COMPONENT CODE 4A

PARTS & SERVICE REF NO. AA02193C

DATE February 28, 2012
(C)
NEWS Page 1 of 8
This Parts & Service News supersedes the previous issuance, AA02193B, dated April 28, 2011. Discard AA02193B.

SUBJECT: STEERING PIN JOINT WEAR LIMITS

PURPOSE: To inform the field of wear specifications for steering pin joints.
APPLICATION: Komatsu Electric Drive Dump Trucks:
630E: (AFE46): 31670-32866, A31435 & Up;
630E: (AFE42): 31678-32848, A31431 & Up;
685E: 31402 & Up;
730E: 32530-32845, A30079 & Up;
830E: 31320-32825, A30544 & Up;
830E-AC: A30001-A30071, A30079-A30108;
830E-1AC: A30072-A30078, A30109 & Up;
860E-1K: A30031 & Up;
860E-1KT: A30003 & Up;
930E: 32604-32816, A30019, A30026-A30120;
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-4SE: A30587 & Up;
960E-1: A30001, A30003 & Up;
960E-1K: A30002, A50003 & Up
Komatsu Mechanical Drive Dump Trucks:
530M: A30001-A30038, 32628;
HD1500-5: A30039-A30160;
HD1500-7: A30001 & Up
FAILURE CODE: 4A10GE
DESCRIPTION:

Steering pin joint wear limits are now available for determining the condition of the pin joints on steering
cylinders and tie rods. Wear specifications for these assemblies are listed in Table 1.

Use extreme caution when performing maintenance on any vehicle with an active steering system.
Serious injury or death can result from contact with moving parts. Always keep a safe distance from
crush points.

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MEASURING STEERING PIN JOINT
WEAR
Required Tools
• Digital dial indicator with remote read
function (Mahr’s: MarCator 1080)
Measurement
To measure the total clearance of the steering pin
joints, perform the following steps:
1. Attach the base of a dial indicator to the tie
rod or steering cylinder to be measured. Use
a digital indicator with remote-read capabil- FIGURE 1. TIE ROD PIN JOINT
ities so that someone is not required to be 1. Steering Arm 3. Indicator Base
under the truck while performing step 3. 2. Indicator Plunger 4. Tie Rod
2. Place the indicator plunger against the
steering arm (or frame for inboard cylinder
joints). Set the plunger at mid-stroke and
then zero the indicator. Refer to Figures 1-3
for indicator set up.
NOTE: As an alternate setup, the base of the dial
indicator may be attached to the steering arm or
the frame while placing the indicator plunger
against the steering cylinder eye or tie rod eye.

3. Turn the front wheels in both directions just

enough to remove the pin play and record
the total indicator movement.
4. Compare the total indicator movement to FIGURE 2. STEERING CYLINDER PIN
the maximum allowable wear (clearance JOINT
limit) in Table 1. 1. Steering Arm 3. Indicator Base
2. Indicator Plunger 4. Steering Cylinder
If total joint clearance exceeds the limit
specified in Table 1, replace the worn com-
ponents. Use items 2, 3, 4, 5 and 6 in Table
1 as a guide to determine which compo-
nents to replace. The press fit between the
spherical bearings and the cylinder and tie
rod housings must be maintained.

FIGURE 3. DATA SET UP

1. Laptop Computer 2. Indicator Data Cable
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If premature wear of the bearings is evident, It is also important to ensure that steering
check the automatic lubrication system to linkage components are tightened to the
ensure the proper amount of lubrication is proper torque. Refer to the appropriate shop
being received at the joint(s) in question. If manual for information on proper torque
lubrication is done manually, ensure that a specifications.
sufficient amount of grease is being applied
regularly. Refer to the appropriate shop
manual for information on proper lubrica-
tion intervals.

FIGURE 4. SPHERICAL BEARING WEAR LIMITS

2. Bearing To Pin Clearance 5. Pin To Arm/Frame Clearance(1)
3. Inner To Outer Bushing Clearance 6. Rod Eye To Bearing Clearance
4. Pin To Arm/Frame Clearance (1)
(1)
Some models are equipped with sleeves between the pin and frame/steering arm.

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TABLE 1. STEERING LINKAGE WEAR SPECIFICATIONS

Criteria

Model No. Location Standard Tolerance Standard Clearance Remedy

Size Shaft Hole Clearance Limit

1.28 mm
1 Total joint clearance --- --- --- ---
0.050 in.

-0.005 mm 0.000 mm 0.005 mm

Bearing To Pin Clear- 50.800 mm -0.0002 in. 0.0000 in. 0.0002 in. 0.03 mm
2
ance 2.0000 in. -0.030 mm -0.001 mm 0.030 mm 0.001 in.
-0.0011 in. 0.0000 in. 0.0011 in.

Inner To Outer Bush- 73.025 mm --- --- --- 0.74 mm

3
ing Clearance 2.8750 in. --- --- --- 0.029 in.

-0.005 mm 0.051 mm -0.046 mm

Pin To Arm/Frame 50.800 mm -0.0002 in. 0.0020 in. -0.0018 in. 0.08 mm
630E, 685E 4 Replace
Clearance 2.0000 in. -0.030 mm -0.051 mm 0.081 mm 0.003 in.
-0.0011 in. -0.0020 in. 0.0032 in.

0.013 mm 0.051 mm -0.064 mm

Pin To Arm/Frame 66.700 mm 0.0005 in. 0.0020 in. -0.0025 in. 0.06 mm
5
Clearance 2.6260 in. -0.013 mm -0.051 mm 0.064 mm 0.002 in.
-0.0005 in. -0.0020 in. 0.0025 in.

0.000 mm -0.013 mm -0.048 mm

Rod Eye To Bearing 80.963 mm 0.0000 in. -0.0005 in. -0.0019 in.
6 N/A
Clearance 3.1880 in. -0.015 mm -0.048 mm 0.002 mm
-0.0005 in. -0.0019 in. 0.0000 in.

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TABLE 1. STEERING LINKAGE WEAR SPECIFICATIONS

Criteria

Model No. Location Standard Tolerance Standard Clearance Remedy

Size Shaft Hole Clearance Limit

1.28 mm
1 Total joint clearance --- --- --- ---
0.050 in.

-0.029 mm 0.000 mm 0.014 mm

Bearing To Pin Clear- 57.150 mm -0.0011 in. 0.0000 in. 0.0006 in. 0.05 mm
2
ance 2.2500 in. -0.049 mm -0.015 mm 0.049 mm 0.002 in.
-0.0019 in. -0.0006 in. 0.0019 in.

Inner To Outer Bush- 84.455 mm --- --- --- 0.84 mm

3
ing Clearance 3.3250 in. --- --- --- 0.033 in.

-0.029 mm 0.025 mm 0.004 mm

Pin To Arm/Frame 57.150 mm -0.0011 in. 0.0010 in. 0.0002 in. 0.07 mm
730E 4
Clearance 2.2500 in. -0.049 mm -0.025 mm 0.074 mm 0.003 in.
-0.0019 in. -0.0010 in. 0.0029 in.

-0.025 mm 0.025 mm 0.000 mm

Pin To Arm/Frame 72.542 mm -0.0010 in. 0.0010 in. 0.0000 in. 0.08 mm
5
Clearance 2.8560 in. -0.051 mm -0.025 mm 0.076 mm 0.003 in.
-0.0020 in. -0.0010 in. 0.0030 in.

0.000 mm -0.039 mm -0.073 mm

Rod Eye To Bearing 90.488 mm 0.0000 in. -0.0015 in. -0.0029 in.
6 N/A
Clearance 3.5625 in. -0.020 mm -0.073 mm -0.019 mm
-0.0008 in. -0.0029 in. -0.0008 in.
Replace
1.28 mm
1 Total joint clearance --- --- --- ---
0.050 in.

-0.025 mm 0.000 mm 0.010 mm

Bearing To Pin Clear- 63.500 mm -0.0010 in. 0.0000 in. 0.0004 in. 0.05 mm
2
ance 2.5000 in. -0.051 mm -0.015 mm 0.051 mm 0.002 in.
-0.0020 in. -0.0006 in. 0.0020 in.

Inner To Outer Bush- 91.186 mm --- --- --- 0.91 mm

3
ing Clearance 3.5900 in. --- --- --- 0.036 in.

-0.025 mm 0.025 mm 0.000 mm

Pin To Arm/Frame 63.500 mm -0.0010 in. 0.0010 in. 0.0000 in. 0.08 mm
830E 4
Clearance 2.5000 in. -0.051 mm -0.025 mm 0.076 mm 0.003 in.
-0.0020 in. -0.0010 in. 0.0030 in.

-0.025 mm 0.025 mm 0.000 mm

Pin To Arm/Frame 82.931 mm -0.0010 in. 0.0010 in. 0.0000 in. 0.08 mm
5
Clearance 3.2650 in. -0.051 mm -0.025 mm 0.076 mm 0.003 in.
-0.0020 in. -0.0010 in. 0.0030 in.

0.000 mm -0.041 mm -0.076 mm

Rod Eye To Bearing 100.013 mm 0.0000 in. -0.0016 in. -0.0030 in.
6 N/A
Clearance 3.9375 in. -0.020 mm -0.076 mm -0.021 mm
-0.0008 in. -0.0030 in. -0.0008 in.

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TABLE 1. STEERING LINKAGE WEAR SPECIFICATIONS

Criteria

Model No. Location Standard Tolerance Standard Clearance Remedy

Size Shaft Hole Clearance Limit

1.28 mm
1 Total joint clearance --- --- --- ---
0.050 in.

-0.025 mm 0.000 mm 0.010 mm

Bearing To Pin Clear- 69.850 mm -0.0010 in. 0.0000 in. 0.0004 in. 0.05 mm
2
ance 2.7500 in. -0.051 mm -0.015 mm 0.051 mm 0.002 in.
-0.0020 in. -0.0006 in. 0.0020 in.

Inner To Outer Bush- 100.330 mm --- --- --- 1.00 mm

3
ing Clearance 3.9500 in. --- --- --- 0.040 in.

-0.025 mm 0.025 mm 0.000 mm

Pin To Arm/Frame 69.850 mm -0.0010 in. 0.0010 in. 0.0000 in. 1.01 mm
930E-1 4 Replace
Clearance 2.7500 in. -0.051 mm -0.025 mm 0.076 mm 0.040 in.
-0.0020 in. -0.0010 in. 0.0030 in.

-0.025 mm 0.025 mm 0.000 mm

Pin To Arm/Frame 85.801 mm -0.0010 in. 0.0010 in. 0.0000 in. 0.08 mm
5
Clearance 3.3780 in. -0.051 mm -0.025 mm -0.076 mm 0.003 in.
-0.0020 in. -0.0010 in. -0.0030 in.

0.000 mm -0.041 mm -0.076 mm

Rod Eye To Bearing 111.125 mm 0.0000 in. -0.0016 in. -0.0030 in.
6 N/A
Clearance 4.3750 in. -0.020 mm -0.076 mm -0.021 mm
-0.0008 in. -0.0030 in. -0.0008 in.

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TABLE 1. STEERING LINKAGE WEAR SPECIFICATIONS

Criteria

Model No. Location Standard Tolerance Standard Clearance Remedy

Size Shaft Hole Clearance Limit

1.28 mm
1 Total joint clearance --- --- --- ---
0.050 in.

-0.025 mm 0.000 mm 0.010 mm

Bearing To Pin Clear- 76.200 mm -0.0010 in. 0.0000 in. 0.0004 in. 0.05 mm
2
ance 3.0000 in. -0.051 mm -0.015 mm 0.051 mm 0.002 in.
-0.0020 in. -0.0006 in. 0.0020 in.

Inner To Outer Bush- 109.538 mm --- --- --- 1.10 mm

3
ing Clearance 4.3125 in. --- --- --- 0.043 in.

-0.025 mm 0.025 mm 0.000 mm

Pin To Arm/Frame 76.200 mm -0.0010 in. 0.0010 in. 0.0000 in. 0.08 mm
930E-2, 4
Clearance 3.0000 in. -0.051 mm -0.025 mm 0.076 mm 0.003 in.
930E-3,
-0.0020 in. -0.0010 in. 0.0030 in.
930E-4; Replace
-0.025 mm 0.025 mm 0.000 mm
860E -0.0010 in. 0.0010 in. 0.0000 in.
Pin To Arm/Frame 92.151 mm 0.08 mm
Clearance (930) 3.6280 in. -0.051 mm -0.025 mm 0.076 mm 0.003 in.
-0.0020 in. -0.0010 in. 0.0030 in.
5
-0.028 mm 0.025 mm 0.003 mm
Pin To Arm/Frame 92.151 mm -0.0011 in. 0.0010 in. 0.0001 in. 0.07 mm
Clearance (860) 3.6280 in. -0.048 mm -0.025 mm 0.073 mm 0.003 in.
-0.0019 in. -0.0010 in. 0.0029 in.

0.000 mm -0.051 mm -0.087 mm

Rod Eye To Bearing 120.650 mm 0.0000 in. -0.0020 in. -0.0034 in.
6 N/A
Clearance 4.7500 in. -0.020 mm -0.087 mm -0.031 mm
-0.0008 in. -0.0034 in. -0.0012 in.

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TABLE 1. STEERING LINKAGE WEAR SPECIFICATIONS

Criteria

Model No. Location Standard Tolerance Standard Clearance Remedy

Size Shaft Hole Clearance Limit

1.28 mm
1 Total joint clearance --- --- --- ---
0.050 in.

-0.036 mm 0.000 mm 0.016 mm

Bearing To Pin Clear- 82.550 mm -0.0014 in. 0.0000 in. 0.0006 in. 0.06 mm
2
ance 3.2500 in. -0.056 mm -0.020 mm 0.056 mm 0.002 in.
-0.0022 in. -0.0008 in. 0.0022 in.

Inner To Outer Bush- 128.016 mm --- --- --- 1.28 mm

3
ing Clearance 5.0400 in. --- --- --- 0.050 in.

-0.036 mm 0.081 mm 0.067 mm

Pin To Arm/Frame 82.550 mm -0.0014 in. 0.0032 in. 0.0026 in. 0.14 mm
960E 4
Clearance 3.2500 in. -0.056 mm 0.031 mm 0.137 mm 0.006 in.
-0.0022 in. 0.0012 in. 0.0054 in.

0.010 mm 0.125 mm 0.065 mm

Pin To Arm/Frame 98.500 mm 0.0004 in. 0.0049 in. 0.0026 in. 0.14 mm
5
Clearance 3.8780 in. -0.010 mm 0.075 mm 0.135 mm 0.006 in.
-0.0004 in. 0.0030 in. 0.0053 in.

0.000 mm -0.049 mm -0.089 mm

Rod Eye To Bearing 139.700 mm 0.0000 in. -0.0019 in. -0.0035 in.
6 N/A
Clearance 5.5000 in. -0.025 mm -0.089 mm -0.024 mm
-0.0010 in. -0.0035 in. -0.0010 in.
Replace
1.20 mm
1 Total joint clearance --- --- --- ---
0.047 in.

-0.030 mm 0.046 mm 0.030 mm

Bearing To Pin Clear- 60.000 mm -0.0011 in. 0.0018 in. 0.0011 in. 0.12 mm
2
ance 2.3620 in. -0.076 mm 0.000 mm 0.122 mm 0.005 in.
-0.0030 in. 0.0000 in. 0.0048 in.

Inner To Outer Bush- 120.000 mm --- --- --- 1.20 mm

3
ing Clearance 4.7240 in. --- --- --- 0.047 in.

-0.030 mm 0.076 mm 0.060 mm

530M, Pin To Arm/Frame 60.000 mm -0.0011 in. 0.0030 in. 0.0024 in. 0.15 mm
HD1500 4
Clearance 2.3620 in. -0.076 mm 0.030 mm 0.152 mm 0.006 in.
-0.0030 in. 0.0011 in. 0.0060 in.

-0.030 mm 0.076 mm 0.060 mm

Pin To Arm/Frame 60.000 mm -0.0011 in. 0.0030 in. 0.0024 in. 0.15 mm
5
Clearance 2.3620 in. -0.076 mm 0.030 mm 0.152 mm 0.006 in.
-0.0030 in. 0.0011 in. 0.0060 in.

0.040 mm 0.040 mm -0.040 mm

Rod Eye To Bearing 135.000 mm 0.0016 in. 0.0016 in. -0.0016 in. 0.03 mm
6
Clearance 5.3150 in. 0.015 mm 0.000 mm 0.025 mm 0.002 in.
0.0005 in. 0.0000 in. 0.0010 in.

AA02193C