Komatsu 860E-1KT Dump Truck Field Assembly Manual SN A30003-A30030 and up - PDF DOWNLOAD

CEAW005702

Field Assembly Manual

860E-1KT DUMP TRUCK SERIAL NUMBERS

A30003 - A30030

®

FOREWORD This m anual is provided to aid assemblers duri ng field assembly of the standard Komatsu 860 E-1K dum p truck.

Variations of des ign requ ired f or specific t ruck orders m ay req uire s ome m odification of the general proc edures 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 l ocation ref erences to “ front”, “rear”, “ri ght”, or “left”, are given in respect t o t he operator's norm al s eated 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.

FAM0018

Introduction

i

This al ert symb ol i s u sed w ith th e signal w ords, CAUT ION, DANG ER, an d 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

FAM0018

TABLE OF CONTENTS

SUBJECT

PAGE NUMBER

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 TRUCK COMPONENT 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

FAM0018

Introduction

iii

KOMATSU 860E-1KT

iv

Introduction

FAM0018

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 rul es or regul ations and federal, s tate, o r local laws. T he s afety p recautions rec ommended h ere are general and m ust be us ed i n c onjunction w ith all prevailing local rules and regulations.

1. All personnel m ust be prop erly t rained f or t he assembly process.

2. Wear s afety eq uipment s uch as s afety glasses, hard toe shoes and hard hat s at al l times duri ng assembly.

3. Thoroughly i nspect t he as sembly s ite. Rem ove weeds, debris and other flammable material.

4. Use o nly s olid, hard wood f or s upports. When using m etal s upport s tands, pl ace wood bl ocks between t he s upport a nd t he f rame to p revent metal to metal contact.

5. Inspect al l l ifting dev ices. Refer to the m anufacturer's s pecifications for correct ca pacities a nd safety procedures when lifting components.

6. Perform a daily inspection of all lifting cables and chains. Re place any questionable i tems. Us e cables and c hains that are properl y 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.

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

10. Disconnect the bat tery c harging al ternator l ead wire bef ore wel ding o n t he f rame or i ts c omponents.

11. When welding, c onnect t he groun d c able t o t he part being welded. DO NOT allow welding current to pass through bearings, engine, etc.

12. DO NOT wel d t he f uel t ank or hydraulic t ank unless the tanks ha ve been properly p urged a nd ventilated.

13. Use the proper t ools for the job to be performed.

Never i mprovise wrenc hes, s crew drivers, sockets, etc. unless specified.

14. Lifting ey es and hook s must be f abricated f rom the proper materials and rated to lift the intended load.

15. When t he we ight of a ny c omponent(s) or any assembly proc edure i s not k nown, contact y our customer support manager for further information.

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

9. Cap screws and/or n uts being repl aced m ust be the same grade as originally supplied.

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Safety Rules, Tools, & Equipment

Page 1-1

TOOLS AND EQUIPMENT FOR ASSEMBLY The f ollowing equi pment is rec ommended f or f ield assembly of the truck.

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

12. Two, ratchet pullers - 2.7 metric ton (3 ton) 13. Two, ratchet pullers - 1.4 metric ton (1.5 ton) 14. Set of standard master mechanics hand tools.

a. Two, 45 m etric ton (50 ton) c ranes 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.

• Thread taps and dies of both inch and metric

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 t on (50 ton) c rane i s al so req uired f or this task.

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

3. One f ork l ift - 68 04 k g (15, 000 l b) c apacity, wi th high lift capability.

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

5. One, propane torche 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 s ufficient amount of wood cribbing - sizes f rom 1. 2 m x 30. 5 cm x 30.5 c m (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

sizes.

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

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.

• Box wrench 1 7/16 in. (PB8326) with 12 inch extension to tighten ROPS cap screws.

• Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2 5/8 in. (Snap-On P/N J15042) to tighten front suspension hardware.

15. Heavy duty 3/ 4 in. & 1 in. s quare dri ve i mpact wrench sets.

16. Impact s ockets f or 3/ 4 i n. & 1 i n. s quare drive tools.

8. Tire handler - Wiggins/Iowa Mold Tooling.

17. Special tools (see list, following pages)

9. Miscellaneous air tools 10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft)

18. Two, hy draulic or pneumatic po rta-power j acks, 4.5 and 9 metric ton (5 and 10 ton)

11. Chains, lifting cables, slings:

19. Various hooks and shackles

• • • • •

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

20. Miscellaneous: i.e. grinders, containers, rags.

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

21. Spreader bars for cab and decks.

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

22. Two ratchet hoists of 2.7 metric ton (3 ton) capacity.

Two, 3 m (10 ft) nylon straps Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) of rope

23. Pry bars 24. Solvent - 38 liters (10 gal) 25. Paint remover - 19 liters (5 gal) 26. Rust preventive grease

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Safety Rules, Tools, & Equipment

7/10 FAM0114

LIFTING SLING GENERAL INFORMATION

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Safety Rules, Tools, & Equipment

Page 1-3

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

EJ2626 (No longer available as complete unit)

Roller Assy.

Power Module Remove & Install

EJ2271

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

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Safety Rules, Tools, & Equipment

7/10 FAM0114

FAM0114 7/10

Part Number

Description

PB8326

Offset Box End Wrench - 1 7/16�

Part Number

Description

EH4638

Sleeve Alignment Tool

Safety Rules, Tools, & Equipment

Use Cab Mounting & Miscellaneous

Use Steering Linkage and Tie Rod Assembly

Page 1-5

Part Number

Description

EM3704 (Rear)

Wear Indicator

EM3702 (Front) EB1723

Use Brake Disc Wear Inspection

Cap, Indicator

EM3703 (Rear) Pin, Indicator EM3701 (Front) WA0010

O-ring, Indicator Pin

TL3995

O-ring, Indicator Cap

EB4813

Housing, Indicator

SV9812

O-ring, Housing

Part Number

Description

PC2525

Harness

Part Number

Description

Use

PC2061

Belt Tension Tester

A/C Belt Tension Check

Part Number

Description

Use

EL8868

V-Belt Alignment Tool

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Use Payload Meter Download

A/C Belt Alignment

Safety Rules, Tools, & Equipment

7/10 FAM0114

FAM0114 7/10

Part Number

Description

EH7817

Alignment Tool

Part Number

Description

PB4684

Hydraulic Coupling

Part Number

Description

PB9067

Bulkhead Connector

Safety Rules, Tools, & Equipment

Use Upper Hoist Pin

Use Miscellaneous

Use Battery Jumper

Page 1-7

Part Number

Description

Use

TZ2734

3/4 in. Square Drive

Torque Adaptor

TZ2733

Handle

Torque Adaptor

Part Number

Description

Use

PC2764

Sling

Body Retention

Part Number

Description

Use

PC0367

Shackle

Body Retention Miscellaneous

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Safety Rules, Tools, & Equipment

7/10 FAM0114

Part Number

Description

Use

EM3705

Brake Assembly Tool Group (Front)

Brake Assembly & Disassembly

EM3706

Brake Assembly Tool Group (Rear)

Brake Assembly & Disassembly

HYDRAULIC SYSTEM FLUSHING TOOLS Part Number

Description

Use

XB5777

Hose Assembly

Flush Steering Circuit

PC3074

Flushing Block (bypass hoist cylinders)

Flush Hoist Circuit

XB7075

Fitting Assembly

Flush Brake Circuit

HYDRAULIC SYSTEM VACUUM PUMP Part Number XB0887

FAM0114 7/10

Description Vacuum Pump

Use To hold oil back while the system is open.

Safety Rules, Tools, & Equipment

Page 1-9

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Safety Rules, Tools, & Equipment

7/10 FAM0114

FAM0114 7/10

Safety Rules, Tools, & Equipment

Page 1-11

NOTES

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Safety Rules, Tools, & Equipment

7/10 FAM0114

TRUCK COMPONENTS AND SPECIFICATIONS Truck And Engine

Operator's Cab

The 860E Dum p Truck is an of f-highway, rear dum p truck with AC Electric Drive. The gross vehicle weight is 454 3 63 k g (1, 001,700 l bs). T he e ngine i s a Komatsu SSDA16V160 rated @ 2700 HP (2014 kW).

The operator c ab has been engi neered for operat or comfort and to al low for efficient and safe op eration of t he t ruck. T he c ab i s rubb er-mounted to reduce noise and v ibration, prov ides wi de v isibility wi th an integral 4-pos t ROPS/FOPS s tructure, and has an advanced analog operator environment. It includes a tinted s afety-glass wi ndshield and po wer-operated side windows, a deluxe interior with a fully adjustable seat wi th l umbar s upport, a f ully a djustable/tilt steering wheel , c ontrols m ounted wi thin eas y reac h of t he operat or, an d an d igital/analog i nstrument panel whi ch prov ides t he op erator wi th al l instruments and ga uges whi ch are nec essary t o control and/or monitor the truck's operating systems.

Main Alternator The di esel engine dri ves an in-line al ternator at engine s peed. The al ternator produc es A C c urrent which i s rec tified t o DC wi thin t he m ain c ontrol cabinet. The rectified DC power is converted back to AC by groups of devices called "inverters", which are also wi thin the m ain control c abinet. E ach i nverter consists of six phase modules under t he control of a gate driver power c onverter (GDP C). T he two GDPCs control the operation of each phase module.

Each phas e m odule c ontains pai red pos itive an d negative s emiconductor s witches referred t o as insulated ga te bipolar transistors (IGBT). The IGBTs cycle on and o ff at varying frequencies to create a n AC power signal from the DC supply.

The AC power s ignal produced by each inverter is a variable-voltage, v ariable-frequency ( VVVF) si gnal.

Frequency and v oltage a re c hanged t o s uit t he operating conditions.

Cooling ai r f or t he c ontrol/power grou p and whee l motors, as well as the alternator itself, is provided by a main blower mounted below the control cabinet.

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 en ergy t hrough built-in gea r trains within the wheel motor assembly. The direction of the wheel motors i s c ontrolled by a di rectional c ontrol lever located on the center console.

Suspension Hydrair IIÂŽ s uspension c ylinders located at eac h wheel provide a smooth and c omfortable ride for the operator and dam pens s hock l oads t o t he c hassis during loading and operation.

FAM0218

Power Steering The truck is equipped with a full time power steering system which p rovides positive steering control with minimum o perator ef fort. The syst em includes nitrogen-charged ac cumulators wh ich aut omatically provide em ergency po wer i f t he s teering hy draulic pressure is reduced below an established minimum.

Dynamic Retarding The dynamic ret arding i s used to s low t he t ruck during no rmal o peration or control s peed coming down a grade. T he dy namic ret arding abi lity of t he electric system is controlled by the operator through the ac tivation of t he ret arder peda l i n t he operat ors cab and by s etting t he RS C (Ret arder S peed Control). Dy namic retarding i s automatically activated, i f t he truck s peed goes to a pres et overspeed setting.

Brake System Service brakes at each wheel are oil-cooled multiple disc brak es applied by an al l-hydraulic ac tuation system. Depres sing the brak e peda l ac tuates bot h front and rear brakes after first applying the retarder.

All wheel brak es will be ap plied automatically i f t he brake s ystem pres sure decreases below a pres et minimum.

The parking brake is a wet disc type, i ntegral to the service brak es, and i s spring-applied a nd hydraulically-released with whee l s peed appl ication protection (will not apply with truck moving).

Truck Components And Specifications

Page 2-1

860E-1K MAJOR COMPONENTS Page 2-2

Truck Components And Specifications

FAM0218

SPECIFICATIONS These specifications are for the standard Komatsu 960E-1 Truck. Customer options may change this listing.

ENGINE Komatsu SSDA16V160 No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Operating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke Rated Brake HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2700 HP (2014 kW) @ 1900 RPM Flywheel HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2550 HP (1902 kW) @ 1900 RPM Weight (Dry)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9608 kg (21,182 lbs) * Weight does not include radiator, sub-frame, or alternator.

AC ELECTRIC DRIVE SYSTEM AC/DC Current Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRLDZ5010-AL Motorized Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Induction Traction Motors Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.526:1 Maximum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5 km/h (40 mph) * Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.

Komatsu must analyze each job condition to ensure proper application.

DYNAMIC RETARDING Electric Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Continuous* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4650 HP (3469 kW) * Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.

BATTERY ELECTRIC SYSTEM Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four 8D, 12 volt wet batteries with disconnect switch Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 CCA Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 140 Amp Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts Cranking Motors (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts

SERVICE CAPACITIES Crankcase (including lube oil filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 liters (74 gallons) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 liters (125 gallons) Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 542 liters (1200 gallons) Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 609 liters (425 gallons) Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 liters (32 gallons) per wheel Inverter Cabinet Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 liters (6.5 gallons)

HYDRAULIC SYSTEMS Hoist and Brake Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931 L/min (246 gpm) @ 1900 RPM and 17 237 kPa (2,500 psi) Steering/Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 18 961 kPa (2,750 psi)

FAM0218

Truck Components And Specifications

Page 2-3

Relief Pressure - Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 237 kPa (2,500 psi) Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 961 kPa (2,750 psi) Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Stage Hydraulic Tank (Vertical/Cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Pressurized Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947 liters (250 gallons) Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line replaceable elements Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Full Flow, 100 Mesh Hoist and Steering Filters (Dual In-Line, High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 Rating =200

SERVICE BRAKES All Hydraulic Actuation with Traction System Wheel Slip/Slide Control Front and Rear Oil-Cooled Multiple Discs on each wheel Total Friction Area / Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 019 cm² (15,038 in²) Maximum Apply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 545 kPa (2,400 psi)

STEERING Twin hydraulic cylinders with accumulator assist to provide constant rate steering Emergency power steering automatically provided by accumulators Turning Circle (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 m (102 ft. 0 in.)

TIRES Radial Tires (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50/80 R57 Rock Service, Deep Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flange mount rims

STANDARD DUM P BO DY CAP ACITIES AND DIMENSIONS Capacity Heaped @ 2:1 (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 m3 (221yd 3) Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 m3 (160 yd 3) Width ( Front Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64 m (25 ft. 1 in.)

Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.87 m (25 ft. 10 in.)

Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38 m (20 ft 11 in.)

Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° NOTE: Optional capacity dump bodies are available.

Page 2-4

Truck Components And Specifications

FAM0218

WEIGHT DISTRIBUTION Vehicle Weights Standard Trolley Chassis140 046 kg(308,749 lbs) Standard Komatsu body33 643 kg(74,171 lbs) Standard tire weight 23 033 kg(50,780 lbs) Option Allowance3 629 kg (8,000 lbs) Empty Vehicle Weight 200 351 kg(441,700 lbs) Front Axle ( 49%) 98 361 kg(216,850 lbs) Rear Axle ( 51%)101 990 kg(224,850 lbs) Gross Vehicle Weight454 363 kg(1,001,700 lbs) Front Axle ( 33.5%) 152 392 kg(335,871 lbs) Rear Axle ( 66.5%)301 971 kg(665,829 lbs) Max. Nominal Payload*254 012 kg(560,000 lbs) NOTE: All weights shown with 100% fuel load.

* Nominal pay load i s d efined w ithin K omatsu America Co rporation’s pay load p olicy documentation. In general, the nominal payload must be adjusted for the specific vehicle configuration and site app lication. T he figures l isted are provided f or basic produc t description purposes. P lease c ontact your K omatsu di stributor f or s pecific appl ication requirements.

FAM0218

Truck Components And Specifications

Page 2-5

Page 2-6

Truck Components And Specifications

FAM0218

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. C ontact your cu stomer su pport m anager fo r c oncerns o r q uestions ab out l ifting t ruck c omponents.

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

ITEM

KILOGRAMS

POUNDS

CHASSIS Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 602 . . . . . . . . . . . . . . . . . . . . . . 3,530 Tire (50/80 R57). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 839 . . . . . . . . . . . . . . . . . . . . . . 8,463 Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 440 . . . . . . . . . . . . . . . . . . . . . 11,993 Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 763 . . . . . . . . . . . . . . . . . . . . . 54,594 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 696 . . . . . . . . . . . . . . . . . . . . . . 3,740 Dump Body (standard Komatsu Rock body) . . . . . . . . . . . . . . . . . . . . . . .33 643 . . . . . . . . . . . . . . . . . . . . . 74,171

DECK AND DECK SUPPORT COMPONENTS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 268 . . . . . . . . . . . . . . . . . . . . . . 5,000 RH Deck (with retarding grid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 904 . . . . . . . . . . . . . . . . . . . . . . 8,606 LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 . . . . . . . . . . . . . . . . . . . . . . 1,574 Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 . . . . . . . . . . . . . . . . . . . . . . . . 514 Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 . . . . . . . . . . . . . . . . . . . . . . . . 974 Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 . . . . . . . . . . . . . . . . . . . . . . . . 392 LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919 . . . . . . . . . . . . . . . . . . . . . . 2,027 RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 . . . . . . . . . . . . . . . . . . . . . . 1,378 LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 . . . . . . . . . . . . . . . . . . . . . . . . 298 RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . . 150 Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 . . . . . . . . . . . . . . . . . . . . . . . . 397 Diagonal Ladder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . . . . . . . . . . . . 119

FAM0316 5/11

Major Component Weights

Page 3-1

ITEM

KILOGRAMS

POUNDS

POWER MODULE Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890 . . . . . . . . . . . . . . . . . . . . . . . 1,960 Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340 Retarding Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 880 . . . . . . . . . . . . . . . . . . . . . . . 6,350 Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 629 . . . . . . . . . . . . . . . . . . . . . . . 8,000 24V Auxillary Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690 . . . . . . . . . . . . . . . . . . . . . . . 1,521 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 520 . . . . . . . . . . . . . . . . . . . . . . . 7,760 Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 619 . . . . . . . . . . . . . . . . . . . . . . 21,206 Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 678 . . . . . . . . . . . . . . . . . . . . . . . 3,700

HYDRAULIC COMPONENTS Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 . . . . . . . . . . . . . . . . . . . . . . . . 380 Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .941 . . . . . . . . . . . . . . . . . . . . . . . 2,075 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 . . . . . . . . . . . . . . . . . . . . . . . . 350 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .716 . . . . . . . . . . . . . . . . . . . . . . . 1,580

FRONT AXLE COMPONENTS Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 460 . . . . . . . . . . . . . . . . . . . . . . . 3,219 Spindle, Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 035 . . . . . . . . . . . . . . . . . . . . . . 11,100 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314 . . . . . . . . . . . . . . . . . . . . . . . . 693 Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 880 . . . . . . . . . . . . . . . . . . . . . . . 6,350

REAR AXLE COMPONENTS Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919 . . . . . . . . . . . . . . . . . . . . . . . 2,025 Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 . . . . . . . . . . . . . . . . . . . . . . . . 802 Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 934 . . . . . . . . . . . . . . . . . . . . . . 13,082 Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 . . . . . . . . . . . . . . . . . . . . . . . . 324 Electric Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 356 . . . . . . . . . . . . . . . . . . . . . . . 9,603 Wheel Motor & Rear Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 359 . . . . . . . . . . . . . . . . . . . . . . 27,247 Wheel Motor & Rear Brake Assembly (with Electric Wheel Motor) . . . . . 16 715 . . . . . . . . . . . . . . . . . . . . . . 36,850 Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 . . . . . . . . . . . . . . . . . . . . . . . . 670

Page 3-2

Major Component Weights

5/11 FAM0316

FIELD WELDING FOR ASSEMBLY OR REPAIR When wel ding on K omatsu equi pment, whet her at initial f ield assembly or duri ng norm al m aintenance repairs, special procedures must be followed.

Due t o t he c ontinuous program of res earch an d development, periodic revisions may be made to this publication. I t i s rec ommended t hat c ustomers c ontact their distributors for information on the latest revision.

The welding i nformation c ontained i n this c hapter is general information that must be followed unless otherwise s pecified in a det ailed repair proc edure provided on an engi neering drawi ng or a det ailed 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), F lux Core (FCAW), or “S tick” el ectrode welding (S MAW), are approved proc esses for field installation and m aintenance wel ding. W elding of highly stressed structural members such as castings, torque t ubes, t op and bo ttom plates on t he frame rails, and t he c urved i ntersection points of frames should be done with the specific detailed instructions from K omatsu P roduct Service. See A nnex A for repair proc edures. T hese rep air proc edures are detailed instructions for most high stressed structural members.

APPROVED CONSUMABLES

WELDER QUALIFICATION AND TRAINING

GMAW - LW102-15 or ER80S-D2

The welding t echnique m ust be of t he hi ghest s tandard t o produc e t he soundest wel d possible. Only welders who hav e been t rained and qual ified for structural steel wel ding in al l pos itions, in c onformance with the American Welding Society (AWS) D1.1 or (A WS) D14. 3 onl y, are al lowed t o perf orm t he welding. T he wel ding i nstructions f or f ield as sembly of K omatsu components are norm ally prov ided by engineering drawi ngs. A dditional det ailed wel ding instructions f or field repairs are prov ided i n the field repair manual SEB14001. A full understanding of the AWS standard welding symbols is necessary to perform and i nspect 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 wel d m ust be hom ogeneous wi th low porosity, free from cracks, and slag inclusions.

2. Each weld must have complete fusion between the base m etal and wel d m etal added by the electrode.

3. All welds must b e reas onably s mooth, without excessive def ormity, and all c raters filled. N o cracks are permitted.

4. The toe of a wel d t o a stressed m ember m ust have a s mooth t ransition. E xcessive c onvexity in multi-pass fillet welds is not permitted. Excessive convexity produ ces high residual stress i n the throat of the weld, and is not permitted.

5. Undercut in excess of 0.8 mm (0.03 in.) on critical wel ds m ust be rewo rked by t he appl ication of welding an additional cover pass. It is important t hat t his pas s i s bl ended w ith the ex isting weld.

FAM0407

Field Welding For Assembly Or Repair

Page 4-1

6. When we lding i n t he v ertical position, always weld us ing t he vertical up t echnique. Large wash wel d weav es s hould not be us ed when welding on truck frames. Properly applied multiple pass wel ding i s t he requi red proc edure o n truck frames.

2. Low A mbient Temperature - DO NOT wel d in temperatures bel ow 50° F (10° C). A t l ow t emperature c onditions, preh eating of al l wel ding joint work areas i s required. S ee 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 m ultiple pass procedure. It is also required that al l slag i s r emoved and t ie in al l areas .

Grind al l wel ds where a w eld crosses o r intersects with another weld.

3. Weld Cooling - Protect the wel d area f rom a rapid c ooling r ate. Heat ret ardation may be accomplished t hrough t he us e of heat l amps, torches, insulating blankets, etc.

MATERIALS, CONTROLS, AND PRECAUTIONS The s teel us ed in t he fabrication of al l K omatsu equipment is of high strength low alloy (HSLA) material o f di fferent grades . T he s tandard du mp body main plates are made from abrasion resistant materials. T hese m aterials of fer t hemselves v ery we ll t o welding during fabrication, and repair.

The welding c onsumables are of ten supplied by Komatsu America Corp. wi th t he new equi pment as part of the field welding / assembly package. For field welding and r epairs, the approv ed c onsumables as detailed, s hould be proc ured f rom a l ocal, r eliable supplier. Ot her hi ghly s pecialized wel ding c onsumables are available but have limited use on Komatsu structural c omponents. A pproval i s requi red from your Komatsu customer support manager.

4. Moisture - Any moisture on the steel surfaces to be wel ded m ust be rem oved bef ore wel ding.

Electrodes must be s tored in sealed containers until needed. Electrodes m ust be k ept in a warming oven at the work location until used to prevent any m oisture abs orption w hich m ight affect weld quality.

5. Foreign M aterials - A ny f oreign s ubstances (dirt, paint, rust, s cale, a nd c arbon de posits from cuttings) m ust be removed p rior t o we lding. Cl ean all weld areas a nd s urfaces wi th a grinder to ensure that all foreign materials have been removed.

WELD INSPECTION

Control of the welding area environment is essential for p roducing p roper and sound wel ds. E ssentially, five areas require attention and control.

All welding repai rs are subject t o i nspection by a Komatsu appointed inspector or l aboratory to insure quality. A fter t he we ld has be en m ade i t c an be inspected by a number of non-destructive evaluation techniques. The i nspections c an include any of t he methods listed bel ow. A ll as sembly wel ds and weld repairs that are deemed unacceptable by the inspector m ust be c orrected at no additional c ost to Komatsu. A ll wel d rep airs are al so subject t o additional inspection.

1. Air M ovement - A void areas where a ir m ovement from wind, drafts, or blowers is prevalent.

This is part icularly i mportant whe n a s hielding gas i s being u sed as part o f the wel ding process.

1. Visual Inspection - This is the process o f looking for po tential de fects such as undersized welds t hat c an be c hecked wi th wel d ga uges for, surface cracks, su rface p orosity, cra ters, and undercuts.

Page 4-2

Field Welding For Assembly Or Repair

FAM0407

2. Dye P enetrant I nspection - T his i s an easily applied proc ess whi ch i ndicates c racks or surface c onditions. T he proc ess is rel atively i nexpensive, but doe s not produc e a perm anent record except by normal photography.

3. Fluorescent Penetrant I nspection - S imilar t o dye penet rant i nspection. T his proc ess us es a black (ultraviolet) l ight f or i ncreased ef ficiency and accuracy.

4. Magnetic P article Inspection - T his proc ess requires special equipment that is usually more costly than the dye penetrant inspections. T his process does not prov ide a perm anent rec ord except by normal photography.

5. Ultrasonic Inspection - This is a popular method of ex amining wel d di scontinuities. Specialized equipment and operator certification is required.

With s ome eq uipment pri nted data i s a vailable of the test providing a pe rmanent re cord. Also, operator r ecords wi th equi pment s ettings and test results are normally recorded.

6. X-Ray I nspection - T his p rocess provides a view of t he wel d an d bas e m aterials but i t i s highly s pecialized. This p rocedure prov ides a permanent visual record, but is more expensive than most other inspection techniques.

RECORDS Komatsu requires record keeping of all welding work.

This i nformation i s valuable when personnel or job conditions change. The service and warranty departments of Komatsu must be pro vided with i nspection reports and ph otographs of t he we ld area be fore, during, and after t he repai r. The phot ographs m ust be c lear and c lose enough to s how t he wel d j oint preparation complete, with backer bars installed, etc. just pri or to wel ding. T hese ph otos easily identify i f the required preheating and post heating have been done wi th a three i nch c ircumference around t he weld repai r area. Wi thout this doc umentation, Komatsu will not cover any weld repair claim made under warranty. No exceptions will be made.

ANNEX A The f ollowing are general repai r proc edures, wh ich must b e f ollowed f or al l repai r a nd rewo rk of major load carrying members on Komatsu equipment.

1. The repair or rework a rea m ust be prot ected from wind and moisture during the entire procedure. If the repair work is to done outside additional precautions m ust b e taken to p rotect the weld repair proc ess f rom outside el ements. All welding should be done at an ambient temperature of 10°C (50°F) or above.

2. Clean a nd g rind the ent ire repair area t o remove a ll rust, grease, o ils, pai nt, a nd any other foreign materials likely to contaminate the weld.

FAM0407

Field Welding For Assembly Or Repair

Page 4-3

3. Air arc the entire crack leaving a V-shape joint.

The dept h of t he V ( or U s haped) jo int w ill b e determined by the depth of the crack. The width to depth rat io s hould be approximately 1. 25:1 and never less than 1:1. All cracks through the parent m aterial will require a slightly wider root opening t han the ori ginal, u sually 6 m m (0.25 in.) t o al low t he installation of a backup strip.

Backup s trips are requ ired f or al l c racks t hat have gone through the parent material and cannot be welded from both sides. If a wel d repair allows ac cess to both s ides of t he plate, no backup s trip i s requi red as l ong as c omplete weld p enetration i s ac hieved. I f backup s trips are not used, t he s urface pro file on bot h sides must be ground smooth with no undercut. Documentation must s upport t his repair. P hotographs of surface condition are required by the service and warranty departments of Komatsu.

4. Use dye pene trant t o ensure t he 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 g ouges w ith w eld a nd grind a ll 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 unt il the surrounding surface area reac hes 150° C (300°F) at a distance of 76 mm (3 in.) from all areas to be welded.

Page 4-4

9. All wel ds are t o be made with a pproved c onsumables o nly. The S MAW (Stick) wel ding rod must be us ed wi thin four hou rs after bei ng removed from a new sealed container or from a 52°C ( 125°F) m inimum drying ov en. A ny rod that ex ceeds t his ex posure time m ust be dri ed for on e hour at 427° C (800° F) bef ore bei ng used. Keep all weld starts and stops to a minimum.

10. When the weld is complete, immediately (before the w eldment c ools) po st heat the en tire 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 co ol sl owly. In s ome ca ses t his m ight require wrapping with insulation blankets.

11. Grind all butt-welded repairs smooth using 36 or finer gri t gri nding m aterial. A ll gri nding marks should be parallel t o t he di rection of pri mary stress if possible (and if known).

12. Hammer peen t he t oes of repair f illet welds as detailed in Annex B, see attached.

13. Inspect repaired areas ( for s urface de fects) using magnetic particle or dye penetrant inspection procedures.

14. If surface defects are f ound, remove all defects by gri nding t o a m aximum de pth of 1. 5 mm (0.06 i n.). Larger def ects m ust be rem oved as per t he abov e m entioned proc edures. A ll s pot welding also requires preheating and post heating.

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FAM0407

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 4. 6 mm (0.25 in.) diameter spherical tip bit

2. Tungsten c arbide rot ary b urr 13 m m (0. 50 i n.) diameter with 13 mm (0.50 in.) spherical tip

5. Protective c lothing, gl oves, i ncludes ey e, f ace, and ear protection.

4. Adequate lighting

Procedure 1. The toe of the weld should serve as a guide for the pee ning tool res ulting i n the area of def ormation bei ng app roximately equally di vided between t he bas e m aterial and t he wel d m etal face to the specified depth and not to exceed 5 mm (0.19 in.) in width. Refer to Figure 4-1.

NOTE: P eening shall only b e perf ormed a fter wel d acceptance by visual inspection.

2. The wel d m ust hav e a s mooth prof ile and the toe m ust ha ve a go od t ransition t o t he parent material (no overlap) before the peening operation i s perf ormed. Gri nding t he weld f ace and toe area i s perm itted t o c orrect unac ceptable conditions. V isual i nspection/acceptance i s t o be done af ter peeni ng wi th t he app ropriate radius and depth gauge.

3. Hold the hammer tool at approximately one half the i ncluded angle between the wel d f ace an d the parent material and perpend icular t o t he direction of t ravel. T his wi ll norm ally requ ire approximately f our pas ses o f t he p eening t ool with t he pres sure of near f ull operat or weight being applied. T he dept h of the i ndentation must b e be tween 0. 6 m m t o 0.8 mm (0.02 t o 0.03 in.).

FAM0407

3. Adequate air supply 5. Protective c lothing, gl oves, i ncludes ey e, f ace, and ear protection Procedure 1. The toe of the weld should serve as a guide for the burr tool res ulting i n the m aterial removed being approx imately eq ually di vided b etween 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 we ld m ust hav e a s mooth prof ile and t he toe m ust h ave a go od t ransition t o t he parent material (no overlap) before the grinding operation i s perf ormed. Gri nding t he wel d f ace and toe area i s perm itted t o c orrect unac ceptable conditions. V isual i nspection/acceptance t o be done af ter grinding wi th t he appropriate radius and depth gauge.

3. The axis of the t ool should b e m aintained at about 45° t o t he p arent pl ate and i nclined at about 45° to the direction of travel. The depth of the gri nding m ust be bet ween 0. 8 m m t o 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.

Field Welding For Assembly Or Repair

Page 4-5

FIGURE 4-1. TOE HAMMER PEENING

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FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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Page 4-7

BIBLIOGRAPHY American Welding S ociety B ulletin No. D14. 3-94/ D1.1 - Specification for Wel ding E arthmoving an d Construction Equipment Metals and How t o Wel d Them - J ames F. Li ncoln Arc Welding Foundation. Cleveland, Ohio Procedure Handb ook of Arc Welding - Li ncoln Electric Company, Cleveland, Ohio American Welding Society - Welding Handbook British Standard BS5135 - Metal Arc Welding of Carbon and Carbon-Manganese Steels Welding Steels Without Hy drogen Crac king - T he Welding Institute, F. R. Coe, Author

SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK Prior t o we lding a nd/or repai ring an A C dri ve t ruck, maintenance pers onnel s hould not ify a K omatsu service repres entative. On ly qual ified p ersonnel, specifically trained for servicing the AC drive system, should perform this service.

If i t i s nec essary t o perform wel ding or repai r to the truck without the field engineer present, the following procedures s hould be f ollowed to ensure t hat t he truck i s s afe f or m aintenance personnel to wo rk o n and to reduce the chance for damage to equipment. .

Engine S hutdown P rocedure B efore W elding o r Performing Maintenance Normal operat ion of t he dri ve s ystem a t s hutdown will l eave t he system safe t o m aintain. Ho wever, i n the event o f a system failure, performing the following procedure prior to any maintenance activities will ensure that no hazardous voltages are present in the AC drive system.

1. Before shutting down the engine, verify the status o f all t he drive syst em s tatus l ights o n th e status indicator panel.

If any drive system warning messages are displayed, DO NOT attempt to open any cabinets, disconnect any c ables, or rea ch i nside t he retarder grid cabinet without a trained drive system technician present - even if engine is off.

Only qualified personnel, specifically trained for servicing the A-C drive system, must perform this service.

2. If there are no drive system warning messages, follow al l of t he i nstructions f or “Safe P arking Procedures.”

3. After the engine has stopped, open the access panel at the left front side of the control cabinet.

Verify t hat the green link v oltage l ight i s i lluminated and t he DC bus voltage gauge reads 0.0 V. Notify q ualified drive syst em m aintenance personnel if the green link voltage light remains off l onger t han f ive m inutes af ter en gine s hutdown.

4. Locate t he alternator c utoff s witch in t he front access panel on the left side of the main control cabinet. P lace t he CU TOFF switch in t he O N position. This will prevent the alternator from reenergizing and creating system voltage until the switch is returned to the previous position.

Anytime the engine is operating: •

DO NOT o pen an y o f the cabinet d oors o r remove any covers.

•

DO NOT use any of the power cables for hand holds or foot steps.

DO NOT touch the retarding grid elements.

5. Ensure both battery disconnect switches are i n the OFF position. Verify that the battery disconnects are functioning.

6. Leave t he d rive s ystem i n t he res t m ode u ntil the truck is to be moved.

Before o pening any cab inets, rem oving an y covers, o r to uching a retarding grid el ement o r power ca ble, the engine must be shut d own and the green link voltage light must be illuminated.

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Precautions Befo re W elding o r P erforming Maintenance

6. Power c ables and wi ring harne sses m ust be protected from weld spatter and heat.

1. Open the access panel at the right front side of the c ontrol cabinet. V erify that the gree n l ink voltage li ght is illu minated and the D C bus voltage gauge reads 0.0 V. Notify qualified drive system maintenance personnel if the green link voltage l ight rem ains of f l onger than f ive minutes after engine shutdown.

Always fasten the wel ding m achine ground (-) lead to the piece being welded. The grounding clamp must be attached as near as possible to the weld area.

2. Locate the alternator cutoff switch access panel at t he ri ght f ront s ide of t he c ontrol c abinet.

Place t he CUT OFF s witch i n t he O N pos ition.

This will prev ent t he al ternator f rom reenergizing and creating system voltage until the switch is returned to its former position.

3. Before doi ng any wel ding on t he truck, al ways disconnect the bat tery c harging al ternator l ead wire.

4. Do not we ld o n an y d rive sy stem components! Co nsult your K omatsu s ervice representative bef ore at tempting any wel ding procedures.

5. Power cables must be cleated in wood or other non-ferrous m aterials. DO NOT repai r c able cleats by encircling the power cables with metal clamps or h ardware. A lways inspect p ower cable insulation before servicing the cables and returning t he t ruck t o service. Di scard c ables with broken insulation.

Avoid l aying wel ding c ables ov er or near t he truck el ectrical harne sses. W elding v oltage could be induced into the electrical harness and cause damage to components.

Before welding o n t he t ruck, disconnect t he battery charging alternator lead wire and isolate the el ectronic control c omponents. A lso, disconnect t he neg ative and po sitive battery cables of the t ruck. F ailure t o do so m ay seriously dam age t he bat tery an d el ectrical equipment.

Never al low wel ding c urrent t o pas s through ball beari ngs, rol ler be arings, suspensions or hydraulic cylinders.

7. If the green link voltage light is o ff a nd the DC bus voltage gauge reads more than 0.0 V after following the precautions, a fault has occurred.

Leave al l cabinet doors i n pl ace. Do not touch the retarding grid elements. Do not disconnect any power c ables or us e them as hand or foot holds.

Notify y our K omatsu s ervice r epresentative immediately. Onl y qualified pers onnel who are specifically t rained f or s ervicing t he A C dri ve system should perform this service.

8. After wel ding or m aintenance i s complete, install al l covers a nd c lose all ac cess doo rs.

Place t he al ternator c utout s witch and battery disconnect s witches i n t heir o riginal pos itions.

Reconnect al l ha rnesses be fore s tarting t he truck.

NOTE: Leave t he d rive s ystem i n t he “res t� mode until the truck is to be moved.

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Field Welding For Assembly Or Repair

Page 4-9

NOTES

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RECEIVING & ASSEMBLY PREPARATION Color Coded Boxes 1. Inspect al l c omponents f or pos sible s hipping 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 s upport bl ocks un der t he c hassis. T he support blocks m ust be approximately 84 cm (33 in.) high.

4. Install support blocks under the rear axle housing. The support blocks m ust be approx imately 30 cm (1 2 i n.) h igh and s pread ou t along the axle. The support blocks must be a minimum of 51 m m (2 i n.) away f rom t he wheel m otor mounting face.

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

6. Check al l el ectrical c onnectors and verify t hey are f ree of pai nt and/or corrosion. Cl ean any connector wi th q uestionable el ectrical continuity.

7. Check al l f actory i nstalled c omponents f or t he proper tightening torque.

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

A parts check l ist will be i ncluded i n eac h s hipping crate that is shipped with the truck. The list consists of several color coded tables that represent a portion of the as sembly proc ess. T he part s listed in eac h table w ill be pac ked in waterproof c orrugated P VC boxes that match the color of the header row of that table.

The colored boxes, s hown i n F igure 5-1, wi ll be packed i nto s hipping c rates and s hipped with t he truck. Assembly technicians can then locate the colored box es t hat match t he c olor of t he op eration (table) b eing pe rformed. T he box es wi ll be pac ked into t he c rate in chronological order. P arts need ed early in t he as sembly process w ill be l ocated near the top of the crates.

To allow f or m aximum f lexibility, the c olor code may differ from unit to unit. However, colors shown on the check sheet w ill s till ma tch t he color of the p acking boxes used.

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

Tables i n the checklist that have no color code contain parts that are not boxed. Similarly, tables that are color coded m ay also c ontain parts t hat are not boxed. These parts are highlighted in yellow.

FIGURE 5-1. COLOR CODED BOXES

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Receiving & Assembly Preparation

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ASSEMBLY LAYOUT Page 5-2

Receiving & Assembly Preparation

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CHASSIS ASSEMBLY Due t o differences i n m achine configurations and shipping res trictions/requirements t hroughout t he world, the shipping and packaging of large machines varies. P hotographs o r i llustrations us ed i n t he f ollowing proc edures are prov ided onl y as a gene ral guideline. Actual assembly may be different, but this general proc edure provides a basic ou tline f or assembly.

NOTE: T he hy draulic tank and ac cumulators may have be en rem oved for shipping purposes a nd m ay require local installation.

Each s hipment m ay b e di fferent, dep ending on t he 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 b ody welding may be done i n ei ther order, or s imultaneously. The m ost logical order depends on available resources such as cranes, welders, assemblers, etc.

5. Static checkout (electrical & mechanical) 6. Flush the hydraulic system 7. Install the body 8. Dynamic checkout (electrical & mechanical)

RECOMMENDED ASSEMBLY DATA

9. Site cleanup

1. Service Report (Pre-Delivery) 2. Acknowledgement of Receipt of Company Warranty 3. Assembly Drawings & Schematics 4. Fluid S pecifications (refer t o t he l ubrication chart in Section 10, Appendix) 5. Suspension Oiling & Chargi ng P rocedure (available in Section 10, Appendix) 6. Fan Dri ve A djustment Procedure (available i n the engine service manual) 7. Toe-In A djustment P rocedure (Section 10, Appendix) 8. Hydraulic Chec kout P rocedure (Section 10, Appendix) 9. Brake Checkout Procedure (Section 10, Appendix) 10. Propulsion S ystem Chec kout P rocedure (av ailable in Section 10 of this manual) 11. Filter List (available in parts book) 12. Lubrication & S ervice P M F orms (av ailable i n the operation and maintenance manual) 13. Component Wei ghts - f or c rane ref erence (available in Section 3 of this manual) 14. Standard Torque Chart (available in Section 1 0 of this manual) 15. Field Assembly I nspection Repo rt F orm (av ailable in Section 10 of this manual)

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Chassis Assembly

Page 6-1

ORDER OF ASSEMBLY

3. Operator Cab

The assembly procedure is organized in levels. Generally, the tasks in a given level may be performed in any order or si multaneously. However , all t asks in that l evel m ust be c ompleted bef ore proc eeding t o the next level. Each level depends on the installation of components from the previous level.

LEVEL 5

NOTE: A s s tated earl ier, s hipping and packaging of large m achines w ill v ary. S ome o f t hese s teps m ay change due to different shipping configurations and/ or truck options.

LEVEL 6

2. Uprights/Air Cleaners

3. Diagonal Support Beams - Leave loose until left deck is bolted in place.

4. Deck Support (on horsecollar over suspension) NOTE: I t is eas ier t o install and t ighten the c ap screws retaining t he deck s upports before t he f ront suspensions are installed. However, do not install the deck supports f irst unl ess there i s a suitable m eans of installing the suspensions with the deck support in place.

8. Front Suspensions 9. Diagonal Ladder LEVEL 2 1. Air Cleaner Piping 2. Center Deck 3. Control Cabinet 4. Auxiliary Control Cabinet LEVEL 3 1. Spindles/Hubs 2. Steering Cylinders 3. Tie Rod LEVEL 4 1. LH Deck

4. Wheel Motors

1. Front Tires 2. Rear Tires

1. Clearance Lights

NOTE: Do no t weld the uprights/air cleaners until all decks and the operator cab are i nstalled. Ra tchet hoists m ay be requi red t o help t ie all the s tructures together for a proper fit.

7. Fuel Tank

3. Blower - Air Intake Ductwork

LEVEL 7

1. Chassis - Unload and crib for assembly.

6. Hydraulic Tank

2. Weld Uprights

3. Hoist Cylinders

LEVEL 1

5. Rear Suspension

1. Exhaust Pipes

2. Body Pads/Shims/Guides 3. Front Mud Flaps LEVEL 8 1. Dump Body LEVEL 9 1. Hoist Cylinders 2. Rear Mud Flaps 3. Install Exhaust System and Blankets LEVEL 10 1. Clean the Truck 2. Decals 3. Lighting Wiring 4. Charge Suspensions 5. Charge Accumulators 6. Add Fluids NOTE: P rior t o s tarting t he e ngine, v erify t hat t he steering pump case is full of oil.

7. Hydraulic System Flushing LEVEL 11 1. System Checkouts 2. Install Dump Body 3. Charge the Air Conditioning System 4. Clean Assembly Rear 5. Touch Up Paint 6. Train Operators 7. Optional - Install Fire Suppression System

2. RH Deck/Grid Box

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Chassis Assembly

5/11 FAM0618

CHASSIS ASSEMBLY The photographs referenced in this procedure depict an actual truck assembly. Assembly at another location m ay be di fferent. However, t his out line wi ll provide a general basis for assembly.

Follow al l safety reco mmendations in this m anual. Follow a ll local, s tate, a nd federal r egulations.

In the procedures that follow, many very heavy components will be required t o be l ifted into p lace an d secured.

Disconnect the battery cab les before welding on the truck. Failure to do so may seriously damage the b atteries an d el ectrical eq uipment. Di sconnect th e b attery charging al ternator l ead wi re before welding on the frame or its components.

Fasten the welding machine g round cable to the component being welded.

DO N OT allow welding c urrent t o pa ss t hrough bearings.

DO NO T l ay we lding cab les o ver truck el ectrical cables and harnesses. Welding voltages could be induced into the truck wiring an d cau se damage to components.

DO NO T w eld o n th e fuel tan k o r th e h ydraulic tank unless they have been properly purged and ventilated.

• Inspect all lifting devices. Slings, chains, and cables used fo r l ifting co mponents must b e inspected d aily fo r ser viceable co ndition.

Refer to th e m anufacturer’s g uidelines fo r correct capacities a nd safety procedures when l ifting c omponents. Replace an y questionable items.

Maintain fire co ntrol equipment. I nspect fire extinguishers regularly to en sure t hey are fu lly charged and in good working condition.

• Slings, ch ains an d ca bles u sed fo r l ifting must be rated for approximately two times the intended load.

• When i n do ubt a s to the we ight of components o r an y assem bly p rocedure, contact yo ur customer su pport m anager fo r further information.

• Lifting eyes an d h ooks m ust be fab ricated from the proper materials and rated to lift the intended load.

Mark ca p sc rews an d n uts w ith p aint or ink before ti ghtening to th e sp ecified to rque. T his method p rovides veri fication th at th e h ardware has been properly tightened.

• Never stand b eneath a su spended l oad. Guy ropes ar e reco mmended fo r g uiding an d positioning a suspended load.

• Before lifting, en sure th ere i s ad equate clearance fro m o verhead stru ctures o r electric power lines.

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Page 6-3

GENERAL PRECAUTIONS AND INSTRUCTION

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

1. Clean and rem ove all f oreign m aterial f rom component mounting surfaces.

2. Mount t he f ront s uspensions first s o t hat dec k substructures can be i nstalled while other components are installed.

3. DO NOT wel d t he f ront upri ghts unt il al l up per decks are installed.

4. Install the fuel return hose on the rearward most fitting on the fuel tank.

5. Properly tighten the deck mounting bolts before the exhaust tubes, etc. are installed.

6. Verify al l electrical c onnectors are f ree f rom paint a nd/or c orrosion. Cl ean any c onnector that may be questionable.

7. Do not tighten t he di agonal ROPS beam u ntil after the ope rator c ab and L H air i ntake t ubes are in place.

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

9. Verify al l wi ring i s properl y c onnected bef ore attempting to start the engine.

Page 6-4

11. Use blocks for charging the suspension (oil and nitrogen). F ollow t he procedures outlined i n Section 10, Appendix.

12. Steering accumulators are normally not charged with ni trogen whe n s hipped f rom t he f actory.

Use p roper prec autions when c hecking the nitrogen pressure and oil level in the cylinder.

13. Brake ac cumulators are norm ally c harged wi th nitrogen when s hipped f rom t he f actory. Us e proper precautions when checking pressures.

14. Verify the automatic lubrication reservoir is full, lines purge d of ai r and al l i njectors working properly prior to startup.

15. Purge air from the steering pump and a ll of the hydraulic p ump suction l ines before the engi ne is s tarted f or t he f irst t ime. Pressure wi ll not build i n the brak e and s teering c ircuit i f ai r i s present. A ir i n t he s ystem m ay d amage t he pump. Refer to t he H ydraulic Che ckout P rocedure in Section 10 of this manual.

16. Activate t he ba ttery di sconnect s witches wh en arc welding. Connect the weld ground n ear the weld area.

Chassis Assembly

5/11 FAM0618

NOTES:

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Chassis Assembly

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 (Figure 6-2). The weight of the chassis, as shipped, is approximately 56 250 kg (124,000 lbs).

2. Place the chassis on adequate support blocks in a level position. The support blocks must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm (12 in.) high under the rear axle housing (Figure 63). Placement of the chassis at this height will allow easier installation of the truck components.

3. Thoroughly clean the chassis.

FIGURE 6-1. CHASSIS ON TRAILER

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FIGURE 6-2. LIFTING THE CHASSIS

FIGURE 6-3. CHASSIS SUPPORT BLOCKS

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Page 6-7

4. On the frame, thoroughly clean the left hand deck support mounting surface of all paint and rust. Refer to figure 6-4. Also thoroughly remove all paint or rust the left hand deck support structure mounting surface. a. Lift the LH deck support into position (Figure 6-6). The weight of the deck support is approximately 442 kg (974 lbs). b. Attach t he s upport i nto p lace wi th c ap c rews, nut s and f lat was hers. T ighten t he c ap s crews t o 3 300 (2,434 ft lb).

5. Repeat for the RH deck support. The weight of the deck support is approximately 178 kg (392 lb). Tighten the mounting cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-4. DECK SUPPORT CLEANING

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FIGURE 6-5. DECK SUPPORT CLEANING

FIGURE 6-6. DECK INSTALLATION

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Page 6-9

6. Install the diagonal ladder (Figure 6-7). The weight of the diagonal ladder is approximately 200 kg (440 lb).

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

NOTE: Depending on the truck options when ordered, the diagonal ladder might be installed in either a RH or LH configuration.

FIGURE 6-7. DIAGONAL LADDER INSTALLATION

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5/11 FAM0618

7. Remove the deck mounting hardware and remove the center deck. Grind or cut off the center deck shipping brackets. Install the center deck after both left and right uprights and all the diagonal braces are installed.

NOTE: As an alternate method, the center deck can stay on the truck. The front deck supports are located on each upright. Before installing the uprights, the center deck must be raised up slightly to allow for the installation of the uprights. Loosen the rear deck support hardware. Slightly raise the front of the center deck and install two wood blocks as shown to temporarily hold the center deck in the raised position. However, with the center deck in place, it will be harder to install and tighten the diagonal support braces below the deck.

FIGURE 6-8. CENTER DECK

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Page 6-11

8. Lift the LH and RH upright/air c leaner as semblies into pos ition. The wei ght of t he LH upri ght/air cleaner assembly i s a pproximately 919 kg (2, 027 lb). The wei ght of the RH u pright/air c leaner assembly 625 k g (1,378 lb). Install the four cap screws for each upright (Figure 6-9). Tighten the cap screws to 465 ± 47 N·m (343 ± 34 ft lb).

9. If t he c enter de ck was not removed f rom the c hassis, rem ove t he two wood blocks s upporting the c enter deck. Allow the center deck to rest on the front supports located on the uprights. Install center deck hardware, but do not tighten at this time.

NOTE: Use shims (EM9049) as required to level the center deck with the left and right decks. Tighten the mounting cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

NOTE: Do not weld the torque tubes on the uprights until left and right decks and the cab are installed.

FIGURE 6-9. INSTALLING THE UPRIGHT/AIR CLEANER ASSEMBLIES

Page 6-12

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10. Lift the LH diagonal tube into position (Figure 6-10). The weight of the tube is approximately 135 kg (298 lb).

11. If the truck is equipped with the trolley option, there will be another support tube that connects the two diagonal tubes together. It may be easier to position the center support tube below the center deck before installing the right hand diagonal tube. Install the mounting hardware but do not tighten at this time.

12.

NOTE: Do not tighten the cap screws until both decks and the cab are in place.

FIGURE 6-10. LEFT HAND DIAGONAL TUBE INSTALLATION

13. Tap the c ab mounting ho les t o rem ove any pai nt or debris from the threads. Tap size is M24 x 3.

14. Lift the cab onto the deck supports. The weight of the cab i s ap proximately 2 268 k g (5, 000 l b). I nstall 1 /2 of the m ounting hardware a s s hown i n F igure 6 -41.

Tighten the c ab m ounting hardware t o standard torque. Ref er to S tandard T ables i n S ection 10, Appendix.

15. Tighten all of the hardware f or the left hand di agonal tube to standard torque.

16. Securely tack wel d the l eft upri ght and t he l eft d eck support in place.

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

FIGURE 6-11. LIFTING THE CAB

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Page 6-13

18. If equipped with trolley, lift the RH diagonal tube into position. Refer to Figure 6-12. The weight of the tube is 68 kg (150 lb).

FIGURE 6-12. RIGHT HAND DIAGONAL TUBE INSTALLATION 19. Lift the air intake tubes and hump hoses into place (Figure 6-13). Install and tighten the clamps that secure the hoses. The support rods will be connected later.

FIGURE 6-13. AIR INTAKE TUBE INSTALLATION

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20. Remove all dirt, rust and paint from the mounts for the hydraulic tank.

21. Lift the tank into position (Figure 6-14). The weight of the hydraulic tank is approximately 716 kg (1,580 lb). a. Tighten the four mounting cap screws near the top of the tank to 622 ± 62 N·m (459 ± 45 ft lb). b. Tighten the two mounting cap screws at the rubber dampers on the inner side of the tank to 800 ± 80 N·m (590 ± 59 ft lb).

FIGURE 6-14. HYDRAULIC TANK INSTALLATION

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Page 6-15

22. Clean the mounts for the fuel tank and l ift the tank into position (Figure 6-15). The weight of the fuel tank is approximately 1 696 kg (3,740 lb). a. Tighten the four mounting cap screws at the top of the tank to 711 ± 72 N·m (525 ± 53 ft lb). b. Tighten the four mounting cap screws at the rubber dampers on the inner side of the tank to 420 ± 42 N·m (310 ± 31 ft lb).Connect the piping to the hydraulic tank and properly tighten all fittings (Figure 6-16 a nd Figure 6-17). c. Connect the fuel supply and return lines to the fuel tank.

FIGURE 6-15. FUEL TANK INSTALLATION

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23. Connect the piping to the hydraulic tank and properly tighten all fittings (Figure 6-16 and Figure 6-17).

FIGURE 6-16. HYDRAULIC TANK PIPING INSTALLATION

FIGURE 6-17. HYDRAULIC TANK PIPING INSTALLATION

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Chassis Assembly

Page 6-17

24. Install the two hoist circuit filters and t he steering circuit filter onto the provided brackets at the inner side of the fuel tank (Figure 6-18).

FIGURE 6-18. FILTER INSTALLATION

Page 6-18

Chassis Assembly

5/11 FAM0618

25. Raise the hoist cylinder into position over the pivot point on the frame (Figure 6-19). The weight of each hoist cylinder is approximately 941 kg (2,075 lb). Position the cylinder so the air bleed vent plug is on top and facing the front of the truck.

26. Install spacer (6, Figure 6-20). Align the bearing eye with the pivot point and push the cylinder into place.

27. Install retaining plate (3), locking plate (2), and cap screws (1). Tighten the cap screws to 298 N·m (220 ft lb).

Bend the locking plate tabs over the cap screw flats.

28. Secure each hoist cylinder to the frame with the cylinder clamp, cap screws and lockwashers.

FIGURE 6-20. HOIST CYLINDER INSTALLATION

FIGURE 6-19. LIFTING THE HOIST CYLINDER

FAM0618 5/11

1. Cap Screw 2. Lock Plate 3. Retainer

Chassis Assembly

4. Retainer Ring 5. Bearing 6. Spacer

Page 6-19

NOTE: E nsure the l eft de ck support s tructure is m ounted, and al l m ounting hardware i s tightened t o specified torque before install the left suspension.

29. Remove all paint, rust, dirt and foreign debris from the suspension mounting surfaces (Figure 6-21 and Figure 6-22).

30. 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 isopropyl alcohol, acetone or lacquer thinner.

31. Inspect the suspension and frame mounting surfaces for damage or wear. Check for the following criteria: 

Flatness of each surface must be within 0.25 mm (0.010 in.).



Surface finish must not exceed 0.635 µm (250 µ in.) roughness average (RA), medium tool cut.

If m easurements are no t wi thin s pecifications, contact y our K omatsu c ustomer service m anager f or further instructions.

32. Clean and dry all suspension mounting hardware. Use the same cleaning agent that was used to clean the mounting surfaces.

FIGURE 6-21. CLEANING THE FRONT SUSPENSION MOUNTING SURFACES

FIGURE 6-22. CLEANING THE FRONT SUSPENSION MOUNTING SURFACES

Page 6-20

Chassis Assembly

5/11 FAM0618

High tightening torque is required to load the front suspension mounting cap screws. Repeated tightening will r esult i n cap s crew fatigue an d damage. DO NO T reuse mounting cap scr ews, w ashers and n uts.

Replace the hardware after each use.

Suspension m ounting cap sc rews are specially h ardened to m eet or exceed g rade 8 specifications.

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

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.

33. Lubricate t he c ap s crew t hreads, c ap s crew he ad s eats, washer f aces a nd n ut seats wi th a lithium b ased chassis grease (multi-purpose EP, NLGI #2, with a maximum of 5% moly).

34. Identify and separate the hardware according to location on the suspension (Figure 6-23).

35. The hardened flat washers used on the front suspensions may be punched during the manufacturing process. I f t here i s a punc hed l ip, i nstall t he was hers with the punched lip away from the cap screw head to prevent damage (Figure 6-24).

FIGURE 6-24. HARDENED FLAT WASHER INSTALLATION 1. Hardened Flat Washer

FAM0618 5/11

Chassis Assembly

2. Cap Screw

Page 6-21

FIGURE 6-23. FRONT SUSPENSION MOUNTING HARDWARE 1.

2.

3.

4.

5.

6.

7.

8.

9.

Page 6-22

Cap Screw - 1 1/2" - 6NC x 6 1/2" (G8) Flat Washer - 1 1/2" (G8) Nut - 1 1/2" - 6NC (G8) Cap Screw - 1 3/4" - 5NC x 14 1/2" (G8) Flat Washer - 1 3/4" (G8) Nut - 1 3/4" - 5NC (G8) Spacer Shear Key Part Of Frame

Chassis Assembly

5/11 FAM0618

36. Lift t he f ront s uspension i nto pos ition on the f rame (Figure 6-25). T he weight of eac h f ront s uspension cylinder is approximately 2 880 kg (6,350 lb).

FIGURE 6-25. LIFTING THE FRONT SUSPENSION

37. Install t he mounting hardware and t he s hear k ey.

Install the s hear key flush with the s ide face of the suspension (Figure 6-26). a. Install one w asher under eac h c ap s crew h ead and one was her under eac h nut (where applicable). b. Initially tighten the hardware to 1 356 ± 136 N·m (1,000 ± 100 lb ft) in the sequence shown in Figure 6-21. Use a properl y c alibrated t orque wrench to ensure accuracy.

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

FIGURE 6-26. INSTALLING THE FRONT SUSPENSION

FAM0618 5/11

Chassis Assembly

Page 6-23

c.

T h e m o u n t i n g c a p s c r e w s n o w

m u 6-27. TIGHTENING SEQUENCE MAP FIGURE s t be loosened one at time and then tightened one at t ime by t urning t he hardwa re by a specified num ber of degrees . This i s known as the turn-of-the-nut method. The first set of cap s crews t o be a djusted will be a t t he upper m ounting j oint. T he cap s crews m ust be loosened one at time and t hen tightened by advancing a s pecified r otational degree.

Use the map shown in Figure 6-27 for proper tightening sequence.

Page 6-24

Chassis Assembly

5/11 FAM0618

Upper Mounting Joint - 60° Advance 38. Loosen the first cap screw. (Sequence is 1, 2, 3, 4, 9 an d 10. ) A ll ot her c ap s crews must be maintained a t 1356 ± 136 N·m (1 000 ± 100 lb ft).

39. Tighten the cap screw to 95 N·m (70 lb ft).

NOTE: Do not ex ceed 4 r pm t ightening s peed. Do not hammer or jerk the wrench while tightening.

40. Mark a c orner of t he c ap s crew head with a paint marker a s shown i n F igure 6-28. Draw a reference line on the suspension surface next to the m arked c orner on t he c ap screw. Draw a reference line on the suspension 60 degrees in advance of the m arked corner on t he c ap screw.

42. Make new ref erence lines along the cap screw, nut and frame at the rear of the joint as shown in F igure 6-29. These ref erence l ines wi ll be used to verify the cap screws ha ve maintained their torque.

43. Repeat this process in sequence for the remaining cap screws in the upper mounting joint.

NOTE: If for any reason these fasteners ne ed to be checked f or t ightness af ter c ompleting t his procedure, loosen and inspect all 14 cap screws and repeat the entire process. The hardware, again, must be cleaned and lubricated before repeating.

41. Advance t he c ap screw t o t he 60° advance mark. Hol d t he nut at t he rear of t he j oint s tationary while tightening.

FIGURE 6-29.

FIGURE 6-28.

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Chassis Assembly

Page 6-25

Lower Mounting Joint - 120° Advance 44. Loosen the first cap screw. (Sequence is 5, 6, 7, 8, 11, 12, 13 and 14.) All other cap screws must remain tightened.

• Tighten cap screws 5, 6, 7, and 8 to 136 N·m (100 lb ft).

• Tighten cap screws 11, 12, 13 and 14 to 271 N·m (200 lb ft).

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

45. Mark a corner of the cap screw head with a paint marker as shown in Figure 6-30. Draw a reference line on the suspension surface (or frame) next to the marked corner on the cap screw. Draw a ref erence line on the suspension surface (or frame) 120 degrees in advance of the marked corner on the cap screw.

46. Advance the cap screw to the 120° advance mark. Hold the nut at the rear of the joint (where applicable) stationary while tightening.

FIGURE 6-30.

Page 6-26

Chassis Assembly

5/11 FAM0618

47. Make new reference lines along the cap screw, nut and frame at the rear of the joint as shown in Figure 6-29.

For the four cap screws with spacers, refer to Figure 6-31. These reference lines will be used to verify the cap screws have maintained their torque.

48. 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.

FIGURE 6-31.

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Chassis Assembly

Page 6-27

49. Clean the tapered portion of the suspension rod and the bore of the spindle. Lubricate spindle bore and suspension rod taper with a lithium based chassis grease (multi-purpose, EP, NLGI #2).

NOTE: Ne ver use any l ubricants on the spindle bore containing copper, such as m any “anti’-seize” compounds.

Products containing copper will contribute to corrosion in this area.

50. Lift the spindle/brake assembly into position (Figure 6-32 and Figure 6-33). The weight of each spindle/brake assembly is approximately 5 035 kg (11,100 lb).

NOTE: A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the assembly for easier mounting on the front suspension.

Page 6-28

Chassis Assembly

5/11 FAM0618

FIGURE 6-32. SPINDLE/BRAKE ASSEMBLY INSTALLATION

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Chassis Assembly

Page 6-29

51. Use blocks and a hydraulic jack to lift the retainer plate to the bottom of each front suspension. The weight of the retainer plate is approximately 52 kg (115 lb). Refer to Figure 6-33.

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 the cap screws or tools.

52. Lubricate the 14 ret ainer plate cap screw threads, head seats and flat washers with a l ithium based chassis grease (multi-purpose EP, NLGI #2, non-moly). Install the 14 retainer plate cap screws with flat washers. (Figure 6-34). Evenly tighten the cap screws to 678 N·m (500 ft lb). Continue tightening the cap screws in increments of 339 N·m (250 ft lb) to obtain a final torque of 2 705 ± 270 N·m (1,995 ± 200 ft lb).

53. After installation is complete, connect the brake piping to each brake.

Page 6-30

Chassis Assembly

5/11 FAM0618

FIGURE 6-34

FIGURE 6-33. SPINDLE/BRAKE ASSEMBLY INSTALLATION

FIGURE 6-34. RETAINER PLATE INSTALLATION

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Chassis Assembly

Page 6-31

54. Connect the steering cylinders and the tie rod to the steering arms (Figure 6-35 and Figure 6-36). Ensure the spacers and sleeves are properly assembled. Ensure the anti-rotation tabs on the tie rod ends are on the bottom side of the tie rod when installed. Use alignment tool EH4638 to assist in holding spacers and sleeves in place for pin installation. Tighten pin retaining hardware to 1 017 N·m (750 ft lb).

55. The tie rod toe-in must be adjusted once the tires and the body are installed. Refer to the Toe-in Adjustment procedure in Section 10, Appendix. Ensure the clamping cap screws on tie rod are tight after adjusting toe-in.

56. Check cap screw torque on steering arm cap screws. Cap screw torque is 2 705 ± 271 Nm (1,995 ± 200 ft lb).

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

FIGURE 6-35. STEERING CYLINDER INSTALLATION

Page 6-32

Chassis Assembly

5/11 FAM0618

FIGURE 6-36. TIE ROD INSTALLATION

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Chassis Assembly

Page 6-33

57. Install the han drails on t he RH dec k. I f not i nstalled, l ift the retarding gri d i nto place on t he RH dec k. T he weight of the retarding grid is approximately 2 881 kg (6,351 lb).

58. Tighten the eight retarding grid mounting cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix. If desired, the deck mounted mufflers could also be attached to the deck at this time. Leave the muffler clamps loose until exhaust piping is connected.

59. Lift the RH deck into position on the chassis and loosely install the six deck mounting cap screws (Figure 638). The weight of the assembly is approximately 3 935 kg (8,675 lb).

60. Install the handrails and lift the LH deck into place (Figure 6-39). The weight of the LH deck with handrails is approximately 714 kg (1,574 lb). Loosely install the six deck mounting cap screws.

61. After all decking is in place, level the center, left and right decks with shims so the walking surface is smooth and even between the three deck structures.

• Right deck shims: EM9043 & EM9046 • Center deck shims: EM9049 • Left deck shims: EM9042 & EM9047 62. Tighten the mounting cap screws on each deck to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-37. RIGHT DECK INSTALLATION

63.

Page 6-34

Chassis Assembly

5/11 FAM0618

FIGURE 6-38. RIGHT DECK INSTALLATION

FIGURE 6-39. LEFT DECK INSTALLATION

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Chassis Assembly

Page 6-35

64. Clean the threads in the cab mounting plates (6, Figure 6-41) and (8).

65. Lift the operator cab into position (Figure 6-40). The weight of the cab is approximately 2 268 kg (5,000 lb).

FIGURE 6-40. LIFTING THE CAB

Page 6-36

Chassis Assembly

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66. Install the cab mounting hardware as shown in Figure 6-41. The six rear inner cap screws are longer than the other cap s crews, and m ust be i nstalled from below t he cab. Us e flat washers and nut s on t hese six c ap screws. Install and tighten the 32 cap screws to 800 ± 80 N·m (590 ± 59 ft lb).

FIGURE 6-41. CAB MOUNTING PADS 1. Cap Screw 2. Flat Washer 3. Bushing 4. Sleeve

FAM0618 5/11

5.

6.

7.

8.

Plate (Front - Top) Plate (Front - Bottom) Cap Screw Plate (Rear - Bottom)

Chassis Assembly

9. Plate (Rear - Top) 10. Nut

Page 6-37

67. Lift t he el ectrical c ontrol c abinets i nto po sition (Figure 6-42). T he wei ght of the c ontrol c abinets is approximately 4 319 kg (9,521 lb) and includes the 24V auxiliary control cabinet. Install the mounting hardware and shims. Tighten the mounting cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix

FIGURE 6-42. CONTROL CABINET INSTALLATION

Page 6-38

Chassis Assembly

5/11 FAM0618

68. Install an y rem aining handrai ls. Tighten the cap screws to the standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-43. HANDRAIL INSTALLATION

FAM0618 5/11

Chassis Assembly

Page 6-39

69. Tighten the hardware for the diagonal tubes. For the RH tube, tighten the 12 cap screws to 240 ± 24 N·m (177 ± 17 ft lb). For the LH t ube, tighten the 16 cap screws to 800 ± 80 N·m (590 ± 59 ft lb). If there is a c enter tube (trolley trucks only), tighten the mounting cap screws to standard torque.

70. Weld the LH and RH uprights to the front frame tube (Figure 6-44 and Figure 6-45). Remove the hardware holding the upright to the frame and grind off the blocks.

FIGURE 6-44. WELDING THE UPRIGHTS

FIGURE 6-45. CROSS TUBE WELD JOINT SPECIFICATION

Page 6-40

Chassis Assembly

5/11 FAM0618

71. Lift the two bumper extensions into place (Figure 6-46). Tighten the cap screws to the standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-46. BUMPER EXTENSION INSTALLATION

72. Connect the wiring for the control cabinet, auxiliary control cabinet, and retarding grid. Refer to the assembly drawings and schematics.

73. Lift the air intake ductwork into position. The weight of the right side inlet duct is approximately 53 kg (117 lb).

The weight of the left side inlet duct is approximately 46 kg (101 lb).

74. Tighten the connecting hardware to the standard torque. Refer to Standard Tables in Section 10, Appendix.

FAM0618 5/11

Chassis Assembly

Page 6-41

75. The weight of the transmission and brake assembly (1, Figure 6-47) wi thout the electric motor is 12 359 kg (27,247 lb). Transmission (1) must be positioned so the top of the unit is at the very top.

76. Install seal (2) onto transmission (1).

77. Remove the shipping bracket from the non-drive end of the electric motor.

78. Apply a thin layer of ENS grease (4271211871) to the mating splines on the electric motor shaft, the transmission shaft splines (12) and the grease seal (13) on the transmission shaft.

79. Install brackets (15) and (16) to the motor. Install hose (14) with fittings and filter to the transmission.

80. Add 620 ml (2 oz) of ENS grease to grease cavity (11) inside adapter (10). Install adapter on electric motor.

81. The motor has two air inlet covers (9) located on each side of the electric motor. One cover must be removed, and a separate air duct structure (5) must be installed. The location of the air duct structure is determined by which side the wheel motor is installed on the truck so that it will connect with the air duct inside the rear axle housing. I nstall ai r duc t s tructure wi th hardware that was retaining t he c over. Seal the ai r duc t s tructure t o wheel motor housing with sealant (VS7492).

82. Install the neoprene seal to each air duct inside the rear axle housing. This will help seal the gap between the axle housing air duct and the air duct structure (5) on the electric motor.

1. Transmission 2. Seal 3. Lifting Eyes 4. Electric Motor

Page 6-42

5.

6.

7.

8.

FIGURE 6-47. WHEEL MOTOR ASSEMBLY 9. Cover Ductwork 10. Adapter Gasket 11. Grease Cavity Cap Screw 12. Transmission Shaft Flat Washer

Chassis Assembly

13. Seal 14. Hose 15. Bracket 16. Bracket

5/11 FAM0618

83. Install three lifting eyes into the wheel motor housing at locations (3, Figure 6-47). Attach appropriate lifting device t o al l t hree l ifting ey es ( 3) o n t he e lectric m otor ( Figure 6-48). T he wei ght of t he el ectric m otor i s approximately 4 356 kg (9,603 lb). Use a suitable lifting device that can handle the load safely.

FIGURE 6-48. ELECTRIC WHEEL MOTOR INSTALLATION

FAM0618 5/11

Chassis Assembly

Page 6-43

84. Lift the motor into position on the wheel motor transmission (Figure 6-49). The electric motor shaft may have to be turned slightly to line up the drive splines.

85. The hardened flat washers (1, Figure 6-50) used on the electric motor may be punched during the manufacturing process. Install the washers with the punched lip away from the cap screw head to prevent damage as shown in Figure 6-50 if necessary.

86. Install 24 cap screws (7, Figure 6-47) and the flat washers that secure electric motor (4) to the transmission.

Tighten the cap screws to 1 600 ± 160 N·m (1,180 ± 118 ft lb). Attach hose (14, Figure 6-47) to brackets (15) and (16).

FIGURE 6-49. ELECTRIC MOTOR AND TRANSMISSION ASSEMBLY INSTALLATION

Page 6-44

Chassis Assembly

5/11 FAM0618

FIGURE 6-50. HARDENED FLAT WASHER INSTALLATION 1. Hardened Flat Washer

2. Cap Screw

87. Thoroughly clean the threaded holes and the mounting faces of the rear axle housing and wheel motor.

88. 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.

89. Check the mounting faces of the rear axle housing and the wheel motor for surface defects (nicks, scratches, etc.). Repair any defects before installing the wheel motor.

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 the tools.

90. Apply a l ithium bas ed chassis greas e (multi-purpose E P, NL GI #2, wi th a m aximum of 5% moly) to t he threaded holes in the rear axle housing.

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

The wheel motors must be properly aligned before installing them into the axle housing. The wheel motor has openings for hydraulic lines which must align with the hoses from the axle housing.

FAM0618 5/11

Chassis Assembly

Page 6-45

92. Ensure the ductwork on the electric motor is properly aligned with the ductwork inside the axle housing. If the ductwork on the electric motor is on the wrong side, the ductwork can be switched with the cover on the opposite side of the electric motor.

Each complete wheel motor assembly weighs approximately 16 715 kg (36,850 lb). Ensure that the lifting devices are capable of handling the load safely.

NOTE: Wh en l ifting t he whe el m otor a ssemblies, do not l ift wi th o r under t he el ectric m otor. S hipping fasteners installed in the outboard rim bolt circle must remain in place during lifting and installation of wheel motors.

93. Lift the wheel motor into position on the rear axle housing. Ensure that all cables and hoses are clear before installation. The bolt holes are not symmetrical, so the wheel motor assembly will only attach to the axle housing one way.

94. If the brake system hoses are installed, guide them through the spindle holes during installation.

95. Select the hardware to be installed in Group 1 of the tightening sequence. Refer to Figure 6-51.

NOTE: T he hardened f lat was hers us ed on t he f ront s uspensions m ay be punc hed duri ng t he m anufacturing process. Install the washers with the punched lip away from the cap screw head to prevent damage (Figure 6-50) if necessary.

96. Inspect eac h c ap screw for rus t, corrosion and s urface def ects on any seat or thread. Do not use any c ap screw if a defect is suspected.

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

Page 6-46

Chassis Assembly

5/11 FAM0618

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

Install an d tighten al l of the hardware i n a group b efore p roceeding t o the next g roup i n t he t ightening sequence. Remove the guide pins that were installed in step 75 when installing the hardware for Groups 3 and 4.

99. Repeat Step 95 through Step 98for each remaining group in the tightening sequence. Refer to Figure 6-51.

100. After all of the hardware i n 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 eac h cap screw in Group 1 t o 2 006 N·m (1,480 ft lb). Repeat this step for each remaining group in the tightening sequence. Refer to Figure 6-51.

FIGURE 6-51. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

FAM0618 5/11

Chassis Assembly

Page 6-47

All propulsion system power cables must be properly secured in wood or other non-ferrous cable clamps.

If any clamps are cracked or broken, replace them with new parts. Inspect the cable insulation and replace an entire cable if the insulation is damaged.

101. Connect a ll power c ables (1, F igure 6-52) and el ectrical harnesses to t heir approp riate l ocations on t he wheel motor, including the wheel speed sensors.

102. If the hydraulic tank has been filled with oil, install a vacuum pump on the hydraulic tank to prevent oil loss when the fittings on lines are opened.

103. Connect brake apply line (2) and parking brake line (3) to the ports on the brake assembly back plate.

104. Install brake cooling hoses (4).

105. After all hydraulic lines have been connected, remove the vacuum pump from the hydraulic tank.

106. Check the oil level in each wheel motor. Rotate one of the eight plugs to the 6 o’clock position and remove the plug. The oil level should be even with the bottom of the plug opening. Fill the wheel motor with the recommended oil as necessary.

Page 6-48

Chassis Assembly

5/11 FAM0618

FIGURE 6-52. WHEEL MOTOR INSTALLATION 1. Power Cables 2. Brake Apply Hose

FAM0618 5/11

3. Parking Brake Hose 4. Brake Cooling Hose

Chassis Assembly

Page 6-49

Front Wheel Installation NOTE: Rem ove al l paint and rust f rom t he t apered m ating s urfaces on t he rims, wheel s, and wedg es where contact is made. Check the stud threads for any damage before installing the wheels.

107. Grip the tire and rim assembly with the tire handler (Figure 6-53). Align the tire inflation hose and the wheel hub. Position the rim onto the wheel hub studs.

108. Lubricate all stud threads and nut seating flanges with lithium based (multi purpose, EP, NLGI #2, non-moly) grease. Install and tighten the nuts in the following sequence: a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten each nut to 1 166 ± 136 N·m (860 ± 100 ft lb). b. Install three nuts directly below the 3 o'clock position and t hree nuts directly above the 9 o'clock position.

Tighten the nuts to 1 166 ± 136 N·m (860 ± 100 ft lb). c. Install three nuts directly above the 3 o'clock position and three nuts directly below the 9 o'clock position.

Tighten these nuts to 1 166 ± 136 N·m (860 ± 100 ft lb). d. Install the remaining nuts and tighten them in a clockwise pattern to 1 166 ± 136 N·m (860 ± 100 ft lb). e. Retighten all nuts in a clockwise pattern to 1 166 ± 136 N·m (860 ± 100 ft lb).

After the tru ck has been assembled an d has been operated for a sh ort p eriod o f time, the torque on th e wheels must be checked again. Tighten the wheel nuts to the specified torque.

Page 6-50

Chassis Assembly

5/11 FAM0618

FIGURE 6-53. FRONT TIRE INSTALLATION WITH TIRE HANDLER

FIGURE 6-54. WHEEL NUTS

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Chassis Assembly

Page 6-51

Rear Wheel Installation NOTE: Remove all paint and rust from the mating surfaces on the rims and wheels where contact is made. Check the stud threads for any damage before installing the wheels.

109. Bleed the ai r f rom the dis c br akes before in stalling the r ear t ires. R efer to the shop manual for t he br ake bleeding procedures.

110. Grip the inner tire and rim with the tire handler and lift the tire onto the wheel hub (Figure 6-56). Align extension (4, Figure 6-55) for mating with inner extension (7).

111. Lubricate all s tud t hreads and nut s eating flanges wi th a l ithium bas ed (m ulti purpose, EP, NLGI #2, nonmoly) grease. Install and tighten the nuts in the following sequence: a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten each nut to 1 166 ± 136 N·m (860 ± 100 ft lb). b. Install three nuts directly below the 3 o'clock position and t hree nuts directly above the 9 o'clock position.

Tighten the nuts to 1 166 ± 136 N·m (860 ± 100 ft lb). c. Install three nuts directly above the 3 o'clock position and three nuts directly below the 9 o'clock position.

Tighten these nuts to 1 166 ± 136 N·m (860 ± 100 ft lb). d. Install the remaining nuts and tighten them in a clockwise pattern to 1 166 ± 136 N·m (860 ± 100 ft lb). e. Retighten all nuts in a clockwise pattern to 1 166 ± 136 N·m (860 ± 100 ft lb).

112. Install inner extension (7) to extension (4) at bracket (8) before installing the outer tires.

113. Install adapter ring (9) to outer wheel hub using flanged nuts (11). Use the same torque and procedure as described in Step 111.

114. Instal outer wheel assembly to wheel motor using flanged nuts (10). Use the procedure as described in Step 111, but substitute the torque value with 2 326 ± 136 N·m (1,715 ± 100 ft lb).

FIGURE 6-55. REAR WHEEL ASSEMBLY 6. Flanged Nut 1. Wheel Motor Mounting Flange 7. Inner Extension 2. Inner Wheel Rim 8. Bracket 3. Disc Brake Assembly 9. Adapter Ring 4. Extension 10. Flanged Nut 5. Wheel Hub

Page 6-52

Chassis Assembly

11. Flanged Nut 12. Wheel Motor Transmission 13. Extension 14. Bracket 15. Outer Wheel Rim

5/11 FAM0618

DO NOT move the truck without the rear, outer tires installed. Serious damage to the wheel motor hub and torque tube may result. The adapter rings and outer dual tires must be installed.

FIGURE 6-56. INNER REAR TIRE INSTALLATION WITH TIRE HANDLER

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Chassis Assembly

Page 6-53

FIGURE 6-57. OUTER REAR TIRE INSTALLATION WITH TIRE HANDLER

After the tru ck has been assembled an d has been operated for a sh ort p eriod o f time, the torque on th e wheels must be checked again. Tighten the wheel nuts to the specified torque.

Page 6-54

Chassis Assembly

5/11 FAM0618

115. Connect the electrical harnesses and hydraulic hoses below the operator cab (Figure 6-58).

FIGURE 6-58. CAB HARNESS AND HOSE INSTALLATION

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Chassis Assembly

Page 6-55

116. Weld both rear mud flap brackets into place on the backside of the deck supports. Install the rear mud flaps and front mud flaps on the underside of each deck (Figure 6-59).

FIGURE 6-59. MUD FLAP INSTALLATION

117. Install all exhaust piping and mufflers. Ensure all exhaust pipe clamps are tight. Also install the exhaust blankets.

Before the engine is started the first time, the hydraulic system should be set u p to perform the flushing procedure. Refer to the h ydraulic system flushing procedure in the Appendix. The p urpose o f h ydraulic system flushing is to eliminate contaminants that could have been introduced into the hydraulic system during truck asse mbly. P erforming the flushing p rocedure wi ll remove th ese co ntaminants fro m th e hydraulic system and minimize the potential for hydraulic system component damage at startup.

118. Do not s tart t he engi ne unl ess t he hydraul ic system flushing t ools are i nstalled and ready t o perf orm t he flushing procedure. Refer to the appendix for the hydraulic system flushing procedure.

119. The truck is now ready for dump body installation.

Page 6-56

Chassis Assembly

5/11 FAM0618

DUMP BODY ASSEMBLY GENERAL INFORMATION

The t otal w eight o f t he body i s a pproximately 33 643 kg (74,171 lb). Use two cranes for assembling the body. A 45 metric ton (50 ton) crane and a 109-136 m etric to ns (120 -150 to n) cr ane ar e required. The larger crane is needed to help turn the b ody o ver after co mpletion o f th e u nderside 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 bei ng welded in a c old c limate, i t i s advisable to m ove t he part s to be wel ded i nto an enclosed shop area. Surfaces to be wel ded 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 po rtable enc losure and pre-heat the parts prior to welding.

In most instances, it is easier to assemble and weld the bo dy whi le the sections a re ups ide down. A fter the pi vot, gui de pi n, and body pads are wel ded i n place, the body can be t urned o ver a nd the remainder of the assembly can be completed.

All pai nt m ust be removed f rom surfaces t o be welded. Use a wire b rush or pai nt removal equ ipment.

Refer t o t he as sembly drawi ngs s hipped wi th t he truck f or s pecific wel ding det ails and t he part s required for assembly.

Body secti ons m ust b e a ssembled as o riginally manufactured. Match the shipping numbers stenciled o n the b ody sections to m ate th e correct parts. DO NOT mix components.

FIGURE 7-1. BODY PARTS NOMENCLATURE (Flat pack configuration shown) 1. Canopy 2. Front Sheet

FAM0711 5/11

3. RH Side Sheet 4. Lift Hole

Dump Body Assembly

5. Floor 6. LH Side Sheet

7-1

BODY WELDING INFORMATION

BODY ASSEMBLY

Follow the guidelines l isted below whe n welding the body: • Use dry weld rod or weld wire.

• Weld s urfaces m ust b e dry an d abov e 10°C (50°F).

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

NOTE: References t o LH a nd RH i n t he following procedures assume the body is in its normal, upright position, as shown in Figure 7-1.

1. Remove the paint from the weld areas.

2. Lift t he LH bod y s ection and s upport the rear edge of the f loor with wood blocks and a j ack stand. See Figure 7-3 and Figure 7-4.

• The following sequence must be f ollowed for the front sheet: 1. For the first pass, back step and skip weld in 10 increments al ong the ent ire l ength of t he j oint.

Refer toFigure 7-2.

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

• The body f loor “ V” groov e m ust a lso be wel ded using t he s ame proc edure as t he f ront s heet.

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

FIGURE 7-3. LH BODY SECTION

FIGURE 7-2. FRONT SHEET & FLOOR JOINT WELDING SEQUENCE

FIGURE 7-4. LH BODY SECTION

7-2

Dump Body Assembly

5/11 FAM0711

3. Lift the center body section and pl ace it next to the LH body section. Support the center edge of the floor with wood blocks and a jack stand. See Figure 7-5

7. Install c ap s crews (7), (8) an d (9) wi th t he f lat washers a nd n uts. Attach a we dge or a clamp inside the body as necessary to align the floor sheets. See Figure 7-9.

4. Use the crane and a lift truck to align the body sections. Install c ap s crew (1, Figure 7-6) with the sleeves, flat washers and nut.

8. Lift the RH body section and place it next to the LH/center body s ection assembly. Support t he center edge of the floor with wood blocks and a jack stand. See Figure 7-7 9. Use the crane and a lift truck to align the body sections. Install c ap s crew (1, Figure 7-8) with the sleeves, flat washers and nut.

FIGURE 7-5. CENTER BODY SECTION

NOTE: Figure 7-6 shows the hardware num bered in installation s equence. Cap s crews (1) and (2) are installed with s leeves. T he rem ainder of the c ap screws do not have sleeves.

FIGURE 7-7. RH BODY SECTION

NOTE: Figure 7-8 shows the hardware num bered in installation sequence. Cap s crews (1) and (2) are installed with s leeves. T he rem ainder of t he c ap screws do not have sleeves.

FIGURE 7-6. CAP SCREW INSTALLATION

5. Install cap screw (2) with the sleeves, flat washers and nut.

6. Install cap screws (3), (4), (5) an d (6) w ith the flat washers an d nu ts. A ttach a wedg e or a clamp inside the body as necessary to align the front sheets. See Figure 7-9.

FAM0711 5/11

FIGURE 7-8. CAP SCREW INSTALLATION

Dump Body Assembly

7-3

10. Install cap screw (2) with the sleeves, flat washers and nut.

11. Install c ap s crews ( 3), (4), (5) and (6) wi th t he flat washers and n uts. A ttach a w edge o r a clamp inside the body as necessary to align the front sheets. See Figure 7-9.

13. Install the backer strips on the front sheet center joints as shown o n the assembly drawi ng. See Figure 7-11.

NOTE: T he backer s trips m ust be t ack wel ded i n a location where t he tack wi ll be burne d away on t he first pass.

12. Install cap s crews (7), (8) and (9) with t he f lat washers and nuts. A ttach wedges or clamps inside the bod y as nec essary to al ign t he floor sheets. See Figure 7-9.

FIGURE 7-11. BACKER STRIP INSTALLATION FIGURE 7-9. ALIGNMENT WEDGES 14. Check t he a lignment and f it of al l j oints. Com plete t he wel ds at t he floor j oints an d the front sheets. See Figure 7-12 and Figure 7-13. Refer to the assembly drawi ngs f or wel ding requirements.

FIGURE 7-10. BODY SECTIONS ASSEMBLED

If eq uipped, DO NO T i nstall the h eated body exhaust b oxes o nto the body a t this ti me. The exhaust boxes must be installed after the body is installed onto the truck.

7-4

FIGURE 7-12. WELDING THE FLOOR JOINTS

Dump Body Assembly

5/11 FAM0711

16. Tack wel d t he canopy s ide pl ates. Attach wedges or clamps to the plates as necessary to align the canopy joints. See Figure 7-15.

FIGURE 7-13. FRONT SHEET JOINT WELDS

15. Use a lift truck to move the canopy into position.

Support t he edges of t he c anopy wi th woo d blocks. See Figure 7-14. Align the canopy wi th the body and tack weld i t to the bo dy. Refer to the as sembly drawi ngs f or wel ding req uirements.

FIGURE 7-15. CANOPY SIDE PLATE INSTALLATION

17. Tack w eld the c anopy gussets i n p lace. Wh en all t he gu ssets are i nstalled, c omplete t he remaining welding on the canopy. See Figure 716. Refer to the assembly drawings for welding requirements.

FIGURE 7-14. CANOPY INSTALLATION

FIGURE 7-16. CANOPY GUSSET NSTALLATION

FAM0711 5/11

Dump Body Assembly

7-5

18. Install body gui de (1, Figure F igure 7-17) and the body pad mounts (2).

FIGURE 7-17. BODY GUIDE & BODY PAD MOUNT INSTALLATION 1. Body Guide

FIGURE 7-19. TURNING OVER THE BODY

2. Body Pad Mount

19. Once the body unders ide i s c ompleted, t he body c an be t urned ov er. Us e t wo c ranes t o invert the b ody, a 45 m etric ton (50 t on) crane and a 109-136 m etric ton (120-150 t on) crane.

Figure 7-18 through Figure 7-22 shows a typical example of a body bei ng inverted wi th two cranes.

FIGURE 7-20. TURNING OVER THE BODY

FIGURE 7-18. TURNING OVER THE BODY

FIGURE 7-21. TURNING OVER THE BODY

7-6

Dump Body Assembly

5/11 FAM0711

22. Install the mud f lap brac kets, c learance l ight housings (see Figure 7-24), etc, as specified on the installation drawings.

FIGURE 7-22. TURNING OVER THE BODY

20. Position the body onto wood blocks as shown in Figure 7-23.

FIGURE 7-24. CLEARANCE LIGHT HOUSING

23. Install the top rail caps (see Figure 7-25) and any optional equipment such as body liners.

FIGURE 7-23. BODY SUPPORT BLOCKING FIGURE 7-25. TOP RAIL CAP INSTALLATION 21. Refer to Figure 7-2 and the assembly drawings to complete the welds on the inside of the body and top of the canopy.

FAM0711 5/11

Dump Body Assembly

7-7

24. Clean and paint the weld joints.

FIGURE 7-26. PAINTING THE WELD JOINTS

7-8

Dump Body Assembly

5/11 FAM0711

FINAL ASSEMBLY SAFETY • Inspect all lifting d evices. S lings, ch ains, an d cables u sed fo r l ifting components m ust b e 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 i n d oubt as to th e weight o f co mponents o r an y as sembly p rocedure, co ntact yo ur c ustomer support manager for further information.

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

• Never stan d b eneath a su spended l oad. G uy ro pes are reco mmended fo r guiding an d positioning a suspended load.

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

BEFORE STARTING THE ENGINE

Before the engine is started the first time, the hydraulic system should be set u p to perform the flushing procedure. Refer to the h ydraulic system flushing procedure in the Appendix. The p urpose o f h ydraulic system flushing is to eliminate contaminants that could have been introduced into the hydraulic system during truck asse mbly. P erforming the flushing p rocedure wi ll remove th ese co ntaminants fr om th e hydraulic system and minimize the potential for hydraulic system component damage at startup.

FAM0816 7/10

Final Assembly

Page 8-1

NOTE: The following figures show a typical example of a dump body installation. The truck and dump body shown may not represent your truck model in exact detail.

FIGURE 8-1.

NOTE: Body welding and chassis assembly must be completed before proceeding.

1. Before the body i s l ifted off t he ground, tie guy ropes t o each of the four c orners of the body for ai ding in installation.

There are two methods of installing the body depending on the cranes that are 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, Figure 8-2 and Figure 8-3). 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.

Page 8-2

Final Assembly

7/10 FAM0816

FIGURE 8-2.

FIGURE 8-3.

FAM0816 7/10

Final Assembly

Page 8-3

2. With the body in position, install shims (6, Figure 8-4) in both b ody pi vots. Install e nough shims t o fill t he outboard ga ps an d 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 bo th 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) and (9).

4. Install s houlder bol t (1, F igure 8-4) t hrough the pi n.

Install flat washer (10) and nut (2). With nut tight, the bolt and was her s hould not be t ight ag ainst the flat spot faces. Tighten nut (2) to 339 N¡m (250 ft lb).

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

FIGURE 8-4. DUMP BODY PIVOT PIN 1.

2.

3.

4.

5.

Shoulder Bolt Nut Body Pivot Pin Body Ear Body Pivot Bushing

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

FIGURE 8-5. INSTALLING THE BODY PIVOT PIPNS

Page 8-4

Final Assembly

7/10 FAM0816

FIGURE 8-6. CONNECTING THE HOIST CYLINDER TO THE DUMP BODY

6. Align the hoi st c ylinder upper bus hings wi th t he bod y (Figure 8-6). A lign t he retaining c ap screw hole a nd install pin (2, Figure 8-7).

Install shoulder bolt (4, Figure 8-7) 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).

FIGURE 8-7. HOIST CYLINDER 1. Dump Body 2. Hoist Cylinder Pin 3. Hoist Cylinder

FAM0816 7/10

4. Shoulder Bolt 5. Flat Washer 6. Nut

Final Assembly

Page 8-5

FIGURE 8-8. BODY PAD INSTALLATION 1. Dump Body 2. Pad Mounting Hardware

3. Frame 4. Body Pad

5. Shim 6. Mounting Pad

7. Shim the body pads as required. Tighten pad mounting hardware (2, Figure 8-8) to 88 N¡m (65 ft lb).

All pads except the two rear pads should contact the frame with approximately equal compression of the rubber. A ga p of approximately 1.9 m m (0 .075 in.) is required at each rear pad. This can be ac complished by using one less shim at each rear pad.

8. 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 8-6

Final Assembly

7/10 FAM0816

FIGURE 8-9. MUD FLAP INSTALLATION - DUMP BODY AND FUEL TANK

FIGURE 8-10. MUD FLAP INSTALLATION - HYDRAULIC TANK 9. Install the mud flaps onto the body and chassis (Figure 8-9 and Figure 8-10).

FAM0816 7/10

Final Assembly

Page 8-7

10. Install both body guide brackets loosely into place (Figure 8-11). O nce in position, slowly lower the body and m ark the position in which the brackets are to be welded.

FIGURE 8-11. BODY GUIDE BRACKET INSTALLATION

The body guides must be centered between wear plates (3, Figure 8-12), wi th a m aximum gap of 4. 8 m m (0. 19 in.) at each side.

FIGURE 8-12. BODY GUIDE 1. Dump Body 2. Body Guide

Page 8-8

Final Assembly

3. Body Guide Bracket Wear Plates

7/10 FAM0816

11. With t he body in i ts lowered pos ition on t he frame rai l, the pos ition of t he body up l imit switch actuator a rm (4, F igure 8 -13) c an be marked on the underside of the body. Refer to the assembly drawings for precise positioning specifications.

12. Raise the body enough to be able to weld the mounting pad to the underside of the body.

Before welding, install support blocks between the body and the frame.

13. Raise the body and a ttach the bo dy retention cable or sling. Remove the support blocks.

FIGURE 8-13. BODY UP SWITCH ADJUSTMENT To avo id seri ous p ersonal i njury o r d eath, th e body u p retention cab le m ust b e installed anytime pe rsonnel are required to perform m aintenance on the vehicle with the dump body in the raised position.

1. Switch Mounting Bracket 2. Adjustment Cap Screws 3. Proximity Switch

4. Actuator Arm 5. Adjustment Screws

The Komatsu b ody-up safety sling c an o nly be used with a Komatsu body. Non-OEM body may not acco mmodate the Komatsu body-up sa fety sling. The en d u ser must en sure th at a p roper cable/sling is used.

14. Weld the body guide brackets into place.

FAM0816 7/10

Final Assembly

Page 8-9

FIGURE 8-14. HOIST LIMIT SWITCH INSTALLATION

15. With the body in the raised position, set the hoist limit switch and weld the target into position (Figure 8-14).

The switch should activate 152 mm (6 in.) before maximum cylinder stroke. Refer to the assembly drawings for precise welding specifications.

16. With the body in the raised position, install the grease lines for the hoist cylinders and clamp them along the inside of the body.

Page 8-10

Final Assembly

7/10 FAM0816

17. Install the LH and RH engine service lights (Figure 8-15).

FIGURE 8-15. ENGINE SERVICE LIGHTS 18. Install the automatic lubrication system and the engine reserve oil system (Figure 8-16). Refer to the installation drawings. Verify that all electrical and hydraulic connections are correct.

FIGURE 8-16. AUTOMATIC LUBRICATION SYSTEM AND ENGINE RESERVE OIL SYSTEM

FAM0816 7/10

Final Assembly

Page 8-11

FIGURE 8-17. FIRE SUPPRESSION SYSTEM

19. If required, install the fire suppression system (Figure 8-17). This installation is normally performed by the fire suppression system distributor.

20. Paint the truck as needed.

Page 8-12

Final Assembly

7/10 FAM0816

FIGURE 8-18. ANTI-SKID STRIPS 21. Install the anti-skid strips at the designated areas on the decks (Figure 8-18).

22. Install all decals at their designated areas.

23. After completing the assembly of the truck: a. Verify that all cap screw heads or nuts are marked with paint, indicating they have been properly tightened. b. Check all hydraulic lines and electrical connections for secure installation. c. Notify q ualified m aintenance p ersonnel that t he t ruck i s read y for t he final st atic and dynam ic syst ems checkout.

24. Perform the hydraulic flushing procedure when the truck is started up for the first time. Refer to the hydraulic flushing procedure in the Appendix.

FAM0816 7/10

Final Assembly

Page 8-13

NOTES:

Page 8-14

Final Assembly

7/10 FAM0816

FINAL CHECKOUT Final checkout requires truck operation.

1. Complete delivery and warranty forms.

5. Before t he engine i s started the f irst time, t he hydraulic system should be s et up t o perform the flushing procedure. Refer to the hydraulic system flushing procedure in the Appendix. The purpose of h ydraulic syst em fl ushing i s to e liminate co ntaminants t hat c ould have b een introduced into the h ydraulic system during truck assembly. Performing the flushing procedure wi ll rem ove these contaminants from the hydraulic system and minimize t he potential f or hy draulic s ystem c omponent 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 ope ration. Several checks and tasks are out lined in Section 10, Appendix.

3. If equi pped, v erify t he shut-off valves on hydraulic tank suction lines are open.

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

Place t he ope ration and maintenance m anual and safety manuals in the operator cab, if not already there.

Any personnel i nvolved i n the f inal c heck-out of the truck must read and unders tand al l safety and operating instructions in the operation and maintenance manual.

the

4. Purge any ai r f rom t he pum ps and suction l ines.

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 t o bl eed t he air from the pumps and the suction lines.

FAM0908 7/10

8. Operate t he t ruck i n a t raffic-free a rea unt il s afe operation has been validated.

9. Release t he truck for use af ter al l c hecks hav e been completed and all deficiencies corrected.

Final Checkout

Page 9-1

NOTES

Page 9-2

Final Checkout

7/10 FAM0908

APPENDIX This chapter contains additional information and proc edures 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 - FAM1104 2. Suspension Oiling And Charging Procedure - FAM1202 3. Toe In Adjustment Procedure - FAM1302 4. Automatic Lubrication System Checkout Procedure - FAM1402 5. Reserve Oil System Checkout Procedure - EJ6271 6. Air Conditioning Checkout Procedure - EL4302 7. Air Conditioning Drive Belt Adjustment Procedure - EL9330 8. Hydraulic Checkout Procedure - EM7621 9. Brake Checkout Procedure - EM7602 10. VHMS Setup Procedure - EM2128 11. VHMS Checkout Procedure - EM2129 12. Interface Module Checkout Procedure - XB1214 13. Payload Meter III Checkout Procedure - EJ3061 14. Electrical Checkout Procedure - XB1656 15. Komatsu Haul Truck Commissioning Procedure - XB1623 16. Standard Torque Charts and CoversionTables - FAM1501 17. Hydraulic System Flushing Procedure - FAM1602 18. Field Assembly Inspection Report 19. 50 Hour Post-Commissioning Checksheet FAM1013 7/10

Appendix

Page 10-1

NOTES

Page 10-2

Appendix

7/10 FAM1013

LUBRICATION CHART

LUBRICATION CHART

FAM1104 5/11

Lubrication Chart

F11-1

NOTES

F11-2

Lubrication Chart

5/11 FAM1104

OILING AND CHARGING PROCEDURE GENERAL These p rocedures c over the O iling and C harging of HYDRAIR®II suspensions on Komatsu Electric Drive Dump Trucks.

Suspensions which have be en properly charged will provide i mproved handling and ri de c haracteristics while also extending the fatigue life of the truck frame and improving tire wear.

NOTE: I nflation pres sures a nd ex posed piston lengths are c alculated f or a norm al t ruck gros s vehicle we ight ( GVW). A dditions t o t ruck wei ght by adding body liners, tailgates, water tanks, etc. should be considered part of the payload. Keeping the truck GVW wi thin t he specification shown on t he Grade/ Speed Ret ard c hart i n t he operator c ab wi ll ex tend the service life of the truck main frame and allow the HYDRAIR®II s uspensions t o produc e a c omfortable ride.

®

All HY DRAIR II su spensions ar e ch arged with compressed n itrogen g as with su fficient p ressure to cause injury and/or damage if improperly handled. Follow all safety i nstructions, cau tions, and wa rnings pr ovided i n t he following procedures to prevent any accidents during Oiling and Charging.

Proper c harging of HY DRAIR ®II s uspensions requires that three basic conditions be established in the following order:

For best resul ts, HYDRAIR ® II s uspensions s hould be c harged i n pai rs (fronts together and rears together). I f rears are to be c harged, t he fronts should be charged first.

NOTE: F or l onger life of s uspension c omponents, a Friction M odifier should be adde d to the suspension oil. S ee Specifications Chart , F IGURE 12-6 at t he end of this chapter.

NOTE: S et up di mensions s pecified i n t he c harts must be m aintained duri ng oi ling a nd c harging procedures. Howev er, af ter t he t ruck ha s be en 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 bo th front and rear suspension are t o be serviced at the same time, service the front suspensions first.

Do not rem ove the front suspension n itrogen charging blocks until after the rear suspensions have been completely serviced.

1. Oil level must be correct.

2. Suspension pi ston rod ex tension f or ni trogen charging must be correct.

3. Nitrogen charge pressure must be correct.

FAM1202 5/11

Oiling and Charging Procedures

F12-1

HYDRAIR® CHARGING KIT Assemble service k it as s hown i n F igure 12-1 an d attach to container of pure dry nitrogen (8).

Installation of Charging Kit 1. Remove prot ective c overs and charging v alve caps from suspensions to be charged.

2. Turn " T" hand les (1, F igure 12-1) of adapt ers (2) completely counterclockwise.

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

4. Turn s wivel nut (s mall hex ) on c harging valve three f ull t urns c ounterclockwise to unseat t he valve.

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: B y selective o pening and c losing of out let valves (3), a nd i nlet v alve (4), s uspensions m ay be charged separately or together.

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

2. Turn " T" ha ndles (1) c ounterclockwise t o release charging valve cores.

3. Remove c harging v alve adapt ers (2) f charging valves.

rom

4. Tighten s wivel nut (small hex ) on charging valve. If a new c harging v alve i s bei ng us ed, tighten s wivel nut t o 15 Nm (1 1 f t lb) t orque, then l oosen and retighten swivel nut to 15 Nm (11 f t l b) t orque. A gain l oosen s wivel n ut a nd retighten t o 6 Nm (50 i n l b) t orque. Repl ace valve cap (1) and tighten to finger tight.

5. Install c harging v alve caps and protective c overs on both suspensions.

FIGURE 12-1. HYDRAIR ® CHARGING KIT NOTE: A rrangement of part s m ay v ary f rom 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

5/11 FAM1202

SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS Prior to starting oiling and charging procedures, supports s hould be f abricated whi ch wi ll maintain t he correct exposed piston rod extensions.

Rear support blocks for nitrogen charging are no longer necessary. Rear suspensions still require support blocks for oil charging.

Exposed piston rod extensions are specified for both oil level an d nitrogen charging for HYDRAIR ÂŽII suspensions. T hese di mensions are l isted i n t he Table below. Measure dimensions from the face of the cylinder gland to the machined surface on the spindle at the f ront s uspension. Measure f rom t he f ace of t he cylinder gland to the piston flange at the rear suspension.

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 t he u nloaded t ruck on a hard, l evel s urface. P lace the di rectional control l ever in PARK. Place wheel chocks in front and behi nd 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 s uspension t ravels u p an d do wn during the suspension charging process.

2. Thoroughly c lean area around the c harging valve o n the suspensions. Remove the protective covers from the charging valves.

All H YDRAIRÂŽII su spensions ar e ch arged with compressed nitrogen g as with su fficient p ressure to cause injury and/or damage if improperly handled. Follow all the safety notes, cautions and warnings i n these procedures to p revent accidents during servicing and charging.

Front Suspension Oiling

When b locks a re in p lace on a su spension, th ey must b e secured wi th a strap o r o ther m eans to avoid accidental d ischarge. An u nsecured b lock could f ly l oose as we ight i s ap plied, p resenting the possibility of serious injury to nearby personnel an d/or d amage to th e eq uipment. Over head clearance m ay b e red uced rap idly an d su ddenly when nitrogen pressure is released!

NOTE: F or l onger life of s uspension c omponents, a Friction M odifier should be adde d to the suspension oil. S ee Specifications Chart , Figure12-6 at t he e nd of this chapter.

FAM1202 5/11

Oiling and Charging Procedures

F12-3

1. Position a nd s ecure oiling h eight d imension blocks i n p lace (F igure 12-2). When n itrogen pressure is released, suspensions will lower to rest o n the b locks. En sure the b locks do n ot mar or s cratch t he p lated s urfaces of t he 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 m ask o r g oggles wh ile relieving nitrogen pressure.

2. Remove charging valve cap. Turn the charging valve s wivel nut (s mall h ex) counterclockwise three f ull t urns t o uns eat v alve s eal. DO NOT TURN LA RGE HE X. T he charging v alve body has a bl eeder groove i n i ts m ounting t hreads but f or s afety of a ll personnel t he valve body MUST NOT be l oosened until A LL ni trogen pressure has been vented from the suspension.

3. Depress t he c harging v alve c ore t o rel ease nitrogen pres sure f rom t he s uspension. Whe n all nitrogen has been vented to the atmosphere, the s uspension should ha ve c ollapsed s lowly and be seated solidly on the support blocks.

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

5. Fill t he suspension with c lean H YDRAIRÂŽ oi l (with 6% friction modifier) until the cylinder is full to the top of the fill plug bor e. Drip pans should be used and all spillage cleaned from outside of the suspension. Allow the suspension to stand for at l east 15 m inutes t o c lear any t rapped nitrogen and/or bubbles from the oil. Add m ore suspension o il i f nec essary. I nstall a new fill plug O-ring, and install the plug.

F12-4

FIGURE 12-2. FRONT SUSPENSION Table 1: FRONT SUSPENSION DIMENSIONS (EMPTY) OILING HEIGHT

25.4 mm (1.0 in.)

CHARGING HEIGHT

229 mm (9.01 in.)

CHARGING PRESSURE

*3 365 kPa (488 psi)

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

Oiling and Charging Procedures

5/11 FAM1202

Front Suspension Nitrogen Charging

2. Tighten valve body (large hex, 6) to 23 Nm (17 ft lb) torque. The valve swivel nut (small hex, 4) must be unseated by t urning c ounterclockwise three full turns.

Lifting equipment (crane or hydraulic jacks) must be of su fficient cap acity to l ift the tru ck w eight.

Be certain that all personnel are clear of lift area before lift is started . Clearances u nder th e tru ck may be suddenly reduced.

1. If rem oved, install the charging v alve wi th new O-ring (9, F igure 12-3). Lu bricate the O -ring with clean HYDRAIR®oil.

Dry nitrogen is the only gas approved for use in HYDRAIR ®II su spensions.Charging o f th ese components with o xygen o r o ther g ases may result i n an exp losion wh ich could cau se fatal ities, serious injuries and/or major property damage. Use o nly n itrogen g as m eeting the specifications shown in chart (Figure 12-6).

3. Install HYDRAIR ® Chargi ng Kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit. 4. Charge t he s uspensions wi th ni trogen gas t o 50.8 mm (2 in.) greater than the charging height listed in Table 1. Close inlet valve (4, Figure 121).

NOTE: If th e tru ck starts to lift o ff the b locks b efore charging pressure is attained, stop charging.

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

FIGURE 12-3. CHARGING VALVE 1. Valve Cap 2. Seal 3. Valve Core 4. Swivel Nut 5. Rubber Washer

6. Valve Body 7. O-Ring 8. Valve Stem 9. O-Ring

NOTE: Us e c aution t o prev ent damage t o plated cylinder s urfaces and oi l s eals when i nstalling t he blocks.

6. Remove the center hose from manifold (6).

Be aw are wh en r elieving n itrogen g as, the tru ck may drop suddenly onto the charging blocks.

7. To l ower t he truck ont o t he c harging blocks, open inlet valve (4) u ntil t he p ressure has dropped bel ow the pressure l isted i n Table 1, and then close the valve.

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

FAM1202 5/11

Oiling and Charging Procedures

F12-5

9. Charge the s uspensions t o the pres sure l isted in Table 1. DO NOT use an overcharge of nitrogen to lift t he s uspensions of f of t he c harging blocks.

10. Close i nlet v alve (4, F igure 12-1). Leav e out let 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. lb).

13. If a ne w c harging v alve i s be ing us ed, t ighten swivel nut to 15 Nm (1 1 ft l b) t orque, then loosen and retighten swivel nut to 15 Nm (11 ft lb) t orque. A gain l oosen s wivel nu t an d retighten to 6 N·m (50 i n. l b) t orque. Repl ace valve cap (1) and tighten finger tight.

14. Install protective guard over charging valve.

NOTE: I f t he rear s uspension are t o be s erviced at this time, leave the nitrogen charging blocks in place on t he f ront s uspensions u ntil af ter t he rear suspensions are completely serviced.

Ensure t hat there i s adequate o verhead clearance before raising the body.

15. Raise the truck body in order to extend the front suspensions and allow for removal of the nitrogen c harging bl ocks. E nsure t hat s ufficient overhead c learance ex ists bef ore rai sing t he body. I f t he s uspensions do not ex tend af ter raising the body, turn the steering wheel left and right in very small movements several times. If the s uspensions s till do not ex tend eno ugh t o allow for rem oval of the bl ocks, use a c rane or floor jacks t o rai se t he t ruck and r emove t he blocks.

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 ri ng at t he ba se of t he p iston. Operator c omments on steering response and suspension rebound should also be noted.

NOTE: T he empty ride hei ght m ay be less t han t he charging ri de height. A lso, t he s uspension h eight between t he left and ri ght s uspensions m ay not always be the same due t o the fuel l evel i n the fuel tank.

REAR SUSPENSION 1. Park t he u nloaded t ruck on a hard, l evel s urface. M ove the di rectional c ontrol lever to t he 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 s uspension t ravels u p an d do wn during the suspension charging process.

3. Thoroughly clean the area around the charging valve o n the suspensions. Remove the protective covers f rom t he charging v alves and t he metal covers from the suspension piston.

NOTE: F or l onger life of s uspension c omponents, a Friction Modifier m ust b e adde d t o t he s uspension oil. See Specifications Chart, Figure 12-6 at the end of this chapter.

Any time the suspensions are recharged, the calibration of the Payload Meter system is affected. Refer to the P ayload M eter III ™ s ection and pe rform a “Clean T ruck T are”. T his wi ll ens ure ac curate pay load records.

F12-6

Oiling and Charging Procedures

5/11 FAM1202

Rear Suspension Oiling 1. Position an d s ecure oi ling s upport bl ocks (2, Figure 30-12) in place so the blocks are seated between m ain frame (1) and r ear axle hous ing (3). A block should be used on both the left and right sides of the truck.

Make certain all personnel are clear and support blocks are secure before relieving nitrogen pressure from th e su spension. Use a face m ask o r goggles when venting nitrogen.

2. Remove charging valve cap. Turn the charging valve s wivel nut (s mall h ex) counterclockwise three f ull t urns t o uns eat v alve s eal. DO NOT TURN LA RGE HE X. T he charging v alve body has a b leeder groove i n its m ounting t hreads, but f or safety of al l personnel, t he v alve body MUST NOT be l oosened until A LL ni trogen pressure has been vented from the suspension.

3. Depress t he c harging v alve c ore t o rel ease nitrogen pres sure f rom t he s uspension. Whe n nitrogen pres sure has been v ented to atmosphere, l oosen and rem ove t he fill pl ug. T he suspension s hould have c ollapsed s lowly as gas pressure was released. Truck weight is now supported by the support blocks.

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.)

*1 469 kPa (213 psi)

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

FAM1202 5/11

Oiling and Charging Procedures

F12-7

NOTE: A pl astic tube can be us ed to hel p bleed off trapped air inside the piston.

5. Install t he v ent pl ug and pressure s ensor ont o the suspension.

4. Remove t he vent pl ug, pres sure sensor, and charging valve (See F igure 1 2-5). Use one of the open p orts t o f ill the suspension with clean Hydrair oil ( with 6% f riction m odifier). F ill until clean oil seaps f rom t he op en port s. Us e d rip pans a nd c lean a ll s pillage f rom the o utside of the s uspension. A llow the suspension t o s ettle for at l east 15 m inutes t o c lear any t rapped nitrogen and bubbl es f rom the oi l. Add more suspension oil if necessary.

6. Install a n ew O-ri ng o nto the c harging v alve.

Lubricate the O-ring with clean Hydrair II oil.

7. Install the charging valve o nto the suspension.

Tighten valve b ody (6, F igure 30-11) to 23 Nm (17 ft lb).

Rear Suspension Nitrogen Charging

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 cl ear o f l ift are a before lift i s started . Cl earances under the truck may be suddenly reduced.

Ensure th e au tomatic a pply ci rcuit h as n ot applied th e service b rakes d uring truck m aintenance. If the front brakes are applied during rear suspension c harging, th e axl e can not pivot fo r frame raising / lowering, and the rear suspension may be unable to move up or down.

1. If r emoved, i nstall c harging valve with new Oring (9, F igure 12-3). Lubri cate the O-ri ng wi th clean HYDRAIR ÂŽoil.

FIGURE 12-5. REAR SUSPENSION 1. Main Frame 2. Charging Valve

F12-8

2. Tighten valve body (large hex, 6) to 23 Nm (17 ft lb) torque. The valve swivel nut (small hex, 4) must be unseated by t urning c ounterclockwise three full turns.

3. Rear Axle Housing

Oiling and Charging Procedures

5/11 FAM1202

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

Dry nitrogen is the only gas approved for use in HYDRAIR ®II suspensions. Ch arging o f these components with o xygen o r o ther g ases m ay result i n an exp losion wh ich could cau se fatal ities, serious injuries and/or major property damage. Use o nly n itrogen g as m eeting th e specifications shown in chart (Figure 12-6).

3. Install HYDRAIR ® Chargi ng 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.) great er t han the c harging h eight listed in Table 2.

Be aw are wh en r elieving n itrogen g as, the tru ck may drop suddenly onto the charging blocks.

5. Slowly release gas until the suspensions match the charging height listed in Figure 12-4.

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

9. If t he charging v alve is bei ng reused, t ighten swivel nu t (4, F igure 12-3) t o 6 Nm (50 i n l b) torque.

10. If a n ew c harging v alve i s be ing us ed, t ighten swivel nut t o 15 Nm (1 1 ft l b) t orque, then loosen and ret ighten the s wivel nut t o 15 Nm (11 f t l b) t orque. A gain, l oosen t he s wivel nut and ret ighten t o 6 Nm (50 i n l b) t orque.

Replace valve cap (1) and tighten finger tight.

11. Install t he prot ective guards ov er t he c harging valves and install the metal covers over the piston rods.

Any time the suspensions are recharged, the calibration of the Payload Meter system is affected. Refer to the P ayload M eter I II ™ s ection and pe rform a “Clean T ruck T are”. T his wi ll ens ure ac curate payload records.

The rear s uspensions are now ready for operat ion.

Visually check pi ston ex tension both with t he t ruck loaded and empty. Record the extension dimensions.

Maximum do wnward t ravel i s i ndicated by t he di rt ring a t t he ba se of the pi ston rod. Ope rator c omments on steering response and suspension rebound should also be noted.

Any time the suspensions are recharged, the calibration of the Payload Meter system is affected. Refer to the P ayload M eter I II ™ s ection and pe rform a “Clean T ruck T are”. T his wi ll ens ure ac curate payload records.

7. Ensure bot h of t he s uspension cylinders are extended the same distance ± 10 mm (0.39 in.).

If t he di fference i n t he ex tension f rom side t o side exceeds 10 m m (0.39 in.), check the front suspensions f or equal ex tension. Adjust t he front as necessary.

NOTE: A low left front suspension will cause the right rear s uspension t o b e hi gh. A l ow ri ght f ront suspension will cause the left rear s uspension to be high.

FAM1202 5/11

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 Mobil 424 Chevron Tractor Hydraulic FluidMobil DTE 15 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

5/11 FAM1202

TOE-IN ADJUSTMENT 1. Center t he front whee ls by s traightening t he steering wheel. Turn the key switch OFF. Allow at l east 90 s econds f or t he ac cumulators t o depressurize. DO NOT turn the steering whee l during this time.

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

3. Check t he t oe-in by measuring t he 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 3-1.

Radial tires must have eq ual m easurements at the f ront and t he rear of t he t ires. E qual m easurements results in 0 toe-in.

860E-1K TOE-IN DATA Nominal tie-rod length, radial tires to achieve: 0 toe-in

3668 mm (144.4 in.)

4. If the measurements are n ot equal, a djust t he tie rod . Loosen the clamp l ocknuts on t he tie rod. Rot ate the tie rod as necessary t o obtain the correct toe-in setting of 0.

5. When t he adj ustment i s c omplete, t ighten t he locknuts on the tie rod to 420 ± 42 N·m (310 ± 31 ft l b). Repeat t he t ightening s equence until the specified torque is maintained.

FIGURE 3-1. MEASURING TOE-IN

6. Remove t he wh eel c hocks f rom the rear wheels.

FAM1302 4/11

Toe-In Adjustment

Page F13-1

NOTES

Page F13-2

Toe-In Adjustment

4/11 FAM1302

AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE GREASE REQUIREMENTS Required Lubricant Grease r equirements will d epend o n am bient temperatures encountered during truck operation: • Above 3 2°C (90°F) Use NLG I N o. multipurpose grease (MPG).

2

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

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

SYSTEM PRIMING The system m ust b e f ull o f grease and f ree o f a ir pockets to function properly. After maintenance, if the primary or secondary lubrication lines were replaced, it will b e n ecessary to p rime t he system to eject a ll entrapped air.

1. Fill lube reservoir with lubricant, if necessary.

2. To purge air from the main supply line, remove the main s upply line at t he grease c anister.

Connect an external grease supply to the line.

3. Remove pl ugs from each i njector group in sequence (right front, left front, and rear axle).

4. Using the external grease source, pump grease until greas e appears at the group of i njectors and re-i nstall t he pipe pl ug. Repeat for remaining injector groups.

FIGURE 14-1. PUMP/RESERVOIR COMPONENTS 1.

2.

3.

4.

5.

6.

7.

Hose From Filter Outlet to Injectors Hydraulic Motor Pressure Reducing Valve Solenoid Valve Override Switch Vent Valve

8. Pressure Gauge (optional) 9. Pump Assembly 10. Flow Control Valve 11. Grease Reservoir

5. Remove t he caps f rom eac h injector an d connect an ex ternal g rease s upply t o t he z erk on t he i njector and pum p u ntil greas e ap pears at the f ar end of t he i ndividual g rease hos e or the joint being greased.

FAM1402 7/10

Automatic Lubrication System

F14-1

Pump Pressure Control

SYSTEM CHECKOUT

High p ressure hydraulic fluid from the truck steering system is reduced to 2240 - 2413 kPa (325 - 350 psi) by t he pres sure reduc ing v alve l ocated on t he manifold on top o f t he pum p m otor. T his pres sure can be read if pipe plug (3, Figure 14-2) is removed, and a gauge i s installed on t he m anifold. P ressure should be c hecked oc casionally to v erify t he pressure is within the above limits.

To check system operation, proceed as follows:

Pressure Control Valve Adjustment The pres sure c ontrol v alve (1) has been f actory adjusted and the setting should not be disturbed.

Flow Control Valve Adjustment NOTE: The flow control valve (5) is factory adjusted to 9.5 lpm (2.5 gpm). Do not change this setting.

1. Remove the dust covers from the injectors.

2. Start the engine.

3. Actuate the manual override button at the pump assembly and obs erve pin movement a t each injector.

4. Check f or pum p, ho se o r i njector damage or leakage with the system under pressure.

5. After c hecking s ystem, s top the en gine.

Observing norm al prec autions rega rding hi gh voltage present in the propulsion system before attempting to repair lube system.

6. Re-install the injector dust covers.

Lubrication Cycle Operation

PUMP HOUSING OIL The pump hou sing must be f illed to the prope r level with SAE 10W-30 motor oil. Check the oil level at the 1,000 hour m aintenance interval. To add oil, remove dipstick (4, Figure 42-2) on t op of the pump housing and fill the housing to the proper level marked on the dipstick.

The time bet ween l ube events is det ermined by t he setting s elected i n t he dash panel. Ref er to F igure 14-3 f or l ubrication menu s creens. Wi th t he k ey switch O N, s croll through the di splay menu s creens and s elect either 8, 15, 24 or 30 m inutes between lube cycles. The default setting is 15 minutes.

NOTE: Turning the key switch to the ON position will not initiate a lube cycle. To initiate a lube cycle while the truck i s stationary, s elect m anual l ube us ing t he dash di splay p anel, or us e the s witch on t he lubrication pump.

The truck must be moving before the lube system will initiate l ube c ycles bas ed on the t ime i nterval selected.

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

F14-2

4. Dipstick 5. Flow Control Valve

Automatic Lubrication System

7/10 FAM1402

PREVENTATIVE MAINTENANCE The f ollowing m aintenance proc edures s hould be used to insure proper system operation.

Main Level Screens Screen 1

Load = 240 t LC = 25

2100 rpm

Daily Lubrication System Inspection

<

SC = 20 mph

ˇ

ˆ Screen 2

OK

TT = 6000 t

Inspect greas e l evel hei ght a fter eac h s hift of operation. Greas e us age s hould be consistent f rom day-to-day operations.

Load = 240 t LC = 25

TT = 6000 t

10,000 m

SC = 20 mph

•

ˇ

ˆ

Screen 3

Load = 240 t LC = 25

TT = 6000 t

3560.9 h

SC = 20 mph

ˇ

ˆ

1 Active Warnings Press < to View

a. Repair or repl ace al l da maged f eed l ine hoses.

Advance to screen 1 if moving and no realtime data.

ˇ

Advance to screen 4 .

b. Make sure that all air i s purged and all n ew feed line hoses are f illed with grease before sending the truck back into service.

ˆ Screen 5

Realtime Data OK to View (future development) Advance to screen 5 OR screen 4 OR screen 3.

Screen 6

ˇ

ˆ

4. Inspect k ey lubrication poi nts f or a bead of lubricant around s eal. I f a lubrication poi nt appears dry, troubleshoot and repair problem.

Advance to screen 1 if moving.

Payload Data OK to View

Screen 7

Lack of l ubricant us age woul d indicate an inoperative syst em. E xcessive usage woul d indicate a broken supply line.

2. Check f ilter by pass indi cator w hen f illing reservoir. Replace element if bypassing.

3. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points.

Screen 4

<

1. Check grease reservoir level.

Switch 2

Switch 1

ˇ

ˆ

1 Repair Item OK to View

Screen 8

ˇ

ˆ

2 Maintenance Items OK to View

Screen 9

ˇ

ˆ

System Controls Press OK to View

Manual Lube

OK

ˆ

Press OK to Start Screen 9, subscreen 0

Screen 9, subscreen max.

Screen 10

Screen 11

English Español Français OK Portuguese

ˆ

ˇ

Configure System Press OK to Edit

Lube Interval 8 15 24 30

OK

ˆ

Press OK to Edit Screen 11, subscreen 0

Screen 11, subscreen max.

80414

FIGURE 14-3. LUBRICATION MENU

FAM1402 7/10

Automatic Lubrication System

F14-3

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

TROUBLE

Pump Does Not Operate

Pump Will Not Prime

Pump Will Not Build Pressure

POSSIBLE CAUSES

SUGGESTED CORRECTIVE ACTION

Lube system 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.

Lube cycle malfunction.

VHMS - Check fault logs

Solenoid valve malfunctioning.

Replace the solenoid valve assembly

Relay malfunctioning

Replace relay

Motor or pump malfunction.

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

Low lubricant supply.

Dirt in reservoir, pump inlet clogged, filter clogged.

Air trapped in lubricant supply line.

Prime system to remove trapped air.

Lubricant supply line leaking.

Check lines and connections to repair leakage.

Vent valve leaking.

Clean or replace vent valve.

Pump worn or scored.

Repair or replace pump assembly. (Refer to shop manual for rebuild instructions.)

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

Injector Indicator Stem Does Not Operate

Pressure Gauge Does Not Register Pressure

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 shop manual for rebuild instructions.)

No system pressure to the pump motor.

Check hydraulic hose from steering system.

No 24 VDC signal at pump solenoid.

Determine problem in 24 VDC electric system.

Pressure reducing valve set too low.

Refer to â&#x20AC;&#x153;Pressure Control Valve Adjustmentâ&#x20AC;?.

24V Relay (RB7K8) may be defective.

F14-4

Replace relay.

Automatic Lubrication System

7/10 FAM1402

TROUBLE Pump Pressure Builds Very Slowly Or Not At All

Controller Does Not Operate

Bearing Points Excessively Lubricated

Bearing Points Are Not Sufficiently Lubricated

FAM1402 7/10

POSSIBLE CAUSES No signal at solenoid.

SUGGESTED CORRECTIVE ACTION Check wiring for open circuit. Also check for fault codes on dash panel display.

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.

Lube cycle interval set to low.

Select larger lube cycle interval.

Injector output adjustment setting too high.

Readjust to lower setting.

Lube cycle interval set to high.

Select smaller lube cycle interval.

Injector output adjustment setting too low.

Readjust injector output setting.

System too large for pump output.

Calculate system requirements per planning manual.

Automatic Lubrication System

F14-5

NOTES

F14-6

Automatic Lubrication System

7/10 FAM1402

NOTES:

NOTES:

NOTES:

KOMATSU

CHECKOUT PROCEDURE

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NAME: IM Checkout 860E Update WRITTEN BY: Helge Mollhagen

DATE: 01/22/09

CHECKED BY:

DATE:

APPROVED BY:

DATE:

MACHINE & MODEL: 860E Update

0

NEW RELEASE

DASH A SIZE

DESCRIPTION OF CHANGE MICROFILM

DATE

ECN

BY

CK’D

Purpose: This procedure is used to checkout the IM installation.

Necessary Equipment: 1.

This checkout procedure and vehicle wiring schematic.

2.

Laptop computer with IM Realtime Data Monitor Software Installed. This software can be found on the Komatsu America Extranet: https://www.komatsuamerica.net/northamerica/ 3.

RS232 serial cable with a male DB9 connector on one end and a female connector on the other end.

4.

3/8 inch nut driver, voltmeter, 3 inch (or longer) jumper wire

INSTALL THE APPLICATION CODE Before the Interface Module can be put to work, the application code must be installed.

Application code must be matched to the truck model that the Interface Module is installed on.

Go to the Komatsu America Extranet: https://www.komatsuamerica.net/northamerica/ to get the necessary files and instructions.

How to use the IM Realtime Data Monitor software: Connect a DB9 straight through cable from the serial port on the laptop to the IM Diagnostic connector in the cab or auxiliary cabinet. The IM must be powered to communicate with the laptop.

Double click the shortcut to IM Realtime Monitor on the Desktop screen. After the program runs, a blank window shows up. On the menu select “Select Serial Port” to pick the serial port used and then select “Start/Stop” to view the data.

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CHECKOUT PROCEDURE

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CHECK FOR FAULT CODES ASSOCIATED WITH THE INTERFACE MODULE Key on then run the IM Realtime Data Monitor Software and confirm that there are no fault codes associated with the Interface Module. If any are found, these circuits should be analyzed to determine the cause of the fault and they should be repaired or if required the IM should be replaced.

INTERFACE MODULE I/O Use the IM Realtime Data Monitor software to confirm the functionality of all IM inputs and serial connections. The key switch must be on for all tests below.

CHECK DIGITAL INPUTS TO THE INTERFACE MODULE 1.

2.

3.

4.

5.

6.

7.

8.

9.

Hydraulic Tank Level (IM2-k) – Disconnect wire 34LL from Hydraulic Tank Level sensor at TB47-H. Short wire 34LL to IM to ground at TB47-H momentarily and confirm state change (one to zero). Reconnect wire 34LL from Hydraulic Tank Level sensor to TB47-H. Low Steering Precharge (IM2-W) – Disconnect wire 51A1 from TB45-L momentarily and confirm state change (zero to one).

Pump Filter Switches (IM2-Y) – Disconnect wire 39 from TB47-A momentarily and confirm state change (zero to one).

Park Brake Request (IM3-V) – Short the engine oil pressure switch wire circuit 36 on TB26-L to ground. Move shift lever from neutral to park position and confirm state change (one to zero) on circuit 52C. Remove the ground from TB26-L. Auto Lube Switch (IM3-Y) – Disconnect wire 68P from lube pressure switch at TB38-P leaving 68P connected to the IM at TB38-P. Short TB38-P to ground momentarily and confirm state change (one to zero). Reconnect disconnected wire.

Batt+(control power) (IM3-M) -- Confirm this is a one. Turn key switch off and confirm state remains a one for at least a few seconds. Turn key switch back on.

Starter Motor 1 Energized (IM3-R) – Disconnect wire 11SM1 from cranking motor to TB29K at TB29-K. Momentarily short TB29-K to 24V and confirm state change (zero to one).

Reconnect disconnected wire.

Starter Motor 2 Energized (IM3-S) – Disconnect wire 11SM2 from cranking motor to TB29G at TB29-G. Momentarily short TB29-G to 24V and confirm state change (zero to one).

Reconnect disconnected wire.

Crank Sense (IM3-U) – Open the Starter Disconnect switch so that there is no battery voltage to the starters. Momentarily short TB43-F to 24V and confirm state change (zero to one).

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10. Selector Switch (Park) (IM3-T) – Place shifter into park position and confirm 1 state then shift into neutral and confirm 0 state. Return shifter to park position.

11. Selector Switch (FNR) (IM2-N) – Place shifter into park position and confirm 0 state then shift into forward, neutral, and reverse and confirm 1 state in each of these positions.

Return shifter to park position.

12. Strg Bleed Pressure Sw (IM2-Z) – Disconnect the steering bleed down pressure switch, identified by circuit 33JA, at TB47-E and confirm state change (zero to one). Reconnect the switch.

13. Brake Lock Switch Power Supply (IM3-L) – Use Sibas to simulate a vehicle speed of 2 kph and turn on the park brake latch circuit. Confirm state change (zero to one). Leave vehicle speed at 2 kph until completion of step 16.

14. Brake Lock (IM2-i) –With shifter in the park position, actuate brake lock switch and confirm state change (zero to one). Turn off brake lock switch. (The Brake Lock Switch Power Supply test, item 15, must be completed before this test can be successfully completed.)

Reset vehicle speed to zero.

15. Engine Shutdown (IM3-F) – Disconnect wire 21INS from the Cummins ECM at TB44-D leaving wire 21INS to IM connected at TB44-D. Momentarily short TB44-D to 24V and confirm state change (zero to one). Reconnect disconnected wire.

16. Secondary Engine Shutdown sw (IM3-E) – Actuate the Secondary Engine Shutdown switch and confirm state change (one to zero).

17. Snapshot In-Progress (IM2-L) – Actuate the Data Store Switch. Confirm state change (zero to one).

18.

Low Steering Pressure sw1 (IM2-S) – Short wire 33F to ground at TB27-M momentarily and confirm state change (one to zero).

19. Brake Accum Pressure sw (IM2-U) – Disconnect wire 33BP from the brake accumulator pressure switch at TB25-B. Momentarily short wire 33BP to ground at TB25-B. Confirm state change (one to zero). Reconnect wire 33BP from the brake accumulator pressure switch to TB25-B. 20. Right Rear Park Brake Released (IM2-T) – Short wire 52H to ground at TB46-T momentarily and confirm state change (one to zero).

21. Brake Lock Degrade sw (IM2-V) – Short wire 33T to ground at TB27-J momentarily and confirm state change (one to zero).

22. Left Front Park Brake Released (IM2-X) – Short wire 52F to ground at TB46-J momentarily and confirm state change (one to zero).

23. Right Front Park Brake Set (IM2-a) – Momentarily disconnect Right Front Park Brake Pressure switch, identified by circuit 52D, and confirm state change (zero to one).

24. Left Front Park Brake Set (IM2-d) – Momentarily disconnect Left Front Park Brake Pressure switch, identified by circuit 52G, and confirm state change (zero to one).

25. Right Rear Park Brake Set (IM2-f) – Momentarily disconnect Right Rear Park Brake Pressure switch, identified by circuit 52J, and confirm state change (zero to one).

26. Circuit Breaker Tripped (IM2-g) – Short wire 31CB to ground at TB26-T momentarily and confirm state change (one to zero).

27. Crank Request (IM2-j) – Open the Starter Disconnect switch so that there is no battery voltage to the starters. Momentarily turn key switch to the crank position and confirm state change (zero to one).

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CHECKOUT PROCEDURE

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28. Left Rear Park Brake Set (IM2-m) – Momentarily disconnect Left Rear Park Brake Pressure switch, identified by circuit 52K, and confirm state change (zero to one).

29. Mode sw4 (IM2-q) – Actuate the “up arrow” LCD screen navigation switch and confirm state change (one to zero).

30. Left Rear Park Brake Released (IM3-D) – Short wire 52L to ground at TB46-X momentarily and confirm state change (one to zero).

31. Keyswitch (IM3-G) – confirm this is a one.

32. Mode sw1 (IM3-H) – Actuate the “left arrow” LCD screen navigation switch and confirm state change (one to zero).

33. Mode sw2 (IM3-J) – Actuate the “OK” LCD screen navigation switch and confirm state change (one to zero).

34. Mode sw3 (IM3-K) – Actuate the “down arrow” LCD screen navigation switch and confirm state change (one to zero).

35. Right Front Park Brake Released (IM3-P) – Short wire 52E to ground at TB46-E momentarily and confirm state change (one to zero).

CHECK ANALOG INPUTS TO THE INTERFACE MODULE Verify that the used analog inputs are in the range of the values listed below.

1.

2.

3.

4.

5.

6.

7.

8.

9.

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Steering Pressure [kPa] (IM3-d): Momentarily disconnect steering pressure sensor, identified by circuit 33SP, and confirm fault A204, Steering Pressure Sensor Low, is active.

Reconnect sensor.

Ambient Air Temp [C] (IM3-e): Confirm reported temperature matches ambient temperature within 3 C. Fuel Level [%] (IM3-g): confirm reported % level matches actual fuel level in tank +/- 5%.

12V DC Inverter Voltage (Battery Voltage A) [V] (IM3-h): confirm reported voltage is +/- 1 volt of actual measured 12V DC inverter voltage.

Brake Pressure [kPa] (IM3-p): Disconnect service brake pressure sensor located in brake cabinet (reference circuit 33BPS) and confirm fault A205, Brake Pressure Sensor Low, is active. Reconnect sensor.

Right Rear Brake Oil Temp [C] (IM3-m): Disconnect right rear brake oil temp sensor, identified by circuit 34BT4, and confirm fault A167, Hydraulic Oil Temp – Right Rear Sensor Low, is active. Reconnect sensor.

Left Rear Brake Oil Temp [C] (IM3-i): Disconnect left rear brake oil temp sensor, identified by circuit 34BT3, and confirm fault A166, Hydraulic Oil Temp – Left Rear Sensor Low, is active. Reconnect sensor.

Right Front Brake Oil Temp [C] (IM3-r): Disconnect right front brake oil temp sensor, identified by circuit 34BT2, and confirm fault A169, Hydraulic Oil Temp – Right Front Sensor Low, is active. Reconnect sensor.

Left Front Brake Oil Temp [C] (IM3-t): Disconnect left front brake oil temp sensor, identified by circuit 34BT1, and confirm fault A168, Hydraulic Oil Temp – Left Front Sensor Low, is active. Reconnect sensor.

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CHECKOUT PROCEDURE

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10. Hoist Pressure 2 [kPa] (IM3-q): Short wire 33HP2 to ground at TB45-G momentarily and confirm fault A203, Hoist Pressure 2 Sensor Low, is active.

11. Hoist Pressure 1 [kPa] (IM3-s): Short wire 33HP1 to ground at TB45-A momentarily and confirm fault A202, Hoist Pressure 1 Sensor Low, is active.

12. Battery Voltage 24V [V] (IMint): confirm reported voltage at TB38-X is +/- 1 volt of actual measured battery voltage.

CHECK SERIAL INTERFACES TO THE IM 1.

Proper operation of the serial interfaces to the IM is assured if faults A184, A233, A237, and A257 are not active.

CHECK OUTPUTS FROM THE INTERFACE MODULE Note: Before performing these next steps, the key switch must be turned off for at least 7 minutes to allow the IM to completely shutdown. Confirm that the IM has shutdown by verifying that the green LED on the IM controller has stopped flashing.

While performing the following IM output checks, ensure that no output short circuit fault codes are reported by the IM Realtime Data Monitor software.

1.

2.

3.

4.

5.

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Park Brake Solenoid (IM1-E), Brake Auto Apply (IM1-R). Short the engine oil pressure switch wire circuit 36 to ground on TB26-L. Key on and shift into neutral. Confirm that park brake solenoid is energized by verifying that coil is magnetized. Confirm that the auto apply solenoid is de-energized. Use Sibas pc program to set the truck speed to a speed above 1 kph. Shift into park. Confirm that the park brake solenoid remains energized. Reduce the truck speed to 0 kph. Confirm that the auto apply solenoid energizes and after one second confirm that the park brake solenoid de-energizes and after one half second confirm that the auto apply solenoid de-energizes. Remove the ground from TB26-L. Crank Enable Output (IM1-B). Disconnect circuit 21PS from pre-lube relay at TB43-E prior to performing this step. Place shifter in park and confirm that circuit 21PS on TB43-E is 24 volts while cranking. Place shifter in neutral and confirm that circuit 21PS on TB43-E is 0 volts while cranking. Reconnect circuit 21PS to pre-lube relay.

IM On Signal (IM1-K). With keyswitch on, confirm voltage at TB47-L is approximately 0 volts.

Strg Bleed Relay (IM1-P). Confirm steering bleed down solenoid is de-energized.

Disconnect steering bleed down pressure switch, identified by circuit 33JA, from harness.

Turn key switch off and confirm that steering bleed down solenoid is energized by verifying that coil is magnetized. Reconnect steering bleed down pressure switch to harness.

Red Warn (IM1-G), Sonalert (IM1-M). Disconnect the IM from the CAN/RPC network by unplugging the its T-connection to the network then confirm the following on the dash panel: a. all status panel indicators flash on/off b. the red warning indicator flashes on/off

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c. two separate audible alarms can be heard sounding on/off d. a loss of communications message is displayed on the LCD in the speedometer e. the needles in all of the gauges are moving through their entire range of motion Reconnect the IM to the CAN/RPC network.

860E S/N ___________________ IM Installation Checkout Checklist Function Description

Expected Result Result

Hydraulic Tank Level input Low Steering Precharge

1 to 0

Pump Filter Switches

0 to 1

Park Brake Request

1 to 0

Auto Lube Switch

1 to 0

Batt +

1

Starter Motor 1 Energized Starter Motor 2 Energized Crank Sense

0 to 1

Comments

0 to 1

0 to 1 0 to 1

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(OK/Fail)

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Function Description

Expected Result Result

Selector Switch (Park)

1 to 0

Selector Switch (FNR)

0 to 1

Strg Bleed Pressure Sw

0 to 1

Brake Lock Switch Power Supply Brake Lock

0 to 1

Engine Shutdown

0 to 1

Secondary Engine Shutdown Snapshot In-Progress

1 to 0

Low Steering Pressure sw1 Brake Accum Pressure sw Right Rear Park Brake Released Brake Lock Degrade sw

1 to 0

(OK/Fail)

Comments

0 to 1

0 to 1

1 to 0 1 to 0 1 to 0

Left Front Park Brake 1 to 0 Released Right Front Park Brake 0 to 1 Set Left Front Park Brake Set 0 to 1 Right Rear Park Brake Set Circuit Breaker Tripped

0 to 1

Crank Request

0 to 1

Left Rear Park Brake Set

0 to 1

Mode sw4

1 to 0

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1 to 0

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Function Description

Expected Result Result

Left Rear Park Brake Released Keyswitch

1 to 0

Mode sw1

1 to 0

Mode sw2

1 to 0

Mode sw3

1 to 0

Right Front Park Brake Released

1 to 0

Steering Pressure

fault A204

Ambient Air Temp

ambient temp +/- 3C

Fuel Level

tank level +/- 5%

12V DC Inverter Voltage

measured voltage +/- 1V

Brake Pressure

fault A205

Right Rear Brake Oil Temp Left Rear Brake Oil Temp Right Front Brake Oil Temp Left Front Brake Oil Temp Hoist Pressure 2

fault A167

fault A203

Hoist Pressure 1

fault A202

Battery Voltage 24V

measured voltage +/- 1V

CAN/J1939

no fault A184

Comments

1

fault A166 fault A169 fault A168

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(OK/Fail)

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Function Description

Expected Result Result

Drive System CAN/RPC

no fault A233

Display CAN/RPC

no fault A237

Payload CAN/RPC

no fault A257

Park Brake Solenoid

energized/de-energized

Brake Auto Apply

energized/de-energized

Crank Enable Output

24 V, 0 V

IM On Signal

0V

Steering Bleed Relay

de-energized/energized

Status Indicators

Flash on/off

Red Warn

Flash on/off

2 audible alarms

Sound on/off

LCD Screen

Warning message displayed Needles sweeping continuously

5 gauges

(OK/Fail)

Comments

Completed By: _________________________________________ Date: _______________________

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NAME: Electric Checkout Procedure WRITTEN BY: J. Miller

DATE: 01/21/09

CHECKED BY:

DATE:

APPROVED BY:

DATE:

MACHINE & MODEL: 860E-1KT, 960E-1KT

0 DASH A SIZE

NEW RELEASE DESCRIPTION OF CHANGE MICROFILM

DATE

ECN

BY

CK’D

MICROFILM This procedure is to be used in conjunction with the Siemens Drive System Checkout Procedure, Interface Module Checkout Procedure and the Hydraulic System Checkout Procedure.

General Description: This checkout procedure prescribes the tests and procedures to check out the function and operation of the A/C propulsion system, hydraulic system and the 24 volt control & lighting system.

The Checkout Procedure must be completed to provide a permanent record of the various systems testing for each unit.

The main control cabinet consists of a control cabinet with: Auxiliary three-phase liquid cooled rectifier, phase inverters and chopper modules, with micro-processed control unit (PSC), electrical coolant pump, auxiliary transformer, main blower fan, alternator field regulator and retard contactors.

Also, the auxiliary control box contains the Interface Module (IM), Payload Meter 3, ORBCOM-status reporting system control module and the truck interface control wiring connection points, along with the 24v power distribution and fuse protection.

Note: Look at the “ISO” symbol on the left dash of the operator’s cab that indicates on (a circle with a continuous closed line, up and down) and off (a circle with an interrupted line up and down) to be sure of the proper position of the switch.

TABLE OF CONTENTS Welding and Safety Procedures

Page 2

II.

AC Drive System Description

Page 4

III.

Resistance Checks

Page 5

IV.

Megger Preparation and Testing

Page 6

V.

Control System Checkout A. Circuit Checks with Key Switch Power Off B. Circuit Checks with Key Switch Power On

Page 8

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I.

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CHECKOUT PROCEDURE

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VI.

IM System Checkout (See Procedure – Check-out Group)

Page 12

VII.

Siemens Drive System Function Test and Engine Start Up. (See Procedure – Check-out group)

Page 13

VIII.

Hydraulic System Checkout (See Procedure – Check-out Group)

Page 13

IX.

Siemens Drive System Self-Load Test Procedures (See Procedure – Check-out Group)

I.

Welding and Safety Procedures A. Prior to welding and/or repairing on the AC Drive truck, maintenance personnel should attempt to notify the KAC field engineer.

B. If it is necessary to perform welding or repair to the truck without the field engineer present, the following procedure should be performed to insure the truck is safe for the maintenance person to work on and reduce the chance for damage to equipment.

C. Normal shutdown consists of: 1. Truck stopped, put selector switch in park position. (This applies the Park Brake).

2. Apply the HVDC Power-Off (REST) Switch. (Retard contactors are engaged and high voltage link energy is diffused through the grid).

3. The in the control cabinet Diagnostic Box – (Which is located in the compartment, in the front of the control cabinet, closest to the operator cab) the (Yellow) link energized light should be “OFF” and on the DC-Link Voltmeter should indicate “0” voltage.

4. Turn key switch to the “OFF” position. (The normal way to stop the engine of the truck is by use of the key. When the key is turned off, the steering hydraulic system pressure should also bleed down).

5. To insure that the link will not be re-energized, turn the Field Regulator Cutoff Switch to the OFF position of the switch. Verify Link Voltage has discharged by looking at Link Voltage Meter located in the same compartment.

D. Preliminary procedure for establishing the AC Drive System is safe for maintenance personnel to perform service and welding on:

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NOTE: While the AC Drive System Truck is running (engine on), none of the cabinet doors or covers should be open or removed. None of the power cables should be

KOMATSU

CHECKOUT PROCEDURE

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used as hand or foot holds and the return grid elements should not be touched. Even after shutting off the engine, the following procedure should be used before opening any cabinets or touching a grid element or a power cable. The system (link hot) is not dependent on selector switch position or accelerator pedal being pushed, (If the FR cutoff switch is in the normal position (on), the Rest Switch is turned off, and the engine is running, the drive system link is “hot” with dangerous voltage).

NOTE: Normal operation of the drive system at shutdown should leave the system safe to operate. In the event of a system failure, performing the following procedure will insure that hazardous voltages are not present in the drive system.

NOTE: If there is any question whether the system has potential hazardous voltage, return to operator cab and perform normal shutdown.

1. Before shutting down the engine, verify the status of the drive system warning lights in the operator dash display. If any of the red drive system link warning lights are on, do not attempt to open any cabinets, disconnect any cables, or reach inside the retard grid cabinet without a trained drive system technician present – even after shutting down the engine.

2. If all red drive system warning lights are off, set the selector switch in the park position, then shut down the engine and chock the wheels.

3. After the engine has been off for at least five (5) minutes, inspect the Link Voltage Meter in the Diagnostic Box on the front of the main control cabinet and verify that the link voltage has been discharged. If the link voltage is discharged, then the retard grids, wheel motors, alternator and power cables connecting these devices are safe to work on.

4. If, after the following above procedure, a fault has occurred. Or the link voltage has not discharged, 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 footholds. Notify the KAC field engineer or Siemens engineer immediately.

5. Before welding on the truck, disconnect the power connector plug X1M from inside the Auxiliary electrical cabinet connector interface. Also, the ECM harness connectors to the QSK engine controller must be disconnected.

6. Do not weld on the control cabinet. The metal panels on the cabinet are designed for environmental sealing and should not be modified.

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7. Do not weld on the retard grid exhaust louvers – they are made of stainless steel. Some power cable panels throughout the truck are made of aluminum

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CHECKOUT PROCEDURE

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or stainless steel. They must be repaired with the same material or the power cables may be damaged by inductive heating.

8. Power cables must be clamped with wood or other non-ferrous material clamps. Do not repair cable cleats by encircling the power cables with metal clamps or hardware.

Always inspect power cable insulation prior to servicing the cables and prior to returning the truck to service. Replace any cables with damaged insulation.

9. When welding, the welding ground electrode should be attached as close to the welding point as possible. Power cables and wiring harnesses should be protected from weld spatter and heat.

II.

AC System Description A. Control Cabinet contains: 1. Control Group a. SIBAS Control Panel b. Power Rectifiers c. Rectifier Liquid Cooling System 2. Auxiliary Cooling Blower 3. Retard Grid Assembly 4. AC Propulsion Motors B. Test equipment needed to fully test AC system 1. One PTU (Portable Test Unit, Laptop Computer, RS232 serial cable with male DB9 connector). (The checkout would more efficiently be conducted with two PTU’s) 2. Vehicle wiring schematic.

3. One 5000 Volt Megger 4. Several jumper wires 5. One Multi-Meter C. Portable Test Unit (PTU) is used to test, download and record system parameters on the SIBAS panel.

1. The PTU can be plugged into the DB9 port – “Diag.3” in the Diagnostic Test Center.

(Which is located on the back wall of operator cab the behind the passenger seat).

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2. The PTU can also be plugged into the DB9 port on the front side of the SIBAS Control Panel inside the control cabinet, upper section, closest to the operator cab.

WARNING: CHECK TO BE SURE LINK VOLTAGE IS DRAINED DOWN!!!! before performing test.

III.

Resistance Checks A. Preparation 1. Disconnect and insulate circuit wire 21PT1 from engine starter relay located in the battery control box.

2. Turn all (two) battery disconnects to the “OFF” position or remove the battery positive cables and insulate from the battery posts and ground. Note: that the 24VDC battery posts are bussed together in the battery control box and the battery box has only two sets of 8D batteries. This truck is started via the key switch and the computers on the truck become active after the engine is started.

3. Disconnect the XM1 power connector in the Auxiliary control cabinet. This will isolate the Siemens control system.

4. Turn key switch to “OFF” position.

5. Turn all lights and switches off.

B. In the Auxiliary cabinet, measure for voltage of each circuit: 11 (insulated buss bar), 11 (TB34), 11B1 (standoff insulator); 712 (TB34), 11S (TB30), 11SP (TB43), 71 (TB34), 11ST (battery disconnect box). All voltages should be zero.

C. Check the resistance with a Fluke meter, from ground to the following points. All points should register some resistance value from a few ohms to infinity. All circuits and circuit breakers are turned off.

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1. 15SM1 on TB41, 15SM2 on TB42 2. 15RWS on TB21, 15LWS on TB21 3. 11SP on TB43 4. 11S on TB30 5. 11INT on TB38 6. 15PV on TB29 7. 10V1 on TB25, 10V2 on TB23, 10V3 on TB43 8. 12V on TB37 9. 24VIM on TB47 10. 5VIM on TB31

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11. 85 on TB37 Note: All circuits should show some resistance from a few ohms to K Ohms. STOP and troubleshoot any direct short (00 ohms) to ground.

D. Restore circuits to original form, making sure key switch is put to off position.

E. Diode polarity visual inspection â&#x20AC;&#x201C; A/C System 1. Necessary to avoid damage to the A/C system digital I/O cards from possible high currents caused by diodes being connected backwards.

2. Verify that the diodes are installed identically on the relay and diode boards in the auxiliary control cabinet. Check the diodes in the brake cabinet. The negative or cathode end of the diode can be identified by the while band at that end. This should be a visual check with the negative (band) connected to the power circuit, when the diodes are connected across a coil or solenoid.

DIODE LOCATION AUTO APPLY SOLENOID KEY SWITCH SIGNAL DIODES STEERING BLEED DOWN SOLENOID PARK BRAKE SOLENOID 12 V POWER RELAY CONTROL POWER RELAY KEY SWITCH POWER RELAY IV.

DIODE CIRCUIT DR3

I/O

NEGATIVE CKT & LOC 52PBO JB4C

POSITIVE CKT & LOC 52ABA JB4F

712M TB34-B

712K TB37-B

D45, D46

PARK BRK RLY-1 RB6-K8 KEYSWITCH

D26

RB7-K1

33J TB27-E

33JB TB47-F

DR1

71BC JB4E

52CS JB4D

12VPRD

PRK BRK RELAY RB6-K8 712 POWER

712 12VPR-86

0 12PR-85

CPRD

SIBAS CN1XA-25

11SP CPR-86

0 CPR-85

KSPRD

START COMMAND

712M KSPR-86

0 KSPR-85

Megger Preparation and Testing

WARNING: CHECK TO BE SURE LINK VOLTAGE IS DRAINED DOWN, before performing test!!!!

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A. Safety Measures

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1. Truck and test personnel should be in a clean, dry area, free from explosive fumes and dust.

2. Area around truck should be roped off with appropriate Megger voltage signs visible to personnel approaching area from ten feet away.

3. Truck frame should be grounded.

4. Insulating gloves should be worn by people applying the high voltage.

5. Personnel conducting test must not touch any components or wiring in the box while voltage is applied.

6. Any circuits that are disconnected must be insulated from any other circuits and from ground.

7. After the Megger test, discharge the circuit that was tested to discharge any capacitive charge that may have occurred: Use high voltage gloves and hot stick to discharge link.

CAUTION: Megger Test can charge up link capacitors (Discharging link is from (+) link bus to (-) link bus) (WARNING: Link Voltage can be hazardous).

B. General Test Instructions The following instructions will help obtain accurate readings using battery powered, digital Megger insulation test instruments.

1. The black lead with the alligator clip should be connected to the circuit to be tested, with the red probe held to vehicle chassis ground. This procedure is per standard testing instructions.

2. Use the lowest range possible to make the test, and record the resistance reading.

This will require starting with a low range test, then changing to a higher range if the reading is not within the range selected. This procedure is the only way to get an accurate reading. A reading at a higher range will affect accuracy.

XB1656

3. If 500 volt Megger is not available, a current limited Megger rated 1500 volts max at 2 MA max should be used. (NOTE: Link and capacitors will charge to the test equipmentâ&#x20AC;&#x2122;s potential voltage).

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 8 of 11

4. After initiating the 500 volts to begin the test, the operator MUST wait until either, the meter reading stabilizes, or if it continues to change, two minutes have elapsed, before reading and recording the results. Under certain conditions, the reading may tend to continue to increase. This is normal. The two-minute time period is a selected value that was agreed to, by all interested parties.

5. The resistance of insulating materials decreases rapidly with an increase in temperature. To make reliable comparisons between readings, they should be corrected to a base temperature, such as 25C (77F). When recording insulation resistance readings, be sure to record the temperature as well.

C. Megger test preparation (NOTE: Before performing this test, verify the motor cables in the rear axle box are insulated).

1. Turn off the truck battery disconnect switches 2. Remove the following wire from the engine start relay. Tape back, insulate, and leave this wire off until the engine is ready to be started (Note: Engine start relay is located in battery control box).

•

QSK – 21PT1.

3. Put the HVDC power-off switch (REST) in the activated position.

(Located – Operator Cab dash panel, lower right.)

4. Megger test preparation (NOTE: Before performing this test, verify the motor cables in the rear axle box are insulated).

D. Megger Test (CAUTION: Use high voltage gloves and a hot stick to short the link to ground before performing step 1 and again between steps 1 and 2).

1.

V.

Go to “Siemens Commissioning Procedure” and start the section on “Power Cable Insulation Test” and complete this procedure. (Starting on page 3.)

Control System Checkout WARNING: CHECK TO BE SURE LINK VOLTAGE IS DRAINED OFF!!! before performing test.

NOTE: Verify that the key switch is in the off position.

XB1656

A. Verify that circuit 21PT1 is disconnected and insulate from engine start relay is located in the battery control box on the left front platform. This will prevent the engine from starting while checkout testing is being done.

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 9 of 11

B. Turn on battery disconnects, make sure the engine emergency shutdown switch (in the Operator cab) is in the “Run” position (switch pushed down), all Relay Board circuit breakersON, and all power fuses in the Auxillary Cabinet - fuse panels are “active”.

C. With the headlight switch in the “OFF” position, the Selector switch in the “Park” position, only the following dash light Switches will be lighted: Headlight Switch, Ladder light switch, Fog light switch, and Hazard light switch.

D. Switch “On” the Head light switch to the running light position (first position). Verify that the Running/Clearance lights, Tail lights, Instrument Panel lights, and on the Center consol the lights for the Selector switch, Engine shutdown switch and Reset switch are lighted.

E. Turn on the Key switch, the following dash panel switches are lighted: Headlight switch, Ladder light switch, Manual Backup switch, Fog light switch, Display Mode Control switches 2 & 1, Speed control switch, Traction Control – Off switch, Grid Dry switch, High Voltage DC (Rest) switch and Hazard light switch are lighted.

Move the Selector switch from “Park” to Neutral or Forward position, the Brake Lock switch should now be lighted along with the other switches listed above.

F. Verify the panel light dimmer can adjust the instrument display panel brightness.

G. Turn the Headlight switch to the headlight position (last/top position). The Low beam head lights in the lower and upper grill should turn on. NOTE: Hi-beam-On indicator in dash panel should not be illuminated.

H. Move the “Combo” signal, headlight lever on the steering column to the High beam position.

The Low beam headlights should remain on and the Hi-beam headlights should come on.

NOTE: The Hi-beam-On indicator in dash should be illuminated.

Turn the “Combo switch lever to the Right and Left turn signal positions and verify that the Clearance lights on the decks, dump body and on the instrument panel flash properly.

I. Adjust the operator cab window positions with the switches on the Selector switch console.

J. Turn the Ladder light switch On and Off, from inside the operator cab and at the foot of the ladder. The two platform lights (if installed), the diagonal ladder light and the deck light, should be illuminated.

K. Turn on and off the fog light switch. The front fog lights should turn on and off (Trucks may have optional front and rear axle fog lights).

XB1656

L. At the left & right front frame rail, turn on & off the engine service lights. The engine service lights can be turned on or off from either side.

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 10 of 11

M. Check the horn for proper operation.

N. Check cigarette lighter for proper operation.

O. Shift the Selector switch to the Reverse position, the Back-up horns and the Manual backup lights should operate. Move the Selector switch to Neutral or Forward position and the Backup horns and light should turn off.

P. Turn all switches off, put Selector switch in the Park position, turn key switch to the OFF position. All lights should be off.

Q. Return to the “Siemens IGBT Commissioning Procedure” – section “24 Volt Check” beginning on page 4. Continue testing according to this procedure until reaching the section “Start Engine and Verify Engine Speed Control”.

(At this point, restore 21PT1 wiring to engine start relay located in battery compartment).

Continue to follow the Siemens Truck Commissioning Procedure until completing the section “Start Engine and Verify Speed Control”. Stop and proceed to next section of this procedure.

VI.

IM System Checkout A. Connect the PTU (laptop computer) to the Operator Cab – IM diagnostic port (DIAG 5). Verify that the latest software configuration has been loaded into the Interface Module (IM) and that it is the current software.

B. Review the IM system error code report and resolve all reported faults.

VII.

Drive System Initial Checkout A. Return to the “Siemens Truck Commissioning Procedure” and complete the following Sections of this procedure: 1. Charging Up the DC bus.

2. Main blower, Water Pump, and Grid Box Fan rotation check.

(At this stage of the truck checkout procedure, the hydraulic system should be setup before proceeding to the load box horsepower testing of the drive system.)

VIII.

Hydraulic System Checkout. (See Procedure – Check-out Group) A. Complete Checkout Procedure of the hydraulic system per the vehicle specific procedure.

Drive system checkout. (Continuation of Section VII.) Return to “Siemens Truck Commissioning Procedure”.

XB1656

IX.

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 11 of 11

A. Complete section â&#x20AC;&#x201C; Engine self-load test.

B. Reset the fault codes on all systems before releasing the unit for operation.

XB1656

NOTES:

STANDARD TORQUE CHARTS AND CONVERSION TABLES This manual prov ides U. S. s tandard an d m etric (S I) 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 t ables, standard c onversion f actors f or m ost commonly us ed m easurements are provided i n Table XIII.

Komatsu d oes not rec ommend t he use of s pecial friction-reducing lubricants, such as Coppe r Co at, Never-Seez®, an d ot her s imilar products, on t he threads of s tandard f asteners whe re standard t orque values are applied. The use of special friction-reducing lubricants wi ll s ignificantly al ter t he c lamping f orce 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 lb to N•m) Table IX . . . Torque Conversions (ft lb 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 s tandard t orque values l isted, these standard torque values are to be u sed with simple lithium base chassis g rease (m ulti-purpose EP NL GI) or a rustpreventive grease (see list, page A5-2) on the threads and seats unless specified otherwise.

Verify t hreads and tapped hol es 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 s pecial f riction-reducing l ubricants are us ed, excessive s tress and possible break age of t he fasteners may result.

TORQUE GRADE 8 N•m

ft lbs

0.97

9.5

10

1.11

10.8

11

Grade 8

TORQUE GRADE 5

TORQUE 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

ft lbs

kg•m

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 Cap Screws (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.

• Cap s crew threads and seats s hall be l ubricated when assembled.

• Capscrew threads and seats shall not be lubricated when as sembled. T hese specifications are b ased on al l c apscrews, nut s, and hardened was hers 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 NLG I) or a rus t prev entive greas e (s ee l ist, this page) on the threads.

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

• The m aximum torque t olerance s hall be ±10% of the torque value shown.

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

NOTE: I f zinc-plated hardware i s used, e ach pi ece must be lubricated with s imple l ithium bas e c hassis grease (multi-purpose E P NLGI) or a r ust prev entive grease (s ee l ist, t his page) t o ac hieve t he s ame clamping forces provided below.

• Torques a re calculated to give a c lamping force of approximately 75% of proof load.

• The m aximum t orque t olerance s hall be wi thin ±10% of the torque value shown.

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*

0.500 -13

105

142

14.5

M12 x 1.75

0.562 - 12

150

203

20.7

M14 x 2

TORQUE N•m

TORQUE ft lbs

TORQUE kg•m

12

9

1.22

30

22

3.06

55

40

5.61

95

70

9.69

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

1.125 - 12

1330

1800

184

1.250 - 7

1715

2325

237

1.250 - 12

1840

2495

254

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, P roduct No. 667 05 from M obil Oi l Corporation.

• Rust Ban 326 from Humble Oil Company.

• Rustolene B Grease from Sinclair Oil Co. • Rust P reventive Grea se - Code 312 f Southwest Grease and Oil Company.

rom t he

NOTE: T his l ist represents the c urrent en gineering approved sources for use in Komatsu manufacture. It is not ex clusive. Ot her products m ay m eet t he 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 bs

l0

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 bs

l0

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. s sq. ft. –

ft2

To Convert From

TO

mile – mi.

0.6210

2

sq. in. – in.

0.1550

2

2

q. 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

pound (force) – lbs in. lbs. (force)

psi (pressure)

kilopascals (kPa)

6.895

kilogram-meters (kg•m)

Newton meters (N•m)

9.807

psi (pressure)

megapascals (MPa)

0.007

kilopascals (kPa)

psi

0.1450

psi (pressure)

kilograms/cm2 (kg/cm2)

0.0704

megapascals (MPa)

psi

145.038

psi

14.2231

kilopascals (kPa)

98.068

ton

0.0011

ton (short)

kilogram (kg)

907.2

ton (short)

metric ton

0.0907

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

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 SYSTEM FLUSHING

Hydraulic System Flushing Procedure

When a new t ruck i s as sembled and t he engi ne i s started f or the v ery first t ime, t he hy draulic s ystem must be f lushed i mmediately t o rem ove c ontamination that may hav e been i ntroduced duri ng t he field assembly process. DO NOT start the eng ine u nless all flushing equipment is installed and read y for use.

The flushing procedure w ill h elp e liminate h armful contamination t hat may l ead t o premature pum p or valve failures. Starting the engine just one t ime without performing the flushing procedure may contaminate the hydraulic system.

Hoist system bypass blocks (PC3074), steering system f lushing hos e (XB5777) and f itting as sembly (XB7075) m ust be on-s ite bef ore or d uring f ield assembly, s o when t he truck is started f or t he f irst time, t he hy draulic s ystem c an be f lushed an d 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 i nch inside diameter an d m eet S AE 10 0R12 s pecifications.

1. If the tires are i nstalled on t he 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 t he engi ne and c learance f or turning t he f ront s pindles l ock to lock wi thout risk of collapsing the cribbing.

2. Inspect all hydraulic h oses to ens ure t hat t hey are properly routed and securely connected.

3. Ensure that both brake ac cumulators and bot h steering a ccumulators are prop erly precharged with nitrogen to 9 650 kPa (1,400 psi). Refer to the s hop m anual f or t he accumulator c harging procedure.

4. Confirm t hat t he steering pres sure is rel eased by t urning t he s teering whe el. N o s teering movement should occur.

5. If a ny f ault codes are di splayed, t roubleshoot the s ystem and repair the probl em before proceeding.

6. Install accurate pressure gau ges at t he following locations: • Pressure t est port “T P3” (4, F igure 1 6-1) on t he bleed down manifold - 35 000 kPa (5,000 psi).

• Pressure test po rt (1, F igure 16-2) f or t he front brake cooling circuit - 3 450 kPa (500 psi).

Hydraulic fluid escap ing u nder pressure can have sufficient force to enter a person's body by penetrating th e sk in an d cau se ser ious i njury, and p ossibly d eath, i f p roper m edical treatm ent by a p hysician familiar with this type of injury is not received immediately.

Before d isconnecting p ressure lines, r emoving fittings or replacing components in the hydraulic circuits, or installing test gauges, ALWAYS bleed down the steering and brake accumulators.

NOTE: T he hoi st cy linder bypass bl ocks shoul d b e saved f or pos sible us e l ater i n c ase t he hy draulic system needs t o be f lushed af ter a c omponent failure.

FAM1602 5/11

• Pressure t est port s (2) on bot h hi gh pres sure hoist filters - 24 000 kPa (3,500 psi).

• Pressure t est port (1, F igure 16-3) for the rear brake cooling circuits - 3 450 kPa (500 psi).

• Pressure test port “GPA” (2, Figure 16-4) located on the steering pump - 35 000 kPa (5,000 psi).

If any hydraulic pressure is detected on the pressure gauge installed at th e "TEST" port, there is residual oil p ressure i n the system . Do n ot loosen or remove any hydraulic hoses, fittings or components. T he steering accu mulators h ave not been properly depressurized. Locate and correct th e depressurization p roblem. Al ways relieve all hydraulic p ressure before d isconnecting any hydraulic lines or fittings. Always tighten all co nnections sec urely b efore ap plying p ressure. Co nfirm th at the steer ing p ressure i s released by turning the steering wheel. No steering movement should occur.

Hydraulic System Flushing

F16-1

7. Ensure pres sure gau ge c onnected at " TP3" reads 0 kPa (0 psi) before removing plugs (1 & 2, Figure 16-1). Remove plugs (1 & 2) from the bleed down manifold. Connec t j umper hose assembly (X B5777) bet ween " QD s upply" port and t he "QD return" port on t he bl eed down manifold. T ighten al l c onnections securely before applying pressure.

9. Connect the four hoist cylinder hoses (3, Figure 16-2) t ogether a s shown us ing by pass bl ocks (4). T he hardware f or connecting t he ho ses t o the blocks is the same hardware for connecting the hoses to the hoist cylinders. Ensure that all of t he c onnections are secure. Cover al l op en ports to prevent contamination.

8. If the hydraulic tank has already been filled with oil, a vacuum pump (XB0887) must be installed on t he hydraulic t ank t o p revent oil s pillage before disconnecting any brake cooling hoses.

FIGURE 16-2. TEST PORT LOCATIONS AND HOIST FLUSHING HOOKUP 1. Test Port (Front Brake Cooling Circuit) 2. Test Port (Hoist Filters) 3. Hoist Cylinder Hoses 4. Bypass Blocks (PC3074)

FIGURE 16-1. BLEED DOWN MANIFOLD 4. Test Port (TP3) 1. Plug - QD Supply Port 5. Test Port (TP2) 2. Plug - QD Return Port 3. Bleed Down Manifold

F16-2

Hydraulic System Flushing

5/11 FAM1602

10. At the rear axle ho using, connect brake cooling l ines (1, 2 & 3, Figure 16-5) t ogether using fitting assembly (3, Figure 16-7). Cap the three open f ittings on t he ax le hous ing with clean caps. S everal hos e c lamps m ay hav e t o be removed to c onnect the t hree hos es to t he f itting assembly.

10. At the left front brake assembly, connect cooling hoses ( 1 & 3, F igure 16-6) t ogether using adapter (2). Ca p the open f ittings on t he brake assembly. A t t he ri ght f ront brak e a ssembly, connect t he t wo c ooling hos es t ogether us ing another a dapter. Ca p t he o pen f ittings on t he brake assembly.

NOTE: The adapters are installed on the truck when it is shipped from the factory.

11. The s teering pum p c ase m ust be f illed wi th oi l before startup to avoid pump da mage. Disconnect the hose that is connected to fitting (1, Figure 16-4). T hen rem ove f itting (1). F ill t he 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. Re-install fitting (1) and reconnect the hose.

NOTE: Fi lling t he s teering pump c ase w ith oil does not el iminate the n eed t o bl eed ai r f rom t he pum p suction line.

FIGURE 16-3. BRAKE COOLING MANIFOLD 1. Test Port (Rear Brake Cooling Pressure) 2. Test Port (Front Brake Supply Pressure) 3. Test Port (Front Brake Return Pressure) 4. Test Port (Hoist Return Pressure) 5. Test Port (Rear Brake Return Pressure)

FIGURE 16-4. STEERING PUMP & HOIST SYSTEM QUICK DISCONNECTS 1. Fitting (Pump Case Drain) 2. Test Port (GPA)

FAM1602 5/11

Hydraulic System Flushing

F16-3

12. If a vacuum pump was installed on the hydraulic tank, remove it after all of the hose connections are complete.

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

13. Fill the hy draulic t ank w ith clean t ype C -4 hydraulic oil. Ensure that the oil level is visible in the center of the upper sight glass.

14. To bleed trapped air from inside the pum p suction hos es, l oosen the cap s crews wh ere t he three suction hos es at tach t o t he i nlet of eac h pump. Ensure that the O-ring does not fall out of the groove. After oil app ears, retighten the cap screws to the standard torque.

FIGURE 16-6. FRONT WHEEL BRAKE LINES 1. Cooling Hose 2. Adapter (EG1794)

FIGURE 16-5. REAR AXLE BRAKE COOLING LINES 1. LBCR - Left Brake Cooling Return 2. BCS - Brake Cooling Supply 3. RBCR - Right Brake Cooling Return

F16-4

3. Cooling Hose 4. Brake Apply Hose

FIGURE 16-7. FITTING ASSEMBLY 1. 90° Swivel Elbow (PC3062) 2. T-Fitting (WB0426) 3. Fitting Assembly (XB7075)

Hydraulic System Flushing

5/11 FAM1602

Do not apply the b rakes o r tu rn th e steeri ng wheel at an y ti me d uring this p rocedure u ntil Step 29.

16. Ensure b oth brake ac cumulator bl eed do wn valves (1, Figure 16-8) are open.

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

18. Turn t he k ey switch ON but do not s tart t he engine. Verify that the low steering accumulator precharge warning is not displayed. If the warning is displayed, correct the problem before proceeding.

19. 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 readings are not correct, s top t he engine.

Locate and repair the problem before proceeding. If t he pressure readi ngs are correct, proceed to the next step. D o not turn the steering wheel or apply the brakes at this time.

Do n ot o perate th e e ngine at l ow idle fo r m ore than 30 seco nds. The steering pump pressure at test p ort " GPA" must b e at o r ab ove 1 725 kP a (250 p si) d uring the fl ushing process to p rovide adequate i nternal p ump l ubrication. S teering pump damage will result if the pressure is below 1 725 kPa (250 psi) for more than 30 seconds.

20. If t he oi l pres sure readings i n Step 19 are c orrect, i ncrease t he engine s peed t o obt ain oi l pressure at t est po rt " GPA" of 1 725 k Pa ( 250 psi). Move the hoist control lever to the POWER UP or t o t he P OWER DOW N pos ition. T he pressure readings at the front brake cooling port (1, Figure 16-2) and rear brake cooling test port (1, Figure 1 6-3) should b e 0 kPa (0 psi). If the pressure is not 0 kPa (0 psi), the hoist valve piping (or pilot lines) may be connected incorrectly, or t he ho ist v alve c ould be defective. Correct the plumbing problem or replace the hoist valve and repeat this step.

• With t he engi ne at l ow i dle, and t he oi l t emp at 21° C (70° F), oi l pres sure at the hoi st f ilters should be approximately 552 kPa (80 psi) or less.

• Oil pressure at s teering pum p t est port "GPA" should be approximately 690 kPa (100 psi).

FIGURE 16-8. BRAKE MANIFOLD 1. Accumulator Bleed Down Valves 2. Brake Manifold

FAM1602 5/11

Hydraulic System Flushing

F16-5

21. If all pump pressures and brake cooling oil supply pressures are correct as stated in Steps 18 and 19, increase engine speed to 1500 rpm and flush t he s ystem f or 2 0 m inutes. Duri ng t his time, m ove t he hoist c ontrol l ever t o t he POWER UP pos ition for 30 s econds, and t hen move i t t o t he P OWER D OWN po sition f or 3 0 seconds. Repea t t his hoi st control c ycle five times. This p rocess will ca rry a ny system co ntaminants to the hydraulic filters.

Monitor the pres sure gauge s at t he f ront and rear brak e c ooling test ports du ring t his s tep.

The pressure readings should always be 0 kPa (0 ps i) when the hoist v alve i s in t he P OWER UP or P OWER DOWN pos itions, and approximately 345 kPa (50 p si) whi le i n t he HOLD or FLOAT positions.

22. When t he 20 m inute flushing proc ess is c omplete, t urn t he key switch t o t he OFF po sition and allow at least two minutes after the engine has s topped f or t he s teering ac cumulators t o completely depressurize.

23. Install a vacuum pump on t he hydraulic tank to prevent oil leakage before disconnecting hoses.

Remove the adap ters f rom both f ront whee l brake cooling hoses and re-connect the cooling hoses to the front brake assemblies.

24. Remove the tee fitting assembly from the three rear brake cooling hoses. Re-connect the three rear brake cooling hoses to the axle housing.

25. Check t he pres sure gauge c onnected t o t he "TP3" port on t he bl eed down m anifold. I f any pressure is still in the s ystem, t he b leed down process did not complete. Locate and repair the problem. If the pressure is 0 kPa (0 psi), remove the jumper hos e and f ittings installed in t he bleed down manifold. Install the two plugs (1 & 2, F igure 16-1) prev iously rem oved bac k i nto the bleed down manifold.

26. Remove the v acuum p ump f rom the hy draulic tank. Chec k the hy draulic tank oi l level. I f nec essary, add oil.

27. Close bot h b rake ac cumulator bl eed do wn valves (1, Figure 16-8).

28. To flush the accumulators, start the engine and operate t he engine unt il t he pres sure at t he "TP3" port on t he bl eed down m anifold i s approximately 21 200 k Pa (3, 075 ps i). This is the pressure where the steering pump unloader valve shifts and unloads the pump.

• If the accumulator pressure exceeds 21 546 kPa (3,125 p si), i mmediately t urn t he eng ine of f and open t he brak e accumulator bl eed down valves.

Refer t o S teering pum p pres sure c ontrol adjustments in t he s hop m anual, t hen repeat Step 27.

• If t he ac cumulator pres sure does not reac h 20 856 k Pa (3,025 psi), c heck f or f aults on t he instrument p anel. I f there i s a bl eed down fault active, locate and correct the problem. If no faults are ac tive, ref er t o S teering pum p pres sure control a djustments in the s hop m anual, then repeat Step 27.

29. When t he pressure gau ge c onnected to " TP3" reads approximately 21 200 kPa (3,075 psi): a. For the first time only through this step: • Leave the key switch in the ON position, and use the engi ne s hut down s witch on t he c enter console t o s top t he engi ne. (S tatus m essage A184 will be displayed.)

• After t he engi ne has stopped, c onfirm that steering accumulator bleed down does not occur, and that no bl eed down faults or any other faults are generated. b. The s econd an d s ubsequent t imes through this step: • Turn the key switch to the OFF position. Confirm that after the engi ne h as s topped t he steering accumulator bl eed d own pro cess begins.

Confirm t hat s tatus A 235 " Steering b leed i n process" i s d isplayed an d that the buzzer beeps one time.

• Confirm that accumulator bleed down c ompletes within two minutes. Also confirm that bleed down fault A236 " Steering bl eed f ault" or any ot her bleed down fault does not become ac tive. T he pressure ga uge at the bl eed d own m anifold pressure test port "TP3" will be 103 kPa (15 ps i) or less after a successful bleed down.

NOTE: Do not combine Step 27 with any other steps.

Do not appl y t he brak es or s teer t he t ruck duri ng Step 27.

F16-6

Hydraulic System Flushing

5/11 FAM1602

30. If Step 28-b results are s atisfactory, open bot h brake ac cumulator bl eed down v alves (1, F igure 16 - 8) on the brake m anifold to completely depressurize t he brak e a ccumulators. A fter al l hydraulic pres sure has been rel eased, c lose both ac cumulator bl eed down v alves. Repeat Steps 27 - 29 five times.

31. To f lush t he s teering s ystem, s tart the en gine.

Allow t he ac cumulators t o fully charge and t he steering pump to unload.

32. If the truck is sitting on c ribbing and no whe els are i nstalled, s kip t his s tep. I f t he t ires are installed, apply the service brake and move the directional c ontrol l ever t o neut ral. A pply t he wheel brake lock, t hen rel ease t he s ervice brakes. This wi ll rel ease t he parking b rake t o allow the front wheels to be steered.

33. Turn the s teering wh eel f ull l eft a nd t hen full right ten times.

34. If the truck was sitting on tires, apply the service brakes and move the directional control lever to the PARK po sition. T urn the wheel b rake l ock switch to OFF, then release the service brakes.

35. Turn t he k ey s witch t o the OF F pos ition. A llow at l east two m inutes af ter t he engine has stopped f or t he s teering ac cumulators t o c ompletely depressurize. The pressure gauge at the bleed down m anifold pres sure t est po rt " TP3" will be 103 kPa (15 psi) or less after a successful bleed down.

36. The hy draulic s ystem flushing proc edure has been completed. All hydraulic system high pressure filter elements must be replaced. a. A v acuum pum p c an be c onnected t o t he hydraulic t ank t o prevent oi l loss whi le changing the filters. b. Remove the hoi st and s teering hy draulic filter elements. Clean the housings and i nstall new filter elements. c. If installed, remove the vacuum pump.

FAM1602 5/11

37. Remove a ll pres sure gau ges and re-i nstall t he dust caps on all quick disconnect fittings.

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

39. Proceed t o t he s teering an d brak e s ystem checkout proc edures i n t he F ield Assembly Manual.

40. After t he s teering and b rake s ystem c heckout procedures are completed, rem ove hoist c ylinder bypass blocks (4, Figure 16-2) and c onnect the hoi st cylinder h oses t o t he hoist c ylinders.

Ensure t he hoses an d po rts are c lean to prevent contamination.

NOTE: Do not ex tend t he hoi st cylinders unt il t he body is installed.

41. To f lush t he s teering s ystem, s tart the en gine.

Allow t he ac cumulators t o fully charge and t he steering pump to unload.

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

43. Turn the k ey s witch t o t he OF F position a nd allow at least two m inutes after the engi ne has stopped f or t he s teering ac cumulators t o c ompletely depressurize. The pressure gauge at the bleed down m anifold pressure test port "TEST" will be 103 kPa (15 psi) or less after a successful bleed down.

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

45. The hy draulic s ystem flushing proc edure has been completed. All hydraulic system high pressure filter elements must be replaced. a. Close bot h hoi st pump suction l ine s hutoff valves and t he s teering pump suction l ine shutoff valve. b. Remove the hoi st and s teering hy draulic filter elements. Clean the housings and i nstall new filter elements. c. Open bot h hoist pum p suction l ine shutoff valves and t he s teering pump suction l ine shutoff valve.

Hydraulic System Flushing

F16-7

46. Remove al l pres sure gaug es and re-i nstall t he dust caps on all quick disconnect fittings.

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

48. Proceed t o t he s teering an d brak e s ystem checkout proc edures i n t he Field Assembly Manual.

49. After t he s teering and b rake s ystem c heckout procedures are completed, rem ove hoist c ylinder bypass blocks (3, Figure 16-3) and connect the hoist c ylinder hoses (2) t o the hoi st c ylinders. Ensure the hos es and ports are c lean t o prevent contamination.

NOTE: Do not ex tend t he hoi st cylinders unt il t he body is installed.

F16-8

Hydraulic System Flushing

5/11 FAM1602

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 860E-1K

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

Date of Inspection

Wheel Motor Traction Motor

CUSTOMER UNIT NUMBER

860E-1KT Service Meter Reading

Serial Numbers Location of Machine at Inspection

LH

RH RH

Wheel Motor Transmission Serial Numbers

LH

Distributor’s Name

Dump Body Manufacturer Komatsu

Other

Customer’s Name

Dump Body Style

Customer’s Address

KAC Area Service Manager Signature

Dump Body S/N Date

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation.

All four copies are to be distributed as shown below.

Send White Reports to

Manager of Technical Support Komatsu America Corp.

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

Send Canary Reports to

Manager of Field Assembly Komatsu America Corp.

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

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

Mark each item with the appropriate symbol as shown below.

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 1 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Inspection Around Machine 1

Parts

Visually inspect unit for loose parts and debris.

2

Hardware

Visually inspect unit for missing and/or loose mounting hardware.

3

Hoses and Cables

Visually inspect 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

Verify oil level is visible through upper sight glass with dump body down.

8

Anchor Pin

Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and properly tightened hardware.

9

Wheel Motors

Inspect oil specification and proper oil level.

10

Fuel Tank

Verify fuel tank mounting is secure and there are no fuel leaks.

11

Radiator

Inspect coolant fill level, cold temperature protection, and DCA additive.

Verify all ladders and handrails are secure and hardware is tight.

12

Decks and Ladders

Visually inspect installation of grid blower, rectifier assembly and control box for correct assembly of components and proper clamping, no loose contacts, no damaged or poorly crimped cables.

Inspect all wiring and connections in battery box and ensure there is no rubbing or chafing.

13

Verify battery mounting hardware is secure.

Battery

Verify electrolyte is at proper level and caps are securely installed.

Verify all battery terminals are secure.

14

Steering Components

Visually inspect installation of steering cylinders, tie rod, and accumulators per print.

15

Hydraulic Components

Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations to ensure all hardware is secure and there are no leaks.

Hardware Torque 1

Suspension

Verify front suspension mounting cap screws have been properly tightened per appropriate shop manual procedure.

Verify torque on front wheel nuts is at 1 166 ± 136 N·m (860 ± 100 ft lb).

2 Wheels (See Note below.)

Verify torque on rear inside wheel nuts and outer wheel nuts are 1 166 ± 136 N·m (860 ± 100 ft lb).

Verify torque on rear outside adapter ring is at 2 326 ± 136 N·m (1,715 ± 100 ft lb).

Verify torque on left rops beam cap screws is at 800 N·m (590 ft lb).

3

Rops

4

Center Beam

If equipped with trolley option, verify torque on center beam cap screws is 240 N·m (177 ft lb).

5

Cab

Verify torque on cab mounting cap screws is at 800 N·m (590 ft lb).

6

Wheel Motor

Verify torque on wheel motor to axle housing mounting cap screws is at 2 007 N·m (1,480 ft lb).

7

Tie Rod Clamp Nuts

Verify torque on tie rod clamp nuts is at 420 ± 42 N·m (310 ± 31 ft lb).

Verify torque on right cross beam cap screws is at 240 N·m (177 ft lb).

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

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 2 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Cab Compartment 1

Cab Doors

Verify doors open and close smoothly and latch works properly.

2

Cab Windows

Verify windows can be opened and closed smoothly.

3

Door Locks

4

Interior

5

Document Holder

6

Cab Seats

7

Steering Wheel

8

Wiper

9 10

Verify left and right door locks work properly with key.

Visually inspect interior for completeness of assembly.

Visually inspect for cracked glass, torn upholstery, dirt, stains, holes, etc.

Verify O&M manual and safety manual are in the holder.

Inspect operatorâ&#x20AC;&#x2122;s seat adjustments.

Inspect seat belts and tethers for proper installation.

Check tilt and telescoping functions.

Verify adjustable lever can be locked securely.

Verify wiper functions at all speeds and range does not extend beyond glass surface.

Verify windshield washer functions properly and washer fluid bottle is full.

Cigarette Lighter

Check lighter operation, should pop out after 10 seconds and be hot.

Horn

Check for proper sound and no looseness in horn button.

11

Backup Horn

Check for proper sound and function.

12

Shift Lever

Check for proper function and no binding or looseness.

13

Gauges

Verify gauges are installed straight and operating correctly.

14

Hydraulic Fittings

Visually inspect all hydraulic fittings under cab and hydraulic brake cabinet for leaks. If equipped, inspect all pantograph fittings for leaks.

15

Hoist

Check operation of hoist lever in all four positions.

1

Dome Light

Verify dome light operates properly.

2

Dimmer Switch

Lights Verify dimmer operates properly.

Verify all headlights (high and low beams) and fog lights are functional.

3

Headlights/Fog Lights

Verify high beam indicators on instrument panel are functional.

Verify lights are at proper angle.

Visually inspect front and rear turn signal operation on left and right sides.

4

Turn Signal

Verify turn signal indicators on instrument panel operate properly.

Verify switch turns off after turn is completed.

Verify flasher operates properly.

5

Hazard Flashers

6

Backup Light

Verify backup lights operate properly when shift lever is in REVERSE.

7

Manual Backup Light

Verify switch and light function properly.

8

Service Brake

Verify service brake lights and indicator operate properly.

9

Retarder Lights

Verify retarder lights operate properly.

CEAW005902

Verify hazard indicator on instrument panel operates properly.

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 3 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Service Inspection 1

Hydraulic System

Perform hydraulic flushing procedure at initial start up.

Front suspension oiling height is 25.4 mm (1 in.).

2

Suspensions

Rear suspension oiling height is 54.0 mm (2.1 in.).

(See Note below.)

Front charging height is 229 mm (9.01 in.) at 3 365 kPa (488 psi).

Rear charging height is 270 mm (10.63 in.) at 1 467 kPa (213 psi).

3

Accumulators

Verify nitrogen charge in both steering and brake accumulators is at 9 653 kPa (1,400 psi).

(Charging pressure will vary with ambient temperature. Refer to chart in shop manual.)

4

Engine Prelube

Ensure prelube is functional prior to engine startup.

5

Engine Starting

Ensure engine starts easily.

6

Engine Noise

Verify there is no abnormal noise from engine.

7

Brake Lock

Verify when switch is ON and shift lever is in NEUTRAL, brake is applied and indicator is ON.

8

Parking Brake

Verify when shift lever is in PARK, parking brake is applied and indicator is ON. Verify with pedal depressed, front brake pressure (BF) is 17 235 ± 517 kPa (2,500 ± 75 psi).

9

Brake Pressures

Verify with pedal depressed, rear brake pressure (BR) is 17 235 ± 517 kPa (2,500 ± 75 psi).

Verify brake lock pressure is 13 790 ± 689 kPa (2,000 ± 100 psi).

Verify parking brake release pressure is 11 480 ± 1 275 kPa (1,665 ± 185 psi).

10

Verify steering wheel turns smoothly from lock to lock.

Steering

Verify steering system is free of noise and vibrations.

Verify POWER UP relief pressure is 17 237 kPa (2,500 psi).

Verify POWER DOWN relief pressure is 10 340 kPa (1,500 psi).

11

Verify hoist limit switch is operational and set correctly. (Measure on hoist cylinder 3rd stage.

Cylinder should stop 152 mm (6 in.) before full extension.)

Hoist

Verify hoist HOLD position operates properly.

Verify there is no heavy shock when dump body returns to frame in FLOAT. POWER UP with loaded dump body is 20-24 seconds.

12

Hoist Times

POWER DOWN with empty dump body is 13-15 seconds.

FLOAT to frame with empty dump body is 22-26 seconds.

Ensure body up switch activates body up alarm and indicator.

Ensure automatic lubrication system is serviced, tank is full and air is purged from system.

13

Lubrication

14

Payload Meter

Calibrate and check payload meter operation per shop/O&M manual instructions.

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 dump body is shimmed correctly prior to truck release.

18

Electrical Checks

19

IM Programming

Ensure automatic lubrication system is operating properly and timer is set as desired.

Ensure electrical checkout procedure has been completed and signed off.

(See appropriate field assembly manual or shop manual for procedure.)

Ensure IM is programmed with its own unique configuration file and copy of file is saved.

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

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 4 of 5

ADDITIONAL COMMENTS ________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly 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 860E-1K

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

Date of Inspection

Wheel Motor Traction Motor

CUSTOMER UNIT NUMBER

860E-1KT 960E-1K Service Meter Reading

Serial Numbers Location of Machine at Inspection

LH

RH RH

Wheel Motor Transmission Serial Numbers

LH

Distributor’s Name

Dump Body Manufacturer Komatsu

Other

Customer’s Name

Dump Body Style

Customer’s Address

KAC Area Service Manager Signature

Dump Body S/N Date

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Send white reports to:

Manager of Technical Support Komatsu America Corp.

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

Send canary reports to:

Manager of Field Assembly Komatsu America Corp.

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

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

CEAW006003

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 4

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 in P

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

Control Cabinet

Verify the coolant fill level inside the control cabinet.

11

Steering Components

Verify proper installation of the steering cylinders, tie rod, and accumulators.

12

Hydraulic Components

Visually inspect the hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations. All hardware must be secure, and no leaks evident.

13

Leakage

Visually inspect the entire machine for leaks.

Hardware Torque 1

Steering Arm to Front Suspension

Verify hardware torque is 2 705 N·m (1,995 ft lb).

2

Steering Cylinder To Frame

Verify hardware torque is 1 017 N·m (750 ft lb).

3

Steering Cylinder to Steering Arm

Verify hardware torque is 1 017 N·m (750 ft lb).

4

Tie Rod Pin Retainer

Verify hardware torque is 1 017 N·m (750 ft lb).

5

Tie Rod Clamp Nuts

Verify hardware torque is 420 ± 42 N·m (310 ± 31 ft lb).

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.

CEAW006003

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 4

No.

Inspection Item

As Found Condition

Acceptance Procedures

Corrective Action

Service Inspection Front suspension oiling height is 25.4 mm (1 in.).

Suspensions 860E-1K 860E-1KT

Rear suspension oiling height is 54.0 mm (2.1 in.).

Front charging height is 229 mm (9.01 in.) at 3 365 kPa (488 psi).

Rear charging height is 270 mm (10.63 in.) at 1 469 kPa (213 psi).

Front suspension oiling height is 25.4 mm (1 in.).

1

Rear suspension oiling height is 53.0 mm (2.1 in.).

Suspensions 960E-1K

Front charging height is 219 mm (8.62 in.) at 3 282 kPa (476 psi).

Rear charging height is 218 mm (8.60 in.) at 1 351 kPa (196 psi).

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

2

Accumulators

3

Steering

Verify the nitrogen charge in both steering and brake accumulators is at 9 653 kPa (1,400 psi).

(Charging pressure will vary with ambient temperature.

Refer to the chart in the shop manual.)

Verify the steering system is operating smoothly while turning from lock to lock.

Verify the steering system is free of noise and vibration.

4

5

Ensure the automatic lubrication system contains no air and is filled to the proper level.

Lubrication

Ensure the automatic lubrication system is operating properly and the timer is set as desired.

Hydraulic Filters

Verify the 50 hour change of all hydraulic filters has been completed.

NOTE: Elements are supplied from the factory in the parts crate.

Pressure

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

Komatsu Drive & Control System Komatsu Rotating Components

9

(Wheel Motors, Main Traction Alternator, Grid Blower)

10

VHMS

CEAW006003

Size Manufacturer

Check drive control system operation per O&M manual.

Troubleshoot, correct and delete any error codes.

Visually inspect wheel motor armature condition.

Visually main traction alternator condition.

Inspect grid blower motor armature condition.

Verify VHMS is functioning properly per O&M manual.

Troubleshoot and repair any problems.

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 4

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:______________________________________________________________

__________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW006003

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 4

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