Upload
lucia-berry
View
606
Download
16
Tags:
Embed Size (px)
Citation preview
7/16/2019 930E-4 field Assembly.pdf
1/335
CEAW004600
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS A30462 & UP
7/16/2019 930E-4 field Assembly.pdf
2/335
7/16/2019 930E-4 field Assembly.pdf
3/335
7/16/2019 930E-4 field Assembly.pdf
4/335
7/16/2019 930E-4 field Assembly.pdf
5/335
FAM0013 Introduction
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-4 dump truck. Vari
ations of design required for specific truck orders may require some modification of the general procedures out
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect thecurrent 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.
7/16/2019 930E-4 field Assembly.pdf
6/335
7/16/2019 930E-4 field Assembly.pdf
7/335
ii Introduction FAM0013
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.
CAUTION is used for general reminders
of proper safety practices
orto direct the readers attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
WARNING identifies a specific potential hazard
which may result
in either injury or death
if proper precautions are not used.
7/16/2019 930E-4 field Assembly.pdf
8/335
7/16/2019 930E-4 field Assembly.pdf
9/335
FAM0013 Introduction i
TABLE OF CONTENTS
SUBJECT PAGE NUMBER
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
7/16/2019 930E-4 field Assembly.pdf
10/335
7/16/2019 930E-4 field Assembly.pdf
11/335
iv Introduction FAM0013
NOTES
7/16/2019 930E-4 field Assembly.pdf
12/335
7/16/2019 930E-4 field Assembly.pdf
13/335
FAM0108 Safety Rules, Tools, & Equipment Page 1-1
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES
The following list of safety practices is intended for use
by personnel during field assembly of the truck.
This list of safety rules is not intended to replace local
safety rules or regulations and federal, state, or local
laws. The safety precautions recommended here are
general and must be used in conjunction with all pre-
vailing local rules and regulations.
1. All personnel must be properly trained for the
assembly process.
2. Wear safety equipment such as safety glasses,
hard toe shoes and hard hats at all times during
assembly.
3. Thoroughly inspect the assembly site. Remove
weeds, debris and other flammable material.
4. Use only solid, hard wood for supports. When
using metal support stands, place wood blocksbetween the support and the frame to prevent
metal to metal contact.
5. Inspect all lifting devices. Refer to the manufac-
turer's specifications for correct capacities and
safety procedures when lifting components.
6. Perform a daily inspection of all lifting cables and
chains. Replace any questionable items. Use
cables and chains that are properly rated for the
load to be lifted.
7. DO NOT stand beneath a suspended load. Use of
guy ropes are recommended for guiding and posi-
tioning a suspended load.8. Maintain fire control equipment. Inspect fire extin-
guishers regularly to ensure they are fully charged
and in good working condition.
9. Cap screws and/or nuts being replaced must be
the same grade as originally supplied.
Before welding, refer to Special Precautions When
Servicing A 930E Truck, in Section 4.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its compo
nents.
11. When welding, connect the ground cable to the
part being welded. DO NOT allow welding curren
to pass through bearings, engine, etc.
12. DO NOT weld the fuel tank or hydraulic tank
unless the tanks have been properly purged and
ventilated.
13. Use the proper tools for the job to be performed
Never improvise wrenches, screw drivers, sock
ets, etc. unless specified.
14. Lifting eyes and hooks must be fabricated from
the proper materials and rated to lift the intended
load.
15. When the weight of any component(s) or any
assembly procedure is not known, contact you
customer support manager for further information.
7/16/2019 930E-4 field Assembly.pdf
14/335
7/16/2019 930E-4 field Assembly.pdf
15/335
Page1-2 Safety Rules, Tools, & Equipment FAM0108
TOOLS AND EQUIPMENT FOR ASSEMBLY
The following equipment is recommended for field
assembly of the truck.
1. Equipment and tool storage trailer with a lockable
door. Approximately 12 x 2.5 m (40 x 8 ft)
2. Cranesa. Two, 45 metric ton (50 ton) cranes to remove
the chassis from the freight trailer and place on
cribbing. These cranes can also be used to lift
the assembled body onto to the chassis.
b. One, 109-136 metric tons (120-150 ton) crane.
The crane is needed to turn the body over after
completion of the underside welding. A 45 met-
ric ton (50 ton) crane is also required for this
task.
3. One fork lift - 6804 kg (15,000 lb) capacity, with
high lift capability.
4. Two, 300 amp portable welding units and an oxy-
acetylene cutting set.
5. One, propane torches for weld preheating.
6. Portable air compressor - 3.5 cmm (125 cfm) and
690 kPa (100 psi) capacity.
Two, 15 m (50 ft) air hoses.
7. Metal stands and a sufficient amount of wood
cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm
(14 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm
(4 ft. x 6 in. x 6 in.) - such as railway cross ties
8. Tire handler - Wiggins/Iowa Mold Tooling.
9. Miscellaneous air tools
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft)
11. Chains, lifting cables, slings:
Two, 4 point slings, 3 m (10 ft) in length
Two, 4 point slings, 2 m (6 ft) in length
Two, 1 m (4 ft) and two, 2 m (6 ft)
Two, 3 m (10 ft) nylon straps
Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of
rope
12. Two, ratchet pullers - 2.7 metric ton (3 ton)
13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)
14. Set of standard master mechanics hand tools.
Thread taps and dies of both inch and metric
sizes.
Metric sockets and open end wrenches, 6mm to
36mm.
Inch sockets and open end wrenches up to 1 3/
4 in.
Torque wrenches - 339 Nm (250 ft lb) with 18:1
multiplier. Torque wrenches - 339 Nm (600 ft lb)
with 4:1 multiplier. Hydrotorque - 1 1/2 in. drive
with capability of 5559 Nm (4100 ft lb) or
greater. Box wrench 1 3/8 in. (Snap-On p/n X440B) with
12 inch extension to tighten ROPS cap screws.
Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2
5/8 in. (Snap-On P/N J15042) to tighten front
suspension hardware.
15. Heavy duty 3/4 in. & 1 in. square drive impact
wrench sets.
16. Impact sockets for 3/4 in. & 1 in. square drive
tools.
17. Special tools (see list, following pages)
18. Two, hydraulic or pneumatic porta-power jacks,
4.5 and 9 metric ton (5 and 10 ton)
19. Various hooks and shackles
20. Miscellaneous: i.e. grinders, containers, rags.
21. Spreader bars for cab and decks.
22. Two ratchet hoists of 2.7 metric ton (3 ton) capac-
ity.
23. Pry bars
24. Solvent - 38 liters (10 gal)
25. Paint remover - 19 liters (5 gal)26. Rust preventive grease
7/16/2019 930E-4 field Assembly.pdf
16/335
7/16/2019 930E-4 field Assembly.pdf
17/335
FAM0108 Safety Rules, Tools, & Equipment Page 1-3
LIFTING SLING GENERAL INFORMATION
7/16/2019 930E-4 field Assembly.pdf
18/335
7/16/2019 930E-4 field Assembly.pdf
19/335
Page1-4 Safety Rules, Tools, & Equipment FAM0108
1. T Handle Valve2. 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
EB1759 Nitrogen
Charging Kit
Suspension &
Accumulator
Nitrogen
Charging
Part Number Description Use
EJ2626
(No longer
available as
complete unit)
Roller Assy. Power Module
Remove & Install
EJ2271 Roller Mount
PC0706 Bearing
TH9449 BearingRetainer
Ring
TG1680 Roller
Retainer
Ring
C1645 Cap screw
0.75 -10 NC
x 2 1/4 in.
C1542 Lockwasher
0.75 in.
EH8686 Roller Ring
7/16/2019 930E-4 field Assembly.pdf
20/335
7/16/2019 930E-4 field Assembly.pdf
21/335
FAM0108 Safety Rules, Tools, & Equipment Page 1-5
Part Number Description Use
PB8326 Offset Box End
Wrench,
1, 7/16 in.
Miscellaneous
Part Number Description Use
TZ2734 3/4 in. Torque
Adapter
Miscellaneous
Part Number Description Use
TZ2733 Tubular Handle Use with
PB8326 &
TZ2734
7/16/2019 930E-4 field Assembly.pdf
22/335
7/16/2019 930E-4 field Assembly.pdf
23/335
Page1-6 Safety Rules, Tools, & Equipment FAM0108
Part Number Description Use
BF4117 Seal Installa-
tion Tool
Front & Rear
Disc Brake
Floating Ring
Seal Installation
ED3347 Seal Installa-
tion Tool
Rear Axle/Hub
Adaptor Float-
ing Ring Seal
Installation
Part Number Description Use
EH4638 Sleeve
Alignment Tool
Steering Linkage
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
7/16/2019 930E-4 field Assembly.pdf
24/335
7/16/2019 930E-4 field Assembly.pdf
25/335
FAM0108 Safety Rules, Tools, & Equipment Page 1-7
Part Number Description Use
EF9160 Harness Payload Meter
Download
Part Number Description Use
EH7817 Alignment Tool Upper Hoist Pin
Part Number Description Use
PB4684 Hydraulic
Coupling
Miscellaneous
Part Number Description Use
PB9067 Bulkhead
Connector
Battery Jumper
7/16/2019 930E-4 field Assembly.pdf
26/335
P t N b D i ti U
7/16/2019 930E-4 field Assembly.pdf
27/335
Page1-8 Safety Rules, Tools, & Equipment FAM0108
Part Number Description Use
TZ2100
TZ2727
TZ2729
Socket (1 7/8 in.)
Socket (2 1/4 in.)
Socket (1 1/4 in.)
Misc.
Part Number Description Use
TZ2730
TZ2731
Adapter (1-1 1/2 in.)
Adapter (3/4-1 in.)
Socket adapter
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
TR0533
Extension (8 in.)
Extension (17 in.)
Miscellaneous
7/16/2019 930E-4 field Assembly.pdf
28/335
7/16/2019 930E-4 field Assembly.pdf
29/335
FAM0108 Safety Rules, Tools, & Equipment Page 1-9
7/16/2019 930E-4 field Assembly.pdf
30/335
7/16/2019 930E-4 field Assembly.pdf
31/335
Page1-10 Safety Rules, Tools, & Equipment FAM0108
7/16/2019 930E-4 field Assembly.pdf
32/335
TRUCK COMPONENTS AND SPECIFICATIONS
Truck And Engine Operator's Cab
7/16/2019 930E-4 field Assembly.pdf
33/335
FAM0212 Truck Components And Specifications Page 2-1
Truck And Engine
The 930E-4 dump truck is an off-highway, rear dump
truck with A/C electric drive. The gross vehicle weight
is 1,106,000 lbs. (501 673 kg). The engine is a
Komatsu SSDA16V160 rated @ 2700 HP (2014 kW).
Alternator (GE-GTA41)
The diesel engine drives an in-line alternator at
engine speed. The alternator produces A/C current
which is rectified to DC within the main control cabi-
net. The rectified DC power is converted back to A/C
by groups of devices called "inverters", also within
the main control cabinet. Each inverter consists of six
"phase modules" under the control of a "gate drive
unit" (GDU). The GDU controls the operation of each
phase module.
Each phase module contains an air-cooled solid-
state switch referred to as a "gate turn-off thyristor"(GTO). The GTO cycles on and off at varying fre-
quencies to create an A/C power signal from the DC
supply.
The A/C power signal produced by each inverter is a
variable-voltage, variable-frequency signal (VVVF).
Frequency and voltage are changed to suit the oper-
ating conditions.
Cooling air for the control / power group and wheel
motors, as well as the alternator itself, is provided by
dual fans mounted on the alternator shaft.
A/C Induction Traction Motorized Wheels
The alternator output supplies electrical energy to the
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase A/C induction
motors with full-wave A/C power.
The two wheel motors convert electrical energy back
to mechanical energy through built-in gear trains
within the wheel motor assembly. The direction of the
wheel motors is controlled by a forward or reverse
hand selector switch located on the center console.
Suspension
HydrairII suspension cylinders located at each
wheel provide a smooth and comfortable ride for the
operator and dampens shock loads to the chassis
during loading and operation.
Operator s Cab
The operator cab has been engineered for operato
comfort and to allow for efficient and safe operation
of the truck. The cab provides wide visibility, with an
integral 4-post ROPS/FOPS, and an advanced ana
log operator environment. It includes a tinted safetyglass windshield and power-operated side windows
a deluxe interior with a fully adjustable seat with lum-
bar support, a fully adjustable/tilt steering wheel, con
trols mounted within easy reach of the operator, and
an analog instrument panel which provides the oper
ator with all instruments and gauges which are nec
essary to control and/or monitor the truck's operating
systems.
Power Steering
The truck is equipped with a full time power steering
system which provides positive steering control withminimum operator effort. The system includes nitro
gen-charged accumulators which automatically pro
vide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
Dynamic Retarding
The dynamic retarding is used to slow the truck dur
ing normal operation or control speed coming down a
grade. The dynamic retarding ability of the electric
system is controlled by the operator through the acti
vation of the retarder pedal (or by operating a leve
on the steering wheel) in the operators cab and bysetting the RSC (Retarder Speed Control). Dynamic
Retarding is automatically activated, if the truck
speed goes to a preset overspeed setting.
Brake System
Service brakes at each wheel are oil-cooled multiple
disc brakes applied by an all-hydraulic actuation sys
tem. Depressing the brake pedal actuates both fron
and rear brakes, after first applying the retarder. Al
wheel brakes will be applied automatically, if 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/hydraulically-released with wheel speed
application protection (will not apply with truck mov
ing).
7/16/2019 930E-4 field Assembly.pdf
34/335
7/16/2019 930E-4 field Assembly.pdf
35/335
Page 2-2 Truck Components And Specifications FAM0212
930E-3 MAJOR COMPONENTS
7/16/2019 930E-4 field Assembly.pdf
36/335
SPECIFICATIONS
These specifications are for the standard Komatsu 930E Truck. Customer Options may change this listing.
ENGINE SERVICE CAPACITIES
7/16/2019 930E-4 field Assembly.pdf
37/335
FAM0212 Truck Components And Specifications Page 2-3
ENGINE
Komatsu SSDA16V160
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rpmHigh Idle . . . . . . . . . . . . . . . . . . . . . . . . . . 1910 rpm
Rated Full Load . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Rated Brake HP. . . 2700 HP (2014 kW) @ 1900 rpm
Flywheel HP . . . . . 2550 HP (1902 kW) @ 1900 rpm
Weight* (Wet) . . . . . . . . 21,182 pounds (9608 kg)* Weight does not include Radiator, Sub-frame, or Alternator
A/C ELECTRIC DRIVE SYSTEM
(AC/DC Current)
Alternator . . . . . . . . . . . . . General Electric GTA - 41
Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 12,000 cfm (340 m/ min)Motorized Wheels . . GDY106 A/C Induction Traction
Standard Gear Ratio*. . . . . . . . . . . . . . . . . 32.62:1
Maximum Speed . . . . . . . . . . 40 mph (64.5 km/h)*NOTE: Wheel motor application depends upon GVW, haul road
grade and length, rolling resistance, and other parameters.
Komatsu & G.E. must analyze each job condition to assure proper
application.
DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . . Standard
Maximum Rating . . . . . . . . . . . . 5400 HP (4026 kW)
Continuous . . . . . . . . . . . . . . . . 3300 HP (2460 kW)
Continuously rated high-density blown grids with retard at engineidle and retard in reverse propulsion.
BATTERY ELECTRIC SYSTEM
Batteries 4 x 8D 1450CCA, 12 volt, in series/parallel,
. . . . and 2x30H 800CCA, 220-ampre-hour batteries,
. . . . . . . . . . bumper mounted with disconnect switch
Alternator . . . . . . . . . . . 24 Volt, 260 Ampere Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt
Cranking Motors (2). . . . . . . . . . . . . . . . . . . . 24 Volt
SERVICE CAPACITIES
. . . . . . . . . . . . . . . . . . U.S. Gallons . . . . . . . Liters
Crankcase * . . . . . . . . . . . . . . . . 74 . . . . . . . . . .280
* Includes Lube Oil Filters
Cooling System . . . . . . . . . . . . .157 . . . . . . . . . .594Fuel . . . . . . . . . . . . . . . . . . . . .1200. . . . . . . . .4542
Hydraulic System . . . . . . . . . . . .350 . . . . . . . . 1325
Wheel Motor Gear Box. . . 25/Wheel . . . . . 95/Whee
HYDRAULIC SYSTEMS
Hoist & Brake Cooling Pump:. . . . . . . . Tandem Gea
Rated @ . . . . . . 270 GPM (1022 l/min.) @ 1900 rpm
. . . . . . . . . . . . . . . . . . . . .and 2500 psi (17 237 kPa
Steering/Brake Pump:Pressure Compensated Piston
Rated @ . . . . . . . 65 GPM (246 l/min.) @ 1900 rpm
. . . . . . . . . . . . . . . . . . . . .and 2750 psi (18 961 kPa
Relief Pressure-Hoist . . . . . . . 2500 psi (17 237 KPa
Relief Pressure-Steering . . . . 4000 psi (27 579 KPa
Hoist Cylinders (2) . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . 250 US Gal. (947 Liters
Filtration . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Hoist & Steering Filters . . . . . .Beta 12 Rating =200
. . . . . . . . . . . . . . . . . . .Dual In-Line, High Pressure
SERVICE BRAKES
All Hydraulic Actuation . . . . . . . with Traction System
. . . . . . . . . . . . . . . . . . . . . Wheel Slip / Slide ControFront and Rear Oil-Cooled Multiple Discs-each whee
Total Friction Area / Brake . . 15,038 in (97 025 cm
Maximum Apply Pressure . . . 2500 psi (17 238 kPa
STEERING
Turning Circle (SAE). . . . . . . . . . .97 ft. 7 in. (29.7 m
Twin hydraulic cylinders with accumulator assist to
provide constant rate steering.
7/16/2019 930E-4 field Assembly.pdf
38/335
STANDARD DUMP BODY CAPACITIESAND DIMENSIONS
Capacity,
Heaped @ 2:1 (SAE) . . . . . . . . . 276 yd3 (211 m3)
WEIGHT DISTRIBUTION
Empty Vehicle . . . . . . . . Pounds . . . . (Kilograms)
Front Axle (49.3%) . . . . . 227,738 . . . . . . . 103 301
Rear Axle (50.7%). . . . . .237,034 . . . . . . . 107 518
7/16/2019 930E-4 field Assembly.pdf
39/335
Page 2-4 Truck Components And Specifications FAM0212
p @ ( ) y ( )
Struck . . . . . . . . . . . . . . . . . . . . .224 yd3 (171 m3)
Width (Inside) . . . . . . . . . . . . . . . 26 ft. 9 in. (8.15 m)
Depth . . . . . . . . . . . . . . . . . . . . . . 10 ft. 7 in. (3.2 m)
Loading Height . . . . . . . . . . . . . . 23 ft. 2in. (7.06 m)Dumping Angle. . . . . . . . . . . . . . . . . . . . . . . . . . 45
*OPTIONAL capacity dump bodies are available.
TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . 53/80 R63
Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless
Rims . . . .(patented Phase I New Generation rims)
Total (50% Fuel) . . . . . . 464,772 . . . . . . . 210 819
Standard Komatsu body . . 66,936 . . . . . . . . 30,362
Standard tire weight. . . . . . 57,600 . . . . . . . . 26,127
Loaded Vehicle . . . . . . .Pounds Kilograms
Front Axle (33.9%) . . . . . 363,000 164 656
Rear Axle (66.1%). . . . . .737 000 . . . . . . . 334 301
Total * . . . . . . . . . . . . . 1,106,000 . . . . . . . 501 673
Nominal Payload* . . . . . . 641,228 . . . . . . . 290,859
* Nominal payload is as defined within Komatsu
America Corporations payload policy documenta-
tion. Nominal payload must be adjusted should the
weight of any customized body or tires fitted vary
from that of the standard Komatsu body and tires as
shown above. Nominal payload must also beadjusted to take into account the additional weight of
any custom/optional extras fitted to the truck which
are not stated within the Standard Features list of the
applicable specification sheet.
OVERALL TRUCK DIMENSIONS
7/16/2019 930E-4 field Assembly.pdf
40/335
MAJOR COMPONENT WEIGHTS
7/16/2019 930E-4 field Assembly.pdf
41/335
FAM0312 Major Component Weights Page 3-1
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected beforeeach use. Lifting equipment must be in good condition and rated for approximately two times the weigh
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,813 . . . . . . . . . . . . . . . . . . . . . . 6,202
Tire 53/80 R63 (148" OD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500
Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,122 . . . . . . . . . . . . . . . . . . . . . 15,702
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21,866 . . . . . . . . . . . . . . . . . . . . . 48,206
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,711 . . . . . . . . . . . . . . . . . . . . . . 3,772
DECK AND DECK SUPPORT COMPONENTSCab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,725 . . . . . . . . . . . . . . . . . . . . . . 6,008
RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937 . . . . . . . . . . . . . . . . . . . . . . 2,066
LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 . . . . . . . . . . . . . . . . . . . . . . 1,455
Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . .551
Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654 . . . . . . . . . . . . . . . . . . . . . . 1,442
Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 . . . . . . . . . . . . . . . . . . . . . . . .602
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 . . . . . . . . . . . . . . . . . . . . . . 1,60
RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578 . . . . . . . . . . . . . . . . . . . . . . 1,274
LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 . . . . . . . . . . . . . . . . . . . . . . . .298
RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . .150
Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 . . . . . . . . . . . . . . . . . . . . . . . .397
Diagonal Ladder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . . . . . . . . . . . . 119
7/16/2019 930E-4 field Assembly.pdf
42/335
ITEM KILOGRAMS POUNDS
POWER MODULE
Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 . . . . . . . . . . . . . . . . . . . . . . . . 613
7/16/2019 930E-4 field Assembly.pdf
43/335
Page 3-2 Major Component Weights FAM0312
Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891 . . . . . . . . . . . . . . . . . . . . . . .1,964
Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 . . . . . . . . . . . . . . . . . . . . . . . . 340
Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,082 . . . . . . . . . . . . . . . . . . . . . . .6,795
Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,176 . . . . . . . . . . . . . . . . . . . . . . .7,002
Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,993 . . . . . . . . . . . . . . . . . . . . . . .8,803
Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9305 . . . . . . . . . . . . . . . . . . . . . . 20,514
Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1996 . . . . . . . . . . . . . . . . . . . . . . .4,400
HYDRAULIC COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . . . . . . . . . . . . . . . 379Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .932 . . . . . . . . . . . . . . . . . . . . . . .2,055
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . . . . . . . . . . . . . . . . . . . . . . . 322
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731 . . . . . . . . . . . . . . . . . . . . . . .1,612
FRONT AXLE COMPONENTS
Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,496 . . . . . . . . . . . . . . . . . . . . . . .3,298
Spindle, Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,803 . . . . . . . . . . . . . . . . . . . . . .10,589
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331 . . . . . . . . . . . . . . . . . . . . . . . . 730
Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,790 . . . . . . . . . . . . . . . . . . . . . . .6,151
REAR AXLE COMPONENTS
Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,242 . . . . . . . . . . . . . . . . . . . . . . .4,943
Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 . . . . . . . . . . . . . . . . . . . . . . . . 351
Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371 . . . . . . . . . . . . . . . . . . . . . . . . 818
Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,568 . . . . . . . . . . . . . . . . . . . . . .14,480
Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 . . . . . . . . . . . . . . . . . . . . . . . . 324
Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 . . . . . . . . . . . . . . . . . . . . . .39,683
Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 . . . . . . . . . . . . . . . . . . . . . . . . 675
7/16/2019 930E-4 field Assembly.pdf
44/335
FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at
initial field assembly or during normal maintenance
repairs, special procedures must be followed.
Due to the continuous program of research and
WELD PROCEDURES
Electric arc welding, either the semi-automatic MIG
(GMAW), Flux Core (FCAW), or Stick electrode
welding (SMAW) are approved processes for field
7/16/2019 930E-4 field Assembly.pdf
45/335
FAM0403 Field Welding For Assembly Or Repair 4-1
Due to the continuous program of research and
development, periodic revisions may be made to this
publication. It is recommended that customers con-
tact their distributors for information on the latest revi-
sion.
The welding information contained in this chapter is
general information that must be followed unless oth-
erwise specified in a detailed repair procedure pro-
vided on an engineering drawing or a detailed
specific repair procedure. Additional specific informa-
tion, or detailed instructions can be obtained through
your local Komatsu customer support manager.
WELDER QUALIFICATION ANDTRAINING
The welding technique must be of the highest stan-
dard to produce the soundest weld possible. Only
welders who have been trained and qualified for
structural steel welding in all positions, in conform-
ance with the American Welding Society (AWS) D1.1
or (AWS) D14.3 only, are allowed to perform the
welding. The welding instructions for field assembly
of Komatsu components are normally provided by
engineering drawings. Additional detailed welding
instructions for field repairs are provided in the field
repair manual SEB14001. A full understanding of theAWS standard welding symbols is necessary to per-
form and inspect such field welds. Weld sizes speci-
fied on the drawings are intended to reflect minimum
requirements.
welding (SMAW), are approved processes for field
installation and maintenance welding. Welding o
highly stressed structural members such as castingstorque tubes, top and bottom plates on the frame
rails, and the curved intersection points of frames
should be done with the specific detailed instructions
from Komatsu Product Service. See Annex A fo
repair procedures. These repair procedures are
detailed instructions for most high stressed structura
members.
APPROVED CONSUMABLES
GMAW - LW102-15 or ER80S-D2
FCAW - E70T-5, E71T-8, or E71T8-NI1
SMAW - E7018-1, E8018-C1, or E8018-C3
WELD QUALITY REQUIREMENTS
1. Each weld must be homogeneous with low
porosity, free from cracks, and slag inclusions.
2. Each weld must have complete fusion between
the base metal and weld metal added by the
electrode.
3. All welds must be reasonably smooth, withouexcessive deformity, and all craters filled. No
cracks are permitted.
4. The toe of a weld to a stressed member mus
have a smooth transition. Excessive convexity
in multi-pass fillet welds is not permitted. Exces
sive convexity produces high residual stress in
the throat of the weld, and is not permitted.
5. Undercut in excess of 0.8 mm (0.03 in.) on criti
cal welds must be reworked by the application
of welding an additional cover pass. It is impor
tant that this pass is blended with the existing
weld.
7/16/2019 930E-4 field Assembly.pdf
46/335
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.
7 Sl i t b d f ll ld b d d
2. Low Ambient Temperature - DO NOT weld in
temperatures below 50F (10C). At low tem-
perature conditions, preheating of all welding
joint work areas is required. See preheat and
post heating requirements as detailed in Annex
A.
3 W ld C li P t t th ld f
7/16/2019 930E-4 field Assembly.pdf
47/335
4-2 Field Welding For Assembly Or Repair FAM0403
7. Slag is to be removed from all weld beads, and
must be completely removed before each pass
in a multiple pass procedure. It is also required
that all slag is removed and tie in all areas.
Grind all welds where a weld crosses or inter-
sects with another weld.
MATERIALS, CONTROLS, ANDPRECAUTIONS
The steel used in the fabrication of all Komatsu
equipment is of high strength low alloy (HSLA) mate-
rial of different grades. The standard dump body
main plates are made from abrasion resistant materi-
als. These materials offer themselves very well to
welding during fabrication, and repair.
The welding consumables are often supplied by
Komatsu America Corp. with the new equipment as
part of the field welding / assembly package. For field
welding and repairs, the approved consumables as
detailed, should be procured from a local, reliable
supplier. Other highly specialized welding consum-
ables are available but have limited use on Komatsu
structural components. Approval is required from
your Komatsu customer support manager.
Control of the welding area environment is essential
for producing proper and sound welds. Essentially,
five areas require attention and control.
1. Air Movement - Avoid areas where air move-
ment from wind, drafts, or blowers is prevalent.
This is particularly important when a shielding
gas is being used as part of the welding pro-
cess.
3. Weld Cooling - Protect the weld area from a
rapid cooling rate. Heat retardation may be
accomplished through the use of heat lamps,
torches, insulating blankets, etc.
4. Moisture - Any moisture on the steel surfaces to
be welded must be removed before welding.
Electrodes must be stored in sealed containers
until needed. Electrodes must be kept in a
warming oven at the work location until used to
prevent any moisture absorption which might
affect weld quality.
5. Foreign Materials - Any foreign substances
(dirt, paint, rust, scale, and carbon deposits
from cuttings) must be removed prior to weld-
ing. Clean all weld areas and surfaces with agrinder to ensure that all foreign materials have
been removed.
WELD INSPECTION
All welding repairs are subject to inspection by a
Komatsu appointed inspector or laboratory to insure
quality. After the weld has been made it can be
inspected by a number of non-destructive evaluation
techniques. The inspections can include any of the
methods listed below. All assembly welds and weldrepairs that are deemed unacceptable by the inspec-
tor must be corrected at no additional cost to
Komatsu. All weld repairs are also subject to addi-
tional inspection.
1. Visual Inspection - This is the process of look-
ing for potential defects such as undersized
welds that can be checked with weld gauges
for, surface cracks, surface porosity, craters,
and undercuts.
7/16/2019 930E-4 field Assembly.pdf
48/335
2. Dye Penetrant Inspection - This is an easily
applied process which indicates cracks or sur-
face conditions. The process is relatively inex-
pensive, but does not produce a permanent
record except by normal photography.
3 Fluorescent Penetrant Inspection Similar to
RECORDS
Komatsu requires record keeping of all welding work
This information is valuable when personnel or job
conditions change. The service and warranty depart
ments of Komatsu must be provided with inspection
reports and photographs of the weld area before
during and after the repair The photographs mus
7/16/2019 930E-4 field Assembly.pdf
49/335
FAM0403 Field Welding For Assembly Or Repair 4-3
3. Fluorescent Penetrant Inspection - Similar to
dye penetrant inspection. This process uses ablack (ultraviolet) light for increased efficiency
and accuracy.
4. Magnetic Particle Inspection - This process
requires special equipment that is usually more
costly than the dye penetrant inspections. This
process does not provide a permanent record
except by normal photography.
5. Ultrasonic Inspection- This is a popular method
of examining weld discontinuities. Specialized
equipment and operator certification is required.
With some equipment printed data is available
of the test providing a permanent record. Also,
operator records with equipment settings and
test results are normally recorded.
6. X-Ray Inspection - This process provides a
view of the weld and base materials but it is
highly specialized. This procedure provides a
permanent visual record, but is more expensive
than most other inspection techniques.
during, and after the repair. The photographs mus
be clear and close enough to show the weld joinpreparation complete, with backer bars installed, etc
just prior to welding. These photos easily identify i
the required preheating and post heating have been
done with a three inch circumference around the
weld repair area. Without this documentation
Komatsu will not cover any weld repair claim made
under warranty. No exceptions will be made.
ANNEX A
The following are general repair procedures, which
must be followed for all repair and rework of majo
load carrying members on Komatsu equipment.
1. The repair or rework area must be protected
from wind and moisture during the entire proce
dure. If the repair work is to done outside addi
tional precautions must be taken to protect the
weld repair process from outside elements. Al
welding should be done at an ambient tempera
ture of 10C (50F) or above.
2. Clean and grind the entire repair area toremove all rust, grease, oils, paint, and any
other foreign materials likely to contaminate the
weld.
7/16/2019 930E-4 field Assembly.pdf
50/335
3. Air arc the entire crack leaving a V-shape joint.
The depth of the V (or U shaped) joint will be
determined by the depth of the crack. The width
to depth ratio should be approximately 1.25:1
and never less than 1:1. All cracks through the
parent material will require a slightly wider root
opening than the original, usually 6 mm (0.25
in ) to allow the installation of a backup strip
9. All welds are to be made with approved con-
sumables only. The SMAW (Stick) welding rod
must be used within four hours after being
removed from a new sealed container or from a
52C (125F) minimum drying oven. Any rod
that exceeds this exposure time must be dried
for one hour at 427C (800F) before being
used Keep all weld starts and stops to a mini
7/16/2019 930E-4 field Assembly.pdf
51/335
4-4 Field Welding For Assembly Or Repair FAM0403
in.) to allow the installation of a backup strip.
Backup strips are required for all cracks thathave gone through the parent material and can-
not be welded from both sides. If a weld repair
allows access to both sides of the plate, no
backup strip is required as long as complete
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.5. After air arcing and inspections (Steps 3 & 4) all
areas cut by the air arc should be cleaned thor-
oughly with a grinder to remove all possible car-
bon deposits and dye penetrant.
6. Fill gouges with weld and grind all surfaces
smooth to avoid defects in the new weld.
7. Grind all surfaces to be welded so they are free
of slag, rust, and any other foreign materials.
8. Preheat the entire weld joint area until the sur-
rounding surface area reaches 150C (300F)
at a distance of 76 mm (3 in.) from all areas to
be welded.
used. Keep all weld starts and stops to a mini-
mum.
10. When the weld is complete, immediately (before
the weldment cools) post heat the entire weld
area to 150C (300F). Even if the area is over
150C (300F) heat must be applied to maintain
this temperature for 15 minutes, and then allow
it to cool slowly. In some cases this might
require wrapping with insulation blankets.
11. Grind all butt-welded repairs smooth using 36 or
finer grit grinding material. All grinding marks
should be parallel to the direction of primary
stress if possible (and if known).
12. Hammer peen the toes of repair fillet welds as
detailed in Annex B, see attached.
13. Inspect repaired areas (for surface defects)
using magnetic particle or dye penetrant inspec-
tion procedures.
14. If surface defects are found, remove all defects
by grinding to a maximum depth of 1.5 mm
(0.06 in.). Larger defects must be removed as
per the above mentioned procedures. All spot
welding also requires preheating and post heat-
ing.
7/16/2019 930E-4 field Assembly.pdf
52/335
ANNEX B
1.0 TOE HAMMER PEENING
Equipment:
1. Hand held pneumatic hammer
2. Adequate air supply
3 Adequate lighting
2.0 TOE GRINDING WITH A ROTARY BURR
Equipment:
1. High speed rotary air tool (15,000-20,000 rpm)
7/16/2019 930E-4 field Assembly.pdf
53/335
FAM0403 Field Welding For Assembly Or Repair 4-5
3. Adequate lighting
4. 6 mm (0.25 in.) diameter spherical tip bit
5. Protective clothing, gloves, includes eye, face,
and ear protection.
Procedure
1. The toe of the weld should serve as a guide for
the peening tool resulting in the area of defor-
mation being approximately equally divided
between the base material and the weld metal
face to the specified depth and not to exceed 5
mm (0.19 in.) in width. Refer to Figure 4-1.
NOTE: Peening shall only be performed after weldacceptance by visual inspection.
2. The weld must have a smooth profile and the
toe must have a good transition to the parent
material (no overlap) before the peening opera-
tion is performed. Grinding the weld face and
toe area is permitted to correct unacceptable
conditions. Visual inspection/acceptance is to
be done after peening with the appropriate
radius and depth gauge.
3. Hold the hammer tool at approximately one half
the included angle between the weld face and
the parent material and perpendicular to thedirection of travel. This will normally require
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.).
2. Tungsten carbide rotary burr 13 mm (0.50 in.diameter with 13 mm (0.50 in.) spherical tip
3. Adequate air supply
4. Adequate lighting
5. Protective clothing, gloves, includes eye, face
and ear protection
Procedure
1. The toe of the weld should serve as a guide fo
the burr tool resulting in the material removed
being approximately equally divided between
the base material and the weld metal face to the
specified depth and not exceed 8 mm (0.31 in.in width. Refer to Figure 4-2.
2. The weld must have a smooth profile and the
toe must have a good transition to the paren
material (no overlap) before the grinding opera
tion is performed. Grinding the weld face and
toe area is permitted to correct unacceptable
conditions. Visual inspection/acceptance to be
done after grinding with the appropriate radius
and depth gauge.
3. The axis of the tool should be maintained a
about 45 to the parent plate and inclined a
about 45 to the direction of travel. The depth othe grinding must be between 0.8 mm to 1.0
mm (0.030 to 0.040 in.). The final surface mus
be clean, smooth and free of all traces of under-
cut or slag.
7/16/2019 930E-4 field Assembly.pdf
54/335
7/16/2019 930E-4 field Assembly.pdf
55/335
4-6 Field Welding For Assembly Or Repair FAM0403
FIGURE 4-1. TOE HAMMER PEENING
7/16/2019 930E-4 field Assembly.pdf
56/335
7/16/2019 930E-4 field Assembly.pdf
57/335
FAM0403 Field Welding For Assembly Or Repair 4-7
FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR
7/16/2019 930E-4 field Assembly.pdf
58/335
BIBLIOGRAPHY
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earthmoving and
Construction Equipment
Metals and How to Weld Them - James F. Lincoln
Arc Welding Foundation. Cleveland, Ohio
Procedure Handbook of Arc Welding - Lincoln Elec-tric Company, Cleveland, Ohio
SPECIAL PRECAUTIONS WHENSERVICING AN A/C DRIVE SYSTEMTRUCK
Consult a qualified technician, specifically trained for
servicing the A/C drive system, before welding on the
truck.
The following procedures must be followed to ensurethe safety of maintenance personnel and to help pre-
7/16/2019 930E-4 field Assembly.pdf
59/335
4-8 Field Welding For Assembly Or Repair FAM0403
tric Company, Cleveland, Ohio
American Welding Society - Welding Handbook
British Standard BS5135 - Metal Arc Welding of Car-
bon and Carbon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The
Welding Institute, F. R. Coe, Author
y p p p
vent damage to the equipment.
Anytime the engine is on:
Do not open any of the cabinet doors or
remove any covers.
Do not use power cables for hand holds or
foot steps. Do not touch retarder grid elements.
Before opening any cabinets or touching a grid
element or a power cable, the engine and all
warning lights must be off.
Engine Stop Procedure Prior To Maintenance
Perform the following procedure prior to maintenance
to ensure that no hazardous voltages are present in
the A/C drive system.
1. Before turning off the engine, verify the status
of all the drive system warning lights on the
overhead display panel. Use the lamp test
switch to verify that all lamps are functioning
properly.
2. If all red drive system warning lights are off,
turn the engine off.
3. After the engine has been off for at least five
minutes, inspect the link voltage lights. The
lights are located on the exterior of the main
control cabinet and back wall of the operator's
cab (DID panel). If all lights are off, the retard-ing grids, wheel motors, alternator, and power
cables connecting these devices are safe to
work on.
7/16/2019 930E-4 field Assembly.pdf
60/335
Locate the GF cut-out switch in the access
panel on the left side of the main control cabi-
net. Place the switch in the CUTOUT position.
This will prevent the alternator from re-energiz-
ing and creating system voltage until the switch
is returned to its former position.
After repairs, replace all covers and doors and
place the GF cutout switch and battery discon-nect switches in their original positions. Recon-
t ll h i t t ti th t k
General Welding Guidelines
1. Open the battery disconnect switches and dis
connect the battery charging alternator lead
wire.
2. Disconnect all electrical harnesses from the
Engine Control System (ECS). The ECS is
located inside the electrical cabinet behind the
operator's cab. Disconnect the ground strapfrom the ECS.
7/16/2019 930E-4 field Assembly.pdf
61/335
FAM0403 Field Welding For Assembly Or Repair 4-9
nect all harnesses prior to starting the truck.
Leave the drive system in the rest mode until
the truck is to be moved.
4. If the red lights on the exterior of the control
cabinet and/or the back wall of the operator's
cab continue to be illuminated, a fault has
occurred.
Leave all cabinet doors in place. DO NOT touch
the retard grid elements. DO NOT disconnect
any power cables or use them as hand or foot
holds.
Notify your Komatsu customer service manager
immediately. Only qualified personnel, specifi-
cally trained for servicing the A/C drive system,
may perform this service.
3. 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.
4. DO NOT weld on the rear of the control cabinet
The metal panels on the back of the cabinet are
part of the capacitors and cannot be heated.
5. DO NOT weld on the retard grid exhaust lou
vers.
6. Some power cable panels throughout the truck
are made of aluminum or stainless steel. Theymust be repaired with the same material or the
power cables may be damaged.
7. Power cables must be cleated in wood or othe
non-ferrous materials. DO NOT repair cable
cleats by encircling the power cables with meta
clamps or hardware. Inspect power cable insu
lation prior to servicing the cables and prior to
returning the truck to service. Discard cables
with broken insulation.
8. Protect power cables and wiring harnesses
from weld spatter and heat.
9. DO NOT lay welding cables over or near thevehicle electrical harnesses. Welding voltage
may be induced into the electrical harnesses
and cause damage to components.
10. DO NOT allow welding current to pass through
ball bearings, roller bearings, suspensions, o
hydraulic cylinders.
7/16/2019 930E-4 field Assembly.pdf
62/335
NOTES
7/16/2019 930E-4 field Assembly.pdf
63/335
4-10 Field Welding For Assembly Or Repair FAM0403
7/16/2019 930E-4 field Assembly.pdf
64/335
RECEIVING & ASSEMBLY PREPARATION
1. Inspect all components for possible shipping
damages. Note any damage found and report to
shipping agent.
2. Spread out all parts and organize per unit num-
ber. Check for missing parts. List the unit num-ber of all major components. Verify the cab and
decks are with the correct chassis.
5. Clean all mounting surfaces on the chassis and
on the individual components.
6. Check all electrical connectors and verify they
are free of paint and/or corrosion. Clean any
connector with questionable electrical continu
ity.
7. Check all factory installed components for the
7/16/2019 930E-4 field Assembly.pdf
65/335
FAM0503 Receiving & Assembly Preparation Page 5-1
3. Install support blocks under the chassis. The
support blocks must be approximately 84 cm
(33 in.) high.
4. Install support blocks under the rear axle hous-
ing. The support blocks must be approximately
30 cm (12 in.) high and spread out along the
axle. The support blocks must be a minimum of
51 mm (2 in.) away from the wheel motor
mounting face.
proper tightening torque.
8. Arrange the work site as shown on the following
page.
7/16/2019 930E-4 field Assembly.pdf
66/335
7/16/2019 930E-4 field Assembly.pdf
67/335
Page 5-2 Receiving & Assembly Preparation FAM0503
ASSEMBLYLAYOUT
7/16/2019 930E-4 field Assembly.pdf
68/335
CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines
varies. Photographs or illustrations used in the fol-
lowing procedures are provided as general guide-
lines only. Actual assembly may be different, but this
general procedure provides a basic outline forassembly.
Items like the hydraulic tank and the accumulators
h b d f hi i d ill h t
BASIC ASSEMBLY PROCEDURE
1. Site preparation
2. Unload truck components
3. Assemble the chassis
4. Weld the body
NOTE: Chassis assembly and body welding may be
7/16/2019 930E-4 field Assembly.pdf
69/335
FAM0612 Chassis Assembly Page 6-1
may have been removed for shipping and will have to
be locally installed.
Each shipment may be different, depending on the
truck configuration and destination.
RECOMMENDED ASSEMBLY DATA
1. Service Report (Pre-Delivery)
2. Acknowledgement of Receipt of Company War-
ranty
3. Assembly Blueprints & Schematics
4. Fluid Specifications (refer to the lubrication
chart in Section 10, Appendix)
5. Suspension Oiling & Charging Procedure
(available in Section 10, Appendix)
6. Fan Drive Adjustment Procedure (available in
the engine service manual)
7. Toe-In Adjustment Procedure (Section 10,
Appendix)
8. Hydraulic Checkout Procedure (Section 10,
Appendix)
9. Brake Checkout Procedure (Section 10, Appen-
dix)
10. Propulsion System Checkout Procedure (avail-
able in Section 10 of this manual)
11. Filter List (available in parts book)
12. Lubrication & Service PM Forms (available in
the operation and maintenance manual)
13. Component Weights - for crane reference
(available in Section 3 of this manual)14. Standard Torque Chart (available in Section 10
of this manual)
15. Field Assembly Inspection Report Form (avail-
able in Section 10 of this manual)
done in either order, or simultaneously. The mos
logical order depends on available resources such as
cranes, welders, assemblers, etc.
5. Static checkout (electrical & mechanical)
6. Install the body
7. Dynamic checkout (electrical & mechanical)
8. Site cleanup
7/16/2019 930E-4 field Assembly.pdf
70/335
ORDER OF ASSEMBLY
The assembly procedure is organized in levels. Gen-
erally, the tasks to be done at a given level may be
performed in any convenient order or simultaneously.
However, all tasks in that level must be completed
before proceeding to the next higher level. Each level
depends on the installation of components from the
previous level.
NOTE: As stated earlier, shipping and packaging of
large machines will vary. Some of these steps may
change due to different shipping configurations and/
LEVEL 3
1. Spindles/Hubs
2. Steering Cylinders
3. Tie Rod
LEVEL 41. LH Deck
2. RH Deck/Grid Box
3 Operator Cab
7/16/2019 930E-4 field Assembly.pdf
71/335
Page 6-2 Chassis Assembly FAM0612
g pp g g
or truck options.
LEVEL 1
1. Chassis - Unload and crib for assembly.
2. Auxiliary Control Cabinet (temporary)
3. Deck Support (on horsecollar over suspension).
NOTE: It is easier to install and weld the deck
supports before the front suspensions are installed.
However, do not install the deck supports first, unless
there is a suitable means of installing the suspension
with the deck support in place.
4. Rear Suspension
5. Hydraulic Tank
6. Fuel Tank
7. Front Suspensions
8. Diagonal Ladder
9. Uprights/Air Cleaners10. Diagonal Support Beams (leave loose until left
deck is bolted in place)
NOTE: Do not weld the air cleaner / uprights until all
decks and the operator cab are installed. Ratchet
hoists may be required to help tie all the structures
together for a proper fit.
LEVEL 2
1. Air Cleaner Piping
2. Center Deck
3. Control Cabinet
4. Auxiliary Control Cabinet
3. Operator Cab
LEVEL 5
1. Exhaust Pipes
2. Weld Uprights
3. Blower - Air Intake Ductwork
4. Wheel Motors
LEVEL 6
1. Front Tires
2. Rear Tires
3. Hoist Cylinders
LEVEL 7
1. Clearance Lights
2. Body Pads/Shims/Guides
3. Front Mud Flaps
LEVEL 81. Dump Body Installation
LEVEL 9
1. Hoist Cylinders
2. Rock Ejectors
3. Rear Mud Flaps
7/16/2019 930E-4 field Assembly.pdf
72/335
LEVEL 10
1. Clean the Truck
2. Decals
3. Lighting Wiring
4. Charge Suspensions
5. Charge Accumulators
6. Add Fluids
7. Charge the Air Conditioning System
CHASSIS ASSEMBLY
The photographs referenced in this procedure depic
an actual truck assembly. Assembly at another loca
tion may be different. However, this outline will pro
vide a general basis for assembly.
Follow all safety recommendations in this man
ual. Follow all local, state, and federal regula
7/16/2019 930E-4 field Assembly.pdf
73/335
FAM0612 Chassis Assembly Page 6-3
NOTE: Prior to starting the engine, verify that the
steering pump case is full of oil.
LEVEL 11
1. System Checkouts
2. Exhaust Blankets
3. Clean Assembly Rear4. Touch Up Paint
5. Train Operators
6. Optional - Install Fire Suppression System
ual. Follow all local, state, and federal regula
tions.
In the procedures that follow, many very heavy com
ponents will be required to be lifted into place and
secured.
Inspect all lifting devices. Slings, chains, andcables used for lifting components must beinspected daily for serviceable conditionRefer to the manufacturers guidelines forcorrect capacities and safety procedureswhen lifting components. Replace anyquestionable items.
Slings, chains and cables used for liftingmust be rated for approximately two times theintended load.
When in doubt as to the weight ocomponents or any assembly procedurecontact your customer support manager fofurther information.
Lifting eyes and hooks must be fabricatedfrom the proper materials and rated to lift theintended load.
Never stand beneath a suspended load. Guyropes are recommended for guiding andpositioning a suspended load.
Before lifting, ensure there is adequateclearance from overhead structures oelectric power lines.
7/16/2019 930E-4 field Assembly.pdf
74/335
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 wirebefore welding on the frame or its components.
Fasten the welding machine ground cable to the
component being welded.
GENERAL PRECAUTIONS ANDINSTRUCTION
1. Clean and remove all foreign material from
component mounting surfaces.
2. Mount the front suspensions first so that deck
substructures can be installed while other com-
ponents are installed.
3. DO NOT weld the front uprights until all upper
decks are installed.
4. Install the fuel return hose on the rearward most
fitting on the fuel tank.
5 Torque the deck mounting bolts before the
7/16/2019 930E-4 field Assembly.pdf
75/335
Page 6-4 Chassis Assembly FAM0612
DO NOT allow welding current to pass through
bearings.
DO NOT lay welding cables over truck electrical
cables and harnesses. Welding voltages could be
induced into the truck wiring and cause damage
to components.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly purged andventilated.
Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
charged and in good working condition.
Mark cap screws and nuts with paint or ink after
tightening to the specified torque. This method
provides verification that the hardware has been
properly tightened.
5. Torque the deck mounting bolts before the
exhaust tubes, etc. are installed.
6. Verify all electrical connectors are free from
paint and/or corrosion. Clean any connector
that may be questionable.
7. Do not torque the diagonal ROPS beam until
after the operator cab & LH air intake tubes are
in place.8. Before installing the cab to the substructure, tap
all threaded holes to remove paint.
9. Verify all wiring is properly connected before
attempting to start the engine.
10. Recheck the torque on hardware installed at the
factory.
11. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.
12. Steering accumulators are normally not charged
with nitrogen when shipped from the factory.Use proper precautions when checking the
nitrogen pressureand oil level in the cylinder.
13. Brake accumulators are normally charged with
nitrogen when shipped from the factory. Use
proper precautions when checking pressures.
14. Verify the lube system is lubricated, purged and
all levels full prior to start up.
15. Purge air from the steering pump before truck
operation. Pressure will not build in the brake
and steering circuit if air is present. Air in the
system may damage the pump. Refer to the
Hydraulic Checkout Procedure in Section 10 ofthis manual.
16. Use the battery disconnect switch when arc
welding. Connect the weld ground near the
weld area.
7/16/2019 930E-4 field Assembly.pdf
76/335
NOTES
7/16/2019 930E-4 field Assembly.pdf
77/335
FAM0612 Chassis Assembly Page 6-5
7/16/2019 930E-4 field Assembly.pdf
78/335
7/16/2019 930E-4 field Assembly.pdf
79/335
Page 6-6 Chassis Assembly FAM0612
1. Lift the chassis off the truck/trailer (Figure 6-1) or rail car using two cranes with a minimum capacity of 50 tons
each. Place the chassis on adequate support blocks in a level position. The weight of the chassis, asshipped, is approximately 60,382 kg (133,000 lb).
The support blocks must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm (12 in.)
high under the rear axle housing (Figure 6-2). Placement of the chassis at this height will allow easy installa-
tion of truck components.
Thoroughly clean the chassis.
7/16/2019 930E-4 field Assembly.pdf
80/335
7/16/2019 930E-4 field Assembly.pdf
81/335
FAM0612 Chassis Assembly Page 6-7
FIGURE 6-1.
FIGURE 6-2.
7/16/2019 930E-4 field Assembly.pdf
82/335
2. Lift the LH deck support into position. The weight of the deck support is approximately 654 kg (1442 lb).
a. Bolt the support into place.
b. Tack weld the support.
c. The four tapped pads on each support and the corresponding blocks on the horsecollar must be removed
to allow for a complete weld around the joint.
7/16/2019 930E-4 field Assembly.pdf
83/335
Page 6-8 Chassis Assembly FAM0612
d. Remove the plate and backer strip from the back of the LH deck support (see inset in Figure 6-7). Install
the backer strip at the end of the deck support. Install the plate at the end of the deck support.
e. Weld completely around the support without leaving any gaps. Finish welding around the plate.
f. Grind all areas, and clean. Paint after welding is complete.
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.
Refer to Figures 6-3 thru 6-8.
Repeat for the RH deck support. The weight of the deck support is approximately 273 kg (602 lb).
7/16/2019 930E-4 field Assembly.pdf
84/335
7/16/2019 930E-4 field Assembly.pdf
85/335
FAM0612 Chassis Assembly Page 6-9
FIGURE 6-3.
FIGURE 6-4.
7/16/2019 930E-4 field Assembly.pdf
86/335
7/16/2019 930E-4 field Assembly.pdf
87/335
Page 6-10 Chassis Assembly FAM0612
FIGURE 6-5.
FIGURE 6-6.
7/16/2019 930E-4 field Assembly.pdf
88/335
7/16/2019 930E-4 field Assembly.pdf
89/335
FAM0612 Chassis Assembly Page 6-11
FIGURE 6-7.
FIGURE 6-8.
7/16/2019 930E-4 field Assembly.pdf
90/335
7/16/2019 930E-4 field Assembly.pdf
91/335
Page 6-12 Chassis Assembly FAM0612
3. Position the top rear suspension eye between the ears on the frame, as shown in Figure 6-9.
4. Lubricate pin (1). Align the retaining cap screw hole with the hole in the mounting bore, and partially push the
pin in until secure.
5. Insert spacer (4) and continue to push the pin in through the spherical bearing. Insert the remaining spacer
and continue to install the pin in until the retaining cap screw hole is aligned with the hole in the pin.
NOTE: Note the proper orientation of the spacers as shown in Figure 6-9.
6. Install cap screw (2) and locknut (3). Tighten to 465 Nm (343 ft lb).
7/16/2019 930E-4 field Assembly.pdf
92/335
7/16/2019 930E-4 field Assembly.pdf
93/335
FAM0612 Chassis Assembly Page 6-13
FIGURE 6-9. REAR SUSPENSION MOUNTING PIN
(Typical, Top and Bottom)
1. Pin
2. Retainer Cap Screw3. Locknut
4. Bearing Spacer
5. Retainer Ring
6. Bearing
7. Cap Screw8. Washer
9. Sleeve
7/16/2019 930E-4 field Assembly.pdf
94/335
7. Clean the mounts for the hydraulic tank.
8. Lift the tank into position. (Figure 6-10). The weight of the hydraulic tank is approximately 731 kg (1612 lb).
Tighten the four mounting cap screws near the top of the tank to 622 62 Nm (459 46 ft lb).
Tighten the two mounting cap screws near the bottom of the tank to 800 80 Nm (590 59 ft lb).
7/16/2019 930E-4 field Assembly.pdf
95/335
Page 6-14 Chassis Assembly FAM0612
10. Clean the mounts for the fuel tank and lift the tank into position. (Figure 6-11) The weight of the fuel tank is
approximately 1690 kg (3725 lb).
Tighten the four mounting cap screws near the top of the tank to 712 71 Nm (525 52 ft lb).
Tighten the four mounting cap screws near the bottom of the tank to 298 30 Nm (220 22 ft lb).
7/16/2019 930E-4 field Assembly.pdf
96/335
7/16/2019 930E-4 field Assembly.pdf
97/335
FAM0612 Chassis Assembly Page 6-15
FIGURE 6-10.
FIGURE 6-11.
7/16/2019 930E-4 field Assembly.pdf
98/335
7/16/2019 930E-4 field Assembly.pdf
99/335
Page 6-16 Chassis Assembly FAM0612
10. Connect the piping to the hydraulic tank and properly tighten all fittings.
Refer to Figures 6-12 and 6-13.
NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened. The valves
are open when the handles are parallel with the hoses.
7/16/2019 930E-4 field Assembly.pdf
100/335
7/16/2019 930E-4 field Assembly.pdf
101/335
FAM0612 Chassis Assembly Page 6-17
FIGURE 6-12.
FIGURE 6-13.
7/16/2019 930E-4 field Assembly.pdf
102/335
11. Install the two hoist filters onto the bracket at the inner side of the fuel tank. Connect the fuel supply and return
lines to the fuel tank.
Refer to Figure 6-14.
7/16/2019 930E-4 field Assembly.pdf
103/335
Page 6-18 Chassis Assembly FAM0612
12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.
Refer to Figure 6-15.
7/16/2019 930E-4 field Assembly.pdf
104/335
7/16/2019 930E-4 field Assembly.pdf
105/335
FAM0612 Chassis Assembly Page 6-19
FIGURE 6-14.
FIGURE 6-15.
7/16/2019 930E-4 field Assembly.pdf
106/335
13. Lift the front suspension into position. Refer to Figure 6-18. The weight of each front suspension cylinder is
approximately 2790 kg (6150 lb). Lubricate the cap screw threads, cap screw head seats and nut seats with
rust preventive grease. The hardware for the front suspension must be tightened according to the "turn-of-
the-nut" method as described below.
"Turn-Of-The-Nut" Tightening Procedure
a. Tighten all 14 cap screws (1, 6, 8, Figure 6-19) to 542 5 Nm (400 40 ft lb).
b. Maintain this torque on the top two corner
cap screws and the bottom, outer four cap
screws (without spacers).
c. Loosen the eight remaining cap screws and
then tighten again as follows:
d. For the four cap screws (1, Figure 6-19) at
the upper mount, initially tighten the cap
screws to 95 Nm (70 ft lb), then advance
the cap screw head 60 as outlined in Steps
d-1 through d-3 Refer to Figure 6-16
1.) Mark a reference line on a corner of the
hexagonal cap screw head or nut and the
mounting surface opposite this corner, as
shown. Then mark the position located
60 or 120 clockwise relative to the first
reference line on the mounting surface.
Refer to Figures 6-16 and 6-17.
2.) Scribe a reference mark at the opposite
end of the turning member to ensure that
either the cap screw head or nut, remains
stationary.
3.) Each corner of a hexagon represents 60.
7/16/2019 930E-4 field Assembly.pdf
107/335
Page 6-20 Chassis Assembly FAM0612
d 1 through d 3. Refer to Figure 6 16.
For the bottom four cap screws (6, Figure
6-19), initially tighten the cap screws to 136
Nm (100 ft lb), then advance the cap
screw head 120 as outlined in Steps d-1
through d-3. Refer to Figure 6-17.
The turning member, either the cap screwhead or nut, is turned until the marked
corner is adjacent with the marked refer-
ence line. Ensure that the opposite end of
the turning member has NOT turned dur-
ing the tightening procedure.
NOTE: Do not exceed 4 rpm tightening
speed. Do not hammer or jerk the wrench
during the tightening procedure.
e. Loosen the top two corner cap screws (1)
and the bottom outer four cap screws (8),
(without spacers).
1.) Tighten the top two corner cap screws to95 Nm (70 ft lb), then advance the cap
screw heads 60.
2.) Tighten the bottom, outer four cap screws
to 271 Nm (200 ft lb), then advance the
cap screw heads 120.
NOTE: If for any reason, these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 cap screws and
repeat the entire process. The hardware must be
cleaned and lubricated.
FIGURE 6-16. 60 DEGREE ADVANCE
FIGURE 6-17. 120 DEGREE ADVANCE
7/16/2019 930E-4 field Assembly.pdf
108/335
7/16/2019 930E-4 field Assembly.pdf
109/335
FAM0612 Chassis Assembly Page 6-21
FIGURE 6-18.
FIGURE 6-19. SUSPENSION INSTALLATION
1. Cap Screws, Washers
2. Nuts, Washers
3. Housing
4. Mounting Surface
5. Shear Bar
6. Cap Screws, Washers
7. Piston
8. Cap Screws, Washers
9. Spacer
10. Nuts, Washers
7/16/2019 930E-4 field Assembly.pdf
110/335
14. Install the diagonal ladder. The weight of the diagonal ladder is approximately 180 kg (397 lb).
Refer to Figure 6-20.
Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.
7/16/2019 930E-4 field Assembly.pdf
111/335
Page 6-22 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
112/335
7/16/2019 930E-4 field Assembly.pdf
113/335
FAM0612 Chassis Assembly Page 6-23
FIGURE 6-20.
7/16/2019 930E-4 field Assembly.pdf
114/335
15. Lift LH & RH uprights into position and install the four cap screws for each upright. Tighten to 465 47 Nm
(343 34 ft lb). The weight of the LH upright is approximately 726 kg (1601 lb). The weight of the RH upright
is approximately 578 kg (1274 lb).
Refer to Figures 6-21 and 6-22.
NOTE: DO NOT weld the torque tubes on the uprights until the decks are installed.
7/16/2019 930E-4 field Assembly.pdf
115/335
Page 6-24 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
116/335
7/16/2019 930E-4 field Assembly.pdf
117/335
FAM0612 Chassis Assembly Page 6-25
FIGURE 6-21.
FIGURE 6-22.
7/16/2019 930E-4 field Assembly.pdf
118/335
16. If installed (some trucks are shipped with the center deck not installed), remove the center deck to enable
easy installation of the air intake tubing and the two diagonal cross tubes. The weight of the center deck is
approximately 250 kg (550 lb).
Refer to Figure 6-23.
7/16/2019 930E-4 field Assembly.pdf
119/335
Page 6-26 Chassis Assembly FAM0612
17. Lift the LH diagonal tube into position (Figure 6-24). The weight of the tube is approximately 135 kg (298 lb).
Do not tighten the cap screws until the deck and the cab are in place.
7/16/2019 930E-4 field Assembly.pdf
120/335FIGURE 6-23.
7/16/2019 930E-4 field Assembly.pdf
121/335
FAM0612 Chassis Assembly Page 6-27
FIGURE 6-24.
7/16/2019 930E-4 field Assembly.pdf
122/335
18. Lift the RH diagonal tube into position (Figure 6-25). The weight of the tube is 68 kg (150 lb). Do not tighten
the cap screws until the decks are in place.
7/16/2019 930E-4 field Assembly.pdf
123/335
Page 6-28 Chassis Assembly FAM0612
19. Lift the six air intake tubes and hump hoses into place. Install and tighten the clamps that secure the hoses.
Refer to Figure 6-26.
7/16/2019 930E-4 field Assembly.pdf
124/335
FIGURE 6 25
7/16/2019 930E-4 field Assembly.pdf
125/335
FAM0612 Chassis Assembly Page 6-29
FIGURE 6-25.
FIGURE 6-26.
7/16/2019 930E-4 field Assembly.pdf
126/335
20. Lift the center deck into position. (Figure 6-27). Tighten the four cap screws to 465 47 Nm (343 34 ft lb).
7/16/2019 930E-4 field Assembly.pdf
127/335
Page 6-30 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
128/335
7/16/2019 930E-4 field Assembly.pdf
129/335
FAM0612 Chassis Assembly Page 6-31
FIGURE 6-27.
7/16/2019 930E-4 field Assembly.pdf
130/335
21. Lift the electrical control cabinet into position. The weight of the cabinet is approximately 3045 kg (6714 lb).
Install the mounting hardware and shims. Tighten the 10 cap screws to 1600 160 Nm (1180 118 ft lb).
Refer to Figure 6-28.
7/16/2019 930E-4 field Assembly.pdf
131/335
Page 6-32 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
132/335
7/16/2019 930E-4 field Assembly.pdf
133/335
FAM0612 Chassis Assembly Page 6-33
FIGURE 6-28.
7/16/2019 930E-4 field Assembly.pdf
134/335
22. Clean the tapered portion of the suspension rod and the bore of the spindle. Lubricate the two surfaces with
multi purpose grease number 2 (5% molybdenum disulphide).
Lift the spindle/brake assembly into position. The weight of each spindle/brake assembly is approximately
5393 kg (11,890 lb). Refer to Figures 6-29 thru 6-33.
A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the
assembly for easier mounting to the suspension.
Lift the retainer plates to the bottom of each suspension using blocks and a hydraulic jack.
Install the fourteen cap screws.
E l ti ht th t 678 N (500 ft lb) C ti t ti ht th i i t f 330
7/16/2019 930E-4 field Assembly.pdf
135/335
Page 6-34 Chassis Assembly FAM0612
Evenly tighten the cap screws to 678 Nm (500 ft lb). Continue to tighten the cap screws in increments of330
Nm (250 ft lb) until 2705 270 Nm (1,995 200 ft lb) is reached.
After installation is complete, connect the brake piping to each brake.
7/16/2019 930E-4 field Assembly.pdf
136/335
7/16/2019 930E-4 field Assembly.pdf
137/335
FAM0612 Chassis Assembly Page 6-35
FIGURE 6-29.
7/16/2019 930E-4 field Assembly.pdf
138/335
7/16/2019 930E-4 field Assembly.pdf
139/335
Page 6-36 Chassis Assembly FAM0612
FIGURE 6-30.
FIGURE 6-34
FIGURE 6-31.
7/16/2019 930E-4 field Assembly.pdf
140/335
7/16/2019 930E-4 field Assembly.pdf
141/335
FAM0612 Chassis Assembly Page 6-37
FIGURE 6-32.
FIGURE 6-33.
7/16/2019 930E-4 field Assembly.pdf
142/335
23. Connect the steering cylinders and the tie rod to the steering arms.
The tie rod toe-in must be adjusted once the tires and the body are installed. The toe-in adjustment procedure
is located in Section 10, Appendix.
Refer to Figure 6-34.
7/16/2019 930E-4 field Assembly.pdf
143/335
Page 6-38 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
144/335
7/16/2019 930E-4 field Assembly.pdf
145/335
FAM0612 Chassis Assembly Page 6-39
FIGURE 6-34.
7/16/2019 930E-4 field Assembly.pdf
146/335
24. Install the handrails and lift the LH deck into place (Figure 6-35). The weight of the LH deck with handrails is
approximately 720 kg (1587 lb). Loosely install the eight cap screws.
After all decking is in place, tighten the cap screws on each deck to 465 47 Nm (343 34 ft lb).
7/16/2019 930E-4 field Assembly.pdf
147/335
Page 6-40 Chassis Assembly FAM0612
25. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 3082 kg (6795 lb).
Tighten the eight cap screws to 800 80 Nm (590 59 ft lb).
26. Install the handrails on the RH deck.
27. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approxi-
mately 4100 kg (9039 lb). Refer to Figure 6-36.
7/16/2019 930E-4 field Assembly.pdf
148/335
FIGURE 6-35.
7/16/2019 930E-4 field Assembly.pdf
149/335
FAM0612 Chassis Assembly Page 6-41
FIGURE 6-36.
7/16/2019 930E-4 field Assembly.pdf
150/335
28. Lift the operator cab into position. The weight of the cab is approximately 2725 kg (6008 lb). Refer to Figures
6-37 and 6-38.
Remove any paint from the cab mounting holes.
Determine if shims are required at each mounting pad. The gap between the cab and the ROPS support must
not exceed 1 mm (0.039 in.). Install shims at each mounting pad as required.
Install and tighten the thirty two cap screws to 800 80 Nm (590 59 ft lb).
29. Tighten the hardware for the diagnonal tubes. For the RH tube, tighten the 12 cap screws to 240 24 Nm
(177 17 ft lb). For the LH tube, tighten the 16 cap screws to 800 80 Nm (590 59 ft lb).
7/16/2019 930E-4 field Assembly.pdf
151/335
Page 6-42 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
152/335
FIGURE 6-37.
7/16/2019 930E-4 field Assembly.pdf
153/335
FAM0612 Chassis Assembly Page 6-43
FIGURE 6-38.
7/16/2019 930E-4 field Assembly.pdf
154/335
30. Weld the LH & RH uprights to the front frame tube. Refer to Figure 6-39.
7/16/2019 930E-4 field Assembly.pdf
155/335
Page 6-44 Chassis Assembly FAM0612
31. Lift the two bumper extensions into place. Refer to Figure 6-40.
Tighten the cap screws to standard torque.
7/16/2019 930E-4 field Assembly.pdf
156/335
FIGURE 6-39.
7/16/2019 930E-4 field Assembly.pdf
157/335
FAM0612 Chassis Assembly Page 6-45
FIGURE 6-40.
7/16/2019 930E-4 field Assembly.pdf
158/335
32. Install any remaining handrails. Tighten the cap screws to standard torque.
7/16/2019 930E-4 field Assembly.pdf
159/335
Page 6-46 Chassis Assembly FAM0612
7/16/2019 930E-4 field Assembly.pdf
160/335
7/16/2019 930E-4 field Assembly.pdf
161/335
FAM0612 Chassis Assembly Page 6-47
FIGURE 6-41.