KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual SERIAL NUMBERS (SN:A30566 & UP) – PDF DOWNLOAD

CEAW006802

Field Assembly Manual

830E-1AC DUMP TRUCK SERIAL NUMBERS

A30566 & UP

®

FOREWORD This manual is provided to aid assemblers during field assembly of the standard Komatsu 830E-AC dump truck.

Variations of design required for specific truck orders may require some modification of the general procedures outlined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the truck.

General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the current production truck model.

This manual lists metric (SI) and U.S. standard dimensions throughout.

All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated position.

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.

FAM0019 10/11

Introduction

i

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

DANGER Identifies a specific potential hazard which will result in either injury or death if proper precautions are not used.

WARNING identifies a specific potential hazard which may result in either injury or death if proper precautions are not used.

CAUTION is used for general reminders of proper safety practices or to direct the reader’s attention to avoid unsafe or improper practices which may result in damage to the equipment.

ii

Introduction

10/11 FAM0019

TABLE OF CONTENTS

SUBJECT

PAGE NUMBER

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

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

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

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

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

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

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

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

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

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

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

FAM0019 10/11

Introduction

iii

KOMATSU 830E-AC

iv

Introduction

10/11 FAM0019

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 prevailing 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 blocks between the support and the frame to prevent metal to metal contact.

5. Inspect all lifting devices. Refer to the manufacturer'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 positioning a suspended load.

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, sockets, 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 your customer support manager for further information.

Use of Tie-Off Anchor During Maintenance and Repair While working at heights during assembly, maintenance or repair of the haul truck, workers should wear an appropriate fall protection harness and attach it to a tie-off anchor or tie-off point.

Komatsu anchor (58B-98-75190) is available for use with fall protection harnesses. Carefully read and understand the harness maker’s instructions before using any fall protection harness.

The load carrying capacity of anchor (58B-97-75190) is 2 270 kg (5,000 lb).

8. Maintain fire control equipment. Inspect fire extinguishers regularly to ensure they are fully charged and in good working condition.

NOTE: The anchor must not be used for lifting.

9. Cap screws and/or nuts being replaced must be the same grade as originally supplied.

BODY-UP RETENTION CABLE

Before welding, refer to Special Precautions When Servicing An AC Drive System Truck, in Section 4.

10. Disconnect the battery charging alternator lead wire before welding on the frame or its components.

11. When welding, connect the ground cable to the part being welded. DO NOT allow welding current to pass through bearings, engine, etc.

FAM0115 10/11

To avoid serious personal injury or death, the body up retention cable must be installed anytime personnel are required to perform maintenance on the vehicle with the dump body in the raised position.

The Komatsu body-up safety sling can only be used with a Komatsu body. Non-OEM body may not accommodate the Komatsu body-up safety sling.

The end user must ensure that a proper cable/sling is used.

Safety Rules, Tools, & Equipment

F01-1

TOOLS AND EQUIPMENT FOR ASSEMBLY

12. Two, ratchet pullers - 2.7 metric ton (3 ton)

The following equipment is recommended for field assembly of the truck.

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 1. Equipment and tool storage trailer with a lockable door. Approximately 12 x 2.5 m (40 x 8 ft) 2. Cranes

sizes.

• Metric sockets and open end wrenches, 6mm to 36mm.

a. 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.

• Inch sockets and open end wrenches up to 1 3/ 4 in.

• Torque wrenches - 339 N·m (250 ft lb) with 18:1 multiplier. Torque wrenches - 339 N·m (600 ft lb) with 4:1 multiplier. Hydrotorque - 1 1/2 in. drive with capability of 5559 N·m (4100 ft lb) or greater.

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 metric ton (50 ton) crane is also required for this task.

• Box wrench 1 3/8 in. (Snap-On p/n X440B) with

3. One fork lift - 6804 kg (15,000 lb) capacity, with high lift capability.

• Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2

4. Two, 300 amp portable welding units and an oxyacetylene cutting set.

5/8 in. (Snap-On P/N J15042) to tighten front suspension hardware.

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)

F01-2

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) capacity.

11. Chains, lifting cables, slings:

• • • • •

12 inch extension to tighten ROPS cap screws.

Two, 4 point slings, 3 m (10 ft) in length

23. Pry bars

Two, 4 point slings, 2 m (6 ft) in length

24. Solvent - 38 liters (10 gal)

Two, 1 m (4 ft) and two, 2 m (6 ft)

25. Paint remover - 19 liters (5 gal)

Two, 3 m (10 ft) nylon straps

26. Rust preventive grease

Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of rope

27. Body sling if a non OEM body is installed.

Safety Rules, Tools, & Equipment

10/11 FAM0115

LIFTING SLING GENERAL INFORMATION

FAM0115 10/11

Safety Rules, Tools, & Equipment

F01-3

Part Number

Description

Use

EB1759

Nitrogen Charging Kit

Suspension & Accumulator Nitrogen Charging

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

Part Number

Description

Use

EJ2627 (No longer available as complete unit)

Roller Assy.

Power Module Remove & Install

EJ2629

Roller Mount

PC0706

Bearing

TH9449

Bearing Retainer 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

F01-4

Safety Rules, Tools, & Equipment

10/11 FAM0115

Part Number

Description

Use

TZ3535

Offset Box End Wrench, 1, 1/2 in.

Miscellaneous

Part Number

Description

Use

TZ2734

3/4 in. Torque Adapter

Miscellaneous

Part Number

Description

Use

TZ2733

Tubular Handle

Use with TZ2734 & TZ3535

FAM0115 10/11

Safety Rules, Tools, & Equipment

F01-5

Part Number

Description

Use

TY2150

Seal Installation Tool

Front Face Seals

Part Number

Description

Use

TY4576

Sleeve Alignment Tool

Steering Linkage and Tie Rod

TZ0992

Sleeve Alignment Tool

Rear Suspension & AntiSway Bar

Part Number

Description

Use

PB6039

Hydraulic Coupling

Hydraulic Flushing

F01-6

Safety Rules, Tools, & Equipment

10/11 FAM0115

Part Number

Description

Use

PC2525

Harness

Payload Meter Download

Download from Komatsu America Extranet

Software

Payload Meter Data Manager

Part Number

Description

Use

EH7817

Alignment Tool

Upper Hoist Pin

Part Number

Description

TZ2100 TZ2726 TZ2727 TZ2728 TZ2729 TV7567 PB6825

Socket (1 7/8 in.)

Socket (1 1/8 in.)

Socket (2 1/4 in.)

Socket (2 3/4 in.)

Socket (1 1/4 in.)

Socket (1 5/16 in.)

Impact Socket (1 5/8 in.)

FAM0115 10/11

Use

Miscellaneous

Safety Rules, Tools, & Equipment

F01-7

Part Number

Description

Use

TZ2730 TZ2731

Adapter (1-1 1/2 in.)

Adapter (3/4-1 in.)

Socket adapter

Part Number

Description

Use

WA4826 TG1106

Lifting Eye Bolt

Miscellaneous

Part Number

Description

Use

TV1186 TR0532 TR0533

Extension (3 1/2 in.)

Extension (8 in.)

Extension (17 in.)

Miscellaneous

F01-8

Safety Rules, Tools, & Equipment

10/11 FAM0115

HYDRAULIC SYSTEM FLUSHING TOOLS Part Number

Description

Use

XB5776

Hose Assembly

Flush Steering Circuit

PC3074

Flushing Block (bypass hoist cylinders)

Flush Hoist Circuit

Part Number

Description

Use

PC2969

Sling

Body Retention

Part Number

Description

Use

PC0367

Shackle

Body Retention Miscellaneous

HYDRAULIC SYSTEM VACUUM PUMP Part Number XB0887

FAM0115 10/11

Description Vacuum Pump

Use To hold oil back while the system is open.

Safety Rules, Tools, & Equipment

F01-9

F01-10

Safety Rules, Tools, & Equipment

10/11 FAM0115

FAM0115 10/11

Safety Rules, Tools, & Equipment

F01-11

NOTES:

F01-12

Safety Rules, Tools, & Equipment

10/11 FAM0115

TRUCK COMPONENTS AND SPECIFICATIONS Truck And Engine

Operator's Cab

The 830E-AC dump truck is an off-highway, rear dump truck with AC electric drive. The gross vehicle weight is 385 852 kg (850,650 lbs.). The engine is a Komatsu SDA16V160 rated @ 1865 kW (2500 hp).

The operator cab has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab provides wide visibility, with an integral 4-post ROPS/FOPS structure, and an advanced analog operator environment. It includes a tinted safety-glass windshield and power-operated side windows, a deluxe interior with a fully adjustable seat with lumbar support, a fully adjustable tilt/telescope steering wheel, controls mounted within easy reach of the operator, and an analog instrument panel which provides the operator with all instruments and gauges which are necessary to control and/or monitor the truck's operating systems.

Alternator (G.E. GTA-41) The diesel engine drives an in-line alternator at engine speed. The alternator produces AC current which is rectified to DC within the main control cabinet. The rectified DC power is converted back to AC 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.

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.

AC 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 AC induction motors with full-wave AC 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 the directional control lever located on the center console.

Suspension

Power Steering The truck is equipped with a full time power steering system which provides positive steering control with minimum operator effort. The system includes nitrogen-charged accumulators which automatically provide emergency power if the steering hydraulic pressure is reduced below an established minimum.

Dynamic Retarding The dynamic retarding is used to slow the truck during normal operation or control speed coming down a grade. The dynamic retarding ability of the electric system is controlled by the operator through the activation of the retarder pedal in the operators cab and by setting the RSC (Retarder Speed Control).

Dynamic retarding is automatically activated, if the truck speed goes to a preset overspeed setting.

Brake System

HydrairÂŽII 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.

The braking system consists of an all hydraulic actuation system. Depressing the brake pedal actuates wheel-speed single disc front brakes and armaturespeed dual disc rear brakes. The brakes can also be activated by operating a switch on the instrument panel. The brakes will be applied automatically if system pressure decreases below a preset minimum.

The parking brake is integral with the service brake caliper, and is spring-applied and hydraulicallyreleased. The park brake is applied by moving the directional control lever to the PARK position.

FAM0220

Truck Components And Specifications

Page 2-1

FIGURE 2-1. TRUCK COMPONENTS 1.

2.

3.

4.

5.

6.

7.

Operator Cab Reserve Oil System Steps and Ladder Radiator Auto Lubrication Engine Suspension

Page 2-2

8. Wheel Hub 9. Disc Brake

10. Steering Linkage 11. Alternator 12. Hoist Filters 13. Steering Filter 14. Fuel Tank

15. Hoist Cylinder 16. Rear Axle Housing 17. Disc Brake 18. Rear Tires 19. Rear Suspension 20. Rear Axle Hatch

Truck Components And Specifications

21. Hydraulic Tank 22. Hoist and Steering Pump 23. Steering Accumulators

FAM0220

SPECIFICATIONS These specifications are for the standard Komatsu 830E-AC Truck. Customer options may change this listing.

ENGINE Komatsu SDA16V160 (Optional SSDA16V160) No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operating Cycle . . . . . . . . . . . . . . . . . . . . . . 4-Stroke Rated Brake HP. . . . 1865 kW (2500 hp)@ 1900 rpm Flywheel HP . . . . . 1761 kW (2360 hp) @ 1900 rpm Weight* (Wet) 8 558 kg (18,867 lbs) * Weight does not include Radiator, Sub-frame, or Alternator

AC ELECTRIC DRIVE SYSTEM (AC/DC Current)

SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters. (U.S. Gal.) Crankcase * . . . . . . . . . . . . . . . . . 280.0. . . . . (74.0) * Includes Lube Oil Filters Cooling System . . . . . . . . . . . . . . . . 568. . . . . (150) Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542. . . . (1200) Hydraulic System . . . . . . . . . . . . . . . 946. . . . . (250) Hydraulic Tank . . . . . . . . . . . . . . . . . 946. . . . . (250) Wheel Motor Gear Box (each) . . . . . . 38. . . . . . (10) HYDRAULIC SYSTEMS* Pumps Hoist . . . . . . . . . . . . . . . . . . . . . Tandem Gear Pump Rated @ . . . . . 851 lpm (225 gpm) @ 1900 rpm and . . . . . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi) Steering/Brake . . . . . Pressure Compensating Piston Rated @ . . . . . . .246 lpm (65 gpm) @ 1900 rpm and . . . . . . . . . . . . . . . . . . . . . . . .18 961 kPa (2,750 psi) System Relief Pressures

Alternator . . . . . . . . . . . . .General Electric GTA - 41 Dual Impeller, In-Line Blower 255 m3/min (9000 cfm) Motorized Wheels . . . .GEB25 AC Induction Traction Motors Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1 Maximum Speed* . . . . . . . . . 64.5 km/h (40 mph) (*w/40.00-57 Tires and 31.875:1 gear train) *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 . . . . . . . . . . . . 3 207 kW (4,300 hp)

24 VDC ELECTRIC SYSTEM Batteries . . . . 4 x 8D 1450 CCA, 12 volt batteries in Series/Parallel w/Disconnect Switch Alternator . . . . . . . . . . . 24 Volt, 140 Ampere Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt Cranking Motors (2). . . . . . . . . . . . . . . . . . . . .24 Volt

Hoist . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi) Steering/Brakes . . . . . . . . . . .27 580 kPa (4,000 psi) Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . 3-Stage Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized Filtration . . . . . . . . . . . . in-line replaceable elements Suction . . . . . . . . . . . . Single, Full Flow, 100 Mesh Hoist & Steering . . . . . . . . Full Flow, Dual In-Line, . . . . . . . . . . . High Pressure Beta 12 Rating =200 *With Quick Disconnects for powering disabled truck and system diagnostics.

SERVICE BRAKES Actuation . . . . . . . . . . . . . . . . . . . . . . . . All Hydraulic Front . . . . . . . . . . . . . . . . Wheel Speed, Single Disc Inboard Mounted . . . . . . . . . . . . . . . . . 3 Calipers Disc Diameter, O.D. . . . . . . . 1213 mm (47.75 in.)

Rear . . . . . . . . . . . . . . . Armature Speed, Dual Disc Disc Diameter, O.D. . . . . . . . . 635 mm (25.00 in.)

Emergency Brake- .Automatically Applied (Standard) Wheel Brake Lock . . . . . . . Manual Switch on Panel . . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping) DISC PARKING BRAKE Each Rear Wheel . . . . . Integral with Service Caliper . . . . . . . . . . . Spring Applied, Hydraulically Released STEERING Turning Circle - Front Wheel Track. . . 28.4 m (93 ft.)

Twin hydraulic cylinders with accumulator assist to provide constant rate steering. Emergency power steering automatically provided by accumulators.

FAM0220

Truck Components And Specifications

Page 2-3

DUMP BODY CAPACITIES AND DIMENSIONS Standard, Heaped @ 2:1 (SAE) . . 147 m3 (193 yd 3) Struck . . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd 3) Loading Height Empty . . . . . . . . 6.61 m (21 ft. 8 in.)

Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Non-heated body w/exhaust mufflers . . . . . Standard

TIRES Radial Tires (standard) . . . . . . . . . . . . . . . 40.00 R57 Optional Tires . . . . . . . . . . . . . . . . . . . . . . 46/90 R57 Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless Rims, standard 5 piece . . Rated to 827 kPa (120 psi)

WEIGHT DISTRIBUTION Empty Vehicle . . . . Kilograms. . . . . . . . (Pounds) Front Axle . . . . . . . . . . . 82 747. . . . . . . . (182,426) Rear Axle. . . . . . . . . . . . 82 902. . . . . . . . (182,768) Total (100% fuel) . . . . . 165 649. . . . . . . . (365,194) Standard Komatsu body 27 669. . . . . . . . . (61,000) Standard tire weight. . . . 21 081. . . . . . . . . (46,476) Loaded Vehicle . . . Kilograms. . . . . . . . (Pounds) Front Axle . . . . . . . . . . 127 330. . . . . . . . (280,715) Rear Axle. . . . . . . . . . . 258 522. . . . . . . . (569,935) Total * . . . . . . . . . . . . . 385 852. . . . . . . . (850,650) Nominal Payload *. . . . 220 199. . . . . . . . (485,456) . . . . . . . . . . . . . (242 U.S. Ton) *Nominal payload is defined by Komatsu America Corporation’s payload policy documentation. In general, the nominal payload must be adjusted for the specific vehicle configuration and site application.

The figures above are provided for basic product description purposes. Please contact your Komatsu distributor for specific application requirements.

OVERALL TRUCK DIMENSIONS (Empty with Standard Body)

Length . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height with Canopy . . . . . . . . . . . . . . . .

Height with Dump Body Up . . . . . . . . . .

Turning Circle (on front track) . . . . . . . .

Page 2-4

14.4 m (47 ft. 3 in.)

7.32 m (24 ft. 0 in.)

6.96 m (22 ft. 10 in.)

13.52 m (44 ft. 4 in.)

28.4 m (93 ft. 0 in.)

Truck Components And Specifications

FAM0220

MAJOR COMPONENT WEIGHTS

The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before each use. Lifting equipment must be in good condition and rated for approximately two times the weight being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result.

Optional equipment added onto the truck may cause an increase to the component weights listed in this chapter. Contact your customer support manager for concerns or questions about lifting truck components.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 306 . . . . . . . . . . . . . . . . . . . . . . 2,879 Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 309 . . . . . . . . . . . . . . . . . . . . . . 9,500 Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 615 . . . . . . . . . . . . . . . . . . . . . 12,379 Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 288 . . . . . . . . . . . . . . . . . . . . . 40,318

DECK AND DECK SUPPORT COMPONENTS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 177 . . . . . . . . . . . . . . . . . . . . . . 4,800 RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604 . . . . . . . . . . . . . . . . . . . . . . 1,331 LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 . . . . . . . . . . . . . . . . . . . . . . 1,568 Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 . . . . . . . . . . . . . . . . . . . . . . . . 474 Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 . . . . . . . . . . . . . . . . . . . . . . 1,080 Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 . . . . . . . . . . . . . . . . . . . . . . . . 489 LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668 . . . . . . . . . . . . . . . . . . . . . . 1,472 RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 . . . . . . . . . . . . . . . . . . . . . . 1,169 LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 . . . . . . . . . . . . . . . . . . . . . . . . 265 Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 . . . . . . . . . . . . . . . . . . . . . . . . 388 Vertical Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . . 77

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Major Component Weights

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ITEM

KILOGRAMS

POUNDS

POWER MODULE Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 . . . . . . . . . . . . . . . . . . . . . . . . 421 Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788 . . . . . . . . . . . . . . . . . . . . . . . 1,737 Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340 Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 080 . . . . . . . . . . . . . . . . . . . . . . . 4,585 Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 176 . . . . . . . . . . . . . . . . . . . . . . . 7,002 Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 . . . . . . . . . . . . . . . . . . . . . . . . 445 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 993 . . . . . . . . . . . . . . . . . . . . . . . 8,803 Engine (Komatsu SDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 558 . . . . . . . . . . . . . . . . . . . . . . 18,867 Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 905 . . . . . . . . . . . . . . . . . . . . . . . 4,200

FLUID COMPONENTS Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 . . . . . . . . . . . . . . . . . . . . . . . . 309 Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .796 . . . . . . . . . . . . . . . . . . . . . . . 1,755 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 . . . . . . . . . . . . . . . . . . . . . . . . 278 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 . . . . . . . . . . . . . . . . . . . . . . . . 717 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 711 . . . . . . . . . . . . . . . . . . . . . . . 3,772

FRONT AXLE COMPONENTS Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 216 . . . . . . . . . . . . . . . . . . . . . . . 7,090 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 . . . . . . . . . . . . . . . . . . . . . . . . 496 Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 228 . . . . . . . . . . . . . . . . . . . . . . . 4,912 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 . . . . . . . . . . . . . . . . . . . . . . . . 364

REAR AXLE COMPONENTS Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 146 . . . . . . . . . . . . . . . . . . . . . . . 2,527 Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 . . . . . . . . . . . . . . . . . . . . . . . . 763 Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 086 . . . . . . . . . . . . . . . . . . . . . . 11,213 Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 . . . . . . . . . . . . . . . . . . . . . . . . 330 Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12 201 . . . . . . . . . . . . . . . . . . . . . . 26,899

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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 development, periodic revisions may be made to this publication. It is recommended that customers contact their distributors for information on the latest revision.

The welding information contained in this chapter is general information that must be followed unless otherwise specified in a detailed repair procedure provided on an engineering drawing or a detailed specific repair procedure. Additional specific information, or detailed instructions can be obtained through your local Komatsu customer support manager.

WELD PROCEDURES Electric arc welding, either the semi-automatic “MIG” (GMAW), Flux Core (FCAW), or “Stick” electrode welding (SMAW), are approved processes for field installation and maintenance welding. Welding of highly stressed structural members such as castings, torque 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 for repair procedures. These repair procedures are detailed instructions for most high stressed structural members.

APPROVED CONSUMABLES WELDER QUALIFICATION AND TRAINING

GMAW - LW102-15 or ER80S-D2

The welding technique must be of the highest standard to produce the soundest weld possible. Only welders who have been trained and qualified for structural steel welding in all positions, in conformance 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 the AWS standard welding symbols is necessary to perform and inspect such field welds. Weld sizes specified on the drawings are intended to reflect minimum requirements.

SMAW - E7018-1, E8018-C1, or E8018-C3

FCAW - E70T-5, E71T-8, or E71T8-NI1

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, without excessive deformity, and all craters filled. No cracks are permitted.

4. The toe of a weld to a stressed member must have a smooth transition. Excessive convexity in multi-pass fillet welds is not permitted. Excessive 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 critical welds must be reworked by the application of welding an additional cover pass. It is important that this pass is blended with the existing weld.

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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 multiple pass welding is the required procedure on truck frames.

2. Low Ambient Temperature - DO NOT weld in temperatures below 50°F (10°C). At low temperature conditions, preheating of all welding joint work areas is required. See preheat and post heating requirements as detailed in Annex A.

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 intersects with another weld.

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.

MATERIALS, CONTROLS, AND PRECAUTIONS The steel used in the fabrication of all Komatsu equipment is of high strength low alloy (HSLA) material of different grades. The standard dump body main plates are made from abrasion resistant materials. 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 consumables are available but have limited use on Komatsu structural components. Approval is required from your Komatsu customer support manager.

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 welding. Clean all weld areas and surfaces with a grinder to ensure that all foreign materials have been removed.

WELD INSPECTION

Control of the welding area environment is essential for producing proper and sound welds. Essentially, five areas require attention and control.

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 weld repairs that are deemed unacceptable by the inspector must be corrected at no additional cost to Komatsu. All weld repairs are also subject to additional inspection.

1. Air Movement - Avoid areas where air movement from wind, drafts, or blowers is prevalent.

This is particularly important when a shielding gas is being used as part of the welding process.

1. Visual Inspection - This is the process of looking for potential defects such as undersized welds that can be checked with weld gauges for, surface cracks, surface porosity, craters, and undercuts.

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RECORDS 2. Dye Penetrant Inspection - This is an easily applied process which indicates cracks or surface conditions. The process is relatively inexpensive, but does not produce a permanent record except by normal photography.

3. Fluorescent Penetrant Inspection - Similar to dye penetrant inspection. This process uses a black (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.

Komatsu requires record keeping of all welding work.

This information is valuable when personnel or job conditions change. The service and warranty departments of Komatsu must be provided with inspection reports and photographs of the weld area before, during, and after the repair. The photographs must be clear and close enough to show the weld joint preparation complete, with backer bars installed, etc. just prior to welding. These photos easily identify if 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 major load carrying members on Komatsu equipment.

1. The repair or rework area must be protected from wind and moisture during the entire procedure. If the repair work is to done outside additional precautions must be taken to protect the weld repair process from outside elements. All welding should be done at an ambient temperature of 10°C (50°F) or above.

2. Clean and grind the entire repair area to remove all rust, grease, oils, paint, and any other foreign materials likely to contaminate the weld.

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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.

Backup strips are required for all cracks that have gone through the parent material and cannot 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. Documentation must support this repair. Photographs 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 thoroughly with a grinder to remove all possible carbon 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 surrounding surface area reaches 150°C (300°F) at a distance of 76 mm (3 in.) from all areas to be welded.

Page 4-4

9. All welds are to be made with approved consumables only. The SMAW (Stick) welding rod must be used within four hours after being removed from a new sealed container or from a 52°C (125°F) minimum drying oven. Any rod that exceeds this exposure time must be dried for one hour at 427°C (800°F) before being used. Keep all weld starts and stops to a minimum.

10. When the weld is complete, immediately (before the weldment cools) post heat the entire weld area to 150°C (300°F). Even if the area is over 150°C (300°F) 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 inspection 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 heating.

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FAM0403

ANNEX B 2.0 TOE GRINDING WITH A ROTARY BURR

1.0 TOE HAMMER PEENING Equipment:

Equipment:

1. Hand held pneumatic hammer 2. Adequate air supply

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

3. Adequate lighting

2. Tungsten carbide rotary burr 13 mm (0.50 in.) diameter with 13 mm (0.50 in.) spherical tip

4. 6 mm (0.25 in.) diameter spherical tip bit 5. Protective clothing, gloves, includes eye, face, and ear protection.

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 for the peening tool resulting in the area of deformation 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.

Procedure

NOTE: Peening shall only be performed after weld acceptance by visual inspection.

1. The toe of the weld should serve as a guide for 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 parent material (no overlap) before the peening operation 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.

2. The weld must have a smooth profile and the toe must have a good transition to the parent material (no overlap) before the grinding operation 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. Hold the hammer tool at approximately one half the included angle between the weld face and the parent material and perpendicular to the direction 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.).

3. The axis of the tool should be maintained at about 45° to the parent plate and inclined at about 45° to the direction of travel. The depth of the grinding must be between 0.8 mm to 1.0 mm (0.030 to 0.040 in.). The final surface must be clean, smooth and free of all traces of undercut or slag.

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FIGURE 4-1. TOE HAMMER PEENING

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FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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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 Electric Company, Cleveland, Ohio

SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK Consult a qualified technician, specifically trained for servicing the AC drive system, before welding on the truck.

The following procedures must be followed to ensure the safety of maintenance personnel and to help prevent damage to the equipment.

American Welding Society - Welding Handbook British Standard BS5135 - Metal Arc Welding of Carbon and Carbon-Manganese Steels Welding Steels Without Hydrogen Cracking - The Welding Institute, F. R. Coe, Author

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 AC 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 retarding grids, wheel motors, alternator, and power cables connecting these devices are safe to work on.

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Locate the GF cut-out switch in the access panel on the left side of the main control cabinet. Place the switch in the CUTOUT position.

This will prevent the alternator from re-energizing 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 disconnect switches in their original positions. Reconnect 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, specifically trained for servicing the AC drive system, may perform this service.

General Welding Guidelines 1. Open the battery disconnect switches and disconnect 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 strap from the ECS. 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 louvers.

6. Some power cable panels throughout the truck are made of aluminum or stainless steel. They must be repaired with the same material or the power cables may be damaged.

7. Power cables must be cleated in wood or other non-ferrous materials. DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Inspect power cable insulation 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 the vehicle 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, or hydraulic cylinders.

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NOTES

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RECEIVING & ASSEMBLY PREPARATION Preparation

Color Coded Boxes

Inspection, Cleaning, Setup

A parts check list will be included in each shipping crate that is shipped with the truck. The list consists of several color coded tables that represent a portion of the assembly process. The parts listed in each table will be packed in waterproof corrugated PVC boxes that match the color of the header row of that table.

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 number. Check for missing parts. List the unit number of all major components. Verify the cab and decks are with the correct chassis.

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 housing. The support blocks must be approximately 30 cm (12 in.) high and spread out along the axle. The support blocks must be a minimum of 51 mm (2 in.) away from the wheel motor mounting face.

5. Clean all mounting surfaces on the chassis and on the individual components.

6. Check all electrical connectors and verify they are free of paint and/or corrosion. Clean any connector with questionable electrical continuity.

7. Check all factory installed components for the proper tightening torque.

The colored boxes, shown in Figure 5-1, will be packed into shipping crates and shipped with the truck. Assembly technicians can then locate the colored boxes that match the color of the operation (table) being performed. The boxes will be packed into the crate in chronological order. Parts needed early in the assembly process will be located near the top of the crates.

To allow for maximum flexibility, the color code may differ from unit to unit. However, colors shown on the check sheet will still match the color of the packing boxes used.

Due to the limited amount of different colored boxes available, some colors may be repeated.

Tables in the checklist that have no color code contain parts that are not boxed. Similarly, tables that are color coded may also contain parts that are not boxed. These parts are highlighted in yellow.

8. Arrange the work site as shown on the following page.

FIGURE 5-1. COLOR CODED BOXES

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ASSEMBLY LAYOUT Page 5-2

Receiving & Assembly Preparation

FAM0508

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 following procedures are provided as general guidelines only. Actual assembly may be different, but this general procedure provides a basic outline for assembly.

Items like the hydraulic tank and the accumulators 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.

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 done in either order, or simultaneously. The most logical order depends on available resources such as cranes, welders, assemblers, etc.

5. Static checkout (electrical & mechanical)

RECOMMENDED ASSEMBLY DATA

6. Hydraulic Flushing 7. Install the body

1. Service Report (Pre-Delivery)

8. Dynamic checkout (electrical & mechanical)

2. Acknowledgement of Receipt of Company Warranty

9. Site cleanup

3. Assembly Blueprints & Schematics 4. Fluid Specifications (refer to the lubrication chart in Section 10, Appendix) 5. Suspension Oiling & Charging (available in Section 10, Appendix)

Procedure

6. Fan Drive Adjustment Procedure (available in the engine service manual) 7. Hydraulic System Flushing Procedure (Section 10 Appendix) 8. Toe-In Adjustment Procedure (Section 10, Appendix) 9. Hydraulic Checkout Procedure (Section 10, Appendix) 10. Brake Checkout Procedure (Section 10, Appendix) 11. Propulsion System Checkout Procedure (available in Section 10 of this manual) 12. Filter List (available in parts book) 13. Lubrication & Service PM Forms (available in the operation and maintenance manual) 14. Component Weights - for crane reference (available in Section 3 of this manual) 15. Standard Torque Chart (available in Section 10 of this manual) 16. Field Assembly Inspection Report Form (available in Section 10 of this manual)

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Chassis Assembly

Page 6-1

ORDER OF ASSEMBLY

LEVEL 5

The assembly procedure is organized in levels. Generally, 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/ or truck options.

LEVEL 1

1. Operator Cab 2. Blower Inlet Duct 3. Front Tires 4. Rear Tires

LEVEL 6 1. Weld Uprights

LEVEL 8 Dump Body Installation

LEVEL 7

1. Chassis - Unload and crib for assembly.

1. Hoist Cylinders

2. Deck Supports

2. Rock Ejectors

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.

3. Mud Flaps 4. Clearance Lights 5. Body Pads/Shims/Guides 6. Exhaust Blankets

3. Hydraulic Tank

LEVEL 8

4. Fuel Tank 5. Front Suspensions

1. Clean the Truck

6. Uprights/Air Cleaners

2. Lighting Wiring

7. Diagonal Support Beam

3. Charge Suspensions

8. Platform

4. Charge Accumulators 5. Add Fluids

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. Spindles/Hubs 3. Diagonal Ladder

NOTE: Prior to starting the engine, verify that the steering pump case is full of oil.

6. Hydraulic System Flushing

LEVEL 9 1. System Checkouts 2. Charge the Air Conditioning System 3. Decals

LEVEL 3

4. Touch Up Paint

1. Control Cabinet

5. Train Operators

2. Auxiliary Control Cabinet

6. Optional - Install Fire Suppression System

3. Center Deck 4. Steering Cylinders 5. Tie Rod 6. LH Deck 7. RH Deck/Grid Box 8. Wheel Motors

Page 6-2

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FAM0621

CHASSIS ASSEMBLY The photographs referenced in this procedure depict an actual truck assembly. Assembly at other locations may be different. However, this outline will provide a general basis for assembly.

Follow all safety recommendations in this manual. Follow all local, state, and federal regulations.

In the procedures that follow, many very heavy components will be required to be lifted into place and secured.

Disconnect the battery cables before arc welding on the truck. Failure to do so may seriously damage the batteries and electrical equipment. Disconnect the battery charging alternator lead wire before welding on the frame or its components.

Fasten the welding machine ground cable to the component being welded.

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 cleaned and ventilated.

• Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected daily for serviceable condition.

Refer to the manufacturer’s guidelines for correct capacities and safety procedures when lifting components. Replace any questionable items.

Maintain fire control equipment. Inspect fire extinguishers regularly to ensure they are fully charged and in good working condition.

• Slings, chains and cables used for lifting must be rated for approximately two times the intended load.

• When in doubt as to the weight of components or any assembly procedure, contact your customer support manager for further information.

Mark cap screws and nuts with paint or ink before tightening to the specified torque. This method provides verification that the hardware has been properly tightened.

• Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load.

• Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a suspended load.

• Before lifting, ensure there is adequate clearance from overhead structures or electric power lines.

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Page 6-3

GENERAL PRECAUTIONS AND INSTRUCTION 1. Clean and remove all foreign material from component mounting surfaces.

2. DO NOT weld the front uprights to the bumper until all upper decks are installed.

3. Tighten the deck mounting cap screws before the exhaust tubes, etc. are installed.

4. Verify all electrical connectors are free from paint and/or corrosion. Clean any connector that may be questionable.

5. Do not tighten the diagonal ROPS beam cap screws until after the operator cab & LH air intake tubes are in place.

6. Before installing the cab to the substructure, tap all threaded holes to remove paint.

7. Verify all wiring is properly connected before attempting to start the engine.

10. Use the proper precautions when checking the nitrogen pressure and oil level in the accumulators.

11. Verify the lube system is lubricated, purged and all levels full prior to start up.

12. 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 of this manual.

13. Use the battery disconnect switch when arc welding. Connect the weld ground near the weld area.

14. Before the truck is started for the first time, the hydraulic system must be flushed. Refer to the hydraulic system flushing procedure in the Appendix.

8. Recheck the torque on hardware installed at the factory.

9. Use blocks for charging the suspension (oil & nitrogen). Follow the procedures outlined in Section 10, Appendix.

Page 6-4

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NOTES:

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Page 6-5

1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each. Lift the chassis onto adequate support blocks or stands. The weight of the chassis, as shipped, is approximately 48,943 kg (107,900 lb).

The support blocks/stands must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm (12 in.) high under the rear axle housing (Figure 6-1). Placement of the chassis at this height will allow easy installation of truck components.

Thoroughly clean the chassis.

Page 6-6

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FIGURE 6-1.

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Page 6-7

2. Clean the mating surfaces for the deck supports and the frame to prepare for installation. The surfaces must be free of paint, rust, dirt, grease and oil. (Figure 6-2 & Figure 6-3)

Page 6-8

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FIGURE 6-2.

FIGURE 6-3.

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Chassis Assembly

Page 6-9

NOTE: If more than one truck is being assembled at one time, ensure the uprights, deck supports and diagonal braces are installed on the correct chassis. These parts are marked with the truck serial number to ensure proper assembly.

3. Lift the LH deck support into position. The weight of the deck support is approximately 490 kg (1,080 lb). Bolt the support into place. Refer to Figure 6-4. Do not weld the left hand deck support in place at this time.

4. Lift the RH deck support into position. The weight of the right hand deck support is approximately 222 kg (489 lb). a. Bolt the deck support into place. b. Tack weld the deck support in place. c. The four tapped pads on the deck support and the corresponding blocks on the horsecollar must be removed to allow for a complete weld around the joint. d. Completely weld all around the deck support as described on the assembly drawing. e. Grind all areas smooth and clean. Paint the weld and surrounding area after welding is complete.

5. Remove the center deck to enable easy installation of the air intake tubing and the diagonal cross tube (Figure 6-5). The weight of the center deck is approximately 250 kg (550 lb).

Do not discard the hardware at the rear of the deck. This hardware is to be used for installation.

Page 6-10

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FIGURE 6-4.

FIGURE 6-5.

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Page 6-11

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

7. Attach the left upright to a crane using adequate lifting apparatus. Attach a ratchet hoist to the lifting apparatus (on the front side) to enable the upright to pivot for proper alignment during installation. Install the four cap screws to mount the upright. Tighten the cap screws to standard torque. The weight of the LH upright is approximately 668 kg (1472 lb). Refer to Figure 6-7.

DO NOT weld the torque tubes on the uprights at this time.

Page 6-12

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FIGURE 6-6.

FIGURE 6-7.

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Page 6-13

8. Lift the right hand upright into position and install the four cap screws to mount the upright. Tighten to standard torque. Refer to Standard Tables in Section 10, Appendix. The weight of the RH upright is approximately 530 kg (1169 lb). Refer to Figure 6-8.

DO NOT weld the torque tubes on the uprights at this time.

10. Attach the upper radiator stabilizers rods to the uprights. Refer to Figure 6-9. Do not tighten at this time.

Adjustment will come after the decks and uprights are fully installed.

Page 6-14

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FAM0621

FIGURE 6-8.

FIGURE 6-9.

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Chassis Assembly

Page 6-15

11. Clean both mounting surfaces for the left hand diagonal tube (Figure 6-10). The surfaces must be free of paint, rust, dirt, grease and oil.

12. Lift the left hand diagonal tube into position (Figure 6-11). The weight of the diagonal tube is approximately 120 kg (265 lb). Leave the cap screws loose.

13. Tap the cab mounting holes to remove any paint from the threads. Tap size is 1.00 x 8NC. Lift the cab onto the deck supports and install 1/2 of the mounting hardware. Verify no gaps exist between the mounting pads of the cab. If gaps are present, the upright and/or deck support may need to be repositioned. Tighten the cab mounting hardware to standard torque. Refer to Standard Tables in Section 10, Appendix.

14. Tighten all of the hardware for the left hand diagonal tube to standard torque.

15. Securely tack weld the left upright and the left deck support in place.

16. Remove the cab mounting hardware and remove the cab.

Page 6-16

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FIGURE 6-10.

FIGURE 6-12.

1. Cab 2. Deck Support

3. Diagonal Beam 4. Left Upright

FIGURE 6-11.

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Page 6-17

17. Completely weld the left hand deck support in place. Refer to Figure 6-13. a. The four tapped pads on the left deck support and the corresponding blocks on the horsecollar must be removed to allow for a complete weld around the joint. b. Completely weld all around the left deck support as described on the assembly drawing. c. Grind all areas smooth and clean. Paint the weld and surrounding area.

If the tapped pads are not removed, a complete weld around the support can not be achieved. Gaps in the weld around the support may result in premature frame cracking in this area.

18. Completely weld the left hand upright to the front frame tube. Refer to Figure 6-14. After the upright is securely tack welded in place, remove the cap screws. Also cut the cap screw blocks off of the frame. Finish welding the uprights in place as instructed per the assembly drawing provided with the truck.

Page 6-18

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FIGURE 6-13.

FIGURE 6-14.

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Page 6-19

19. Remove all paint from the mounts for the hydraulic tank and the fuel tank. Refer to Figure 6-15.

20. Lift the hydraulic tank into position on the cradles. (Figure 6-16). The weight of the hydraulic tank is approximately 325 kg (717 lb).

Install the four cap screws with special flat washers and the cradle caps at the top of the tank. Tighten cap screws to 616 ± 61 N·m (454 ± 45 ft lb).

Install the rubber dampeners and mounting hardware at the rear of the tank. Tighten the two cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

Page 6-20

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FIGURE 6-15.

FIGURE 6-16.

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Chassis Assembly

Page 6-21

21. Lift the fuel tank into position on the cradles. (Figure 6-17) The weight of the fuel tank is approximately 1 711 kg (3,772 lb).

Install the four cap screws with special flat washers and the cradle caps at the top of the tank. Tighten to standard torque. Refer to Standard Tables in Section 10, Appendix.

Install the rubber dampeners and mounting hardware at the rear of the tank. Tighten the four cap screws to standard torque.

22. Prepare the hydraulic filters for mounting on the fuel tank. Ensure all filter hardware is properly tightened.

Refer to Figure 6-18.

Page 6-22

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FIGURE 6-17.

FIGURE 6-18.

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Chassis Assembly

Page 6-23

23. Connect the piping to the hydraulic tank and properly tighten all fittings.

Refer to Figure 6-19.

NOTE: When the machine is ready for operation, the hydraulic tank shut-off valves must be opened.

24. Install the hydraulic filters onto the bracket at the rear of the fuel tank. Refer to Figure 6-20.

Connect the fuel supply line to the fitting at the rear of the tank, and connect the return line to the fitting at the top of the tank.

Page 6-24

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FIGURE 6-19.

FIGURE 6-20.

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Chassis Assembly

Page 6-25

25. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.

Refer to Figure 6-21 & Figure 6-22.

Page 6-26

Chassis Assembly

FAM0621

FIGURE 6-21.

FIGURE 6-22.

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Chassis Assembly

Page 6-27

26. Clean and dry the mounting surfaces on both the suspension and the frame. Use a cleaning agent that does not leave a film after evaporation, such as trichlorethylene, tetrachlorethylene, acetone or lacquer thinner.

High tightening torque is required to load the front suspension mounting cap screws. Repeated tightening will result in cap screw fatigue and damage. DO NOT reuse mounting cap screws, washers and nuts.

Replace the hardware after each use.

Suspension mounting cap screws are specially hardened to meet or exceed grade 8 specifications.

Replace only with cap screws of correct hardness. Refer to the appropriate parts book for the correct part numbers. .

27. The use of dry threads in this application is not recommended. Due to the high tightening forces required to load these cap screws, dry threads or threads lubricated with anti-seize compounds may result in damage. Only use a lithium based chassis grease (multi-purpose, EP, NLGI #2, with a maximum moly content of 5%).

28. Lubricate the cap screw threads, cap screw head seats, washer faces, and nut seats with a lithium based chassis grease (multi-purpose, EP, NLGI #2, with a maximum moly content of 5%).

Page 6-28

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FAM0621

FIGURE 6-23. INSTALLATION OF HARDENED FLAT WASHER 1. Hardened Flat Washer

2. Cap Screw

29. The hardened flat washers used on the front suspensions may be punched during the manufacturing process.

If there is a punch lip on the flat washer, install the flat washer to position the punch lip away from the cap screw head to prevent damage. See Figure 6-23.

30. Lift the front suspension into position. Refer to Figure 6-24. The weight of each front suspension cylinder is approximately 2 228 kg (4,912 lb). Install the mounting hardware and tighten according to the "turn-of-the-nut" method outlined on the following pages.

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Chassis Assembly

Page 6-29

"Turn-Of-The-Nut" Tightening Procedure a. Initially tighten the hardware to 1 356 ± 136 N·m (1,000 ± 100 lb ft) in the sequence shown in Figure 6-27. Use a properly calibrated torque wrench to ensure accuracy.

NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening.

The mounting cap screws will now need to be loosened and then tightened using turn-of-the-nut method. The first set of cap screws to be adjusted will be at the upper mounting joint. The cap screws must be loosened one at time and then tightened by advancing a specified rotational degree. Use the map shown in Figure 6-27 for proper tightening sequence.

Upper Mounting Joint - 60° Advance The proper sequence for the upper mounting joint is 1-2-3-4-9-10. Refer to Figure 6-27. b. Loosen only the first cap screw. All other cap screws must be maintained at 1 356 ± 136 N·m (1,000 ± 100 lb ft). c. Tighten the cap screw to 95 N·m (70 lb ft). d. Mark a corner of the cap screw head with a paint marker as shown in Figure 6-25. Draw a reference line on the suspension surface next to the marked corner on the cap screw.

Draw a second reference line on the suspension 60 degrees in advance of the marked corner on the cap screw.

FIGURE 6-24.

e. Hold the nut at the rear of the joint stationary while tightening. Advance the cap screw to the 60° advance mark. f. Make new reference lines along the cap screw, nut and frame at the rear of the joint as shown in Figure 6-26. These reference lines will be used to verify the cap screws have maintained their torque. g. Repeat this process in sequence for the remaining five cap screws in the upper mounting joint.

Page 6-30

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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, again, must be cleaned and lubricated before repeating.

FIGURE 6-25. 60 DEGREE

FIGURE 6-27. SUSPENSION INSTALLATION

Lower Mounting Joint - 90° Advance The proper sequence for the lower mounting joint is 5-6-7-8-11-12-13-14. Refer to Figure 6-27. h. Loosen the first cap screw. All other cap screws must remain tight.

FIGURE 6-26. MAKING REFERENCE LINES

i. Tighten the cap screw to 203 N·m (150 lb ft).

NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening.

FAM0621

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Page 6-31

j. Mark a corner of the cap screw head with a paint marker as shown in Figure 6-28. Draw a reference line on the suspension surface (or frame) next to the marked corner on the cap screw. Draw a second reference line on the suspension surface (or frame) 90 degrees in advance of the marked corner on the cap screw.

m.Repeat this process in sequence for the remaining cap screws in the lower mounting joint.

NOTE: If for any reason these fasteners need to be checked for tightness after completing this procedure, loosen and inspect all 14 cap screws and repeat the entire process. The hardware, again, must be cleaned and lubricated before repeating.

Inspection Visual inspections of the bolted joints are necessary after the truck has been released for use. Inspect the joints at each front suspension at the following intervals: 8 hours, 50 hours, 250 hours, and 500 hours.

If the reference lines on the hardware (Figure 6-26 and Figure 6-29) have remained in alignment, the truck may remain in use.

FIGURE 6-28. 90 DEGREE ADVANCE

k. Hold the nut stationary at the rear of the joint (where applicable) while tightening. Then advance the cap screw to the 90° advance mark. l. Make new reference lines along the cap screw, nut and frame at the rear of the joint as shown in Figure 6-26. For the four cap screws with spacers, refer to Figure 6-29.

These reference lines will be used to verify the cap screws have maintained their torque.

If at least one of the cap screws has shown signs of movement, the truck must be taken out of service.

The suspension mounting cap screws must be removed, cleaned, and inspected. If any cap screws have any signs of damage, replace all cap screws.

Install the cap screws again, according to this installation procedure.

FIGURE 6-29. 90 DEGREE ADVANCE

Page 6-32

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FAM0621

31. Install the hanger brackets for the intake tubes.

Refer to Figure 6-30.

FIGURE 6-30.

32. Lift the air intake tubes into place. Install and tighten the clamps that secure the hoses.

Refer to Figure 6-31 - Figure 6-33. The intake tubes are assembled and adjusted for installation on the truck. DO NOT loosen any of the connections during installation.

FIGURE 6-31.

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Page 6-33

FIGURE 6-32.

Page 6-34

Chassis Assembly

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FIGURE 6-33.

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Page 6-35

33. Lift the center deck into position (Figure 6-34). Install the mounting hardware and tighten to standard torque.

Refer to Standard Tables in Section 10, Appendix.

34. Clean the tapered portion of the suspension rod and the bore of the spindle. Clean and check the tapped holes in bottom of Hydrair® piston for damaged threads. Retap holes, if necessary, with 1.250 in. - 12NF tap.

Lubricate spindle bore and suspension rod taper with a lithium based chassis grease (multi-purpose, EP, NLGI #2). Refer to Figure 6-35.

NOTE: Never use any lubricants on the spindle bore containing copper, such as many “anti’-seize” compounds.

Products containing copper will contribute to corrosion in this area.

Page 6-36

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FAM0621

FIGURE 6-34.

FIGURE 6-35.

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Chassis Assembly

Page 6-37

35. Lift the retainer plate into position under the spindle. The weight of the retainer plate is approximately 48 kg (106 lb). Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brake assembly is approximately 3 216 kg (7,090 lb). Refer to Figure 6-36.

NOTE: The use of dry threads in this application is not recommended. Due to the high tightening forces required to load these cap screws, dry threads may cause damage to tools.

36. Lubricate cap screw threads, cap screw head seats and washer face with lithium based chassis grease (multipurpose, EP, NLGI #2, with a maximum moly content of 5%). Install the twelve retainer plate cap screws.

Refer to Figure 6-37. Tighten cap screws using the following procedure: a. Tighten cap screws uniformly to 678 N·m (500 ft lb) torque. b. Continue to uniformly tighten the cap screws in increments of 339 N·m (250 ft lb) to obtain a final torque of 2 142 N·m (1,580 ft lb).

37. Repeat the previous steps for the remaining wheel.

38. Check cap screw torque on steering arm cap screws. Cap screw torque is 2 705 ± 271 N·m (1,995 ± 200 ft lb).

NOTE: If the steering arms have to be installed, lubricate cap screw threads, cap screw head seats and washers with a lithium based chassis grease (multi-purpose EP, NLGI #2).

Page 6-38

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FIGURE 6-36.

FIGURE 6-37.

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Page 6-39

39. Prepare the steering cylinder and tie rod mounting surfaces. Refer to Figure 6-38.

Page 6-40

Chassis Assembly

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FIGURE 6-38.

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Chassis Assembly

Page 6-41

40. Move the steering cylinder rod eye into position on the steering arm. Lubricate the mounting pin with grease.

Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 ± 71 N·m (525 ± 53 ft lb). Refer to Figure 6-39 & Figure 6-40.

NOTE: Use alignment sleeve (TY4576) to aid in assembly of the steering cylinder joints.

41. Lift the tie rod into position on the steering arms. Ensure the anti-rotation tabs on the tie rod ends are on the bottom side of the tie rod when installed. The weight of the tie rod is 165 kg (364 lb). Lubricate the mounting pins with grease. Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 ± 71 N·m (525 ± 53 ft lb).

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. Ensure the clamping cap screws on tie rod are tight after adjusting toe-in.

NOTE: Use alignment sleeve (TY4576) to aid in assembly of the tie rod joints.

Page 6-42

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FIGURE 6-39.

FIGURE 6-40.

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Page 6-43

42. Install the handrails onto the LH deck and lift the deck into place (Figure 6-41). The weight of the LH deck with handrails is approximately 802 kg (1,768 lb). Loosely install the eight deck mounting cap screws.

NOTE: After each deck is in place, tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

43. Cab Mounting a. Tap the cab mounting holes to remove any paint from the threads. Tap size is 1.00 x 8NC. b. Lift the operator cab into position (Figure 6-42). The weight of the cab is approximately 2 177 kg (4,800 lb). c. Check for any gaps between cab mounting plates and the frame mounting plates. Use shims EL1949 (front) or EL1950 (rear) as required to reduce the gap to less than 1.0 mm (0.04 in.). d. Install and tighten the 32 cab mounting cap screws to 1 017 N¡m (750 ft lb) torque.

Page 6-44

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FIGURE 6-41.

FIGURE 6-42.

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Page 6-45

44. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 2364 kg (5212 lb).

Install the grid mounting cap screws and tighten to standard torque. Refer to Standard Tables in Section 10, Appendix.

NOTE: On domestic trucks, the retarding grids are already installed on the deck.

45. Install the handrails on the RH deck.

46. Lift the RH deck into position and install the six cap screws. The weight of the assembly is approximately 3 100 kg (6,834 lb). Tighten the mounting cap screws to standard torque. Refer to Figure 6-43.

47. After the right deck is bolted in place, weld the right hand upright to the front frame tube. Refer to Figure 6-44.

After the upright is securely tack welded in place, remove the cap screws. Also cut the cap screw blocks off of the frame. Finish welding the uprights in place as instructed per the assembly drawing provided with the truck.

48. After both left hand and right hand decks are installed and both uprights welded, adjust the stabilizers to vertically level the radiator.

49. Adjust the radiator shroud bumpers, located below each deck, on each side of the radiator shroud. Adjust bumpers so that they just contact the shroud, but no pre-load.

Page 6-46

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FIGURE 6-43.

FIGURE 6-44.

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Page 6-47

50. Lift the two bumper extensions into place. The weight of each bumper extension is approximately 123 kg (271 lb). Refer to Figure 6-45 & Figure 6-46. The left hand bumper extension supports the isolation box. Ensure all wires are out of the way before installation.

Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

Page 6-48

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FIGURE 6-45.

FIGURE 6-46.

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Page 6-49

51. Lift the control cabinet into position. The weight of the control cabinet is approximately 3 400 kg (7,500 lb).

Install the mounting hardware. Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

Refer to Figure 6-47 and Figure 6-48.

Page 6-50

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FIGURE 6-47.

FIGURE 6-48.

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Page 6-51

52. Install the mounting bracket for the control cabinet vent cover and install the cover. Figure 6-49 & Figure 6-50.

Connect the wiring for the electrical control cabinet, auxiliary control cabinet, and grid box. Refer to Figure 651 through Figure 6-55.

Page 6-52

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FIGURE 6-49.

FIGURE 6-50.

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Page 6-53

FIGURE 6-51.

FIGURE 6-52.

Page 6-54

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FIGURE 6-53.

FIGURE 6-54.

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Page 6-55

FIGURE 6-55.

Page 6-56

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NOTES:

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Page 6-57

53. Lift the transition duct into place on the alternator, and install the mounting hardware, Figure 6-56. Install flexible duct to connect transition duct to alternator.

54. Install the blower hose with clamps to the control cabinet and the transition duct.

Refer to Figure 6-57 & Figure 6-58.

FIGURE 6-56.

Page 6-58

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FIGURE 6-57.

FIGURE 6-58.

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Page 6-59

55. LIft the air intake ductwork into position and install the mounting hardware, Figure 6-59. The weight of the inlet duct is approximately 191 kg (421 lb). Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

Install the flexible duct with cap screws, flat washers and lock washers, Figure 6-60.

Page 6-60

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FIGURE 6-59.

FIGURE 6-60.

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Page 6-61

56. Install the power cables with mounting blocks on the air inlet duct, Figure 6-61.

Page 6-62

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FIGURE 6-61.

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Page 6-63

57. Install the diagonal ladder. The weight of the diagonal ladder is approximately 179 kg (395 lb).

Refer to Figure 6-62.

Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

NOTE: The diagonal ladder may not always be installed in the direction (R to L) as shown in Figure 6-62.

Page 6-64

Chassis Assembly

FAM0621

FIGURE 6-62.

FAM0621

Chassis Assembly

Page 6-65

58. Install both engine access ladders on the truck frame. Tighten mounting hardware to standard torque. Refer to Figure 6-63 and Figure 6-64.

Page 6-66

Chassis Assembly

FAM0621

FIGURE 6-63.

FIGURE 6-64.

FAM0621

Chassis Assembly

Page 6-67

59. Thoroughly clean the threaded holes and the mounting faces of the rear axle housing and wheel motor. Refer to Figure 6-65.

60. Inspect the threaded holes in the rear axle housing for damage. Re-tap any holes that have damaged threads.

Thoroughly clean any threaded holes that have been re-tapped.

61. Apply a lithium based chassis grease (multi-purpose, EP NLGI #2, with a maximum of 5% moly) to the threaded cap screw holes in the rear axle housing.

62. Install two guide pins 180° apart (3 o’clock and 9 o’clock positions) in the rear axle housing.

Each complete wheel motor assembly weighs approximately 12 201 kg (26,899 lb). Ensure that the lifting devices are capable of handling the load safely.

NOTE: When lifting the wheel motors, do not lift under the brake assembly. Shipping fasteners installed in the outboard rim bolt circle must remain in place during lifting and installation of wheel motors.

63. Lift the wheel motor into position on the rear axle housing. Ensure that all cables and hoses are clear before installation. Refer to Figure 6-66.

Page 6-68

Chassis Assembly

FAM0621

FIGURE 6-65.

FIGURE 6-66.

FAM0621

Chassis Assembly

Page 6-69

64. Select the hardware to be installed in Group 1 of the tightening sequence. Refer to Figure 6-68. Inspect each cap screw for rust, corrosion and surface defects on any seat or thread. Do not use any cap screw if a defect is suspected.

65. Lubricate the cap screw threads, cap screw head seats and washer faces with a lithium based chassis grease (multi-purpose, EP NLGI #2, with a maximum of 5% moly).

NOTE: The hardened flat washers used in this application may have a punch lip on one side due to the manufacturing process. Therefore, the washers must be installed with the punched lip away from the head of the mounting cap screws to prevent damage to the fillet between the cap screw head and the shank. Refer to Figure 667.

66. Install the hardware for Group 1. Tighten each cap screw to 542 N·m (400 ft lb).

67. Repeat Steps 64 - 66 for each remaining group in the tightening sequence. Refer to Figure 6-68.

Install and tighten all of the hardware in a group before proceeding to the next group in the tightening sequence. Remove the guide pins that were installed in Step 62 when installing the hardware for Groups 3 and 4.

68. After all of the hardware in all of the groups has been installed and tightened to 542 N·m (400 ft lb), move back to Group 1. Increase the torque on each cap screw in Group 1 to 2 006 N·m (1,480 ft lb). Repeat this step for each remaining group in the tightening sequence. Refer to Figure 6-68.

Page 6-70

Chassis Assembly

FAM0621

FIGURE 6-67. FLAT WASHER 1. Washer

2. Cap Screw

FIGURE 6-68. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

FAM0621

Chassis Assembly

Page 6-71

69. Connect the power cables and the speed sensors to each of the wheel motors.

70. Open rear hatch to access the interior of the axle housing.

71. Connect brake supply hoses to the fittings on the axle housing and brake assemblies.

72. Connect both breathers (2) to the wheel motors. Ensure that there are no sharp bends or kinks in the breather hoses.

Refer to Figure 6-69.

73. Check the oil level in each wheel motor. Fill the wheel motor with the recommended oil as necessary.

Page 6-72

Chassis Assembly

FAM0621

FIGURE 6-69.

FAM0621

Chassis Assembly

Page 6-73

FIGURE 6-70. FRONT WHEEL ASSEMBLY 1. Valve Assembly 2. Bead Seat Band 3. Rim 4. O-Ring 5. Side Flange

6. Lock Ring 7. Wheel Retainer Lug 8. Nut 9. Capscrew 10. Flat Washer

11. Lockwasher 12. Nut 13. Clamp 14. Capscrew 15. Flatwasher

16. Lockwasher 17. Bent Plate 18. Hub

NOTE: Lubricate threads on studs and wheel nuts with a lithium based chassis grease (multi-purpose, EP NLGI #2, non-moly).

74. Use a tire handler to lift the front wheel into position on the wheel hub. Install wheel retainer lugs (7, Figure 6-70 and lubricated nuts (8). Evenly tighten each nut to 407 N·m (300 ft lb). Tighten the nuts in the sequence shown in Figure 6-71.

75. Spin the wheel and check rim run-out. Maximum runout is 5 mm (0.20 in.). If run-out exceeds specifications, loosen all nuts and tighten again.

If run-out is within specifications, tighten each nut to 746 N·m (550 ft lb). Tighten the nuts in the sequence shown in Figure 6-71.

FIGURE 6-71. TIGHTENING SEQUENCE After the truck has been assembled and is operational, the truck must be operated for a short period of time, and the torque on the wheels re-checked. Tighten the wheels to the specified torque. Recheck the torque on a daily basis until the torque is maintained. Check the torque at regular intervals, thereafter.

Page 6-74

Chassis Assembly

FAM0621

FIGURE 6-72.

FIGURE 6-73.

FAM0621

Chassis Assembly

Page 6-75

76. Use a tire handler to lift the inner dual wheel onto the wheel motor hub. Use caution when positioning. DO NOT damage the tire inflation extension.

77. Use a lifting device to install spacer (6, Figure 6-74) onto wheel motor hub. The weight of the spacer is approximately 88 kg (194 lb). Tap the spacer against the inner dual.

78. Lift the outer dual into position on the wheel motor hub.

Due to its size and weight, keep personnel away from the wheel assembly during installation.

NOTE: Position the outer dual wheel so that tire valve bracket aligns with the inner wheel inflation hose.

FIGURE 6-74. REAR WHEEL ASSEMBLY 1. Side Flange 2. Outer Wheel Rim 3. Bead Seat Band 4. O-Ring

Page 6-76

5. Lock Ring 6. Spacer 7. Valve Cap 8. Core

13. Inner Wheel Rim 9. Clamp 10. Nut 11. Wheel Retainer Wedge 12. Valve Extension Tube

Chassis Assembly

FAM0621

NOTE: Lubricate threads on studs and wheel nuts with a lithium based chassis grease (multi-purpose, EP NLGI #2, non-moly).

79. Install the wedges onto the studs and secure in place with the lubricated wheel nuts. Evenly tighten each nut in an alternating (criss-cross) pattern as shown in Figure 6-75. Tighten the nuts to 407 N¡m (300 ft lb).

80. Spin the wheel and check rim run-out. Maximum runout is 5 mm (0.20 in.). If run-out exceeds specifications, loosen all of the nuts. Again, tighten the nuts as specified in the previous step.

81. If run-out is within specifications, tighten each nut in sequence to 746 N¡m (550 ft lb).

After the truck has been assembled and is operational, the truck must be operated for a short period of time, and the torque on the wheels re-checked. Tighten the wheels to the torque specified above. Recheck the torque on a daily basis until the torque is maintained.

Check the torque at regular intervals thereafter.

FIGURE 6-75. TIGHTENING SEQUENCE

82. Secure the inner and outer dual tire inflation lines to the bracket on the outer rim. Tighten the cap screws to standard torque.

FIGURE 6-76.

FAM0621

Chassis Assembly

Page 6-77

83. Attach a lifting device to the radiator surge tank. Lift the tank into position on the radiator (Figure 6-77). Install the mounting hardware to the surge tank.

Install the hoses to the radiator and the surge tank. (Figure 6-78)

Page 6-78

Chassis Assembly

FAM0621

FIGURE 6-77.

FIGURE 6-78.

FAM0621

Chassis Assembly

Page 6-79

84. Lift the surge tank cover into position and install the mounting hardware (Figure 6-79). The weight of the cover is approximately 98 kg (216 lb).

Page 6-80

Chassis Assembly

FAM0621

FIGURE 6-79.

FAM0621

Chassis Assembly

Page 6-81

85. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-80 thru Figure 6-83.

86. Connect the hydraulic piping from the operator’s cab to the hydraulic cabinet and route the hoses appropriately.

FIGURE 6-80.

FIGURE 6-81.

Page 6-82

Chassis Assembly

FAM0621

FIGURE 6-82.

FIGURE 6-83.

FAM0621

Chassis Assembly

Page 6-83

87. Install the exhaust system piping and hangers. The deck mounted muffler exhaust is shown Figure 6-84. Also install all exhaust blankets. Refer to the installation prints for other optional exhaust systems.

Page 6-84

Chassis Assembly

FAM0621

FIGURE 6-84.

FAM0621

Chassis Assembly

Page 6-85

88. Install exhaust blankets (6, 7, 8, 9 & 11, Figure 6-85). Then install blankets (5) and (10). Blankets should have 50 mm (2 in.) overlap on the ends.

89. Install the remaining exhaust blankets.

Page 6-86

Chassis Assembly

FAM0621

FIGURE 6-85. EXHAUST BLANKETS 1. Exhaust Blanket 2. Exhaust Blanket 3. Exhaust Blanket 4. Exhaust Blanket 5. Exhaust Blanket 6. Exhaust Blanket

FAM0621

7. Exhaust Blanket 8. Exhaust Blanket 9. Exhaust Blanket 10. Exhaust Blanket 11. Exhaust Blanket 12. Exhaust Blanket

Chassis Assembly

13. Exhaust Blanket 14. Exhaust Blanket 15. Exhaust Blanket 16. Exhaust Blanket

Page 6-87

90. Install the mud-flaps and mud guards.

91. Install any remaining handrails. Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

92. Before the engine is started the first time, the hydraulic system should be set up to perform the flushing procedure. Refer to the hydraulic system flushing procedure in the Appendix. The purpose of hydraulic system flushing is to eliminate contaminants that could have been introduced into the hydraulic system during truck assembly. Performing the flushing procedure will remove these contaminants from the hydraulic system and minimize the potential for hydraulic system component damage at startup.

Hydraulic system contamination can cause premature failure of hydraulic system components. To guard against premature hydraulic system component failure, perform the hydraulic system flushing procedure.

93. The truck is now ready for body installation.

Page 6-88

Chassis Assembly

FAM0621

DUMP BODY ASSEMBLY GENERAL INFORMATION

The total weight of the body is approximately 26,853 kg (59,201 lb). Use two cranes for assembling the body. A 45 metric ton (50 ton) crane and a 109-136 metric tons (120-150 ton) crane are required. The larger crane is needed to help turn the body over after completion of the underside welding.

Assembly of the body must be performed on flat terrain with an adequate area for welding machines and for maneuvering lifting equipment.

If the body is being welded in a cold climate, it is advisable to move the parts to be welded into an enclosed shop area. Surfaces to be welded must be dry and the temperature must be above 10°C (50°F).

If shop space is not available, it may be necessary to provide a portable enclosure and pre-heat the parts prior to welding.

In most instances, it is easier to assemble and weld the body while the sections are upside down. After the pivot, guide pin, and body pads are welded in place, the body can be turned over and the remainder of the assembly can be completed.

All paint must be removed from surfaces to be welded. Use a wire brush or paint removal equipment.

Refer to the assembly blueprints shipped with the truck for specific welding details and the parts required for assembly.

Body sections must be assembled as originally manufactured. Match the shipping numbers stenciled on the body sections to mate the correct parts. DO NOT mix components.

FIGURE 7-1. BODY PARTS NOMENCLATURE 1. Canopy 2. Front Sheet 3. RH Side Sheet

FAM0710

4. Lift Hole 5. Floor 6. Pivot

Dump Body Assembly

7. LH Side Sheet

Page 7-1

BODY ASSEMBLY NOTE: References to LH and RH in the following procedures assume the body is in its' normal, upright position, as shown in Figure 7-1.

1. Organize the body sections in a large, flat, open space. Position the sections side by side and upside down. Arrange the sections so they are properly oriented for assembly. Refer to Figure 7-2 for domestic configuration, and 7-3 for international configuration.

FIGURE 7-4.

5. Use the hydraulic jack to align the body halves at the rear. Install cap screw (1, Figure 7-5) and the sleeve.

NOTE: Figure 7-5 shows the hardware numbered in installation sequence. Cap screws (1, 2 & 7) are marked with an asterisk (*). These cap screws are installed with sleeves. The remainder of the cap screws do not have sleeves.

6. Install cap screw (2) and the sleeve at the front of the floor.

FIGURE 7-2. DOMESTIC LAYOUT

7. Install cap screw (3) in the front sheet near the floor. Attach a wedge or a clamp inside the body as necessary to align the front sheet.

8. Use a wedge to align the front sheet and canopy. Install cap screws (4, 5 & 6).

9. Install cap screw (7) and the sleeve in the front of the canopy.

10. Install cap screws (8 & 9).

11. Install the backer strips on the front sheet center joint as shown on the assembly blueprint.

FIGURE 7-3. INTERNATIONAL LAYOUT

NOTE: The backer strips must be tack welded in a location where the tack will be burned away on the first pass.

12. Loosely install cap screws (10 & 11) in the floor.

13. Loosen cap screws (1 & 2).

2. Remove the paint from the weld areas.

3. Lift the RH body half and support the front sheet, side sheets, and rear edge of the floor with blocks. Refer to Figure 7-4.

4. Lift the LH body and support with blocks under the front sheet and side sheet. Position a hydraulic jack on blocks at the tail end to support the floor at the rear. Refer to Figure 7-5.

Page 7-2

14. Attach appropriate lifting apparatus to the body pivot. Insert the lifting apparatus through the body pin bores. The weight of the pivot is approximately 1492 kg (3289 lb). DO NOT damage the bores.

15. Lift the pivot over the body. Lower the pivot into position against the rear of the body, as shown in Figure 7-6. Align the pivot with the body sills.

Dump Body Assembly

FAM0710

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

FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE

FIGURE 7-6. BODY PIVOT INSTALLATION

FAM0710

Dump Body Assembly

Page 7-3

16. If necessary, use a hydraulic jack or crane to raise the center of the body to allow the pivot to fit inside the bolsters. Loosely install the cap screws in the pivot.

BODY WELDING Follow the guidelines listed below when welding the body:

17. If assembling an international body (threepiece), lift the canopy into position at this time.

Install the canopy cap screws and tighten.

• Weld surfaces must be dry and above 10°C (50°F).

18. Tighten all floor, front sheet, and canopy cap screws. Use a chalk line to align the front of the canopy.

• If stick electrode is used, use as large a diameter rod as practical to weld the floor and front sheet joints.

19. Tighten the pivot cap screws.

20. Install the filler plates and backer strips for the pivot to body sill weld joints.

21. Check the alignment and fit of all components 22. Tack weld the joints.

• Use dry weld rod or weld wire.

• The following sequence must be followed for the front sheet: First Pass: Back step and skip weld in 10 increments along the entire length of the joint.

Refer to Figure 7-7.

Repeat the same procedure until the entire joint is filled. DO NOT stop welding until entire joint is complete.

• The body floor “V” groove must also be welded using the same procedure as the front sheet.

Weld from the front to the rear. Refer to Figure 77.

FIGURE 7-7. FRONT SHEET & FLOOR JOINT WELDING SEQUENCE

1. Complete the welds at the center seam, the front sheet and the canopy. Refer to the assembly blueprints for welding requirements.

2. Remove the canopy alignment blocks.

Page 7-4

Dump Body Assembly

FAM0710

3. Install the remaining gussets, the body guide and the body pad mounts. Refer to Figures 7-8 through 7-11.

DO NOT install the heated body exhaust boxes onto the body at this time. The exhaust boxes must be installed after the body is installed onto the truck.

FIGURE 7-10.

FIGURE 7-8.

FIGURE 7-11.

4. Once the body underside is completed, the body can be turned over. Use two cranes to invert the body, a 45 metric ton (50 ton) crane and a 109-136 metric ton (120-150 ton) crane.

The following photographs show a typical example of a body being inverted with two cranes.

FIGURE 7-9.

FAM0710

Position the body onto support blocks as shown in Figure 7-18.

Dump Body Assembly

Page 7-5

FIGURE 7-12.

FIGURE 7-14.

FIGURE 7-15.

FIGURE 7-13.

FIGURE 7-16.

Page 7-6

Dump Body Assembly

FAM0710

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

FIGURE 7-17.

FIGURE 7-19.

6. Install the mud flap brackets, clearance light housings (Figure 7-21), etc. as specified on the installation blueprints.

FIGURE 7-18.

FIGURE 7-20.

FAM0710

Dump Body Assembly

Page 7-7

7. Install any optional equipment such as body liners and side boards.

8. Clean the weld joints and paint.

Page 7-8

Dump Body Assembly

FAM0710

FINAL ASSEMBLY • Inspect all lifting devices. Slings, chains, and cables used for lifting components must be inspected daily for serviceable condition. Refer to the manufacturer’s guidelines for correct capacities and safety procedures when lifting components. Replace any questionable items.

• Slings, chains and cables used for lifting must be rated for approximately two times the intended load.

• When in doubt as to the weight of components or any assembly procedure, contact your customer support manager for further information.

• Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load.

• Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a suspended load.

• Before lifting the body, ensure there is adequate clearance between the body and overhead structures or electric power lines.

Before the engine is started the first time, the hydraulic system should be set up to perform the flushing procedure. Refer to the hydraulic system flushing procedure in the appendix. The purpose of hydraulic system flushing is to eliminate contaminants that could have been introduced into the hydraulic system during truck assembly. Performing the flushing procedure will remove these contaminants from the hydraulic system and minimize the potential for hydraulic system component damage at startup.

FAM0820 6/11

Final Assembly

Page 8-1

1. Body welding and chassis assembly must be completed before proceeding.

Before the body is lifted off the ground, tie guy ropes to each of the four corners of the body for aiding in installation.

There are two methods of installing the body depending on the cranes available. a. If the truck is operational and can be driven, two 50 ton cranes can be used, one positioned at either side of the body. The body can then be lifted high enough to allow the truck to be reverse propelled under the body (Figure 8-1). b. If a large crane of approximately 150 ton is available, the body can be lifted over the chassis and installed in a similar fashion to that in Step a.

2. With the body in position, install shims (6, Figure 8-4) in both body pivots. Install enough shims to fill the outboard gaps and to center the body on the frame pivot. DO NOT install shims at the inside. A minimum of one shim is required at the outboard end of both frame pivots.

3. Align the hole in pivot pin (3) with the cap screw hole in body ear (4). Push the pivot pin through shims (6), frame pivot (7), and into pivot bushings (5 & 9).

4. Install shoulder bolt (1, Figure 8-4) through the pin. Install flat washer (10) and nut (2). With nut tight, the bolt and washer should not be tight against the flat spot faces. Tighten nut (2) to 339 Nm (250 ft lb).

5. Install the pivot pin at the opposite side of the body.

6. Connect the lubrication lines to lube the pivot pins.

Page 8-2

Final Assembly

6/11 FAM0820

FIGURE 8-1.

FIGURE 8-2.

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Final Assembly

Page 8-3

FIGURE 8-3.

Page 8-4

Final Assembly

6/11 FAM0820

FIGURE 8-4. DUMP BODY PIVOT PIN 1. Shoulder Bolt 2. Nut 3. Body Pivot Pin 4. Body Ear 5. Body Pivot Bushing

FAM0820 6/11

6. Shim 7. Frame Pivot 8. Pivot Bushing 9. Body Pivot Bushing 10. Flat Washer

Final Assembly

Page 8-5

7. Align the hoist cylinder upper bushings with the body. Refer to Figure 8-5. Align the retaining cap screw hole and install pin (2, Figure 8-6).

Install shoulder bolt (4, Figure 8-6) flat washer (5) and nut (6). With nut tight, the bolt and washer should not be tight against the flat spot faces. Tighten nut (6) to 339 N¡m (250 ft lb).

8. Install the lubrication lines that lubricate the hoist cylinder pins.

Page 8-6

Final Assembly

6/11 FAM0820

FIGURE 8-5.

FIGURE 8-6. HOIST CYLINDER UPPER MOUNT 1. Dump Body 2. Hoist Cylinder Pin 3. Hoist Cylinder

FAM0820 6/11

4. Shoulder Bolt 5. Flat Washer 6. Nut

Final Assembly

Page 8-7

9. Shim the body pads as required. All pads, except the two rear pads, should contact the frame with approximately equal compression of the rubber. Refer to Figure 8-7.

A gap of approximately 1.5 mm (0.06 in.) is required at each rear pad. This can be accomplished by using one less shim at each rear pad.

10. Inspect pad contact. If pad contact appears to be unequal, correct as necessary.

Proper body pad to frame contact is required for maximum pad life.

Page 8-8

Final Assembly

6/11 FAM0820

FIGURE 8-7. BODY PAD INSTALLATION 3. Dump Body 5. Frame 7. Shim 4. Pad Mounting Hardware 6. Body Pad 8. Mounting Pad

FAM0820 6/11

Final Assembly

Page 8-9

11. Tack weld the rock ejector mounting brackets into position on the underside of the body. The ejectors must be positioned on the center line between the rear tires within 6.0 mm (0.25 in.). Before welding, drop a plumb line to check rock ejector clearance. Position the rock ejector a distance of 88 mm (3.5 in.) from the wheel housing. Refer to Figure 8-10.

NOTE: With rock ejector arm (1) hanging vertical as shown in Figure 8-9, there must be no gap at stop block (3).

If the rock ejector arms are bent during operation, they must be removed and straightened. Inspect the mounting brackets, pins and stops at each shift change for wear and/or damage. Repair as necessary.

Page 8-10

Final Assembly

6/11 FAM0820

FIGURE 8-8.

FIGURE 8-9. ROCK EJECTOR MOUNTING 1. Rock Ejector Arm 2. Pin

3. Stop Block 4. Mounting Bracket

FIGURE 8-10. ROCK EJECTOR INSTALLATION 3. Wheel Spacer 1. Rock Ejector Arm 2. Wear Sleeve

FAM0820 6/11

Final Assembly

Page 8-11

12. Install any remaining mud guards or flaps (Figures 8-11 & 8-12).

Page 8-12

Final Assembly

6/11 FAM0820

FIGURE 8-11.

FIGURE 8-12.

FAM0820 6/11

Final Assembly

Page 8-13

13. Install both body guide brackets loosely into place (Figure 8-13).

Once in position, slowly lower the body and mark the position in which the brackets are to be welded. The body guides must be centered between wear plates (3), with a maximum gap of 4.8 mm (0.19 in.) at each side.

14. Raise the body and attach the body retention cable. Remove the support blocks. Weld the body guide brackets into place.

To avoid serious personal injury or death, the body up retention cable must be installed anytime personnel are required to perform maintenance on the vehicle with the dump body in the raised position.

The Komatsu body-up safety sling can only be used with a Komatsu body. Non-OEM body may not accommodate the Komatsu body-up safety sling. The end user must ensure that a proper cable/sling is used.

Page 8-14

Final Assembly

6/11 FAM0820

FIGURE 8-13. BODY GUIDE 1. Dump Body 2. Body Guide

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3. Body Guide Wear Plates

Final Assembly

Page 8-15

15. Adjust the body up switch.

Figure 8-14 shows the body-up switch (2) and the magnet (1) used to activate the switch.

If switch adjustment is necessary, follow the procedure below: a. With the body resting completely on the frame, loosen switch mounting bracket cap screws and the magnet adjustment cap screws. b. Position the upper edge of the magnet (1) 131.5 mm (5.18 in.) (Dimension A, Figure 8-14) from the bottom of mounting bracket. Tighten cap screws. c. Adjust the proximity switch (2) so the passing distance between the two targets is 45 mm (1.77 in) (Dimension B). Tighten cap screws. Refer to the assembly prints for specifications.

16. Hoist limit switch adjustment a. Prior to adjustment, the dump body must be raised to 152 mm (6 in.) of the maximum hoist cylinder extension and supported in that location. b. Loosen proximity switch adjustment cap screws (4, Figure 8-15). Slide switch (1) up or down to position the top of the switch 30 mm (1.18 in.) (Dimension B) away from the lower edge of magnet (2). Tighten the cap screws when adjusted properly. If necessary, cap screws (3) could also be loosened to move the magnet to obtain the 30 mm (1.18 in.) gap.

NOTE: Since a magnetic target is used to activate the switch, a larger initial distance in setting the switch is required. This is due to the fact that magnetic fields are not crisp 90 degree boxed fields but are instead curved about the shape of the magnet. Refer to Figure 8-17. The sensing field boundary limit takes on the same curved sensing area shape of the magnet field. The curved sensing area results in the actuation of the switch approximately 30 mm (1.18 in.) prior to reaching the edge of the magnet. Therefore, it is crucial that the 30 mm (1.18 in.) is observed when setting the hoist limit switch.

Page 8-16

Final Assembly

6/11 FAM0820

FIGURE 8-14. BODY-UP SWITCH ADJUSTMENT 1. Magnet

2. Body-Up Switch

FIGURE 8-15. HOIST LIMIT SWITCH (SIDE VIEW) 1. Proximity Switch 2. Magnet

FAM0820 6/11

3. Cap Screws 4. Cap Screws

Final Assembly

5. Dump Body

Page 8-17

c. Loosen cap screws (2, Figure 8-16) securing proximity switch (3) to the mounting bracket. Slide the switch to the left or right until the passing distance between the two targets is 45 mm (1.77 in.) (Dimension A).

Tighten the cap screws after adjusting. Refer to Figure 8-17 for an illustration of optimum setting of the switch. d. Lower the body onto the frame. e. Check the operation of the proximity switch to verify that the hoist cylinders stop before reaching maximum cylinder stroke. If the cylinders extend to full stroke, adjust the proximity switch as necessary to prevent full cylinder extension.

FIGURE 8-16. HOIST LIMIT SWITCH (REAR VIEW) 1. Magnet 2. Cap Screws

Page 8-18

3. Proximity Switch

Final Assembly

6/11 FAM0820

FIGURE 8-17. HOIST LIMIT SWITCH OPTIMUM SETTING ADJUSTMENT

FAM0820 6/11

Final Assembly

Page 8-19

17. Install the LH & RH engine inspection lights (Figure 8-18).

Page 8-20

Final Assembly

6/11 FAM0820

FIGURE 8-18.

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Final Assembly

Page 8-21

18. Install bolt-on components such as the lubrication system. a. Remove the pipe plug from each injector bank, one at a time. b. Disconnect hose (22, Figure 8-20) and connect it to a grease supply source. Pump grease into the hose until grease appears at the injector bank where the pipe plug was removed. Install pipe plug. c. At another injector bank, remove pipe plug, and pump grease into hose (22) until grease appears at the open port at the injector bank. Install plug. d. Remove the plug at injector bank on the rear axle housing. Pump grease into hose (22) until grease appears at the open port at the injector bank. Install plug. e. At each injector bank, remove cover on each injector. Pump grease into the zerk until grease appears at the lube point where the hose is connected. Install cap, and repeat process on each injector on the truck.

19. Verify that all electrical and hydraulic connections are correct. Refer to Figure 8-19 and Figure 8-20

FIGURE 8-19.

Page 8-22

Final Assembly

6/11 FAM0820

FIGURE 8-20. LUBRICATION SYSTEM

1. L.H. Suspension, Bottom Bearing 2. L.H. Hoist Cylinder, Top Bearing 3. L.H. Hoist Cylinder, Bottom Bearing 4. L.H. Anti-Sway Bar Bearing 5. L.H. Suspension, Top Bearing 6. L.H. Body Pivot Pin 7. R.H. Body Pivot Pin 8. Grease Supply From Pump 9. R.H. Suspension, Bottom Bearing 10. R.H. Hoist Cylinder, Top Bearing 11. R.H. Hoist Cylinder, Bottom Bearing 12. Rear Axle Pivot Pin

FAM0820 6/11

13. R.H. Anti-Sway Bar Bearing 14. R.H. Suspension, Top Bearing 15. Truck Frame 16. Vent Hose 17. Pipe Plug (Oil Level) 18. Pressure Switch, N.O. - 20 684 kPa (3,000 psi) 19. Grease Pump 20. Vent Valve 21. Filter 22. Grease Supply to Injectors 23. Injectors 24. Pressure Switch, N.O. - 13 790 kPa (2,000 psi)

Final Assembly

Page 8-23

20. If equipped, install the fire system. Refer to Figures 8-21 & 8-22.

This installation is normally performed by the fire system distributor.

Page 8-24

Final Assembly

6/11 FAM0820

FIGURE 8-21.

FIGURE 8-22.

FAM0820 6/11

Final Assembly

Page 8-25

21. If equipped with the optional camera system, install the four cameras. Three cameras mount to the front of the truck, and one camera mounts on the rear of the truck. Refer to Figure 8-25 for camera location.

22. To install the front cameras, attach each camera assembly (1, Figure 8-23) to one of the three locations on the front of the truck. Use the slots in the mounting hardware to adjust camera viewing area. If needed, the final adjustment will take place during camera system setup. Connect the camera cable (4) to the cable installed on the truck. Secure all camera cables with clamps supplied on the truck.

NOTE: During camera installation, ensure the triangle arrow printed inside the camera lens is pointing straight up.

If necessary, adjustment can be made by loosening clamp hardware (2, Figure 8-24) on each camera and rotate the camera inside camera socket (3) to level the camera. If the camera is not level, the view displayed on the camera monitor inside the cab will not be level.

23. Install rear camera (3, Figure 8-24) just below the rear tail light assembly. Use the slots in the mounting brackets to adjust camera viewing area. If needed, the final adjustment will take place during camera system setup.

Connect camera cable (4) to the cable installed on the truck. Route cable (4) through all clamps supplied on the truck.

24. Once the truck is fully operational, refer to the Appendix in this manual and perform the camera system checkout procedure.

FIGURE 8-24. REAR CAMERA

FIGURE 8-23. FRONT CAMERAS 1. Camera Assembly 2. Mounting Hardware

Page 8-26

3. Adjustment Hardware 4. Cable

1. Mounting Hardware 2. Clamp Hardware

Final Assembly

3. Camera Socket 4. Cable

6/11 FAM0820

FIGURE 8-25. CAMERA LOCATIONS 1. Front Center Camera 2. Right Front Camera

FAM0820 6/11

3. Left Front Camera 4. Rear Camera

Final Assembly

Page 8-27

25. Paint the truck as needed.

26. Install all decals on their designated areas (Figure 8-26). Refer to installation drawings for exact decal location.

NOTE: Diagonal ladder may not always be installed (right to left) as shown.

Page 8-28

Final Assembly

6/11 FAM0820

FIGURE 8-26.

FAM0820 6/11

Final Assembly

Page 8-29

27. After completing the assembly of the truck, verify that all cap screw heads or nuts are marked with paint, indicating they have been properly tightened.

Check all hydraulic lines and electrical connections for secure installation.

Notify qualified maintenance personnel that the truck is ready for final static and dynamic systems checkout.

Page 8-30

Final Assembly

6/11 FAM0820

FINAL CHECKOUT

1. Complete delivery and warranty forms.

5. Before the engine is started the first time, the hydraulic system should be set up to perform the flushing procedure. Refer to the hydraulic system flushing procedure in the appendix. The purpose of hydraulic system flushing is to eliminate contaminants that could have been introduced into the hydraulic system during truck assembly. Performing the flushing procedure will remove these contaminants from the hydraulic system and minimize the potential for hydraulic system component damage at startup.

2. Check all coolant and lubricants for proper levels and specifications. The lubrication chart is shown in Section 10, Appendix.

6. Perform a final check of all systems and prepare for operation. The checks and tasks are outlined in Section 10, Appendix.

3. Verify the shut-off valves on the hydraulic tank suction lines are open.

7. Burnish the brakes as outlined in the shop manual. After burnishing, perform a static brake system checkout. The static brake system checkout can be found in Section 10, Appendix.

Final checkout requires truck operation.

Place the operation and maintenance manual and safety manuals in the operator cab, if not already there.

Any personnel involved in the final check-out of the truck must read and understand all safety and operating instructions in the operation and maintenance manual.

4. Purge any air from the pumps and suction lines.

Pressure will not build if air is present. Operating the pumps with air in the system will result in damage. Refer to the truck assembly section for more information on how to bleed the air from the pumps and suction lines.

8. Charge the A/C system with freon as described in the shop manual. Check the performance of the A/C system.

9. Complete the checks listed in the Field Assembly Inspection Report Form. A copy of the form is provided with the truck and is also available in Section 10, Appendix.

10. Operate the truck in a traffic-free area until safe operation has been validated.

11. Release the truck for use after all checks have been completed and all deficiencies corrected.

FAM0909 7/10

Final Checkout

Page 9-1

NOTES

Page 9-2

Final Checkout

7/10 FAM0909

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

1. Lubrication Chart - FAM1103 2. Suspension Oiling And Charging Procedure - FAM1203 3. Toe In Adjustment Procedure - FAM1301 4. Automatic Lubrication System Checkout Procedure - FAM1404 5. Air Conditioning Checkout Procedure - EM4003-2 6. Hydraulic Checkout Procedure - EL2603-0 7. Brake Checkout Procedure - EL6704-1 8. VHMS Checkout Procedure - EM2129-1 9. Interface Module Checkout Procedure - XB0254-0

10. Additional Interface Module Checkout Procedure - EM7279-1

11. Payload Meter III Checkout Procedure - EJ3061-3

12. Electrical Checkout Procedure - EF9650-10

13. Amendments to Electrical Checkout Procedure - EM8300-3

14. Standard Torque Charts and Conversion Tables - FAM1501

15. Hydraulic System Flushing Procedure - FAM1601

16. Static Brake System Checkout - FAM1701

17. Camera System Checkout - XB9700-0

FAM1021 6/11

Appendix

Page 10-1

18. Field Assembly Inspection Report

19. 50 Hour Post Commissioning Checksheet

Page 10-2

Appendix

6/11 FAM1021

LUBRICATION CHART FAM1103

Lubrication Chart

F11-1

NOTES

F11-2

Lubrication Chart

FAM1103

OILING AND CHARGING PROCEDURE GENERAL These procedures cover the Oiling and Charging of HYDRAIR®II suspensions on Komatsu Electric Drive Dump Trucks.

Suspensions which have been properly charged will provide improved handling and ride characteristics while also extending the fatigue life of the truck frame and improving tire wear.

NOTE: Inflation pressures and exposed piston lengths are calculated for a normal truck gross vehicle weight (GVW). Additions to truck weight by adding body liners, tailgates, water tanks, etc. should be considered part of the payload. Keeping the truck GVW within the specification shown on the Grade/ Speed Retard chart in the operator cab will extend the service life of the truck main frame and allow the HYDRAIR®II suspensions to produce a comfortable ride.

®

All HYDRAIR II suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury and/or damage if improperly handled. Follow all safety instructions, cautions, and warnings provided in the following procedures to prevent any accidents during Oiling and Charging.

Proper charging of HYDRAIR ®II suspensions requires that three basic conditions be established in the following order:

For best results, HYDRAIR® II suspensions should be charged in pairs (fronts together and rears together). If rears are to be charged, the fronts should be charged first.

NOTE: For longer life of suspension components, a Friction Modifier should be added to the suspension oil. See Specifications Chart, Figure 12-6 at the end of this chapter.

NOTE: Set up dimensions specified in the charts must be maintained during oiling and charging procedures. However, after the truck has been operated, these dimensions may vary.

EQUIPMENT LIST •

HYDRAIR® Charging Kit

•

Jacks and/or Overhead Crane

•

Support Blocks (Front and Rear) for: Oiling Height Dimensions Nitrogen Charging Height Dimensions

•

HYDRAIR® Oil (See Specifications Chart)

•

Friction Modifier (See Specifications Chart)

•

Dry Nitrogen (See Specifications Chart)

If both front and rear suspension are to be serviced at the same time, service the front suspensions first.

Do not remove the front suspension nitrogen charging blocks until after the rear suspensions have been completely serviced.

1. Oil level must be correct.

2. Suspension piston rod extension for nitrogen charging must be correct.

3. Nitrogen charge pressure must be correct.

FAM1203 1/11

Oiling and Charging Procedures

F12-1

HYDRAIR® CHARGING KIT Assemble service kit as shown in Figure 12-1 and attach to container of pure dry nitrogen (8).

Installation of Charging Kit 1. Remove protective covers and charging valve caps from suspensions to be charged.

2. Turn "T" handles (1, Figure 12-1) of adapters (2) completely counterclockwise.

5. Attach charging valve adapters (2) to each suspension charging valve stem.

6. Turn "T" handles (1) clockwise (this will depress core of charging valve and open the gas chamber of the suspension).

7. Open both outlet valves (3).

NOTE: By selective opening and closing of outlet valves (3), and inlet valve (4), suspensions may be charged separately or together.

3. Ensure outlet valves (3) and inlet valve (4) are closed (turned completely clockwise).

4. Turn swivel nut (small hex) on charging valve three full turns counterclockwise to unseat the valve.

Removal of Charging Kit 1. Close both outlet valves (3).

2. Turn "T" handles (1) counterclockwise to release charging valve cores.

3. Remove charging valve adapters (2) from charging valves.

4. If charging valve is being reused, tighten swivel nut (4, Figure 12-3) to 6 N·m (50 in. lbs) torque.

If a new charging valve is being used, tighten swivel nut to 15 N·m (11 ft lbs) torque, then loosen and retighten swivel nut to 15 N·m (11 ft lbs) torque. Again loosen swivel nut and retighten to 6 N·m (50 in. lbs) final torque.

Install valve cap (1) and tighten finger tight.

5. Install charging valve caps and protective covers on both suspensions.

FIGURE 12-1. HYDRAIR ® CHARGING KIT NOTE: Arrangement of parts may vary from illustration above, depending on Charging Kit P/N. 1. “T” Handle Valve 2. Charging Valve Adapter 3. Manifold Outlet Valves (from gauge) 4. Inlet Valve (from regulator) 5. Regulator Valve (Nitrogen Pressure) 6. Manifold 7. Charging Pressure Gauge (Suspensions) 8. Dry Nitrogen Gas (Specifications Figure 12-6)

F12-2

Oiling and Charging Procedures

1/11 FAM1203

SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS Prior to starting oiling and charging procedures, supports should be fabricated which will maintain the correct exposed piston rod extensions.

Nitrogen charging support blocks for the rear suspension are no longer necessary. However, oiling blocks are necessary to properly set the oiling height.

Exposed piston rod extensions are specified for both oil level and nitrogen charging for HYDRAIR ÂŽII suspensions. These dimensions are listed in the Tables 1 and 2. Measure dimensions from the face of the cylinder gland to the machined surface on the spindle at the front suspension. On the rear suspensions, measure from the surface of the bearing retainer to the flat surface on the piston flange.

Support blocks may be made in various forms. Mild steel materials are recommended. Square stock or pipe segments [1 in. (25 mm) minimum] may be used. Blocks must be capable of supporting the weight of the truck during oiling and charging procedures while avoiding contact with plated surfaces and seals on the suspension. Refer to Figure 12-2 for front suspension support block placement and Figure 12-4 for rear support block placement.

FRONT SUSPENSION 1. Park the unloaded truck on a hard, level surface. Place the directional control lever in PARK. Place wheel chocks in front and behind two rear tires to prevent roll away.

NOTE: Do not place wheel chocks around front tires.

The front tires will roll forward and backward a small amount as the suspension travels up and down during the suspension charging process.

2. Thoroughly clean area around the charging valve on the suspensions. Remove the protective covers from the charging valves.

All HYDRAIRÂŽII suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury and/or damage if improperly handled. Follow all the safety notes, cautions and warnings in these procedures to prevent accidents during servicing and charging.

Front Suspension Oiling

When blocks are in place on a suspension, they must be secured with a strap or other means to avoid accidental discharge. An unsecured block could fly loose as weight is applied, presenting the possibility of serious injury to nearby personnel and/or damage to the equipment. Overhead clearance may be reduced rapidly and suddenly when nitrogen pressure is released!

NOTE: For longer life of suspension components, a Friction Modifier should be added to the suspension oil. See Specifications Chart, Figure 12-6 at the end of this chapter.

FAM1203 1/11

Oiling and Charging Procedures

F12-3

1. Position and secure oiling height dimension blocks in place (Figure 12-2). When nitrogen pressure is released, suspensions will lower to rest on the blocks. Ensure the blocks do not mar or scratch the plated surfaces of the pistons or damage wiper seals in the lower bearing retainer. Support blocks must seat on the spindle and the cylinder housing. The blocks should be positioned 180° apart to provide stability.

Wear a face mask or goggles while relieving nitrogen pressure.

2. Remove charging valve cap. Turn the charging valve swivel nut (small hex) counterclockwise three full turns to unseat valve seal. DO NOT TURN LARGE HEX. The charging valve body has a bleeder groove in its mounting threads but for safety of all personnel the valve body MUST NOT be loosened until ALL nitrogen pressure has been vented from the suspension.

3. Depress the charging valve core to release nitrogen pressure from the suspension. When all nitrogen has been vented to the atmosphere, the suspension should have collapsed slowly and be seated solidly on the support blocks.

FIGURE 12-2. FRONT SUSPENSION

4. Remove top fill plug next to the charging valve (Figure 12-2).

TABLE 1: FRONT SUSPENSION DIMENSIONS (EMPTY)

5. Fill the suspension with clean HYDRAIRÂŽ oil (with 6% friction modifier) until the cylinder is full to the top of the fill plug bore. Drip pans should be used and all spillage cleaned from outside of the suspension. Allow the suspension to stand for at least 15 minutes to clear any trapped nitrogen and/or bubbles from the oil. Add more suspension oil if necessary. Install a new fill plug O-ring, and install the plug.

OILING HEIGHT

CHARGING HEIGHT

CHARGING PRESSURE

25.4 mm (1.0 in.)

229 mm (9.00 in.)

*2 696 kPa (391psi)

* Charging pressures are for reference only and may vary depending on body weights.

NOTE: The front suspension holds approximately 89.7 l (23.7 gal) of oil.

F12-4

Oiling and Charging Procedures

1/11 FAM1203

Front Suspension Nitrogen Charging

2. Tighten valve body (large hex, 6) to 23 N·m (17 ft lbs) torque. The valve swivel nut (small hex, 4) must be unseated by turning counterclockwise three full turns.

Lifting equipment (crane or hydraulic jacks) must be of sufficient capacity to lift the truck weight.

Be certain that all personnel are clear of lift area before lift is started. Clearances under the truck may be suddenly reduced.

1. If removed, install the charging valve with new O-ring (9, Figure 12-3). Lubricate the O-ring with clean HYDRAIR®oil.

Dry nitrogen is the only gas approved for use in HYDRAIR ®II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in chart (Figure 12-6).

3. Install HYDRAIR ® Charging Kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit. 4. Charge the suspensions with nitrogen gas to a height just high enough to install the nitrogen charging blocks, but not to exceed 27.9 cm (11 in). Close inlet valve (4, Figure 12-1).

5. Remove the oiling blocks from the suspensions and install the nitrogen charging blocks. Secure the blocks to prevent accidental dislodging.

NOTE: Use caution to prevent damage to plated cylinder surfaces and oil seals when installing the blocks.

FIGURE 12-3. CHARGING VALVE 6. Remove the center hose from manifold (6).

1.

2.

3.

4.

5.

Valve Cap Seal Valve Core Swivel Nut Rubber Washer

6. Valve Body 7. O-Ring 8. Valve Stem 9. O-Ring Be aware when relieving nitrogen gas, the truck may drop suddenly onto the charging blocks.

7. To lower the truck onto the charging blocks, open inlet valve (4) until the pressure has dropped below the pressure listed in Figure 122, and then close the valve.

8. Install the center hose to manifold (6).

FAM1203 1/11

Oiling and Charging Procedures

F12-5

9. Charge the suspensions to the pressure listed in Table 1. DO NOT use an overcharge of nitrogen to lift the suspensions off of the charging blocks.

10. Close inlet valve (4, Figure 12-1). Leave outlet valves (3) open for five minutes in order to allow the pressures in the suspensions to equalize.

11. Close outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit. 12. If charging valve is being reused, tighten swivel nut (4, Figure 12-3) to 6 N·m (50 in. lbs) torque.

If a new charging valve is being used, tighten swivel nut to 15 N·m (11 ft lbs) torque, then loosen and retighten swivel nut to 15 N·m (11 ft lbs) torque. Again loosen swivel nut and retighten to 6 N·m (50 in. lbs) final torque.

Install valve cap (1) and tighten finger tight.

The front HYDRAIR® suspensions are now ready for operation. Visually check the extension with the truck both empty and loaded. Record the extension dimensions. Maximum downward travel is indicated by the dirt ring at the base of the piston. Operator comments on steering response and suspension rebound should also be noted.

NOTE: The empty ride height may be less than the charging ride height. Also, the suspension height between the left and right suspensions may not always be the same due to the fuel level in the fuel tank.

REAR SUSPENSION

13. Install protective guard over charging valve.

NOTE: If the rear suspension are to be serviced at this time, leave the nitrogen charging blocks in place on the front suspensions until after the rear suspensions are completely serviced.

14. Raise the truck body in order to extend the front suspensions and allow for removal of the nitrogen charging blocks. Ensure that sufficient overhead clearance exists before raising the body. If the suspensions do not extend after raising the body, turn the steering wheel left and right in very small movements several times. If the suspensions still do not extend enough to allow for removal of the blocks, use a crane or floor jacks to raise the truck and remove the blocks.

Any time the suspensions are recharged, the calibration of the Payload Meter system is affected. Refer to the Payload Meter III ™ section and perform a “Clean Truck Tare”. This will ensure accurate payload records.

F12-6

Do not mix rod up with rod down designed suspensions on the same truck. Both rear suspensions must be of the same type.

1. Park the unloaded truck on a hard, level surface. Move the directional control lever to the PARK position.

2. Place wheel chocks in front and behind two sets of rear wheels to prevent roll away.

NOTE: Do not place wheel chocks around front tires.

The front tires will roll forward and backward a small amount as the suspension travels up and down during the suspension charging process.

3. Thoroughly clean the area around the charging valve on the suspensions. Remove the protective covers from the charging valves and the metal covers from the suspension piston.

NOTE: For longer life of suspension components, a Friction Modifier must be added to the suspension oil. See Specifications Chart, Figure 12-6 at the end of this chapter.

Oiling and Charging Procedures

1/11 FAM1203

Rear Suspension Oiling 1. Position and secure oiling support blocks (2, Figure 12-4) in place so the blocks are seated between main frame (1) and rear axle housing (3). A block should be used on both the left and right sides of the truck.

Ensure all personnel are clear and support blocks are secure before relieving nitrogen pressure from the suspension. Use a face mask or goggles when venting nitrogen.

2. Remove charging valve cap. Turn the charging valve swivel nut (small hex) counterclockwise three full turns to unseat valve seal. DO NOT TURN LARGE HEX. The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body MUST NOT be loosened until ALL nitrogen pressure has been vented from the suspension.

3. Depress the charging valve core to release nitrogen pressure from the suspension. When nitrogen pressure has been vented to atmosphere, loosen and remove the fill plug. The suspension should have collapsed slowly as gas pressure was released. Truck weight is now supported by the support blocks.

4. Adjust oiling support blocks (2, Figure 12-4) to obtain the oiling height dimension shown in Table 2.

FIGURE 12-4. REAR SUSPENSION 1. Main Frame 2. Oiling Support Block

3. Rear Axle Housing

TABLE 2: REAR SUSPENSION DIMENSIONS (EMPTY) OILING HEIGHT

CHARGING HEIGHT

CHARGING PRESSURE

54.2 mm (2.13 in.)

270 mm (10.63 in.)

*1 186 kPa (172psi)

* Charging pressures are for reference only and may vary depending on body weights.

NOTE: Use a plastic tube to help bleed off trapped air inside the piston.

5. Remove vent plug (2, Figure 12-5), pressure sensor (3), and charging valve (4). Use one of the open ports to fill the suspension with clean HYDRAIRÂŽ Oil (with 6% friction modifier). Fill until clean oil seeps from the open ports. Use drip pans should be used and all spillage cleaned from the outside of the suspension.

Allow the suspension to settle for at least 15 minutes to clear any trapped nitrogen and bubbles from the oil. Add more suspension oil if necessary.

NOTE: The rear suspension holds approximately 51.1 l (13.5 gal) of oil.

6. Install the vent plug and pressure sensor onto the suspension.

FAM1203 1/11

Oiling and Charging Procedures

F12-7

7. Install a new O-ring onto the charging valve.

Lubricate the O-ring with clean Hydrair II oil.

Rear Suspension Nitrogen Charging

8. Install the charging valve onto the suspension.

Tighten valve body (6, Figure 12-3) to 23 Nm (17 ft lb).

Lifting equipment (overhead or mobile cranes, or hydraulic jacks) must be of sufficient capacity to lift the truck weight. Be certain that all personnel are clear of lift area before lift is started. Clearances under the truck may be suddenly reduced.

Ensure the automatic apply circuit has not applied the service brakes during truck maintenance. If the front brakes are applied during rear suspension charging, the axle cannot pivot for frame raising / lowering, and the rear suspension may be unable to move up or down.

1. If removed, install charging valve with new Oring (9, Figure 12-3). Lubricate the O-ring with clean HYDRAIR ®oil.

2. Tighten valve body (large hex, 6) to 23 N·m (17 ft lbs) torque. The valve swivel nut (small hex, 4) must be unseated by turning counterclockwise three full turns.

FIGURE 12-5. REAR SUSPENSION 1. Main Frame 2. Vent Plug / Fill Port 3. Pressure Sensor / Fill Port

4. Charging Valve / Fill Port 5. Rear Axle Housing

Dry nitrogen is the only gas approved for use in HYDRAIR ®II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in chart (Figure 12-6).

3. Install HYDRAIR ® Charging Kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit. 4. Charge the suspensions with nitrogen gas to 38 mm (1.5 in.) greater than the charging height listed in Table 2.

F12-8

Oiling and Charging Procedures

1/11 FAM1203

10. If the charging valve is being reused, tighten swivel nut (4, Figure 12-3) to 6 N·m (50 in. lbs) torque.

5. Remove the oiling charging blocks.

Be aware when relieving nitrogen gas, the truck may lower suddenly.

6. Slowly release gas until the suspensions match the charging height listed in Table 2.

7. Close inlet valve (4, Figure 12-1). Leave outlet valves (3) open for five minutes in order to allow the pressures in the suspensions to equalize.

8. Ensure both of the suspension cylinders are extended the same distance ± 10 mm (0.39 in.).

If the difference in the extension from side to side exceeds 10 mm (0.39 in.), check the front suspensions for equal extension. Adjust the front as necessary.

NOTE: A low left front suspension will cause the right rear suspension to be high. A low right front suspension will cause the left rear suspension to be high.

If a new charging valve is being used, tighten swivel nut to 15 N·m (11 ft lbs) torque, then loosen and retighten swivel nut to 15 N·m (11 ft lbs) torque. Again, loosen swivel nut and retighten to 6 N·m (50 in. lbs) final torque.

Install valve cap (1) and tighten finger tight.

11. Install the protective guards over the charging valves. Install the rubber covers with hose clamps over the suspension housings.

Any time the suspensions are recharged, the calibration of the Payload Meter system is affected. Refer to the Payload Meter III ™ section and perform a “Clean Truck Tare”. This will ensure accurate payload records.

The rear HYDRAIR® suspensions are now ready for operation. Visually check piston extension both with the truck loaded and empty. Record the extension dimensions. Maximum downward travel is indicated by the dirt ring at the base of the piston rod. Operator comments on steering response and suspension rebound should also be noted.

9. Close outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit.

FAM1203 1/11

Oiling and Charging Procedures

F12-9

OIL AND NITROGEN SPECIFICATIONS CHART HYDRAIR ® II OIL SPECIFICATIONS Ambient Temperature Range

-30°F & above (-34.5°C & above)

Part No.

Approved Sources

VJ3911 (need to add 6% of AK3761)

Sunfleet TH Universal Tractor Fluid Mobilfluid 424 Chevron Tractor Hydraulic FluidMobil DTE 15M Conoco Power Tran III Fluid Texaco TDH Oil Petro Canada Duratran Fluid AMOCO ULTIMATE Motor Oil Shell Canada Donax TDL 5W-30

AK4063

Suspension Oil (premixed with 6% Friction Modifier)

AK4064

-55°F & above (-48.5°C & above)

5 Gallon container 55 Gallon container

VJ5925 (need to add 6% of AK3761)

Emery 2811, SG-CD, 5W-30 Mobil Delvac I, 5W-40

Petro Canada Super Arctic Motor Oil, 0W-30 Conoco High Performance Synthetic Motor Oil, 5W-30

AK4065

Suspension Oil (premixed with 6% Friction Modifier)

5 Gallon container

AK4066

55 Gallon container

NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and VJ5925 oils are supplied in 5 gallon (19 Liter) cans.

FRICTION MODIFIER

FRICTION MODIFIER Mixing Instructions (94% Suspension oil, 6% Friction Modifier)

Part Number

Suspension Oil

Amount of Friction Modifier to add

AK3761 (5 Gallon container of 100% Friction Modifier)

1 gallon of suspension oil

add 7.7 oz.

5 gallons of suspension oil

add 38.4 oz.

55 gallons of suspension oil

add 3.3 gal.

NITROGEN GAS (N2)SPECIFICATIONS ®

Nitrogen gas used in HYDRAIR II Suspension Cylinders must meet or exceed CGA specification G-10.1 for Type 1, Grade F Nitrogen Gas

Property

Value

Nitrogen

99.9% Minimum

Water

32 PPM Maximum

Dew Point

-68°F (-55°C) Maximum

Oxygen

0.1% Maximum

FIGURE 12-6. SPECIFICATIONS CHART

F12-10

Oiling and Charging Procedures

1/11 FAM1203

TOE-IN ADJUSTMENT 1. Center the front wheels by straightening the steering wheel. Turn the key switch OFF. Allow at least 90 seconds for the accumulators to depressurize. DO NOT turn the steering wheel during this time.

2. Chock the front and back of the rear wheels.

3. Check the toe-in by measuring the distance between the centers of the front tires. Measure on the horizontal centerline at both the front and the rear of the tires. Refer to Figure 13-1.

Radial tires must have equal measurements at the front and the rear of the tires. Equal measurements results in 0 toe-in.

830E TOE-IN DATA Nominal tie-rod length, radial tires to achieve: 0 toe-in

3658 mm (144.0 in.)

4. If the measurements are not equal, adjust the tie rod. Loosen the clamp locknuts on the tie rod. Rotate the tie rod as necessary to obtain the correct toe-in setting of 0.

5. When the adjustment is complete, tighten the tie rod clamp cap screws and locknuts to 420 N¡m (310 ft lb). Reapply torque to each capscrew and locknut until the specified torque is maintained.

FIGURE 13-1. MEASURING TOE-IN

6. Remove the wheel chocks from the rear wheels.

FAM1301 1/11

Toe-In Adjustment

Page F13-1

NOTES

Page F13-2

Toe-In Adjustment

1/11 FAM1301

AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION The automatic lubrication system is a pressurized lubricant delivery system which delivers a controlled amount of lubricant to designated lube points. The system is controlled by an electronic timer which signals a solenoid valve to operate a hydraulic motor powered grease pump. Hydraulic oil for pump operation is supplied by the truck steering circuit.

Grease output is proportional to the hydraulic motor input flow. A pump control manifold, mounted on top of the hydraulic motor, controls input flow and pressure. A 24VDC solenoid mounted on the manifold turns the pump on and off.

The pump is driven by the rotary motion of the hydraulic motor, which is then converted to reciprocating motion through an eccentric crank mechanism.

The reciprocating action causes the pump cylinder to move up and down. The pump is a positive displacement, double-acting type as grease output occurs on both the up and the down stroke.

During the down stroke, the pump cylinder is extended into the grease. Through the combination of shovel action and vacuum generated in the pump cylinder chamber, the grease is forced into the pump cylinder. Simultaneously, grease is discharged through the outlet of the pump. The volume of grease during intake is twice the amount of grease output during one cycle. During the upstroke, the inlet check valve closes. One half of the grease taken in during the previous stroke is transferred through the outlet check and discharged to the outlet port.

Over-pressurizing the system, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts may result in equipment damage and/or serious personal injury.

• DO NOT exceed the stated maximum working pressure of the pump or the lowest rated component in the system.

• Do not alter or modify any part of this system unless approved by the factory.

• Do not attempt to repair or disassemble the equipment while the system is pressurized.

• Make sure all fluid connections are securely tightened before using this equipment.

• Always read and follow the fluid manufacturer's recommendations regarding fluid compatibility, and the use of protective clothing and equipment.

FIGURE 14-1. PUMP & RESERVOIR 1. Hose From Filter 2. Vent Hose 3. Hydraulic Motor 4. Pressure Reducing Valve 5. Solenoid Valve 6. Override Switch

FAM1404

7. Vent Valve 8. Pipe Plug 9. Pump Assembly 10. Flow Control Valve 11. Pressure Switch 12. Grease Reservoir

• Check all equipment regularly. Repair or replace worn or damaged parts immediately.

This equipment generates very high grease pressure. Extreme caution must be used when operating this equipment as material leaks from loose or ruptured components can inject fluid through the skin and into the body causing serious bodily injury including possible need for amputation.

Adequate protection is recommended to prevent splashing of material onto skin or into the eyes.

If any fluid appears to penetrate the skin, get emergency medical care immediately! Do not treat as a simple cut. Tell attending physician exactly what fluid was injected.

Automatic Lubrication System

F14-1

FIGURE 14-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION NOTE: The above illustration shows the standard location for the lube pump and reservoir (right platform). This assembly may be located on the left platform on some models.

1. L.H. Suspension, Bottom Bearing 2. L.H. Hoist Cylinder, Top Bearing 3. L.H. Hoist Cylinder, Bottom Bearing 4. L.H. Anti-Sway Bar Bearing 5. L.H. Suspension, Top Bearing 6. L.H. Body Pivot Pin 7. R.H. Body Pivot Pin 8. Grease Supply From Pump 9. R.H. Suspension, Bottom Bearing 10. R.H. Hoist Cylinder, Top Bearing 11. R.H. Hoist Cylinder, Bottom Bearing 12. Rear Axle Pivot Pin

F14-2

13. R.H. Anti-Sway Bar Bearing 14. R.H. Suspension, Top Bearing 15. Truck Frame 16. Vent Hose 17. Pipe Plug (Oil Level) 18. Pressure Switch, N.O. - 20 684 kPa (3,000 psi) 19. Grease Pump 20. Vent Valve 21. Filter 22. Grease Supply to Injectors 23. Injectors 24. Pressure Switch, N.O. - 13 790 kPa (2,000 psi)

Automatic Lubrication System

FAM1404

SYSTEM COMPONENTS

Flow Control Valve

Filter

Flow control valve (10, Figure 14-1), mounted on the manifold, controls the amount of oil flow to the hydraulic motor. The flow control valve has been factory adjusted and the setting should not be disturbed.

Filter assembly (21, Figure 14-2), mounted on the grease reservoir, filters the grease prior to refilling the reservoir from the shop supply. A bypass indicator alerts service personnel when the filter requires replacement.

Solenoid Valve Solenoid valve (5, Figure 14-1), when energized, allows oil to flow to the hydraulic motor.

Hydraulic Motor and Pump Rotary hydraulic pump (3 & 9, Figure 14-1) is a fully hydraulically operated grease pump. An integrated pump control manifold is incorporated with the motor to control input flow and pressure.

NOTE: The pump crankcase oil level must be maintained to the level of the pipe plug (17, Figure 14-2) or use the dip stick. If necessary, refill with 10W-30 motor oil.

Vent Valve With vent valve (7, Figure 14-1) closed, the pump continues to operate until maximum grease pressure is achieved. As this occurs, the vent valve opens and allows the grease pressure to drop to zero, so the injectors can recharge for their next output cycle.

Lubrication Cycle Timer

Hydraulic oil supply inlet pressure must not exceed 24 132 kPa (3500 psi). Exceeding the rated pressure may result in damage to the system components and personal injury.

Grease Reservoir Reservoir (12, Figure 14-1) has an approximate capacity of 41 kg (90 lb) of grease. When the grease supply is replenished by filling the system at the service center, the grease is passed through the filter to remove contaminants before it flows into the reservoir.

Pressure Reducing Valve Pressure reducing valve (4, Figure 14-1), located on the manifold, reduces the hydraulic supply pressure (from the truck steering circuit) to a suitable operating pressure for the hydraulic motor used to drive the lubricant pump. The pressure control valve has been factory adjusted and the setting should not be disturbed unless grease output pressure is outside the recommendations.

A pressure gauge can be installed where pipe plug (8, Figure 42-1) is located. The pressure gauge will indicate hydraulic oil pressure to the inlet of the hydraulic motor. Normal pressure is 2241 - 2413 kPa (325 - 350 psi).

FAM1404

The solid state lubrication cycle timer provides a 24 VDC timed-interval signal to energize solenoid valve (3, Figure 14-3) providing oil flow to operate the grease pump motor. This timer is mounted in the Electrical Interface Cabinet.

Over Pressure Cut Off Switch Pressure switch (18, Figure 14-2) is a normally open switch set at 20 684 kPa (3,000 psi). This switch deenergizes the pump solenoid relay if the grease line pressure reaches the switch pressure setting, turning off the motor and pump.

Grease Pressure Failure Switch Pressure switch (24, Figure 14-2) is a normally open switch set at 13 789 kPa (2,000 psi). If the appropriate grease pressure is not achieved during the normal pump cycle, the warning system will be activated, illuminating the warning lamp in the overhead display to notify the operator a problem exists in the lube system.

Injectors Each injector (23, Figure 14-2) delivers a controlled amount of pressurized lubricant to a designated lube point. Refer to Figure 14-2 for locations.

Relief Valve (unloader valve) Relief valve (14, Figure 14-2) protects the pump from high pressures. This relief valve is set at 27 580 kPa (4,000 psi).

Automatic Lubrication System

F14-3

SYSTEM OPERATION Normal Operation 1. During truck operation, the lubrication cycle timer will energize the system at a preset time interval.

2. The timer provides 24 VDC to energize the pump solenoid valve (3, Figure 14-3), allowing hydraulic oil provided by the truck steering pump circuit to flow to the pump motor and initiate a pumping cycle.

3. The hydraulic oil from the steering circuit is directed through the pressure reducing valve (4) and flow control valve (6) before entering the motor. Pump pressure can be read on optional pressure gauge (5) mounted on the manifold.

4. With oil flowing into the hydraulic motor, the grease pump will operate, pumping grease from the reservoir to the injectors (13), through a check valve (10) and to the vent valve (11).

5. During this period, the injectors will meter the appropriate amount of grease to each lubrication point.

6. When grease pressure reaches pressure switch (18, Figure 14-2) setting, the switch contacts will close and energize the relay RB7-K5, removing power from the hydraulic motor/pump solenoid and the pump will stop. The relay will remain energized until grease pressure drops (pressure switch opens again) and the timer turns off.

7. After the pump solenoid valve is de-energized, hydraulic pressure in the manifold drops and the vent valve (11, Figure 14-3) will open, releasing grease pressure in the lines to the injector banks. When this occurs, the injectors are then able to recharge for the next lubrication cycle.

8. The system will remain at rest until the lubrication cycle timer turns on and initiates a new grease cycle.

9. During the normal lubrication cycle, if grease pressure fails to reach 13 790 kPa (2,000 psi) within 120 seconds at the pressure switch located on the rear axle housing, an amber indicator light will illuminate on the overhead panel.

FIGURE 14-3. HYDRAULIC SCHEMATIC 1.

2.

3.

4.

5.

F14-4

Hydraulic Oil Return Hydraulic Oil Supply Pump Solenoid Valve Pressure Reducing Valve Motor Pressure Gauge

6. Flow Control Valve 7. Hydraulic Motor 8. Grease Pump 9. Pressure Switch (N.O.) 10. Check Valve

Automatic Lubrication System

11. Vent Valve 12. Orifice 13. Injector Bank 14. Relief Valve

FAM1404

GENERAL INSTRUCTIONS Lubricant Required For System Grease requirements will depend on ambient temperatures encountered during truck operation:

• Above 32°C (90°F) - Use NLGI No. 2 multipurpose grease (MPG).

• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 multipurpose grease (MPG).

• Below -32°C (-25°F) - Refer to local supplier for extreme lubricant requirements.

cold

weather

System Priming The system must be full of grease and free of air pockets to function properly. After maintenance, if the primary or secondary lubrication lines were replaced, it will be necessary to prime the system to eject all entrapped air.

1. Fill lube reservoir with lubricant, if necessary.

2. To purge air from the main supply line, remove the main supply line at the grease canister.

Connect an external grease supply to the line.

3. Remove plugs from each injector group in sequence (right front, left front, and rear axle).

4. Using the external grease source, pump grease until grease appears at the group of injectors and re-install the pipe plug. Repeat for remaining injector groups.

5. Remove the caps from each injector and connect an external grease supply to the zerk on the injector and pump until grease appears at the far end of the individual grease hose or the joint being greased.

Filter Assembly

FIGURE 14-4. FILTER ASSEMBLY 1.

2.

3.

4.

5.

Housing Bypass Indicator O-Ring Backup Ring Element

6.

7.

8.

9.

Spring Bowl O-Ring Plug

Filter element (5, Figure 14-4) must be replaced if bypass indicator (2) shows excessive element restriction.

FAM1404

Automatic Lubrication System

F14-5

LUBRICANT PUMP Pump Housing Oil Level The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Oil level should be checked at 1,000 hour intervals. To add oil, remove dipstick (4, Figure 42-5) on top of the pump housing and fill the housing to the proper level marked on the dipstick.

If the pump is not equipped with dipstick (4), remove oil level plug (5) and fill the housing to the bottom of the plug hole.

Pump Pressure Control High pressure hydraulic fluid from the truck steering system is reduced by the pressure reducing valve located on the manifold on top of the pump motor.

This pressure can be read if pipe plug (3) is removed, and a gauge is installed on the manifold.

FIGURE 14-5. PUMP CONTROLS 1. Pressure Control Valve 2. Override Switch 3. Pipe Plug

F14-6

Automatic Lubrication System

4. Dipstick 5. Oil Level Plug 6. Flow Control Valve

FAM1404

SYSTEM CHECKOUT To check system operation (not including timer), proceed as follows: 1. Remove the dust covers from the injectors.

2. Start the engine.

3. Actuate the manual override button at the pump assembly and observe pin movement at each injector.

4. Check for pump, hose or injector damage or leakage with the system under pressure.

5. After checking system, stop the engine.

Observing normal precautions regarding high voltage present in the propulsion system before attempting to repair lube system.

6. Re-install the injector dust covers.

The time between lube events is determined by the setting of the Off Time rotary switch (1, Figure 14-6).

Off time switch is used to select units of time.

Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or 30 minutes.

Cover (3) contains three LED windows and a manual lube switch. The LEDs indicate system operation and status. When power is on, a green LED will illuminate. When the pump is on, another green LED will illuminate. A red LED will illuminate when an alarm condition occurs.

Lubrication Controller Adjustment The lubrication controller is factory set to the following switch settings:

Lubrication Controller Check

Dip Switch 1 - 120 SEC (not adjustable)

Pressing the manual lube button on the enclosure cover will initiate a lube event (see Figure 14-6).

Dip Switch 2 - CONTROLLER (not adjustable)

Lubrication Controller Components

Dip Switch 4 - MEMORY OFF

Mode switch (2, Figure 14-6) consists of four dip switches. The first, second and third dip switches are not functional. These settings have been pre-set and are not changeable.

Rotary Switch - 15 minutes

The fourth dip switch is used to select “memory off” or “memory on”. When the switch is set to “memory off”, a lube cycle will occur each time power is turned on. The lube cycle will start at the beginning of the on time setting.

Dip Switch 3 - MINUTES (not adjustable)

NOTE: Only dip switch 4 and the rotary switch are adjustable.

When the switch is set to “memory on”, the controller will function as follows: 1. When power is turned off during ‘off time’ (between cycles), the lube cycle will resume at the point of interruption after power is restored.

In other words, the controller will remember its position in the cycle.

2. When power is turned off during ‘on time’ (during a cycle), the controller will reset to the beginning of the lube cycle after power is restored.

FAM1404

Automatic Lubrication System

F14-7

FIGURE 14-6. LUBRICATION CYCLE TIMER 1. Off Time Switch 2. Mode Switch

F14-8

3. Cover

Automatic Lubrication System

FAM1404

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

TROUBLE

Pump Does Not Operate

POSSIBLE CAUSES

SUGGESTED CORRECTIVE ACTION

Lube system is not grounded.

Correct grounding connections to pump assembly and truck chassis.

Electrical power loss

Locate cause of power loss and repair. 24 VDC power required. Ensure key switch is ON.

Timer malfunction

Replace timer assembly.

Solenoid valve malfunction

Replace the solenoid valve assembly.

Relay malfunction

Replace relay.

Motor or pump malfunction

Repair or replace motor and/or pump assembly. (Refer to Service Manual for rebuild instructions.)

NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as specified.

Pump Will Not Prime

Pump Will Not Build Pressure

Low lubricant supply

Dirt in reservoir, pump inlet clogged, filter clogged.

Trapped air in lubricant supply line

Prime system to remove trapped air.

Lubricant supply line is leaking.

Check lines and connections to repair leakage.

Vent valve is leaking.

Clean or replace vent valve.

Pump is worn or scored.

Repair or replace pump assembly. (Refer to Service Manual for rebuild instructions.)

NOTE: Normally, during operation, the injector indicator stem will move into the body of the injector when pressure builds properly. When the system vents (pressure release) the indicator stem will again move out into the adjusting yoke.

Injector Indicator Stem Does Not Operate

Pressure Gauge Does Not Register Pressure (pressure gauge not included with pump)

Malfunctioning injector - Usually indicated by the pump building pressure and then venting.

Replace individual injector assembly.

All injectors inoperative Pump build up not sufficient to cycle injectors.

Service and/or replace pump assembly.

(Refer to Service Manual for rebuild instructions.)

No system pressure to pump motor No 24 VDC signal at pump solenoid

Check hydraulic hose from steering system.

Pressure reducing valve setting is too low.

Determine problem in 24 VDC electric system.

24V Relay (RB7K8 or RB7K5) may be defective.

Refer to “Pressure Control Valve Adjustment�.

Replace relay.

FAM1404

Automatic Lubrication System

F14-9

TROUBLE Pump Pressure Builds Very Slowly Or Not At All

Controller Does Not Operate

“PUMP ON” LED Lights, But Load Connected To Terminals 3 & 4 Will Not Energize

Load Connected To Terminals 3 & 4 Energized, But “PUMP ON” LED Does Not Light

POSSIBLE CAUSES

SUGGESTED CORRECTIVE ACTION

No signal at solenoid.

Check timer.

No electric power to controller.

Turn on electric power to pump. “POWER” LED should light, “PUMP ON” LED should light when “MANUAL LUBE” is pressed.

Printed circuit board failure.

Remove and replace.

Failure of the printed circuit board or keypad.

Remove and replace.

Controller memory mode is OFF.

Switch controller memory mode to ON.

Injector output adjustment setting is too high.

Readjust to lower setting.

Timer/controller cycle time setting is too low.

Set to longer cycle time or reevaluate lube requirements.

Injector output adjustment setting is too low.

Readjust injector output setting.

Timer/controller cycle time setting does not deliver lubricant often enough.

Set to shorter cycle time or reevaluate lube requirements.

System is too large for pump output.

Calculate system requirements per planning manual.

Bearing Points Excessively Lubricated

Bearing Points Are Not Sufficiently Lubricated

F14-10

Automatic Lubrication System

FAM1404

NOTES:

NOTES:

NOTES:

NOTES:

NOTES:

STANDARD TORQUE CHARTS AND CONVERSION TABLES This manual provides U.S. standard and metric (SI) units for most specifications.

EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values

References throughout the manual to standard torques or other standard values will be to one of the following charts or tables. For values not shown in these charts or tables, standard conversion factors for most commonly used measurements are provided in Table XIII.

Komatsu does not recommend the use of special friction-reducing lubricants, such as Copper Coat, Never-Seez®, and other similar products, on the threads of standard fasteners where standard torque values are applied. The use of special friction-reducing lubricants will significantly alter the clamping force during the tightening process.

Standard torque values are not to be used when “turnof-the-nut” tightening procedures are recommended.

INDEX OF TABLES Table I . . . . . . . . Standard Torque Chart (SAE) Table II . . . Standard Torque, 12-Point, Grade 9 Table III . . . Standard Metric Assembly Torque Table IV . . . . . . . JIC Swivel Nuts Torque Chart Table V. . . . . . . . . . .Pipe Thread Torque Chart Table VI . . . . . . . . . O-Ring Boss Torque Chart Table VII. . . . . O-Ring Face Seal Torque Chart Table VIII . . Torque Conversions (ft lbs to N•m) Table IX . . Torque Conversions (ft lbs to kg•m) Table X. . . . Pressure Conversions (psi to kPa) Table XI . . Pressure Conversions (psi to MPa) Table XII. . . . . . . . . .Temperature Conversions Table XIII . . . . Common Conversion Multipliers

Grade 5

Capscrew Thread Size

kg•m

1/4-20

7

1/4-28

8

When the torque tables specify “lubricated threads” for the standard torque values listed, these standard torque values are to be used with simple lithium base chassis grease (multi-purpose EP NLGI) or a rustpreventive grease (see list, page A5-2) on the threads and seats unless specified otherwise.

Verify threads and tapped holes are free of burrs and other imperfections before installing hardware.

TABLE I. -STANDARD TORQUE CHART SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY (LUBRICATED THREADS) - TOLERANCES ±10%

TORQUE GRADE 5 ft lbs

. . A5-1 . . A5-2 . . A5-2 . . A5-3 . . A5-3 . . A5-3 . . A5-3 . . A5-4 . . A5-4 . . A5-4 . . A5-5 . . A5-5 . . A5-6

If special friction-reducing lubricants are used, excessive stress and possible breakage of the fasteners may result.

TORQUE GRADE 8 N•m

ft lbs

0.97

9.5

10

1.11

10.8

11

Grade 8

N•m

Capscrew Thread Size

1.38

13.6

3/4-16

235

32.5

319

335

46.3

454

1.52

14.9

7/8-9

350

48.4

475

500

69.2

678

kg•m

TORQUE GRADE 5 ft lbs

kg•m

TORQUE GRADE 8 N•m

ft lbs

kg•m

N•m

5/16-18

15

2.07

20.3

21

2.90

28

7/8-14

375

51.9

508

530

73.3

719

5/16-24

16

2.21

22

22

3.04

30

1.0-8

525

72.6

712

750

103.7

1017

3/8-16

25

3.46

34

35

4.84

47

1.0-12

560

77.4

759

790

109.3

1071

3/8-24

30

4.15

41

40

5.5

54

1.0-14

570

78.8

773

800

110.6

1085

7/16-14

40

5.5

54

58

8.0

79

1 1/8-7

650

89.9

881

1050

145

1424

7/16-20

45

6.2

61

62

8.57

84

1 1/8-12

700

96.8

949

1140

158

1546

1/2-13

65

9

88

90

12.4

122

1 1/4-7

910

125.9

1234

1480

205

2007

1/2-20

70

9.7

95

95

13.1

129

1 1/4-12

975

134.8

1322

1580

219

2142

9/16-12

90

12.4

122

125

17.3

169

1 3/8-6

1200

166

1627

1940

268

2630

9/16-18

95

13.1

129

135

18.7

183

1 3/8-12

1310

181

1776

2120

293

2874

5/8-11

125

17.3

169

175

24.2

237

1 1/2-6

1580

219

2142

2560

354

3471

5/8-18

135

18.7

183

190

26.2

258

1 1/2-12

1700

235

2305

2770

383

3756

3/4-10

220

30.4

298

310

42.8

420

1 ft lbs = 0.138 kg•m = 1.356 N•m

FAM1501 11/05

Standard Torque Charts and Conversion Tables

F15-1

STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Capscrews (SAE)

STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews & Class 10 Nuts

The following specifications apply to required assembly torques for all 12-point, grade 9 (170,000 psi minimum tensile) capscrews.

The following specifications apply to required assembly torques for all metric Class 10.9 finished hexagon head capscrews and Class 10 nuts.

• Capscrew threads and seats shall be lubricated when assembled.

• Capscrew threads and seats shall not be lubricated when assembled. These specifications are based on all capscrews, nuts, and hardened washers being phosphate and oil coated.

NOTE: Unless the instructions specifically recommend otherwise, these standard torque values are to be used with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust preventive grease (see list, this page) on the threads.

• Torques are calculated to give a clamping force of approximately 75% of proof load.

• The maximum torque tolerance shall be ±10% of the torque value shown.

NOTE: If zinc-plated hardware is used, each piece must be lubricated with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust preventive grease (see list, this page) to achieve the same clamping forces provided below.

• Torques are calculated to give a clamping force of approximately 75% of proof load.

• The maximum torque tolerance shall be within ±10% of the torque value shown.

TABLE II. STANDARD ASSEMBLY TORQUE for 12-Point, Grade 9 Cap screws

TABLE III. STANDARD ASSEMBLY TORQUE for Metric Class 10.9 Cap screws & Class 10 Nuts

CAPSCREW SIZE*

TORQUE ft lbs

TORQUE N•m

TORQUE kg•m

0.250 - 20

12

16

1.7

0.312 - 18

24

33

3.3

M6 x1

0.375 - 16

42

57

5.8

M8 x 1.25

0.438 -14

70

95

9.7

M10 x 1.5

CAPSCREW SIZE*

TORQUE N•m

TORQUE ft lbs

TORQUE kg•m

12

9

1.22

30

22

3.06

55

40

5.61

0.500 -13

105

142

14.5

M12 x 1.75

95

70

9.69

0.562 - 12

150

203

20.7

M14 x 2

155

114

15.81

0.625 - 11

205

278

28.3

M16 x 2

240

177

24.48

0.750 - 10

360

488

49.7

M20 x 2.25

465

343

47.43

0.875 - 9

575

780

79.4

M24 x 3

800

590

81.6

1.000 - 8

860

1166

119

M30 x 3.5

1600

1180

163.2

1.000 - 12

915

1240

126

M36 x 4

2750

2028

280.5

1.125 - 7

1230

1670

170

* Shank Diameter (mm) - Threads per millimeter

1.125 - 12

1330

1800

184

1.250 - 7

1715

2325

237

1.250 - 12

1840

2495

254

This table represents standard values only. Do not use these values to replace torque values which are specified in assembly instructions.

1.375 - 6

2270

3080

313

1.375 - 12

2475

3355

342

1.500 - 6

2980

4040

411

1.500 - 12

3225

4375

445

* Shank Diameter (in.) - Threads per inch This table represents standard values only. Do not use these values to replace torque values which are specified in assembly instructions.

Suggested* Sources for Rust Preventive Grease: • American Anti-Rust Grease #3-X from Standard Oil Company (also American Oil Co.) • Gulf Norust #3 from Gulf Oil Company.

• Mobilarma 355, Product No. 66705 from Mobil Oil Corporation.

• Rust Ban 326 from Humble Oil Company.

• Rustolene B Grease from Sinclair Oil Co. • Rust Preventive Grease - Code 312 from the Southwest Grease and Oil Company.

NOTE: This list represents the current engineering approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list.

F15-2

Standard Torque Charts and Conversion Tables

11/05 FAM1501

TABLE IV. TORQUE CHART FOR JIC 37° SWIVEL NUTS WITH OR WITHOUT O-RING SEALS

TABLE VI. TORQUE CHART FOR O-RING BOSS FITTINGS

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

–2

0.125

0.312 – 24

4 ±1

–2

0.125

0.312 – 24

4 ±2

–3

0.188

0.375 – 24

8 ±3

–3

0.188

0.375 – 24

5 ±2

–4

0.250

0.438 – 20

12 ±3

–4

0.250

0.438 – 20

8 ±3

–5

0.312

0.500 – 20

15 ±3

–5

0.312

0.500 – 20

10 ±3

–6

0.375

0.562 – 18

18 ±5

–6

0.375

0.562 – 18

13 ±3

–8

0.500

0.750 – 16

30 ±5

–8

0.500

0.750 – 16

24 ±5

– 10

0.625

0.875 – 14

40 ±5

– 10

0.625

0.875 – 14

32 ±5

– 12

0.750

1.062 – 12

55 ±5

– 12

0.750

1.062 – 12

48 ±5

– 14

0.875

1.188 – 12

65 ±5

– 14

0.875

1.188 – 12

54 ±5

– 16

1.000

1.312 – 12

80 ±5

– 16

1.000

1.312 – 12

72 ±5

– 20

1.250

1.625 – 12

100 ±10

– 20

1.250

1.625 – 12

80 ±5

– 24

1.500

1.875 – 12

120 ±10

– 24

1.500

1.875 – 12

80 ±5

– 32

2.000

2.500 – 12

230 ±20

– 32

2.000

2.500 – 12

96 ±10

TABLE V. TORQUE CHART FOR PIPE THREAD FITTINGS

TABLE VII. TORQUE CHART FOR O-RING FACE SEAL FITTINGS

SIZE CODE

PIPE THREAD SIZE

WITH SEALANT ft lbs

WITHOUT SEALANT ft lbs

–2

0.125 – 27

15 ±3

20 ±5

–4

0.250 – 18

20 ±5

25 ±5

–6

0.375 – 18

25 ±5

35 ±5

–8

0.500 – 14

35 ±5

45 ±5

– 12

0.750 – 14

45 ±5

55 ±5

– 16

1.000 – 11.50

55 ±5

65 ±5

– 20

1.250 – 11.50

70 ±5

80 ±5

– 24

1.500 – 11.50

80 ±5

95 ±10

– 32

2.000 – 11.50

95 ±10

120 ±10

FAM1501 11/05

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

–4

0.250

0.438 – 20

11 ±1

–6

0.375

0.562 – 18

18 ±2

–8

0.500

0.750 – 16

35 ±4

– 10

0.625

0.875 – 14

51 ±5

– 12

0.750

1.062 – 12

71 ±7

– 16

1.000

1.312 – 12

98 ±6

– 20

1.250

1.625 – 12

132 ±7

– 24

1.500

1.875 – 12

165 ±15

Standard Torque Charts and Conversion Tables

F15-3

TABLE VIII. TORQUE CONVERSIONS Foot Pounds (ft lbs) to Newton-meters (N•m) ft lbs

0

1

2

3

4

5

6

7

8

9

0

(N·m)

1.36

2.71

4.07

5.42

6.78

8.14

9.49

10.85

12.20

10

13.56

14.91

16.27

17.63

18.98

20.34

21.69

23.05

24.40

25.76

20

27.12

28.47

29.83

31.18

32.54

33.90

35.25

36.61

37.96

39.32

30

40.67

42.03

43.39

44.74

46.10

47.45

48.81

50.17

51.52

52.87

40

54.23

55.59

56.94

58.30

59.66

60.01

62.37

63.72

65.08

66.44

50

67.79

69.15

70.50

71.86

73.21

74.57

75.93

77.28

78.64

80.00

60

81.35

82.70

84.06

85.42

86.77

88.13

89.48

90.84

92.20

93.55

70

94.91

96.26

97.62

98.97

100.33

101.69

103.04

104.40

105.75

107.11

80

108.47

109.82

111.18

112.53

113.89

115.24

116.60

117.96

119.31

120.67

90

122.03

123.38

124.74

126.09

127.45

128.80

130.16

131.51

132.87

134.23

See NOTE on page A5-5 regarding Table usage

TABLE IX. TORQUE CONVERSIONS Foot Pounds (ft lbs) to kilogram-meters (kg•m) ft lbs

0

1

2

3

4

5

6

7

8

9

0

(kg.m)

0.138

0.277

0.415

0.553

0.692

0.830

0.968

1.106

1.245

10

1.38

1.52

1.66

1.80

1.94

2.07

2.21

2.35

2.49

2.63

20

2.77

2.90

3.04

3.18

3.32

3.46

3.60

3.73

3.87

4.01

30

4.15

4.29

4.43

4.56

4.70

4.84

4.98

5.12

5.26

5.39

40

5.53

5.67

5.81

5.95

6.09

6.22

6.36

6.50

6.64

6.78

50

6.92

7.05

7.19

7.33

7.47

7.61

7.74

7.88

8.02

8.16

60

8.30

8.44

8.57

8.71

8.85

8.99

9.13

9.27

9.40

9.54

70

9.68

9.82

9.96

10.10

10.23

10.37

10.51

10.65

10.79

10.93

80

11.06

11.20

11.34

11.48

11.62

11.76

11.89

12.03

12.17

12.30

90

12.45

12.59

12.72

12.86

13.00

13.14

13.28

13.42

13.55

13.69

See NOTE on page A5-5 regarding Table usage

TABLE X. PRESSURE CONVERSIONS Pounds/square inch (psi) To Kilopascals (kPa) Formula: psi x 6.895 = kPa psi

0

1

2

3

4

5

6

7

8

9

0

(kPa)

6.895

13.79

20.68

27.58

34.47

41.37

48.26

55.16

62.05

10

68.95

75.84

82.74

89.63

96.53

103.42

110.32

117.21

124.1

131.0

20

137.9

144.8

151.7

158.6

165.5

172.4

179.3

186.2

193.1

200.0

30

206.8

213.7

220.6

227.5

234.4

241.3

248.2

255.1

262.0

268.9

40

275.8

282.7

289.6

296.5

303.4

310.3

317.2

324.1

331.0

337.9

50

344.7

351.6

358.5

365.4

372.3

379.2

386.1

393.0

399.9

406.8

60

413.7

420.6

427.5

434.4

441.3

448.2

455.1

462.0

468.9

475.8

70

482.6

489.5

496.4

503.3

510.2

517.1

524.0

530.9

537.8

544.7

80

551.6

558.5

565.4

572.3

579.2

586.1

593.0

599.9

606.8

613.7

90

620.5

627.4

634.3

641.2

648.1

655.0

661.9

668.8

675.7

682.6

See NOTE on page A5-5 regarding Table usage

F15-4

Standard Torque Charts and Conversion Tables

11/05 FAM1501

TABLE XI. PRESSURE CONVERSIONS Pounds/square inch (psi) To Megapascals (MPa) Formula: psi x 0.0069 = MPa psi

0

10

20

30

40

50

60

70

80

90

0

(MPa)

0.069

0.14

0.21

0.28

0.34

0.41

0.48

0.55

0.62

100

0.69

0.76

0.83

0.90

0.97

1.03

1.10

1.17

1.24

1.31

200

1.38

1.45

1.52

1.59

1.65

1.72

1.79

1.86

1.93

2.00

300

2.07

2.14

2.21

2.28

2.34

2.41

2.48

2.55

2.62

2.69

400

2.76

2.83

2.90

2.96

3.03

3.10

3.17

3.24

3.31

3.38

500

3.45

3.52

3.59

3.65

3.72

3.79

3.86

3.93

4.00

4.07

600

4.14

4.21

4.27

4.34

4.41

4.48

4.55

4.62

4.69

4.76

700

4.83

4.90

4.96

5.03

5.10

5.17

5.24

5.31

5.38

5.45

800

5.52

5.58

5.65

5.72

5.79

5.86

5.93

6.00

6.07

6.14

900

6.21

6.27

6.34

6.41

6.48

6.55

6.62

6.69

6.76

6.83

See NOTE below regarding Table usage

NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example: Example: Convert 975 psi to kilopascals (kPa).

1. Select Table X. 2. Go to psi row 90, column 7; read 668.8 97 psi = 668.8 kPa.

3. Multiply by 10: 970 psi = 6688 kPa. 4. Go to psi row 0, column 5; read 34.475 psi = 34.47 kPa. Add to step 3.

5. 970 + 5 psi = 6688 + 34 = 6722 kPa.

TABLE XII. TEMPERATURE CONVERSIONS Formula: F° - 32 / 1.8 = C° or C° x 1.8 + 32 = F° CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT C° F° C° F° C° F° 121 250 482 63 145 293 4 40 104 118 245 473 60 140 284 2 35 95 116 240 464 57 135 275 –1 30 86 113 235 455 54 130 266 –4 25 77 110 230 446 52 125 257 –7 20 68 107 225 437 49 120 248 –9 15 59 104 220 428 46 115 239 – 12 10 50 102 215 419 43 110 230 – 15 5 41 99 210 410 41 105 221 – 18 0 32 96 205 401 38 100 212 – 21 –5 23 93 200 392 35 95 293 – 23 – 10 14 91 195 383 32 90 194 – 26 – 15 5 88 190 374 29 85 185 – 29 – 20 –4 85 185 365 27 80 176 – 32 – 25 – 13 82 180 356 24 75 167 – 34 – 30 – 22 79 175 347 21 70 158 – 37 – 35 – 31 77 170 338 18 65 149 – 40 – 40 – 40 74 165 329 15 60 140 – 43 – 45 – 49 71 160 320 13 55 131 – 46 – 50 – 58 68 155 311 10 50 122 – 48 – 55 – 67 66 150 302 7 45 113 – 51 – 60 – 76 NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the center, unmarked column.

FAM1501 11/05

Standard Torque Charts and Conversion Tables

F15-5

TABLE XIII COMMON CONVERSION MULTIPLIERS

COMMON CONVERSION MULTIPLIERS METRIC TO ENGLISH

COMMON CONVERSION MULTIPLIERS ENGLISH TO METRIC To Convert From

Multiply By

TO

Multiply By

inch – in.

millimeter (mm)

25.40

millimeter (mm)

inch – in.

0.0394

inch – in.

centimeter (cm)

2.54

centimeter (cm)

inch – in.

0.3937

foot – ft

meter (m)

0.3048

meter (m)

foot – ft

3.2808

yard – yd

meter (m)

0.914

meter (m)

yard – yd

1.0936

1.61

kilometer (km)

mile – mi.

kilometer (km) 2

sq. in. – in. sq. ft. –

ft2

To Convert From

TO

mile – mi.

0.6210

2

sq. in. – in.

0.1550

2

2

sq. centimeters (cm )

6.45

(cm2)

929

sq. centimeters (cm )

sq. ft. – ft2

0.001

2

sq. centimeters

sq. centimeters (cm )

cu. in. – in.3

cu. centimeters (cm3)

16.39

cu. centimeters (cm3)

cu in – in.3

0.061

cu. in. – in.3

liters (l)

0.016

liters (l)

cu in – in.3

61.02

cu. ft. – ft3

cu. meters (m3)

0.028

cu. meters (m3)

cu ft – ft3

35.314

cu. ft. – ft3

liters (l)

28.3

liters (l)

cu ft – ft3

0.0353

ounce – oz

kilogram (kg)

0.028

grams (g)

ounce – oz.

0.0353

fluid ounce – fl oz

milliliter (ml)

29.573

milliliter (ml)

fluid ounce – fl oz.

0.0338

pound (mass)

kilogram (kg)

0.454

kilogram (kg)

pound (mass)

2.2046

Newton (N)

4.448

Newton (N)

pound (force) – lbs

0.2248

Newton meters (N•m)

0.113

Newton-meters (N•m)

kilogram meters (kg•m)

0.102

ft lbs (force)

Newton meters (N•m)

1.356

Newton-meters (N·m)

ft lbs

0.7376

ft lbs (force)

kilogram meters (kg•m)

0.138

kilogram-meters (kg•m)

ft lbs

7.2329

Newton meters (N•m)

9.807

psi

0.1450

pound (force) – lbs in. lbs. (force)

psi (pressure)

kilopascals (kPa)

6.895

kilogram-meters (kg•m)

psi (pressure)

megapascals (MPa)

0.007

kilopascals (kPa)

psi (pressure)

kilograms/cm2 (kg/cm2)

0.0704

ton (short)

kilogram (kg)

907.2

ton (short)

metric ton

0.0907

megapascals (MPa) kilograms/cm

(kg/cm2)

kilograms/cm2 (kg/cm2)

quart – qt

liters (l)

0.946

kilogram (kg)

gallon – gal

liters (l)

3.785

metric ton

HP (horsepower)

Watts

745.7

liters (l)

HP (horsepower)

kilowatts (kw)

0.745

liters (l)

F15-6

2

psi

145.038

psi

14.2231

kilopascals (kPa)

98.068

ton

0.0011

ton

1.1023

quart – qt

1.0567

gallon – gal

0.2642

Watts

Horsepower HP

0.00134

kilowatts (kw)

Horsepower HP

1.3410

Standard Torque Charts and Conversion Tables

11/05 FAM1501

HYDRAULIC SYSTEM FLUSHING PROCEDURE Hydraulic System Flushing Procedure

SYSTEM FLUSHING When a new truck is assembled and the engine is started for the very first time, the hydraulic system must be flushed immediately to remove contamination that may have been introduced during the field assembly process. DO NOT start the engine unless all flushing equipment is installed and ready for use.

The flushing procedure will help eliminate harmful contamination that may lead to premature pump or valve failures. Starting the engine just one time without performing the flushing procedure may contaminate the hydraulic system.

Hoist system bypass blocks (PC3074) and steering system flushing hose (XB5776) must be on-site before or during field assembly, so when the truck is started for the first time, the hydraulic system can be flushed and any debris can be removed from the hydraulic system.

All flushing hoses must be rated to withstand 27 580 kPa (4,000 psi) pressure. The hoses must be 1 inch inside diameter and meet SAE 100R12 specifications.

1. If the tires are installed on the truck, chock the left and right rear wheels securely on both sides to prevent truck movement. If the truck is sitting on cribbing, ensure it is secure enough to allow safe operation of the engine and clearance for turning the front spindles lock to lock without risk of collapsing the cribbing.

2. Inspect all hydraulic hoses to ensure that they are properly routed and securely connected.

3. Connect a laptop PC to the interface module.

Start the Interface Real-time Data Monitor program.

4. If any fault codes are displayed, troubleshoot the system and repair the problem before proceeding.

5. Ensure that both brake accumulators and both steering accumulators are properly precharged with nitrogen to 9 650 kPa (1,400 psi). Refer to the shop manual for the accumulator charging procedure.

6. Confirm that the steering pressure is released by turning the steering wheel. No steering movement should occur.

7. Install accurate pressure gauges at the following locations: • Pressure test port “TEST” (6, Figure 16-1) on the bleed down manifold - 35 000 kPa (5,000 psi).

Hydraulic fluid escaping under pressure can have sufficient force to enter a person's body by penetrating the skin and cause serious injury, and possibly death, if proper medical treatment by a physician familiar with this type of injury is not received immediately.

Before disconnecting pressure lines, removing fittings or replacing components in the hydraulic circuits, or installing test gauges, ALWAYS bleed down the steering and brake accumulators.

NOTE: The hoist cylinder bypass blocks should be saved for possible use later in case the hydraulic system needs to be flushed after a component failure.

FAM1601

• Pressure test port “GPA” (2, Figure 16-2) located on the steering pump - 35 000 kPa (5,000 psi).

• Pressure test ports (1, Figure 16-3) on both high pressure hoist filters - 24 000 kPa (3,500 psi).

If any hydraulic pressure is detected on the pressure gauge installed at the "TEST" port, there is residual oil pressure in the system. Do not loosen or remove any hydraulic hoses, fittings or components. The steering accumulators have not been properly depressurized. Locate and correct the depressurization problem. Always relieve all hydraulic pressure before disconnecting any hydraulic lines or fittings. Always tighten all connections securely before applying pressure. Confirm that the steering pressure is released by turning the steering wheel. No steering movement should occur.

Hydraulic System Flushing

F16-1

8. Connect jumper hose (XB5776) between “QD Supply" disconnect (4, Figure 16-1) and “QD Return" disconnect (3) on the bleed down manifold.

NOTE: Do not connect any hoses to disconnect fittings (2 & 5, Figure 16-1).

9. Connect the four hoist cylinder hoses (2, Figure 16-3) together as shown using bypass blocks (3). Ensure that all connections are secure. The hardware for connecting the hoses to the blocks is the same hardware for connecting the hoses to the hoist cylinders. Cover all open ports to prevent contamination.

10. The steering pump case must be filled with oil before startup to avoid pump damage. Disconnect the hose connected to fitting (1, Figure 162). Then remove fitting (1). Fill the steering pump case with clean type C-4 hydraulic oil through the case drain port. It may require up to 2.9 liters (3 quarts) of oil. Reinstall fitting (1) and reconnect the hose.

NOTE: Filling the steering pump case does not eliminate the need to bleed air from the pump suction line.

11. Fully open all three hydraulic shutoff valves in the pump suction lines. The valves are fully open when the valve handle is in-line with the hose.

Serious pump damage will occur if any shutoff valve is not fully open when the engine is started.

FIGURE 16-1. BLEED DOWN 1. Bleed Down Manifold 2. Brake Disconnect 3. "QD Return" Disconnect 4. "QD Supply" Disconnect 5. Brake Disconnect 6. Test Port “TEST”

F16-2

FIGURE 16-2. STEERING PUMP 1. Pump Case Drain Fitting 2. Test Port "GPA"

Hydraulic System Flushing

FAM1601

12. Fill the hydraulic tank with clean type C-4 hydraulic oil. Ensure that the oil level is visible in the center of the upper sight glass.

13. To bleed trapped air from inside the pump suction hoses, loosen the cap screws where the three suction hoses attach to the inlet of each pump. Ensure that the O-ring does not fall out of the groove. After oil appears, retighten the cap screws to the standard torque.

16. Move the hoist control lever to the FLOAT position.

17. Turn the key switch ON, but do not start the engine. Verify that the low steering accumulator precharge warning is not displayed. If this warning is displayed, correct the problem before proceeding.

14. Check the hydraulic tank oil level. If necessary, add oil.

Do not apply the brakes or turn the steering wheel at any time during this procedure until Step 29.

FIGURE 16-4. BRAKE MANIFOLD 1. Accumulator Bleed Down Valves 2. Brake Manifold FIGURE 16-3. TEST PORT LOCATIONS 1. Test Port (Hoist Filters) 2. Hoist Cylinder Hoses 3. Bypass Blocks (PC3074)

15. Open brake accumulator bleed down valves (1, Figure 16-4) on the brake manifold.

FAM1601

18. Start the engine and operate at low idle. Within 30 seconds after starting the engine, check the two oil pressures listed below. If the oil pressure

Hydraulic System Flushing

F16-3

readings are not correct, stop the engine.

Locate and repair the problem before proceeding. If the pressure readings are correct, proceed to the next step. Do not turn the steering wheel or apply the brakes at this time.

• With the engine at low idle, and the oil temp at 21° C (70° F), oil pressure at the hoist filters should be approximately 517 kPa (75 psi) or less.

• Oil pressure at steering pump test port "GPA" should be approximately 690 kPa (100 psi).

Do not operate the engine at low idle for more than 30 seconds. The steering pump pressure at test port "GPA" must be at or above 1 725 kPa (250 psi) during the flushing process to provide adequate internal pump lubrication. Steering pump damage will result if the pressure is below 1 725 kPa (250 psi) for more than 30 seconds.

19. If all pump pressures are correct as stated in Step 18, increase engine speed to 1500 rpm and flush the system for 20 minutes. During this time, move the hoist control lever to the POWER UP position for 30 seconds, and then move it to the POWER DOWN position for 30 seconds. Repeat this hoist control cycle five times. This process will carry any system contaminants to the hydraulic filters.

20. When the 20 minute flushing process is complete, turn the key switch to the OFF position and allow at least two minutes after the engine has stopped for the steering accumulators to completely depressurize.

21. Check the pressure gauge connected to the "TEST" port on the bleed down manifold. If any pressure is still in the system, the bleed down process did not complete. Locate and repair the problem. If the pressure is 0 kPa (0 psi), remove the steering circuit jumper hose from the bleed down manifold.

F16-4

22. Check the hydraulic tank oil level. If necessary, add oil.

23. Close the brake accumulator bleed down valves (1, Figure 16-4).

24. To flush the accumulators, start the engine and operate the engine until the pressure at the "TEST" port on the bleed down manifold is approximately 24 304 kPa (3,525 psi). This is the pressure where the unloader valve shifts and unloads the steering pump.

• If the accumulator pressure exceeds 24 648 kPa (3,575 psi), immediately turn the engine off and open the brake accumulator bleed down valves.

Refer to steering pump pressure control adjustments in the shop manual, then repeat Step 24.

• If the accumulator pressure does not reach 23 960 kPa (3,475 psi), check for faults on the Interface Real-time Data Monitor. If there is a bleed down fault active, locate and correct the problem. If no faults are active, refer to steering pump pressure control adjustments in the shop manual, then repeat Step 24.

25. Turn the key switch to the OFF position and confirm that after the engine has stopped, the steering accumulator bleed down process begins. Confirm that accumulator bleed down completes within two minutes. Also confirm that bleed down fault A236 "Steering bleed fault" or any other bleed down fault does not become active. The pressure gauge at the bleed down manifold pressure test port "TEST" will be 103 kPa (15 psi) or less after a successful bleed down.

26. Open both brake accumulator bleed down valves on the brake manifold to completely depressurize the brake accumulators. Then close both brake accumulator bleed down valves.

27. Repeat Steps 24 through 26 five times.

Hydraulic System Flushing

FAM1601

28. To flush the steering system, start the engine.

Allow the accumulators to fully charge and the steering pump to unload.

29. Now turn the steering wheel full left and then full right ten times.

30. Turn the key switch to the OFF position and allow at least two minutes after the engine has stopped for the steering accumulators to completely depressurize. The pressure gauge at the bleed down manifold pressure test port "TEST" will be 103 kPa (15 psi) or less after a successful bleed down.

31. Check the hydraulic tank oil level. If necessary, add oil.

32. The hydraulic system flushing procedure has been completed. All hydraulic system high pressure filter elements must be replaced.

33. Remove all pressure gauges and re-install the dust caps on all quick disconnect fittings.

34. Check the hydraulic tank oil level. If necessary, add oil.

35. Proceed to the steering and brake system checkout procedures in the Field Assembly Manual.

36. After the steering and brake system checkout procedures are completed, remove hoist cylinder bypass blocks (3, Figure 16-3) and connect the hoist cylinder hoses (2) to the hoist cylinders. Ensure the hoses and ports are clean to prevent contamination.

NOTE: Do not extend the hoist cylinders until the body is installed.

a. Close both hoist pump suction line shutoff valves and the steering pump suction line shutoff valve. b. Remove the hoist and steering hydraulic filter elements. Clean the housings and install new filter elements. c. Open both hoist pump suction line shutoff valves and the steering pump suction line shutoff valve.

FAM1601

Hydraulic System Flushing

F16-5

NOTES

F16-6

Hydraulic System Flushing

FAM1601

STATIC BRAKE SYSTEM CHECKOUT STATIC BRAKE SYSTEM CHECKOUT

OPERATION

This brake system checkout is to be performed after the hydraulic system checkout procedure is complete. The brake pads must also be burnished before performing this test.

The static brake test utilizes a momentary switch and a check light located in the overhead display panel.

The static brake test allows the operator to check the service brake, parking brake and the dynamic retarder. The purpose of these tests is to verify the functionality of the service brake, parking brake and retarder systems at the time they are tested.

Brake Test Switch

After performing each test, it is the operator’s responsibility to determine if the truck passed each test and if the truck is safe for operation.

The order of performing the brake tests, (service brake, parking brake or retard system) does not matter. Each brake test is a separate test, where one brake system or all three can be tested at any time.

If an operator has questions during brake testing, refer to the drive system Diagnostic Information Display (DID) panel, located on the back wall of the cab for guidance.

If the truck fails any brake test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

Events The following events have been added to the drive system software to support the brake test feature.

• 645-1 Service Brake test Performed • 645-2 Parking Brake Test Performed • 645-3 Retard Test Performed • 645-4 Brake Test Switch stuck closed

The Events Log will record when and which brake tests have been performed.

FAM1701

The brake test switch is used to initiate a brake test. Press on the momentary switch to enter the brake test mode. If certain conditions are met, the operator can enter a brake test sequence.

Brake Check Light The amber light is used to indicate when the truck is in the brake test mode. When illuminated, a brake test is ready.

When flashing, the brake test is at the validation point, or the retard system test is finished.

Description The operator can choose which brake test to perform, and will set the truck controls based on the settings in Table 1. The drive system will detect the position of the directional control lever, and will prepare for the appropriate test. The operator will then press the brake test switch.

If the brake check light is illuminated solid after pressing the brake test switch, the system is in brake test mode and is ready for the chosen test to be initiated by the operator. After testing, the operator will then determine if the truck passed the brake tests, and if it is safe for operation.

If the brake check light does not illuminate immediately after pressing the brake test switch, there is most likely a problem with the setup. Refer to the setup conditions and take action to prepare the truck for a brake test.

Static Brake System Checkout

F17-1

PERFORMING THE BRAKE TESTS

If there is a problem with the truck setup, the DID panel will display the problem.

Setup

For example if the engine is off:

Before performing any brake test, the following conditions must be met:

ERROR Entering Brake Test Engine not running

• Dump body empty If the Truck is loaded:

NOTE: The drive system will not enter any brake test if the truck is loaded.

ERROR Entering Brake Test Truck is NOT Empty

• Truck located outside on a flat area, where truck movement is allowed.

If all of the conditions are correct, except the brakes are not set correctly, an error message will be displayed. For example, if the service brake and parking brake are both applied together: ERROR Entering Brake Test Set Brakes for Test

Ensure the area around the truck is free of personnel and objects. Some truck movement could occur during brake testing.

Brake Test Exit Criteria The drive system is unable to determine if the truck is on a hill or in a parking ditch. Testing during these conditions will affect test results.

Numerous conditions can occur which may interrupt a brake test, including the following: • Any of the setup conditions becoming false • Drive system fault which restricts the LINK or Propel mode

Before performing any brake test, the truck must be in the following state:

• Truck Speed greater than 3.2 kph (2.0 mph)

• Engine on (low idle)

• Drive system at torque level for more than 30 seconds

• Drive system ready (Ready Mode) • Dump body down

• Brake test requested, but not initiated by the operator within 60 seconds after pressing the brake test switch

• No drive system warning lights ON (Can not be in LIMP mode.)

• Zero ground speed

Table 1: BRAKE TEST SETTINGS Test Type

Wheel Brake Lock

Service Brake Pedal

Directional Control Lever

Service Brake

OFF

FULLY APPLIED

NEUTRAL

Parking Brake

OFF

RELEASED

PARK

Retard Test

OFF

RELEASED

PARK

F17-2

Static Brake System Checkout

FAM1701

Service Brake Test 1. Firmly depress the service brake pedal.

9. Release the accelerator pedal and the torque will be reduced, the test will stop and the brake check light will turn off.

2. Place the directional control lever in the NEUTRAL position. Ensure the wheel brake lock switch is OFF.

10. Place the directional control lever in the PARK position. Release the service brake pedal.

3. Press the brake test switch and wait for the brake check light to be on solid.

11. If the truck failed the service brake test, notify maintenance personnel immediately.

4. Fully depress the service brake pedal. Ensure full brake application is reached. Failure to reach full brake application will affect the service brake test results.

5. The DID panel will display: Service Brake Test READY Press Accel Pedal to Start 6. With the service brake pedal still fully applied, fully depress the accelerator pedal. The drive system controller will enter propel mode and generate torque up to the service brake limit.

Maintain full service brake pressure during the test.

NOTE: The drive system can only detect if the service brakes are applied. It can not detect the percentage of application. It is up to the operator to press hard enough on the service brake pedal to achieve a full brake application.

7. The DID panel will display: Service Brake Test ACTIVE Check Truck Movement when Light Flashes 8. Once torque has reached the limit for the service brake test, the brake check light will begin to flash. This is the indication for the operator to make a determination as to the status of the service brake system.

If the truck fails the service brake test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

NOTE: If the operator partially or fully releases the accelerator pedal during the test, torque will be reduced and the brake check light will go back on solid when torque falls below the test set point. The operator can re-apply the accelerator pedal to increase torque and the brake check light will again flash when the torque is at the test limit.

If the test exits abnormally, or if the operator simply does not press the accelerator pedal far enough to achieve the torque level for the service brake test, the DID panel will display: Brake Test ERROR Test did NOT complete

• If the truck did not move: The service brake system passed the test. • If the truck moved during the test: The service brake system failed the test.

FAM1701

Static Brake System Checkout

F17-3

Retard System Test:

Parking Brake Test 1. Place the directional control lever in the PARK position.

1. Place the directional control lever in the PARK position.

2. Press the brake test switch and wait for the brake check light to be on solid.

2. Press the brake test switch and wait for the brake check light to be on solid.

3. The DID panel will display:

3. The DID panel will display:

Parking Brake or Retard Test READY Press Accel or Retard Pedal to Start 4. Fully depress the accelerator pedal. The drive system controller will enter propel mode and generate torque up to the park brake limit.

5. The DID panel will display: Park Brake Test ACTIVE Check Truck Movement when Light Flashes 6. Once the torque has reached the limit for the parking brake test, the brake check light will begin to flash. This is the indication for the operator to make a determination as to the status of the parking brake system. • If the truck did not move: The park brake system passed the test. • If the truck moved during the test: The park brake test has failed. Release the accelerator pedal. If the truck starts to roll, apply the service brakes to hold the truck stationary.

Notify maintenance personnel immediately.

Parking Brake or Retard Test READY Press Accel or Retard Pedal to Start 4. Fully depress the retard pedal. The drive system controller will ramp up the engine speed, close RP1, close RP2, close RP3 (if present), turn on the choppers, and test the retarding system. The system will verify current flow through each grid leg and the grid blower motor.

5. The DID panel will display the current status of the test.

Retard System Test ACTIVE RP1 RP2 RP3 CHOP (Elements are added as the test progresses.)

6. Upon successful completion of the test, the light will flash for 10 seconds indicating a successful test. The DID panel will display: Retard System Test PASSED or Retard System Test FAILED or Incomplete NOTE: If the brake check light never flashes, but turns off, the test has failed.

If the truck fails the parking brake test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

7. When the operator releases the accelerator pedal, torque will be reduced, the test will stop and the brake check light will turn off.

If the truck fails the retard system test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

7. When the operator releases the retard pedal, the test will stop and the brake check light will turn off.

8. If the retard system failed the test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

F17-4

Static Brake System Checkout

FAM1701

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

MACHINE MODEL (Circle One) 730E

830E-1AC

930E-4

930E-4SE

Service Meter Reading

MACHINE SERIAL NUMBER

ENGINE MODEL

Date of Inspection

Wheel Motor Serial Numbers

Location of Machine at Inspection

ENGINE SERIAL NUMBER

LH

Dump Body Manufacturer Komatsu

CUSTOMER UNIT NUMBER

RH Other

Distributor’s Name

Dump Body Style

Customer’s Name

KAC Area Service Manager Signature

Date

Customer’s Address

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation.

All four copies are to be distributed as shown below.

Send White Reports to

Manager of Technical Support Komatsu America Corp.

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

Send Canary Reports to

Manager of Field Assembly Komatsu America Corp.

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

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

Mark each item with the appropriate symbol as shown below.

CEAW003216

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 1 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Inspection Around Machine 1

Parts

Visual inspection of unit for loose parts and debris

2

Hardware

Visual inspection of unit for missing and/or loose mounting hardware

3

Hoses and Cables

Visual inspection of hydraulic hoses and electric cables to ensure they are securely clamped and clear from sharp edges and not rubbing each other

4

Ground Straps

Verify all ground straps are secure (sub frame, anchor etc.)

5

Engine Oil Level

Verify engine oil level is in operating range

6

Engine Fan

Inspect fan-to-shroud clearance and belt alignment

7

Hydraulic Oil Level

Oil level visible through the upper sight glass with body down

8

Hatch Door (730E, 830E-1AC)

Verify adequate latch seal on the rear axle hatch door to prevent dust entry

9

Anchor Pin

Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and properly tightened hardware

10

Wheel Motors

Inspect oil specification and proper oil level

11

Fuel Tank

Verify fuel tank mounting is secure and there are no fuel leaks

12

Radiator

Inspect coolant fill level, cold temperature protection, and DCA additive Inspect all ladders and handrails are secure and hardware is tight

13

Decks and Ladders

Visual inspection of installation of grid blower, rectifier assembly and control box for correct assembly of components and proper clamping, no loose contacts, no damaged or poorly crimped cables Inspect all wiring and connections in battery box - no rubbing or chafing

14

Verify battery mounting hardware is secure

Battery

Verify electrolyte at proper level and caps are securely installed Verify all battery terminals are secure

15 16

Steering Components

Visually inspect installation of steering cylinders, tie rod, and accumulators per print

Hydraulic Components

Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations (all hardware secure, no leaks)

Hardware Torque 1

Verify front suspension mounting cap screws have been properly tightened per appropriate service manual procedure using the “turn of the nut” method

Suspension Wheels 730E, 830E-1AC

Verify torque on all wedge nuts at 746 N·m (550 ft lb)

(See Note below chart) Verify torque on front wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lb)

2 930E-4, 930E-4SE (See Note below chart)

Verify torque on rear inside wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lb) Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft lb)

Rops

830E-1AC

Verify torque on left rops beam cap screws at 1017 N·m (750 ft lb)

730E,930E-4, 930E-4SE

Verify torque on left rops beam cap screws at 800 N·m (590 ft lb))

3

930E-4, 930E-4SE 730E Trolley

Verify torque on right diagonal beam cap screws at 240 N·m (177 ft lb) Verify torque on right diagonal beam cap screws at 800 N·m (590 ft lb) Verify torque on pantograph support cross beam cap screws at 240 N·m (177 ft lb)

NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mounting tightening procedure.

CEAW003216

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 2 of 5

730E, 930E-4 930E-4SE

4

830E-1AC

Acceptance Procedures

Maintenance

Inspection Item Cab

Accepted

No.

Verify torque on cab mounting cap screws at 800 N·m (590 ft lb) Verify torque on cab mounting cap screws at 1017 N·m (750 ft lb)

5

Wheel Motor

Verify torque on wheel motor mounting cap screws at 2007 N·m (1480 ft lb)

6

Tie Rod Clamp Nuts

Verify torque tie rod clamp nuts at 420 ± 42 N·m (310 ± 31 ft lb)

Cab Compartment 1

Cab Doors

Verify doors open and close smoothly, latch works properly

2

Cab Windows

Verify windows can be opened and closed smoothly

3

Door Locks

Verify left and right door locks work properly with key Visually inspect interior for completeness of assembly

4

Interior

5

Cab Seats

Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.

Inspect operators seat adjustments (slide lever, back rest operation, seat inclination, seat height etc.)

Inspect seat belt for proper installation (and seat tethers)

6

Passenger Seat

Verify back rest operates without interference

7

Steering Wheel

8

Wiper

9

Document Holder

Verify that the OMM and Safety manuals are present

10

Cigarette Lighter

Check lighter operation, should pop up after 10 seconds and be hot (730E only)

11

Horn

Check for proper sound, no looseness in horn button

12

Back Up Horn

Check for proper sound, and function

13

Shift Tower

Check for proper function, no binding or looseness

14

Gauges

Verify gauges are installed straight and operating correctly

15

Hydraulic Fittings

Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet

16

Hoist

Check operation of the hoist lever in all four positions

Check tilt and telescoping functions Check adjustable lever can be locked securely Verify wiper works at all speed settings and range does not extend beyond glass surface Verify the windshield washer works properly and washer fluid bottle is full

Lights Verify all headlights working, high and low beams 1

Headlights

Verify high beam indicators are functional

2

Instrument Panel

Check switch depresses and all lights function

3

Dimmer Switch

Verify dimmer operates properly

4

Dome Light

Verify dome light is on when the switch is ON

5

Turn Signal

Verify lights at proper angle

Visually inspect front and rear turn signal operation on left and right sides Directional indicators operate properly Switch turns off after turn is completed Verify flasher operates properly

6

Hazard Flashers

7

Back Up Light

Verify back up light operates properly when shifter is in R position

8

Manual Back Up Light

Verify switch and light work properly

9

Fog Light (optional)

Verify fog lights and indicator lights operating properly

CEAW003216

Verify hazard indicator lights operating properly

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 3 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Brake Lights 1

Service Brake

Verify service brake lights operating properly

2

Brake Lock

Verify brake lock light operating properly

3

Emergency Brake

Verify emergency brake light operating properly

4

Parking Brake

Verified parking brake light operating properly

5

Retarder Lights

Verify retard light operating properly

Service Inspection 1

Hydraulic System

Perform flushing procedure at initial startup Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear

Suspension

730E

(See Note below chart)

Front charge height, 229 mm (9 in.) at 2 758 kPa (400 psi) Rear charge height, 276 mm (10.9 in. ) at 1 420 kPa (206 psi) Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear

2

830E-1AC (See Note below chart)

Front charge height, 229 mm (9 in.) at 2 689 kPa (390 psi) Rear charge height, 241 mm (9.5 in.) at 1 724 kPa (250 psi) Suspension oiling height at 25.4 mm (1 in.) front and 53.0 mm (2.1 in.) rear

930E-4, 930E-4SE (See Note below chart)

Front charge height, 229 mm (9 in.) at 2 930 kPa (425 psi) Rear charge height, 218 mm (8.6 in.) at 1 482 kPa (215 psi)

3

Verify nitrogen charge in accumulators is at 9 653 kPa (1400 psi) for all models, for both steering and brakes (charge pressure will vary with ambient temperature, refer to chart in SM)

Accumulators

4

Engine Prelube

Ensure prelube is working prior to engine starting

5

Engine Starting

Ensure engine starts easily

6

Engine Noise

No abnormal noise from engine

7

Brake Lock

Verify when switch is ON, brakes are applied and light is illuminated. Must be in Neutral.

8a

Parking Brake

Verify when switch is ON, brakes are applied and light is illuminated

730E 8b

830E-1AC, 930E-4, 930E-4SE

Verify when directional control lever is in PARK, brakes are applied and light is illuminated Verify with pedal depressed, front brake pressure is 17 236 ± 689 kPa (2500 ± 100 psi)

Brake Pressure

730E

Verify with pedal depressed, rear brake pressure is 11 721 ± 517 kPa (1700 ± 75 psi) Verify brake lock pressure is 10 342 ± 689 kPa (1500 ± 100 psi) Verify parking brake pressure is 17 926 ± 689 kPa (2600 ± 100 psi) Verify with pedal depressed, front brake pressure is 20 684 ± 1034 kPa (3000 ± 150 psi)

830E-1AC

9

Verify with pedal depressed, rear brake pressure is 10 894 ± 517 kPa (1580 ± 75 psi) Verify brake lock pressure is 10 342 ± 689 kPa (1500 ± 100 psi) Verify parking brake pressure is 17 236 ± 689 kPa (2500 ± 100 psi) Verify with pedal depressed, front brake pressure (BF) is 17 236 ± 517 kPa (2500 ± 75 psi)

930E-4, 930E-4SE

Verify with pedal depressed, rear brake pressure (BR) is 17 236 ± 517 kPa (2500 ± 75 psi) Verify brake lock pressure is 17 236 ± 689 kPa (2500 ± 100 psi) Verify parking brake release pressure is 19 995 ± 1 035 kPa (2900 ± 150 psi)

NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling and charging instructions.

CEAW003216

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 4 of 5

10

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Verify that steering system is operating smoothly, turning from lock to lock

Steering

Verify steering system is free of noise and vibration Verify hoist pressure is 17 236 kPa (2500 psi) power up, and 10 342 kPa (1500 psi) power down

11

Verify hoist limit switch is operational and is set correctly (measure on the hoist cylinder - 3rd stage), cylinder should stop 152 mm (6 inches) before full extension

Hoist

Verify that the hoist hold position operates properly Verify that there is no heavy shock when the body returns to the frame in float Power up loaded - 21-23 seconds Hoist Times

730E

Power down - 15-17 seconds Float down empty - 22-24 seconds Power up loaded - 25-27 seconds

830E-1AC

12

Power down - 15-17 seconds Float down empty - 23-25 seconds Power up loaded - 21-23 seconds

930E-4, 930E-4SE

Power down - 23-25 seconds Float down empty - 24-26 seconds

All Trucks

Ensure body up switch activates the body up alarm and light in the cab

13

Lubrication

14

Payload Meter Sys.

Ensure automatic lube system is serviced and full (and air bled from system) Ensure automatic lube system is operating properly and timer is set as desired Calibrate and check payload meter operation per O&M manual

15

Error Codes

Troubleshoot any error codes and delete

16

Machine

Record machine model-type, machine serial number and engine serial number

17

Dump Body

Ensure the dump body is shimmed correctly prior to truck release

18

Electrical Checks

Ensure the electrical checkout procedure has been completed and signed off on, including megger testing (see appropriate Field Assembly Manual or Shop Manual for procedure)

19

Truck Programming

Ensure the truck is programed with it’s own unique configuration file and a copy of the file saved

ADDITIONAL COMMENTS__________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CEAW003216

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 5 of 5

NOTES:

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

MACHINE MODEL (Circle One)

MACHINE SERIAL NUMBER

ENGINE MODEL

Date of Inspection

Wheel Motor

ENGINE SERIAL NUMBER

CUSTOMER UNIT NUMBER

730E 830E

830E1-AC

930E-4

930E-4SE

Service Meter Reading

Serial Numbers Location of Machine at Inspection

LH

Dump Body Manufacturer Komatsu

RH Other

Distributor’s Name

Dump Body Style

Customer’s Name

KAC Area Service Manager Signature

Date

Customer’s Address

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Send white reports to:

Manager of Technical Support Komatsu America Corp.

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

Send canary reports to:

Manager of Field Assembly Komatsu America Corp.

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

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

CEAW004205

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 1 of 5

No.

Inspection Item

Acceptance Procedures

As Found Condition

Corrective Action

Inspection Around Machine 1

Parts

Visually inspect the truck for loose parts and debris.

2

Hardware

Visually inspect the truck for missing and/or loose mounting hardware.

3

Hoses and Cables

Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped and clear of sharp edges and other objects that may cause chaffing.

4

Engine Oil Level

Verify the engine oil level is at the proper operating range.

5

Hydraulic Oil Level

Verify the oil level is visible through the upper sight glass with the body down.

6

Anchor Pin

Visually inspect the anchor hitch pin and anti-sway bar assembly for proper installation and properly tightened hardware.

7

Wheel Motors

Verify the correct oil is being used and oil is at the proper level.

8

Fuel Tank

Verify the fuel tank mounting is secure and there are no fuel leaks.

9

Radiator

Inspect the coolant fill level, cold temperature protection, and DCA additive.

10

Steering Components

Verify proper installation of the steering cylinders, tie rod, and accumulators.

11

Hydraulic Components

Visually inspect the hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations. All hardware must be secure, and no leaks evident.

12

Leakage

Visually inspect the entire machine for leaks.

Hardware Torque 730E - Verify hardware torque Target: 2705 N·m (1995 ft lb) 1

Steering Arm To Suspension

830E, 830E-1AC- Verify hardware torque Target: 2705 N·m (1995 ft lb) 930E-4, 930E-4SE - Verify hardware torque Target: 2705 N·m (1995 ft lb) 730E - Verify hardware torque Target: 464 N·m (342 ft lb)

2

Steering Cylinder To Frame

830E, 830E-1AC - Verify hardware torque Target: 712 N·m (525 ft lb) 930E-4, 930E-4SE - Verify hardware torque Target: 1017 N·m (750 ft lb) 730E - Verify hardware torque Target: 464 N·m (342 ft lb)

3

Steering Cylinder To Steering Arm

830E, 830E-1AC - Verify hardware torque Target: 712 N·m (525 ft lb) 930E-4, 930E-4SE - Verify hardware torque Target: 1017 N·m (750 ft lb)

CEAW004205

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 2 of 5

No.

Inspection Item

Acceptance Procedures

As Found Condition

Corrective Action

730E - Verify hardware torque Target: 464 N·m (342 ft lb) 4

Tie Rod Pin Retainer

830E, 830E-1AC - Verify hardware torque Target: 712 N·m (525 ft lb) 930E-4, 930E-4SE - Verify hardware torque Target: 1017 N·m (750 ft lb)

5

Tie Rod Clamp Nut

All Models - Verify hardware torque Target: 420 ± 42 N·m (310 ± 31 ft lb) 730E - Verify hardware torque -

6

Front Brake Caliper Mounting (Capscrew with Nut)

Target: 1085 N·m (800 ft lb) 830E, 830E-1AC - Verify hardware torque Target: 1085 N·m (800 ft lb) 730E - Verify hardware torque -

7

Front Brake Caliper Mounting (Capscrew Only)

Target: 1166 N·m (860 ft lb) 830E, 830E-1AC - Verify hardware torque Target: 1166 N·m (860 ft lb) 730E - Verify hardware torque -

8

Rear Service Brake Caliper Mounting

Target: 780 N·m (575 ft lb) 830E, 830E-1AC - Verify hardware torque Target: 780 N·m (575 ft lb) 730E - Verify hardware torque -

9

Rear Brake Adapter Mounting

Target: 488 N·m (360 ft lb) 830E, 830E-1AC - Verify hardware torque Target: 488 N·m (360 ft lb) 730E - Verify hardware torque -

10

Brake Disc To Adapter Mounting

Target: 278 N·m (205 ft lb) 830E, 830E-1AC - Verify hardware torque Target: 278 N·m (205 ft lb)

Wheels 730E, 830E-1AC

Verify torque on all wedge nuts at 746 N·m (550 ft lb)

(See Note below chart) Verify torque on front wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lb)

11 930E-4, 930E-4SE (See Note below chart)

Verify torque on rear inside wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lb) Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft lb)

NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mounting tightening procedure.

Cab Compartment 1

Horn

Check for proper tone and volume. Ensure there is no looseness in the horn button.

2

Back Up Horn

Check for proper tone, volume, and function.

3

Gauges

Verify all gauges are installed straight and are operating correctly.

4

Glass

Verify no cracks exist on cab windows. Ensure all windows are properly sealed.

5

Seat/Seat belts

Verify the cab seats and seat belts are in proper working condition.

CEAW004205

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 3 of 5

No.

Inspection Item

As Found Condition

Acceptance Procedures

Corrective Action

Service Inspection Suspension oiling height: 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear Suspension

730E

(See Note below)

Front charge height: 229 mm (9 in.) at 2758 kPa (400 psi) Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206 psi) Suspension oiling height: 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear

830E, 830E-1AC 1

(See Note below)

Front charge height: 229 mm (9 in.) at 2689 kPa (390 psi) Rear charge height: 241 mm (9.5 in.) at 1724 kPa (250 psi) Suspension oiling height: 25.4 mm (1 in.) front and 53.0 mm (2.1 in.) rear

930E-4, 930E-4SE (See Note below)

Front charge height: 229 mm (9 in.) at 2930 kPa (425 psi) Rear charge height: 218 mm (8.6 in.) at 1482 kPa (215 psi)

NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling and charging instructions.

2

Accumulators

3

Steering

Verify the nitrogen charge in the accumulators is at 9653 kPa (1400 psi) for all models, for both steering and brakes. (Charge pressure will vary with ambient temperature, refer to chart in SM) Verify that steering system is operating smoothly while turning from lock to lock.

Verify the steering system is free of noise and vibration.

4

Ensure the automatic lube system contains no air and is filled to the proper level.

Lubrication

Ensure the automatic lube system is operating properly and the timer is set as desired.

Verify the 50 hour change of all hydraulic filters has been completed.

5

Hydraulic Filters

6

Tires

Check and record the tire pressure/size/manufacturer for future reference

7

Payload Meter System

Calibrate and check payload meter operation per O&M manual. Troubleshoot any error codes and delete after repair.

8

GE Drive/Control System

Check drive control system operation per O&M manual.

Troubleshoot, correct and delete any error codes.

GE Rotating

Visually inspect wheel motor armature condition - brush wear, commutator color, etc.

NOTE: Elements are supplied from the factory in the parts crate.

Pressure Size Manufacturer

9

Components (Wheel Motors, MTA, Grid Blower)

Inspect MTA slip rings and brushes.

Inspect grid blower motor commutator condition, brush wear, etc.

10

Wheel Motor Sun Pinion End Play

Measure and record sun pinion end play for both RH and LH wheel motors

11

VHMS

Verify the VHMS system is functioning properly per O&M manual. Troubleshoot and repair any problems.

CEAW004205

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 4 of 5

MINE OPTIONS - List any mine/site specific options or modifications made to the unit.

No.

Description of Modification

Reason For Installation

1 2 3 4 5 6

ADDITIONAL COMMENTS:______________________________________________________________

__________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW004205

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 5 of 5

NOTES:

®

www.komatsuamerica.com

Komatsu America Corp.

2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072

Copyright 2011 Komatsu Printed in U.S.A.