KOMATSU 960E-1K DUMP TRUCK FIELD ASSEMBLY MANUAL - PDF

CEAW006500

Field Assembly Manual

DUMP TRUCK SERIAL NUMBERS

A50003 & UP

®

FOREWORD This manual is provided to aid assemblers during field assembly of the standard Komatsu 960E-1K dump truck.

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

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

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

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

It is recommended that all maintenance personnel read and understand the materials in the service manual before performing maintenance and/or operational checks on the assembled truck.

FAM0020

Introduction

i

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

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

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

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

ii

Introduction

FAM0020

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

FAM0020

Introduction

iii

81970

KOMATSU 960E-1K

iv

Introduction

FAM0020

SAFETY RULES, TOOLS & EQUIPMENT SAFETY RULES The following list of safety practices is intended for use by personnel during field assembly of the truck.

This list of safety rules is not intended to replace local safety rules or regulations and federal, state, or local laws. The safety precautions recommended here are general and must be used in conjunction with all prevailing local rules and regulations.

1. All personnel must be properly trained for the assembly process.

2. Wear safety equipment such as safety glasses, hard toe shoes and hard hats at all times during assembly.

3. Thoroughly inspect the assembly site. Remove weeds, debris and other flammable material.

4. Use only solid, hard wood for supports. When using metal support stands, place wood blocks between the support and the frame to prevent metal to metal contact.

5. Inspect all lifting devices. Refer to the manufacturer's specifications for correct capacities and safety procedures when lifting components.

6. Perform a daily inspection of all lifting cables and chains. Replace any questionable items. Use cables and chains that are properly rated for the load to be lifted.

7. DO NOT stand beneath a suspended load. Use of guy ropes are recommended for guiding and positioning a suspended load.

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

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

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

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

12. DO NOT weld the fuel tank or hydraulic tank unless the tanks have been properly purged and ventilated.

13. Use the proper tools for the job to be performed.

Never improvise wrenches, screw drivers, sockets, etc. unless specified.

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

15. When the weight of any component(s) or any assembly procedure is not known, contact your customer support manager for further information.

BODY-UP RETENTION CABLE

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

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

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

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

FAM0113 2/11

Safety Rules, Tools, & Equipment

Page 1-1

TOOLS AND EQUIPMENT FOR ASSEMBLY The following equipment is recommended for field assembly of the truck.

12. Two, ratchet pullers - 2.7 metric ton (3 ton) 1. Equipment and tool storage trailer with a lockable door. Approximately 12 x 2.5 m (40 x 8 ft) 2. Cranes a. Two, 45 metric ton (50 ton) cranes to remove the chassis from the freight trailer and place on cribbing. These cranes can also be used to lift the assembled body onto to the chassis. b. One, 109-136 metric tons (120-150 ton) crane.

The crane is needed to turn the body over after completion of the underside welding. A 45 metric ton (50 ton) crane is also required for this task.

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

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

5. One, propane torches for weld preheating.

6. Portable air compressor - 3.5 cmm (125 cfm) and 690 kPa (100 psi) capacity.

Two, 15 m (50 ft) air hoses.

7. Metal stands and a sufficient amount of wood cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm (14 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm (4 ft. x 6 in. x 6 in.) - such as railway cross ties

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

• Thread taps and dies of both inch and metric sizes.

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

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

• Torque wrenches - 339 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 3/8 in. (Snap-On p/n X440B) with 12 inch extension to tighten ROPS cap screws.

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

15. Heavy duty 3/4 in. & 1 in. square drive impact wrench sets.

16. Impact sockets for 3/4 in. & 1 in. square drive tools.

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, hydraulic or pneumatic porta-power jacks, 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 Two, 4 point slings, 2 m (6 ft) in length

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

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

23. Pry bars

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

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

2/11 FAM0113

LIFTING SLING GENERAL INFORMATION

FAM0113 2/11

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

EH8687 (No longer available as complete unit)

Roller Assy.

Power Module Remove & Install

EH8681

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

2/11 FAM0113

FAM0113 2/11

Part Number

Description

PC1980

Offset Box End Wrench - 1 11/16�

Use Cab Mounting & Miscellaneous

Part Number

Description

BF4117

Seal Installation Tool

Front and Rear Disc Brake Floating Ring Seal Installation

ED3347

Seal Installation Tool

Rear Axle/ Hub Adapter Floating Ring Seal Installation

Part Number

Description

EK5877

Sleeve Alignment Tool

Safety Rules, Tools, & Equipment

Use

Use Steering Linkage and Tie Rod Assembly

Page 1-5

Part Number

Description

EM3708 (Rear)

Wear Indicator

EM1275 (Front) EB1723

Cap, Indicator

EM3707 (Rear)

Pin, Indicator

Use Brake Disc Wear Inspection

EM1274 (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 A/C Belt Tool Alignment

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Use Payload Meter Download

Safety Rules, Tools, & Equipment

2/11 FAM0113

FAM0113 2/11

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

PC2228

3/4 in. Square Drive Wrench

Miscellaneous

Part Number

Description

Use

WA4826

Lifting Eye Bolt

Miscellaneous

Part Number

Description

Use

PC2660

Sling

Body Retention

Part Number

Description

Use

PC0367

Shackle

Body Retention Miscellaneous

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Safety Rules, Tools, & Equipment

2/11 FAM0113

Part Number

Description

Use

EK6089

Brake Assembly Tool Group (Front)

Brake Assembly & Disassembly

EK6090

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

HYDRAULIC SYSTEM VACUUM PUMP Part Number XB0887

FAM0113 2/11

Safety Rules, Tools, & Equipment

Description

Use

Vacuum Pump

To hold oil back while the system is open

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Safety Rules, Tools, & Equipment

2/11 FAM0113

FAM0113 2/11

Safety Rules, Tools, & Equipment

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NOTES

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Safety Rules, Tools, & Equipment

2/11 FAM0113

TRUCK COMPONENTS & SPECIFICATIONS MAJOR COMPONENT DESCRIPTIONS

Operator's Cab

Truck And Engine

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

The 960E-1K dump truck is an off-highway, rear dump truck with AC electric drive. The gross vehicle weight is 576,062 kg (1,270,000 lbs). The engine is a Komatsu SSDA18V170 rated @ 2611 kW (3500 hp).

Main Alternator The diesel engine drives an in-line alternator at engine speed. The alternator produces AC current which is rectified to DC within the main control cabinet. The rectified DC power is converted back to AC by groups of devices called "inverters", which are also within the main control cabinet. Each inverter consists of six phase modules under the control of a gate driver power converter (GDPC). The two GDPCs control the operation of each phase module.

Each phase module contains paired positive and negative semiconductor switches referred to as insulated gate bipolar transistors (IGBT). The IGBTs cycle on and off at varying frequencies to create an AC power signal from the DC supply.

The AC power signal produced by each inverter is a variable-voltage, variable-frequency (VVVF) signal.

Frequency and voltage are changed to suit the operating conditions.

Cooling air for the control/power group and wheel 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 energy through built-in gear trains within the wheel motor assembly. The direction of the wheel motors is controlled by a directional control lever located on the center console.

Suspension Hydrair IIÂŽ suspension cylinders located at each wheel provide a smooth and comfortable ride for the operator and dampens shock loads to the chassis during loading and operation.

FAM0221

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

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

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

Brake System Service brakes at each wheel are oil-cooled multiple disc brakes applied by an all-hydraulic actuation system. Depressing the brake pedal actuates both front and rear brakes after first applying the retarder.

All wheel brakes will be applied automatically if the brake system pressure decreases below a preset minimum.

The parking brake is a dry disc type, mounted inboard on each rear wheel motor, and is springapplied and hydraulically-released with wheel speed application protection (will not apply with truck moving).

Truck Components And Specifications

Page 2-1

960E-1K MAJOR COMPONENTS Page 2-2

Truck Components And Specifications

FAM0221

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

ENGINE Komatsu SSDA18V170 No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke Rated Brake HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3500 HP (2611 kW) @ 1900 RPM Flywheel HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3429 HP (2558 kW) @ 1900 RPM Weight (Dry)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 300 kg (22,701 lb) * 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* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38.12:1 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* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 HP (4476 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 liters (90 gallons) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .799 liters (211 gallons) Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5300 liters (1400 gallons) Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325 liters (350 gallons) Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 liters (32 gallons) per wheel Inverter Cabinet Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 liters (7 gallons)

FAM0221

Truck Components And Specifications

Page 2-3

HYDRAULIC SYSTEMS Hoist and Brake Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931 L/min (246 gpm) @ 1900 RPM and 18,960 kPa (2750 psi) Steering/Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 20,685 kPa (3000 psi) Relief Pressure - Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18,960 kPa (2750 psi) Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27,580 kPa (4000 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103,729 cm² (16,078 in²) Maximum Apply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18,960 kPa (2750 psi)

STEERING Twin hydraulic cylinders with accumulator assist to provide constant rate steering Emergency power steering automatically provided by accumulators Turning Circle (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.9 m (104 ft. 8 in.)

TIRES Radial Tires (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53/80 R63 Rock Service, Deep Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flange mount rims

STANDARD DUMP BODY CAPACITIES AND DIMENSIONS Capacity Heaped @ 2:1 (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 m3 (313 yd3) Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 m3 (250 yd3) Width (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68 m (28 ft. 6 in.)

Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 m (10 ft. 7 in.)

Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 m (23 ft. 5 in.)

Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

WEIGHT DISTRIBUTION Empty Vehicle Front Axle (47%). . . . . . . . . . 117,845 kg (259,804 lb) Rear Axle (53 %) . . . . . . . . .130,885 kg (288,553 lb) Total (with 50% fuel) . . . . . . .248,730 kg (548,357 lb)

Loaded Vehicle Front Axle (35%) . . . . . . . . . 199,580 kg (440,000 lb) Rear Axle (65%) . . . . . . . . . 376,482 kg (830,000 lb) Total. . . . . . . . . . . . . . . . . . 576,482 kg (1,270,000 lb)

Standard Komatsu body . . . . . .30,362 kg (66,936 lb) Standard tire weight . . . . . . . . .26,127 kg (57,600 lb)

Nominal Payload* . . . . . . . . 327,332 kg (721,643 lb)

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Truck Components And Specifications

FAM0221

* Nominal payload is defined within Komatsu America Corporation’s payload policy documentation. Nominal payload must be adjusted if the weight of any customized body or tires vary from that of the standard Komatsu body and tires. Nominal payload must also be adjusted to take into account the additional weight of any custom/optional extras fitted to the truck which are not stated within the Standard Features list of the applicable specification sheet.

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Truck Components And Specifications

Page 2-5

NOTES

Page 2-6

Truck Components And Specifications

FAM0221

MAJOR COMPONENT WEIGHTS

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

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

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

ITEM

KILOGRAMS

POUNDS

CHASSIS Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 970 . . . . . . . . . . . . . . . . . . . . . . 6,548 Tire (56/80 R63). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500 Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,279 . . . . . . . . . . . . . . . . . . . . . 16,048 Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 177 . . . . . . . . . . . . . . . . . . . . . 64,324 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 056 . . . . . . . . . . . . . . . . . . . . . . 4,533

DECK AND DECK SUPPORT COMPONENTS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 268 . . . . . . . . . . . . . . . . . . . . . . 5,000 RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 076 . . . . . . . . . . . . . . . . . . . . . . 2,372 LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707 . . . . . . . . . . . . . . . . . . . . . . 1,559 Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 . . . . . . . . . . . . . . . . . . . . . . . .631 Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755 . . . . . . . . . . . . . . . . . . . . . . 1,665 Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 . . . . . . . . . . . . . . . . . . . . . . . .705 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

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Major Component Weights

Page 3-1

ITEM

KILOGRAMS

POUNDS

POWER MODULE Air Intake Ducts Wheel Motor Blower (upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 . . . . . . . . . . . . . . . . . . . . . . . . 117 Alternator Blower (upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 . . . . . . . . . . . . . . . . . . . . . . . . 102 Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955 . . . . . . . . . . . . . . . . . . . . . . .2,105 Air Cleaner Assembly Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 . . . . . . . . . . . . . . . . . . . . . . . . 193 Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340 Main Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 037 . . . . . . . . . . . . . . . . . . . . . . .2,285 Retarding Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 039 . . . . . . . . . . . . . . . . . . . . . . .6,700 Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 175 . . . . . . . . . . . . . . . . . . . . . . .7,000 Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690 . . . . . . . . . . . . . . . . . . . . . . .1,525 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 010 . . . . . . . . . . . . . . . . . . . . . . .8,842 Engine (Komatsu SSDA18V170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 300 . . . . . . . . . . . . . . . . . . . . . . 22,701 Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 100 . . . . . . . . . . . . . . . . . . . . . . .4,630

HYDRAULIC COMPONENTS Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 . . . . . . . . . . . . . . . . . . . . . . . . 380 Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .998 . . . . . . . . . . . . . . . . . . . . . . .2,200 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 . . . . . . . . . . . . . . . . . . . . . . . . 426 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .590 . . . . . . . . . . . . . . . . . . . . . . .1,300

FRONT AXLE COMPONENTS Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 460 . . . . . . . . . . . . . . . . . . . . . . .3,219 Spindle, Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 180 . . . . . . . . . . . . . . . . . . . . . . 11,420 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 . . . . . . . . . . . . . . . . . . . . . . . . 763 Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 255 . . . . . . . . . . . . . . . . . . . . . . .7,176

REAR AXLE COMPONENTS Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .913 . . . . . . . . . . . . . . . . . . . . . . .2,013 Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 . . . . . . . . . . . . . . . . . . . . . . . . 350 Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 . . . . . . . . . . . . . . . . . . . . . . . . 847 Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 825 . . . . . . . . . . . . . . . . . . . . . . 17,250 Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 . . . . . . . . . . . . . . . . . . . . . . . . 325 Wheel Motor & Rear Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 035 . . . . . . . . . . . . . . . . . . . . . . 46,375 Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326 . . . . . . . . . . . . . . . . . . . . . . . . 719

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Major Component Weights

FAM0318

FIELD WELDING FOR ASSEMBLY OR REPAIR When welding on Komatsu equipment, whether at initial field assembly or during normal maintenance repairs, special procedures must be followed.

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

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

WELD PROCEDURES Electric arc welding, either the semi-automatic “MIG” (GMAW), Flux Core (FCAW), or “Stick” electrode welding (SMAW), are approved processes for field installation and maintenance welding. Welding of highly stressed structural members such as castings, torque tubes, top and bottom plates on the frame rails, and the curved intersection points of frames should be done with the specific detailed instructions from Komatsu Product Service. See Annex A for repair procedures. These repair procedures are detailed instructions for most high stressed structural members.

APPROVED CONSUMABLES WELDER QUALIFICATION AND TRAINING

GMAW - LW102-15 or ER80S-D2

The welding technique must be of the highest standard to produce the soundest weld possible. Only welders who have been trained and qualified for structural steel welding in all positions, in conformance with the American Welding Society (AWS) D1.1 or (AWS) D14.3 only, are allowed to perform the welding. The welding instructions for field assembly of Komatsu components are normally provided by engineering drawings. Additional detailed welding instructions for field repairs are provided in the field repair manual SEB14001. A full understanding of the AWS standard welding symbols is necessary to perform and inspect such field welds. Weld sizes specified on the drawings are intended to reflect minimum requirements.

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

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

WELD QUALITY REQUIREMENTS 1. Each weld must be homogeneous with low porosity, free from cracks, and slag inclusions.

2. Each weld must have complete fusion between the base metal and weld metal added by the electrode.

3. All welds must be reasonably smooth, without excessive deformity, and all craters filled. No cracks are permitted.

4. The toe of a weld to a stressed member must have a smooth transition. Excessive convexity in multi-pass fillet welds is not permitted. Excessive convexity produces high residual stress in the throat of the weld, and is not permitted.

5. Undercut in excess of 0.8 mm (0.03 in.) on critical welds must be reworked by the application of welding an additional cover pass. It is important that this pass is blended with the existing weld.

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Field Welding For Assembly Or Repair

Page 4-1

6. When welding in the vertical position, always weld using the vertical up technique. Large wash weld weaves should not be used when welding on truck frames. Properly applied multiple pass welding is the required procedure on truck frames.

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

7. Slag is to be removed from all weld beads, and must be completely removed before each pass in a multiple pass procedure. It is also required that all slag is removed and tie in all areas.

Grind all welds where a weld crosses or intersects with another weld.

3. Weld Cooling - Protect the weld area from a rapid cooling rate. Heat retardation may be accomplished through the use of heat lamps, torches, insulating blankets, etc.

MATERIALS, CONTROLS, AND PRECAUTIONS The steel used in the fabrication of all Komatsu equipment is of high strength low alloy (HSLA) material of different grades. The standard dump body main plates are made from abrasion resistant materials. These materials offer themselves very well to welding during fabrication, and repair.

The welding consumables are often supplied by Komatsu America Corp. with the new equipment as part of the field welding / assembly package. For field welding and repairs, the approved consumables as detailed, should be procured from a local, reliable supplier. Other highly specialized welding consumables are available but have limited use on Komatsu structural components. Approval is required from your Komatsu customer support manager.

4. Moisture - Any moisture on the steel surfaces to be welded must be removed before welding.

Electrodes must be stored in sealed containers until needed. Electrodes must be kept in a warming oven at the work location until used to prevent any moisture absorption which might affect weld quality.

5. Foreign Materials - Any foreign substances (dirt, paint, rust, scale, and carbon deposits from cuttings) must be removed prior to welding. Clean all weld areas and surfaces with a grinder to ensure that all foreign materials have been removed.

WELD INSPECTION

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

All welding repairs are subject to inspection by a Komatsu appointed inspector or laboratory to insure quality. After the weld has been made it can be inspected by a number of non-destructive evaluation techniques. The inspections can include any of the methods listed below. All assembly welds and weld repairs that are deemed unacceptable by the inspector must be corrected at no additional cost to Komatsu. All weld repairs are also subject to additional inspection.

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

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

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

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Field Welding For Assembly Or Repair

FAM0407

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

3. Fluorescent Penetrant Inspection - Similar to dye penetrant inspection. This process uses a black (ultraviolet) light for increased efficiency and accuracy.

4. Magnetic Particle Inspection - This process requires special equipment that is usually more costly than the dye penetrant inspections. This process does not provide a permanent record except by normal photography.

5. Ultrasonic Inspection - This is a popular method of examining weld discontinuities. Specialized equipment and operator certification is required.

With some equipment printed data is available of the test providing a permanent record. Also, operator records with equipment settings and test results are normally recorded.

6. X-Ray Inspection - This process provides a view of the weld and base materials but it is highly specialized. This procedure provides a permanent visual record, but is more expensive than most other inspection techniques.

Komatsu requires record keeping of all welding work.

This information is valuable when personnel or job conditions change. The service and warranty departments of Komatsu must be provided with inspection reports and photographs of the weld area before, during, and after the repair. The photographs must be clear and close enough to show the weld joint preparation complete, with backer bars installed, etc. just prior to welding. These photos easily identify if the required preheating and post heating have been done with a three inch circumference around the weld repair area. Without this documentation, Komatsu will not cover any weld repair claim made under warranty. No exceptions will be made.

ANNEX A The following are general repair procedures, which must be followed for all repair and rework of major load carrying members on Komatsu equipment.

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

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

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

The depth of the V (or U shaped) joint will be determined by the depth of the crack. The width to depth ratio should be approximately 1.25:1 and never less than 1:1. All cracks through the parent material will require a slightly wider root opening than the original, usually 6 mm (0.25 in.) to allow the installation of a backup strip.

Backup strips are required for all cracks that have gone through the parent material and cannot be welded from both sides. If a weld repair allows access to both sides of the plate, no backup strip is required as long as complete weld penetration is achieved. If backup strips are not used, the surface profile on both sides must be ground smooth with no undercut. Documentation must support this repair. Photographs of surface condition are required by the service and warranty departments of Komatsu.

4. Use dye penetrant to ensure the cracks are completely removed.

5. After air arcing and inspections (Steps 3 & 4) all areas cut by the air arc should be cleaned thoroughly with a grinder to remove all possible carbon deposits and dye penetrant.

6. Fill gouges with weld and grind all surfaces smooth to avoid defects in the new weld.

7. Grind all surfaces to be welded so they are free of slag, rust, and any other foreign materials.

8. Preheat the entire weld joint area until the surrounding surface area reaches 150°C (300°F) at a distance of 76 mm (3 in.) from all areas to be welded.

Page 4-4

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

10. When the weld is complete, immediately (before the weldment cools) post heat the entire weld area to 150°C (300°F). Even if the area is over 150°C (300°F) heat must be applied to maintain this temperature for 15 minutes, and then allow it to cool slowly. In some cases this might require wrapping with insulation blankets.

11. Grind all butt-welded repairs smooth using 36 or finer grit grinding material. All grinding marks should be parallel to the direction of primary stress if possible (and if known).

12. Hammer peen the toes of repair fillet welds as detailed in Annex B, see attached.

13. Inspect repaired areas (for surface defects) using magnetic particle or dye penetrant inspection procedures.

14. If surface defects are found, remove all defects by grinding to a maximum depth of 1.5 mm (0.06 in.). Larger defects must be removed as per the above mentioned procedures. All spot welding also requires preheating and post heating.

Field Welding For Assembly Or Repair

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

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

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

3. Adequate air supply 4. Adequate lighting 5. Protective clothing, gloves, includes eye, face, and ear protection

Procedure 1. The toe of the weld should serve as a guide for the peening tool resulting in the area of deformation being approximately equally divided between the base material and the weld metal face to the specified depth and not to exceed 5 mm (0.19 in.) in width. Refer to Figure 4-1.

Procedure

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

1. The toe of the weld should serve as a guide for the burr tool resulting in the material removed being approximately equally divided between the base material and the weld metal face to the specified depth and not exceed 8 mm (0.31 in.) in width. Refer to Figure 4-2.

2. The weld must have a smooth profile and the toe must have a good transition to the parent material (no overlap) before the peening operation is performed. Grinding the weld face and toe area is permitted to correct unacceptable conditions. Visual inspection/acceptance is to be done after peening with the appropriate radius and depth gauge.

2. The weld must have a smooth profile and the toe must have a good transition to the parent material (no overlap) before the grinding operation is performed. Grinding the weld face and toe area is permitted to correct unacceptable conditions. Visual inspection/acceptance to be done after grinding with the appropriate radius and depth gauge.

3. Hold the hammer tool at approximately one half the included angle between the weld face and the parent material and perpendicular to the direction of travel. This will normally require approximately four passes of the peening tool with the pressure of near full operator weight being applied. The depth of the indentation must be between 0.6 mm to 0.8 mm (0.02 to 0.03 in.).

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

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FIGURE 4-1. TOE HAMMER PEENING

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FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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BIBLIOGRAPHY American Welding Society Bulletin No. D14.3-94/ D1.1 - Specification for Welding Earthmoving and Construction Equipment Metals and How to Weld Them - James F. Lincoln Arc Welding Foundation. Cleveland, Ohio Procedure Handbook of Arc Welding - Lincoln Electric Company, Cleveland, Ohio American Welding Society - Welding Handbook British Standard BS5135 - Metal Arc Welding of Carbon and Carbon-Manganese Steels Welding Steels Without Hydrogen Cracking - The Welding Institute, F. R. Coe, Author

SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK Prior to welding and/or repairing an AC drive truck, maintenance personnel should notify a Komatsu service representative. Only qualified personnel, specifically trained for servicing the AC drive system, should perform this service.

If it is necessary to perform welding or repair to the truck without the field engineer present, the following procedures should be followed to ensure that the truck is safe for maintenance personnel to work on and to reduce the chance for damage to equipment. .

Engine Shutdown Procedure Before Welding or Performing Maintenance Normal operation of the drive system at shutdown will leave the system safe to maintain. However, in the event of 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 of all the drive system status lights on the status indicator panel.

If any drive system warning messages are displayed, DO NOT attempt to open any cabinets, disconnect any cables, or reach inside the 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 all of the instructions for “Safe Parking Procedures.”

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

Verify that the green link voltage light is illuminated and the DC bus voltage gauge reads 0.0 V. Notify qualified drive system maintenance personnel if the green link voltage light remains off longer than five minutes after engine shutdown.

4. Locate the alternator cutoff switch in the front access panel on the left side of the main control cabinet. Place the CUTOFF switch in the ON 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 open any of the cabinet doors or 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 in the OFF position. Verify that the battery disconnects are functioning.

6. Leave the drive system in the rest mode until the truck is to be moved.

Before opening any cabinets, removing any covers, or touching a retarding grid element or power cable, the engine must be shut down and the green link voltage light must be illuminated.

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Performing

6. Power cables and wiring harnesses must be protected from weld spatter and heat.

1. Open the access panel at the right front side of the control cabinet. Verify that the green link voltage light is illuminated and the DC bus voltage gauge reads 0.0 V. Notify qualified drive system maintenance personnel if the green link voltage light remains off longer than five minutes after engine shutdown.

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

Precautions Before Maintenance

Welding

or

2. Locate the alternator cutoff switch access panel at the right front side of the control cabinet.

Place the CUTOFF switch in the ON position.

This will prevent the alternator from reenergizing and creating system voltage until the switch is returned to its former position.

3. Before doing any welding on the truck, always disconnect the battery charging alternator lead wire.

4. Do not weld on any drive system components! Consult your Komatsu service representative before attempting any welding procedures.

5. Power cables must be cleated in wood or other non-ferrous materials. DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Always inspect power cable insulation before servicing the cables and returning the truck to service. Discard cables with broken insulation.

Avoid laying welding cables over or near the truck electrical harnesses. Welding voltage could be induced into the electrical harness and cause damage to components.

Before welding on the truck, disconnect the battery charging alternator lead wire and isolate the electronic control components. Also, disconnect the negative and positive battery cables of the truck. Failure to do so may seriously damage the battery and electrical equipment.

Never allow welding current to pass through ball bearings, roller bearings, suspensions or hydraulic cylinders.

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

Leave all cabinet doors in place. Do not touch the retarding grid elements. Do not disconnect any power cables or use them as hand or foot holds.

Notify your Komatsu service representative immediately. Only qualified personnel who are specifically trained for servicing the AC drive system should perform this service.

8. After welding or maintenance is complete, install all covers and close all access doors.

Place the alternator cutout switch and battery disconnect switches in their original positions.

Reconnect all harnesses before starting the truck.

NOTE: Leave the drive system in the “rest� mode until the truck is to be moved.

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NOTES

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RECEIVING & ASSEMBLY PREPARATION Preparation

Color Coded Boxes

Inspection, Cleaning, Setup

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

1. Inspect all components for possible shipping damages. Note any damage found and report to shipping agent.

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

3. Install support blocks under the chassis. The support blocks must be approximately 84 cm (33 in.) high.

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

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

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

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

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

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

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

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

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

FIGURE 5-1. COLOR CODED BOXES

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Receiving & Assembly Preparation

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ASSEMBLY LAYOUT Page 5-2

Receiving & Assembly Preparation

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CHASSIS ASSEMBLY Due to differences in machine configurations and shipping restrictions/requirements throughout the world, the shipping and packaging of large machines varies. Photographs or illustrations used in the following procedures are provided as general guidelines only. Actual assembly may be different, but this general procedure provides a basic outline for assembly.

Items like the hydraulic tank and the accumulators may have been removed for shipping and will have to be locally installed.

Each shipment may be different, depending on the truck configuration and destination.

BASIC ASSEMBLY PROCEDURE 1. Site preparation 2. Unload truck components 3. Assemble the chassis 4. Weld the body NOTE: Chassis assembly and body welding may be done in either order, or simultaneously. The most logical order depends on available resources such as cranes, welders, assemblers, etc.

5. Static checkout (electrical & mechanical) 6. Hydraulic Flushing 7. Install the body

RECOMMENDED ASSEMBLY DATA

8. Dynamic checkout (electrical & mechanical) 9. Site cleanup

1. Service Report (Pre-Delivery) 2. Acknowledgement of Receipt of Company Warranty 3. Assembly Blueprints & Schematics 4. Fluid Specifications (refer to the lubrication chart in Section 10, Appendix) 5. Suspension Oiling & Charging Procedure (available in Section 10, Appendix) 6. Fan Drive Adjustment Procedure (available in the engine service manual) 7. Hydraulic System Flushing Procedure (Section 10 Appendix) 8. Toe-In Adjustment Procedure (Section 10, Appendix) 9. Hydraulic Checkout Procedure (Section 10, Appendix) 10. Brake Checkout Procedure (Section 10, Appendix) 11. Propulsion System Checkout Procedure (available in Section 10 of this manual) 12. Filter List (available in parts book) 13. Lubrication & Service PM Forms (available in the operation and maintenance manual) 14. Component Weights - for crane reference (available in Section 3 of this manual) 15. Standard Torque Chart (available in Section 10 of this manual) 16. Field Assembly Inspection Report Form (available in Section 10 of this manual)

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ORDER OF ASSEMBLY

LEVEL 5

The assembly procedure is organized in levels. Generally, the tasks in a given level may be performed in any order or simultaneously. However, all tasks in that level must be completed before proceeding to the next level. Each level depends on the installation of components from the previous level.

NOTE: As stated earlier, shipping and packaging of large machines will vary. Some of these steps may change due to different shipping configurations and/ or truck options.

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

4. Deck Support (on horsecollar over suspension) NOTE: It is easier to install and weld the deck supports before the front suspensions are installed.

However, do not install the deck supports first unless there is a suitable means of installing the suspension with the deck support in place.

9. Diagonal Ladder LEVEL 2 1. Air Cleaner Piping 2. Center Deck

LEVEL 6 1. Front Tires 2. Rear Tires 3. Hoist Cylinders

3. Front Mud Flaps

NOTE: Do not weld the uprights/air cleaners until all decks and the operator cab are installed. Ratchet hoists may be required to help tie all the structures together for a proper fit.

8. Front Suspensions

4. Wheel Motors

2. Body Pads/Shims/Guides

2. Uprights/Air Cleaners

7. Fuel Tank

3. Blower - Air Intake Ductwork

1. Clearance Lights

1. Chassis - Unload and crib for assembly.

6. Hydraulic Tank

2. Weld Uprights

LEVEL 7

LEVEL 1

5. Rear Suspension

1. Exhaust Pipes

LEVEL 8 1. Dump Body LEVEL 9 1. Hoist Cylinders 2. Rear Mud Flaps LEVEL 10 1. Clean the Truck 2. Decals 3. Lighting Wiring 4. Charge Suspensions 5. Charge Accumulators 6. Add Fluids 7. Charge the Air Conditioning System NOTE: Prior to starting the engine, verify that the steering pump case is full of oil.

LEVEL 11

3. Control Cabinet

1. System Checkouts

4. Auxiliary Control Cabinet

2. Exhaust Blankets

LEVEL 3 1. Spindles/Hubs 2. Steering Cylinders 3. Tie Rod

3. Clean Assembly Rear 4. Touch Up Paint 5. Train Operators 6. Optional - Install Fire Suppression System

LEVEL 4 1. LH Deck 2. RH Deck/Grid Box 3. Operator Cab

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

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

Disconnect the battery cables before welding on the truck. Failure to do so may seriously damage the batteries and electrical equipment.

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

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

DO NOT allow welding current to pass through bearings.

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

DO NOT lay welding cables over truck electrical cables and harnesses. Welding voltages could be induced into the truck wiring and cause damage to components.

DO NOT weld on the fuel tank or the hydraulic tank unless they have been properly purged and ventilated.

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

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

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

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

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

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

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

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

Hardware Tightening Method

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

1. Snug down all of the hardware with an impact wrench or appropriate ratchet.

2. Apply a paint mark down the side of the hardware and onto the component surface. Make sure that all of the hardware that is being tightened is marked.

3. Apply the specified torque to all of the marked hardware.

All of the marks should now be offset, showing that the hardware has been properly tightened.

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General Precautions and Instruction 1. Clean and remove all foreign material from component mounting surfaces.

2. Mount the front suspensions first so that deck substructures can be installed while other components are installed.

3. DO NOT weld the front uprights until all upper decks are installed.

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

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

To help prevent contamination that may lead to premature pump failures, flush the hydraulic system before the initial truck start-up.

17. Before the truck is started for the first time, the hydraulic system must be flushed. Refer to the appendix for the hydraulic system flushing procedure.

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

7. Do not torque the diagonal ROPS beam until after the operator cab and LH air intake tubes are in place.

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

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

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

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

12. Steering accumulators are normally not charged with nitrogen when shipped from the factory.

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

13. Brake accumulators are normally charged with nitrogen when shipped from the factory. Use proper precautions when checking pressures.

14. Verify the automatic lubrication system is lubricated, purged and all levels full prior to startup.

15. Purge air from the steering pump before truck operation. Pressure will not build in the brake and steering circuit if air is present. Air in the system may damage the pump. Refer to the Hydraulic Checkout Procedure in Section 10 of this manual.

16. Activate the battery disconnect switches when arc welding. Connect the weld ground near the weld area.

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Unloading the Chassis

FIGURE 6-1. LIFTING THE CHASSIS

1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each (Figure 6-1). The weight of the chassis, as shipped, is approximately 60,382 kg (133,000 lbs).

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FIGURE 6-2. CHASSIS SUPPORT BLOCKS

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 62). Placement of the chassis at this height will allow easier installation of the truck components.

3. Thoroughly clean the chassis.

4. If installed, remove the center deck.

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Rear Suspension Installation

FIGURE 6-3. REAR SUSPENSION INSTALLATION

5. Lift the upper rear suspension eye between the ears on the frame (Figure 6-3). Orient the cylinder so that the charging valve faces the opposite suspension cylinder as shown.

NOTE: The suspension assembly must be retracted as far as possible before installation.

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FIGURE 6-4. REAR SUSPENSION CYLINDER PIN INSTALLATION 1. Suspension Cylinder 2. Shoulder Bolt 3. Flat Washer

4. Locknut 5. Pin 6. Sleeve

7. Bearing Spacer 8. Retaining Ring 9. Bearing

NOTE: Bearing (9, Figure 6-4), retaining rings (8) and sleeves (6) should already be installed at the factory.

6. Check the fit of the pins in the bores before installing the suspension.

7. Lubricate all pin-to-bearing and pin-to-sleeve contact surfaces with anti-seize compound. Lubricating the pin surfaces aids in removal and installation, as well as prevention of rust and corrosion.

8. Align the hole in pin (5) with the hole in the mounting bore. Drive in the pin only far enough to hold the pin in position.

9. Insert bearing spacer (7) between the upper cylinder bore and the rear axle housing bore. Note the proper orientation of the spacers as shown in Figure 6-4. Continue to drive in the pin through the spacer and bearing (9).

10. Insert the remaining bearing spacer on the other side of the upper cylinder bore, and continue to drive in the pin until the hole in the rear axle housing is aligned with the hole in pin (5) 10. Install shoulder bolt (2), flat washer (3) and locknut (4). If further alignment of the holes is necessary, install a pin removal tool onto the pin. Use the tool and a large pipe wrench or other suitable device to align the holes.

Tighten the locknut to 68 N¡m (50 ft lb).

11. Adjust the piston rod height until the lower mount bearing aligns with the rear axle housing bore, and repeat the above procedure to install the bottom pin. Mounting components in the top and bottom joints are identical.

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Miscellaneous Installations NOTE: The following steps can be performed early in the erection process while preparation work for the major components is being done.

FIGURE 6-5. RETARDING GRID INSTALLATION

12. Weld the deck mud flap brackets into place on the underside of each deck.

13. If not installed, lift the retarding grid into place on the RH deck (Figure 6-5). The weight of the retarding grid is approximately 2 494 kg (5,500 lb). Tighten the six retarding grid mounting cap screws to 465 ± 46 N·m (343 ± 34 ft lb).

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FIGURE 6-6. HANDRAIL AND MIRROR INSTALLATION

14. Install handrails (1, Figure 6-6) and mirrors (2) on both decks. Tighten the cap screws to the standard torque.

Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

15. Install the horn on the bottom of the LH deck. Tighten the cap screws to the standard torque. Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

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FIGURE 6-7. DIAGONAL LADDER INSTALLATION

16. Install the radiator stabilizer bars and the bumpers on the radiator grille housing.

17. 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 Torque Tables And Conversion Charts in Section 10, Appendix.

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

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FIGURE 6-8. GRILLE HANDRAIL INSTALLATION 18. Install the grille handrail (Figure 6-8). Tighten the cap screws to the standard torque. Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

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Deck Support Installation NOTE: The following steps must be performed in the order that is given to properly align the cab mounting bolt holes.

FIGURE 6-9. DECK SUPPORT INSTALLATION

19. Lift the LH deck support into position (Figure 6-9). The weight of the deck support is approximately 755 kg (1,665 lb). Bolt the support into place. Do not weld the support at this time.

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FIGURE 6-10. INSTALLING THE LH UPRIGHT/AIR CLEANER ASSEMBLY

20. Lift the LH upright/air cleaner assembly into position. The weight of the LH upright/air cleaner assembly is approximately 1 182 kg (2,606 lb). Install the four cap screws for the upright (Figure 6-10). Tighten the cap screws to 465 ± 47 N·m (343 ± 34 ft lb).

NOTE: Do not weld the torque tube on the LH upright until the cab fit has been determined.

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21. Lift the LH diagonal tube into position and install the capscrews loosely (Figure 6-11). The weight of the tube is approximately 135 kg (298 lb).

NOTE: Do not tighten the cap screws until the cab fit has been determined.

FIGURE 6-11. DIAGONAL TUBE INSTALLATION

FIGURE 6-12. DETERMINING CAB FIT 1. Cab 2. Deck Support

3. LH Diagonal Beam 4. Left Upright

22. Lift the cab onto the deck supports and install the mounting hardware (Figure 6-12). Verify that no gaps exist between the mounting pads of the cab. If gaps are present, the upright and/or deck support may need to be repositioned.

23. Tighten the 16 cap screws that secure the LH diagonal tube to 800 ± 80 N·m (590 ± 59 ft lb).

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24. Tack weld the support.

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

25. The four tapped pads on each support and the corresponding blocks on the horsecollar must be removed to allow for a complete weld around the joint (Figure 6-13).

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FIGURE 6-13. DECK SUPPORT WELD JOINT SPECIFICATIONS

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FIGURE 6-14. DECK SUPPORT FINISH WELDING

26. Weld completely around the support without leaving any gaps. Refer to Figure 6-14.

27. Grind all weld areas. Clean and paint after welding is complete.

28. Lift the RH deck support into position. The weight of the deck support is approximately 320 kg (705 lb). Bolt the support into place.

29. Repeat Steps 23 - 26 for the RH deck support.

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FIGURE 6-15. WELDING THE UPRIGHT

FIGURE 6-16. CROSS TUBE WELD JOINT SPECIFICATION

30. Weld the LH upright to the front frame tube (Figure 6-15 and Figure 6-16).

31. Remove the cab after welding is complete. Continue with the assembly process.

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32. Lift the RH upright/air cleaner assembly into position. The weight of the RH upright/air cleaner assembly 888 kg (1,958 lb). Install the four cap screws for the upright (Figure 6-10). Tighten the cap screws to 465 ± 47 N·m (343 ± 34 ft lb).

NOTE: Do not weld the torque tube on the RH upright until the decks are installed.

FIGURE 6-17. AIR INTAKE TUBE INSTALLATION

33. Lift the air intake tubes and hump hoses into place (Figure 6-17). Install and tighten the clamps that secure the hoses.

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FIGURE 6-18. CENTER DECK INSTALLATION 1. Cap Screw 2. Flat Washer 3. Lockwasher

4. Nut 5. Shim

34. Lift the center deck into position (Figure 6-18).

35. Loosely install four cap screws (1), eight flat washers (2), four lockwahers and four nuts (4).

36. Install the air intake tube support rods.

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Hoist Cylinder Installation

FIGURE 6-19. LIFTING THE HOIST CYLINDER

37. Raise the hoist cylinder into position over the pivot point on the frame (Figure 6-19). The weight of each hoist cylinder is approximately 998 kg (2,200 lb). Position the cylinder so the air bleed vent plug is on top and facing the front of the truck.

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

39. 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.

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

FIGURE 6-20. HOIST CYLINDER INSTALLATION 1. Cap Screw 2. Lock Plate 3. Retainer

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4. Retainer Ring 5. Bearing 6. Spacer

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Tank Installation

FIGURE 6-21. FUEL TANK INSTALLATION 1. Cap 2. Lockwasher 3. Cap Screw

4. Rubber Mount 5. Large Washer 6. Flat Washer

7. Lockwasher 8. Cap Screw

41. Clean the mounts for the fuel tank. Lift the tank into position (Figure 6-21). The weight of the fuel tank is approximately 2 056 kg (4,533 lb). a. Install caps (1, Figure 6-21), lockwashers (2) and cap screws (3) at the top of the tank. Tighten the four cap screws to 711 ± 72 N·m (525 ± 53 ft lb). b. Install four two-piece rubber mounts (4), large washers (5), flat washers (6), lockwashers (7) and cap screws (8) at the rear of the tank. Tighten the four cap screws to 420 ± 42 N·m (310 ± 31 ft lb).

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FIGURE 6-22. HYDRAULIC TANK INSTALLATION 1. Cap 2. Lockwasher 3. Cap Screw

4. Rubber Mount 5. Large Washer 6. Lockwasher

7. Cap Screw

42. Clean the mounts for the hydraulic tank. Lift the tank into position (Figure 6-22). The weight of the hydraulic tank is approximately 590 kg (1,300 lb). a. Install caps (1, Figure 6-21), lockwashers (2) and cap screws (3) at the top of the tank. Tighten the four cap screws to 622 ± 62 N·m (459 ± 45 ft lb). b. Install two rubber mounts (4), large washers (5), lockwashers (6) and cap screws (7) at the rear of the tank.

Tighten the four cap screws to 800 ± 80 N·m (590 ± 59 ft lb).

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Front Suspension Installation

FIGURE 6-23. CLEANING THE FRONT SUSPENSION MOUNTING SURFACES

FIGURE 6-24. CLEANING THE FRONT SUSPENSION MOUNTING SURFACES 43. Remove all paint, rust, dirt and foreign debris from the suspension mounting surfaces (Figure 6-23 and Figure 6-24).

44. 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.

45. 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 measurements are not within specifications, contact your Komatsu customer service manager for further instructions.

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

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

Replace the hardware after each use.

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

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

The use of dry threads in this application is not recommended. Due to the high tightening forces required to load these cap screws, dry threads or threads lubricated with anti-seize compounds may result in damage. Only use the approved lubricant specified below.

47. Lubricate the cap screw threads, cap screw head seats, washer faces and nut seats with 5% molybdenumdisulphide grease.

48. Identify and separate the hardware according to location on the suspension (Figure 6-25).

FIGURE 6-25. FRONT SUSPENSION MOUNTING HARDWARE 1. Cap Screw - 1 1/2" - 6NC x 6 1/2" (G8) 2. Flat Washer - 1 1/2" (G8) 3. Nut - 1 1/2" - 6NC (G8) 4. Cap Screw - 1 3/4" - 5NC x 14 1/2" (G8) 5. Flat Washer - 1 3/4" (G8) 6. Nut - 1 3/4" - 5NC (G8) 7. Spacer 8. Shear Key 9. Part Of Frame

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NOTE: The hardened flat washers used on the front suspensions may be punched during the manufacturing process. To prevent damage, assemble the washers on the cap screws so that the punched lip is facing away from the cap screw head (Figure 6-26).

FIGURE 6-26. HARDENED FLAT WASHER INSTALLATION 1. Hardened Flat Washer

2. Cap Screw

49. Lift the front suspension into position on the frame (Figure 6-27). The weight of each front suspension cylinder is approximately 3 255 kg (7,176 lb).

FIGURE 6-27. LIFTING THE FRONT SUSPENSION

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50. Install the mounting hardware and the shear key.

Install the shear key flush with the side face of the suspension (Figure 6-28).

a. Install one washer under each cap screw head and one washer under each 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 properly calibrated torque wrench to ensure accuracy.

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

FIGURE 6-28. INSTALLING THE FRONT SUSPENSION c. The mounting cap screws will now need to be loosened and then tightened using angleadvance. The first set of cap screws to be adjusted will be at the upper mounting joint. The cap screws must be loosened one at time and then tightened by advancing a specified rotational degree. Use the map shown in Figure 6-29 for proper tightening sequence.

FIGURE 6-29. TIGHTENING SEQUENCE

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Chassis Assembly

Page 6-29

Upper Mounting Joint - 60° Advance

51. Loosen the first cap screw. All other cap screws must be maintained at 1356 ± 136 N·m (1000 ± 100 lb ft).

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

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

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

54. Advance the cap screw to the 60° advance mark.

Hold the nut at the rear of the joint stationary while tightening.

FIGURE 6-30.

55. Make new reference lines along the cap screw, nut and frame at the rear of the joint as shown in Figure 6-31. These reference lines will be used to verify the cap screws have maintained their torque.

56. Repeat this process in sequence for the remaining cap screws in the upper 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.

Page 6-30

Chassis Assembly

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Lower Mounting Joint - 90° Advance

57. Loosen the first cap screw. All other cap screws must remain tightened.

58. Tighten the cap screw to 475 N·m (350 lb ft).

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

59. Mark a corner of the cap screw head with a paint marker as shown in Figure 6-32. Draw a reference line on the suspension surface (or frame) next to the marked corner on the cap screw. Draw a reference line on the suspension surface (or frame) 90 degrees in advance of the marked corner on the cap screw.

FIGURE 6-32.

60. Advance the cap screw to the 90° advance mark.

Hold the nut at the rear of the joint (where applicable) stationary while tightening.

61. Make new reference lines along the cap screw, nut and frame at the rear of the joint as shown in Figure 6-31. For the four cap screws with spacers, refer to Figure 6-33. These reference lines will be used to verify the cap screws have maintained their torque.

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

FIGURE 6-33.

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

Chassis Assembly

Page 6-31

Front Spindle/Brake Assembly Installation

FIGURE 6-34. SPINDLE/BRAKE ASSEMBLY INSTALLATION

63. Clean the tapered portion of the suspension rod and the bore of the spindle. Lubricate the two surfaces with multi-purpose grease No. 2 (5% molybdenum disulphide).

Do not position the lifting sling around the tapered side of the wheel mounting flange. Damage to the toric seal at the brake assembly may result.

64. Attach a lifting sling as shown, and lift the spindle/brake assembly into position (Figure 6-34 and Figure 6-35).

The weight of each spindle/brake assembly is approximately 5 180 kg (11,420 lb).

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

65. Use blocks and a hydraulic jack to lift the retainer plate to the bottom of each front suspension.

Page 6-32

Chassis Assembly

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FIGURE 6-35. SPINDLE/BRAKE ASSEMBLY INSTALLATION

FIGURE 6-36. RETAINER PLATE INSTALLATION 66. Install the 15 retainer plate cap screws (Figure 6-36). 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).

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Chassis Assembly

Page 6-33

Steering Cylinder and Tie Rod Installation

FIGURE 6-37. STEERING CYLINDER INSTALLATION 1. Steering Cylinder 2. Spherical Bearing 3. Bearing Seal

4. Spacer 5. Washer 6. Pin (Steering Arm)

7. Retainer 8. Nut 9. Cap Screw

10. Pin (Frame) 11. Upper Sleeve 12. Lower Sleeve

67. Connect steering cylinders (1, Figure 6-37) to the steering arms. Tighten pin retaining cap screws (9) to 1 017 ± 102 N·m (750 ± 75 ft lb).

NOTE: Spherical bearings (2, Figure 6-37) and bearing seals (3) should already be installed at the factory.

Page 6-34

Chassis Assembly

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FIGURE 6-38. TIE ROD INSTALLATION 1. Tie Rod 2. Spacer 3. Pin

4. Retainer 5. Nut 6. Cap Screw

7. Upper Sleeve 8. Lower Sleeve

68. Connect tie rod (1, Figure 6-38) to the steering arms. Tighten pin retaining cap screws (9) to 1 017 ± 102 N·m (750 ± 75 ft lb).

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Chassis Assembly

Page 6-35

Deck, Cab and Control Cabinet Installation

FIGURE 6-39. RH DECK INSTALLATION

FIGURE 6-40. RH DECK INSTALLATION 1. Cap Screw (70 mm) 2. Flat Washer

3. Locknut 4. Cap Screw (80 mm)

5. Shims (Front) 6. Shims (Rear)

69. Lift the RH deck into position (Figure 6-39). The weight of the deck/retarding grid assembly is approximately 4 400 kg (9,700 lb).

70. Loosely install three cap screws (1, Figure 6-40) and five cap screws (4), flat washers (2) and locknuts (3).

Page 6-36

Chassis Assembly

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FIGURE 6-41. LH DECK INSTALLATION

FIGURE 6-42. LH DECK INSTALLATION 1. Cap Screw 2. Flat Washer

3. Spacer 4. Locknut

5. Shims

71. Lift the LH deck into place (Figure 6-41). The weight of the LH deck is approximately 885 kg (1,951 lb).

72. Loosely install cap screws (1, Figure 6-42), flat washers (2), spacers (3) and locknuts (4) in six locations.

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Chassis Assembly

Page 6-37

73. After all decking is in place, level the center, LH and RH 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 74. Tighten the mounting cap screws on each deck to the standard torque. Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

75. Lift the operator cab into position (Figure 6-43).

The weight of the cab is approximately 2 268 kg (5,000 lb).

76. Remove any paint from the cab mounting holes.

77. Determine whether shims are required at each mounting pad (Figure 6-44). The gap between the cab and the ROPS support must not exceed 1 mm (0.039 in.). Install shims at each mounting pad as required.

78. Install 32 flat washers and cap screws. Tighten the cap screws to 800 ± 80 N·m (590 ± 59 ft lb).

FIGURE 6-43. LIFTING THE CAB

FIGURE 6-44. CAB MOUNTING PADS

Page 6-38

Chassis Assembly

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FIGURE 6-45. CONTROL CABINET INSTALLATION

79. Lift the electrical control cabinets into position (Figure 6-45). The combined weight of the control cabinets is approximately 3 865 kg (8,525 lb).

80. Install 10 mounting cap screws and nuts with 20 flat washers. Tighten the cap screws to the standard toruqe.

Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

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Chassis Assembly

Page 6-39

FIGURE 6-46. WELDING THE UPRIGHT

FIGURE 6-47. CROSS TUBE WELD JOINT SPECIFICATION

81. Tighten the 12 cap screws for the RH diagonal tube to 240 ± 24 N·m (177 ± 17 ft lb).

82. Weld the RH upright to the front frame tube (Figure 6-46 and Figure 6-47).

Page 6-40

Chassis Assembly

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83. Lift the two bumper extensions into place (Figure 6-48).

Tighten the cap screws to the standard torque. Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

FIGURE 6-48. BUMPER EXTENSION INSTALLATION

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Chassis Assembly

Page 6-41

Blower Ductwork Installation

FIGURE 6-49. BLOWER DUCTWORK INSTALLATION 1. Alternator Blower Inlet Duct 2. Wheel Motor Blower Inlet Duct

3. Main Blower Assembly 4. Traction Alternator

84. Lift the blower ductwork into position. The weight of alternator blower inlet duct (1, Figure 6-49) is approximately 46 kg (102 lb). The weight of wheel motor blower inlet duct (2) is approximately 53 kg (117 lb).

85. Tighten the connecting hardware to the standard torque. Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

Page 6-42

Chassis Assembly

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Wheel Motor Installation 86. The weight of the transmission and brake assembly (1, Figure 6-50) without the electric motor is approximately 12 359 kg (27,247 lb). Transmission (1) must be positioned so the top of the unit is at the very top.

87. Peel the paper backing from new seal (2) and install the seal onto transmission (1).

88. Remove the shipping bracket from the non-drive end of the electric motor. Install three lifting eyes into the wheel motor housing at locations (3).

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

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

91. 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. Install the air duct structure with the hardware that was retaining the cover. Seal the air duct structure to wheel motor housing with sealant (VS7492).

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

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

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FIGURE 6-50. WHEEL MOTOR ASSEMBLY 5. Air Duct Structure 8. Flat Washer 6. Gasket 9. Cover 7. Cap Screw 10. Adapter

Chassis Assembly

11. Grease Cavity 12. Transmission Shaft 13. Seal

Page 6-43

FIGURE 6-51. ELECTRIC WHEEL MOTOR INSTALLATION

93. Install the wheel motor breather kit.

94. Attach an appropriate lifting device to all three lifting eyes (3) on the electric motor (Figure 6-51). The weight of the electric motor is approximately 4 500 kg (9,921 lb). Use a suitable lifting device that can handle the load safely.

Page 6-44

Chassis Assembly

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95. Lift the motor into position on the wheel motor transmission (Figure 6-52). The electric motor shaft may have to be turned slightly to line up the drive splines.

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

Install the washers with the punched lip away from the cap screw head to prevent damage (Figure 6-53) if necessary.

97. Install 24 cap screws (7, Figure 6-50) 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).

FIGURE 6-52. WHEEL MOTOR AND TRANSMISSION ASSEMBLY INSTALLATION

FIGURE 6-53. HARDENED FLAT WASHER INSTALLATION 1. Hardened Flat Washer

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2. Cap Screw

Chassis Assembly

Page 6-45

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

99. 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.

100. 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.

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

102. 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.

103. Ensure that 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.

104. Ensure that seals (4, Figure 6-54) are in place on inner duct (3), and the inner duct is positioned forward enough to clear the wheel motor during installation.

FIGURE 6-54. REAR AXLE DUCT INSTALLATION 1. Cooling Air Hose 2. Transition

Page 6-46

3. Inner Duct 4. Seals

Chassis Assembly

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Each complete wheel motor assembly weighs approximately 21 000 kg (46,300 lb). Ensure that the lifting devices are capable of handling the load safely.

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

105. Lift the wheel motor into position on the rear axle housing. Ensure that all cables and hoses are clear before installation.

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

107. To hold inner duct (3, Figure 6-54) in place, loosely install four cap screws in the locations that correspond to the cutout bolt holes at the top and bottom of transition (2).

108. Ensure that inner duct (3) is aligned with the wheel motor ductwork flange. Move the wheel motor or inner duct as needed.

High tightening force is required to install the cap screws that secure the wheel motors to the rear axle housing. Repeated tightening will result in cap screw fatigue and damage.

Do not reuse any wheel motor mounting hardware (cap screws and hardened washers). Replace the hardware after one use.

Do not retighten any wheel motor mounting cap screw that has loosened after the truck has been placed into operation. If any wheel motor mounting cap screw has loosened during truck operation, all of the cap screws and hardened washers must be replaced with new hardware.

The cap screws that are used to secure the wheel motors to the rear axle housing are specially hardened to meet or exceed grade 8 specifications. Replace these cap screws with only new cap screws of the correct hardness. Refer to the appropriate parts book for the correct part number.

The use of dry threads in this application is not recommended. Due to the high tightening force that is required to install the wheel motor mounting cap screws, dry threads may cause damage to tools, cap screws or the rear axle housing.

Komatsu does not recommend the use of special friction-reducing lubricants, such as Copper Coat, Never-SeezÂŽ or other similar products, on the threads of standard fasteners where standard torque values are applied. The use of special friction-reducing lubricants will significantly alter the clamping force during the tightening process. If a special friction-reducing lubricant is used, excessive stress and possible breakage of the fasteners may result.

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Chassis Assembly

Page 6-47

109. Select the hardware to be installed in Group 1 of the tightening sequence. Refer to Figure 6-55.

Inspect each cap screw for rust, corrosion and surface defects on any seat or thread. Do not use any cap screw if a defect is suspected.

110. 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).

111. Install the hardware for Group 1. Tighten each cap screw to 1 017 N·m (750 ft lb).

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

112. Repeat Step 109 through Step 111 for each remaining group in the tightening sequence. Refer to Figure 655.

113. After all of the hardware in all of the groups has been installed and tightened to 1 017 N·m (750 ft lb), move back to Group 1. Increase the torque on each cap screw in Group 1 to 3 471 N·m (2,560 ft lb). Repeat this step for each remaining group in the tightening sequence. Refer to Figure 6-55.

114. Install the gasket and transition (2, Figure 6-54) on the rear axle housing. Tighten the mounting hardware to standard torque. Refer to Torque Tables And Conversion Charts in Section 10, Appendix.

FIGURE 6-55. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

Page 6-48

Chassis Assembly

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Front Wheel Installation

NOTE: Remove all dirt and rust from mating parts before installing the tire and rim assembly.

115. Grip the tire and rim assembly with the tire handler (Figure 6-56). Align the tire inflation hose and the wheel hub. Position the rim onto the wheel hub studs.

116. Lubricate all stud threads and nut seating flanges with lithium base 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 2 326 ± 136 N·m (1,715 ± 100 ft lb). b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.

Tighten the nuts to 2 326 ± 136 N·m (1,715 ± 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 2 326 ± 136 N·m (1,715 ± 100 ft lb). d. Install the remaining nuts and tighten them in a clockwise pattern to 2 326 ± 136 N·m (1,715 ± 100 ft lb). e. Retighten all nuts in a clockwise pattern to 2 326 ± 136 N·m (1,715 ± 100 ft lb).

After the truck has been assembled and has been operated for a short period of time, the torque on the wheels must be checked again. Tighten the wheel nuts to the specified torque.

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Chassis Assembly

Page 6-49

FIGURE 6-56. FRONT TIRE INSTALLATION WITH TIRE HANDLER

FIGURE 6-57. WHEEL NUTS

Page 6-50

Chassis Assembly

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Rear Wheel Installation

FIGURE 6-58. 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

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

NOTE: Clean all mating surfaces and check the stud threads before installing the wheels.

117. Bleed the air from the disc brakes before installing the rear tires. Refer to the shop manual for the brake bleeding procedures.

118. Grip the inner tire and rim with the tire handler and lift the tire onto the wheel hub (Figure 6-59). Align extension (4, Figure 6-58) for mating with inner extension (7).

119. Lubricate all stud threads and nut seating flanges with a lithium base 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 2 326 ± 136 N·m (1,715 ± 100 ft lb). b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.

Tighten the nuts to 2 326 ± 136 N·m (1,715 ± 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 2 326 ± 136 N·m (1,715 ± 100 ft lb). d. Install the remaining nuts and tighten them in a clockwise pattern to 2 326 ± 136 N·m (1,715 ± 100 ft lb). e. Retighten all nuts in a clockwise pattern to 2 326 ± 136 N·m (1,715 ± 100 ft lb).

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

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Chassis Assembly

Page 6-51

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 6-59. INNER REAR TIRE INSTALLATION WITH TIRE HANDLER

Page 6-52

Chassis Assembly

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FIGURE 6-60. OUTER REAR TIRE INSTALLATION WITH TIRE HANDLER

121. Position the rim adapters into place on each outer rim. Install the flanged nuts and tighten them to 2 325 ± 136 N·m (1,715 ± 100 ft lb). Refer to Step 100 for the correct tightening sequence.

122. Install the outer tires (Figure 6-60). Install and tighten the wheel nuts to 2 325 ± 136 N·m (1,715 ± 100 ft lb).

Refer to Step 117 for the correct tightening sequence.

After the truck has been assembled and has been operated for a short period of time, the torque on the wheels must be checked again. Tighten the wheel nuts to the specified torque.

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Chassis Assembly

Page 6-53

Exhaust Piping Installation 123. Install all exhaust tubes (2, Figure 6-61) and mufflers (1). Ensure that all exhaust tube clamps are tight.

124. Install the exhaust blankets.

FIGURE 6-61. EXHAUST PIPING INSTALLATION

Page 6-54

Chassis Assembly

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Hoses and Electrical Harnesses

FIGURE 6-62. CAB HARNESS AND HOSE INSTALLATION

125. Connect the electrical harnesses and hydraulic hoses below the operator cab (Figure 6-62).

126. Connect the wiring for the control cabinets and retarding grid. Refer to the assembly drawings and schematics.

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.

127. Connect all power cables and electrical harnesses to their appropriate locations on the wheel motor.

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Chassis Assembly

Page 6-55

FIGURE 6-63. REAR AXLE BLOWER HOSE INSTALLATION 1. Blower Hoses 2. Tubes

3. Hoses 4. Blower Duct

128. Connect both blower hoses (1, Figure 6-63), tubes (2) and hoses (3) between the transitions on the rear axle and blower duct (4) on the main blower assembly.

Page 6-56

Chassis Assembly

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FIGURE 6-64. REAR AXLE MANIFOLD BRAKE LINE INSTALLATION 1. Left Brake Cooling Return Line 2. Brake Cooling Supply Line 3. Right Brake Cooling Return Line

4. Tank Return Line 5. Brake Accumulator Line 6. Parking Brake Line

7. Rear Brake Apply Line 8. LBP Test Port 9. RBP Test Port

129. Connect the rear brake lines to the manifold on the rear axle housing (Figure 6-64).

130. Connect the rear brake apply lines, rear brake cooling lines and the parking brake line to the ports on the brake assembly back plate.

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Chassis Assembly

Page 6-57

FIGURE 6-65. HYDRAULIC TANK PIPING INSTALLATION 131. Connect the piping to the hydraulic tank and properly tighten all fittings (Figure 6-65).

FIGURE 6-66. FILTER INSTALLATION 132. Install the two hoist circuit filters and the steering circuit filter onto the provided brackets at the inner side of the fuel tank (Figure 6-66). Also connect the fuel tank harness. to the filters.

Page 6-58

Chassis Assembly

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FIGURE 6-67. FUEL HOSE INSTALLATION 1. Supply Hose 2. Return Hose

3. Vent

133. Connect supply hose (1, Figure 6-67) and return hose (2) to the fuel tank. Install vent (3) and the overflow tube.

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Chassis Assembly

Page 6-59

FIGURE 6-68. FRONT BRAKE LINE INSTALLATION 1. Brake Cooling Line (to return manifold)) 2. Brake Cooling Line (to heat exchanger)

3. Brake Apply Line 4. Speed Sensor Connector

134. Connect front brake apply line (3) and the front brake cooling lines (1) and (2). Connect the speed sensor harness to connector (4).

Page 6-60

Chassis Assembly

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Before Starting the Engine

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

135. Do not start the engine unless the hydraulic system flushing tools are installed and ready to perform the flushing procedure. Refer to the appendix for the hydraulic system flushing procedure.

136. 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. Refer to Figure 6-69. Fill the wheel motor with the recommended oil as necessary.

FIGURE 6-69. WHEEL MOTOR OIL LEVEL

137. Check the hydraulic tank oil level before and after engine start-up. Service the hydraulic tank oil as necessary.

The truck is now ready for dump body installation.

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Chassis Assembly

Page 6-61

NOTES

Page 6-62

Chassis Assembly

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DUMP BODY ASSEMBLY GENERAL INFORMATION

The total weight of the body is approximately 42 851 kg (94,470 lb). Use two cranes for assembling the body. A 45 metric ton (50 ton) crane and a 109-136 metric tons (120-150 ton) crane are required. The larger crane is needed to help turn the body over after completion of the underside welding.

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

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

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

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

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

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

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

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

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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 listed below when welding the body: • Use dry weld rod or weld wire.

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

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

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

1. Remove the paint from the weld areas.

2. Lift the LH body section and support the rear edge of the floor with wood blocks and a jack stand. See Figure 7-3 and Figure 7-4.

• The following sequence must be followed for the front sheet: 1. For the first pass, back step and skip weld in 10 increments along the entire length of the joint.

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

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

FIGURE 7-3. LH BODY SECTION

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

FIGURE 7-4. LH BODY SECTION

7-2

Dump Body Assembly

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3. Lift the center body section and place 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 cap screws (7), (8) and (9) with the flat washers and nuts. Attach a wedge 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 cap screw (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 section assembly. Support the 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 cap screw (1, Figure 7-8) with the sleeves, flat washers and nut.

FIGURE 7-5. CENTER BODY SECTION

NOTE: Figure 7-6 shows the hardware numbered in installation sequence. Cap screws (1) and (2) are installed with sleeves. The remainder of the cap screws do not have sleeves.

FIGURE 7-7. RH BODY SECTION

NOTE: Figure 7-8 shows the hardware numbered in installation sequence. Cap screws (1) and (2) are installed with sleeves. The remainder of the cap 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) and (6) with the flat washers and nuts. Attach a wedge or a clamp inside the body as necessary to align the front sheets. See Figure 7-9.

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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 cap screws (3), (4), (5) and (6) with the flat washers and nuts. Attach a wedge or 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 on the assembly drawing. See Figure 7-11.

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

12. Install cap screws (7), (8) and (9) with the flat washers and nuts. Attach wedges or clamps inside the body as necessary to align the floor sheets. See Figure 7-9.

FIGURE 7-11. BACKER STRIP INSTALLATION FIGURE 7-9. ALIGNMENT WEDGES 14. Check the alignment and fit of all joints. Complete the welds at the floor joints and the front sheets. See Figure 7-12 and Figure 7-13. Refer to the assembly drawings for welding requirements.

FIGURE 7-10. BODY SECTIONS ASSEMBLED

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

7-4

FIGURE 7-12. WELDING THE FLOOR JOINTS

Dump Body Assembly

FAM0711

16. Tack weld the canopy side plates. 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 the edges of the canopy with wood blocks. See Figure 7-14. Align the canopy with the body and tack weld it to the body. Refer to the assembly drawings for welding requirements.

FIGURE 7-15. CANOPY SIDE PLATE INSTALLATION

17. Tack weld the canopy gussets in place. When all the gussets are installed, complete the 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

Dump Body Assembly

7-5

18. Install body guide (1, Figure Figure 7-17) and the body pad mounts (2).

FIGURE 7-19. TURNING OVER THE BODY FIGURE 7-17. BODY GUIDE & BODY PAD MOUNT INSTALLATION 1. Body Guide

2. Body Pad Mount

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

Figure 7-18 through Figure 7-22 shows a typical example of a body being inverted with 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

FAM0711

22. Install the mud flap brackets, clearance light housings (see Figure 7-24), etc, as specified on the installation drawings.

FIGURE 7-22. TURNING OVER THE BODY FIGURE 7-24. CLEARANCE LIGHT HOUSING 20. Position the body onto wood blocks as shown in Figure 7-23.

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

Dump Body Assembly

7-7

24. Clean and paint the weld joints.

FIGURE 7-26. PAINTING THE WELD JOINTS

7-8

Dump Body Assembly

FAM0711

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

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

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

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

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

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

FAM0815 3/11

Final Assembly

Page 8-1

Dump Body Installation 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. LIFTING THE DUMP BODY

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

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

There are two methods of installing the body depending on the cranes 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). 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

3/11 FAM0815

FIGURE 8-2. INSTALLING THE BODY PIVOT PINS

FIGURE 8-3. DUMP BODY PIVOT PIN 1. Shoulder Bolt 2. Flat Washer 3. Nut

FAM0815 3/11

4. Body Pivot Pin 5. Pivot Bushing 6. Body Pivot Ear

Final Assembly

7. Pivot Bushing 8. Shim 9. Body Pivot Bushing

Page 8-3

FIGURE 8-4. CONNECTING THE HOIST CYLINDER TO THE DUMP BODY

2. With the body in position, install shims (8, Figure 8-3) in both body pivots. Install enough shims to fill the outboard gaps and to center the body on the frame pivot. DO NOT install shims at the inside. A minimum of one shim is required at the outboard end of both frame pivots.

3. Align the hole in body pivot pin (4) with the bolt hole in body pivot ear (6). Push the pivot pin through the frame pivot and into pivot bushings (5) and (7).

4. Install shoulder bolt (1) through the pin. Install a flat washer (2) and nut (3). Tighten the nut to to 339 N¡m (250 ft lb).

5. Repeat for the body pivot pin on the opposite side of the body.

6. Align the hoist cylinder upper bushings with the body (Figure 8-4). Align the bolt holes and install spacers (2, Figure 8-5) and pin (3) . Install shoulder bolt (4), flat washer (5) and nut (6). Tighten the nut to 339 N¡m (250 ft lb).

7. After the body is installed, perform the toe-in adjustment. Refer to Toe-In adjustment Procedure in Section 10, Appendix.

FIGURE 8-5. HOIST CYLINDER UPPER MOUNT 1. Mounting Bracket 2. Spacer 3. Pin

Page 8-4

Final Assembly

4. Shoulder Bolt 5. Flat Washer 6. Nut

3/11 FAM0815

Body Pad & Body Guide Installation

FIGURE 8-6. BODY PAD INSTALLATION 1. Dump Body 2. Body Pad

3. Shim 4. Mounting Hardware

8. Shim the body pads as required. Tighten pad mounting hardware (4, Figure 8-6) 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 gap of approximately 1.9 mm (0.075 in.) is required at each rear pad. This can be accomplished by using one less shim at each rear pad.

9. 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.

FAM0815 3/11

Final Assembly

Page 8-5

10. Install both body guide brackets loosely into place (Figure 8-7). Once in position, slowly lower the body and mark the position in which the brackets are to be welded.

FIGURE 8-7. BODY GUIDE BRACKET INSTALLATION

The body guides must be centered between wear plates (3, Figure 8-8), with a maximum gap of 4.8 mm (0.19 in.) at each side.

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

Page 8-6

Final Assembly

3. Body Guide Bracket Wear Plates

3/11 FAM0815

Body Up Switch & Hoist Limit Switch Installation

FIGURE 8-9. BODY UP SWITCH INSTALLATION 1. Body Up Switch 2. Switch Mounting Bracket

3. Magnet Assembly 4. Bracket

11. With the body lowered onto the frame rail, install body up switch (1, Figure 8-9) and switch mounting plate (2) on the frame. Install bracket (4) and magnet assembly (3) on the body.

Dimension “A” : 45 mm (1.77 in.)

Dimension “B” : 32.3 mm (1.27 in.)

NOTE: The tapped pads are tack welded onto the frame and body. If necessary, the tapped pads can be repositioned.

12. Fully raise the body and install the body retention sling. Remove the support blocks.

Refer to the Safety section of the Operation & Maintenance Manual for information about properly securing the body using the body retention sling.

13. Weld the body guide brackets into place.

FAM0815 3/11

Final Assembly

Page 8-7

FIGURE 8-10. HOIST LIMIT SWITCH 1. Hoist Limit Switch 2. Switch Mounting Plate

3. Magnet Assembly 4. Actuator Arm

14. Raise the body so that the hoist cylinders are within 152 mm (6 in.) of maximum travel. Install hoist limit switch (1, Figure 8-10) and switch mounting plate (2) on the frame. Install actuator arm (4) and magnet assembly (3) on the body.

15. Adjust the hoist limit switch to achieve an air gap (dimension “A�) of 45 mm (1.77 in.) between the switch and the magnet. Tighten the capscrews.

NOTE: The tapped pads are tack welded onto the frame and body. If necessary, the tapped pads can be repositioned.

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 8-8

Final Assembly

3/11 FAM0815

Miscellaneous Installations

FIGURE 8-11. AUTOMATIC LUBRICATION SYSTEM AND ENGINE RESERVE OIL SYSTEM

17. Install the automatic lubrication system and the engine reserve oil system (Figure 8-11). Refer to the installation drawings. Verify that all electrical and hydraulic connections are correct.

FAM0815 3/11

Final Assembly

Page 8-9

18. Install all service lights (Figure 8-12).

FIGURE 8-12. SERVICE LIGHTS

19. Install the fire suppression system (if equipped). This installation is normally performed by the fire suppression system distributor.

20. Install the mud flaps on the body, decks, hydraulic tank and fuel tank.

21. Paint the truck as needed.

22. Install all decals at their designated areas.

Page 8-10

Final Assembly

3/11 FAM0815

FIGURE 8-13. COMPLETED TRUCK

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

FAM0815 3/11

Final Assembly

Page 8-11

NOTES

Page 8-12

Final Assembly

3/11 FAM0815

FINAL CHECKOUT Final checkout requires truck operation.

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

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

1. Complete delivery and warranty forms.

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

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

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

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

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

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

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

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

FAM0903 3/09

Final Checkout

Page 9-1

NOTES

Page 9-2

Final Checkout

3/09 FAM0903

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

1. Lubrication Chart - XB9917 2. Suspension Oiling And Charging Procedure 3. Toe-In Adjustment Procedure 4. Hydraulic System Flushing Procedure 5. Steering Column Alignment Procedure - EJ2845 6. Seat Belt Checkout Procedure - SM2700 7. Automatic Lubrication System Checkout Procedure - EJ4060 8. Reserve Oil System Checkout Procedure - EJ6271 9. Air Conditioning Checkout Procedure - EL4302 10. Hydraulic Checkout Procedure - EL2606 11. Brake Checkout Procedure - XB5769 12. VHMS Setup Procedure - EM2128 13. VHMS Checkout Procedure - EM2129 14. Payload Meter III Checkout Procedure - EJ3061 15. Electrical Checkout Procedure - XB1656 16. Truck Commisioning Procedure - XB1623 17. Torque Tables and Conversion Charts 18. Field Assembly Inspection Report 19. 50 Hour Post-Commissioning Checksheet

FAM1018

Appendix

Page 10-1

NOTES

Page 10-2

Appendix

FAM1018

LUBRICATION CHART

NOTES

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

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

All Hydrair II suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury and/or damage if improperly handled.

Follow all safety instructions, cautions, and warnings provided in the following procedures to prevent any accidents during oiling and charging.

Equipment list • Hydrair charging kit • Jacks and/or overhead crane • Support blocks for: • Oiling height dimensions (front and rear) • Charging height dimensions (front only) • Hydrair II oil • Friction modifier • Dry nitrogen Installing the charging kit 1. Assemble the charging kit as shown in Figure 41, and attach it to a container of pure dry nitrogen (8).

2. Remove the protective covers and charging valve caps from the suspensions.

3. Turn "T" handle valves (1) of charging valve adapters (2) completely counterclockwise.

Proper charging of Hydrair II suspensions requires that three basic conditions be established in the following order: 1. The oil level must be correct.

2. The suspension piston rod extension for nitrogen charging must be correct.

3. The nitrogen charge pressure must be correct.

For best results, Hydrair II suspensions should be charged in pairs (fronts together and rears together).

If rear suspensions are to be charged, the front suspensions should be charged first.

NOTE: For longer life of suspension components, a friction modifier should be added to the suspension oil. See the oil and nitrogen specification charts in the Specifications section.

NOTE: Setup dimensions must be maintained during oiling and charging procedures. However, after the truck has been operated, these dimensions may vary.

FIGURE 4-1. HYDRAIR CHARGING KIT NOTE: The arrangement of parts may vary from the illustration depending on the kit part number.

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 Container

4. Make sure that outlet valves (3) and inlet valve (4) are closed (turned completely clockwise).

Support blocks for oiling and charging dimensions

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

Before starting the oiling and charging procedures, supports should be fabricated to maintain the correct exposed piston rod extensions.

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

7. Turn "T" handle valves (1) clockwise. This will depress the core of the charging valve and open the gas chamber of the suspension.

8. Open both outlet valves (3).

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

Removing the charging kit 1. Close both outlet valves (3).

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

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

4. Tighten the swivel nut (small hex) on the charging valve. If a new charging valve is being used, tighten the swivel nut to 15 Nm (11 ft lb), then loosen and retighten the swivel nut to 15 Nm (11 ft lb). Loosen the swivel nut again and retighten to 6 Nm (50 in lb). Install the valve cap finger-tight.

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

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

Exposed piston rod extensions are specified for both oil level and nitrogen charging for Hydrair II suspensions. These dimensions are listed in the tables below. Measure the dimensions from the face of the cylinder gland to the machined surface on the spindle at the front suspension. At the rear suspension, measure from the face of the cylinder gland to the piston flange.

Support blocks may be made in various forms. Mild steel materials are recommended. Square stock or pipe segments at least 25 mm (1 in.) may be used.

The 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 4-2 for front suspension support block placement and Figure 4-4 for rear support block placement.

Table 1: FRONT SUSPENSION DIMENSIONS (EMPTY) OILING HEIGHT

25.4 mm (1.0 in.)

CHARGING HEIGHT

219 mm (8.62 in.)

CHARGING PRESSURE

*3 282 kPa (476 psi)

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

Table 2: REAR SUSPENSION DIMENSIONS (EMPTY) OILING HEIGHT

CHARGING HEIGHT

CHARGING PRESSURE

53.0 mm (2.1 in.)

218 mm (8.60 in.)

*1 351 kPa (196 psi)

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

Front suspension oiling

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

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

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

Wear a face mask or goggles while relieving nitrogen pressure. Make sure that all personnel are clear and support blocks are secure before relieving nitrogen pressure from the suspension.

An unsecured block could fly loose as weight is applied, causing serious injury to nearby personnel and/or damage to the equipment.

Overhead clearance may be reduced rapidly and suddenly when nitrogen pressure is released.

NOTE: For longer life of suspension components, a friction modifier should be added to the suspension oil. See the oil and nitrogen specification charts in the Specifications section.

1. Park the unloaded truck on a hard, level surface and chock the wheels.

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

3. Position and secure oiling height dimension blocks 180° apart to provide stability (See Figure 4-2). When nitrogen pressure is released, the suspensions will lower and rest on the blocks.

Ensure that the blocks do not mar or scratch the plated surfaces of the pistons or damage wiper seals in the lower bearing retainer. Support blocks must seat on the spindle and the cylinder housing.

4. Remove the charging valve cap. Turn the swivel nut (small hex) counterclockwise three full turns to unseat the valve seal. Do not turn the large hex. The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body must not be loosened until all nitrogen pressure has been released from the suspension.

FIGURE 4-2. FRONT SUSPENSION

6. Fill the suspension with clean Hydrair II oil (with 6% friction modifier) until the cylinder is full to the top of the fill plug bore. Use drip pans and clean all spillage from the outside of the suspension. Allow the suspension to settle for at least 15 minutes to clear any trapped nitrogen and bubbles from the oil. Add more suspension oil if necessary. Install a new O-ring on the fill plug and install the plug.

Front suspension nitrogen charging

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

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

1. If removed, install the charging valve with new O-ring (9, Figure 4-3). Lubricate the O-ring with clean Hydrair oil.

2. Tighten valve body (large hex) (6) to 23 Nm (17 ft lb). Swivel nut (small hex) (4) must be unseated by turning it counterclockwise three full turns.

Dry nitrogen is the only gas approved for use in Hydrair II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in the oil and nitrogen specification charts in the Specifications section.

3. Install the Hydrair charging kit and a bottle of pure dry nitrogen. Refer to "Installing the charging kit".

4. Charge the suspensions with nitrogen gas to 50.8 mm (2 in.) greater than the charging height listed in Table 1. Close inlet valve (4, Figure 41).

NOTE: If the truck starts to lift off the blocks before 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.

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

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

7. Open inlet valve (4) until the pressure drops below the pressure listed in Table 1, then close the valve.

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

FIGURE 4-3. 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

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

10. Close inlet valve (4). Leave outlet valves (3) open for five minutes to allow the pressures in the suspensions to equalize.

11. Close outlet valves (3). Remove the charging kit components. Refer to "Removing the charging kit".

12. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 6 Nm (50 in lb).

13. If a new charging valve is being used, tighten the swivel nut to 15 Nm (11 ft lb), then loosen and retighten the swivel nut to 15 Nm (11 ft lb).

Loosen the swivel nut again and retighten to 6 Nm (50 in lb). Install the valve cap finger-tight.

14. Install the protective guard over the charging valve.

Ensure that there is adequate clearance before raising the body.

overhead

15. Raise the truck body in order to extend the front suspensions, allowing for removal of the nitrogen charging blocks. If the suspensions do not extend after raising the body, turn the steering wheel from stop to stop several times.

If the suspensions still do not extend enough to allow for removal of the blocks, use a crane or floor jacks to raise the truck and remove the blocks.

The front suspensions are now ready for operation.

Visually check piston extension with the truck both empty and loaded. Record the extension dimensions.

Maximum downward travel is indicated by the dirt ring at the base of the piston. Operator comments on steering response and suspension rebound should also be noted.

Rear suspension oiling

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

Wear a face mask or goggles while relieving nitrogen pressure. Make sure that all personnel are clear and support blocks are secure before relieving nitrogen pressure from the suspension.

An unsecured block could fly loose as weight is applied, causing serious injury to nearby personnel and/or damage to the equipment.

Overhead clearance may be reduced rapidly and suddenly when nitrogen pressure is released.

NOTE: For longer life of suspension components, a friction modifier should be added to the suspension oil. See the oil and nitrogen specification charts in the Specifications section.

1. Park the unloaded truck on a hard, level surface and chock the wheels.

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

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

4. Remove charging valve cap (1, Figure 4-3).

Turn swivel nut (small hex) (4) counterclockwise three full turns to unseat the valve seal. Do not turn valve body (large hex) (6). The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body must not be loosened until all nitrogen pressure has been released from the suspension.

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

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

Lubricate the O-ring with clean Hydrair II oil.

9. Install the charging valve onto the suspension.

Tighten valve body (6, Figure 4-3) to 23 Nm (17 ft lb).

FIGURE 4-4. OILING BLOCK INSTALLATION 1. Main Frame 2. Oiling Support Block

3. Rear Axle Housing

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

NOTE: A plastic tube can be used to help bleed off trapped air inside the piston.

6. Remove the vent plug, pressure sensor, and charging valve (See Figure 4-5). Use one of the open ports to fill the suspension with clean Hydrair oil (with 6% friction modifier). Fill until clean oil seaps from the open ports. Use drip pans and clean all spillage from the outside of the suspension. Allow the suspension to settle for at least 15 minutes to clear any trapped nitrogen and bubbles from the oil. Add more suspension oil if necessary.

FIGURE 4-5. REAR SUSPENSION 1. Main Frame 2. Charging Valve 3. Rear Axle Housing

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

Rear suspension nitrogen charging

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

Lifting equipment must be of sufficient to lift the truck weight. Make sure personnel are clear of lift area before started. Clearances under the truck suddenly reduced.

capacity that all lifting is may be

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

1. If removed, install charging valve with new Oring (9, Figure 4-3). Lubricate the O-ring with clean Hydrair oil.

2. Tighten valve body (large hex) (6) to 23 Nm (17 ft lb). Swivel nut (small hex) (4) must be unseated by turning it counterclockwise three full turns.

Dry nitrogen is the only gas approved for use in Hydrair II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in the Specifications Chart at the end of this section.

3. Install the Hydrair charging kit and a bottle of pure dry nitrogen. Refer to "Installing the charging kit".

4. Charge the suspensions with nitrogen gas to 38 mm (1.5 in.) greater than the charging height listed in Table 2.

7. Make sure that both of the suspension cylinders are extended the same distance Âą 10 mm (0.39 in.). If the difference in the extension from side to side exceeds this amount, check the front suspensions for equal extension. Adjust the front suspensions as necessary.

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

8. Close outlet valves (3). Remove the charging kit components. Refer to "Removing the charging kit".

9. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 6 Nm (50 in lb).

10. If a new charging valve is being used, tighten the swivel nut to 15 Nm (11 ft lb), then loosen and retighten the swivel nut to 15 Nm (11 ft lb).

Loosen the swivel nut again and retighten to 6 Nm (50 in lb). Install the valve cap finger-tight.

11. Install the protective guards over the charging valves. Install the rubber covers over the piston rods.

The rear suspensions are now ready for operation.

Visually check piston extension with the truck both empty and loaded. Record the extension dimensions.

Maximum downward travel is indicated by the dirt ring at the base of the piston. Operator comments on steering response and suspension rebound should also be noted.

OIL AND NITROGEN SPECIFICATIONS CHARTS 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 Fluid Mobil D.T.E. 15 Conoco Power Tran III Fluid Petro Texaco TDH Oil 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-30

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 HYDRAIR®

Nitrogen gas used in 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

TOE-IN ADJUSTMENT PROCEDURE NOTE: Before returning the truck to operation, the steering system must first be centered in the straight ahead position.

1. Check the toe-in by measuring the distance between the centers of the front tires. Measure on the horizontal centerline at the front and rear of the tires. Refer to Figure 30-1.

Radial tires should have equal measurements (zero toe-in).

2. Loosen the clamp locknuts on the tie rod.

Rotate the tie rod as necessary to obtain the correct toe-in setting. The nominal tie rod length when installed is 3 696 mm (145.5 in.).

3. When the adjustment is complete, tighten the clamp locknuts on the tie rod to 420 Âą 42 Nm (310 Âą 31 ft lb).

4. Remove the blocks from the rear wheels.

FIGURE 30-1. MEASURING TOE-IN

NOTES

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

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

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

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

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

Special hydraulic system flushing tools for the 960E truck have been released. Hoist system bypass blocks (PC3074) and steering system flushing hose (XB5777) must be on-site before or during field assembly, so when the truck is started for the first time, the hydraulic system can be flushed and any debris can be removed from the hydraulic system.

Fitting assembly (XB7075) shown as (3, Figure 7) will also be required. Refer to Parts and Service News AA10081 for more information regarding hydraulic system flushing tools.

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

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

6. Install accurate pressure gauges at the following locations:

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

•Pressure test port “TP3” (4, Figure 1) on the bleed down manifold - 35 000 kPa (5,000 psi).

•Pressure test port (1, Figure 2) for the front brake cooling circuit - 3 450 kPa (500 psi).

•Pressure test ports (2) on both high pressure hoist filters - 24 000 kPa (3,500 psi).

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

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

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

•Pressure test port (1, Figure 3) for the rear brake cooling circuits - 3 450 kPa (500 psi).

•Pressure test port “GPA” (2, Figure 4) located on the steering pump - 35 000 kPa (5,000 psi). .

If any hydraulic pressure is detected on the pressure gauge installed at TP3, there is residual oil pressure in the system. Do not loosen or remove any hydraulic hoses, fittings or components. The steering accumulators have not been properly depressurized. Locate and correct the depressurization problem. Always relieve all hydraulic pressure before disconnecting any hydraulic lines or fittings. Always tighten all connections securely before applying pressure. Confirm that the steering pressure is released by turning the steering wheel. No steering movement should occur.

7. Ensure pressure gauge connected at "TP3" reads 0 kPa (0 psi) before removing plugs (1 & 2, Figure 1). Remove plugs (1 & 2) from the bleed down manifold. Connect jumper hose assembly (XB5777) between "QD supply" port and the "QD return" port on the bleed down manifold. Tighten all connections securely before applying pressure.

8. Connect the four hoist cylinder hoses (3, Figure 2) together as shown using bypass blocks (4).

The hardware for connecting the hoses to the blocks is the same hardware for connecting the hoses to the hoist cylinders. Ensure that all of the connections are secure. Cover all open ports to prevent contamination.

FIGURE 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 1. BLEED DOWN MANIFOLD 1. Plug - QD Supply Port 4. Test Port (TP3) 2. Plug - QD Return Port 5. Test Port (TP2) 3. Bleed Down Manifold

9. At the rear axle housing, connect brake cooling lines (1, 2 & 3, Figure 5) together using fitting assembly (3, Figure 7). Cap the three open fittings on the axle housing with clean caps. Several hose clamps may have to be removed to connect the three hoses to the fitting assembly.

10. At the left front brake assembly, connect cooling hoses (1 & 3, Figure 6) together using adapter (2). Cap the open fittings on the brake assembly. At the right front brake assembly, connect the two cooling hoses together using another adapter. Cap the open fittings on the brake assembly.

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

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

NOTE: The adapters are installed on the truck when it is shipped from the factory.

FIGURE 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 4. STEERING PUMP & HOIST SYSTEM QUICK DISCONNECTS 1. Fitting (Pump Case Drain) 2. Test Port (GPA)

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

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

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

FIGURE 6. FRONT WHEEL BRAKE LINES 1. Cooling Hose 2. Adapter (EG1794)

3. Cooling Hose 4. Brake Apply Hose

FIGURE 7. FITTING ASSEMBLY

FIGURE 5. REAR AXLE BRAKE LINES 1. BS - Left & Right Brake Cooling Supply 2. LBR - Left Brake Cooling Return 3. LBR - Left Brake Cooling Return

1. 90° Swivel Elbow (PC3062) 2. T-Fitting (WB0426) 3. Fitting Assembly (XB7075)

Do not apply the brakes or turn the steering wheel at any time during this procedure until Step 31.

15. Ensure both brake accumulator bleed down valves (1, Figure 8) are open.

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

19. If the oil pressure readings in Step 18 are correct, increase the engine speed to obtain oil pressure at test port "GPA" of 1 725 kPa (250 psi). Move the hoist control lever to the POWER UP or to the POWER DOWN position. The pressure readings at the front brake cooling port (1, Figure 2) and rear brake cooling test port (1, Figure 3) should be 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 the hoist valve could be defective. Correct the plumbing problem or replace the hoist valve and repeat this step.

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

18. Start the engine and operate at low idle. Within 30 seconds after starting the engine, check the two oil pressures listed below. If the oil pressure readings are not correct, stop the engine.

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

•With the engine at low idle, and the oil temp at 21° C (70° F), oil pressure at the hoist filters should be approximately 552 kPa (80 psi) or less.

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

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

FIGURE 8. BRAKE MANIFOLD 1. Accumulator Bleed Down Valves 2. Brake Manifold

20. 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 the system for 20 minutes. During this time, move the hoist control lever to the POWER UP position for 30 seconds, and then move it to the POWER DOWN position for 30 seconds. Repeat this hoist control cycle five times. This process will carry any system contaminants to the hydraulic filters.

Monitor the pressure gauges at the front and rear brake cooling test ports during this step.

The pressure readings should always be 0 kPa (0 psi) when the hoist valve is in the POWER UP or POWER DOWN positions, and approximately 345 kPa (50 psi) while in the HOLD or FLOAT positions.

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

22. Remove the adapters from both front wheel brake cooling hoses and re-connect the cooling hoses to the front brake assemblies.

23. Remove the tee fitting assembly from the three rear brake cooling hoses. Re-connect the three rear brake cooling hoses to the axle housing.

24. Check the pressure gauge connected to the "TP3" port on the bleed down manifold. If any pressure is still in the system, the bleed down process did not complete. Locate and repair the problem. If the pressure is 0 kPa (0 psi), remove the jumper hose and fittings installed in the bleed down manifold. Install the two plugs (1 & 2, Figure 1) previously removed back into the bleed down manifold.

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

26. Close both brake accumulator bleed down valves (1, Figure 8).

NOTE: Do not combine Step 27 with any other steps.

Do not apply the brakes or steer the truck during Step 27.

27. To flush the accumulators, start the engine and operate the engine until the pressure at the "TP3" port on the bleed down manifold is approximately 24 304 kPa (3,525 psi). This is the pressure where the steering pump unloader valve shifts and unloads the pump.

•If the accumulator pressure exceeds 24 648 kPa (3,575 psi), immediately turn the engine off and open the brake accumulator bleed down valves. Refer to Steering pump pressure control adjustments in the shop manual, then repeat Steps 26 and 27.

•If the accumulator pressure does not reach 23 960 kPa (3,475 psi), check for faults on the instrument panel. If there is a bleed down fault active, locate and correct the problem. If no faults are active, refer to Steering pump pressure control adjustments in the shop manual, then repeat Step 27.

28. When the pressure gauge connected to "TP3" reads approximately 24 304 kPa (3,525 psi): a. For the first time only through this step: •Leave the key switch in the ON position, and use the engine shut down switch on the center console to stop the engine. (Status message A184 will be displayed.)

•After the engine has stopped, confirm that steering accumulator bleed down does not occur, and that no bleed down faults or any other faults are generated. b. The second and subsequent times through this step: •Turn the key switch to the OFF position. Confirm that after the engine has stopped the steering accumulator bleed down process begins.

Confirm that status A235 "Steering bleed in process" is displayed and that the buzzer beeps one time.

•Confirm that accumulator bleed down completes within two minutes. Also confirm that bleed down fault A236 "Steering bleed fault" or any other bleed down fault does not become active.

The pressure gauge at the bleed down manifold pressure test port "TP3" will be 103 kPa (15 psi) or less after a successful bleed down.

29. If Step 28-b results are satisfactory, open both brake accumulator bleed down valves (1, Figure 8) on the brake manifold to completely depressurize the brake accumulators. After all hydraulic pressure has been released, close both accumulator bleed down valves. Repeat Steps 27 - 29 five times.

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

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

31. Turn the steering wheel full left and then full right ten times.

32. Turn the key switch to the OFF position. Allow at least two minutes after the engine has stopped for the steering accumulators to completely depressurize. The pressure gauge at the bleed down manifold pressure test port "TP3" will be 103 kPa (15 psi) or less after a successful bleed down.

33. The hydraulic system flushing procedure has been completed. All hydraulic system high pressure filter elements must be replaced. a. A vacuum pump can be connected to the hydraulic tank to prevent oil loss while changing the filters. b. Remove the hoist and steering hydraulic filter elements. Clean the housings and install new filter elements. c. If installed, remove the vacuum pump.

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

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

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

37. After the steering and brake system checkout procedures are completed, remove hoist cylinder bypass blocks (4, Figure 2) and connect the hoist cylinder hoses to the hoist cylinders.

Ensure the hoses and ports are clean to prevent contamination.

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

NOTES

KOMATSU

CHECKOUT PROCEDURE

IEJ4060-2 Page 1 of 2

NAME: Auto Lube Grease Procedure WRITTEN BY:

DATE:

B. Anderson CHECKED BY:

7-4-00 DATE:

M. McMullen APPROVED

BY:

7-7-00 DATE:

MACHINE & MODEL: Electric Trucks

2

Change Note 'Note some pumps, etc.

0 DASH ASIZE

DESCRIPTION OF CHANGE MICROFILM

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THE FOllOWING PROCEDURE MUST BE DONE ON INITIAL START-UP FOR THE LINCOLN INDUSTRIAL ROTARY HYDRAULIC GREASE PUMP WITH ADJUSTABLE CONTROLS. 1.

Check adjustment of pressure regular valve which should be set at 325 to 350 psi. (note this valve is parallel to pump motor and is suppose to be factory set @ 350 psi).

2.

Flow control valve should be set so a cycle would take 18 seconds to complete. (note this valve is perpendicular to pump motor).

LINCOLN INDUSTRIAL ROTARY HYDRAULIC GREASE PUMP WITH FIXED PUMP CONTROLS NO ADJUSTMENT CAN BE MADE. I.

Observe gauge during cycle 325 psi minimum pressure should be obtained.

2.

Flow control valve should be set so a cycle would take 16 to 20 secondsto complete.

THE FOllOWING PROCEDURES MUST BE DONE IN ORDER TO REMOVE ANY TRAPPED AIR THAT IS IN THE lUBE SYSTEMS AND PROPERLY lUBE THE SPHERICAL BEARINGS. 1. On initial start up of the system.

2.

When any parts or hoses are replaced or removed.

3.

During the factory build of the truck (before the truck ships). This includes ship loose parts.

4.

Prior to delivery of new units after field erection.

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KOMATSU

CHECKOUT PROCEDURE

IEJ4060-2 PaQe 2 of 2

PROCEDURE:

AUTO LUBE SYSTEMS

1. To purge the air from the main supply line, remove the main supply line at the Lincoln Lube canister and connect the shop grease pump to the supply line. (Some adaptation may be required to connect the shop grease pump to the supply line).

2.

Remove the pipe plugs from each injector group in sequence, (right front, left front and rear axle). Using the shop grease pump, pump the grease, until grease appears at the group of injectors and re-install the pipe plug. Repeat for the other 2 groups of injectors.

3.

Remove the shop grease pump from the main supply line and reconnect the main supply line to the grease canister.

4.

Remove the injector caps from each injector and connect the shop grease pump to the zerk fitting on the injector and pump grease until grease appears at the far end of the individual grease hose or at the joint that is being greased.

5.

Repeat Step 4 for all injectors on the truck.

PROCEDURE: 1.

STANDARD LUBE SYSTEMS

Connect the shop grease pump to each zerk fitting on the truck and pump grease until grease comes out of the far end of the individual grease hose or the joint that is being greased.

PROCEDURE:

FOR GREASING SPHERICAL BEARINGS (FACTORY ASSEMBLY)

Greasing the spherical bearings can be done by one or more of the following:

.

. .

Using the shop grease gun, pump the spherical bearing full of grease until grease is visible from both sides of the bearing. This is to be done on all spherical bearings.

On sub-assemblies not installed and not subject to final assembly inspection - install a zerk fitting into the port where the grease hose will be connected or use a tapered rubber adapter to push against the grease port.

On sub-assemblies where spherical bearings are installed and subject to final assembly inspection

-

use the standard grease system or the

Lincoln Lube System already installed and purged.

PROCEDURE:

DRIVE SHAFTS

Grease all universal joints and slipjoints until grease appears.

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NOTE: DO NOT use Initial Startup and Flushing procedure (steps 4 through 18) for 960E-1K trucks. Refer to Hydraulic System Flushing Procedure earlier in the Appendix.

TORQUE TABLES AND CONVERSION CHARTS

This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard units in parentheses. When torque values are not specified in the assembly instructions contained in this manual, use the standard torque value for the hardware being used. Standard value torque tables are contained in this chapter for metric and SAE hardware.

References throughout the manual to standard torques or other standard values will be to one of the following tables. Do not use standard values to replace specific torque values in assembly instructions.

NOTE: This truck is assembled with both metric and SAE (U.S.) hardware. Reference the correct table when determining the proper torque value.

For values not shown in any of the charts or tables, standard conversion factors for most commonly used measurements are provided in the following tables.

INDEX OF TABLES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

TABLE 1

Standard Tightening Torque For Metric Cap screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

TABLE 2

Standard Tightening Torque For SAE Grade 5 & 8 Cap Screws and Nuts . . . . . . . . . . . . . . . . 12-3

TABLE 3

Standard Tightening Torque 12-Pt, Grade 9, Cap Screws (SAE) . . . . . . . . . . . . . . . . . . . . . . . 12-4

TABLE 4

Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

TABLE 5

Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

TABLE 6

Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

TABLE 7

JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

TABLE 8

Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

TABLE 9

O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

TABLE 10

O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

TABLE 11

Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

TABLE 12

Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

TABLE 13

Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values

STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts

The Komatsu engineering department does not recommend the use of special friction-reducing lubricants, such as Copper Coat, Never-Seez®, and other similar products, on the threads of standard fasteners where standard torque values are applied.

The use of special friction-reducing lubricants will significantly alter the clamping force being applied to fasteners during the tightening process.

The following specifications apply to required assembly torques for all metric class 10.9 finished hexagon head cap screws and class 10 nuts.

If special friction-reducing lubricants are used with the standard torque values listed in this chapter, excessive stress and possible breakage of the fasteners may result.

Where the torque tables specify “Lubricated Threads” for the standard torque values listed, these standard torque values are to be used with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust-preventive grease (see below) on the threads and seats unless specified otherwise.

NOTE: Ensure the threads of fasteners and tapped holes are free of burrs and other imperfections before assembling.

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

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

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

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

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

• In the following table under “Cap Screw Size”, the first number represents the shank diameter (mm). The second number represents threads per millimeter.

Example: M20 x 2.25 M20 = shank diameter (20 mm) 2.25 = threads per millimeter

• Gulf NoRust #3 from Gulf Oil Company.

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

• Rust Ban 326 from Humble Oil Company.

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

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

TABLE 1.

Standard Tightening Torque for Metric Class 10.9 Cap screws & Class 10 Nuts Cap Screw Size

Torque N•m

Torque ft lb

Torque kg•m

M6 x1

12

9

1.22

M8 x 1.25

30

22

3.06

M10 x 1.5

55

40

5.61

M12 x 1.75

95

70

9.69

M14 x 2

155

114

15.81

M16 x 2

240

177

24.48

M20 x 2.25

465

343

47.43

M24 x 3

800

590

81.6

M30 x 3.5

1600

1180

163.2

M36 x 4

2750

2028

280.5

STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assembly torques for all grade 5 and grade 8 cap screws.

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

• Cap screw threads and seats shall be lubricated when assembled.

• In the following table under Cap Screw Size, the first number represents the shank diameter (in.).

The second number represents threads per inch.

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

Example: 7/16 - 20 7/16 = shank diameter (7/16 inch (0.438 inch)) 20 = threads per inch

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

TABLE 2.

Standard Tightening Torque for SAE Hex Head Cap Screw And Nut Assembly Torque Grade 5

Torque Grade 8

Cap Screw Size

N·m

ft lb

kg·m

N·m

ft lb

1/4-20

9.5

7

0.97

13.6

10

1/4-28

10.8

8

1.11

14.9

11

5/16-18

20.3

15

2.07

28

21

Torque Grade 5

Torque Grade 8

kg·m

Cap Screw Size

N·m

ft lb

kg·m

N·m

ft lb

kg·m

1.38

3/4-16

319

235

32.5

454

335

46.3

1.52

7/8-9

475

350

48.4

678

500

69.2

2.90

7/8-14

508

375

51.9

719

530

73.3

5/16-24

22

16

2.21

30

22

3.04

1.0-8

712

525

72.6

1017

750

103.7

3/8-16

34

25

3.46

47

35

4.84

1.0-12

759

560

77.4

1071

790

109.3

3/8-24

41

30

4.15

54

40

5.5

1.0-14

773

570

78.8

1085

800

110.6

7/16-14

54

40

5.5

79

58

8.0

1 1/8-7

881

650

89.9

1424

1050

145

7/16-20

61

45

6.2

84

62

8.57

1 1/8-12

949

700

96.8

1546

1140

158

1/2-13

88

65

9

122

90

12.4

1 1/4-7

1234

910

125.9

2007

1480

205

1/2-20

95

70

9.7

129

95

13.1

1 1/4-12

1322

975

134.8

2142

1580

219

9/16-12

122

90

12.4

169

125

17.3

1 3/8-6

1627

1200

166

2630

1940

268

9/16-18

129

95

13.1

183

135

18.7

1 3/8-12

1776

1310

181

2874

2120

293

5/8-11

169

125

17.3

237

175

24.2

1 1/2-6

2142

1580

219

3471

2560

354

5/8-18

183

135

18.7

258

190

26.2

1 1/2-12

2305

1700

235

3756

2770

383

3/4-10

298

220

30.4

420

310

42.8

1 ft. lb. = 0.138 kg·m = 1.356 N.m

STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assembly torques for all 12-point, grade 9 (170,000 psi minimum tensile), cap screws.

• Cap screw threads and seats shall be lubricated when assembled.

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

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

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

TABLE 3.

Standard Tightening Torque for 12-Point, Grade 9 Cap Screws Cap Screw Size*

Torque N·m

Torque ft lb

Torque kg·m

0.250 - 20

16

12

1.7

0.312 - 18

33

24

3.3

0.375 - 16

57

42

5.8

0.438 -14

95

70

9.7

0.500 -13

142

105

14.5

0.562 - 12

203

150

20.7

0.625 - 11

278

205

28.3

0.750 - 10

488

360

49.7

0.875 - 9

780

575

79.4

1.000 - 8

1166

860

119

1.000 - 12

1240

915

126

1.125 - 7

1670

1230

170

1.125 - 12

1800

1330

184

1.250 - 7

2325

1715

237

1.250 - 12

2495

1840

254

1.375 - 6

3080

2270

313

1.375 - 12

3355

2475

342

1.500 - 6

4040

2980

411

1.500 - 12

4375

3225

445

* Shank Diameter (in.) - Threads per inch

TABLE 4.

Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Thread Size

Band Width

Newton meters (N·m)

Inch Pounds (in. lb)

0.25-28 UNF

19.05 mm (0.75 in.)

8.5 ± 0.6 N·m

75 ± 5 in lb

Cap Screw Thread Diameter (mm) 10 12 16

Thread Diameter of Nut (mm) 14 18 22 24 30 33 36 42

Width Across Flat (mm) 14 17 22

TABLE 5.

Tightening Torque For Split Flange Clamp Bolts Newton meters (N·m) Tolerances ±10% 66 112 279

Foot Pounds (ft lb) Tolerances ±10% 48 83 206

Kilogram meters (kg·m) Tolerances ±10% 6.7 11.5 28.5

Width Across Flat (mm) 19 24 27 32 36 41 46 55

TABLE 6.

Tightening Torque For Flared Tube And Hose Fittings Newton meters (N·m) Tolerances ±10% 25 50 80 140 175 195 245 295

Foot Pounds (ft lb) Tolerances ±10% 18 36 58 101 130 145 180 215

Kilogram meters (kg·m) Tolerances ±10% 2.5 5 8 14 18 20 25 30

TABLE 7.

Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Code

Tube Size (OD)

Threads UNF-2B

Newton meters (N·m)

Foot Pounds (ft lb)

–2

0.125

0.312 – 24

5±1

4±1

–3

0.188

0.375 – 24

11 ± 4

8±3

–4

0.250

0.438 – 20

16 ± 4

12 ± 3

–5

0.312

0.500 – 20

20 ± 4

15 ± 3

–6

0.375

0.562 – 18

24 ± 7

18 ± 5

–8

0.500

0.750 – 16

40 ± 7

30 ± 5

– 10

0.625

0.875 – 14

54 ± 7

40 ± 5

– 12

0.750

1.062 – 12

75 ± 7

55 ± 5

– 14

0.875

1.188 – 12

88 ± 7

65 ± 5

– 16

1.000

1.312 – 12

108 ± 7

80 ± 5

– 20

1.250

1.625 – 12

136 ± 14

100 ± 10

– 24

1.500

1.875 – 12

163 ± 14

120 ± 10

– 32

2.000

2.500 – 12

312 ± 27

230 ± 20

TABLE 8.

Torque Chart For Pipe Thread Fittings Size Code

Pipe Thread Size

With Sealant N·m

With Sealant ft lb

Without Sealant N·m

Without Sealant ft lb

–2

0.125 – 27

20 ± 4

15 ±3

27 ± 7

20 ± 5

–4

0.250 – 18

27 ± 7

20 ±5

34 ± 7

25 ± 5

–6

0.375 – 18

34 ± 7

25 ±5

48 ± 7

35 ± 5

–8

0.500 – 14

48 ± 7

35 ±5

61 ± 7

45 ± 5

– 12

0.750 – 14

61 ± 7

45 ±5

75 ± 7

55 ± 5

– 16

1.000 – 11.50

75 ± 7

55 ±5

88 ± 7

65 ± 5

– 20

1.250 – 11.50

95 ± 7

70 ±5

108 ± 7

80 ± 5

– 24

1.500 – 11.50

108 ± 7

80 ±5

129 ± 14

95 ± 10

– 32

2.000 – 11.50

129 ± 14

95 ±10

163 ± 14

120 ± 10

TABLE 9.

Torque Chart For O-ring Boss Fittings Size Code

Tube Size (OD) Threads UNF-2B

Newton meters (N·m)

Foot Pounds (ft lb)

4±3

4±2

–2

0.125

0.312 – 24

–3

0.188

0.375 – 24

7±3

5±2

–4

0.250

0.438 – 20

11 ± 4

8±3

–5

0.312

0.500 – 20

14 ± 4

10 ± 3

–6

0.375

0.562 – 18

18 ± 4

13 ± 3

–8

0.500

0.750 – 16

33 ± 7

24 ± 5

– 10

0.625

0.875 – 14

43 ± 7

32 ± 5

– 12

0.750

1.062 – 12

65 ± 7

48 ± 5

– 14

0.875

1.188 – 12

73 ± 7

54 ± 5

– 16

1.000

1.312 – 12

98 ± 7

72 ± 5

– 20

1.250

1.625 – 12

109 ± 7

80 ± 5

– 24

1.500

1.875 – 12

109 ± 7

80 ± 5

– 32

2.000

2.500 – 12

130 ± 14

96 ± 10

TABLE 10.

Torque Chart For O-ring Face Seal Fittings Size CodeE

Tube Size (O.D.)

Threads UNF-2B

Newton meters (N·m)

Foot Pounds (ft lb)

–4

0.250

0.438 – 20

15 ± 1

11 ± 1

–6

0.375

0.562 – 18

24 ± 3

18 ± 2

–8

0.500

0.750 – 16

48 ± 5

35 ± 4

– 10

0.625

0.875 – 14

69 ± 7

51 ± 5

– 12

0.750

1.062 – 12

96 ± 10

71 ± 7

– 16

1.000

1.312 – 12

133 ± 8

98 ± 6

– 20

1.250

1.625 – 12

179 ± 10

132 ± 7

– 24

1.500

1.875 – 12

224 ± 20

165 ± 15

TABLE11.

Common Conversion Multipliers Metric To English To Convert From

To

Multiply By

millimeter (mm)

inch (in.)

0.0394

centimeter (cm)

inch (in.)

0.3937

meter (m)

foot (ft)

3.2808

meter (m)

yard (yd)

1.0936

kilometer (km)

mile (mi)

0.6210

square centimeters (cm2)

square inch (in.2)

0.1550

square centimeters (cm2)

square feet (ft2)

0.001

cubic centimeters (cm3)

cubic inch (in.3)

0.061

liters (l)

cubic inch (in.3)

61.02

cubic meters (m3)

cubic feet (ft3)

35.314

liters (l)

cubic feet (ft3)

0.0353

grams (g)

ounce (oz)

0.0353

milliliter (ml)

fluid ounce (fl oz)

0.0338

kilogram (kg)

pound (mass)

2.2046

Newton (N)

pounds (lb)

0.2248

Newton meters (N·m)

kilogram meters (kg·m)

0.102

Newton meters (N·m)

foot pounds (ft lb)

0.7376

kilogram meters (kg·m)

foot pounds (ft lb)

7.2329

kilogram meters (kg·m)

Newton meters (N·m)

9.807

kilopascals (kPa)

pounds/square inch (psi)

0.1450

pounds/square inch (psi)

145.038

kilograms/cm (kg/cm )

pounds/square inch (psi)

14.2231

kilograms/cm2 (kg/cm2)

kilopascals (kPa)

98.068

kilogram (kg)

short ton (tn)

0.0011

metric ton

short ton (tn)

1.1023

liters (l)

quart (qt)

1.0567

megapascals (MPa) 2

2

liters (l)

gallon (gal)

0.2642

Watts (W)

horsepower (hp)

0.00134

kilowatts (kW)

horsepower (hp)

1.3410

TABLE 12.

Common Conversion Multipliers English to Metric To

Multiply By

inch (in.)

millimeter (mm)

25.40

inch (in.)

centimeter (cm)

2.54

To Convert From

foot (ft)

meter (m)

0.3048

yard (yd)

meter (m)

0.914

mile (mi)

kilometer (km)

1.61

square centimeters (cm )

6.45

square feet (ft2)

square centimeters (cm2)

929

cubic inches (in.3)

cubic centimeters (cm3)

16.39

cubic inches (in.3)

liters (l)

0.016

cubic feet (ft3)

cubic meters (m3)

0.028

cubic feet (ft.3)

liters (l)

28.3

ounce (oz)

kilogram (kg)

0.028

fluid ounce (fl oz)

milliliter (ml)

29.573

pound (lb)

kilogram (kg)

0.454

pound (lb)

Newton (N)

4.448

inch pounds (in. lb)

Newton meters (N·m)

0.113

foot pounds (ft lb)

Newton meters (N·m)

1.356

foot pounds (ft lb)

kilogram meters (kg·m)

0.138

kilogram meters (kg·m)

Newton meters (N·m)

9.807

pounds/square inch (psi)

kilopascals (kPa)

6.895

square inch

(in.2

)

2

pounds/square inch (psi)

megapascals (MPa)

0.007

pounds/square inch (psi)

kilograms/square centimeter

0.0704

(kg/cm2) short ton (tn)

kilogram (kg)

907.2

short ton (tn)

metric ton (t)

0.0907

quart (qt)

liters (l)

0.946

gallon (gal)

liters (l)

3.785

horsepower (hp)

Watts (w)

745.7

horsepower (hp)

kilowatts (kw)

0.745

Celsius C° 121 118 116 113 110 107 104 102 99 96 93 91 88 85 82 79 77 74 71 68 66

250 245 240 235 230 225 220 215 210 205 200 195 190 185 180 175 170 165 160 155 150

TABLE 13.

Temperature Conversions Formula: F° - 32  1.8 = C° or C° x 1.8 + 32 = F° Fahrenheit Celsius Fahrenheit Celsius F° C° F° C° 482 63 145 293 4 473 60 140 284 2 464 57 135 275 –1 455 54 130 266 –4 446 52 125 257 –7 437 49 120 248 –9 428 46 115 239 – 12 419 43 110 230 – 15 410 41 105 221 – 18 401 38 100 212 – 21 392 35 95 293 – 23 383 32 90 194 – 26 374 29 85 185 – 29 365 27 80 176 – 32 356 24 75 167 – 34 347 21 70 158 – 37 338 18 65 149 – 40 329 15 60 140 – 43 320 13 55 131 – 46 311 10 50 122 – 48 302 7 45 113 – 51

40 35 30 25 20 15 10 5 0 –5 – 10 – 15 – 20 – 25 – 30 – 35 – 40 – 45 – 50 – 55 – 60

Fahrenheit F° 104 95 86 77 68 59 50 41 32 23 14 5 –4 – 13 – 22 – 31 – 40 – 49 – 58 – 67 – 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.

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

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

CUSTOMER UNIT NUMBER

960E-1 960E-1K Service Meter Reading

Date of Inspection

Wheel Motor Traction Motor Serial Numbers

Location of Machine at Inspection Distributor’s Name

LH

RH

Serial Numbers

LH

RH

Dump Body Manufacturer Komatsu

Other

Wheel Motor Transmission

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.

CEAW005605

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.

Visually inspect installation of steering cylinders, tie rod, and accumulators per print.

14

Frame

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 Nm (860 ± 100 ft lb).

2

3

Wheels

Verify torque on rear inside wheel nuts is at 1 166 ± 136 Nm (860 ± 100 ft lb).

(See Note below.)

Verify torque on rear outside wheel nuts and adapter ring is at 2 326 ± 136 Nm (1,715 ± 100 ft lb).

Verify torque on left rops beam cap screws is at 881 Nm (650 ft lb).

Rops

Verify torque on right cross beam cap screws is at 240 Nm (177 ft lb).

4

Cab

Verify torque on cab mounting cap screws is at 1 424 Nm (1,050 ft lb).

5

Wheel Motor

Verify torque on wheel motor mounting cap screws is at 3 471 Nm (2,560 ft lb).

6

Tie Rod Clamp Nuts

Verify torque on tie rod clamp nuts is at 420 ± 42 Nm (310 ± 31 ft lb).

NOTE: Refer to the appropriate Disassembly and Assembly section in the shop manual for the complete wheel mounting tightening procedure.

CEAW005605

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

Verify left and right door locks work properly with key.

Visually inspect interior for completeness of assembly.

4

Interior

5

Cab Seats

6

Steering Wheel

7

Wiper

8

Document Holder

Verify O&M manual and safety manual are present.

9

Cigarette Lighter (960E-1K )

Check lighter operation. Should pop up in 10 sec. and be hot.

10

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.

15

Hoist

Check operation of hoist lever in all four positions.

1

Dome Light

Verify dome light operates properly.

2

Dimmer Switch

Verify dimmer operates properly.

Visually inspect for cracked glass, torn upholstery, dirt, stains, holes, etc.

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.

Lights

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.

CEAW005605

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 flushing procedure at initial startup.

Front suspension oiling height is 25.4 mm (1 in.).

2

Suspensions

Rear suspension oiling height is 53.0 mm (2.1 in.).

(See Note below.)

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).

Verify nitrogen charge in both steering and brake accumulators is at 9 653 kPa (1,400 psi).

3

Accumulators

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.

(Charging pressure will vary with ambient temperature. Refer to chart in shop manual.)

Verify with pedal depressed, front brake pressure (BF) is 16 545 ± 517 kPa (2,400 ± 75 psi).

9

Brake Pressures

Verify with pedal depressed, rear brake pressure (BR) is 16 545 ± 517 kPa (2,400 ± 75 psi).

Verify brake lock pressure is 13 790 ± 689 kPa (2,000 ± 100 psi).

Verify parking brake release pressure is 22 753 ± 1 378 kPa (3,300 ± 200 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 18 960 kPa (2,750 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 22-26 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

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.

Calibrate and check payload meter operation per shop/O&M manual instructions.

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.

CEAW005605

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 ________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW005605

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

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

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

CUSTOMER UNIT NUMBER

860E-1K 860E-1KT 960E-1K Service Meter Reading

Date of Inspection

Wheel Motor Traction Motor Serial Numbers

Location of Machine at Inspection Distributor’s Name

LH

RH

Serial Numbers

LH

RH

Dump Body Manufacturer Komatsu

Other

Wheel Motor Transmission

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 Pin

Visually inspect the anchor hitch pin and anti-sway bar assembly for proper installation and properly tightened hardware.

7

Wheel Motors

Verify the correct oil is being used and oil is at the proper level.

8

Fuel Tank

Verify the fuel tank mounting is secure and there are no fuel leaks.

9

Radiator

Inspect the coolant fill level, cold temperature protection, and DCA additive.

10

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

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).

860E-1K 860E-1KT

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

7

8

Check and record the tire pressure/size/manufacturer for future reference

Tires

Payload Meter System Komatsu Drive & Control System Komatsu Rotating Components

9

(Wheel Motors, Main Traction Alternator, Grid Blower)

10

VHMS

CEAW006003

Size Manufacturer

Calibrate and check payload meter operation per O&M manual. Troubleshoot any error codes and delete after repair.

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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