Professional Documents
Culture Documents
Field Assembly
Manual
DUMP TRUCK
®
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-4 dump truck. Vari-
ations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.
FAM0013 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.
ii Introduction FAM0013
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
iv Introduction FAM0013
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 A 930E 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.
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
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.
CHASSIS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,813 . . . . . . . . . . . . . . . . . . . . . . 6,202
Tire 53/80 R63 (148" OD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,122 . . . . . . . . . . . . . . . . . . . . . 15,702
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21,866 . . . . . . . . . . . . . . . . . . . . . 48,206
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,711 . . . . . . . . . . . . . . . . . . . . . . 3,772
POWER MODULE
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 . . . . . . . . . . . . . . . . . . . . . . . . 613
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891 . . . . . . . . . . . . . . . . . . . . . . .1,964
Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,082 . . . . . . . . . . . . . . . . . . . . . . .6,795
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,176 . . . . . . . . . . . . . . . . . . . . . . .7,002
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,993 . . . . . . . . . . . . . . . . . . . . . . .8,803
Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9305 . . . . . . . . . . . . . . . . . . . . . . 20,514
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1996 . . . . . . . . . . . . . . . . . . . . . . .4,400
HYDRAULIC COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . . . . . . . . . . . . . . . 379
Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .932 . . . . . . . . . . . . . . . . . . . . . . .2,055
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . . . . . . . . . . . . . . . . . . . . . . . 322
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731 . . . . . . . . . . . . . . . . . . . . . . .1,612
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.
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.
LEVEL 2
1. Air Cleaner Piping
2. Center Deck
3. Control Cabinet
4. Auxiliary Control Cabinet
FIGURE 6-2.
If the tapped pads are not removed, a complete weld around the support can not be achieved. The gaps in
the weld around the support may result in premature frame cracking in this area.
Repeat for the RH deck support. The weight of the deck support is approximately 273 kg (602 lb).
FIGURE 6-4.
FIGURE 6-6.
FIGURE 6-8.
10. Clean the mounts for the fuel tank and lift the tank into position. (Figure 6-11) The weight of the fuel tank is
approximately 1690 kg (3725 lb).
Tighten the four mounting cap screws near the top of the tank to 712 ± 71 N·m (525 ± 52 ft lb).
Tighten the four mounting cap screws near the bottom of the tank to 298 ± 30 N·m (220 ± 22 ft lb).
FIGURE 6-11.
NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened. The valves
are open when the handles are parallel with the hoses.
FIGURE 6-13.
12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.
Refer to Figure 6-15.
FIGURE 6-15.
For the bottom four cap screws (6, Figure 2.) Tighten the bottom, outer four cap screws
6-19), initially tighten the cap screws to 136 to 271 N·m (200 ft lb), then advance the
N·m (100 ft lb), then advance the cap cap screw heads 120°.
screw head 120° as outlined in Steps d-1 NOTE: If for any reason, these fasteners need to be
through d-3. Refer to Figure 6-17. 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 6-22.
17. Lift the LH diagonal tube into position (Figure 6-24). The weight of the tube is approximately 135 kg (298 lb).
Do not tighten the cap screws until the deck and the cab are in place.
FIGURE 6-24.
19. Lift the six air intake tubes and hump hoses into place. Install and tighten the clamps that secure the hoses.
Refer to Figure 6-26.
FIGURE 6-26.
A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the
assembly for easier mounting to the suspension.
Lift the retainer plates to the bottom of each suspension using blocks and a hydraulic jack.
Install the fourteen cap screws.
Evenly tighten the cap screws to 678 N·m (500 ft lb). Continue to tighten the cap screws in increments of 330
N·m (250 ft lb) until 2705 ± 270 N·m (1,995 ± 200 ft lb) is reached.
FIGURE 6-34
FIGURE 6-31.
FIGURE 6-33.
After all decking is in place, tighten the cap screws on each deck to 465 ± 47 N·m (343 ± 34 ft lb).
25. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 3082 kg (6795 lb).
Tighten the eight cap screws to 800 ± 80 N·m (590 ± 59 ft lb).
27. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approxi-
mately 4100 kg (9039 lb). Refer to Figure 6-36.
FIGURE 6-36.
29. Tighten the hardware for the diagnonal tubes. For the RH tube, tighten the 12 cap screws to 240 ± 24 N·m
(177 ± 17 ft lb). For the LH tube, tighten the 16 cap screws to 800 ± 80 N·m (590 ± 59 ft lb).
FIGURE 6-38.
31. Lift the two bumper extensions into place. Refer to Figure 6-40.
Tighten the cap screws to standard torque.
FIGURE 6-40.
34. Install the air intake ductwork and tighten the connecting hardware. The weight of the inlet duct is approxi-
mately 278 kg (613 lb).
Refer to Figures 6-42- 6-48.
FIGURE 6-44.
FIGURE 6-46.
FIGURE 6-50.
The axle housing also contains dimples at the 3 o’clock and 9 o’clock positions next to the wheel motor
mounting rings. Refer to Figure 6-52.
When installing the wheel motors, ensure the markings on both components line up. The top cap screw
hole on the axle housing may also be determined by counting the holes in between the two sets of punch
marks. The top hole on the axle housing should line up with the “CL” stamping on the wheel motor.
FIGURE 6-52.
FIGURE 6-54.
FIGURE 6-56.
FIGURE 6-58.
NOTE: Remove all dirt and rust from mating parts before installing the tire and rim assembly.
39. Grip the tire and rim assembly with the tire handler. Align the tire inflation hose and the wheel hub. Position
the rim onto the wheel hub studs.
40. Lubricate all stud threads and nut seating flanges with lithium base grease. Install and tighten the nuts in the
following sequence:
a. Install 6 nuts at the 12 O'clock and 6 nuts at the 6 O'clock positions. Tighten each nut to 2326 ± 136 N·m
(1715 ± 100 ft lb).
b. Install 3 nuts directly below the 3 O'clock and 3 nuts directly above the 9 O'clock positions. Tighten the nuts
to 2326 ± 136 N·m (1715 ± 100 ft lb).
c. Install 3 nuts directly above the 3 O'clock and 3 nuts directly below the 9 O'clock positions. Tighten these
nuts to 2326 ± 136 N·m (1715 ± 100 ft lb).
d. Install the remaining nuts and tighten in a clockwise pattern to 2326 ± 136 N·m (1715 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2326 ± 136 N·m (1715 ± 100 ft lb).
After the truck has been assembled and is operational, the truck must be operated for a short period of
time, and the torque on the wheels re-checked. Tighten the wheels to the specified torque.
FIGURE 6-60.
NOTE: Clean all mating surfaces and check the stud threads before installing the wheels.
41. Bleed the disc brakes before installing the rear tires. Refer to Section J of the service manual for brake bleed-
ing procedures.
42. Grip the inner tire and rim with the tire handler and lift onto wheel hub (5, Figure 6-61). Align extension (4) for
mating with inner extension (7).
43. Lubricate all stud threads and nut seating flanges with a lithium base grease. Install and tighten the nuts in the
following sequence:
a. Install 6 nuts at the12 O'clock position and 6 nuts at the 6 O'clock position. Tighten to 2326 ± 136 N·m
(1715 ± 100 ft lb).
b. Install 3 nuts directly below the 3 O'clock position and 3 nuts directly above the 9 O'clock position. Tighten
to 2326 ± 136 N·m (1715 ± 100 ft lb).
c. Install 3 nuts directly above the 3 O'clock position and 3 nuts directly below the 9 O'clock position. Tighten
to 2326 ± 136 N·m (1715 ± 100 ft lb).
d. Install the remaining nuts in a clockwise pattern. Tighten to 2326 ± 136 N·m (1715 ± 100 ft lb).
e. Retighten all nuts in a clockwise pattern to the required 2326 ± 136 N·m (1715 ± 100 ft lb).
44. Install inner extension (7, Figure 6-61) and clamps (8) before installing the outer tires.
FIGURE 6-63.
45. Position the rim adaptors into place on each outer rim. Install the fifty flanged nuts and tighten the nuts to 2325
± 136 N·m (1715 ± 100 ft lb). Refer to Rear Wheel Installation for the correct tightening sequence.
Install the outer tires and tighten the fifty nuts to 2325 ± 136 N·m (1715 ± 100 ft lb). Refer to Rear Wheel
Installation for the correct tightening sequence.
Refer to Figure 6-64.
After the truck has been assembled and is operational, the truck must be operated for a short period of
time, and the torque on the wheels re-checked. Tighten the wheels to the torque specified above.
46. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-65.
FIGURE 6-65.
FIGURE 6-67.
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.
FIGURE 7-10.
FIGURE 7-8.
FIGURE 7-11.
FIGURE 7-14.
FIGURE 7-15.
FIGURE 7-13.
FIGURE 7-16.
FIGURE 7-17.
FIGURE 7-19.
FIGURE 7-18.
FIGURE 7-20.
• 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.
FIGURE 8-2.
Proper body pad to frame contact is required for maximum pad life.
NOTE: With rock ejector arm (1) hanging vertical as shown in Figure 8-12, there must be no gap at stop block (3,
Figure 8-11).
If the rock ejector arms are bent during operation, they must be removed and straightened. Inspect mount-
ing brackets (4, Figure 8-11), pins (2) and stops (3) at each shift change for wear and/or damage. Repair as
necessary.
FIGURE 8-14.
FIGURE 8-17.
13. With the body in its lowered position on the frame rail, the position of the body up limit switch actuator arm
(Figure 8-20) can be marked on the underside of the body. Refer to the assembly prints for precise positioning
specifications.
Raise the body enough to be able to weld the mounting pad to the underside of the body.
Before welding, install support blocks between the body and the frame.
14. Raise the body and attach the body retention cable. Remove the support blocks.
15. Weld the body guide brackets into place. Refer to Figures 8-19 & 8-20.
1. Dump Body 3. Body Guide Wear 1. Switch Mounting Bracket 4. Actuator Arm
2. Body Guide Plates 2. Adjustment Cap Screws 5. Adjustment Screws
3. Proximity Switch
FIGURE 8-22.
19. With the body in the raised position, install the grease lines for the hoist cylinders and clamp along the inside
of the body (Figure 8-25).
FIGURE 8-25.
FIGURE 8-27.
FIGURE 8-29.
FIGURE 8-31.
25. Install the anti-skid strips at the designated areas on the decks (Figure 8-33).
FIGURE 8-34.
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.
REAR SUSPENSION
1. Park the unloaded truck on a hard, level
surface. Apply the parking brake, and chock the
wheels.
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the
protective covers from the charging valves and
the rubber covers from the suspension piston.
1. If removed, install charging valve with new O- 11. Install the protective guards over the charging
ring (9, Figure 4-3). Lubricate the O-ring with valves. Install the rubber covers over the piston
clean Hydrair oil. rods.
2. Tighten valve body (6) (large hex) to 23 N·m (17 The rear Hydrair suspensions are now ready for
ft lb). Swivel nut (4) (small hex) must be operation. Visually check piston extension with the
unseated by turning it counterclockwise three truck both empty and loaded. Record the extension
full turns. dimensions. Maximum downward travel is indicated
by the dirt ring at the base of the piston. Operator
comments on steering response and suspension
rebound should also be noted.
Necessarv Eauipment:
1. Checkout procedure and system schematic.
2. Laptop computer with VHMS PC software installed (VHMS Technical Analysis
Toolbox), and VHMS Watcher software.
3. RS232 serial cable with a male DB9 connector on one end and a female connector
on the other end.
4. You will need the correct CGCDatcsv file for use with the specific truck model you
are checking out This .csv file is used with the VHMS Watcher software to identify
by name the input signals that the Interface Module (1M)sends to VHMS.
PLM3 NOTE
Use the Payload Data Manager software to verify the PLM3 installed software.
PLM3 software EJ0575-3 or later is required for the Interface Module to properly acquire
truck speed on model 830E and 930E trucks. Go to PLM3 web site,
www.kac-peoria.com navload'for software and instructions.
_~r012~:::~~~i~~{~~"'.:~-':::~"":=:~~"~"-"~'~~'~- :t:s'$~~1::!:7~='~'"'
::;:'2 ..HMS !:ielp
; If !
Ready
:j
Start I; : :iI ~ 6Jt) lJ
EfiJl I~ ~ Interface Module Re...1 J;J Can8anFF J ~ Untitled - VhmsWatc...1
We must see 4 lines of message like shown above, if 2 or 3 lines then it did not work. If it does not
work, the problem is with serial communication (maybe the key switch is off, or the serial port is
wrong, or is assigned to other software).
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Page 3 of 15
KOMATSU CHECKOUT PROCEDURE
I EK8480-1
Paqe 4 of 15
6. Next, click VHMS item on menu bar again, when the menu pops up, this time click
Regist&Display, then a screen like this will show up:
0
ll ~_."---J
Rel!.dy :J
For Help. press F1 I;NUM
::Ell Start I :!I ~ [J t1 JJ . r,~Interll!.ce Module Reml JJ CanBI!.nFF j @ Document.. WordPl!.d I r~ Untitled - VhmsW... I~~; 2:10PM
That is the main screen of the Watcher program. On the table list on the right, click to highlight the
selected item we want to view the value, then click the "Add" bar. The selected item will show up in
the 6 slots on the left of the screen (so we can view up to 6 items at a time). The screen shows an
example when only two items are selected to view: Eng_Speed and CooL Temp. After finishing
selecting items to view, click on the START/STOP button, the values of the items will show up. This
button is like a toggle switch, click it a second time, then the data capture is disabled. When 6 items
are selected, to view another item, we have to remove one item by clicking the Delete button, then
repeat the process of Add a new item to view. Remember, before Delete, need to click the
START/STOP button, so that the data capture is disabled, after removing an item and replacing with
a new item by ADD, need to click the START/STOP button again to enable data capture.
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Page 4 of IS
KOMATSU CHECKOUT PROCEDURE
I EK8480-1
PaQe 5 of 15
1. Ambient Air Temperature - should read close to actual ambient. (Ambient air temp 385)
2. Steering Pressure - Insert 1330 :t20 ohm resistor in place of the sensor and read 12140
:t1000 kPa. (Steer Press 574)
3. BrakePressure- Insert1330:t20 ohm resistor in place of the sensor and read 12140 :t1000
kPa. (Brake_Press 515)
4. HoistPressure1 - Insert1330:t20 ohm resistor in place of the sensor and read 12140
:t1000 kPa. (Hoist_Press_1 529)
5. Hoist Pressure 2 - Insert 1330 :1:20ohm resistor in place of the sensor and read 12140
:t1000 kPa. (Hoist_Press_2 530)
6. Pump Filter Switches - short wire 39 to ground at the switches for 3 seconds and confirm
state change (zero to one). (Pump_Filter_Sw 559)
7. Low Steering Precharge - short wire 51A to ground at the switches and confirm state
change (zero to one). The warning state should be sustained until the key switch is turned
off and back on. (Low_Str_Precharg_Sw 538)
8. Hydraulic Tank Level- disconnect wire 34L from tank probe and confirm state change (zero
to one). (Hydraulic_Level 532)
9. Auto Lube Switch - short wire 68LLP1 to ground at RB6 (830E models) or RB7 (930E
models) or at the Lincoln Lube Timer (960E models) for and confirm state change (zero to
one). The warning state should be sustained until the key switch is turned off and back on.
(Auto_Lube 502)
1. Brake Oil Temperature RR - confirm as being near ambient on a cold truck. (564)
2. Brake Oil Temperature LR - confirm as being near ambient on a cold truck. (536)
3. Brake Oil Temperature RF - confirm as being near ambient on a cold truck. (563)
4. Brake Oil Temperature LF - confirm as being near ambient on a cold truck. (535)
5. No Propel/Retard - short wire 75-6P to ground at TB26-C momentarily and confirm state
change (zero to one).
6. No Propel - short wire 75NP to ground at TB25-P momentarily and confirm state change
(zero to one).
7. Propel System Caution - short wire 79W to ground at TB26-D momentarily and confirm state
change (zero to one).
8. Propel System Temp Caution - short wire 34TW to ground at TB26-B momentarily and
confirm state change (zero to one).
9. Propel System Reduced Level - short wire 72LP to ground at TB25-W momentarily and
confirm state change (zero to one).
10. Reduced Retard - short wire 76LR to ground at TB25-T momentarily and confirm state
change (zero to one).
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KOMATSU CHECKOUT PROCEDURE
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1. Hydraulic Tank Temperature (RR Hydraulic Oil Temp on VHMS Watcher) - confirm as being
near ambient on a cold truck. (564)
2. Motor Temperature High - short wire 722L to ground at TB21E-B momentarily and confirm
state change (zero to one). (558)
3. Motor Blower Off - short wire 32B to ground at TB21E-E momentarily and confirm state
change (zero to one). (555)
4. Diode Fault - short wire 79VD to ground at TB21D-G momentarily and confirm state change
(zero to one). (551)
5. Electric Drive System Fault - short wire 79VS to ground at TB21D-E momentarily and
confirm state change (zero to one). (516)
6. Ground Fault - short wire 79VG to ground at TB21D-F momentarily and confirm state
change (zero to one). (557)
1. Park Brake Set Switch - with engine running, toggle Park Brake Switch and confirm state
change (zero to one).
2. Engine Speed 1M- with engine running observe reported speed.
3. Vehicle Speed - observe reported speed while testing the speedometer with the GE DID
panel. Set to 20 mph and observe 20mph on speedometer as well as within VHMS.
4. Battery 12V A - check with batteries fully charged or being charged. Voltage should be
about 12 volts.
5. Battery 12V B - check with batteries fully charged or being charged. Voltage should be
about 12 volts.
6. Battery 12V C - check with batteries fully charged or being charged. Voltage should be
about 12 volts.
1. Check the High Hydraulic Temperature Lamp by pressing the lamp test rocker switch. The
lamp should light.
1. Check the output of Brake Cooling RPM Advance 1, Brake Cooling RPM Advance 2, Brake
Oil Temperature Gauge (930E only), and High Brake Oil Temp Lamp by placing a 169
ohm resistor (a range of 1520 to 1860 should work) in place of any of the four input
temperature probes. I
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--~~~ ~---~------
~- ~-- -------
Actuate and hold the lamp test switch in the operator's cab. The following lamps are driven by
the Interface Module and should come on (along with all the other lamps):
1. Park Brake Lamp
2. Low Fuel Lamp
3. Batt Charge Alt Failure Lamp
4. 1MWarning Lamp
5. High Brake Oil Temp Lamp
The functionality of the Fuel Level output can be confirmed by observing the needle position of the
gauge when the low fuel lamp comes on.
1. Dismount the sending unit only from the tank and position the gauge to a low level with a
screwdriver. The shaft of the screwdriver will turn this magnetically coupled sending unit
to any position you desire.
2. Set the gauge to empty. After 15 seconds, the Low Fuel Light should come on.
3. Return the gauge to the approximate position of the actual fuel in the tank before remounting
it.
The Park Brake Solenoid and Brake Apply output can be checked with the following procedure.
1. Turn parking brake off. Park brake valve should be energized and brake auto apply valve
should not. Energization of these valves can be determined by checking voltage across
the valves or check for magnetism in the valve with a screwdriver.
2. Use the GE DID panel to set the truck speed to some elevated value such as is used to
calibrate the speedometer. The park brake valve should continue to be energized. The
auto apply valve should continue to be off.
3. With the truck speed signal still high, turn the park brake on. The park brake valve should
continue to be energized, and the auto apply valve should stay off. m
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KOMATSU CHECKOUT PROCEDURE
I EK8480-1
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4. Now remove the high truck speed signal. The auto apply valve should pulse on for about 1.5
seconds, and the park brake valve should turn off after the auto apply valve has been on
for 1 second.
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KOMATSU CHECKOUT PROCEDURE
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16.Select "Setup". (DO NOT select "Data Clear & Setup" this time.)
17.Hold down the "ALT" key and press "S". Set the service meter reading hours. (SMR). Record in
Item 10 on Form 3.
18.Select "Apply" and accept the confirmation prompts.
19.Configure the OrbComm settings. Select "EDIT" in the Communication Settings window.
20.Set the file transfer settings as follows and record in Item 11 on Form 3.
21. Set GCC (Ground Control Center) to the appropriate setting and record in item 12 on From 3
Key Switch on. START Engine. Wait 30 seconds. Record item 14 on Form 3.
27. Press and hold the GE data store switch (this will trigger a VHMS Manual Snapshot) for 3
seconds, and then release. (The GE DataStore switch is located on the bottom rear of the
console to the right of the driver's seat.) The white "Data Store in Progress" LED should light
solid and bright. The LED may glow dim (not completely off) before the GE DatStore switch is
pushed. The white LED will begin a slow flash after 5 minutes, then flash rapidly for 30 secorJOSm
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- -- u_- --- -- --- - _u- - - --
beginning at 7 minutes. Record proper operation of the manual data store in item 15 on Form 3
28.Wait until the Data Store in Progress LED has finished flashing. Wait another minute, then turn
the key switch off and stop the engine. Record item 17 on Form 3.
29. Start the VHMS Technical Analysis Tool Box program. (user name = 'usr' and password = '1')
30.Select the Download icon and select the correct comm port when prompted, usually COM1.
31.Select "Connection"
32.Verify that the date & time displayed on the download screen are correct for the current local
date/time and that the displayed Service Meter hours are equal to the value entered previously.
Record in item 19 Form 3.
33.Verify that a Manual Snapshot (MFAO)has been recorded. The display should show an item
named 'Snapshot' with code MFAOand text "Manual Trigger". Record in item 20 on Form 3.
34.Select the 'Select All' option (from the bottom right of window) and perform a download. Record
in item 21 on Form 3.
35.Verify that the 'Download Completed' message is displayed. Click on "exit". Record item 22 on
Form 3.
36. From the Technical Analysis Tool Box launch the View program.
37. Find the data from the download performed in step 31. The data can be identified by the file
name which has the date in which it was created. Select the correct file and click "OK".
38.Verify that a Manual Snapshot (MFAO)was recorded by selecting "Fault History" on the upper
left corner of the screen. The MFAOfault should be recorded with the time of the manual
snapshot and SMR hours entered previously.
39. Select the MACHINE HISTORY option from the list on the left side of the screen.
40.Verify that the Key ON/OFF and Engine ON/OFF records are recorded correctly.
41. Exit the VHMS Technical Analysis Toolboxsoftware. Record in item 23 on Form 3.
42. Start the Setting Tool program. Enter the Service ID field as in step 7 above.
43. Select the radio button labeled 'Setup and Clear'.
44.Accept all the current settings, then Apply and Exit. Record in item 24 on Form 3.
45. Record remaining items on Form 3 and Fax a copy of Form 3 to VHMS/WebCARE support
center FAX: 81-3-5561-4766.
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KOMATSU CHECKOUT PROCEDURE
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( DB information]
1. Distributor name 2. Branch Name
5. DB code (GCPS)
[ Customer information]
6. Customer name 7. Site name
[ Machine information]
8. Model Name 9. Serial No.
[ Remark]
Please fill in the form below and fax or send by mail to Customer Support Gr., Kltd. to activate
Orbcomm terminal.
Terminal
e-mail address
Signature
Note:
It will take one or two weeks to activate after being received this sheet.
Orbcomm terminal is unable to communicate before activation being completed. m
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KOMATSU CHECKOUT PROCEDURE
I EK8480-1
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(W!bC'.PR:settirg wll be I11ICiI aftB"Call Qner receives ttis sheet.)
~Call Qner Phone-+81-3-5561-2765
FAX -+81-3-55614766
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KOMATSU CHECKOUT PROCEDURE
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STANDARD TORQUE CHARTS AND CONVERSION TABLES
This manual provides dual dimensioning for most EFFECT OF SPECIAL LUBRICANTS
specifications. U.S. standard units are specified first, On Fasteners and Standard Torque Values
with metric (SI) units in parentheses.
The Komatsu engineering department does not
References throughout the manual to standard torques recommend the use of special friction-reducing
or other standard values will be to one of the following lubricants, such as Copper Coat, Never-Seez®, and
charts or tables. For values not shown in these charts other similar products, on the threads of standard
or tables, standard conversion factors for most fasteners where standard torque values are applied.
commonly used measurements are provided in TABLE The use of special friction-reducing lubricants will
XIII, page A5-6. significantly alter the clamping force being applied to
Standard torque values are not to be used when “turn- fasteners during the tightening process.
of-the-nut” tightening procedures are recommended. If special friction-reducing lubricants are used with the
standard torque values listed below in Table I,
INDEX OF TABLES excessive stress and possible breakage of the
TABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1 fasteners may result.
TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2
Where the torque tables specify “Lubricated Threads”
TABLE III . . Standard Metric Assembly Torque . . A5-2
for the standard torque values listed, these standard
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . A5-3
torque values are to be used with simple lithium base
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3
chassis grease (multi-purpose EP NLGI) or a rust-
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3
preventive grease (see list, page A5-2) on the threads
TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3
and seats unless specified otherwise.
TABLE VIII . Torque Conversions (ft lbs to N•m) . . A5-4
TABLE IX . Torque Conversions (ft lbs to kg•m) . . A5-4 NOTE: Ensure the threads of fasteners and tapped
TABLE X . . Pressure Conversions (psi to kPa) . . A5-4 holes are free of burrs and other imperfections before
TABLE XI . Pressure Conversions (psi to MPa) . . A5-5 assembling.
TABLE XII . . . . . . . .Temperature Conversions . . A5-5
TABLE XIII . . . Common Conversion Multipliers . . A5-6
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
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
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
See NOTE on page A5-5 regarding Table usage
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
See NOTE on page A5-5 regarding Table usage
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.
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
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
SERIAL NUMBER SERIAL NUMBER NUMBER
730E 830E
830E-AC 930E-4
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Customer’s Address
Inspector’s Comments:
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 Gold Reports to the Service Manager at the KAC Distributor who sold the truck.
CEAW003209 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)
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-AC Verify torque on all wedge nuts at 746 N·m (550 ft lbs)
(See Note below chart)
930E-4 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.
CEAW003209 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 2 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Cab Compartment
1 Cab Doors Verify doors open and close smoothly, 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
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
CEAW003209 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 3 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Service Inspection
1 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-AC Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
(See Note below chart) Front charge height, 229 mm (9 in.) at 2689 kPa (390 psi)
Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)
930E-4 Suspension oiling height at 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear
(See Note below chart) Front charge height, 229 mm (9 in.) at 2930 kPa (425 psi)
Rear charge height, 190 mm (7.5 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
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
7 Parking Brake Verify when switch is ON, brakes are applied and light is illuminated
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-AC 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 brake lock pressure is 10,342 ± 689 kPa (1500 ± 100 psi)
Verify parking brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)
930E-4 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 brake lock pressure is 13,790 ± 689 kPa (2000 ± 100 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.
CEAW003209 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 4 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
No. Inspection Item Acceptance Procedures
11 Hoist Times 730E Power up loaded - 21-23 seconds
Power down - 15-17 seconds
Float down empty - 22-24 seconds
830E, 830E-AC Power up loaded - 25-27 seconds
Power down - 15-17 seconds
Float down empty - 23-25 seconds
930E-4 Power up loaded - 21-23 seconds
Power down - 23-25 seconds
Float down empty - 24-26 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 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__________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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CEAW003209 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 5 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
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
SERIAL NUMBER SERIAL NUMBER NUMBER
730E 830E
830E-AC 930E-4
Service Meter Reading Date of Inspection Wheel Motor
Serial Numbers LH RH
Location of Machine at Inspection Dump Body Manufacturer
Komatsu Other
Customer’s Address
Inspector’s Comments:
Signature Remark:
Send gold reports to the Service Manager at the KAC Distributor who sold the truck
CEAW004201 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
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
Inspection Around Machine
1 Parts Visually inspect the truck for loose parts and debris.
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.
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-AC- Verify hardware torque -
Target: 2705 N·m (1995 ft lbs)
930E-4 - Verify hardware torque -
Target: 2705 N·m (1995 ft lbs)
2 Steering Cylinder To 730E - Verify hardware torque -
Frame Target: 464 N·m (342 ft lbs)
830E, 830E-AC - Verify hardware torque -
Target: 712 N·m (525 ft lbs)
930E-4 - Verify hardware torque -
Target: 1017 N·m (750 ft lbs)
3 Steering Cylinder To 730E - Verify hardware torque -
Steering Arm Target: 464 N·m (342 ft lbs)
830E, 830E-AC - Verify hardware torque -
Target: 712 N·m (525 ft lbs)
930E-4 - Verify hardware torque -
Target: 1017 N·m (750 ft lbs)
CEAW004201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 2 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
4 Tie Rod Pin Retainer 730E - Verify hardware torque -
Target: 464 N·m (342 ft lbs)
830E, 830E-AC - Verify hardware torque -
Target: 712 N·m (525 ft lbs)
930E-4 - Verify hardware torque -
Target: 1017 N·m (750 ft lbs)
5 Front Brake Caliper 730E - Verify hardware torque -
Mounting Target: 1085 N·m (800 ft lbs)
(Capscrew with Nut) 830E, 830E-AC - Verify hardware torque -
Target: 1085 N·m (800 ft lbs)
6 Front Brake Caliper 730E - Verify hardware torque -
Mounting Target: 1166 N·m (860 ft lbs)
(Capscrew Only)
830E, 830E-AC - Verify hardware torque -
Target: 1166 N·m (860 ft lbs)
7 Rear Service Brake 730E - Verify hardware torque -
Caliper Mounting Target: 780 N·m (575 ft lbs)
830E, 830E-AC - Verify hardware torque -
Target: 780 N·m (575 ft lbs)
8 Rear Brake Adapter 730E - Verify hardware torque -
Mounting Target: 488 N·m (360 ft lbs)
830E, 830E-AC - Verify hardware torque -
Target: 488 N·m (360 ft lbs)
9 Brake Disc To Adapter 730E - Verify hardware torque -
Mounting Target: 278 N·m (205 ft lbs)
830E, 830E-AC - Verify hardware torque -
Target: 278 N·m (205 ft lbs)
Cab Compartment
1 Horn Check for proper tone and volume. Ensure there is no
looseness in the horn button.
2 Back Up Horn Check for proper tone, volume, and function.
3 Gauges Verify all gauges are installed straight and are operating
correctly.
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.
CEAW004201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 3 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
No. Inspection Item Acceptance Procedures As Found Corrective
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-AC Suspension oiling height: 25.4 mm (1 in.) front and 25.4
(See Note below) mm (1 in.) rear
Front charge height: 229 mm (9 in.) at 2689 kPa (390
psi)
Rear charge height: 241 mm (9.5 in.) at 1724 kPa (250
psi)
930E-4 Suspension oiling height: 25.4 mm (1 in.) front and 25.4
(See Note below) mm (1 in.) rear
Front charge height: 229 mm (9 in.) at 2930 kPa (425
psi)
Rear charge height: 190 mm (7.5 in.) at 1482 kPa (215
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.
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.
CEAW004201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 4 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
ADDITIONAL COMMENTS:______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CEAW004201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 5 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
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