnet. The sensing field boundary limit takes on
the same curved sensing area shape of the magnet
field. The curved sensing area results in the
actuation of the switch approximately 25 mm (1 in.)
prior to reaching the edge of the magnet. Therefore,
it is crucial that the 25 mm (1 in.) is observed when
setting the body limit switch.
3. If necessary, loosen the cap screws securing
the proximity switch to the mounting bracket
and slide the switch in or out until the passing
distance between the two targets is 45 mm
(1.77 in). Tighten the cap screws after adjusting.
Refer to Figure 8-12 for an illustration of opti-
mum setting of the switch.
4. Lower the body onto the frame. FIGURE 8-13. HOIST LIMIT SWITCH
OPTIMUM SETTING
5. Check operation of the switch to verify that the
hoist cylinders extend, but stop before reaching
maximum cylinder stroke. If the cylinders
extend full stroke, adjust the switch, as neces-
sary, to prevent full extension.

FINAL CHECKOUT
Final checkout requires truck operation. 4. Purge any air from the pumps. Pressure will not
build if air is present. Operating the pumps with
Place the operation and maintenance manual and
air in the system will result in damage.
safety manuals in the operator cab, if not already
there. 5. Perform a final check of all systems. Several
checks are outlined in Section 10, Appendix.
Any personnel involved in the final check-out of the
6. Complete the checks listed in the Field Assem-
truck must read and understand all safety and oper-
bly Inspection Report Form. A copy of the form
ating instructions in the operation and maintenance
is provided with the truck and is also available in
manual.
Section 10, Appendix.
7. Operate the truck in a traffic-free area until safe
1. Complete delivery and warranty forms. operation has been validated.
2. Check all coolant and lubricants for proper lev- 8. Release the truck for use after all checks have
els and specifications. The lubrication chart is been completed and all deficiencies corrected.
shown in Section 10, Appendix.
3. Verify the shut-off valves in the hydraulic cabi-
net are open.
FAM0906 Final Checkout 9-1

NOTES
9-2 Final Checkout FAM0906

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 - EK8443
2. Suspension Oiling And Charging Procedure
3. Toe In Adjustment Procedure
4. Automatic Lubrication System Checkout Procedure
5. Air Conditioning Checkout Procedure - EL4302
6. Air Conditioning Drive Belt Adjustment Procedure - EL9330
7. Hydraulic Checkout Procedure - EF9081
8. Brake Checkout Procedure - EK3826
9. Payload Meter II Checkout Procedure - EJ5372
10. Electrical Checkout Procedure - EH0910
11. Standard Tables
12. Field Assembly Inspection Report - CEAW003505
13. 50 Hour Post-Commisioning Checksheet - CEAW004300
FAM1006 Appendix 10-1

NOTES
10-2 Appendix FAM1006

NOTES
OILING AND CHARGING PROCEDURES
GENERAL
These procedures detail the oiling and charging of Equipment List
the front and rear suspensions. Suspensions which
1. Service Kits:
have been properly charged will provide improved
handling and a better ride while improving the service - EC6027 Oil Charging Kit (Figure 4-5)
life of the suspensions, the truck main frame, and - EC3331Nitrogen Charging Kit (Figure 4-6)
other main components. 2. Jacks and/or overhead crane
NOTE: Inflation pressures and oiling/charging 3. Spacers (two) for oiling height; 95 mm (3.7 in.)
dimensions are calculated for original truck Gross 4. Oil - any of the following are acceptable:
Vehicle Weight (GVW). Any accumulation of dirt/
mud/debris on the truck or in the body must be • HO-MVK (Koma-Hydro MV)
removed before starting these procedures. Additions • Shell Tellus T32
to the truck weight (tailgates, water tanks, etc.) must
be considered part of the payload. Keeping the truck • Shell Tellus 46
GVW within the specification will result in a better • Castrol Hyspin AWS 46
ride and will extend the service life of the truck main
frame and suspensions.
5. Dry nitrogen (See Nitrogen Specifications Chart)
Proper charging of suspensions requires three basic
conditions be established in the following order: NITROGEN GAS SPECIFICATIONS
1. The oil level must be correct. PROPERTY VALUE
Nitrogen gas used in Nitrogen 99.9% Min.
2. The suspension piston rod extension for nitro-
suspension cylin-
gen charging must be correct, and this dimen- ders must meet or
sion maintained during nitrogen charging. Water 32 PPM Max.
exceed CGA Specifi-
3. Nitrogen charge pressure must be correct. cation G-10.1 for Dew Point -55°C(-68°F) Max.
Type 1, Grade F
For best results, suspensions must be charged in Nitrogen Gas. Oxygen 0.1% Max.
pairs (fronts together and rears together).
NOTE: Setup dimensions specified in the charts
must be maintained during oiling and charging
procedures. However, after the truck has been
operated, these dimensions will change.
All suspensions are charged with compressed
nitrogen gas with sufficient pressure to cause
injury or damage if improperly handled. Follow
all safety notes, cautions, and warnings in these
procedures to prevent accidents during servicing
and charging.
It is extremely important to properly maintain oil
and nitrogen levels on the suspension cylinders.
The oil is not only used to provide dampening,
but also to lubricate internal parts. If an oil leak is
present, it must be repaired, immediately. Excess
nitrogen charging will not compensate for an oil
leak. The lack of oil will cause excess friction in
the cylinder leading to suspension cylinder fail-
ure.
FRONT SUSPENSION Front Suspension Oiling
1. Park the unloaded truck on a hard, level sur-
face. Apply the parking brake, and block the
wheels.
2. Check that the bottom of each cylinder cover is
within the range designated by the arrows (Fig- Lifting equipment (crane or hydraulic jacks) must
ure 4-1) signifying correct nitrogen charge. be capable of lifting the weight of the truck.
Ensure that all personnel are clear of the lift area
3. If each suspension is within the area indicated
before the lift is started.
by the arrows, no service is necessary for the
front suspensions. See the note below for
guidelines. If a suspension is not within the area
indicated by the arrows, the front suspensions
will have to be serviced.
NOTE: The oil level must be checked:
• Before charging or adding nitrogen. A common mistake when adjusting the oiling
height is the failure to recognize and/or properly
• When there are signs of oil leakage. react to oil that contains trapped nitrogen or
• After rebuild/repair and the suspension is "foamy oil". Oil, such as this, is common when
installed on the truck the truck has recently been operating and the
suspension oil and gas haven’t been allowed to
.
settle and separate. This condition needs to be
handled properly to ensure that the suspension
receives the proper amount of oil. Failure to do
so may cause a low oil level resulting in prema-
ture component wear. Premature bearing and
seal wear can, in many cases, be attributed to
this occurrence.
If the truck has been operating, allow three to
four hours for the oil and nitrogen gas to sepa-
rate. An alternative is to purge the foamy oil and
replace with new oil. The wrong oiling height will
be observed if the oil level is checked\adjusted
with foamy oil or with air bubbles present.
FIGURE 4-1. FRONT SUSPENSION HEIGHT
Oil Quantity (approximate): 62.4 Liters (16.5 Gallons)
NOTE: DO NOT fill the suspension cylinder with oil

based on quantity alone. Oil quantities are given as
reference, only. Fill/adjust the oil level in the front
suspension to the oiling height listed in Figure 4-3.
Each suspension is equipped with a charging valve NOTE: If oil is discharged with the gas, tighten the
(3, Figure 4-2), an air bleed valve (1) and a pressure pressure sensor valve assembly slightly so only the
sensor (2). The pressure sensor assembly is used if gas will be discharged. If this is not possible, the
the truck is equipped with the payload meter and/or foamy oil will need to be purged from the suspension
the variable rate suspension. Disconnect the sensor during the oiling procedure, prior to charging.
wiring harness before continuing.
wheels.
2. Remove the outside suspension covers and
thoroughly clean the area around charging
valves (3, Figure 4-2).
3. Place a hydraulic jack (1, Figure 4-3) under the
main frame, and raise the jack until it contacts
the frame. The jack must be rated for a mini-
mum of 50 tons.
4. While wearing a face mask or goggles, dis-
charge the nitrogen pressure from the suspen-
sion by loosening pressure sensor valve FIGURE 4-2. VALVE AND SENSOR LOCATION
assembly (2, Figure 4-4) one revolution. DO 1. Air Bleed Valve 3. Charging Valve
NOT exceed one revolution. Nitrogen pressure 2. Pressure Sensor
cannot be released by loosening the pressure
sensor, itself. The schrader valve in the valve
assembly (2) will prevent nitrogen from being
released.
Releasing the nitrogen gas from the valve core of

charging valve (3, Figure 4-2) will damage the
valve core. Release the gas by loosening air
bleed valve (1, Figure 4-2) or sensor valve assem-
bly (2, Figure 4-4).
Loosening the pressure sensor valve assembly

more than three revolutions may result in the FIGURE 4-3. OIL HEIGHT
component being forced out of the suspension
by the gas pressure inside. This can cause seri- 1. Jack (50 ton min.) A: 97 ± 3 mm
ous bodily injury. DO NOT exceed one revolution. 2. Frame (3.8 ± 0.12 in.)
Wear a face mask or goggles while relieving
nitrogen pressure.
5. Adjust the hydraulic jack (1, Figure 4-3) so that
dimension "A" of the cylinder is 97 ±3 mm (3.8 ±
0.12 in.).
6. After all nitrogen pressure has been relieved,
tighten valve assembly (2, FIgure 4-4).
FIGURE 4-4. PRESSURE SENSOR

1. Schrader Valve 3. Sensor
2. Valve Assembly FIGURE 4-5. OIL CHARGING KIT (EC6027)
1. Hose 6. Pressure Sensor
2. Connector 7. Air Bleed Valve
3. Adapter 8. Air Bleed Hole
7. Remove charging valve (5, Figure 4-5), and 4. Fitting 9. Oil Pump Lever
install fitting (4). 5. Charging Valve 10. Oil Pump
8. Install adapter (3) to fitting (4), then connect the
hose and oil pump.
NOTE: Pressure sensor (6) must be installed, and
the air bleed valve (7) must be loose to ensure there
are no air pockets inside the suspension.
9. Loosen air bleed valve (7), then pump oil into Use caution when tightening the valves and fit-
the cylinder until no air bubbles or foamy oil is tings on the suspensions. DO NOT overtighten.
discharged from air bleed valve hole (8). Overtightening can damage the fittings or the
suspension housing resulting in gas and oil
leaks. Tighten to the specified torque.
10. When no more air bubbles or foamy oil is dis-
charged, tighten air bleed valve (7) to 44 ± 5
N·m (33 ± 3 ft lbs).
11. Remove pressure sensor valve assembly (6),
then operate the oil pump until no air bubbles or
foamy oil is discharged from the plug hole.
12. After all air and/or foamy oil is discharged,
install and tighten the pressure sensor valve
assembly to 44 ± 5 N·m (33 ± 3 ft lbs).
13. After filling with oil, remove the oil pump and fit-
tings, then install charging valve (5) and tighten
the valve to 44 ± 5 N·m (33 ± 3 ft lbs).
Front Suspension Nitrogen Charging
Dry nitrogen is the only gas approved for use in

the suspensions. Charging the suspensions with
oxygen or other gases may result in an explosion
which could cause serious injuries, fatalities,
and/or major property damage. Refer to Nitrogen
Gas Specifications at the beginning of this chap-
ter.
1. Remove the caps from charging valves (3, Fig-

ure 4-2).
NOTE: Before installing regulator (11, Figure 4-6,

blow out the cylinder connector with nitrogen gas,
965 kPa (140 psi) or more, to clean out all dirt or
dust. Dirt or dust in the system can cause
suspension failures.
FIGURE 4-6. NITROGEN CHARGING KIT (EC3331)
2. Connect the regulator to the nitrogen cylinder. 1. Nitrogen Cylinder Gauge
Open the valve on the gas cylinder, and check 2. Charging System Gauge
the pressure reading on regulator gauge (1). 3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Connection Valve w/EC2253 Adapter Installed
NOTE: The internal pressure of the gas cylinder must 6. Valve "T" Handle
be substantially higher than the suspension charging 7. Discharge Plug
pressure (refer to the chart in Figure 4-7). 8. Air Bleed Valve
9. Manifold
10. Charging Pressure Gauge (Suspensions)
3. Install the nitrogen charging kit to the suspen- 11. Regulator Valve (Nitrogen Pressure)
sions, as shown in Figure 4-6. 12. Dry Nitrogen Gas
4. Slowly turn the handle of regulator (11) clock- (see Nitrogen Gas Specifications at the begin-
wise. Adjust the pressure, shown on gauge (2), ning of this chapter)
to the required charging pressure (refer to the
NOTE: Parts may vary from the illustration above
chart in Figure 4-7). Then, open valves (3 & 4,
depending on the charging kit part number.
Figure 4-6) to fill the suspension cylinders with
nitrogen gas.
5. Fill the left and right cylinders at the same time.
Verify the required charging pressure on gauge 7. Turn handle (6) on valve adapter (5) fully coun-
(10) by closing valve (4). terclockwise to close the charging valve. Then,
6. When the left and right cylinders reach the remove the charging equipment, the hydraulic
specified length as shown in Figure 4-7, close jack, and install the suspension covers.
valve (4, Figure 4-6) to stop the flow of nitrogen 8. Use soapy water to check the charging valve,
gas. Turn the handle of regulator (11) counter- the air bleed valve and the pressure sensor fit-
clockwise to close the valve. tings for leaks. Repair as necessary.
9. Install the caps and O-rings onto charging
REAR SUSPENSION
General Information
If the rear suspension is being filled with oil while
installed on the truck, the angle in which the rear sus-
pension is positioned coupled with the location of the
charging valve port results in a significantly large vol-
ume of air being trapped inside the suspension. This
has the effect of lowering the oiling height since the
rear suspension can not be filled with the correct
amount of oil. To compensate for this, all HD1500/
530M rear suspensions being filled with oil while
installed on the truck should use the new "Installed
On Truck" oiling heights listed in Table 1.
When the suspension is in a vertical position while off
the truck, the oiling height will be different. All rear
suspensions being filled with oil while off the truck
should use the "On Bench" oiling heights listed in
Table 1.
FIGURE 4-7. FRONT SUSPENSION
Additionally, all HD1500 trucks beginning at serial
number A30053 were built with a new rear suspen-
sion assembly (EJ6044) that utilizes a shorter rear
DIMENSION CHARGING CHARGING suspension housing (1, Figure 4-11). The perfor-
HEIGHT PRESSURE mance characteristics of this suspension can be
improved by reducing the amount of oil in the cylin-
der to a new specification. The new rear suspensions
FRONT "A" 287 ± 10 mm 2758 kPa
can be identified by measuring the length of housing
(11.3 ± 0.4 in.) (400 psi)
(1). The new housing is approximately 34 mm (1.3
in.) shorter than the previous housing. The new
housing has an overall length of 510 mm (20 in.) from
Dimension "A" is measured from the top of the cover the surface adjacent to bearing retainer (2) to the top
to the top of the suspension cylinder plate. DO NOT of the cap. The previous housing measured 544 mm
include the capscrews in the measurement. The (21.3 in.). See Table 1 for the new oiling heights for
removal of an access panel on the top cover is each version of the rear suspension.
required.
NOTE: Replacement parts for original suspensions
(with the longer housing) are still available, as well as
NOTE: Setup dimensions specified in the charts the complete suspension assembly.
must be maintained during oiling and charging proce-
dures. However, after the truck has been operated,
these dimensions may vary. After charging the sus- NOTE: A short housing suspension can not be used
pensions, operate the empty truck over a short with a long housing suspension on the same truck.
course and then park the truck on a level surface. The difference in oiling and charging heights would
Record the dimensions again and save for periodic make it difficult to properly service each suspension,
reference. and could possibly cause premature suspension and/
or driveline failures.
Rear Suspension Oiling
1. Check whether dimension "A" (refer to Figure 4-
11) on each suspension cylinder is within the
specified value listed in Table 1. Refer to Gen-
eral Information for an explanation of listings in
Table 1. If dimension “A” is within specifications,
Service personnel must be aware that the trucks
no service is necessary for the rear suspen-
in a fleet could have different sized suspensions,
sions. See the note below for guidelines.
thus requiring different oiling and charging
height dimensions. Also, during the lifetime of a NOTE: The oil level must be checked;
truck, the original suspensions could be replaced
• Before charging or adding nitrogen.
by the newer suspensions (with the shorter
housing), requiring different oiling and charging • When there are signs of oil leakage.
heights. The service technician must properly • After repair/rebuilds.
identify each rear suspension cylinder before
performing any oiling or charging procedures. 2. If a suspension (Dimension “A”) is not within the
specified value, the rear suspensions must be
NOTE: The oiling block height has also changed. serviced.
Refer to Table 1 for the approximate block height.
Due to variances in frames and axle housings, one
oiling block height will not be accurate for all trucks.
Shims may also be required in addition to the block
to aid during the oil filling procedure. The oiling
A common mistake when adjusting the oiling
height of the cylinder must always be determined by
height is the failure to recognize and/or properly
using Dimension A or C, only.
react to oil that contains trapped nitrogen or
The “final charging height” in Table 1 is for suspen- "foamy oil". Oil, such as this, is common when
sions at normal operating temperature and must not the truck has recently been operating and the
be exceeded. After charging a cold suspension, suspension oil and gas haven’t been allowed to
operate the truck for several hours and check/adjust settle and separate. This condition needs to be
the charging height at normal operating temperature. handled properly to ensure that the suspension
If the suspensions are not checked/adjusted at nor- receives the proper amount of oil. Failure to do
mal operating temperature, the suspension height so may cause a low oil level resulting in prema-
may be incorrect, possibly causing excessive drive- ture component wear. Premature bearing and
line angles that could result in damage to powertrain seal wear can, in many cases, be attributed to
components. this occurrence.
If the truck has been operating, allow three to
four hours for the oil and nitrogen gas to sepa-
rate. An alternative is to purge the foamy oil and
replace with new oil. The wrong oiling height will
be observed if the oil level is checked\adjusted
with foamy oil or with air bubbles present.
Oil Quantity (approximate):

. . . . . . . . . . Long housing - 31.4 Liters (8.3 Gallons)
. . . . . . . . . . Short housing - 30.4 Liters (8.0 Gallons)
NOTE: DO NOT fill the suspension cylinder with oil

based on quantity alone. Oil quantities are given as
reference, only. Fill/adjust the oil level in the rear
suspension cylinders based on the oiling height
dimensions given in Table 1.
All suspensions are charged with compressed
nitrogen gas with sufficient pressure to cause
injury or damage if improperly handled. Follow
all safety notes, cautions and warnings in these
procedures to prevent accidents during servicing
and charging.

wheels.
2. Remove the outside suspension covers and
thoroughly clean the area around charging
3. Position the oiling spacer between the stopper
and the axle housing as shown in Figure 4-8 (if
servicing while on the truck). Dimension "A",
Figure 4-11, must be equal to the proper dimen-
sion listed in Table 1. FIGURE 4-9. OIL CHARGING KIT (EC6027)
NOTE: Oiling block dimensions are listed in Table 1. 1. Hose 6. Pressure Sensor
2. Connector 7. Oil Pump
3. Adapter 8. Dust Cover Band
4. Fitting 9. Dust Cover
5. Charging Valve
FIGURE 4-8. OILING BLOCK INSTALLATION

1. Oiling Block 3. Dust Cover
2. Cylinder
FIGURE 4-10. PRESSURE SENSOR
1. Schrader Valve 3. Pressure Sensor

2. Valve Assembly
Dimension "A" is measured from the retainer to the bottom of
the cylinder rod. Do not measure from the capscrews or cap-
screw heads.
Dimension "B" is measured from the housing surface (adjoin-
ing the bearing retainer) to the top of the cap.
Dimension "C" is measured from the center line of the top pin
to the center line of the bottom pin.
FIGURE 4-11. REAR SUSPENSION

1. Housing 2. Retainer
TABLE 1. REAR SUSPENSION OILING & CHARGING DIMENSIONS
Long Housing Short Housing

(EG6924 or EJ5532) (EJ6044)
mm (inch) mm (inch)
Housing Length (Dimension B) 544 (21.3) 510 (20.0)
Installed On Truck 187 ± 3 (7.4 ± 0.1) 221 ± 3 (8.7 ± 0.1)

Oiling Height (Dimension A)
On Bench 120 ± 3 (4.7 ± 0.1) 154 ± 3 (6.1 ± 0.1)
Installed On Truck 1148 ± 3 (45.2 ± 0.1) 1148 ± 3 (45.2 ± 0.1)

Oiling Height (Dimension C)
On Bench 1081 ± 3 (42.6 ± 0.1) 1081 ± 3 (42.6 ± 0.1)
Final Charge Height Dimension A 200 ± 10 (7.9 ± 0.4) 234 ± 10 (9.2 ± 0.4)
(Operating Temperature) Dimension C 1161 ± 10 (45.7 ± 0.4) 1161 ± 10 (45.7 ± 0.4)
Approximate Oiling Spacer Height 95 (3.7) 95 (3.7)

4. Disconnect the pressure sensor. 6. After all nitrogen pressure has been relieved,
remove the pressure sensor valve assembly.
7. Remove charging valve (5, Figure 4-9), and
install fitting (4).
8. Install adapter (3) to fitting (4). Connect the
Releasing the nitrogen gas from the valve core of hose and the oil pump.
charging valve (5, Figure 4-9) will damage the 9. Operate the pump until no air bubbles or foamy
valve core. Release the gas by loosening pres- oil is discharged from the plug hole.
sure sensor valve assembly (2, Figure 4-10) one
10. After all air and/or foamy oil is discharged,
revolution.
install the sensor valve assembly.
Use caution when tightening the valves and fit-

Loosening the pressure sensor valve more than tings on the suspensions. DO NOT overtighten.
three revolutions may result in the component Overtightening can damage the fittings or the
being forced out of the suspension by the gas suspension housing resulting in gas and oil
pressure inside. DO NOT exceed one revolution. leaks. Tighten to the specified torque.
Wear a face mask or goggles while relieving
nitrogen pressure.
11. Tighten the pressure sensor valve assembly to
44 ± 5 N·m (33 ± 3 ft lbs).
NOTE: If oil is discharged with the gas, tighten the 12. After the completion of oiling, remove the oil
valve slightly so only the gas will be discharged. If pump, and install charging valve (5). Tighten to
this is not possible, the foamy oil will need to be 44 ± 5 N·m (33 ± 3 ft lbs).
purged from the suspension during the oiling
procedure, prior to charging.
Rear Suspension Nitrogen Charging
Verify that all personnel are clear and support

blocks are secure before relieving nitrogen pres-
sure from the suspension. Use a face mask or Dry nitrogen is the only gas approved for use in
goggles when venting the nitrogen. suspensions. Charging of these components
with oxygen or other gases may result in an
explosion which could cause serious injuries,
5. While wearing a face mask or goggles, dis-
fatalities and/or major property damage. Refer to
charge the nitrogen pressure from the suspen-
Nitrogen Gas Specifications at the beginning of
sion by loosening pressure sensor valve
this chapter.
assembly (2, Figure 4-10) one revolution. DO
NOT loosen more than one revolution. 1. Remove the caps from charging valves (5, Fig-
ure 4-9).
NOTE: Before installing regulator (11, Figure 4-6),
blow out the connector with nitrogen gas at 965 kPa
(140 psi) or more, to clean out all dirt or dust. Dirt or
dust in the system causes failures.
2. Open the valve on the gas cylinder, and check Length Adjustment - Front And Rear Cylinders
the pressure at regulator gauge (1).
NOTE: Internal pressure of the gas cylinder must be NOTE: Adjust the installed length of the cylinder with
substantially higher than the suspension charging the truck on level ground and the body empty.
pressure, 1882 kPa (273 psi).
3. Slowly turn the handle of regulator (11, Figure

4-6) clockwise, and adjust the pressure at
gauge (2) to the required charging pressure,
1882 kPa (273 psi). Open valves (3 & 4) to fill
Depending on the ambient temperature, the gas
the suspension cylinders with nitrogen gas.
in the suspension may expand or contract
4. Fill the left and right cylinders at the same time. changing the length of the cylinder. In locations
Verify the required charging pressure is present where there are wide differences in temperature
at gauge (10). throughout the year, inspect the suspension
5. When the left and right cylinders reach the height periodically and adjust to keep the length
specified length, as shown in Figure 4-11, close within the specified range shown in Figures 4-7
valve (4) to stop the flow of nitrogen gas. Turn and 4-11 (Table 1).
the handle of regulator (11) counterclockwise to
close off nitrogen flow. 1. To reduce the sliding resistance of the cylinder,
6. When the left and right cylinders reach the drive the truck forward approximately 15 m (50
specified length, as shown in Figure 4-11 (Table ft.) and stop suddenly, then drive in reverse to
1), close valves (3 & 4, Figure 4-6) to stop the original position and stop suddenly again.
flow of nitrogen gas. Turn the handle on regula- Repeat this cycle 3-4 times, and finally, allow
tor (11) counterclockwise to close the valve. the truck to stop slowly without depressing the
7. Turn handle (6) on valve adapter (5) counter- brake. Then measure the installed length. If
clockwise to close the charging valve. After the equipped with variable rate damping, do not
valve is completely closed, remove the charging depress the service brake; use the retarder con-
equipment. trol lever to brake the truck.
8. Use soapy water to check the charging valve, 2. If the result of the check shows that the length is
the air bleed valve and the pressure sensor fit- too long, release nitrogen gas to adjust the
tings for leaks. Repair as necessary. length. Loosen the pressure sensor valve
9. Install the caps and O-rings onto the charging assembly no more than one revolution to
valves. release the nitrogen gas. When doing this,
release only a small amount of gas; the cylinder
should not move. If too much nitrogen gas is
released and the cylinder moves, the installed
length may be below the specified length.
DO NOT release nitrogen pressure by depressing

the tip of the valve core. Damage to the valve
core may result.
3. After releasing nitrogen gas and adjusting the
length, repeat Step 1 to check the installed
length again.
4. Repeat Steps 1-4 to adjust the cylinder to the
specified length.
5. Use soapy water to check the charging valve,
the air bleed valve and the pressure sensor fit-
tings for leaks. Repair as necessary.
Check the area around the piston rod gland for
leaks, as well.
6. The rear suspensions are now ready for opera-
tion. Visually check piston rod extensions both
with truck loaded and empty. Record extension
dimensions. Maximum downward travel is indi-
cated by the dirt ring at the base of the piston.
Operator comments on steering and suspen-
sion rebound should also be noted.
TOE IN ADJUSTMENT
The correct toe-in specification for these model trucks is zero (0) with the truck at the empty vehicle weight. As the
truck is loaded, the geometry of the suspension and steering will result in minor toe-in angles.
Adjustment Procedure
5. Measure the distance from the edge of the tire
1. Park the truck on a hard, level surface and
rim to the flat face of the frame. Measure this
chock the rear wheels.
distance at both the front and the rear of the left
2. Ensure the front and rear suspensions are oiled hand wheel. Refer to Figure 11-2.
and charged according to shop manual specifi-
6. Calculate the average distance from the two
cations. Refer to Suspension Oiling and Charg-
measurements obtained in Step 5. Record the
ing Procedures in this section. The suspensions
measurement.
must be properly charged and oiled to ensure
accurate toe adjustment. 7. Start the truck and steer the wheels until the
average measurement is achieved at the front
3. Inspect steering and suspension components
and rear of the left hand tire.
and replace any damaged and/or worn parts.
4. Place a hydraulic jack below the front suspen-
sion to A-arm pin on both sides of the truck. Ele-
vate the truck until the lower portions of the tires
are no longer bulged, but allow for full tread
contact with the ground across each tire.
Keep personnel away from the truck when oper-
Ensure the two jacks are at the same height.
ating the steering wheel. Personal injury may
Refer to Figure 11-1.
result. Depressurize the accumulators before
making adjustments to the steering linkage.
FIGURE 11-1. RAISING THE TRUCK

FIGURE 11-2. TIRE TO FRAME DISTANCES
8. Mark the centerlines of the tires on the faces of 13. Check tire wear periodically. If abnormal wear is
the tread at the front and rear of each tire. The evident, check for damaged or worn steering
vertical centerline should be a distance of 1220 components, and verify the toe is properly
mm (48 in.) from the ground surface. The hori- adjusted. Replace components as necessary,
zontal centerline should be exactly half the and adjust the toe.
width of the tire. Refer to Figure 11-3.
9. Measure the distances between centerlines at
the front and rear of the wheels. Record the
measurements.
10. Adjust the length of the tie rods until the two
measurements obtained in Step 9 are within 3
mm (0.118 in.) of one another. The tie rods Adjust the toe after replacing integral steering
must be adjusted equally. One full turn of the tie system components. Failure to adjust the toe
rods is approximately equal to 25.4 mm (1 in.) after replacing any components that may effect
of toe adjustment. the steering geometry may cause premature wear
11. Record the final distances between the front to the tires and other components.
and rear centerlines for future reference.
12. Remove the jacks and the wheel chocks from 14. Check the toe adjustment at every 500 hour
the truck. Operate the truck through several interval. If abnormal tire wear is evident, check
complete turn cycles. Recheck the measure- the adjustment, immediately.
ments, and readjust if necessary.
FIGURE 11-3. MARKING CENTERLINES ON THE TIRES
NOTES
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
RESERVOIR FILL PROCEDURE

Required Lubricant
• Above 32°C (90°F) - Use NLGI No.2 multi-
purpose grease.
• -32° to 32°C (-25° to 90°F) - Use NGLI No. 1
multi-purpose grease.
• Below -32°C (-25°F) - Refer to local supplier for
extreme cold weather lubricant requirements.
1. Remove top vent plug (14, Figure 3-1).

2. Remove bottom fill plug (15).
3. Connect the line from the lubricant delivery sys-
tem to bottom fill port (15). Fill the reservoir until
grease begins to come out of the top vent hole,
above.
4. Disconnect the line from the lubricant delivery
system and install plugs (14 & 15).
FIGURE 3-1. TYPICAL AUTO LUBE SYSTEM

1. Pump Cylinder 9. Solenoid Valve, SV1
2. Cyl. Pressure Gauge 10. Pressure Reducing
3. Valve Body Assy Valve
4. Orifice Assembly 11. Vent Valve Assy.
5. Pump Assembly 12. Grease Return Line
6. Canister/Reservoir 13. Grease Supply Line
7. Pump Cycle Timer 14. Top Vent Plug
8. Solenoid Valve, SV2 15. Fill Supply Port
SYSTEM PRIMING SYSTEM CHECKOUT
The system must be full of grease and free of air To check system operation (not including timer), pro-
pockets to function properly. After installation, it will ceed as follows:
be necessary to prime the system to eject all
1. Turn the key switch OFF and shut down the
entrapped air.
engine to de-energize the system. Install a
1. Fill the reservoir with lubricant. 35,000 kPa (5000 psi) pressure gauge in
2. Remove the plugs from all injector manifold grease supply line (13, Figure 3-1).
dead ends and supply lines. 2. Start the engine to energize the system.
NOTE: To operate the grease pump when priming 3. Lift the passenger seat, and connect a jumper
the lube system, start the engine to energize the wire between the SOL and LUBE SW terminals
system. Connect a jumper wire between the LUBE on the 24 VDC solid state lube timer. The pump
SW and SOL terminals on the solid state timer. The should begin to operate.
accumulators must be pressurized in order for the 4. Keep the jumper wire connected until the pump
grease pump to operate. stalls.
3. Operate the grease pump until grease flows 5. Observe the pressure gauge in the grease sup-
from any one plug opening in the system. ply line. Pressure should be 17,200 - 20,700
Replace the plug in this opening. kPa (2500 - 3000 psi).
4. Repeat Step 3 until all lines are full and all plugs
replaced.
NOTE: Fill each supply line with grease before
connecting the lines to the injector outlets and
bearings. This will prevent having to cycle the
individual injectors once for each 25 mm (1 in.) DO NOT exceed maximum pump pressure of
length of supply line between the injector and bearing 24,100 kPa (3500 psi). Exceeding this value will
fitting. damage components and may result in possible
injury to nearby personnel.
If the pressure is not correct, adjust the pres-
sure reducing valve as necessary. Refer to the
service manual for proper adjustment proce-
dures.
NOTE: DO NOT exceed 300 psi (2,100 kPa) on the
cylinder pressure gauge.
6. Disconnect the jumper wire. The system should
vent.
7. Turn the key switch OFF to de-energize the
system. Remove the 35,000 kPa (5000 psi)
pressure gauge and connect system compo-
nents.
Preventive Maintenance Procedures
The following maintenance procedures should be 4. Inspect all bearing points for a bead of lubricant
used to insure proper system operation. around the bearing seal.
Daily Lubrication System Inspection It is good practice to manually lube each bear-
ing point at the grease fitting provided on each
1. Check grease reservoir level. injector. This will indicate if there are any frozen
Inspect grease level height after each shift of or plugged bearings, and will help flush the
operation. Grease usage should be consistent bearings of contaminants.
from day-to-day operations. 5. System Checkout
• Lack of lubricant usage would indicate an Remove all SL-1 injector cover caps to allow
inoperative system. visual inspection of the injector cycle indicator
• Excessive usage would indicate a broken supply pins during system operation.
line. Lift the passenger seat and connect a jumper
2. Check all grease feed lines hoses from the SL-1 wire between the SOL terminal and the LUBE
injectors to the lubrication points. SW terminal on the 24VDC solid state timer.
Repair or replace all worn / broken feed line Start the engine. The hydraulic grease pump
hoses. should operate.
Make sure that all air is purged and all new feed Keep the jumper wire connected until the pump
line hoses are filled with grease before sending stalls out at 2000 psi.
the truck back into service.
With the pump in the stalled-out mode, check
3. Inspect key lubrication points for a bead of lubri- each SL-1 injector assembly. The cycle indica-
cant around seal. tor pin should be retracted inside the injector
Make note of all lubrication points that look dry. body.
Notify maintenance staff for repair service. Once all of the SL-1 injectors have been
inspected under pressure, remove the jumper
250 Hour Inspection
wire between the SOL terminal and LUBE SW
1. Check all grease feed line hoses from the SL-1 terminal on the timer assembly. The pump
injectors to the lubrication points. should shut off, and the system should vent
back to the grease reservoir, and the pressure
Repair or replace all worn / broken feed line
should drop to zero.
hoses.
With the system vented, check all of the SL-1
Make sure that all air is purged and all new feed
injector indicator pins. All of the pins should be
line hoses are filled with grease before sending
visible.
the truck back into service.
2. Check all grease supply line hoses from the NOTE: Refer to the system troubleshooting chart in
pump to the SL-1 injectors. the service manual if the injectors are not working
properly. Replace or repair injectors, if defective.
Repair or replace all worn / broken supply lines.
Reinstall all injector cover caps.
Make sure that all air is purged and all new sup-
ply line hoses are filled with grease before Check timer operation. With the engine on, the
sending the truck back into service. lube system should activate within 5 minutes.
The system should build 13,790 kPa (2000 psi)
3. Check grease reservoir level.
within 25-40 seconds. If the system is working
Fill reservoir if low. properly, the machine is ready for operation. If
the system is malfunctioning, refer to the trou-
Check reservoir for contaminants. Clean, if
bleshooting chart in the service manual.
required.
Check that all filler plugs, covers and breather
vents on the reservoir are intact and free of con-
taminants.
NOTE
NOTES
NOTES
KomatsuDleS.er
iII:ImIIiIt CHECK-OUT PROCEDURE I EF9081
'8.e 1 of
~ 3
NAME HDYRAULIC MACHINE & MODEL

SYSTEM 530M
WRITTEN BY DATE
P. Roach 5/21/96
CHECKED BY DATE
5/21/96 1 Keleased to l:'roductlon ) .l.l./)ft IOO'jT .t'K K.Jj
K. Byard
,.." I BY 0 STA.ASY. GP US[O ON N/R
DATE DASH DESCAII'TIOH
OF C:MANCO[ DATE [CN BY CI<"O
A Siul MICROFILM r I I I I I I I I I I r r I I II I I
INITIAL STARTUP & FLUSHING
1. Precharge steering accumulators to 1400 psi with dry

Nitrogen.
2. Install calibrated gauges at following locations:
a. 5000 psi gauge at _bleed-down manifold (steering
pressure) .
b. 5000 psi gauge at manifold center of horsecollar - each

port (crossover relief pressures).
c. Multiple range gauge at each hoist & brake cooling pump
outlet.
3. Flushinq: Disconnect "steer Supply" and "steer Rtn" Ports
at the bleed down manifold. Using special fitting with .25
dia. orifice and speci~l hose, connect steer supply and
steer rtn ports together.
4. Fill hydraulic tank to upper sight glass.
Note: Hydraulic oil will have to be added during initial

startup - pump damage will occur if this is not done!
5. Remove case drain line from top of piston pump. with clean
container, fill pump case with clean hydraulic oil. Replace
drain line.
6. Place hoist control lever in float position.
7. start engine at cold lo-idle (1025 rpm). Pressure at both
hoist pumps should be approx. 75 psi or less at 70° F. oil
temperature. Pressure at brake cooling pumps should be
approximately 25 psi or less at 70° F. oil temperature.
8. steering pump pressure should be approximately 500 psi at
!I:
- 70° F. oil temperature.
C"':I
9. If all pump pressures are okay, increase engine to 1500 rpm
=ct
c;:,
and flush for 20 minutes. t:J:j
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-....,
r-
10. After flushing is complete, stop engine and remove special
a
00
I-'
flushing plumbing. Reconnect original plumbing.
II:
.....,
I
t:::J I-'
Komatsu Dresser Company Hau1pak Division

671-1-9-88 Peoria, Illinois 61639 'a88 1 of 3
Komatsu Dresser
mm CHECK-OUT PROCEDURE EF9081
PaRe 2 of
- 3
1 ]
STEERING CHECKOUT
1. The Steering Pump Compensator should be preset to 2750 psi.

start engine; after accumulator has filled, steering pump
pressure should be 2750 ~ 50 psi. If it is necessary to
adjust the pressure, loosen locknut on compensator adjust -
to 2750 ~ 50 psi. Then tighten lock-nut.
2. To flush accumulator, start engine and let steering pressure
build to 2750 psi. stop engine. discharge accumulator
complete. Repeat this 5 times. Note! Do not steer during
the accumulator flushing procedure.
3. To check cross over relief pressure, raise steering pump
compensator setting to 3150 psi, then steer into stop and
continue to turn steering wheel, one gauge should read
approx. 3100 psi. Now steer into opposite stop. Gauge
should read approx. 3100 psi. After checking cross over
relief pressures, reset comDensator settinq to 2750 Dsi.
Then tiqhten locknut.
Note: It is required that both L.H. & R.H. crossover relief

pressures are to be checked (these relief valves work
independently).
------------------------------------------------------------
STEERING LEAKAGE MEASUREMENT PROCEDURE
------------------------------------------------------------
a. To check combinedleakagefrom the steeringunit and the
flow amplifier, disconnect steering return hose from bleed
down manifold (face nearest horsecollar) cap fitting on
manifold, and start engine. Maximum allowable combined
leakage is 60 cubic inches (984 mI.) from steering return
hose. If leakage is excessive, perform next step.
b. Remove steering unit tank line at the flow amplifier. Plug
flow amplifier tank port. start engine and measure leakage
from steering unit tank line. Leakage not to exceed 10
cubic inches (164 mI.). If leakage is excessive, replace
steering unit. If o.k. perform next step.
c. Measure leakage from flow amplifier at the steering return
hose. Maximum allowable leakage is 50 cubic inches (820
mI.). If leakage is excessive, replace flow amplifier. t':I
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\0
0
d. Disconnect return to tank line from bleed down manifold. 00
......
Plug return to tank hose. Measure leakage from return
fitting in manifold. Maximum allowable leakage from bleed
down solenoid and steering relief is 2.0 cubic inches
.
( 32 8 mI.) I
......
Komatsu Dresser Company Haulpak Division

671-2-9-88 Peoria, Illinois 61639 Pau 2 of 3
Komatsu Dresser
~ CHECK-OUT PROCEDURE EF9081
PaRe
-3
3 of
11
HOIST CHECKOUT
1. Disconnect hoist lines at distribution manifold and cap

power up and power down port (4) places.
2. start engine at lo-idle. Place hoist lever in power up

position. Pressure at both hoist pumps to be 2750 ~ 100
psi.
3. Place hoist lever in power down position. Pressure at both
hoist pumps to be 1500 ~ 200 psi.
Note! The main relief valves in the hoist valve are pre-
adjusted and are not externally adjustable.
4. Reconnect hoist cylinder piping and after all checkout
procedures are complete, ensure hydraulic tank is filled to
top sight glass.
i:'1
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1.0
a
(X)
>-'
I
>-'
Komatsu Dresser Company Haulpak Division

671-2-9-88 Peoria, Illinois 61639 Pau 3 of ;S
NOTES
KOMATSU CHECKOUT PROCEDURE
IE K3826-0
PaQe 1 of 12
NAME: MACHINE & MODEL:

BRAKE SYSTEM CHECKOUT 530M/HD1500
WRITTEN
G SprouseBY: ~:12-10-02
S,HE KED BY: DATE:

f>.J f.,..)OMJ J'L;- tJ-0'-
AP ROVED BY: DATE: 0
DASH
t. j,IA~JK:Jill /'Z--1'7 -(; 1. A SIZE
Necessarv Eauicment:
1. Checkout procedure and system schematic.
2. Accumulator charging outfit with good gauges and either K type bottles of dry
nitrogen or T type with a gas intensifier.
3. Clear plastic hose and bucket for bleeding brakes of air.
4. If truck is only partially assembled and this check-out is done without brakes
installed, brake simulators are required in order to simulate the brake volumes.
5. At least 4 calibrated gauges with quick disconnect couplings, capable of measuring
up to 3000 psi.
Assumctions:
1. All components used within the brake system are to specification.
2. Any parts that do not function as described will be replaced or adjusted. (Notify
Quality Control Department in the event of problems or to obtain adjusting procedures
for individual components.)
3. The hydraulic source for the brake system (the steering system) is in proper
operation and the compensator has been adjusted.
Note: Refer to steering and hoist check-out procedures and specifications.

Initial System Set Uc:
1. Install pressure measuring instruments at:

a. Front brake test port (brake cabinet)
b. Two rear brake test ports (brake cabinet)
c. Test port LAP1 (brake manifold)
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IEK3826.0
PaQe 2 of 12
2. Open each brake accumulator bleed down valve and precharge both accumulators
to 1400 psi. Allow gas temperature to approach ambient temperature before completing
precharge process.
Note: For best performance, charge accumulators in the ambient condition in
which the machine will be operating.
3. Close both accumulator bleed down valves. If brakes have not been assembled to
truck when checkout is performed, attach a brake simulator to each of the brake
application lines.
4. * Start engine to fill accumulators with oil. Observe rising brake pressure as system
charges. Brake pressure should begin to fall when the auto apply valve releases. The
brake pressures when auto apply releases should be approximately 1350 to 1650 psi
front and rear. Record the brake pressures at auto apply release.
5. Partially depress brake pedal and bleed air from each brake or brake simulator.
Parkina Brake
Note: Move the pressure measuring instrument from the LAP1 test port to the
park brake or PK2 port on the brake manifold.
6. Make sure that parking brake and automatic slack adjusters are properly adjusted.
(refer to park brake assembly drawing)
7. * Apply brake lock. Release parking brake with park brake switch. Verify that park
brake status light indicates parking brake is released. Record parking brake release
pressure. (pressure should be 2750 :t 50 psi)
8. Cycle park brake switch several times to assure crisp applications and release of
pressure and proper function of status light.
9. * Release park brake with the park brake switch. Apply emergency brake switch
and ensure that this switch actuates park brake and service brakes. Record park brake
pressure, which should be 0, front brake pressure, left rear brake pressure, and right
rear brake pressure. Release emergency brake, set park brake with the park brake
switch, and release brake lock.
Note: Return the pressure measuring device to the LAP1 port from which it was
removed. If the truck is equipped with optional slippery road switch, put the
switch in the "dry road" position.
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IEK3826-0
PaQe 3 of 12
10. * Quickly and completely depress pedal and check to see that front brake pressure
is 2100 :!:75 psi and that rear brake pressure is 2100:!: 75 psi within one second.
Record front and rear brake pressures. Holding pedal fully applied; both pressures
should remain above their minimum values for a minimum of 20 seconds.
11. * Release pedal. Brake pressure should return to zero within two seconds and
there should be no residual pressure trapped in the brakes. Record pressures.
Note: Steps 12 and 13 apply only to trucks equipped with the optional slippery
road switch. For those trucks, put switch in "slippery road" position.
12. * Quickly and completely depress pedal and check to see that rear brake pressure
is 2100:!: 75 psi within one second. Front brake pressure should remain at zero.
Record front and rear brake pressures.
13. * Release pedal. Rear brake pressure should return to zero within two seconds and
there should be no residual pressure trapped in the brakes. Record front and rear brake
pressures.
Brake Lock
14. * Apply brake lock. Rear brake pressure should be 2000 psi and front brake
pressure should be zero. Record brake pressures.
15. Cycle brake lock several times to assure crisp application and release of pressure.
Low-Brake Pressure and Auto-Applv
16. Allow engine to run until low brake accumulator pressure stabilizes at or above 2700
psi.
17. * Shut engine down. Allow the steering accumulator to bleed completely down.
Disable the steering pressure switch, located beneath the steering accumulator, by
placing a jumper across the pressure switch. Turn key switch on. After two minutes,
record the low accumulator pressure. (LAP1 port). If LAP1 pressure is below 2100 psi,
then leakage in the system is excessive and needs to be identified.
18. * Crack the front brake accumulator bleed down valve and observe LAP1 pressure.
The low brake pressure lamp and buzzer must actuate at 1850:!: 75 psi. Record this
value. Brake pressures should begin to rise (auto apply) when LAP1 reaches 1650:!:
100 psi, and brake lights and retard lights should energize. (Brake lights and retard
lights energizing confirms operation of 1000psi NC pressure switch). Close front brake m
accumulator bleed down valve. ~
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19. * Record front and rear brake pressures when auto apply is actuated.
20. Start engine to recharge hydraulic system. Allow engine to run until low brake
accumulator pressure stabilizes at or above 2700 psi.
21. * Shut engine down. Allow the steering accumulator to bleed completely down.
Turn key switch on. Crack the rear brake accumulator bleed down valve and observe
LAP1 pressure. Verify that the low brake pressure lamp and buzzer, and auto apply set
points are with 100 psi of those recorded in Step 20. Close the rear brake accumulator
bleed down valve.
22. * Record front and rear brake pressures when auto apply is actuated. Enable the
steering pressure switch by removing the jumper.
Reacclications
23. Start engine to recharge hydraulic system. Allow engine to run until low brake
accumulator pressure stabilizes at or above 2700 psi.
24. * Shut engine down, but leave key switch on. Do not allow steering accumulator to
bleed down. Make repeated slow, complete brake applications every 15 seconds until
Low Brake Accumulator pressure warning comes on. Record the number of brake
applications prior to Low Brake Accumulator pressure warning comes on. Low brake
accumulator pressure warning must not come on before the sixth application.
RCM Calibration
25. Install calibrated gauges at the following ports; BR, BL, C-1, and C-2. The ports,
BR and BL, are located in the manifold where the right rear and left rear brake pressure
transducers are located. Ports C-1 and C-2 are located on the ppc valve. Port C-1 is
right brake ppc pressure and C-2 is left brake ppc pressure.
26. Using the MOM display, select the 'BRAKE CONTROLLER' menu, and then the
'REALTIME DATA' menu. Use the FWD button to move forward to the screen
displaying real-time pressure and current.
27. Watching the 'AMT. OF RE. LE. OP' line on the MOM, move the retard lever to
apply approximately 20% retard. Using the diagnostic ports on the ppc valve, C-1 and
C-2, bleed air from hydraulic line between ppc and relay valve. Both ports, C-1 and C-2,
will need to be bled.
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Purpose of Calibration
1. This procedure will calibrate the RCM brake controller to minimize brake application
pressure differences between the left rear and right rear brakes initiated in the
hydraulic valves. Due to tolerances in the hydraulic valves, there may be occasions
where the LH and RH rear brake pressure will not be equal for a given retard
command. To minimize this inequality, the RCM can be calibrated to adjust the
retard command to each PPC valve in order to produce consistent brake output
pressure from the valves.
2. This procedure will calibrate the RCM brake controller to the installed retard lever.
Due to tolerances and adjustment of the retard lever, there may be cases where a
given retard lever cannot reach the high (100%) or low (0%) extremes of its
intended travel. The calibration procedure will set the high and low points based on
the physical limits of the installed lever.
When to Perform Calibration

This routine is intended to be carried out on the truck by the mechanic after any of the
following occurs:
a. PPC manifold assembly is replaced
b. Rear brake relay valve is replaced
c. Retard handle is replaced
d. Brake pressure transducer is replaced
e. Abnormality of the PPC is suspected
f. Abnormality of the retard handle is suspected
g. Initial delivery of the truck to a customer
h. RCM is reprogrammed or replaced
How to Perform Calibration

28. This procedure is rather simple, but must be followed in the exact order as given.
There is a 30 second window after turning ignition key switch ON in which to initiate the
calibration routine, after which it can not be activated. If the sequence below is not
followed closely, initiation will likely not occur.
29. Insure key switch is OFF.
30. Activate the AUXILLIARY BRAKE switch located on the lower right of the instrument
panel by pushing the red knob forward into the dash.
31. Put the BRAKE LOCK switch located on the center console into the applied (ON)
position which is with the right hand portion of the switch pushed inward.
m
32. Make sure brake pedal is fully up with no brake pedal switch actuation.
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IEK3826-0
PaQe 6 of 12
33. Make sure the retard handle is at the no-apply position, which is with the lever in the
fully upward position, turned as far as possible counter-clockwise (up).
34. Turn the key switch on and wait for the MOM to display "OK to Start Engine".
35. Simultaneously pull out (turn OFF) the AUXILLIARY BRAKE switch and press the
BRAKE LOCK switch to the left (OFF position). At this point the LH dash amber colored
brake light will blink at a quick rate of approximately 3 times per second. If the dash
brake light does not begin blinking, repeat the procedure from Step 1 above.
36. While the amber dash brake light is blinking, move the retard handle to full apply
(down) and back to full release (up) four times. The lamp will now blink at a slower rate
of approximately 1 time per second.
37. Now start the engine and leave at idle. After approximately 30 seconds, the
controller will begin application of the brakes to calibrate itself to the PPC system. This
process will take approximately 1 minute. (The pressure commands can be observed
on the 'Brake Controller - Real-Time Data' screen on the MOM display.)
38. After the pressure cycling has completed, the brake light will stop blinking and the
system will return to normal operation.
Note 1: At any time during the calibration process, pressing the brake foot pedal or
moving the truck will cause the RCMto abort the calibration. Ifthe
calibration process is aborted, the RCMwill revert to the previous
calibration stored in its internal memory.
Note 2: If the RCM detects an error condition during the calibration process, a
Calibration Fault (J019 or J021) will be reported to the MOM. If a Calibration
Fault occurs, the RCMwill abort the calibration process and will use the
default calibration stored in its internal memory.
39. Using the MOM display, select the 'BRAKE CONTROLLER' menu, and then the
'REALTIME DATA' menu. Use the FWD button to move forward to the screen
displaying real-time pressure and current.
40. * Watching the 'AMT. OF RE. LE. OP' line on the MOM, move the retard lever to
the off (up) position. Record % retard. Move the retard lever to the full on position
(down), record the % retard. Move the retard lever to apply % retard values in the table
and record the pressure values specified in the table. When all data is collected,
complete the graph for Calibration.
m
41. Open each brake accumulator bleed down valve and bleed down the entire brake
system.
* Asterisk denotes item to be recorded to Data Sheet.
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530M/HD1500 HYDRAULIC BRAKE SYSTEM

CHECK-OUT DATA SHEET
Step 4 Front Brake Pressure when auto apply releases
Left Rear Brake Pressure when auto apply releases
Right Rear Brake Pressure when auto apply releases
Parkinq Brake System
Step 7 Park Brake Release Pressure
Step 9 Park Brake Pressure with Emergency Brake Applied
Front Brake Pressure with Emergency Brake Applied
Left Rear Brake Pressure with Emergency Brake

Applied
Right Rear Brake Pressure with Emergency Brake

Applied
SERVICE BRAKE SYSTEM/RETARDER
Step 1a Front Brake Pressure (pedal applied)
Left Rear Brake Pressure (pedal applied)
Right Rear Brake Pressure (pedal applied)
Step 11 Front Brake Pressure (pedal released)
Left Rear Brake Pressure (pedal released)
Right Rear Brake Pressure (pedal released)
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530M_HD1500_EK3826- O_brk_chk_pro.doc Page 7 of 12
IEK3826-o
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Note: Steps 12 & 13 apply to trucks equipped with optional slippery road switch
Step 12 Front Brake Pressure (pedal applied)
Left Rear Brake Pressure (pedal applied)
Right Rear Brake Pressure (pedal applied)
Step 13 Front Brake Pressure (pedal released)
Left Rear Brake Pressure (pedal released)
Right Rear Brake Pressure (pedal released)
BRAKE LOCK
Step 14 Front Brake Pressure (brake lock applied)
Left Rear Brake Pressure (brake lock applied)
Right Rear Brake Pressure (brake lock applied)
LOW BRAKE PRESSURE AND AUTO APPLY
Step 17 LAP pressure after two minutes
Step 18 LAP pressure when low brake pressure fault occurs
LAP pressure when auto apply occurs
Step 19 Front Brake Pressure after auto apply
Right Rear Brake Pressure after auto apply
Left Rear Brake Pressure after auto apply
Step 21 LAP pressure when low brake pressure fault occurs

m
LAP pressure when auto apply occurs "
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Step 22 Front Brake Pressure after auto apply
Right Rear Brake Pressure after auto apply
Left Rear Brake Pressure after auto apply
REAPPLICATIONS
Step 24 Number of applications to LAP pressure warning
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Step 40 After Calibration
Retarder Lever % Retard, E

Off Up Position
On Down Position
F G
MOM Left MOM Right
Brake Pressure, Brake Pressure,
% Retard psi psi
After
Calibration 0
attempt: 20
on/off
solenoid 40
valve and
60
ppc's
plugged in 80
100
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Calibration
2500
2000
<!J
"ii) ~ 1500
- .-
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~LL .
a.. ~ 1000
-J
500
a
a 20 40 60 80 100
% Retard
"
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IEK3826-Q
Page 12 of 12
Machine Unit No. SIN
Name of Mechanic or Inspector doing Check Out
"
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530M_HD 1500_EK3826_0_brk_chk_pro.doc Page 12 of 12

EJ5372 - Payload Meter 2 Checkout Procedure
....-.............-............ ......................--......... ................................--.--....--.-..........-....
NAME: MACHINE & MODEL:

Payload Meter 2 Checkout HD785, HD1500, 730E, 830E, 930E
Procedure
WRITTEN BY: DATE:
D. Lindell 29 Jan
00
CHECKED BY: DATE:
2 UPDATEDTO INCLUDENEWCAB 11...01 DTl
HARNESS lO1 Io' GGJtl
1 Added HD1500 Notes, ch'd gain 03...01 108707 DTL GGH
APPROVED BY: DATE: 0 Group Used On ...EJ6226 NIR1497 DTL
DASH DESCRIPTION OF CHANGE DATE ECN BY chk'd
G. Horst 2-5-01
A SIZE MICROFilM
I I I I I I I I I I I I I I I
p qy 1 0 a~ M e t e r 2
Checkout Pro c e d u r e
Checkout Overview
The basic steps to check out the Payload Meter 2 are: check the switch settings on the side panel, configure the internal
settings using the front panel buttons, check the discrete inputs and check the sensor inputs. Several dummy loads are
attached to the harnesses in the place of actual sensors. The values from these dummy loads are checked using the Service
Check Mode of the Payload Meter 2.
Payload Meter 2 - Checkout Procedure Page I

<!dAll Rights Reserved... November 27,2001
-...........-.....----.....-......................... ....---......-.......-...-....-.-.......-....--..................--.--........................-............-.......-................... ....------.......... ........-.--....----
1 S W i ~h SeU ing S
1.1 Confirm that the switch settinf!s on the side of the oavload meter are in the orooer oosition
There are a series of switches located behind the panel on the left side of the payload meter. Figure I shows the switch
numbers. The following switch positions should be confirmed before the meter is installed.
Note: Using the Payload Light Check box, the Payload Light Check can be done while the PLM2 is removed.
Note: In preparation for testing later in the procedure, the dummy loads for the suspensions can also be installed while power
is off and the PLM2 is removed.
Note: If switch 5 is in the UP position, the UP:OOand PLOOcannot be checked
0 0
0 0
Figure 1- Left side of Payload Meter

There are a series of switches located behind the panel on the left side of the payload meter. Figure I shows the switch
numbers. The following switch positions should be confirmed before the meter is installed.
Switch No. Position
1 Gt gain- Payload Gain, turn right (-20 %) to turn left (+20%)
B Buzzer Volume - DO NOT ADJUST
2 7 - Speed Regulation, 0 = 107%, 7 = 100% F = 92%
3 7 - Distance Regulation, 0 = 107%, 7 = 100% F = 92%
4 4 - 685E
5 - 630E Set Switch 4 to the position indicated for the truck
where the meter is to be installed.
B - 730E
C - 930E
D - HDI500 (530M)
E - HD785 (330M)
F - 830E
DOWN - 5 DOWN - Memory Functions, UP - NO Memory Functions
6 DOWN - DOWN - Short Tons, Up... Metric Tons
8 UP -
Be sure to properly set each switch for the truck model.
Payload Meter 2 - Checkout Procedure Page 2

«:JAll Rights Reserved... November 27,2001
2 Payload OutDut Check

1.2 Check the Pav/oad LieMs
1. Turn offkeyswitch power
2. Disconnect the harness from the payload meter at P243. Looking at the back of the payload meter, this is the connector
on the left. In the appendix of this document it is also referred to as CN!.
3. Connect the Payload Light Check box to P243 and the payload meter.
4. Turn on keyswitch power
5. Turn the switch on the Payload Light Check box to GREEN. Confirm that the proper lamp is illuminated on the side of
the truck.
6. Turn the switch on the Payload Light Check box to AMBER. Confirm that the proper lamp is illuminated on the side of
the truck.
7. Turnthe switchonthe PayloadLightCheckboxto RED. Confirmthattheproperlampis illuminatedonthe sideofthe
truck.
8. For the 930E, continue to Check the 930E/GE Outputs
9. For all other trucks, turn off keyswitch power
10. Remove the Payload Light Check box and reconnect the P243 to the payload meter
11. Reinstall the payload meter.
1.3 Check the 930£/6£ OutDuts
1. Turn the switch on the Payload Light Check box to MS. Confirm that the 73MS signal to GE has switched from Ground
to nearly 24v ( a recent test showed 21.2v). This signal can be found at RB6. Confirm that 73LS is connected to
Ground.
2. Turn the switch on the Payload Light Check harness to LS. Confirm that the 73LS signal to GE has switched from
Ground to 24v. This signal can be found at RB7. Confirm that 73MS is connected to Ground.
3. Turn off the keyswitch
4. Remove the Payload Light Check harness and reconnect the P243 to the payload meter
5. Reinstallthepayloadmeter
Payload Meter 2 ... Checkout Procedure Page 3

to All Rights Reserved... November 27,2001
EJ5372 - Payload..............-...-..........-............-....
Meter 2 Checkout....-.-......--....
...........-..........---..........
Procedure .......-....-........
3 Confi2:uration
1.4 Checki11f!the Service Check Mode - Settinf! "UP:OO"
1. Turn on keyswitch power. The chart "Display Sequence at Power-Up" in the Appendix allows several configuration
settings to be checked as the P M2 owers up. Wait for this sequence to complete before continuing.
2. Press and hold the

ILiGHTI
IHC and
[iiijHTl
8I
EI
lDTAl
buttons until "CHEC" is flashing on the meter.
3. Pressandholdthe
DE£]
and Ifi
[ill] . . .
buttonsuntil"S.SEL" ISdisplayedon themeter.
4. Press
~
~ once and "UP:xx" will be displayed.
ILiGHTI
5. IHCJ until "UP: 0" is displayed. Onlv "UP: 0" is recommended.
6. Press.' .. and "CHEC" will be displayed.
7. Press 8]
I'IODE
and the meter will return to normal operation
1.5 Checkin theService Check Mode - Settinf! "PL:OO"
1. Press and hold the ILiGHTI

IHC and
EI buttons until "CHEC" is flashing on the meter.
~~
IHC and ~ buttons until "S.SEL" is displayed on the meter.
3. Press ~
~ once and "UP:xx" will be displayed.
4. Press ~
~ once and "PLxx" will be displayed.
5. Press the ~ILiGHTI until "PLOO" is displayed.

8I
I'IODE
6. Press and "CHEC" will be displayed.
7. Press (8)
I'IODE
and the meter will return to normal operation.

1.6 Settinf! the OP mode and Date/Time
The Operator Check Mode is used to check and change several settings. These should be checked before the payload meter
is put into service.
1. Push and hold the

(8 1'10DE
8
1'10DE
button until "Cd:dP" is displayed.
2. Push the once. "A.CLE" will be displayed.
3. Push the 8] I'IODE
once. "F.CHC" will flash on the display. Refer to the manual for viewing fault codes.
4. Push the 8I I'IODE
once. "d:xxx" will be displayed. This is the truck ID number stored in memory.

<9 All Rights Reserved - November 27,2001
6. Push the S MOOE
once. "SP:62" will be displayed when English units are used (Switch 7 is DOWN). The speed limit
should be set to 62 to avoid unnecessary faults and warnings. Use

~~ ~
IHC and to set. This setting will be 100 for
metric units (Switch 7 is UP).
8IMOOE
7. Push the once. "OP:12" will be displayed. Set to "OP:12" for mines usin Modular Mining. Set to "OP: 0" for
mines without Modular Mining. Set to "OP:10" for HDI500(530M) trucks. Use
~~IHC and ~ to set.
8. Pushthe 8IMOOE
once. Thecurrenttimeshouldbe displayedwiththeminutesflashing.Thetimeanddatecanbe set
using the IUBHTI

IHC button. The
day, month, and year.
~ SFT will cycle through all the settings starting with minutes and moving through hour,
9. Push the S MOOE
to return to normal operation.

~ All Rights Reserved - November 27, 2001
4 Service Check Mode
1.7 Checkthe discreteinputs:
Enter the Service Check Mode of the Payload Meter 2. This mode displays the live status of the inputs to the Payload Meter
2 system
This procedure can be used to monitor the current input signals to the payload meter.
I. Press and hold the

IUUHTI
IHC and
IE31buttons until "CH EC" is flashing on the meter.
ag
2. Press and hold the ~and~~ ~ buttons until "S.CHE" is flashing on the meter.
3. Press the ~
~ to view the status of the Brake Lock or Neutral Switch. The Neutral switch is used on the mechanical
drive trucks. The display will show C I:
C I :00 Brake Lock On or Neutral Switch On: signal = open
C I :-- Brake Lock Off or Neutral Switch Off: signal = ground
4. Press the
W
~ to view the status of the Body Up Switch. The display will show C2:
C2:00 Body Down: signal = ground
C2:-- Body Up: signal = open
5. Press the ~
~ to view the status of the Engine Oil Pressure input. The HDI500 and late modeI730E/830E/930E trucks
use a cab harness that is wired to indicate Engine Run at all times. The display will show C3:
C3:00 Engine Run: signal = open
C3:-- Engine Stop: signal = ground
6. Press the
~
~ to view the status ofthe Alternator Charge input. The HDI500 and late model730E/830E/930E trucks
use a cab harness that is wired to indicate Alternator Charging at all times. The display will show C4:
C4:00 Alternator Charging: signal = 24vdc
C4:-- Alternator Off: signal = open
7. Press the~,
~ the display will show C5, ignore this input setting.
8. Press the
~
~, the display will show C6, ignore this input setting.
9. Press the~, ~ the display will show C7, ignore this input setting.
10. Press the

~
~, the display will show C8, ignore this input setting.

(Q All Rights Reserved - November 27,2001
T- - un- ----

-~~.m~-;~::~~e
D ~~ ~t~m~:~~~::~:~:~~-~~p~:. The~;:;::~-~;I::::W C9:XX-::~;~::~:
the sp:::.mTh::~~::~~-:~st be
off and a washer must be across the Body Up switch. The speed input for each truck model is different:
-
HD785, HD1500 Start the truck and put the drive system in gear. The speed signal is generated by a sensor in
the transmission and the drive system must be engaged to generate a speed signal to the payload meter. Confirm
that the speed on the payload meter is within 10% of the speed on the speedometer
730E, 830E - From the checkout procedure for the specific truck model, use the speedometer calibration procedure
on the opposite wheel motor to simulate a speed signal into the payload system. Confirm that the speed displayed
is within 10% of the speedometer speed.
930E - Connect the 930E Wheel Speed Test harness to P512 at the left side of the truck frame. Using a signal
generator, input a 238hz, lOv p-p sine wave. This will send the signal across circuit 714(pin B on connector P512)
and circuit 714A (pin C on connector P512). Confirm that the PLM2 displays 30mph ::I:2mph.The speed input
e uency for the 930e to the PLM2 is 7.9 hz/mph.
12. Press SJ
E3
MODE
once and "CHEC" will flash on the display
13. Press S MODE
once and the meter will return to normal operation.
NOTE: 730E unit 119 and above, 830E unit 620 and above, 930E unit 159 and above and the HD1500 are wired to indicate
Engine Run and Alternator Charging at all times. This is done in the cab harness by opening the oil pressure input and
supplying 24v keyswitch signal to the alternator R-terminal input. On older trucks it is possible to simulate the engine
.
running inputs (Engine Oil Pressure and Alternator Charge). This should be done when kevswitch power is off.
Open circuit 21 C to the Oil Pressure Starter Interlock and short 21 D across the Oil Pressure Circuit used for the
.. hour meter. These must be done together with the keyswitch off.
Turn the keyswitch on to check the signals.
Turn power off and return both signals to their original installation.
1.8 Check the sensor inouts
1.8.1 Install the PLM2 Dummy Load #1 (item 002, EJ5366) in place of the left front suspension pressure sensor.
1.8.2 Install the PLM2 Dummy Load #2 (item 003, EJ5367) in place of the right front suspension pressure sensor.
1.8.3 Install the PLM2 Dummy Load #3 (item 004, EJ5368) in place of the left rear suspension pressure sensor.
1.8.4 Install the PLM2 Dummy Load #4 (item 005, EJ5369) in place of the right rear suspension pressure sensor.
1.8.5 Check the value of the inputs using the Service Check Mode procedure below. The inputs are not 'live' and will
not display changes in the values. (A laptop PC running the Payload Meter 2 software for Windows can also be
used to check the values of the inputs.) On the HD1500, the MOM display can be used to monitor this
information. Be sure the communications switch between the MOM and the PLM2 is in the proper position to
prevent F97 fault codes
1 Press and hold the
2 Press and hold the

3 Pressthe
4 Pressthe
5 Pressthe
6 Pressthe
7 Pressthe
8 Pressthe
9 Pressthe
10
11 Pressthe
12 Pressthe
13 Pressthe
14 Pressthe
15 Pressthe
16 If it is not, use the procedure in the
17 Press the to view the current payload, ignore this value.
18 Press the ~IUGHTI to view the backup battery voltage, confirm that this is higher than 3.3v.
19 Press (S
MOOE
once and "CHEC" will flash on the display.
20 Press S
MOOE
once and the meter will return to normal operation.
-
Payload Meter 2 Checkout Procedure Page 8
~ All Rights Reserved - November 27, 2001
5 ADpendix
1.9 Pavload Meter Connections
CN1
13 8 CN2 6 9 CN3 6 1 CN44
++++
1++++1
7 7 12 5 5 8
Figure 2 PLM 2 Back Panel

AMP MIC-MKII 13pins White
1
2
3
4
5
6
7
8
9
10
11
12
13 GND (Power GND)
Figure 3 CN! Connector

AMP 040 12 . Black
1 Engine Oil Pressure Switch
2 Sensor Power Out + I8V
3 Sensor GND
4 Sus. Pressure Sensor (Left Front)
5 Sus. Pressure Sensor (Right Front)
6 Sus. Pressure Sensor (Left Rear)
7 Sus. Pressure Sensor (Right Rear)
8 Inclinometer
9 Body Rise Signal
10 Break Lock Signal/Neutral Signal
11
12
Figure 4 CN2 Connector
AMP MIC-MKII 9 . - --- Whi (RS-232C P

---- --,
1 RIS
2 SG
3 RD
4 IX
5 CIS
6 DIR
7 DSR
8
9
Figure 5 CN3 Connector

................-....................-.-.-....................---.........-.-.-...--..---...-.--.-.......-.....-.-....... ....-.......-......--
5
6
7
8 Power +4V
Figure 6 CN4
81 600tl
.1
Connecting Face View
1 I GNO BLACK
2 . +15 RED
3 EI 1M WHITE
IUI
J"t'Jn t7.(fr!
39F supplies 18vdc to IEllllllAl 10. lllE caOi SIIiIII...
supply power to
sensors ...
~DNNECTION DIAGRAM
Typical Sensor Connection (from drawing 7861-92-1620)

(g All Rights Reserved - November 27, 200 I
.§~.?~??...=..-,=.~ylg~9m~.~!~~m?g~~~~.~.~!m~E.~~.~9~E~mm m.m m.m...
6 P L-M2 F a u Lt Cod e s
FAULT CAUSE CORRECTIVE ACTION DECK PRIORI

LIGHTS TY
b-FL Steady Brake Lock On and Body is UP Flash I
and not dumping.
b-FL Flashing Brake Lock Off and Body is UP I
Cd Flashing Remove memory card during 2
download
F-09 Internal battery voltage below Open controller check internal battery and 3
2.7 volts connections
L.FUL Flashing Less than 300 haul cycle data Down load data to PC and clear memory. 4
sets memory capacity remain See Operator Check Mode, Clearing the
haul cycle data memory.
L.FUL Steady 2900 Haul cycles have been Down load data to PC and clear memory. 4
stored and the oldest data is See Operator Check Mode, Clearing the
being overwritten haul cycle data memory.
E.FUL Flashing Less than 10 engine start data Down load data to PC and clear memory. 4
sets memory capacity remain See Operator Check Mode, Clearing the
E.FUL Steady I 15 engine start data sets have Down load data to PC and clear memory. 4
been stored and the oldest data is See Operator Check Mode, Clearing the
F.FUL Flashing Less than 10 fault data sets Down load data to PC and clear memory. 4
memory capacity remain See Operator Check Mode, Clearing the
F.FUL Steady 230 fault data sets have been Down load data to PC and clear memory. 4
stored and the oldest data is See Operator Check Mode, Clearing the
Payload Meter 2 - Checkout Procedure Page I I

({;)All Rights Reserved - November 27, 2001
EJ5372 - Meter 2 Checkout Procedure
H.FULFlashing Haul cycle counter or payload 4

totalizerare nearcapacity. Press:[f!]
SFT
to display totals, then press
Ii] forat least2 seconds,thenpress

CLR.
H.FUL Steady
Ii] againforat least2 seconds.
ClR.
4
Haul cyclecounterexceeded
9999or payload totalizer
exceeded 999900. Press:[f!] to display totals, then press
SFT
Ii]
ClR. for at least 2 seconds, then press
Em]
ClR. again for at least 2 seconds.
F-18 Battery alternator R terminal is Trouble shoot wiring. Fault is reset when 5
shorted or disconnected. The engine is started with proper wiring
input to the PLM in less than 2V restored.
F-20 Flashes Sensor power (normally 18V) is Trouble shoot wiring Flash 6
less than 15V or over 20V.
F-21 Flashes Left front pressure signal Trouble shoot wiring, likely an open circuit Flash 7
(normally 1-5V) is less than IV
F-22 Flashes Right front pressure signal Trouble shoot wiring, likely an open circuit Flash 8
(normally 1-5V) is less than 1V
F-23 Flashes Left rear pressure signal Trouble shoot wiring, likely an open circuit Flash 9
(normally 1-5V) is less than IV
F-24 Flashes Right rear pressure signal Trouble shoot wiring, likely an open circuit Flash 10
(normally 1-5V) is less than 1V
F-25 Flashes Left front pressure signal Trouble shoot wiring, likely sensor wires are Flash 11
(normally 1-5V) is greater than shorted together
5V
F-26 Flashes Right front pressure signal Trouble shoot wiring, likely sensor wires are Flash 12
5V
F-27 Flashes Left rear pressure signal Trouble shoot wiring, likely sensor wires are Flash 13
5V

to All Rights Reserved -November 27,2001
F-28 Flashes Right rear pressure signal Trouble shoot wiring, likely sensor wires are Flash 14
5V
F-31 Flashes Inclinometer input less than Trouble shoot wiring, likely an open circuit Flash 15
I.57V (more than + 10 degrees, (Inclinometer output is 2.6V when
nose up) horizontal,
calibration: -103mV/degree)
F-32 Flashes Inclinometer input greater than Trouble shoot wiring, likely sensor wires are Flash 16
3.63V (more than -10 degrees, shorted together
nose down)
F.CAL No calibration has been Perform calibration Flash 17
performed or cal data has been
cleared
F-4I Flashes Light relay # I driver short Trouble shoot wiring, relay coil likely 18
circuit. shorted
F-42 Flashes Light relay #2 driver short Trouble shoot wiring, relay coil likely 19
circuit. shorted
circuit. shorted
circuit. shorted
circuit. shorted
L.bad Flashes 23
SP:SP Flashes Payload meter speed limit setting Set the speed limit, using Operator Check 24
is being exceeded Mode, to 62 mph or 99 Km/h depending on
the position of the unit selection switch
(switch #7 behind the right side panel)
F-71, F-73,F-80, F- Communications port error Check communicationwiring (RS-232) to 25
8] Modular Mining Hub or to Scoreboard
F-91, F-92,F-93, F-
94
F-95, F-96,F-97, F-
98
All Flashing

i£JAll Rights Reserved - November 27, 2001
~~?~7.?~~~ylg~~~~~~~?gh~<?~g~~'=~?<?~~~~~m
7 Payload Circuit Numbers
Circuit Designation Circuit Description

mm..
39F,39Fl...39F5 + mm.................................................................................
18 volt sensor power supply
39FA pressure signal RR
...............................................................
39FB pressure signal LR
39FC
39FD pressure signal LF
mm.....................................
39FE inclinometer
39FG sensor mm.....................
ground
39A PLM lamp output - green
mmmmmmmmmmmm ...................................
PLM lamp output

mm
- amber
mmmmm
PLM lamp output - red

mm........................................................................
PLM lampmm.....................................................
output - unused
p output - unused
mm............................................................
+24 volt PLM power
39BA
39CA
73FSL
73MSL
714A speed signal
714AT
63L
39H
PLM RS232
...........................................
PLM RS232
5L4 scoreboard I to scoreboard 2
35L9
21C essure (gnd = off, open = run)
mm..................................................................................
2ID minal (open = off,+24V = run)

IQ All Rights Reserved -November 27,2001
..~.~.?~.??.~ ~.~yl.~.~9 ~~!~.~m? gh~..~.~.~.~.~ ~T~.~.~9.~T~....
8 Service Check Mode

This procedure can be used to monitor the current input signals to the payload meter.
Press and hold the

ILiGHTI
IHC and
gag buttons until "CHEC" is flashing on the meter.
Press and hold the

I'ffi;ffi
m [fi]
~
CAl
and
lDT~l
mD .
buttons until .,
"5.CHE" ISflashmg on the meter.
P he~ Iethr--- h the foIl- _n 'fc

____moon u__n
C1 Brake Lock C1 :00 - Brake Lock On
C1:- - Brake Lock Off
C2 Body Up C2:oo -Body Down
C2:- - Bodv Up
C3 Engine Oil Pressure C3:oo -Engine Run
C3:- - Engine Stopped
C4 Alternator R Terminal C4:oo -Alternator Charging
C4:- -Alternator Stopped
C5 Analog 1 - Not Used
C6 Analog 2 - Not Used
C7 Digital I - Not Used
C8 Dioital 2 - Not Used
C9 Speed Vehicle Speed (MPH)
C10 Travel Distance - travel
distance under the current xx.xx Miles
loaded or emptv state
C11 Current Truck Status 03:01 - Empty Stopped
Note: The number after the 0 1:02 - Empty Traveling
colon may be different than 06:03 - Loading
displayed here. 02:04 - Loaded Traveling
-
04:05 Loaded Stopped
05:06 - Dumping
C12(a)* Time Emptv Traveling S1 :xx - Minutes*IO
C12(b) Time Empty Stopped -
S2:xx Minutes*IO
C12(c) Time Loaded Traveling S3:xx - Minutes*IO
C12(d) Time Loaded Stop S4:xx - Minutes*IO
C12(e) Time Dumping -
S5:xx Minutes*IO
C12(f) Time Loading S6:xx - Minutes*IO
*After 9.9 minutes, "51 :-" will be displayed
4. Press I8MODE
5. Press 9 9 once and the meter will return to normal operation.

r0 All Rights Reserved -November 27,2001
§~.?~!?..~m.'=.c:tyl~c:t~
~.~.~~.~m?
gh~..~.~.~.~.~...,=r~.~.~.~..~.~~......
9 Settin~ the Ot ~aln

Using this mode the Gt gain can be checked. This mode captures the pressures and inclinometer the instant the buttons are
pressed.

~
~ 81
and Ighuttons until "CHEC" is flashing on the meter.
2. Press and ~ the ~

~ until "ALLO"is flashing on the display. "A.FUL" may also be displayed.
3. Press the ~
~
to cycle through the following data. The sequence repeats.
Item & Description Units
1. Current Time Hour:Minute
2. Pressure Front Left Psi
3. Pressure Front Right Psi
4. Pressure Rear Left Psi
5. Pressure Rear Right Psi
6. Front Axle Weight Ton
7. Rear Axle Weight Ton
8. Degree of Incline :1:°nose up positive
9. Incline Factor - Front Axle
10. Incline Factor - Rear Axle
11. Link Factor - Front Axle
12. Link Factor - Rear Axle
13. Calibration Weight Ton
14. Gt - Trimmer Gain
15. Current Load Ton
16. Backup Battery Voltage Volts
4. Press (8MODE

MODE
5. Press once and the meter will return to normal operation.
Adjust the gain pot at switch 1 under the panel on the side of the payload meter. Turn to the left to adjust the gain up, turn to the right to adjust the gain
down. Make Yzturn changes and recheck the value using the procedure above.

iC)All Rights Reserved. November 27,2001
-~~?'~??=!:~y'IS>~9.~~~~~?g~~C?~g~~!:~g~~9~E~m
10 Disolav Seauence at Power-DD
NOTE: The HD1500 and late model730E/830E/930E trucks use a cab harness that is wired to indicate Engine Run and
Alternator Charging at all times.. This is done in the cab harness by opening the oil pressure input and supplying 24v
keyswitch signal to the alternator R-terminal input. In this case. the PLM will not display the entire sequence at startup.
DISPLAYS AT START-UP 7. The display will show:

d.XXX
POWER ON: This display indicates the Machine IDcode where
"xxx" indicates a value between 0 and 200.
All external display lamps (Figure 20-2) will come on
and stay on for approximately 27 seconds during the
8. The display will show:
"Power-up Process". O.XXX
The .Power-up Process" will display the PlM settings. This display indicates the Operator ID code where
Each display will occur for approximately 3 seconds: "xxx" indicates a value between 0 and 200.
9. The display will show: SP:XX

1. The display will show: 88:88 This display indicates the Speed Limit setting
In addition, a buzzer will sound and the following where "xx" indicates a value between 0 and 99
lamps will light for 3 seconds: km/h.
eReception Pilot Lamp (2, Figure 20-1) 10. The display will show: DP:XX
e Transmission Pilot lamp (3, Figure 20-1)
-Memory Card Pilot Lamp'(4, Figure 20-1) This display indi~tes the Option code setting.
Refer to "Operator Check Mode. Setting the Op-
2. Thedisplaywillshow: [0: XX tion Code" and to "Method of Operation" for more
information on this function. '
The "xx" indicates the Truck Model. Refer to

"Initial Setup of Payload Meter" for codedefini-
'
tions.
3. Thedisplaywillshow: [d : - -
This display indicates the status of
the Memory Card where: [d. .00 NORMAL OPERATION
"Cd: - -" indicates Card Not Used, and If the truck engine is started before the preceding
"Cd: 00" Indicates Card Is Used.
"Power-up Process" is completed, the display will shift
4. The display will show: to normal operation.
This display indicates the status of [L:- -
the Inclinometer for the PLM.
where [ L.:O0 If the engine is running when the payload meter starts
up. only "o:XXX" and "d:XXX" will display before
"Cl: - -" indicates Indinometer Not Used, and switching to normal operations.
"Cl : 00" indicates Indinometer Is Used.
5. Thedisplaywillshow:
This display indicates method of
US:
-
--
measurementwhere: US '00
"US: - _" indicates METRIC Tons.
"US: 00" indicates U.S. Tons.
6.Thedisplaywill show: 5U:--

Thisfunctionis notused. 5 U:o0
"SU : - ." indicates Switch 8 is up.
"SU: 00" indicates Switch 8 is down.

tB All Rights Reserved - November 27,200 I
1 1 Executing the Forced Initialization

WARNING- This procedure will erase and reset the payload meter to its original "out of the box" state. All memory
locations will be erased. The payload meter will have to go through all the steps described in the Initial Setup Procedure
described on page Error! Bookmark not defined. of this document. Note - the engine must be offfor this procedure.
'E31
ILiGHTI
IH( and ~ buttons until "CHEC" is flashing on the meter.

I ([R
(AL I [ill] IH(I
fiQTill I LIGHT . . .
buttons until "0000" ISflashmg
3. Press and hold

~
~ until the payload meter beeps and resets. The meter will cycle through its entire standard "power
on" sequence codes. At this point all memory locations have been reset.
Note - The payload meter will need to be calibrated before pressures can be viewed using the tront panel. The OP, UP and
PL modes will be reset to their original configuration.

ilJ All Rights Reserved - November 27,200 I
EJ~~?~..=...~~yl~~.9~.~te~?g~~<?~~~!£!~<?~9.~!.~_..........-- ...........-.....---....
12 Payload Meter 2 Checkout Sheet

Item Confirmation of proper operation Checked
Switch Settings Continn proper setting for truck model
Green Light Green light illuminates when 39A is grounded
Amber Light Amber light illuminates when 39B is grounded
Read Light Red light illuminates when 39C is grounded

73MS 73MS switched to 24v when 73MSL is grounded
73LS 73LS switched to 24v when 73SLS is grounded
UP Setting UP:OO
PL Setting PL:OO
OP Setting OP:OOfor no Dispatch, OP:1Ofor HD1500, OP12 for Dispatch

Date/Time Proper date and time
Brake Lock C 1:00 = BrakeLockON,C1:--BrakeLockOFF
Body Up C2:00 = Body Down, C2 = Body Up

C3:00 = EngineRun,C3:--= EngineStop
Engine Run
(New units should indicate engine run with engine off)
Alternator R-tenn C4:oo = Alternator Charge, C4:-- Alternator Stop
(New units should indicate alternator charging with engine off)
Speed Speed input OK
Left Front Suspension Pressure Input OK, 970 - 1150 psi
Right Front Suspension Pressure Input OK, 710 - 870 psi
Left Rear Suspension Pressure Input OK, 490 - 625 psi
Right Rear Suspension Pressure Input OK, 290 - 410 psi

Inclinometer Inclinometer OK
Gt Gain Gain = 1.0
Battery Voltage Battery Voltage> 3.3v
Removed Dummy Loads
Restored Connections used to Simulate Running Engine
Continned By
Date
Truck
(Q All Rights Reserved -November 27,2001
NOTES
KOMARU EH0910 - 01
Komatsu Mining Systems, Inc. - Peoria Operations
NAME 530M TRUCK ELECTRICAL CHECKOUT PROCEDURE USED ON 530M
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS I WRITTEN BY JAMES R. RELAFORD DATE 12/01/97
AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL I CHECKED BY R. CALDWELL DATE 12/01/97
TO THE INTEREST OF THE COMPANY. I APPROVED BY B. A. HARBISON DATE 12/01/97
REVISED AND REDREW THE DOCUMENT JRR Rc..

RELEASED FOR PRODUCTIONAND 1ST USED ON GROUP #EH0905 JRR RC
DESCRIPTION OF CHANGE BY CHKD
I. OVERVIEW
This checkout procedure describes the testing and adjustment procedures for the 530M
controllers and 24 vdc electrical systems. This procedure is written for trucks with Cummins
Centry engines with a Cense monitoring panel. The trucks have the following controllers:
Powertrain Management Controller (PMC)

Transmission Controller (ATC)
Retarder/Brake Controller (RCM)
Payload Meter II (PLM)
Electronic Display Panel (EDP) - "Instrument Dash Panel"
Message for Operation and Management (MOM)
- with and without dimming function
A simulator may be used to imitate the sensors on these components to complete the checkout
test if the major sub-assemblies like the front wheel spindles with suspensions or the rear axle
are not installed on the truck. These would include the suspension pressure sensors, the brake
wear sensors, and the brake oil temperature sensor.
PAGE 1
KOMARU EH0910 - 01
II. TABLE OF CONTENTS

I. OVERVIEW 1
II. TABLE OF CONTENTS 2
III. GENERAL 4
A. SAFETY NOTES 4
B. TEST PERSONNEL 4
C. TOOLS, EQUIPMENT, AND TRUCK COMPONENTS 4
IV. ABBREVIATIONS AND DEFINITIONS 5
V. PREPO WER CHECKOUT ; ~ ; 6
A. TRUCK CONDITION PRELIMINARY REQUIREMENTS 6

B. PREPOWER TEST 6
VI. PO WER/G ROUND CHECKOUT 7
A. TRUCK CONDITION PRELIMINARY REQUIREMENTS 7

B. POWER AND GROUND TEST 8
VII. KE Y0 FF CONTRO LLER CHECKO UT 9
A. TRUCK CONDITION PRELIMINARY REQUIREMENTS '"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' 9

B. KEY SWITCH OFF TEST 9
VIII. KEY 0 N CONTRO LLER CHECKOUT 10
A. TRUCK CONDITION REQUIREMENTS 10

B. INITIAL CONTROLLER OUTPUT CHECKS 10
C. INSTRUMENT PANEL CHECKOUT 11
D. CONTROLLER SWITCH AND SOFTWARE CHECKS 12
E. ENGINE SIGNALSAT ZERO RPM TEST 13
1. ENGINE AT ZERO RPM ENGINE CHECKOUT 13
2. ENGINE AT ZERO RPM TRANSMISSION CHECKOUT 14
3. ENGINE AT ZERO RPM BRAKE CHECKOUT 16
4. ENGINE AT ZERO RPM PMC CHECKOUT 17
5. MOM EDP SIGNALS AT ZERO RPM CHECKOUT 18
6. ENGINE AT ZERO RPM PLM CHECKOUT 18
PAGE 2
KOMARU EH0910 - 01
F. COMPONENT FUNCTIONAL TEST 19

1. SWITCH ACTUATION CHECKOUT 19
2. SWITCH VOLTAGE CHECKOUT 22
3. MULTITASK SWITCH(S) CHECKOUT 23
IX. ENGINE RUNNING CONTROLLER CHECKOUT 24

B. PRELIMINARY PRECAUTIONS 24
C. ENGINE RUNNING TEST 24
1. ENGINE RUNNING ENGINE CHECKOUT ""'"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' 24
2. ENGINE RUNNING TRANSMISSION CHECKOUT 25
3. ENGINE RUNNING BRAKE CHECKOUT 26
4. ENGINE RUNNING PMC CHECKOUT 27
X. TRUCK MOVING CONTRO LLER CHECKOUT 28

B. PRELIMINARY PRECAUTIONS 28
C. TRUCK MOVING TEST 28
1. WHEEL SPEED CHECKOUT 28
2. ELECTRONIC DASH CHECKOUT 28
XI. CHECKOUT DATA CLEANUP 29

B. CHECKOUT DATA CLEANUP 29
XII. SERIAL NUMBER DOCUMENTATION 30
PAGE 3
KOMADU EH0910 - 01
III. GENERAL
A. SAFETY NOTES
- Follow all safety regulations required by the employer, all necessary precautions at the job
site or shop, and any manufacturer recommendations for the components used on the truck.
- Carefully study the Operator's Handbook before starting the engine or driving the truck.
- Carefully study the Service and/or MairitenanceManual before servicing.
- All situations cannot be covered by these SAFETY NOTES, the safety rules in the
Operator's Handbook, or the Service / Maintenance Manual. Local conditions and regulations
may add many more regulations and procedures to these list.
B. TEST PERSONNEL
- This checkout procedure was written on the basis that the personnel performing the checkout
would be qualified operators or technicians.
- This checkout procedure would be easier to perform if the test personnel had the following
knowledge:
operation of the MOM screens
operation of a laptop PC
operation of the DAD software
operation of the Cummins Centry Maintenance software
operation of a volt/ohm meter or an electrical multi-meter
physical location of the truck components, switches, and sensors
C. TOOLS, EQUIPMENT,ANDTRUCKCOMPONENTS
- The following tools and equipment should be considered as necessary in performing a

checkout of the truck:
this checkout procedure
a current Electrical Schematic and Hydraulic Schematic
a current 24 vdc Hookup Drawing
a current Hydraulic and Brake Checkout Procedure
Shop Manual for PMC System
MOM Operation Manual
PLM II Operation & Maintenance Manual
DAD Operation Manual
a volt/ohm meter or multi-meter
an assortment of shop hand tools
- This checkout procedure was written on the basis that all of the components used on the
truck are to specification and are installed and adjusted properly. Furthermore, all of the
electrical connectors and terminals are properly mated and/or terminated unless noted in a
specific checkout procedure.
PAGE 4
KOMAnu EH0910 - 01
IV. ABBREVIATIONS AND DEFINITIONS
2DD 2 Digit Display
AEM Advanced Engine Monitor "SEE CENSE"
ATC Automatic Transmission Controller
Cx Connectors at the left rear side of the engine
CENSE Cummins Engine Monitor Panel (previously AEM)
CENTRY Cummins Engine Controller
EDP Electronic Display Panel (Instrument Dash Panel)
GND Electrical ground
Keyswitch The keyswitch located inside the operator's cab on the dash panel.
MOM Message for Operation and Maintenance
PLM Payload Meter
PMC Powertrain Management Controller
RBI Relay board number I
RB4 Relay board number 4
RB5 Relay board number 5
RB6A Relay board number 6A
RB6B Relay board number 6B
RB6C Relay board number 6C
RCM Retarder/Brake Controller
SSP Suspension Controller
PAGE 5
KOMARU EH0910 - 01
v. PREPOWER CHECKOUT
A. TRUCK CONDITIONPRELIMINARYREQUIREMENTS
All battery cables are disconnected from the batteries and the battery equalizer.
The key switch and all of the circuit breakers are in the off position.
The battery disconnect switch is in the off position.
The ground level kill switch is in the off position.
The emergency brake switch is in the off position.
All light switches are in the off positions including all of the dome lights.
Unplu~ all of the connectors on all of the controllers, MOM, and EDP.
Unplug the connector to the drivers seat air pump motor.
B. PREPOWER TEST
All of the following resistance tests are measured from the battery box area but could
be measured from the terminal points in the operator cab. Refer to the 24-Volt
Electrical Schematic for circuit function and termination points.
STEP TEST ITEM CHECKINGMETHOD EXPECTED MEASURED PASSED
NO. RESULT RESULT (J)
SHORT CIRCUIT TEST ON 12AND24 VDCCIRCUITS
1. Circuit #1 Measure the ohms resistance between
circuit # 1 and GND at the battery box > 1 Meg 0
2. Circuit #2 Measure the ohms resistance between
circuit #2 and GND at the battery box > 1 Meg 0
3. Circuit # 11 - Close the battery disconnect switch
- Measure the ohms resistance > 1 KQ
between circuit # 1 and GND
4. Circuit # 11S - Close the Ground Level Kill switch
- Measure the ohms resistance > 1 KO
5. Circuit #13 & 15 - Turn the key switch to the RUN
or ON position. >300
- Measure the ohms resistance
6. Circuit #21 - Turn the key switch to the
ENGINE START position. >300
7. Circuit #12V Measure the ohms resistance between
circuit #4 and GND at the battery box > 1 Meg 0
PAGE6
KOMADU EH0910 - 01
STEP TEST ITEM CHECKING METHOD EXPECTED MEASURED PASSED

NO. RESULT RESULT (./ )
SHORT CIRCUIT TEST ON 12AND24 VDC CIRCUITS
8. Circuit #12 - Unplug CN031 (AIC Controls)
- Measure the ohms resistance > 1 KQ
between circuit #3 and GND at the
battery box
9. Circuit Breakers - Turn on circuit breakers #1 - #8
#1 -6 - Measure the ohms resistance > 1 KQ
between circuit #1 and GND.
#7 - 16 - Measure the ohms resistance > 1 KQ
#17 - 20 - Measure the ohms resistance > 1 KQ
12. Circuit Breakers - Unplug CN013 (AM/FM Radio)
#21 - 24 - Turn on circuit breakers #21 - #24 > 1 KQ
#25 - 32 - Measure the ohms resistance >IKQ
14. Relay Board - Turn on all of the circuit breakers
Circuit Breakers on the relay boards > 1 KQ
VI. POWER/GROUNDCHECKOUT
A. TRUCK CONDITIONPRELIMINARYREQUIREMENTS
All battery cables are disconnected from the batteries and the battery equalizer.
All of the connectors on all of the controllers, MOM, and EDP are unplugged.
The key switch and all of the circuit breakers are in the off position.
The battery disconnect switch is in the off position.
The ground level kill switch is in the off position.
The emergency brake switch is in the off position.
All light switches are in the off positions including all of the dome lights.
The engine is NOT running (RPM=O).
Unplug the Prelube Timer on the engine (Typically CN177)
PAGE 7
KOMARU EH0910 - 01
B. POWER ANDGROUND TEST
Perfonn the following steps and monitor the wiring and components:
Connect all of the cables going to the battery equalizer.

Connect all of the cables going to the batteries.
Close the batteries disconnect switch to the ON position.
Close the ground level kill switch to the ON position.
Turn the key switch to the ON position.
Turn on each of the circuit breaker one at a time.
Check for 24 vdc voltage on Check for continuity to gnd Check for continuity to gnd
the following points: on the following points: on the following points:
CONNECTOR PASSED CONNECTOR PASSED CONNECTOR PASSED
AND PIN I.D. (./ ) AND PIN I.D. (./ ) AND PIN I.D. (./ )
ATCI-07 ATCI-08 PMC2A-06
ATCI-09 ATCl-16 PMC2A-20
ATCl-17 ATC2-21 PMC2B-23
CI-K ATC3A-14 PMC2B-36
CI-R ATC3A-16 RCMI-03
C5-G ATC3A-17 RCMI-06
EDP-P5-06 ATC3A-18 RCMl-lO
PLMI-Ol ATC5A-Ol RCM2-17
PLMl-lO ATC5B-30 SSPI-09
PMCl-13 ATC5B-31 SSP2B-32
PMCl-14 ATC5B-33 SSPl-17
PMCl-15 CI-Q Check for continuity to gnd
RCMI-Ol C5-H Onthe followingpoint:
RCM3-27 C6-G MOM GND TB [
SSPI-08 EDP-PI-03
SSPl-17 EDP-PI-04 NOTE: The old MOM
Check on the following point: EDP-P2-08 has the 24v Power Point
MOM 24v TB I I
EDP-P5-12 and the GND Point on
EDP-P8-16
the DCIDC converter.
EDP-PIO-08
Place the Keyswitch in the EDP-Pll-02
START position and check EDP-P12-02
for 24 vdc voltage on the PLMI-08
following points: PLMl-13
CONNECTOR PASSED PLM2-03
AND PIN I.D. (./ ) PMCl-16
ATCl-17 PMCl-17
PMCl-13 PMC2A-02
PMC2A-04
PAGE 8
KOMARU EH0910 - 01
VII. KEYOFF CONTROLLER CHECKOUT
A. TRUCKCONDITIONPRELIMINARYREQUIREMENTS
The key switch is in the off position

The engine is NOT running (RPM=O).
All of the connectors on all ofthe controllers, MOM, and EDP are plugged in.
Connect all of the cables going to the battery equalizer.
Connect all of the cables going to the batteries.
Close the batteries disconnect switch to the ON position.
Close the ground level kill switch to the ON position.
All of the circuit breakers are turned on.
B. KEYSWITCHOFF TEST
Make the following visual checks:
CHK TEST CHECKINGMETHOD EXPECTED PASSED

NO. ITEM RESULT ( ./ )
PANELILLUMINATIONCHECK
1. ATC See the 200 LED on ATC panel. All off.
2. EDP See the instrument dash panel. All off.
3. MOM See the screen of MOM. All off.
4. PLM See the 200 LED on PLM panel. All off.
5. PMC See the 200 LED on PMC panel. All off.
6. SSP See the 200 LED on SSP panel. All off.
PAGE 9
KOMARU EH0910 - 01
VIII. KEVON CONTROLLER CHECKOUT
A. TRUCK CONDITION REQUIREMENTS

Truck is totally prepared for operation.
Attach a metal plate to the body sensor if the dumpbody is not installed.
Engine is NOT running (RPM=O)
Unplug the Prelube Timer on the engine (CNl77)
Unplug the Ether Start Bottle at the engine (CN132)
Unplug the Brake Lock Solenoid in the Hydraulic Cabinet (CN164)
Unplug the Park Brake Solenoid in the Hydraulic Cabinet (CN165)
Unplug the Emergency Brake Solenoid in the Hydraulic Cabinet (CN169)
Disconnect the Front Brake Cut Solenoid in the Hydraulic Cabinet
Unplug the Hoist Limit Solenoid #1 connector (CN162)
Disconnect the terminal on the Hoist Limit Solenoid #2
B. INITIALCONTROLLER OUTPUT CHECKS
Turn the key switch to the ON position and observe the following:
CHK TEST CHECKING EXPECTEDRESULT PASSED

NO. ITEM METHOD (./ )
LED OUTPUTDISPLAYS
1. ATC Read 2DD 8.8 is displayed on the ATC 2DD LED for 3 seconds.
LEDs Then 53, OA,78, 80 is displayed & ended by --
NOTE: 78, 80 will change because of the Version.
Fault codes will be cycled on the 2DD LED after the - -
0.0 will display if no active fault codes are detected.
O.Cwill display when the transmission ECMV oil
temperature is >59 of.
2. EDP Read 2DD All LCD areas on the panel come on for 3 seconds.
LEDs All caution and pilot lamps except Centry caution
lamp comes on for 3 seconds.
3. MOM Read 2DD After the system message (In Japanese),
LEDs (i1) MOM is displayed for 3 seconds
(i2) Initial Check 1 is displayed.
4. PLM Read 2DD 88.88 is displayed on the PLM 2DD for 3 seconds.
LEDs all PLM LEDs & buzzer are turned on for 3 seconds.
5. PMC Read 2DD 0 C and 0 d are displayed on the PMC 2DD LED
LEDs 00 is displayed when PMC detects no active fault.
6. RCM Read 2DD The fault codes are shown in sequence on the 2DD.
LEDs Then 00 is displayed when no active faults are detected.
PAGE 10
KOMARU EH0910 - 01
C. INSTRUMENTPANEL CHECKOUT
Perform the following checkout procedure steps:
CHK TEST ITEM CHECKING EXPECTED RESULT PASSED

NO. METHOD (./ )
DASHPANELLAMP OUTPUTS
1. Park Brake Turn on the Park Parking pilot lamp comes on.
Brake switch
2. Right Side Apply the right side All caution and the pilot lamps except the
Lamp Check lamp check switch Centry caution lamp will come on.
3. Left Side Apply the left side The Centry caution lamp will come on.
Lamp Check lamp check switch
4. Fl Switch Turn the F 1 start The assigned area in the panel is turned on.
switch on.
5. Shift Limit Turn the shift limit The assigned area in the panel is turned on.
Switch switch on.
6. Neutral Shift Place the shift lever Shift position indicates Non EDP.
Position in the N position.
7. Reverse Shift Place the shift lever Shift position indicates R on EDP.
Position in the R position.
8. Drive Shift Place the shift lever Shift position indicates D on EDP. Buzzer
Position in the D position. sounds & Master Warning Lamp flashes.
9. 5th Gear Shift Place the shift lever Shift position indicates 5 on EDP.
Position in position #5.
10. 4th Gear Shift Place the shift lever Shift position indicates 4 on EDP.
11. 3rd Gear Shift Place the shift lever Shift position indicates 3 on EDP.
12. Low Shift Place the shift lever Shift position indicates Lon EDP.
Position in the L position.
13. Dumpbody Remove the body The float caution lamp comes on.
Floating sensor magnet
PAGE 11
KOMARU EH0910 - 01
D. CONTROLLERSWITCHANDSOFTWARE CHECKS
Perform the following checkout procedure steps:
CHK TEST CHECKING METHOD EXPECTED RESULT PASSED

NO. ITEM (./ )
CONTROLLERSWITCH ANDSOFTWAREDEFAULTSETTINGS
1. ATC See MOM screen #S32-1/3. SWI : D (= 530M)
SW2 : 2 (= with PMC)
2. EDP See MOM screen #S32-1/3. SWI : 3 (= Large size tire)
SW2 : any position is OK. (Notused.)
3. PMC See MOM screen #S32-1/3. 4027 (= Standard)
4227 (= Standard + ASR)
4. PLM See 2DD LEDs on the 8888 (Initial check)
PLM. COOd(Model = 530M)
CdOO(Memory card = Used)
CLOO(Inclinometer = Used)
USOO(Unit = US tons)
SU-- (SW disable = Not used)
dOOO(Machine ID =0)
0000 (Open ID = 0)
SP62 (Speed warning = 62 mile)
OPlO (Op. code = PMC connected)
5. Max. gear See MOM screen # t33. F7
6. Max. gear See MOM screen # t34. DEFAULT
(Body up)
7. Unit See MOM screen # t4 mile/h
kpsi
F
US. GAL
US. ton
8. MOM's See MOM screen t2. Set current date and time.
clock
PAGE12
KOMAnu EH0910 - 01
E. ENGINESIGNALSAT ZERO RPM TEST
1. ENGINEAT ZERO RPM ENGINECHECKOUT

Performthe followingenginecheckoutsteps:
SCREEN TEST ITEM CHECKINGMETHOD EXPECTED OBSERVED PASSED

NUMBER RESULT RESULT (./')
MOM SCREENCHECKS
s211 ENGINE
s211-1/10 ECM TEMPERATURE Read MOM screen ATMOS.
TEMP.
s211-3/10 TURBO INLET TEMP Read MOM screen ATMOS.
RIGHT BANK TEMP.
TURBO INLET TEMP Read MOM screen ATMOS.
LEFT BANK TEMP.
AMBIENT AIR PRE Read MOM screen 14.2 +/- 0.5 psia
INT. MAN!. TMP.LF Read MOM screen ATMOS.
TEMP.
INT. MAN!. TMP.LR Read MOM screen ATMOS.
TEMP.
INT. MAN!. TMP.RF Read MOM screen ATMOS.
TEMP.
INT. MAN!. TMP.RR Read MOM screen ATMOS.
TEMP.
s211-4/10 OIL TEMP. Read MOM screen ATMOS.
TEMP.
s211-5/10 COOLANT TEMP. Read MOM screen ATMOS.
TEMP.
s211-6/10 EXH. TEMP. L1 Read MOM screen ATMOS.
TEMP.
EXH. TEMP. L2 Read MOM screen ATMOS.
TEMP.
TEMP.
TEMP.
s211-7/10 EXH. TEMP. L5 Read MOM screen ATMOS.
TEMP.
TEMP.
TEMP.
TEMP.
PAGE 13
KOMARU EH0910 - 01
SCREEN TESTITEM CHECKING METHOD EXPECTED OBSERVED PASSED

NUMBER RESULT RESULT (./ )
MOM SCREENCHECKS
s211-8/10 EXH. TEMP. Rl Read MOM screen ATMOS.
TEMP.
EXH. TEMP. R2 Read MOM screen ATMOS.
TEMP.
TEMP.
TEMP.
s211-9/10 EXH. TEMP. R5 Read MOM screen ATMOS.
TEMP.
TEMP.
TEMP.
TEMP.
2. ENGINEAT ZERO RPM TRANSMISSIONCHECKOUT
Perform the following transmission checkout steps:

SCREEN TEST ITEM CHECKING METHOD EXPECTED OBSERVED PASSED
s221 TRANSMISSION CONTROLLER
s221-6/14 TIC OUT OIL TMP Read MOM screen ATMOS.
TEMP.
ECMV OIL TMP Read MOM screen ATMOS.
TEMP.
TIMLUB OIL TMP Read MOM screen ATMOS.
TEMP.
s221-7/14 LIMP HOME SW. Read MOM screen
Limp home jumper installed OFF
TIM CUT RELAY Read MOM screen. ON
Ground the negative side of the
Transmission Cut relay
[RB6A-2( -)]
HIGH. GEAR SW.2 Read MOM screen OFF
High Gear Sw. #2 ON
HIGH. GEAR SW.l Read MOM screen OFF
High Gear Sw. #1 ON
PAGE14
KOMARU EH0910 - 01

NUMBER RESULT RESULT (.t )
s221-8/14 FRT. BR. OIL TMP Read MOM screen ATMOS.
TEMP.
R.BR. OIL TMP L Read MOM screen ATMOS.
TEMP.
R.BR. OIL TMP R Read MOM screen ATMOS.
TEMP.
s221-9/14 BCV SOLENOID 1 Read MOM screen ON
Rear brake off.
Read MOM screen OFF
Rear brake on.
BCV SOLENOID 2 Rear brake off. ON
Rear brake on. OFF
s221-10/14 BODY SEATING Place a magnet next to frame ON
SW sensor Circuit open. (Body down)
Remove magnet from frame OFF
sensor. Circuit closed. (Body up)
ACCEL PEDAL Pedal up-Idle 3.8 +/- 0.2 V
Pedal down-Full throttle 1.2 +/- 0.2 V
SHIFT WAIT Read MOM screen 19%
THROTTLE Read MOM screen 274 Hz
MODIF.
BRAKE Read MOM screen 0%
COMMAND
s221-11/14 COOLANT TEMP. Read MOM screen ATMOS.
TEMP.
s221-13/14 POWER SUPPLY Read MOM screen 24 +/- 1 V
PAGE 15
KOMARU EH0910 - 01
3. ENGINEAT ZERO RPM BRAKECHECKOUT
Perform the following brake checkout steps:

s231 BRAKE CONTROLLER
s231-2/4 LEFT ASR PPC CO With the retard lever in OmA
the full OFF position
Read MOM screen
With the retard lever in 714 mA
the full ON position
Read MOM screen
RIGHT ASR PPC COMM. With the retard lever in OmA
Read MOM screen
With the retard lever in 714 mA
Read MOM screen
BR. OPE. PRESS. RL Read MOM screen 0 kpsi +.06
BR. OPE. PRESS. RR Read MOM screen 0 kpsi +.06
AMT. OF RE. LE. OP With the retard lever in 0%
Read MOM screen
With the retard lever in 100%
Read MOM screen
AMT. OF THROT. MD Read MOM screen 0%
s231-3/4 AMT. OF BR. COMM. Read MOM screen 0%
EMERGENCY BRAKE SWITCH OFF OFF
SWITCH SWITCH ON ON
FRONT BRAKE CUT SWITCH OFF OFF
SWITCH SWITCH ON ON
BRAKE LOCK SWITCH SWITCH OFF OFF
SWITCH ON ON
FOOT BRAKE PEDAL PEDAL PRESSED ON
PEDAL RELEASED OFF
LOW BR. ACC. PRESS With the Accumulator ON
discharged
Read MOM screen
PRESS. IMBALA. SW Read MOM screen OFF
PAGE16
KOMABU EH0910 - 01

NUMBER RESULT RESULT (./)
8231-4/4 KEY SWITCH Read MOM screen ON
ASR ON/OFF Read MOM screen OFF
ASR MANUAL SW With the ASR Switch OFF
is in the OFF position
Read MOM screen
PW. SUPPLY(BRAKE) Read MOM screen 24V +/- 1
SR. METER BR. CON Read MOM screen hr
4. ENGINEAT ZERO RPM PMC CHECKOUT

Perfonnthe followingPMC checkoutsteps:
NUMBER RESULT RESULT (./)
8251 PMC
8251-2/9 DERATE MODE STA Mode ON and Read MOM screen OFF
ALTERNATE TORQ. Mode ON and Read MOM screen OFF
ALTERNATE DROOP Mode ON and Read MOM screen OFF
VALIDATION SW.2 Pedal up. (Idle) OFF
Pedal down. (Full throttle) ON
VALIDATION SW.1 Pedal up. (Idle) ON
Pedal down. (Full throttle) OFF
8251-3/9 SHIFT WAIT Read MOM screen 20%
BR. COMMAND TIM Read MOM screen 0%
BR. COMMAND BR Read MOM screen 0%
THROT. MOD. TIM Read MOM screen 0%
THROT. MOD. BRA Read MOM screen 0%
ACCEL. PEDAL Pedal up. (OFF) 0.45 +/- 0.10 V
Pedal down. (Full throttle) 3.65 +/- 0.10 V
THROTTLE Pedal up. (OFF) & AISS OFF
Brake on AND coolant 192 Hz
temperature <86F
Pedal up. (OFF) 150 Hz
(AISS SW ON)
Pedal down. (Full throttle) 376 Hz
8251-9/9 POWER SUPPLY Read MOM screen 24V +/- I
PAGEl?
KOMARU EH0910 - 01
5. MOMEDP SIGNALSAT ZERO RPM CHECKOUT
Perform the following EDP checkout steps:

SCREEN TEST ITEM CHECKINGMETHOD EXPECTEDRESULT PASSED
NUMBER (./ )
s261 ELECTRICAL DISPLAY PANEL
s261-3/5 MODECHANGESW.2 SW OFF. OFF
(OPTIONAL) SWON. ON
MODE CHANGE SW.1 SW OFF. OFF
(OPTIONAL) SWON. ON
6. ENGINEAT ZERO RPM PLM CHECKOUT
Perform the following PLM checkout steps:

s271 PAYLOAD METER CONTROLLER
s271-1/2 SUS. PRESS. SENSOR- FL Read MOM screen Kpsi
SUS. PRESS. SENSOR- FR Read MOM screen Kpsi
SUS. PRESS. SENSOR- RL Read MOM screen Kpsi
SUS. PRESS. SENSOR- RR Read MOM screen Kpsi
BODY FLOAT Key ON. ON
Remove magnets next to
body sensors.
SHIFT LEVER N Read MOM screen ON
PAGE18
KOMAnu EH0910 - 01
F. COMPONENT FUNCTIONALTEST
1. SWITCH ACTUATION CHECKOUT
Make the following visual/audio checks:
CHK SWITCH TO EXPECTED RESULT PASSED

NO. ACTIVATE (.t )
1. Head light OFF Position - All external lights are off
151Step Position - the decksidelampsare lit
- the rear outside taillights are lit
2ndStep Position - the deck side lamps are lit
- the rear outside taillights are lit
- the head lights are lit
- the dash lights are lit.
2. Head Light Withthe head lightsoff - the headlightsshould
Dimmer flash on when the switch is activated
Withthe head lightson - the head lights and the
high beam indicator light will switch from hi to
low beams when the switch is activated
3. Dash Lighting With the head light switch in the ON position
Dimmer Pot and Rotating the potentiometer knob:
- the brightness of the dash lights will change
- the brightness of the 3 warning lamps in the
left pod dash panel will change.
4. Left Turn - the front left side marker lights will flash
Signal - the left rear turn signal light will flash
- the left EDP indicator will be lit
5. Right turn - the front right side marker lights will flash
Signal - the right rear turn signal light will flash
- the right EDP indicator will be lit
6. Hazard Lights - the front side marker lights will flash
- the rear turn signal lights will flash
- the right
and left EDP turn indicator will be lit
7. Horn (Steering The front horn will sound when pushed
Wheel Center)
8. Horn ( Turn The front horn will sound when pushed
Signal Lever)
9. Manual Backup - the right deck mounted backup light will be lit
- the left deck mounted backup light will be lit
PAGE 19
KOMARU EH0910 - 01

NO. ACTIVATE .t
( )
10. Directional Place the shift lever in the R position:
Shifter - the rear axle backup light will be lit
- the rear backup warning alarm will sound
- the right deck mounted backup light will be lit
- the left deck mounted backup light will be lit
11. Windshield Intermittent Position (Optional): The wipers
Wiper will swipe the windshield with a time delay.
Low Speed Position: the wipers will swipe the
windows at the low speed.
High Speed Position: The wipers will swipe the
windshield at the high speed.
12. Windshield Fluid will be sprayed on to the windshield if
Washer there is fluid in the reservoir bottle.
13. Ladder Light - the left ladder lights will be lit
(Operator Cab) - the (optional) right ladder lights will be lit
14. Fog Light The optional Fog Lights will be lit.
15. Retarder Lever The two rear outside Retarder Lights are lit.
The optional cab roof mounted Retarder light
will be lit
16. Brake Pedal The three rear centered Brake Lights are lit.
17. Check Lamp When the switch is in the left position:
- all of the left pod warning lamps are lit
(except the "Check Engine Warning Lamp")
When the switch is in the right position:
- the "Check Engine Warning Lamp" will be lit
18. Mode Change (Switch is optional) Pushing the switch once
Switch #1 will show an "E" code on the EDP
19. Mode Change (Switch is optional) Pushing the switch once
Switch #2 will show an "E" code on the EDP
20. MOM Dimmer The MOM screen will change brightness
21. AlC Heater Fan Each position will have a different fan speed
22. Defroster The Defroster Actuator will move the Defroster
Actuator air diverter door to the open and closed
positions
23. Floor Vent The Floor Vent Actuator will move the Floor
Actuator Vent air diverter door to the open and closed
positions
24. Recirculating The Recirculating Actuator will move the
Actuator Recirculating air diverter door to the open and
closed positions
PAGE 20
KOMAUU EH0910 - 01
CHK SWITCH TO EXPECTEDRESULT PASSED

NO. ACTIVATE (,f )
25. RightWindow The right window will go up and down
26. LeftWindow The left window will go up and down
27. CigarLighter Check for glowing element after time period
28. CabDomeLight The light will come on and go off
29. Components The light will come on and go off
BoxWorkLight
30. AMlFMRadio - The Radio power will come on and go off
with the power switch.
- The volume of the speakers will go up and
down with the volume control knob.
- The stations will change with the tuner knob.
- The clock time will not be lost or changed
after the power switch has been cycled.
31. LeftHydraulic The light will come on and go off
CabinetWork
Lamp
32. RightHydraulic The light will come on and go off
CabinetWork
Lamp
33. Ladder Light - the left ladder lights will be lit
(Left Ladder) - the (optional) right ladder lights will be lit
34. Left Engine Both the left and right engine service lights will
Service Lts Sw come on and go off.
35. Right Engine Both the left and right engine service lights will
Service Lts Sw come on and go off.
PAGE 21
KOMARU EH0910 - 01
2. SWITCHVOLTAGE CHECKOUT
Make the following voltage or actuation checks:

NO. ACTIVATE (.t )
1. Keyswitch to Measure 24 vdc at terminal position #3 of the
the START Prelube Timer connector (CN177)
2. Ether Start Measure 24 vdc at terminal position #A of the
Ether Start Bottle connector (CN132)
3. SlipperyRoad (Optional Switch) Measure 24 vdc at terminal
Sw. in the OFF to the wire that goes to the Front Brake Cutout
position Solenoid
4. Brake Lock Measure 24 vdc at terminal position #A ofthe
Brake Lock Solenoid connector (CN164)
5. Park Brake in Measure 24 vdc at terminal position #A of the
the OFFposition Park Brake Solenoid connector (CN165)
6. Emergency Measure 24 vdc at terminal position #A of the
Brake in the Park Brake Solenoid connector (CN165)
OFF position Measure 24 vdc at terminal to the wire that goes
to the Front Brake Cutout Solenoid
Measure 0 vdc at terminal position #A of the
Emergency Brake Solenoid connector (CN169)
7. Emergency Measure 0 vdc at terminal position #A of the
Brake in the Park Brake Solenoid connector (CN165)
ON position Measure 0 vdc at terminal to the wire that goes
to the Front Brake Cutout Solenoid
Measure 24 vdc at terminal position #A of the
Emergency Brake Solenoid connector (CN169)
8. Hoist Limit Measure 24 vdc at terminal position #A of the
Proximity Hoist Limit Solenoid #1 connector (CN162)
(Place a metal Measure 24 vdc at the terminal of the Hoist
plate next to Limit #2 Solenoid
switch)
PAGE22
KOMADU EH0910 - 01
3. MULTITASK SWITCH@) CHECKOUT
Make the following checks using the given procedure steps:
CHK STEP PROCEDURE EXPECTEDRESULT PASSED

NO. NO. (.t )
1. A. Remove the metal plate from The Dump Body Float
Dump Body Status switch Light will be lit
B. Unplug Lateral Inclinometer The Lateral Inclinometer
Connector (CN037) Light will be lit
C. Replace the metal plate next The Lateral Inclinometer
to the Dump Body Status and the Dump Body
switch Float Light will go off.
2. A. Unplug Centry Connector #C5 Measure 24 vdc at
terminal position #G of
the Centry Engine
Connector (C5)
B. Turnthe Keyswitchto theOFF Measure 0 vdc at
position terminal position #G of
the Centry Engine
Connector (C5)
C. Turnthe Keyswitchto the ON Measure 24 vdc at
position terminal position #G of
the Centry Engine
Connector (C5)
D. Turnthe GroundLevelKill Measure 0 vdc at
switch to the OFFposition terminal position #G of
the Centry Engine
Connector (C5)
E. Turnthe GroundLevelKill Measure 24 vdc at
switch to the ON position terminal position #G of
the Centry Engine
Connector (C5)
F. Turn the Battery Disconnect Measure 0 vdc at
Switch to the OFFposition terminal position #G of
the Centry Engine
Connector (C5)
G. Turn the Battery Disconnect Measure 24 vdc at
Switch to the ONposition terminal position #G of
the Centry Engine
Connector (C5)
PAGE23
KOMAUU EH0910 - 01
IX. ENGINE RUNNING CONTROLLER CHECKOUT
A. TRUCKCONDITIONREQUIREMENTS

All of the battery cables to the batteries are connected.
Attach a metal plate to the body sensor if dumpbody is not installed.
The engine is running at an idle speed.
B. PRELIMINARYPRECAUTIONS
Use proper shop safety procedures before starting the engine.
C. ENGINE RUNNING TEST
1. ENGINE RUNNING ENGINE CHECKOUT

Perform the following engine checkout steps:
SCREEN TEST ITEM CHECKING EXPECTED OBSERVED PASSED

NUMBER METHOD RESULT RESULT (./ )
MOM SCREEN CHECKS
s211 ENGINE (CENSE)
s211-1/10 ENG. SPEED See MOM screen. 1000 +/- 30 rpm
FUEL RAIL PRo See MOM screen. kpsi
ECM TEMP. See MOM screen. ATMOS. TEMP.
s211-2/10 ENG. SPEED(CENSE) Pedal up. (Idle) 1000
(AISS OFF, Brake +/- 30 rpm
on & Coolant<86F)
Pedal up. (Idle) 750
(AISS SW ON) +/- 25 rpm
BLOWBY PRESS. See MOM screen. inch H2O
ENG. SPEED(CENTRY) Pedal up. (Idle) 1000 rpm
on & Coolant<86F
INT A. MAN!. PRo LB See MOM screen. kpsi
INT A. MANl. PR. RB See MOM screen. kpsi
PAGE24
KOMARU EH0910 - 01
Komatsu Minin~ Systems, Inc. - Peoria Operations

NUMBER METHOD RESULT RESULT (.t )
MOM SCREEN CHECKS
s211 ENGINE (CENSE)
s211-4/1 0 ENG. SPEED See MOM screen. 1000 +1- 30 rpm
OIL LEVEL See MOM screen.
OIL PR. PRE. FIL See MOM screen. kpsi
OIL PRo POST FIL See MOM screen. kpsi
OIL TEMP. See MOM screen. ATMOS. TEMP.
s211-5/1 0 ENG. SPEED See MOM screen. 1000 +1- 30 rpm
COOLANT LEVEL See MOM screen.
COOLANT PRESS. See MOM screen. kpsi
COOLANT TEMP. See MOM screen. ATMOS. TEMP.
2. ENGINERUNNINGTRANSMISSIONCHECKOUT
Perform the following transmission checkout steps:

NUMBER METHOD RESULT RESULT (.t)
MOM SCREEN CHECKS
s221-6/14 ENG. SPEED See MOM screen. 1000 +1- 30 rpm
TIMOUTP. SPEED See MOM screen. rpm
TIC OUT OIL TMP See MOM screen. ATMOSPHERE
TEMP.
ECMV OIL TMP See MOM screen. ATMOSPHERE
TEMP.
TIM LUB OIL TMP See MOM screen. ATMOSPHERE
TEMP.
SOLENOID LlC See MOM screen. mA
TIC IN PRESS. See MOM screen. kpsi
TIC OUT PRESS. See MOM screen. kpsi
PAGE 25
KOMARU EH0910 - 01
3. ENGINERUNNINGBRAKECHECKOUT
Performthe followingbrakecheckoutsteps:
SCREEN TESTITEM CHECKING METHOD EXPECTED OBSERVED PASSED
MOM SCREEN CHECKS
TIM OUTP. SPEED See MOM screen. rpm
RETARD PPC COM. See MOM screen. mA
LEFT ASR PPC CO See MOM screen. mA
R ASR PPC COMM. See MOM screen. mA
BR. OPE. PRESS. RL With the retard lever in 0 kpsi +.06
Read MOM screen
With the retard lever in 2.1 kpsi +/- .25
Read MOM screen
BR. OPE. PRESS. RR With the retard lever in 0 kpsi +.06
Read MOM screen
With the retard lever in 2.1 kpsi +/- .25
Read MOM screen
AMT. OF RE. LE. OP See MOM screen. %
AMT. OF THROT. MD See MOM screen. %
AMT. OF BR. COMM. See MOM screen. 0%
LOW BR. ACC PRES SWON OFF
PRESS. 1MBALA. SW SWON OFF
KEY SW SWON ON
ASR ON/OFF ASR ON
PW. SUPPLY BRAKE See MOM screen. 26 V +/- 1
SR. METER BR. CON See MOM screen. hr
PAGE 26
KOMAUU EH0910 - 01
4. ENGINE RUNNING PMC CHECKOUT
Perform the following PMC checkout steps:

MOM SCREEN CHECKS
8251 PMC
s251-4/9 ENG. SPEED (T/M) Pedal up. (Idle) 1000
on & Coolant<86F
TIM OUTP. SPEED (TIM) See MOM screen. rpm
ENG. SPEED(PMC) Pedal up. (Idle) 1000 rpm
on & Coolant<86F)
Pedal up. (Idle) 750 rpm
TIM OUTP. SP PMC See MOM screen. rpm
KEY SW. "C" PMC See MOM screen. ON
EMERGENCY BRAKE Turn on the
emergency brake
switch
F. BR. FILTER RES See MOM screen. OFF
R. BR. FIL. REST. L See MOM screen. OFF
R.BR. FIL. REST. R See MOM screen. OFF
HYD. FILTER RES See MOM screen. OFF
PAGE 27
KOMARU EH0910 - 01
x. TRUCK MOVING CONTROLLER CHECKOUT
A. TRUCK CONDITIONREQUIREMENTS
All previous Checkouts have been preformed

All of the battery cables to the batteries are connected.
Attach a metal plate to the body sensor if dumpbody is not installed.
The engine is running at an idle speed.
B. PRELIMINARYPRECAUTIONS
Use proper shop safety procedures before starting the engine.
C. TRUCK MOVING TEST
1. WHEEL SPEED CHECKOUT
Perform the following truck moving checkout steps:

MOM SCREEN CHECKS
S231 BRAKE CONTROLLER
S231-1/4 WHEEL SPEED (FL) See MOM screen. rpm
WHEEL SPEED (FR) See MOM screen. rpm
WHEEL SPEED (RL) See MOM screen. rpm
WHEEL SPEED (RR) See MOM screen. rpm
2. ELECTRONICDASH CHECKOUT
Perform the following truck moving checkout steps:
CHECK TEST ITEM CHECKING PASSED

NO. METHOD (.t )
EDP SCREEN DISPLAY CHECKS
1. SPEEDOMETER DISPLAY See EDP screen.
2. COOLANT TEMPERATURE GAUGE See EDP screen.
3. TORQUE CONVERTER OIL TEMPERATURE GAUGE See EDP screen.
4. RETARDER OIL TEMPERATURE GAUGE See EDP screen.
5. TACHOMETER See EDP screen.
6. FUEL GAUGE See EDP screen.
PAGE 28
KOMAnu EH0910 01 -
XI. CHECKOUT DATA CLEANUP
A. TRUCKCONDITIONREQUIREMENTS

All of the battery cables to the batteries are connected
Engine is NOT running (RPM=O)
B. CHECKOUTDATACLEANUP
Clear out the following electronic information using the following screens:
STEP TEST ITEM CHECKINGMETHOD EXPECTEDRESULT CLEARED

NO. (./ )
1. Clear fault history
1. ATC Clear faults with MOM screen s223 1. All faults are cleared.
2. RCM Clear faults with MOM screen s2331. All faults are cleared.
3. PMC Clear faults with MOM screen s2521. All faults are cleared.
4. EDP Clear faults with MOM screen s2621. All faults are cleared.
2. Clear snapshot data
1. ATC Clear data with DAD screen s2232. All data are cleared.
2. RCM Clear data with DAD screen s2332. All data are cleared.
3. PMC Clear data with DAD screen s25. All data are cleared.
3. Clear trend data
1. Engine Clear data with DAD All data are cleared.
screen s2125.
2. ATC Clear data with DAD All data are cleared.
screen s2221- s222E.
3. RCM Clear data with DAD All data are cleared.
screen s2321- s232E.
4. Record service meter
1. Mechanical See Electronic display panel. (Record the number.)
Also on the next page
2. Electrical See MOM screen s261-1/5 (Record the number.)
Also on the next page
PAGE 29
KOMARU EH0910 - 01
r
XII. SERIAL NUMBER DOCUMENTATION
Record the following information from the components mounted on the truck:
SERIAL NUMBER DOCUMENTATION

UNIT NUMBER I SERIAL NUMBER
DESCRIPTION SERIAL NUMBER PART NUMBER SOFTWARE I.D.

PMC CONTROLLER
ATC CONTROLLER
RCM CONTROLLER
PLM CONTROLLER
MOM PANEL
EDP DASH PANEL
ENGINE
ENGINE CONTROLLER
ENGINE MONITOR
TRANSMISSION
SSP CONTROLLER
PAGE30
STANDARD TABLES
This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard
units in parentheses. References throughout the manual to standard torques or other standard values will be to
one of the following tables. Do not use standard values to replace specific torque values in assembly instructions.
For values not shown in any of the charts or tables, standard conversion factors for most commonly used measure-
ments are provided in Tables 1 and 17.
NOTE: Portions of this truck may be assembled with SAE (US) hardware. Ensure the correct table is referenced
when determining the proper torque.
INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page TABLE1. Common Conversion Multipliers
Metric To English
TABLE 1 Common Conversions Multipliers
Metric -to- English . . . . . . . . . A5-1 Multiply
To Convert From To By
TABLE 2 Standard Tightening Torque For
millimeter (mm) inch (in.) 0.0394
Metric Cap Screws and Nuts . . . . . A5-2
centimeter (cm) inch (in.) 0.3937
TABLE 3 Standard Tightening Torque
meter (m) foot (ft) 3.2808
For Split Flange Bolts . . . A5-2
meter (m) yard (yd) 1.0936
TABLE 4 Tightening Torque For Flared kilometer (km) mile (mi) 0.6210
Tube And Hose Fittings . . . . . . . A5-2
square centimeters (cm2) square inch (in.2) 0.1550
TABLE 5 Temperature Conversions . . . . . A5-3 2)
square centimeters (cm square feet (ft2) 0.001
TABLE 6 Torque Conversions cubic centimeters (cm 3)
cubic inch (in.3) 0.061
kg·m to ft lb. . . . . . . . . . . A5-3
liters (l) cubic inch (in. ) 3 61.02
TABLE 7 Torque Conversions 3 3
cubic meters (m ) cubic feet (ft ) 35.314
kg·m to N·m . . . . . . . . . . A5-3
liters (l) cubic feet (ft )3 0.0353
TABLE 8 Pressure Conversions
grams (g) ounce (oz) 0.0353
kg/cm2 to psi . . . . . . . . . . . A5-4
milliliter (ml) fluid ounce (fl oz) 0.0338
TABLE 9 Pressure Conversions kilogram (kg) pound (mass) 2.2046
kg/cm2 to kPa . . . . . . . . . . . A5-4 Newton (N) pounds (lb) 0.2248
TABLE 10 Pressure Conversions Newton meters (N·m) kilogram meters (kg·m) 0.102
psi to kPa . . . . . . . . . . . . . A5-4 Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram meters (N·m) foot pounds (ft lb) 7.2329
For SAE Cap Screws and Nuts . . . . A5-5 kilogram meters (N·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038
12-Pt, Grade 9, Cap Screws (SAE). . . . A5-5
kilograms/cm2 (kg/cm2) pounds/square inch (psi) 14.2231
TABLE 13 JIC 37° Swivel Nuts
Torque Chart (SAE) . . . . . . . . A5-6 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
kilogram (kg) short ton (tn) 0.0011
TABLE 14 Pipe Thread Torque Chart (SAE) . A5-6
metric ton short ton (tn) 1.1023
TABLE 15 O-Ring Boss Torque Chart (SAE) . A5-6 liters (l) quart (qt) 1.0567
TABLE 16 O-Ring Face Seal liters (l) gallon (gal) 0.2642
Torque Chart (SAE) . . . . . . . . . A5-6 Watts (W) horsepower (hp) 0.00134
TABLE 17 Common Conversions Multipliers kilowatts (kW) horsepower (hp) 1.3410

English -to- Metric . . . . . . . . . A5-7
TABLE 18 Sealants And Adhesives. . . . . . . A5-8
Standard Tables Page-1

TABLE 2. Standard Tightening Torque For
Metric Hex Head Cap Screws And Nut
Cap Screw Thread Width Kilogram meters Newton meters Foot Pounds
Diameter Across Flat (kg·m) (N·m) (ft lb)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
6 10 1.35 13.2 10
8 13 3.2 31.4 23
10 17 6.7 65.7 48
12 19 11.5 112 83
14 22 18.0 177 130
16 24 28.5 279 206
18 27 39.0 383 282
20 30 56.0 549 405
22 32 76.0 745 550
24 36 94.5 927 684
27 41 135 1320 975
30 46 175 1720 1266
33 50 225 2210 1630
36 55 280 2750 2025
39 60 335 3280 2420
TABLE 3. Tightening Torque For

Split Flange Bolts
Cap Screw Thread Width Kilogram meters Newton meters Foot Pounds
Diameter Across Flat (kg·m) (N·m) (ft lb)
10 14 6.7 65.7 48
12 17 11.5 112 83
16 22 28.5 279 206
TABLE 4. Tightening Torque For

Flared Tube And Hose Fittings
Thread Width Kilogram meters Newton meters Foot Pounds

Diameter of Nut Across Flat (kg·m) (N·m) (ft lb)
14 19 2.5 25 18
18 24 5 50 36
22 27 8 80 58
24 32 14 140 101
30 36 18 175 130
33 41 20 195 145
36 46 25 245 180
42 55 30 295 215
Page-2 Standard Tables

TABLE 5. Temperature Conversions
Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F°
Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit
C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
TABLE 6. Torque Conversions

kilogram meter (kg·m) to foot pounds - (ft lb)
1 kg·m=7.2339 ft lb
kg·m 0 1 2 3 4 5 6 7 8 9
0 (ft lb) 7.23 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.5 303.8 311.0 318.2 325.5 332.7 339.9 347.2 354.4
50 361.6 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
TABLE 7. Torque Conversions

kilogram meter - kg·m To Newton meters (N·m)
1 kg·m=9.807 N·m
kg·m 0 1 2 3 4 5 6 7 8 9
0 (N.m) 9.8 19.6 29.4 39.2 49.0 58.8 68.6 78.5 88.3
10 98.1 107.9 117.7 127.5 137.3 147.1 156.9 166.7 176.5 186.3
20 196.1 205.9 215.8 225.6 235.4 245.2 255.0 264.8 274.6 284.4
30 294.2 304.0 313.8 323.6 333.4 343.2 353.1 362.9 372.7 382.5
40 392.3 402.1 411.9 421.7 431.5 441.3 451.1 460.9 470.7 480.5
50 490.4 500.2 510.0 519.8 529.6 539.4 549.2 559.0 568.8 578.6
60 588.4 598.2 608.0 617.8 627.6 637.5 647.3 657.1 666.9 676.7
70 686.5 696.3 706.1 716.0 725.7 735.5 745.3 755.1 764.9 774.8
80 784.6 794.4 804.2 814.0 823.8 833.6 843.4 853.2 863.0 872.8
90 882.6 892.4 902.2 912.1 921.9 931.7 941.5 951.3 961.1 970.9

TABLE 8. Pressure Conversions
kilograms per square centimeter (kg/cm2) to pounds per square inch (psi)
2
1 kg/cm =14.2231 psi
kg/cm2 0 1 2 3 4 5 6 7 8 9
0 (psi) 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 185.0 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.2 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.1 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.0 782.3 796.5 810.7 824.9 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 952.9 967.2 981.4
70 995.6 1009.8 1024.1 1038.3 1052.5 1066.7 1081.0 1095.2 1109.4 1123.6
80 1137.8 1152.1 1166.3 1180.5 1194.7 1209.0 1223.2 1237.4 1251.6 1265.9
90 1280.1 1294.3 1308.5 1322.7 1337.0 1351.2 1365.4 1379.6 1393.9 1408.1

2
kilograms per square centimeter (kg/cm ) to kilopascals (kPa)
2
1 kg·cm =98.068 kPa
2 0 1 2 3 4 5 6 7 8 9
kg/cm
0 (kPa) 98 196 294 392 490 588 686 785 883
10 981 1079 1177 1275 1373 1471 1569 1667 1765 1863
20 1961 2059 2157 2256 2354 2452 2550 2648 2746 2844
30 2942 3040 3138 3236 3334 3432 3530 3629 3727 3825
40 3923 4021 4119 4217 4315 4413 4511 4609 4707 4805
50 4903 5001 5100 5198 5296 5394 5492 5590 5688 5786
60 5884 5982 6080 6178 6276 6374 6472 6571 6669 6767
70 6865 6963 7061 7159 7257 7355 7453 7551 7649 7747
80 7845 7944 8042 8140 8238 8336 8434 8532 8630 8728
90 8826 8924 9022 9120 9218 9316 9415 9513 9611 9709

pounds per square inch (psi) to kilopascals (kPa)
Formula: psi x 6.895 = kPa
0 1 2 3 4 5 6 7 8 9
psi
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
NOTE: Tables such as Table 6, 7, 8, 9 and 10 may be used as in the following example:
Example: Convert 955 kg·m to foot pounds (ft lb). 950 kg·m = 6871 ft lb
1. Select Table 6. 4. Go to kg·m row 0, column 5; reads 49.0
5 kg·m = 49 ft lb Add to step 3.
2. Go to kg·m row 90, column 5; reads 687.1
95 kg·m = 687.1 ft lb 5. 950 + 5 kg·m = 6871 + 49 = 6920 ft lb
955 kg·m = 6920 ft lb
3. Multiply by 10:

TABLE 11
Standard Torque Chart
SAE Hex Head Cap Screw And Nut Assembly
(Lubricated Threads)
Tolerances ±10%
Cap Torque - Torque - Cap Torque - Torque -
Screw Grade 5 Grade 8 Screw Grade 5 Grade 8
Thread Thread
Size ft lb kg·m N·m ft lb kg·m N·m Size ft lb kg·m N·m ft lb kg·m N·m
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lb = 0.138 N·m = 1.356 N.m
TABLE 12 - Standard Tightening Torque

TABLE 12 - Standard Tightening Torques For 12- for 12-Point, Grade 9 Cap Screws
Point, Grade 9, Cap Screws (SAE)
Torque Torque Torque
The following specifications apply to required assem- Cap Screw Size* ft lb N·m kg·m
bly torques for all 12-Point, grade 9 (170,000 psi min- 0.250 - 20 12 16 1.7
imum tensile), cap screws. 0.312 - 18 24 33 3.3
• Cap screw threads and seats shall be lubricated 0.375 - 16 42 57 5.8
when assembled. 0.438 -14 70 95 9.7
Unless instructions specifically recommend 0.500 -13 105 142 14.5
otherwise, these standard torque values are to be 0.562 - 12 150 203 20.7
used with simple lithium base chassis grease (multi-
0.625 - 11 205 278 28.3
purpose EP NLGI) or a rust- preventive grease (see
list, this page) on the threads. 0.750 - 10 360 488 49.7
0.875 - 9 575 780 79.4
• Torques are calculated to give a clamping force
of approximately 75% of proof load. 1.000 - 8 860 1166 119
• The maximum torque tolerance shall be ±10% of 1.000 - 12 915 1240 126
the torque value shown. 1.125 - 7 1230 1670 170
1.125 - 12 1330 1800 184
1.250 - 7 1715 2325 237
1.250 - 12 1840 2495 254
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
1.500 - 12 3225 4375 445
* Shank Diameter (in.) - Threads per inch

TABLE 13. TABLE 15.
Torque Chart For JIC 37° Swivel NutS Torque Chart For
With Or Without O-ring Seals O-ring Boss Fittings
Size Tube Size Threads Torque Size Tube Size Threads Torque
Code (OD) UNF-2B ft lb Code (OD) UNF-2B ft lb
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
TABLE 14 TABLE 16
Torque Chart For Torque Chart For
Pipe Thread Fittings O-ring Face Seal Fittings
With Without Size Tube Size Threads Torque

Size Pipe Thread Sealant Sealant Code (O.D.) UNF-2B ft lb
Code Size ft lb ft lb –4 0.250 0.438 – 20 11 ±1
–2 0.125 – 27 15 ±3 20 ±5 –6 0.375 0.562 – 18 18 ±2
–4 0.250 – 18 20 ±5 25 ±5 –8 0.500 0.750 – 16 35 ±4
–6 0.375 – 18 25 ±5 35 ±5 – 10 0.625 0.875 – 14 51 ±5
–8 0.500 – 14 35 ±5 45 ±5 – 12 0.750 1.062 – 12 71 ±7
– 12 0.750 – 14 45 ±5 55 ±5 – 16 1.000 1.312 – 12 98 ±6
– 16 1.000 – 11.50 55 ±5 65 ±5 – 20 1.250 1.625 – 12 132 ±7
– 20 1.250 – 11.50 70 ±5 80 ±5 – 24 1.500 1.875 – 12 165 ±15
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10

TABLE 17 - Common Conversion Multipliers
English to Metric
To Convert To Multiply
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 (in. ) 2

square centimeters (cm )2 6.45
square feet (ft2) square centimeters (cm2) 929
cubic inches (in.3) cubic centimeters (cm3) 16.39
cubic inches (in.3) liters (l) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft.3) 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 18. Sealants And Adhesives
Nomenclature Code Three Bond * Applications
LT-1A TB1521 Used to apply rubber pads, rubber gaskets and cork plugs.
LT-1B 1000B - 1000W Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
seal is needed.
LT-2 TB1374 Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-2A TB2411 Preventing bolts, nuts and plugs from loosening and leaking oil. (1)
Adhesives
LT-2B TB2403 Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
LT-2C TB2430 or Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
TB2440
LT-3 Main bond TB2001 Provides an airtight, electrically insulating seal. Used for aluminum surfaces.
Hardening agent
TB2105
LG-1 TB1108B Used with gaskets and packings to increase sealing effect.
LG-3 TB1107 Heat-resistant gasket for precombustion chambers and exhaust piping.
Liquid Gasket LG-4 TB1104 Used by itself on mounting surfaces on the final drive and transmission cases.
Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)
LG-5 TB1110 Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
tings in hydraulic circuits of less than 50 mm (2 in) in diameter.
Anti-friction LM-P - Applied to bearings and taper shafts to facilitate press-fitting and to prevent stick-
compound ing, burning or rusting.
Grease G2-LI - Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Vaseline - - Used for protecting battery electrode terminals from corrosion.
* NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations.
(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of
1965 kPa (285 psi) or less.
(2) Used for threaded areas (for example, stud, etc.) which are not removable, and a pressure of 1965 kPa
(285 psi) or less.
The sealants and adhesives listed below are manufactured

and sold by Three Bond USA, Inc. For information concerning Part Numbers
Three Bond products, call or write to: Three Bond Komatsu
Three Bond USA, Inc. TB1374 09940-00030

6184 Schumacher Park Drive TB1521 790-129-9030
West Chester, OH 45069 TB1104 790-129-9020
Telephone: (513) 779-7300 TB1108B 790-129-9010

Fax: (513) 779-7375

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 CUSTOMER UNIT

SERIAL NUMBER ENGINE MODEL SERIAL NUMBER NUMBER
HD1500-5
Service Meter Reading Date of Inspection
Location of Machine at Inspection Dump Body Manufacturer

Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

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

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

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.
CEAW003505 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
N
o. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visually inspect the unit for loose parts and debris.
2 Hardware Check for missing hardware.
3 Hoses & Cables Verify hoses and cables are free from kinks, sharp edges, chafing, and are properly
attached.
4 Ground Straps Check all ground straps for secure connections.
5 Engine Fan Inspect the fan to shroud clearance and belt alignment.
6 Decks and Ladders Check for proper installation of decks, ladders, handrails, and anti-skid strips.
7 Belt Tension Verify correct tension on engine accessory belts.
8 Tire Inflation Verify tire pressure is within specifications.
9 Tire Flaw Check tires for visible damage or flaws.
10 Cylinders Verify that cylinder plated surfaces are free from rust and other flaws.
11 Verify that batteries are mounted tightly.
12 Battery Verify that battery connections are clean and tight.
13 Verify that caps are tight and electrolyte solution is at the proper level.
Cab Compartment
1 Cab Doors Inspect doors open and close smoothly, latch works properly, O. & M. Manual in door
2 Cab Windows Check window operation. Should open and close smoothly.
3 Door Locks Verify left and right door locks work properly with key.
4 Interior Visually inspect interior for completeness of assembly.
5 Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
6 Verify operators seat adjusts properly (slide lever, back rest operation, seat inclination, seat
Cab Seats height etc.).
7 Inspect seat belt for proper installation (and seat tethers).
8 Passenger Seat Verify back rest tilts forward and back.
9 Steering Wheel Check tilt and telescoping functions.
10 Verify adjustable lever can be locked securely.
11 Wiper Verify wiper works in all speeds, and range does not extend beyond glass surface.
12 Verify windshield washer works properly and washer fluid bottle is full.
13 Cigarette Lighter Inspect lighter operation; should pop up hot after 10 seconds.
14 Horn Check for proper sound, no looseness in horn button.
15 Back Up Alarm Check for proper sound and function.
16 Gauges Verify that gauges are installed straight and operate properly.
17 Indicator Lights Verify that indicator lights illuminate properly.
18 MOM Display Verify MOM display functions properly.
19 Hydraulic Fittings Inspect all hydraulic fittings in front of cab and rear of cab.
20 HVAC System Verify heater and air conditioning systems function properly.
21 Radio Verify all radio functions operate properly.
Maintenance
Accepted
N
Lights
1 Verify headlights work, high and low beams.
2 Headlights Verify high beam indicator is functional.
3 Verify lights are at proper angle.
4 Panel Dimmer Switch Verify dimmer controls brightness of display panel.
5 Verify front and rear turn signals operate properly on left and right sides.
6 Turn Signal Directional indicators operate properly.
7 Switch turns off after turn is completed.
8 Hazard Flashers Verify flasher operates properly.
9 Indicator lights operate properly.
10 Back Up Light Verify back up lights operates properly when transmission control is in “R” position.
11 Ladder Light Verify ladder lights illuminate with switch ON.
12 Dome Light Verify dome light operates with the switch ON.
13 Backup/Deck Lights Verify backup lights illuminate with switch ON.
Brake Lights
1 Service Brake Lights Verify service brake lights and indicator illuminate with service brake pedal depressed.
2 Brake Lock Verify brake lock indicator light illuminates when activated.
3 Auxiliary Brake Verify auxiliary brake indicator light illuminates when activated.
4 Parking Brake Verify parking brake indicator light illuminates with the parking brake on.
5 Retarder Lights Verify retard indicator light illuminates when activated.
Fluid Levels
1 Fluid Levels Check all fluid levels and observe condition of fluids.
Bolt Torque Checks
1 Drive Shaft (Engine to Verify capscrews are tightened to specified torque.
Transmission)
2 Drive Shaft (Transmis- Verify capscrews are tightened to specified torque.
sion to Differential)
3 Engine Mount Verify capscrews are tightened to specified torque.
4 Transmission Mount Verify capscrews are tightened to specified torque.
5 Cab Mount Verify capscrews are tightened to specified torque.
6 Front Support (LH & RH) Verify capscrews are tightened to specified torque.
7 Hydraulic Tank Verify capscrews are tightened to specified torque.
8 Fuel Tank Verify capscrews are tightened to specified torque.
9 Wheels Verify capscrews are tightened to specified torque.
10 Steering Wheel Verify capscrews are tightened to specified torque.
Leakage
1 Machine Verify that no oil leaks are found throughout the machine.
Maintenance
Accepted
N
Safety Functions
1 Transmission Range Verify transmission control will not shift out of N without pressing the release button
Selector
2 Neutral Safety Verify engine will not start in any position unless transmission range selector is in N. In this
position, centralized warning lamp illuminates, and buzzer sounds.
3 Parking Brake (ON) When parking brake is ON and transmission range selector is in any position other than N,
centralized warning lamp illuminates, and buzzer sounds.
4 Hoist Control When hoist control is any position other than FLOAT and transmission range selector is in
any position other than N, centralized warning lamp illuminates, and buzzer sounds.
5 When hoist control is any position other than FLOAT and transmission range selector is in
R, the truck will not move.
Suspension Cylinders
1 Front Suspension Verify that front suspension cylinder oiling height is 97 ± 3 mm (3.8 ± 0.12 in.). Refer to the
note below.
2 Rear Suspension Verify that rear suspension cylinder oiling height is 221 ± 3 mm (8.7 ± 0.12 in.). Refer to the
note below.
NOTE: Refer to Section H, Oiling And Charging Procedures, in the shop manual for the proper procedures for servicing front and rear sus-
pensions.
Engine Performance
1 Engine Starting Verify that engine starts without difficulty.
2 Engine Noise Verify that no abnormal engine noise exists.
3 Exhaust Gas Color Check for abnormal exhaust colorations during operation.
4 Exhaust Gas Leakage Inspect all exhaust joints for leakage.
Transmission Performance
1 Transmission Noise Verify that no abnormal transmission noise exists.
2 Transmission Shifting Verify transmission shifts smoothly in all speeds.
Braking
1 Service Brake Verify that service brakes do not pull to either side and steering wheel does not vibrate.
2 Check rpm required to overcome the service brakes with the transmission in F5.
Measurement__________rpm
3 Retarder Verify that machine does not pull to either side and steering wheel does not vibrate during
retardation.
4 Check rpm required to overcome the retarder with the transmission in F5.
5 Emergency Brake Verify that the machine will not move with the transmission range selector in F5.
6 Parking Brake Check rpm required to overcome the parking brake with the transmission in F5.
7 Brake Lock Verify brake lock actuates the rear brakes.
Steering
1 Steering Wheel Check steering wheel mounting. Should not have any play on mount.
2 Steering Verify that steering wheel turns easily, steering is smooth, and free from noise or vibration.
3 Emergency Steering Verify that emergency steering functions properly.
Maintenance
Accepted
N
Hoist / Dump Body
1 Hoist Control Lever Verify that control lever functions properly.
2 Hoist Limiter Verify that hoist limiter functions properly.
3 Body Raise Speed Check body raise speed with the dump body empty.
Hydraulic Oil Temperature_________ Engine Speed________ Body Raise Time
________
4 Body Lower Speed Check body lower speed with the dump body empty.
Hydraulic Oil Temperature_________ Engine Speed________ Body Raise Time
________
5 Body Raise/Emergency Verify that the dump body can be raised using emergency steering function.
Steering
Service Inspection
1 Lubrication Ensure automatic lube system is serviced and full (and air bled from system)
Ensure automatic lube system is operating properly and timer is set as desired
2 Payload Meter Sys. Calibrate and check payload meter operation per O&M manual
3 PLM Error Codes Troubleshoot any error codes and delete
Additional Comments:
NOTES
50 HOUR POST-COMMISSIONING CHECKSHEET
Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.
MACHINE MODEL MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
HD1500-5
Service Meter Reading Date of Inspection
Location of Machine at Inspection Dump Body Manufacturer

Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

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

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

mounting hardware.
3 Hoses and Cables Visually inspect hydraulic hoses and electric cables to
ensure they are securely clamped and clear of sharp
edges and other objects that may cause chaffing.
4 Engine Oil Level Verify the engine oil level is at the proper operating
range.
5 Engine Checks Check the air intake system and verify all intake tube
clamps are tightened securely. Ensure no leaks exist.
Inspect the entire engine. Ensure there are no fluid leaks
or abnormalities.
6 Transmission Oil Level Verify the transmission oil level is in the proper operating
range. (Overfilling may lead to overheating.)
7 Hydraulic Oil Level Verify hydraulic oils are filled to the proper levels.
8 Rear Axle Visually inspect axle mounting rods and rear suspen-
sions for proper installation and proper tightening torque.
Verify the correct oil is being used and the housing filled
to the proper oil level.
9 Fuel Tank Verify the fuel tank mounting is secure and there are no
fuel leaks.
10 Radiator Inspect the coolant fill level, cold temperature protection,

and DCA additive.
11 Steering Components Verify proper installation of the steering cylinders, tie
rod, and accumulators.
12 Hydraulic Components Visually inspect the hoist valve, pumps, filters, hydraulic
tank and hoist cylinder installations. All hardware must
be secure, and no leaks evident.
13 Leakage Visually inspect the entire machine for leaks.
Hardware Torque
1 Steering Lever Assembly Verify hardware torque -
To Suspension Housing Target: 929 N·m (685 ft lbs)
2 Steering Cylinder To Verify hardware torque -
Frame Target: 155 N·m (114 ft lbs)
3 Steering Cylinder To Verify hardware torque -
Center Lever Target: 155 N·m (114 ft lbs)
4 Tie Rod Pin Retainer Verify hardware torque -
Target: 155 N·m (114 ft lbs)
5 Front Brake To Spindle Verify hardware torque -
Target: 929 N·m (685 ft lbs)
Cab Compartment
1 Horn Check for proper tone and volume. Ensure there is no
looseness in the horn button.
2 Back Up Horn Check for proper tone, volume, and function.
3 Gauges Verify all gauges are installed straight and are operating
correctly.
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
4 Glass Verify no cracks exist on cab windows. Ensure all win-
dows are properly sealed.
5 Seat/Seat belts Verify the cab seats and seat belts are in proper working
condition.
Service Inspection
1 Front Suspension Verify that the front suspension cylinder heights are
within the arrows on the cylinder decal.
Rear Suspension Verify that the rear suspension cylinder heights are
within specifications.
NOTE: Refer to Section H, Oiling and Charging Pro-
cedure, in the appropriate service manual for com-
plete suspension oiling and charging instructions.
2 Steering Verify that steering system is operating smoothly while
turning from lock to lock.
Verify the steering system is free of noise and vibration.
3 Lubrication Ensure the automatic lube system contains no air and is
filled to the proper level.
Ensure the automatic lube system is operating properly
and the timer is set as desired.
4 Hydraulic Filters Verify the 50 hour change of all hydraulic filters has been
completed.
NOTE: Elements are supplied from the factory in the
parts crate.
5 Tires Check and record the tire pressure/size/manufacturer for Pressure
future reference Size
Manufacturer
6 Payload Meter System Calibrate and check payload meter operation per O&M
manual. Troubleshoot any error codes and delete after
repair.
7 MOM Check MOM system operation per shop manual. Trou-
bleshoot, correct, and delete any error codes.
8 DAD Download DAD and repair any reoccurring fault codes in
the event recorder.
9 VHMS (If equipped) Verify the VHMS system is functioning properly per O&M
manual. Troubleshoot and repair any problems.
10 Dump Body Check the dump body for proper alignment, shimming,
and for any abnormal body pad wear. Verify that the
body limit switch and the hoist control lever are adjusted
correctly and working as intended.
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No. Description of Modification Reason For Installation

1
ADDITIONAL COMMENTS__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
®
www.komatsuamerica.com
Komatsu America Corp. Copyright 2006 Komatsu

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

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CEAW003001

SERIAL NUMBERS A30039 & UP

DANGER Identifies a specific potential hazard

WARNING identifies a specific potential hazard

CAUTION is used for general reminders

SUBJECT PAGE NUMBER

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

MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

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

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

FAM0007 Introduction iii

FAM0106 Safety Rules, Tools, & Equipment Page 1-1

Page1-2 Safety Rules, Tools, & Equipment FAM0106

FAM0106 Safety Rules, Tools, & Equipment Page 1-3

PART NO. DESCRIPTION USE

PART NO. DESCRIPTION USE

Page1-4 Safety Rules, Tools, & Equipment FAM0106

During Retard Control & Monitor (RCM) trouble-

FAM0106 Safety Rules, Tools, & Equipment Page 1-5

Page1-6 Safety Rules, Tools, & Equipment FAM0106

Final Drive Assembly

FAM0206 Major Components and Specifications 2-1

2-2 Major Components and Specifications FAM0206

FAM0206 Major Components and Specifications 2-3

2-4 Major Components and Specifications FAM0206

ITEM KILOGRAMS POUNDS

CHASSIS AND CAB

FAM0306 Major Component Weights 3-1

ENGINE, TRANSMISSION AND RELATED COMPONENTS

FRONT AXLE COMPONENTS

REAR AXLE COMPONENTS

3-2 Major Component Weights FAM0306

FAM0404 Field Welding Procedures 4-1

4-2 Field Welding Procedures FAM0404

FAM0404 Field Welding Procedures 4-3

4-4 Field Welding Procedures FAM0404

FAM0404 Field Welding Procedures 4-5

4-6 Field Welding Procedures FAM0404

FAM0404 Field Welding Procedures 4-7

4-8 Field Welding Procedures FAM0404

FAM0504 Receiving & Assembly Preparation 5-1

5-2 Receiving & Assembly Preparation FAM0504

FAM0606 Chassis Assembly 6-1

10. RH deck, handrail and mirrors

6-2 Chassis Assembly FAM0606

• Slings, chains and cables used for lifting

FAM0606 Chassis Assembly 6-3

6-4 Chassis Assembly FAM0606

FAM0606 Chassis Assembly 6-5

6-6 Chassis Assembly FAM0606

FAM0606 Chassis Assembly 6-7

6-8 Chassis Assembly FAM0606

FAM0606 Chassis Assembly 6-9

6-10 Chassis Assembly FAM0606

FAM0606 Chassis Assembly 6-11

6-12 Chassis Assembly FAM0606

FAM0606 Chassis Assembly 6-13

6-14 Chassis Assembly FAM0606