COMPONENT CODE 5A

PARTS & SERVICE REF NO. AA15122A

DATE July 26, 2016
(C)
NEWS Page 1 of 4

SUBJECT: FRONT SUSPENSION CYLINDER CAP CAPSCREW IMPROVEMENT

PURPOSE: To inform the field of an improved front suspension cylinder cap kit.
APPLICATION: Komatsu Electric Drive Dump Trucks:
930E-2: A30012, A30098, A30100, A30121-A30293, A30295-A30303;
930E-2SE: A30183;
930E-3: A30294, A30304-A30461;
930E-3SE: A30171-A30389;
930E-4: A30462 & Up;
930E-4AT: A30504 & Up;
930E-4SE: A30587 & Up
FAILURE CODE: 5A30FF
DESCRIPTION:

Komatsu has identified a improvement to the front suspension that will reduce wear on the front suspension
A cylinder cap capscrews. Kit (58F-00-10701) adds spacers and longer capscrews to provide a more robust
joint. See Table 1.

TABLE 1. FRONT SUSPENSION CAP SPACER KIT (58F-00-10701)

Item Part Number Description Quantity

1 58E-06-02740 PLM Harness 1

2 58E-06-10051 Pressure Sensor 1

3 58F-50-00090 Cover 1
A 4 58F-50-00500 Spacer 2

5 VH2584 Terminal Ring 3

6 VM5587 Condulet Locknut 1

7 VM5736 Cord Grip 1

8 VN9161 Capscrew - 7/8" - 9NC X 5" 24

9 WA0363 Flat Washer - 7/8" 24

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Read the entire procedure below and ensure all safety precautions are taken before performing this
removal and installation. REFER TO TRUCK SHOP MANUAL for additional information on raising
a truck with a jack, securing a raised truck, relieving nitrogen pressure and oiling and charging the
suspension. Failure to follow these procedures and precautions could result in serious injury up to and
including death.

Kit Installation
1. Park and secure truck.
2. Block and secure the front end of the truck to remove weight from the front tires.
3. Discharge the nitrogen pressure from the front suspension.
4. Disconnect the PLM pressure sensor wires in the appropriate junction box. Remove the existing
PLM sensor cover and pressure sensor. Do not discard the sensor cover hardware.
5. Remove and discard the existing capscrews and washers from the cylinder cap.
6. Inspect the suspension housing threads for damage. Repair as needed.
7. Install spacers (4, Figure 1). Align the gap between the spacers with the lifting eye holes. See Figure 3.
8. Apply a lithium based grease to the threads, underside of capscrews (8) and bolt side of flat washers (9).

Do not use special friction-reducing lubricants, such as CopperCoat TM, Never-Seez®, or other similar
products, on the threads of standard capscrews. The use of special friction-reducing lubricants will
significantly alter the clamping/torque force being applied to capscrews during the tightening process.
Excessive stress may occur and the capscrews could break.

9. Install all capscrews (8) and flat washers (9) hand tight, then tighten to 68 N·m ± 14 N·m (50 ± 10 ft
lb) in the numbered sequence shown in Figure 3. Use a marker to write the number on the top of the
capscrews after each has been tightened.
10. Use a calibrated torque wrench to tighten the capscrews to 678 ± 68 N·m (500 ± 50 ft lb) in the num-
bered sequence shown in Figure 3.
11. Install new pressure sensor (2).
12. Use the existing hardware to install cover (3) over the sensor. Tighten the capscrews to 34 ± 4 N·m
(25 ± 3 ft lb).
13. Connect PLM harness (1) to pressure sensor (2) and route the harness to the appropriate junction box
using the existing clamps and hardware. Use new cord grip (7) and condulet locknut (6) to connect
the PLM harness to the junction box.

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JUNCTION BOX
9 6
7
1

3
2 5
4

73415

A FIGURE 1. FRONT SUSPENSION CYLINDER CAPSCREW KIT (58F-00-10701)

1. PLM Harness 4. Spacer 7. Cord Grip
2. Pressure Sensor 5. Ring Terminal 8. Capscrew
3. Cover 6. Condulet Locknut 9. Flat Washer

4
9

BEFORE AFTER 73423

FIGURE 2. BEFORE AND AFTER KIT INSTALLATION (58F-00-10701)

A
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14. Cut off any excess cable from the PLM harness and strip back the cable jacket to expose the wire
conductors.
15. Label each of the wires in the PLM harness. See Table 2. Use the terminal rings provided with the kit
to terminate each wire to the appropriate location in the junction box.
16. Oil and charge the suspension. Refer to the shop manual for the procedures.
17. Test the new PLM sensor by using the IM software to verify operation.

ALIGN THE GAP BETWEEN THE SPACERS

WITH THE LIFTING EYE HOLES

5 1 24
9 20
13 16
17 12
21 8

3 4
7 22
11 18
15 14
19 10
23 2 6

73416

FIGURE 3. CAPSCREW TIGHTENING PATTERN

TABLE 2. PLM HARNESS WIRE LABELING

Sensor Circuit Color From Pin To Location

39F Black 1 TB90-D

Right Front 39FC White 2 TB90-E

SHLD Bare - TB90-F

39F Black 1 TB70-D

Left Front 39FC White 2 TB70-E

SHLD Bare - TB70-F

AA15122A