Manual Armado 830 AC Serial Numbers A30109 - A30239 CEAW005100

CEAW005100
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS A30109 - A30239
®
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 830E-AC dump truck.
Variations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.
FAM0012 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 FAM0012
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
FAM0012 Introduction iii

KOMATSU 830E-AC
iv Introduction FAM0012
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES
The following list of safety practices is intended for use
by personnel during field assembly of the truck.
This list of safety rules is not intended to replace local
safety rules or regulations and federal, state, or local
laws. The safety precautions recommended here are Before welding, refer to Special Precautions When
general and must be used in conjunction with all pre- Servicing An AC Drive System Truck, in Section 4.
vailing local rules and regulations.
1. All personnel must be properly trained for the
10. Disconnect the battery charging alternator lead
assembly process.
wire before welding on the frame or its compo-
2. Wear safety equipment such as safety glasses, nents.
hard toe shoes and hard hats at all times during
assembly. 11. When welding, connect the ground cable to the
part being welded. DO NOT allow welding current
3. Thoroughly inspect the assembly site. Remove to pass through bearings, engine, etc.
weeds, debris and other flammable material.
12. DO NOT weld the fuel tank or hydraulic tank
4. Use only solid, hard wood for supports. When
unless the tanks have been properly purged and
using metal support stands, place wood blocks
ventilated.
between the support and the frame to prevent
metal to metal contact. 13. Use the proper tools for the job to be performed.
5. Inspect all lifting devices. Refer to the manufac- Never improvise wrenches, screw drivers, sock-
turer's specifications for correct capacities and ets, etc. unless specified.
safety procedures when lifting components. 14. Lifting eyes and hooks must be fabricated from
6. Perform a daily inspection of all lifting cables and the proper materials and rated to lift the intended
chains. Replace any questionable items. Use load.
cables and chains that are properly rated for the 15. When the weight of any component(s) or any
load to be lifted. assembly procedure is not known, contact your
7. DO NOT stand beneath a suspended load. Use of customer support manager for further information.
guy ropes are recommended for guiding and posi-
tioning a suspended load.
8. Maintain fire control equipment. Inspect fire extin-
guishers regularly to ensure they are fully charged
and in good working condition.
9. Cap screws and/or nuts being replaced must be
the same grade as originally supplied.
FAM0110 5/08 Safety Rules, Tools, & Equipment F01-1

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
F01-2 Safety Rules, Tools, & Equipment 5/08 FAM0110

LIFTING SLING GENERAL INFORMATION

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

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

EJ2627 Roller Assy. Power Module
(No longer Remove & Install
available as
complete unit)
EJ2629 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

TZ3535 Offset Box End Miscellaneous
Wrench,
1, 1/2 in.

TZ2734 3/4 in. Torque Miscellaneous
Adapter

TZ2733 Tubular Handle Use with TZ2734
& TZ3535

TY2150 Seal Installation Front Face
Tool Seals

TY4576 Sleeve Steering Link-
Alignment Tool age and Tie Rod
TZ0992 Sleeve Rear Suspen-
Alignment Tool sion & Anti-
Sway Bar

PB6039 Hydraulic Miscellaneous
Coupling

PC2061 Belt Tension Tester A/C Belt Ten-
sion

EL8868 V-Belt Align- Aligning A/C
ment Tool pulleys

PC2525 Harness Payload Meter
Download
AK4720 Software Payload Meter
Data Manager

EH7817 Alignment Tool Upper Hoist Pin

TZ2100 Socket (1 7/8 in.)
TZ2728 Socket (2 3/4 in.) Miscellaneous
TV7567 Socket (1 5/16 in.)
PB6825 Impact Socket
(1 5/8 in.)

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

WA4826 Lifting Eye Bolt Miscellaneous
TG1106

TV1186 Extension (3 1/2 in.) Miscellaneous
TR0532 Extension (8 in.)
TR0533 Extension (17 in.)

TRUCK COMPONENTS AND SPECIFICATIONS
Truck And Engine Operator's Cab
The 830E-AC dump truck is an off-highway, rear The operator cab has been engineered for operator
dump truck with AC electric drive. The gross vehicle comfort and to allow for efficient and safe operation
weight is 385 852 kg (850,650 lbs.). The engine is a of the truck. The cab provides wide visibility, with an
Komatsu SDA16V160 rated @ 1865 kW (2500 hp). integral 4-post ROPS/FOPS structure, and an
advanced analog operator environment. It includes a
tinted safety-glass windshield and power-operated
Alternator (G.E. GTA-41) 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/tele-
engine speed. The alternator produces AC current scope steering wheel, controls mounted within easy
which is rectified to DC within the main control cabi- reach of the operator, and an analog instrument
net. The rectified DC power is converted back to AC panel which provides the operator with all instru-
by groups of devices called "inverters", also within ments and gauges which are necessary to control
the main control cabinet. Each inverter consists of six and/or monitor the truck's operating systems.
"phase modules" under the control of a "gate drive
unit" (GDU). The GDU controls the operation of each Power Steering
phase module.
The truck is equipped with a full time power steering
Cooling air for the control / power group and wheel system which provides positive steering control with
motors, as well as the alternator itself, is provided by minimum operator effort. The system includes nitro-
dual fans mounted on the alternator shaft. gen-charged accumulators which automatically pro-
vide emergency power if the steering hydraulic
AC Induction Traction Motorized Wheels pressure is reduced below an established minimum.
The alternator output supplies electrical energy to the
two wheel motors attached to the rear axle housing.
Dynamic Retarding
The motorized wheels use three-phase AC induction The dynamic retarding is used to slow the truck dur-
motors with full-wave AC power. ing normal operation or control speed coming down a
grade. The dynamic retarding ability of the electric
The two wheel motors convert electrical energy back
system is controlled by the operator through the acti-
to mechanical energy through built-in gear trains
vation of the retarder pedal in the operators cab and
within the wheel motor assembly. The direction of the
by setting the RSC (Retarder Speed Control).
wheel motors is controlled by the directional control
Dynamic retarding is automatically activated, if the
lever located on the center console.
truck speed goes to a preset overspeed setting.
Suspension Brake System
Hydrair®II suspension cylinders located at each
The braking system consists of an all hydraulic actu-
wheel provide a smooth and comfortable ride for the
ation system. Depressing the brake pedal actuates
operator and dampens shock loads to the chassis
wheel-speed single disc front brakes and armature-
during loading and operation.
speed dual disc rear brakes. The brakes can also be
activated by operating a switch on the instrument
panel. The brakes will be applied automatically if sys-
tem pressure decreases below a preset minimum.
The parking brake is integral with the service brake
caliper, and is spring-applied and hydraulically-
released. The park brake is applied by moving the
directional control lever to the PARK position.
FAM0211 Truck Components And Specifications Page 2-1

830E MAJOR COMPONENTS
Page 2-2 Truck Components And Specifications FAM0211

SPECIFICATIONS
These specifications are for the standard Komatsu SERVICE CAPACITIES
830E-AC Truck. Customer options may change this . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters. (U.S. Gal.)
listing. Crankcase * . . . . . . . . . . . . . . . . . 280.0. . . . . (74.0)
* Includes Lube Oil Filters
ENGINE Cooling System . . . . . . . . . . . . . . . . 568. . . . . (150)
Komatsu SDA16V160 Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542. . . . (1200)
(Optional SSDA16V160) Hydraulic System . . . . . . . . . . . . . . . 946. . . . . (250)
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic Tank . . . . . . . . . . . . . . . . . 901. . . . . (238)
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke Wheel Motor Gear Box (each) . . . . . . 38. . . . . . (10)
Rated Brake HP. . . . 1865 kW (2500 hp)@ 1900 rpm
HYDRAULIC SYSTEMS*
Flywheel HP . . . . . 1761 kW (2360 hp) @ 1900 rpm
Weight* (Wet) 9 608 kg (21,182 lbs) Pumps
* Weight does not include Radiator, Sub-frame, or Hoist . . . . . . . . . . . . . . . . . . . . . Tandem Gear Pump
Alternator Rated @ . . . . . 851 lpm (225 gpm) @ 1900 rpm and
. . . . . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi)
Steering/Brake . . . . . Pressure Compensating Piston
Rated @ . . . . . . .246 lpm (65 gpm) @ 1900 rpm and
AC ELECTRIC DRIVE SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . .18 961 kPa (2,750 psi)
(AC/DC Current)
System Relief Pressures
Alternator . . . . . . . . . . . . . General Electric GTA - 41
Hoist . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi)
Dual Impeller, In-Line Blower 255 m3/min (9000 cfm) Steering/Brakes . . . . . . . . . . .27 580 kPa (4,000 psi)
Motorized Wheels . . . .GEB25 AC Induction Traction Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . 3-Stage
Motors Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1 Filtration . . . . . . . . . . . . in-line replaceable elements
Maximum Speed* . . . . . . . . . 64.5 km/h (40 mph) Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh
(*w/40.00-57 Tires and 31.875:1 gear train) Hoist & Steering . . . . . . . . Full Flow, Dual In-Line,
*NOTE: Wheel motor application depends upon GVW, haul road . . . . . . . . . . . High Pressure Beta 12 Rating =200
grade and length, rolling resistance, and other parameters.
Komatsu & G.E. must analyze each job condition to assure proper *With Quick Disconnects for powering disabled truck
application. and system diagnostics.
DYNAMIC RETARDING
SERVICE BRAKES
Electric Dynamic Retarding . . . . . . . . . . . . . Standard
Actuation . . . . . . . . . . . . . . . . . . . . . . . .All Hydraulic
Maximum Rating . . . . . . . . . . . . . 2983 kW (4000 hp)
Front . . . . . . . . . . . . . . . . Wheel Speed, Single Disc
Inboard Mounted . . . . . . . . . . . . . . . . . 3 Calipers
24 VDC ELECTRIC SYSTEM Disc Diameter, O.D. . . . . . . . 1213 mm (47.75 in.)
Batteries . . . . 4 x 8D 1450 CCA, 12 volt batteries in Rear . . . . . . . . . . . . . . . Armature Speed, Dual Disc
Series/Parallel w/Disconnect Switch Disc Diameter, O.D. . . . . . . . . 635 mm (25.00 in.)
Alternator . . . . . . . . . . . 24 Volt, 260 Ampere Output Emergency Brake- .Automatically Applied (Standard)
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt Wheel Brake Lock . . . . . . . Manual Switch on Panel
Cranking Motors (2). . . . . . . . . . . . . . . . . . . . .24 Volt . . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping)
DISC PARKING BRAKE

Each Rear Wheel . . . . . Integral with Service Caliper
. . . . . . . . . . . Spring Applied, Hydraulically Released
STEERING
Turning Circle - Front Wheel Track. . . 28.4 m (93 ft.)
Twin hydraulic cylinders with accumulator assist to
provide constant rate steering. Emergency power
steering automatically provided by accumulators.
FAM0211 Truck Components And Specifications Page 2-3

DUMP BODY CAPACITIES AND DIMENSIONS WEIGHT DISTRIBUTION
Standard, Heaped @ 2:1 (SAE) . . 147 m3 (193 yd3)
Empty Vehicle . . . . Kilograms. . . . . . . . (Pounds)
Struck . . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd3)
Front Axle . . . . . . . . . . . 82 747. . . . . . . . (182,426)
Loading Height Empty . . . . . . . . 6.61 m (21 ft. 8 in.)
Rear Axle. . . . . . . . . . . . 82 902. . . . . . . . (182,768)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Non-heated body w/exhaust mufflers . . . . . Standard Total (100% fuel) . . . . . 165 649. . . . . . . . (365,194)
Standard Komatsu body 27 669. . . . . . . . . (61,000)
Standard tire weight. . . . 21 081. . . . . . . . . (46,476)
TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . 40.00 R57 Loaded Vehicle . . . Kilograms. . . . . . . . (Pounds)
Optional Tires . . . . . . . . . . . . . . . . . . . . . . 46/90 R57 Front Axle . . . . . . . . . . 127 330. . . . . . . . (280,715)
Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless Rear Axle. . . . . . . . . . . 258 522. . . . . . . . (569,935)
Rims, standard 5 piece. . Rated to 827 kPa (120 psi)
Total * . . . . . . . . . . . . . 385 852. . . . . . . . (850,650)
Nominal Payload *. . . . 220 199. . . . . . . . (485,456)
. . . . . . . . . . . . . (242 U.S. Ton)
*Nominal payload is defined by Komatsu America

Corporation’s payload policy documentation. In gen-
eral, the nominal payload must be adjusted for the
specific vehicle configuration and site application.
The figures above are provided for basic product
description purposes. Please contact your Komatsu
distributor for specific application requirements.
OVERALL TRUCK DIMENSIONS

(Empty with Standard Body)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 m (47 ft. 3 in.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32 m (24 ft. 0 in.)
Height with Canopy . . . . . . . . . . . . . . . . 6.96 m (22 ft. 10 in.)
Height with Dump Body Up . . . . . . . . . . 13.52 m (44 ft. 4 in.)
Turning Circle (on front track) . . . . . . . . 28.4 m (93 ft. 0 in.)
Page 2-4 Truck Components And Specifications FAM0211

MAJOR COMPONENT WEIGHTS
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before
each use. Lifting equipment must be in good condition and rated for approximately two times the weight
being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result.
Optional equipment added onto the truck may cause an increase to the component weights listed in this
chapter. Contact your customer support manager for concerns or questions about lifting truck compo-
nents.
NOTE: All component weights are dry weights. The additional weight of coolant, fuel, and oil that may be in the
components are not calculated into this list.
ITEM KILOGRAMS POUNDS
CHASSIS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,306 . . . . . . . . . . . . . . . . . . . . . . 2,879
Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5,615 . . . . . . . . . . . . . . . . . . . . . 12,379
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18,288 . . . . . . . . . . . . . . . . . . . . . 40,318
DECK AND DECK SUPPORT COMPONENTS

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,177 . . . . . . . . . . . . . . . . . . . . . . 4,800
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604 . . . . . . . . . . . . . . . . . . . . . . 1,331
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 . . . . . . . . . . . . . . . . . . . . . . 1,568
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 . . . . . . . . . . . . . . . . . . . . . . . .474
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 . . . . . . . . . . . . . . . . . . . . . . 1,080
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 . . . . . . . . . . . . . . . . . . . . . . . .489
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668 . . . . . . . . . . . . . . . . . . . . . . 1,472
RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 . . . . . . . . . . . . . . . . . . . . . . 1,169
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 . . . . . . . . . . . . . . . . . . . . . . . .265
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 . . . . . . . . . . . . . . . . . . . . . . . .388
Vertical Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . .77
FAM0311 Major Component Weights Page 3-1

ITEM KILOGRAMS POUNDS
POWER MODULE
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 . . . . . . . . . . . . . . . . . . . . . . . . 421
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788 . . . . . . . . . . . . . . . . . . . . . . .1,737
Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,364 . . . . . . . . . . . . . . . . . . . . . . .5,212
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,176 . . . . . . . . . . . . . . . . . . . . . . .7,002
Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 . . . . . . . . . . . . . . . . . . . . . . . . 445
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,993 . . . . . . . . . . . . . . . . . . . . . . .8,803
Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,558 . . . . . . . . . . . . . . . . . . . . . . 18,867
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,905 . . . . . . . . . . . . . . . . . . . . . . .4,200
FLUID COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 . . . . . . . . . . . . . . . . . . . . . . . . 309
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .796 . . . . . . . . . . . . . . . . . . . . . . .1,755
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 . . . . . . . . . . . . . . . . . . . . . . . . 278
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 . . . . . . . . . . . . . . . . . . . . . . . . 717
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,711 . . . . . . . . . . . . . . . . . . . . . . .3,772
FRONT AXLE COMPONENTS

Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,216 . . . . . . . . . . . . . . . . . . . . . . .7,090
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 . . . . . . . . . . . . . . . . . . . . . . . . 496
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,228 . . . . . . . . . . . . . . . . . . . . . . .4,912
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 . . . . . . . . . . . . . . . . . . . . . . . . 364
REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,146 . . . . . . . . . . . . . . . . . . . . . . .2,527
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 . . . . . . . . . . . . . . . . . . . . . . . . 763
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,086 . . . . . . . . . . . . . . . . . . . . . . 11,213
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 . . . . . . . . . . . . . . . . . . . . . . . . 330
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12,201 . . . . . . . . . . . . . . . . . . . . . . 26,899
Page 3-2 Major Component Weights FAM0311

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

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

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

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

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

FIGURE 4-1. TOE HAMMER PEENING

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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

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

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

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

NOTES

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

ASSEMBLY LAYOUT
Page 5-2 Receiving & Assembly Preparation FAM0503

CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines BASIC ASSEMBLY PROCEDURE
varies. Photographs or illustrations used in the fol-
lowing procedures are provided as general guide- 1. Site preparation
lines only. Actual assembly may be different, but this 2. Unload truck components
general procedure provides a basic outline for 3. Assemble the chassis
assembly. 4. Weld the body
Items like the hydraulic tank and the accumulators NOTE: Chassis assembly and body welding may be
may have been removed for shipping and will have to done in either order, or simultaneously. The most
be locally installed. logical order depends on available resources such as
Each shipment may be different, depending on the cranes, welders, assemblers, etc.
truck configuration and destination. 5. Static checkout (electrical & mechanical)
6. Install the body
7. Dynamic checkout (electrical & mechanical)
RECOMMENDED ASSEMBLY DATA 8. Site cleanup
1. Service Report (Pre-Delivery)
2. Acknowledgement of Receipt of Company War-
ranty
3. Assembly Blueprints & Schematics
4. Fluid Specifications (refer to the lubrication
chart in Section 10, Appendix)
5. Suspension Oiling & Charging Procedure
(available in Section 10, Appendix)
6. Fan Drive Adjustment Procedure (available in
the engine service manual)
7. Toe-In Adjustment Procedure (Section 10,
Appendix)
8. Hydraulic Checkout Procedure (Section 10,
Appendix)
9. 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)
FAM0611 5/08 Chassis Assembly F6-1

ORDER OF ASSEMBLY LEVEL 5
The assembly procedure is organized in levels. Gen- 1. Operator Cab
erally, the tasks to be done at a given level may be 2. Blower Inlet Duct
performed in any convenient order or simultaneously. 3. Front Tires
However, all tasks in that level must be completed
4. Rear Tires
before proceeding to the next higher level. Each level
depends on the installation of components from the
previous level. LEVEL 6
1. Weld Uprights
NOTE: As stated earlier, shipping and packaging of
large machines will vary. Some of these steps may
change due to different shipping configurations and/ LEVEL 8
or truck options.
Dump Body Installation
LEVEL 7
LEVEL 1 1. Hoist Cylinders
1. Chassis - Unload and crib for assembly. 2. Rock Ejectors
2. Deck Supports 3. Mud Flaps
NOTE: It is easier to install and weld the deck 4. Clearance Lights
supports before the front suspensions are installed. 5. Body Pads/Shims/Guides
However, do not install the deck supports first, unless 6. Exhaust Blankets
there is a suitable means of installing the suspension
with the deck support in place. LEVEL 8
3. Hydraulic Tank
1. Clean the Truck
4. Fuel Tank
2. Lighting Wiring
5. Front Suspensions
3. Charge Suspensions
6. Uprights/Air Cleaners
4. Charge Accumulators
7. Diagonal Support Beam
5. Add Fluids
6. Charge the Air Conditioning System
NOTE: Do not weld the air cleaner / uprights until all
decks and the operator cab are installed. Ratchet
hoists may be required to help tie all the structures NOTE: Prior to starting the engine, verify that the
together for a proper fit. steering pump case is full of oil.
LEVEL 2 LEVEL 9
1. Air Cleaner Piping 1. System Checkouts
2. Spindles/Hubs 2. Decals
3. Diagonal Ladder 3. Touch Up Paint
4. Train Operators
LEVEL 3 5. Optional - Install Fire Suppression System
1. Control Cabinet
2. Auxiliary Control Cabinet
3. Center Deck
4. Steering Cylinders
5. Tie Rod
6. LH Deck
7. RH Deck/Grid Box
8. Wheel Motors
F6-2 Chassis Assembly 5/08 FAM0611

CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at other loca-
tions may be different. However, this outline will pro-
vide a general basis for assembly.
Disconnect the battery cables before arc welding
on the truck. Failure to do so may seriously dam-
age the batteries and electrical equipment. Dis-
connect the battery charging alternator lead wire
before welding on the frame or its components.
Follow all safety recommendations in this man- Fasten the welding machine ground cable to the
ual. Follow all local, state, and federal regula- component being welded.
tions. DO NOT allow welding current to pass through
bearings.
DO NOT lay welding cables over truck electrical
In the procedures that follow, many very heavy com-
cables and harnesses. Welding voltages could be
ponents will be required to be lifted into place and
induced into the truck wiring and cause damage
secured.
to components.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly cleaned and
ventilated.
Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
• Inspect all lifting devices. Slings, chains, and charged and in good working condition.
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 Mark cap screws and nuts with paint or ink after
components or any assembly procedure, tightening to the specified torque. This method
contact your customer support manager for provides verification that the hardware has been
further information. properly tightened.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the
intended load.
• Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
positioning a suspended load.
• Before lifting, ensure there is adequate
clearance from overhead structures or
electric power lines.

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

NOTES

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

FIGURE 6-1.

2. On domestic trucks, the auxiliary control cabinet (Figure 6-2) is attached to the frame of the truck and wired.
The electrical wiring cannot easily be disconnected. Lift the cabinet onto the control cabinet support to allow
the installation of other components (Figure 6-3). The weight of the auxiliary control cabinet is approximately
202 kg (445 lb).
Use caution when moving the auxiliary control cabinet. Lifting the cabinet too high may cause damage to
the wiring and electrical connections. DO NOT pull the wiring taut when lifting.
NOTE: On international trucks, the auxiliary control cabinets are not attached to the chassis. The cabinets are
installed on the main control cabinet, separate from the chassis.

FIGURE 6-2.
FIGURE 6-3.

3. Clean the mating surfaces for the deck supports to prepare for installation. (Figures 6-4 & 6-5)

FIGURE 6-4.
FIGURE 6-5.

4. Lift the LH deck support into position. The weight of the deck support is approximately 490 kg (1080 lb).
a. Bolt the support into place.
b. Tack weld the support.
c. The four tapped pads on each support and the corresponding blocks on the horsecollar must be removed
to allow for a complete weld around the joint.
d. Grind all areas, and clean. Paint after welding is complete.
Refer to Figures 6-6 thru 6-7.
If the tapped pads are not removed, a complete weld around the support can not be achieved. Gaps in the
weld around the support may result in premature frame cracking in this area.
5. Repeat for the RH deck support. The weight of the deck support is approximately 222 kg (489 lb).

FIGURE 6-6.
FIGURE 6-7.

10. Prepare the hydraulic filters for mounting on the fuel tank. Ensure all filter hardware is properly tightened.
11. Clean the mounts for the hydraulic tank and the fuel tank.

FIGURE 6-8.
FIGURE 6-9.

12. Lift the hydraulic tank into position on the cradles. (Figure 6-10). The weight of the hydraulic tank is approxi-
mately 325 kg (717 lb).
Install the four cap screws and the cradle caps at the top of the tank. Tighten to 616 ± 61 N·m (454 ± 45 ft lb).
Install the rubber dampeners and mounting hardware at the rear of the tank. Tighten the two cap screws to
standard torque. Refer to Standard Tables in Section 10, Appendix.
13. Lift the fuel tank into position on the cradles. (Figure 6-11) The weight of the fuel tank is approximately 1711
kg (3772 lb).
Install the four cap screws and the cradle caps at the top of the tank. Tighten to standard torque. Refer to
Standard Tables in Section 10, Appendix.
Install the rubber dampeners and mounting hardware at the rear of the tank. Tighten the four cap screws to
standard torque.

FIGURE 6-10.
FIGURE 6-11.

10. Connect the piping to the hydraulic tank and properly tighten all fittings.
Refer to Figures 6-12.
NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened.
11. Install the hydraulic filters onto the bracket at the rear of the fuel tank. Refer to Figure 6-13.
Connect the fuel supply line to the fitting at the rear of the tank, and connect the return line to the fitting at the
top of the tank.

FIGURE 6-12.
FIGURE 6-13.

12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.
Refer to Figure 6-14 & 6-15.

FIGURE 6-14.
FIGURE 6-15.

13. Clean and dry the mounting surfaces on both 14. Lubricate the cap screw threads, cap screw
the suspension and the frame. Use a cleaning head seats, washer faces, and nut seats with a
agent that does not leave a film after evapora- rust preventive compound.
tion, such as trichlorethylene, tetrachlorethyl-
ene, acetone or lacquer thinner.
High tightening torque is required to load the

front suspension mounting cap screws.
Repeated tightening will result in cap screw
fatigue and damage. DO NOT reuse mounting
cap screws, washers and nuts. Replace the
hardware after each use.
Suspension mounting cap screws are specially
hardened to meet or exceed grade 8
specifications. Replace only with cap screws of
correct hardness. Refer to the appropriate parts
book for the correct part numbers. FIGURE 6-16. INSTALLATION OF HARDENED
. FLAT WASHER
1. Hardened Flat Washer 2. Cap Screw
The use of dry threads in this application is not 15. The hardened flat washers use on the front sus-
recommended. Due to the high tightening forces pensions are punched during the manufacturing
required to load these cap screws, dry threads or process. Assemble the cap screws and wash-
threads lubricated with anti-seize compounds ers, and position the punch lip away from the
may result in damage. Only use the approved cap screw head to prevent damage. See Figure
lubricants listed below. 6-16.
• American Anti-Rust Grease #3-X from Standard 16. Lift the front suspension into position. Refer to
Oil Division of American Oil Company Figure 6-17. The weight of each front suspen-
• Rustolene D grease from Sinclair Oil Company sion cylinder is approximately 2228 kg (4,912
lb). Install the mounting hardware and tighten
• Gulf NoRust #3 from Gulf Oil Company
according to the "turn-of-the-nut" method out-
• Rust Ban 326 from Humble Oil Company lined on the following pages.
• 1973 Rustproof from the Texas Company
• Rust Preventive Grease-Code 312 from the
Southwest Grease and Oil Company
NOTE: If none of the rust preventive greases listed
above are available for field assembly, use one of the
following lubricants:
• SAE 30 weight oil
• 5% Molybdenum - Disulphide Grease
DO NOT use anti-seize compounds.

FIGURE 6-17.

"Turn-Of-The-Nut" Tightening Procedure
a. Tighten all 14 cap screws (1, 6, 8, Figure 6- 1.) Mark a reference line on a corner of the
20) to 542 ± 5 N·m (400 ± 40 ft lb). hexagonal cap screw head or nut and the
mounting surface opposite this corner, as
b. Maintain this torque on the top two corner
shown. Then mark the position located
cap screws and the bottom, outer four cap
60° or 90° clockwise relative to the first
screws (without spacers).
reference line on the mounting surface.
c. Loosen the eight remaining cap screws and Refer to Figures 6-18 and 6-19.
then tighten again as follows:
2.) Scribe a reference mark at the opposite
d. Initially tighten the four cap screws (1) at the end of the turning member to ensure that
upper mount to 95 N·m (70 ft lb). Then, either the cap screw head or nut, remains
advance the cap screw heads 60° as out- stationary.
lined in Steps d-1 through d-3. Refer to Fig-
3.) Each corner of a hexagon represents 60°.
ure 6-18.
The turning member, either the cap screw
head or nut, is turned until the marked
corner is adjacent with the marked refer-
ence line. Prevent the opposite end of the
turning member from turning during the
tightening procedure.
NOTE: Do not exceed 4 rpm tightening
speed. Do not hammer or jerk the wrench
while tightening.
e. Loosen the top two corner cap screws (1,
Figure 6-20) and the bottom outer four cap
screws (8), (without spacers).
FIGURE 6-18. 60 DEGREE ADVANCE 1.) Tighten the top two corner cap screws to
95 N·m (70 ft lb), then advance the cap
screw heads 60°.
Initially tighten the bottom four cap screws 2.) Tighten the bottom, outer four cap screws
(6, Figure 6-20) to 136 N·m (100 ft lb). to 203 N·m (150 ft lb), then advance the
Then, advance the cap screw heads 120° cap screw heads 90°.
as outlined in Steps d-1 through d-3. Refer
NOTE: If for any reason, these fasteners need to be
to Figure 6-19.
checked for tightness after completing this
procedure, loosen and inspect all 14 cap screws and
repeat the entire process. The hardware must be
cleaned and lubricated.
FIGURE 6-19. 90 DEGREE ADVANCE

FIGURE 6-20. SUSPENSION INSTALLATION
1. Cap Screws, Washers 6. Cap Screws, Washers

2. Nuts, Washers 7. Piston
3. Housing 8. Cap Screws, Washers
4. Mounting Surface 9. Spacer
5. Shear Bar 10. Nuts, Washers

17. Remove the center deck to enable easy installation of the air intake tubing and the diagonal cross tube (Fig-
ure 6-21). The weight of the center deck is approximately 250 kg (550 lb).
Do not discard the hardware at the rear of the deck. This hardware is to be used for installation.

FIGURE 6-21.

18. Prepare the upright mating surfaces for installation. Refer to Figure 6-22.
19. Attach either upright to a crane using adequate lifting apparatus. Attach a ratchet hoist to the lifting apparatus
to enable the upright to pivot for proper alignment. Refer to Figure 6-23.

FIGURE 6-22.
FIGURE 6-23.

20. Lift the LH & RH uprights into position and install the four cap screws for each upright. Tighten to standard
torque. Refer to Standard Tables in Section 10, Appendix. The weight of the RH upright is approximately 530
kg (1169 lb). The weight of the LH upright is approximately 668 kg (1472 lb).
Refer to Figure 6-24.
DO NOT weld the torque tubes on the uprights until the decks are installed.
21. Attach the upper radiator stabilizers rods to the uprights. Refer to Figure 6-25. After the decks are installed
and the uprights welded, adjust the stabilizers to vertically level the radiator.

FIGURE 6-24.
FIGURE 6-25.

22. Prepare the mounting surfaces for the LH diagonal tube (Figure 6-26).
23. Lift the tube into position (Figure 6-27). The weight of the diagonal tube is approximately 120 kg (265 lb).
Do not tighten the cap screws until the deck and the cab are in place.

FIGURE 6-26.
FIGURE 6-27.

24. Install the hanger brackets for the intake tubes. Refer to Figure 6-28.
25. Lift the air intake tubes into place. Install and tighten the clamps that secure the hoses.
Refer to Figure 6-29 - 6-31. The intake tubes are assembled and adjusted for installation on the truck. DO
NOT loosen any of the connections during installation.

FIGURE 6-28.
FIGURE 6-29.

FIGURE 6-30.

FIGURE 6-31.

26. Lift the center deck into position (Figure 6-32). Install the mounting hardware and tighten to standard torque.
Refer to Standard Tables in Section 10, Appendix.
27. Clean the tapered portion of the suspension rod and the bore of the spindle. Clean and check the tapped
holes in bottom of Hydrair® piston for damaged threads. Retap holes, if necessary, with 1.250 in. - 12NF tap.
Lubricate the two surfaces with multi purpose grease number 2 (5% molybdenum disulphide). Refer to Figure
6-33.
NOTE: Never use any lubricants on the spindle bore containing copper, such as many “anti’-seize” compounds.
Products containing copper will contribute to corrosion in this area.

FIGURE 6-32.
FIGURE 6-33.

28. Lift the retainer plate into position under the spindle. The weight of the retainer plate is approximately 48 kg
(106 lb). Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brake
assembly is approximately 3216 kg (7090 lb). Refer to Figure 6-34.
29. Install the twelve retainer plate cap screws. Refer to Figure 6-35. Tighten cap screws using the following pro-
cedure:
a. Tighten cap screws uniformly to 678 N·m (500 ft lbs) torque.
b. Continue to uniformly tighten the cap screws in increments of 339 N·m (250 ft lbs) to obtain a final torque
of 2142 N·m (1580 ft lbs).
30. Repeat the previous steps for the remaining wheel.

FIGURE 6-34.
FIGURE 6-35.

31. Prepare the steering cylinder and tie rod mounting surfaces. Refer to Figure 6-36.

FIGURE 6-36.

32. Move the steering cylinder rod eye into position on the steering arm. Lubricate the mounting pin with grease.
Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 ± 71 N·m (525 ± 53 ft
lb). Refer to Figures 6-37 & 6-38.
NOTE: Use alignment sleeve (TY4576) to aid in assembly of the steering cylinder joints.
33. Lift the tie into position on the steering arms. The weight of the tie rod is 165 kg (364 lb). Lubricate the mount-
ing pins with grease. Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 ±
71 N·m (525 ± 53 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.
NOTE: Use alignment sleeve (TY4576) to aid in assembly of the tie rod joints.

FIGURE 6-37.
FIGURE 6-38.

34. Install the handrails onto the LH deck and lift the deck into place (Figure 6-39). The weight of the LH deck with
handrails is approximately 802 kg (1768 lb). Loosely install the eight deck mounting cap screws.
NOTE: After each deck is in place, tighten the cap screws to standard torque. Refer to Standard Tables in Section
10, Appendix.
35. Lift the operator cab into position. The weight of the cab is approximately 2177 kg (4800 lb). Refer to Figure 6-
40.
Tap the cab mounting holes to remove any paint.
Install and tighten the forty cap screws to standard torque.
36. Tighten the hardware for the LH diagonals tube to standard torque. Refer to Standard Tables in Section 10,
Appendix.

FIGURE 6-39.
FIGURE 6-40.

37. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 2364 kg (5212 lb).
Install the mounting cap screws and tighten to standard torque. Refer to Standard Tables in Section 10,
Appendix.
NOTE: On domestic trucks, the retarding grids are already installed on the deck.
38. Install the handrails on the RH deck.
39. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approxi-
mately 3100 kg (6834 lb). Refer to Figure 6-41.
40. Weld the LH & RH uprights to the front frame tube. Refer to Figure 6-42.
NOTE: Adjust the radiator shroud bumpers, located below each deck, on each side of the radiator shroud. Adjust
bumpers so that they just contact the shroud, but no pre-load.

FIGURE 6-41.
FIGURE 6-42.

41. Lift the two bumper extensions into place. The weight of each bumper extension is approximately 123 kg (271
lb). Refer to Figure 6-43 & 6-44.
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-43.
FIGURE 6-44.

42. Domestic trucks only - Lift the auxiliary control cabinet out of the way to allow placement of the control cabi-
net. The weight of the auxiliary control cabinet is approximately 202 kg (445 lb). Refer to Figure 6-45.
43. Lift the control cabinet into position. The weight of the cabinet is approximately 3176 kg (7002 lb). On interna-
tional trucks, the auxiliary control cabinet is already attached to the main control cabinet. The weight of this
assembly is 3378 kg (7447 lb)
Install the mounting hardware. Tighten the cap screws to standard torque. Refer to Standard Tables in Sec-
tion 10, Appendix.
44. Domestic trucks only - Lift the auxiliary control cabinet into position on the LH side of the main electrical con-
trol cabinet on domestic trucks. Refer to Figure 6-48.
Install the six cap screws to the cabinet and tighten the cap screws to standard torque.

FIGURE 6-45.
FIGURE 6-46.

FIGURE 6-47.
FIGURE 6-48.

FIGURE 6-49.
NOTE: Figure 6-50 shows the international configuration with the auxiliary cabinet already
attached to the control cabinet.

45. Install the mounting bracket for the control cabinet vent cover and install the cover. Figure 6-50 & 6-51.
Connect the wiring for the electrical control cabinet, auxiliary control cabinet, and grid box.
Lift the transition duct into place on the alternator, and install the mounting hardware. Clamp all wiring.
Refer to FIgures 6-52- 6-58.

FIGURE 6-50.
FIGURE 6-51.

FIGURE 6-52.
FIGURE 6-53.

FIGURE 6-54.
FIGURE 6-55.

FIGURE 6-56.
FIGURE 6-57.

FIGURE 6-58.

46. Install the blower hose and clamps to the control cabinet and transition duct.
Refer to Figure 6-59 & 60.

FIGURE 6-59.
FIGURE 6-60.

47. LIft the air intake ductwork into position and install the mounting hardware. The weight of the inlet duct is
approximately 191 kg (421 lb). Tighten the cap screws to standard torque. Refer to Standard Tables in Sec-
tion 10, Appendix.
Refer to Figure 6-61 & 6-62.

FIGURE 6-61.
FIGURE 6-62.

48. Install the diagonal ladder. The weight of the diagonal ladder is approximately 179 kg (395 lb).
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-63.

49. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assem-
blies installed is approximately 12,201 kg (26,899 lb). Refer to Figure 6-64 &6-65.
The hardened flat washers used in this application are punched during the manufacturing process. Therefore,
the washers must be installed with the punched lip away from the head of the mounting cap screws to prevent
damage to the fillet between the cap screw head and the shank. Refer to Figure 6-67.
Tighten the wheel motor mounting cap screws to 2007 ± 201 N·m (1480 ± 148 ft lb).
NOTE: When lifting the wheel motors, do not lift under the brake assembly. Shipping fasteners installed in the
outboard rim bolt circle must remain in place during lifting and installation of wheel motors.
FIGURE 6-64.
FIGURE 6-65.

FIGURE 6-66.
FIGURE 6-67.
1. Washer 2. Cap Screw

50. Connect the power cables and the speed sensors to each of the wheel motors. Connect the apply lines, brake
cooling supply lines, and return lines to each wheel.

FIGURE 6-68.

FIGURE 6-69. FRONT WHEEL ASSEMBLY
1. Valve Assembly 6. Lock Ring 11. Lockwasher 16. Lockwasher

2. Bead Seat Band 7. Wheel Retainer Lug 12. Nut 17. Bent Plate
3. Rim 8. Nut 13. Clamp 18. Hub
4. O-Ring 9. Capscrew 14. Capscrew
5. Side Flange 10. Flat Washer 15. Flatwasher
51. Use a tire handler to lift the front wheel into position
on the wheel hub. Install wheel retainer lugs (7, Fig-
ure 6-69 and lubricated nuts (8). Evenly tighten each
nut to 407 N·m (300 ft lb). Tighten the nuts in the
sequence shown in Figure 6-60.
52. Spin the wheel and check rim run-out. Maximum run-
out is 5 mm (0.20 in.). If run-out exceeds specifica-
tions, loosen all nuts and tighten again.
If run-out is within specifications, tighten each nut to
746 N·m (550 ft lb). Tighten the nuts in the sequence
shown in Figure 6-70.
After the truck has been assembled and is operational, FIGURE 6-70. TIGHTENING SEQUENCE
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. Recheck the torque on
a daily basis until the torque is maintained. Check the
torque at regular intervals, thereafter.

FIGURE 6-71.
FIGURE 6-72.

FIGURE 6-73. REAR WHEEL ASSEMBLY
1. Side Flange 5. Lock Ring 9. Clamp 13. Inner Wheel Rim

2. Outer Wheel Rim 6. Spacer 10. Nut
3. Bead Seat Band 7. Valve Cap 11. Wheel Retainer Wedge
4. O-Ring 8. Core 12. Valve Extension Tube
53. Use a tire handler to lift the inner dual wheel onto the wheel motor hub. Use caution when positioning. DO
NOT damage the tire inflation extension.
54. Use a lifting device to install spacer (6, Figure 6-73) onto wheel motor hub. The weight of the spacer is
approximately 88 kg (194 lb). Tap the spacer against the inner dual.
55. Lift the outer dual into position on the wheel motor hub.
Due to its size and weight, keep personnel away from the wheel assembly during installation.
NOTE: Position the outer dual wheel so that tire valve bracket aligns with the inner wheel inflation hose.

56. Install the wedges onto the studs and secure in place
with the lubricated wheel nuts. Evenly tighten each nut
in an alternating (criss-cross) pattern as shown in Fig-
ure 6-74. Tighten the nuts to 407 N·m (300 ft lb).
57. Spin the wheel and check rim run-out. Maximum run-
out is 5 mm (0.20 in.). If run-out exceeds specifica-
tions, loosen all of the nuts. Again, tighten the nuts as
specified in the previous step.
58. If run-out is within specifications, tighten each nut in
sequence to 746 N·m (550 ft lb).
After the truck has been assembled and is operational,

the truck must be operated for a short period of time, FIGURE 6-74. TIGHTENING SEQUENCE
and the torque on the wheels re-checked. Tighten the
wheels to the torque specified above.Recheck the
torque on a daily basis until the torque is maintained.
Check the torque at regular intervals, thereafter.
59. Secure the inner and outer dual tire inflation lines to the bracket on the outer rim. Tighten the cap screws to
standard torque.
FIGURE 6-75.

60. Attach a lifting device to the radiator surge tank. Lift the tank into position on the radiator (Figure 6-76). Install
the mounting hardware to the surge tank.
Install the hoses to the radiator and the surge tank. (Figure 6-77)

FIGURE 6-76.
FIGURE 6-77.

61. Lift the surge tank cover into position and install the mounting hardware (Figure 6-78). The weight of the cover
is approximately 98 kg (216 lb).

FIGURE 6-78.

62. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-79 & 6-80.
63. Connect the hydraulic piping from the operator’s cab to the hydraulic cabinet and route the hoses appropri-
ately.
FIGURE 6-79.
FIGURE 6-80.

FIGURE 6-81.
FIGURE 6-82.

64. Install the mud-flaps and mud guards.
65. Install any remaining handrails. Tighten the cap screws to standard torque. Refer to Standard Tables in Sec-
tion 10, Appendix.
66. The truck is now ready for body installation.

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

advisable to move the parts to be welded into an
enclosed shop area. Surfaces to be welded must be
dry and the temperature must be above 10°C (50°F).
If shop space is not available, it may be necessary to
provide a portable enclosure and pre-heat the parts
The total weight of the body is approximately prior to welding.
26,853 kg (59,201 lb). Use two cranes for assem- In most instances, it is easier to assemble and weld
bling the body. A 45 metric ton (50 ton) crane and the body while the sections are upside down. After
a 109-136 metric tons (120-150 ton) crane are the pivot, guide pin, and body pads are welded in
required. The larger crane is needed to help turn place, the body can be turned over and the remain-
the body over after completion of the underside der of the assembly can be completed.
welding.
All paint must be removed from surfaces to be
Assembly of the body must be performed on flat ter- welded. Use a wire brush or paint removal equip-
rain with an adequate area for welding machines and ment.
for maneuvering lifting equipment. Refer to the assembly blueprints shipped with the
truck for specific welding details and the parts
required for assembly.
Body sections must be assembled as originally

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

1. Canopy 4. Lift Hole 7. LH Side Sheet
2. Front Sheet 5. Floor
3. RH Side Sheet 6. Pivot
FAM0710 Dump Body Assembly 7-1

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

procedures assume the body is in its' normal, upright
position, as shown in Figure 7-1.
1. Organize the body sections in a large, flat,
open space. Position the sections side by side
and upside down. Arrange the sections so they
are properly oriented for assembly. Refer to
Figure 7-2 for domestic configuration, and 7-3
for international configuration.
FIGURE 7-4.
5. Use the hydraulic jack to align the body halves
at the rear. Install cap screw (1, Figure 7-5) and
the sleeve.
NOTE: Figure 7-5 shows the hardware numbered in
installation sequence. Cap screws (1, 2 & 7) are
marked with an asterisk (*). These cap screws are
installed with sleeves. The remainder of the cap
screws do not have sleeves.
6. Install cap screw (2) and the sleeve at the front
FIGURE 7-2. DOMESTIC LAYOUT of the floor.
7. Install cap screw (3) in the front sheet near the
floor. Attach a wedge or a clamp inside the
body as necessary to align the front sheet.
8. Use a wedge to align the front sheet and can-
opy. Install cap screws (4, 5 & 6).
9. Install cap screw (7) and the sleeve in the front
of the canopy.
10. Install cap screws (8 & 9).
11. Install the backer strips on the front sheet center
joint as shown on the assembly blueprint.
NOTE: The backer strips must be tack welded in a
location where the tack will be burned away on the
FIGURE 7-3. INTERNATIONAL LAYOUT first pass.
12. Loosely install cap screws (10 & 11) in the floor.
13. Loosen cap screws (1 & 2).
2. Remove the paint from the weld areas. 14. Attach appropriate lifting apparatus to the body
3. Lift the RH body half and support the front pivot. Insert the lifting apparatus through the
sheet, side sheets, and rear edge of the floor body pin bores. The weight of the pivot is
with blocks. Refer to Figure 7-4. approximately 1492 kg (3289 lb). DO NOT dam-
4. Lift the LH body and support with blocks under age the bores.
the front sheet and side sheet. Position a 15. Lift the pivot over the body. Lower the pivot into
hydraulic jack on blocks at the tail end to sup- position against the rear of the body, as shown
port the floor at the rear. Refer to Figure 7-5. in Figure 7-6. Align the pivot with the body sills.
7-2 Dump Body Assembly FAM0710

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

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

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

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

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

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

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

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

5. Refer to Figure 7-7 and the body assembly
print to complete the welds on the inside of the
body.
FIGURE 7-17.
FIGURE 7-19.
6. Install the mud flap brackets, clearance light

housings (Figure 7-21), etc. as specified on the
installation blueprints.
FIGURE 7-18.
FIGURE 7-20.

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

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

1. Body welding and chassis assembly must be completed before proceeding.
Before the body is lifted off the ground, tie guy ropes to each of the four corners of the body for aiding in instal-
lation.
There are two methods of installing the body depending on the cranes available.
a. If the truck is operational and can be driven, two 50 ton cranes can be used, one positioned at either side
of the body. The body can then be lifted high enough to allow the truck to be reverse propelled under the
body (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.
2. With the body in position, install shims (6, Figure 8-4) in both body pivots. Install enough shims to fill the out-
board 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 pivot pin (3) with the cap screw hole in body ear (4). Push the pivot pin through shims (6),
frame pivot (7), and into pivot bushings (5 & 9).
4. Install cap screw (1) through the pin and tighten nut (2) to 407 N·m (300 ft lb). Use washers, as necessary on
the nut side only, to provide proper thread contact.
5. Install the pivot pin at the opposite side of the body.
Page 8-2 Final Assembly FAM0811

FIGURE 8-1.
FIGURE 8-2.

FIGURE 8-3.

FIGURE 8-4. DUMP BODY PIVOT PIN
1. Cap Screw 6. Shim

2. Lock Nut 7. Frame Pivot
3. Body Pivot Pin 8. Pivot Bushing
4. Body Ear 9. Body Pivot Bushing
5. Body Pivot Bushing

6. Align the hoist cylinder upper bushings with the body. Refer to Figure 8-5. Align the retaining cap screw hole
and install pin (2, Figure 8-6).
Install the pin retaining cap screws and nuts. Tighten to 407 N·m (300 ft lbs).

FIGURE 8-5.
FIGURE 8-6. HOIST CYLINDER UPPER MOUNT

1. Dump Body 3. Hoist Cylinder
2. Hoist Cylinder Pin 4. Pin Retainer

7. 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 8-7.
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.
8. Inspect pad contact. If pad contact appears to be unequal, correct as necessary.
Proper body pad to frame contact is required for maximum pad life.

FIGURE 8-7. BODY PAD INSTALLATION
3. Dump Body 5. Frame 7. Shim
4. Pad Mounting Hardware 6. Body Pad 8. Mounting Pad

9. Tack weld the rock ejector mounting brackets into position on the underside of the body. The ejectors must be
positioned on the center line between the rear tires within 6.0 mm (0.25 in.). Before welding, drop a plumb line
to check rock ejector clearance. Position the rock ejector a distance of 88 mm (3.5 in.) from the wheel hous-
ing. Refer to Figure 8-10.
NOTE: With rock ejector arm (1) hanging vertical as shown in Figure 8-9, there must be no gap at stop block (3).
If the rock ejector arms are bent during operation, they must be removed and straightened. Inspect the
mounting brackets, pins and stops at each shift change for wear and/or damage. Repair as necessary.

FIGURE 8-8.
FIGURE 8-9. ROCK EJECTOR MOUNTING
1. Rock Ejector Arm 3. Stop Block

2. Pin 4. Mounting Bracket
FIGURE 8-10. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 3. Wheel Spacer
2. Wear Sleeve

10. Install any remaining mud guards or flaps (Figures 8-11 & 8-12).

FIGURE 8-11.
FIGURE 8-12.

11. Install both body guide brackets loosely into place (Figure 8-13).
Once in position, slowly lower the body and mark the position in which the brackets are to be welded. The
body guides must be centered between wear plates (3), with a maximum gap of 4.8 mm (0.19 in.) at each
side.

FIGURE 8-13. BODY GUIDE
1. Dump Body 3. Body Guide Wear

2. Body Guide Plates

12. Adjust the body up limit switch.
Adjust the switch bracket to maintain an air gap between the sensing area and target of 12.7 mm (0.50 in.) to
15.7 mm (0.62 in.). Adjust the switch to cover the bottom 53.8 mm (2.12 in.) of the target. Secure the compo-
nents in place.
13. Raise the body and attach the body retention cable. Remove the support blocks. Weld the body guide brack-
ets into place.

FIGURE 8-14. BODY-UP SWITCH ADJUSTMENT

14. Install the exhaust system piping and hangers. The deck mounted muffler exhaust is shown Figure 8-15.
Refer to the installation prints for other optional exhaust systems.

FIGURE 8-15.

15. With the body in the raised position, adjust the body hoist limit switch. Position the target so that it covers the
entire switch sensing area. Adjust the gap between the target and the switch to 12.7 - 14.7 mm (0.50 - 0.58
in.). Secure the target into position.
The switch should activate 152 mm (6 in.) before maximum cylinder stroke.
16. Install the LH & RH engine inspection lights (Figure 8-17).

FIGURE 8-16.
FIGURE 8-17.

17. Install add-on components such as the lubrication system. Verify that all electrical and hydraulic connections
are correct. Refer to Figure 8-19.
FIGURE 8-18.

FIGURE 8-19.
1. L.H. Suspension, Bottom Bearing 13. R.H. Anti-Sway Bar Bearing

2. L.H. Hoist Cylinder, Top Bearing 14. R.H. Suspension, Top Bearing
3. L.H. Hoist Cylinder, Bottom Bearing 15. Truck Frame
4. L.H. Anti-Sway Bar Bearing 16. Vent Hose
5. L.H. Suspension, Top Bearing 17. Pipe Plug (Oil Level)
6. L.H. Body Pivot Pin 18. Pressure Switch, N.O., 17 237 kPa (2500 psi)
7. R.H. Body Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. R.H. Suspension, Bottom Bearing 21. Filter
10. R.H. Hoist Cylinder, Top Bearing 22. Grease Supply to Injectors
11. R.H. Hoist Cylinder, Bottom Bearing 23. Injectors
12. Rear Axle Pivot Pin 24. Pressure Switch, N.O., 13 790 kPa (2000 psi)

18. Install the fire system. Refer to Figures 8-20 & 8-21.
This installation is normally performed by the fire system distributor.

FIGURE 8-20.
FIGURE 8-21.

19. Paint the truck as needed.
20. Install the anti-skid strips at the designated areas on the decks (Figure 8-22).
21. Install all decals on their designated areas (Figure 8-23).

FIGURE 8-22.
FIGURE 8-23.

22. After completing the assembly of the truck, verify that all cap screw heads or nuts are marked with paint, indi-
cating they have been properly tightened.
Check all hydraulic lines and electrical connections for secure installation.
Notify qualified maintenance personnel that the truck is ready for final static and dynamic systems checkout.

FIGURE 8-24.

NOTES

FINAL CHECKOUT
Final checkout requires truck operation.
Place the operation and maintenance manual and 4. Purge any air from the pumps. Pressure will not
safety manuals in the operator cab, if not already there. build if air is present. Operating the pumps with air
in the system will result in damage.
Any personnel involved in the final check-out of the
5. Perform a final check of all systems and prepare
truck must read and understand all safety and operat-
for operation. Several checks and tasks are out-
ing instructions in the operation and maintenance man-
lined in Section 10, Appendix.
ual.
6. Complete the checks listed in the Field Assembly
Inspection Report Form. A copy of the form is pro-
1. Complete delivery and warranty forms. vided with the truck and is also available in Sec-
tion 10, Appendix.
2. Check all coolant and lubricants for proper levels
and specifications. The lubrication chart is shown 7. Operate the truck in a traffic-free area until safe
in Section 10, Appendix. operation has been validated.
3. Verify the shut-off valves in the hydraulic cabinet 8. Release the truck for use after all checks have
are open. been completed and all deficiencies corrected.
FAM0903 Final Checkout Page 9-1

NOTES
Page 9-2 Final Checkout FAM0903

APPENDIX
This chapter contains additional information and procedures for aiding in field assembly of the truck. Refer to the
list below for contents of this chapter. Refer to the latest service manual for additional information on servicing the
truck.
1. Lubrication Chart - FAM1103
2. Suspension Oiling And Charging Procedure - FAM1201
3. Toe In Adjustment Procedure - FAM1301
4. Automatic Lubrication System Checkout Procedure - FAM1401
5. Air Conditioning Checkout Procedure - EL4302
6. Air Conditioning Drive Belt Adjustment Procedure - EL9330
7. Hydraulic Checkout Procedure - EL2603
8. Brake Checkout Procedure - EL6704
9. VHMS Checkout Procedure - EM2129-1
10. Interface Module Checkout Procedure - EM5627-2
11. Additional Interface Module Checkout Procedure - EM7279-0
12. Payload Meter III Checkout Procedure - EJ3061
13. Electrical Checkout Procedure - EF9650
14. Standard Torque Charts and Conversion Tables - FAM1501
15. Field Assembly Inspection Report
16. 50 Hour Post Commissioning Checksheet
FAM1010 Appendix F10-1

NOTES
F10-2 Appendix FAM1010

LUBRICATION CHART
FAM1103 Lubrication Chart F11-1

NOTES
F11-2 Lubrication Chart FAM1103

OILING AND CHARGING PROCEDURE
GENERAL For best results, HYDRAIR® II suspensions should
These procedures cover the Oiling and Charging of be charged in pairs (fronts together and rears
together). If rears are to be charged, the fronts
HYDRAIR®II suspensions on Komatsu Electric Drive
should be charged first.
Dump Trucks.
NOTE: For longer life of suspension components, a
Suspensions which have been properly charged will
Friction Modifier should be added to the suspension
provide improved handling and ride characteristics
oil. See Specifications Chart, Figure 4-5 at the end of
while also extending the fatigue life of the truck frame
this chapter.
and improving tire wear.
NOTE: Set up dimensions specified in the charts
NOTE: Inflation pressures and exposed piston
must be maintained during oiling and charging
lengths are calculated for a normal truck gross
procedures. However, after the truck has been
vehicle weight (GVW). Additions to truck weight by
operated, these dimensions may vary.
adding body liners, tailgates, water tanks, etc. should
be considered part of the payload. Keeping the truck
GVW within the specification shown on the Grade/
EQUIPMENT LIST
Speed Retard chart in the operator cab will extend • HYDRAIR® Charging Kit
the service life of the truck main frame and allow the
• Jacks and/or Overhead Crane
HYDRAIR®II suspensions to produce a comfortable
ride. • Support Blocks (Front and Rear) for:
Oiling Height Dimensions
Nitrogen Charging Height Dimensions
• HYDRAIR® Oil (See Specifications Chart)

®
All HYDRAIR II suspensions are charged with • Friction Modifier (See Specifications Chart)
compressed nitrogen gas with sufficient pres-
• Dry Nitrogen (See Specifications Chart)
sure to cause injury and/or damage if improperly
handled. Follow all safety instructions, cautions,
and warnings provided in the following proce-
dures to prevent any accidents during Oiling and
Charging. If both front and rear suspension are to be serviced
at the same time, service the front suspensions first.
Proper charging of HYDRAIR®II suspensions Do not remove the front suspension nitrogen charg-
requires that three basic conditions be established in ing blocks until after the rear suspensions have been
the following order: completely serviced.
1. Oil level must be correct.
2. Suspension piston rod extension for nitrogen
charging must be correct.
3. Nitrogen charge pressure must be correct.
FAM1201 3/08 Oiling and Charging Procedures F12-1

HYDRAIR® CHARGING KIT 5. Attach charging valve adapters (2) to each sus-
pension charging valve stem.
Assemble service kit as shown in Figure 4-1 and
6. Turn "T" handles (1) clockwise (this will depress
attach to container of pure dry nitrogen (8).
core of charging valve and open the gas cham-
Installation of Charging Kit ber of the suspension).
7. Open both outlet valves (3).
1. Remove protective covers and charging valve
caps from suspensions to be charged. NOTE: By selective opening and closing of outlet
2. Turn "T" handles (1, Figure 4-1) of adapters (2) valves (3), and inlet valve (4), suspensions may be
completely counterclockwise. charged separately or together.
3. Ensure outlet valves (3) and inlet valve (4) are
closed (turned completely clockwise).
4. Turn swivel nut (small hex) on charging valve Removal of Charging Kit
three full turns counterclockwise to unseat the 1. Close both outlet valves (3).
valve. 2. Turn "T" handles (1) counterclockwise to
release charging valve cores.
3. Remove charging valve adapters (2) from
charging valves.
4. Tighten swivel nut (small hex) on charging
valve. If a new charging valve is being used,
tighten swivel nut to 14.2 N·m (10.5 ft lbs)
torque, then loosen and retighten swivel nut to
14.2 N·m (10.5 ft lbs) torque. Again loosen
swivel nut and retighten to 5.4 N·m (4 ft lbs)
torque. Replace valve cap (1) and tighten to 3.3
N·m (2.5 ft lbs) torque (finger tight).
5. Install charging valve caps and protective cov-
ers on both suspensions.
FIGURE 4-1. HYDRAIR® CHARGING KIT

NOTE: Arrangement of parts may vary from
illustration above, depending on Charging Kit P/N.
1. “T” Handle Valve

2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas (Specifications Figure 4-5)
F12-2 Oiling and Charging Procedures 3/08 FAM1201

SUPPORT BLOCKS FOR OILING AND FRONT SUSPENSION
CHARGING DIMENSIONS 1. Park the unloaded truck on a hard, level sur-
face. Place the directional control lever in
PARK. Place wheel chocks in front and behind
Prior to starting oiling and charging procedures, sup-
two rear tires to prevent roll away.
ports should be fabricated which will maintain the
correct exposed piston rod extensions. NOTE: Do not place wheel chocks around front tires.
The front tires will roll forward and backward a small
amount as the suspension travels up and down
during the suspension charging process.
2. Thoroughly clean area around the charging

Rear support blocks for nitrogen charging are no valve on the suspensions. Remove the protec-
longer necessary. Rear suspensions still require tive covers from the charging valves.
support blocks for oil charging.
Exposed piston rod extensions are specified for both
oil level and nitrogen charging for HYDRAIR®II sus-
pensions. These dimensions are listed in the Tables
below Figures 4-2 and 4-4. Measure dimensions All HYDRAIR®II suspensions are charged with
from the face of the cylinder gland to the machined compressed nitrogen gas with sufficient pres-
surface on the spindle at the front suspension. Mea- sure to cause injury and/or damage if improperly
sure from the face of the cylinder gland to the piston handled. Follow all the safety notes, cautions and
flange at the rear suspension. warnings in these procedures to prevent acci-
dents during servicing and charging.
Support blocks may be made in various forms. Mild
steel materials are recommended. Square stock or
pipe segments [1 in. (25 mm) minimum] may be Front Suspension Oiling
used. Blocks must be capable of supporting the
weight of the truck during oiling and charging proce-
dures while avoiding contact with plated surfaces
and seals on the suspension. Refer to Figure 4-2 for
front suspension support block placement and Figure When blocks are in place on a suspension, they
4-4 for rear support block placement. 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!
NOTE: For longer life of suspension components, a
Friction Modifier should be added to the suspension
oil. See Specifications Chart, Figure 4-5 at the end of
this chapter.

1. Position and secure oiling height dimension
blocks in place (Figure 4-2). When nitrogen
pressure is released, suspensions will lower to
rest on the blocks. Ensure the blocks do not
mar or scratch the plated surfaces of the pis-
tons or damage wiper seals in the lower bearing
retainer. Support blocks must seat on the spin-
dle and the cylinder housing. The blocks should
be positioned 180° apart to provide stability.
Wear a face mask or goggles while relieving

nitrogen pressure.
2. Remove charging valve cap. Turn the charging
valve swivel nut (small hex) counterclockwise
three full turns to unseat valve seal. DO NOT
TURN LARGE HEX. The charging valve body
has a bleeder groove in its mounting threads
but for safety of all personnel the valve body
MUST NOT be loosened until ALL nitrogen
pressure has been vented from the suspension.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
all nitrogen has been vented to the atmosphere,
the suspension should have collapsed slowly
and be seated solidly on the support blocks. FIGURE 4-2. FRONT SUSPENSION
4. Remove top fill plug next to the charging valve
(Figure 4-2). FRONT SUSPENSION DIMENSIONS (EMPTY)
® TRUCK MODEL & OILING CHARGING CHARGING
5. Fill the suspension with clean HYDRAIR oil OPTIONS HEIGHT HEIGHT PRESSURE
(with 6% friction modifier) until the cylinder is full mm (IN.) mm (IN.) kPa (psi)
to the top of the fill plug bore. Drip pans should 830E* 25.4 (1.0) 229 (9.0) 2689 (390)
be used and all spillage cleaned from outside of
the suspension. Allow the suspension to stand 830E** 25.4 (1.0) 229 (9.0) 2827 (410)
for at least 15 minutes to clear any trapped * with standard Rock Body
** with Combination Body / Tailgate
nitrogen and/or bubbles from the oil. Add more Note: If truck starts to lift off blocks before charging pressure is
suspension oil if necessary. Install a new fill attained, STOP CHARGING.
plug O-ring, and install the plug.

Front Suspension Nitrogen Charging 2. Tighten valve body (large hex, 6) to 16.5 ft lbs
(22.4 N·m) torque. The valve swivel nut (small
hex, 4) must be unseated by turning counter-
clockwise three full turns.
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
Dry nitrogen is the only gas approved for use in
may be suddenly reduced.
HYDRAIR®II suspensions.Charging of these
1. If removed, install the charging valve with new components with oxygen or other gases may
O-ring (9, Figure 4-3). Lubricate the O-ring with result in an explosion which could cause fatali-
clean HYDRAIR®oil. ties, serious injuries and/or major property dam-
age. Use only nitrogen gas meeting the
specifications shown in chart (Figure 4-5).
3. Install HYDRAIR® Charging Kit and a bottle of

pure dry nitrogen. Refer to Installation of Charg-
ing Kit.
4. Charge the suspensions with nitrogen gas to a
height just high enough to install the nitrogen
charging blocks, but not to exceed 27.9 cm (11
in). Close inlet valve (4, Figure 4-1).
5. Remove the oiling blocks from the suspensions
and install the nitrogen charging blocks. Secure
the blocks to prevent accidental dislodging.
NOTE: Use caution to prevent damage to plated cyl-
inder surfaces and oil seals when installing the
blocks.
FIGURE 4-3. CHARGING VALVE 6. Remove the center hose from manifold (6).
1. Valve Cap 6. Valve Body

2. Seal 7. O-Ring
3. Valve Core 8. Valve Stem
4. Swivel Nut 9. O-Ring
5. Rubber Washer Be aware when relieving nitrogen gas, the truck
may drop suddenly onto the charging blocks.
7. To lower the truck onto the charging blocks,

open inlet valve (4) until the pressure has
dropped below the pressure listed in Figure 4-2,
and then close the valve.
8. Install the center hose to manifold (6).

9. Charge the suspensions to the pressure listed NOTE: The empty ride height may be less than the
in Figure 4-2. DO NOT use an overcharge of charging ride height. Also, the suspension height
nitrogen to lift the suspensions off of the charg- between the left and right suspensions may not
ing blocks. always be the same due to the fuel level in the fuel
tank.
10. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes in order to allow
the pressures in the suspensions to equalize.
11. Close outlet valves (3) and remove charging kit
components. Refer to Removal of Charging Kit.
12. If charging valve is being reused, tighten swivel REAR SUSPENSION
nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs) torque.
1. Park the unloaded truck on a hard, level sur-
13. If a new charging valve is being used, tighten face. Move the directional control lever to the
swivel nut to 14.2 N·m (10.5 ft lbs) torque, then PARK position.
loosen and retighten swivel nut to 14.2 N·m 2. Place wheel chocks in front and behind two sets
(10.5 ft lbs) torque. Again loosen swivel nut of rear wheels to prevent roll away.
and retighten to 5.4 N·m (4 ft lbs) torque.
Replace valve cap (1) and tighten to 3.3 N·m NOTE: Do not place wheel chocks around front tires.
(2.5 ft lbs) torque (finger tight). The front tires will roll forward and backward a small
amount as the suspension travels up and down
14. Install protective guard over charging valve.
during the suspension charging process.
NOTE: If the rear suspension are to be serviced at
this time, leave the nitrogen charging blocks in place
on the front suspensions until after the rear 3. Thoroughly clean the area around the charging
suspensions are completely serviced. valve on the suspensions. Remove the protec-
tive covers from the charging valves and the
metal covers from the suspension piston.
15. Raise the truck body in order to extend the front
suspensions and allow for removal of the nitro-
gen charging blocks. Ensure that sufficient
overhead clearance exists before raising the
body. If the suspensions do not extend after When the blocks are in place on a suspension,
raising the body, turn the steering wheel left and they must be secured in place with a strap or
right in very small movements several times. If other means to insure the blocks staying in place
the suspensions still do not extend enough to while being used. An unsecured block could fly
allow for removal of the blocks, use a crane or loose as weight is applied, presenting the possi-
floor jacks to raise the truck and remove the bility of serious injury and/or damage.
blocks. NOTE: For longer life of suspension components, a
Any time the suspensions are recharged, the calibra- Friction Modifier must be added to the suspension
tion of the Payload Meter system is affected. Refer to oil. See Specifications Chart, Figure 4-5 at the end of
the Payload Meter III ™ section and perform a this chapter.
“Clean Truck Tare”. This will ensure accurate pay-
load records.
The front HYDRAIR® suspensions are now ready for

operation. Visually check the extension with the truck
both empty and loaded. Record the extension dimen-
sions. Maximum downward travel is indicated by the
dirt ring at the base of the piston. Operator com-
ments on steering response and suspension rebound
should also be noted.

Rear Suspension Oiling
1. If the suspensions are extended, position and REAR SUSPENSION DIMENSIONS (EMPTY)
secure oiling height dimension blocks (sup- TRUCK MODEL & OILING CHARGING *CHARGING
OPTIONS HEIGHT HEIGHT PRESSURE
ports) in place (See Figure 4-4) so the blocks mm (IN.) mm (IN.) kPa (psi)
are seated between the piston flange and the
830E* 25.4 (1.0) 241 (9.5) 1724 (250)
cylinder housing. Ensure the blocks do not mar
or scratch the plated surfaces on the piston or 830E** 25.4 (1.0) 241 (9.5) 2172 (315)
damage the wiper seals in the cylinder barrel. * with standard Rock Body
** with Combination Body / Tailgate
Support blocks must seat on the piston flange Note: If truck starts to lift off blocks before charging pressure is
and the cylinder housing. The blocks should be attained, STOP CHARGING.
positioned 180° apart to provide stability.
Make certain all personnel are clear and support

blocks are secure before relieving nitrogen pres-
sure from the suspension. Use a face mask or
goggles when venting nitrogen.
2. Remove charging valve cap. Turn the charging

valve swivel nut (small hex) counterclockwise
three full turns to unseat valve seal. DO NOT
TURN LARGE HEX. The charging valve body
has a bleeder groove in its mounting threads,
but for safety of all personnel, the valve body
MUST NOT be loosened until ALL nitrogen
pressure has been vented from the suspension.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
nitrogen pressure has been vented to atmo-
sphere, loosen and remove the fill plug. The
suspension should have collapsed slowly as
gas pressure was released. Truck weight is now FIGURE 4-4. REAR SUSPENSION
supported by the support blocks.
4. Use a plastic tube to help bleed off trapped air
inside the piston. Remove vent plugs and the
bleeder screw. Service the suspension with Rear Suspension Nitrogen Charging
clean HYDRAIR® Oil (with 6% friction modifier)
until clean oil comes out of the port where the
bleeder screw and plug were removed from the
side of the housing. Drip pans should be used
and all spillage cleaned from the outside of the
suspension. Install the bleeder and vent plugs. Lifting equipment (overhead or mobile cranes, or
Continue to fill the oil until it reaches the fill port. hydraulic jacks) must be of sufficient capacity to
Allow the suspension to stand for at least 15 lift the truck weight. Be certain that all personnel
minutes to clear any trapped nitrogen and/or air are clear of lift area before lift is started. Clear-
bubbles from the oil. Add oil if necessary, and ances under the truck may be suddenly reduced.
install the fill plug.

5. Slowly release gas until the suspensions match
the charging height listed in Figure 4-4.
6. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes in order to allow
the pressures in the suspensions to equalize.
Ensure the automatic apply circuit has not 7. Ensure both of the suspension cylinders are
applied the service brakes during truck mainte- extended the same distance ± 10 mm (0.39 in.).
nance. If the front brakes are applied during rear If the difference in the extension from side to
suspension charging, the axle cannot pivot for side exceeds 10 mm (0.39 in.), check the front
frame raising / lowering, and the rear suspension suspensions for equal extension. Adjust the
may be unable to move up or down. front as necessary.
1. If removed, install charging valve with new O- NOTE: A low left front suspension will cause the right
ring (9, Figure 4-3). Lubricate the O-ring with rear suspension to be high. A low right front
clean HYDRAIR®oil. suspension will cause the left rear suspension to be
high.
2. Tighten valve body (large hex, 6) to 22.4 N·m
(16.5 ft lbs) torque. The valve swivel nut (small 8. Close outlet valves (3) and remove charging kit
hex, 4) must be unseated by turning counter- components. Refer to Removal of Charging Kit.
clockwise three full turns. 9. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs)
torque.
10. If a new charging valve is being used, tighten
swivel nut to 14.2 N·m (10.5 ft lbs) torque, then
Dry nitrogen is the only gas approved for use in loosen and retighten the swivel nut to 14.2 N·m
HYDRAIR®II suspensions. Charging of these (10.5 ft lbs) torque. Again, loosen the swivel
components with oxygen or other gases may nut and retighten to 5.4 N·m (4 ft lbs) torque.
result in an explosion which could cause fatali- Replace valve cap (1) and tighten to 3.3 N·m
ties, serious injuries and/or major property dam- (2.5 ft lbs) torque (finger tight).
age. Use only nitrogen gas meeting the 11. Install the protective guards over the charging
specifications shown in chart (Figure 4-5). valves and install the metal covers over the pis-
ton rods.
3. Install HYDRAIR® Charging Kit and a bottle of Any time the suspensions are recharged, the calibra-
pure dry nitrogen. Refer to Installation of Charg- tion of the Payload Meter system is affected. Refer to
ing Kit. the Payload Meter III ™ section and perform a
4. Charge the suspensions with nitrogen gas to a “Clean Truck Tare”. This will ensure accurate pay-
height just high enough to install the nitrogen load records.
charging blocks, but not to exceed 29.2 cm
(11.5 in). Close inlet valve (4, Figure 4-4). The rear HYDRAIR® suspensions are now ready for
operation. Visually check piston extension both with
the truck loaded and empty. Record the extension
dimensions. Maximum downward travel is indicated
by the dirt ring at the base of the piston rod. Operator
comments on steering response and suspension
rebound should also be noted.
Be aware when relieving nitrogen gas, the truck
may drop suddenly onto the charging blocks.

OIL AND NITROGEN SPECIFICATIONS CHART
HYDRAIR® II OIL SPECIFICATIONS

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

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

Property Value
Nitrogen gas used inHYDRAIR® II Nitrogen 99.9% Minimum
Suspension Cylinders must meet or
Water 32 PPM Maximum
exceed CGA specification G-10.1 for
Type 1, Grade F Nitrogen Gas Dew Point -68°F (-55°C) Maximum
Oxygen 0.1% Maximum
FIGURE 4-5. SPECIFICATIONS CHART

NOTES:

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

Nominal tie-rod length, radial tires 3658 mm
to achieve: 0 toe-in (144.0 in.)
4. If the measurements are not equal, adjust the

tie rod. Loosen the clamp locknuts on the tie
rod. Rotate the tie rod as necessary to obtain
the correct toe-in setting of 0.
5. When the adjustment is complete, tighten the
locknuts on the tie rod to 420 ± 42 N·m (310 ± FIGURE 3-1. MEASURING TOE-IN
31 ft lb).
6. Remove the wheel chocks from the rear
wheels.
FAM1301 Toe-In Adjustment Page F13-1

NOTES
Page F13-2 Toe-In Adjustment FAM1301

AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
GREASE REQUIREMENTS
Grease requirements will depend on ambient
temperatures encountered during truck operation:
• Above 32°C (90°F) - Use NLGI No.2
multipurpose grease (MPG).
• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1
multipurpose grease (MPG).
• Below -32°C (-25°F) - Refer to local supplier for
extreme cold weather lubricant requirements.
PUMP HOUSING OIL

The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Oil level should be
checked at 1000 hour intervals. To add oil, remove
oil level plug (4, Figure 14-2) and fill housing to
bottom of plug hole.
SYSTEM PRIMING
The system must be full of grease and free of air
pockets to function properly. After maintenance, if
the primary or secondary lubrication lines were
replaced, it will be necessary to prime the system to
eject all entrapped air. FIGURE 14-1. PUMP/RESERVOIR COMPONENTS
1. Fill lube reservoir with lubricant, if necessary. 1. Hose From Filter 7. Vent Valve
2. To purge air from the main supply line, remove 2. Vent Hose 8. Pipe Plug
the main supply line at the grease canister. 3. Hydraulic Motor 9. Pump Assembly
Connect an external grease supply to the line. 4. Pressure Reducing 10. Flow Control Valve
3. Remove plugs from each injector group in Valve 11. Pressure Switch
sequence (right front, left front, and rear axle). 5. Solenoid Valve 12. Grease Reservoir
6. Override Switch
4. Using the external grease source, pump grease
until grease appears at the group of injectors
and re-install the pipe plug. Repeat for
remaining injector groups.
5. Remove the caps from each injector and
connect an external grease supply to the zerk
on the injector and pump until grease appears
at the far end of the individual grease hose or
the joint being greased.
FAM1401 Automatic Lubrication System F14-1

Pump Pressure Control SYSTEM CHECKOUT
High pressure hydraulic fluid from the truck steering To check system operation (not including timer),
system is reduced to 2240 - 2413 kPa (325 - 350 psi) proceed as follows:
by the pressure reducing valve located on the 1. Start the engine.
manifold on top of the pump motor. This pressure
can be read if pipe plug (3) is removed, and a gauge 2. Actuate the override switch at the reservoir/
is installed on the manifold. Pressure should be pump assembly.
checked occasionally to verify the pressure is within 3. The motor and pump should operate until the
the above limits. system attains 17,237 kPa (2500 psi).
4. Once the required pressure is achieved, the
Pressure Control Valve Adjustment pump motor should turn off and the system
The pressure control valve (1) has been factory should vent.
adjusted and the setting should not be disturbed. 5. Check for pump, hose or injector damage or
leakage with the system under pressure.
Flow Control Valve Adjustment
6. After checking system, stop the engine.
NOTE: The flow control valve (5) is factory adjusted Observing normal precautions regarding high
to 9.5 lpm (2.5 gpm). Do not change this setting. voltage present in the propulsion system before
attempting to repair lube system.
Lubrication Controller Check

Pressing the manual lube button on the enclosure
cover will initiate a lube event (see Figure 14-3).
Lubrication Controller Operation

The time between lube events is determined by the
setting of the rotary switch, which selects the
numeral setting, and the dip switch, which selects the
units in either minutes or hours.
Lubrication Controller Components

Mode switch (2, Figure 14-3) consists of four dip
switches. The first dip switch controls the maximum
amount of “on time”, either 30 seconds or 120
seconds.
The second dip switch controls the mode, either
timer mode or controller mode. When the switch is
set to the timer mode, the amount of time that the
FIGURE 14-2. PUMP CONTROLS pump is on will be determined by the setting of the
dip switch (30 seconds or 120 seconds). When the
1. Pump Pressure Control 4. Oil Level Plug switch is set to the controller mode, a pressure
2. Override Switch 5. Flow Control Valve switch must be installed in the lube supply line. The
3. Pressure Gauge pressure switch will detect supply line pressure, and
will reset the timer at a set pressure. If the pump fails
to reach the set pressure within the dip switch setting
(30 seconds or 120 seconds), the controller will
initiate an alarm.
F14-2 Automatic Lubrication System FAM1401

The third dip switch is for selecting the units for the Off time switch (1) is used to select units of time.
“off time” to be used in conjunction with off time Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or
switch (1). Hours or minutes may be selected. 30. The mode switch determines whether the off time
units will be minutes or hours.
The fourth dip switch is used to select “memory off”
or “memory on”. When the switch is set to “memory
off”, a lube cycle will occur each time power is turned
Cover (3) contains three LED windows and a manual
on. The lube cycle will start at the beginning of the on
lube switch. The LEDs indicate system operation and
time setting.
status. When power is on, a green LED will
When the switch is set to “memory on”, the controller illuminate. When the pump is on, another green LED
will function as follows: will illuminate. A red LED will illuminate when an
alarm condition occurs.
1. When power is turned off during ‘off time’
(between cycles), the lube cycle will resume at
the point of interruption after power is restored.
In other words, the controller will remember its
position in the cycle.
2. When power is turned off during ‘on time’
(during a cycle), the controller will reset to the
beginning of the lube cycle after power is
restored.
FIGURE 14-3. LUBRICATION CYCLE TIMER
1. Off Time Switch 3. Cover

2. Mode Switch

Lubrication Controller Adjustment 250 Hour Inspection
The lubrication controller is factory adjusted to the 1. Check all grease feed line hoses from the SL-1
following switch settings: Injectors to the lubrication points (see, Figure 3-
1).
Dip Switch 1 - 120 SEC
a. Repair or replace all worn / broken feed line
Dip Switch 2 - TIMER hoses.
Dip Switch 3 - MINUTES b. Make sure that all air is purged and all new
Dip Switch 4 - MEMORY OFF feed line hoses are filled with grease before
sending the truck back into service.
3. Rotary Switch - 15 minutes
2. Check all grease supply line hoses from the
pump to the SL-1 injectors.
a. Repair or replace all worn / broken supply
lines.
b. Make sure that all air is purged and all new
supply line hoses are filled with grease
before sending the truck back into service.
3. Check grease reservoir level.
PREVENTATIVE MAINTENANCE
a. Fill reservoir if low.
The following maintenance procedures should be
b. Check reservoir for contaminants. Clean, if
used to insure proper system operation.
required.
Daily Lubrication System Inspection c. Check that all filler plugs, covers and
1. Check grease reservoir level. breather vents on the reservoir are intact and
free of contaminants.
Inspect grease level height after each shift of
4. Inspect all bearing points for a bead of lubricant
operation. Grease usage should be consistent from
around the bearing seal.
day-to-day operations.
It is good practice to manually lube each bearing
• Lack of lubricant usage would indicate an
point at the grease fitting provided on each Injector.
inoperative system. Excessive usage would
This will indicate if there are any frozen or plugged
indicate a broken supply line.
bearings, and will help flush the bearings of
2. Check filter bypass indicator when filling
contaminants.
reservoir. Replace element if bypassing.
3. Check all grease feed line hoses from the SL-1
Injectors to the lubrication points.
a. Repair or replace all damaged feed line
hoses.
b. Make sure that all air is purged and all new
feed line hoses are filled with grease before
sending the truck back into service.
4. Inspect key lubrication points for a bead of
lubricant around seal. If a lubrication point
appears dry, troubleshoot and repair problem.

5. System Checkout NOTE: With engine running, lube system should
activate within 5 minutes. The system should build
a. Remove all SL-1 injector cover caps to allow
13,790 to17,237 kPa (2000 to 2500 psi) within 25-40
visual inspection of the injector cycle
seconds.
indicator pins during system operation.
b. Start truck engine.
c. Actuate the manual override switch (6, i. If the system is working properly, the truck is
Figure 3-1). The hydraulic motor and grease ready for operation.
pump should operate. j. If the system is malfunctioning, refer to the
d. With the grease under pressure, check each troubleshooting chart.
SL-1 injector assembly. The cycle indicator
pin should be retracted inside the injector
body. 1000 Hour Inspection
e. When the system attains 17,237 kPa (2500 1. Check pump housing oil level and correct if
psi), the pump should shut off and the necessary.
pressure in the system should drop to zero,
venting back to the grease reservoir.
f. With the system vented, check all of the SL-1
injector indicator pins; all of the pins should
be visible. Replace or repair injectors, if
defective.
g. Reinstall all injector cover caps.
h. Check timer operation.

NOTES

) I
KOMATSU CHECKOUT PROCEDURE

IEL4302-1
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NAME: MACHINE & MODEL:

AlC CHECKOUT PROCEDURE ALL TRUCKS
WRITTEN BY: DATE:
Bill Anderson 9/7/04

CHECKED BY: DATE:
Mike McMullen 9/17/04 1 Item 2 (b) chanQed aDDroved oil - was 2356151 4/13/05 \\'-ILL. BA 'bAt
APPROVED BY: DATE: 112074
DASH DESCRIPTION OF CHANGE DATE ECN BY CK'D
A SIZE MICROFILM
T. Heller 9-17-04 I I
T T I I I I I I I I I I 1T T 1 I I
1. Keep AlC Components sealed until prepared to charge system. The PAG oil in compressor and desiccant in receiver-
drier both attract moisture leaving system open for contamination.
2. At field erection the following steps need to be taken to make A-C system operational.
a. Remove compressor and drain oil.

b. Add 7 oz. of new GM PAG oil to compressor sump (thru drain hole) and reinstall. Use approved oil GM
12378526.
c. Add 7 oz. of new GM PAG oil to inlet side of accumulator or receiver-drier.
d. Connect all hoses and components for A-C system. Note: Lubricate oil rings before assembly.
e. Evacuatesystem down to minimum of 29.00" Hg for a minimum of 45 minutes.
f. Shut off vacuum pump and observe gauges, system should hold a minimum vacuum of 28.00" Hg for 15
minutes. If vacuum does not hold, fmd and repair leak, then evacuate system again.
g. Charge system with 7.4# of 134a refrigerant.
h. Observe pressures and check for leaks.
i. Observe cab vent outlet temperatures, fan on low and temperature setting on maximum.
j. Check evaporator condensation drain line to see if open.
3. Refer to Service Manual for recommended pressures, temperatures and trouble shooting guide.
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NOTES:
NOTES:
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NAME: MACHINE & MODEL:

BRAKE SYSTEM CHECKOUT 830E wi Rear Combo Brake
WRITTEN
Mike RabasBY: ~:04/08/05
DATE:
5/~/ClS"
DATE:
DASH
A SIZE
~I )/0 \
Necessarv Eauipment:
1. Checkout procedure and hydraulic system schematic.

2. Accumulator charging outfit with good gauges and either K type bottles of dry nitrogen
or T type bottles with a gas intensifier.
3. Clear plastic hose and bucket for bleeding brakes or simulators of air.
4. If truck is only partially assembled and this checkout is to be done without brakes
installed, brake simulators are required in order to simulate the brake volume.
5. At least 3 calibrated gauges with quick-disconnect couplings, capable of measuring up
to 5000 PSI.
Assumptions:
1. All components used within the brake system are to specification.

2. Any parts that do not function as described, will be replaced or adjusted.
Note:
Notify Quality Control Department for problems or to obtain adjusting
procedures for individual components.
3. The hydraulic source for the brake system (the steering system) is in proper operation
and the compensator has been adjusted.
Note: Refer to steering and hoist for check-out procedures and specifications.
WARNING!
Block wheels of truck to prevent a possible rollaway
BEFORE performing this procedure
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Brake Accumulators Precharae

Note:
Permanent damage to bladder accumulators will result if the engine is
started without the accumulators being properly precharged
Note:
Use only dry Nitrogen to precharge accumulators
Note:
Precharge rates of all bladder accumulators must follow details in step (c)
or permanent damage to bladders will result
a. Open both needle valves in brake cabinet to vent oil side of all brake accumulators to
tank. This will also vent the oil side of the front steering accumulator to tank.
CAUTION!
The rear steerina accumulator is not vented to tank thru the opened needlevalves!
b. Be certain that hydraulic pressure is relieved from the steering system by activating the
bleed down solenoid. The solenoid will vent the rear steering accumulator to tank since it
is not vented when the needle valves are opened in step (a).
c. Accumulators are to be precharged only with dry Nitrogen as follows:
I. Check Nitrogen precharge of each accumulator. The precharge pressure of each

brake accumulator should be 1400 PSI. Follow Steps II, III and IV below for each
accumulator.
Note:
Precharge Pressure is 1400 PSI at 70 degrees (F)
II. If the precharge is below 100 PSI, The accumulator's bladder will not be fully
expanded. To fully expand the bladder precharge must be slowly applied. To do this,
set the regulator 25 PSI above the pressure measured in step I. Slowly increase
precharge pressure to the regulator setting so that it takes 3 minutes to initially
increase the precharge pressure 25 PSI
Note:
Failure to add Nitrogen precharge slowly at the rate listed above will result in
permanent damage to the accumulator's bladder
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If the precharge pressure is still below 100 PSI after adding the additional Nitrogen at
the rate listed above, slowly raise the precharge pressure until 100 PSI is obtained.
Once the pressure is above 100 PSI, follow step III.
III. If the precharge pressure is 100 PSI or above, the accumulator bladder is fully
expanded and the precharging rate can be safely increased until 1400 PSI is
reached. Allow the precharge to set for 15 minutes. Adjust the precharge pressure to
1400 PSI as necessary.
IV. * Record Final precharqe pressure for each Brake Accumulator
Initial System Set Up:

1. Install pressure measuring instruments at:
a. Test Port BR (Brake Cabinet)
b. Test Port BF (Brake Cabinet)
c. Test Port LAP1 (Brake Manifold)
2. Close both brake accumulator bleed down valves. If brakes have not been assembled
to truck when checkout is performed, attach a brake simulator to each brake application
line.
3. * Start engine to fill accumulators with oil. Observe rising brake pressures as system
charges. Brake pressure should begin to fall when the AUTO APPLY valve releases.
The brake pressures when AUTO APPLY releases should be approximately
2100 +/- 100 PSI front and 1580 +/-75 PSI rear. Record the brake pressures when
AUTO APPLY releases (BR & BF).
4. Partially depress brake pedal and bleed air from each brake or brake simulator.
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IEL6704-0
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Parkina Brake
Note:
Move one of the pressure measuring instruments from either the BR or BF
locations to the park brake test port (PK2) on the Brake Manifold.
5. * Apply BRAKE LOCK. Release parking brake with PARK BRAKE switch. Verify that
PARK BRAKE Status Lamp indicates that the parking brake is released. Record parkinq
brake release pressure. (pressure should be 2500 :t 100 PSI)
6. Cycle PARK BRAKE switches several times to assure crisp applications and release of
pressure and proper function of status light.
7. Apply PARKING BRAKE and release BRAKE LOCK
Service Brake
Note:
Return the pressure measuring device to the port (BRor BF)from which it was
removed
8. Slowly depress brake pedal. Rear Brake pressure should begin to rise before the Front
Brake Pressure. Rear Brake Pressure should be between 45 and 205 PSI when the Front
Brake Pressure begins to rise. Force feedback of pedal on foot should be smooth with no
abnormal noise or mechanical roughness.
9. * Slowly depress brake pedal and record the rear brake pressure (BR) at which the stop
lights energize. Record Rear Brake Pressure (BR). (This pressure should be 75 :t 5 PSI.).
10. * Quickly and completely depress pedal and check to see that front brake pressure is
3000 :t 150 PSI (BF) and that the rear brake pressure is 1580 :t 75 PSI (BR) within 1
second. Holding pedal fully applied, both pressures should remain above their
minimum values for a minimum of 20 seconds. Record Front and Rear Brake pressures
(BF and_BR).
11. * Release pedal. Brake pressure should return to zero within two seconds and there
should be no residual pressure trapped in brakes. Record Front and Rear Brake
pressures (~ and B~
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BRAKE LOCK/Secondary
12. Disconnect lead wire on BRAKE LOCK solenoid, located on brake manifold in hydraulic
cabinet and to the immediate right of the PK2 port. Install jumper to connect lead wires
to timer
13.* Apply BRAKE LOCK. BRAKE LOCK pressure degradation switch should sound
warning buzzer. Depress brake pedal until warning stops and then very slowly release
pedal until warning resumes. Record Rear Brake pressure (BR) when warninq
resumes.
Note:
BRAKE LOCK degradation switch should trigger when BR pressure drops to
1000 :t 25 PSI, however, there is a two second delay between the time the switch
makes and the lamp/buzzer activates.
14. Connect lead wire on BRAKE LOCK solenoid.
15. * Cycle BRAKE LOCK several times to assure crisp application of and release of
pressure and proper function of status light. Record rear brake pressure (BR)
(BRAKE LOCK pressure should be 1500::!: 100 PSI.)
Low Brake Pressure and AUTO APPLY
16. Allow engine to run until/ow brake accumulator pressure stabilizes at or above 3200
PSI.
17. * Shut engine down. Allow the steering accumulators to bleed completely down.
Disable steering pressure switch from the brake warning circuit by unplugging the diode
between circuits 33 and 33F. Turn key switch on. After 2 minutes, record the low
accumulator pressure, (LAP1 port) If LAP1 pressure is below 2600 PSI, then leakage in
the system is excessive and the source of the leakage needs to be identified.
18. * Crack the front brake accumulator bleed down valve and observe LAP1 pressure.
The Low Brake Pressure Lamp and buzzer must actuate at 2300 ::!:75 PSI. Record this
pressure (LAP1). Brake pressures should begin to rise (AUTO APPLY) when LAP1
reaches 2100::!:100PSI. Record the LAP1 pressure. the Front Brake pressure and the
Rear Brake pressure (BR). Close front brake accumulator bleed down valve.
m
19. Start engine to recharge hydraulic system. Allow engine to run until low brake r-
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accumulator pressure stabilizes at or above 3200 PSI. ......
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IEL6704-0
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20. Shut engine down. Allow the steering accumulators to bleed completely down. Turn
key switch on. Crack the rear brake accumulator bleed down valve and observe LAP1
pressure. Verify that the Low Brake Pressure Lamp and buzzer, and AUTO APPLY set
point are within 100 PSI of those recorded in Step 18. Record the LAP1 pressures for
Low Brake Pressure Lamp& Buzzer. LAP1 pressure for AUTO APPLY, the Front Brake
pressure and the Rear Brake pressure (BR). Close the rear brake accumulator bleed
down valve.
21. Enable the steering pressure switch by plugging in the diode removed between circuits
33 and 33F.
Reapplications
22. Start engine to recharge hydraulic system. Allow engine to run until low brake
accumulator pressure stabilizes at or above 3200PSI.
23. * Shut engine down. Do not allow steering accumulator to bleed down. Make repeated
slow, complete brake applications with pedal until Low Brake Pressure warning comes
on. Record the number of brake applications prior to Low Brake Pressure warninq.
Low Brake Pressure warning must not actuate prior to the sixth pedal application.
AUTO APPLY must not occur until after Low Brake Pressure warning.
24. Shut engine down and turn off keyswitch. Open each brake accumulator bleed down
valve. Remove all instrumentation and simulators. Close Brake accumulator bleed
down valve. This concludes the brake system checkout.
m
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Q)
.......
0
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* Asterisk denotes item to be recorded
0
IEL6704-o
PaQ8 7 of 8
830E- wI Rear Combo Brake Hydraulic Brake System

Checkout Data Sheet
ACCUMULATORPRECHARGE
Step c -IV Front Brake Accumulator Precharge Pressure
Rear Brake Accumulator Precharge Pressure
Initial System Set Up:

Step 3 Rear brake (BR) pressure when AUTO APPLY releases.
Front brake (BF) pressure when AUTO APPLY releases.
Parkina Brake System
Step 5 Parking brake release pressure.
Service Brake System
Step 9 Rear brake (BR) pressure when stop lights energize.
Step 10 Rear brake (BR) pressure (pedal applied).
Front brake (BF) pressure (pedal applied).
Step 11 Rear brake pressure (pedal released).
Front brake pressure (pedal released).
BRAKE LOCK/Secondarv System
Step 13 Rear Brake (BR) pressure when brake degradation

fault occurs.
Step 15 Rear Brake (BR) pressure when BRAKE LOCK is

applied.
m
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en
......
0
~I
0
IEL6704-0
Page 8 of 8
Low Brake Pressure and AUTO APPLY
Step 17 LAP1 pressure after 2 minutes.
Step 18 LAP1 pressure when Low Brake Pressure Lamp and

Buzzer activate.
LAP1 pressure when AUTO APPLY occurs.
Front brake apply (BF) pressure after AUTO APPLY
Rear brake apply (BR) pressure after AUTO APPLY
Step 20 LAP1 pressure when AUTO APPLY occurs.
Front brake apply (BF) pressure after AUTO APPLY
Rear brake apply (BR) pressure after AUTO APPLY
Reapplications
Step 23 Number of applications prior to Low Brake Pressure

Lamp and Buzzer activating.
Machine Unit No. SIN
Name of Mechanic or Inspector doing Check Out
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0
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0
NOTES:
STANDARD TORQUE CHARTS AND CONVERSION TABLES
This manual provides U.S. standard and metric (SI) EFFECT OF SPECIAL LUBRICANTS
units for most specifications. On Fasteners and Standard Torque Values
References throughout the manual to standard torques Komatsu does not recommend the use of special
or other standard values will be to one of the following friction-reducing lubricants, such as Copper Coat,
charts or tables. For values not shown in these charts Never-Seez®, and other similar products, on the
or tables, standard conversion factors for most threads of standard fasteners where standard torque
commonly used measurements are provided in Table values are applied. The use of special friction-reducing
XIII. lubricants will significantly alter the clamping force
Standard torque values are not to be used when “turn- during the tightening process.
of-the-nut” tightening procedures are recommended. If special friction-reducing lubricants are used,
excessive stress and possible breakage of the
INDEX OF TABLES fasteners may result.
Table I . . . . . . . . Standard Torque Chart (SAE) . . A5-1
When the torque tables specify “lubricated threads” for
Table II . . . Standard Torque, 12-Point, Grade 9 . . A5-2
the standard torque values listed, these standard
Table III . . . Standard Metric Assembly Torque . . A5-2
torque values are to be used with simple lithium base
Table IV . . . . . . . JIC Swivel Nuts Torque Chart . . A5-3
chassis grease (multi-purpose EP NLGI) or a rust-
Table V. . . . . . . . . . .Pipe Thread Torque Chart . . A5-3
preventive grease (see list, page A5-2) on the threads
Table VI . . . . . . . . . O-Ring Boss Torque Chart . . A5-3
and seats unless specified otherwise.
Table VII. . . . . O-Ring Face Seal Torque Chart . . A5-3
Table VIII . . Torque Conversions (ft lbs to N•m) . . A5-4
Verify threads and tapped holes are free of burrs and
Table IX . . Torque Conversions (ft lbs to kg•m) . . A5-4
other imperfections before installing hardware.
Table X. . . . Pressure Conversions (psi to kPa) . . A5-4
Table XI . . Pressure Conversions (psi to MPa) . . A5-5
Table XII. . . . . . . . . .Temperature Conversions . . A5-5
Table XIII . . . . Common Conversion Multipliers . . A5-6
Grade 5 TABLE I. -STANDARD TORQUE CHART

Grade 8
SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS) - TOLERANCES ±10%
Cap- TORQUE - TORQUE - Cap- TORQUE - TORQUE -
screw GRADE 5 GRADE 8 screw GRADE 5 GRADE 8
Thread Thread
ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m
Size Size
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lbs = 0.138 kg•m = 1.356 N•m
FAM1501 11/05 Standard Torque Charts and Conversion Tables F15-1

STANDARD ASSEMBLY TORQUES STANDARD ASSEMBLY TORQUES
For 12-Point, Grade 9 Capscrews (SAE) For Class 10.9 Capscrews & Class 10 Nuts
The following specifications apply to required assembly The following specifications apply to required assembly
torques for all 12-point, grade 9 (170,000 psi minimum torques for all metric Class 10.9 finished hexagon head
tensile) capscrews. capscrews and Class 10 nuts.
• Capscrew threads and seats shall be lubricated • Capscrew threads and seats shall not be lubricated
when assembled. when assembled. These specifications are based
on all capscrews, nuts, and hardened washers
NOTE: Unless the instructions specifically recommend being phosphate and oil coated.
otherwise, these standard torque values are to be used
with simple lithium base chassis grease (multi-purpose NOTE: If zinc-plated hardware is used, each piece
EP NLGI) or a rust preventive grease (see list, this must be lubricated with simple lithium base chassis
page) on the threads. grease (multi-purpose EP NLGI) or a rust preventive
grease (see list, this page) to achieve the same
• Torques are calculated to give a clamping force of clamping forces provided below.
approximately 75% of proof load.
• Torques are calculated to give a clamping force of
• The maximum torque tolerance shall be ±10% of
approximately 75% of proof load.
the torque value shown.
• The maximum torque tolerance shall be within
±10% of the torque value shown.
TABLE II. STANDARD ASSEMBLY TORQUE
for 12-Point, Grade 9 Cap screws TABLE III. STANDARD ASSEMBLY TORQUE
for Metric Class 10.9 Cap screws & Class 10 Nuts
CAPSCREW TORQUE TORQUE TORQUE
SIZE* ft lbs N•m kg•m CAPSCREW TORQUE TORQUE TORQUE
0.250 - 20 12 16 1.7 SIZE* N•m ft lbs kg•m
0.312 - 18 24 33 3.3 M6 x1 12 9 1.22
0.375 - 16 42 57 5.8 M8 x 1.25 30 22 3.06
0.438 -14 70 95 9.7 M10 x 1.5 55 40 5.61
0.500 -13 105 142 14.5 M12 x 1.75 95 70 9.69
0.562 - 12 150 203 20.7 M14 x 2 155 114 15.81
0.625 - 11 205 278 28.3 M16 x 2 240 177 24.48
0.750 - 10 360 488 49.7 M20 x 2.25 465 343 47.43
0.875 - 9 575 780 79.4 M24 x 3 800 590 81.6
1.000 - 8 860 1166 119 M30 x 3.5 1600 1180 163.2
1.000 - 12 915 1240 126 M36 x 4 2750 2028 280.5
1.125 - 7 1230 1670 170 * Shank Diameter (mm) - Threads per millimeter
1.125 - 12 1330 1800 184 This table represents standard values only. Do not use these
1.250 - 7 1715 2325 237 values to replace torque values which are specified in assembly
1.250 - 12 1840 2495 254 instructions.
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342
Suggested* Sources for Rust Preventive Grease:
1.500 - 6 2980 4040 411 • American Anti-Rust Grease #3-X from Standard Oil
1.500 - 12 3225 4375 445 Company (also American Oil Co.)
* Shank Diameter (in.) - Threads per inch • Gulf Norust #3 from Gulf Oil Company.
This table represents standard values only. Do not use these
values to replace torque values which are specified in assembly
• Mobilarma 355, Product No. 66705 from Mobil Oil
instructions. Corporation.
• Rust Ban 326 from Humble Oil Company.
• Rustolene B Grease from Sinclair Oil Co.
• Rust Preventive Grease - Code 312 from the
Southwest Grease and Oil Company.
NOTE: This list represents the current engineering
approved sources for use in Komatsu manufacture. It is
not exclusive. Other products may meet the same
specifications of this list.
F15-2 Standard Torque Charts and Conversion Tables 11/05 FAM1501

TABLE IV. TABLE VI.
TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR
WITH OR WITHOUT O-RING SEALS O-RING BOSS FITTINGS
SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B ft lbs CODE (O.D.) UNF-2B ft lbs
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
TABLE V. TABLE VII.

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

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

TABLE VIII. TORQUE CONVERSIONS
Foot Pounds (ft lbs) to Newton-meters (N•m)
ft lbs 0 1 2 3 4 5 6 7 8 9
0 (N·m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage
TABLE IX. TORQUE CONVERSIONS

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

Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
psi 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6

TABLE XI. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
psi 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa). 3. Multiply by 10:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to psi row 0, column 5; read 34.475
2. Go to psi row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
TABLE XII. TEMPERATURE CONVERSIONS

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

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

TABLE XIII
COMMON CONVERSION MULTIPLIERS
COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS

ENGLISH TO METRIC METRIC TO ENGLISH
To Convert Multiply Multiply

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

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

fluid ounce – fl oz milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl oz. 0.0338
pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046
pound (force) – lbs Newton (N) 4.448 Newton (N) pound (force) – lbs 0.2248
in. lbs. (force) Newton meters (N•m) 0.113 Newton-meters (N•m) kilogram meters (kg•m) 0.102
ft lbs (force) Newton meters (N•m) 1.356 Newton-meters (N·m) ft lbs 0.7376
ft lbs (force) kilogram meters (kg•m) 0.138 kilogram-meters (kg•m) ft lbs 7.2329
psi (pressure) kilopascals (kPa) 6.895 kilogram-meters (kg•m) Newton meters (N•m) 9.807
psi (pressure) megapascals (MPa) 0.007 kilopascals (kPa) psi 0.1450
psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 megapascals (MPa) psi 145.038
ton (short) kilogram (kg) 907.2 kilograms/cm 2 (kg/cm2) psi 14.2231
ton (short) metric ton 0.0907 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
quart – qt liters (l) 0.946 kilogram (kg) ton 0.0011
gallon – gal liters (l) 3.785 metric ton ton 1.1023
HP (horsepower) Watts 745.7 liters (l) quart – qt 1.0567
HP (horsepower) kilowatts (kw) 0.745 liters (l) gallon – gal 0.2642
Watts Horsepower HP 0.00134
kilowatts (kw) Horsepower HP 1.3410

FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
MACHINE MODEL
(Circle One) MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT
730E SERIAL NUMBER SERIAL NUMBER NUMBER
830E 830E-1AC
930E-4 930E-4SE
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

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

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

2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.
Send Pink Reports to your KAC Regional Service Manager
Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.
Mark each item with the appropriate symbol as shown below.
CEAW003211 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visual inspection of unit for loose parts and debris
2 Hardware Visual inspection of unit for missing and/or loose mounting hardware
3 Hoses and Cables Visual inspection of hydraulic hoses and electric cables to ensure they are securely
clamped and clear from sharp edges and not rubbing each other
4 Ground Straps Verify all ground straps are secure (sub frame, anchor etc.)
5 Engine Oil Level Verify engine oil level is in operating range
6 Engine Fan Inspect fan-to-shroud clearance and belt alignment
7 Hydraulic Oil Level Oil level visible through the upper sight glass with body down
8 Hatch Door Verify adequate latch seal on the rear axle hatch door to prevent dust entry
(730E, 830E, 830E-1AC)
9 Anchor Pin Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and prop-
erly tightened hardware
10 Wheel Motors Inspect oil specification and proper oil level
11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks
12 Radiator Inspect coolant fill level, cold temperature protection, and DCA additive
13 Decks and Ladders Inspect all ladders and handrails are secure and hardware is tight
Visual inspection of installation of grid blower, rectifier assembly and control box for correct
assembly of components and proper clamping, no loose contacts, no damaged or poorly
crimped cables
14 Battery Inspect all wiring and connections in battery box - no rubbing or chafing
Verify battery mounting hardware is secure
Verify electrolyte at proper level and caps are securely installed
Verify all battery terminals are secure
15 Frame Visually inspect installation of steering cylinders, tie rod, and accumulators per print
Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder
installations (all hardware secure, no leaks)
Hardware Torque
1 Suspension Verify front suspension mounting cap screws have been properly tightened per appropriate
service manual procedure using the “turn-of-the-nut” method
2 Wheels 730E Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
830E, 830E-1AC Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
930E-4, 930E-4SE Verify torque on front wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs)
(See Note below chart) Verify torque on rear inside wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs)
Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft
lbs)
3 Rops Verify torque on left rops beam cap screws at 949 N·m (700 ft lbs)
Verify torque on right cross beam cap screws at 240 N·m (177 ft lbs)
4 Cab Verify torque on cab mounting cap screws at 949 N·m (700 ft lbs)
5 Wheel Motor Verify torque on wheel motor mounting cap screws at 2007 N·m (1480 ft lbs)
NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mount-
ing tightening procedure.
Maintenance
Accepted
Cab Compartment
1 Cab Doors Verify doors open and close smoothly, latch works properly, O&M manual in door
2 Cab Windows Verify windows can be opened and closed smoothly
3 Door Locks Verify left and right door locks work properly with key
4 Interior Visually inspect interior for completeness of assembly
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
5 Cab Seats Inspect operators seat adjustments (slide lever, back rest operation,
seat inclination, seat height etc.)
Inspect seat belt for proper installation (and seat tethers)
6 Passenger Seat Verify back rest operates without interference
7 Steering Wheel Check tilt and telescoping functions
Check adjustable lever can be locked securely
8 Wiper Verify wiper works all speeds, & range does not extend beyond glass surface
Verify the windshield washer works properly and washer fluid bottle is full
9 Cigarette Lighter Check lighter operation, should pop up after 10 seconds and be hot (730E,830E only)
10 Horn Check for proper sound, no looseness in horn button
11 Back Up Horn Check for proper sound, and function
12 Shift Tower Check for proper function, no binding or looseness
13 Gauges Verify gauges are installed straight and operating correctly
14 Hydraulic Fittings Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet
15 Hoist Check operation of the hoist lever in all four positions
Lights
1 Headlights Verify all headlights working, high and low beams
Verify high beam indicators are functional
Verify lights at proper angle
2 Instrument Panel Check switch depresses and all lights function
2a Dimmer Switch Verify dimmer operates properly
2b Turn Signal Visually inspect front and rear turn signal operation on left and right sides
Directional indicators operate properly
Switch turns off after turn is completed
3 Hazard Flashers Verify flasher operates properly
Verify hazard indicator lights operating properly
4 Back Up Light Verify back up light operates properly when shifter is in R position
5 Manual Back Up Light Verify switch and light work properly
6 Fog Light (optional) Verify fog lights and indicator lights operating properly
Brake Lights
1 Service Brake Verify service brake lights operating properly
2 Brake Lock Verify brake lock light operating properly
3 Emergency Brake Verify emergency brake light operating properly
4 Parking Brake Verified parking brake light operating properly
5 Dome Light Verify dome light is on when the switch is ON
6 Retarder Lights Verify retard light operating properly
Maintenance
Accepted
Service Inspection
1 Suspension 730E Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear
(See Note below chart) Front charge height, 229 mm (9 in.) at 2758 kPa (400 psi)
Rear charge height, 276 mm (10.9 in. ) at 1420 kPa (206 psi)
830E, 830E-1AC Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)
930E-4, 930E-4SE Suspension oiling height at 25.4 mm (1 in.) front and 53.0 mm (2.1 in.) rear
Rear charge height, 218 mm (8.6 in.) at 1482 kPa (215 psi)
2 Accumulators Verify nitrogen charge in accumulators is at 9653 kPa (1400 psi) for all models, for both
steering and brakes (charge pressure will vary with ambient temperature, refer to chart in SM)
3 Engine Prelube If equipped, ensure prelube is working prior to engine starting
4 Engine Starting Ensure engine starts easily
5 Engine Noise No abnormal noise from engine
6 Brake Lock Verify when switch is ON, brakes are applied and light is illuminated. Must be in Neutral.
7a Parking Brake Verify when switch is ON, brakes are applied and light is illuminated
730E, 830E
7b 830E-1AC, 930E-4, Verify when directional control lever is in PARK, brakes are applied and light is illuminated
930E-4SE
8 Brake Pressure 730E Verify with pedal depressed, front brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)
Verify with pedal depressed, rear brake pressure is 11,721 ± 517 kPa (1700 ± 75 psi)
Verify brake lock pressure is 10,342 ± 689 kPa (1500 ± 100 psi)
Verify parking brake pressure is 17,926 ± 689 kPa (2600 ± 100 psi)
830E, 830E-1AC Verify with pedal depressed, front brake pressure is 20,684 ± 1034 kPa (3000 ± 150 psi)
Verify with pedal depressed, rear brake pressure is 13,652 ± 689 kPa (1980 ± 100 psi)
Verify parking brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)
930E-4, 930E-4SE Verify with pedal depressed, front brake pressure (BF) is 17,236 ± 517 kPa (2500 ± 75 psi)
Verify with pedal depressed, rear brake pressure (BR) is 17,236 ± 517 kPa (2500 ± 75 psi)
Verify parking brake release pressure is 18,616 ± 689 kPa (2700 ± 100 psi)
9 Steering Verify that steering system is operating smoothly, turning from lock to lock
Verify steering system is free of noise and vibration
10 Hoist Verify hoist pressure is 17,236 kPa (2500 psi) power up, and 10,342 kPa (1500 psi) power
down
Verify hoist limit switch is operational and is set correctly (measure on the hoist cylinder - 3rd
stage), cylinder should stop 6 inches before full extension
Verify that the hoist hold position operates properly
Verify that there is no heavy shock when the body returns to the frame in float
NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete
suspension oiling and charging instructions.
Maintenance
Accepted
11 Hoist Times 730E Power up loaded - 21-23 seconds
Power down - 15-17 seconds
Float down empty - 22-24 seconds
830E, 830E-1AC Power up loaded - 25-27 seconds
930E-4, 930E-4SE Power up loaded - 21-23 seconds
All Trucks Ensure body up switch activates the body up alarm and light in the cab
12 Lubrication Ensure automatic lube system is serviced and full (and air bled from system)
Ensure automatic lube system is operating properly and timer is set as desired
13 Payload Meter Sys. Calibrate and check payload meter operation per O&M manual
14 Error Codes Troubleshoot any error codes and delete
15 Machine Record machine model-type, machine serial number and engine serial number
16 Dump Body Ensure the dump body is shimmed correctly prior to truck release
17 Electrical Checks Ensure the electrical checkout procedure has been completed and signed off on, including
megger testing (see appropriate Field Assembly Manual or Shop Manual for procedure)
18 Truck Programming Ensure the truck is programed with it’s own unique configuration file and a copy of the file
saved
ADDITIONAL COMMENTS__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
NOTES:
50 HOUR POST-COMMISSIONING CHECKSHEET
Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.
MACHINE MODEL
(Circle One) MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT
730E SERIAL NUMBER SERIAL NUMBER NUMBER
830E 830E1-AC
930E-4 930E-4SE
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

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

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

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

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

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

1
ADDITIONAL COMMENTS:______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
NOTES:

Manual Armado 830 AC Serial Numbers A30109 - A30239 CEAW005100

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SERIAL NUMBERS A30109 - A30239

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SUBJECT PAGE NUMBER

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

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

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

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

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

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

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

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

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

FAM0012 Introduction iii

FAM0110 5/08 Safety Rules, Tools, & Equipment F01-1

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

F01-2 Safety Rules, Tools, & Equipment 5/08 FAM0110

FAM0110 5/08 Safety Rules, Tools, & Equipment F01-3

1. “T” Handle Valve

Part Number Description Use

F01-4 Safety Rules, Tools, & Equipment 5/08 FAM0110

Part Number Description Use

Part Number Description Use

FAM0110 5/08 Safety Rules, Tools, & Equipment F01-5

Part Number Description Use

Part Number Description Use

Part Number Description Use

F01-6 Safety Rules, Tools, & Equipment 5/08 FAM0110

Part Number Description Use

Part Number Description Use

FAM0110 5/08 Safety Rules, Tools, & Equipment F01-7

Part Number Description Use

Part Number Description Use

Part Number Description Use

F01-8 Safety Rules, Tools, & Equipment 5/08 FAM0110

FAM0211 Truck Components And Specifications Page 2-1

Page 2-2 Truck Components And Specifications FAM0211

DISC PARKING BRAKE

FAM0211 Truck Components And Specifications Page 2-3

*Nominal payload is defined by Komatsu America

OVERALL TRUCK DIMENSIONS

Page 2-4 Truck Components And Specifications FAM0211

ITEM KILOGRAMS POUNDS

DECK AND DECK SUPPORT COMPONENTS

FAM0311 Major Component Weights Page 3-1

FRONT AXLE COMPONENTS

REAR AXLE COMPONENTS

Page 3-2 Major Component Weights FAM0311

FAM0403 Field Welding For Assembly Or Repair 4-1

4-2 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-3

4-4 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-5

4-6 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-7

Before opening any cabinets or touching a grid

Engine Stop Procedure Prior To Maintenance

Perform the following procedure prior to maintenance

4-8 Field Welding For Assembly Or Repair FAM0403

FAM0403 Field Welding For Assembly Or Repair 4-9

4-10 Field Welding For Assembly Or Repair FAM0403

FAM0503 Receiving & Assembly Preparation Page 5-1