CEAW009700

Field Assembly
Manual

980E-5
DUMP TRUCK
SERIAL NUMBERS 980E-5 A50003 and up

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

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

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

Copyright 2018 Komatsu

Printed in U.S.A.
December 2018 Komatsu America Corp.
 READ AND UNDERSTAND THE OPERATION
& MAINTENANCE MANUAL BEFORE OPERATING
THIS VEHICLE OR PERFORMING ANY
MAINTENANCE.

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

Operators and maintenance personnel must read this manual, must
be trained and authorized by the employer, before operating or
maintaining this machine. This manual should be kept in or near the
machine for reference and periodically reviewed by all personnel
who come in contact with the machine.

WARNING: Breathing diesel engine exhaust exposes you to

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

WARNING: This product can expose you to chemicals including

lead, which is known to the State of California to cause cancer and
birth defects or other reproductive harm.
For more information go to www.P65warnings.ca.gov
 FOREWORD

This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-5 dump truck. Vari-
ations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.

FAM0037 Introduction i
 This alert symbol is used with the signal words, CAUTION, DANGER, and
WARNING in this manual to alert the reader to hazards arising from improper
operating and maintenance practices.

DANGER Identifies a specific potential hazard

which will result
in either injury or death
if proper precautions are not used.

WARNING identifies a specific potential hazard

which may result
in either injury or death
if proper precautions are not used.

CAUTION is used for general reminders

of proper safety practices
or
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.

ii Introduction FAM0037
 TABLE OF CONTENTS

SUBJECT PAGE NUMBER

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

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

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

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

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

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

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

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

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

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

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

FAM0037 Introduction iii

 KOMATSU 980E-5

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

Before welding, refer to Special Precautions When

Servicing An AC Drive System Truck in Section 4.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its compo-
nents.

FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-1

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

Page 1-2 Safety Rules, Tools, & Equipment 3/17 FAM0125

LIFTING SLING GENERAL INFORMATION

FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-3

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

1. “T” Handle Valve

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

Part Number Description Use

EJ2626 Roller 930E-4
Assembly

EH8687 930E-4SE
(No longer Power Module
available as Removal &
complete unit)
Installation
EJ2271 Roller Mount 930E standard
EH8681 Roller Mount 930E SE
PC0706 Bearing
TH9449 Bearing
Retainer Ring
TG1680 Roller
Retainer Ring
C1645 Capscrew -
3/4” - 10NC x
2 1/4”
C1542 Lockwasher -
3/4”
EH8686 Roller Ring

Page 1-4 Safety Rules, Tools, & Equipment 3/17 FAM0125

Part Number Description Use
PB8326 Offset Box End Miscellaneous
Wrench,
1, 7/16 in.

Part Number Description Use

TZ2734 3/4 in. Torque Miscellaneous
Adapter

Part Number Description Use

TZ2733 Tubular Handle Use with
PB8326 &
TZ2734

FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-5

 Part Number Description Use
BF4117 Seal Installa- Front & Rear
tion Tool Disc Brake
Floating Ring
Seal Installation
ED3347 Seal Installa- Rear Axle/Hub
tion Tool Adaptor Float-
ing Ring Seal
Installation

Part Number Description Use

EH4638 Sleeve Steering Linkage
Alignment Tool and Tie Rod

Part Number Description Use

EF9302 Wear Indicator Brake Disc Wear
EB1723 Cap, Indicator
EF9301 Pin Indicator
WA0010 O-ring, Indica-
tor Pin
TL3995 O-ring, Indica-
tor Cap
EB4813 Housing, Indi-
cator
SV9812 O-ring, housing

Page 1-6 Safety Rules, Tools, & Equipment 3/17 FAM0125

Part Number Description Use
PC2525 Harness Payload Meter
III Download

Part Number Description Use

EH7817 Alignment Tool Upper Hoist Pin

Part Number Description Use

PB4684 Hydraulic Miscellaneous
Coupling

Part Number Description Use

PB9067 Bulkhead Battery Jumper
Connector

FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-7

 Part Number Description Use
TZ2100 Socket (1 7/8 in.) Misc.
TZ2727 Socket (2 1/4 in.)
TZ2729 Socket (1 1/4 in.)

Part Number Description Use

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

Part Number Description Use

WA4826 Lifting Eye Bolt Miscellaneous

Part Number Description Use

PC0370 Sling Body Retention

Part Number Description Use

PC0367 Shackle Miscellaneous

Part Number Description Use

TR0532 Extension (8 in.) Miscellaneous
TR0533 Extension (17 in.)

Page 1-8 Safety Rules, Tools, & Equipment 3/17 FAM0125

KOMVISION® CALIBRATION TOOLS
Part Number Description Use
58E-98-00600 Tripod Stand Radar
Calibration

Part Number Description Use

XB0841 Reflector Radar
Calibration

Part Number Description Use

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

FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-9

HIGH VOLTAGE TOOLS

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

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

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

Page 1-10 Safety Rules, Tools, & Equipment 3/17 FAM0125

BODY PAD SPACER TOOL
Part Number Description Use
XC2293 Spacer Body Pad
Shimming

15.9

40.0

20.0

* NOTE INCH EQUIVALENT MATERIAL

TYP
3.0
R

2.00" PLATE
387.5

355.6

TYP

50.8
REF
8.0
R

XC2293 SPACER BLOCK DIMENSION

FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-11

Page 1-12 Safety Rules, Tools, & Equipment 3/17 FAM0125
FAM0125 3/17 Safety Rules, Tools, & Equipment Page 1-13
 NOTES

Page 1-14 Safety Rules, Tools, & Equipment 3/17 FAM0125

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

AC Induction Traction Motorized Wheels Dynamic Retarding Grid

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

The parking brake is a dry disc type, mounted

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

FAM0238 Truck Components And Specifications 2-1

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

2-2 Truck Components And Specifications FAM0238

 FIGURE 2-1. TRUCK COMPONENTS
1. Operator Cab 10. Suspension 19. Pump Filters 28. Selective Catalytic
2. Auto Lubrication 11. Front Brakes 20. Pump Filter Reduction (SCR)
3. Retractable Ladder 12. Steering Arm 21. Hoist Cylinder System
4. Steps and Ladders 13. Steering Accumulator 22. Rear Axle Housing 29. Steering Pump
5. Radiator 14. Auxiliary Blowers 23. Rear Brakes 30. Hydraulic Tank
6. Engine 15. Hoist Filters 24. Rear Tires 31. Hoist Pump
7. Stage 1 Fuel Filters 16. Fuel Tank 25. Rear Suspension 32. Alternator
8. Front Tires 17. DEF Tank and Pumps 26. Rear Axle Hatch 33. Stage Two Fuel Filters
9. Grid Blowers 18. DEF Filters 27. Dosing Modules

FAM0238 Truck Components And Specifications 2-3

SPECIFICATIONS HYDRAULIC SYSTEMS
Hoist and Brake Cooling Pump . . . . . . Tandem Gear
These specifications are for the standard Komatsu
Rating . . . 931 L/min (246 gpm) @ 1900 RPM and
980E-5 truck. Customer options may change this
18 960 kPa (2,750 psi)
listing.
Steering/Brake Pump Pressure Compensated Piston
Rating . . . 246 L/min (65 gpm) @ 1900 RPM and
ENGINE
20 685 kPa (3,000 psi)
Komatsu SSDA18V170 Relief Pressure - Hoist . . . . . 18 960 kPa (2,750 psi)
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Relief Pressure - Steering/Brake . 27 580 kPa (4,000
Operating Cycle . . . . . . . . . . . . . . . . . . . . . . 4-Stroke psi)
Rated Brake HP 2 610 kW (3,500 HP) @ 1900 RPM Hoist Cylinders (2). . . . . . . . . . . . . 3-Stage Hydraulic
Flywheel HP . . . 2 495 kW (3,346 HP) @ 1900 RPM Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized
Weight (Dry)* . . . . . . . . . . . . . .10 300 kg (22,701 lb) Tank Capacity. . . . . . . . . . . 947 liters (250 gallons)
* Weight does not include radiator, sub-frame, or Filtration. . . . . . . . . . . . . In-line replaceable elements
alternator. Suction . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High
AC ELECTRIC DRIVE SYSTEM Pressure). . . . . . . . . . . . . . . . . . Beta 12 Rating =200
AC/DC Current
SERVICE BRAKES
Alternator . . . . . . . . . . . . . . General Electric GTA-39
All Hydraulic Actuation with Traction System Wheel
Dual Impeller, In-Line Blower . . . . . . . . . . . . . . . . . . .
Slip/Slide Control
. . . . . . . . . . . . . . . . . . . . . 340 m³/ min (12,000 cfm)
Front and Rear Oil-Cooled Multiple Discs on each
Motorized Wheels. . . . . . . . . . . . . . . . . .
wheel
AC Induction Traction . . . . . . . . . . Motors (GDY108)
Total Friction Area / Brake . 103 729 cm² (16,078 in²)
Standard Gear Ratio* . . . . . . . . . . . . . . . 35.03:1
Maximum Apply Pressure . . . 18 960 kPa (2,750 psi)
Maximum Speed . . . . . . . . 60.7 km/h (37.7 mph)
* Wheel motor application depends upon GVW,
STEERING
haul road grade and length, rolling resistance, and
other parameters. Komatsu and GE must analyze Twin hydraulic cylinders with accumulator assist to
each job condition to ensure proper application. provide constant rate steering
Emergency power steering automatically provided by
DYNAMIC RETARDING accumulators
Turning Circle (SAE) . . . . . . . . . 32.0 m (105 ft. 0 in.)
Electric Dynamic Retarding . . . . . . . . . . . . Standard
Continuous* . . . . . . . . . . . . . . . 4 476 kW (6,000 HP)
TIRES
* Continuously rated high-density blown grids with
retard at engine idle and retard in reverse propulsion. Radial Tires (standard) . . . . . . . . . . . . . . . 59/80 R63
Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless
BATTERY ELECTRIC SYSTEM Rims . . . . . . . . . . . . . . . . Rated to 827 kPa (120 psi)
Batteries . . . . . Four x8D, 12 volt, in series/parallel,
STANDARD DUMP BODY CAPACITIES AND
bumper mounted with isolation station
DIMENSIONS
Cold Cranking Amps . . . . . . . . . . . . . . 1400 CCA Capacity
Alternator . . . . . . . . . . . 24 Volt, 250 Ampere Output
Heaped @ 2:1 (SAE) . . . . . . . . . . 250 m3 (327 yd3)
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Cranking Motors (2) . . . . . . . . . . . . . . . . . . . 24 Volts Struck . . . . . . . . . . . . . . . . . . . . . . .191 m3 (250 yd3)
Width (Inside) . . . . . . . . . . . . . . . 8.68 m (28 ft. 6 in.)
SERVICE CAPACITIES Depth. . . . . . . . . . . . . . . . . . . . . . . 3.2 m (10 ft. 7 in.)
Crankcase (including lube oil filters) 363 liters (96 Loading Height . . . . . . . . . . . . . . 7.09 m (23 ft. 2 in.)
gallons) Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Cooling System . . . . . . . . . . .799 liters (211 gallons) NOTE: Optional capacity dump bodies are available.
Fuel Tank . . . . . . . . . . . . . 5 300 liters (1400 gallons)
Hydraulic System . . . . . . . . 1 325 liters (350 gallons)
Wheel Motor Gear Box . . . . 95 liters (25 gallons) per
wheel
DEF Tank . . . . . . . . . . . . . . . . . . . . . 318. . . . . . (84)

2-4 Truck Components And Specifications FAM0238

WEIGHT DISTRIBUTION * Nominal payload is defined within Komatsu Amer-
ica Corporation’s payload policy documentation.
Empty Vehicle Nominal payload must be adjusted if the weight of
Front Axle (46.7%). . . . . . . . 122 662 kg (270,423 lb) any customized body or tires vary from that of the
Rear Axle (53.3 %) . . . . . . . 139 741 kg (308,077 lb) standard Komatsu body and tires. Nominal payload
Total (with 50% fuel) . . . . . . 262 403 kg (578,500 lb) must also be adjusted to take into account the addi-
tional weight of any custom/optional extras fitted to
Standard Komatsu body . . . . . 42 638 kg (94,000 lb) the truck which are not stated within the Standard
Standard tire weight. . . . . . . . . 32 585 kg (71,838 lb) Features list of the applicable specification sheet.

Loaded Vehicle
Front Axle (32.8%). . . . . . .205 489 kg (453,025 lb)
Rear Axle (67.2%) . . . . . . .419 788 kg (925,475 lb)
Total . . . . . . . . . . . . . . . . . .625 839 kg (1,378,500 lb)
Nominal Payload* . . . . . . . . 362 874 kg (800,000 lb)

10.0 m 32’10”

15.0 m
49’3”

1.8 m 5’10”

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

8.0 m
26’4”

4.53 m
14’10”

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

FAM0238 Truck Components And Specifications 2-5

2-6 Truck Components And Specifications FAM0238
 MAJOR COMPONENT WEIGHTS

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

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

ITEM KILOGRAMS POUNDS

CHASSIS
Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 377 . . . . . . . . . . . . . . . . . . . . . . 7,445
Tire (59/80 R63). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 431 . . . . . . . . . . . . . . . . . . . . . 11,973
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 808 . . . . . . . . . . . . . . . . . . . . . 19,418
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 760 . . . . . . . . . . . . . . . . . . . . . 65,610
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 542 . . . . . . . . . . . . . . . . . . . . . . 1,200
Diesel Exhaust Fluid (DEF) Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 . . . . . . . . . . . . . . . . . . . . . . . . . .8

DECK AND DECK SUPPORT COMPONENTS

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

FAM0328 Major Component Weights 3-1

 ITEM KILOGRAMS POUNDS

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

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

FRONT AXLE COMPONENTS

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

REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 028 . . . . . . . . . . . . . . . . . . . . . . .2,266
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447 . . . . . . . . . . . . . . . . . . . . . . . . 986
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 382 . . . . . . . . . . . . . . . . . . . . . . 16,275
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 . . . . . . . . . . . . . . . . . . . . . . . . 353

3-2 Major Component Weights FAM0328

 ITEM KILOGRAMS POUNDS
Wheel Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 300 . . . . . . . . . . . . . . . . . . . . . 51,368
Electric Wheel Transmission/Rear Wheel Brake w/Hub Adapter . . .17 168 . . . . . . . . . . . . . . . . . . . . . 37,849
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 132 . . . . . . . . . . . . . . . . . . . . . 13,519
Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 . . . . . . . . . . . . . . . . . . . . . . . .381
Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 . . . . . . . . . . . . . . . . . . . . . . . . 911

FAM0328 Major Component Weights 3-3

 NOTES

3-4 Major Component Weights FAM0328

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

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

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

MATERIALS, CONTROLS, AND WELD INSPECTION

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

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

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

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

ANNEX B 2.0 TOE GRINDING WITH A ROTARY BURR

1.0 TOE HAMMER PEENING Equipment:

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

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

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

 FIGURE 4-1. TOE HAMMER PEENING

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

 FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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

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

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

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

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

 RECEIVING & ASSEMBLY PREPARATION
Preparation Coded Boxes
A parts check list will be included in each shipping
Inspection, Cleaning, Setup
crate that is shipped with the truck. The list consists
1. Inspect all components for possible shipping of tables that represent a portion of the assembly
damages. Note any damage found and report to process. The parts listed in each table will be packed
shipping agent. in waterproof corrugated PVC boxes.
2. Spread out all parts and organize per unit num- The boxes will be packed into shipping crates and
ber. Check for missing parts. List the unit num- shipped with the truck. Refer to Figure 5-1, Figure 5-
ber of all major components. Verify the cab and 2 and Figure 5-3. Assembly technicians can then
decks are with the correct chassis. locate the boxes that match the operation (table)
3. Install support blocks under the chassis. The being performed. The boxes will be packed into the
support blocks must be approximately 84 cm crate in chronological order. Parts needed early in
(33 in.) high. the assembly process will be located near the top of
4. Install support blocks under the rear axle hous- the crates.
ing. The support blocks must be approximately
30 cm (12 in.) high and spread out along the
axle. The support blocks must be a minimum of
51 mm (2 in.) away from the wheel motor
mounting face.
5. Clean all mounting surfaces on the chassis and
on the individual components.
6. Clean and tap all mounting capscrew holes.
7. Check all electrical connectors and verify they
are free of paint and/or corrosion. Clean any
connector with questionable electrical continu-
ity.
8. Check all factory installed components for the
proper tightening torque.
9. Arrange the work site as shown on the following
page.

FIGURE 5-1.

FAM0514 Receiving & Assembly Preparation 5-1

 FIGURE 5-2. FIGURE 5-3.

5-2 Receiving & Assembly Preparation FAM0514

 ASSEMBLY LAYOUT

FAM0514 Receiving & Assembly Preparation 5-3

 NOTES

5-4 Receiving & Assembly Preparation FAM0514

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

FAM0648 Chassis Assembly 6-1

ORDER OF ASSEMBLY 15. Front Suspensions
16. Spindles
The assembly procedure is organized in order. Gen-
erally, the tasks to be done at a given may be per- 17. Tie Rod
formed in any convenient order or simultaneously. 18. Assemble Induction Motor to Transmission
However, all tasks in that order must be completed
before proceeding to the next higher order. Each task 19. Wheel Motors
depends on the installation of components from the 20. Air Intake Tubes
previous order.
21. Right, Left, and Center Deck
NOTE: As stated earlier, shipping and packaging of 22. Remount Cab
large machines will vary. Some of these tasks may
change due to different shipping configurations and/ 23. Retarding Grid
or truck options. 24. Control Cabinet
1. Chassis - Unload and arrange ALL parts 25. Transformer
2. Remove Decks From Shipping Configuration
26. Cooling Blowers]
3. Inspect and Inventory Parts and Components
27. Blower Ducting
4. Uprights/Air Cleaners
28. Exhaust
5. Diagonal Beams
6. Deck Supports 29. Battery Box
7. Operator Cab 30. Diagonal Ladder
8. Weld Uprights 31. Bumper Extension, Oil Reserve, and Grease
9. Weld Deck Supports Pump

10. Hydraulic Tank 32. Mud Flaps and Light Bars

11. Fuel Tank 33. Mount Tires, Rim Adapter, and Torque

12. DEF Tank 34. Body

13. Rear Suspension 35. Optional Equipment

14. Hydraulic Cylinders

6-2 Chassis Assembly FAM0648

CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at another loca-
tion may be different. However, this outline will pro-
vide a general basis for assembly.
Disconnect the battery cables before welding on
the truck. Failure to do so may seriously damage
the batteries and electrical equipment. Discon-
nect the battery charging alternator lead wire
before welding on the frame or its components.

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 purged 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 HARDWARE TIGHTENING METHOD
correct capacities and safety procedures NOTE: Mark capscrews and nuts with paint or ink
when lifting components. Replace any
before tightening to the specified torque. This
questionable items.
method provides verification that the hardware has
• Slings, chains and cables used for lifting been properly tightened.
must be rated for approximately two times the
intended load. 1. Snug down all of the hardware with an impact
wrench or appropriate ratchet.
• When in doubt as to the weight of
components or any assembly procedure, 2. Apply a paint mark down the side of the hard-
contact your customer support manager for ware and onto the component surface. Make
further information. sure that all of the hardware that is being tight-
ened is marked.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the 3. Apply the specified torque to all of the marked
intended load. hardware.
• Never stand beneath a suspended load. Guy All of the marks should now be offset, showing
ropes are recommended for guiding and that the hardware has been properly tightened.
positioning a suspended load.
• Before lifting, ensure there is adequate
clearance from overhead structures or
electric power lines.

FAM0648 Chassis Assembly 6-3

GENERAL PRECAUTIONS AND 10. Use the proper precautions when checking the
INSTRUCTIONS nitrogen pressure and oil level in the accumula-
tors.
1. Clean and remove all foreign material from
component mounting surfaces. 11. Verify the lube system is lubricated, purged and
all levels full prior to start up.
2. DO NOT weld the front uprights to the bumper
until cab and all upper decks are installed. 12. Purge air from the steering pump before truck
operation. Pressure will not build in the brake
3. Tighten the deck mounting capscrews before
and steering circuit if air is present. Air in the
the exhaust tubes, etc. are installed.
system may damage the pump. Refer to the
4. Verify all electrical connectors are free from Hydraulic Checkout Procedure in Section 10 of
paint and/or corrosion. Clean any connector this manual.
that may be questionable.
13. Use the battery disconnect switch when arc
5. Do not tighten the diagonal beam (ROPS) cap-
welding. Connect the weld ground near the
screws until after the operator cab and LH air
weld area.
intake tubes are in place.
6. Before installing the cab to the substructure, tap 14. Before the truck is started for the first time, the
all threaded holes to remove paint. hydraulic system must be flushed. Refer to the
hydraulic system flushing procedure in the
7. Verify all wiring is properly connected before Appendix.
attempting to start the engine.
8. Recheck the torque on hardware installed at the
factory.
9. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.

6-4 Chassis Assembly FAM0648

CHASSIS AND COMPONENT SERIAL have the component PN and SN identified on it for
NUMBER (SN) IDENTIFICATION proper installation.

During assembly it is important that each component The following chart lists the chassis components
be installed on the correct chassis. along with a brief description and a graphic of where
the SN stamp is located.
Failure to install the correct components on the cor-
rect chassis can result in weld fitments, hydraulic and
electrical connection issues.

Structural components will be stamped with at least

the last two digits of the chassis serial number (SN).
These include the uprights, diagonal beams, deck
DO NOT mix components from different trucks.
supports and cab.
Components such as deck supports are marked
Cylinders, suspensions, spindles, retarding grid and with the serial number of the corresponding
wheel motors will be stamped with the components truck unit. Only use components of the unit num-
individual part number (PN) and SN not the chassis ber that is being assembled.
SN. The shipping documentation of the chassis will

CHASSIS STAMPED LOCATION OF COMPONENT GRAPHIC INDICATING SN

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

Mounting Plate Edge of Mounting Plate

FAM0648 Chassis Assembly 6-5

 CHASSIS STAMPED LOCATION OF COMPONENT GRAPHIC INDICATING SN
COMPONENT SERIAL NUMBER (SN) LOCATION
Deck Support Locator Block on Deck
Support

Operator Cab Mounting Pad on Cab

6-6 Chassis Assembly FAM0648

CHASSIS STAMPED LOCATION OF COMPONENT GRAPHIC INDICATING SN
COMPONENT SERIAL NUMBER (SN) LOCATION
Inside Operator Cab Door Frame and Floor

Control Cabinet Upper LH side of Control

Cabinet

Front Suspension Next to the Keyway

FAM0648 Chassis Assembly 6-7

 CHASSIS STAMPED LOCATION OF COMPONENT GRAPHIC INDICATING SN
COMPONENT SERIAL NUMBER (SN) LOCATION
Spindle Top of the Spindle Edge

Hoist Cylinder On the Barrel

6-8 Chassis Assembly FAM0648

CHASSIS STAMPED LOCATION OF COMPONENT GRAPHIC INDICATING SN
COMPONENT SERIAL NUMBER (SN) LOCATION
Rear Suspension Below Warning Decal

Wheel Motor Edge of Flange

FAM0648 Chassis Assembly 6-9

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

FIGURE 6-1.

6-10 Chassis Assembly FAM0648

 2. Place the chassis on adequate support blocks this height will allow easy installation of the
in a level position. The weight of the chassis, as truck components.
shipped, is approximately 64 410 kg (142,000
NOTE: Remove right, left, and center decks from
lb).The support blocks must be approximately
chassis. They will be re-installed at the time of
84 cm (33 in.) high at the front, and approxi-
installing of the diagonal beams.
mately 30 cm (12 in.) high under the rear axle
housing Figure 6-2. Placement of the chassis at 3. Thoroughly clean the chassis.

FIGURE 6-2.

FAM0648 Chassis Assembly 6-11

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

FIGURE 6-4.

FIGURE 6-3.

6-12 Chassis Assembly FAM0648

 5. Attach each uprights to a crane using adequate
lifting apparatus. Attach a ratchet hoist to the
lifting apparatus (on the front side) to enable the
upright to pivot for proper alignment during
installation (see to Figure 6-5 and Figure 6-6).
Install the four capscrews to mount the upright.
NOTE: Do not weld the torque tubes on the uprights
at this time.
6. Lift each upright into their position and install
the four capscrews to mount the upright.
Tighten to standard torque. Refer to Standard
Tables in Section 10, Appendix. Tighten to 465
± 47 N·m (343 ± 34 ft lb). The weight of the
uprights with air cleaner attached is approxi-
mately 822 kg (1,812 lb).
NOTE: Do not weld the torque tubes on the uprights
at this time.

FIGURE 6-6.

FIGURE 6-5.

FAM0648 Chassis Assembly 6-13

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

85175

FIGURE 6-7.

6-14 Chassis Assembly FAM0648

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

FIGURE 6-8.

FIGURE 6-8.

FAM0648 Chassis Assembly 6-15

 FIGURE 6-9. FIGURE 6-10.

6-16 Chassis Assembly FAM0648

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

FIGURE 6-11.

FIGURE 6-12.

FAM0648 Chassis Assembly 6-17

 FIGURE 6-13. FIGURE 6-15.

FIGURE 6-16.
FIGURE 6-14.

6-18 Chassis Assembly FAM0648

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

FIGURE 6-17.

FAM0648 Chassis Assembly 6-19

Deck Support Welding

FIGURE 6-18. DECK SUPPORT BEFORE WELDING

REF DETAIL B

SECTION VIEW
SECTION VIEW RH DECK SUPPORT
LH DECK SUPPORT

SECTION A-A DETAIL B 86329

FIGURE 6-19. WELDING SPECIFICATIONS

6-20 Chassis Assembly FAM0648

11. Tack weld the backer bars inside the deck sup- 12. The backer bars must be tack welded in loca-
port. Refer to Figure 6-20 and 6-21. tions where the tack will be burned away on the
next weld pass. Refer to Figure 6-20 and 6-21

FIGURE 6-20. WELDING INSIDE THE DECK SUPPORT

FIGURE 6-21. BACKER BAR INSTALLATION

FAM0648 Chassis Assembly 6-21

 13. Weld the LH upright to the front frame tube.
Refer to Figure 6-22.

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.
14. Remove the four capscrews and tapped pads
on the deck support and the corresponding
blocks on the horsecollar to allow for a com-
plete weld around the joint.
15. Weld completely around the support without
leaving any gaps.
16. Grind and clean all areas. Paint after welding is
complete.
17. Repeat the deck support welding procedure for
the RH deck support.

FIGURE 6-22.
FIGURE 6-23.

6-22 Chassis Assembly FAM0648

18. Remove any paint from the cab mounting holes. 20. Tighten the capscrews that secure the LH diag-
onal beam.
19. Lift the cab onto the deck supports and install
the mounting hardware snugly but do not torque 21. Lift the RH deck support into position. The
at this stage. Verify no gaps exist between the weight of the RH deck support is approximately
mounting pads of the cab. If gaps are present, 408 kg (900 lb). Bolt the support into place.
the upright and/or deck support may need to be
repositioned.

FIGURE 6-24. DETERMINING CAB FIT

1. Cab 3. LH Diagonal Beam

2. Deck Support 4. Left Upright

22. Remove the cab after welding is complete. Con- a. Install the four mounting capscrews near the
tinue with the assembly process. top of the tank. Tighten to 622 ± 62 N·m (459
± 46 ft lb).
23. Remove all paint from the mounts for the
hydraulic tank. b. Install the two mounting capscrews near the
bottom of the tank. Tighten to 800 ± 80 N·m
24. Lift the tank into position. Refer to Figure 6-25.
(590 ± 59 ft lb).
The weight of the hydraulic tank is approxi-
mately 603 kg (1,329 lb).

FAM0648 Chassis Assembly 6-23

 FIGURE 6-25. HYDRAULIC TANK INSTALLATION

6-24 Chassis Assembly FAM0648

25. Connect the piping to the hydraulic tank and NOTE: When the machine is ready for operation, the
properly tighten all fittings. Refer to Figure 6-26. hydraulic tank shut-off valves must be opened. The
valves are open when the handles are parallel with
the hoses.

FIGURE 6-26. FIGURE 6-27.

26. Install the fuel tank quick fill box at the bottom of 27. Install three pressure switch assemblies, then
the hydraulic tank. Refer to Figure 6-27. install the two hoist filters and one steering filter
onto the bracket at the inner side of the fuel
tank. Refer to Figure 6-28.

1 1

3 2

86307

FIGURE 6-28.

1. Pressure Switch Assembly 2. Hydraulic Filter - Steering 3. Hydraulic Filter Assembly

FAM0648 Chassis Assembly 6-25

 28. Connect supply hose (1, Figure 6-29) and
return hose (2) to the fuel tank. Install vents (3)
and the overflow tubes.

86308

FIGURE 6-29. FUEL HOSE INSTALLATION

1. Supply Hose 3. Vent

2. Return Hose

6-26 Chassis Assembly FAM0648

29. Clean the mounts for the fuel tank. b. Install the rubber dampeners, flat washers
and capscrews in the lower mounts at the
30. Lift the tank with DEF Tank into position. The
rear of the fuel tank. Tighten the capscrews
weight of the fuel tank is approximately 2 056 kg
to 800 ± 80 N·m (590 ± 59 ft lb).
(4,533 lb). Refer to Figure 6-30.
c. Tighten the capscrews at the top of the fuel
a. Install the mounting caps, washers and cap-
tank to 712 ± 72 N·m (525 ± 53 ft lb).
screws at the top of the fuel tank. Do not
tighten the capscrews at this time.

FIGURE 6-30. FUEL TANK WITH DEF TANK INSTALLATION

1. Cap 4. Rubber Mount 7. Lockwasher

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

FAM0648 Chassis Assembly 6-27

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

FIGURE 6-31. REAR SUSPENSION CYLINDER PIN INSTALLATION

1. Suspension Cylinder 5. Pin 9. Bearing

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

6-28 Chassis Assembly FAM0648

38. Raise the hoist cylinder into position over the
pivot point on the frame. The weight of each
hoist cylinder is approximately 1 174 kg (2,588
lb). Position the cylinder with the air bleed vent
plug on top, and facing the front of the truck.
Refer to Figure 6-32.

FIGURE 6-33.

1. Capscrew 4. Retainer Ring

2. Locking Plate 5. Bearing
FIGURE 6-32. 3. Retaining Plate 6. Spacer
39. Install spacer (6, Figure 6-33). Align the bearing
eye with the pivot point and push the cylinder
into place.
40. Install retaining plate (3), locking plate (2), and
capscrews (1). Tighten the capscrews to 465 ±
47 N·m (343 ± 34 ft lb). Bend the locking plate
tabs over the capscrew flats (Figure 6-34).

FIGURE 6-34.

FAM0648 Chassis Assembly 6-29

Front Suspension Installation 42. Clean and dry the mounting surfaces on both
the suspension and the frame. Use a cleaning
41. Remove all paint, rust, dirt and foreign debris
agent that does not leave a film after evapora-
from the suspension mounting surfaces. Refer
tion, such as isopropyl alcohol, acetone or lac-
to Figure 6-35 and Figure 6-36.
quer thinner.
43. Inspect the suspension and frame mounting
surfaces for shipping damage. Check for the fol-
lowing criteria:
Flatness of each surface must be within
0.25 mm (0.010 in.).
Surface finish must not exceed 0.635 µm
(250 µ in.) roughness average (RA),
medium tool cut.
If measurements are not within specifications,
contact your Komatsu customer service man-
ager for further instructions.
44. Clean and dry all suspension mounting hard-
ware. Use the same cleaning agent that was
FIGURE 6-35. used to clean the mounting surfaces.

FIGURE 6-36.

6-30 Chassis Assembly FAM0648

High tightening torque is required to load the The use of dry threads in this application is not
front suspension mounting capscrews. Repeated recommended. Due to the high tightening forces
tightening will result in capscrew fatigue and required to load these capscrews, dry threads or
damage. DO NOT reuse mounting capscrews, threads lubricated with anti-seize compounds
washers and nuts. Replace the hardware after may result in damage. Only use the approved
each use. lubricant specified below.
Suspension mounting capscrews are specially
45. Lubricate the capscrew threads, capscrew head
hardened to meet or exceed grade 8 specifica-
seats, washer faces and nut seats with 3%
tions. Replace only with capscrews of correct
molybdenum-disulphide grease.
hardness. Refer to the appropriate parts book for
the correct part numbers. 46. Identify and separate the hardware according to
location on the suspension. Refer to Figure 6-
37.

FIGURE 6-37.

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

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

FAM0648 Chassis Assembly 6-31

 47. Lift the front suspension into position on the
frame. The weight of each front suspension cyl-
inder is approximately 4 372 kg (9,639 lb).
Refer to Figure 6-38 and Figure 6-39.

FIGURE 6-39.

FIGURE 6-38.

6-32 Chassis Assembly FAM0648

 48. Install the mounting hardware and the shear
key. Install the shear key flush with the side face
of the suspension. Refer to Figure 6-40.
a. Install one washer under each capscrew
head and one washer under each nut (where
applicable).
b. Initially tighten the hardware to 1 356 ± 136
N·m (1,000 ± 100 lb ft) in the sequence
shown in Figure 6-41. Use a properly cali-
brated torque wrench to ensure accuracy.
NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.
c. The mounting capscrews will now need to be
loosened and then tightened using angle-
advance. The first set of capscrews to be
adjusted will be at the upper mounting joint.
The capscrews must be loosened one at
time and then tightened by advancing a
specified rotational degree. Use the map
shown in Figure 6-41 for proper tightening
sequence.

TO TRUCK FRAME
FIGURE 6-41. SUSPENSION INSTALLATION

.
TO SUSPENSION

86383

FIGURE 6-40. SHEAR KEY ORIENTATION

FAM0648 Chassis Assembly 6-33

Upper Mounting Joint - 60° Advance 53. Make new reference lines along the capscrew,
nut and frame at the rear of the joint as shown
The proper sequence for the upper mounting joint is
in Figure 6-43. These reference lines will be
1-2-3-4-9-10. Refer to Figure 6-41.
used to verify the capscrews have maintained
49. Loosen the first capscrew. All other capscrews their torque.
must be maintained at 1 356 ± 136 N·m (1,000
± 100 lb ft).
50. Tighten the capscrew to 95 ± 9 N·m (70 ± 7 lb
ft).
NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.
51. Mark a corner of the capscrew head with a paint
marker as shown in Figure 6-42. Draw a refer-
ence line on the suspension surface next to the
marked corner on the capscrew. Draw a refer-
ence line on the suspension 60 degrees in
advance of the marked corner on the capscrew.

FIGURE 6-43.

54. Repeat this process in sequence for the remain-

ing capscrews in the upper mounting joint.
NOTE: If for any reason these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 capscrews and
repeat the entire process. The hardware, again, must
FIGURE 6-42. be cleaned and lubricated before repeating.

52. Advance the capscrew to the 60° advance

mark. Hold the nut at the rear of the joint sta-
tionary while tightening.

6-34 Chassis Assembly FAM0648

Lower Mounting Joint - 90° Advance
The proper sequence for the lower mounting joint is
5-6-7-8-11-12-13-14. Refer to Figure 6-41.
55. Loosen the first capscrew. All other capscrews
must remain tightened.
56. Tighten the capscrew to 475 N·m (350 lb ft).
NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.
57. Mark a corner of the capscrew head with a paint
marker as shown in Figure 6-44. Draw a refer-
ence line on the suspension surface (or frame) FIGURE 6-45.
next to the marked corner on the capscrew.
Draw a reference line on the suspension sur-
face (or frame) 90° in advance of the marked 60. Repeat this process in sequence for the remain-
corner on the capscrew. ing capscrews in the lower mounting joint.
NOTE: If for any reason these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 capscrews and
repeat the entire process. The hardware, again, must
be cleaned and lubricated before repeating.

FIGURE 6-44.

58. Advance the capscrew to the 90° advance

mark. Hold the nut at the rear of the joint (where
applicable) stationary while tightening.
59. Make new reference lines along the capscrew,
nut and frame at the rear of the joint as shown
in Figure 6-43. For the four capscrews with
spacers, refer to Figure 6-45. These reference
lines will be used to verify the capscrews have
maintained their torque.

FAM0648 Chassis Assembly 6-35

 61. Clean the tapered portion of the suspension rod 62. Lift the spindle/brake assembly into position.
and the bore of the spindle. Lubricate the two The weight of each spindle/brake assembly is
surfaces with multipurpose NLGI 2 EP (extreme approximately 6 690 kg (14,750 lb). Refer to
pressure) grease (6% lithium complex mini- Figure 6-46.
mum).
NOTE: A ratchet hoist may be used at the lower
portion of the steering arm to the lifting hook to aid in
leveling the assembly for easier mounting to the
suspension.

FIGURE 6-46.

6-36 Chassis Assembly FAM0648

63. Lift the retainer plates to the bottom of each
suspension using a hydraulic jack. Refer to
Figure 6-47.

FIGURE 6-47.

FAM0648 Chassis Assembly 6-37

 64. Lubricate the 15 capscrews on the threads and 65. Install the capscrews. Evenly tighten the cap-
seats with lithium based chassis grease (multi- screws to 678 N·m (500 ft lb). Continue to
purpose, EP NLGI). tighten the capscrews in increments of 339 N·m
(250 ft lb) until the final torque of 2 705 ± 135
N·m (1,995 ± 100 ft lb) is reached. Refer to
Figure 6-48.

FIGURE 6-48.

66. After installation is complete, connect the brake

piping to each brake and wheel speed sensor.

6-38 Chassis Assembly FAM0648

67. Install the tie rod and both steering cylinders on NOTE: Installation of the steering cylinders is the
the steering arms. Use sleeve alignment tool same as the tie rod assembly.
(58B-98-01180) to hold spacers (2, Figure 6-49)
The tie rod toe-in must be adjusted once the
and bearings in line for insertion of pin (8).
tires and the body are installed. The toe-in
Tighten nuts (3) to 420 ± 41 N·m (310 ± 30 ft
adjustment procedure is located in Section 10,
lb).
Appendix.

2
4

7
1

2
6

5
4
3
86300

FIGURE 6-49. TIE ROD INSTALLATION

1. Tie Rod Assembly 4. Flat Washer 7. Sleeve

2. Spacer 5. Retainer 8. Pin
3. Nut 6. Sleeve 9. Capscrew

FAM0648 Chassis Assembly 6-39

Wheel Motor Installation 73. Install two guide pins 180° apart (3 o’clock and
9 o’clock positions) in the rear axle housing.
NOTE: Refer to the drive system manual for wheel
motor to transmission mating procedures.
68. Thoroughly clean the capscrew holes and the
mounting faces of the rear axle housing and
wheel motor.
69. Inspect the capscrew holes in the rear axle Each complete wheel motor assembly weighs
housing for damage. Re-tap any holes that approximately 23 300 kg (51,368 lb). Ensure that
have damaged threads. Thoroughly clean any the lifting devices are capable of handling the
capscrew holes that have been re-tapped. load safely.
70. Check the mounting faces of the rear axle
housing and the wheel motor for surface
defects (nicks, scratches, etc). Repair any
defects before installing the wheel motor.
71. Check the flatness of both mounting faces of
When lifting the wheel motor assembly, do not
the rear axle housing. Check the flatness at
place straps/cables on, or lift from the inner
four equally spaced intervals (for example, 0°,
wheel rim adapter ring (6, Figure 6-50). Lifting
45°, 90° and 135°).
straps, or cables, should be placed so the weight
The maximum allowable variation in flatness is of the wheel motor assembly is supported by the
2.29 mm (0.09 in.). Do not use a rear axle wheel motor mounting flange (8) and the
housing that does not meet this specification. machined hub surface (4). Shipping fasteners
72. Apply a lithium based grease containing 3% installed in the outer wheel rim adapter ring must
molybdenum-disulphide to the threaded cap- remain in place during lifting and installation of
screw holes in the rear axle housing. wheel motors.

1 2 3 4 5 6 7 8 9

86384

FIGURE 6-50.
1. Electric Wheel Transmission 4. Machined Hub Surface 7. Brake Assembly
2. Shipping Fasteners 5. Non-machined Hub Surface 8. Wheel Motor Mounting Flange
3. Outer Wheel Rim Adapter Ring 6. Inner Wheel Rim Adapter Ring 9. Electric Wheel Motor

6-40 Chassis Assembly FAM0648

 74. Lift the wheel motor into position on the rear Refer to Figure 6-51.
axle housing. Ensure that all cables and hoses
If the brake system hoses are installed, guide them
are clear before installation.
through the spindle holes during installation.

FIGURE 6-51.

The wheel motors must be properly aligned When installing the wheel motors, ensure that
before installing them onto the rear axle housing. the markings on both components line up. The
The wheel motor has markings which help top capscrew hole on the rear axle housing may
determine installation orientation. A set of also be determined by counting the holes
dimples is located at the 3 o’clock and 9 o’clock between the two sets of punch marks. The top
positions. A centerline symbol depicts the 12 hole on the rear axle housing should line up with
o’clock position of the wheel motor. Refer to the “CL” stamping on the wheel motor.
Figure 6-52.
NOTE: The spacing for the bottom 36 holes does not
match the spacing of the top holes.

FAM0648 Chassis Assembly 6-41

 FIGURE 6-52. WHEEL MOTOR DIMPLE MARKINGS

6-42 Chassis Assembly FAM0648

 75. Select the hardware to be installed in Group 1
of the tightening sequence. Refer to Figure 6-
54.
High tightening force is required to install the 76. Inspect each capscrew for rust, corrosion and
capscrews that secure the wheel motors to the surface defects on any seat or thread. Do not
rear axle housing. Repeated tightening will result use any capscrew if a defect is suspected.
in capscrew fatigue and damage.
77. Lubricate the capscrew threads, capscrew
Do not reuse any wheel motor mounting head seats and washer faces with a lithium
hardware (capscrews and hardened washers). based grease containing 3% molybdenum-
Replace the hardware after one use. disulphide.
NOTE: The special hardened washers that are used
Do not re-tighten any wheel motor mounting in this application may have a punch lip on one side
capscrew that has loosened after the truck has due to the manufacturing process. When placing this
been placed into operation. If any wheel motor washer under the capscrew head, the washers must
mounting capscrew has loosened during truck be installed with the punch lip facing away from the
operation, all of the capscrews and hardened capscrew head to prevent damage to the fillet
washers must be replaced with new hardware. between the capscrew head and the shank. Refer to
Figure 6-53.
The capscrews that are used to secure the wheel
motors to the rear axle housing are specially
hardened to meet or exceed Grade 9
specifications. Replace these capscrews with
only new capscrews of the correct hardness.
Refer to the appropriate parts book for the
correct part number.

The use of dry threads in this application is not

recommended. Due to the high tightening force
that is required to install the wheel motor
mounting capscrews, dry threads may cause
damage to tools, capscrews or the rear axle
housing.

Komatsu does not recommend the use of special

friction-reducing lubricants, such as Copper
Coat, Never-Seez® or other similar products, on
FIGURE 6-53. INSTALLATION OF HARDENED
the threads of standard fasteners where standard
WASHER
torque values are applied. The use of special
friction-reducing lubricants will significantly alter 1. Washer 2. Capscrew
the clamping force during the tightening process.
If a special friction-reducing lubricant is used,
excessive stress and possible breakage of the
fasteners may result.

FAM0648 Chassis Assembly 6-43

 78. Install the hardware for Group 1. Tighten each 80. After all of the hardware in all of the groups has
capscrew to 542 N·m (400 ft lb). been installed and tightened to 542 N·m (400
ft lb), move back to Group 1. Increase the
79. Repeat steps 86 - 88 for each remaining group
torque on each capscrew in Group 1 to 4 040
in the tightening sequence. Refer to Figure 6-
N·m (2,980 ft lb). Repeat this step for each
54.
remaining group in the tightening sequence.
Refer to Figure 6-54.

Install and tighten all of the hardware in a group

before proceeding to the next group in the
tightening sequence. Remove the guide pins that
were installed in step 83 when installing the
hardware for Groups 3 and 4.

GROUP 2
8 CAPSCREWS

GROUP 6 GROUP 7
8 CAPSCREWS 8 CAPSCREWS

GROUP 4 GROUP 3
8 CAPSCREWS 8 CAPSCREWS

GROUP 8 GROUP 5
9 CAPSCREWS 9 CAPSCREWS

GROUP 1
8 CAPSCREWS

86302

FIGURE 6-54. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

6-44 Chassis Assembly FAM0648

81. Connect the power cables and the speed sen- and return lines to each wheel. Refer to
sors to each of the wheel motors. Connect the Figure 6-55.
brake apply lines, brake cooling supply lines

FIGURE 6-55.

FAM0648 Chassis Assembly 6-45

 FIGURE 6-56.

FIGURE 6-57.

6-46 Chassis Assembly FAM0648

Parking Brake Installation 83. Install the parking brake adapter, retainer plate,
hardened flat washer and capscrew. Tighten the
82. Use a cleaner containing organic-based sol-
capscrew to 712 ± 72 N·m (525 ± 53 ft lb).
vents, such as acetone, methanol or ethanol, to
Refer to Figure 6-58.
clean the rust preventive coating from the park-
ing brake adapter teeth. Water-based cleaners,
such as mild soaps and detergents, do not ade-
quately remove the rust preventive coating.

FIGURE 6-58.

FAM0648 Chassis Assembly 6-47

 84. Attach a lifting device to the parking brake 86. Seat the parking brake assembly against the
assembly and lift into position. Refer to Figure housing and install the eight capscrews and
Figure 6-59. washers. Tighten the capscrews to 420 ± 42
N·m (310 ± 31 ft lb).
85. Use a port-a-power to release spring pressure
and allow the alignment of the brake discs
during installation.

FIGURE 6-59.

6-48 Chassis Assembly FAM0648

87. Lift the air intake tubes and hump hoses into
place. Install and tighten the clamps that secure
the hoses. Refer to Figure 6-60.

FIGURE 6-60.

FAM0648 Chassis Assembly 6-49

 88. Lift the center deck into position. Tighten the
four capscrews to 465 ± 47 N·m (343 ± 34 ft lb).
Refer to Figure 6-61

FIGURE 6-61.

6-50 Chassis Assembly FAM0648

89. Install the handrails and lift the LH deck into install the eight capscrews. Refer to Figure 6-
place. The weight of the LH deck with handrails 62.
is approximately 1 007 kg (2,220 lb). Loosely

FIGURE 6-62.

FAM0648 Chassis Assembly 6-51

 90. Install the handrails and lift the RH deck into
position. The weight of the RH deck is approxi-
mately 1 030 kg (2,271 lb). Loosely install the
six capscrews. Refer to Figure 6-63.
91. Tighten the hardware for the diagonal beams.
For the RH beam, tighten the 12 capscrews to
240 ± 24 N·m (177 ± 17 ft lb). For the LH beam,
tighten the 16 capscrews to 800 ± 80 N·m (590
± 59 ft lb). Refer to Figure 6-7.

FIGURE 6-63.

92. After the right deck is bolted in place, weld the

right hand upright to the front frame tube. Refer
to Figure 6-64.
93. After the upright is securely tack welded in
place, remove the capscrews. Also cut the cap-
screw blocks off of the frame. Finish welding the
uprights in place as instructed per the assembly
FIGURE 6-64.
drawing provided with the truck.

6-52 Chassis Assembly FAM0648

94. After all decking is in place, tighten the cap- 96. Install and tighten the eight capscrews to 465 ±
screws on each deck to 465 ± 47 N·m (343 ± 34 47 N·m (343 ± 34 ft lb).
ft lb).
95. Lift the retarding grid into place on the RH deck.
The weight of the grid is approximately 2 742 kg
(6,045 lb). Refer to Figure 6-65.

85179

FIGURE 6-65. RETARDING GRID INSTALLATION

FAM0648 Chassis Assembly 6-53

 97. Cab Mounting d. Check for any gaps between cab mounting
plates and the frame mounting plates. Use
a. Tap the cab mounting holes to remove any
shims EL1949 (front) or EL1950 (rear) as
paint from the threads. Tap size is 1.00 x
required to reduce the gap to less than 1.0
8NC.
mm (0.04 in.).
b. Lift the operator cab into position (Figure 6-
e. Install and tighten the 28 cab mounting cap-
66). The weight of the cab with brake cabinet
screws to 2 750 N·m (2,028 ft lb). Refer to
is approximately 2 948 kg (6,500 lb).
Figure 6-67.
c. Lift angle should be 45° or greater.

FIGURE 6-66. CAB INSTALLATION

FIGURE 6-67.

6-54 Chassis Assembly FAM0648

98. Lift the electrical control cabinet, with attached (8,173 lb). Install the mounting hardware and
auxiliary control cabinet, into position. The shims. Tighten the 9 capscrews to 1 600 ± 160
weight of the cabinets is approximately 3 707 kg N·m (1,180 ± 118 ft lb). Refer to Figure 6-68.

85181

FIGURE 6-68.

FAM0648 Chassis Assembly 6-55

 1 2 3 4 5

16 15 14 13 12 11 10
85184

FIGURE 6-69. AUXILIARY CONTROL CABINET EXTERNAL WIRING

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

6-56 Chassis Assembly FAM0648

 4 4
2
1 3

11 12 13
5 6 7

14 15 16
8 9 10

FIGURE 6-70. CONTROL CABINET EXTERNAL WIRING

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

FAM0648 Chassis Assembly 6-57

 99. Connect the wiring for the electrical control cab- NOTE: The auxiliary control cabinet may be shipped
inet, auxiliary control cabinet and retarding grid with the external wiring already connected.
box. Refer to Figure 6-71 through Figure 6-73.

FIGURE 6-71.

FIGURE 6-72.

6-58 Chassis Assembly FAM0648

 100. Lift the transformer into place. The weight of
the transformer is approximately 356 kg (785
lbs). Refer to Figure 6-74 through Figure 6-78.
Ensure that all wires are out of the way before
installation.
Tighten the capscrews to standard torque.
Refer to Standard Tables in Section 10, Appen-
dix.

FIGURE 6-73. FIGURE 6-74.

FAM0648 Chassis Assembly 6-59

 FIGURE 6-75. FIGURE 6-76.

6-60 Chassis Assembly FAM0648

 FIGURE 6-77. FIGURE 6-78.

FAM0648 Chassis Assembly 6-61

 101. Install the air intake ductwork. Connect the top • The weight of the wheel motor blower inlet
portion of the flexible duct to the intake duct is approximately 337 kg (743 lb). Refer
ductwork first, then attach the bottom of the to Figure 6-79.
flexible duct to the alternator. Tighten the con- • The weight of the alternator blower inlet duct
necting hardware to the standard torque. Refer is approximately 200 kg (441 lb). Refer to
to Torque Tables and Conversion Charts in Figure 6-80.
Section 10, Appendix.

FIGURE 6-79.

FIGURE 6-80.

6-62 Chassis Assembly FAM0648

102. Install the battery box on the front bumper. The and cable are properly routed and securely
weight of the battery box is approximately 560 connected. Tighten the mounting hardware to
kg (1,235 lb). Ensure that all of the harnesses standard torque. Refer to Figure 6-81.

FIGURE 6-81. BATTERY BOX INSTALLATION

FAM0648 Chassis Assembly 6-63

 103. Install the diagonal ladder. The weight of the
diagonal ladder is approximately 298 kg (657
lb). Shim as required to align the vertical lad-
der support with the radiator housing and to
align the landing with the rubber pads on the
face of the radiator housing. Tighten the cap-
screws to 95 ± 9 N·m (70 ± 7 ft lb).
Refer to Figure 6-82.

85176

FIGURE 6-82. DIAGONAL LADDER INSTALLATION

6-64 Chassis Assembly FAM0648

104. Lift the LH bumper extension into place. The Tighten the capscrews to standard torque.
weight of the bumper extension is approxi- Refer to Standard Tables in Section 10, Appen-
mately 131 kg (289lb). Refer to Figure 6-83. dix.
The LH bumper extension supports the isola-
tion station and lubrication system. Ensure that
all wires are out of the way before installation.

85174

FIGURE 6-83. LH BUMPER EXTENSION INSTALLATION

1 2

4 3
5 83659

FIGURE 6-84. BUMMPER EXTENSION INSTALLATION MOUNTING HARDWARE

1. Capscrew - M16 3. Capscrew - M12 5. Nut - M12
2. Flat Washer - M16 4. Flat Washer

FAM0648 Chassis Assembly 6-65

 105. Lift the RH bumper extension into place. The reserve oil system. Ensure that all wires are
weight of bumper extension is approximately out of the way before installation.
144 kg (318lb). Refer to Figure 6-85. The RH
Tighten the capscrews to standard torque.
bumper extension supports the optional
Refer to Standard Tables in Section 10, Appen-
dix.

85173

FIGURE 6-85. RH BUMPER EXTENSION INSTALLATION

1 2

4 3
5 83659

FIGURE 6-86. BUMPER EXTENSION INSTALLATION MOUNTING HARDWARE

1. Capscrew - M16 3. Capscrew - M12 5. Nut - M12

2. Flat Washer - M16 4. Flat Washer

6-66 Chassis Assembly FAM0648

106. Install the optional bolt-on reserve oil system: a. Install the optional reserve oil system on the
RH bumper and tighten the bolts to standard
torque. Refer toFigure 6-87.

FIGURE 6-87. RESERVE OIL SYSTEM

FAM0648 Chassis Assembly 6-67

 b. Connect the electrical connectors (1, line (3, Figure 6-88) on the reserve oil sys-
Figure 6-88) on the reserve oil system to the tem to the intake valve (1, Figure 6-89) on
truck. Connect the suction line (2) on the the truck. Connect the remote fill line (4,
reserve oil system to the return valve (2, Figure 6-88) to the remote fill station.
Figure 6-89) on the truck. Connect the return

1 1

2 85137

FIGURE 6-88. RESERVE OIL SYSTEM

1. Electrical Connectors 3. Return Line

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

6-68 Chassis Assembly FAM0648

 1 2

85127

FIGURE 6-89. ENGINE CRANKCASE FITTINGS

1. Intake Fitting 2. Return Fitting

FAM0648 Chassis Assembly 6-69

 107. Install the bolt-on lubrication system. Refer to a. Connect the lubrication system to the LH
Figure 6-90. bumper and tighten the hardware to stan-
dard torque.

FIGURE 6-90. LUBRICATION SYSTEM

b. Remove the pipe plug (5, Figure 6-91) from grease into the hose until grease appears at
each injector bank, one at a time. the injector bank where the pipe plug was
removed. Install pipe plug.
d. At another injector bank, remove pipe plug,
and pump grease into hose (22) until grease
appears at the open port at the injector bank.
Install plug.
e. Remove the plug at injector bank on the rear
axle housing. Pump grease into hose (22)
until grease appears at the open port at the
injector bank. Install plug.
f. At each injector bank, remove cap (4,
Figure 6-91) on each injector. Pump grease
into the grease fitting (2) until grease
FIGURE 6-91. appears the far end of the individual grease
1. Injector Indicator 4. InjectorGreaseFitting line or the joint that is being greased. Install
2. InjectorGrease Fitting Cap cap and repeat process on each injector on
3. Injector Cover 5. Injector Manifold Plug the truck.
108. .Verify that all electrical and hydraulic connec-
c. Disconnect hose (22, Figure 6-92) and con- tions are correct. Refer to Figure 6-92
nect it to a grease supply source. Pump

6-70 Chassis Assembly FAM0648

.

FIGURE 6-92. LUBRICATION SYSTEM

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

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

FAM0648 Chassis Assembly 6-71

 109. Install the isolation station on the LH bumper 110. Install the optional quick fill station system (2)
and tighten the hardware to standard torque.
Refer to Figure 6-93.

2
86353

FIGURE 6-93. ISOLATION STATION AND QUICK FILL STATION

1. Isolation Station 2. Quick Fill Station

6-72 Chassis Assembly FAM0648

Front Wheel Installation c. Install three nuts directly above the 3 o'clock
position and three nuts directly below the 9
NOTE: Clean all mating surfaces. Clean out tapped
o'clock position. Tighten these nuts to 2 655
holes and re-tap the threads if necessary before
± 136 N·m (1,958 ± 100 ft lb).
installing the wheels.
d. Install the remaining nuts and tighten in a
111. Grip the tire and rim assembly with the tire
clockwise pattern to 2 655 ± 136 N·m (1,958
handler. Align the tire inflation hose and the
± 100 ft lb).
wheel hub. Position the rim onto the wheel hub
studs. Refer to Figure 6-94.
112. Lubricate all stud threads and nut seating
flanges with lithium base grease. Refer to
Figure 6-95. Install and tighten the nuts in the
following sequence: After the truck has been assembled and is opera-
tional, the truck must be operated for a short
a. Install six nuts at the 12 o'clock position and
period of time, and the torque on the wheels re-
six nuts at the 6 o'clock position. Tighten
checked. Tighten the wheels to the specified
each nut to 2 655 ± 136 N·m (1,958 ± 100 ft
torque.
lb).
b. Install three nuts directly below the 3 o'clock e. Retighten all nuts in a clockwise pattern to
position and three nuts directly above the 9 the required 2 655 ± 136 N·m (1,958 ± 100 ft
o'clock position. Tighten the nuts to 2 655 ± lb).
136 N·m (1,958 ± 100 ft lb).

FAM0648 Chassis Assembly 6-73

 FIGURE 6-94.

FIGURE 6-95.

6-74 Chassis Assembly FAM0648

Rear Wheel Installation b. Install three nuts directly below the 3 o'clock
position and three nuts directly above the 9
NOTE: Clean all mating surfaces. Clean out tapped
o'clock position. Tighten to 2 655 ± 136 N·m
holes and re-tap the threads if necessary before
(1,958 ± 100 ft lb).
installing the wheels.
c. Install three nuts directly above the 3 o'clock
113. Grip the inner tire and rim with the tire handler
position and three nuts directly below the 9
and lift the wheel onto the wheel hub. Refer to
o'clock position. Tighten to 2 655 ± 136 N·m
Figure 6-97 and 6-98. Align flexible extension
(1,958 ± 100 ft lb).
(3, Figure 6-96) for mating with flexible exten-
sion (4). d. Install the remaining nuts in a clockwise pat-
tern. Tighten to 2 655 ± 136 N·m (1,958 ±
114. Lubricate all stud threads and all nut seating
100 ft lb).
flanges with a lithium base grease. Install and
tighten the nuts in the following sequence: e. Re-tighten all nuts in a clockwise pattern to
the required 2 655 ± 136 N·m (1,958 ± 100 ft
a. Install six nuts at the 12 o'clock position and
lb).
six nuts at the 6 o'clock position. Tighten to
2 655 ± 136 N·m (1,958 ± 100 ft lb). 115. Install flexible extension (4, Figure 6-96) and
associate hardware before installing the outer
tires.

1 2 3 4 5 6 7 8

86376

FIGURE 6-96. REAR WHEEL ASSEMBLY

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

FAM0648 Chassis Assembly 6-75

 DO NOT move the truck without the rear, outer
tires installed. Serious mechanical damage to the
wheel motor hub and torque tube may result. The
adapter rings and outer dual tires must be
installed. The mounting capscrews must be tight-
ened to 2 655 N·m (1,958 ft lb).
116. Position the adaptor rings (5, Figure 6-96) onto
the outer wheel studs (6) located on the wheel
motor, with the gaps between the ring halves
placed at the 12 o'clock and 6 o'clock posi-
tions. Install the fifty seven flanged nuts (7)
and tighten the nuts to 2 655 ± 136 N·m (1,958
± 100 ft lb). Refer to Rear Wheel Installation
for the correct tightening sequence.

FIGURE 6-97.

FIGURE 6-99.
FIGURE 6-98.

6-76 Chassis Assembly FAM0648

 FIGURE 6-100.
FIGURE 6-102.

After the truck has been assembled and is opera-

tional, the truck must be operated for a short
period of time, and the torque on the wheels re-
checked. Tighten the wheels to the torque speci-
fied above.
117. Grip the outer tire and rim with the tire handler
and lift the wheel onto the wheel hub. Refer to
Figure 6-103. Install the fifty seven flanged
nuts and tighten the nuts to 2 655 ± 136 N·m
(1,958 ± 100 ft lb). Refer to Rear Wheel Instal-
lation for the correct tightening sequence.

FIGURE 6-101.

FAM0648 Chassis Assembly 6-77

 FIGURE 6-103.

6-78 Chassis Assembly FAM0648

118. Connect the electrical harnesses and hydraulic
hoses below the operator’s cab. Refer to
Figure 6-104 and Figure 6-105.

FIGURE 6-104.

FIGURE 6-105.

FAM0648 Chassis Assembly 6-79

 119. Install the mud flaps on the LH and RH
uprights. Refer to Figure 6-106.

1 2

85186 85187

FIGURE 6-106.

120. Install the front LH and RH mud flaps on the 122. Install the mud flaps. Refer to Figure 6-107
underside of each deck. and Figure 6-108.
121. Weld both rear LH and RH mud flap brackets
into place on the backside of the deck sup-
ports.

6-80 Chassis Assembly FAM0648

 FIGURE 6-107.

FIGURE 6-108.

FAM0648 Chassis Assembly 6-81

Before Starting the Engine
Alternator Rotor Lock

Be careful not to damage fiberglass housing on

alternator.
Follow the steps listed below to prepare the alterna-
tor rotor lock for operation. Refer to Figure 6-109
through Figure 6-111.
123. Remove warning tags from rotor lock tool (Fig-
ure 6-109). Place a protective sheet in the
alternator housing to protect the fiberglass
housing from damage.
124. Loosen jam nuts and collapse the rotor lock
tool enough to allow it to be removed. Unscrew
capscrews to remove mount.
125. Remove rotor lock tool then remove bracket.

FIGURE 6-110. ALTERNATOR ROTOR LOCK

FIGURE 6-109. ALTERNATOR ROTOR LOCK

FIGURE 6-111. ALTERNATOR ROTOR LOCK

6-82 Chassis Assembly FAM0648

126. Position drive shaft (Figure 6-112) between
alternator shaft (Figure 6-113) and hydraulic
pump flange (Figure 6-114).
a. Attach the drive shaft to the alternator shaft
using capscrews then torque capscrews to
54 N·m (40 ft lb).
b. Attach the drive shaft to the hydraulic pump
flange using capscrews and nuts, then
torque capscrews and nuts to 47 N·m (35 ft
lb).
c. Install drive shaft cover. Refer to Figure 6-
115.
d. Remove the protective sheet from the alter-
nator housing, then remove the warning tag
from the steering wheel.

FIGURE 6-113. DRIVE SHAFT ATTACHED TO

ALTERNATOR SHAFT

FIGURE 6-112. DRIVE SHAFT

FAM0648 Chassis Assembly 6-83

 FIGURE 6-114. DRIVE SHAFT ATTACHED TO FIGURE 6-115. DRIVE SHAFT INSTALLED
HYDRAULIC PUMP FLANGE

127. Install any remaining handrails. Tighten the

capscrews to standard torque. Refer to Stan-
dard Tables in Section 10, Appendix.

6-84 Chassis Assembly FAM0648

Before the engine is started the first time, the
hydraulic system should be set up to perform the
flushing procedure. Refer to the hydraulic
system flushing procedure within the 980E-5
Hydraulic System Checkout Procedure in the
appendix of this manual. The purpose of
hydraulic system flushing is to eliminate
contaminants that could have been introduced
into the hydraulic system during truck assembly.
Performing the flushing procedure will remove
these contaminants from the hydraulic system
and minimize the potential for hydraulic system
component damage at startup.
128. Do not start the engine unless the hydraulic
system flushing tools are installed and ready to FIGURE 6-116.
perform the flushing procedure. Refer to 980E-
5 Hydraulic System Checkout Procedure in the
appendix for the hydraulic system flushing pro- 131. Check the spindle oil level at the front suspen-
cedure. sion prior to moving the truck.
129. The parking brake must be flushed before 132. Check the hydraulic tank oil level and check for
operating the truck. Refer to the appendix for leaks before and after engine start-up. Service
the parking brake flushing procedure. the hydraulic tank oil as necessary.
130. Check the oil level in each wheel motor. Rotate 133. The truck is now ready for dump body installa-
one of the eight plugs to the 6 o’clock position tion.
and remove the plug. The oil level should be
even with the bottom of the plug opening.
Refer to Figure 6-116. Fill the wheel motor with
the recommended oil as necessary.

FAM0648 Chassis Assembly 6-85

 NOTES

6-86 Chassis Assembly FAM0648

 DUMP BODY ASSEMBLY

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

advisable to move the parts to be welded into an
enclosed shop area. Surfaces to be welded must be
dry and the temperature must be above 10°C (50°F).
If shop space is not available, it may be necessary to
provide a portable enclosure and pre-heat the parts
The total weight of the body is approximately prior to welding.
30 362 kg (66,937 lb). Use two cranes for assem- In most instances, it is easier to assemble and weld
bling the body. A 45 metric ton (50 ton) crane and the body while the sections are upside down. After
a 109-136 metric tons (120-150 ton) crane are the pivot, guide pin, and body pads are welded in
required. The larger crane is needed to help turn place, the body can be turned over and the remain-
the body over after completion of the underside der of the assembly can be completed.
welding.
All paint must be removed from surfaces to be
Assembly of the body must be performed on flat ter- welded. Use a wire brush or paint removal equip-
rain with an adequate area for welding machines and ment.
for maneuvering lifting equipment. Refer to the assembly drawings shipped with the
truck for specific welding details and the parts
required for assembly.

Body sections must be assembled as originally

manufactured. Match the shipping numbers sten-
ciled on the body sections to mate the correct
parts. DO NOT mix components.

FIGURE 7-1. BODY PARTS NOMENCLATURE

1. Canopy 4. Lift Hole 7. LH Side Sheet
2. Front Sheet 5. Floor
3. RH Side Sheet 6. Pivot

FAM0703 4/16 Dump Body Assembly Page 7-1

BODY ASSEMBLY

NOTE: References to LH and RH in the following

procedures assume the body is in its' normal, upright
position, as shown in Figure 7-1.
1. Organize the body sections in a large, flat,
open space. Position the sections side by side
and upside down. Arrange the sections so they
are properly oriented for assembly. Refer to
Figure 7-2 for domestic configuration, and
Figure 7-3 for international configuration.

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

Page 7-2 Dump Body Assembly 4/16 FAM0703

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

FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE

FIGURE 7-6. BODY PIVOT INSTALLATION

FAM0703 4/16 Dump Body Assembly Page 7-3

 16. If necessary, use a hydraulic jack or crane to
raise the center of the body to allow the pivot to
fit inside the bolsters. Loosely install the cap-
screws in the pivot.
17. If assembling an international body (three-
piece), lift the canopy into position at this time.
Install the canopy capscrews and tighten.
18. Tighten all floor, front sheet, and canopy cap-
screws. Use a chalk line to align the front of the
canopy.
19. Tighten the pivot capscrews. FIGURE 7-7. FRONT SHEET & FLOOR JOINT
WELDING SEQUENCE
20. Install the filler plates and backer strips for the
pivot to body sill weld joints.
21. Check the alignment and fit of all components
1. Complete the welds at the center seam, the
22. Tack weld the joints. front sheet and the canopy. Refer to the assem-
bly drawings for welding requirements.
BODY WELDING 2. Remove the canopy alignment blocks.
Follow the guidelines listed below when welding the 3. Install the remaining gussets, the body guide
body: and the body pad mounts. Refer to Figure 7-8
through Figure 7-11.
• Use dry weld rod or weld wire.
• Weld surfaces must be dry and above 10°C
(50°F).
• If stick electrode is used, use as large a diameter
rod as practical to weld the floor and front sheet
joints. DO NOT install the heated body exhaust boxes
• The following sequence must be followed for the onto the body at this time. The exhaust boxes
front sheet: must be installed after the body is installed onto
the truck.
First Pass: Back step and skip weld in 10
increments along the entire length of the joint.
Refer to Figure 7-7.
Repeat the same procedure until the entire joint
is filled. DO NOT stop welding until entire joint is
complete.
• The body floor “V” groove must also be welded
using the same procedure as the front sheet.
Weld from the front to the rear. Refer to Figure 7-
7.

FIGURE 7-8.

Page 7-4 Dump Body Assembly 4/16 FAM0703

 FIGURE 7-11.

FIGURE 7-9. 4. Once the body underside is completed, the

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

FIGURE 7-10.

FIGURE 7-12.

FAM0703 4/16 Dump Body Assembly Page 7-5

 FIGURE 7-15.

FIGURE 7-13.

FIGURE 7-16.

FIGURE 7-14.

Page 7-6 Dump Body Assembly 4/16 FAM0703

 5. Refer to Figure 7-7 and the body assembly
print to complete the welds on the inside of the
body.

FIGURE 7-17.

FIGURE 7-19.

FIGURE 7-18.

FIGURE 7-20.

FAM0703 4/16 Dump Body Assembly Page 7-7

 6. Install the mud flap brackets, clearance light 7. Install any optional equipment such as body lin-
housings (Figure 7-21), etc. as specified on the ers and side boards (Figure 7-22).
installation drawings.

84652

FIGURE 7-21. FIGURE 7-22.

8. Clean and paint the weld joints.

Page 7-8 Dump Body Assembly 4/16 FAM0703

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

FAM0827 Final Assembly Page 8-1

 1. Body welding and chassis assembly must be a. If the truck is operational and can be driven,
completed before proceeding. two 50 ton cranes can be used, one posi-
tioned at either side of the body. The body
Before the body is lifted off the ground, tie guy
can then be lifted high enough to allow the
ropes to each of the four corners of the body for
truck to be reverse propelled under the body.
aiding in installation.
Refer to Figure 8-1, Figure 8-2 and Figure 8-
There are two methods of installing the body 3.
depending on the cranes available. b. If a large crane of approximately 150 ton is
available, the body can be lifted over the
chassis and installed in a similar fashion to
that in Step a.

FIGURE 8-1.

Page 8-2 Final Assembly FAM0827

 FIGURE 8-2.

FIGURE 8-3.

FAM0827 Final Assembly Page 8-3

 2. Install shims (8, Figure 8-5) in both body pivots, 3. Align the hole in body pivot pin (4) with the bolt
as required, to fill the outside gaps and center hole in the pin retainer on the outer body pivot
the body on the frame pivot. ear. Push the body pivot pin through the outer
body pivot ear, the frame pivot, and the inner
NOTE: Do not install shims on the inside. A
body pivot ear.
minimum of one shim is required at the outside end
of both frame pivots. 4. Install shoulder bolt (1) through the body pivot
pin. Install flat washer (2) and nut (2). Tighten
the nut to 339 N•m (250 ft lb).

Page 8-4 Final Assembly FAM0827

 FIGURE 8-4.

FIGURE 8-5. DUMP BODY PIVOT PIN

1. Shoulder Bolt 4. Body Pivot Pin 7. Pivot Bushing
2. Flat Washer 5. Pivot Bushing 8. Shim
3. Nut 6. Body Pivot Ear 9. Body Pivot Bushing

FAM0827 Final Assembly Page 8-5

 5. Align the hoist cylinder bearing eye with the 7. Install shoulder bolt (4) through each pin.
bore of hoist cylinder upper mounting bracket
NOTE: Do not use a flat washer under the head of
(1, Figure 8-7).
the shoulder bolt. This will ensure that the shoulder
6. Align the bolt hole in pivot pin (3) with the bolt bolt does not run out of threads when tightening.
hole in mounting bracket (1). Install the pivot pin
8. Install flat washer (5) and nut (6) onto the
through the first spacer (2), then align the
threaded end of each shoulder bolt. Tighten the
second spacer with the bore on the other side of
nuts to 339 N·m (250 ft lb).
hoist cylinder bearing eye. Finish installing the
pin through second spacer (2).

Page 8-6 Final Assembly FAM0827

 FIGURE 8-6.

FIGURE 8-7. HOIST CYLINDER UPPER MOUNT

1. Mounting Bracket 3. Pivot Pin 5. Flat Washer
2. Spacer 4. Shoulder Bolt 6. Nut

FAM0827 Final Assembly Page 8-7

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

FIGURE 8-8. BODY PAD INSTALLATION

1. Dump Body 3. Shim

2. Body Pad 4. Mounting Hardware

Page 8-8 Final Assembly FAM0827

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

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

FAM0827 Final Assembly Page 8-9

 FIGURE 8-11. ROCK EJECTOR MOUNTING
1. Rock Ejector Arm 3. Stop Block
2. Pin 4. Mounting Bracket

FIGURE 8-10.

If the rock ejector arms are bent during opera-

tion, they must be removed and straightened.
Inspect mounting brackets (4, Figure 8-11), pins
(2) and stops (3) at each shift change for wear
and/or damage. Repair as necessary.
12. Tack weld rock ejector mounting brackets into
position on the underside of the body. Refer to
Figure 8-11.
The ejectors must be positioned on the center
line between the rear tires within 6.0 mm (0.25
in.). Before welding, drop a plumb line to check
rock ejector clearance. Position the rock ejector
a distance of 455 mm (17.9 in.) from the wheel
housing. Refer to Figure 8-12
NOTE: With rock ejector arm (1) hanging vertical as
shown in Figure 8-12, there must be no gap at stop
block (3, Figure 8-11).

FIGURE 8-12. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 2. Wheel Housing

Page 8-10 Final Assembly FAM0827

13. Install the mud flaps onto the body and chassis.
Refer to Figure 8-13 and Figure 8-14.

FIGURE 8-13.

FIGURE 8-14.

FAM0827 Final Assembly Page 8-11

 14. Install both body guide brackets loosely into
place. Refer to Figure 8-15.

FIGURE 8-15.

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

Page 8-12 Final Assembly FAM0827

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

FIGURE 8-18. BODY-UP SWITCH INSTALLATION

1. Switch Mounting Bracket 4. Magnet Assembly

2. Adjustment Capscrews 5. Bracket
3. Proximity Switch

FIGURE 8-16. BODY GUIDE

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

FAM0827 Final Assembly Page 8-13

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

FIGURE 8-19.

FIGURE 8-20.

Page 8-14 Final Assembly FAM0827

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

FIGURE 8-24.

FIGURE 8-25.

FAM0827 Final Assembly Page 8-15

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

FIGURE 8-23. HOIST LIMIT SWITCH (SIDE VIEW)

1. Proximity Switch 4. Capscrews

2. Magnet 5. Dump Body
3. Capscrews

Page 8-16 Final Assembly FAM0827

 FIGURE 8-25. HOIST LIMIT SWITCH OPTIMUM
SETTING ADJUSTMENT

FIGURE 8-24.

d. Loosen capscrews (2, Figure 8-23) securing

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

FAM0827 Final Assembly Page 8-17

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

FIGURE 8-26.

Page 8-18 Final Assembly FAM0827

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

FIGURE 8-27.

FAM0827 Final Assembly Page 8-19

Miscellaneous Installations a. Connect the lubrication system to the LH
bumper and tighten the bolt to standard
25. Install the lubrication system:
torque. Refer to Figure 8-28.

FIGURE 8-28. LUBRICATION SYSTEM

FIGURE 8-29.

1. Injector Indicator 4. Injector Grease Zerk

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

Page 8-20 Final Assembly FAM0827

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

FAM0827 Final Assembly Page 8-21

 FIGURE 8-30. LUBRICATION SYSTEM

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

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

Page 8-22 Final Assembly FAM0827

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

FIGURE 8-31. ISOLATION STATION

FAM0827 Final Assembly Page 8-23

 27. If equipped, install the optional Scoreboard(s).
Refer to Figure 8-32.

85178

FIGURE 8-32. LH SCOREBOARD INSTALLATION

1. Load Lights
2. Payload Meter Scoreboard (Optional)

28. Install the LH and RH engine bay lights. Refer to

Figure 8-33.

1 2

85195

FIGURE 8-33. ENGINE BAY LIGHTS

1. LH Bay Lights 2. RH Bay Lights

Page 8-24 Final Assembly FAM0827

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

FIGURE 8-34. CAMERA AND RADAR LOCATIONS

1. RH Front Camera 5. Radar 1

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

FAM0827 Final Assembly Page 8-25

 FIGURE 8-35. CAMERA AND RADAR LOCATIONS

1. RH Front Camera 3. Radar 3

2. RH Rear Camera 4. Radar 4

Page 8-26 Final Assembly FAM0827

 FIGURE 8-36. CAMERA AND RADAR LOCATIONS

1. Rear Camera 3. Radar 6

2. Radar 5

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

FAM0827 Final Assembly Page 8-27

 FIGURE 8-37.

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

Page 8-28 Final Assembly FAM0827

 FIGURE 8-38.

FIGURE 8-39.

FAM0827 Final Assembly Page 8-29

 NOTES

Page 8-30 Final Assembly FAM0827

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

FAM0903 5/13 Final Checkout Page 9-1

 NOTES

Page 9-2 Final Checkout 5/13 FAM0903

 APPENDIX
This chapter contains additional information and procedures for aiding in field assembly of the truck. Refer to the
list below for contents of this chapter. Refer to the latest service manual for additional information on servicing the
truck.
1. Lubrication Chart - FAM1105

2. Torque Tables and Conversion Charts - FAM1502

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

4. Oiling and Charging Specifications Chart -FAM1204

5. Toe-In Adjustment Procedure - FAM1306

6. Automatic Lubrication System Priming - FAM1406

7. Brake Test Checkout Procedure - 58E-06-09750

8. Parking Brake Bleeding/Flushing Procedure - FAM1801

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

10. Alternator Lock Checkout Procedure - 58E-01-00540

11. Interface Module Checkout Procedure - 58B-06-03391

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

13. Automatic Lubrication System - FAM1405

14. Parts & Service News - AA18054

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

16. Air Conditioning Checkout Procedure - EM4003

17. Hydraulic System Checkout Procedure - 58B-60-20400

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

19. KOMTRAX Plus Setup Procedure - EM2128

20. KOMTRAX Plus Checkout Procedure - EM2129

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

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

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

24. Komatsu Wireless Bridge Checkout Procedure - 58F-06-05340

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

FAM1048 Appendix 10-1

 26. Seat Belt Checkout Procedure - SM2700

27. Field Assembly Inspection Report - CEAW008201

28. 50 Hour Post-Commissioning Checksheet - CEAW008302

10-2 Appendix FAM1048

 LUBRICATION CHART

FAM1105 Lubrication Chart F11-1

 NOTES

F11-2 Lubrication Chart FAM1105

 STANDARD TORQUE CHARTS AND CONVERSION TABLES

This manual provides dual dimensioning for many

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

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

TABLE 1 Standard Tightening Torque For Metric Capscrews and Nuts. . . . . . . . . . . . . . . . . . . . . . FAM15-2
TABLE 2 Standard Tightening Torque For SAE Grade 5 & 8 Capscrews and Nuts . . . . . . . . . . . . . FAM15-3
TABLE 3 Standard Tightening Torque 12-Pt, Grade 9, Capscrews (SAE) . . . . . . . . . . . . . . . . . . . . FAM15-4
TABLE 4 Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-5
TABLE 5 Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . FAM15-5
TABLE 6 Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-5
TABLE 7 JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-6
TABLE 8 Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-6
TABLE 9 O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-7
TABLE 10 O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-7
TABLE 11 Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-8
TABLE 12 Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-9
TABLE 13 Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAM15-10

FAM1502 Standard Torque Charts and Conversion Tables F15-1

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

Where the torque tables specify “Lubricated • Torques are calculated to give a clamping force
Threads” for the standard torque values listed, these of approximately 75% of proof load.
standard torque values are to be used with simple • The maximum torque tolerance shall be within
lithium base chassis grease (multi-purpose EP NLGI) ±10% of the torque value shown.
or a rust-preventive grease (see below) on the
• In the following table under “Capscrew Size”, the
threads and seats unless specified otherwise. first number represents the shank diameter
NOTE: Ensure the threads of fasteners and tapped (mm). The second number represents threads
holes are free of burrs and other imperfections before per millimeter.
assembling. Example: M20 x 2.25
M20 = shank diameter (20 mm)
Suggested* Sources for Rust Preventive Grease:
• American Anti-Rust Grease #3-X from Standard 2.25 = threads per millimeter
Oil Company (also American Oil Co.)
• Gulf NoRust #3 from Gulf Oil Company.
• Mobilarma 355, Product No. 66705 from Mobil
Oil Corporation.
• Rust Ban 326 from Humble Oil Company.
TABLE 1.
• Rustolene B Grease from Sinclair Oil Co. Standard Tightening Torque
for Metric Class 10.9 Capscrews & Class 10 Nuts
• Rust Preventive Grease - Code 312 from the
Southwest Grease and Oil Company. Capscrew Torque Torque Torque
Size N•m ft lb kg•m
NOTE: This list represents the current engineering M6 x1 12 9 1.22
approved sources for use in Komatsu manufacture. It
M8 x 1.25 30 22 3.06
is not exclusive. Other products may meet the same
specifications of this list. M10 x 1.5 55 40 5.61
M12 x 1.75 95 70 9.69
M14 x 2 155 114 15.81
M16 x 2 240 177 24.48
M20 x 2.25 465 343 47.43
M24 x 3 800 590 81.6
M30 x 3.5 1600 1180 163.2
M36 x 4 2750 2028 280.5

F15-2 Standard Torque Charts and Conversion Tables FAM1502

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

TABLE 2.
Standard Tightening Torque
for SAE Hex Head Cap Screw And Nut Assembly

Cap Torque - Torque - Cap Torque - Torque -

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

FAM1502 Standard Torque Charts and Conversion Tables F15-3

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

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

Torque Torque Torque

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

F15-4 Standard Torque Charts and Conversion Tables FAM1502

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

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

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

FAM1502 Standard Torque Charts and Conversion Tables F15-5

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

TABLE 8.
Torque Chart For
Pipe Thread Fittings

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

F15-6 Standard Torque Charts and Conversion Tables FAM1502

 TABLE 9.
Torque Chart For
O-ring Boss Fittings

Size Newton meters Foot Pounds

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

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

Size Tube Size Newton meters Foot Pounds

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

FAM1502 Standard Torque Charts and Conversion Tables F15-7

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

square centimeters (cm2) square inch (in2) 0.1550

square centimeters (cm2) square feet (ft2) 0.001

cubic centimeters (cm3) cubic inch (in3) 0.061

liters (l) cubic inch (in3) 61.02

cubic meters (m3) cubic feet (ft3) 35.314

liters (l) cubic feet (ft3) 0.0353

grams (g) ounce (oz) 0.0353

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

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

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

kilogram (kg) short ton (tn) 0.0011

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

F15-8 Standard Torque Charts and Conversion Tables FAM1502

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

square inch (in2) square centimeters (cm2) 6.45

square feet (ft2) square centimeters (cm2) 929

cubic inches (in3) cubic centimeters (cm3) 16.39

cubic inches (in3) liters (l) 0.016

cubic feet (ft3) cubic meters (m3) 0.028

cubic feet (ft3) liters (l) 28.3

ounce (oz) kilogram (kg) 0.028

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

FAM1502 Standard Torque Charts and Conversion Tables F15-9

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

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

F15-10 Standard Torque Charts and Conversion Tables FAM1502

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

All suspensions are charged with compressed Front Suspension

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

Before starting oiling and charging procedures,

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

58E-60-02200 3/18 Suspension Oiling and Charging Procedures 1

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

PISTON ROD

SPINDLE

MEASURE HERE

Lifting equipment (crane or hydraulic jacks) must

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

2 Suspension Oiling and Charging Procedures 3/18 58E-60-02200

 Table 1: Front Suspension Oiling and Charging Height Dimensions

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

58E-60-02200 3/18 Suspension Oiling and Charging Procedures 3

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

4 Suspension Oiling and Charging Procedures 3/18 58E-60-02200

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

MEASURE HERE

85633

FIGURE 1-2. REAR SUPENSION

58E-60-02200 3/18 Suspension Oiling and Charging Procedures 5

 Table 2: Rear Suspension Oiling and Charging Height Dimensions

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

6 Suspension Oiling and Charging Procedures 3/18 58E-60-02200

 OIL AND NITROGEN SPECIFICATIONS CHART

HYDRAIR® II OIL SPECIFICATIONS

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

FRICTION MODIFIER FRICTION MODIFIER Mixing Instructions

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

NITROGEN GAS (N2)SPECIFICATIONS

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

FAM1204 Oil and Nitrogen Specifications Chart 12-1

 NOTES

12-2 Oil and Nitrogen Specifications Chart FAM1204

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

86311

FIGURE 3-2. TIE ROD ASSEMBLY

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

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

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

FIGURE 3-1. MEASURING TOE-IN

FAM1306 Toe-In Adjustment Procedure 13-1

 NOTES

13-2 Toe-In Adjustment Procedure FAM1306

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

PUMP PRIMING PROCEDURE

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

1 72784

FIGURE 1. PRIMING THE PUMP

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

FAM1406 Automatic Lubrication System Priming 14-1

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

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

FIGURE 2. BRAKE COOLING MANIFOLD

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

14-2 Automatic Lubrication System Priming FAM1406

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

If the truck fails any brake test, notify mainte-

nance personnel immediately. DO NOT resume
operation unless the truck passes all brake tests.

Events
The following events have been added to the drive
system software to support the brake test feature.
• 645-1 Service Brake Test Performed FIGURE 1-1.
• 645-2 Parking Brake Test Performed
• 645-3 Retard Test Performed
• 645-4 Retard Test Failed
• 645-5 Brake Test Switch stuck closed
• 645-6 Drive Brake Test Performed

58E-06-09750 Pre-Shift Brake Test - Test Procedure 1

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

Brake Test Exit Criteria

Numerous conditions can occur which may interrupt
FIGURE 1-2. a brake test, including the following:
• Any of the setup conditions becoming false
Description • System Fault which restricts the LINK or Propel
The operator can choose which brake test to perform mode
and will set the truck controls based on the settings in • Truck Speed > 2.0 mph in Service Brake test
Table 1, “BRAKE TEST SETTINGS,” on page 3. The
• One rotation of motor rotor in Park brake or Drive
drive system will detect the position of the directional brake tests
control lever, and will prepare for the appropriate test.
The operator will then press the brake test switch. • Truck at torque level for more then 30 seconds

If the brake check light is illuminated solid after • Test requested, (button), but not initiated (pedal)
pressing the brake test switch, the system is in brake for 60 secs.
test mode and is ready to begin the test. The
operator then has 60 seconds to choose and initiate
PERFORMING THE BRAKE TESTS
the test to be performed. After testing, the operator
Setup
will then determine if the truck passed the brake
tests, and if it is safe for operation. Before performing any brake test, the following
conditions must be met:
If the brake check light does not illuminate
immediately after pressing the brake test switch, • Dump body empty
there is most likely a problem with the setup. Refer to NOTE: The drive system will not enter any brake test
the setup conditions and take action to prepare the if the truck is loaded.
truck for a brake test.
• Truck located outside on a flat area, where truck
If there is a problem with the truck setup, the VID movement is allowed.
panel will display the problem.

2 Pre-Shift Brake Test - Test Procedure 58E-06-09750

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

BRAKE TEST SETTINGS

Test Type Wheel Brake Service Brake Directional
Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF OFF/RELEASED PARK
Drive Brake ON OFF/RELEASED NEUTRAL
(HSA enabled)
Retard Test OFF OFF/RELEASED PARK

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

58E-06-09750 Pre-Shift Brake Test - Test Procedure 3

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

4 Pre-Shift Brake Test - Test Procedure 58E-06-09750

Retard System Test: Drive Brake System Test:

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

58E-06-09750 Pre-Shift Brake Test - Test Procedure 5

 NOTES

6 Pre-Shift Brake Test - Test Procedure 58E-06-09750

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

84289

FIGURE 1. PARKING BRAKE BLEEDING/FLUSHING PROCEDURE

1. Bleeder Screw

FAM1801 Park Brake Bleeding/Flushing Procedure 18-1

 NOTES

18-2 Park Brake Bleeding/Flushing Procedure FAM1801

 ALTERNATOR TO ENGINE ASSEMBLY CHECKOUT PROCEDURE
Care must be exercised when mounting alternator to 2. Locate the dial indicator base on the machined
engine on electric drive vehicles to avoid early face of the flywheel/flexplate and zero the probe
crankshaft bearing failures. on the face of the flywheel housing adaptor
plate.
Attaching GE Alternator to Cummins QSK60 & 78 3. Move crankshaft frontwards. Use engine
Engines barring device, slowly rotate the engine
NOTE: The following instructions must be followed crankshaft turn and document reading. Move
for new or re-power installations or whenever the crankshaft frontwards after every 1/4 turn and
engine and/or alternator is serviced. continue procedure for two full revolutions
documenting reading every 1/4 turn.
General Instructions 4. The difference between the highest and lowest
1. Loosen or remove fan belts prior to measuring values for each revolution is the radial runout
crankshaft end play to ensure that it moves TIR. If the average of the two measurements
easily back and forth. exceeds tolerance limits below, contact
2. When taking measurements always clean engineering for next steps.
mating surfaces and take four equally spaced Highest Reading- Lowest Reading= TIR
readings, then average all four. TR =
3. Clockwise (CW) or counterclockwise (CCW) is Limits are shown below:
while looking at front or damper end of engine.
Max Value mm (in)
4. All measurements are set to three decimal
places. Cummins "0" Flywheel Housing: 0.25 (0.01 0)
used on QSK60's
5. Be sure that a surface reference (ie.flat steel
bar) used for dial indicating is calibrated Cummins "00" Flywheel Housing: 0.30 (0.012)
used on QSK78
periodically for flatness and dimensional
accuracy to within +/-.0009". Also, be sure all
instruments used for measurements are
calibrated on a periodic basis.
6. Do not pry or hammer on engine vibration
damper.
7. Forward is defined as the front of truck and
rearward is defined as the rear of the truck.
8. Refer to Appendix 1 (page 10) for Summary of
Radial and Axial Run out Limits.
9. Additional Engine Measurements (page 9): It is
assumed that these dimensions are within
specification from the supplier and are therefore
not required for new installations. These steps
may be used for Service rebuilds and/or
troubleshooting to confirm these dimensions
are within tolerance specification as outlined by
Cummins.

Engine Flywheel Adaptor Plate Face Runout (See

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

FIGURE 1-1. MEASURING FLYWHEEL HOUSING

ADAPTOR PLATE FACE RUNOUT

58B-01-20100 11/18 Alternator to Engine Assembly Checkout Procedure 1

Cummins Crankshaft End Play (See
Figure 1-2)
5. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the
crankshaft. Measure total crankshaft endplay.
Move crankshaft forward and rearwards as far
as possible. This is accomplished by removing
a hand-hole cover and prying gently on a
crankshaft counter weight or using a rubber
mallet on the front end of the crank. Confirm the
measurement is equal in both forward and rear
directions. Record values and confirm end play
is within Cummins limits.
Total Crankshaft Endplay: ________
Total Crankshaft Endplay /2: ________
FIGURE 1-3. USING PRY BAR ON CRANKSHAFT
Cummins end play limits: 0.13-0.51 mm (0.005- COUNTER WEIGHT
0.020 in.).

Engine Flywheel to Flywheel Adaptor Plate

- Measurement "C" (See Figure 1-4)
6. Move the crankshaft rearward to its end travel.
7. Bolt a flat calibrated steel bar across the
flywheel housing as a surface reference to
measure the distance between the flywheel
housing to flywheel adaptor plate (CR1).

FIGURE 1-2. RUBBER MALLET USED TO MOVE

CRANKSHAFT REARWARD TO MEASURE
ENGINE END PLAY

2 Alternator to Engine Assembly Checkout Procedure 11/18 58B-01-20100

 8. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CR2, CR3, CR.
1st measurement (12:00 O'clock): CR1
2nd measurement (6:00 O'clock): CR2
3rd measurement (3:00 O'clock): CR3
4th measurement (9:00 O'clock): CR4
Caver.1 = (CR1+CR2+CR3+CR4)/ 4 =
9. Move the crankshaft frontward to its end travel.
10. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CF2, CF3, CF4
1st measurement (12:00 O'clock): CF1
2nd measurement (6:00 O'clock): CF2
3rd measurement (3:00 O'clock): CF3
4th measurement (9:00 O'clock): CF4
Caver.2 = (CF1+CF2+CF3+CF4)/ 4 =
11. The Total Engine Axial Play of the engine is
calculated as TEAP= (Caver.1 - Caver.2) = __
12. The mean absolute value of the relative location
of the flywheel with respect to flywheel housing
FIGURE 1-4. FLAT BAR USED TO MEASURE is:
DISTANCE BETWEEN ENGINE FLYWHEEL AND C = TEAP/2 + Caver.1 = __
FLYWHEEL

58B-01-20100 11/18 Alternator to Engine Assembly Checkout Procedure 3

Alternator Housing to Rotor Measurement- rotor and stator. Refer to PSN AA12108 for rotor
Measurement "A" (See Figure 1-5 through shipping locks.
Figure 1-8)
NOTE: Whenever alternator is removed from the
13. For GTA41 alternator use 5/8"-11 x 4.5 bolt or engine for extended storage or transportation of the
rotor saddle to support the alternator adapter. alternator, rotor shipping locks must be installed.
For GTA39 alternator place shims between

FIGURE 1-5. BOLT OR ROTOR SADDLE USED AT 6 O’CLOCK POSITION TO SUPPORT ROTOR ON GTA41
ALTERNATOR

FIGURE 1-6. SHIMMING OF GTA39 ALTERNATOR ROTOR

4 Alternator to Engine Assembly Checkout Procedure 11/18 58B-01-20100

 14. Position the Alternator Rotor Rearward by Alternately tighten each bolt until rotor reaches
placing an offset push bar across the center of end of travel. (Do not exceed 12 ft-lbs). Refer to
rotor Position the two 5/8" - 11 bolts through the Figure 1-7.
bar ends and fasten to housing on both ends.

FIGURE 1-7.

15. Offset push bar is to remain in position to hold other affecting the readings. When taking the
the rotor in rearward position. Bolt a calibrated measurements, make sure the readings are
flat steel bar to the rotor as a reference to taken from the mating surfaces. Refer to
measure the distance between the alternator Figure 1-8.
housing and rotor to determine the reading A1.
Make sure the bars are not contacting each

FIGURE 1-8.MEASURING DISTANCE BETWEEN ALTERNATOR HOUSING AND ROTOR

58B-01-20100 11/18 Alternator to Engine Assembly Checkout Procedure 5

 16. Repeat the same procedure in three more A(Non_SRB) = Aavg + 0.014 in. = ______
locations, 90 degrees apart from each other in
A(GTA51 SRB) = Aavg + 0.010 in. = ______
the perimeter, to find the values A2, A,3, A4.
A(GTA39, GTA41, GTA49 SRB) = Aavg. +
1st measurement (45°) A1
0.008 in. = ______
2nd measurement (135°): A2 18. Refer to Figure 1-9 below. If measurement C is
3rd measurement (225°): A3 greater than A, subtract A from C; the shim
pack is to be added between Rotor and
4th measurement (315°): A4 Flywheel (location B). If measurement A is
17. Assume that the rotor end play is set by the greater than C, subtract C from A; the shim
factory to the nominal value of 0.0273" (Non- pack is to be added between the Alternator
SRB), 0.021" (GTA51 SRB), 0.017" (GTA39, Housing and Engine Flywheel Housing (location
GTA41, GTA49 SRB). Since the mean relative D). Use a combination to shim within 1 mm
position is the rotor centered in housing, add ½ (.004 in). See Table 1, “SHIM COBINATION
of rotor end play from previous rearward DATA below.
measurement (step 12). Therefore,
If C > A: shim = C - A; shim at Rotor
If A > C: shim = A - C; shim at Housing

FIGURE 1-9.
Table 1: SHIM COMBINATION DATA

SHIM LOCATION QSK78 (SAE 00) QSK50 & 60 (SAE 0)

P/N - Alt. Hsg. To FW Hsg. Adaptor (Location D) EJ1056 (.004") TM3466 (.004")
EJ1055 (.007") EJ1055 (.007")
TW6616 (.010")
P/N ‐ Alt. Rotor to Flexdrive (Location B) EL3332 (.004") TM3467 (.004")
EL3331 (.007") TM3469 (.007")

6 Alternator to Engine Assembly Checkout Procedure 11/18 58B-01-20100

 19. Remove bolt or saddle bracket supporting rotor Measurements after Joining the Alternator
on GTA41 alternator or remove shims placed and Engine
between rotor and stator on GTA39 alternator. 23. With the Magnetic base, or similar device,
20. Carefully move the alternator into place and mounted on the front of the engine and the
engage the engine drive end and the alternator indicator on the front of the crankshaft, measure
rotor. the total crankshaft endplay.
21. Fasten the flywheel housing adapter to the NOTE: The total engine crankshaft endplay must
alternator and tighten bolts to 175 ft lbs (131 N match the original measurement before the alternator
M). was installed. If the endplay after the alternator and
22. Install and torque the drive ring plate to engine are assembled is less than the original
alternator rotor bolts to 175 ft lbs. measurement, re-shimming is required.
24. Total Crankshaft Endplay : ________
25. Rotate the crankshaft one full revolution and
listen for any unusual noise caused by moving
components contacting stationary parts.
26. Reset and record Engine Fan Belt Tension.

58B-01-20100 11/18 Alternator to Engine Assembly Checkout Procedure 7

 Engine / Alternator Attachment Checkout Data Sheet
ENGINE MEASUREMENTS STEP 10 ______ CF1 (12:00 o'clock position)
STEP 4 ______ Total indicated runout of flywheel ______ CF2 (3:00 o'clock position)
adapter housing face ______ CF3 (6:00 o'clock position)
STEP 5 ______ Total Crankshaft Endplay ______ CF4 (9:00 o'clock position)
STEP 8 ______ CR1 (12:00 o'clock position) ______ Cavg.F =
______ CR2 (3:00 o'clock position) (CF1+CF2+CF3+CF4) / 4
______ CR3 (6:00 o'clock position) STEP 11 ______ TEAP= (Cavg.F - Cavg.R)
______ CR4 (9:00 o'clock position) STEP 12 ______ C = TEAP/2 + Cavg.F
______ Cavg.R =
(CR1+CR2+CR3+CR4) / 4

Summary of Axial & Radial Runout Limits

SAE 0 Flywheel SAE 0 Flywheel SAE 00 Flywheel
Description
(QSK50) (QSK60) (QSK78)
0.005” (.13 mm) - 0.005” (.13 mm) - 0.005” (.13 mm) -
Crankshaft Endplay
0.020” (.51 mm) 0.020” (.51 mm) 0.020” (.52 mm)
Alternator Endplay (Non SRB) 0.0273” (0.69 mm) 0.0273” (0.69 mm) 0.0273” (0.69 mm)
Alternator Endplay (GTA 51
0.021” (0.53 mm) 0.021” (0.53 mm) 0.021” (0.53 mm)
SRB)
Alternator Endplay
0.017” (0.43 mm) 0.017” (0.43 mm) 0.017” (0.43 mm)
(GTA39, GTA41, GTA49 SRB)
FW Housing Radial Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012” (0.30 mm)
FW Housing Face Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012” (0.30 mm)
FW (Flywheel) Radial Runout 0.003” (0.08 mm) 0.003” (0.08 mm) 0.005” (0.13 mm)
FW (Flywheel) Face Runout 0.035” (0.89 mm) 0.035” (0.89 mm) 0.040” (1.0 mm)
STEP 17 ______ A (Non-SRB) = Aavg + 0.014"
ALTERNATOR MEASUREMENTS
______ A(GTA 51SRB) = Aavg + 0.010"
STEP 16 ______ A1 (45°)
______ A(GTA39, GTA41, GTA49 SRB) =
______ A2 (135°) Aavg. + 0.008"
______ A3 (225°)
______ A4 (315°)
______ Aavg = (A1+A2+A3+A4) /4

8 Alternator to Engine Assembly Checkout Procedure 11/18 58B-01-20100

SHIM CALCULATION
STEP 18 ______ If C > A: shim = C - A;
shim at Rotor
______ If A > C: shim = A - C; shim at
Housing

Additional Engine Measurements (For

ENGINE MEASUREMENT (AFTER Reference Only- Not Required For
ALTERNATOR ATTACHMENT) Production Assembly):
STEP 23 ______ Total Crankshaft Endplay It is assumed that these following dimensions are
within specification from the supplier and are
The total engine crankshaft endplay must match the
therefore not required for new installations. However,
original measurement taken before the alternator
these measurements must be used for service
was installed. If the endplay after the alternator and
rebuilds and/or troubleshooting to confirm these
engine are assembled is less than the original
dimensions are within tolerance specification of the
measurement, re-shimming is required.
engine manufacturer.
Reference Cummins AEB 24.46 and Cummins
Service Bulletin 4021669
1. Engine Flywheel Housing Face Runout
(Appendix 2)
2. Engine Flywheel Housing Radial Runout
(Appendix 3)
3. Engine Flywheel/Flexplate Face Runout
(Appendix 4)
4. Engine Flywheel/Flexplate Radial Runout
(Appendix 5)

58B-01-20100 11/18 Alternator to Engine Assembly Checkout Procedure 9

References Appendices
1. Cummins AEB 24.46 1. Summary of Axial & Radial Runout Limits
2. Cummins Service Bulletin #4021669 2. Engine Flywheel Housing Face Runout
3. Komatsu Check Out Procedure EJ1062-2 3. Engine Flywheel Housing Radial Runout
(QSK78, 930E-SE, 960E) 4. Engine Flywheei/Fiexplate Face Runout
4. Komatsu Check Out Procedure EH0586 5. Engine Flywheei/Fiexplate Radial Runout
(QSK60, 830E & 930E)

Appendix 1

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

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

10 Alternator to Engine Assembly Checkout Procedure 11/18 58B-01-20100

Appendix 2 Appendix 3

FIGURE 1-11. FLYWHEEL HOUSING FACE

RUNOUT MEASUREMENT
FIGURE 1-10. FLYWHEEL HOUSING FACE
RUNOUT MEASUREMENT
Flywheel Housing Radial Runout
Flywheel Housing Radial Runout Locate the dial indicator base on the machined face
of the flywheel/flexplate and 0 the probe on the ID of
Locate the dial indicator base on the machined face the pilot bore of the flywheel housing. Using the
of the flywheel/flexplate and 0 the probe on the ID of engine barring device, slowly rotate the engine crank
the pilot bore of the flywheel housing. Using the through 2 full revolutions. When complete insure dial
engine barring device, slowly rotate the engine crank indicator returns to 0. The difference between the
through 2 full revolutions. When complete insure dial highest and lowest values is the radial runout TIR.
indicator returns to 0. The difference between the Limits are shown in the table below:
highest and lowest values is the radial runout TIR.
Limits are shown in the table below: Max Value mm (in)

Max Value mm (in) Cummins "0" Flywheel Housing 0.25 (0.010)

Cummins "0" Flywheel Housing 0.25 (0.010) Cummins "00" Flywheel Housing 0.30 (0.012)

Cummins "00" Flywheel Housing 0.30 (0.012) SAE Standard J617 0.48 (0.019)

SAE Standard J617 0.48 (0.019)

58B-01-20100 11/18 Alternator to Engine Assembly Checkout Procedure 11

Appendix 4 Appendix 5

85628 85629

FIGURE 1-12. FLYWHEEL HOUSING FACE FIGURE 1-13. FLYWHEEI/FIEXPLATE RADIAL

RUNOUT MEASUREMENT RUNOUT MEASUREMENT

Flywheel/Flexplate Face Runout Flywheel/Flexplate Radial Runout

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

Max Value Max Value mm (in)

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

12 Alternator to Engine Assembly Checkout Procedure 11/18 58B-01-20100

 ALTERNATOR LOCK CHECKOUT PROCEDURE
Remove Alternator Shipping Bracket placed on the NOTE: These bolts are reused at the end of
Engine end of adapter plate. Refer to Figure 1-1. assembly line for installation before shipping the
truck.
NOTE: Alternator has (4) 375-16 x 12.00 grade 8 hex
head bolts as ship loose these are used in Step 3.

FIGURE 1-1.

Care must be exercised when disassembling Cover

Str Top, Cover Str Bottom and Drive Shaft and instal-
lation. Refer to Table 1 below.
Table 1:
830E 930E 930E-SE 960E 980E
Drive Shaft XB1736 EL6424 EJ9748 EL6424 EL6424
Cover Top
Drive Shaft XB1737 EL6425 58F-60-00150 EL6425 EL6425
Cover Bottom
Drive Shaft PC0183 PC0183 PC0183 PC0183 PC0183

58E-01-00540 Alternator Lock Checkout Procedure 18-1

Disassembling Cover Str Top, Cover Str Bottom Part No. Description Quantity
and Drive Shaft
EK7573 SCREW CAPTIVE 2
The following instructions must be followed for new WINGED
or re-power installations.
EK7907 RETAINER 2
1. Carefully remove assembly Cover Str Top and
Cover Str Bottom and mounting hardware. 2. Carefully remove Drive Shaft and mounting
Refer Figure 1-2. hardware. Refer to Figure 1-3.

FIGURE 1-2. FIGURE 1-3.

The following component should be packaged with

The following components should be packaged with
other shipped loose components:
other shipped loose components:

Part No. Description Quantity

Part No. Description Quantity
PC0183 SHAFT ASSY DRIVE 1
SEE CHART COVER STR BOTTOM 1
SEE CHART COVER STR TOP 1 The following hardware that was used to attach Drive
Shaft to Alternator and Hydraulic Pump should be
TD0791 C/S .375-16 X 1.25 5
discarded:
G5 ZINC
TC1231 L/W .375 5
Part No. Description Quantity
TG5720 C/S .375-16 X 1.00 2
G5 ZINC SG7814 C/S .375-24 X 1.25 G8 8
WA4726 F/W .375 ZINC 4 VN9037 C/S .375-16 X 1.25 G8 8
HE5611 NUT LOCK 2 WA0386 NUT HEX .375-16 UNC 8
.38-16 UNC G8 G8

18-2 Alternator Lock Checkout Procedure 58E-01-00540

 3. After completion of assembly of the truck and Assembly at Site-
checkout, complete the following: 1. Remove the tag attached to Hydraulic pump
• Rebar the engine to align the hub holes with hub.
bearing cap holes. 2. Carefully remove four (4) .375-16 x 12.00 grade
• Only requires to align one hole, the other three 8 hex head bolts from Alternator hub,
holes are 90 deg apart, they would line up
automatically. Installation of the Drive Shaft
• Insert the four (4) bolts 3/8-16X12.00 Grade 8 Care must be exercised when assembling Drive
Hex Head bolts and torque them to 13ft-lbs (+/- 1 Shaft. Add a protective sheet inside the alternator
ft-lbs). Refer to Figure 1-4. housing to protect the fiberglass housing from being
damaged.
The following components are in a container with the
truck:

Part No. Description Quantity

SEE CHART COVER STR BOTTOM 1
SEE CHART COVER STR TOP 1
TD0791 C/S .375-16 X 1.25 5
G5 ZINC
TC1231 L/W .375 5
TG5720 C/S .375-16 X 1.00 2
G5 ZINC
WA4726 F/W .375 ZINC 4
HE5611 NUT LOCK .38-16 2
UNC G8
FIGURE 1-4.
EK7573 SCREW CAPTIVE 2
WINGED
4. Add Tag, Warning (58E-98-02190) and Tyrap
EK7907 RETAINER 2
(vz4843) to Steering Wheel in cab and to
Hydraulic pump hub. PC0183 SHAFT ASSY DRIVE 1
SG7814 C/S .375-24 X 1.25 G8 8
VN9037 C/S .375-16 X 1.25 G8 8
WA0386 NUT HEX .375-16 8
UNC G8

58E-01-00540 Alternator Lock Checkout Procedure 18-3

 1. Assemble Drive Shaft with Female end (the end 3. Attach Drive Shaft to Hydraulic Pump flange
will have two grease fittings on it) going first using eight cap screws .375-16 x 1.25
between the Hydraulic Pump Mount and the (VN9037) and eight nut hex .375-16 (WA0386).
Fiberglass housing of the Alternator. Refer to
Figure 1-5 and Figure 1-6.

FIGURE 1-6.

• Torque eight cap screws .375-16 x 1.25

FIGURE 1-5.
(VN9037) and eight nut hex .375-16 (WA0386) to
35 ft-lbs.
2. Attach Drive Shaft (female end) to Alternator 4. Assemble Cover Str Top to Housing Pump
Shaft using eight cap screws .375-24 x 1.25 Mount using five cap screws .375-16 x 1.25
(SG7814). (TD0791) and five lock washer .375 (TC1231).
• Torque eight cap screws .375-24 x 1.25 Refer to Figure 1-7.
(SG7814) to 40 ft-lbs.

FIGURE 1-7.

18-4 Alternator Lock Checkout Procedure 58E-01-00540

 5. Assemble Cover Str Top to Cover Str Bottom
using two cap screw .375-16 X 1.00 (TG5720,
two flat washers .375 (WA4726) and two nut
lock .38-16 (HE5611). Refer to Figure 1-7.
6. To lock Cover Str Top to Cover Str Bottom use
two Screw Captive Winged (EK7573) and two
Retainer (EK7907).
7. Remove Tag (Figure 1-8), Warning (58E-98-
02190) and Tyrap (vz4843) from Steering
Wheel in cab.

FIGURE 1-8.

58E-01-00540 Alternator Lock Checkout Procedure 18-5

 NOTES

18-6 Alternator Lock Checkout Procedure 58E-01-00540

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

Install the Application Code

Before the Interface Module can be put to work, the
application code must be installed. Application code
must be matched to the truck model that the
Interface Module is installed on.
To get the necessary files and instructions, go to the
Komatsu America Extranet:
https://www.komatsuamerica.net/northamerica/
Validate the correct IM software is installed by using
the IM Realtime Data Monitoring software to locate
the CRC number of installed IM software. Compare
the CRC number on the IM Realtime Data Monitoring
software to the CRC number on the text document
inside of the software zip file found on the extranet.
Confirm these numbers are the same.

58B-06-03391 Interface Module Checkout Procedure 1

Interface Module I/O 11. Selector Switch (FNR) (IM2-N) - Place shifter
into park position and confirm 0 state then shift
Use the IM Realtime Data Monitor software to
into neutral, forward, and reverse and confirm 1
confirm the functionality of all IM inputs and serial
state for each of these positions. Return shifter
connections. The key switch must be on for all tests
to park position.
below.
12. Strg Bleed Pressure SW (IM2-Z) - Disconnect
Check Digital Inputs to the Interface Module connector SABS at the Steering Bleed Pressure
1. Hydraulic Tank Level (IM2-k) - Disconnect Switch and confirm state change (zero to one).
connector CN712 at Hydraulic Tank Level Reconnect SABS.
Sensor. Short pin C to ground momentarily and 13. Brake Lock Switch Power Supply (IM3-L) -
confirm state change (one to zero). Reconnect Ensure that shifter is in park position. Use GE's
CN712. wPTU software to turn on FWD True output
2. Low Steering Precharge (IM2-W) - This step signal. Confirm state change (zero to one).
requires properly pre-charged steering Leave GE FWD True signal on until completion
accumulators. Disconnect one of the Low of step 20.
Accumulator Precharge Switches momentarily 14. Brake Lock (IM2-i) - Actuate brake lock switch
and confirm state change (zero to one). and confirm state change (zero to one). Turn off
Reconnect switch. GE FWD True signal. Confirm input state
3. Pump Filter Switches (IM2-Y) - Disconnect remains at one. Turn off brake lock switch.
connector CN730 at Steering Filter Pressure Confirm input state returns to zero. (The Brake
Switch momentarily and confirm state change Lock Switch Power Supply test, item 19, must
(zero to one). Reconnect CN730. be completed before this test can be
4. Park Brake Released (IM2-M) - Short wire 73S1 successfully completed). Turn off GE FWD True
to ground at TB32-M momentarily and confirm signal.
state change (one to zero). 15. Service Brake Set SW (IM3-C) - Short wire 44R
5. Park Brake Request (IM3-V) - Short the engine at TB35 - F to 24 volts momentarily and confirm
oil pressure switch wire circuit 36 on TB28-A to state change (zero to one).
ground. Move shift lever from neutral to park 16. Cummins Shutdown Delay (1M3-F) -
position and confirm state change (one to zero). Disconnect wire 21 NSL from the Engine ECM
Remove the ground from TB28-A. at TB27-E leaving wire 21NSL to IM connected
6. GE Batt + (IM3-M) - confirm this is a one. at TB27-E. Momentarily short TB27-E to 24V
7. Starter Motor 1 Energized (IM3-R) - Disconnect and confirm state change (zero to one).
wire 11SM1 from cranking motor to TB28-F at Reconnect disconnected wire.
TB28-F. Momentarily short TB28-F to 24V and 17. Secondary Engine Shutdown SW (1M3-E) -
confirm state change (zero to one). Reconnect Actuate the Secondary Engine Shutdown
disconnected wire. switch and confirm state change (one to zero).
8. Starter Motor 2 Energized (IM3-S) - Disconnect
18. Keyswitch (1M3-G) - confirm state is a one.
wire 11SM2 from cranking motor to TB28-G at
TB28-G. Momentarily short TB28-G to 24V and 19. Mode sw1 (IM3-H) - Actuate the “left arrow”
confirm state change (zero to one). Reconnect LCD screen navigation switch and confirm state
disconnected wire. change (one to zero).
9. Crank Sense (IM3-U) - Open the Start Battery 20. Mode sw2 (IM3-J) - Actuate the “OK” LCD
Disconnect switch so that there is no battery screen navigation switch and confirm state
voltage to the starters. Momentarily short TB28- change (one to zero).
J to 24V and confirm state change (zero to
21. Mode sw3 (IM3-K) - Actuate the “down arrow”
one). After removing 24V short from TB28-J,
LCD screen navigation switch and confirm state
close the Start Battery Disconnect switch.
change (one to zero)
10. Selector Switch (Park) (IM3-T) - Place shifter
22. Mode sw4 (IM2-q) - Actuate the “up arrow” LCD
into park position and confirm 1 state then shift
screen navigation switch and confirm state
into neutral and confirm 0 state. Return shifter
change (one to zero).
to park position.

2 Interface Module Checkout Procedure 58B-06-03391

 23. Crank Request (IM2-j) - Open the Starter 35. No Propel/Retard (GE CPU Running) (IM2-n) -
Disconnect switch so that there is no battery Confirm state is a zero. Turn off the GE
voltage to the starters. Momentarily turn keyswitch. Confirm state changes to a one.
keyswitch to the crank position and confirm Turn GE keyswitch back on. Confirm state
state change (zero to one). changes to a zero once GE is booted back up
(see DID panel), which can take up to 45
24. Park Brake Set (IM2-f) - Momentarily disconnect
seconds.
Park Brake Pressure switch, identified by circuit
33, and confirm state change (zero to one). 36. Engine Air Filter (IM2-X) – Unplug Air
Restriction Switch 2 (located on top of the
25. Seat Belt SW (1M2-g) - Buckle seat belt. Then
engine air intake pipe) and confirm state
unbuckle seat belt and confirm state change
change (zero to one). Reconnect Air Restriction
(zero to one).
Switch 2.
26. Snapshot In - Progress (IM2-L) - Actuate the
37. Shifter Fault (IM2-m) - Disconnect wire 72IM
Data Store Switch. Confirm state change (one
from TB22-G and confirm state change (zero to
to zero).
one). Reconnect wire 72IM.
27. Low Steering Pressure sw1 (IM2-S) - Using a
back - probe, short wire 33F to ground at *AUTONOMOUS TRUCKS ONLY*
connector CN14 pin 6 momentarily and confirm
Check Autonomous Inputs the Interface Module
state change (one to zero). Remove back -
probe. Autonomous and Manual Mode SW (IM2-e, IM2-s) -
Put the autonomous/manual mode switch in manual
28. Brake Accum Pressure SW (IM2-U) -
mode. The position is indicated by a 0. The position
Momentarily short wire 33BP to ground at TB32
that the mode switch is not in is indicated by a 1.
- E. Confirm state change (one to zero).
Only one of the inputs can be 1 at any given point,
29. Brake Lock Degrade SW (IM2-V) - Short wire the other one must be the opposite. Then switch to
33T to ground at TB32 - F momentarily and autonomous mode and confirm opposite states on
confirm state change (one to zero). the inputs and wait 30 seconds. Finally, switch back
30. Keyswitch Direct (IM2 - P) - Confirm state is a to manual mode and confirm state change. Make
one. Turn keyswitch off for 1 second and then sure no fault codes are created when shifting
back on. Confirm state changes to zero and between modes.
then back to one. Manual Mode Auto Apply Pressure switch (IM2-d) -
31. Auto Lube Level (IM3-W) - Disconnect With the autonomous/manual mode switch in manual
connector CN511 at the Auto Lube Low Level mode, disconnect wire from TB51-E and confirm
Switch, short pin C to ground momentarily and change on (0 to 1). Fault A335 should show at that
confirm state change (one to zero). Reconnect point. Reconnect disconnected wire and confirm
connector CN511. state change (1 to 0).
32. Auto Lube Press SW (IM3-Y) - Short wire 68P
to ground at TB60-B momentarily and confirm
state change (one to zero).
33. Body Up SW (IM2-R) - For trucks without a
body installed yet, place washer on body
proximity sensor, confirm state change, them
remove washer and confirm state change
again. For truck with body installed, make sure
that the body is lowered down all the way, and
then momentarily disconnect wire 71 F at TB35
- S and confirm state change (one to zero).
Reconnect disconnected wire.
34. Dynamic Retard (IM3-Z) - Momentarily short
wire 74ZA to ground at TB21-D and confirm
state change (one to zero).

58B-06-03391 Interface Module Checkout Procedure 3

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

4 Interface Module Checkout Procedure 58B-06-03391

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

58B-06-03391 Interface Module Checkout Procedure 5

 S/N ___________________
IM Installation Checkout Checklist

Software Validation Check

IM Realtime Display CRC Number Software Drawing CRC Number Comments

Function Description Expected Result Result (OK/Fail) Comments

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

6 Interface Module Checkout Procedure 58B-06-03391

Function Description Expected Result Result (OK/Fail) Comments
22 - Mode switch 4 input 1 to 0
23 - Crank Request input 0 to 1
24 - Park Brake Set input 0 to 1
25 - Seat Belt switch 0 to 1
26 - Snapshot input 1 to 0
27 - Low Steering Pressure 1 to 0
switch input
28 - Brake Accumulator 1 to 0
Pressure switch input
29 - Brake Lock Degrade 1 to 0
switch input
30 - Keyswitch Direct input 1 to 0 to 1
31 - Auto Lube Level switch 1 to 0 to 1
input
32 - Auto Lube Pressure 1 to 0
switch input
33 - Body Up switch input w/o body 0 to 1 to 0 with body
1 to 0
34- Dynamic Retard input 1 to 0
35 - GE CPU Running 0 to 1 to 0
36 - Engine Air Filter 0 to 1
37 - Shifter Fault 0 to 1
AUTONOMOUS ONLY INPUT CHECKS:
1 - Autonomous Mode Req. 1 to 0 to 0
Input
2 - Manual Mode Req. Input 0 to 0 to 0
3 - Manual Mode Auto Apply 0 to 1 to 0
Pressure SW input 1 in manual mode triggers fault
A335
ANALOG INPUT CHECKS:
1 - Steering Pressure fault A204
2 - Ambient Air Temp ambient temp+/ - 3C
3 - Fuel Level tank level+/ - 5%
4 - Converter Voltage (12V) 13.5 +/ - 0.5V (12V)
5 - Brake Pressure fault A205
6 - Right Rear Brake Oil fault A167
Temp
7 - Left Rear Brake Oil fault A166
8 - Right Front Brake Oil fault A169
Temp
9 - Left Front Brake Oil Temp fault A168
10 - Hoist Pressure 2 fault A203
11 - Hoist Pressure 1 fault A202

58B-06-03391 Interface Module Checkout Procedure 7

Function Description Expected Result Result (OK/Fail) Comments
12 - Battery Voltage 24V measured battery voltage
+/- 1V
SERIAL COMM CHECKS:
1 - CAN/J1939, Drive no fault A184, A233, A237,
System CAN/RPC, Display A257
CAN/RPC, Payload
CAN/RPC
OUTPUT CHECKS:
1a - Park Brake Solenoid energized/de-energized
1b - Brake Lock Solenoid energized/de-energized in
park brake setting sequence
2 - Start Enable output 24 V, OV
3 - IM On Signal output OV
4 - Electronic Dash Panel Items 4a-e function as
check described
5 - Steering Bleed Solenoid Solenoid de-energized then
output energized

IM Software Version Number: _________________________________

Completed By: _________________________________ Date: _______________________

8 Interface Module Checkout Procedure 58B-06-03391

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

Adjust Injector Settings

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

Lube Pump Start-up / Purging Procedure Timer

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

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

 NOTES

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

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

FAM1405 8/18 Automatic Lubrication System F14-1

 FIGURE 1-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION

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

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

F14-2 Automatic Lubrication System 8/18 FAM1405

SYSTEM COMPONENTS Flow Control Valve

Filter Flow control valve (10), mounted on the manifold,

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

Rotary hydraulic pump (3, Figure 1-1) is a fully Vent Valve

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

FAM1405 8/18 Automatic Lubrication System F14-3

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

FIGURE 1-3. HYDRAULIC SCHEMATIC

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

F14-4 Automatic Lubrication System 8/18 FAM1405

GENERAL INSTRUCTIONS
Lubricant Required For System
Grease requirements will depend on ambient
temperatures encountered during truck operation:
• Above 32°C (90°F) - Use NLGI No. 2
multipurpose grease (MPG).
• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1
multipurpose grease (MPG).
• Below -32°C (-25°F) - Refer to local
supplier for extreme cold weather
lubricant requirements.

Filter Assembly
Filter element (5, Figure 1-4) must be replaced if
bypass indicator (2) shows excessive element
restriction.

FIGURE 1-4. FILTER ASSEMBLY

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

FAM1405 8/18 Automatic Lubrication System F14-5

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

Pump Pressure Control

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

F14-6 Automatic Lubrication System 8/18 FAM1405

SYSTEM CHECKOUT
To check system operation proceed as follows: Main Level Screens

1. Remove the dust covers from the injectors. Screen 1 Load = 240 t OK
LC = 25 TT = 6000 t

2. Start the engine. 2100 rpm SC = 20 mph <

3. Actuate the manual override button at the pump
ˇ Switch 1 Switch 2

assembly and observe pin movement at each

Screen 2
ˆ
Load = 240 t
injector.
LC = 25 TT = 6000 t

4. Check for pump, hose or injector damage or 10,000 m SC = 20 mph

leakage with the system under pressure.

ˇ
5. After checking system, stop the engine. Screen 3
ˆ
Load = 240 t
Observing normal precautions regarding high LC = 25 TT = 6000 t

voltage present in the propulsion system before 3560.9 h SC = 20 mph

attempting to repair lube system.

ˆ ˇ
6. Re-install the injector dust covers.
Screen 4

1 Active Warnings
Lubrication Cycle Operation Press < to View
<
The time between lube events is determined by the
ˇ
Advance to screen 1 if moving and no

setting selected in the dash panel. Refer to Figure 1- Advance to screen 4 .

realtime data.

6 for lubrication menu screens. With the key switch ˆ

Screen 5

ON, scroll through the display menu screens and Realtime Data
select either 8, 15, 24 or 30 minutes between lube OK to View
(future development)
cycles. The default setting is 15 minutes.
ˇ
Advance to screen 1 if moving.
Advance to screen 5 OR

NOTE: Turning the key switch to the ON position will

screen 4 OR screen 3.
Screen 6
ˆ
not initiate a lube cycle. To initiate a lube cycle while Payload Data
OK to View
the truck is stationary, select manual lube using the
dash display panel, or use the switch on the ˇ
lubrication pump. The truck must be moving before Screen 7
ˆ
the lube system will initiate lube cycles based on the 1 Repair Item
OK to View
time interval selected.
ˇ
Screen 8
ˆ
2 Maintenance Items
OK to View

ˇ
Screen 9
ˆ
Manual Lube
OK
System Controls
Press OK to View
Press OK to Start
Screen 9,
ˆ Screen 9,
subscreen 0
subscreen max.

Screen 10
English
Español
Français
OK Portuguese

ˇ
Screen 11
ˆ
Lube Interval
OK
Configure System 8 15 24 30
Press OK to Edit
Press OK to Edit
ˆ
Screen 11,
Screen 11,
subscreen 0
subscreen max.

80414

FIGURE 1-6. LUBRICATION MENU

FAM1405 8/18 Automatic Lubrication System F14-7

 SYSTEM TROUBLESHOOTING CHART
If the following procedures do not correct the problem, contact a factory authorized service center.

TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

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

F14-8 Automatic Lubrication System 8/18 FAM1405

 TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

Pump Pressure Builds No signal at solenoid. Check interface module.

Very Slowly Or Not At All

Bearing Points Injector output adjustment setting is Readjust to lower setting.

Excessively Lubricated too high.

Timer/controller cycle time setting is Set to longer cycle time or reevaluate lube
too low. requirements.

Injector output adjustment setting is Readjust injector output setting.

too low.

Bearing Points Are Not

Sufficiently Lubricated
Timer/controller cycle time setting Set to shorter cycle time or reevaluate
does not deliver lubricant often lube requirements.
enough.

System is too large for pump output. Calculate system requirements per
planning manual.

FAM1405 8/18 Automatic Lubrication System F14-9

 NOTES

F14-10 Automatic Lubrication System 8/18 FAM1405

 PSN
COMPONENT CODE 88

PARTS & SERVICE REF NO. AA18054

DATE July 24, 2018
NEWS Page 1 of 4

SUBJECT: FAULT CODE-BASED TROUBLESHOOTING GUIDE FOR AUTOMATIC

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

The following is a troubleshooting guide for the automatic lubrication system based on possible fault
codes. See AA17027 for troubleshooting information on previous trucks.

AA18054
Page 2 of 4

TABLE 1: AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING

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

Hydraulic supply pressure may

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

AA18054
 Page 3 of 4
TABLE 1: AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING
Fault Code Description Possible Condition Possible Cause Corrective Action
Follow Auto Lube Checkout
Low or empty
procedure to fill reservoir and
grease reservoir
purge system of air.
Check hydraulic supply for
proper pressure and flow and
repair as necessary.

Hydraulic supply pressure may

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

A190 Grease vent valve is

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

AA18054
Page 4 of 4
TABLE 1: AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING
Fault Code Description Possible Condition Possible Cause Corrective Action
Low auto lube grease level
is detected.

Code occurs when input

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

NOTE: A low auto lube

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

Grease pump does not Faulty solenoid Repair electrical fault and
run. circuit check fuse.

Refer to electrical schematic.

Overload on output 1T Remove valves and flush pump
Stuck solenoid
manifold. If fault persists,
valve
Code occurs when IM replace solenoid valve.
detects over current or Grease pump does not
A361 Auto lube circuit Repair electrical fault and
over temp on output 1T. run.
Output is turned off when short to ground, check fuse.
overload is detected. overload, or open
Resets at power down. load Refer to electrical schematic.

AA18054
 RESERVE OIL SYSTEM CHECKOUT PROCEDURE
NOTE: The following procedure must be done with 2. Start engine.
"auto fill option" on initial fill of the reserve system. 3. System should begin operation oil is circulated
between the engine oil pan and reserve oil tank.
AFC control start-up / fast fill procedure:
4. Watch the R2000DF pumping unit led indicator
1. Power up truck so that 24v is supplied to lights.
reserve AFC control box.
5. The running oil signal is steady (green led)
2. Remove the reserve oil fill cap to prevent it from when oil is transferring from the engine oil pan
dislodging during remote fill. to the oil reserve tank.
3. Connect Wiggins oil supply hose and turn on 6. If signal is flashing (green led) pump R2000DF
pressure. is receiving air from the engine oil pan (the
4. Energize AFC controls by pulling out power on running oil level is below the withdrawal point of
switch (top switch).Switch fast fill valve open- the pick up tube)- reserve pump should return
signal light should illuminate. oil back to the engine oil pan continuously
5. Push start button- valve open, when oil in the adjusting the running oil level and raising the oil
reserve tank reaches the proper level the switch level until air is no longer drawn by the reserve
mounted on top of the reserve tank will signal pump.
back to the AFC box and the fast fill valve will 7. Over a period of time both signals (solid i
close automatically and terminate filling of oil flashing of the led lights) should be seen; i.e.
reserve tank. The empty light should go out and there are some periods of steady signals and
the full light should come on. some periods of flashing signals. This verifies
6. Turn off pressure to hose. that the system is operating properly and the
engine oil level is correct.
7. Push start button for a couple of seconds to
relieve pressure in line. 8. If the red led is on this indicates that the pump
is not able to return oil to the engine oil pan
8. Disconnect fill hose.
either because the pump is not frozen) or
9. Turn off AFC power- push in “top switch”. because the reserve tank is empty.
10. Tank should be full with oil showing in all sight 9. Shut down the engine and allow adequate time
glasses but not overfull. for oil to drain down in the engine. Recheck the
NOTE: The following procedure must be done on oil level it should be between the normal marks
start-up of reserve system. (do not go above high static mark).
NOTE: Consult engineering if the engine oil level is
Reserve pump R2000DF start-up and led descrip-
too high or low.
tion:
1. Ensure that both engine and oil reserve tank oil
levels are at the correct level. Engine must be
full to static high mark on dipstick.

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

 NOTES

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

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

EM4003-2 Air Conditioning System Checkout Procedure 1

 NOTES

2 Air Conditioning System Checkout Procedure EM4003-2

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

NOTE: The interface module (IM) checkout

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

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

Hydraulic system checkout procedures 4. Chock the rear tires.

Required equipment 5. Ensure that all personnel and equipment are

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

1 1 83138

FIGURE 1. BRAKE MANIFOLD

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

Do not engage the battery disconnect switch or

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

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

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

86260

FIGURE 2. JUNCTION MANIFOLD

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

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

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

1. Automatic Lubrication 3. Override Switch

Pump 4. Hydraulic Motor
2. Manifold
1

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

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

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

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

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

Hydraulic system flushing procedure

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

84722

FIGURE 5. BLEEDDOWN MANIFOLD

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

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

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

e. Connect hose/needle valve assembly to port

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

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

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

Do not operate at low idle for more than 30

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

If fault code A236 is shown on the message

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Machine Model____________Unit Number ____________ Serial Number ____________

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

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

20. Pressure at bleeddown manifold test port TP3:

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

24. Flow amplifier shock valve pressures:

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

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

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

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

Steering pump unload pressure: (3525 psi nominal) ___________

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

27f. 5 minutes after auxiliary accumulator bleeddown:

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

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

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

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

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

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

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

33d. After steering accumulator bleeddown:

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

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

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

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

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

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

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

(ISO 21/18/15 or lower)___________

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

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

Name of Technician or Inspector Performing Checkout: _________________________

Badge number: ________________________

Date & shift completed:

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

 NOTES

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

 BRAKE SYSTEM CHECKOUT PROCEDURE
Scope of Checkout Procedure: Pre-Checkout Items:
The Brake Checkout Procedure will check the The following Pre-checkout Items must be reviewed,
hydraulic, electrical and software control subsystems understood, and completed prior to conducting the
of the brake system. Brake System Checkout Procedure:
1. All components used within the brake system
Purpose of Checkout Procedure: must be to factory specification.
This Brake Checkout Procedure will verify the 2. Any parts that do not function as described
operation of the brake system by: must be replaced or adjusted.
1. Checking the pressure settings of brake NOTE: Notify Quality Control Department if problems
components. are identified while performing this procedure, or to
2. Checking the functionality of brake system. obtain adjusting procedures for individual
3. Checking the functionality of brake fault components.
detection. NOTE: Refer to the appropriate truck Shop Manual if
NOTE: This procedure does not verify brake performing this procedure in the field.
performance. 3. The hydraulic source for the brake system (the
NOTE: This procedure does not verify the system steering system) is in proper operation and the
controls for autonomous mode operation. steering pump has been adjusted. Refer to
Hydraulic System Checkout Procedure.
Necessary Equipment: 4. All steering, all brake and auxiliary
accumulators are properly precharged. Refer to
1. 980E Brake System Checkout Procedure, 980E
appropriate truck Hydraulic System Checkout
Hydraulic System Checkout Procedure, and
Manual for auxiliary, brake and steering
980E Brake Schematic.
accumulator precharging procedures. Do not
2. Accumulator charging system with calibrated start the truck engine without all steering, all
gauges and cylinders of dry nitrogen with, or brake and the auxiliary accumulators being
without, a gas intensifier. properly precharged.
3. Clear plastic hose and bucket for bleeding air 5. Interface Module checkout procedures must be
from service brakes and park brakes, or brake successfully completed before this brake
simulators. checkout is performed. Failure to do so may
4. If truck is only partially assembled and this result in improper brake system operation and/
checkout is to be done without brakes installed, or brake fault detection.
brake simulators are required in order to 6. Electrical system checkout must be
simulate the brake volume. successfully completed before this brake
5. At least four calibrated pressure gauges with system checkout is performed.
quick-disconnect couplings, capable of 7. All steering, brake and auxiliary accumulators
measuring up to 24 132 kPa (3,500 psi). must be bled down before loosening any
6. Interface Module Real-time Data Monitor hydraulic fitting. Refer to the bleeddown
software. procedure in the appropriate truck Hydraulic
System Checkout Manual.
8. Carefully disconnect all hoses, tubing, gauges,
plugs, etc. in case hydraulic pressure is
trapped.
9. The Brake System Checkout Procedure may be
performed without the truck wheels or tires
being installed.

58B-60-20410 Brake System Checkout Procedure 1

 Initial System Set Up:
1. Install pressure gauges inside the brake cabinet
at the following port locations:
a. Junction manifold test port BR
10. If truck wheels and tires are installed, chock the b. Junction manifold test port BF
left and right rear wheels securely on both sides
c. Brake manifold test port LAP1
to prevent truck movement and a possible roll
away before performing this procedure. If the 2. *Brake accumulator precharge:
truck is sitting on cribbing, ensure it is secure a. Confirm all steering, brake and auxiliary
enough to allow safe operation of the engine. accumulators are precharged to 9 653 kPa
NOTE: The appropriate truck Hydraulic System (1,400 psi). Refer to precheckout item 4.
Checkout Manual must be successfully completed b. *Record the precharge pressure for each
before performing this brake system checkout. brake accumulator.
3. Close the brake and auxiliary accumulator
Software Operation and Configuration bleeddown valves. If brakes have not been
1. Interface Module Realtime Data Monitor assembled to truck when this checkout is
software may be used to view all faults, system performed, attach brake simulators to the brake
status and wheel speed signals, instead of application lines.
using cab panel display for this checkout 4. *Start engine to fill accumulators with oil.
procedure. Observe rising brake pressures at BF and BR
2. Current software may be downloaded from as system charges. Brake pressure should
begin to fall when the Auto Apply valve
https://www.komatsuamerica.net/northamerica/
releases. Auto Apply should release when the
komtraxvhmsplm/vhmsplm/usefulinformation/
gauge at LAP1 displays approximately 10 859 -
software/
13 962 kPa (1,575 - 2,025 psi) (rising). Record
the brake accumulator pressure LAP1 when
Hydraulic Isolation and Troubleshooting
Auto Apply releases.
The Brake Lock and Park Brake solenoid circuits
may be isolated for hydraulic troubleshooting the NOTE: The specified Auto Apply pressure
Brake Lock, Park Brake, and Park Brake Control adjustment range is 11 376 ± 517 kPa (1,650 ± 75
Logic Check sections of this manual. Isolated psi) (falling) for both front and rear. This is checked in
troubleshooting tests are only necessary if problems step 27. The 11 376 -517/+2 586 kPa (1,650 -75/
are found, and not required to complete the checkout +375 psi) (rising) of this step is a resultant pressure
detailed in this manual. and is not to be used for Auto Apply sequence valve
adjustment.
GE Display Panel 5. Partially depress brake pedal and bleed air from
each brake or brake simulator. Shift into Neutral
Configure the GE display panel to metric units, i.e.
and bleed air from park brakes or park brake
kph for ground speed. Remain at 0 kph ground
simulators. Return shift lever to Park.
speed until otherwise noted.
6. *Slowly depress brake pedal. Rear brake
Truck Starting Procedure pressure (BR) should begin to rise before front
brake pressure (BF). Rear brake pressure (BR)
Shift lever must be in Park to start truck. Shift lever is should be between 310 and 1 413 kPa (45 and
to remain in Park unless otherwise noted. Confirm 205 psi) when front brake pressure (BF) begins
GE display panel is set to 0 kph ground speed when to rise. Record the pressure at BR when BF
starting engine. begins to rise.
7. *Slowly depress brake pedal. Force feedback of
pedal on foot should be smooth with no
abnormal noise or mechanical roughness.
Slowly depress brake pedal and record BR
pressure at which the stop lights energize. BR
pressure should be 517 ± 35 kPa (75 ± 5 psi).

2 Brake System Checkout Procedure 58B-60-20410

 8. *Quickly and completely depress pedal and proper function of status light. Fault A118
check to see that front brake pressure (BF) is should not display. Record the pressure at PP3
17 237 ± 517 kPa (2,500 ± 75 psi) and that the and BR, which should each be 13 790 ± 689
rear brake pressure (BR) is 17 237 ± 517 kPa kPa (2,000 ± 100 psi).
(2,500 ± 75 psi) within 1 second. Record the BF
and BR pressures. Holding pedal fully applied,
both pressures should remain above their
minimum values for a minimum of 20 seconds.
Brake Lock Hydraulic Circuit
Record the BF and BR pressures again.
Troubleshooting Guide:
If Brake Lock will not operate as in step 13, confirm
Brake Lock/Secondary all brake lock circuit plumbing is correct.
9. Remove electric power to brake lock solenoid, If all plumbing is found to be correct, allow steering
located on brake manifold in hydraulic cabinet accumulators to fully charge. Disconnect wire 52B to
and to the immediate right of the PK2 port. brake lock solenoid at TB32-J and apply 24 volts to
disconnected wire 52B. Verify pressure at test port
PP3 is 3 790 ± 689 kPa (2,000 ± 100 psi). Ignore
resulting brake lock faults.
a. If pressure is outside range, adjust pressure
Before performing Step 10, be sure truck wheels reducing valve as needed.
are blocked to prevent a possible roll away b. If pressure will not adjust, replace pressure
before performing this procedure. reducing valve.
10. Place shift lever into Neutral. Leave in Neutral c. If solenoid will not energize, verify wiring to
for steps 11, 12, and 13. solenoid is correct. If wiring is correct and
11. *Apply brake lock. Brake lock will not apply solenoid will not energize, replace brake lock
without engine running. Brake lock pressure solenoid.
degradation switch will cause Fault A118 to d. If brake lock valve will not operate, replace
occur since brake lock solenoid is brake lock cartridge valve.
disconnected. Depress brake pedal until Fault
Reconnect wire 52B to TB32-J. Repeat step 13 to
A118 clears and then very slowly release pedal
confirm proper system operation.
until Fault A118 occurs. Record the BR
pressure at which Fault A118 resumes. Fault NOTE: Move pressure gauge from the PP3 location
A265 will also display during this step. to park brake test port PK3 or test port on the park
brake simulator.
NOTE: Brake lock degradation switch should trigger
when BR pressure drops to 6 895 ± 172 kPa (1,000 ±
25 psi), however, there is a three second delay Park Brake
between the time the switch activates and Fault A118 Hydraulic pressure values and the corresponding
occurs. pressure switch states for park brake applied and
park brake released are shown in TABLE 1,
12. Reconnect electric power to brake lock
“PRESSURE SWITCH STATES below.
solenoid. Remove pressure gauge from BF and
place in PP3.
Table 1: PRESSURE SWITCH STATES
13. *Cycle the brake lock several times to assure
crisp application and release of pressure and

Pressure at PK3 Pressure Switch States

75 psi 1,250 psi
Park Brake Applied 0 kPa (0 psi) closed open
Park Brake Released 21 374 - 24 132 kPa (3,100 - 3,500 psi) open closed

58B-60-20410 Brake System Checkout Procedure 3

 16. Apply park brake by moving shift lever to Park.
Keep shift lever in Park and brake lock switch
Off until indicated in following steps.
NOTE: Install pressure gauges to test ports LBP and
RBP on the axle box hydraulic connection plate.
Any switch not in the state as described above and/
or indicated as a fault by the IM, or any hydraulic 17. *Quickly and completely depress pedal and
pressure outside the values above indicates park check to see that left rear service brake
brake system problems. The electrical and hydraulic pressure LBP is 16 548 ± kPa (2,400 ± 75 psi)
circuits must be diagnosed to locate and correct the and that the right rear service brake pressure
problem. Do not drive truck until all brake system RBP is 16 548 ± kPa (2,400 ± 75 psi) within one
problems are corrected. second. Record both pressures. Holding pedal
fully applied, both pressures should remain
14. *Start engine and leave running throughout above their minimum values for a minimum of
steps 14, 15, and 16. This step checks for 20 seconds. Record both pressures after a
correct park brake apply and release pressures. minimum of 20 seconds.
a. *Place shift lever in Park, then release park
18. *Release pedal. Brake pressure at LBP and
brake by placing shift lever in Neutral. Verify
RBP should return to zero within two seconds
that park brake status light indicates park
and there should be no residual pressure
brake is released. Record the park brake
trapped in brakes. Record the pressures.
pressure at test port PK3. Pressure should
be 21 374 - 24 132 kPa (3,100 - 3,500 psi). NOTE: Move pressure gauges to the left and right
front service brake test ports on the spindles or on
b. *Place shift lever in Park. Record the
the front brake simulators. (LFBP and RFBP are
pressure at PK3. Pressure should be 0 psi.
indicated on brake schematic but are not stamped on
spindles).
Park Brake Hydraulic Circuit
Troubleshooting Guide: 19. *Quickly and completely depress pedal and
check to see that left front brake pressure LFBP
If Park Brake will not operate as in steps 14 (a) and
is 16 548 ± kPa (2,400 ± 75 psi) and that right
(b), confirm all park brake circuit plumbing is correct.
front brake pressure RFBP is 16 548 ± kPa
If all plumbing is found to be correct, allow steering (2,400 ± 75 psi) within one second. Record both
accumulators to fully charge. Place shift lever in Park pressures. Holding pedal fully applied, both
and properly block wheels to prevent truck from pressures should remain above their minimum
rolling. Disconnect wire 52CS to park brake solenoid valves for a minimum of 20 seconds. Record
at TB32-K and ground disconnected wire 52CS. both pressures after a minimum of 20 seconds.
Verify pressure at test port PK3 is 21 374 - 24 132 20. *Release pedal. Brake pressure at LFBP and
kPa (3,100 - 3,500 psi). Ignore resulting park brake
RFBP should return to zero within two seconds
faults.
and there should be no residual pressure
a. If pressure is outside range, confirm steering trapped in brakes. Record both pressures.
pump pressure compensator is properly
NOTE: Move pressure gauges to BF and BR ports in
adjusted.
the brake cabinet.
b. If solenoid will not energize, verify wiring to
solenoid is correct. If wiring is correct and
solenoid will not energize, replace park
brake solenoid.
c. If park brake solenoid valve will not operate,
replace park brake cartridge valve.
d. Reconnect the wire 52CS to TB32-K. Repeat
step 14 (a and b) to confirm proper system
operation.
15. Cycle shift lever several times in/out of Park to
assure crisp application and release of pressure
and proper function of status light.

4 Brake System Checkout Procedure 58B-60-20410

Low Brake Pressure and Auto Apply 27. *With the front brake accumulator bleeddown
valve still cracked open, allow the pressure at
21. Start engine and allow low brake accumulator
LAP1 to continue to drop. Brake pressures at
pressure (LAP1) to increase to a minimum of 22
test ports BF and BR will begin to rise when the
063 kPa 3,200 psi). Allow engine to continue to
auto apply sequence valve shifts and activates
run for at 3 least minutes after the steering
the auto apply system. Record the pressure at
pump unloads for the first time.
LAP1, BF and BR when BF begins to rise.
22. Place shift lever in Neutral. Turn the key switch
OFF to stop the engine. Allow the steering • LAP1 should be 11 376 ± 517 kPa (1,650 ± 75
psi).
accumulators to completely bleed down.
• BF pressure should be 0 kPa (0 psi).
23. Turn the key switch to RUN position, but do not
start the engine. After two minutes record the • BR pressure should be 0 kPa (0 psi).
low accumulator pressure at LAP1. If the 28. *Record final pressures with the brake auto
pressure at LAP1 is below 14 479 kPa (2,100 apply system active.
psi), then leakage in the system is excessive
and the source of the leakage must be identified • LAP1 should be 11 376 ± 517 kPa (1,650 ± 75
and corrected. psi).

24. Restart the engine and allow pressure at LAP1 • BF pressure should be 9 825 kPa (1,425 psi) or
to increase to 22 063 kPa (3,200 psi) or above. higher.
Turn key switch OFF to stop the engine and • BR pressure should be ± 517 kPa (2,400 ± 75
allow the steering accumulators to bleed down. psi).
25. Turn key switch to RUN position, but do not start NOTE: Adjustment of auto apply sequence valve will
the engine. Place shift lever in Neutral. Provide be necessary if auto apply pressure of 1650 75 psi
speed signal from GE display panel of 3.0 kph. are not obtained. Repeat steps 21 through 28 if valve
adjustment is performed.
NOTE: Speed signal must exceed 2 kph during steps
26 through 28. Fault A260 will display 1.5 seconds 29. Close the front brake accumulator bleeddown
after the speed signal is generated. valve. Use the GE display panel to reset vehicle
speed to 0 kph. Fault 260 will clear. Place the
26. *Crack open the front brake accumulator
shift lever in Park and start the engine. Allow
bleeddown valve (valve to the right on brake
the pressure at LAP1 to increase to 22 063 kPa
manifold) and observe LAP1 pressure. The low
(3,200 psi) or above.
brake pressure fault A261 should be generated
at 12 755 ± 359 kPa (1,850 ± 52 psi) when the 30. Turn the key switch OFF to stop the engine and
low brake pressure switch in port LAP2 trips. allow steering accumulators to completely bleed
Record the pressure at LAP1, BF and BR when down.
fault A261 first displays. Record if fault A260 is 31. Turn the key switch to RUN position, but do not
displayed. start the engine. Place the shift lever in Neutral.
• LAP1 should be 12 755 ± 359 kPa (1,850 ± 52 Provide speed signal from E display panel of
psi). 3.0 kph. Fault 260 will display 1.5 seconds later.
• BF pressure should be 0 kPa (0 psi). 32. *Crack open the rear brake accumulator
bleeddown valve and observe LAP1 pressure.
• BR pressure should be 0 kPa (0 psi).
Verify low brake pressure Fault A261 is
NOTE: The brake warning system will warn the generated within 689 kPa (100 psi) of that
operator when the lowest pressure in either the front observed in step 26. Record the pressure at
or rear accumulator falls below the low brake LAP1, BF and BR.
pressure switch setting. The brake auto apply system
• LAP1 should be 12 755 ± 359 kPa (1,850 ± 52
will activate and automatically apply the front and
psi).
rear service brakes if the lowest pressure in either
the front or rear brake accumulator drops below 11 • BF pressure should be 0 kPa (0 psi).
376 ± 517 kPa (1,650 ± 75 psi). • BR pressure should be 0 kPa (0 psi).

58B-60-20410 Brake System Checkout Procedure 5

 33. *With the rear brake accumulator bleeddown Park Brake Control Logic Check
valve still cracked open, allow the pressure at
40. *This step will verify control logic of park brake
LAP1 to continue to drop. Brake pressures at
control. If any steps below are not passed, the
test ports BF and BR will begin to rise when the
problem must be located and corrected. Brake
auto apply sequence valve shifts. Verify auto
lock switch is to remain off during this entire
apply occurs when LAP1 is within 689 kPa (100
step. GE speed input from the display panel is
psi) of that observed in step 27. Record the
to remain at 0 kph, and changed only in the
pressure at LAP1, BF and BR at the point BR
steps designated.
starts to rise. Record if Fault A260 is displayed.
NOTE: Energizing the park brake solenoid valve
• LAP1 should be 11 376 ± 517 kPa (1,650 ± 75
pressurizes and releases the park brakes;
psi)
deenergizing vents and applies the brakes.
• BF pressure should be 0 kPa (0 psi)
Park Brake and Park Brake Protection with Brake
• BR pressure should be 0 kPa (0 psi)
Lock Sequencing:
34. *Record final pressures with the brake auto
If park brake application is requested, the following
apply system active.
1.5 sec operating sequence is performed when the
• LAP1 should be 11 376 ± 517 kPa (1,650 ± 75 vehicle speed is less than or equal to 0.8 kph:
psi)
• BF pressure should be 9 825 kPa (1,425 psi) or
higher Park Brake and Park Brake Protection with Brake
Lock Sequencing
• BR pressure should be ± 517 kPa (2,400 ± 75
psi) Time (sec) Brake Lock Park Brake
Solenoid Solenoid
35. Remove speed signal from GE display panel
and set to zero (0) kph. Close the rear brake 0.0 - 1.0 Energized energized
accumulator bleeddown valve. 1.0 - 1.5 Energized deenergized
above 1.5 Deenergized deenergized
Brake Reapplications
36. Start engine and increase brake accumulator
a. *With engine running and system pressure at
pressure to increase to a minimum of 22 063
least 21 374 (3,100 psi) at LAP1, place the
kPa (3,200 psi) at LAP1.
shift lever in Neutral. Apply park brake by
37. Shut engine down using engine shutdown placing shift lever in Park. Confirm proper
switch on center console to prevent steering operation of the park brake, the status light,
accumulators from bleeding down. Place shift and that no faults are generated. Record
lever into Neutral. Supply speed signal of 3.0 highest pressure observed at PK3, PP3, BF
kph from GE display panel. and BR during the 1.5 seconds when park
38. *Make repeated slow, complete brake brake application sequence is being
applications with pedal until low accumulator performed. Pressure at PK3 should be 21
pressure Fault A261 displays. Fault A261 must 374 to 24 132 kPa (3,100 to 3,500 psi) and
not actuate prior to the sixth pedal application. then fall to 0 kPa (0 psi). Pressure at PP3
Auto apply must not occur until after Fault A261 should begin at 0 kPa (0 psi) then rise to 13
displays. Record the number of brake 790 ± 689 kPa (2,000 ± 100 psi) and finally
applications prior to Fault A261. fall back to 0 kPa (0 psi). Pressure at BF
should remain at 0 kPa (0 psi) throughout.
39. Reset the speed signal to zero (0) kph at GE Pressure at BR should begin at 0 kPa (0 psi)
display panel. then rise to 13 790 ± 689 kPa (2,000 ± 100
Steps 1 through 39 must be successfully completed psi) and finally fall back to 0 kPa (0 psi).
before continuing to the next step, Park Brake Record pressures at PK3, PP3, BF and BR
Control Logic Check. at end of step a. Pressure at PK3, PP3, BF
and BR should be 0 kPa (0 psi).

6 Brake System Checkout Procedure 58B-60-20410

 b. *Run engine to charge accumulators to 3100 e. *This step verifies that the parking brake will
psi minimum at LAP1 and then release the not apply if it is requested while the truck is
park brake by placing the shift lever in moving:
Neutral. Stop engine using the engine
1)With the engine running and LAP1
shutdown switch on the center console.
pressure above 21 374 kPa (3,100 psi),
Confirm that the park brake applies and that
Move the shift lever to Neutral.
the park brake status light indicates that the
park brake is applied. Also, confirm that no 2)Place a jumper wire between circuit 36 and
park brake faults are generated. Record Gnd.
highest pressure observed at PK3, PP3, BF
3)Stop engine using engine shutdown
and BR during the 1.5 seconds immediately
switch. Do not turn the key switch OFF.
following park brake application. Pressure at
PK3 should be 21 374 to 24 132 kPa (3,100 4) Set the GE display panel speed to 1.0
to 3,500 psi) and then fall to 0 kPa (0 psi). kph.
Pressure at PP3 should begin at 0 kPa (0
5) Move the shift lever to the Park position.
psi) then rise to 13 790 ± 689 kPa (2,000 ±
100 psi) and finally fall back to 0 kPa (0 psi). 6) Confirm the parking brake does not apply.
Pressure at BF should remain at 0 psi Record pressures.
throughout. Pressure at BR should begin at
• PK3 pressure should be 21 374 to 24
0 kPa (0 psi) then rise to 13 790 ± 689 kPa 132 kPa (3,100 to 3,500 psi)
(2,000 ± 100 psi) and finally fall back to 0
kPa (0 psi). • PP3, BF and BR pressures should be
0 kPa (0 psi)
Record pressures at PK3, PP3, BF and BR
at end of step b. Pressure at PK3, PP3, BF 7) Fault A230 will display if pressure switch
and BR should be 0 kPa (0 psi). is installed while performing this step.

c. *With the engine running and system NOTE: Fault A230 can also be created by
pressure at least 21 374 (3,100 psi) at LAP1 unplugging the pressure switch.
and the shift lever in Park, turn the key 8) Reset the GE display panel speed to 0.0
switch off. Confirm that the park brake kph. Remove jumper wire.
remains applied. Record highest pressure
observed at PK3, PP3, BF and BR after the Brake Lock Control Logic Check
engine is completely stopped. Pressure at
PK3, PP3, BF and BR should be 0 kPa (0 41. *This step will verify control logic of Brake Lock
psi). control. If any steps below are not passed, the
problem must be located and corrected. GE
d. *With the engine running and system speed input from the display panel is to remain
pressure at least 21 374 (3,100 psi) at LAP1 at 0 kph, and changed only in the steps
and the shift lever in Neutral, turn the key designated.
switch off. Confirm that the park brake
applies. Record highest pressure observed a. *With the engine running and system
at PK3, PP3, BF and BR during the first 1.5 pressure at least 21 374 kPa (3,100 psi) at
seconds when park brake application is LAP1 and the shift lever in Neutral, attempt
requested. Pressure at PK3 should be 21 to apply and release the brake lock by
374 to 24 132 kPa (3,100 to 3,500 psi) and actuating the brake lock switch. Confirm
then fall to 0 kPa (0 psi), PP3, BF, and BR proper operation of the brake lock and the
should remain at 0 kPa (0 psi). brake lock status light and that no faults are
generated. Record highest pressure
NOTE: Since key switch is off, brake lock sequencing observed at PK3, PP3, BF and BR during
with park brake will not occur. this step. Pressure at PK3 should remain at
Record pressures at PK3, PP3, BF and BR 21 374 to 24 132 kPa (3,100 to 3,500 psi),
at end of step d. Pressure at PK3, PP3, BF PP3 should reach 13 790 ± 689 kPa (2,000 ±
and BR should be 0 kPa (0 psi). 100 psi) and then fall to 0 kPa (0 psi), BF
should remain at 0 kPa (0 psi), and BR
should reach 13 790 ± 689 kPa (2,000 ± 100
psi) and then fall to 0 kPa (0 psi).

58B-60-20410 Brake System Checkout Procedure 7

Record final pressures at PK3, PP3, BF and BR. e. *During the Smart Timed Shutdown with shift
lever in Park and at least 21 374 kPa (3,100
b. *With the engine running and system
psi) at LAP1, attempt to apply the brake lock
pressure at least 21 374 kPa (3,100 psi) at
using the brake lock switch. Confirm that the
LAP1 and the shift lever in Park, attempt to
brake lock does not apply and that the status
apply the brake lock by actuating the brake
light indicates properly. Record highest
lock switch. Confirm that the brake lock does
pressure observed at PK3, PP3, BF and BR
not apply and that the brake lock status light
during this step. Pressure at PK3, PP3, BF
is not energized. (Faults A272 and A274
and BR should remain at 0 kPa (0 psi).
should not display. Fault A272 will be
generated if the brake lock switch has power Record final pressures at PK3, PP3, BF and BR at
to apply the brake lock when it shouldn't. end of step e.
Fault A274 will be generated if brake lock
f. *This step verifies that the Brake Lock
application and park brake application occur
function will activate when applied while the
at the same time). Record highest pressure
truck is moving.
observed at PK3, PP3, BF and BR during
this step. Pressure at PK3, PP3, BF and BR 1) With the engine running and LAP1
should remain at 0 kPa (0 psi). pressure above 3100 PSI, move the shift
lever to Neutral.
Record pressures at PK3, PP3, BF and BR at end of
step b. 2) Using GE wPTU software, set the FWD
True output ON.
c. With the engine running and system
pressure at least 21 374 kPa (3,100 psi) at 3) Stop engine using engine shutdown
LAP1 and the brake lock applied and shift switch. Do not turn the key switch OFF.
lever in Neutral, move shift lever to Park.
4) Set the GE display panel speed to 1.0
Confirm that the park brake applies and the
kph.
brake lock releases and that the status lights
indicate properly. Record highest pressure 5) Place a jumper wire between circuit 36
observed at PK3, PP3, BF and BR during and Gnd.
this step. Pressure at PK3 should be 21 374
6) Apply brake lock using brake lock switch.
to 24 132 kPa to (3,100 to 3,500 psi) and
then fall to 0 kPa (0 psi), PP3 should be 13 7) Confirm brake lock is active. Record
790 ± 689 kPa (2,000 ± 100 psi) and then fall pressures:
to 0 kPa (0 psi), BF should remain at 0 psi,
• PK3 pressure should be 21 374 to 24 132
and BR should increase to 13 790 ± 689 kPa kPa to (3,100 to 3,500 psi)
(2,000 ± 100 psi) and then fall to 0 kPa (0
psi). • BF pressure should be 0 kPa (0 psi)
Record final pressures at PK3, PP3, BF and BR at • PP3 and BR pressures should be 13 790
end of step c. ± 689 kPa (2,000 ± 100 psi)

d. *With the engine running and system 8) Remove jumper wire. Reset GE display
pressure at least 3100 psi at LAP1, shift panel speed to 0.0 kph. Using GE wPTU
lever in Neutral, brake lock applied, actuate software, reset the FWD True output
the Engine Shutdown Switch on center OFF.
console. Confirm that the brake lock g. *This step verifies that the Brake Lock
releases and the park brake applies and that function will remain activated after the truck
the status lights indicate properly. Record is stopped if it was applied while the truck is
highest pressure observed at PK3, PP3, BF moving.
and BR during this step. Pressure at PK3
should be 21 374 to 24 132 kPa to (3,100 to 1) With the engine running and LAP1
3,500 psi) and then fall to 0 kPa (0 psi), PP3 pressure above 3100 psi, move the shift
and BR should be 13 790 ± 689 kPa (2,000 ± lever to Neutral
100 psi) and then fall to 0 kPa (0 psi), BF 2) Using GE wPTU software, set the FWD
should remain at 0 kPa (0 psi). True output to ON
Record final pressures at PK3, PP3, BF and BR at
end of step d.

8 Brake System Checkout Procedure 58B-60-20410

 3) Stop engine using engine shutdown *11) Confirm faults A272 and A274 becomes
switch. Do not turn the key switch OFF. active after the speed signal is reset to 0.0
kph.
4) Set the GE display panel speed to 1.0
kph. 12) Using GE wPTU software, reset the FWD
True output to OFF.
5) Place a jumper wire between circuit 36
and Gnd. *13) Turn brake lock switch OFF. Confirm that
brake lock function releases. Record
6) Apply brake lock using brake lock switch.
pressures:
*7 Confirm brake lock function is active.
• PK3 and BF pressures should be 0 kPa (0
Record pressures: psi)
• PK3 pressure should be 21 374 to 24 132 • PP3 and BR pressures should be 0 kPa (0
kPa to (3,100 to 3,500 psi) psi)
• BF pressure should be 0 kPa (0 psi) 14) Remove jumper wire.
• PP3 and BR pressures should be 13 790 ± 42. Remove pressure gauges and brake simulators.
689 kPa (2,000 ± 100 psi)
8) Move the shift lever to Park
9) Reset the GE display panel speed to 0.0
kph
*10) Confirm brake lock function remains
active. Record pressures:
• BF pressure should be 0 kPa (0 psi)
• PP3 and BR pressures should be 13 790
± 689 kPa (2,000 ± 100 psi)

This concludes the 980E-4/U79 Brake System Checkout Procedure.

The Brake System Checkout Data Sheet follows.

58B-60-20410 Brake System Checkout Procedure 9

 980E-4/U79 Brake System Checkout Data Sheet
NOTE: The acceptance range of each measurement is listed within parentheses, ().

Initial startup and Service Brake Checks

Accumulator Precharge Pressure

Step 2 b __________ 9 653 kPa (1,400 psi) Front brake accumulator precharge pressure
__________ 9 653 kPa (1,400 psi) Rear brake accumulator precharge pressure

Initial System Set Up

Step 4___________ 11 376 -517/+2 586 kPa (1,650 -75/+375 psi) Brake accumulator
pressure (LAP1) when Auto Apply releases
Step 6___________ 310 - 1 413 kPa (45-205 psi) Rear brakes relay valve pilot pressure
(BR) when BF starts to rise
___________ 0 - 35 kPa (0-5 psi) Front service brakes relay valve pilot pressure
(BF) when BR is between 310 - 1 413 kPa (45-205 psi)
Step 7___________ 517 ± 35 kPa (75 ± 5 psi) Rear service brakes relay valve pilot pres
sure (BR) when Brake lights energize
Step 8___________ 17 237 ± 517 (2,500 ± 75 psi) Front service brakes relay valve pilot
pressure (BF), one sec after pedal applied
___________ 17 237 ± 517 (2,500 ± 75 psi) Rear service brakes relay valve pilot
pressure (BR), one sec after pedal applied
___________ 17 237 ± 517 (2,500 ± 75 psi) Front service brakes relay valve pilot
pressure (BF), 20 sec minimum after pedal applied
___________ 17 237 ± 517 (2,500 ± 75 psi) Rear service brakes relay valve pilot
pressure (BR), 20 sec minimum after pedal applied

Brake Lock/Secondary System

Step 11 __________ 6 895 ± 172 kPa (1,000 ± 25 psi) Rear service brakes relay valve
pilot pressure (BR) when brake degradation fault A118 occurs
Step 13__________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot pressure (BR) when brake lock is applied
__________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake Lock pressure (PP3)
when applied

10 Brake System Checkout Procedure 58B-60-20410

Park Brake System

Step 14a ___________ 21 374-24 132 kPa (3,100-3,500 psi) Park brake pressure (PK3) for
park brake release
Step 14b ___________ 0 kPa (0 psi) Park brake pressure (PK3) for park brake apply

Service Brake System

Step 17 ___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Left rear service brake pressure
(LBP), one sec after pedal applied
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Right rear service brake pressure
(RBP), one sec after pedal applied
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Left rear service brake pressure
(LBP), 20 sec minimum after pedal applied
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Right rear service brake pressure
(RBP), 20 sec minimum after pedal applied
Step 18 ___________ 0 kPa (0 psi) Left rear service brake pressure (LBP), within two sec
after pedal released
___________ 0 kPa (0 psi) Right rear service brake pressure (RBP), within two
sec after pedal released
Step 19 ___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Left front service brake pressure
(LFBP), one sec after pedal applied
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Right front service brake pressure
(RFBP), one sec after pedal applied
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Left front service brake pressure
(LFBP), 20 sec minimum after pedal applied
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) (2400 ± 75 psi) Right front service
brake pressure (RFBP), 20 sec minimum after pedal applied
Step 20 ___________ 0 kPa (0 psi) Left front service brake pressure (LFBP), within two
sec after pedal released
___________ 0 kPa (0 psi) Right front service brake pressure (RFBP) within two
sec after pedal released

Low Brake Pressure and Auto Apply

Step 23 ___________ above 14 479 kPa (above 2,100 psi) Low brake accumulator pres-
sure (LAP1) after two minutes
Step 26 ___________ (1850 ± 52 psi) Low brake accumulator pressure (LAP1) when low
brake pressure fault A261 occurs
___________ 0 kPa (0 psi) Front service brake pressure (BF) when fault A261
occurs

58B-60-20410 Brake System Checkout Procedure 11

 ___________ 0 kPa (0 psi) Rear service brake pressure (BR) when fault A261
occurs
___________ (yes) Fault A260 displayed?

Step 27 ___________ 11 376 ± 517 kPa (1,650 ± 75 psi) Low brake accumulator pressure
(LAP1) when BF starts to rise
___________ 0 kPa (0 psi) Front service brake pressure (BF) when BF starts to
rise
___________ 0 kPa (0 psi) Rear service brake pressure (BR) when BF starts to
rise
Step 28 ___________ 11 376 ± 517 kPa (1,650 ± 75 psi) Low brake accumulator pressure
(LAP1) when auto brake apply completes
___________ (1,425 psi or higher) Front service brake pressure (BF) when auto
brake apply completes
___________ (2,400 ± 75 psi) Rear service brake pressure (BR) when auto brake
apply completes
Step 32 ___________ (1,850 ± 52 psi) Low brake accumulator pressure (LAP1) when low
brake pressure fault A261 occurs
___________ 0 kPa (0 psi) Front service brake pressure (BF) when fault A261
occurs
___________ 0 kPa (0 psi) Rear service brake (BR) pressure when fault A261
occurs
Step 33 ___________ 11 376 ± 517 kPa (1,650 ± 75 psi) Low brake accumulator pressure
(LAP1) when BR starts to rise
___________ 0 kPa (0 psi) Front service brake pressure (BF) when BR starts to
rise
___________ 0 kPa (0 psi) Rear service brake pressure (BR) when BR starts to
rise
___________ (yes) Fault A260 displayed?

Step 34 ___________ 11 376 ± 517 kPa (1,650 ± 75 psi) Low brake accumulator pressure
(LAP1) when auto brake apply completes
___________ 16 547 ± 517 kPa (2,400 ± 75 psi) Front service brake pressure (BF)
when auto brake apply completes
___________ 9 825 kPa (1,425 psi or higher) Rear service brake pressure (BR)
when auto brake apply completes

12 Brake System Checkout Procedure 58B-60-20410

Brake Reapplications

Step 38 __________ (6 or more) Number of pedal applications prior to fault A261

Park Brake Control Logic Check

Step 40 a - Maximum pressures during 1.5 sec park brake application sequence:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park brake pilot pressure
(PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)
Pressures at completion of step 40 a:
___________ 0 kPa (0 psi) Park brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brake relay valve pilot pressure (BR)
Step 40 b - Maximum pressures during 1.5 sec park brake application sequence:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park brake pilot pressure
(PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)
Pressures at completion of step 40 b:
___________ 0 kPa (0 psi) Park brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brake relay valve pilot pressure (BR)
Step 40 c - Maximum pressures:
___________ 0 kPa (0 psi) Park brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brake relay valve pilot pressure (BR)

58B-60-20410 Brake System Checkout Procedure 13

 Step 40 d - Maximum pressures during 1.5 sec park brake application sequence:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park brake pilot pressure
(PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brake relay valve pilot pressure (BR)
Pressures at completion of step 40 d:
____________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
Step 40 e - Pressures at completion of park brake application sequence:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park brake pilot pressure
(PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
___________ (yes) Fault A230 displays?

Brake Lock Control Logic Check

Step 41 a - Maximum pressures with brake lock on:

___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park Brake pilot pressure
(PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake Lock pressure (PP3)
__________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)
Pressures at completion of step 41 a with brake lock off:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park brake pressure (PK3)
___________ 0 kPa (0 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)

14 Brake System Checkout Procedure 58B-60-20410

 Step 41 b - Maximum pressures:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
___________ (no) Fault A272 displayed?
___________ (no) Fault A274 displayed?
Pressures at completion of step 41 b:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
___________ (no) Fault A272 displayed?
___________ (no) Fault A274 displayed?
Step 41 c - Maximum pressures:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park Brake pilot pressure
(PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)
Pressures at completion of step 41 c:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
Step 41 d - Maximum pressures:
___________ 20 684 - 24 132 kPa (3,100 - 3,500 psi) Park Brake pilot pressure
(PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)

58B-60-20410 Brake System Checkout Procedure 15

 Pressures at completion of step 41 d:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
Step 41 e - Maximum pressures during Smart Timed Shutdown:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
Pressures at completion of step 41 e:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)
Step 41 f - Pressures at completion:
___________ (3100-3500 psi) Park brake pilot pressure (PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)
Step 41 g - Pressures at completion of substep 7:
___________ (3100-3500 psi) Park brake pilot pressure (PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake lock pressure (PP3)
__________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
__________ (2000 ± 100 psi) Rear service brakes relay valve pilot press. (BR)
Pressures at completion of step 41 g, substep 10 & 11:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Brake lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 13 790 ± 689 kPa (2,000 ± 100 psi) Rear service brakes relay valve
pilot press. (BR)
___________ (yes) Fault A272 displayed?
___________ (yes) Fault A274 displayed?

16 Brake System Checkout Procedure 58B-60-20410

 Pressures at completion of step 41 g, substep 13:
___________ 0 kPa (0 psi) Park Brake pilot pressure (PK3)
___________ 0 kPa (0 psi) Brake Lock pressure (PP3)
___________ 0 kPa (0 psi) Front service brakes relay valve pilot pressure (BF)
___________ 0 kPa (0 psi) Rear service brakes relay valve pilot pressure (BR)

_________________________________________________
Signature of inspector or mechanic performing checkout

_________________________________________________
Name & badge no. (printed)

Date & shift checkout completed: ________________

Machine: ____________ Unit No.: ____________ Serial No.: ____________

58B-60-20410 Brake System Checkout Procedure 17

 NOTES

18 Brake System Checkout Procedure 58B-60-20410

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

KOMTRAX Plus Setup

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

EM2128-1 KOMTRAX Plus Setup Procedure 1

 7. Select VHMS Setting. Click “Next”.

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

2 KOMTRAX Plus Setup Procedure EM2128-1

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

10. Enter engine information. Click "Next".

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

EM2128-1 KOMTRAX Plus Setup Procedure 3

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

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

4 KOMTRAX Plus Setup Procedure EM2128-1

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

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

EM2128-1 KOMTRAX Plus Setup Procedure 5

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

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

6 KOMTRAX Plus Setup Procedure EM2128-1

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

EM2128-1 KOMTRAX Plus Setup Procedure 7

 Orbcomm Controller Example VHMS Controller Example

Part Number = 7826-12-2201

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

8 KOMTRAX Plus Setup Procedure EM2128-1

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

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

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

EM2129-1 1/18 KOMTRAX Plus Checkout Procedure 1

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

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

FIGURE 1-1. KOMTRAX PLUS CONTROLLER

2 KOMTRAX Plus Checkout Procedure 1/18 EM2129-1

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

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

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

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

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

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

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

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

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

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

EM2129-1 1/18 KOMTRAX Plus Checkout Procedure 3

 NOTES

4 KOMTRAX Plus Checkout Procedure 1/18 EM2129-1

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

58B-06-02400 3/17 Payload Meter IV Checkout Procedure 1

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

85702

FIGURE 1-1. PLM IV MOUNTING ORIENTATION

1. Position (1) 3. Position (3)
2. Position (2) 4. Position (4)
DO NOT modify unless required. Default payload
gain factor is 100%, but the setting is adjustable
between 90% and 110%. It is highly advised NOT
to change the default payload gain value, as this
change will affect all payload calculations.

2 Payload Meter IV Checkout Procedure 3/17 58B-06-02400

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

58B-06-02400 3/17 Payload Meter IV Checkout Procedure 3

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

4 Payload Meter IV Checkout Procedure 3/17 58B-06-02400

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

58B-06-02400 3/17 Payload Meter IV Checkout Procedure 5

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

6 Payload Meter IV Checkout Procedure 3/17 58B-06-02400

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

FIGURE 1-3. PLM IV COMMUNICATION MODULE

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

58B-06-02400 3/17 Payload Meter IV Checkout Procedure 7

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

8 Payload Meter IV Checkout Procedure 3/17 58B-06-02400

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

58B-06-02400 3/17 Payload Meter IV Checkout Procedure 9

 Payload Meter IV Checkout Procedure Confirmation

Value Initial

PLM Software Version: _______________ ___________

User switch and display works properly (Non-EDD truck) ___________

Electronic Dash Display Payload Screen works (EDD truck) ___________

Left-Front Pressure: _________________ ___________

Right-Front Pressure: ________________ ___________

Left-Rear Pressure: _________________ ___________

Right-Rear Pressure: ________________ ___________

Inclinometer: ______________________ ___________

Green light works properly ___________

Amber light works properly ___________

Red light works properly ___________

Brake Lock input works properly ___________

Body Up input works properly ___________

Speed input works properly ___________

Date: _______________________

Truck: ________________________

By: ______________________________________

10 Payload Meter IV Checkout Procedure 3/17 58B-06-02400

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

58F-06-30042 Electrical System Checkout Procedure 1

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

2 Electrical System Checkout Procedure 58F-06-30042

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

Preparation 24VIM TB32-H

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

58F-06-30042 Electrical System Checkout Procedure 3

Voltage Check

CIRCUIT CONNECTION DESCRIPTION

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

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

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

4 Electrical System Checkout Procedure 58F-06-30042

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

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

58F-06-30042 Electrical System Checkout Procedure 5

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

6 Electrical System Checkout Procedure 58F-06-30042

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

58F-06-30042 Electrical System Checkout Procedure 7

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

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

9. Engine Running Tests (Self-load Test)

8 Electrical System Checkout Procedure 58F-06-30042

Checkout Completion Report

Function Description Criteria Results OK/FAIL

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

58F-06-30042 Electrical System Checkout Procedure 9

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

10 Electrical System Checkout Procedure 58F-06-30042

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

FIGURE 1-1.STARTUP LOGO SCREEN

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

 FIGURE 1-2.MONITOR PANEL

1. Monitor Display 6. Monitor Display Mode Switch

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

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

85119

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

1. Program Part Number
2. Application Number

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

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

FIGURE 1-6.CAMERA POSITIONS

12. Set the following positions for camera 1 and

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Settings

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

2 ________ (yes/no) Blinking icon exists.

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

5 ________ Program part number.

________ Application number.

Main settings

10 ________ Setting for Machine code.

________ Setting for Offset.

________ Setting for Body Width.

________ Setting for Forward Option.

________ Setting for Rear wheel to end.

________ (yes/no) Diagonal Ladder LH.

________ (yes/no) Diagonal Ladder RH.

________ Forward Low-High speed

________ Reverse Low-High speed

________ Hysteresis.

________ Image Magnification Bird View.

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

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

All Camera Positions

12 a _______ Camera 1 Offset X.

b. ______ Camera 1 Offset Y.

c. ______ Camera 1 Offset Z.

d. ______ Camera 1 Roll.

e. ______ Camera 1 Pitch.

f. ______ Camera 1 Yaw.

13 a _______ Camera 2 Offset X.

b. ______ Camera 2 Offset Y.

c. ______ Camera 2 Offset Z.

d. ______ Camera 2 Roll.

e. ______ Camera 2 Pitch.

f. ______ Camera 2 Yaw.

14 a _______ Camera 3 Offset X.

b. ______ Camera 3 Offset Y.

c. ______ Camera 3 Offset Z.

d. ______ Camera 3 Roll.

e. ______ Camera 3 Pitch.

f. ______ Camera 3 Yaw.

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

 15 a _______ Camera 4 Offset X.

b. ______ Camera 4 Offset Y.

c. ______ Camera 4 Offset Z.

d. ______ Camera 4 Roll.

e. ______ Camera 4 Pitch.

f. _______ Camera 4 Yaw.

16 a _______ Camera 5 Offset X.

b. ______ Camera 5 Offset Y.

c. ______ Camera 5 Offset Z.

d. ______ Camera 5 Roll.

e. ______ Camera 5 Pitch.

f. _______ Camera 5 Yaw.

17 a _______ Camera 6 Offset X.

b. ______ Camera 6 Offset Y.

c. ______ Camera 6 Offset Z.

d. ______ Camera 6 Roll.

e. ______ Camera 6 Pitch.

f. _______ Camera 6 Yaw.

Radar Area

21 a _______ Outside Front value.

b. ______ Outside Side value.

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

Radar Threshold

22 a. ______ Radar 1 Power Setting.

b. ______ Radar 2 Power Setting.

c._______ Radar 3 Power Setting.

d. ______ Radar 4 Power Setting.

e. ______ Radar 5 Power Setting.

f. ______ Radar 6 Power Setting.

g. ______ Radar 7 Power Setting.

h. ______ Radar 8 Power Setting.

Radar All Positions

23 a. ______ Position 1 Offset X.

b. ______ Position 1 Offset Y.

c._______ Position 1 Offset Z.

d. ______ Position 1 Roll.

e. ______ Position 1 Pitch.

f. ______ Position 1 Yaw.

24 a. ______ Position 2 Offset X.

b. ______ Position 2 Offset Y.

c._______ Position 2 Offset Z.

d. ______ Position 2 Roll.

e. ______ Position 2 Pitch.

f. ______ Position 2 Yaw.

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

 25 a. ______ Position 3 Offset X.

b. _______ Position 3 Offset Y.

c. _______ Position 3 Offset Z.

d. ______ Position 3 Roll.

e. ______ Position 3 Pitch.

f. _______ Position 3 Yaw.

26 a. ______ Position 4 Offset X.

b. _______ Position 4 Offset Y.

c. _______ Position 4 Offset Z.

d. ______ Position 4 Roll.

e. ______ Position 4 Pitch.

f. _______ Position 4 Yaw.

27 a. ______ Position 5 Offset X.

b. _______ Position 5 Offset Y.

c. _______ Position 5 Offset Z.

d. ______ Position 5 Roll.

e. ______ Position 5 Pitch.

f. _______ Position 5 Yaw.

28 a. ______ Position 6 Offset X.

b. _______ Position 6 Offset Y.

c. _______ Position 6 Offset Z.

d. ______ Position 6 Roll.

e. ______ Position 6 Pitch.

f. _______ Position 6 Yaw.

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

 29 a. ______ Position 7 Offset X.

b. ______ Position 7 Offset Y.

c._______ Position 7 Offset Z.

d. ______ Position 7 Roll.

e. ______ Position 7 Pitch.

f. ______ Position 7 Yaw.

30 a. ______ Position 8 Offset X.

b. ______ Position 8 Offset Y.

c._______ Position 8 Offset Z.

d. ______ Position 8 Roll.

e. ______ Position 8 Pitch.

f. ______ Position 8 Yaw.

34 a _______ Auto Calibration.

b _______ Manual Calibration.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

42 ________ (yes/no) audible alarm sounds.

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

44 ________ (yes/no) audible alarm sounds.

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

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

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

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

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

48 ________ (yes/no) System errors exist.

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

51 a _______ Truck Model Number.

b _______ Truck Serial Number.

c _______ Person Name.

d _______ Date completed.

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

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

Necessary Equipment
1. Laptop computer
2. Bullet Titanium wireless radio (purchased
locally)
3. Two (2) Ethernet cables
4. Latest config file from Komatsu extranet

Purchase wireless radios

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

Manufacturer: Ubiquiti Networks

FIGURE 1-1.
Device: Bullet Titanium
Part Number: BM2-TI
QTY: One (1) per truck

58F-06-05340 Wireless Bridge Checkout Procedure 1

 4. Select KOMTRAX Plus / PLM 5. Select PMO Software

FIGURE 1-2. FIGURE 1-3.

6. KWB config files can be found on this page.

The part number is 58F-06-7042x.zip.
7. Download to PC for use in the next section.

2 Wireless Bridge Checkout Procedure 58F-06-05340

Configure Bullet wireless radio: Komatsu equipment such as loaders and mechanical
drive trucks.
The configuration file contains the settings required
to configure the bullet radio for communication with 1. Unpack the Bullet radio, power cable and POE
the 0002KPLUS wireless network. The file is generic, adapter.
so it can be used on each radio with no specific 2. Make connections as seen in the image below.
changes per truck. For convenience, 002KPLUS is
the same wireless network used by other Tier 4

FIGURE 1-4.

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

58F-06-05340 Wireless Bridge Checkout Procedure 3

 FIGURE 1-5.

4 Wireless Bridge Checkout Procedure 58F-06-05340

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

FIGURE 1-6.

11. Under Configuration Management click 13. Wait ~30 seconds, click “Main”, verify the
“Choose File” select the configuration file you information matches the fields below. If not, a
downloaded from the extranet site for the Bullet problem has occurred and steps 11 and 12
radio, “58F-06-7042x_0002Kplus_bullet.cfg”. should be repeated. This check only works
12. Click “Upload”, next click “Apply” on the blue when the bullet is not in range of a powered
ribbon that appears toward the top of the 0002Kplus access point. If the access point
screen. cannot be powered off this step should be
skipped.

FIGURE 1-7.

58F-06-05340 Wireless Bridge Checkout Procedure 5

Install Bullet radio on truck: mounted to the antenna station on the front handrail
on the left side of the truck.
Trucks equipped with KWB come with the required
cables and hardware. The Bullet radio will be

FIGURE 1-8.

1. Antenna 2. Hydrosorb Clamp

1. Antenna should be installed on bracket from 3. Install rubber washer on cable gland body if not
installation of GPS and KWB group. Connect already completed.
Bullet radio to antenna.
2. Install bolted half of hydrosorb clamp around
the Bullet and tighten bolts.

6 Wireless Bridge Checkout Procedure 58F-06-05340

 FIGURE 1-10.

5. Plug in the ethernet cable to the Bullet radio (2).

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

Configure access point (if not already

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

4. Slide compression nut (7, Figure 1-9) and cable

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

58F-06-05340 Wireless Bridge Checkout Procedure 7

 FIGURE 1-11.

1. LAN Ethernet Port 2. reset Button

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

8 Wireless Bridge Checkout Procedure 58F-06-05340

 FIGURE 1-12.

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

58F-06-05340 Wireless Bridge Checkout Procedure 9

 FIGURE 1-13.

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

FIGURE 1-14.

Test Connection: 3. Tool will automatically discover truck and

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

10 Wireless Bridge Checkout Procedure 58F-06-05340

 FIGURE 1-15. FIGURE 1-16.

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

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

58F-06-05340 Wireless Bridge Checkout Procedure 11

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

FIGURE 1-17.

12 Wireless Bridge Checkout Procedure 58F-06-05340

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

FIGURE 1-18.

58F-06-05340 Wireless Bridge Checkout Procedure 13

 NOTES

14 Wireless Bridge Checkout Procedure 58F-06-05340

 RETRACTABLE LADDER SYSTEM CHECKOUT PROCEDURE
Scope of Checkout Procedure The following items must be reviewed and under-
stood before performing the Retractable Ladder Sys-
This checkout procedure will setup and verify the
tem (RLS) Checkout Procedure:
operation of the Retractable Ladder System (RLS).
• Electrical System Checkout Manual
• Interface Module Checkout Procedure
Necessary Equipment
• Hydraulic Checkout Manual
1. Auxiliary Hydraulic System Checkout
Procedure and Schematic (if equipped). • Brake Checkout Manual
2. (4) 0 - 34 474 kPa (0 - 5,000 psi) calibrated • Auxiliary Hydraulic Systems Checkout Manual
gauges with quick-disconnect couplings.
All accumulators (steering, brake and auxiliary) must
be properly pre-charged before using this checkout
Required Software
manual.
Interface Module Realtime Data Monitor software is
recommended for trucks equipped with an electronic
display panel. The latest version may be downloaded
from the Komatsu America Extranet, https://
www.komatsuamerica.net/northamerica/.
The truck is not to be started without the Steer-
Data to Record ing, Brake and Auxiliary System (if equipped)
Steps in this document requiring recording of data accumulators being properly pre-charged. Low
are indicated with an asterisk (*). A consolidated accumulator pre-charge could cause damage to
form for recording data is located in the Checkout the accumulators.
Data Sheet section at the end of this document.
NOTE: Refer to Auxiliary Systems Hydraulic Diagram
Procedure Steps
when performing the steps of this checkout manual. 1. Verify the following:

NOTE: Be sure accumulators are bled down before a. The engine keyswitch is OFF.
loosening any hydraulic fitting. For bleeddown details b. Upper deck manual lowering valve knob is
refer to OUT (manual position).
Factory installations: Hydraulic Checkout c. Ground level lowering switch button is OUT
Manual (normal operating position).
Field installations: Auxiliary Hydraulic Systems d. Ladder is in the full DOWN position.
Checkout Manual
e. Auxiliary accumulator bleeddown valve (Fig-
NOTE: Carefully disconnect all hoses, tubing, ure 1-1) is open.
gauges and plugs in case hydraulic pressure is 2. Connect a 0 - 34 474 kPa (0 - 5,000 psi)
trapped within. pressure gauge at accumulator tap and
distribution manifold port GA and ladder
Precheckout Items manifold ports GDOWN, GP and GUP. Each
gauge should display less than 103 kPa (15
psi).
a. Close the auxiliary accumulator manual
bleeddown valve (Figure 1-1) after verifying
the pressure at port GA is as specified.
Wheels (if installed) must be properly blocked
before performing this procedure to prevent a b. If pressure is present at port GDOWN, GP or
possible roll away. GUP, slowly cycle the cab ladder momentary
switch (Figure 1-2), UP - DOWN, until the
pressure is relieved.

58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 1

 FIGURE 1-3. LADDER MANIFOLD

1. Ladder Down Relief 3. Ladder Solenoid

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

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

85644

FIGURE 1-2. LADDER MOMENTARY SWITCH

(LOCATED IN CAB)

1. UP 2. DOWN

3. Press the cab ladder momentary switch (Figure

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

2 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

 1 85645

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

ELECTRONIC DISPLAY PANEL (EDP)
1. Ladder Down Indicator Light

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

TRUCKS WITHOUT EDP
1. Ladder Down Indicator Light

7. Move the directional control lever to PARK and Record the ladder system supply pressure at
start engine. Allow engine to idle for five manifold port GA.
minutes to allow pressures to stabilize. 9. *Turn the ladder pressure reducing valve
8. *Port GA gauge should read greater than 18 adjustment clockwise (in) and count the number
0615 kPa (2,700 psi). All other gauges should of turns required to increase the ladder system
read less than 103 kPa (15 psi). operating pressure at port GP to 9 997 ± 1 034
kPa (1,450 ± 150 psi). The ladder should not
move.

58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 3

 Record the number of turns required to increase i) Port GUP gauge displays more than 3 447
port GP ladder system operating pressure to 9 kPa (500 psi).
997 kPa (1,450 psi).
ii) Port GDOWN gauge displays less than
NOTE: The pressure adjustment in this step 103 kPa (15 psi).
establishes a reference position for future steps of b. After an additional 15 seconds,
this checkout manual. Use step 26 to set the
pressure reducing valve for normal operation. c. Port GUP gauge returns to less than 103
kPa (15 psi).
10. Continue to turn the ladder pressure reducing
valve adjustment clockwise (in) until the port GP Port GDOWN pressure returns to more than
gauge displays 11 721 (+/-345) kPa (1,700 (+/- 3 447 kPa (500 psi).
50) psi). DO Not adjust the ladder pressure d. The ground level alarm sounds for approxi-
reducing valve above the maximum limit of the mately 20 seconds.
specified range. Port GDOWN gauge should
display the same pressure as GP. Port GUP 15. Press the cab ladder momentary switch to the
gauge should display 103 kPa (15 psi) or less. DOWN position.

NOTE: This pressure adjustment in this step is only 16. Start the engine and operate at low idle for five
to verify the ladder relief valve settings. Use step 26 minutes to allow pressures to stabilize.
to set the pressure reducing valve for normal 17. Stop the engine using the keyswitch in the cab.
operation.
18. Adjust the ladder up relief valve during a 15 sec-
11. Stop the engine using the keyswitch in the cab. ond valve actuation period, as detailed in this
12. While observing the port GDOWN and port GP step. The ladder should not move any time
gauges, slowly turn the ladder down relief valve during this step.
adjustment counterclockwise (out) until the a. Press the cab ladder momentary switch to
valve begins to open. the UP position.
NOTE: Relief valve opening is indicated when the b. Allow five seconds for the ladder solenoid
GDOWN pressure begins to fall or pulsate with an valve to actuate.
incremental turn of the adjustment. The opening may c. Within the following 15 seconds, observe the
be accompanied by an audible hydraulic hiss. port GP and port GUP gauges and slowly
a. Tighten the ladder down relief valve adjust- turn the ladder up relief valve adjustment
ment locknut. counterclockwise (out) until the valve begins
to open.
b. *Verify the ladder down relief valve begins to
open at 11 721 (+/- 1 172) kPa (1,700 (+/- NOTE: Relief valve opening is indicated when the
170) psi). GUP pressure begins to fall or pulsate with an
incremental turn of the adjustment. The opening may
Record port GDOWN pressure when the down
be accompanied by an audible hydraulic hiss.
relief valve begins to open.
d. If adjustment is not completed within the 15
13. Allow the ladder down relief valve to close and
second valve actuation period,
the pressures at ports GDOWN and port GP to
stabilize. Valve closing can be expedited by i) Tighten the ladder up relief valve
momentarily opening the auxiliary accumulator adjustment locknut.
bleeddown valve (Figure 1-1). Do not vent the
ii) *Verify the ladder up relief valve begins to
accumulator below 10 342 kPa (1,500 psi), as
open at 11 721 (+/- 1 172) kPa (1,700 (+/-
displayed on the port GA gauge. If vented
170) psi).
below 10 342 kPa (1,500 psi), briefly restart the
engine to raise the accumulator pressure. Record the pressure at port GUP when the up
14. Press the cab ladder momentary switch (Figure relief valve begins to open.
1-2) to the UP position. The ladder should not iii) Continue to step 19.
move. Verify the following:
e. If adjustment is not completed within the 15
a. After five seconds have lapsed second valve actuation period,

4 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

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

58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 5

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

6 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

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

58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 7

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

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

8. Ladder system supply pressure (GA) >18 615 kPa (>2,700 psi) _________

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

12. Ladder down relief pressure (GDOWN) 11 721 ± 1 172 kPa (1,700 ± 170 psi) _________

18. Ladder up relief pressure (GUP) 11 721 ± 1 172 kPa (1,700 ± 170 psi) _________

26. Ladder system pressure (GP) 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________

29a. When the cab switch UP is pressed with the ground lowering switch OUT and the upper deck lowering knob
IN (normal positions), do the following occur:
- ladder raises smoothly after a five second delay? (yes) _________
- ladder down indicator light remains illuminated during raising? (yes) _________
- ladder down indicator light turns off when ladder is full UP? (yes) _________
- Fault A333 appears? (n/a if truck cab is not display equipped) (no) _________
- cab alarm sounds? (no) _________
- ground level alarm sounds for 20 seconds or until ladder is UP? (yes) _________
- pressures with ladder fully UP:
- GDOWN: ladder cylinder (0 +25/-0 psi) _________
- GP: ladder system supply 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
- GUP: ladder cylinder 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________

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

8 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

- pressures with ladder fully DOWN:
- GDOWN: ladder cylinder 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
- GP: ladder system supply 9 997 ± 1 000 kPa (1,450 ± 145 psi) _________
- GUP: ladder cylinder 0 +172/ kPa (0 +25/-0 psi) _________

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

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

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

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

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

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

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

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

35. When the cab switch UP is pressed with the ground lowering switch IN, do the following occur:
- ladder moves from full DOWN? (no) _________
- ground alarm sounds for 20 seconds then silences? (yes) _________
- ladder down indicator light flashes after 15 seconds? (yes) _________
- Fault A333 appears after 15 seconds? (if equipped) (yes) _________
- cab alarm sounds after 15 seconds? (yes) _________

58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 9

36. When the ground lowering switch is pulled OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light flashes? (yes) _________
- Fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (no) _________

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

39. When the upper lowering valve knob is OUT, do the following occur:
- ladder moves smoothly to full DOWN position? (yes) _________
- ladder down indicator light flashes when ladder is not fully UP? (yes) _________
- Fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds during lowering and at ladder full DOWN? (yes) _________
- ground level alarm sounds? (no) _________

40. When the cab switch DOWN is pressed with the upper lowering valve knob OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light illuminates? (yes) _________
- Fault A333 appears? (if equipped) (no) _________
- an alarm sounds? (no) _________

41. When the cab switch UP is pressed with the upper lowering valve knob OUT, do the following occur:
- ladder moves from full DOWN? (no) _________
- ground alarm sounds for 20 seconds then silences? (yes) _________
- ladder down indicator light flashes after 15 seconds? (yes) _________
- Fault A333 appears after 15 seconds? (if equipped) (yes) _________
- cab alarm sounds after 15 seconds? (yes) _________

42. When the upper lowering valve knob is IN, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light flashes? (yes) _________
- Fault A333 appears? (if equipped) (yes) _________
- cab alarm sounds? (yes) _________
- ground level alarm sounds? (no) _________

10 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

43. When the cab switch DOWN is pressed with the upper lowering valve knob IN, do the following occur:
- ladder moves from full DOWN? (no) _________
- ladder down indicator light illuminates without flashing? (yes) _________
- Fault A333 appears? (if equipped) (no) _________
- an alarm sounds? (no) _________

47. Number of full ladder raise strokes down and up with the engine off.
(3.5 lower & raise cycles minimum) strokes down (4 minimum) _________
strokes up (3 minimum) _________

________________________________________________________________________
Name of Mechanic or Inspector performing Checkout

__________________________________
Date & Shift Checkout completed:

Machine: ___________________ Unit No. _________________ S/N ________________

58E-00-10490 1/18 Retractable Ladder System Checkout Procedure 11

 NOTES

12 Retractable Ladder System Checkout Procedure 1/18 58E-00-10490

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

SM2700-2 Seat Belts and Tethers Checkout Procedure 1

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

Initials / Date

Seat belts are installed on operator seat. _____________________

Tethers are installed on operator seat. _____________________

Tethers are correctly mounted to the floor. _____________________

Tethers are correctly adjusted. _____________________

Seat belts are installed on passenger seat. _____________________

Tethers are installed on passenger seat. _____________________

Tethers are correctly mounted to the floor. _____________________

Tethers are correctly adjusted. _____________________

Signature_________________________________ Date________________ Unit No.________________

2 Seat Belts and Tethers Checkout Procedure SM2700-2

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

FIGURE 4.TYPICAL SEAT INSTALLATION WITH

FIGURE 2.TYPICAL TETHER/SEAT BELT INTEGRAL TETHER
INSTALLATION - OPERATOR SEAT ON TRUCKS EARLY MECHANICAL SEAT WITHOUT
WITH OR WITHOUT AIR EXTERNAL TETHERS
1. Tether Belt 2. Seat Belt 1. Tether Cable 2. Seat Belt

SM2700-2 Seat Belts and Tethers Checkout Procedure 3

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

FIGURE 8.TYPICAL 2PT SEAT / BELT

PASSENGER SEAT INSTALLATION -
FIGURE 6.TYPICAL 3PT SEAT / BELT CURRENT MODELS
INSTALLATION - CURRENT MODELS 730E-8, 830E, 860E, 930E and 960E
HD1500-7, 730E, 830E, 860E, 930E and 960E

4 Seat Belts and Tethers Checkout Procedure SM2700-2

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

MACHINE MODEL MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
980E-4

Service Meter Reading Wheel Motor Traction Motor

Date of Inspection
Serial Numbers LH RH
Location of Machine at Inspection Wheel Motor Transmission
Serial Numbers LH RH
Distributor’s Name Dump Body Manufacturer
Komatsu Other
Customer’s Name Dump Body Style Dump Body S/N

Customer’s Address
KAC Area Service Manager Signature Date

Inspector’s Comments:

Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:

Signature Remark:

Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation.
All four copies are to be distributed as shown below.

Send White Reports to Manager of Technical Support

Komatsu America Corp.
2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send Canary Reports to Manager of Field Assembly

Komatsu America Corp.
2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send Pink Reports to your KAC Regional Service Manager

Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.

Mark each item with the appropriate symbol as shown below.

CEAW008201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visually inspect unit for loose parts and debris.
2 Hardware Visually inspect unit for missing and/or loose mounting hardware.
Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped and
3 Hoses and Cables
clear from sharp edges and not rubbing each other.
4 Ground Straps Verify all ground straps are secure (sub-frame, anchor, etc).
5 Engine Oil Level Verify engine oil level is in operating range.
6 Engine Fan Inspect fan-to-shroud clearance and belt alignment.
7 Hydraulic Oil Level Verify oil level is visible through upper sight glass with dump body down.
Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and
8 Anchor Pin
properly tightened hardware.
Front Wheel Bearing Oil
9 Inspect for proper oil level.
Level
10 Wheel Motors Inspect oil specification and proper oil level.
11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks.
12 Radiator Inspect coolant fill level, cold temperature protection, and DCA additive.
Verify all ladders and handrails are secure and hardware is tight.

13 Decks and Ladders Visually inspect installation of grid blower, rectifier assembly and control box for correct
assembly of components and proper clamping, no loose contacts, no damaged or poorly
crimped cables.
Inspect all wiring and connections in battery box and ensure there is no rubbing or chafing.
Verify battery mounting hardware is secure.
14 Battery
Verify electrolyte is at proper level and caps are securely installed.
Verify all battery terminals are secure.
Visually inspect installation of steering cylinders, tie rod, and accumulators per print.
15 Frame Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations to
ensure all hardware is secure and there are no leaks.
Hardware Torque
Verify front suspension mounting cap screws have been properly tightened per appropriate
1 Suspension
shop manual or field assembly manual procedure.
Verify torque on front wheel nuts is at 2 655 ± 136 N·m (1 958 ± 100 ft lb).
Wheels Verify torque on rear inside wheel nuts is at 2 655 ± 136 N·m (1 958 ± 100 ft lb).
2
(See Note below.) Verify torque on rear outside wheel nuts and adapter ring is at 2 655 ± 136 N·m (1 958 ± 100
ft lb).
Verify torque on left ROPS beam cap screws is at 800 N·m (590 ft lb).
3 ROPS
Verify torque on right cross beam cap screws is at 240 N·m (177 ft lb).
4 Cab Verify torque on cab mounting cap screws is at 1 424 N·m (1,050 ft lb).
5 Wheel Motor Verify torque on wheel motor mounting cap screws is at 4 040 N·m (2,980 ft lb).
6 Tie Rod Clamp Nuts Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).

NOTE: Refer to the appropriate Disassembly and Assembly section in the shop manual for the complete
wheel mounting tightening procedure.

CEAW008201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 2 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Cab Compartment
1 Cab Doors Verify doors open and close smoothly and latch works properly.
2 Cab Windows Verify windows can be opened and closed smoothly.
3 Door Locks Verify left and right door locks work properly with key.
Visually inspect interior for completeness of assembly.
4 Interior
Visually inspect for cracked glass, torn upholstery, dirt, stains, holes, etc.
Inspect operator seat adjustments.
5 Cab Seats
Inspect seat belts and tethers for proper installation.
Check tilt and telescoping functions.
6 Steering Wheel
Verify adjustable lever can be locked securely.
Verify wiper functions at all speeds and range does not extend beyond glass surface.
7 Wiper
Verify windshield washer functions properly and washer fluid bottle is full.
8 Document Holder Verify O&M manual and safety manual are present.
10 Horn Check for proper sound and no looseness in horn button.
11 Backup Horn Check for proper sound and function.
12 Directional Control Lever Check for proper function and no binding or looseness.
13 Gauges Verify gauges are installed straight and operating correctly.
14 Hydraulic Fittings Visually inspect all hydraulic fittings under cab and hydraulic brake cabinet for leaks.
15 Hoist Check operation of hoist lever in all four positions.
Lights
1 Dome Light Verify dome light operates properly.
2 Dimmer Switch Verify dimmer operates properly.
Verify all headlights (high and low beams) and fog lights are functional.
3 Headlights/Fog Lights Verify high beam indicators on instrument panel are functional.
Verify lights are at proper angle.
Visually inspect front and rear turn signal operation on left and right sides.
4 Turn Signal Verify turn signal indicators on instrument panel operate properly.
Verify switch turns off after turn is completed.
Verify flasher operates properly.
5 Hazard Flashers
Verify hazard indicator on instrument panel operates properly.
6 Backup Light Verify backup lights operate properly when shift lever is in REVERSE.
7 Manual Backup Light Verify switch and light function properly.
8 Service Brake Verify service brake lights and indicator operate properly.
9 Retarder Lights Verify retarder lights operate properly.

CEAW008201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 3 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 Maintenance
Accepted
No. Inspection Item Acceptance Procedures
Service Inspection
1 Hydraulic System Perform flushing procedure at initial startup.
Front suspension oiling height is 25.4 mm (1 in.).
Rear suspension oiling height is 53.0 mm (2.1 in.).
Suspensions
2 Standard: Front suspension charging height is 228.6 mm (9 in.) at 3 047 kPa (442 psi).
(See Note below.)
Oil Sands: Front suspension charging height is 165.1 mm (6.5 in.) at 3 047 kPa (442 psi).
Rear suspension charging height is 212.3 mm (8.36 in.) at 1 455 kPa (211 psi).
Verify nitrogen charge in both steering and brake accumulators is at 9 653 kPa (1,400 psi).
3 Accumulators
(Charging pressure will vary with ambient temperature. Refer to chart in shop manual.)
4 Engine Prelube Ensure prelube is functional prior to engine startup.
5 Engine Starting Ensure engine starts easily.
6 Engine Noise Verify there is no abnormal noise from engine.
Verify when switch is ON, directional control lever is in NEUTRAL, brake is applied and
7 Brake Lock
indicator is ON.
8 Parking Brake Verify when directional control lever is in PARK, parking brake is applied and indicator is ON.
Verify with pedal depressed, front brake pressure (BF) is 16 545 ± 515 kPa (2,400 ± 75 psi).
Verify with pedal depressed, rear brake pressure (BR) is 16 545 ± 515 kPa (2,400 ± 75 psi).
9 Brake Pressures
Verify brake lock pressure is 13 790 ± 690 kPa (2,000 ± 100 psi).
Verify parking brake release pressure is 22 750 ± 1 380 kPa (3,300 ± 200 psi).
Verify steering wheel turns smoothly from lock to lock.
10 Steering
Verify steering system is free of noise and vibrations.
Verify POWER UP relief pressure is 18 960 ± 690 kPa (2,750 ± 100 psi).
Verify POWER DOWN relief pressure is 10 340 ± 520 kPa (1,500 ± 75 psi).
Verify hoist limit switch is operational and set correctly. (Measure on hoist cylinder 3rd stage.
11 Hoist
Cylinder should stop 152 mm (6 in.) before full extension.)
Verify hoist lever HOLD position operates properly.
Verify there is no heavy shock when dump body returns to frame in FLOAT.
POWER UP at 1,900 rpm with empty dump body is 22-26 seconds.
POWER DOWN at 780 rpm with empty dump body is 12-14 seconds.
12 Hoist Times
FLOAT to frame at 780 rpm with empty dump body is 14-18 seconds.
Ensure body up switch activates body up alarm and indicator.
Ensure automatic lubrication system is serviced, tank is full and air is purged from system.
13 Lubrication
Ensure automatic lubrication system is operating properly and timer is set as desired.
14 Payload Meter Calibrate and check payload meter operation per shop/O&M manual instructions.
15 Error Codes Troubleshoot any fault codes and delete.
16 Machine Record machine model type, machine serial number and engine serial number.
17 Dump Body Ensure dump body is shimmed correctly prior to truck release.
Ensure electrical checkout procedure has been completed and signed off.
18 Electrical Checks
(See appropriate field assembly manual or shop manual for procedure.)
19 IM Programming Ensure IM is programmed with its own unique configuration file and copy of file is saved.

NOTE: Refer to the appropriate Testing and Adjusting section in the shop manual for complete suspension
oiling and charging instructions.

CEAW008201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 4 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
ADDITIONAL COMMENTS ________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CEAW008201 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 5 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 50 HOUR POST-COMMISSIONING CHECKSHEET

Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.

MACHINE MODEL MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
980E-4

Service Meter Reading Date of Inspection

Wheel Motor Traction Motor
Serial Numbers LH RH

Location of Machine at Inspection

Wheel Motor Transmission
Serial Numbers LH RH

Distributor’s Name Dump Body Manufacturer (circle one)

Komatsu Other

Customer’s Name Dump Body Style Dump Body S/N

Customer’s Address KAC Area Service Manager Signature Date

Inspector’s Comments:

Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:

Signature Remark:

Send white reports to: Manager of Technical Support

Komatsu America Corp.
2300 N.E. Adams St., P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send canary reports to: Manager of Field Assembly

Komatsu America Corp.
2300 N.E. Adams St., P.O. Box 240
Peoria, IL 61650-0240 U.S.A.

Send pink reports to your KAC Regional Service Manager

Send gold reports to the Service Manager at the KAC Distributor who sold the truck

CEAW008302 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 4
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 As Found Corrective
No. Inspection Item Acceptance Procedures
Condition Action
Inspection Around Machine

1 Parts Visually inspect the truck for loose parts and debris.

Visually inspect the truck for missing and/or loose mounting

2 Hardware
hardware.
Visually inspect hydraulic hoses and electrical cables to
3 Hoses and Cables ensure they are securely clamped and clear of sharp edges
and other objects that may cause chaffing.
4 Engine Oil Level Verify the engine oil level is at the proper operating range.
Verify the oil level is visible through the upper sight glass with
5 Hydraulic Oil Level
the body down.
Visually inspect the anchor hitch pin and anti-sway bar
6 Anchor Pin assembly for proper installation and properly tightened
hardware.
Verify the correct oil is being used and oil is at the proper
7 Wheel Motors
level.
Verify the fuel tank mounting is secure and there are no fuel
8 Fuel Tank
leaks.
Inspect the coolant fill level, cold temperature protection, and
9 Radiator
DCA additive.
Verify proper installation of the steering cylinders, tie rod, and
10 Steering Components
accumulators.
Visually inspect the hoist valve, pumps, filters, hydraulic tank
11 Hydraulic Components and hoist cylinder installations. All hardware must be secure
and no leaks evident.

12 Leakage Visually inspect the entire machine for leaks.

Hardware Torque
Steering Arm to Verify hardware torque is 2 705 ± 271 N·m (1,995 ± 200 ft
1
Front Suspension lb).
Steering Cylinder To
2 Verify hardware torque is 420 ± 42 N·m (310 ± 31 ft lb).
Frame
Steering Cylinder to
3 Verify hardware torque is 420 ± 42 N·m (310 ± 31 ft lb).
Steering Arm
4 Tie Rod Pin Retainer Verify hardware torque is 420 ± 42 N·m (310 ± 31 ft lb).
5 Tie Rod Clamp Nuts Verify hardware torque is 1 017 ± 102 N·m (750 ± 75 ft lb).
Cab Compartment
Check for proper tone and volume. Ensure there is no
1 Horn
looseness in the horn button.

2 Back Up Horn Check for proper tone, volume, and function.

Verify all gauges are installed straight and are operating

3 Gauges
correctly.
Verify no cracks exist on cab windows. Ensure all windows
4 Glass
are properly sealed.
Verify the cab seats, seat belts and tethers are in proper
5 Seat/Seat Belts
working condition.

CEAW008302 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 2 of 4
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
 As Found Corrective
No. Inspection Item Acceptance Procedures
Condition Action
Service Inspection
Front suspension oiling height is 25.4 mm (1 in.).
Rear suspension oiling height is 53.0 mm (2.1 in.).
Standard: Front suspension charging height is 228.6 mm
(9 in.) at 3 047 kPa (442 psi).
Suspensions
1 Oil Sands: Front suspension charging height is 165.1 mm
(6.5 in.) at 3 047 kPa (442 psi).
Rear suspension charging height is 212.3 mm (8.36 in.) at
1 455 kPa (211 psi).
NOTE: Refer to the field assembly manual or the appropriate Testing and Adjusting section in the shop manual for complete suspension
oiling and charging instructions.
Verify the nitrogen charge in both steering and brake
accumulators is at 9 653 kPa (1,400 psi).
2 Accumulators
(Charging pressure will vary with ambient temperature.
Refer to the chart in the shop manual.)
Verify the steering system is operating smoothly while turning
3 Steering from lock to lock.
Verify the steering system is free of noise and vibration.
Ensure the automatic lubrication system contains no air and
is filled to the proper level.
4 Lubrication
Ensure the automatic lubrication system is operating properly
and the timer is set as desired.
Verify the 50 hour change of all hydraulic filters has been
5 Hydraulic Filters
completed.
Pressure

Check and record the tire pressure/size/manufacturer for Size

6 Tires
future reference
Manufacturer

Calibrate and check the payload meter operation per O&M

7 Payload Meter System
manual. Troubleshoot any fault codes and delete after repair.
Check the drive control system operation per shop manual.
8 Drive/Control System
Troubleshoot any fault codes and delete after repair.
Rotating Components Visually inspect the wheel motor armature condition (brush
(Wheel Motors, wear, commutator color, etc).
9 Main Traction Alternator, Inspect the alternator slip rings and brushes.
Grid Blower) Inspect the grid blower motor commutator condition (brush
wear, etc).
Wheel Motor Sun Pinion
End Play Measure and record the sun pinion end play for both RH and
10
LH wheel motors.

Verify KOMTRAX Plus is functioning properly per O&M

11 KOMTRAX Plus
manual. Troubleshoot and repair any problems.

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Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.

No. Description of Modification Reason For Installation

ADDITIONAL COMMENTS:______________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager