CEAW008110

Field Assembly
Manual

980E-4
DUMP TRUCK
SERIAL NUMBERS 980E-4 A40052 and up

ENGINE 18V170
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2016 Komatsu

Printed in U.S.A.
Komatsu America Corp.
December 2016
 FOREWORD

This manual is provided to aid assemblers during field assembly of the standard Komatsu 980E-4 dump truck. Vari-
ations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.

FAM0030 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 FAM0030
 TABLE OF CONTENTS

SUBJECT PAGE NUMBER

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

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

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

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

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

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

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

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

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

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

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

FAM0030 Introduction iii

 86258

KOMATSU 980E

iv Introduction FAM0030
 SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES 12. DO NOT weld the fuel tank or hydraulic tank
unless the tanks have been properly purged and
The following list of safety practices is intended for use
ventilated.
by personnel during field assembly of the truck.
13. Use the proper tools for the job to be performed.
This list of safety rules is not intended to replace local
Never improvise wrenches, screw drivers, sock-
safety rules or regulations and federal, state, or local
ets, etc. unless specified.
laws. The safety precautions recommended here are
general and must be used in conjunction with all pre- 14. Lifting eyes and hooks must be fabricated from
vailing local rules and regulations. the proper materials and rated to lift the intended
load.
1. All personnel must be properly trained for the
assembly process. 15. When the weight of any component(s) or any
2. Wear safety equipment such as safety glasses, assembly procedure is not known, contact your
hard toe shoes and hard hats at all times during customer support manager for further information.
assembly.
Use of Tie-Off Anchor During Maintenance and
3. Thoroughly inspect the assembly site. Remove Repair
weeds, debris and other flammable material.
While working at heights
4. Use only solid, hard wood for supports. When
during assembly, mainte-
using metal support stands, place wood blocks
nance or repair of the haul
between the support and the frame to prevent
truck, workers should wear
metal to metal contact.
an appropriate fall protec-
5. Inspect all lifting devices. Refer to the manufac- tion harness and attach it
turer's specifications for correct capacities and to a tie-off anchor or tie-off
safety procedures when lifting components. point.
6. Perform a daily inspection of all lifting cables and
Komatsu anchor (58B-98-75190) is available for use
chains. Replace any questionable items. Use
with fall protection harnesses. Carefully read and
cables and chains that are properly rated for the
understand the harness maker’s instructions before
load to be lifted.
using any fall protection harness.
7. DO NOT stand beneath a suspended load. Use of
guy ropes are recommended for guiding and posi- The load carrying capacity of anchor (58B-97-75190) is
tioning a suspended load. 2 270 kg (5,000 lb).
8. Maintain fire control equipment. Inspect fire extin- NOTE: The anchor must not be used for lifting.
guishers regularly to ensure they are fully charged
and in good working condition.
9. Cap screws and/or nuts being replaced must be BODY-UP RETENTION SLING
the same grade as originally supplied.

To avoid serious personal injury or death, the body

up retention sling must be installed anytime per-
Before welding, refer to Special Precautions When sonnel are required to perform maintenance on the
Servicing An AC Drive System Truck in Section 4. vehicle with the dump body in the raised position.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its compo- The Komatsu body-up safety sling can only be
nents. used with a Komatsu body. Non-OEM body may not
accommodate the Komatsu body-up safety sling.
11. When welding, connect the ground cable to the The end user must ensure that a proper cable/sling
part being welded. DO NOT allow welding current is used.
to pass through bearings, engine, etc.

FAM0118 5/13 Safety Rules, Tools, & Equipment 1-1

TOOLS AND EQUIPMENT FOR ASSEMBLY
The following equipment is recommended for field
assembly of the truck.

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

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

11. Chains, lifting cables, slings: 19. Various hooks and shackles

• Two, 4 point slings, 3 m (10 ft) in length 20. Miscellaneous: i.e. grinders, containers, rags.
21. Spreader bars for cab and decks.
• Two, 4 point slings, 2 m (6 ft) in length
22. Two ratchet hoists of 2.7 metric ton (3 ton) capac-
• Two, 1 m (4 ft) and two, 2 m (6 ft)
ity.
• Two, 3 m (10 ft) nylon straps 23. Pry bars
• Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of 24. Solvent - 38 liters (10 gal)
rope
25. Paint remover - 19 liters (5 gal)
26. Rust preventive grease

1-2 Safety Rules, Tools, & Equipment 5/13 FAM0118

LIFTING SLING GENERAL INFORMATION

FAM0118 5/13 Safety Rules, Tools, & Equipment 1-3

 Part Number Description Use
EB1759 Nitrogen Suspension &
Charging Kit Accumulator
Nitrogen
Charging

1. “T” Handle Valve

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

Part Number Description Use

EH8687 Roller Assy. Power Module
(No longer Remove & Install
available as
complete unit)
EH8681 Roller Mount
PC0706 Bearing
TH9449 Bearing
Retainer
Ring
TG1680 Roller
Retainer
Ring
C1645 Cap screw
0.75 -10 NC
x 2 1/4 in.
C1542 Lockwasher
0.75 in.
EH8686 Roller Ring

1-4 Safety Rules, Tools, & Equipment 5/13 FAM0118

 Part Number Description Use
PC1980 Offset Box End Cab Mounting &
Wrench - 1 11/16” Miscellaneous

Part Number Description Use

BF4117 Seal Installation Front and Rear
Tool Disc Brake
Floating Ring
Seal Installation
ED3347 Seal Installation Rear Axle/
Tool Hub Adapter
Floating Ring
Seal Installation

Part Number Description Use

EK5877 Sleeve Steering Linkage
Alignment Tool and Tie Rod
Assembly

FAM0118 5/13 Safety Rules, Tools, & Equipment 1-5

Part Number Description Use
EM3708 (Rear) Wear Indicator Brake Disc Wear
EM1275 (Front) Inspection

EB1723 Cap, Indicator

EM3707 (Rear) Pin, Indicator
EM1274 (Front)
WA0010 O-ring, Indicator
Pin
TL3995 O-ring, Indicator
Cap
EB4813 Housing,
Indicator
SV9812 O-ring, Housing

Part Number Description Use

PC2525 Harness Payload Meter III®
Download

1-6 Safety Rules, Tools, & Equipment 5/13 FAM0118

 Part Number Description Use
EH7817 Alignment Tool Upper Hoist Pin

Part Number Description Use

PB9067 Bulkhead Battery Jumper
Connector

Part Number Description Use

PC2228 3/4 in. Square Miscellaneous
Drive Wrench

FAM0118 5/13 Safety Rules, Tools, & Equipment 1-7

 Part Number Description Use
WA4826 Lifting Eye Bolt Miscellaneous

Part Number Description Use

PC2660 Sling Body Retention

Part Number Description Use

PC0367 Shackle Body Retention
Miscellaneous

Part Number Description Use

EK6089 Brake Assembly Brake Assembly
Tool Group & Disassembly
(Front)
EK6090 Brake Assembly Brake Assembly
Tool Group & Disassembly
(Rear)

1-8 Safety Rules, Tools, & Equipment 5/13 FAM0118

 Part Number Description Use
XB5777 Hose Assembly Flush Steering
Circuit
PC3074 Flushing Block Flush Hoist/
(bypass hoist Brkae Cooling
cylinders) Circuit

Part Number Description Use

XB7075 Fitting Assembly Flush Hoist/
Brkae Cooling
Circuit

Part Number Description Use

XB0887 Vacuum Pump To hold oil back
while the system
is open

FAM0118 5/13 Safety Rules, Tools, & Equipment 1-9

 HIGH VOLTAGE TOOLS

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

Item Number Part Number Description Use

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

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

1-10 Safety Rules, Tools, & Equipment 5/13 FAM0118

FAM0118 5/13 Safety Rules, Tools, & Equipment 1-11
1-12 Safety Rules, Tools, & Equipment 5/13 FAM0118
 MAJOR COMPONENTS AND SPECIFICATIONS
Truck And Engine Operator's Cab
The 980E Dump Truck is an off-highway, rear dump The operator cab has been engineered for operator
truck with AC Electric Drive. The gross vehicle weight comfort and to allow for efficient and safe operation
is 625 277 kg (1,378,500 lb). The engine is a of the truck. The cab provides wide visibility, with an
Komatsu SSDA18V170 rated @ 2 611 kW (3,500 integral 4-post ROPS/FOPS structure, and an
HP). advanced analog operator environment. It includes a
tinted safety-glass windshield and power-operated
Traction Alternator side windows, a deluxe interior with a fully adjustable
The diesel engine drives an in-line alternator at seat with lumbar support, a fully adjustable tilt/
engine speed. The alternator produces AC current telescope steering wheel, controls mounted within
which is rectified to DC within the main control easy reach of the operator, and a digital/analog
cabinet. instrument panel which provides the operator with all
instruments and gauges which are necessary to
Main Control Cabinet control and/or monitor the truck's operating systems.
negative semiconductor switches referred to as Power Steering
insulated gate bipolar transistors (IGBT). The IGBTs
cycle on and off at varying frequencies to create an The truck is equipped with a full time power steering
AC power signal from the DC supply. The AC power system which provides positive steering control with
signal produced by each inverter is a variable- minimum operator effort. The system includes
voltage, variable-frequency (VVVF) signal. nitrogen-charged accumulators which automatically
Frequency and voltage are changed to suit the provide emergency power if the steering hydraulic
operating conditions. pressure is reduced below an established minimum.

AC Induction Traction Motorized Wheels Dynamic Retarding Grid

The alternator output supplies electrical energy to the The dynamic retarding grid is used to slow the truck
two wheel motors attached to the rear axle housing. during normal operation or control speed coming
The motorized wheels use three-phase AC induction down a grade. The dynamic retarding ability of the
motors with full-wave AC power. electric system is controlled by the operator through
the activation of the retarder pedal (or by operating a
The two wheel motors convert electrical energy back lever on the steering column) in the operator’s cab
to mechanical energy through built-in gear trains and by setting the speed control. Dynamic Retarding
within the wheel motor assembly. The direction of the is automatically activated if the truck speed goes to a
wheel motors is controlled by a forward or reverse preset overspeed setting.
hand selector switch located on the center console.
Brake System
Suspension
Service brakes at each wheel are oil-cooled multiple
HYDRAIR® II suspension cylinders located at each disc brakes applied by an all-hydraulic actuation
wheel provide a smooth and comfortable ride for the system. Depressing the brake pedal actuates both
operator and dampens shock loads to the chassis front and rear brakes after first applying the retarder.
during loading and operation. All wheel brakes will be applied automatically if the
brake system pressure decreases below a preset
minimum.

The parking brake is a dry disc type, mounted

inboard on each rear wheel motor, and is spring-
applied and hydraulically-released with wheel speed
application protection (will not apply with truck
moving).

FAM0234 4/16 Truck Components And Specifications 2-1

 3 4 5

6
1

27
7
7

8
8

26 25
9
24

23 10
22
11
21 12
13 13
14

15 15

16 17 18 20 19 20 18 17 16
86265

MAJOR COMPONENTS

2-2 Truck Components And Specifications 4/16 FAM0234

 1. Operator Cab 15. Wheel Motor Transmission
2. Engine Mounted Fuel Filters 16. Rear Tires
3. Auto Lubrication 17. Wet Disc Brake
4. Radiator 18. Rear Suspension
5. Reserve Oil System 19. Rear Axle Hatch
6. Engine 20. AC Electric Motor
7. Front Suspension 21. Hydraulic Tank
8. Wet Disc Brake 22. Steering Pump
9. Brake Accumulators 23. Hoist Pump
10. Hoist Filters 24. Hydraulic Brake Filter
11. Steering Filter 25. Steering Accumulators
12. Fuel Tank 26. Alternator
13. Hoist Cylinder 27. Auxiliary Accumulator
14. Rear Axle Housing

FAM0234 4/16 Truck Components And Specifications 2-3

SPECIFICATIONS
These specifications are for the standard Komatsu 960E truck. Customer options may change this listing.

ENGINE

Komatsu SSDA18V170
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 610 kW (3,500 HP) @ 1900 RPM
Flywheel HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 495 kW (3,346 HP) @ 1900 RPM
Weight (Dry)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 300 kg (22,701 lb)
* Weight does not include radiator, sub-frame, or alternator.

AC ELECTRIC DRIVE SYSTEM

AC/DC Current
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Electric GTA-39
Dual Impeller, In-Line Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 m³/ min (12,000 cfm)
Motorized Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Induction Traction Motors (GDY108)
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.03:1
Maximum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.5 kph (40 mph)
* Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.
Komatsu and GE must analyze each job condition to ensure proper application.

DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard
Continuous* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 476 kW (6,000 HP)
* Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.

BATTERY ELECTRIC SYSTEM

Batteries . . . . . . . . . . . . . . . . . . . . . . .Four 8D, 12 volt, in series/parallel, bumper mounted with disconnect switch
Cold Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 CCA
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 250 Ampere Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Cranking Motors (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts

SERVICE CAPACITIES
Crankcase (including lube oil filters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 liters (90 gallons)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799 liters (211 gallons)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 300 liters (1400 gallons)
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 325 liters (350 gallons)
Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 liters (25 gallons) per wheel

2-4 Truck Components And Specifications 4/16 FAM0234

HYDRAULIC SYSTEMS
Hoist and Brake Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .931 L/min (246 gpm) @ 1900 RPM and 18 960 kPa (2,750 psi)
Steering/Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 20 685 kPa (3,000 psi)
Relief Pressure - Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 960 kPa (2,750 psi)
Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 580 kPa (4,000 psi)
Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947 liters (250 gallons)
Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable elements
Suction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Beta 12 Rating =200

SERVICE BRAKES
All Hydraulic Actuation with Traction System Wheel Slip/Slide Control
Front and Rear Oil-Cooled Multiple Discs on each wheel
Total Friction Area / Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 729 cm² (16,078 in²)
Maximum Apply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 960 kPa (2,750 psi)

STEERING
Twin hydraulic cylinders with accumulator assist to provide constant rate steering
Emergency power steering automatically provided by accumulators
Turning Circle (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.0 m (105 ft. 0 in.)

TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59/80 R63
Rock Service, Deep Tread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless
Rims, standard 5 piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rated to 827 kPa (120 psi)

STANDARD DUMP BODY CAPACITIES AND DIMENSIONS

Capacity
Heaped @ 2:1 (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 m3 (327 yd3)
Struck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 m3 (250 yd3)
Width (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.68 m (28 ft. 6 in.)
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 m (10 ft. 7 in.)
Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.09 m (23 ft. 2 in.)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

WEIGHT DISTRIBUTION

Empty Vehicle Loaded Vehicle

Front Axle (46.7%). . . . . . . . 122 662 kg (270,423 lb) Front Axle (32.8%) . . . . . . 205 489 kg (453,025 lb)
Rear Axle (53.3 %) . . . . . . . 139 741 kg (308,077 lb) Rear Axle (67.2%) . . . . . . 419 788 kg (925,475 lb)
Total (with 50% fuel) . . . . . . 262 403 kg (578,500 lb) Total . . . . . . . . . . . . . . . . . 625 839 kg (1,378,500 lb)

Standard Komatsu body . . . . . 42 638 kg (94,000 lb) Nominal Payload*. . . . . . . . .362 874 kg (800,000 lb)
Standard tire weight. . . . . . . . . 32 585 kg (71,838 lb)

FAM0234 4/16 Truck Components And Specifications 2-5

 10.0 m 32’10”

15.0 m
49’3”

1.8 m 5’10”

5.8 m 19’
9.1 m 29’10”
13.90 m 45’7”
7.09 m 980
23’3”

8.0 m
26’4”

4.53 m
14’10”

2.17 m
7’1”
1.65 m
1.22 m 5’5”
4’0”
6.5 m 21’4”
4.60 m 15’1” 6.65 m 21’10” 4.47 m 14’8”
8.0 m 26’4”
15.72 m 51’7”
9.6 m 31’6”
86214

* Nominal payload is defined within Komatsu America Corporation’s payload policy documentation. Nominal payload must be
adjusted if the weight of any customized body or tires vary from that of the standard Komatsu body and tires. Nominal payload
must also be adjusted to take into account the additional weight of any custom/optional extras fitted to the truck which are not
stated within the Standard Features list of the applicable specification sheet.

2-6 Truck Components And Specifications 4/16 FAM0234

 MAJOR COMPONENT WEIGHTS

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

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

ITEM KILOGRAMS POUNDS

CHASSIS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 377 . . . . . . . . . . . . . . . . . . . . . . 7,445
Tire (59/80 R63). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 431 . . . . . . . . . . . . . . . . . . . . . 11,973
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 808 . . . . . . . . . . . . . . . . . . . . . 19,418
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 760 . . . . . . . . . . . . . . . . . . . . . 65,610
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 056 . . . . . . . . . . . . . . . . . . . . . . 4,533

DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 725 . . . . . . . . . . . . . . . . . . . . . . 6,008
RH Deck w/Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 030 . . . . . . . . . . . . . . . . . . . . . . 2,271
LH Deck w/Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 007 . . . . . . . . . . . . . . . . . . . . . . 2,220
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 . . . . . . . . . . . . . . . . . . . . . . . .620
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 951 . . . . . . . . . . . . . . . . . . . . . . 2,097
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 . . . . . . . . . . . . . . . . . . . . . . . .900
LH Upright w/Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 045 . . . . . . . . . . . . . . . . . . . . . . 2,304
RH Upright w/Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 953 . . . . . . . . . . . . . . . . . . . . . . 2,100
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 . . . . . . . . . . . . . . . . . . . . . . . .298
RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . .150
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 . . . . . . . . . . . . . . . . . . . . . . . .657
Diagonal Ladder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . . .121
Retarding Grid Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 742 . . . . . . . . . . . . . . . . . . . . . . 6,045
Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 . . . . . . . . . . . . . . . . . . . . . . 1,173

FAM0325 4/16 Major Component Weights 3-1

 ITEM KILOGRAMS POUNDS

POWER MODULE
Air Intake Ducts
Wheel Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337 . . . . . . . . . . . . . . . . . . . . . . . . 743
Alternator Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 . . . . . . . . . . . . . . . . . . . . . . . . 441
Air Cleaner Assembly
Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 . . . . . . . . . . . . . . . . . . . . . . . . 193
Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 175 . . . . . . . . . . . . . . . . . . . . . . .7,000
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 035 . . . . . . . . . . . . . . . . . . . . . . .2,282
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 900 . . . . . . . . . . . . . . . . . . . . . . 15,212
Engine (Komatsu SSDA18V170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 840 . . . . . . . . . . . . . . . . . . . . . . 26,100
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 520 . . . . . . . . . . . . . . . . . . . . . . .3,350

HYDRAULIC COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268 . . . . . . . . . . . . . . . . . . . . . . . . 591
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 174 . . . . . . . . . . . . . . . . . . . . . . .2,588
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 . . . . . . . . . . . . . . . . . . . . . . . . 573
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603 . . . . . . . . . . . . . . . . . . . . . . .1,329
Hydraulic Brake Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 . . . . . . . . . . . . . . . . . . . . . . . . 401

FRONT AXLE COMPONENTS

Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 588 . . . . . . . . . . . . . . . . . . . . . . .3,500
Spindle, Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 690 . . . . . . . . . . . . . . . . . . . . . . 14,750
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352 . . . . . . . . . . . . . . . . . . . . . . . . 776
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 372 . . . . . . . . . . . . . . . . . . . . . . .9,639
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 . . . . . . . . . . . . . . . . . . . . . . . . 573

REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 028 . . . . . . . . . . . . . . . . . . . . . . .2,266
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447 . . . . . . . . . . . . . . . . . . . . . . . . 986
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 382 . . . . . . . . . . . . . . . . . . . . . . 16,275
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 . . . . . . . . . . . . . . . . . . . . . . . . 353
Wheel Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 300 . . . . . . . . . . . . . . . . . . . . . . 51,368
Electric Wheel Transmission/Rear Wheel Brake w/Hub Adapter . . . 17 168 . . . . . . . . . . . . . . . . . . . . . . 37,849
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 132 . . . . . . . . . . . . . . . . . . . . . . 13,519
Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 . . . . . . . . . . . . . . . . . . . . . . . . 381
Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413 . . . . . . . . . . . . . . . . . . . . . . . . 911

3-2 Major Component Weights 4/16 FAM0325

 FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at WELD PROCEDURES
initial field assembly or during normal maintenance
Electric arc welding, either the semi-automatic “MIG”
repairs, special procedures must be followed.
(GMAW), Flux Core (FCAW), or “Stick” electrode
Due to the continuous program of research and welding (SMAW), are approved processes for field
development, periodic revisions may be made to this installation and maintenance welding. Welding of
publication. It is recommended that customers con- highly stressed structural members such as castings,
tact their distributors for information on the latest revi- torque tubes, top and bottom plates on the frame
sion. rails, and the curved intersection points of frames
should be done with the specific detailed instructions
The welding information contained in this chapter is
from Komatsu Product Service. See Annex A for
general information that must be followed unless oth-
repair procedures. These repair procedures are
erwise specified in a detailed repair procedure pro-
detailed instructions for most high stressed structural
vided on an engineering drawing or a detailed
members.
specific repair procedure. Additional specific informa-
tion, or detailed instructions can be obtained through
APPROVED CONSUMABLES
your local Komatsu customer support manager.
GMAW - LW102-15 or ER80S-D2
WELDER QUALIFICATION AND TRAINING FCAW - E70T-5, E71T-8, or E71T8-NI1
The welding technique must be of the highest stan-
SMAW - E7018-1, E8018-C1, or E8018-C3
dard to produce the soundest weld possible. Only
welders who have been trained and qualified for
WELD QUALITY REQUIREMENTS
structural steel welding in all positions, in confor-
mance with the American Welding Society (AWS) 1. Each weld must be homogeneous with low
D1.1 or (AWS) D14.3 only, are allowed to perform the porosity, free from cracks, and slag inclusions.
welding. The welding instructions for field assembly 2. Each weld must have complete fusion between
of Komatsu components are normally provided by the base metal and weld metal added by the
engineering drawings. Additional detailed welding electrode.
instructions for field repairs are provided in Welding 3. All welds must be reasonably smooth, without
Manual I (SEBF14001), and Welding Manual II excessive deformity, and all craters filled. No
(SEBF15002). A full understanding of the AWS stan- cracks are permitted.
dard welding symbols is necessary to perform and
4. The toe of a weld to a stressed member must
inspect such field welds. Weld sizes specified on the
have a smooth transition. Excessive convexity
drawings are intended to reflect minimum require-
in multi-pass fillet welds is not permitted. Exces-
ments.
sive convexity produces high residual stress in
the throat of the weld, and is not permitted.
5. Undercut in excess of 0.8 mm (0.03 in) on criti-
cal welds must be reworked by the application
of welding an additional cover pass. It is import-
ant that this pass is blended with the existing
weld.
6. When welding in the vertical position, always
weld using the vertical up technique. Large
wash weld weaves should not be used when
welding on truck frames. Properly applied multi-
ple pass welding is the required procedure on
truck frames.

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

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

MATERIALS, CONTROLS, AND WELD INSPECTION

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

Page 4-2 Field Welding For Assembly Or Repair 5/13 FAM0403

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

FAM0403 5/13 Field Welding For Assembly Or Repair Page 4-3

ANNEX B 2.0 TOE GRINDING WITH A ROTARY BURR

1.0 TOE HAMMER PEENING Equipment:

Equipment: 1. High speed rotary air tool (15,000-20,000 rpm)

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

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

 FIGURE 4-1. TOE HAMMER PEENING

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

 FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

Page 4-6 Field Welding For Assembly Or Repair 5/13 FAM0403

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

FAM0403 5/13 Field Welding For Assembly Or Repair Page 4-7

 8. Do not weld on the retard grid exhaust louvers - 11. If the red lights on the exterior of the control cab-
they are made of stainless steel. Some power inet and/or the back wall of the center console
cable panels throughout the truck are also continue to be illuminated after following the
made of aluminum or stainless steel. They must above procedure, a fault has occurred.
be repaired with the same material or the power
Leave all cabinet doors in place; Do not touch
cables may be damaged.
the retard grid elements; do not disconnect any
9. Power cables must be cleated in wood or other power cables, or use them as hand or foot
non-ferrous materials. Do not repair cable holds.
cleats by encircling the power cables with metal
clamps or hardware. Always inspect power 12. Replace all covers and doors and place the GF
cable insulation prior to servicing the cables and cutout switch and battery disconnect switches
prior to returning the truck to service. Discard in their original positions. Reconnect all har-
cables with broken insulation. nesses prior to starting the truck.

10. Power cables and wiring harnesses must be Leave the drive system in the rest mode until
protected from weld spatter and heat. Always the truck is to be moved.
fasten the welding machine ground (-) lead to
the piece being welded; the grounding clamp
must be attached as near as possible to the
weld area.
Always avoid laying welding cables over or
near the vehicle electrical harnesses. Welding
voltage could be induced into the electrical
harness and cause damage to components.
Never allow welding current to pass through FIGURE 4-3. INFORMATION DISPLAY PANEL
ball bearings, roller bearings, suspensions, or
1. Control Power Switch
hydraulic cylinders.
2. GF Cutout Switch
3. Capacitor Charge Light

Page 4-8 Field Welding For Assembly Or Repair 5/13 FAM0403

 RECEIVING & ASSEMBLY PREPARATION
Preparation Color Coded Boxes

Inspection, Cleaning, Setup A parts check list will be included in each shipping
crate that is shipped with the truck. The list consists
1. Inspect all components for possible shipping of several color coded tables that represent a portion
damages. Note any damage found and report to of the assembly process. The parts listed in each
shipping agent. table will be packed in waterproof corrugated PVC
2. Spread out all parts and organize per unit num- boxes that match the color of the header row of that
ber. Check for missing parts. List the unit num- table.
ber of all major components. Verify the cab and The colored boxes, shown in Figure 5-1, will be
decks are with the correct chassis. packed into shipping crates and shipped with the
3. Install support blocks under the chassis. The truck. Assembly technicians can then locate the col-
support blocks must be approximately 84 cm ored boxes that match the color of the operation
(33 in.) high. (table) being performed. The boxes will be packed
4. Install support blocks under the rear axle hous- into the crate in chronological order. Parts needed
ing. The support blocks must be approximately early in the assembly process will be located near
30 cm (12 in.) high and spread out along the the top of the crates.
axle. The support blocks must be a minimum of To allow for maximum flexibility, the color code may
51 mm (2 in.) away from the wheel motor differ from unit to unit. However, colors shown on the
mounting face. check sheet will still match the color of the packing
5. Clean all mounting surfaces on the chassis and boxes used.
on the individual components.
Due to the limited amount of different colored boxes
6. Clean and tap all mounting capscrew holes. available, some colors may be repeated.
7. Check all electrical connectors and verify they
Tables in the checklist that have no color code con-
are free of paint and/or corrosion. Clean any
tain parts that are not boxed. Similarly, tables that are
connector with questionable electrical continu-
color coded may also contain parts that are not
ity.
boxed. These parts are highlighted in yellow.
8. Check all factory installed components for the
proper tightening torque.
9. Arrange the work site as shown on the following
page.

FIGURE 5-1. COLOR CODED BOXES

FAM0508 Receiving & Assembly Preparation 5-1

5-2
TIE ROD/
AIR INTAKE/ CONTROL DIAGONAL BEAM
EXHAUST TUBING CABINET
CRANE
BATTERY
BOX
LH UPRIGHT RH UPRIGHT DIAGONAL
LADDER
FRONT FRONT
SUSPENSION SUSPENSION
SPINDLE SPINDLE

DECK SUPPORT DECK SUPPORT

GRID
BOX
BODY
CAB

HANDRAILS
FUEL
TANK
CENTER
DECK
SMALL PARTS, JIGS AND TOOLS

Receiving & Assembly Preparation

WHEEL MOTOR WHEEL MOTOR

TIRES/RIMS

LH RH
DECK DECK
WELDER

CRANE CRANE
FORKLIFT

84798

ASSEMBLY LAYOUT

FAM0508
 CHASSIS ASSEMBLY
Due to differences in machine configurations and BASIC ASSEMBLY PROCEDURE
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines 1. Site Preparation
varies. Photographs or illustrations used in the fol- 2. Unload Truck Components
lowing procedures are provided only as a general 3. Assemble the Chassis
guideline. Actual assembly may be different, but this 4. Weld the Body
general procedure provides a basic outline for
assembly. NOTE: Chassis assembly and body welding may be
done in either order, or simultaneously. The most
NOTE: The hydraulic tank and accumulators may logical order depends on available resources such as
have been removed for shipping purposes and may cranes, welders, assemblers, etc.
require local installation.
5. Static Checkout (electrical & mechanical)
Each shipment may be different, depending on the 6. Install the Body
truck configuration and destination.
7. Dynamic Checkout (electrical & mechanical)
8. Site Cleanup

RECOMMENDED ASSEMBLY DATA

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

FAM0635 Chassis Assembly 6-1

ORDER OF ASSEMBLY LEVEL 4
1. Reserve Oil System
The assembly procedure is organized in levels. Gen-
erally, the tasks to be done at a given level may be 2. Lubrication System
performed in any convenient order or simultaneously. 3. Isolation Station
However, all tasks in that level must be completed 4. Retarding Grid
before proceeding to the next higher level. Each level
5. Operator Cab
depends on the installation of components from the
previous level. 6. Control Cabinet
7. Auxiliary Control Cabinet
NOTE: Shipping and packaging of large machines
will vary. Some of these steps may change due to
different shipping configurations and/or truck options.
LEVEL 5
1. Blower - Air Intake Ductwork
LEVEL 1 2. Wheel Motors
1. Chassis - Unload and crib for assembly.
2. Engine Access Ladders LEVEL 6
3. Deck Support (on horsecollar over suspension). 1. Front Tires

NOTE: It is easier to install and weld the deck 2. Rear Tires

supports before the front suspensions are installed. 3. Front Mud Flaps
However, do not install the deck supports first, unless 4. Charge Accumulators
there is a suitable means of installing the suspension
with the deck support in place. NOTE: Prior to starting the engine, verify that the
4. LH Uprights/Air Cleaners steering pump case is full of oil and the hydraulic
system has been flushed.
5. LH Diagonal Support Beam (leave loose until
left deck is bolted in place) LEVEL 7
6. Rear Suspension 1. Remove Alternator Rotor Lock
7. Fuel Tank
8. Hydraulic Tank
9. Hoist Cylinders (lower)
10. Front Suspensions
11. Spindles/Hubs Alternator Rotor Lock must be removed prior to
starting the truck.
12. Steering Cylinders/Tie Rod
2. Hydraulic Flushing Procedure
LEVEL 2 3. Add Fluids
1. LH Bumper Extension 4. Clean the Truck
2. Battery Box 5. Decals
3. Diagonal Ladder 6. Lighting Wiring
4. RH Uprights/Air Cleaners 7. Charge the Air Conditioning System
5. RH Diagonal Support Beam (leave loose until 8. System Checkouts
right deck is bolted in place) 9. Clean Assembly Rear
10. Touch Up Paint
LEVEL 3
11. Train Operators
1. Air Cleaner Piping
2. Center Deck
3. LH Deck
4. RH Deck
5. RH Bumper Extension

6-2 Chassis Assembly FAM0635

LEVEL 8
1. Dump Body Installation
2. Hoist Cylinders (upper)
CHASSIS ASSEMBLY
3. Body Pads/Shims The photographs referenced in this procedure depict
an actual truck assembly. Assembly at another loca-
LEVEL 9 tion may be different. However, this outline will pro-
vide a general basis for assembly.
1. Charge Suspensions
2. Rock Ejectors
3. Hatch Cover
4. Rear Mud Flaps
5. Body Guides/Limit Switch
Follow all safety recommendations in this man-
6. Exhaust/Mufflers
ual. Follow all local, state, and federal regula-
7. Hoist Limit Switch tions.
8. Exhaust Blankets

LEVEL 10 In the procedures that follow, many very heavy com-

1. PLM Scoreboards ponents will be required to be lifted into place and
secured.
2. Engine Bay Lights
®
3. KomVision
4. Optional - Install Fire Suppression System

• Inspect all lifting devices. Slings, chains, and

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

FAM0635 Chassis Assembly 6-3

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

6-4 Chassis Assembly FAM0635

 16. Damage will occur if the Alternator Rotor Lock is NOTE: To help prevent contamination that may lead
not removed prior to first start. to premature pump failures, flush the hydraulic
system before the initial truck start-up.
17. Before the truck is started for the first time, the
hydraulic system must be in the flushing config-
uration. Refer to the hydraulic system flushing
Alternator Rotor Lock must be removed prior to procedure within the 980E-4 Hydraulic System
starting the truck. Checkout Procedure in the appendix of this
manual.

FAM0635 Chassis Assembly 6-5

 FIGURE 6-1.

1. Lift the chassis off the truck/trailer Figure 6-1 or rail car using a crane configuration with a minimum capacity
of 100 tons.

FAM0635 Chassis Assembly 6-6

 FIGURE 6-2.

2. Place the chassis on adequate support blocks in a level position. The weight of the chassis, as shipped, is
approximately 64 410 kg (142,000 lb).The support blocks must be approximately 84 cm (33 in.) high at the
front, and approximately 30 cm (12 in.) high under the rear axle housing Figure 6-2. Placement of the chassis
at this height will allow easy installation of the truck components.

3. Thoroughly clean the chassis.

DO NOT mix components from different trucks. Components such as deck supports are marked with the
serial number of the corresponding truck unit. Only use components of the unit number that is being
assembled.

FAM0635 Chassis Assembly 6-7

 FIGURE 6-3. FIGURE 6-4.

4. Install the engine access ladders, handrails and platforms (if equipped) on the truck frame. Tighten mounting
hardware to standard torque. Refer to Figure 6-3 and Figure 6-4.

6-8 Chassis Assembly FAM0635

 FIGURE 6-5.

5. Lift the LH deck support into position. The weight of the LH deck support is approximately 951 kg (2,097 lb).
Bolt the support into place. Do not weld the support at this time.
Refer to Figure 6-5.

FAM0635 Chassis Assembly 6-9

 FIGURE 6-6.

6. Lift the LH upright into position and install the four capscrews, four nuts and eight flat washers. Tighten to 465
± 47 N·m (343 ± 34 ft lb). The weight of the LH upright with air cleaners is approximately 1 045 kg (2,304 lb).
Refer to Figure 6-6.
NOTE: DO NOT weld the torque tube on the upright.

6-10 Chassis Assembly FAM0635

 85175

FIGURE 6-7.

7. Lift the LH diagonal beam into position. Route the coolant deaeration lines over the LH diagonal beam then
install the capscrews loosely. The weight of the beam is approximately 135 kg (298 lb). Refer to Figure 6-7.
NOTE: Do not tighten the capscrews until the deck and the cab are in place.

FAM0635 Chassis Assembly 6-11

 FIGURE 6-8. DETERMINING CAB FIT

1. Cab 3. LH Diagonal Beam

2. Deck Support 4. Left Upright

8. Remove any paint from the cab mounting holes.

9. Lift the cab onto the deck supports and install the mounting hardware snugly but do not torque at this stage.
Verify no gaps exist between the mounting pads of the cab. If gaps are present, the upright and/or deck sup-
port may need to be repositioned.

10. Tighten the capscrews that secure the LH diagonal beam.

10. Lift the RH deck support into position. The weight of the RH deck support is approximately 408 kg (900 lb).
Bolt the support into place.

6-12 Chassis Assembly FAM0635

Deck Support Welding

FIGURE 6-9. DECK SUPPORT BEFORE WELDING

REF DETAIL B

SECTION VIEW
SECTION VIEW RH DECK SUPPORT
LH DECK SUPPORT

SECTION A-A DETAIL B 86329

FIGURE 6-10. WELDING SPECIFICATIONS

FAM0635 Chassis Assembly 6-13

 11. Tack weld the backer bars inside the deck support. Refer to Figure 6-11 and 6-12.

FIGURE 6-11. WELDING INSIDE THE DECK SUPPORT

12. The backer bars must be tack welded in locations where the tack will be burned away on the next weld pass.
Refer to Figure 6-11 and 6-12.

FIGURE 6-12. BACKER BAR INSTALLATION

6-14 Chassis Assembly FAM0635

If the tapped pads are not removed, a complete weld around the support can not be achieved. The gaps in
the weld around the support may result in premature frame cracking in this area.

13. Remove the four capscrews and tapped pads on the deck support and the corresponding blocks on the hor-
secollar to allow for a complete weld around the joint.

14. Weld completely around the support without leaving any gaps.

15. Grind and clean all areas. Paint after welding is complete.

16. Repeat the deck support welding procedure for the RH deck support.

FIGURE 6-13.

FAM0635 Chassis Assembly 6-15

 FIGURE 6-14.

17. Weld the LH upright to the front frame tube. Refer to Figure 6-14.

18. Remove the cab after welding is complete. Continue with the assembly process.

6-16 Chassis Assembly FAM0635

Rear Suspension Installation
19. Secure rear suspension assembly (1, Figure 6-15) to a fork lift and raise it into position. The suspension
assembly should be retracted as far as possible before installation.

20. Position the top suspension eye between the ears on the frame. Orient the cylinder so that the charging valve
faces the opposite suspension cylinder.

21. Lubricate all pin-to-bearing and pin-to-sleeve contact surfaces with anti-seize compound. Lubricating the pin
surfaces aids in removal and installation, as well as prevention of rust and corrosion.

22. Align the hole in pin (5) with the hole in the mounting bore. Drive in the pin far enough so that the pin does not
fall out.

23. Insert bearing spacer (7) over the pin. Continue to drive the pin through spherical bearing (9). When the pin
emerges, insert the remaining bearing spacer over the pin on the opposite side and continue to drive the pin
until the hole in the axle housing is aligned with the hole in the pin.

24. Install shoulder bolt (2), then install washer (3) and nut (4). If further alignment of the holes is necessary,
install a pin removal tool onto the pin. Use the tool and a large pipe wrench or other suitable device to align
the holes. Tighten the nut to 68 N·m (50 ft lb).

25. Adjust the piston rod height until the lower suspension eye is aligned with the bore in the rear axle housing.
Repeat the above procedure to install the bottom pin. Mounting components in the top and bottom joints are
identical.
NOTE: It may be necessary to lift the frame to properly align pin bores when installing the bottom pin.

FIGURE 6-15. REAR SUSPENSION CYLINDER PIN INSTALLATION

1. Suspension Cylinder 5. Pin 9. Bearing

2. Shoulder Bolt 6. Sleeve 10. Capscrew
3. Flat Washer 7. Spacer 11. Lockwasher
4. Locknut 8. Retaining Ring

FAM0635 Chassis Assembly 6-17

 85539

FIGURE 6-16. FUEL TANK INSTALLATION

1. Cap 4. Rubber Mount 7. Lockwasher

2. Lockwasher 5. Large Washer 8. Capscrew
3. Capscrew 6. Flat Washer

26. Clean the mounts for the fuel tank.

27. Lift the tank into position. The weight of the fuel tank is approximately 2 056 kg (4,533 lb). Refer to Figure 6-
16.
a. Install the mounting caps, washers and capscrews at the top of the fuel tank. Do not tighten the capscrews
at this time.
b. Install the rubber dampeners, flat washers and capscrews in the lower mounts at the rear of the fuel tank.
Tighten the capscrews to 800 ± 80 N·m (590 ± 59 ft lb).
c. Tighten the capscrews at the top of the fuel tank to 712 ± 72 N·m (525 ± 53 ft lb).

6-18 Chassis Assembly FAM0635

 FIGURE 6-17. HYDRAULIC TANK INSTALLATION

28. Clean the mounts for the hydraulic tank.

29. Lift the tank into position. Refer to Figure 6-17. The weight of the hydraulic tank is approximately 603 kg
(1,329 lb).
a. Install the four mounting capscrews near the top of the tank. Tighten to 622 ± 62 N·m (459 ± 46 ft lb).
b. Install the two mounting capscrews near the bottom of the tank. Tighten to 800 ± 80 N·m (590 ± 59 ft lb).

FAM0635 Chassis Assembly 6-19

 FIGURE 6-18.

30. Connect the piping to the hydraulic tank and properly tighten all fittings. Refer to Figure 6-18.

FIGURE 6-19.

31. Install the fuel tank quick fill box at the bottom of the hydraulic tank. Refer to Figure 6-19.

6-20 Chassis Assembly FAM0635

NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened. The valves
are open when the handles are parallel with the hoses.

1 1

3 2

86307

FIGURE 6-20.
1. Pressure Switch Assembly 2. Hydraulic Filter - Steering 3. Hydraulic Filter Assembly

32. Install three pressure switch assemblies, then install the two hoist filters and one steering filter onto the
bracket at the inner side of the fuel tank. Refer to Figure 6-20.

FAM0635 Chassis Assembly 6-21

 3

86308

FIGURE 6-21. FUEL HOSE INSTALLATION

1. Supply Hose 3. Vent

2. Return Hose

33. Connect supply hose (1, Figure 6-21) and return hose (2) to the fuel tank. Install vents (3) and the overflow
tubes.

6-22 Chassis Assembly FAM0635

34. Raise the hoist cylinder into position over the pivot point on the frame. The weight of each hoist cylinder is
approximately 1 174 kg (2,588 lb). Position the cylinder with the air bleed vent plug on top, and facing the
front of the truck. Refer to Figure 6-22.
35. Install spacer (6, Figure 6-23). Align the bearing eye with the pivot point and push the cylinder into place.
36. Install retaining plate (3), locking plate (2), and capscrews (1). Tighten the capscrews to 465 ± 47 N·m (343 ±
34 ft lb). Bend the locking plate tabs over the capscrew flats.

FIGURE 6-22.

FIGURE 6-23.

1. Capscrew 4. Retainer Ring

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

FAM0635 Chassis Assembly 6-23

Front Suspension Installation

FIGURE 6-24.

FIGURE 6-25.

37. Remove all paint, rust, dirt and foreign debris from the suspension mounting surfaces. Refer to Figure 6-24
and 6-25.

38. Clean and dry the mounting surfaces on both the suspension and the frame. Use a cleaning agent that does
not leave a film after evaporation, such as isopropyl alcohol, acetone or lacquer thinner.

39. Inspect the suspension and frame mounting surfaces for damage or wear. Check for the following criteria:
 Flatness of each surface must be within 0.25 mm (0.010 in.).
 Surface finish must not exceed 0.635 µm (250 µ in.) roughness average (RA), medium tool cut.
If measurements are not within specifications, contact your Komatsu customer service manager for further
instructions.

40. Clean and dry all suspension mounting hardware. Use the same cleaning agent that was used to clean the
mounting surfaces.

6-24 Chassis Assembly FAM0635

High tightening torque is required to load the front suspension mounting capscrews. Repeated tightening
will result in capscrew fatigue and damage. DO NOT reuse mounting capscrews, washers and nuts.
Replace the hardware after each use.

Suspension mounting capscrews are specially hardened to meet or exceed grade 8 specifications.
Replace only with capscrews of correct hardness. Refer to the appropriate parts book for the correct part
numbers.

The use of dry threads in this application is not recommended. Due to the high tightening forces required
to load these capscrews, dry threads or threads lubricated with anti-seize compounds may result in dam-
age. Only use the approved lubricant specified below.

41. Lubricate the capscrew threads, capscrew head seats, washer faces and nut seats with 3% molybdenum-
disulphide grease.
42. Identify and separate the hardware according to location on the suspension. Refer to Figure 6-26.

FIGURE 6-26.

1. Capscrew - 1 1/2" - 6NC x 6 1/2" (G8)

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

FAM0635 Chassis Assembly 6-25

 FIGURE 6-27. FIGURE 6-28.

43. Lift the front suspension into position on the 44. Install the mounting hardware and the shear
frame. The weight of each front suspension cyl- key. Install the shear key flush with the side face
inder is approximately 4 372 kg (9,639 lb). of the suspension. Refer to Figures 6-28 & 6-
Refer to Figure 6-27. 29.
a. Install one washer under each capscrew
head and one washer under each nut (where
applicable).
b. Initially tighten the hardware to 1 356 ± 136
N·m (1,000 ± 100 lb ft) in the sequence
shown in Figure 6-30. Use a properly cali-
brated torque wrench to ensure accuracy.
NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.

6-26 Chassis Assembly FAM0635

 TO TRUCK FRAME

TO SUSPENSION

86383
FIGURE 6-29. SHEAR KEY ORIENTATION

FIGURE 6-30.

c. The mounting capscrews will now need to be

loosened and then tightened using angle-
advance. The first set of capscrews to be
adjusted will be at the upper mounting joint.
The capscrews must be loosened one at
time and then tightened by advancing a
specified rotational degree. Use the map
shown in Figure 6-30 for proper tightening
sequence.

FAM0635 Chassis Assembly 6-27

Upper Mounting Joint - 60° Advance
The proper sequence for the upper mounting joint is 1-2-3-4-9-10. Refer to Figure 6-30.

45. Loosen the first capscrew. All other capscrews must be maintained at 1 356 ± 136 N·m (1,000 ± 100 lb ft).

46. Tighten the capscrew to 95 ± 9 N·m (70 ± 7 lb ft).

NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening.

47. Mark a corner of the capscrew head with a paint

marker as shown in Figure 6-31. Draw a reference
line on the suspension surface next to the marked
corner on the capscrew. Draw a reference line on the
suspension 60 degrees in advance of the marked
corner on the capscrew.

48. Advance the capscrew to the 60° advance mark. Hold

the nut at the rear of the joint stationary while tighten-
ing.
FIGURE 6-31.

49. Make new reference lines along the capscrew, nut

and frame at the rear of the joint as shown in
Figure 6-32. These reference lines will be used to
verify the capscrews have maintained their torque.

50. Repeat this process in sequence for the remaining

capscrews in the upper mounting joint.

NOTE: If for any reason these fasteners need to be

checked for tightness after completing this procedure,
loosen and inspect all 14 capscrews and repeat the entire
process. The hardware, again, must be cleaned and
lubricated before repeating.
FIGURE 6-32.

6-28 Chassis Assembly FAM0635

Lower Mounting Joint - 90° Advance
The proper sequence for the lower mounting joint is 5-6-7-8-11-12-13-14. Refer to Figure 6-30.

51. Loosen the first capscrew. All other capscrews must remain tightened.

52. Tighten the capscrew to 475 N·m (350 lb ft).

NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening.

53. Mark a corner of the capscrew head with a paint

marker as shown in Figure 6-33. Draw a reference
line on the suspension surface (or frame) next to the
marked corner on the capscrew. Draw a reference line
on the suspension surface (or frame) 90° in advance
of the marked corner on the capscrew.

54. Advance the capscrew to the 90° advance mark.

Hold the nut at the rear of the joint (where applicable)
FIGURE 6-33. stationary while tightening.

55. Make new reference lines along the capscrew, nut

and frame at the rear of the joint as shown in
Figure 6-32. For the four capscrews with spacers,
refer to Figure 6-34. These reference lines will be
used to verify the capscrews have maintained their
torque.

56. Repeat this process in sequence for the remain-

ing capscrews in the lower mounting joint.

FIGURE 6-34.
NOTE: If for any reason these fasteners need to be
checked for tightness after completing this procedure,
loosen and inspect all 14 capscrews and repeat the
entire process. The hardware, again, must be cleaned
and lubricated before repeating.

FAM0635 Chassis Assembly 6-29

 FIGURE 6-35.

57. Clean the tapered portion of the suspension rod and the bore of the spindle. Lubricate the two surfaces with
multipurpose NLGI 2 EP (extreme pressure) grease (6% lithium complex minimum).

58. Lift the spindle/brake assembly into position. The weight of each spindle/brake assembly is approximately
6 690 kg (14,750 lb). Refer to Figure 6-35.

NOTE: A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the
assembly for easier mounting to the suspension.

6-30 Chassis Assembly FAM0635

 FIGURE 6-36.

59. Lift the retainer plates to the bottom of each suspension using a hydraulic jack. Refer to Figure 6-36.

FAM0635 Chassis Assembly 6-31

 FIGURE 6-37.

60. Lubricate the 15 capscrews on the threads and seats with lithium based chassis grease (multipurpose, EP
NLGI).

61. Install the capscrews. Evenly tighten the capscrews to 678 N·m (500 ft lb). Continue to tighten the capscrews
in increments of 339 N·m (250 ft lb) until the final torque of 2 705 ± 135 N·m (1,995 ± 100 ft lb) is reached.
Refer to Figure 6-37.

62. After installation is complete, connect the brake piping to each brake.

6-32 Chassis Assembly FAM0635

 9

2
4

7
1

2
6

5
4
3
86300

FIGURE 6-38. TIE ROD INSTALLATION

1. Tie Rod Assembly 6. Sleeve

2. Spacer 7. Sleeve
3. Nut 8. Pin
4. Flat Washer 9. Capscrew
5. Retainer

NOTE: Installation of the steering cylinders is the same as the tie rod assembly.

63. Install the tie rod and both steering cylinders on the steering arms. Use sleeve alignment tool (58B-98-01180)
to hold spacers (2, Figure 6-38) and bearings in line for insertion of pin (8). Tighten nuts (3) to 420 ± 41 N·m
(310 ± 30 ft lb).

The tie rod toe-in must be adjusted once the tires and the body are installed. The toe-in adjustment procedure
is located in Section 10, Appendix.

FAM0635 Chassis Assembly 6-33

 85174

FIGURE 6-39. LH BUMPER EXTENSION INSTALLATION

64. Lift the LH bumper extension into place. The weight of the bumper extension is approximately 131 kg (289lb).
Refer to Figure 6-39. The LH bumper extension supports the isolation station and lubrication system. Ensure
that all wires are out of the way before installation.
Tighten the capscrews to standard torque. Refer to Standard Tables in Section 10, Appendix.

6-34 Chassis Assembly FAM0635

 1 2

4 3
5 83659

FIGURE 6-40. BUMMPER EXTENSION INSTALLATION MOUNTING HARDWARE

1. Capscrew - M16 3. Capscrew - M12

2. Flat Washer - M16 4. Flat Washer
5. Nut - M12

FAM0635 Chassis Assembly 6-35

 FIGURE 6-41. BATTERY BOX INSTALLATION

65. Install the battery box on the front bumper. The weight of the battery box is approximately 560 kg (1,235 lb).
Ensure that all of the harnesses and cable are properly routed and securely connected. Tighten the mounting
hardware to standard torque. Refer to Figure 6-41.

6-36 Chassis Assembly FAM0635

 85176

FIGURE 6-42. DIAGONAL LADDER INSTALLATION

66. Install the diagonal ladder. The weight of the diagonal ladder is approximately 298 kg (657 lb). Shim as
required to align the vertical ladder support with the radiator housing and to align the landing with the rubber
pads on the face of the radiator housing. Tighten the capscrews to 95 ± 9 N·m (70 ± 7 ft lb).
Refer to Figure 6-42.

FAM0635 Chassis Assembly 6-37

 FIGURE 6-43.

67. Lift the RH upright into position and install the four capscrews, four nuts and eight flat washers. Tighten to 465
± 47 N·m (343 ± 34 ft lb). The weight of the RH upright with air cleaners is approximately 953 kg (2,100 lb).
Refer to Figure 6-43.
NOTE: DO NOT weld the torque tube on the upright until the decks are installed.

6-38 Chassis Assembly FAM0635

 FIGURE 6-44.

68. If installed, remove the center deck to enable easier installation of the air intake tubing and the two diagonal
beams. The weight of the center deck is approximately 281 kg (620 lb).

69. Lift the RH diagonal beam into position. The weight of the beam is 68 kg (150 lb). Refer to Figure 6-44.
NOTE: Do not tighten the capscrews until the decks are in place.

FAM0635 Chassis Assembly 6-39

 FIGURE 6-45.

70. Lift the air intake tubes and hump hoses into place. Install and tighten the clamps that secure the hoses. Refer
to Figure 6-45.

6-40 Chassis Assembly FAM0635

 FIGURE 6-46.

71. Lift the center deck into position. Tighten the four capscrews to 465 ± 47 N·m (343 ± 34 ft lb). Refer to
Figure 6-46

FAM0635 Chassis Assembly 6-41

 FIGURE 6-47.

72. Install the handrails and lift the LH deck into place. The weight of the LH deck with handrails is approximately
1 007 kg (2,220 lb). Loosely install the eight capscrews. Refer to Figure 6-47.

6-42 Chassis Assembly FAM0635

 85177

FIGURE 6-48.

73. Install the handrails and lift the RH deck into position. The weight of the RH deck is approximately 1 030 kg
(2,271 lb). Loosely install the six capscrews. Refer to Figure 6-48.
74. Tighten the hardware for the diagonal beams. For the RH beam, tighten the 12 capscrews to 240 ± 24 N·m
(177 ± 17 ft lb). For the LH beam, tighten the 16 capscrews to 800 ± 80 N·m (590 ± 59 ft lb). Refer to
Figure 6-7 and Figure 6-44.

FAM0635 Chassis Assembly 6-43

 FIGURE 6-49.

75. After the right deck is bolted in place, weld the right hand upright to the front frame tube. Refer to Figure 6-49.
76. After the upright is securely tack welded in place, remove the capscrews. Also cut the capscrew blocks off of
the frame. Finish welding the uprights in place as instructed per the assembly drawing provided with the truck.

6-44 Chassis Assembly FAM0635

 85173

FIGURE 6-50. RH BUMPER EXTENSION INSTALLATION

77. Lift the RH bumper extension into place. The weight of bumper extension is approximately 144 kg (318lb).
Refer to Figure 6-50. The RH bumper extension supports the optional reserve oil system. Ensure that all
wires are out of the way before installation.
Tighten the capscrews to standard torque. Refer to Standard Tables in Section 10, Appendix.

FAM0635 Chassis Assembly 6-45

 1 2

4 3
5 83659

FIGURE 6-51. BUMPER EXTENSION INSTALLATION MOUNTING HARDWARE

1. Capscrew - M16 4. Flat Washer

2. Flat Washer - M16 5. Nut - M12
3. Capscrew - M12

6-46 Chassis Assembly FAM0635

78. Install the optional bolt-on reserve oil system.
a. Install the optional reserve oil system on the RH bumper and tighten the bolts to standard torque. Refer to
Figure 6-52.

FIGURE 6-52. RESERVE OIL SYSTEM

FAM0635 Chassis Assembly 6-47

 b. Connect the electrical connectors (1, Figure 6-53) on the reserve oil system to the truck. Connect the suc-
tion line (2) on the reserve oil system to the return valve (2, Figure 6-54) on the truck. Connect the return
line (3, Figure 6-53) on the reserve oil system to the intake valve (1, Figure 6-54) on the truck. Connect the
remote fill line (4, Figure 6-53) to the remote fill station.

1 1

2 85137

FIGURE 6-53. RESERVE OIL SYSTEM

1. Electrical Connectors 3. Return Line

2. Suction Line from 4. Remote Fill Line
Engine Oil Pan

6-48 Chassis Assembly FAM0635

 1 2

85127

FIGURE 6-54. ENGINE CRANKCASE FITTINGS

1. Intake Fitting 2. Return Fitting

FAM0635 Chassis Assembly 6-49

 79. Install the bolt-on lubrication system. Refer to Figure 6-55.
a. Connect the lubrication system to the LH bumper and tighten the hardware to standard torque.

FIGURE 6-55. LUBRICATION SYSTEM

b. Remove the pipe plug (5, Figure 6-56) from each injector bank, one at a time.
c. Disconnect hose (22, Figure 6-57) and connect it to a grease supply source. Pump grease into the hose
until grease appears at the injector bank where the pipe plug was removed. Install pipe plug.
d. At another injector bank, remove pipe plug, and pump grease into hose (22) until grease appears at the
open port at the injector bank. Install plug.
e. Remove the plug at injector bank on the rear axle housing. Pump grease into hose (22) until grease
appears at the open port at the injector bank. Install plug.
f. At each injector bank, remove cap (4, Figure 6-56) on each injector. Pump grease into the grease fitting (2)
until grease appears the far end of the individual grease line or the joint that is being greased. Install cap
and repeat process on each injector on the truck.

FIGURE 6-56.
1. Injector Indicator 4. InjectorGreaseFitting
2. Injector Grease Fitting Cap
3. Injector Cover 5. Injector Manifold Plug

6-50 Chassis Assembly FAM0635

Verify that all electrical and hydraulic connections are correct. Refer to Figure 6-57.

FIGURE 6-57. LUBRICATION SYSTEM

1. LH Suspension, Bottom Bearing 13. RH Anti-Sway Bar Bearing

2. LH Hoist Cylinder, Top Bearing 14. RH Suspension, Top Bearing
3. LH Hoist Cylinder, Bottom Bearing 15. Grease Reservoir
4. LH Anti-Sway Bar Bearing 16. Vent Hose
5. LH Suspension, Top Bearing 17. Pipe Plug (Oil Level)
6. LH Body Pivot Pin 18. Pressure Switch, N.O. - 20 684 kPa (3,000psi)
7. RH Body Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. RH Suspension, Bottom Bearing 21. Filter
10. RH Hoist Cylinder, Top Bearing 22. Grease Supply to Injectors
11. RH Hoist Cylinder, Bottom Bearing 23. Injectors
12. Rear Axle Pivot Pin 24. Pressure Switch, N.O. - 13 790 kPa (2,000 psi)

FAM0635 Chassis Assembly 6-51

80. Install the isolation station on the LH bumper and tighten the hardware to standard torque. Refer to Figure 6-58.

2
86353

FIGURE 6-58. ISOLATION STATION AND QUICK FILL STATION

1. Isolation Station 2. Quick Fill Station

81. Install the optional quick fill station system (2, Figure 6-58).

6-52 Chassis Assembly FAM0635

 85179

FIGURE 6-59. RETARDING GRID INSTALLATION

82. After all decking is in place, tighten the capscrews on each deck to 465 ± 47 N·m (343 ± 34 ft lb).
83. Lift the retarding grid into place on the RH deck. The weight of the grid is approximately 2 742 kg (6,045 lb).
Refer to Figure 6-59.
84. Install and tighten the eight capscrews to 465 ± 47 N·m (343 ± 34 ft lb).

FAM0635 Chassis Assembly 6-53

 85180

FIGURE 6-60. CAB INSTALLATION

85. Lift the operator cab into position. The weight of the cab is approximately 2 725 kg (6,008 lb). Refer to
Figure 6-60.

6-54 Chassis Assembly FAM0635

 FIGURE 6-61.

86. Install and tighten the 32 capscrews to 1 424 ± 142 N·m (1,050 ± 105 ft lb). Refer to Figure 6-61.
NOTE: The gap between the cab and the ROPS support must not exceed 1 mm (0.04 in.).

FAM0635 Chassis Assembly 6-55

 85181

FIGURE 6-62.

87. Lift the electrical control cabinet, with attached auxiliary control cabinet, into position. The weight of the cabi-
nets is approximately 3 707 kg (8,173 lb). Install the mounting hardware and shims. Tighten the 9 capscrews
to 1 600 ± 160 N·m (1,180 ± 118 ft lb). Refer to Figure 6-62.

6-56 Chassis Assembly FAM0635

 1 2 3 4 5

16 15 14 13 12 11 10
85184

FIGURE 6-63. AUXILIARY CONTROL CABINET EXTERNAL WIRING

1. Cab/Aux Cabinet Diagnostic GE 5. Aux Cabinet Hydraulic Harness 12. Left Rear Frame Rail Harness
Harness 6. Power Cable (Red) 13. Left Front Frame Rail Harness
2. Cab/Aux Cabinet Diagnostics 7. Ground Cable (Black) 14. Right Front Frame Rail Harness
Harness 8. Auxiliary Cabinet Engine Harness 15. Wiring Ethernet Harness
3. Aux Cabinet/Cab Dash Harness 9. Engine Harness 16. Front Wheel Speed Sensor
4. Aux Cabinet/Cab Overhead 10. Right Front Frame Rail Harness Harness
Harness 11. Rear Wheel Speed Harness

FAM0635 Chassis Assembly 6-57

 4 4
2
1 3

11 12 13
5 6 7

14 15 16
8 9 10

FIGURE 6-64. CONTROL CABINET EXTERNAL WIRING

1. Cable 74J 4. Alternator Cables 8. Cable 7M1A2 13. Cable 7M2C1
2. Cable 71D (T1, T2, T3) 9. Cable 7M1B1 14. Cable 7M2A2
3. Alternator Cables 5. Cable 7M1A1 10. Cable 7M1C2 15. Cable 7M2B1
(Brush Holders) 6. Cable 7M1B2 11. Cable 7M2A1 16. Cable 7M2C2
7. Cable 7M1C1 12. Cable 7M2B2

6-58 Chassis Assembly FAM0635

 88. Connect the wiring for the electrical control cabinet, auxiliary control cabinet and retarding grid box. Refer to
Figure 6-65 through Figure 6-67.
NOTE: The auxiliary control cabinet may be shipped with the external wiring already connected.

FIGURE 6-65.

FIGURE 6-66.

FAM0635 Chassis Assembly 6-59

 FIGURE 6-67.

6-60 Chassis Assembly FAM0635

89. Install the air intake ductwork. Connect the top portion of the flexible duct to the intake ductwork first, then
attach the bottom of the flexible duct to the alternator. Tighten the connecting hardware to the standard
torque. Refer to Torque Tables and Conversion Charts in Section 10, Appendix.
• The weight of the wheel motor blower inlet duct is approximately 337 kg (743 lb). Refer to Figure 6-68.
• The weight of the alternator blower inlet duct is approximately 200 kg (441 lb). Refer to Figure 6-69.

FIGURE 6-68.

FIGURE 6-69.

FAM0635 Chassis Assembly 6-61

Parking Brake Installation

FIGURE 6-70.

90. Use a cleaner containing organic-based solvents, such as acetone, methanol or ethanol, to clean the rust pre-
ventive coating from the parking brake adapter teeth. Water-based cleaners, such as mild soaps and deter-
gents, do not adequately remove the rust preventive coating.

91. Install the parking brake adapter, retainer plate, hardened flat washer and capscrew. Tighten the capscrew to
712 ± 72 N·m (525 ± 53 ft lb). Refer to Figure 6-70.

6-62 Chassis Assembly FAM0635

 FIGURE 6-71.

92. Attach a lifting device to the parking brake assembly and lift into position. Refer to Figure 6-71.

93. Use a port-a-power to release spring pressure and allow the alignment of the brake discs during installation.

94. Seat the parking brake assembly against the housing and install the eight capscrews and washers. Tighten
the capscrews to 420 ± 42 N·m (310 ± 31 ft lb).

FAM0635 Chassis Assembly 6-63

Wheel Motor Installation
NOTE: Refer to the drive system manual for wheel motor to transmission mating procedures.
95. Thoroughly clean the capscrew holes and the mounting faces of the rear axle housing and wheel motor.
96. Inspect the capscrew holes in the rear axle housing for damage. Re-tap any holes that have damaged
threads. Thoroughly clean any capscrew holes that have been re-tapped.
97. Check the mounting faces of the rear axle housing and the wheel motor for surface defects (nicks, scratches,
etc). Repair any defects before installing the wheel motor.
98. Check the flatness of both mounting faces of the rear axle housing. Check the flatness at four equally spaced
intervals (for example, 0°, 45°, 90° and 135°).
The maximum allowable variation in flatness is 2.29 mm (0.09 in.). Do not use a rear axle housing that does
not meet this specification.
99. Apply a lithium based grease containing 3% molybdenum-disulphide to the threaded capscrew holes in the
rear axle housing.
100. Install two guide pins 180° apart (3 o’clock and 9 o’clock positions) in the rear axle housing.

Each complete wheel motor assembly weighs approximately 23 300 kg (51,368 lb). Ensure that the lifting
devices are capable of handling the load safely.

1 2 3 4 5 6 7 8 9

86384

FIGURE 6-72.
1. Electric Wheel Transmission 4. Machined Hub Surface 7. Brake Assembly
2. Shipping Fasteners 5. Non-machined Hub Surface 8. Wheel Motor Mounting Flange
3. Outer Wheel Rim Adapter Ring 6. Inner Wheel Rim Adapter Ring 9. Electric Wheel Motor

6-64 Chassis Assembly FAM0635

When lifting the wheel motor assembly, do not place straps/cables on, or lift from the inner wheel rim
adapter ring (6, Figure 6-72). Lifting straps, or cables, should be placed so the weight of the wheel motor
assembly is supported by the wheel motor mounting flange (8) and the machined hub surface (4). Shipping
fasteners installed in the outer wheel rim adapter ring must remain in place during lifting and installation
of wheel motors.
101. Lift the wheel motor into position on the rear axle housing. Ensure that all cables and hoses are clear before
installation. Refer to Figure 6-73.
If the brake system hoses are installed, guide them through the spindle holes during installation.

FIGURE 6-73.

The wheel motors must be properly aligned before installing them onto the rear axle housing. The wheel
motor has markings which help determine installation orientation. A set of dimples is located at the 3
o’clock and 9 o’clock positions. A centerline symbol depicts the 12 o’clock position of the wheel motor.
Refer to Figure 6-74.

The axle housing also contains dimples at the 3 o’clock and 9 o’clock positions next to the wheel motor
mounting rings. Refer to Figure 6-75.

When installing the wheel motors, ensure that the markings on both components line up. The top
capscrew hole on the rear axle housing may also be determined by counting the holes between the two
sets of punch marks. The top hole on the rear axle housing should line up with the “CL” stamping on the
wheel motor.

NOTE: The spacing for the bottom 36 holes does not match the spacing of the top holes.

FAM0635 Chassis Assembly 6-65

 FIGURE 6-74. WHEEL MOTOR DIMPLE MARKINGS

PUNCH MARKS

86310

FIGURE 6-75. REAR AXLE HOUSING DIMPLE MARKINGS

6-66 Chassis Assembly FAM0635

High tightening force is required to install the capscrews that secure the wheel motors to the rear axle
housing. Repeated tightening will result in capscrew fatigue and damage.

Do not reuse any wheel motor mounting hardware (capscrews and hardened washers). Replace the
hardware after one use.

Do not retighten any wheel motor mounting capscrew that has loosened after the truck has been placed
into operation. If any wheel motor mounting capscrew has loosened during truck operation, all of the
capscrews and hardened washers must be replaced with new hardware.

The capscrews that are used to secure the wheel motors to the rear axle housing are specially hardened to
meet or exceed Grade 9 specifications. Replace these capscrews with only new capscrews of the correct
hardness. Refer to the appropriate parts book for the correct part number.

The use of dry threads in this application is not recommended. Due to the high tightening force that is
required to install the wheel motor mounting capscrews, dry threads may cause damage to tools,
capscrews or the rear axle housing.

Komatsu does not recommend the use of special friction-reducing lubricants, such as Copper Coat,
Never-Seez® or other similar products, on the threads of standard fasteners where standard torque values
are applied. The use of special friction-reducing lubricants will significantly alter the clamping force during
the tightening process. If a special friction-reducing lubricant is used, excessive stress and possible
breakage of the fasteners may result.

102. Select the hardware to be installed in Group 1 of the tightening sequence. Refer to Figure 6-77.
103. Inspect each capscrew for rust, corrosion and surface defects on any seat or thread. Do not use any cap-
screw if a defect is suspected.
104. Lubricate the capscrew threads, capscrew head seats and washer faces with a lithium based grease con-
taining 3% molybdenum-disulphide.

NOTE: The special hardened washers that are used in this

application may have a punch lip on one side due to the
manufacturing process. When placing this washer under
the capscrew head, the washers must be installed with the
punch lip facing away from the capscrew head to prevent
damage to the fillet between the capscrew head and the
shank. Refer to Figure 6-76.

FIGURE 6-76. INSTALLATION OF HARDENED

WASHER
1. Washer 2. Capscrew

FAM0635 Chassis Assembly 6-67

 105. Install the hardware for Group 1. Tighten each capscrew to 542 N·m (400 ft lb).
106. Repeat steps 108 - 111 for each remaining group in the tightening sequence. Refer to Figure 6-77.

Install and tighten all of the hardware in a group before proceeding to the next group in the tightening
sequence. Remove the guide pins that were installed in step 106 when installing the hardware for Groups
3 and 4.

107. After all of the hardware in all of the groups has been installed and tightened to 542 N·m (400 ft lb), move
back to Group 1. Increase the torque on each capscrew in Group 1 to 4 040 N·m (2,980 ft lb). Repeat this
step for each remaining group in the tightening sequence. Refer to Figure 6-77.

GROUP 2
8 CAPSCREWS

GROUP 6 GROUP 7
8 CAPSCREWS 8 CAPSCREWS

GROUP 4 GROUP 3
8 CAPSCREWS 8 CAPSCREWS

GROUP 8 GROUP 5
9 CAPSCREWS 9 CAPSCREWS

GROUP 1
8 CAPSCREWS

86302

FIGURE 6-77. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

6-68 Chassis Assembly FAM0635

108. Connect the power cables and the speed sensors to each of the wheel motors. Connect the brake apply
lines, brake cooling supply lines and return lines to each wheel. Refer to Figure 6-78 through Figure 6-80.

FIGURE 6-78.

FAM0635 Chassis Assembly 6-69

 FIGURE 6-79.

FIGURE 6-80.

6-70 Chassis Assembly FAM0635

Front Wheel Installation

NOTE: Clean all mating surfaces. Clean out tapped holes and re-tap the threads if necessary before installing the
wheels.
109. Grip the tire and rim assembly with the tire handler. Align the tire inflation hose and the wheel hub. Position
the rim onto the wheel hub studs. Refer to Figure 6-81.

110. Lubricate all stud threads and nut seating flanges with lithium base grease. Refer to Figure 6-82. Install and
tighten the nuts in the following sequence:
a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten each nut to 2 655 ±
136 N·m (1,958 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.
Tighten the nuts to 2 655 ± 136 N·m (1,958 ± 100 ft lb).
c. Install three nuts directly above the 3 o'clock position and three nuts directly below the 9 o'clock position.
Tighten these nuts to 2 655 ± 136 N·m (1,958 ± 100 ft lb).
d. Install the remaining nuts and tighten in a clockwise pattern to 2 655 ± 136 N·m (1,958 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2 655 ± 136 N·m (1,958 ± 100 ft lb).

After the truck has been assembled and is operational, the truck must be operated for a short period of
time, and the torque on the wheels re-checked. Tighten the wheels to the specified torque.

FAM0635 Chassis Assembly 6-71

 FIGURE 6-81.

FIGURE 6-82.

6-72 Chassis Assembly FAM0635

Rear Wheel Installation

1 2 3 4 5 6 7 8

86376

FIGURE 6-83. REAR WHEEL ASSEMBLY

1. Inner Wheel Rim 3. Flexible Extension 5. Adapter Ring 7. Flanged Nut
2. Disc Brake Assembly 4. Flexible Extension 6. Wheel Stud 8. Outer Wheel Rim

NOTE: Clean all mating surfaces. Clean out tapped holes and re-tap the threads if necessary before installing the
wheels.

111. Grip the inner tire and rim with the tire handler and lift the wheel onto the wheel hub. Refer to Figure 6-84 and
6-85. Align flexible extension (3, Figure 6-83) for mating with flexible extension (4).

112. Lubricate all stud threads and all nut seating flanges with a lithium base grease. Install and tighten the nuts in
the following sequence:
a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.
Tighten to 2 655 ± 136 N·m (1,958 ± 100 ft lb).
c. Install three nuts directly above the 3 o'clock position and three nuts directly below the 9 o'clock position.
Tighten to 2 655 ± 136 N·m (1,958 ± 100 ft lb).
d. Install the remaining nuts in a clockwise pattern. Tighten to 2 655 ± 136 N·m (1,958 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2 655 ± 136 N·m (1,958 ± 100 ft lb).

113. Install flexible extension (4, Figure 6-83) and associate hardware before installing the outer tires.

FAM0635 Chassis Assembly 6-73

 FIGURE 6-84.

FIGURE 6-85.

6-74 Chassis Assembly FAM0635

DO NOT move the truck without the rear, outer tires installed. Serious mechanical damage to the wheel
motor hub and torque tube may result. The adapter rings and outer dual tires must be installed. The
mounting capscrews must be tightened to 2 655 N·m (1,958 ft lb).

114. Position the adaptor rings (5, Figure 6-83) onto the outer wheel studs (6) located on the wheel motor, with
the gaps between the ring halves placed at the 12 o'clock and 6 o'clock positions. Install the fifty seven
flanged nuts (7) and tighten the nuts to 2 655 ± 136 N·m (1,958 ± 100 ft lb). Refer to Rear Wheel Installation
for the correct tightening sequence.

115. Grip the outer tire and rim with the tire handler and lift the wheel onto the wheel hub. Refer to Figure 6-86.
Install the fifty seven flanged nuts and tighten the nuts to 2 655 ± 136 N·m (1,958 ± 100 ft lb). Refer to Rear
Wheel Installation for the correct tightening sequence.

After the truck has been assembled and is operational, the truck must be operated for a short period of
time, and the torque on the wheels re-checked. Tighten the wheels to the torque specified above.

FIGURE 6-86.

FAM0635 Chassis Assembly 6-75

 116. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-87 and
Figure 6-88.

FIGURE 6-87.

FIGURE 6-88.

6-76 Chassis Assembly FAM0635

117. Install the mud flaps on the LH and RH uprights. Refer to Figure 6-89.

1 2

85186 85187

FIGURE 6-89.

118. Install the front LH and RH mud flaps on the underside of each deck.
119. Weld both rear LH and RH mud flap brackets into place on the backside of the deck supports.
120. Install the mud flaps. Refer to Figure 6-90 and Figure 6-91.

FAM0635 Chassis Assembly 6-77

 FIGURE 6-90.

FIGURE 6-91.

6-78 Chassis Assembly FAM0635

Before Starting the Engine
Alternator Rotor Lock

Be careful not to damage fiberglass housing on alternator.

121. Remove warning tags from rotor lock tool (4, Figure 6-92) and bracket (5). Place a protective sheet in the
alternator housing to protect the fiberglass housing from damage.
122. Loosen jam nuts (1) and collapse the rotor lock tool (4) enough to allow it to be removed. Unscrew cap-
screws (2) to remove mount (3).
Remove rotor lock tool (4), then remove bracket (5).
123. Position drive shaft (2, Figure 6-93) between alternator shaft (1) and hydraulic pump flange (5).
NOTE: The female end of the slip joint must be oriented toward the alternator.
Attach the drive shaft to the alternator shaft (1) using capscrews0 (6), then torque capscrews to 54 N·m (40
ft lb).
Attach the drive shaft to the hydraulic pump flange (5) using capscrews (3) and nuts (4), then torque cap-
screws (3) and nuts (4) to 47 N·m (35 ft lb).
124. Connect top cover (4, Figure 6-94 ) to pump mount (1) using capscrews (3) and lockwashers (2). Connect
bottom cover (8) to top cover using capscrews (5), flat washers (6), and locknuts (7). Secure the covers
using winged captive screws and retainers.
125. Remove the protective sheet from the alternator housing, then remove the warning tag from the steering
wheel.

1. Jam Nuts 3. Mount 5. Bracket

2. Capscrews 4. Rotor Lock Tool

FIGURE 6-92.

FAM0635 Chassis Assembly 6-79

 FIGURE 6-93.

FIGURE 6-94.

6-80 Chassis Assembly FAM0635

Before the engine is started the first time, the hydraulic system should be set up to perform the flushing
procedure. Refer to the hydraulic system flushing procedure within the 980E-4 Hydraulic System Checkout
Procedure in the appendix of this manual. The purpose of hydraulic system flushing is to eliminate
contaminants that could have been introduced into the hydraulic system during truck assembly.
Performing the flushing procedure will remove these contaminants from the hydraulic system and
minimize the potential for hydraulic system component damage at startup.

126. Do not start the engine unless the hydraulic system flushing tools are installed and ready to perform the
flushing procedure. Refer to 980E-4 Hydraulic System Checkout Procedure in the appendix for the hydraulic
system flushing procedure.
127. The parking brake must be flushed before operating the truck. Refer to the appendix for the parking brake
flushing procedure.
128. Check the oil level in each wheel motor. Rotate one of the eight plugs to the 6 o’clock position and remove
the plug. The oil level should be even with the bottom of the plug opening. Refer to Figure 6-95. Fill the
wheel motor with the recommended oil as necessary.
129. Check the spindle oil level at the front suspension prior to moving the truck.
130. Check the hydraulic tank oil level and check for leaks before and after engine start-up. Service the hydraulic
tank oil as necessary.
The truck is now ready for dump body installation.

PROPER
OIL LEVEL

G050084

FIGURE 6-95. WHEEL MOTOR OIL LEVEL

FAM0635 Chassis Assembly 6-81

 NOTES

6-82 Chassis Assembly FAM0635

 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.
33 643 kg (74,171 lb). Use two cranes for assem- In most instances, it is easier to assemble and weld
bling the body. A 45 metric ton (50 ton) crane and the body while the sections are upside down. After
a 109-136 metric tons (120-150 ton) crane are the pivot, guide pin, and body pads are welded in
required. The larger crane is needed to help turn place, the body can be turned over and the remain-
the body over after completion of the underside der of the assembly can be completed.
welding.
All paint must be removed from surfaces to be
Assembly of the body must be performed on flat ter- welded. Use a wire brush or paint removal equip-
rain with an adequate area for welding machines and ment.
for maneuvering lifting equipment. Refer to the assembly drawings shipped with the
NOTE: Body sections must be assembled as truck for specific welding details and the parts
originally manufactured. Match the shipping numbers required for assembly.
stenciled on the body sections to mate the correct
parts. DO NOT mix components.

FIGURE 7-1. BODY PARTS NOMENCLATURE

(Flat pack configuration shown)
1. Canopy 3. RH Side Sheet 5. Floor
2. Front Sheet 4. Lift Hole 6. LH Side Sheet

FAM0711 9/11 Dump Body Assembly 7-1

BODY WELDING INFORMATION BODY ASSEMBLY
Follow the guidelines listed below when welding the
NOTE: References to LH and RH in the following
body:
procedures assume the body is in its normal, upright
• Use dry weld rod or weld wire. position, as shown in Figure 7-1.
• Weld surfaces must be dry and above 10°C 1. Remove the paint from the weld areas.
(50°F). 2. Lift the LH body section and support the rear
• If stick electrode is used, use as large a diameter edge of the floor with wood blocks and a jack
rod as practical to weld the floor and front sheet stand. See Figure 7-3 and Figure 7-4.
joints.
• The following sequence must be followed for the
front sheet:
1. For the first pass, back step and skip weld in 10
increments along the entire length of the joint.
Refer toFigure 7-2.
2. 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 7-3. LH BODY SECTION

FIGURE 7-2. FRONT SHEET & FLOOR JOINT

WELDING SEQUENCE

FIGURE 7-4. LH BODY SECTION

7-2 Dump Body Assembly 9/11 FAM0711

 3. Lift the center body section and place it next to 7. Install cap screws (7), (8) and (9) with the flat
the LH body section. Support the center edge of washers and nuts. Attach a wedge or a clamp
the floor with wood blocks and a jack stand. See inside the body as necessary to align the floor
Figure 7-5. sheets. See Figure 7-9.
4. Use the crane and a lift truck to align the body 8. Lift the RH body section and place it next to the
sections. Install cap screw (1, Figure 7-6) with LH/center body section assembly. Support the
the sleeves, flat washers and nut. center edge of the floor with wood blocks and a
jack stand. See Figure 7-7.
9. Use the crane and a lift truck to align the body
sections. Install cap screw (1, Figure 7-8) with
the sleeves, flat washers and nut.

FIGURE 7-5. CENTER BODY SECTION

NOTE: Figure 7-6 shows the hardware numbered in

installation sequence. Cap screws (1) and (2) are FIGURE 7-7. RH BODY SECTION
installed with sleeves. The remainder of the cap
screws do not have sleeves.
NOTE: Figure 7-8 shows the hardware numbered in
installation sequence. Cap screws (1) and (2) are
installed with sleeves. The remainder of the cap
screws do not have sleeves.

FIGURE 7-6. CAP SCREW INSTALLATION

5. Install cap screw (2) with the sleeves, flat wash-

ers and nut.
6. Install cap screws (3), (4), (5) and (6) with the
FIGURE 7-8. CAP SCREW INSTALLATION
flat washers and nuts. Attach a wedge or a
clamp inside the body as necessary to align the
front sheets. See Figure 7-9.

FAM0711 9/11 Dump Body Assembly 7-3

 10. Install cap screw (2) with the sleeves, flat wash- NOTE: The backer strips must be tack welded in a
ers and nut. location where the tack will be burned away on the
first pass.
11. Install cap screws (3), (4), (5) and (6) with the
flat washers and nuts. Attach a wedge or a
clamp inside the body as necessary to align the
front sheets. See Figure 7-9.
12. Install cap screws (7), (8) and (9) with the flat
washers and nuts. Attach wedges or clamps
inside the body as necessary to align the floor
sheets. See Figure 7-9.

FIGURE 7-11. BACKER STRIP INSTALLATION

14. Check the alignment and fit of all joints. Com-

plete the welds at the floor joints and the front
FIGURE 7-9. ALIGNMENT WEDGES sheets. See Figure 7-12 and Figure 7-13. Refer
to the assembly drawings for welding require-
ments.

FIGURE 7-10. BODY SECTIONS ASSEMBLED

NOTE: If equipped, DO NOT install the heated body FIGURE 7-12. WELDING THE FLOOR JOINTS
exhaust boxes onto the body at this time. The
exhaust boxes must be installed after the body is
installed onto the truck.

13. Install the backer strips on the front sheet center

joints as shown on the assembly drawing. See
Figure 7-11.

7-4 Dump Body Assembly 9/11 FAM0711

 16. Tack weld the canopy side plates. Attach
wedges or clamps to the plates as necessary to
align the canopy joints. See Figure 7-15.

FIGURE 7-13. FRONT SHEET JOINT WELDS

FIGURE 7-15. CANOPY SIDE PLATE

15. Use a lift truck to move the canopy into position. INSTALLATION
Support the edges of the canopy with wood
blocks. See Figure 7-14. Align the canopy with
the body and tack weld it to the body. Refer to
17. Tack weld the canopy gussets in place. When
the assembly drawings for welding require-
all the gussets are installed, complete the
ments.
remaining welding on the canopy. See Figure 7-
16. Refer to the assembly drawings for welding
requirements.

FIGURE 7-14. CANOPY INSTALLATION

FIGURE 7-16. CANOPY GUSSET NSTALLATION

FAM0711 9/11 Dump Body Assembly 7-5

 18. Install body guide (1, Figure Figure 7-17) and
the body pad mounts (2).

FIGURE 7-19. TURNING OVER THE BODY

FIGURE 7-17. BODY GUIDE & BODY PAD
MOUNT INSTALLATION

1. Body Guide 2. Body Pad Mount

19. 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.
Figure 7-18 through Figure 7-22 shows a typical
example of a body being inverted with two
cranes.

FIGURE 7-20. TURNING OVER THE BODY

FIGURE 7-18. TURNING OVER THE BODY

FIGURE 7-21. TURNING OVER THE BODY

7-6 Dump Body Assembly 9/11 FAM0711

 22. Install the mud flap brackets, clearance light
housings, etc, as specified on the installation
drawings.

23. Install the top rail caps (see Figure 7-24) and
any optional equipment such as body liners.

FIGURE 7-22. TURNING OVER THE BODY

20. Position the body onto wood blocks as shown in

Figure 7-23.

FIGURE 7-24. TOP RAIL CAP INSTALLATION

24. Clean and paint the weld joints (see Figure 7-

25).

FIGURE 7-23. BODY SUPPORT BLOCKING

21. Refer to Figure 7-2 and the assembly drawings

to complete the welds on the inside of the body
and top of the canopy.
FIGURE 7-25. PAINTING THE WELD JOINTS

FAM0711 9/11 Dump Body Assembly 7-7

 NOTES

7-8 Dump Body Assembly 9/11 FAM0711

 FINAL ASSEMBLY

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

FAM0832 4/16 Final Assembly 8-1

Dump Body Installation
NOTE: The following figures show a typical example of a dump body installation. The truck and dump body shown
may not represent your truck model in exact detail.

FIGURE 8-1. LIFTING THE DUMP BODY

NOTE: Body welding and chassis assembly must be completed before proceeding.
1. Before the body is lifted off the ground, tie guy ropes to each of the four corners of the body for aiding in
installation.
There are two methods of installing the body depending on the cranes that are available.
a. If the truck is operational and can be driven, two 50 ton cranes can be used, one positioned at either side
of the body. The body can then be lifted high enough to allow the truck to be reverse propelled under the
body (Figure 8-1).
b. If a large crane of approximately 150 ton is available, the body can be lifted over the chassis and installed
in a similar fashion to that in Step a.

8-2 Final Assembly 4/16 FAM0832

 FIGURE 8-2. INSTALLING THE BODY PIVOT PINS

FIGURE 8-3. DUMP BODY PIVOT PIN

1. Shoulder Bolt 4. Body Pivot Pin 7. Pivot Bushing

2. Flat Washer 5. Pivot Bushing 8. Shim
3. Nut 6. Body Pivot Ear 9. Body Pivot Bushing

FAM0832 4/16 Final Assembly 8-3

 FIGURE 8-4. CONNECTING THE HOIST CYLINDER TO THE DUMP BODY

2. With the body in position, install shims (8, Figure

8-3) in both body pivots. Install enough shims to
fill the outboard gaps and to center the body on
the frame pivot. DO NOT install shims at the
inside. A minimum of one shim is required at the
outboard end of both frame pivots.
3. Align the hole in body pivot pin (4) with the bolt
hole in body pivot ear (6). Push the pivot pin
through the frame pivot and into pivot bushings
(5) and (7).
4. Install shoulder bolt (1) through the pin. Install a
flat washer (2) and nut (3). Tighten the nut to 339
N·m (250 ft lb).
5. Repeat for the body pivot pin on the opposite side
of the body.
6. Align the hoist cylinder upper bushings with the
body (Figure 8-4). Align the bolt holes and install
spacers (2, Figure 8-5) and pin (3) . Install shoul-
der bolt (4), flat washer (5) and nut (6). Tighten
the nut to 339 N·m (250 ft lb).
7. After the body is installed, perform the toe-in
adjustment. Refer to Toe-In adjustment Proce-
dure in Section 10, Appendix.
FIGURE 8-5. HOIST CYLINDER UPPER MOUNT
1. Mounting Bracket 4. Shoulder Bolt
2. Spacer 5. Flat Washer
3. Pin 6. Nut

8-4 Final Assembly 4/16 FAM0832

Body Pad & Body Guide Installation

FIGURE 8-6. BODY PAD INSTALLATION

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

1. Shim the body pads as required. All pads, except the two rear pads, should contact the frame with approxi-
mately equal compression of the rubber. Refer to Figure 8-6.
A gap of approximately 1.5 mm (0.06 in.) is required at each rear pad. This can be accomplished by using one
less shim at each rear pad.
If pad contact appears to be unequal, refer to “Body Pad Shimming Procedure”.

Install mounting hardware (4, Figure 8-6) with the capscrew heads facing the frame, and with the nuts and
washers facing the dump body. Installing the mounting hardware in the opposite direction can result in
damage to the hardware, body, body pads and frame.

FAM0832 4/16 Final Assembly 8-5

 2. Install both body guide brackets loosely into place (Fig-
ure 8-7). Once in position, slowly lower the body and
mark the position in which the brackets are to be welded.

FIGURE 8-7. BODY GUIDE BRACKET

INSTALLATION

The body guides must be centered between wear plates

(3, Figure 8-8), with a maximum gap of 4.8 mm (0.19 in.)
at each side.

FIGURE 8-8. BODY GUIDE

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

8-6 Final Assembly 4/16 FAM0832

Body Pad Shimming Procedure
Proper contact between the body pad and frame is required to ensure maximum pad life. All pads (except the rear
pad on each side) should contact the frame with approximately equal compression of the rubber. A gap of
approximately 1.9 mm (0.075 in.) is required at each rear pad. This can be accomplished by using one less shim at
each rear pad.
If pad contact appears to be unequal, perform the following shimming procedure.
1. Park the truck on a flat, level surface.
2. Raise the unloaded dump body to a height that is sufficient to allow access to all of the body pads.

To avoid serious personal injury or death, the body retention sling must be installed anytime personnel are
required to perform maintenance on the truck with the dump body in the raised position.
3. Install the body retention sling. Refer to “Securing The Body” in Section 20 of the Operation & Maintenance
Manual for the body retention sling installation procedure.
4. Remove all of the body pads and shims.
5. Bolt one spacer block (XC2293) to each side of the body. Use the pad mounting holes closest to the front of
the dump body.
6. Remove the body retention sling. Lower the dump body onto the spacer blocks.
7. Check the dump body’s position and fit on the truck. If there is any interference when the body is on the
spacer blocks, contact your local Komatsu distributor to resolve the issue.
8. With the body lowered, measure the distance from the
frame rail to each pair of bolt holes at the dump body’s
pad mounting locations. There will be a total of eight
measurements “A” per side. Refer to Figure 3-9.
9. Subtract the body pad thickness of 39.7 mm (1.56 in.)
from each measurement that was recorded in Step 8.
There will be a total of eight measurements “B” per
side. Refer to Figure 3-9.
“A” - 39.7 mm (1.56 in.) = “B”
10. Divide each measurement “B” by the single shim thick-
ness of 1.5 mm (0.06 in.) to determine the number of
shims required for each mounting location.
“B” / 1.5 mm (0.06 in.) = number of shims
11. Remove one shim from the calculation for the most
rearward body pad on both sides.
NOTE: Using half shims is allowed if necessary. Half shims
must be installed at the top of the stack.
NOTE: The frame rail and the body bolster do not have to FIGURE 8-9. MEASUREMENT DETAILS
be parallel.
1. Shims 2. Body Pad

FAM0832 4/16 Final Assembly 8-7

Body Up Switch & Hoist Limit Switch Installation

FIGURE 8-10. BODY UP SWITCH INSTALLATION

1. Body Up Switch 3. Magnet Assembly

2. Switch Mounting Bracket 4. Bracket

1. With the body lowered onto the frame rail, install body up switch (1, Figure 8-10) and switch mounting plate
(2) on the frame. Install bracket (4) and magnet assembly (3) on the body.

Dimension “A” : 45 mm (1.77 in.)

Dimension “B” : 32.3 mm (1.27 in.)

NOTE: The tapped pads are tack welded onto the frame and body. If necessary, the tapped pads can be
repositioned.

2. Fully raise the body and install the body retention sling. Remove the support blocks.
Refer to the Safety section of the Operation & Maintenance Manual for information about properly securing
the body using the body retention sling.

3. Weld the body guide brackets into place.

8-8 Final Assembly 4/16 FAM0832

 FIGURE 8-11. HOIST LIMIT SWITCH

1. Hoist Limit Switch 3. Magnet Assembly

2. Switch Mounting Plate 4. Actuator Arm

4. Raise the body so that the hoist cylinders are within 152 mm (6 in.) of maximum travel. Install hoist limit switch
(1, Figure 8-11) and switch mounting plate (2) on the frame. Install actuator arm (4) and magnet assembly (3)
on the body.
The distance between the bottom of the tapped pad on the body and the top of the switch (dimension “B”)
must be 83.1 mm (3.27 in.).

5. Adjust the hoist limit switch to achieve an air gap (dimension “A”) of 45 mm (1.77 in.) between the switch and
the magnet. Tighten the capscrews.
NOTE: The tapped pads are tack welded onto the frame and body. If necessary, the tapped pads can be
repositioned.

6. With the body in the raised position, install the grease lines for the hoist cylinders and clamp them along the
inside of the body.

FAM0832 4/16 Final Assembly 8-9

Miscellaneous Installations
1. Install all service lights (Figure 8-12).

FIGURE 8-12. SERVICE LIGHTS

2. Install the fire suppression system (if equipped). This installation is normally performed by the fire suppres-
sion system distributor.

Unauthorized welding on the truck frame is not permitted. Contact Komatsu Engineering for approval prior
to welding on the frame of the truck.

8-10 Final Assembly 4/16 FAM0832

 3. Paint the truck as needed.

4. Install all decals at their designated areas.

FIGURE 8-13. COMPLETED TRUCK

5. After completing the assembly of the truck:

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

FAM0832 4/16 Final Assembly 8-11

 NOTES

8-12 Final Assembly 4/16 FAM0832

 FINAL CHECKOUT
Final checkout requires truck operation. 5. Perform a final check of all systems and prepare
for operation, including the pre-shift brake test.
Place the operation and maintenance manual and
Several checks and tasks are outlined in Section
safety manuals in the operator cab, if they are not
10, Appendix.
already there.
6. Complete the checks listed in the Field Assembly
Personnel involved in the final check-out of the truck Inspection Report Form. A copy of the form is pro-
must read and understand all safety and operating vided with the truck and is also available in Sec-
instructions in the operation and maintenance manual. tion 10, Appendix.
7. Operate the truck in a traffic-free area until safe
operation has been validated.
1. Complete delivery and warranty forms.
8. Release the truck for use after all checks have
2. Check all coolant and lubricants for proper levels
been completed and all deficiencies corrected.
and specifications. The lubrication chart is shown
in Section 10, Appendix.
3. Verify the shut-off valves on the hydraulic tank
suction lines are open.
4. Purge air from the pumps and suction lines. Pres-
sure will not build if air is present. Operating the
pumps with air in the system will result in damage.
Refer to the truck assembly section for more infor-
mation on how to bleed the air from the pumps
and suction lines.

FAM0903 5/13 Final Checkout Page 9-1

 NOTES

Page 9-2 Final Checkout 5/13 FAM0903

 APPENDIX

This chapter contains additional information and procedures for aiding in field assembly of the truck. Refer to the
list below for contents of this chapter. Refer to the latest service manual for additional information on servicing the
truck.

1. Lubrication Chart - 58B-93-00090

2. Torque Tables and Conversion Charts - FAM-1

3. Suspension Oiling And Charging Procedure - 58E-60-02200

4. Oiling and Charging Specifications Chart -FAM1204

5. Toe-In Adjustment Procedure - FAM1306

6. Automatic Lubrication System Priming - FAM1406

7. Brake Test Checkout Procedure - EM9966-3

8. Parking Brake Bleeding/Flushing Procedure - FAM1801

9. Alternator/Engine Assembly Checkout Procedure - 58B-01-20100

10. Interface Module Checkout Procedure - 58B-06-03292

11. Automatic Lubrication System Checkout Procedure - 58F-90-00300

12. Reserve Oil System Checkout Procedure - 58F-90-00400

13. Air Conditioning Checkout Procedure - EM4003

14. Hydraulic Checkout Procedure - 58B-60-20400

15. Brake Checkout Procedure - 58B-60-20410

16. KOMTRAX Plus Setup Procedure - EM2128

17. KOMTRAX Plus Checkout Procedure - EM2129

18. Payload Meter IV Checkout Procedure - 58B-06-02400

19. Electrical Checkout Procedure - 58F-06-30042

20. Komvision Checkout Procedure - 58E-43-10000

21. Komatsu Wireless Bridge Checkout Procedure - 58F-06-11130

22. Retractable Ladder Checkout - 58E-00-10490

FAM1039 Appendix 10-1

 23. Seat Belt Checkout Procedure - SM2700

24. Field Assembly Inspection Report

25. 50 Hour Post-Commissioning Checksheet

10-2 Appendix FAM1039

 LUBRICATION CHART

Lube Chart 980E 4/16 Lubrication Chart 1

 NOTES

2 Lubrication Chart 4/16 Lube Chart 980E

 TORQUE TABLES AND CONVERSION CHARTS

This manual provides dual dimensioning for many

specifications. Metric units are specified first, with
References throughout the manual to standard
U.S. standard units in parentheses. When torque val-
torques or other standard values will be to one of
ues are not specified in the assembly instructions
the following tables. Do not use standard values
contained in this manual, use the standard torque
to replace specific torque values in assembly
value for the hardware being used. Standard value
instructions.
torque tables are contained in this chapter for metric
and SAE hardware.
NOTE: This truck is assembled with both metric and For values not shown in any of the charts or tables,
SAE (U.S.) hardware. Reference the correct table standard conversion factors for most commonly used
when determining the proper torque value. measurements are provided in the following tables.

INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

TABLE 1 Standard Tightening Torque For Metric Capscrews and Nuts. . . . . . . . . . . . . . . . . . . . . . . . FAM-2
TABLE 2 Standard Tightening Torque For SAE Grade 5 & 8 Capscrews and Nuts . . . . . . . . . . . . . . . FAM-3
TABLE 3 Standard Tightening Torque 12-Pt, Grade 9, Capscrews (SAE) . . . . . . . . . . . . . . . . . . . . . . FAM-4
TABLE 4 Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-5
TABLE 5 Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-5
TABLE 6 Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-5
TABLE 7 JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-6
TABLE 8 Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-6
TABLE 9 O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-7
TABLE 10 O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-7
TABLE 11 Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-8
TABLE 12 Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-9
TABLE 13 Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM-10

8/15 TORQUE TABLES AND CONVERSION CHARTS FAM-1

EFFECT OF SPECIAL LUBRICANTS STANDARD TIGHTENING TORQUES
On Fasteners and Standard Torque Values For Class 10.9 Capscrews & Class 10 Nuts
The Komatsu engineering department does not The following specifications apply to required
recommend the use of special friction-reducing assembly torques for all metric class 10.9 finished
lubricants, such as Copper Coat, Never-Seez®, and hexagon head capscrews and class 10 nuts.
other similar products, on the threads of standard
• Capscrew threads and seats shall not be
fasteners where standard torque values are applied.
lubricated when assembled. These specifications
The use of special friction-reducing lubricants will are based on all capscrews, nuts, and hardened
significantly alter the clamping force being applied to washers being phosphate and oil coated.
fasteners during the tightening process.
If zinc-plated hardware is used, each piece must
If special friction-reducing lubricants are used with be lubricated with simple lithium base chassis
the standard torque values listed in this chapter, grease (multipurpose EP NLGI) or a rust
excessive stress and possible breakage of the preventive grease (see list, this page) to achieve
fasteners may result. the same clamping forces provided below.

Where the torque tables specify “Lubricated • Torques are calculated to give a clamping force
Threads” for the standard torque values listed, these of approximately 75% of proof load.
standard torque values are to be used with simple • The maximum torque tolerance shall be within
lithium base chassis grease (multipurpose EP NLGI) ±10% of the torque value shown.
or a rust-preventive grease (see below) on the
• In the following table under “Capscrew Size”, the
threads and seats unless specified otherwise. first number represents the shank diameter
NOTE: Ensure the threads of fasteners and tapped (mm). The second number represents threads
holes are free of burrs and other imperfections before per millimeter.
assembling. Example: M20 x 2.25

Suggested* Sources for Rust Preventive Grease: M20 = shank diameter (20 mm)

• American Anti-Rust Grease #3-X from Standard 2.25 = threads per millimeter
Oil Company (also American Oil Co.)
• Gulf NoRust #3 from Gulf Oil Company.
• Mobilarma 355, Product No. 66705 from Mobil
Oil Corporation.
• Rust Ban 326 from Humble Oil Company.
TABLE 1.
• Rustolene B Grease from Sinclair Oil Co. Standard Tightening Torque
for Metric Class 10.9 Capscrews & Class 10 Nuts
• Rust Preventive Grease - Code 312 from the
Southwest Grease and Oil Company. Capscrew Torque Torque Torque
Size N•m ft lb kg•m
NOTE: This list represents the current engineering M6 x1 12 9 1.22
approved sources for use in Komatsu manufacture. It
M8 x 1.25 30 22 3.06
is not exclusive. Other products may meet the same
specifications of this list. M10 x 1.5 55 40 5.61
M12 x 1.75 95 70 9.69
M14 x 2 155 114 15.81
M16 x 2 240 177 24.48
M20 x 2.25 465 343 47.43
M24 x 3 800 590 81.6
M30 x 3.5 1600 1180 163.2
M36 x 4 2750 2028 280.5

FAM-2 TORQUE TABLES AND CONVERSION CHARTS 8/15

STANDARD TIGHTENING TORQUES
For SAE Grade 5 and Grade 8 Capscrews
The following specifications apply to required assem-
• The maximum torque tolerance shall be ±10% of
bly torques for all grade 5 and grade 8 capscrews.
the torque value shown.
• Capscrew threads and seats shall be lubricated
when assembled. • In the following table under Capscrew Size, the
first number represents the shank diameter (in.).
Unless instructions specifically recommend The second number represents threads per inch.
otherwise, these standard torque values are to be
used with simple lithium base chassis grease Example: 7/16 - 20
(multipurpose EP NLGI) or a rust-preventive 7/16 = shank diameter (7/16 inch (0.438 inch))
grease (see list, previous page) on the threads.
20 = threads per inch
• Torques are calculated to give a clamping force
of approximately 75% of proof load.

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

8/15 TORQUE TABLES AND CONVERSION CHARTS FAM-3

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

TABLE 3.
Standard Tightening Torque for SAE Hex
Head and 12-Point, Grade 9 Capscrews

Torque Torque Torque

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

FAM-4 TORQUE TABLES AND CONVERSION CHARTS 8/15

 TABLE 4.
Tightening Torque For
T-Bolt Type Hose Clamp (SAE J1508 Type TB)
Newton meters Inch Pounds
Thread Size Band Width
(N·m) (in lb)
0.25-28 UNF 19.05 mm (0.75 in) 8.5 ± 0.6 N·m 75 ± 5 in lb

TABLE 5.
Tightening Torque For
Split Flange Clamp Bolts
Cap Screw Thread Width Newton meters Foot Pounds Kilogram meters
Diameter Across Flat (N·m) (ft lb) (kg·m)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
10 14 66 48 6.7
12 17 112 83 11.5
16 22 279 206 28.5

TABLE 6.
Tightening Torque For
Flared Tube And Hose Fittings
Thread Width Newton meters Foot Pounds Kilogram meters
Diameter of Nut Across Flat (N·m) (ft lb) (kg·m)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
14 19 25 18 2.5
18 24 50 36 5
22 27 80 58 8
24 32 140 101 14
30 36 175 130 18
33 41 195 145 20
36 46 245 180 25
42 55 295 215 30

8/15 TORQUE TABLES AND CONVERSION CHARTS FAM-5

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

TABLE 8.
Torque Chart For
Pipe Thread Fittings

Size Pipe Thread With Sealant With Sealant Without Sealant Without Sealant
Code Size N·m ft lb N·m ft lb
–2 0.125 – 27 20 ± 4 15 ±3 27 ± 7 20 ± 5
–4 0.250 – 18 27 ± 7 20 ±5 34 ± 7 25 ± 5
–6 0.375 – 18 34 ± 7 25 ±5 48 ± 7 35 ± 5
–8 0.500 – 14 48 ± 7 35 ±5 61 ± 7 45 ± 5
– 12 0.750 – 14 61 ± 7 45 ±5 75 ± 7 55 ± 5
– 16 1.000 – 11.50 75 ± 7 55 ±5 88 ± 7 65 ± 5
– 20 1.250 – 11.50 95 ± 7 70 ±5 108 ± 7 80 ± 5
– 24 1.500 – 11.50 108 ± 7 80 ±5 129 ± 14 95 ± 10
– 32 2.000 – 11.50 129 ± 14 95 ±10 163 ± 14 120 ± 10

FAM-6 TORQUE TABLES AND CONVERSION CHARTS 8/15

 TABLE 9.
Torque Chart For
O-ring Boss Fittings

Size Newton meters Foot Pounds

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

TABLE 10.
Torque Chart For
O-ring Face Seal Fittings

Size Tube Size Newton meters Foot Pounds

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

8/15 TORQUE TABLES AND CONVERSION CHARTS FAM-7

 TABLE11.
Common Conversion Multipliers
Metric To English
Multiply
To Convert From To
By
millimeter (mm) inch (in) 0.0394
centimeter (cm) inch (in) 0.3937
meter (m) foot (ft) 3.2808
meter (m) yard (yd) 1.0936
kilometer (km) mile (mi) 0.6210

square centimeters (cm2) square inch (in2) 0.1550

square centimeters (cm2) square feet (ft2) 0.001

cubic centimeters (cm3) cubic inch (in3) 0.061

liters (l) cubic inch (in3) 61.02

cubic meters (m3) cubic feet (ft3) 35.314

liters (l) cubic feet (ft3) 0.0353

grams (g) ounce (oz) 0.0353

milliliter (ml) fluid ounce (fl oz) 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pounds (lb) 0.2248
Newton meters (N·m) kilogram meters (kg·m) 0.102
Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram meters (kg·m) foot pounds (ft lb) 7.2329
kilogram meters (kg·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038

kilograms/cm 2 (kg/cm2) pounds/square inch (psi) 14.2231

kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068

kilogram (kg) short ton (tn) 0.0011

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

FAM-8 TORQUE TABLES AND CONVERSION CHARTS 8/15

 TABLE 12.
Common Conversion Multipliers
English to Metric
To Convert Multiply
To
From By
inch (in) millimeter (mm) 25.40
inch (in) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61

square inch (in2) square centimeters (cm2) 6.45

square feet (ft2) square centimeters (cm2) 929

cubic inches (in3) cubic centimeters (cm3) 16.39

cubic inches (in3) liters (l) 0.016

cubic feet (ft3) cubic meters (m3) 0.028

cubic feet (ft3) liters (l) 28.3

ounce (oz) kilogram (kg) 0.028

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

8/15 TORQUE TABLES AND CONVERSION CHARTS FAM-9

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

NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.

FAM-10 TORQUE TABLES AND CONVERSION CHARTS 8/15

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

All suspensions are charged with compressed Front Suspension

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

Before starting oiling and charging procedures,

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

58E-60-02200 8/16 Suspension Oiling and Charging Procedures 1

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

PISTON ROD

SPINDLE

MEASURE HERE

Lifting equipment (crane or hydraulic jacks) must

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

2 Suspension Oiling and Charging Procedures 8/16 58E-60-02200

 Table 1: Front Suspension Oiling and Charging Height Dimensions

Front Suspension
Oiling Height Charging Height Gas Pressure
730E-7
2758kPa (400psi)
730E-7T 38.1mm (1.50in)
730E-8 2772kPa (402psi)
830E-1AC
2696kPa (391psi)
830E-1AT
228.6mm (9.00in)
860E-1K
3365kPa (488psi)
860E-1KT
930E-4
930E-4SE 25.4mm (1.00in) 2930kPa (425psi)
930E-4AT
960E-2K
218.8mm (8.61in) 3282kPa (476psi)
960E-2KT
980E-4
212.3mm (8.36in) 3047kPa (442psi)
980E-4 Oil Sands
Charging pressures are for reference only and may vary depending on body weights.

58E-60-02200 8/16 Suspension Oiling and Charging Procedures 3

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

4 Suspension Oiling and Charging Procedures 8/16 58E-60-02200

 PRESSURE SENSOR/
FILL PORT CHARGING VALVE/
VENT PLUG/FILL PORT FILL PORT

MEASURE HERE

85633

FIGURE 1-2. REAR SUPENSION

58E-60-02200 8/16 Suspension Oiling and Charging Procedures 5

 Table 2: Rear Suspension Oiling and Charging Height Dimensions

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

6 Suspension Oiling and Charging Procedures 8/16 58E-60-02200

 OIL AND NITROGEN SPECIFICATIONS CHART

HYDRAIR® II OIL SPECIFICATIONS

Ambient Temperature Part No. Approved Sources
Range
VJ3911 Mobilfluid 424 Sunfleet TH Universal Tractor Fluid
(need to add Mobil DTE 15M Chevron Tractor Hydraulic Fluid-
6% of Texaco TDH Oil Conoco Power Tran III Fluid
-30°F & above AK3761) AMOCO ULTIMATE Motor Oil Petro Canada Duratran Fluid
(-34.5°C & above) 5W-30 Shell Canada Donax TDL
AK4063 Suspension Oil (premixed with 5 Gallon container
AK4064 6% Friction Modifier) 55 Gallon container
VJ5925 Emery 2811, SG-CD, Petro Canada Super Arctic Motor
(need to add 5W-30 Oil, 0W-30
6% of Mobil Delvac I, 5W-40 Conoco High Performance
-55°F & above AK3761) Synthetic Motor Oil, 5W-30
(-48.5°C & above) AK4065 Suspension Oil (premixed with 5 Gallon container
AK4066 6% Friction Modifier) 55 Gallon container
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and VJ5925
oils are supplied in 5 gallon (19 Liter) cans.

FRICTION MODIFIER FRICTION MODIFIER Mixing Instructions

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

NITROGEN GAS (N2)SPECIFICATIONS

Property Value
Nitrogen gas used inHYDRAIR® II Nitrogen 99.9% Minimum
Suspension Cylinders must meet or
Water 32 PPM Maximum
exceed CGA specification G-10.1 for
Type 1, Grade F Nitrogen Gas Dew Point -68°F (-55°C) Maximum
Oxygen 0.1% Maximum

FAM1204 Oil and Nitrogen Specifications Chart 12-1

 NOTES

12-2 Oil and Nitrogen Specifications Chart FAM1204

 TOE-IN ADJUSTMENT PROCEDURE
NOTE: Before returning the truck to operation, the
steering system must first be centered in the straight
ahead position. 1 3 2 5 3 4
1. Check the toe-in by measuring the distance
between the centers of the front tires. Measure
on the horizontal centerline at the front and rear
of the tires. Refer to Figure 3-1.
Radial tires should have equal measurements
(zero toe-in).

86311

FIGURE 3-2. TIE ROD ASSEMBLY

1. Threaded Rod End 4. Locknut
2. Capscrew 5. Clamps
3. Hardened Flat Washer

2. Loosen locknuts (4, Figure 3-2). Rotate the tie

rod as necessary to obtain the correct toe-in
setting. The tie rod length when installed is
3 683 ± 10mm (145.0 ± 0.4 in.).
3. When this adjustment is complete, hold the
head of each capscrew (2) with a wrench and
use a torque wrench to tighten each locknut to
1017 ± 102 N·m (750 ± 75 ft lb).
Reapply torque to each locknut (4) until the specified
torque is maintained.

FIGURE 3-1. MEASURING TOE-IN

FAM1306 Toe-In Adjustment Procedure 13-1

 NOTES

13-2 Toe-In Adjustment Procedure FAM1306

 AUTOMATIC LUBRICATION SYSTEM PRIMING
The automatic lubrication pump must not be allowed to operate without proper lubrication. Damage to pump seals
may occur, which may cause grease to leak from the pump and contamination to enter the system.
To avoid damage to the pump, ensure that the grease in the reservoir is filled to the proper level before operating
the truck. If the grease level becomes insufficient during truck operation, stop the truck and fill the reservoir imme-
diately or disconnect the pump until the reservoir can be filled.
Refer to the following procedures to properly prime the automatic lubrication system after maintenance has been
performed.

PUMP PRIMING PROCEDURE

NOTE: Do not connect the electrical harness to the automatic lubrication pump until the reservoir has been filled
and the pump, lines, and injectors have been purged of air.
1. Pump grease through filter (1, Figure 1) until the reservoir is filled to the proper level.
2. Remove pump main supply line (2). Connect a temporary hose in its place. Route the temporary hose into a
proper waste container.
3. Start the engine. While the engine is operating, actuate manual override valve (3) to operate the pump.
4. Once grease is flowing fully from the temporary hose, release the manual override valve to stop the pump.
Full grease flow should occur within two minutes.
5. Remove the temporary hose and reconnect the main supply line. Properly dispose of the grease in the waste
container.

1 72784

FIGURE 1. PRIMING THE PUMP

1. Filter
2. Main Supply Line
3. Manual Override Valve

FAM1406 Automatic Lubrication System Priming 14-1

SYSTEM PRIMING PROCEDURE
The system must be full of grease and free of air pockets to function properly. After maintenance, if any primary or
secondary lubrication lines were replaced, it will be necessary to prime the system to eject all entrapped air.
To prime the main supply lines, perform the following:
1. Remove injector manifold plug (5, Figure 2) from the injector manifold. Always start with the injector manifold
that is closest to the pump. The last grease line to be purged should be the main grease line to the rear axle
(longest grease line).
2. Disconnect main supply line (2, Figure 1). Connect an external grease supply to the main supply line.
3. Pump grease into main supply line (2) until grease appears at the injector manifold plug.
4. Reinstall the injector manifold plug. Repeat for the remaining injector groups.

After all main supply lines are purged of air, the injector circuits must now be primed.
To prime the secondary supply lines, perform the following:
1. If necessary, disconnect an injector grease line from the component that particular injector supplies grease to.
2. Remove injector grease Zerk cap (4) from each injector and connect an external grease supply to injector
grease Zerk (2) on the injector.
3. Pump grease into the injector until grease appears at the far end of the individual grease line or the joint that
is being greased.
4. Reconnect the injector grease line to the component, remove the external grease supply, and reinstall the
injector grease Zerk cap.
5. Repeat steps 1 through 4 until all secondary supply lines have been primed.
6. After all grease lines are primed, actuate manual override valve (3, Figure 1) to cycle the automatic lubrication
pump a few times to lubricate the components.

FIGURE 2. BRAKE COOLING MANIFOLD

1. Injector Indicator
2. Injector Grease Zerk
3. Injector Cover
4. Injector Grease Zerk Cap
5. Injector Manifold Plug

14-2 Automatic Lubrication System Priming FAM1406

 BRAKE TEST CHECKOUT PROCEDURE
The purpose of the brake system checkout b. The operator simply does not press the
procedure is to check the functionality of the service accelerator pedal far enough to achieve the
brake, parking brake and dynamic retarder. torque level for the service brake test.
Performing the brake system tests requires the c. The service brake test is not initiated within
truck’s dump body to be empty. The truck must be on 60 seconds after pressing the brake test
a flat even surface with space to move in forward and switch.
reverse positions. d. The drive system is at torque level for more
Table 1 shows the brake settings required to than 30 seconds.
configure the truck to the proper state for each test.

Table 1: Brake Test Settings

Test Type Wheel Service Directional
If the truck fails any brake test, notify mainte-
Brake Brake Pedal Control
nance personnel immediately. Do not resume
Lock Lever
operation unless the truck passes all brake tests.
Service OFF FULLY NEUTRAL
1. Verify the wheel brake lock is off.
Brake APPLIED
2. Firmly depress the service brake pedal.
Parking OFF RELEASED PARK
Brake 3. Place the directional control lever in the
NEUTRAL position.
Retard OFF RELEASED PARK
Brake 4. Press the brake test momentary switch (1,
Figure 1-1). The brake check light (2) should
illuminate solid amber.
NOTE: The Diagnostic information Display (DID)
panel, located on the back wall of the cab displays 5. Fully depress the service brake pedal. Ensure
information about the test being performed. full brake application is reached.
6. Fully depress the accelerator pedal. The Brake
Prerequisites: Check light (2) begins to flash.The DID panel
a. Set the engine to low idle. displays:

b. Verify drive system is in Ready Mode. Service brake test active.

c. Verify the truck dump body is in the down Check truck movement when light flashes.
position. The Brake Check light (2) begins to flash once
d. Verify the truck shows zero ground speed. the test is finished. If the truck did not move
since the test began the service brake system
Testing The Service Brake passed the test.
The purpose of this test is to check the service brake 7. Release the accelerator pedal. The test will
functionality. stop and the brake check light will turn off.
8. Place the directional control lever in the PARK
The following conditions may interrupt or interfere
position.
with the service brake test:
9. Release the service brake pedal.
a. Failure to reach full brake application will
affect the service brake test results.

EM9966-3 4/16 Brake Test Checkout Procedure 1

 4. Fully depress the accelerator pedal. The DID
panel displays:
Park brake test active
Check truck movement when light flashes
5. The Brake Check light (2) begins to flash. If the
truck did not move the park brake system
passed the test.
6. Release the accelerator pedal. The test will
stop and the brake check light will turn off.

Testing The Retard System

The purpose of this test is to check the retard brake
functionality.
FIGURE 1-1.BRAKE TEST SWITCH The following conditions may interrupt or interfere
1. Momentary Test Switch 2. Brake Check Light with the retard brake test.
Pushing the retard/brake pedal far enough to
Testing The Parking Brake engage service brakes will cancel retarder test.
The purpose of this test is to check the parking brake The retard test is not initiated within 60 seconds
functionality. after pressing the brake test switch.
The following conditions may interrupt or interfere The drive system is at torque level for more
with the parking brake test: than 30 seconds.
The operator simply does not press the
accelerator pedal far enough to achieve the
torque level for the parking brake test.
The parking brake test is not initiated within 60 If the truck fails any brake test, notify mainte-
seconds after pressing the brake test switch. nance personnel immediately. Do not resume
The Drive system is at torque level for more operation unless the truck passes all brake tests.
than 30 seconds. 1. Verify the wheel brake lock is off
2. Place the directional control lever in the PARK
position.
3. Press the brake test momentary switch (1,
If the truck fails any brake test, notify mainte- Figure 1-1). The brake check light (2) should
nance personnel immediately. Do not resume illuminate solid amber. The DID panel displays:
operation unless the truck passes all brake test. Parking brake or retard test ready
1. Verify the wheel brake lock is off. Press accel or retard pedal to start
2. Place the directional control lever in the PARK 4. Fully depress the retard pedal.
position.
5. Close RP1, RP2 and RP3 if present.
3. Press the brake test momentary switch (1,
6. Turn on the choppers and test the retarding
Figure 1-1). The brake check light (2) should
system. The DID panel displays:
illuminate solid amber. The DID panel displays:
Retard system test active
a. Parking brake or retard test ready
b. Press accel or retard pedal to start RP1 RP2 RP3 chop

2 Brake Test Checkout Procedure 4/16 EM9966-3

 7. The brake check light (2) will flash for 10 8. Release the retard pedal. The test will stop and
seconds. The DID panel displays: the brake check light will turn off.
Retard system test passed NOTE: If the brake check light (2) never flashed and
turned off, the retard test failed or was incomplete.

EM9966-3 4/16 Brake Test Checkout Procedure 3

 NOTES

4 Brake Test Checkout Procedure 4/16 EM9966-3

 PARKING BRAKE BLEEDING/FLUSHING PROCEDURE
1. Securely block the wheels to prevent the truck from rolling away.
2. Place the directional control lever in PARK and turn the rest switch ON. Turn the key switch OFF to shut down
the engine and allow 90 seconds for the steering system accumulators to bleed down. Open bleed down
valves to bleed down the brake accumulators.
3. Open the rear axle housing access door. Close the brake accumulator bleed down valves.
4. Start the engine and allow the steering system to fully charge (pump unloads). Then move the directional con-
trol lever to NEUTRAL to disengage the parking brake.
5. Connect a clear plastic hose to bleeder screw (See Figure 1). Place the other end of hose into a container
20L or more.
6. Open the bleeder screw and allow hydraulic oil to run for approximately 20-30L.
7. Repeat Steps 5 and 6 for the other parking brake assembly.
8. Shut off the engine. Remove the bleed equipment and close the rear axle housing hatch.

84289

FIGURE 1. PARKING BRAKE BLEEDING/FLUSHING PROCEDURE

1. Bleeder Screw

FAM1801 Park Brake Bleeding/Flushing Procedure 18-1

 NOTES

18-2 Park Brake Bleeding/Flushing Procedure FAM1801

 ALTERNATOR TO ENGINE ASSEMBLY CHECKOUT PROCEDURE
Care must be exercised when mounting alternator to 2. Locate the dial indicator base on the machined
engine on electric drive vehicles to avoid early face of the flywheel/flexplate and zero the probe
crankshaft bearing failures. on the face of the flywheel housing adaptor
plate.
Attaching GE Alternator to Cummins QSK60 & 78 3. Move crankshaft frontwards. Use engine
Engines barring device, slowly rotate the engine
NOTE: The following instructions must be followed crankshaft turn and document reading. Move
for new or re-power installations or whenever the crankshaft frontwards after every 1/4 turn and
engine and/or alternator is serviced. continue procedure for two full revolutions
documenting reading every 1/4 turn.
General Instructions 4. The difference between the highest and lowest
1. Loosen or remove fan belts prior to measuring values for each revolution is the radial runout
crankshaft end play to ensure that it moves TIR. If the average of the two measurements
easily back and forth. exceeds tolerance limits below, contact
2. When taking measurements always clean engineering for next steps.
mating surfaces and take four equally spaced Highest Reading- Lowest Reading= TIR
readings, then average all four.
TR =
3. Clockwise (CW) or counterclockwise (CCW) is
while looking at front or damper end of engine. Limits are shown below:
4. All measurements are set to three decimal
Max Value mm (in)
places.
5. Be sure that a surface reference (ie.flat steel Cummins "0" Flywheel Housing: 0.25 (0.01 0)
bar) used for dial indicating is calibrated used on QSK60's
periodically for flatness and dimensional Cummins "00" Flywheel Housing: 0.30 (0.012)
accuracy to within +/-.0009". Also, be sure all used on QSK78
instruments used for measurements are
calibrated on a periodic basis.
6. Forward is defined as the front of truck and
rearward is defined as the rear of the truck.
7. Refer to Appendix 1 for Summary of Radial and
Axial Run out Limits.
8. Additional Measurements (page 10): It is
assumed that these dimensions are within
specification from the supplier and are therefore
not required for new installations. These steps
may be used for Service rebuilds and/or
troubleshooting to confirm these dimensions
are within tolerance specification as outlined by
Cummins.

Engine Flywheel Adaptor Plate Face Runout (See

Figure 1-1)
1. Thoroughly clean all mounting surfaces; the
alternator housing, rotor, flywheel, and flywheel
housing.

85619

FIGURE 1-1. MEASURING FLYWHEEL HOUSING

ADAPTOR PLATE FACE RUNOUT

58B-01-20100 Alternator to Engine Assembly Checkout Procedure 1

Cummins Crankshaft End Play (See Engine Flywheel to Flywheel Adaptor Plate
Figure 1-2) - Measurement "C" (See Figure 1-3)
5. Mount a magnetic base on the front of the 6. Move the crankshaft rearward to its end travel.
engine and a dial indicator on the front of the 7. Bolt a flat calibrated steel bar across the
crankshaft. Measure total crankshaft endplay. flywheel housing as a surface reference to
Move crankshaft forward and rearwards as far measure the distance between the flywheel
as possible. This is accomplished by removing housing to flywheel Adaptor Plate (CR1).
a hand-hole cover and prying gently on a
crankshaft counter weight or using a rubber
mallet on the front end of the crank. Confirm the
measurement is equal in both forward and rear
directions. Record values and confirm end play
is within Cummins limits.
Total Crankshaft Endplay: ________
Total Crankshaft Endplay /2: ________
Cummins end play limits: 0.13-0.51 mm (0.005-
0.020 in.).

85621

FIGURE 1-3. FLAT BAR USED TO MEASURE

DISTANCE BETWEEN ENGINE FLYWHEEL AND
FLYWHEEL.

8. Repeat the same procedure in three more

locations, 90 degrees apart from each other in
the perimeter, to find the values CR2, CR3, CR.
1st measurement (12:00 O'clock): CR1
85620
2nd measurement (6:00 O'clock): CR2
FIGURE 1-2. RUBBER MALLET USED TO MOVE
CRANKSHAFT REARWARD 3rd measurement (3:00 O'clock): CR3
4th measurement (9:00 O'clock): CR4
Caver.1 = (CR1+CR2+CR3+CR4)/ 4 =
9. Move the crankshaft frontward to its end travel.

2 Alternator to Engine Assembly Checkout Procedure 58B-01-20100

 10. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CF2, CF3, CF4
1st measurement (12:00 O'clock): CF1
2nd measurement (6:00 O'clock): CF2
3rd measurement (3:00 O'clock): CF3
4th measurement (9:00 O'clock): CF4
Caver.2 = (CF1+CF2+CF3+CF4)/ 4 =
11. The Total Engine Axial Play of the engine is
calculated as TEAP= (Caver.1 - Caver.2) = __
12. The mean absolute value of the relative location
of the flywheel with respect to flywheel housing
is:
C = TEAP/2 + Caver.1 = __
85622
Alternator Housing to Rotor Measurement-
FIGURE 1-4.
Measurement "A" (See Figures 1-4-1-6)
13. Use 5/8"-11 x 4.5 bolt and hand tight the bolt in
the threaded hole provided on the stator frame
to support the alternator adapter. Remove the 15. Remove flat steel bar and bolt a calibrated flat
rotor support from the alternator by removing steel bar across the alternator housing as a
the two mounting bolts. Save the rotor support reference to measure the distance between the
for future re-use and alternator rotor must be alternator housing and rotor to determine the
supported by rotor support whenever alternator reading A11 at the 12:00 position. When taking
is removed from the engine for extended the measurements, make sure the readings are
storage or transportation of the alternator. taken from the mating surfaces.
14. Position the Alternator Rotor Rearward by Flat bar used as reference surface to measure
placing a flat steel bar bolted to the center of distance between alternator housing and rotor.
rotor Position the two 5/8" - 11 bolts through the Refer to Figure 1-5.
bar ends and fasten to housing on both ends.
Alternately tighten each bolt until rotor reaches
end of travel. (Do not exceed 12 ft-lbs).
Flat bar fastened to alternator housing used to
move the alternator rotor axially toward slip ring
(rearward). Bolts are tightened to no more than
12ft-lb. Refer to Figure 1-4.

58B-01-20100 Alternator to Engine Assembly Checkout Procedure 3

 16. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values A12,A13,A14.
1st measurement (12:00 O'clock): A11
2nd measurement (6:00 O'clock): A21
3rd measurement (3:00 O'clock): A31
4th measurement (9:00 O'clock): A41
Aaver.1 = (A11+A12+A13+A14) / 4 =
17. Assume that the rotor end play is set by the
factory to the nominal value of 0.0273" (GE
spec.). Since the mean relative position is the
rotor centered in housing, add 1/2 of rotor end
play from previous rearward measurement
(step 12). Therefore,
A = Aaver1+.014 in =
18. Refer to Figure 1-7 below. If measurement C is
greater than A, subtract A from C; the shim
pack is to be added between Rotor and
Flywheel (location B). If measurement A is
85623 greater than C, subtract C from A; the shim
FIGURE 1-5. pack is to be added between the Alternator
Housing and Engine Flywheel Housing (location
Measuring distance between the alternator D). Use a combination to shim within. 1 mm
housing and rotor. Refer to Figure 1-6. (.004 in). See Table 1 below.
If C > A: shim = C -A: shim at Rotor
If A> C: shim =A- C: shim at Housing

85624
FIGURE 1-6.

4 Alternator to Engine Assembly Checkout Procedure 58B-01-20100

 85625

FIGURE 1-7.

Table 1:
SHIM LOCATION QSK78 (SAE 00) QSK60 (SAE 0)
P/N- Alt. Hsg. To FW Hsg. EJ1056 (.004") EL3331 (.007")
Adaptor (Location D) EJ 1055 (.007") TM" 3468(007”)
TW6616 (.010")
P/N- Alt. Rotor to Flexdrive EL3332 (.004") TM3467 (.004")
(Location C) EL3331 (.007") TM3469 (.007")

19. Carefully move the alternator into place and Measurements after Joining the Alternator
engage the engine drive end and the alternator and Engine
rotor. 22. With the Magnetic base, or similar device,
20. Fasten the flywheel housing adapter to the mounted on the front of the engine and the
alternator and tighten bolts to 175ft lbs (131 N indicator on the front of the crankshaft, measure
M). the total crankshaft endplay. The total engine
crankshaft endplay must match the original
21. Install and torque the drive ring plate to
measurement taken in step 3 (before the
alternator rotor bolts to 175ft lbs.
alternator was installed). If the endplay after the
alternator and engine are assembled is less
than the original measurement. re-shimming is
required.
23. Total Crankshaft Endplay: ______ _

58B-01-20100 Alternator to Engine Assembly Checkout Procedure 5

 24. Remove the 5/8-11 x 4.5 bolts supporting the References
rotor from the alternator and save. 1. Cummins AEB 24.46
25. Rotate the crankshaft one full revolution and 2. Cummins Service Bulletin #4021669
listen for any unusual noise caused by moving
3. Siemens Operating and Maintenance Manual
components contacting stationary parts.
DRLDZ 501 0-8L
26. Reset and record Engine Fan Belt Tension 4. Komatsu Check Out Procedure XC1912-0
(860E with QSK60 and Siemens 510 Alternator)
Additional Engine Measurements (For
5. Komatsu Check Out Procedure EJ1062-2
Reference Only- Not Required For
Production Assembly): (QSK78, 930E-SE, 960E)
6. Komatsu Check Out Procedure EH0586
Reference Cummins AEB 24.46 and Cummins
(QSK60, 830E & 930E)
Service Bulletin 4021669
1. Engine Flywheel Housing Radial Runout Appendices
(Appendix 3) 1. Summary of Axial & Radial Runout Limits
2. Engine Flywheel/Flexplate Face Runout 2. Engine Flywheel Housing Face Runout
(Appendix 4)
3. Engine Flywheel Housing Radial Runout
3. Engine Flywheel/Flexplate Radial Runout
4. Engine Flywheei/Fiexplate Face Runout
(Appendix 5)
5. Engine Flywheei/Fiexplate Radial Runout
4. Attachment Shaft Radial Runout Measurement
(Appendix 6) 6. Attachment Shaft Radial Runout Measurement

Appendix 1

Summary of Axial & Radial Runout Limits in.(mm)

Description SAE 0 Flywheel (QSK60) SAE 00 Flywheel (QSK78)
Engine Endplay .005 (.13 mm) -.020 (.51 mm) .005 (.13 mm)-.020 (.51 mm)
Alternator Endplay (Siemens) 0.031 (.78 mm) 0.031 (.78 mm)
Alternator Endplay (GE) 0.020 (.51 mm) 0.020 (.51 mm)
FW Housing Radial Runout 0.010 (.25 mm) 0.012 (.30 mm)
FW Housing Face Runout 0.010 (.25 mm) 0.012 (.30 mm)
FW (Flywheel) Radial Runout 0.003 (.08 mm) 0.005 (.13 mm)
FW (Flywheel) Face Runout 0.035 (.89 mm) 0.040 (1.0 mm)
Rotor Shaft Radial Runout *0.005 (.13 mm) *0.005 (.13 mm)
(assembled)

*Cummins recent increase from .003". Increased limit for Komatsu taking into account probe mounting location.

6 Alternator to Engine Assembly Checkout Procedure 58B-01-20100

Appendix 2 Appendix 3

85626 85627

FIGURE 1-8. FLYWHEEL HOUSING FACE RUNOUT FIGURE 1-9. FLYWHEEL HOUSING FACE RUNOUT
MEASUREMENT MEASUREMENT

Flywheel Housing Radial Runout Flywheel Housing Radial Runout

Locate the dial indicator base on the machined face Locate the dial indicator base on the machined face
of the flywheel/flexplate and 0 the probe on the ID of of the flywheel/flexplate and 0 the probe on the ID of
the pilot bore of the flywheel housing. Using the the pilot bore of the flywheel housing. Using the
engine barring device, slowly rotate the engine crank engine barring device, slowly rotate the engine crank
through 2 full revolutions. When complete insure dial through 2 full revolutions. When complete insure dial
indicator returns to 0. The difference between the indicator returns to 0. The difference between the
highest and lowest values is the radial runout TIR. highest and lowest values is the radial runout TIR.
Limits are shown in the table below: Limits are shown in the table below:
Max Value mm (in) Max Value mm (in)
Cummins "0" Flywheel Housing 0.25 (0.010) Cummins "0" Flywheel Housing 0.25 (0.010)
Cummins "00" Flywheel Housing 0.30 (0.012) Cummins "00" Flywheel Housing 0.30 (0.012)
SAE Standard J617 0.48 (0.019) SAE Standard J617 0.48 (0.019)

58B-01-20100 Alternator to Engine Assembly Checkout Procedure 7

Appendix 4 Appendix 5

85628 85629

FIGURE 1-10. FLYWHEEL HOUSING FACE FIGURE 1-11. FLYWHEEI/FIEXPLATE RADIAL

RUNOUT MEASUREMENT RUNOUT MEASUREMENT

Flywheel/Flexplate Face Runout Flywheel/Flexplate Radial Runout

Locate the dial indicator base on the machined face Locate the dial indicator base on the machined face
of the flywheel housing and 0 the probe on the face of the flywheel housing and zero the probe on the ID
of the flywheel/flexplate. Using the engine barring of the flywheel/flexplate pilot bore. Using the engine
device, slowly rotate the engine crank through 2 full barring device, slowly rotate the engine crank
revolutions. When complete insure dial indicator through 2 full revolutions. When complete insure dial
returns to 0. The difference between the highest and indicator returns to 0. The difference between the
lowest values is the face runout TIR. Limits are highest and lowest values is the radial runout TIR.
shown in the table below: Limits are shown in the table below:

Max Value Max Value mm (in)

Cummins "0" Flywheel 0.001" x Measured Radius Cummins "0" Flywheel/Flexplate 0.13 (0.005)/0.08
(0.25 mm typ) (0.003)
Cummins "00" Flywheel 0.001" x Measured Radius Cummins "00" Flywheel/Flexplate 0.13 (0.005)
(0.30 mm typ)
SAE Standard J620 0.13 (0.005)
SAE Standard J620 0.0005" x Measured Radius
Max Value mm (in)
Cummins "0" Flexplate 0.89 (0.035)
Cummins "00" Flexplate 1 (0.040)
SAE Standard J620

8 Alternator to Engine Assembly Checkout Procedure 58B-01-20100

Appendix 6 1. Determine the point on the shaft with the
greatest radial runout.
Attachment Shaft Radial Runout 2. Place this at the top, or twelve o'clock position.
Measurement (See Figure 1-12)
3. Loosen the bolts attaching the driven member
Install and tighten the bolts attaching the driven to the flywheel/flexplate completely.
member to the engine flywheel housing. Attach at
4. Tighten the flywheel/flexplate bolts. This should
least four bolts from the driven member to the
allow the driven member to "center" itself and
flywheel/flexplate and tighten.
reduce runout
• Locate the base of the dial indicator on the side 5. Measure the radial runout. If the measurement
of the alternator housing. Insert the probe is less than the maximum allowed value, install
through radial port of the alternator housing until and torque the remainder of the flywheel/
just touching the flywheel/flexplate. The probe
flexplate attachment bolts and check the radial
should be zeroed on a clean, machined surface
of the flywheel/flexplate to measure radial runout runout.
6. If the measurement is greater than the
• Use the engine barring device to slowly rotate the
maximum allowed value, repeat steps 1 through
engine crankshaft through 2 full revolutions.
When complete, make sure the dial indicator 5, OR remove the flywheel bolts and, while
returns to zero. The difference between the holding the attachment stationary, rotate the
maximum and minimum values while rotating is engine crankshaft 30 degrees and attach the
the assembled radial runout. driven member to the flywheel/flexplate and
repeat steps 1 through 5.
• Assembled radial runout maximum value: 0.005
in. (.13 mm). If measured assembled radial
runout is less than the maximum allowed value,
install and torque the remaining bolts attaching
the driven member to the flywheel/flexplate and
flywheel housing. Check the assembled radial
runout to make sure it is still less than the
maximum allowed value.
• If assembled radial runout is greater than the
maximum value, perform the following steps:

58B-01-20100 Alternator to Engine Assembly Checkout Procedure 9

 Radial Measurement
Port

Dial Indicator

Air Wrench to bar engine

through barring hand
hole

85630
FIGURE 1-12.

10 Alternator to Engine Assembly Checkout Procedure 58B-01-20100

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

Install the Application Code

Before the Interface Module can be put to work, the
application code must be installed. Application code
must be matched to the truck model that the
Interface Module is installed on.

To get the necessary files and instructions, go to the

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

58B-06-03292 Interface Module Checkout Procedure 1

Interface Module I/O 9. Crank Sense (IM3-U) - Open the Start Battery
Disconnect switch so that there is no battery
Use the IM Realtime Data Monitor software to
voltage to the starters. Momentarily short TB28-
confirm the functionality of all IM inputs and serial
J to 24V and confirm state change (zero to
connections. The key switch must be on for all tests
one). After removing 24V short from TB28-J,
below.
close the Start Battery Disconnect switch.
Check Digital Inputs to the Interface Module 10. Selector Switch (Park) (IM3-T) - Place shifter
1. Hydraulic Tank Level (IM2-k) - Disconnect into park position and confirm 1 state then shift
connector CN712 at Hydraulic Tank Level into neutral and confirm 0 state. Return shifter
Sensor. Short pin C to ground momentarily and to park position.
confirm state change (one to zero). Reconnect 11. Selector Switch (FNR) (IM2-N) - Place shifter
CN712. into park position and confirm 0 state then shift
2. Low Steering Precharge (IM2-W) - This step into neutral, forward, and reverse and confirm 1
requires properly pre-charged steering state for each of these positions. Return shifter
accumulators. Disconnect one of the Low to park position.
Accumulator Precharge Switches momentarily 12. Strg Bleed Pressure Sw (IM2-Z) - Disconnect
and confirm state change (zero to one). connector SABS at the Steering Bleed Pressure
Reconnect switch. Switch and confirm state change (zero to one).
3. Pump Filter Switches (IM2-Y) - Disconnect Reconnect SABS.
connector CN730 at Steering Filter Pressure
13. Brake Lock Switch Power Supply (IM3-L) -
Switch momentarily and confirm state change
Ensure that shifter is in park position. Use GE's
(zero to one). Reconnect CN730.
wPTU software to turn on FWD True output
4. Park Brake Released (IM2-M) - Short wire 73S1 signal. Confirm state change (zero to one).
to ground at TB32-M momentarily and confirm Leave GE FWD True signal on until completion
state change (one to zero). of step 20.
5. Park Brake Request (IM3-V) - Short the engine 14. Brake Lock (IM2-i) - Actuate brake lock switch
oil pressure switch wire circuit 36 on TB28-A to and confirm state change (zero to one). Turn off
ground. Move shift lever from neutral to park GE FWD True signal. Confirm input state
position and confirm state change (one to zero). remains at one. Turn off brake lock switch.
Remove the ground from TB28-A. Confirm input state returns to zero. (The Brake
6. GE Batt + (IM3-M) - confirm this is a one. Lock Switch Power Supply test, item 19, must
7. Starter Motor 1 Energized (IM3-R) - Disconnect be completed before this test can be
wire 11SM1 from cranking motor to TB28-F at successfully completed). Turn off GE FWD True
TB28-F. Momentarily short TB28-F to 24V and signal.
confirm state change (zero to one). Reconnect 15. Service Brake Set sw (IM3-C) - Short wire 44R
disconnected wire. at TB35 - F to 24 volts momentarily and confirm
8. Starter Motor 2 Energized (IM3-S) - Disconnect state change (zero to one).
wire 11SM2 from cranking motor to TB28-G at
16. Cummins Shutdown Delay (1M3-F) -
TB28-G. Momentarily short TB28-G to 24V and
Disconnect wire 21 NSL from the Engine ECM
confirm state change (zero to one). Reconnect
at TB27-E leaving wire 21NSL to IM connected
disconnected wire.
at TB27-E. Momentarily short TB27-E to 24V
and confirm state change (zero to one).
Reconnect disconnected wire.

2 Interface Module Checkout Procedure 58B-06-03292

 17. Secondary Engine Shutdown sw (1M3-E) - 29. Brake Lock Degrade sw (IM2-V) - Short wire
Actuate the Secondary Engine Shutdown 33T to ground at TB32 - F momentarily and
switch and confirm state change (one to zero). confirm state change (one to zero).
18. Keyswitch (1M3-G) - confirm state is a one. 30. Keyswitch Direct (IM2 - P) - Confirm state is a
19. Mode sw1 (IM3-H) - Actuate the “left arrow” one. Turn keyswitch off for 1 second and then
LCD screen navigation switch and confirm state back on. Confirm state changes to zero and
change (one to zero). then back to one.

20. Mode sw2 (IM3-J) - Actuate the “OK” LCD 31. Auto Lube Level (IM3-W) - Disconnect
screen navigation switch and confirm state connector CN511 at the Auto Lube Low Level
change (one to zero). Switch, short pin C to ground momentarily and
confirm state change (one to zero). Reconnect
21. Mode sw3 (IM3-K) - Actuate the “down arrow” connector CN511.
LCD screen navigation switch and confirm state
change (one to zero) 32. Auto Lube Press sw (IM3-Y) - Short wire 68P to
ground at TB60-B momentarily and confirm
22. Mode sw4 (IM2-q) - Actuate the “up arrow” LCD state change (one to zero).
screen navigation switch and confirm state
change (one to zero). 33. Body Up sw (IM2-R) - For trucks without a body
installed yet, place washer on body proximity
23. Crank Request (IM2-j) - Open the Starter sensor, confirm state change, them remove
Disconnect switch so that there is no battery washer and confirm state change again. For
voltage to the starters. Momentarily turn truck with body installed, make sure that the
keyswitch to the crank position and confirm body is lowered down all the way, and then
state change (zero to one). momentarily disconnect wire 71 F at TB35 - S
24. Park Brake Set (IM2-f) - Momentarily disconnect and confirm state change (one to zero).
Park Brake Pressure switch, identified by circuit Reconnect disconnected wire.
33, and confirm state change (zero to one). 34. Dynamic Retard (IM3-Z) - Momentarily short
25. Seat Belt sw (1M2-g) - Buckle seat belt. Then wire 74ZA to ground at TB21-D and confirm
unbuckle seat belt and confirm state change state change (one to zero).
(zero to one). 35. No Propel/Retard (GE CPU Running) (IM2-n) -
26. Snapshot In - Progress (IM2-L) - Actuate the Confirm state is a zero. Turn off the GE
Data Store Switch. Confirm state change (one keyswitch. Confirm state changes to a one.
to zero). Turn GE keyswitch back on. Confirm state
changes to a zero once GE is booted back up
27. Low Steering Pressure sw1 (IM2-S) - Using a (see DID panel), which can take up to 45
back - probe, short wire 33F to ground at seconds.
connector CN14 pin 6 momentarily and confirm
state change (one to zero). Remove back - 36. Engine Air Filter (IM2-X) – Unplug Air
probe. Restriction Switch 2 (located on top of the
engine air intake pipe) and confirm state
28. Brake Accum Pressure sw (IM2-U) - change (zero to one). Reconnect Air Restriction
Momentarily short wire 33BP to ground at TB32 Switch 2.
- E. Confirm state change (one to zero).

58B-06-03292 Interface Module Checkout Procedure 3

Check Analog Inputs To The Interface Module 8. Left Rear Brake Oil Temp [C] (IM3-i) -
Disconnect left rear brake oil temp sensor and
Verify that the used analog inputs are in the range of
confirm fault A166, Hydraulic Oil Temp - Left
the values listed below.
Rear Sensor Low, is active. Reconnect sensor.
1. Truck Speed [kph] (IM1-gh) - Use GE DID to 9. Right Front Brake Oil Temp [C] (IM3-r) -
simulate vehicle speed and confirm reported Disconnect right front brake oil temp sensor and
speed matches vehicle speed set using GE confirm fault A169, Hydraulic Oil Temp - Right
DID+/ - 2 kph. Front Sensor Low, is active. Reconnect sensor.
2. Steering Pressure [kPa] (1M3-d) - Disconnect
10. Left Front Brake Oil Temp [C] (IM3-t) -
steering pressure sensor, identified by circuit
Disconnect left front brake oil temp sensor and
33SP, and confirm fault A204, Steering
confirm fault A168, Hydraulic Oil Temp - Left
Pressure Sensor Low, is active. Reconnect
Front Sensor Low is active. Reconnect sensor.
sensor.
Hoist Pressure 2 [kPa] (IM3-q) - Short wire
3. Ambient Air Temp [C] (1M3-e) - confirm 33HP2 to ground at TB28-K momentarily and
reported temperature matches ambient confirm fault A203, Hoist Pressure 2 Sensor
temperature within 3°C (5.4°F). Low, is active.
4. Fuel Level [%] (1M3-g) - confirm reported %
11. Hoist Pressure 2 [kPa] (IM3-q): Short wire
level matches actual fuel level in tank +/ - 5%.
33HP2 to ground at TB28-K momentarily and
5. 12V Converter [V] (1M3-h) - confirm reported confirm fault A203, Hoist Pressure 2 Sensor
voltage is 13.5V +/ - 0.5V. (24V Battery voltage Low, is active.
must be greater than 18 volts.)
12. Hoist Pressure 1 [kPa] (IM3-s) Short wire
6. Brake Pressure [kPa] (IM3-p) - Disconnect 33HP1 to ground at TB30 - N momentarily and
service brake pressure sensor located in brake confirm fault A202, Hoist Pressure 1 Sensor
cabinet, identified by circuit 33BPS, and confirm Low, is active.
fault A205, Brake Pressure Sensor Low, is
active. Reconnect sensor. 13. Battery Voltage 24V [V] (IMint) confirm reported
voltage is +/ - 1 volt of actual measured battery
7. Right Rear Brake Oil Temp [C] (IM3-m) -
voltage.
Disconnect right rear brake oil temp sensor and
confirm fault A167, Hydraulic Oil Temp - Right
Rear Sensor Low, is active. Reconnect sensor.

4 Interface Module Checkout Procedure 58B-06-03292

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

58B-06-03292 Interface Module Checkout Procedure 5

 S/N ___________________
IM Installation Checkout Checklist

Function Description Expected Result Result (OK/Fail) Comments

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

6 Interface Module Checkout Procedure 58B-06-03292

Function Description Expected Result Result (OK/Fail) Comments
27 - Low Steering Pressure 1 to 0
switch input
28 - Brake Accumulator 1 to 0
Pressure switch input
29 - Brake Lock Degrade 1 to 0
switch input
30 - Keyswitch Direct input 1 to 0 to 1
31 - Auto Lube Level switch 1 to 0 to 1
input
32 - Auto Lube Pressure 1 to 0
switch input
33 - Body Up switch input w/o body 0 to 1 to 0 with body
1 to 0
34- Dynamic Retard input 1 to 0
35 - No Propel/Retard input 0 to 1 to 0
(GE CPU Running)
36 - Engine Air Filter 0 to 1
ANALOG INPUT CHECKS:
1 - Truck Speed set speed+/ - 2 kph
2 - Steering Pressure fault A204
3 - Ambient Air Temp ambient temp+/ - 3C
4 - Fuel Level tank level+/ - 5%
5 - Converter Voltage 13.5 +/ - 0.5V (12V)
6 - Brake Pressure fault A205
7 - Right Rear Brake Oil fault A167
Temp
8 - Left Rear Brake Oil fault A166
9 - Right Front Brake Oil fault A169
Temp
10 - Left Front Brake Oil fault A168
Temp
11 - Hoist Pressure 2 fault A203
12 - Hoist Pressure 1 fault A202
13 - Battery Voltage 24V measured battery voltage
+/- 1V
SERIAL COMM CHECKS:
1 - CAN/11939, Drive no fault A184, A233, A237,
System CAN/RPC, Display A257
CAN/RPC, Payload
CAN/RPC
OUTPUT CHECKS:
1a - Park Brake Solenoid energized/de-energized
1b - Brake Lock Solenoid energized/de-energized in
park brake setting sequence

58B-06-03292 Interface Module Checkout Procedure 7

Function Description Expected Result Result (OK/Fail) Comments
2 - Start Enable output 24 V, OV
3 - IM On Signal output OV
4 - Electronic Dash Panel Items 4a-e function as
check described
5 - Steering Bleed Solenoid Solenoid de-energized then
output energized

Completed By: _________________________________________ Date: _______________________

8 Interface Module Checkout Procedure 58B-06-03292

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

Adjust Injector Settings

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

Lube Pump Start-up / Purging Procedure Timer

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

58F-90-00300 Automatic Lubrication System Checkout Procedure 1

 NOTES

2 Auto Lube System Checkout Procedure 58F-90-00300

 RESERVE OIL SYSTEM CHECKOUT PROCEDURE
NOTE: The following procedure must be done with 2. Start engine.
"auto fill option" on initial fill of the reserve system. 3. System should begin operation oil is circulated
between the engine oil pan and reserve oil tank.
AFC control start-up / fast fill procedure:
4. Watch the R2000DF pumping unit led indicator
1. Power up truck so that 24v is supplied to lights.
reserve AFC control box.
5. The running oil signal is steady (green led)
2. Remove the reserve oil fill cap to prevent it from when oil is transferring from the engine oil pan
dislodging during remote fill. to the oil reserve tank.
3. Connect Wiggins oil supply hose and turn on 6. If signal is flashing (green led) pump R2000DF
pressure. is receiving air from the engine oil pan (the
4. Energize AFC controls by pulling out power on running oil level is below the withdrawal point of
switch (top switch).Switch fast fill valve open- the pick up tube)- reserve pump should return
signal light should illuminate. oil back to the engine oil pan continuously
5. Push start button- valve open, when oil in the adjusting the running oil level and raising the oil
reserve tank reaches the proper level the switch level until air is no longer drawn by the reserve
mounted on top of the reserve tank will signal pump.
back to the AFC box and the fast fill valve will 7. Over a period of time both signals (solid i
close automatically and terminate filling of oil flashing of the led lights) should be seen; i.e.
reserve tank. The empty light should go out and there are some periods of steady signals and
the full light should come on. some periods of flashing signals. This verifies
6. Turn off pressure to hose. that the system is operating properly and the
engine oil level is correct.
7. Push start button for a couple of seconds to
relieve pressure in line. 8. If the red led is on this indicates that the pump
is not able to return oil to the engine oil pan
8. Disconnect fill hose.
either because the pump is not frozen) or
9. Turn off AFC power- push in “top switch”. because the reserve tank is empty.
10. Tank should be full with oil showing in all sight 9. Shut down the engine and allow adequate time
glasses but not overfull. for oil to drain down in the engine. Recheck the
NOTE: The following procedure must be done on oil level it should be between the normal marks
start-up of reserve system. (do not go above high static mark).
NOTE: Consult engineering if the engine oil level is
Reserve pump R2000DF start-up and led descrip-
too high or low.
tion:
1. Ensure that both engine and oil reserve tank oil
levels are at the correct level. Engine must be
full to static high mark on dipstick.

58F-90-00400 4/16 Reserve Oil System Checkout Procedure 1

 NOTES

2 Reserve Oil System Checkout Procedure 4/16 58F-90-00400

 AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
1. Keep A/C components sealed until prepared to e. Charge system with 3.5 kg (7.4 lbs) of 134a
charge system. The RPAG oil in compressor refrigerant.
and desiccant in receiver-drier both attract
f. Observe pressures and check for leaks.
moisture. Leaving components open will
contaminate the system. g. Set the fan on low speed and temperature
setting on maximum. Observe cab vent
2. At field erection the following steps need to be
outlet temperatures.
taken to make A/C system operational.
h. Check evaporator condensation drain line to
a. Add 250 ml (8.3 oz) of PC2279 PAG
see if water is draining properly.
lubricant to intle side of accumulator.
3. Refer to Shop Manual for recommended
b. Connect all hoses and components for A/C pressures, temperatures and troubleshooting
system. guide.
NOTE: Lubricate O-rings before assembly with 4. If checking or refilling of compressor oil is
mineral oil. required, drain and refill with 300 ml (10.1 oz) of
c. Evacuate system down to minimum of 737 PC2279 PAG oil.
mm (29 in) Hg for a minimum of 45 minutes.
d. Shut off vacuum pump and observe gauges.
System should hold a minimum vacuum of
711 mm (28 in) Hg for 15 minutes. If vacuum
does not hold, find and repair leak. Repeat
Step c.

EM4003-2 Air Conditioning System Checkout Procedure 1

 NOTES

2 Air Conditioning System Checkout Procedure EM4003-2

 980E-4 HYDRAULIC SYSTEM CHECKOUT PROCEDURE
General information on system checkout NOTE: Excessive internal leakage within the brake
circuit may contribute to problems within the steering
The hydraulic system checkout procedures are
circuit. Ensure that brake circuit leakage is not
intended to help the technician diagnose problems in
excessive before troubleshooting the steering circuit.
the steering and hoist circuits. The technician should
read the checkout procedures to become familiar The steering circuit hydraulic pressure is supplied
with the procedures and all the warnings and from the steering/brake pump and steering
cautions before performing any steps. The checkout accumulators. Some steering system problems, such
procedures begin by checking the basic system as spongy or slow steering or abnormal operation of
before checking individual components. the low steering pressure warning, can sometimes
be traced to internal leakage of steering components.
A data sheet is included in this section to record the
If internal leakage is suspected, perform the steering
test information obtained during the hydraulic system
component leakage tests outlined in this section.
checkout procedure. The data sheet is designed to
be printed or copied, then used during the checkout The steering circuit can be isolated from the brake
procedure. circuit by first releasing all steering system pressure,
then releasing all pressure from the brake
accumulators and removing the brake system supply
hose from the bottom of the bleeddown manifold.
Plug the hose and cap the fitting at the bleeddown
manifold to prevent high pressure leakage.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury,
and possibly death, if proper medical treatment
by a physician familiar with this type of injury is
not received immediately. If the steering pump has just been installed, it is
essential that the pump case is full of oil before
Relieve pressure before disconnecting any
starting the engine.
hydraulic lines. Tighten all connections securely
before applying pressure.

NOTE: The interface module (IM) checkout

procedure must be successfully completed and
engine startup must be possible before beginning the
checkout procedures.

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 1

Hydraulic system checkout procedures 4. Chock the rear tires.

Required equipment 5. Ensure that all personnel and equipment are

clear of the tires.
• Steering, hoist and brake cooling hydraulic circuit
schematic 6. Turn the steering wheel back and forth until it
can no longer be turned by hand.
• Service PC with Interface Module Realtime Data
Monitor software 7. Turn both brake accumulator bleed valves (1,
Figure 1) clockwise to bleed down the brake
• Five 35 000 kPa (5,000 psi) calibrated pressure accumulators.
gauges
8. Depress the brake pedal. The service brakes
• Three 24 000 kPa (3,500 psi) calibrated pressure should not apply and the service brake status
gauges
indicator should not illuminate.
• Two 690 kPa (100 psi) calibrated pressure
gauges
• A graduated container marked to measure liquid
volume in cubic inches or milliliters
2
Bleeddown procedure
Ensure that all pressure is removed from the
steering, brake and auxiliary hydraulic circuits before
performing any service work.
1. Park the truck on solid, level ground.
2. Place the hoist lever into the FLOAT position
and verify that the dump body is resting on the
frame.

1 1 83138

FIGURE 1. BRAKE MANIFOLD

The steering accumulator bleeddown solenoid is
energized by the interface module (IM) after the 1. Accumulator Bleed Valves
truck is stopped, the key switch is OFF, and the 2. Brake Manifold
engine is not running. The solenoid will remain
energized until the IM is shut down.

Do not engage the battery disconnect switch or

remove battery power from the truck in any
manner during the steering accumulator
bleeddown process. Steering pressure may
remain in the system, creating a personal injury
risk when hydraulic lines are opened.
3. Stop the engine by turning the key switch to the
OFF position. Wait for two minutes for the
steering accumulators to bleed down
completely.

2 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

 9. Install 35 000 kPa (5,000 psi) pressure gauges 11. To verify that the auxiliary accumulator is bled
in test ports "BR" (1, Figure 2) and "BF" (2) on down, press override switch (3, Figure 4) on
the junction manifold to the right of the brake automatic lubrication pump (1). The automatic
manifold. With the brake pedal depressed, the lubrication pump will not operate if the auxiliary
pressure at each test port should be at 103 kPa accumulator is bled down.
(15 psi) or less after the brake system has been
bled down.
1 2
2 1
3

86250

FIGURE 2. JUNCTION MANIFOLD

1. Test Port "BR"
2. Test Port "BF"

10. Open bleed valve (2, Figure 3) on auxiliary 86183

hydraulic manifold (3) to bleed down auxiliary
FIGURE 4. AUTOMATIC LUBRICATION SYSTEM
accumulator (1).

1. Automatic Lubrication 3. Override Switch

Pump 4. Hydraulic Motor
2. Manifold
1

12. Install a 35 000 kPa (5,000 psi) pressure

gauge in test port "GA" on the auxiliary
hydraulic manifold (3, Figure 3). The pressure
should be at 103 kPa (15 psi) or less after the
auxiliary hydraulic system has been bled down.
13. Install a 35 000 kPa (5,000 psi) pressure
gauge in test port "TP3" on the steering
bleeddown manifold. The pressure should be at
3 103 kPa (15 psi) or less after the steering
system has been bled down.
2 14. After the service work is completed, tighten all
hydraulic connections and close all bleed
valves.

86259
FIGURE 3. AUXILIARY HYDRAULIC MANIFOLD
1. Auxiliary Accumulator
2. Accumulator Bleed Valve
3. Auxiliary Hydraulic Manifold

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 3

Preliminary steps 6. An optional hose/needle assembly for manually
bleeding down the steering accumulators can
1. The steering accumulators, brake accumulators
be used. This hose/needle valve assembly is
and auxiliary system accumulator must have
only for convenience and is not required. It
the correct precharge and must be at normal
provides a way to manually bleed down both
operating temperature. Refer to Testing and
steering accumulators any time during the
adjusting section Accumulators and
checkout procedure.
suspensions for the accumulator charging
procedures. The assembly will consist of two 1/4” diameter
* Record on Data Sheet hoses connected to a needle valve. The hose
material can be 1/4” diameter SAE 100R2,
NOTE: For best performance, charge the which has 35 000 kPa (5000 psi) rating. The
accumulators in the ambient conditions in which the needle valve will allow simple opening/closing
machine will be operating. and must be rated for 27 500 kPa (4,000 psi) or
2. Install 35 000 kPa (5,000 psi) calibrated above. The length of the hoses is not critical
pressure gauges at the following locations: and can be selected to provide the best acces-
sibility to the needle valve. Connect the oppo-
a. steering pump test port "GPA" site ends of the hose/needle valve assembly as
b. bleeddown manifold test port "TP3" follows.
c. bleeddown manifold test port "TP2" a. Ensure that both steering accumulators and
both brake accumulators are bled down.
d. both steering cylinder manifold test ports
b. Remove the plug from #10 SAE boss port (1,
3. Install 24 000 kPa (3,500 psi) calibrated
Figure 5) located near bleeddown manifold
pressure gauges at the following locations:
port "TP3" (2). This port has the same
a. both hoist filter test ports pressure as the steering supply port and
b. overcenter manifold test port "TPD" ACC2 port and will allow both steering
accumulators to bleed down when the
needle valve is opened.
Also, install 690 kPa (100 psi) calibrated pres-
sure gauges at the following locations:
a. front brake cooling test port on the hoist
valve outlet 1
b. rear brake cooling test port on the brake
cooling/hoist return manifold

Hydraulic system flushing procedure

4. Install a jumper hose between the "QD Supply"
and "QD Return" ports on the bleeddown
manifold. The hose must be rated for at least 2
24 000 kPa (3,500 psi) in case the steering
system becomes fully pressurized. However,
the pressure a during the flushing procedure
should be less than 3 500 kPa (500 psi).
5. Use two flushing blocks (PC3074) to join the
piston end and rod end hoist cylinder hoses if
not already assembled.

84722

FIGURE 5. BLEEDDOWN MANIFOLD

1. #10 SAE Boss Port
2. Port "TP3"

4 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

 c. Connect one end of the hose/needle valve 7. If brakes are not installed, connect brake
assembly to the #10 SAE boss port. cooling supply and return hoses together for
this entire checkout procedure. Service brake
d. Remove the plug in brake manifold port "T3"
and parking brake hoses must be fitted with
(1, Figure 6). This port will return oil that is
steel plugs rated for 27 500 kPa (4000 psi) or
bled from the steering accumulators to the
higher during this checkout procedure.
hydraulic tank.
8. Disconnect or disable all auxiliary hydraulic
systems (auto lube, retractable ladder, radiator
shutters, etc) that may be present on the truck.
9. Fill the steering pump case through case drain
port with clean hydraulic oil.
An alternate method to filling the pump case
with oil is by leaving case drain hose connected
and removing small SEA #6 plug marked "PRG"
near the case drain port on top of the pump.
This will vent air from the pump case if the
hydraulic tank is filled with oil. Install and tighten
the plug when oil appears.
1
NOTE: Filling the pump case with oil does not
eliminate the need for bleeding air from the pump
84723 suction line as described in step 11. Both must be
done.
FIGURE 6. BRAKE MANIFOLD
10. Fully open all pump suction line shutoff valves.
1. Port T3 Valves are fully open when the handle is in line
with the hose.

e. Connect hose/needle valve assembly to port

"T3".
f. Retain the plugs that were removed from the
manifolds for replacement when the hose/ Serious pump damage will occur if any shutoff
needle valve assembly is removed. valve is not fully open when the engine is started.
NOTE: Use of optional bleeddown hose/needle valve
assembly does not substitute for the use of jumper 11. Fill hydraulic tank with hydraulic oil to upper
hose installed in step 4. sight glass.
12. Bleed the air from all pump suction lines by
loosening each suction hose at the pump inlet.
Ensure that the O-ring does not fall out of the
groove. When oil appears, retighten the
capscrews.
This hose/valve assembly cannot be connected
or disconnected if the steering accumulators are NOTE: Bleeding the piston pump suction line does
pressurized. not eliminate the need for filling the piston pump case
with oil as described in step 9. Both must be done.
13. Check that the oil level in the hydraulic tank is
The hose/needle valve assembly must be removed still visible in the upper sight glass. Add oil if
when the checkout procedure is completed. The necessary.
original plugs must be installed in the manifold ports
and tightened to the proper torque. 14. Place the hoist control lever in the FLOAT
position.
15. It may be necessary at any time during this
checkout procedure to stop the engine and

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 5

 allow the steering accumulators to bleed down. Start the engine and operate at low idle for no
Steering pressure at bleeddown manifold test more than 30 seconds. At low idle with 21°C
port "TP3" will be 103 kPa (15 psi) or less after (70° F) oil, pressure at the hoist filters should be
a successful bleed down. The pressure gauge approximately 552 kPa (80 psi). Pressure at
installed in bleeddown manifold port "TP3" will steering pump test port "GPA" should be
show the steering accumulator pressure. approximately 689 kPa (100 psi). Pressure at
the front and rear brake cooling test ports
Refer to step 6 if an optional manual method of
should be approximately 172 kPa (25 psi) or
bleeding down the steering accumulators is
less.
desired when performing this checkout proce-
dure.

Do not operate at low idle for more than 30

seconds. Steering pump pressure at test port
If the warning indicator is illuminated, the buzzer "GPA" needs to be at or above 1 724 kPa (250 psi)
is sounding and the steering pressure status during the flushing process to provide adequate
indicator is flashing, do not attempt to remove pump internal lubrication. Steering pump
any hydraulic hose, fitting, plug, switch, etc. damage will result if pressure is below 1 724 kPa
Hydraulic pressure may be trapped. (250 psi). This also applies to steps 17-20.

If fault code A236 is shown on the message

NOTE: Do not turn the steering wheel until step 21.
display, the steering accumulators did not
Do not apply the brakes at any time during this
properly bleed down.
checkout procedure.
Locate and correct any steering accumulator 17. With engine at a speed that is fast enough to
bleeddown problem before proceeding. provide at least 1 724 kPa (250 psi) at steering
pump test port "GPA", move the hoist lever to
the POWER UP or POWER DOWN position.
16. Turn the key switch to ON but do not start the
The front and rear brake cooling oil supply
engine. Verify that the low steering accumulator
pressures should be 0 kPa (0 psi) when the
precharge warning (fault A115) is not displayed.
hoist lever is in POWER UP or POWER DOWN,
If the warning is displayed, correct the problem
This confirms that the hoist valve is functioning
before starting engine.
properly.
* Record on Data Sheet
If the pressures do not drop to 0 kPa (0 psi), the
NOTE: The brake accumulators and the auxiliary hoist valve may be plumbed incorrectly. Stop
system accumulator do not have pressure switches the checkout procedure and check all plumbing,
to warn for low precharge, but they must be including all pilot lines. If there is a plumbing
precharged to 9 653 kPa (1,400 psi) before starting error, repeat this step again. If no plumbing
the engine. Do not start the engine without ensuring error was found or if the pressures still do not
that all accumulators are precharged to 9 653 kPa drop to 0 kPa (0 psi), replace the hoist valve
(1,400 psi). and repeat this step again.

6 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

 18. If all pump pressures and brake cooling oil If the pressure reaches 24 300 kPa (3,525 psi):
supply pressures are as stated in steps 16 and a. The first time through this step:
17, increase engine to 1500 rpm and flush the
system for 20 minutes. During this time, move • Stop engine by leaving the key switch ON
the hoist lever to POWER UP for 30 seconds. and pulling up the engine shutdown switch
Then move the hoist lever to POWER DOWN on the center console. Confirm that
for 30 seconds. Continue to monitor the brake steering accumulator bleed down does not
occur and that no bleeddown faults are
cooling oil supply pressures. The oil supply
generated.
pressure should be 345 kPa (50 psi) or less
when the hoist lever is in HOLD or FLOAT and * Record on Data Sheet
drop to 0 kPa (0 psi) when the hoist lever is in • Turn the key switch OFF and confirm that
POWER UP or POWER DOWN. steering accumulator bleed down begins.
Confirm that bleed down is completed
Cycle the hoist lever as stated above five times.
normally within 90 seconds and that fault
A236 “Steering Bleed Fault” is not active.
Steering pressure at bleeddown manifold
19. After flushing is complete, stop the engine and test port "TP3" will be 103 kPa (15 psi) or
allow steering accumulators to completely less after a successful bleed down.
discharge. Remove the special flushing
* Record on Data Sheet
plumbing. If the optional steering accumulator
hose/needle valve assembly was installed in Continue to step 20c.
step 6, leave it installed. Reconnect all original
b. For the second and all other times through
plumbing. Check that oil is visible in upper sight
step 20, turn the key switch OFF and allow
glass on hydraulic tank. Add oil if necessary.
the steering accumulators to bleed down.
NOTE: If the brakes are not installed, leave the brake The steering pressure at bleeddown
cooling supply and return hoses connected together manifold test port "TP3" will be 103 kPa (15
during this entire checkout procedure. psi) or less after a successful bleed down.
* Record on Data Sheet

NOTE: Step 20 cannot be combined with the flushing c. Open the brake accumulator bleed valves on
procedure in steps 16-18. This flushing procedure the brake manifold and allow the brake
must be performed after step 19 is completed. accumulators to fully bleed down. Open the
bleed valve on the auxiliary hydraulic
NOTE: Do not steer or apply the brakes at any time manifold to bleed down the auxiliary
during step 20. accumulator. Close the bleed valves.
20. Flush the accumulators by starting the engine d. Perform step 20 five times.
and operating until the accumulator pressure is
approximately 24 300 kPa (3,525 psi) when the
unloader valve shifts and unloads the steering 21. After flushing all of the accumulator, the steering
pump. If the pressure will not reach 24 300 kPa system must be flushed. Start the engine. Allow
(3,525 psi), refer to the pump adjustment the accumulators to fully charge and the
procedure in step 26. steering pump to unload. turn the steering
wheel fully to the left and right at least 10 times.
Stop the engine and allow the steering
accumulators to bleed down completely. Add oil
to the hydraulic tank if necessary.

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 7

Flow amplifier adjustment Steering pump unloader valve adjustment
22. In preparation for the steering shock valve 26. The steering pump unloader valve should
checkout, adjust the unloader valve on the unload the pump at a nominal pressure of
steering pump by turning the unloader valve 24 300 kPa (3,525 psi) and reload the
adjustment screw clockwise until a minimum accumulators when the pressure at bleeddown
reload pressure of 25 325 ± 172 kPa (3675 ± 25 manifold port "TP2" falls to 22 240 ± 172 kPa
psi) is measured at bleeddown manifold port (3225 ± 25 psi). The reload pressure is the
"TP2". The unload pressure will be critical pressure to obtain.
approximately 27 400 kPa (3975 psi).
If the pump operates as described, proceed to
Turn the steering wheel to verify that at least the end of this step to record pressures. If not,
25 150 kPa (3650 psi) is maintained. This is adjust the unloader valve as follows:
acceptable pump performance for this part of
a. Install a calibrated multiple range pressure
the checkout procedure.
gauge capable of 35 000 kPa (5,000 psi) at
NOTE: The pump adjustment in this step is to be steering pump test port "GPA".
used only for checking the steering shock valves. It is b. Install a calibrated pressure gauge capable
not intended for normal truck operation. Refer to step of 35 000 kPa (5,000 psi) in bleeddown
26 when adjusting the pump for normal truck manifold test port "TP2".
operation.
c. Fully open all pump suction shutoff valves.
23. Before checking the steering shock valves,
raise the steering relief valve pressure setting. d. Remove the unloader valve adjuster cap and
Remove the external access plug on the flow completely back out the adjustment screw.
amplifier, then turn the internal adjustment e. Start the engine and allow the steering pump
screw clockwise to gently bottom out the relief to unload. When unloaded, the pressure at
valve. steering pump test port "GPA" will be 1 380 -
24. To check the steering shock valve pressure 2 760 kPa (200 - 400 psi).
settings, turn the steering wheel away from the f. Adjust the unloader valve to reload the
cylinder stops, then turn the steering wheel fully accumulators when the pressure at
into a stop and continue to turn the steering bleeddown manifold test port "TP2" falls to
wheel. One gauge on the steering cylinder 19 133 ± 172 kPa (2,775 ± 25 psi). The
manifold should read 24 000 ± 1000 kPa (3480 unload pressure will be approximately
± 145 psi). 21 200 kPa (3,075 psi), but the reload
Turn the steering wheel into opposite stop. The pressure is the critical pressure to obtain.
other gauge on the steering cylinder manifold NOTE: If adjusting after step 20, do not turn the
should read 24 000 ± 1000 kPa (3480 ± 145 steering wheel to make the accumulator pressure
psi). fall. The bleed valves on the brake manifold can be
* Record on Data Sheet opened partially to slowly bleed down the steering
accumulator pressure to allow the pump to cycle
25. After checking the steering shock valve
every 20-30 seconds while adjusting the unloader
pressure settings, lower the steering relief valve
valve.
pressure setting to 20 685 -207/+827 kPa (3000
-30/+120 psi). Turn the steering wheel fully to g. Tighten the adjustment cap and verify that
the left or right into a stop, then adjust the the pressures remain as adjusted. If the
steering pressure at the flow amplifier while reload pressure is 22 065 - 22 400 kPa
slowly turning the steering wheel into the stop. (3,200 - 3,250 psi) as the pump is cycling,
When the appropriate gauge at the steering the pump is properly adjusted. Close the
cylinder manifold reads the correct pressure, bleed valves.
replace the external access plug on the flow * Record on Data Sheet
amplifier. Tighten the plug to the proper torque.
h. If the pump is being adjusted from step 20,
* Record on Data Sheet return to step 20 now and flush the
accumulators without turning the steering
wheel.

8 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

Auxiliary accumulator pressure verification f. With the auxiliary accumulator bleed valve
open, verify that the pressures at test ports
27. The auxiliary accumulator supply valve closes
"TP2" and "TP3" remain above 16 550 kPa
when the steering system supply pressure falls
(2400 psi) for at least five minutes after the
below the minimum required for proper system
auxiliary accumulator is bled down to 103
operation. Oil that is consumed by any auxiliary
kPa (15 psi) or less. If either of the steering
systems is not replaced below this pressure.
accumulator pressures at test port "TP2" or
The supply valve closing pressure is the critical
"TP3" falls or the pressure at auxiliary
pressure to verify. Maximum auxiliary pressure
hydraulic manifold test port “GA” rises,
is equal to the steering pump unload pressure
correct the problem and return to step 27b.
and is not independently adjustable.
* Record on Data Sheet
The auxiliary accumulator supply valve is
located on the auxiliary hydraulic manifold. It is g. Close the bleed valve on the auxiliary
controlled by a non-adjustable pressure switch hydraulic manifold.
in the steering bleeddown manifold. Verify the
auxiliary accumulator supply valve closing pres- System diagnostics
sure as follows: 28. Start the engine to charge the steering
a. Install calibrated 35 000 kPa (5,000 psi) accumulators to at least 22 065 kPa (3200 psi).
pressure gauges in auxiliary hydraulic To prevent the accumulators from bleeding
manifold test ports “GA” and "GP1". down, leave the key switch ON and pull up the
engine shutdown switch on the center console
NOTE: Test port “GP1" is connected directly to to stop the engine.
steering bleeddown manifold test port "TP2". For the
29. Set the wheel speed on the DID panel to 1.0
sake of convenience, "GP1" pressure readings may
kPa. Slowly open the brake accumulator bleed
be used instead of "TP2" pressure readings.
valve on the brake manifold. Observe the
b. Start the engine and allow the steering pump pressure at steering bleeddown manifold test
to unload. Continue to operate the engine at port "TP2" when the buzzer sounds and low
low idle for at least three minutes to allow the steering pressure fault code A247 appears on
accumulator temperatures to stabilize. The the dash panel message display. The fault
pressures at steering bleeddown manifold should occur at a falling pressure of 15 860 ±
test ports "TP2" and "TP3" and auxiliary 420 kPa (2300 ± 61 psi). If outside this range,
hydraulic manifold test port “GA” should be correct the problem.
at least 22 065 kPa (3,200 psi).
* Record on Data Sheet
c. To prevent the accumulators from bleeding
NOTE: Step 30 may be skipped if no excessive
down, leave the key switch ON and pull up
leakage in the steering system is suspected.
the engine shutdown switch on the center
console to stop the engine. 30. To check for leakage in the steering system:
d. Slowly open the bleed valve on the auxiliary a. Disconnect the flow amplifier return hose at
hydraulic manifold. the steering bleeddown manifold and plug
the fitting on the manifold. Disconnect the
e. Observe the pressure at steering bleeddown
steering control unit return hose at the flow
manifold test port "TP2" at which the supply
amplifier and plug the port.
valve closes and the pressure at auxiliary
hydraulic manifold test port “GA” falls below b. Start the engine. Allow the steering
the pressure at "TP2". The supply valve accumulators to fully charge and the steering
should close at a falling pressure of 17 580 pump to unload. Do not turn the steering
+690/-345 kPa (2550 +100/-50 psi). If wheel while the return hoses are
outside this range, correct the problem and disconnected.
return to step 27b.
* Record on Data Sheet

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 9

 c. Measure the leakage from the flow amplifier
and the steering control unit.
• Leakage from the flow amplifier should not
exceed 820 mL (50 in.3) per minute. If
leakage is excessive, replace the flow In the next step, DO NOT use the key switch to
amplifier. shut off the engine. If the key switch is turned
OFF, all accumulator oil will be discharged
• Leakage from the steering control unit
through the open port on the bleeddown
should not exceed 164 mL (10 in.3) per manifold. If the hose/needle valve assembly was
minute. If leakage is excessive, replace the
installed in step 6, use this method to bleed down
steering control unit.
the steering accumulators after leakage is
* Record on Data Sheet measured. If not, the same hose/needle valve
NOTE: Step 31 may be skipped if no excessive assembly can be made and connected between
leakage in the steering bleeddown manifold is bleeddown manifold test port "TP3" and the
suspected. hydraulic tank fill tube. Both steering
accumulators will be bled down when test port
31. To check for leakage in the steering bleeddown "TP3" is opened to the tank.
manifold:
c. Start the engine and allow the steering pump
a. Disconnect the flow amplifier return hose at to unload. Measure the leakage from the
the steering bleeddown manifold and plug tank return port in the steering bleeddown
the fitting on the manifold. Disconnect the manifold. Leakage from the tank return port
steering control unit return hose at the flow
amplifier and plug the port. Disconnect the should not exceed 541 mL (33 in.3) per
tank return hose at the steering bleeddown minute.
manifold. * Record on Data Sheet
32. Reconnect all hoses to the steering bleeddown
manifold.
NOTE: Step 33 may be skipped if no excessive
The hydraulic tank oil level is above the level of leakage in the brake system or auxiliary hydraulic
the tank return line. It is necessary to draw a system is suspected.
vacuum on the hydraulic tank to prevent a large 33. To check for leakage in the brake system and
amount of oil from draining from the tank with auxiliary hydraulic system:
the return line disconnected from the bleeddown
manifold. a. Install pressure gauges at brake manifold
ports "AF3" and "AR3" and at auxiliary
b. Disconnect the hoist pilot valve return hose hydraulic manifold test port “GA”.
at the steering bleeddown manifold and plug
the port. Connect the tank return hose to the b. Start the engine and allow the steering pump
hoist pilot valve return hose, or plug the tank to unload. Continue to operate the engine at
return hose and vent the hoist pilot valve low idle for at least three minutes to allow the
return hose to the tank. Do not plug the accumulator temperatures to stabilize. Do
hoist pilot valve return hose. not operate the service brakes during this
step.
c. With the steering accumulators charged to at
least 22 065 kPa (3,200 psi), turn the key
switch OFF and wait two minutes for the
steering accumulators to bleed down.
d. The pressure gauges at brake manifold ports
"AF3" and "AR3" and at auxiliary hydraulic
manifold test port “GA” should remain above
20 685 kPa (3,000 psi).
* Record on Data Sheet

10 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

 e. Wait 20 minutes, then record each Hoist counterbalance valve adjustment
accumulator pressure again. Note any
NOTE: Skip step 38 if the dump body is not installed.
changes.
* Record on Data Sheet
• Each pressure gauge at brake manifold
ports "AF3" and "AR3" must be less than 38. To adjust the hoist counterbalance valve on the
2 275 kPa (330 psi). This is a loss of 6 900 overcenter manifold, the dump body must be
kPa (1,000 psi) per hour. empty and the hoist cylinder hoses must be
connected to the hoist valve.
• The pressure gauge at auxiliary hydraulic
manifold test port “GA” must be less than a. Move the hoist lever to the FLOAT position
207 kPa (30 psi). This is a loss of 690 kPa and lower the body to the frame, or secure
(100 psi) per hour. the raised body with the proper body
* Record on Data Sheet retention cable or sling. Stop the engine.
f. Remove the pressure gauges from ports b. Loosen the locknut on the needle valve
"AF3", "AR3" and "GA". adjustment stem, then turn the adjustment
stem inward. This will block the hoist cylinder
34. Disconnect and cap the four hoses from the
head pressure from the counterbalance
hoist cylinders.
valve pilot.
35. Start the engine and raise the engine speed to
c. Remove the plug from the "PILOT VENT"
high idle. Move the hoist lever to POWER UP.
port on the overcenter manifold. This will
The pressure gauges at the hoist filters should
vent the counterbalance valve pilot to
read 18 960 ± 690 kPa (2 750 ± 100 psi) at high
atmosphere.
idle.
* Record on Data Sheet NOTE: Do not allow dirt or debris to enter the open
pilot vent port. A clean SAE # 4, 1/4" hydraulic hose
36. Move the hoist lever to POWER DOWN. The can be installed in the port and pointed downward to
pressure gauge at overcenter manifold test port help prevent entry of contaminants.
"TPD" should read 10 340 ± 515 kPa (1 500 ±
75 psi) at high idle. d. Install a calibrated pressure gauge at
overcenter manifold test port "TR". The
* Record on Data Sheet gauge will measure hoist cylinder rod end
37. Move the hoist lever to FLOAT to reduce the pressure, which is the pressure controlled by
pressure in the hoist cylinder hoses. Turn the the counterbalance valve.
key switch OFF to stop the engine. Vent the
NOTE: If adjustment of the counterbalance valve is
residual hoist cylinder hose pressure and
anticipated, skip verification step 38e and proceed to
remove the caps from the hoses. Reconnect the
step 38f.
four hoses to the hoist cylinder.
NOTE: If the dump body is secured in the raised
position, remove the body retention cable or sling.
e. Start the engine and operate at low idle.
Move the hoist lever to POWER UP until the
hoist cylinders are in the third stage and
observe the pressure gauge at overcenter
manifold test port "TR".
• If the pressure is 20 685 kPa (3,000 psi) or
higher, stop raising the dump body
immediately. The pressure setting is too
high and must be lowered. Repeat step
38a, then go to step 38f.

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 11

 • If the pressure is below 20 685 kPa (3,000 Final steps
psi), increase the engine speed by
39. Reconnect or enable any auxiliary hydraulic
approximately 300 rpm and repeat step
38e. Continue testing the pressure setting systems on the truck (auto lube, hydraulic
at increasing 300 rpm intervals until high ladder, radiator shutters, etc).
idle is reached. 40. Perform the individual checkout procedures for
The counterbalance valve pressure must be any auxiliary hydraulic systems.
20 685 kPa (3,000 psi) when the hoist lever is in 41. If the optional hose/needle valve assembly was
POWER UP, the engine is at high idle and the installed in steps 6 or 31, bleed down all of the
hoist cylinder is in the third stage. accumulators, then remove the hose/needle
• If the pressure is correct, repeat step 38a, valve assembly and any associated fittings.
then go to step 38i. Install the port plugs and tighten them to the
proper torques.
• If the pressure does not reach 20 685 kPa
(3,000 psi), step 38a, then go to step 38f. 42. Remove all pressure gauges that were installed
during the checkout procedure.
f. Loosen the locknut on the counterbalance
valve adjustment stem. Turn the adjustment Oil cleanliness check
step fully clockwise to lower the pressure as
much as possible. 43. Before the truck can be put into service, the
cleanliness of the hydraulic oil must be
NOTE: If the dump body is secured in the raised checked. Use the quick disconnect coupling at
position, remove the body retention cable or sling. either hoist filter test port to attach a hose and
g. Start the engine and operate at high idle. obtain an oil sample. Do not use the steering
Move the hoist lever to POWER UP until the filter test port. Do not use a hose that has
hoist cylinders are in the third stage. Adjust been previously used for system flushing.
the counterbalance valve adjustment stem a. The hydraulic system checkout procedure
as needed to obtain a reading of 20 685 kPa must be completed before taking an oil
(3,000 psi) at overcenter manifold test port sample.
"TR".
b. Start the engine and operate at high idle for
NOTE: Turning the adjustment stem clockwise at least ten minutes. Do not operate the
decreases the pressure. Turning the adjustment steering, hoist, brakes or any other hydraulic
stem counterclockwise increases the pressure. The function during the oil sampling procedure.
entire range of the adjustment stem is three turns.
c. Take particle count readings for at least 20
* Record on Data Sheet minutes without changing the engine speed.
h. Repeat step 38a. d. When the particle count level is at or below
i. Install the plug in the "PILOT VENT" port on ISO 21/18/15 standard and is showing a
the overcenter manifold and tighten it to the trend of improving cleanliness or at least
proper torque. maintaining the ISO 21/18/15 standard, the
hydraulic oil meets the acceptable criteria for
j. Turn the needle valve adjustment stem fully
cleanliness.
outward, then tighten the locknut. This
needle valve must be fully open for normal e. If the particle count level of the ISO 21/18/15
hoist operation. standard is not achieved within 20 minutes,
continue operating the engine at high idle
k. Remove the pressure gauge from overcenter
until the conditions in step 43d are achieved.
manifold test port "TR".
* Record on Data Sheet
44. Replace all hydraulic filter elements before the
truck is put into service. Note the service hour
meter reading.
* Record on Data Sheet

12 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

Hydraulic system checkout data sheet
** Acceptable values of each measurement are shown in (parenthesis).

Machine Model____________Unit Number ____________ Serial Number ____________

1e. Steering and brake accumulator precharge pressures:
Front steering accumulator, ACC1 (1400 ± 10 psi at 70º F) ___________ at _______
Rear steering accumulator, ACC2 (1400 ± 10 psi at 70º F) ___________ at _______
Front brake accumulator, AF1 (1400 ± 10 psi at 70º F) ___________ at _______
Rear brake accumulator, AR1 (1400 ± 10 psi at 70º F) ___________ at _______

16. Was low steering accumulator precharge warning A115 displayed before start-up? (circle one)
(No) YES NO

20. Pressure at bleeddown manifold test port TP3:

a.) Does bleed down occur when stopping with engine shutdown switch? (circle one)
(No) YES NO
Pressure at port “TP3” (approximately 3075 psi) ___________
Faults (none) ___________
Pressure at port TP3 and faults after each bleeddown cycle:
1st Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
2nd Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
3rd Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
4th Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
5th Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________

24. Flow amplifier shock valve pressures:

Left shock valve pressure (3480 ± 145 psi) ___________
Right shock valve pressure (3480 ± 145 psi) ___________

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 13

25. Flow amplifier relief valve pressure: (3000 -30/+120 psi) ___________

26g. Steering pump reload pressure: (3225 ± 25 psi) ___________

Steering pump unload pressure: (3525 psi nominal) ___________

27e. Auxiliary accumulator supply valve closing pressure: (2550 +110/-50 psi) ___________

27f. 5 minutes after auxiliary accumulator bleeddown:

Front steering accumulator pressure, TP2 (> 2400 psi) ___________
Rear steering accumulator pressure, TP3 (> 2400 psi) ___________
Auxiliary accumulator pressure, GA (15 psi or less) ___________

29. Pressure when low steering pressure fault A247 occurs: (3000 ± 61 psi) ___________

30. Was steering system leakage checked? (circle one) (Yes) YES NO

Flow amplifier leakage (< 50 in.3/ min.)___________

Steering control unit leakage (< 10 in.3/ min.)___________

31. Was steering bleeddown manifold leakage checked? (circle one) (Yes) YES NO

Steering bleeddown manifold leakage (< 33 in.3/ min.)___________

33d. After steering accumulator bleeddown:

Front brake accumulator pressure, AF3 (> 3000 psi) ___________
Rear brake accumulator pressure, AR3 (> 3000 psi) ___________
Auxiliary accumulator pressure, GA (> 3000 psi) ___________
33e. 20 minutes after steering accumulator bleeddown:
Front brake accumulator pressure, AF3 (< 330 psi below 33d) ___________
Rear brake accumulator pressure, AR3 (< 330 psi below 33d) ___________
Auxiliary accumulator pressure, GA (< 10 psi below 33d) ___________

35. POWER UP pressure at hoist filter: (2750 ± 100 psi) ___________

36. POWER DOWN pressure at overcenter manifold, TPD: (1500 ± 75 psi) ___________

14 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

38. Was dump body installed? (circle one) (Yes) YES NO

If dump body is installed, what is the final pressure of the counterbalance valve at
overcenter manifold port TR with hoist cylinders at third stage
(3000 ± 100 psi) ___________

43. Hydraulic fluid cleanliness level after 10 minutes at high idle:

(ISO 21/18/15 or lower)___________

Particle counter printout attached to these sheets? (circle one) (Yes) YES NO

44. Service meter reading (SMR) when filter elements were replaced:
Brake filter (hours) ___________
Front hoist filter (hours) ___________
Rear hoist filter (hours) ___________
Steering filter (hours) ___________

Name of Technician or Inspector Performing Checkout: _________________________

Badge number: ________________________

Date & shift completed:

58B-60-20400 4/16 980E-4 Hydraulic System Checkout Procedure 15

 NOTES

16 980E-4 Hydraulic System Checkout Procedure 4/16 58B-60-20400

 980E-4 BRAKE SYSTEM CHECKOUT PROCEDURE
General information on system checkout Brake system checkout procedures
The brake system checkout procedures are intended
to help the technician diagnose problems in the
brake circuits. The technician should read the entire
checkout procedure to become familiar with the
procedures and all the warnings and cautions before
The steering system supplies the brake system
performing any steps. The checkout procedures
with operating pressure. Therefor, the steering
begin by checking the basic system before checking
system must be checked for proper operation
individual components.
before checking the brake systems. Successfully
A data sheet is included in this section to record the complete the hydraulic system checkout
test information obtained during the brake system procedure before performing the brake system
checkout procedure. The data sheet is designed to checkout procedures.
be copied and used during the checkout procedure.
This section outlines a procedure to test the
functionality of the entire brake system. Pressure
specifications and other criteria that must be
duplicated for the braking system to be considered
ready for daily operations are provided.
Hydraulic oil escaping under pressure can have The steering circuit can be isolated from the brake
sufficient force to enter a person's body by circuit by first releasing all steering system pressure,
penetrating the skin and cause serious injury, then releasing all pressure from the brake
and possibly death, if proper medical treatment accumulators and removing the brake system supply
by a physician familiar with this type of injury is hose from the bottom of the bleeddown manifold.
not received immediately. Plug the hose and cap the fitting at the bleeddown
Relieve pressure before disconnecting any manifold to prevent high pressure leakage.
hydraulic lines. Tighten all connections securely
Required equipment
before applying pressure.
• Brake hydraulic circuit schematic
• Service PC with Interface Module Realtime Data
NOTE: The interface module (IM) checkout Monitor software
procedure must be successfully completed and
engine startup must be possible before beginning the • Accumulator charging kit (EB1759 or equivalent)
checkout procedures. with gauges and dry nitrogen
• Four 24 100 kPa (3,500 psi) pressure gauges
• Clear plastic hose and bucket for brake bleeding
NOTE: If the brakes are not assembled on the truck,
brake simulators will be required.

58B-60-20410 980E-4 Brake System Checkout Procedure 1

 2

3 8
9

7 4
DETAIL A DETAIL B
6 5

A
B
86261

FIGURE 1. HYDRAULIC BRAKE CABINET - TEST PORTS AND VALVES

1. Low Accumulator Pressure Test Port "LAP1" 6. Parking Brake Solenoid Valve "SV2"
2. Parking Brake Release Pressure Test Port "PK3" 7. Auto Apply Sequence Valve "PS1"
3. Brake Lock Apply Pressure Test Port "PP3" 8. Front Brake Pressure Test Port "BF"
4. Pressure Reducing Valve "PR" 9. Rear Brake Pressure Test Port "BR"
5. Brake Lock Solenoid Valve "SV1"

2 980E-4 Brake System Checkout Procedure 58B-60-20410

Initial system setup 6. Slowly depress the brake pedal. Rear brake
pressure "BR" should begin to rise before front
NOTE: Configure the DID panel to metric units. The
brake pressure "BF". Verify that the rear brake
truck must remain in PARK and at zero ground speed
pressure is 310 - 1415 kPa (45 - 205 psi) when
unless otherwise noted.
the front brake pressure begins to rise.
NOTE: Securely block the tires to prevent the truck * Record on Data Sheet
from rolling away.
7. Slowly depress the brake pedal. Force
1. Install 35 000 kPa (5,000 psi) calibrated feedback of the pedal on your foot should be
pressure gauges at the following locations: smooth with no abnormal noise or mechanical
a. junction manifold test port "BR" roughness. Verify that the stop lights illuminate
when rear brake pressure "BR" is 517 ± 34 kPa
b. junction manifold test port "BF"
(75 ± 5 psi).
c. brake manifold test port "LAP1"
* Record on Data Sheet
2. The steering accumulators, brake accumulators 8. Quickly and completely depress the brake
and auxiliary system accumulator must have pedal. Verify that rear brake pressure "BR" and
the correct precharge and must be at normal front brake pressure "BF" are both 17 235 ± 517
operating temperature. Refer to Testing and kPa (2,500 ± 75 psi) within one second after the
adjusting section Accumulators and brake is applied:
suspensions for the accumulator charging
procedures. Both pressures must remain above their
minimum values for a minimum of 20 seconds
* Record on Data Sheet
while the pedal is fully applied.
NOTE: For best performance, charge the
* Record on Data Sheet
accumulators in the ambient conditions in which the
machine will be operating. Brake lock / secondary braking checkout
3. Close the brake accumulator bleed valves and 9. Disconnect the lead wire from the brake lock
the auxiliary accumulator bleed valve. solenoid valve (5, Figure 1) on the brake
4. Start the engine. Observe the rising brake manifold in the hydraulic brake cabinet.
pressures at test ports "BR" and "BF" as the 10. Move the directional control lever to NEUTRAL.
system charges. The brake pressures should
begin to fall when the auto apply valve releases. 11. Press the brake lock switch. The brake lock will
The auto apply valves should release the front not apply if the engine is not operating. Fault
and rear brakes when the pressure at test port code A118 will become active.
"LAP1" is 11 375 -515/+2 585 kPa (1,650 -75/ Depress the brake pedal until fault code A118 is
+375 psi). cleared, then very slowly release the pedal until
* Record on Data Sheet fault code A118 is active again. Verify that the
rear brake pressure "BR" drops to 6 895 ± 172
5. Partially depress the brake pedal to bleed air
kPa (1,000 ± 25 psi) when the fault reoccurs.
from each brake. Move the directional control
lever to NEUTRAL to bleed air from the parking * Record on Data Sheet
brakes. Then move the directional control lever NOTE: There is a three second delay between the
to PARK. time that the brake lock degradation switch senses
the pressure and fault code A118 occurs. Fault code
A265 will also become active during this step.

58B-60-20410 980E-4 Brake System Checkout Procedure 3

 12. Connect the lead wire to brake lock solenoid Parking brake checkout
valve (6). 14. Move the pressure gauge from test port "PP3"
13. Cycle the brake lock switch several times to to parking brake release pressure "PK3" test
ensure crisp application and release of oil port (2, Figure 1). Start the engine.
pressure and proper function of the status light.
a. Move the directional control lever to PARK,
Check the pressure readings at pressure test then back to NEUTRAL. The parking brake
ports (BR) and (PP3). Verify that the rear brake status light should illuminate, then go out.
pressure "BR" and the pressure at "PP3" are Verify that parking brake release pressure at
both 13 790 ± 690 kPa (2,000 ± 100 psi) when test port "PK3" is 22 753 ± 1378 kPa (3,300
the brake lock is applied. Fault code A118 ± 200 psi).
should also not be displayed. * Record on Data Sheet
* Record on Data Sheet b. Move the directional control lever to PARK.
If the brake lock does not function correctly, Verify that the parking brake apply pressure
ensure that all brake lock circuit plumbing is at test port "PK3" is 0 kPa (0 psi).
correct. * Record on Data Sheet
If the plumbing is correct, allow the steering If the parking brake does not function correctly,
accumulators to fully charge, then disconnect ensure that all parking brake circuit plumbing is
wire 52B to the brake lock solenoid at TB32-J. correct.
Apply 24V to the disconnected wire 52B. Verify
that the pressure reading at pressure test port If the plumbing is correct, allow the steering
"PP3" is 13 790 ± 690 kPa (2,000 ± 100 psi). accumulators to fully charge, then disconnect
Ignore any resulting brake lock faults. wire 52CS to the parking brake solenoid at
TB32-K. Ground the disconnected wire 52CS.
a. If the pressure is out of range, adjust Verify that the pressure reading at pressure test
pressure reducing valve (4, Figure 1) as port "PK3" is 22 753 ± 1 378 kPa (3,300 ± 200
required. psi). Ignore any resulting parking brake faults.
b. If the pressure reducing valve cannot be a. If the pressure is out of range and the
adjusted to achieve the correct pressure, steering pump has a pressure compensator,
replace the pressure reducing valve. verify that the pressure compensator
c. If the brake lock solenoid cannot be adjustment screw is properly adjusted.
energized, verify that the wiring to the b. If parking brake solenoid cannot be
solenoid is correct. If it is correct, then energized, verify that the wiring to the
replace the solenoid. solenoid is correct. If it is correct, then
d. If the brake lock valve will not operate, replace the solenoid.
replace the valve. c. If parking brake solenoid valve (6, Figure 1)
e. Connect wire 52B to TB32-J and repeat step will not operate, replace the valve.
13. d. Connect wire 52CS to TB32-K and repeat
step 14.
15. Cycle the parking brake several times by
moving the directional control lever between
NEUTRAL and PARK to ensure crisp
application and release of oil pressure and
proper function of the status light.

4 980E-4 Brake System Checkout Procedure 58B-60-20410

Service brake checkout
16. Move the directional control lever to PARK and
turn off the brake lock.
17. Move both brake pressure gauges to left rear
brake pressure "LBP" test port (2, Figure 2) and
right rear brake pressure "RBP" test port (1) on
the manifold on the left side of the rear axle
housing.
Quickly and completely depress the brake
pedal. Verify that left rear brake pressure "LBP"
and right rear brake pressure "RBP" are both
16 545 ± 517 kPa (2,400 ± 75 psi). within one
second after the brake is applied:
Both pressures must remain above their
minimum values for a minimum of 20 seconds.
* Record on Data Sheet FIGURE 2. REAR BRAKE PRESSURE TEST
PORTS
18. Release the brake pedal. Verify that both rear
brake pressures "LBP" and "RBP" return to 0 1. Right Rear Brake Pressure "RBP" Test Port
kPa (0 psi) within two seconds. There should be 2. Left Rear Brake Pressure "LBP" Test Port
no residual pressure trapped in the brakes.
* Record on Data Sheet
19. Move both rear brake pressure gauges to front
brake pressure test ports "LFBP" and "RFBP"
(1, Figure 3) on the front brake backplates.
NOTE: These test ports are not stamped on the
spindle.
Quickly and completely depress the brake
pedal. Verify left front brake pressures "LFBP"
and "RFBP" are both 16 545 ± 517 kPa (2,400 ±
75 psi) within one second after the brake is
applied:
Both pressures must remain above their
minimum values for a minimum of 20 seconds. FIGURE 3. FRONT BRAKES
* Record on Data Sheet 1. Test Port - "LFBP" and "RFBP"
20. Release the brake pedal. Verify that both front 1. Bleed Port
brake pressures "LFBP" and "RFBP" return to 0
kPa (0 psi) within two seconds. There should be
no residual pressure trapped in the brakes.
* Record on Data Sheet

58B-60-20410 980E-4 Brake System Checkout Procedure 5

Low brake accumulator pressure and auto apply NOTE: The brake warning system will activate when
checkout the lower pressure in either brake accumulator falls
below 12 755 ± 360 kPa (1,850 ± 52 psi). The auto
21. Move both front brake pressure gauges back to
apply sequence valve will apply the service brakes if
pressure test ports "BF" and "BR" in the
the pressure of either brake accumulator drops below
hydraulic brake cabinet. Start the engine and
11 375 ± 517 kPa (1,650 ± 75 psi).
allow the low brake accumulator pressure
"LAP1" to increase to 22 065 kPa (3,200 psi). 27. While the front brake accumulator bleed valve is
still open, allow low accumulator pressure
22. Move the directional control lever to NEUTRAL.
"LAP1" to continue to drop. Front brake
Turn the key switch OFF and allow 90 seconds
pressures "BF" and "BR" will begin to rise when
for the steering accumulators to bleed down
the auto apply sequence valve (7, Figure 1) is
completely.
activated at 11 375 ± 517 kPa (1,650 ± 75 psi).
23. Turn the key switch ON, but do not start the
engine. Wait for two minutes, then check the Front brake pressures "BF" and "BR" should be
low accumulator pressure reading at low at 0 kPa (0 psi) when the auto apply sequence
accumulator pressure "LAP1" test port (1, valve is activated.
Figure 1). If the pressure is below 14 480 kPa * Record on Data Sheet
(2,100 psi), there is excessive leakage in the 28. Observe the final pressures at "LAP1", "BF" and
system. The source of the leakage must be "BR" while auto apply is active.
identified and repaired.
• "LAP1" should be 11 375 ± 517 kPa (1,650
* Record on Data Sheet
± 75 psi).
24. Start the engine and allow the low brake
• "BF" should be 9 825 kPa (1,425 psi) or
accumulator pressure "LAP1" to increase to higher.
22 065 kPa (3,200 psi) or above. Then, turn the
key switch OFF and allow 90 seconds for the • "BR" should be 16 545 ± 517 kPa (2,400 ±
steering accumulators to bleed down 75 psi).
completely. * Record on Data Sheet
25. Turn the key switch ON, but do not start the NOTE: The auto apply sequence valve will need an
engine. Move the directional control lever to adjustment if it does not activate at 11 375 ± 517 kPa
NEUTRAL. Provide a speed signal of 3 kph (1,650 ± 75 psi). After adjusting the valve, repeat
from the DID panel on the rear wall of the steps 21-28.
operator cab. Fault code A260 will occur after
29. Close the front brake accumulator bleed valve.
the speed signal is generated.
Provide a speed signal of 0 kph from the DID
26. Slowly open front brake accumulator bleed panel on the rear wall of the operator cab. Fault
valve (9) a small amount while observing the code A260 will be cleared.
decreasing pressure at the low accumulator
Move the directional control lever to PARK.
pressure "LAP1" test port. Low brake pressure
Start the engine and allow low brake
fault A261 should occur when the pressure
accumulator pressure "LAP1" to increase to
drops to 12 755 ± 360 kPa (1,850 ± 52 psi) and
22 065 kPa (3,200 psi) or above.
the brake pressure switch in port "LAP2" is
activated. 30. Turn the key switch OFF and allow 90 seconds
for the steering accumulators to bleed down
Front brake pressures "BF" and "BR" should be
completely.
at 0 kPa (0 psi) when fault code A261 appears.
Fault code A260 should also occur. Turn the key switch ON, but do not start the
* Record on Data Sheet engine. Move the directional control lever to
NEUTRAL. Provide a speed signal of 3 kph
from the DID panel on the rear wall of the
operator cab. Fault code A260 will occur after
the speed signal is generated.

6 980E-4 Brake System Checkout Procedure 58B-60-20410

 31. Slowly open rear brake accumulator bleed valve Brake reapplications
(7) a small amount while observing the 35. Start the engine and allow low brake
decreasing pressure at low accumulator accumulator pressure "LAP1" to increase to
pressure "LAP1" test port (15). Low brake 22 065 kPa (3,200 psi) or above.
pressure fault A261 should occur when the
pressure drops to within 690 kPa (100 psi) of 36. Pull up on the engine shutdown switch on the
the observed pressure in step 26. center console to shut off the engine. Do not
turn the key switch OFF. The accumulators
Front brake pressures "BF" and "BR" should be must not be allowed to bleed down.
at 0 kPa (0 psi) when fault code A261 appears.
Move the directional control lever to NEUTRAL.
* Record on Data Sheet
Provide a speed signal of 3 kph from the DID
32. While the rear brake accumulator bleed valve is panel on the rear wall of the operator cab.
still open, allow low accumulator pressure
37. While observing the pressure gauges, make
"LAP1" to continue to drop. Front brake
repeated, slow brake applications until fault
pressures "BF" and "BR" will begin to rise when
code A261 appears. Fault code A261 must not
the auto apply sequence valve is activated
occur before the sixth pedal application. Auto
within 690 kPa (100 psi) of the observed
apply must not occur until after fault code A261
pressure in step 27.
occurs.
Front brake pressures "BF" and "BR" should be * Record on Data Sheet
at 0 kPa (0 psi) when the auto apply sequence
valve is activated. Fault code A260 should also 38. Remove the speed signal from the DID panel.
occur. Set the speed signal to 0 kph.
* Record on Data Sheet
33. Observe the final pressures at "LAP1", "BF" and
"BR" while auto apply is active.
• "LAP1" should be 11 375 ± 517 kPa (1,650
± 75 psi).
• "BF" should be 16 545 ± 517 kPa (2,400 ±
75 psi).
• "BR" should be 9 825 kPa (1,425 psi) or
higher.
* Record on Data Sheet
34. Close the rear brake accumulator bleed valve.
Provide a speed signal of 0 kph from the DID
panel on the rear wall of the operator cab. Fault
code A260 will be cleared.

58B-60-20410 980E-4 Brake System Checkout Procedure 7

Parking brake control logic checkout b. Start the engine. Ensure that low brake
accumulator pressure "LAP1" is 21 718 kPa
39. Do not activate the brake lock switch. Keep the
(3,100 psi) or higher, then move the
speed signal from the DID panel at 0 kph. If any
directional control lever to NEUTRAL.
of the following steps are not successfully
completed, find and correct the problem.
Pull up on the engine shutdown switch on
NOTE: The parking brake will not apply if the truck the center console to shut off the engine. Do
speed is above 0.8 kph (0.5 mph). If the parking not turn the key switch OFF. The
brake is selected and the truck speed is less than 0.8 accumulators must not be allowed to bleed
kph (0.5 mph), the following sequence will occur: down. Verify proper operation of the parking
brake and status light. No faults should be
• From 0 - 1 second, brake lock is applied, parking
brake is released. generated. Record the highest pressure
observed at ports "PK3", "PP3", "BF" and
• From 1 - 1.5 seconds, brake lock is applied, "BR" during the 1.5 seconds of the parking
parking brake is applied. brake application sequence.
• After 1.5 seconds, brake lock is released, parking • The pressure at test port "PK3" should be
brake is applied. 22 753 ± 1 378 kPa (3,300 ± 200 psi), then
This sequence uses the service brakes to completely fall to 0 kPa (0 psi).
stop the truck before allowing the parking brake to • The pressure at test port "PP3" should rise
apply. from 0 kph (0 psi) to 13 790 ± 690 kPa
a. Start the engine. Ensure that the low brake (2,000 ± 100 psi), then fall to 0 kPa (0 psi).
accumulator pressure "LAP1" is 21 718 kPa • Front brake pressure "BF" should remain at
(3,100 psi) or higher, then move the 0 kPa (0 psi).
directional control lever to NEUTRAL.
• Rear brake pressure "BR" should rise from
0 kph (0 psi) to 13 790 ± 690 kPa (2,000 ±
Move the directional control lever to PARK 100 psi), then fall to 0 kPa (0 psi).
and verify proper operation of the parking
* Record on Data Sheet
brake and status light. No faults should be
generated. Record the highest pressure c. Start the engine. Ensure that low brake
observed at ports "PK3", "PP3", "BF" and accumulator pressure "LAP1" is 21 718 kPa
"BR" during the 1.5 seconds of the parking (3,100 psi) or higher and the directional
brake application sequence. control lever is in PARK., then turn the key
switch to OFF. Verify that the parking brake
• The pressure at test port "PK3" should be
remains applied. Record the highest
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). pressure observed at ports "PK3", "PP3",
"BF" and "BR" when the key switch is turned
• The pressure at test port "PP3" should rise to OFF. All of the pressure readings should
from 0 kph (0 psi) to 13 790 ± 690 kPa be 0 kPa (0 psi).
(2,000 ± 100 psi), then fall to 0 kPa (0 psi).
* Record on Data Sheet
• Front brake pressure "BF" should remain at
0 kPa (0 psi).
• Rear brake pressure "BR" should rise from
0 kph (0 psi) to 13 790 ± 690 kPa (2,000 ±
100 psi), then fall to 0 kPa (0 psi).
* Record on Data Sheet

8 980E-4 Brake System Checkout Procedure 58B-60-20410

 d. Start the engine. Ensure that low brake Brake lock control logic checkout
accumulator pressure (LAP1) is 21 718 kPa 40. Remove the speed signal from the DID panel.
(3,100 psi) or higher, then move the Keep the speed signal at 0 kph. If any of the
directional control lever to NEUTRAL and following steps are not successfully completed,
turn the key switch to OFF. Verify that the find and correct the problem.
parking brake applies. Record the highest
pressure observed at ports "PK3", "PP3", a. With the engine running, low brake
"BF" and "BR" during the 1.5 seconds of the accumulator pressure "LAP1" at 21 718 kPa
parking brake application sequence. (3,100 psi) or higher, and the directional
control lever to NEUTRAL, turn the brake
• The pressure at test port "PK3" should be lock switch ON and OFF. Verify proper
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
operation of the brake lock and status light.
fall to 0 kPa (0 psi).
No faults should be generated. Record the
• The pressures at pressure test ports "PP3", highest pressure observed at ports "PK3",
"BF" and "BR" should read 0 kPa (0 psi). "PP3", "BF" and "BR" when the brake lock is
* Record on Data Sheet ON.
NOTE: With the key switch OFF, brake lock • The pressure at test port "PK3" should be
sequencing with the parking brake will not occur. 22 753 ± 1 378 kPa (3,300 ± 200 psi).
e. Start the engine. Ensure that low brake • The pressure at test port "PP3" should rise
accumulator pressure (LAP1) is 21 718 kPa to 13 790 ± 690 kPa (2,000 ± 100 psi), then
(3,100 psi) or higher, then move the fall to 0 kPa (0 psi).
directional control lever to NEUTRAL. • Front brake pressure "BF" should be 0 kPa
(0 psi).
Place a jumper wire between circuit 36 and • Rear brake pressure "BR" should rise to
ground. Pull up on the engine shutdown 13 790 ± 690 kPa (2,000 ± 100 psi), then
switch on the center console to shut off the fall to 0 kPa (0 psi).
engine. Do not turn the key switch OFF.
* Record on Data Sheet
Provide a speed signal of 1 kph from the DID b. With the engine running, low brake
panel on the rear wall of the operator cab. accumulator pressure "LAP1" at 21 718 kPa
Attempt to move the directional control lever (3,100 psi) or higher, and the directional
to PARK. Verify that the parking brake does control lever to PARK, attempt to turn the
not apply and fault code A230 is activated. brake lock switch ON. Verify that the brake
Record the highest pressure observed at lock does not apply, the status light does not
ports "PK3", "PP3", "BF" and "BR". illuminate, and fault codes A272 and A274
are not activated. Record the highest
• The pressure at test port "PK3" should be pressure observed at ports "PK3", "PP3",
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
"BF" and "BR". All of the pressures should
fall to 0 kPa (0 psi).
be 0 kPa (0 psi).
• The pressures at pressure test ports "PP3",
* Record on Data Sheet
"BF" and "BR" should read 0 kPa (0 psi).
* Record on Data Sheet

58B-60-20410 980E-4 Brake System Checkout Procedure 9

 c. With the engine running, low brake e. With the engine running, low brake
accumulator pressure "LAP1" at 21 718 kPa accumulator pressure "LAP1" at 21 718 kPa
(3,100 psi) or higher, directional control lever (3,100 psi) or higher, directional control lever
to NEUTRAL, and brake lock switch ON, in PARK, and brake lock switch OFF, turn the
move the directional control lever to PARK. key switch OFF and attempt to turn on the
Verify that the parking brake applies, the brake lock switch during the timed engine
brake lock releases and the status lights shutdown sequence. Verify that the brake
operate properly. Record the highest lock does not apply and the status light does
pressure observed at ports "PK3", "PP3", not illuminate. Record the highest pressure
"BF" and "BR". observed at ports "PK3", "PP3", "BF" and
"BR". All of the pressures should be 0 kPa (0
• The pressure at test port "PK3" should be
psi).
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). * Record on Data Sheet
• The pressure at test port "PP3" should rise NOTE: The brake lock will remain applied if the brake
to 13 790 ± 690 kPa (2,000 ± 100 psi), then lock switch is turned ON when a truck speed above
fall to 0 kPa (0 psi). 0.8 kph (0.5 mph) is detected. The switch must be
• Front brake pressure "BF" should be 0 kPa turned OFF to release the brake lock.
(0 psi). f. With the engine running and low brake
• Rear brake pressure "BR" should rise to accumulator pressure "LAP1" at 21 718 kPa
13 790 ± 690 kPa (2,000 ± 100 psi), then (3,100 psi) or higher, move the directional
fall to 0 kPa (0 psi). control lever to NEUTRAL.
* Record on Data Sheet
In the wPTU software, set the "FWD True"
d. With the engine running, low brake output to ON. Pull up on the engine
accumulator pressure "LAP1" at 21 718 kPa shutdown switch on the center console to
(3,100 psi) or higher, directional control lever shut off the engine. Do not turn the key
to NEUTRAL, and brake lock switch ON, pull switch OFF.
up on the engine shutdown switch on the
center console to shut off the engine. Do not Provide a speed signal of 1 kph from the DID
turn the key switch OFF. panel on the rear wall of the operator cab.
Place a jumper wire between circuit 36 and
Verify that the parking brake applies, the ground. Turn the brake lock switch ON.
brake lock releases and the status lights Verify proper operation of the brake lock and
operate properly. Record the highest status light. No faults should be generated.
pressure observed at ports "PK3", "PP3", Record the highest pressure observed at
"BF" and "BR". ports "PK3", "PP3", "BF" and "BR".
• The pressure at test port "PK3" should be • The pressure at test port "PK3" should be
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
22 753 ± 1 378 kPa (3,300 ± 200 psi).
fall to 0 kPa (0 psi).
• The pressure at test port "PP3" should be
• The pressure at test port "PP3" should rise 13 790 ± 690 kPa (2,000 ± 100 psi).
to 13 790 ± 690 kPa (2,000 ± 100 psi), then
fall to 0 kPa (0 psi). • Front brake pressure "BF" should be 0 kPa
(0 psi).
• Front brake pressure "BF" should be 0 kPa
(0 psi). • Rear brake pressure "BR" should be
13 790 ± 690 kPa (2,000 ± 100 psi).
• Rear brake pressure "BR" should rise to
13 790 ± 690 kPa (2,000 ± 100 psi), then * Record on Data Sheet
fall to 0 kPa (0 psi).
Remove the jumper wire between circuit 36
* Record on Data Sheet and ground. Reset the speed signal to 0 kph
from the DID panel on the rear wall of the
operator cab. In the wPTU software, set the
"FWD True" output to OFF.

10 980E-4 Brake System Checkout Procedure 58B-60-20410

 g. Verify that the brake lock remains applied Move the directional control lever to PARK.
while the truck is moving. With the engine Reset the speed signal to 0 kph. Fault codes
running and low brake accumulator pressure A272 and A274 should be activated when
"LAP1" at 21 718 kPa (3,100 psi) or higher, the speed signal is at 0 kph. Confirm that
move the directional control lever to brake lock is still activated. Record the
NEUTRAL. highest pressure observed at ports "PK3",
"PP3", "BF" and "BR"
In the wPTU software, set the "FWD True"
• The pressure at test port "PK3" should be 0
output to ON. Pull up on the engine kPa (0 psi).
shutdown switch on the center console to
shut off the engine. Do not turn the key • The pressure at test port "PP3" should be
switch OFF. 13 790 ± 690 kPa (2,000 ± 100 psi).
• Front brake pressure "BF" should be 0 kPa
Provide a speed signal of 1 kph from the DID (0 psi).
panel on the rear wall of the operator cab.
• Rear brake pressure "BR" should be
Place a jumper wire between circuit 36 and 13 790 ± 690 kPa (2,000 ± 100 psi).
ground. Turn the brake lock switch ON.
Confirm that brake lock is activated. Record * Record on Data Sheet
the highest pressure observed at ports In the wPTU software, set the "FWD True"
"PK3", "PP3", "BF" and "BR". output to OFF. Turn the brake lock switch
• The pressure at test port "PK3" should be OFF. Confirm that brake lock is deactivated.
22 753 ± 1 378 kPa (3,300 ± 200 psi). Record the highest pressure observed at
ports "PK3", "PP3", "BF" and "BR". All of the
• The pressure at test port "PP3" should be pressures should be 0 kPa (0 psi).
13 790 ± 690 kPa (2,000 ± 100 psi).
* Record on Data Sheet
• Front brake pressure "BF" should be 0 kPa
(0 psi). 41. Remove the jumper wire between circuit 36 and
ground. Remove the pressure gauges.
• Rear brake pressure "BR" should be
13 790 ± 690 kPa (2,000 ± 100 psi).
* Record on Data Sheet

58B-60-20410 980E-4 Brake System Checkout Procedure 11

Brake system checkout data sheet
** Acceptable values of each measurement are shown in (parenthesis).

Machine Model ___________ Unit Number ____________ Serial Number _____________

ACCUMULATOR PRECHARGE

Step 2b ____________ (1,400 psi) Front brake accumulator precharge pressure

____________ (1,400 psi) Rear brake accumulator precharge pressure

INITIAL SYSTEM SETUP

Step 4 ____________ (1,650 -75/+375 psi) Brake accumulator pressure "LAP1" when
auto apply releases

Step 6 ____________ (1,650 -75/+375 psi) Rear brake pressure "BR" when front brake
pressure "BF" begins to rise

____________ (0-5 psi) Front brake pressure "BF" when front brake pressure "BR"
begins to rise

Step 7 _____________ (75 ± 5 psi) Rear brake pressure "BR" when brake lights activate

Step 8 _____________ (2500 ± 75 psi) Front brake pressure "BF" 1 second after pedal applied

_____________ (2500 ± 75 psi) Rear brake pressure "BR" 1 second after pedal applied

_____________ (2500 ± 75 psi) Front brake pressure "BF" 20 seconds after pedal applied

_____________ (2500 ± 75 psi) Rear brake pressure "BR" 20 seconds after pedal applied

BRAKE LOCK / SECONDARY BRAKE CHECKOUT

Step 11 ____________ (1,000 ± 25 psi) Rear brake pressure "BR" when brake degradation
fault A118 occurs

Step 13 ____________ (2,000 ± 100 psi) Rear brake pressure "BR" when brake lock is applied

____________ (2,000 ± 100 psi) Brake lock pressure "PP3" when brake lock is applied

12 980E-4 Brake System Checkout Procedure 58B-60-20410

PARKING BRAKE CHECKOUT

Step 14a ___________ (3,300 ± 200 psi) Parking brake release pressure "PK3"

Step 14b ___________ (0 psi) Parking brake apply pressure "PK3"

SERVICE BRAKE CHECKOUT

Step 17 ____________ (2400 ± 75 psi) Left rear brake pressure "LBP" 1 second after
pedal applied

____________ (2400 ± 75 psi) Right rear brake pressure "RBP" 1 second after
pedal applied

____________ (2400 ± 75 psi) Left rear brake pressure "LBP" 20 seconds after
pedal applied

____________ (2400 ± 75 psi) Right rear brake pressure "RBP" 20 seconds after
pedal applied

Step 18 ____________ (0 psi) Left rear brake pressure "LBP" when pedal is released

____________ (0 psi) Right rear brake pressure "RBP" when pedal is released

Step 19 ____________ (2400 ± 75 psi) Left front brake pressure "LFBP" 1 second after
pedal applied

____________ (2400 ± 75 psi) Right front brake pressure "RFBP" 1 second after
pedal applied

____________ (2400 ± 75 psi) Left front brake pressure "LFBP" 20 seconds after
pedal applied

____________ (2400 ± 75 psi) Right front brake pressure "RFBP" 20 seconds after
pedal applied

Step 20 ____________ (0 psi) Left front brake pressure "LFBP" when pedal is released

____________ (0 psi) Right front brake pressure "RFBP" when pedal is released

58B-60-20410 980E-4 Brake System Checkout Procedure 13

LOW BRAKE ACCUMULATOR PRESSURE AND AUTO APPLY CHECKOUT

Step 23 ____________ (above 2100 psi) Low brake accumulator pressure "LAP1" after 2 minutes

Step 26 ____________ (1,850 ± 52 psi) Low brake accumulator pressure "LAP1" when
low brake pressure fault A261 occurs

____________ (0 psi) Front brake pressure "BF" when low brake pressure
fault A261 occurs

____________ (0 psi) Rear brake pressure "BR" when low brake pressure
fault A261 occurs

____________ (yes) Is fault A260 displayed?

Step 27 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when front brake
pressure "BF" begins to rise

____________ (0 psi) Front brake pressure "BF" when front brake pressure "BF"
begins to rise

____________ (0 psi) Rear brake pressure "BR" when front brake pressure "BF"
begins to rise

Step 28 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when
auto brake apply completes

____________ (1425 psi or above) Front brake pressure "BF" when auto brake apply
completes

____________ (2,400 ± 75 psi) Rear brake pressure "BR" when auto brake apply
completes

Step 31 ____________ (1,850 ± 52 psi) Low brake accumulator pressure "LAP1" when
low brake pressure fault A261 occurs

____________ (0 psi) Front brake pressure "BF" when low brake pressure
fault A261 occurs

____________ (0 psi) Rear brake pressure "BR" when low brake pressure
fault A261 occurs

14 980E-4 Brake System Checkout Procedure 58B-60-20410

 Step 32 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when
rear brake pressure "BR" begins to rise

____________ (0 psi) Front brake pressure "BF" when rear brake pressure "BR"
begins to rise

____________ (0 psi) Rear brake pressure "BR" when rear brake pressure "BR"
begins to rise

____________ (yes) Is fault A260 displayed?

Step 33 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when
auto brake apply completes

____________ (2,400 ± 75 psi) Front brake pressure "BF" when auto brake apply
completes

____________ (1425 psi or above) Rear brake pressure "BR" when auto brake apply
completes

BRAKE REAPPLICATIONS

Step 37 ____________ (6 or more) Number of brake applications before fault A261 occurs

PARKING BRAKE CONTROL LOGIC CHECKOUT

Step 39a - Maximum pressures during 1.5 second parking brake application sequence

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 39a - Pressures at completion of parking brake application sequence

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

58B-60-20410 980E-4 Brake System Checkout Procedure 15

 Step 39b - Maximum pressures during 1.5 second parking brake application sequence

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 39b - Pressures at completion of parking brake application sequence

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Step 39c - Maximum pressures

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Step 39d - Maximum pressures during 1.5 second parking brake application sequence

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Step 39d - Pressures at completion of parking brake application sequence

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

16 980E-4 Brake System Checkout Procedure 58B-60-20410

 Step 39e - Pressures at completion of parking brake application sequence

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

__________ (yes) Is fault A230 displayed?

BRAKE LOCK CONTROL LOGIC CHECKOUT

Step 40a - Maximum pressures with brake lock ON

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 40a - Pressures at completion with brake lock OFF

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Step 40b - Maximum pressures

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

__________ (no) Is fault A272 displayed?

__________ (no) Is fault A274 displayed?

58B-60-20410 980E-4 Brake System Checkout Procedure 17

 Step 40c - Maximum pressures with parking brake applied / brake lock released

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 40c - Pressures at completion with parking brake applied / brake lock released

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Step 40d - Maximum pressures with engine shutdown switch engaged

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 40d - Pressures at completion with engine shutdown switch engaged

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Step 40e - Maximum pressures during timed engine shutdown sequence

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

18 980E-4 Brake System Checkout Procedure 58B-60-20410

 Step 40f - Pressures at completion with 1 kph speed signal

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 40g - Pressures at completion with 1 kph speed signal

__________ (3,300 ± 200 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

Step 40g - Pressures at completion with 0 kph speed signal

__________ (0 psi) Parking brake pressure "PK3"

__________ (2,000 ± 100 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (2,000 ± 100 psi) Rear brake pressure "BR"

__________ (yes) Is fault A272 displayed?

__________ (yes) Is fault A274 displayed?

Step 40g - Pressures at completion with brake lock OFF

__________ (0 psi) Parking brake pressure "PK3"

__________ (0 psi) Brake lock pressure "PP3"

__________ (0 psi) Front brake pressure "BF"

__________ (0 psi) Rear brake pressure "BR"

Name of Technician or Inspector Performing Checkout ________________________________

DATE

58B-60-20410 980E-4 Brake System Checkout Procedure 19

 NOTES

20 980E-4 Brake System Checkout Procedure 58B-60-20410

 KOMTRAX PLUS SETUP PROCEDURE
Purpose Begin KOMTRAX Plus Setup
This procedure is used to setup the KOMTRAX Plus Key Switch off.
system.
1. Record the following on the Initialization Form:
a. Truck Model
Preliminary Procedures b. Truck Serial Number
The IM Checkout Procedure must be successfully c. Customer Unit Number
completed and engine start must be possible prior to
d. Engine 1 Serial number
beginning this KOMTRAX Plus Setup Procedure.
e. Engine 2 Serial number (typically blank)
f. Transmission or Alternator serial number
Necessary Equipment g. KOMTRAX Plus Controller part number
1. Setup procedure and vehicle wiring schematic. h. KOMTRAX Plus Controller serial number
2. Laptop computer with VHMS Technical Analysis
i. Orbcomm Controller part number
Toolbox and VHMS Setting Tool software
installed. j. Orbcomm Controller serial number
3. RS232 serial cable with a male DB9 connector 2. Verify that the red LED display on the
on one end and a female connector on the other KOMTRAX Plus controller is off.
end. 3. Disconnect the Orbcomm antenna. (WebCARE
must be ready to receive data before
connecting the antenna.)
Check for KOMTRAX Plus System Faults
Key Switch on, DO NOT START Engine.
Key on and run the VHMS Technical Analysis
4. Watch the red LED display on the KOMTRAX
Toolbox Software and confirm that there are no
Plus controller. After a short time the display
active faults not related to items which will be
should start counting up.
configured during this KOMTRAX Plus setup
procedure. If any are found, these circuits should be 5. Connect a lap top PC to the KOMTRAX Plus
analyzed to determine the cause of the fault and they RS232 serial port.
should be repaired before continuing. 6. Start the VHMS Setting Tool software. Click
“Next”.

KOMTRAX Plus Setup

1. It is critical that each item in the setup
procedure be completed before continuing on to
the next.
2. The information recorded on the Initialization
Form at the end of this procedure will be
needed for full registration and commission of
KOMTRAX Plus.

EM2128-1 KOMTRAX Plus Setup Procedure 1

 7. Select VHMS Setting. Click “Next”.

8. Select Set up & All Clear. Click “Next”.

2 KOMTRAX Plus Setup Procedure EM2128-1

 9. Enter the machine information. Click “Next”.
NOTE: Serial No. must be included in this setting and is case sensitive.

10. Enter engine information. Click "Next".

NOTE: Typically, Engine Serial No.2 is left blank.

EM2128-1 KOMTRAX Plus Setup Procedure 3

 11. Enter time zone information. Record all information on Initialization Form. Click “Next”.

12. Enter GCC setting. Caution: KOMTRAX Plus will not communicate over the satellite if the GCC setting is not
correct for the area that the truck operates in. Record setting on Initialization Form. Click “Next”.

4 KOMTRAX Plus Setup Procedure EM2128-1

 13. Review the entered information before applying the changes. Click “Apply”.

14. Select Yes to record the old setting and fault Key Switch on. START Engine. Wait 30 seconds.
data.
Verify that the KOMTRAX Plus controller red LED
display begins counting up and record on Form 3,
Item 14.
17. Press and hold the data store switch (this will
trigger a KOMTRAX Plus Manual Snapshot) for
3 seconds, and then release.
18. Wait until the Data Store in Progress LED has
finished flashing. Wait another minute, then turn
the key switch off and stop the engine. Verify
the KOMTRAX Plus controller red LED display
is off.
15. Success. The setup is complete.
Key Switch on, DO NOT START Engine.
Verify the KOMTRAX Plus controller red LED display
16. Click OK for KOMTRAX Plus to reboot and use begins counting up.
the new settings.
19. Start the VHMS Setting Tool software. Click
“Next”.

EM2128-1 KOMTRAX Plus Setup Procedure 5

 20. Select Review setting information. Click “Next”.

21. Verify that all of the setting information has been 29. Select the MACHINE HISTORY option from the
entered correctly. Exit VHMS Setting Tool. list on the left side of the screen.
22. Start the VHMS Technical Analysis Tool Box 30. Verify that the Key ON/OFF and Engine ON/
program. Enter username and password. (Initial OFF records are recorded correctly.
setting for username is “user” or “usr” and “0” or
31. Exit the VHMS Technical Analysis Toolbox
“1” for the password.)
software.
23. Select the Download icon and select the correct 32. Fill out the remaining items on the attached
com port when prompted (usually COM1). VHMS Initialization request form and email it to
24. Select “Connection”. the address shown on the form along with the
required newly obtained download files which
25. Verify that the date and time displayed on the
can be found in folder
download screen are correct for the current
C:\VHMS_DATA\930E\(truck serial number)\
local date/time and that the displayed Service
(date of download)\CHKxxxx.
Meter hours are equal to the value entered
previously. 33. Reconnect the Orbcomm antenna only when
WebCARE registration is confirmed by
26. Verify that a Manual Snapshot (MFA0) has been
accessing this vehicle's data on the Webcare
recorded. The display should show an item
site.
named “Snapshot” with code MFA0 and text
“Manual Trigger”.
27. Select the “Select All” option (from the bottom
right of window) and perform a download.
28. Verify that the “Download Completed” message
is displayed. Click on “Exit”.

6 KOMTRAX Plus Setup Procedure EM2128-1

 Komatsu America KOMTRAX Plus Initialization Form
Email the completed form to the Service Systems Support Team at ServiceSystems@KomatsuNA.com
Attach the VHMS download files after the initial settings have been performed with the Setting Tool
The Email Subject should be in the form of Model-Type Serial Number VHMS Initialization
(Example: PC1800-6 11001 VHMS Initialization)
Customer Information
Company Name
Site Name
Customer Employee Contact
Mailing Address
Phone Number
Fax Number
Email
Distributor Information
Distributor Name
Distributor Service Systems Support Administrator Name/Email
Branch
Branch Employee Contact and Email
Distributor Code (XXXX XX)
Machine Information
Model and Type
Serial Number
Customer Unit Number
Engine 1 Serial Number
Engine 2 Serial Number
Transmission or Alternator Serial Number
VHMS Controller Part Number
VHMS Controller Serial Number
Orbcomm Controller Part Number
Orbcomm Controller Serial Numbers (5-Digit & 11-Digit)
Setting Tool Information
Setting Date (MM/DD/YYYY)
Setting Time (HH:MM:SS)
GMT (Time Zone)
Daylight Saving Time (YES/NO)
SMR at Setting Date and Time
GCC (Orbcomm Satellite) Code
Orbcomm Activation Date
New WebCARE & MyKomatsu.com User Information
Distributor, Branch and Code
Employee Name
Title
Email
Primary Area of Responsibility (Circle One) Admin Sales Parts Service PSSR Other
Reason for Form Submittal (Check One)
Factory-Installed VHMS Initialization
Retrofitted VHMS Initialization
VHMS Controller Replacement
Major Component (Engine/Transmission) Replacement
Customer or Distributor Change
Setting Tool Information Change
New WebCARE & MyKomatsu.com User Request

EM2128-1 KOMTRAX Plus Setup Procedure 7

 Orbcomm Controller Example VHMS Controller Example

Part Number = 7826-12-2201

Serial Number (5-Digit) = 01042 Part Number = 7826-13-2000
Serial Number (11-Digit) = 4ABDB622244 Serial Number = 000805

8 KOMTRAX Plus Setup Procedure EM2128-1

 KOMTRAX PLUS CHECKOUT PROCEDURE
Purpose 5. After VHMS has been typed, some text followed
by a prompt > will be displayed. This confirms
This procedure is used to checkout the KOMTRAX
that proper communication between the PC and
Plus system.
KOMTRAX Plus has been established.
6. At the prompt, type “ver”. Something similar to
the following will be displayed:
Preliminary Procedures
>ver
1. The KOMTRAX Plus Setup Procedure
(EM2128) must be successfully completed prior VHMS OS Ver 1.6.5.1 Mar 01 2004 16:37:25
to beginning this Checkout Procedure. >
2. This Checkout procedure cannot be completed 7. At the prompt type “dispvhmsinf”. Information
prior to confirming that Orbcomm activation and similar to the following will be displayed:
WebCARE registration (both optional for factory >dispvhmsinf
checkout) are complete.

---- MACHINE INFORMATION --------

Necessary Equipment PRODUCT GROUP: Dumptruck
1. Checkout procedure and vehicle wiring MACHINE_MODEL: 830AC-
schematic. MACHINE_SERIAL:
2. Laptop computer with Tera Term Pro and VHMS ENG_MODEL: QSK60
Technical Analysis Toolbox software installed.
ENG_SERIAL_NO1:
3. RS232 serial cable to connect VHMS serial port
to PC serial port. ENG_SERIAL_NO2:
PRG_NO1: 12000100100
PRG_NO2: 782613R290
Check for KOMTRAX Plus System Faults ---- DEVICES ------------------------
Key on and run the VHMS Technical Analysis PLC NO CONNECTION
Toolbox Software and confirm that there are no
PLM23 Disabled
active faults. If any are found, these circuits should
be analyzed to determine the cause of the fault and PLM3 CONNECTED
they should be repaired before continuing. ---- Condition --------------------
SMR: 90.0 H
DATE 04-10-25 TIME14:44:24
Checkout Procedure
TIMEZONE: 0.0 H SUMMERTIME 0
1. Connect the serial cable from the PC to the
serial port of the KOMTRAX Plus controller. ----Controller Info -------------------
2. Start the serial communications software (Tera PartNumber: 0000000000
Term). Serial No.: 000000
3. Setup the serial communications software by Compo Name: KDE1010
selecting the appropriate serial COM port, and
SilkyID: VA011740744
baud rate equal to 19200.
4. After completing the setup, wait for 5 seconds >
then while holding the CTRL key, type VHMS Use the results of step 6 and 7 to confirm that
(Notice that nothing will display on the screen the correct software is installed in the
while typing). KOMTRAX Plus controller.

EM2129-1 4/16 KOMTRAX Plus Checkout Procedure 1

 8. Verify Orbcomm connection status by checking the Orbcomm Status LED on KOMTRAX Plus controller.
NOTE: The Orbcomm Status LED is the “dot” LED following the second 7-segment LED character which is a “6” in
the KOMTRAX Plus Controller drawing below.

a. If the LED is OFF, then the connection between the KOMTRAX Plus controller and Orbcomm is bad.
Troubleshoot connection.
b. If the LED is ON solid, then the connection between the KOMTRAX Plus controller and Orbcomm is good.
This is OK.
c. If the LED is FLASHING, then the Orbcomm satellite signal is established. This must be verified and may
take as long as 15 minutes to occur.

FIGURE 1-1. KOMTRAX PLUS CONTROLLER

2 KOMTRAX Plus Checkout Procedure 4/16 EM2129-1

 9. This step is optional for factory checkout: While the Orbcomm Status LED is flashing, perform the
following:
At the prompt, type “gccpingw”. The following will be displayed:

>gccpingw
PING executed , Now waiting GCC resp. …(cancel any key hit)
Success round trip 254 sec
>

This confirms the connection with an Orbcomm station is established. If the screen does not confirm success
as shown above then proceed with the following troubleshooting procedures.

Problem 1:
If, after typing “gccpingw”, the following is displayed:

>gccpingw
PING executed , Now waiting GCC resp. …(cancel any key hit)
Error SC NO Connection!
>

Then the system must be powered down. Turn off the key switch and after the vehicle has completely
powered down, turn off the master battery disconnect switches. Then reapply power by turning on the battery
disconnects and the key switch. Repeat the “gccpingw” procedure.

Problem 2:
If, after typing “gccpingw”, the following is displayed:

>gccpingw
PING executed , Now waiting GCC resp. …(cancel any key hit)
Error NO GCC resp. within specified time

Then either the antenna has a bad connection, or the transmitter inside the Orbcomm modem does not work,
or the modem has not been registered with Orbcomm as described in the VHMS Setup Procedure.

10. This step is optional for factory checkout: Test Upload to WebCARE by logging onto WebCARE website
and confirming that satellite uploads of KOMTRAX Plus data are being received. Regular uploads of
KOMTRAX Plus data to WebCARE are made once every 20 hours. In order to verify that uploads are
operating properly without having to wait for 20 hours, a KOMTRAX Plus fault can be generated and this fault
should appear on WebCARE within 1 hour.

EM2129-1 4/16 KOMTRAX Plus Checkout Procedure 3

 NOTES

4 KOMTRAX Plus Checkout Procedure 4/16 EM2129-1

 PAYLOAD METER IV CHECKOUT PROCEDURE
This procedure is used to checkout the Payload 5. In the auxiliary cabinet, check the controller
Meter IV (PLM IV) installation. input voltage between circuit 39G and 0
(ground). This voltage should nominally be
Necessary Equipment: 24VDC from the batteries.
1. Vehicle Electrical Wiring Diagram. 6. Turn ON the Key Switch. The analog
2. 58B-06-03100 - 3.0kΩ, ±1%, 1W resistor speedometer/display gauge on the dashboard
will scroll the truck type across the lower
structures (Qty. 4).
display. The scrolling functionality is not
3. Laptop computer. available on the electronic display gauge. The
4. Cat5e Ethernet cable. payload meter defaults to 930E.
5. Empty USB 2.0 Flash Drive (1 GB to 4 GB). 7. In the auxiliary cabinet, check the sensor supply
6. 58B-06-0260X - Latest PLM IV application voltage between circuit 39F and 0 (ground). The
code, where 'X' is the latest version. voltage should be 18VDC ±1VDC.
7. Voltmeter. 8. Return to the cab and check the speedometer/
display gauge. The gauge will display the
Install the Application Code: current payload. With the 58B-06-03100
resistors attached at the sensor locations, the
Before the payload meter can be checked, the latest
payload should be 0.
application code must be installed. To download the
latest application code, go to the Komatsu America NOTE: For trucks with Electronic Dash Displays,
Extranet:https://www.komatsuamerica.net/ values can be viewed on the electronic display
northamerica/. payload screen.
To configure the laptop computer for communication NOTE: For trucks with the analog speedometer
with PLM IV, please refer to Appendix A - Guide to gauge, the display can be used to quickly show the
Connect to Payload Meter IV. For details on the current readings from the four suspension pressure
application code, refer to Appendix B - Installing sensors and the inclinometer. This can be used
Payload Meter IV Software via USB. during regularly scheduled service periods to check
the state of the suspensions. These displays are live
General Instructions: and will update as the values change. The display is
1. Attach one 58B-06-03100 Resistor Structure in changed by pressing the 'SELECT' button on the
place of the left-front suspension pressure dashboard. The sequence of displays is:
sensor. 58B-06-03100 acts as a suspension • PL= Payload
pressure test load between circuit 39F and
circuit 39FD. • Id= Operator ID
2. Attach one 58B-06-03100 Resistor Structure in • tL= Total Shift Tons
place of the right-front suspension pressure
sensor. 58B-06-03100 acts as a suspension • LC= Shift Load Counter
pressure test load between circuit 39F and
• LF= Left Front Suspension Pressure
circuit 39FC.
3. Attach one 58B-06-03100 Resistor Structure in • rF= Right Front Suspension Pressure
place of the left-rear suspension pressure • Lr= Left Rear Suspension Pressure
sensor. 58B-06-03100 acts as a suspension
pressure test load between circuit 39F and • rr= Right Rear Suspension Pressure
circuit 39FB.
• In= Inclinometer
4. Attach one 58B-06-03100 Resistor Structure in
place of the right-rear suspension pressure NOTE: The live displays cannot be cleared and the
sensor. 58B-06-03100 acts as a suspension SET button will have no effect.
pressure test load between circuit 39F and
circuit 39FA.

58B-06-02400 4/16 Payload Meter IV Checkout Procedure 1

 10. The gauge will quickly display the type of 18. Press and hold the 'SELECT' button on the
information being displayed every 1 minute. For dashboard. "PL =" will be displayed. Release
example, if the left-front pressure is being the button and the current payload will be
displayed, "LF =" will quickly display every displayed.
minute. Only the payload display, “PL =” does 19. Press and hold the 'SELECT' button on the
not display this information. dashboard. "In =" will be displayed. Release
11. Press and hold the 'SELECT' button on the the button and the inclinometer value will be
dashboard. “Id =” will be displayed. Release the displayed. This value is in degrees. The incline
button and the operator id will be displayed. will depend on how the truck is set during
This value should be 0. assembly. Values between ±3° are acceptable.
12. Press and hold the 'SELECT' button on the 20. With the Ethernet cable connecting a laptop to
dashboard. "tL =" will be displayed. Release the payload meter, log into the PLM IV home
the button and the total tons will be displayed. page. Please refer to "Appendix A - Guide to
This value should be 0. connect to PLM IV" for more details to complete
this step.
13. Press and hold the 'SELECT' button on the
dashboard. "LC" will be displayed. Release the The home page will display links to the following
button and the number of loads will be information:
displayed. This value should be 0. • Real Time Data display
14. Press and hold the 'SELECT' button on the • Configuration Options
dashboard. "LF =" will be displayed. Release
• Payload Data View
the button and the left-front pressure will be
displayed. This value should be in metric units. • Payload Data Download
The nominal value should be 25.6 kg/cm2 (364 • Alarm Data View
psi). Values between 19.2 and 32 kg/cm2 (273
psi and 455 psi) are acceptable. • Alarm Data Download

15. Press and hold the 'SELECT' button on the 21. Click on the "System Configurations" link to edit
the truck model, inclinometer position, units,
dashboard. "rF =" will be displayed. Release
date and time, and other configurations. These
the button and the right-front pressure will be
configurations are permanently saved.
displayed. This value should be in metric units.
The nominal value should be 25.6 kg/cm2 (364 There are eight configuration parameters on this
psi). Values between 19.2 and 32 kg/cm2 (273 page. Each critical configuration requires a
psi and 455 psi) are acceptable. password, "Kac2300", in order to save the setting.
For each of the following configurations, save the
16. 14.Press and hold the 'SELECT' button on the
appropriate option according to the truck installation.
dashboard. "Lr =" will be displayed. Release
the button and the left-rear pressure will be a. Truck Model- There are more than 20
displayed. This value should be in metric units. different truck models available for selection.
The nominal value should be 25.6 kg/cm2 (364 The correct truck model must be selected for
psi). Values between 19.2 and 32 kg/cm2 (273 the payload meter to accurately estimate
psi and 455 psi) are acceptable. payloads.
17. Press and hold the 'SELECT' button on the
dashboard. "rr =" will be displayed. Release the
button and the right-rear pressure will be
displayed. This value should be in metric units.
The nominal value should be 25.6 kg/cm2 (364
psi). Values between 19.2 and 32 kg/cm2 (273
psi and 455 psi) are acceptable.

2 Payload Meter IV Checkout Procedure 4/16 58B-06-02400

 b. PLM IV Mounting Orientation (For onboard f. Payload Load Light Test - This setting is
Inclinometers) - It is important to configure used to test the payload load lamps and their
the payload meter according its mounting wiring. This will be tested in step 20.
position on the truck. Please refer to the g. Payload Gain Factor
truck top-down image below for the
selectable positions inside the auxiliary
cabinet. Match the wall the payload meter is
mounted to with the wall number in the
image.

Do not modify unless required. Default payload

gain factor is 100%, but the setting is adjustable
between 90% and 110%. It is highly advised NOT
to change the default payload gain value, as this
change will affect all payload calculations.

h. Truck Tare Default

FIGURE 1-1. PLM IV MOUNTING ORIENTATION

1. Position (1)
2. Position (2)
3. Position (3) Do not modify unless required. This option
forces the payload meter to reset the Truck Tare
c. Operator Display Unit to its default value. DO NOT use this function
UNLESS the payload meter state machine is
• Short Tons: Payload is displayed in short tons, locked up or has calculated an unusually low tare
distance and speed are displayed in miles. value. Check the system for a SENSOR LOW
• Metric Tons: Payload is displayed in metric tons, PRESSURE alarm.
distance and speed are displayed in kilometers
• Long Tons: Payload is displayed in long tons, 22. In order to validate the Payload Load Lights,
distance and speed are displayed in miles make sure the brake lock is ON. The load lights
d. Web page Pressure Units - Suspension can be set ON/OFF for 5 minutes in the
pressure sensor values displayed on Real "System Configurations" webpage. After 5
Time Data Service screen are only for minutes, the lights will return to their default
observation. Selecting kg/cm2 sets the state. Test the following scenarios:
pressure values in metric units. Selecting psi a. Green Light ON, Amber Light OFF, Red Light
will set the pressure values in pound per OFF. Confirm that only the green payload
square inch. (1 kg/cm2 = 14.22 psi) lights on the truck are illuminated.
e. Date and Time - The current payload meter b. Green Light OFF, Amber Light ON, Red Light
time is shown on the Real Time Data Service OFF. Confirm that only the amber payload
page. It is important to set correct Date and lights on the truck are illuminated.
Time information if the truck does not have a
Komtrax Plus. If the truck is equipped with a c. Green Light OFF, Amber Light OFF, Red
Komtrax Plus, it will automatically update the Light ON. Confirm that only the red payload
payload meter date and time when powered lights on the truck are illuminated.
on. The payload meter will hold a date and d. Green Light OFF, Amber Light OFF, Red
time for approximately 30 days without Light OFF. Confirm that all payload lights on
power. If the date and time is lost, set the the truck are off.
current information and keep the system
23. Return to the PLM IV home page.
powered on to recharge the clock power
supply.

58B-06-02400 4/16 Payload Meter IV Checkout Procedure 3

 24. Click on the "Truck Data Configuration" link to 25. On the "Truck Data Configuration" page, record
set the frame serial number, customer unit the current PLM software version. This
number, distributor, and customer. In addition, information should match the installed
the Software Version Number can be verified. application.
Enter all of the following information, then save 26. Return to the PLM IV home page.
them by entering the password "Kac2300"
27. Click on the "Real Time Data Service" link. This
a. Frame Serial Number - The frame serial
web page displays the current PLM IV I/O
number is located on a plate mounted to the
status. This data is refreshed once a second.
truck frame. The plate is outboard on the
lower right rail facing the right front tire. It is a. The weight shown on the real time data
important to enter the correct frame serial screen is the sprung weight and includes the
number as this number is a key field in off- weight of the truck. Given the suspension
truck databases. The field will hold up to 20 pressure dummy loads, the nominal value
alpha-numeric characters. shown should be 113 metric tons (125 short
tons).
b. Customer Unit Number - Most mining
operations assign a number to each piece of b. Confirm that all suspension pressures are
equipment for quick identification. This within range. The nominal value should be
number or name can be entered in the 25.6 kg/cm2 (364 psi). Values between 19.2
Customer Unit Number field. It is important to and 32 kg/cm2 (273 psi and 455 psi) are
enter the customer unit number. This number acceptable. Record the values displayed.
is one of the key fields used in off-truck c. Confirm that the inclinometer is within range
databases. The field will hold up to 20 alpha- and record the value.
numeric characters. If no unique customer
number has been specified, enter the frame d. Confirm that the Body Up input is working
serial number. correctly. Place a steel washer on the body
up switch. The real time data screen should
c. Distributor - This field can hold the name of indicate "OFF". Remove the washer and the
the distributor that helped install the system. real time data screen should indicate "ON".
Komatsu also assigns a distributor number
to each distributor. This number is used on e. Confirm that the Brake Lock input is working
all warranty claims. This distributor number correctly. Turn the Brake Lock ON using the
can also be entered into this field. This switch on the dashboard. The real time data
number is one of the key fields used in off- screen should indicate "ON". Turn the Brake
truck databases. The field will hold up to 20 Lock OFF. The real time data screen should
alpha-numeric characters. If the distributor is indicate "OFF".
not known, enter "UNKNOWN". f. Use the procedure for speedometer
d. Customer Name - This field can hold the calibration for the particular truck type to
name of the mine or operation where the simulate a 25 MPH (40.2 km/h) speed signal.
truck is in service. Komatsu also assigns a Confirm that this value is displayed by the
customer number to each customer. This speedometer on the dashboard and the real
number is used on all warranty claims. This time data screen. The value can be ±1 MPH
customer number can also be entered into (±2 km/h). The brake lock must be off for the
this field. This number is one of the key fields PLM IV to recognize speed input.
used in off-truck databases. The field will 28. On the PC, return to PLM IV home screen.
hold up to 20 alpha-numeric characters. If
29. Remove the Resistor Structure (58B-06-03100)
the customer is not known, enter
from the left front suspension pressure sensor
"UNKNOWN".
location.
e. Enter the password "Kac2300" to allow
saving of the inputted data.
f. Click "SaveTruckData" button to save the
information permanently.

4 Payload Meter IV Checkout Procedure 4/16 58B-06-02400

 30. Wait at least 1 minute then remove the 58B-06- Configuring a PC's Static IP Address
03100 Resistor Structure from the left-rear
For a wired or wireless connection, a static IP
suspension pressure sensor location.
address of the PC is required to allow connectivity. To
31. Wait at least 1 minute then remove the 58B-06- do this, follow the steps below and refer to Figure A
03100 Resistor Structure from the right-rear for help. These instructions were created using
suspension pressure sensor location. Windows 7, but the process is similar for other
32. Wait at least 1 minute then remove the 58B-06- operating systems.
03100 Resistor Structure from the right-front 1. Right Click on the Wired Connection icon in the
suspension pressure sensor location. bottom right corner.
33. Wait at least 1 minute. 2. Click on "Open Network and Sharing Center."
34. From PLM IV home screen, select the "View 3. On the Network and Sharing Center window,
Alarms" link to view alarms list. click on "Change adapter settings" on the left
hand bar.
35. All 'Active Alarms' will be saved within 5
4. On the computer's Wired Connection Device,
seconds. Confirm that the four alarms displayed
right click on "Local Area Connection".
occurred in the proper order:
a. If using wireless, right click on "Wireless
• Left-front suspension low
Network Connection".
• Left-rear suspension low 5. Click on "Properties"
• Right-rear suspension low 6. Click on "Internet Protocol Version 4 (TCP/IPv4)
• Right-front suspension low to highlight the option.
36. Turn the key switch OFF, close all screens, and 7. Click on "Properties."
disconnect the laptop from the payload meter 8. Select the dot for "Use the following IP
system. address:"
9. Fill in the following network settings within
Appendix A range of the PLM IV's IP address:
Guide to Connect to Payload Meter IV • IP Address: 192.168.0.123
PLM IV can be connected to a PC via a Cat5e cable • Subnet Mask: 255.255.0.0
connection to the Ethernet port on the payload meter 10. Click "OK".
communication board or at the Ethernet PC port in
the cab. However, this Ethernet port can be 11. Click "OK".
connected to a wireless radio on the truck if a NOTE: To return the PC's network card to normal
wireless option connection is available. operation, follow steps 1 through 7, but select
Once connected, any web browser such as Internet “Obtain an IP address automatically”.
Explorer, Google Chrome, etc. can be used to
access the webserver. The PC's IP address MUST
be configured within the same network range as the
payload meter.
1. Set PC's IP Address to a static IP (See Steps
Below: "Configuring a PC's Static IP Address").
2. Open Internet Explorer on PC.
3. Enter the IP Address of PLM IV into the Internet
Explorer address bar - Enter 192.168.0.128
4. At the PLM IV login screen, enter username
"plm" and password "pass".
5. Click "Connect".

58B-06-02400 4/16 Payload Meter IV Checkout Procedure 5

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

6 Payload Meter IV Checkout Procedure 4/16 58B-06-02400

 FIGURE 1-3. PLM IV COMMUNICATION MODULE
1. USB 2.0 Type A Connectors
2. 10/100 Mbps Ethernet RJ45 Connector

Payload Meter IV Checkout Procedure Confirmation

________ PLM Software Version

________ User switch and display works properly

________ Left-Front Pressure

________ Right-Rear Pressure

________ Inclinometer

________ Green light works properly

________ Amber light works properly

________ Red light works properly

________ Brake Lock input works properly

________ Body Up input works properly

________ Speed input works properly

________ Date

________ Truck

________ By

58B-06-02400 4/16 Payload Meter IV Checkout Procedure 7

 NOTES

8 Payload Meter IV Checkout Procedure 4/16 58B-06-02400

 ELECTRICAL SYSTEM CHECKOUT PROCEDURE
This checkout procedure is designed for trucks with General Precautions
the electronic dash panel and GE Invertex II. It is to
be used along with the GE Vehicle Test Instructions,
GE Events & Fault Lists, Interface Module Checkout
Procedure, Payload Meter 4 Checkout Procedure,
and the Hydraulic System Checkout found in the
Truck Checkout Group Procedures Before starting the engine, always sound the
horn once prior to cranking. Block wheels of the
General Description truck to prevent possible roll away before per-
This checkout procedure prescribes the tests and forming this procedure.
procedures to check out the function and operation of
the 24 volt control & lighting systems. The Checkout This checkout procedure should be performed by
Procedures must be completed to provide a only qualified trained personnel that have knowledge
permanent record of the various systems testing for of the operation of the truck and the stored energy
each unit. systems on it. Personnel should observe all
The main GE drive control cabinet consists of the precautions established by KAC and at other
following electrical components: Auxiliary three locations where the checkout is being performed. All
phase air cooled rectifier, phase inverters and potentially store energy within the truck should be
chopper modules, Micro-Processed Control unit, released before performing any troubleshooting of
alternator field regulator, and retard contactors. The the systems.
Auxiliary Control Cabinet contains the GE Drive
System interface wiring, truck Interface Module (IM),
Payload Meter IV module (PLM4), Diagnostic and
CAN communications, truck control wiring
connection points, and the 24 volt power distribution
While the AC Drive System Truck is running
and fuse protection. The Komtrax Plus (VHMS)
(engine on), none of the cabinet doors or covers
Module and ORBCOMM Module are located in the
should be open or removed or none of the power
front upper dash panel of the operator cab.
cables should be touched. The system (link hot)
is not dependent on selector switch position or
accelerator pedal being pushed, If the GE cutoff
switch is in the normal position (ON), the Rest
Switch is turned OFF, and the engine is running,
the drive system link is “hot” with dangerous
voltage.

58F-06-30042 Electrical System Checkout Procedure 1

Normal operation of the drive system at shutdown AC Drive System Description
should leave the system safe to operate. In the event
For complete AC Drive System Description read
of a system failure, perform the following procedure
through the GE Vehicle Test Instructions. (See GE
to insure that hazardous voltages are not present in
VTI Procedure from the Checkout Group Procedure).
the drive system.
Drive System Control Group (Invertex II) contains:
1. Before shutting down the engine, verify the
status of the drive system warning lights in the 1. Control Group
operator dash display. If any of the red drive a. Integrated Control Panel II - ICP2
system link warning lights are on, do not
attempt to open any cabinets, disconnect any b. Drive System Controller DSC
cables, or reach inside the retard grid cabinet c. Power Rectifier Panel
without a trained drive system technician
present, even after shutting down the engine. d. Rectifier Inverter and Chopper Modules
2. If all red drive system warning lights are off, set 2. A/C Power Alternator
the selector switch in the park position, then 3. Retard Grid Assembly
shut down the engine and chock the wheels.
4. A/C Propulsion Wheel Motors
3. After the engine has been off for at least five (5)
minutes, inspect the Link Voltage light on the
front of the main control cabinet and verify that Test equipment needed to fully test AC system:
the link voltage has been discharged. If the link
voltage is discharged, then the retard grids, 1. Portable Test Unit (PTU) consisting of:
wheel motors, alternator and power cables *Laptop Computer
connecting these devices are safe to work on.
*RS232 serial cable with male DB9 connector
4. Power cables must be clamped with non-
ferrous material clamps. Do not repair cable 2. Vehicle wiring schematic
cleats by encircling the power cables with metal 3. GE Drive System Electrical schematic
clamps or hardware. Always inspect power
cable insulation prior to servicing the cables and 4. One 5000 Volt Megger
prior to returning the truck to service. Replace 5. Several jumper wires
any cables with damaged insulation.
6. One multimeter 1000V meter
Perform the truck shutdown procedure:
1. With the truck stopped, move the selector
switch to the PARK position. The PTU is used to test, download and record
system parameters on the TCI control panel.
2. Move the HVDC Power-Off switch to the REST
position. The retard contactors are engaged 1. The PTU can be plugged into the DB9 port -
and high voltage link energy is diffused through “Diag.2”, the Ethernet port, or the USB test port
the grid. in the Diagnostic Test Center (located on the
3. The (RED) Link Energized light should be back wall of operator cab, behind the passenger
“OFF” to indicate “0” voltage on the low voltage seat).
section of the control cabinet. (Located on the 2. The PTU can also be plugged into the DB9 port
door on the front of the control cabinet, closest on the front side of the TCI Control Panel inside
to the operator cab). the control cabinet, upper section, closest to the
4. Turn the key switch to the OFF position. When operator cab.
the key is turned off, the steering hydraulic
system pressure should also bleed down.
5. Turn the GE cutoff switch to the OFF position to
ensure that the link will not be re-energized.

2 Electrical System Checkout Procedure 58F-06-30042

Visual Inspection 3. Turn key switch to “OFF” position.
1. Before carrying out this checkout procedure, 4. Turn all lights and switches OFF.
perform a visual inspection of the truck and Inside the Auxiliary Cabinet, check the resistance
verify all electrical connections are made except with a Multi-meter from ground buss circuit 0 to the
the cable connections to the 24V batteries and following points. All points should measure
circuit 21PT to both engine starter relays resistance values from a few ohms to infinity.
located inside battery box.
2. At Battery Isolation Station, verify both the NOTE: All circuits should show resistance from a few
Starter Disconnect Switch and the Main battery ohms to infinity. STOP and troubleshoot any direct
disconnect are turned to OFF position and the shorts (0 ohms) to ground.
battery cables are connected correctly.
3. Check that all fluids are their correct levels; Table 1: Circuit and Connection Resistance
engine oil, engine coolant, transmission,
hydraulic oil. Circuit Connection
11 24V Buss
Resistance Checks
12V VEC91-S7
71CK TB24-N
10V TB31-M
+15VDI TB21-T
Check to be sure link voltage is drained down -15VDI TB21-V
before performing test! 5VDI TB21-W
5VDM TB30-L

Preparation 24VIM TB32-H

18VIM TB30-W
1. Inside battery box, verify both the short jumper
battery cables are removed which connect the
positive and ground between the two batteries 5. Restore all circuits to original form.
that make up 24VDC
2. Inside battery box, verify the 21PT circuit wires
which connect to both engine starter relays (1 &
2) are disconnected and insulated to prevent
the engine from cranking.

58F-06-30042 Electrical System Checkout Procedure 3

Voltage Check

CIRCUIT CONNECTION DESCRIPTION

11A TB35-A
11E1 TB27-A
Check to be sure link voltage is drained off 11E2 TB27-B
before performing test.Key 11E3 TB27-C
Switch OFF Check 11E4 TB27-D

1. Verify that the key switch is in the cutoff 11L TB22-C

position. 11SL TB24-A
2. Verify the GE cutoff switch is in OFF position, 39G TB34-T
and that the GE link is de-energized. 11LL relay HLMR-88 Lo-beam Headlight
3. Verify that circuit 21PT is disconnected and Low Relay
insulated from both engine start relays located
11LR relay HHMR-88 Lo-beam Headlight
in the battery control box on the front platform.
High Relay
4. Make sure the engine emergency shutdown
11HL relay HBHR-88 Hi-beam Headlight
switch in the Operator cab is in the “Run”
Relay
position (switch pushed down) and the ground
level shutdown switch is pulled out. 47B relay BULR-88 Back Up Light Relay
5. Inside the Battery Box, re-connect both battery 85 TB28-C
cables jumper between the two sets of battery
to provide truck 24vdc. Key Switch ON Check
6. Check battery voltage to ground, circuit 11, 1. In the operator turn the key to ON or first
inside the battery box. A battery charger may position turning the key to the right of OFF.
need to be installed if voltage is low.
2. Inside the Auxiliary Cabinet, check the following
7. At Battery Isolation Station, turn the Main circuits inside the auxiliary cabinet for the
battery disconnect Switch to ON position appropriate voltage to ground (0).
leaving the Starter Disconnect Switch to OFF
position.
CIRCUIT CONNECTION VOLTAGE
8. Check battery voltage to ground, circuit 11, REQUIRED
inside the Auxiliary Cabinet on the 24vdc-Buss.
11D TB22-A 24 VDC
9. Inside the Auxiliary Cabinet, check the following
circuits for the appropriate battery voltage to 712 TB24-K 24 VDC
ground. 71CK TB24-N 24 VDC
• Check circuit 11B1 (TB24) to ground (0) for 12 71LS TB23-M 24 VDC
vdc. 71VHM TB28-B 24 VDC
• Check the following circuits for 24 vdc to ground 24VIM TB32-H 24 VDC
(0):
5VIM TB30-K 5 VDC
12V VEC91-S7 12 VDC
18VIM TB30-W 18 VDC

4 Electrical System Checkout Procedure 58F-06-30042

GE Control Switch ON Check 7. Engine Service Lights - At the left & right front
frame rail, turn on & off the engine service
1. In the GE Control Cabinet turn Control Power
lights. The engine service lights can be turned
Switch to the ON position.
on or off from either side.
2. Verify the LED power indicators are illuminated
on the face of GE Invertex II control system. Key Switch ON
3. Continue checking the following circuits inside 1. Operator Switch Indicators - With the key switch
the auxiliary cabinet for the appropriate voltage in the ON position, the following operator switch
to ground (0). indicators will be illuminated; Digital Display
Check circuit for other voltages to ground (0); Module Display Mode 1 & 2, Manual Backup,
Grid Dry, also if equipped, Fog lights, Heated
CIRCUIT CONNECTION VOLTAGE Mirrors, Rotating Beacon, and Camera Select.
REQUIRED 2. Clearance Lights - Turn the headlight switch to
71GE TB24-G 24 VDC the clearance light position (first position). Verify
that the front left/right clearance lights, rear tail
10V TB31-M 10 to 12 VDC lights, Instrument Panel lights are illuminated.
15SRW TB33-M 15 VDC Also on the Center console the directional
15SLW TB33-S 15 VDC selector switch, Engine shutdown Switch and
Body Override / Reset Switch are illuminated.
77P TB29-A 15 VDC With the clearance lights ON, verify the panel
714P TB29-H 15 VDC light dimmer can adjust the back light on the
15VDI TB21-T 15 VDC electronic display panel brightness.

-15VDI TB21-V -15 VDC 3. Dash Lights - With the headlight switch in the
OFF position, the Selector switch in the “Park”
5VDI TB21-W 5 VDC position, the bottom green indicator in the
following operator switches should illuminate;
Truck Function Check Headlight Switch, Ladder light switch, and
Hazard light switch.
If any of the following functions fail to operate, power
down the truck and release all stored energy. Using 4. Headlights - Turn the Headlight switch to the
the electrical wiring diagram, troubleshoot the circuits headlight position (last/top position). The Low
within the associated truck function which failed to beam head lights in the lower and upper grill
operate. should turn ON. Move the “Combo switch” on
the steering column to the High beam position.
Key Switch OFF The Low beam headlights should remain on
and the Hi-beam headlights should come on.
1. Operator Cab Dome Light - Verify operation of
The Hi-beam-On indicator in dash should be
the cab dome light by turning ON and OFF the
illuminated.
of the dome light switch.
5. Fog Lights - If equipped with optional fog lamps,
2. Front Vehicle Horn - Check the front vehicle
verify operation by turning ON and OFF the fog
horn for proper operation.
light switch.
3. Ladder Light Switch - Operate the ladder light
6. Electric Windows - Run the operator cab and
switches from OFF to ON, inside the operator
passenger windows up and down with the
cab and at ground level near the ladder
window switches on the Selector switch console
entrance. The two platform lights, diagonal
to verify operation.
ladder light and the deck light, should illuminate.
7. Backup Horn and Lights - Move the direction
4. Hazard Signals - Operate the hazard switch to
Selector switch to the reverse position, the
verify the front and rear hazard lights flash.
Back-up horns and the backup lights should
5. Hydraulic Brake Cabinet - Verify the dome lights operate. Move the Selector switch to Neutral or
operation in the hydraulic brake cabinet. Forward position and the Backup horn and
6. Isolation Station - In the battery isolation station, lights should turn off.
verify the indicator (ON / OFF) lights for each of
the disconnect switches function properly when
are toggled ON and OFF.

58F-06-30042 Electrical System Checkout Procedure 5

 8. Manual Backup Lights - Turn the Manual Interface Module (IM) System Checkout
Backup switch on and the rear backup lights 1. Connect the PTU (laptop computer) to the
and deck mounted backup lights (if equipped) Operator Cab - IM diagnostic port (DIAG 6).
should operate. Verify that the latest software configuration has
9. Turn Signals - Turn the Combo switch lever to been loaded into the Interface Module (IM) and
the Right and Left turning on the signals to that it is the current software.
verify that the Clearance lights on the decks, 2. Review the IM system error code report and
dump body and on the instrument panel flash resolve all reported faults.
the proper direction.
3. Complete the checkout procedure for "IM
10. Windshield wiper - Operate the windshield Checkout Procedure”.
wipers in Low, High, and Intermittent speeds to
verify operation. Komtrax Plus (VHMS) Checkout
11. Windshield Washer pump - Press the See VHMS Procedure from the Check-out Group
windshield washer button to verify that the Procedures.
washer pump runs and the wiper run
1. Perform the VHMS Setup Procedure.
monetarily.
2. Perform the VHMS Checkout Procedure.
12. Heated Mirrors - Verify both left and right hand
heated mirrors function when the switch is Payload Meter Checkout
turned ON.
See PLM Procedure from the Check-out Group
13. Entertainment Radio - Verify operation of the Procedures.
entertainment radio. Check both front and rear
speakers. 1. In the operator cab connect a laptop computer
PC ethernet port. Load or verify that the latest
14. Operator Cab Air Seats - Check both the driver software configuration has been loaded into the
and passenger air seats by raising and lowering Payload Meter III.
the seat to verify operation.
2. Complete the Checkout Procedure for the PLM
15. Operator HVAC System - Verify operation of the per the vehicle specific procedure.
HVAC with engine running by operating the AC
and the Heater selector switch. Check all GE Vehicle Test Instructions (VTI)
blower speed positions.
Using the GE vehicle test instructions perform the
16. Auxiliary Cabinet Dome Lights - Verify the dome following procedures and checkouts. (See GE VTI
lights operation the auxiliary cabinet. Procedure from the Check-out Group Procedures).
17. Hydraulic Pump Access Light - If equipped 1. GE Truck Initial Checkout Procedure
verify the hydraulic pump module access light 2. Megger Test Procedure
functions correctly by operating the switch
3. Truck Configuration
located on the air duct behind the cab.
4. Installing DSC Software
5. Digital / Analog Checks and Calibrations
6. Digital & Analog checks and calibrations (using
the GE VTI)
7. Inputs & outputs to GE (using GE w/PTU
software)

6 Electrical System Checkout Procedure 58F-06-30042

Digital I/O to GE
GE PTU Name Function Description Criteria
KEYSW Key Sw on Operator Key Switch ON/ OFF
CPSFB Control Power Relay Output for GE Control Power (71GE) ON/OFF
PKBP Park Brake Input Park Brake Applied Pressure Switch ON/OFF
BRAKON Service Brakes ON Service Brake Applied Pressure Switch
WHEELOCK Wheel Brake Lock SW Brake Lock Switch Dash ON/OFF (RPC CAN)
BRAKTSREQ PreShift Brake Test Pre-Shift Park Brake Test Switch ON/OFF
AXLEP Axle Blower PSI SW Traction Motor Pressure Switch ON/OFF
CNTRLP Control Cabinet PSI SW GE Control Cabinet Blower Pressure Switch (RPM
950- 1150)
RSC Retard Spd Control SW Retard Speed Control Switch ON/OFF
SPINDIS Slip Slide Dis Slip Slide Feature Disabled
FORREQ Forward Direction Directional Shift Selector - Reverse Position
REVREQ Reverse Direction Directional Shift Selector - Forward Position
RESTSW Rest Switch DC Power Rest Switch ON/OFF
REST-DO Bodyup Reset Bodyup Override / Rest Reset Switch ON/OFF
DATST Data Store Data Store Switch ON/OFF
GFNCO Generator Field Coil SW Control Cabinet DC Field Cut Switch
PROPLO Propel Lockout Iso Box & GE Cabinet Propel Lockout Switch ON/
OFF
OEMACCIN OEM Accel Inhibit Optional Hyd Access Ladder Down Limit Switch
ENGSTRREQ Eng Start Request Engine Starter Request Key Switch Start
ENGKILL Engine Kill SW Engine Secondary Shutdown Cab & Ground ON/
OFF
ENGWARN Engine Warning Engine Warning Signal (J1939 CAN)
WARMUP Grid Dry SW Grid Dry / Engine Warm Switch ON/OFF
FULPAYLD Full PayLoad Full Payload Signal (RPC CAN)
OVERPAYLD Over Load Over Load Payload Signal (RPC CAN)
BODYDWN Body Down SW Body-up Proximity Switch ON/OFF
AUTON Autonomous Mode AHT Option - Auto / MAN Signal (RPC CAN)

58F-06-30042 Electrical System Checkout Procedure 7

 Engine Shutdown Smart Timer Check
1. Use a multimeter to monitor the voltage on
Analog I/O to GE circuit 21NSL (TB27) to ground.
Function Descrip- Criteria 2. Start and run the engine at an elevated RPM
tion approximately 1500 RPM. After the engine
Power Supply Operating value verified become hot, circuit 21NSL will go from 0 to
24vdc.
Retard Pedal Operation range verified and
Calibrated 3. Let the engine return to idle for approximately 1
minute and turn the key switch to OFF position.
Accelerator Pedal Operation range verified and
The engine should continue to run at idle speed
Calibrated
for approximately 3 minutes or less and then
10V Pot Reference Operating value verified shutdown.
RSC Pot / Retard Operation range verified and
Spd SW Calibrated Body Hoist Limit
1. Verify that the body hoist limit functions by
The following digital circuits to GE are not used as placing a piece of metal in front of the body up
these signals are now communicated over RPC CAN switch located at the rear of the truck.
or not needed. 2. With the key switch turned ON, in the brake
cabinet measure the voltage at the hoist limit
Circuit NO Description GE Connector solenoid, circuit 53H to ground.
77 Truck Speed Freq P303-R 3. With the metal in front of the body up switch,
Signal battery voltage should be read at the hoist limit
solenoid, and zero volts when the metal is
77A Truck Speed Freq P303-f
removed.
Signal
Shield Truck Speed Freq P303-Y
Shield

8. Checks prior to Self-load test (Load Box)

9. Engine Running Tests (Self-load Test)

8 Electrical System Checkout Procedure 58F-06-30042

Checkout Completion Report

Function Description Criteria Results OK/FAIL

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

58F-06-30042 Electrical System Checkout Procedure 9

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

10 Electrical System Checkout Procedure 58F-06-30042

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

FIGURE 1-1.STARTUP LOGO SCREEN

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 1

 FIGURE 1-2.MONITOR PANEL

1. Monitor Display 6. Monitor Display Mode Switch

2. Brightness Switches 7. Reference Line Display Switch
3. System Power Status Indicator 8. Lower Body Display Switch
4. Force Display Switch 9. Object Clear Switch
5. Camera Switches

4. Enter Password “6491” and select “OK” to The first two lines of text on the main menu are the
access the maintenance mode system. part number (1) and the application version number
(2).
The system enters maintenance mode and the
main menu (Figure 1-4) opens. 5. Record the Program part number and
Application number..
2 1

85119

FIGURE 1-3.PASSWORD MODE ENTRY FIGURE 1-4.MAIN MENU PROGRAM

1. Program Part Number
2. Application Number

2 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

 6. Use the diagonal down right key (5,Figure 1-2)
to tab to the “MAIN SETTING” button. Use the
object clear switch (9) to select it.
The main setting input screen opens.(Figure 1-
5)

FIGURE 1-6.CAMERA POSITIONS

12. Set the following positions for camera 1 and

record the values (Figure 1-6) as needed:
a. Offset X
FIGURE 1-5.MAIN SETTING SCREEN b. Offset Y
c. Offset Z
7. Set the truck model using the diagonal down
right arrow (5, Figure 1-2) to move cursor d. Roll
location and the object clear switch (9) to select e. Pitch
entry.
f. Yaw
8. Tab to "SAVE" and select it.
13. Set the following positions for camera 2 and
When save is selected the defaults values for record the values as needed:
that truck model are saved.
a. Offset X
9. Tab to the Back button (Figure 1-5) and select
it. Verify the correct model is saved on the Main b. Offset Y
Menu. (Figure 1-4). c. Offset Z
10. Record the Machine Code Setting and all d. Roll
remaining data inputs (Figure 1-5).
e. Pitch
11. From the Main Menu select Camera Setting
f. Yaw
(Figure 1-4).
14. Set the following positions for camera 3 and
The camera position page opens.(Figure 1-6) record the values as needed:
a. Offset X
b. Offset Y
c. Offset Z
d. Roll
e. Pitch
f. Yaw

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 3

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

4 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

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

23. Set the following positions for Radar All position b. Offset Y
1 and record the values (Figure 1-8) as needed: c. Offset Z
a. Offset X d. Roll
b. Offset Y e. Pitch
f. Yaw

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 5

 28. Set the following positions for Radar All NOTE: This requires the calibration mats to be laid
Positions 6 and record the values (Figure 1-8) accordingly around the machine on level ground. The
as needed: quickest is auto calibration which if successful will
complete automatically in several minutes.
a. Offset X
However, the auto calibration is very sensitive to
b. Offset Y lighting conditions and surroundings. If the auto
c. Offset Z calibration fails the manual calibration will have to be
done. The manual calibration may take upwards to
d. Roll an hour.
e. Pitch 34. Record the calibration used.
f. Yaw a. Auto Calibration.
29. Set the following positions for Radar All b. Manual Calibration.
Positions 7 and record the values (Figure 1-8)
as needed: NOTE: After the successful calibration the Runtime
Screen should show with no errors. Troubleshoot and
a. Offset X correct any errors per shop manual before
b. Offset Y continuing.
c. Offset Z 35. Verify all keys are illuminated by green lighting.
d. Roll 36. Verify all keys are illuminated by amber lighting
e. Pitch when in the depressed state.

f. Yaw 37. Verify radar function by having a person walk

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

6 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

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

b. Verify the screen goes back to active mode c. Person Name.

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

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 7

Settings

1 ________ (yes/no) Logo Screen displayed immediately.

2 ________ (yes/no) Blinking icon exists.

________ (seconds) Time it took for logo screen to change to running screen.

5 ________ Program part number.

________ Application number.

Main settings

10 ________ Setting for Machine code.

________ Setting for Offset.

________ Setting for Body Width.

________ Setting for Forward Option.

________ Setting for Rear wheel to end.

________ (yes/no) Diagonal Ladder LH.

________ (yes/no) Diagonal Ladder RH.

________ Forward Low-High speed

________ Reverse Low-High speed

________ Hysteresis.

________ Image Magnification Bird View.

________ (yes/no) Radar less option on box.

8 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

All Camera Positions

12 a _______ Camera 1 Offset X.

b. ______ Camera 1 Offset Y.

c. ______ Camera 1 Offset Z.

d. ______ Camera 1 Roll.

e. ______ Camera 1 Pitch.

f. ______ Camera 1 Yaw.

13 a _______ Camera 2 Offset X.

b. ______ Camera 2 Offset Y.

c. ______ Camera 2 Offset Z.

d. ______ Camera 2 Roll.

e. ______ Camera 2 Pitch.

f. ______ Camera 2 Yaw.

14 a _______ Camera 3 Offset X.

b. ______ Camera 3 Offset Y.

c. ______ Camera 3 Offset Z.

d. ______ Camera 3 Roll.

e. ______ Camera 3 Pitch.

f. ______ Camera 3 Yaw.

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 9

 15 a _______ Camera 4 Offset X.

b. ______ Camera 4 Offset Y.

c. ______ Camera 4 Offset Z.

d. ______ Camera 4 Roll.

e. ______ Camera 4 Pitch.

f. _______ Camera 4 Yaw.

16 a _______ Camera 5 Offset X.

b. ______ Camera 5 Offset Y.

c. ______ Camera 5 Offset Z.

d. ______ Camera 5 Roll.

e. ______ Camera 5 Pitch.

f. _______ Camera 5 Yaw.

17 a _______ Camera 6 Offset X.

b. ______ Camera 6 Offset Y.

c. ______ Camera 6 Offset Z.

d. ______ Camera 6 Roll.

e. ______ Camera 6 Pitch.

f. _______ Camera 6 Yaw.

Radar Area

21 a _______ Outside Front value.

b. ______ Outside Side value.

10 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

Radar Threshold

22 a. ______ Radar 1 Power Setting.

b. ______ Radar 2 Power Setting.

c._______ Radar 3 Power Setting.

d. ______ Radar 4 Power Setting.

e. ______ Radar 5 Power Setting.

f. ______ Radar 6 Power Setting.

g. ______ Radar 7 Power Setting.

h. ______ Radar 8 Power Setting.

Radar All Positions

23 a. ______ Position 1 Offset X.

b. ______ Position 1 Offset Y.

c._______ Position 1 Offset Z.

d. ______ Position 1 Roll.

e. ______ Position 1 Pitch.

f. ______ Position 1 Yaw.

24 a. ______ Position 2 Offset X.

b. ______ Position 2 Offset Y.

c._______ Position 2 Offset Z.

d. ______ Position 2 Roll.

e. ______ Position 2 Pitch.

f. ______ Position 2 Yaw.

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 11

 25 a. ______ Position 3 Offset X.

b. _______ Position 3 Offset Y.

c. _______ Position 3 Offset Z.

d. ______ Position 3 Roll.

e. ______ Position 3 Pitch.

f. _______ Position 3 Yaw.

26 a. ______ Position 4 Offset X.

b. _______ Position 4 Offset Y.

c. _______ Position 4 Offset Z.

d. ______ Position 4 Roll.

e. ______ Position 4 Pitch.

f. _______ Position 4 Yaw.

27 a. ______ Position 5 Offset X.

b. _______ Position 5 Offset Y.

c. _______ Position 5 Offset Z.

d. ______ Position 5 Roll.

e. ______ Position 5 Pitch.

f. _______ Position 5 Yaw.

28 a. ______ Position 6 Offset X.

b. _______ Position 6 Offset Y.

c. _______ Position 6 Offset Z.

d. ______ Position 6 Roll.

e. ______ Position 6 Pitch.

f. _______ Position 6 Yaw.

12 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

 29 a. ______ Position 7 Offset X.

b. ______ Position 7 Offset Y.

c._______ Position 7 Offset Z.

d. ______ Position 7 Roll.

e. ______ Position 7 Pitch.

f. ______ Position 7 Yaw.

30 a. ______ Position 8 Offset X.

b. ______ Position 8 Offset Y.

c._______ Position 8 Offset Z.

d. ______ Position 8 Roll.

e. ______ Position 8 Pitch.

f. ______ Position 8 Yaw.

34 a _______ Auto Calibration.

b _______ Manual Calibration.

35 ________ (yes/no) Verify all keys are Illuminated by green lighting.

36 ________ (yes/no) Verify all keys are Illuminated by amber lighting when
depressed.

37 a _______ (yes/no) Radar target id follows person correctly.

b _______ (yes/no) Smooth transition of the bird eye view.

38 a _______ (yes/no) Camera 1 select displays.

b _______ (yes/no) Camera 2 select displays.

c _______ (yes/no) Camera 3 select displays.

d _______ (yes/no) Camera 4 select displays.

e _______ (yes/no) Camera 5 select displays.

f _______ (yes/no) Camera 6 select displays.

58E-43-10000-00 KOMVISION® CHECKOUT PROCEDURE 13

 39 a _______ (yes/no) Button function Grid line.

b. ______ (yes/no) Button function body rear hide.

c. ______ (yes/no) Button function display mode.

40 a _______ (yes/no) Display mode bright and dim Button function Grid line.

b. ______ (yes/no) Display mode bright and dim Button function body rear hide.

c. ______ (yes/no) Display mode bright and dim Button function display mode.

41 ________ (yes/no) The display changes to the rear camera view.

42 ________ (yes/no) audible alarm sounds.

43 ________ (yes/no) audible alarm turns off.

44 ________ (yes/no) audible alarm sounds.

45 ________ (yes/no) audible alarm turns off.

46 a _______ (Mph) The speed traveling when the standby screen is activated.

b _______ (yes/no) The screen goes back to active mode when truck is coming to
a stop.

47 a _______ (Mph) The speed traveling when the standby screen is activated.

b _______ (yes/no) The screen goes back to active mode when truck is coming to
a stop.

48 ________ (yes/no) System errors exist.

49 ________ (yes/no) The pre-shift KomVision® check completed.

51 a _______ Truck Model Number.

b _______ Truck Serial Number.

c _______ Person Name.

d _______ Date completed.

14 KOMVISION® CHECKOUT PROCEDURE 58E-43-10000-00

 WIRELESS BRIDGE CHECKOUT PROCEDURE
Purpose 2. Setup the laptop IP address for Wired
communications with the Wireless Bridge. See
This procedure is to setup a Komatsu Wireless
to configure.
Bridge Radio for communication and check out its
function. Initial Wireless Bridge Configuration:
3. Connect the Wireless Bridge to a Laptop or PC
Necessary Equipment using the AC PoE (Power-Over-Ethernet)
1. An Access Point (AP) kit (Part# 58F-00-00201) adapter, see (Figure 1-1) and (Figure 1-2)
refer to Access Point installation procedure # provided in the Access Point Kit.
58F-06-01300.
NOTE: One AP can be used to communicate with
several Komatsu Wireless Bridges.
2. A computer running Windows 98 or newer with
a wireless network connection capability
adaptor (Wi-Fi) is required in order to download
data from the Komatsu Wireless Bridge.

Communication Setup
A computer running a Microsoft TM operating system
(with a wireless network adaptor) is required to
download data through KWB using Access Point
(AP). The individual steps required are different
depending upon the computer operating system and
each computer’s specific wireless adaptor. Please
refer to the computer and/or adaptor manuals for
further details. FIGURE 1-1.POWER-OVER-INTERNET
1. Connect Bullet to PoE
2. Connect Laptop to Laptop

1. Ensure an Access Point (AP) is available for set

up connection to the Wireless Bridge and
powered ON before setting up the Wireless
Bridge for communication.
• AP should be configured according to the
installation procedure.
• Is within range of the computer.
NOTE: Komatsu Wireless Bridge requires the use of
an Access Point. The number of Access Points
needed depends upon the number of computers
used to remotely download data from the wireless FIGURE 1-2.DC PoE INJECTOR TO DC POWER
network.. SUPPLY

1. Connect Auxiliary Power Outlet

2. Connect to Laptop
3. Connect to Bullet

58E-06-11130 4/16 Wireless Bridge Checkout Procedure 1

 4. Open a web browser such as Internet Explorer
and follow steps below
a. Ensure the Laptop is able to communicate
with the Wireless Bridge.
b. In the address bar, type “192.168.1.20” (1,
Figure 1-3) and press enter. The Gargoyle
login page should appear.
FIGURE 1-4.LOGIN PAGE
1. Administrative Password

d. Once logged into the Gargoyle interface

select the “Connection” tab (1, Figure 1-5)
from the left of the screen.

FIGURE 1-3.ADDRESS BAR

1. IP Address

c. Enter “modular” for Admin Password

(1,Figure 1-4).

FIGURE 1-5.CONNECTION STATUS PAGE

1. Connection Tab 4. Save Changes Button
2. SSID to Join 5. Logout
3. Encryption

e. On the “Connection” tab go to SSID to Join f. Encryption must match the encryption or
(2) and type in “KWB_Connect”. security of the Access Point. For this
example there is no encryption

2 Wireless Bridge Checkout Procedure 4/16 58E-06-11130

 g. Select “Save Changes” button (4, Figure 1- Appendix A
5) at the bottom of the tab.
Setting The Computer Subnet Mask And IP
h. Logout (5) and close the window.
Address
5. Disconnect the wired connection between the
Wireless Bridge and the laptop. The Wireless If the adaptor software does not allow for setting an
Bridge is now ready to be installed on the truck. IP address, then this must be done manually. This
prepares the computer to communicate with the
6. Setup the laptop for Wireless communications
KWB and to interact with the automatic download
with the Wireless Bridge. Same instructions as
software.
in Step 3 only instead of setting the IP address
for the Local Area Network Connection, set the The Windows TCP/IP settings must be modified for
IP address for the Wireless Net. the correct subnet mask and an adequate IP
7. Connect to KWB_Connect: address. The steps to reach the point where the
TCP/IP settings can be modified vary according to
• On the laptop, scan for available wireless the operating system and are described below. The
networks and connect to Access Point (AP) SSID actual steps for making the changes to the settings
“KWB_Connect” (1, Figure 1-6) If you are asked are described for the following operating systems.
to confirm connection to an unsecure network,
accept all requests. Windows 2000
• Click on the start menu, select settings and then
“Network and Dial-up Connections”.
• Right click on the wireless network adaptor and
select “properties”. Skip instructions for other
Operating Systems.

Windows XP
• Click on the start menu, right click on “My
Networks” and select “Properties”. A window with
all available networks will be shown.
• Right click on the wireless network and select
“Properties”. Skip instructions for other Operating
Systems.

Windows Vista
FIGURE 1-6.OPEN NETWORK AND SHARING • Click on the Windows menu, right click on
1. Wireless Network Connection “Network” then select “Properties”. A window will
open with the option “Manage network
connections” as one of the options on the left
8. If the KWB_Connect is not detected, refresh the side. Select that option.
wireless network on the laptop computer. If all
connections are correct, and KWB-Connect still • A new window showing all available networks will
does not appear, reboot the AP and KWB. If the open. Right click on the wireless network to be
used to connect to the KWB and select
problem persists, then try resetting the KWB
“Properties”. Vista will inquire if this was an
and reprogramming all the configurations as intentional selection; select “Continue”. Skip
described in the Communication Setup, page 6- instructions for other Operating Systems.
33 section.
Windows 7
NOTE: DO NOT reset the KWB. A “Reset” sets all
the configurations to default. • Click on the Windows start menu, click on
“Control Panel” then select “Network and
Internet”. A window will open with the option
“Network and Sharing Center” Select that option.

58E-06-11130 4/16 Wireless Bridge Checkout Procedure 3

 • A new window showing all available networks will • In the “Internet Protocol Version 4 (TCP/IP V4)
open. Right click on the wireless network to be Properties” window write down the current
used to connect to the KWB and select settings. These settings will be needed to restore
“Properties”. the original computer settings if needed.
• Open the Windows Start menu and select • Select “Use the following IP address”.
“Control Panel”.
• Adjust the IP address to 192.168.1.xxx, where
• Select “Network and Sharing Center”. xxx represents any number between 0 and 127.
• A window showing available networks will open. NOTE: Do Not use 20, because it is the default IP
Right click on the wireless network to be used to address of the Wireless Bridge.
connect to the KWB. Select “Properties”.
• The subnet mask should be set to 255.255.0.0.
• In the window with the list of available protocols,
Select “TCP/IP V4”. Select “Properties”. • Leave the gateway address blank.
• Click “OK” twice.

FIGURE 1-8.IP ADDRESS SETUP

1. Wireless Network Connection 5. Enter IP Address and Subnet Address
2. SSID to Join 6. Click OK
3. Properties 7. Click OK
4. Use The Following IP Address

Appendix B Troubleshooting: 3. Verify Ping to AP - From Windows Command

shell Ping to Access Point default IP Address
1. Static IP Address of your laptop computer
192.168.0.128
should be within the defined range 192.168.1.1
to 192.168.1.127 (not 192.168.1.20) and Net The response should come back from AP.
Mask 255.255.0.0.
a. If not check AP power supply.
2. Verify Only one network connection should be
maintained, disable if your laptop has more than b. Check for CAT 5 Ethernet Wire connection
one network. between POE Adapter (Power on Ethernet)
and AP.

4 Wireless Bridge Checkout Procedure 4/16 58E-06-11130

 4. Verify Ping to KWB-EG - From Windows 9. VHMS Data Auto-down Loader Test - If the
Command shell Ping to KWB-EG default IP truck is being assembled, and user is powering
Address 192.168.1.20 The response should ON VHMS for the first time, then it is
come back from KWB-EG. recommended user to configure VHMS dataset
and then download the VHMS data “manually”
a. If not check AP power supply.
through serial port. This procedure completes
b. Check for CAT 5 Ethernet Wire connection the “VHMS Data Auto-down Loader” tool
between POE Adapter (Power on Ethernet) registration process. Later user can follow data
and AP. download through AP (Access Point).
5. Windows Fire Wall should be disabled. (Set 10. LAN Connection and wireless connection- “No
Windows Fire Wall Status OFF) Procedure to Overlapping IP Address, All laptop computers
Access Fire Wall Settings (Windows 7) Control have a LAN connection capability and wireless
Panel' System and Security' Windows Firewall connection capability. When user want to
Or also be accessed through “Open Network download truck data through AP, make sure
and Sharing Center” by right clicking on the user has different Static IP address and Net
wireless signal bars. Mask for LAN (Local Area Connection)
6. User should have latest version of VHMS Auto connection, than that of Wireless Connection.
download Tool (please refer Komatsu extranet Or disable the LAN Connection capability.
website). It may help if user Closes and Opens (Keep one Network at a Time) Wireless
the tool, if it was open for a period of time. connection configurations should be done as
7. KWB_Connect has no WEP password setup, explained in Step 1.
do not change any settings. Maintain a safe 11. KWB-EG Link Status - Check for LINK LED on
distance from truck to download the data. If the the KWB-EG. If the LINK LED is OFF it
signal strength is too low, the truck may be not indicates there is connection problem, may
listed in the download tool. require to change the harness cable (refer to
8. If ping to KWB is successful but user is not able schematic below). If LINK LED is ON but user is
to download the data from VHMS auto not able to download the data from VHMS auto
download tool. download tool, there must be a configuration
issue on users laptop.
a. Try unplugging the power from the wireless
bridge and plugging it back in. Then wait for
30 sec for it to boot back up. Restart the
VHMS tool.
b. There also may be a configuration issue on
users laptop.

58E-06-11130 4/16 Wireless Bridge Checkout Procedure 5

 NOTES

6 Wireless Bridge Checkout Procedure 4/16 58E-06-11130

 RETRACTABLE LADDER SYSTEM CHECKOUT PROCEDURE
Scope of Checkout Procedure The following items must be reviewed and under-
stood before performing the Retractable Ladder Sys-
This checkout procedure will setup and verify the
tem (RLS) Checkout Procedure:
operation of the Retractable Ladder System (RLS).
• Electrical System Checkout Manual
• Interface Module Checkout Procedure
Necessary Equipment
• Hydraulic Checkout Manual
1. Auxiliary Hydraulic System Checkout
Procedure and Schematic (if equipped). • Brake Checkout Manual
2. (4) 0 - 5000 PSI calibrated gauges with quick- • Auxiliary Hydraulic Systems Checkout Manual
disconnect couplings.
All accumulators (steering, brake and auxiliary) must
be properly pre-charged before using this checkout
Required Software
manual.
Interface Module Realtime Data Monitor software is
recommended for trucks equipped with an electronic
display panel. The latest version may be downloaded
from the Komatsu America Extranet, https://
www.komatsuamerica.net/northamerica/.
The truck is not to be started without the Steer-
Data to Record ing, Brake and Auxiliary System (if equipped)
Steps in this document requiring recording of data accumulators being properly pre-charged. Low
are indicated with an asterisk (*). A consolidated accumulator pre-charge could cause damage to
form for recording data is located in the Checkout the accumulators.
Data Sheet section at the end of this document.
NOTE: Refer to Auxiliary Systems Hydraulic Diagram
Procedure Steps
when performing the steps of this checkout manual. 1. Verify the following:

NOTE: Be sure accumulators are bled down before a. The engine keyswitch is OFF.
loosening any hydraulic fitting. For bleeddown details b. Upper deck manual lowering valve knob is
refer to OUT (manual position).
Factory installations: Hydraulic Checkout c. Ground level lowering switch button is OUT
Manual (normal operating position).
Field installations: Auxiliary Hyd. Systems d. Ladder is in the full DOWN position.
Checkout Manual
e. Auxiliary accumulator bleeddown valve (fig-
NOTE: Carefully disconnect all hoses, tubing, ure 1) is open.
gauges and plugs in case hydraulic pressure is 2. Connect a 0 - 5000 psi pressure gauge at
trapped within. accumulator tap & distribution manifold port GA
and ladder manifold ports GDOWN, GP and
Precheckout Items GUP. Each gauge should display less than 15
psi.
a. Close the auxiliary accumulator manual
bleeddown valve (Figure 1-1) after verifying
the pressure at port GA is as specified.
Wheels (if installed) must be properly blocked b. If pressure is present at port GDOWN, GP or
before performing this procedure to prevent a GUP, slowly cycle the cab ladder momentary
possible roll away. switch (Figure 1-2), UP - DOWN, until the
pressure is relieved.

58E-00-10490 Retractable Ladder System Checkout Procedure 1

 FIGURE 1-3. LADDER MANIFOLD

1. Ladder Down Relief 3. Ladder Solenoid

Valve Valve
2. Ladder UP Relief 4. Ladder Pressure
Valve Reducing Valve

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

85644

FIGURE 1-2. LADDER MOMENTARY SWITCH

(LOCATED IN CAB)

1. UP 2. DOWN

3. Press the cab ladder momentary switch (Figure

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

2 Retractable Ladder System Checkout Procedure 58E-00-10490

 1 85645

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

TRUCKS WITH ELECTRONIC DISPLAY PANEL (EDP)

1. Ladder Down Indicator Light

FIGURE 1-5. CAB DASH INDICATOR PANEL (TYPICAL)

TRUCKS WITHOUT EDP

1. Ladder Down Indicator Light

7. Move the directional control lever to PARK and Record the ladder system supply pressure at
start engine. Allow engine to idle for 5 minutes manifold port GA.
to allow pressures to stabilize. 9. *Turn the ladder pressure reducing valve
8. *Port GA gauge should read greater than 2700 adjustment clockwise (in) and count the number
psi. All other gauges should read less than 15 of turns required to increase the ladder system
psi. operating pressure at port GP to 1450 ± 150
psi. The ladder should not move.

58E-00-10490 Retractable Ladder System Checkout Procedure 3

 Record the number of turns required to increase ii) Port GDOWN gauge displays less than 15
port GP ladder system operating pressure to psi.
1450 psi. b. After an additional 15 seconds,
NOTE: The pressure adjustment in this step c. Port GUP gauge returns to less than 15 psi.
establishes a reference position for future steps of
this checkout manual. Use step 26 to set the Port GDOWN pressure returns to more than
pressure reducing valve for normal operation. 500 psi.
10. Continue to turn the ladder pressure reducing d. The ground level alarm sounds for approxi-
valve adjustment clockwise (in) until the port GP mately 20 seconds.
gauge displays 1700 (+/-50) psi. Do not adjust 15. Press the cab ladder momentary switch to the
the ladder pressure reducing valve above the DOWN position.
maximum limit of the specified range. Port
GDOWN gauge should display the same pres- 16. Start the engine and operate at low idle for 5
sure as GP. Port GUP gauge should display 15 minutes to allow pressures to stabilize.
psi or less. 17. Stop the engine using the keyswitch in the cab.
NOTE: This pressure adjustment in this step is only 18. Adjust the ladder up relief valve during a 15 sec-
to verify the ladder relief valve settings. Use step 26 ond valve actuation period, as detailed in this
to set the pressure reducing valve for normal step. The ladder should not move any time
operation. during this step.
11. Stop the engine using the keyswitch in the cab. a. Press the cab ladder momentary switch to
the UP position.
12. While observing the port GDOWN and port GP
gauges, slowly turn the ladder down relief valve b. Allow 5 seconds for the ladder solenoid
adjustment counterclockwise (out) until the valve to actuate.
valve begins to open. c. Within the following 15 seconds, observe the
NOTE: Relief valve opening is indicated when the port GP and port GUP gauges and slowly
GDOWN pressure begins to fall or pulsate with an turn the ladder up relief valve adjustment
incremental turn of the adjustment. The opening may counterclockwise (out) until the valve begins
be accompanied by an audible hydraulic hiss. to open.
a. Tighten the ladder down relief valve adjust- NOTE: Relief valve opening is indicated when the
ment locknut. GUP pressure begins to fall or pulsate with an
incremental turn of the adjustment. The opening may
b. *Verify the ladder down relief valve begins to
be accompanied by an audible hydraulic hiss.
open at 1700 (+/-170) psi.
d. If adjustment is not completed within the 15
Record port GDOWN pressure when the down
second valve actuation period,
relief valve begins to open.
i) Tighten the ladder up relief valve
13. Allow the ladder down relief valve to close and
adjustment locknut.
the pressures at ports GDOWN and port GP to
stabilize. Valve closing can be expedited by ii) *Verify the ladder up relief valve begins to
momentarily opening the auxiliary accumulator open at 1700 (+/-170) psi.
bleeddown valve (figure 1). Do not vent the
Record the pressure at port GUP when the up
accumulator below 1500 psi, as displayed on
relief valve begins to open.
the port GA gauge. If vented below 1500 psi,
briefly restart the engine to raise the accumula- iii) Continue to step 19.
tor pressure.
e. If adjustment is not completed within the 15
14. Press the cab ladder momentary switch (figure second valve actuation period,
2) to the UP position. The ladder should not
i) Reset the ladder valve timer by pressing
move. Verify the following:
the cab ladder momentary switch to the
a. After 5 seconds have lapsed DOWN position.
i) Port GUP gauge displays more than 500 ii) Return to step 18a.
psi.

4 Retractable Ladder System Checkout Procedure 58E-00-10490

 19. Open the auxiliary accumulator manual bleed- vi)Ground level alarm sounds for 20 seconds
down valve (figure 1). Port GA gauge should or until the ladder is UP.
display less than 15 psi.
Record the response of the ladder, indicator
20. Press the cab ladder momentary switch to the light, display and alarms.
DOWN position.
Record the pressures at the ports GDOWN, GP
21. Turn the ladder pressure reducing valve adjust- and GUP when the ladder is fully UP.
ment fully counterclockwise (out). Note: The
b. *Pressing the cab ladder momentary switch
port GP and GDOWN gauges may display pres-
(figure 2) to the DOWN position results in the
sure due to oil trapped within the ladder cylin-
following:
der. This is acceptable.
22. Using the number of turns recorded in step 8, i) Ladder lowers smoothly 5 seconds after
turn the ladder pressure reducing valve adjust- the switch is depressed.
ment clockwise (in). ii) Ladder down indicator light (figure 4 or 5)
23. Turn the ladder pressure reducing valve adjust- illuminates during lowering.
ment counterclockwise (out) 1.5 turns. iii)Ladder down indicator light remains
24. Close the auxiliary accumulator manual bleed- illuminated when ladder is DOWN.
down valve. iv)Fault A333 does not appear on the cab
25. Start the engine and allow it to operate at low display panel (if equipped).
idle for 5 minutes. The ladder should not move. v) Cab alarm remains silent.
26. *Using the gauge in port GP, increase the lad-
vi)Ground level alarm sounds for 15 seconds
der system pressure to 1450 ± 145 psi by turn-
or until the ladder is DOWN.
ing the ladder pressure reducing valve
adjustment clockwise (in). Tighten the valve Record the response of the ladder, indicator
adjustment locknut. light, display and alarms.
Record the pressure ladder system pressure at Record the pressures at the ports GDOWN, GP
port GP. and GUP when the ladder is fully DOWN.
27. Push the upper deck manual lowering valve 30. *With the ladder in the DOWN position, apply
knob IN (normal operating position). The ladder the service brakes and move the directional
should not move. control lever to NEUTRAL. Verify the following
(during ladder motion):
28. Use the cab ladder momentary switch to raise
and lower the ladder several times. Final ladder a. Ladder begins raising without delay.
movement should be smooth and full. Maximum b. Ladder down indicator light in the cab dash
pressures should remain at or below the limits
indicator panel flashes.
specified in steps 12, 18 and 26.
c. Fault A333 (Hyd Ladder Fault) appears on
29. Verify normal ladder operation: the cab display panel (if the truck cab is
a. *Pressing the cab ladder momentary switch equipped with an electronic display panel).
(figure 2) to the UP position results in the fol- d. Both cab and ground level alarms sound.
lowing:
Record the response of the ladder, indicator
i) Ladder raises smoothly 5 seconds after light, display and each alarm.
the switch is depressed.
31. When the ladder reaches the full UP position,
ii) Ladder down indicator light remains verify the following:
illuminated during raising.
a. Ladder down indicator light turns off.
iii)Ladder down indicator light (figure 4 or 5)
turns off when the ladder is full UP. b. Fault A333 clears from the cab display panel
(if equipped).
iv)Fault A333 does not appear on the cab
c. Both cab and ground level alarms become
display panel (if equipped).
silent.
v) Cab alarm remains silent.

58E-00-10490 Retractable Ladder System Checkout Procedure 5

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

6 Retractable Ladder System Checkout Procedure 58E-00-10490

 41. *With the upper deck manual lowering valve 44. Use the cab ladder switch to raise the ladder.
knob OUT, press the cab ladder momentary 45. Allow the engine to operate at low idle for 5 min-
switch to the UP position. Verify the following: utes.
a. Ladder does not move.
46. Stop the engine using the cab keyswitch.
b. Without delay, the ground level alarm sounds 47. *Using the cab ladder momentary switch, fully
for 20 seconds. lower and then fully raise the ladder. Repeat
c. After a 15 second delay: until the ladder no longer lowers or raises. A
minimum of 3.5 complete lower & raise cycles
i) Cab ladder down indicator light flashes.
(4 lower strokes, 3 raise strokes) should be
ii) Fault A333 (Hyd Ladder Fault) appears on obtained.
the display panel (if equipped).
Record the number of complete lower and raise
iii)Cab alarm sounds. strokes obtained.
Record the response of the ladder, indicator 48. Pull the upper deck manual lowering valve knob
light, display and alarms. OUT and fully lower the ladder.
42. *Push the upper deck manual lowering valve 49. Open the auxiliary accumulator bleeddown
knob IN (normal operating position). Verify the valve. Port GA gauge should display less than
following: 15 psi.
a. Ladder does not move. 50. Disconnect the gauges installed in step 2.
b. Cab ladder down indicator light continues to 51. Push the upper deck manual lowering valve
flash. knob IN (normal operating position).
c. Fault A333 remains on the cab display panel
(if equipped).
d. Cab alarm continues to sound.
e. Ground level alarm remains silent.
Record the response of the ladder, indicator
light, display and alarms.
43. *With the upper deck manual lowering valve
knob IN, press the cab ladder momentary
switch to the DOWN position. Verify the follow-
ing:
a. Ladder does not move.
b. Cab ladder down indicator light illuminates.
c. Fault A333 clears from the cab display panel
(if equipped).
d. Both alarms are silent.
Record the response of the ladder, indicator
light, display and alarms.

58E-00-10490 Retractable Ladder System Checkout Procedure 7

 Retractable Ladder System Checkout Data Sheet
Acceptable values of each measurement are shown in parenthesis, ().

6. Ladder down indicator light illuminates when the ladder is DOWN? (yes) _________

8. Ladder system supply pressure (GA) (>2700 psi) _________

9. Number of adjustment turns to increase ladder system operating pressure to 1450 psi
(no specification) _________

12. Ladder down relief pressure (GDOWN) (1700 ± 170 psi) _________

18. Ladder up relief pressure (GUP) (1700 ± 170 psi) _________

26. Ladder system pressure (GP) (1450 ± 145 psi) _________

29a. When the cab switch UP is pressed with the ground lowering switch OUT and the upper deck lowering knob
IN (normal positions), do the following occur:
- ladder raises smoothly after a 5 second delay? (yes) _________
- ladder down indicator light remains illuminated during raising? (yes) _________
- ladder down indicator light turns off when ladder is full UP? (yes) _________
- fault A333 appears? (n/a if truck cab is not display equipped) (no) _________
- cab alarm sounds? (no) _________
- ground level alarm sounds for 20 seconds or until ladder is UP? (yes) _________
- pressures with ladder fully UP:
- GDOWN: ladder cylinder (0 +25/-0 psi) _________
- GP: ladder system supply (1450 ± 145 psi) _________
- GUP: ladder cylinder (1450 ± 145 psi) _________

29b. When the cab switch DOWN is pressed with the ground lowering switch OUT and the upper deck lowering
knob IN (normal positions), do the following occur:
- ladder lowers smoothly after a 5 second delay? (yes) _________
- ladder down indicator light illuminates during lowering? (yes) _________
- ladder down indicator light illuminates when ladder is full DOWN? (yes) _________
- fault A333 appears? (if equipped) (no) _________
- cab alarm sounds? (no) _________
- ground level alarm sounds for 15 seconds or until ladder is DOWN? (yes) _________

8 Retractable Ladder System Checkout Procedure 58E-00-10490

- pressures with ladder fully DOWN:
- GDOWN: ladder cylinder (1450 ± 145 psi) _________
- GP: ladder system supply (1450 ± 145 psi) _________
- GUP: ladder cylinder (0 +25/-0 psi) _________

30. When NEUTRAL is selected, do the following occur (during motion):

- ladder begins raising without delay? (yes) _________
- ladder down indicator light flashes? (yes) _________
- fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (yes) _________

31. When the ladder is fully UP, do the following occur:

- ladder down indicator light flashes or illuminates? (no) _________
- fault A333 displays? (if equipped) (no) _________
- an alarm sounds? (no) _________

32. When PARK is selected, do the following occur:

- ladder moves from fully UP? (no) _________
- an alarm sounds? (no) _________

33. When the ground lowering switch is pushed IN, do the following occur:
- ladder lowers without delay? (yes) _________
- ladder down indicator light flashes? (yes) _________
- fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (no) _________

34. When the cab switch DOWN is pressed with the ground lowering switch IN, do the following occur:
- ladder down indicator light illuminates without flashing (yes) _________
- fault A333 appears? (if equipped) (no) _________
- an alarm sounds? (no) _________

35. When the cab switch UP is pressed with the ground lowering switch IN, do the following occur:
- ladder moves from full DOWN? (no) _________
- ground alarm sounds for 20 seconds then silences? (yes) _________
- ladder down indicator light flashes after 15 seconds? (yes) _________

58E-00-10490 Retractable Ladder System Checkout Procedure 9

 - fault A333 appears after 15 seconds? (if equipped) (yes) _________
- cab alarm sounds after 15 seconds? (yes) _________

36. When the ground lowering switch is pulled OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light flashes? (yes) _________
- fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (no) _________

37. When the cab switch DOWN is pressed with the ground lowering switch OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light illuminates without flashing? (yes) _________
- fault A333 appears? (if equipped) (no) _________
- an alarm sounds? (no) _________

39. When the upper lowering valve knob is OUT, do the following occur:
- ladder moves smoothly to full DOWN position? (yes) _________
- ladder down indicator light flashes when ladder is not fully UP? (yes) _________
- fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds during lowering and at ladder full DOWN? (yes) _________
- ground level alarm sounds? (no) _________

40. When the cab switch DOWN is pressed with the upper lowering valve knob OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light illuminates? (yes) _________
- fault A333 appears? (if equipped) (no) _________
- an alarm sounds? (no) _________

41. When the cab switch UP is pressed with the upper lowering valve knob OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ground alarm sounds for 20 seconds then silences? (yes) _________
- ladder down indicator light flashes after 15 seconds? (yes) _________
- fault A333 appears after 15 seconds? (if equipped) (yes) _________
- cab alarm sounds after 15 seconds? (yes) _________

42. When the upper lowering valve knob is IN, do the following occur:

10 Retractable Ladder System Checkout Procedure 58E-00-10490

 - ladder moves from full DOWN? (no) _________
- ladder down indicator light flashes? (yes) _________
- fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (no) _________

43. When the cab switch DOWN is pressed with the upper lowering valve knob IN, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light illuminates without flashing? (yes) _________
- fault A333 appears? (if equipped) (no) _________
- an alarm sounds? (no) _________

47. Number of full ladder raise strokes down and up with the engine off.
(3.5 lower & raise cycles minimum) strokes down (4 minimum) _________
strokes up (3 minimum) _________

________________________________________________________________________
Name of Mechanic or Inspector performing Checkout

__________________________________
Date & Shift Checkout completed:

Machine: ___________________ Unit No. _________________ S/N ________________

58E-00-10490 Retractable Ladder System Checkout Procedure 11

 NOTES

12 Retractable Ladder System Checkout Procedure 58E-00-10490

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

SM2700-2 Seat Belts and Tethers Checkout Procedure 1

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

Initials / Date

 Seat belts are installed on operator seat. _____________________

 Tethers are installed on operator seat. _____________________

 Tethers are correctly mounted to the floor. _____________________

 Tethers are correctly adjusted. _____________________

 Seat belts are installed on passenger seat. _____________________

 Tethers are installed on passenger seat. _____________________

 Tethers are correctly mounted to the floor. _____________________

 Tethers are correctly adjusted. _____________________

Signature_________________________________ Date________________ Unit No.________________

2 Seat Belts and Tethers Checkout Procedure SM2700-2

 FIGURE 1.PASSENGER SEAT INSTALLATION
530M / HD1500-5, 730E, 830E & 930E
EARLIER MODELS

1. Tether Belt 3. Components Base

2. Seat Belt FIGURE 3.OPERATOR SEAT INSTALLATION
530M / HD1500-5, 730E, 830E & 930E
BOTH MECHANICAL AND INTERNAL
COMPRESSOR STYLE

FIGURE 4.TYPICAL SEAT INSTALLATION WITH

FIGURE 2.TYPICAL TETHER/SEAT BELT INTEGRAL TETHER
INSTALLATION - OPERATOR SEAT ON TRUCKS EARLY MECHANICAL SEAT WITHOUT
WITH OR WITHOUT AIR EXTERNAL TETHERS
1. Tether Belt 2. Seat Belt 1. Tether Cable 2. Seat Belt

SM2700-2 Seat Belts and Tethers Checkout Procedure 3

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

9
8
7

FIGURE 8.TYPICAL 2PT SEAT / BELT

2 3 4 PASSENGER SEAT INSTALLATION -
FIGURE 6.TYPICAL 3PT SEAT / BELT CURRENT MODELS
INSTALLATION - CURRENT MODELS 730E-8, 830E, 860E, 930E & 960E
HD1500-7, 730E, 830E, 860E,5 930E & 960E
HARNESS DETAIL

4 Seat Belts and Tethers Checkout Procedure SM2700-2

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

MACHINE MODEL MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
980E-4

Service Meter Reading Wheel Motor Traction Motor

Date of Inspection
Serial Numbers LH RH
Location of Machine at Inspection Wheel Motor Transmission
Serial Numbers LH RH
Distributor’s Name Dump Body Manufacturer
Komatsu Other
Customer’s Name Dump Body Style Dump Body S/N

Customer’s Address
KAC Area Service Manager Signature Date

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

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

Send Pink Reports to your KAC Regional Service Manager

Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.

Mark each item with the appropriate symbol as shown below.

CEAW008200 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visually inspect unit for loose parts and debris.
2 Hardware Visually inspect unit for missing and/or loose mounting hardware.
Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped and
3 Hoses and Cables
clear from sharp edges and not rubbing each other.
4 Ground Straps Verify all ground straps are secure (sub-frame, anchor, etc).
5 Engine Oil Level Verify engine oil level is in operating range.
6 Engine Fan Inspect fan-to-shroud clearance and belt alignment.
7 Hydraulic Oil Level Verify oil level is visible through upper sight glass with dump body down.
Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and
8 Anchor Pin
properly tightened hardware.
Front Wheel Bearing Oil
9 Inspect for proper oil level.
Level
10 Wheel Motors Inspect oil specification and proper oil level.
11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks.
12 Radiator Inspect coolant fill level, cold temperature protection, and DCA additive.
Verify all ladders and handrails are secure and hardware is tight.

13 Decks and Ladders Visually inspect installation of grid blower, rectifier assembly and control box for correct
assembly of components and proper clamping, no loose contacts, no damaged or poorly
crimped cables.
Inspect all wiring and connections in battery box and ensure there is no rubbing or chafing.
Verify battery mounting hardware is secure.
14 Battery
Verify electrolyte is at proper level and caps are securely installed.
Verify all battery terminals are secure.
Visually inspect installation of steering cylinders, tie rod, and accumulators per print.
15 Frame Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations to
ensure all hardware is secure and there are no leaks.
Hardware Torque
Verify front suspension mounting cap screws have been properly tightened per appropriate
1 Suspension
shop manual or field assembly manual procedure.
Verify torque on front wheel nuts is at 2 500 ± 136 N·m (1 843 ± 100 ft lb).
Wheels Verify torque on rear inside wheel nuts is at 2 500 ± 136 N·m (1 843 ± 100 ft lb).
2
(See Note below.) Verify torque on rear outside wheel nuts and adapter ring is at 2 655 ± 136 N·m (1 958 ± 100
ft lb).
Verify torque on left ROPS beam cap screws is at 800 N·m (590 ft lb).
3 ROPS
Verify torque on right cross beam cap screws is at 240 N·m (177 ft lb).
4 Cab Verify torque on cab mounting cap screws is at 1 424 N·m (1,050 ft lb).
5 Wheel Motor Verify torque on wheel motor mounting cap screws is at 4 040 N·m (2,980 ft lb).
6 Tie Rod Clamp Nuts Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).

NOTE: Refer to the appropriate Disassembly and Assembly section in the shop manual for the complete
wheel mounting tightening procedure.

CEAW008200 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 2 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Cab Compartment
1 Cab Doors Verify doors open and close smoothly and latch works properly.
2 Cab Windows Verify windows can be opened and closed smoothly.
3 Door Locks Verify left and right door locks work properly with key.
Visually inspect interior for completeness of assembly.
4 Interior
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes, etc.
Inspect operator seat adjustments.
5 Cab Seats
Inspect seat belts and tethers for proper installation.
Check tilt and telescoping functions.
6 Steering Wheel
Verify adjustable lever can be locked securely.
Verify wiper functions at all speeds and range does not extend beyond glass surface.
7 Wiper
Verify windshield washer functions properly and washer fluid bottle is full.
8 Document Holder Verify O&M manual and safety manual are present.
10 Horn Check for proper sound and no looseness in horn button.
11 Backup Horn Check for proper sound and function.
12 Directional Control Lever Check for proper function and no binding or looseness.
13 Gauges Verify gauges are installed straight and operating correctly.
14 Hydraulic Fittings Visually inspect all hydraulic fittings under cab and hydraulic brake cabinet for leaks.
15 Hoist Check operation of hoist lever in all four positions.
Lights
1 Dome Light Verify dome light operates properly.
2 Dimmer Switch Verify dimmer operates properly.
Verify all headlights (high and low beams) and fog lights are functional.
3 Headlights/Fog Lights Verify high beam indicators on instrument panel are functional.
Verify lights are at proper angle.
Visually inspect front and rear turn signal operation on left and right sides.
4 Turn Signal Verify turn signal indicators on instrument panel operate properly.
Verify switch turns off after turn is completed.
Verify flasher operates properly.
5 Hazard Flashers
Verify hazard indicator on instrument panel operates properly.
6 Backup Light Verify backup lights operate properly when shift lever is in REVERSE.
7 Manual Backup Light Verify switch and light function properly.
8 Service Brake Verify service brake lights and indicator operate properly.
9 Retarder Lights Verify retarder lights operate properly.

CEAW008200 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 3 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Service Inspection
1 Hydraulic System Perform flushing procedure at initial startup.
Front suspension oiling height is 25.4 mm (1 in.).
Rear suspension oiling height is 53.0 mm (2.1 in.).
Suspensions
2 Standard: Front suspension charging height is 228.6 mm (9 in.) at 3 047 kPa (442 psi).
(See Note below.)
Oil Sands: Front suspension charging height is 165.1 mm (6.5 in.) at 3 047 kPa (442 psi).
Rear suspension charging height is 212.3 mm (8.36 in.) at 1 455 kPa (211 psi).
Verify nitrogen charge in both steering and brake accumulators is at 9 653 kPa (1,400 psi).
3 Accumulators
(Charging pressure will vary with ambient temperature. Refer to chart in shop manual.)
4 Engine Prelube Ensure prelube is functional prior to engine startup.
5 Engine Starting Ensure engine starts easily.
6 Engine Noise Verify there is no abnormal noise from engine.
Verify when switch is ON, directional control lever is in NEUTRAL, brake is applied and
7 Brake Lock
indicator is ON.
8 Parking Brake Verify when directional control lever is in PARK, parking brake is applied and indicator is ON.
Verify with pedal depressed, front brake pressure (BF) is 16 545 ± 515 kPa (2,400 ± 75 psi).
Verify with pedal depressed, rear brake pressure (BR) is 16 545 ± 515 kPa (2,400 ± 75 psi).
9 Brake Pressures
Verify brake lock pressure is 13 790 ± 690 kPa (2,000 ± 100 psi).
Verify parking brake release pressure is 22 750 ± 1 380 kPa (3,300 ± 200 psi).
Verify steering wheel turns smoothly from lock to lock.
10 Steering
Verify steering system is free of noise and vibrations.
Verify POWER UP relief pressure is 18 960 ± 690 kPa (2,750 ± 100 psi).
Verify POWER DOWN relief pressure is 10 340 ± 520 kPa (1,500 ± 75 psi).
Verify hoist limit switch is operational and set correctly. (Measure on hoist cylinder 3rd stage.
11 Hoist
Cylinder should stop 152 mm (6 in.) before full extension.)
Verify hoist lever HOLD position operates properly.
Verify there is no heavy shock when dump body returns to frame in FLOAT.
POWER UP at 1,900 rpm with empty dump body is 22-26 seconds.
POWER DOWN at 780 rpm with empty dump body is 12-14 seconds.
12 Hoist Times
FLOAT to frame at 780 rpm with empty dump body is 14-18 seconds.
Ensure body up switch activates body up alarm and indicator.
Ensure automatic lubrication system is serviced, tank is full and air is purged from system.
13 Lubrication
Ensure automatic lubrication system is operating properly and timer is set as desired.
14 Payload Meter Calibrate and check payload meter operation per shop/O&M manual instructions.
15 Error Codes Troubleshoot any fault codes and delete.
16 Machine Record machine model type, machine serial number and engine serial number.
17 Dump Body Ensure dump body is shimmed correctly prior to truck release.
Ensure electrical checkout procedure has been completed and signed off.
18 Electrical Checks
(See appropriate field assembly manual or shop manual for procedure.)
19 IM Programming Ensure IM is programmed with its own unique configuration file and copy of file is saved.

NOTE: Refer to the appropriate Testing and Adjusting section in the shop manual for complete suspension
oiling and charging instructions.

CEAW008200 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 4 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
ADDITIONAL COMMENTS ________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CEAW008200 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 5 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 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
980E-4

Service Meter Reading Wheel Motor Traction Motor

Date of Inspection
Serial Numbers LH RH
Location of Machine at Inspection Wheel Motor Transmission
Serial Numbers LH RH
Distributor’s Name Dump Body Manufacturer
Komatsu Other
Customer’s Name Dump Body Style Dump Body S/N

Customer’s Address
KAC Area Service Manager Signature Date

Inspector’s Comments:

Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:

Signature Remark:

Send white reports to: Manager of Technical Support

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

Send canary reports to: Manager of Field Assembly

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

Send pink reports to your KAC Regional Service Manager

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

CEAW008300 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 4
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 As Found Corrective
No. Inspection Item Acceptance Procedures
Condition Action
Inspection Around Machine

1 Parts Visually inspect the truck for loose parts and debris.

Visually inspect the truck for missing and/or loose mounting

2 Hardware
hardware.
Visually inspect hydraulic hoses and electrical cables to
3 Hoses and Cables 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.
Verify the oil level is visible through the upper sight glass with
5 Hydraulic Oil Level
the body down.
Visually inspect the anchor hitch pin and anti-sway bar
6 Anchor Pin assembly for proper installation and properly tightened
hardware.
Verify the correct oil is being used and oil is at the proper
7 Wheel Motors
level.
Verify the fuel tank mounting is secure and there are no fuel
8 Fuel Tank
leaks.
Inspect the coolant fill level, cold temperature protection, and
9 Radiator
DCA additive.
Verify proper installation of the steering cylinders, tie rod, and
10 Steering Components
accumulators.
Visually inspect the hoist valve, pumps, filters, hydraulic tank
11 Hydraulic Components and hoist cylinder installations. All hardware must be secure
and no leaks evident.

12 Leakage Visually inspect the entire machine for leaks.

Hardware Torque
Steering Arm to Verify hardware torque is 2 705 ± 271 N·m (1,995 ± 200 ft
1
Front Suspension lb).
Steering Cylinder To
2 Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).
Frame
Steering Cylinder to
3 Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).
Steering Arm
4 Tie Rod Pin Retainer Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).
5 Tie Rod Clamp Nuts Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).
Cab Compartment
Check for proper tone and volume. Ensure there is no
1 Horn
looseness in the horn button.

2 Back Up Horn Check for proper tone, volume, and function.

Verify all gauges are installed straight and are operating

3 Gauges
correctly.
Verify no cracks exist on cab windows. Ensure all windows
4 Glass
are properly sealed.
Verify the cab seats, seat belts and tethers are in proper
5 Seat/Seat Belts
working condition.

CEAW008300 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 2 of 4
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 As Found Corrective
No. Inspection Item Acceptance Procedures
Condition Action
Service Inspection
Front suspension oiling height is 25.4 mm (1 in.).
Rear suspension oiling height is 53.0 mm (2.1 in.).
Standard: Front suspension charging height is 228.6 mm
(9 in.) at 3 047 kPa (442 psi).
Suspensions
1 Oil Sands: Front suspension charging height is 165.1 mm
(6.5 in.) at 3 047 kPa (442 psi).
Rear suspension charging height is 212.3 mm (8.36 in.) at
1 455 kPa (211 psi).
NOTE: Refer to the field assembly manual or the appropriate Testing and Adjusting section in the shop manual for complete suspension
oiling and charging instructions.
Verify the nitrogen charge in both steering and brake
accumulators is at 9 653 kPa (1,400 psi).
2 Accumulators
(Charging pressure will vary with ambient temperature.
Refer to the chart in the shop manual.)
Verify the steering system is operating smoothly while turning
3 Steering from lock to lock.
Verify the steering system is free of noise and vibration.
Ensure the automatic lubrication system contains no air and
is filled to the proper level.
4 Lubrication
Ensure the automatic lubrication system is operating properly
and the timer is set as desired.
Verify the 50 hour change of all hydraulic filters has been
completed.
5 Hydraulic Filters
NOTE: Elements are supplied from the factory in the parts
crate.
Pressure

Check and record the tire pressure/size/manufacturer for Size

6 Tires
future reference
Manufacturer

Calibrate and check the payload meter operation per O&M

7 Payload Meter System
manual. Troubleshoot any fault codes and delete after repair.
Check the drive control system operation per shop manual.
8 Drive/Control System
Troubleshoot any fault codes and delete after repair.
Rotating Components Visually inspect the wheel motor armature condition (brush
(Wheel Motors, wear, commutator color, etc).
9 Main Traction Alternator, Inspect the alternator slip rings and brushes.
Grid Blower) Inspect the grid blower motor commutator condition (brush
wear, etc).
Wheel Motor Sun Pinion
Measure and record the sun pinion end play for both RH and
10 End Play
LH wheel motors.

Verify KOMTRAX Plus is functioning properly per O&M

11 KOMTRAX Plus
manual. Troubleshoot and repair any problems.

CEAW008300 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 3 of 4
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.

No. Description of Modification Reason For Installation

ADDITIONAL COMMENTS:______________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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CEAW008300 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 4 of 4
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager