Komatsu Dump Truck 860E-1K, 860E--1KT Field Assembly Manual - PDF DOWNLOAD

CEAW007201

Field Assembly Manual

860E DUMP TRUCK

SERIAL NUMBERS

860E-1K 860E-1KT

A30031 & UP A30036 & UP

®

FOREWORD This manual is provided to aid assemblers during field assembly of the standard Komatsu 860E-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.

FAM0021

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

FAM0021

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

FAM0021

Introduction

iii

KOMATSU 860E-1K

iv

Introduction

FAM0021

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.

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

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.

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

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

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

NOTE: The anchor must not be used for lifting.

FAM0116 9/11

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 torch 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 7/16 in. (PB8326) with 12 inch extension to tighten ROPS cap screws.

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

15. Heavy duty 3/4 in. & 1 in. 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

9/11 FAM0116

LIFTING SLING GENERAL INFORMATION

FAM0116 9/11

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

EJ2626 (No longer available as complete unit)

Roller Assy.

Power Module Remove & Install

EJ2271

Roller Mount

PC0706

Bearing

TH9449

Bearing Retainer Ring

TG1680

Roller Retainer Ring

C1645

Cap screw 0.75 -10 NC x 2 1/4 in.

C1542

Lock washer 0.75 in.

EH8686

Roller Ring

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Safety Rules, Tools, & Equipment

9/11 FAM0116

FAM0116 9/11

Part Number

Description

PB8326

Offset Box End Wrench - 1 7/16�

Part Number

Description

EH4638

Sleeve Alignment Tool

Safety Rules, Tools, & Equipment

Use Cab Mounting & Miscellaneous

Use Steering Linkage and Tie Rod Assembly

Page 1-5

Part Number

Description

EM3704 (Rear)

Wear Indicator

EM3702 (Front) EB1723

Cap, Indicator

EM3703 (Rear)

Pin, Indicator

Use Brake Disc Wear Inspection

EM3701 (Front) WA0010

O-ring, Indicator Pin

TL3995

O-ring, Indicator Cap

EB4813

Housing, Indicator

SV9812

O-ring, Housing

Part Number

Description

PC2525

Harness

Page1-6

Use Payload Meter Download

Safety Rules, Tools, & Equipment

9/11 FAM0116

FAM0116 9/11

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

TZ2734

3/4 in. Square Drive

Torque Adaptor

TZ2733

Handle

Torque Adaptor

Part Number

Description

Use

PC2764

Sling

Body Retention

Part Number

Description

Use

PC0367

Shackle

Body Retention Miscellaneous

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Safety Rules, Tools, & Equipment

9/11 FAM0116

Part Number

Description

Use

EM3705

Brake Assembly Tool Group (Front)

Brake Assembly & Disassembly

EM3706

Brake Assembly Tool Group (Rear)

Brake Assembly & Disassembly

HYDRAULIC SYSTEM FLUSHING TOOLS Part Number

Description

Use

XB5777

Hose Assembly

Flush Steering Circuit

PC3074

Flushing Block (bypass hoist cylinders)

Flush Hoist Circuit

XB7075

Fitting Assembly

Flush Brake Circuit

HYDRAULIC SYSTEM VACUUM PUMP Part Number XB0887

FAM0116 9/11

Description Vacuum Pump

Use To hold oil back while the system is open.

Safety Rules, Tools, & Equipment

Page 1-9

XC2293 SPACER BLOCK DIMENSION

Page1-10

Safety Rules, Tools, & Equipment

9/11 FAM0116

R

TYP

REF

R

3.0

TYP

* NOTE INCH EQUIVALENT MATERIAL 2.00" PLATE

50.8

8.0

355.6

387.5

20.0

40.0

15.9

FAM0116 9/11

Safety Rules, Tools, & Equipment

Page 1-11

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Safety Rules, Tools, & Equipment

9/11 FAM0116

TRUCK COMPONENTS AND SPECIFICATIONS Truck And Engine

Operator's Cab

The 860E Dump Truck is an off-highway, rear dump truck with AC Electric Drive. The gross vehicle weight is 454 363 kg (1,001,700 lb). The engine is a Komatsu SSDA16V160 rated @ 2700 HP (2014 kW).

The operator cab has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab is rubber-mounted to reduce noise and vibration, provides wide visibility with an integral 4-post ROPS/FOPS structure, and has 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 digital/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.

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.

FAM0222

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

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

Brake System 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 wet disc type, integral to the service brakes, and is spring-applied and hydraulically-released with wheel speed application protection (will not apply with truck moving).

Truck Components And Specifications

Page 2-1

FIGURE 2-1. TOP VIEW 1.

2.

3.

4.

5.

6.

7.

Operator Cab Auto Lubrication Radiator Reserve Oil System Engine Fuel Filters Suspension

Page 2-2

8. Wet Disc Brake 9. Brake Accumulators 10. Hoist Filters 11. Steering Filter 12. Fuel Tank 13. Hoist Cylinder 14. Rear Axle Housing

15. Wet Disc Brake 16. Wheel Motor Transmission 17. Rear Tires 18. Rear Suspension 19. Rear Axle Hatch 20. AC Electric Motor

Truck Components And Specifications

21. Hydraulic Tank 22. Steering Pump 23. Hoist Pump 24. Steering Accumulators 25. Alternator

FAM0222

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

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

AC ELECTRIC DRIVE SYSTEM AC/DC Current Alternator . . . . . . . . . . . . . . . . .

Motorized Wheels . . . . . . . . . .

Standard Gear Ratio* . . . . .

Maximum Speed. . . . . . . . .

...... ...... ...... ......

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRLDZ5010-AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Induction Traction Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.526:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5 km/h (40 mph)

* Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.

Komatsu must analyze each job condition to ensure proper application.

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

BATTERY ELECTRIC SYSTEM Batteries . . . . . . . . . . . . . . . . . . . . . . .

Cold Cranking Amps. . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . .

Lighting . . . . . . . . . . . . . . . . . . . . . . . .

Cranking Motors (2). . . . . . . . . . . . . . .

....... ....... ....... ....... .......

...... ...... ...... ...... ......

. . . . . Four 8D, 12 volt wet batteries with disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 140 Amp Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts

SERVICE CAPACITIES Crankcase (including lube oil filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 liters (74 gallons) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 liters (125 gallons) Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 542 liters (1200 gallons) Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 325 liters (350 gallons) Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 liters (32 gallons) per wheel Inverter Cabinet Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 liters (6.5 gallons)

FAM0222

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 17 237 kPa (2,500 psi) Steering/Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 18 961 kPa (2,750 psi) Relief Pressure - Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 237 kPa (2,500 psi) Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 961 kPa (2,750 psi) Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Stage Hydraulic Tank (Vertical/Cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Pressurized Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947 liters (250 gallons) Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable elements Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Full Flow, 100 Mesh Hoist and Steering Filters (Dual In-Line, High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 Rating =200

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

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

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

STANDARD DUMP BODY CAPACITIES AND DIMENSIONS Capacity Heaped @ 2:1 (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 m3 (221yd 3) Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 m3 (160 yd 3) Width (Front Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64 m (25 ft. 1 in.)

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

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

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

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Truck Components And Specifications

FAM0222

WEIGHT DISTRIBUTION Vehicle Weights Standard Chassis . . . . . . 137 325 kg . (302,749 lbs) Standard Komatsu body . . 33 643 kg . . (74,171 lbs) Standard tire weight. . . . . 23 033 kg . . (50,780 lbs) Option Allowance. . . . . . . . . 6 350 kg (14,000 lbs) Empty Vehicle Weight 200 351 kg . (441,700 lbs) Front Axle (49%) . . . . . . . 98 361 kg . (216,850 lbs) Rear Axle (51%) . . . . . . . 101 990 kg . (224,850 lbs)

Gross Vehicle Weight . . . 454 363 kg(1,001,700 lbs) Front Axle (33.5%). . . . . 152 392 kg . (335,871 lbs) Rear Axle (66.5%) . . . . . . 301 971 kg . (665,829 lbs) Max. Nominal Payload* . . 254 012 kg . (560,000 lbs) NOTE: All weights shown with 100% fuel load.

* Nominal payload is defined within Komatsu America Corporation’s payload policy documentation. In general, the nominal payload must be adjusted for the specific vehicle configuration and site application. The figures listed are provided for basic product description purposes. Please contact your Komatsu distributor for specific application requirements.

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Truck Components And Specifications

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Page 2-6

Truck Components And Specifications

FAM0222

MAJOR COMPONENT WEIGHTS

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

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

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

ITEM

KILOGRAMS

POUNDS

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

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

FAM0316 5/11

Major Component Weights

Page 3-1

ITEM

KILOGRAMS

POUNDS

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

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

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

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

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Major Component Weights

5/11 FAM0316

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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Field Welding For Assembly Or Repair

FAM0407

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 Color Coded Boxes 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.

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

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.

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.

FIGURE 5-1. COLOR CODED BOXES

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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 only as a general guideline. Actual assembly may be different, but this general procedure provides a basic outline for assembly.

NOTE: The hydraulic tank and accumulators may have been removed for shipping purposes and may require local installation.

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

RECOMMENDED ASSEMBLY DATA

9. Site cleanup

1. Service Report (Pre-Delivery) 2. Acknowledgement of Receipt of Company Warranty 3. Assembly Drawings & Schematics 4. Fluid Specifications (refer to the lubrication chart in Section 10, Appendix) 5. Suspension Oiling & Charging (available in Section 10, Appendix)

Procedure

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

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ORDER OF ASSEMBLY

3. Operator Cab

The assembly procedure is organized in levels. Generally, the tasks in a given level may be performed in any order or 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.

LEVEL 5

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

LEVEL 6

1. Exhaust Pipes 2. Weld Uprights 3. Blower - Air Intake Ductwork 4. Wheel Motors

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

LEVEL 1

LEVEL 7

1. Chassis - Unload and crib for assembly.

2. Uprights/Air Cleaners

1. Clearance Lights

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.

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 tighten the cap screws retaining 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 suspensions with the deck support in place.

2. Body Pads/Shims/Guides 3. Front Mud Flaps LEVEL 8 1. Dump Body LEVEL 9 1. Hoist Cylinders 2. Rear Mud Flaps 3. Install Exhaust System and Blankets LEVEL 10 1. Clean the Truck

5. Rear Suspension

2. Decals

6. Hydraulic Tank

3. Lighting Wiring

7. Fuel Tank

4. Charge Suspensions

8. Front Suspensions

5. Charge Accumulators

9. Diagonal Ladder

6. Add Fluids

LEVEL 2 1. Air Cleaner Piping 2. Center Deck

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

7. Hydraulic System Flushing

3. Control Cabinet 4. Auxiliary Control Cabinet LEVEL 3 1. Spindles/Hubs 2. Steering Cylinders 3. Tie Rod LEVEL 4 1. LH Deck

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

2. RH Deck/Grid Box

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CHASSIS ASSEMBLY 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.

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

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.

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.

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

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

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

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

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

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

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

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GENERAL PRECAUTIONS AND INSTRUCTION

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

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

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

7. Do not tighten 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.

Page 6-4

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 reservoir is full, lines purged of air and all injectors working properly prior to startup.

15. Purge air from the steering pump and all of the hydraulic pump suction lines before the engine is started for the first time. 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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NOTES:

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1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each (Figure 6-2). The weight of the chassis, as shipped, is approximately 56 250 kg (124,000 lbs).

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

3. Thoroughly clean the chassis.

FIGURE 6-1. CHASSIS ON TRAILER

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FIGURE 6-2. LIFTING THE CHASSIS

FIGURE 6-3. CHASSIS SUPPORT BLOCKS

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Page 6-7

4. On the frame, thoroughly clean the left hand deck support mounting surface of all paint and rust. Refer to figure 6-4. Also thoroughly remove all paint or rust the left hand deck support structure mounting surface. a. Lift the LH deck support into position (Figure 6-6). The weight of the deck support is approximately 442 kg (974 lbs). b. Attach the support into place with cap crews, nuts and flat washers. Tighten the cap screws to 3 300 N¡m (2,434 ft lb).

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

FIGURE 6-4. DECK SUPPORT CLEANING

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FIGURE 6-5. DECK SUPPORT CLEANING

FIGURE 6-6. DECK INSTALLATION

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

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

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

FIGURE 6-7. DIAGONAL LADDER INSTALLATION

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

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

FIGURE 6-8. CENTER DECK

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Page 6-11

8. Lift the LH and RH upright/air cleaner assemblies into position. The weight of the LH upright/air cleaner assembly is approximately 919 kg (2,027 lb). The weight of the RH upright/air cleaner assembly 625 kg (1,378 lb). Install the four cap screws for each upright (Figure 6-9). Tighten the cap screws to 465 ± 47 N·m (343 ± 34 ft lb).

9. If the center deck was not removed from the chassis, remove the two wood blocks supporting the center deck. Allow the center deck to rest on the front supports located on the uprights. Install center deck hardware, but do not tighten at this time.

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

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

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

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

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

12.

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

FIGURE 6-10. LEFT HAND DIAGONAL TUBE INSTALLATION

13. Tap the cab mounting holes to remove any paint or debris from the threads. Tap size is M24 x 3.

14. Lift the cab onto the deck supports. The weight of the cab is approximately 2 268 kg (5,000 lb). Install 1/2 of the mounting hardware as shown in Figure 6-41.

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

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

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

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

FIGURE 6-11. LIFTING THE CAB

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Chassis Assembly

Page 6-13

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

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

FIGURE 6-13. AIR INTAKE TUBE INSTALLATION

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

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

FIGURE 6-14. HYDRAULIC TANK INSTALLATION

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Chassis Assembly

Page 6-15

22. Clean the mounts for the fuel tank and lift the tank into position (Figure 6-15). The weight of the fuel tank is approximately 1 696 kg (3,740 lb). a. Tighten the four mounting cap screws at the top of the tank to 711 ± 72 N·m (525 ± 53 ft lb). b. Tighten the four mounting cap screws at the rubber dampers on the inner side of the tank to 800 ± 80 N·m (590 ± 59 ft lb).Connect the piping to the hydraulic tank and properly tighten all fittings (Figure 6-16 and Figure 6-17). c. Connect the fuel supply and return lines to the fuel tank.

FIGURE 6-15. FUEL TANK INSTALLATION

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

FIGURE 6-16. HYDRAULIC TANK PIPING INSTALLATION

FIGURE 6-17. HYDRAULIC TANK PIPING INSTALLATION

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Page 6-17

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

FIGURE 6-18. FILTER INSTALLATION

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

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

27. Install retaining plate (3), locking plate (2), and cap screws (1). Tighten the cap screws to 465 N·m (343 ft lb).

Bend the locking plate tabs over the cap screw flats.

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

FIGURE 6-20. HOIST CYLINDER INSTALLATION

FIGURE 6-19. LIFTING THE HOIST CYLINDER

FAM0618 9/11

1. Cap Screw 2. Lock Plate 3. Retainer

Chassis Assembly

4. Retainer Ring 5. Bearing 6. Spacer

Page 6-19

NOTE: Ensure the left deck support structure is mounted, and all mounting hardware is tightened to specified torque before install the left suspension.

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

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

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

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



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

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

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

FIGURE 6-21. CLEANING THE FRONT SUSPENSION MOUNTING SURFACES

FIGURE 6-22. CLEANING THE FRONT SUSPENSION MOUNTING SURFACES

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9/11 FAM0618

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.

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

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

35. The hardened flat washers used on the front suspensions may be punched during the manufacturing process. If there is a punched lip, install the washers with the punched lip away from the cap screw head to prevent damage (Figure 6-24).

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

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Chassis Assembly

2. Cap Screw

Page 6-21

FIGURE 6-23. FRONT SUSPENSION MOUNTING HARDWARE 1.

2.

3.

4.

5.

6.

7.

8.

9.

Page 6-22

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

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9/11 FAM0618

36. Lift the front suspension into position on the frame (Figure 6-25). The weight of each front suspension cylinder is approximately 2 880 kg (6,350 lb).

FIGURE 6-25. LIFTING THE FRONT SUSPENSION

37. Install the mounting hardware and the shear key.

Install the shear key flush with the side face of the suspension (Figure 6-26).

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 6-26. INSTALLING THE FRONT SUSPENSION

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Page 6-23

c.

T h e m o u n t i n g c a p s c r e w s n o w m u 6-27. TIGHTENING SEQUENCE MAP FIGURE s t be loosened one at time and then tightened one at time by turning the hardware by a specified number of degrees. This is known as the turn-of-the-nut method. The first set of cap screws to be adjusted will be at the upper mounting joint. The cap screws must be loosened one at time and then tightened by advancing a specified rotational degree.

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

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Upper Mounting Joint - 60° Advance

38. Loosen the first cap screw. (Sequence is 1, 2, 3, 4, 9 and 10.) All other cap screws must be maintained at 1356 ± 136 N·m (1000 ± 100 lb ft).

42. Make new reference lines along the cap screw, nut and frame at the rear of the joint as shown in Figure 6-29. These reference lines will be used to verify the cap screws have maintained their torque.

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

39. 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.

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.

40. Mark a corner of the cap screw head with a paint marker as shown in Figure 6-28. Draw a reference line on the suspension surface 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.

41. Advance the cap screw to the 60° advance mark. Hold the nut at the rear of the joint stationary while tightening.

FIGURE 6-29.

FIGURE 6-28.

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Page 6-25

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

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

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

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

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

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

FIGURE 6-30.

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

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

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

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

FIGURE 6-31.

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Page 6-27

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

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

Products containing copper will contribute to corrosion in this area.

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

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

Page 6-28

Chassis Assembly

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FIGURE 6-32. SPINDLE/BRAKE ASSEMBLY INSTALLATION

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Chassis Assembly

Page 6-29

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

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

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

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

Page 6-30

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FIGURE 6-34

FIGURE 6-33. SPINDLE/BRAKE ASSEMBLY INSTALLATION

FIGURE 6-34. RETAINER PLATE INSTALLATION

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Chassis Assembly

Page 6-31

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

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

56. Check cap screw torque on the 24 steering arm mounting cap screws. Cap screw torque is 2 705 ± 271 Nm (1,995 ± 200 ft lb).

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

FIGURE 6-35. STEERING CYLINDER INSTALLATION

Page 6-32

Chassis Assembly

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FIGURE 6-36. TIE ROD INSTALLATION

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Chassis Assembly

Page 6-33

57. Install the handrails on the RH deck. If not installed, lift the retarding grid into place on the RH deck. The weight of the retarding grid is approximately 2 881 kg (6,351 lb).

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

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

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

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

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

FIGURE 6-37. RIGHT DECK INSTALLATION

63.

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FIGURE 6-38. RIGHT DECK INSTALLATION

FIGURE 6-39. LEFT DECK INSTALLATION

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Chassis Assembly

Page 6-35

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

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

FIGURE 6-40. LIFTING THE CAB

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Chassis Assembly

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66. Install the cab mounting hardware as shown in Figure 6-41. The six rear inner cap screws are longer than the other cap screws, and must be installed from below the cab. Use flat washers and nuts on these six cap screws. Install and tighten the 32 cap screws to 800 ± 80 N·m (590 ± 59 ft lb).

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

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5.

6.

7.

8.

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

Chassis Assembly

9. Plate (Rear - Top) 10. Nut

Page 6-37

67. Lift the electrical control cabinets into position (Figure 6-42). The weight of the control cabinets is approximately 4 319 kg (9,521 lb) and includes the 24V auxiliary control cabinet. Install the mounting hardware and shims. Tighten the mounting cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix

FIGURE 6-42. CONTROL CABINET INSTALLATION

Page 6-38

Chassis Assembly

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

FIGURE 6-43. HANDRAIL INSTALLATION

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Chassis Assembly

Page 6-39

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

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

FIGURE 6-44. WELDING THE UPRIGHTS

FIGURE 6-45. CROSS TUBE WELD JOINT SPECIFICATION

Page 6-40

Chassis Assembly

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

FIGURE 6-46. BUMPER EXTENSION INSTALLATION

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

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

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

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

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Chassis Assembly

Page 6-41

75. The weight of the transmission and brake assembly (1, Figure 6-47) without the electric motor is 12 359 kg (27,247 lb). Transmission (1) must be positioned so the top of the unit is at the very top.

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

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

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

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

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

81. The motor has two air inlet covers (9) located on each side of the electric motor. One cover must be removed, and a separate air duct structure (5) must be installed. The location of the air duct structure is determined by which side the wheel motor is installed on the truck so that it will connect with the air duct inside the rear axle housing. Install air duct structure with hardware that was retaining the cover. Seal the air duct structure to wheel motor housing with sealant (VS7492).

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

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

Page 6-42

5.

6.

7.

8.

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

Chassis Assembly

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

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83. Install three lifting eyes into the wheel motor housing at locations (3, Figure 6-47). Attach appropriate lifting device to all three lifting eyes (3) on the electric motor (Figure 6-48). The weight of the electric motor is approximately 4 356 kg (9,603 lb). Use a suitable lifting device that can handle the load safely.

FIGURE 6-48. ELECTRIC WHEEL MOTOR INSTALLATION

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Chassis Assembly

Page 6-43

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

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

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

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

FIGURE 6-49. ELECTRIC MOTOR AND TRANSMISSION ASSEMBLY INSTALLATION

Page 6-44

Chassis Assembly

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

2. Cap Screw

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

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

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

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

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

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

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

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

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Chassis Assembly

Page 6-45

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

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

NOTE: 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.

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

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

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

NOTE: 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 6-50) if necessary.

96. 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.

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

Page 6-46

Chassis Assembly

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98. Install the hardware for Group 1. Tighten each cap screw to 542 N·m (400 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 in step 75 when installing the hardware for Groups 3 and 4.

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

100. After all of the hardware in all of the groups has been installed and tightened to 542 N·m (400 ft lb), move back to Group 1. Increase the torque on each cap screw in Group 1 to 2 006 N·m (1,480 ft lb). Repeat this step for each remaining group in the tightening sequence. Refer to Figure 6-51.

FIGURE 6-51. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE

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Chassis Assembly

Page 6-47

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

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

101. Connect all power cables (1, Figure 6-52) and electrical harnesses to their appropriate locations on the wheel motor, including the wheel speed sensors.

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

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

104. Install brake cooling hoses (4).

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

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

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

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3. Parking Brake Hose 4. Brake Cooling Hose

Chassis Assembly

Page 6-49

Front Wheel Installation

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

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

108. Lubricate all stud threads and nut seating flanges with lithium based (multi purpose, EP, NLGI #2, non-moly) grease. Install and tighten the nuts in the following sequence: a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten each nut to 1 166 ± 136 N·m (860 ± 100 ft lb). b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.

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

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

After the 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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FIGURE 6-53. FRONT TIRE INSTALLATION WITH TIRE HANDLER

FIGURE 6-54. WHEEL NUTS

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Chassis Assembly

Page 6-51

Rear Wheel Installation

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

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

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

111. Lubricate all stud threads and nut seating flanges with a lithium based (multi purpose, EP, NLGI #2, nonmoly) grease. Install and tighten the nuts in the following sequence: a. Install six nuts at the 12 o'clock position and six nuts at the 6 o'clock position. Tighten each nut to 1 166 ± 136 N·m (860 ± 100 ft lb). b. Install three nuts directly below the 3 o'clock position and three nuts directly above the 9 o'clock position.

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

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

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

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

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

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

Page 6-52

Chassis Assembly

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

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

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

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Chassis Assembly

Page 6-53

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

After the 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.

Page 6-54

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

FIGURE 6-58. CAB HARNESS AND HOSE INSTALLATION

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Chassis Assembly

Page 6-55

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

FIGURE 6-59. MUD FLAP INSTALLATION

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

Before the engine is started the first time, the hydraulic system should be set 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.

118. 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.

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

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DUMP BODY ASSEMBLY GENERAL INFORMATION

The total weight of the body is approximately 33 643 kg (74,171 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

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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

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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

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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.

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Dump Body Assembly

7-7

24. Clean and paint the weld joints.

FIGURE 7-26. PAINTING THE WELD JOINTS

7-8

Dump Body Assembly

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

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

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

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

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

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

BEFORE STARING 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.

FAM0816 7/10

Final Assembly

Page 8-1

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

FIGURE 8-1.

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

1. Before the body 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, Figure 8-2 and Figure 8-3). b. If a large crane of approximately 150 ton is available, the body can be lifted over the chassis and installed in a similar fashion to that in Step a.

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Final Assembly

7/10 FAM0816

FIGURE 8-2.

FIGURE 8-3.

FAM0816 7/10

Final Assembly

Page 8-3

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

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

4. Install shoulder bolt (1, Figure 8-4) through the pin.

Install flat washer (10) and locknut (2). Ensure the locknut has been fully installed and is tight against the flat washer. With the nut tight, the bolt and washer should not be tight against the flat spot faces on the frame.

FIGURE 8-4. DUMP BODY PIVOT PIN

NOTE: If nut (2) is a not a self-locking nut, tighten nut (2) to 339 N¡m (250 ft lb).

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

1.

2.

3.

4.

5.

Shoulder Bolt Locknut Body Pivot Pin Body Ear Body Pivot Bushing

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

FIGURE 8-5. INSTALLING THE BODY PIVOT PIPNS

Page 8-4

Final Assembly

7/10 FAM0816

FIGURE 8-6. CONNECTING THE HOIST CYLINDER TO THE DUMP BODY 6. Align the hoist cylinder upper bushings with the body (Figure 8-6). Align the retaining cap screw hole and install pin (2, Figure 8-7).

Install shoulder bolt (4, Figure 8-7) flat washer (5) and locknut (6). Ensure the locknut has been fully installed and is tight against the flat washer. With the nut tight, the bolt and washer should not be tight against the flat spot faces on the dump body.

NOTE: If nut (6) is a not a self-locking nut, tighten nut (2) to 339 N·m (250 ft lb).

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

FAM0816 7/10

4. Shoulder Bolt 5. Flat Washer 6. Locknut

Final Assembly

Page 8-5

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

7. Follow the procedure below to install the body pads.

Use caution when working under the dump body while it is raised. Install the body-up sling correctly before performing any work under the dump body.

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

a. Without any body pads installed, bolt two spacer blocks (1, Figure 8-8) to body location (1, Figure 8-10) using the pad mounting holes closest to the front of the dump body. After the spacer blocks are installed, lower the body completely.

NOTE: Spacer blocks can be made locally. Refer to SAFETY RULES, TOOLS & EQUIPMENT on instructions on how to make the spacer blocks.

b. After lowering the dump body with the spacer bocks installed, check the dump body’s position and fit on the truck. If there is any interference when the body is on the spacer block, contact your local Komatsu distributor to resolve the issue.

FIGURE 8-9. MEASUREMENT DETAILS FIGURE 8-8. SPACER BLOCK INSTALLED

1. Shims

2. Body Pad

1. Spacer Block (XC2293)

Page 8-6

Final Assembly

7/10 FAM0816

c. With the body lowered, measure the distance from the frame rail to the dump body’s pad mounting locations. This will be measurement “A”. Refer to Figure 8-9. There will be a total of eight “A” measurements per side. (Two measurements for each pad as shown at locations 1-4, Figure 8-10.) d. Subtract 50.8 mm (2.0 in.) (which is the spacer block thickness) from measurement “A” at each pad mounting location. The difference will be measurement “B”. There will be a total of eight “B” measurements per side. e. Divide measurement “B” by the shim thickness of 1.5 mm (0.06 in.) to determine the number of shims required for each position. f. Remove one shim from the calculation for the most rearward body pad on both sides, body pad mounting location (4, Figure 8-10).

FIGURE 8-10.

BODY PAD MOUNTING LOCATIONS

1. Body Pad Mounting Location 1 2. Body Pad Mounting Location 2

FAM0816 7/10

3. Body Pad Mounting Location 3 4. Body Pad Mounting Location 4

Final Assembly

Page 8-7

g. Install the body pads (2, Figure 8-11) with the calculated shims at each location. Tighten the pad mounting hardware (4) to 88 N¡m (65 ft lb).

NOTE: Using half shims is allowed if necessary. Half shims must be installed at the top of the stack.

NOTE: The frame rail and the body bolster do not have to be parallel.

FIGURE 8-11. BODY PAD INSTALLATION 1. Dump Body 3. Shim(s) 2. Body Pad 4. Mounting Hardware

Page 8-8

Final Assembly

7/10 FAM0816

FIGURE 8-12. MUD FLAP INSTALLATION - DUMP BODY AND FUEL TANK

FIGURE 8-13. MUD FLAP INSTALLATION - HYDRAULIC TANK 8. Install the mud flaps onto the body and chassis (Figure 8-12 and Figure 8-13).

FAM0816 7/10

Final Assembly

Page 8-9

10. Install both body guide brackets loosely into place (Figure 8-14). Once in position, slowly lower the body and mark the position in which the brackets are to be welded.

The body guides must be centered between wear plates (3, Figure 8-15), with a maximum gap of 4.8 mm (0.19 in.) at each side.

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

FIGURE 8-14. BODY GUIDE BRACKET INSTALLATION

11. Raise the body and attach the body retention cable or sling. Remove the support blocks.

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.

12. Weld the body guide brackets into place.

FIGURE 8-15. BODY GUIDE 1. Dump Body 2. Body Guide

Page 8-10

Final Assembly

3. Body Guide Bracket Wear Plates

7/10 FAM0816

13. Figure 8-16 shows the body-up switch (2) and the magnet (1) used to activate the body up switch. With the body in its lowered position on the frame rail, the position of the magnet mounting plate can be marked on the underside of the body. Weld the magnet mounting bracket to the dump body. Refer to the assembly drawings for precise positioning specifications.

14. Adjust the body up switch.

If switch adjustment is necessary, follow the procedure below: a. With the body resting completely on the frame, loosen switch mounting bracket cap screws and the magnet adjustment cap screws. b. Position the upper edge of the magnet (1) 131.5 mm (5.18 in.) (Dimension A, Figure 8-16) from the bottom of mounting bracket. Tighten cap screws. c. Adjust the proximity switch (2) so the passing distance between the two targets is 45 mm (1.77 in) (Dimension B). Tighten cap screws.

FIGURE 8-16. BODY-UP SWITCH ADJUSTMENT 1. Magnet

FAM0816 7/10

2. Body-Up Switch

Final Assembly

Page 8-11

15. Hoist limit switch adjustment a. Prior to adjustment, the dump body must be raised to 152 mm (6 in.) less than the maximum hoist cylinder extension and the dump body must be supported in that location. b. Loosen proximity switch adjustment cap screws (4, Figure 8-17). Slide switch (1) up or down to position the top of the switch 30 mm (1.18 in.) (Dimension B) away from the lower edge of magnet (2). Tighten the cap screws when adjusted properly. If necessary, cap screws (3) could also be loosened to move the magnet to obtain the 30 mm (1.18 in.) gap.

NOTE: Since a magnetic target is used to activate the switch, a larger initial distance in setting the switch is required. This is due to the fact that magnetic fields are not crisp 90 degree boxed fields but are instead curved about the shape of the magnet. Refer to Figure 8-19. The sensing field boundary limit takes on the same curved sensing area shape of the magnet field. The curved sensing area results in the actuation of the switch approximately 30 mm (1.18 in.) prior to reaching the edge of the magnet. Therefore, it is crucial that the 30 mm (1.18 in.) is observed when setting the hoist limit switch.

FIGURE 8-17. HOIST LIMIT SWITCH (SIDE VIEW) 1. Proximity Switch 2. Magnet

Page 8-12

3. Cap Screws 4. Cap Screws

Final Assembly

5. Dump Body

7/10 FAM0816

c. Loosen cap screws (2, Figure 8-18) securing proximity switch (3) to the mounting bracket. Slide the switch to the left or right until the passing distance between the two targets is 45 mm (1.77 in.) (Dimension A).

Tighten the cap screws after adjusting. Refer to Figure 8-19 for an illustration of optimum setting of the switch. d. Lower the body onto the frame. e. Check the operation of the proximity switch to verify that the hoist cylinders stop before reaching maximum cylinder stroke. If the cylinders extend to full stroke, adjust the proximity switch as necessary to prevent full cylinder extension.

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.

FIGURE 8-18. HOIST LIMIT SWITCH (REAR VIEW) 1. Magnet 2. Cap Screws

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3. Proximity Switch

Final Assembly

Page 8-13

FIGURE 8-19. HOIST LIMIT SWITCH OPTIMUM SETTING ADJUSTMENT

Page 8-14

Final Assembly

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17. Install the LH and RH engine service lights (Figure 8-20).

FIGURE 8-20. ENGINE SERVICE LIGHTS 18. Install the automatic lubrication system and the engine reserve oil system (Figure 8-21). Refer to the installation drawings. Verify that all electrical and hydraulic connections are correct.

FIGURE 8-21. AUTOMATIC LUBRICATION SYSTEM AND ENGINE RESERVE OIL SYSTEM

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Final Assembly

Page 8-15

FIGURE 8-22. FIRE SUPPRESSION SYSTEM

19. If required, install the fire suppression system (Figure 8-22). This installation is normally performed by the fire suppression system distributor.

20. Paint the truck as needed.

21. Install all decals at their designated areas.

22. 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.

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Final Assembly

7/10 FAM0816

FINAL CHECKOUT Final checkout requires truck operation.

1. Complete delivery and warranty forms.

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

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

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

3. If equipped, verify the shut-off valves on the hydraulic tank suction lines are open.

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

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

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

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

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

FAM0908 7/10

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

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

Final Checkout

Page 9-1

NOTES

Page 9-2

Final Checkout

7/10 FAM0908

APPENDIX This chapter contains additional information and 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 - FAM1104 2. Suspension Oiling And Charging Procedure - FAM1202 3. Toe In Adjustment Procedure - FAM1302 4. Automatic Lubrication System Checkout Procedure - FAM1402 5. Reserve Oil System Checkout Procedure - EJ6271 6. Air Conditioning Checkout Procedure - EM4003 7. Hydraulic Checkout Procedure - EM7621 8. Brake Checkout Procedure - EM7602 9. VHMS Setup Procedure - EM2128

10. VHMS Checkout Procedure - EM2129

11. Interface Module Checkout Procedure - XB1214

12. Payload Meter III Checkout Procedure - EJ3061

13. Electrical Checkout Procedure - XB1656

14. Komatsu Haul Truck Commissioning Procedure - XB1623

15. Standard Torque Charts and Conversion Tables - FAM1501

16. Hydraulic System Flushing Procedure - FAM1602

17. Field Assembly Inspection Report

18. 50 Hour Post-Commissioning Check Sheet

FAM1024

Appendix

Page 10-1

NOTES

Page 10-2

Appendix

FAM1024

LUBRICATION CHART

LUBRICATION CHART

FAM1104 5/11

Lubrication Chart

F11-1

NOTES

F11-2

Lubrication Chart

5/11 FAM1104

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

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

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

®

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

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

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

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

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

EQUIPMENT LIST •

HYDRAIR® Charging Kit

•

Jacks and/or Overhead Crane

•

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

•

HYDRAIR® Oil (See Specifications Chart)

•

Friction Modifier (See Specifications Chart)

•

Dry Nitrogen (See Specifications Chart)

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

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

1. Oil level must be correct.

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

3. Nitrogen charge pressure must be correct.

FAM1202 5/11

Oiling and Charging Procedures

F12-1

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

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

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

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

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

7. Open both outlet valves (3).

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

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

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

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

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

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

4. Tighten swivel nut (small hex) on charging valve. If a new charging valve is being used, tighten swivel nut to 15 Nm (11 ft lb) torque, then loosen and retighten swivel nut to 15 Nm (11 ft lb) torque. Again loosen swivel nut and retighten to 6 Nm (50 in lb) torque. Replace valve cap (1) and tighten to finger tight.

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

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

F12-2

Oiling and Charging Procedures

5/11 FAM1202

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

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

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

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

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

NOTE: Do not place wheel chocks around front tires.

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

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

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

Front Suspension Oiling

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

NOTE: For longer life of suspension components, a Friction Modifier should be added to the suspension oil. See Specifications Chart, Figure12-6 at the end of this chapter.

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Oiling and Charging Procedures

F12-3

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

Wear a face mask or goggles while relieving nitrogen pressure.

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

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

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

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

F12-4

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

25.4 mm (1.0 in.)

CHARGING HEIGHT

229 mm (9.01 in.)

CHARGING PRESSURE

*3 365 kPa (488 psi)

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

Oiling and Charging Procedures

5/11 FAM1202

Front Suspension Nitrogen Charging

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

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

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

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

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

3. Install HYDRAIR ® Charging Kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit. 4. Charge the suspensions with nitrogen gas to 50.8 mm (2 in.) greater than the charging height listed in Table 1. Close inlet valve (4, Figure 121).

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.

FIGURE 12-3. CHARGING VALVE 1.

2.

3.

4.

5.

Valve Cap Seal Valve Core Swivel Nut Rubber Washer

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

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).

Be aware when relieving nitrogen gas, the truck may drop suddenly onto the charging blocks.

7. To lower the truck onto the charging blocks, open inlet valve (4) until the pressure has dropped below the pressure listed in Table 1, and then close the valve.

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

FAM1202 5/11

Oiling and Charging Procedures

F12-5

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

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

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

13. If a new charging valve is being used, tighten swivel nut to 15 Nm (11 ft lb) torque, then loosen and retighten swivel nut to 15 Nm (11 ft lb) torque. Again loosen swivel nut and retighten to 6 N·m (50 in. lb) torque. Replace valve cap (1) and tighten finger tight.

14. Install protective guard over charging valve.

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

Ensure that there is adequate clearance before raising the body.

overhead

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

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

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

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

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

NOTE: Do not place wheel chocks around front tires.

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

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

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

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

F12-6

Oiling and Charging Procedures

5/11 FAM1202

Rear Suspension Oiling 1. Position and secure oiling support blocks (2, Figure 30-12) 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.

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

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

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

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

3. Rear Axle Housing

Table 2: REAR SUSPENSION DIMENSIONS (EMPTY) OILING HEIGHT

CHARGING HEIGHT

CHARGING PRESSURE

54.2 mm (2.13 in.)

270 mm (10.63 in.)

*1 469 kPa (213 psi)

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

FAM1202 5/11

Oiling and Charging Procedures

F12-7

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

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

4. Remove the vent plug, pressure sensor, and charging valve (See Figure 12-5). 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.

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

Lubricate the O-ring with clean Hydrair II oil.

7. Install the charging valve onto the suspension.

Tighten valve body (6, Figure 30-11) to 23 Nm (17 ft lb).

Rear Suspension Nitrogen Charging

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

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

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

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

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

F12-8

3. Rear Axle Housing

Oiling and Charging Procedures

5/11 FAM1202

8. Close outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit. 9. If the charging valve is being reused, tighten swivel nut (4, Figure 12-3) to 6 Nm (50 in lb) torque.

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

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

Be aware when relieving nitrogen gas, the truck may drop suddenly onto the charging blocks.

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

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

10. If a new charging valve is being used, tighten swivel nut to 15 Nm (11 ft lb) torque, then loosen and retighten the swivel nut to 15 Nm (11 ft lb) torque. Again, loosen the swivel nut and retighten to 6 Nm (50 in lb) torque.

Replace valve cap (1) and tighten finger tight.

11. Install the protective guards over the charging valves and install the metal covers over the piston rods.

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

The rear suspensions are now ready for operation.

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

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

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

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

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

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

FAM1202 5/11

Oiling and Charging Procedures

F12-9

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

-30°F & above (-34.5°C & above)

Part No.

Approved Sources

VJ3911 (need to add 6% of AK3761)

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

AK4063

Suspension Oil (premixed with 6% Friction Modifier)

AK4064

-55°F & above (-48.5°C & above)

5 Gallon container 55 Gallon container

VJ5925 (need to add 6% of AK3761)

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

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

AK4065

Suspension Oil (premixed with 6% Friction Modifier)

5 Gallon container

AK4066

55 Gallon container

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

FRICTION MODIFIER

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

Part Number

Suspension Oil

Amount of Friction Modifier to add

AK3761 (5 Gallon container of 100% Friction Modifier)

1 gallon of suspension oil

add 7.7 oz.

5 gallons of suspension oil

add 38.4 oz.

55 gallons of suspension oil

add 3.3 gal.

NITROGEN GAS (N2)SPECIFICATIONS ®

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

Property

Value

Nitrogen

99.9% Minimum

Water

32 PPM Maximum

Dew Point

-68°F (-55°C) Maximum

Oxygen

0.1% Maximum

FIGURE 12-6. SPECIFICATIONS CHART

F12-10

Oiling and Charging Procedures

5/11 FAM1202

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

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

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

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

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

3668 mm (144.4 in.)

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

5. When the adjustment is complete, tighten the locknuts on the tie rod to 420 ± 42 N·m (310 ± 31 ft lb). Repeat the tightening sequence until the specified torque is maintained.

FIGURE 3-1. MEASURING TOE-IN

6. Remove the wheel chocks from the rear wheels.

FAM1302 4/11

Toe-In Adjustment

Page F13-1

NOTES

Page F13-2

Toe-In Adjustment

4/11 FAM1302

AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE GREASE REQUIREMENTS Required Lubricant Grease requirements will depend on ambient temperatures encountered during truck operation: • Above 32°C (90°F) - Use multipurpose grease (MPG).

NLGI

No.

2

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

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

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

1. Fill lube reservoir with lubricant, if necessary.

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

Connect an external grease supply to the line.

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

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

FIGURE 14-1. PUMP/RESERVOIR COMPONENTS 1.

2.

3.

4.

5.

6.

7.

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

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

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

FAM1402 7/10

Automatic Lubrication System

F14-1

Pump Pressure Control

SYSTEM CHECKOUT

High pressure hydraulic fluid from the truck steering system is reduced to 2240 - 2413 kPa (325 - 350 psi) by the pressure reducing valve located on the manifold on top of the pump motor. This pressure can be read if pipe plug (3, Figure 14-2) is removed, and a gauge is installed on the manifold. Pressure should be checked occasionally to verify the pressure is within the above limits.

To check system operation, proceed as follows:

Pressure Control Valve Adjustment The pressure control valve (1) has been factory adjusted and the setting should not be disturbed.

Flow Control Valve Adjustment

1. Remove the dust covers from the injectors.

2. Start the engine.

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

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

5. After checking system, stop the engine.

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

6. Re-install the injector dust covers.

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

Lubrication Cycle Operation

PUMP HOUSING OIL The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level at the 1,000 hour maintenance interval. To add oil, remove dipstick (4, Figure 42-2) on top of the pump housing and fill the housing to the proper level marked on the dipstick.

The time between lube events is determined by the setting selected in the dash panel. Refer to Figure 14-3 for lubrication menu screens. With the key switch ON, scroll through the display menu screens and select either 8, 15, 24 or 30 minutes between lube cycles. The default setting is 15 minutes.

NOTE: Turning the key switch to the ON position will not initiate a lube cycle. To initiate a lube cycle while the truck is stationary, select manual lube using the dash display panel, or use the switch on the lubrication pump.

The truck must be moving before the lube system will initiate lube cycles based on the time interval selected.

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

F14-2

4. Dipstick 5. Flow Control Valve

Automatic Lubrication System

7/10 FAM1402

PREVENTATIVE MAINTENANCE The following maintenance procedures should be used to insure proper system operation.

Main Level Screens Screen 1

Load = 240 t LC = 25

2100 rpm

Daily Lubrication System Inspection

<

SC = 20 mph

ˇ

ˆ Screen 2

OK

TT = 6000 t

Inspect grease level height after each shift of operation. Grease usage should be consistent from day-to-day operations.

Load = 240 t LC = 25

TT = 6000 t

10,000 m

SC = 20 mph

ˇ

ˆ

Screen 3

•

Load = 240 t LC = 25

TT = 6000 t

3560.9 h

SC = 20 mph

ˇ

ˆ

1 Active Warnings Press < to View

a. Repair or replace all damaged feed line hoses.

Advance to screen 1 if moving and no realtime data.

ˇ

Advance to screen 4 .

Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate a broken supply line.

2. Check filter bypass indicator when filling reservoir. Replace element if bypassing.

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

Screen 4

<

1. Check grease reservoir level.

Switch 2

Switch 1

b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service.

ˆ Screen 5

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

Screen 6

ˇ

ˆ

4. Inspect key lubrication points for a bead of lubricant around seal. If a lubrication point appears dry, troubleshoot and repair problem.

Advance to screen 1 if moving.

Payload Data OK to View

Screen 7

ˇ

ˆ

1 Repair Item OK to View

Screen 8

ˇ

ˆ

2 Maintenance Items OK to View

Screen 9

ˇ

ˆ

System Controls Press OK to View

Manual Lube

OK

ˆ

Press OK to Start Screen 9, subscreen 0

Screen 9, subscreen max.

Screen 10

Screen 11

English Español Français OK Portuguese

ˆ

ˇ

Configure System Press OK to Edit

Lube Interval 8 15 24 30

OK

ˆ

Press OK to Edit Screen 11, subscreen 0

Screen 11, subscreen max.

80414

FIGURE 14-3. LUBRICATION MENU

FAM1402 7/10

Automatic Lubrication System

F14-3

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

TROUBLE

Pump Does Not Operate

Pump Will Not Prime

Pump Will Not Build Pressure

POSSIBLE CAUSES

SUGGESTED CORRECTIVE ACTION

Lube system not grounded.

Correct grounding connections to pump assembly and truck chassis.

Electrical power loss.

Locate cause of power loss and repair.

24 VDC power required. Ensure key switch is ON.

Lube cycle malfunction.

VHMS - Check fault logs

Solenoid valve malfunctioning.

Replace the solenoid valve assembly

Relay malfunctioning

Replace relay

Motor or pump malfunction.

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

Low lubricant supply.

Dirt in reservoir, pump inlet clogged, filter clogged.

Air trapped in lubricant supply line.

Prime system to remove trapped air.

Lubricant supply line leaking.

Check lines and connections to repair leakage.

Vent valve leaking.

Clean or replace vent valve.

Pump worn or scored.

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

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

Injector Indicator Stem Does Not Operate

Pressure Gauge Does Not Register Pressure

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

Replace individual injector assembly.

All injectors inoperative - pump build up not sufficient to cycle injectors.

Service and/or replace pump assembly.

(Refer to shop manual for rebuild instructions.)

No system pressure to the pump motor.

Check hydraulic hose from steering system.

No 24 VDC signal at pump solenoid.

Determine problem in 24 VDC electric system.

Pressure reducing valve set too low.

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

24V Relay (RB7K8) may be defective.

F14-4

Replace relay.

Automatic Lubrication System

7/10 FAM1402

TROUBLE Pump Pressure Builds Very Slowly Or Not At All

Controller Does Not Operate

POSSIBLE CAUSES No signal at solenoid.

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

No electric power to controller.

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

Lube cycle interval set to low.

Select larger lube cycle interval.

Injector output adjustment setting too high.

Readjust to lower setting.

Lube cycle interval set to high.

Select smaller lube cycle interval.

Injector output adjustment setting too low.

Readjust injector output setting.

System too large for pump output.

Calculate system requirements per planning manual.

Bearing Points Excessively Lubricated

Bearing Points Are Not Sufficiently Lubricated

FAM1402 7/10

Automatic Lubrication System

F14-5

NOTES

F14-6

Automatic Lubrication System

7/10 FAM1402

NOTES:

NOTES:

KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 1 of 9

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

DATE: 01/22/09

CHECKED BY:

DATE:

APPROVED BY:

DATE:

MACHINE & MODEL: 860E Update

0

NEW RELEASE

DASH A SIZE

DESCRIPTION OF CHANGE MICROFILM

DATE

ECN

BY

CK’D

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

Necessary Equipment: 1.

This checkout procedure and vehicle wiring schematic.

2.

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

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

4.

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

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

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

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

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

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

Page 1 of 9

XB1214-0

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KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 2 of 9

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

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

CHECK DIGITAL INPUTS TO THE INTERFACE MODULE 1.

2.

3.

4.

5.

6.

7.

8.

9.

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

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

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

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

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

Reconnect disconnected wire.

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

Reconnect disconnected wire.

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

Page 2 of 9

XB1214-0

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KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 3 of 9

XB121400.doc

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XB1214-0

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

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

Return shifter to park position.

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

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

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

Reset vehicle speed to zero.

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

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

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

18.

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

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

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

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

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

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

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

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

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

KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 4 of 9

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

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

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

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

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

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

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

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

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

XB121400.doc

Page 4 of 9

XB1214-0

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

Reconnect sensor.

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

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

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

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

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

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

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

KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 5 of 9

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

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

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

CHECK SERIAL INTERFACES TO THE IM 1.

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

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

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

1.

2.

3.

4.

5.

XB121400.doc

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XB1214-0

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

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

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

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

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

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

KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 6 of 9

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

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

Expected Result

Hydraulic Tank Level input Low Steering Precharge

1 to 0

Pump Filter Switches

0 to 1

Park Brake Request

1 to 0

Auto Lube Switch

1 to 0

Batt +

1

Starter Motor 1 Energized Starter Motor 2 Energized Crank Sense

0 to 1

Comments

0 to 1

0 to 1 0 to 1

Page 6 of 9

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Result (OK/Fail)

KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 7 of 9

Function Description

Expected Result

Selector Switch (Park)

1 to 0

Selector Switch (FNR)

0 to 1

Strg Bleed Pressure Sw

0 to 1

Brake Lock Switch Power Supply Brake Lock

0 to 1

Engine Shutdown

0 to 1

Secondary Engine Shutdown Snapshot In-Progress

1 to 0

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

1 to 0

Result (OK/Fail)

Comments

0 to 1

0 to 1

1 to 0 1 to 0 1 to 0

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

0 to 1

Crank Request

0 to 1

Left Rear Park Brake Set

0 to 1

Mode sw4

1 to 0

Page 7 of 9

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XB121400.doc

1 to 0

KOMATSU

CHECKOUT PROCEDURE

XB1214-0 Page 8 of 9

Function Description

Expected Result

Left Rear Park Brake Released Keyswitch

1 to 0

Mode sw1

1 to 0

Mode sw2

1 to 0

Mode sw3

1 to 0

Right Front Park Brake Released

1 to 0

Steering Pressure

fault A204

Ambient Air Temp

ambient temp +/- 3C

Fuel Level

tank level +/- 5%

12V DC Inverter Voltage

measured voltage +/- 1V

Brake Pressure

fault A205

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

fault A167

fault A203

Hoist Pressure 1

fault A202

Battery Voltage 24V

measured voltage +/- 1V

CAN/J1939

no fault A184

Comments

1

fault A166 fault A169 fault A168

Page 8 of 9

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Result (OK/Fail)

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CHECKOUT PROCEDURE

XB1214-0 Page 9 of 9

Function Description

Expected Result

Drive System CAN/RPC

no fault A233

Display CAN/RPC

no fault A237

Payload CAN/RPC

no fault A257

Park Brake Solenoid

energized/de-energized

Brake Auto Apply

energized/de-energized

Crank Enable Output

24 V, 0 V

IM On Signal

0V

Steering Bleed Relay

de-energized/energized

Status Indicators

Flash on/off

Red Warn

Flash on/off

2 audible alarms

Sound on/off

LCD Screen

Warning message displayed Needles sweeping continuously

5 gauges

Result (OK/Fail)

Comments

Completed By: _________________________________________ Date: _______________________

Page 9 of 9

XB1214-0

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NOTES:

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 1 of 11

NAME: Electric Checkout Procedure WRITTEN BY: J. Miller

DATE: 01/21/09

CHECKED BY:

DATE:

APPROVED BY:

DATE:

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

0 DASH A SIZE

NEW RELEASE DESCRIPTION OF CHANGE MICROFILM

DATE

ECN

BY

CK’D

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

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

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

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

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

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

TABLE OF CONTENTS Welding and Safety Procedures

Page 2

II.

AC Drive System Description

Page 4

III.

Resistance Checks

Page 5

IV.

Megger Preparation and Testing

Page 6

V.

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

Page 8

XB1656

I.

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 2 of 11

VI.

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

Page 12

VII.

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

Page 13

VIII.

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

Page 13

IX.

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

I.

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

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

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

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

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

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

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

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

XB1656

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

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 3 of 11

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

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

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

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

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

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

4. If, after the following above procedure, a fault has occurred. Or the link voltage has not discharged, leave all cabinet doors in place, do not touch the retard grid elements, do not disconnect any power cables or use them as hand or footholds. Notify the KAC field engineer or Siemens engineer immediately.

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

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

XB1656

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

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 4 of 11

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

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

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

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

II.

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

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

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

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

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CHECKOUT PROCEDURE

XB1656 Page 5 of 11

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

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

III.

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

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

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

4. Turn key switch to “OFF” position.

5. Turn all lights and switches off.

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

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

XB1656

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

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 6 of 11

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

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

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

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

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

DIODE CIRCUIT DR3

I/O

NEGATIVE CKT & LOC 52PBO JB4C

POSITIVE CKT & LOC 52ABA JB4F

712M TB34-B

712K TB37-B

D45, D46

PARK BRK RLY-1 RB6-K8 KEYSWITCH

D26

RB7-K1

33J TB27-E

33JB TB47-F

DR1

71BC JB4E

52CS JB4D

12VPRD

PRK BRK RELAY RB6-K8 712 POWER

712 12VPR-86

0 12PR-85

CPRD

SIBAS CN1XA-25

11SP CPR-86

0 CPR-85

KSPRD

START COMMAND

712M KSPR-86

0 KSPR-85

Megger Preparation and Testing

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

XB1656

A. Safety Measures

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CHECKOUT PROCEDURE

XB1656 Page 7 of 11

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

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

3. Truck frame should be grounded.

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

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

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

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

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

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

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

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

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

XB1656

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

KOMATSU

CHECKOUT PROCEDURE

XB1656 Page 8 of 11

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

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

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

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

•

QSK – 21PT1.

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

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

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

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

1.

V.

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

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

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

XB1656

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

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CHECKOUT PROCEDURE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

XB1656

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

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CHECKOUT PROCEDURE

XB1656 Page 10 of 11

M. Check the horn for proper operation.

N. Check cigarette lighter for proper operation.

O. Shift the Selector switch to the Reverse position, the Back-up horns and the Manual backup lights should operate. Move the Selector switch to Neutral or Forward position and the Backup horns and light should turn off.

P. Turn all switches off, put Selector switch in the Park position, turn key switch to the OFF position. All lights should be off.

Q. Return to the “Siemens IGBT Commissioning Procedure” – section “24 Volt Check” beginning on page 4. Continue testing according to this procedure until reaching the section “Start Engine and Verify Engine Speed Control”.

(At this point, restore 21PT1 wiring to engine start relay located in battery compartment).

Continue to follow the Siemens Truck Commissioning Procedure until completing the section “Start Engine and Verify Speed Control”. Stop and proceed to next section of this procedure.

VI.

IM System Checkout A. Connect the PTU (laptop computer) to the Operator Cab – IM diagnostic port (DIAG 5). Verify that the latest software configuration has been loaded into the Interface Module (IM) and that it is the current software.

B. Review the IM system error code report and resolve all reported faults.

VII.

Drive System Initial Checkout A. Return to the “Siemens Truck Commissioning Procedure” and complete the following Sections of this procedure: 1. Charging Up the DC bus.

2. Main blower, Water Pump, and Grid Box Fan rotation check.

(At this stage of the truck checkout procedure, the hydraulic system should be setup before proceeding to the load box horsepower testing of the drive system.)

VIII.

Hydraulic System Checkout. (See Procedure – Check-out Group) A. Complete Checkout Procedure of the hydraulic system per the vehicle specific procedure.

Drive system checkout. (Continuation of Section VII.) Return to “Siemens Truck Commissioning Procedure”.

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IX.

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CHECKOUT PROCEDURE

XB1656 Page 11 of 11

A. Complete section â&#x20AC;&#x201C; Engine self-load test.

B. Reset the fault codes on all systems before releasing the unit for operation.

XB1656

NOTES:

NOTES:

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

EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values

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

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

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

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

Grade 5

Capscrew Thread Size

kg•m

1/4-20

7

1/4-28

8

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

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

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

TORQUE GRADE 5 ft lbs

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

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

TORQUE GRADE 8 N•m

ft lbs

0.97

9.5

10

1.11

10.8

11

Grade 8

N•m

Capscrew Thread Size

1.38

13.6

3/4-16

235

32.5

319

335

46.3

454

1.52

14.9

7/8-9

350

48.4

475

500

69.2

678

kg•m

TORQUE GRADE 5 ft lbs

kg•m

TORQUE GRADE 8 N•m

ft lbs

kg•m

N•m

5/16-18

15

2.07

20.3

21

2.90

28

7/8-14

375

51.9

508

530

73.3

719

5/16-24

16

2.21

22

22

3.04

30

1.0-8

525

72.6

712

750

103.7

1017

3/8-16

25

3.46

34

35

4.84

47

1.0-12

560

77.4

759

790

109.3

1071

3/8-24

30

4.15

41

40

5.5

54

1.0-14

570

78.8

773

800

110.6

1085

7/16-14

40

5.5

54

58

8.0

79

1 1/8-7

650

89.9

881

1050

145

1424

7/16-20

45

6.2

61

62

8.57

84

1 1/8-12

700

96.8

949

1140

158

1546

1/2-13

65

9

88

90

12.4

122

1 1/4-7

910

125.9

1234

1480

205

2007

1/2-20

70

9.7

95

95

13.1

129

1 1/4-12

975

134.8

1322

1580

219

2142

9/16-12

90

12.4

122

125

17.3

169

1 3/8-6

1200

166

1627

1940

268

2630

9/16-18

95

13.1

129

135

18.7

183

1 3/8-12

1310

181

1776

2120

293

2874

5/8-11

125

17.3

169

175

24.2

237

1 1/2-6

1580

219

2142

2560

354

3471

5/8-18

135

18.7

183

190

26.2

258

1 1/2-12

1700

235

2305

2770

383

3756

3/4-10

220

30.4

298

310

42.8

420

1 ft lbs = 0.138 kg•m = 1.356 N•m

FAM1501 11/05

Standard Torque Charts and Conversion Tables

F15-1

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

STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews & Class 10 Nuts

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

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

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

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

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

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

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

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

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

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

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

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

CAPSCREW SIZE*

TORQUE ft lbs

TORQUE N•m

TORQUE kg•m

0.250 - 20

12

16

1.7

0.312 - 18

24

33

3.3

M6 x1

0.375 - 16

42

57

5.8

M8 x 1.25

0.438 -14

70

95

9.7

M10 x 1.5

CAPSCREW SIZE*

TORQUE N•m

TORQUE ft lbs

TORQUE kg•m

12

9

1.22

30

22

3.06

55

40

5.61

0.500 -13

105

142

14.5

M12 x 1.75

95

70

9.69

0.562 - 12

150

203

20.7

M14 x 2

155

114

15.81

0.625 - 11

205

278

28.3

M16 x 2

240

177

24.48

0.750 - 10

360

488

49.7

M20 x 2.25

465

343

47.43

0.875 - 9

575

780

79.4

M24 x 3

800

590

81.6

1.000 - 8

860

1166

119

M30 x 3.5

1600

1180

163.2

1.000 - 12

915

1240

126

M36 x 4

2750

2028

280.5

1.125 - 7

1230

1670

170

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

1.125 - 12

1330

1800

184

1.250 - 7

1715

2325

237

1.250 - 12

1840

2495

254

1.375 - 6

2270

3080

313

1.375 - 12

2475

3355

342

1.500 - 6

2980

4040

411

1.500 - 12

3225

4375

445

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

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

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

• Rust Ban 326 from Humble Oil Company.

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

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

F15-2

Standard Torque Charts and Conversion Tables

11/05 FAM1501

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

TABLE VI. TORQUE CHART FOR O-RING BOSS FITTINGS

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

–2

0.125

0.312 – 24

4 ±1

–2

0.125

0.312 – 24

4 ±2

–3

0.188

0.375 – 24

8 ±3

–3

0.188

0.375 – 24

5 ±2

–4

0.250

0.438 – 20

12 ±3

–4

0.250

0.438 – 20

8 ±3

–5

0.312

0.500 – 20

15 ±3

–5

0.312

0.500 – 20

10 ±3

–6

0.375

0.562 – 18

18 ±5

–6

0.375

0.562 – 18

13 ±3

–8

0.500

0.750 – 16

30 ±5

–8

0.500

0.750 – 16

24 ±5

– 10

0.625

0.875 – 14

40 ±5

– 10

0.625

0.875 – 14

32 ±5

– 12

0.750

1.062 – 12

55 ±5

– 12

0.750

1.062 – 12

48 ±5

– 14

0.875

1.188 – 12

65 ±5

– 14

0.875

1.188 – 12

54 ±5

– 16

1.000

1.312 – 12

80 ±5

– 16

1.000

1.312 – 12

72 ±5

– 20

1.250

1.625 – 12

100 ±10

– 20

1.250

1.625 – 12

80 ±5

– 24

1.500

1.875 – 12

120 ±10

– 24

1.500

1.875 – 12

80 ±5

– 32

2.000

2.500 – 12

230 ±20

– 32

2.000

2.500 – 12

96 ±10

TABLE V. TORQUE CHART FOR PIPE THREAD FITTINGS

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

SIZE CODE

PIPE THREAD SIZE

WITH SEALANT ft lbs

WITHOUT SEALANT ft lbs

–2

0.125 – 27

15 ±3

20 ±5

–4

0.250 – 18

20 ±5

25 ±5

–6

0.375 – 18

25 ±5

35 ±5

–8

0.500 – 14

35 ±5

45 ±5

– 12

0.750 – 14

45 ±5

55 ±5

– 16

1.000 – 11.50

55 ±5

65 ±5

– 20

1.250 – 11.50

70 ±5

80 ±5

– 24

1.500 – 11.50

80 ±5

95 ±10

– 32

2.000 – 11.50

95 ±10

120 ±10

FAM1501 11/05

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

–4

0.250

0.438 – 20

11 ±1

–6

0.375

0.562 – 18

18 ±2

–8

0.500

0.750 – 16

35 ±4

– 10

0.625

0.875 – 14

51 ±5

– 12

0.750

1.062 – 12

71 ±7

– 16

1.000

1.312 – 12

98 ±6

– 20

1.250

1.625 – 12

132 ±7

– 24

1.500

1.875 – 12

165 ±15

Standard Torque Charts and Conversion Tables

F15-3

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

0

1

2

3

4

5

6

7

8

9

0

(N·m)

1.36

2.71

4.07

5.42

6.78

8.14

9.49

10.85

12.20

10

13.56

14.91

16.27

17.63

18.98

20.34

21.69

23.05

24.40

25.76

20

27.12

28.47

29.83

31.18

32.54

33.90

35.25

36.61

37.96

39.32

30

40.67

42.03

43.39

44.74

46.10

47.45

48.81

50.17

51.52

52.87

40

54.23

55.59

56.94

58.30

59.66

60.01

62.37

63.72

65.08

66.44

50

67.79

69.15

70.50

71.86

73.21

74.57

75.93

77.28

78.64

80.00

60

81.35

82.70

84.06

85.42

86.77

88.13

89.48

90.84

92.20

93.55

70

94.91

96.26

97.62

98.97

100.33

101.69

103.04

104.40

105.75

107.11

80

108.47

109.82

111.18

112.53

113.89

115.24

116.60

117.96

119.31

120.67

90

122.03

123.38

124.74

126.09

127.45

128.80

130.16

131.51

132.87

134.23

See NOTE on page A5-5 regarding Table usage

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

0

1

2

3

4

5

6

7

8

9

0

(kg.m)

0.138

0.277

0.415

0.553

0.692

0.830

0.968

1.106

1.245

10

1.38

1.52

1.66

1.80

1.94

2.07

2.21

2.35

2.49

2.63

20

2.77

2.90

3.04

3.18

3.32

3.46

3.60

3.73

3.87

4.01

30

4.15

4.29

4.43

4.56

4.70

4.84

4.98

5.12

5.26

5.39

40

5.53

5.67

5.81

5.95

6.09

6.22

6.36

6.50

6.64

6.78

50

6.92

7.05

7.19

7.33

7.47

7.61

7.74

7.88

8.02

8.16

60

8.30

8.44

8.57

8.71

8.85

8.99

9.13

9.27

9.40

9.54

70

9.68

9.82

9.96

10.10

10.23

10.37

10.51

10.65

10.79

10.93

80

11.06

11.20

11.34

11.48

11.62

11.76

11.89

12.03

12.17

12.30

90

12.45

12.59

12.72

12.86

13.00

13.14

13.28

13.42

13.55

13.69

See NOTE on page A5-5 regarding Table usage

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

0

1

2

3

4

5

6

7

8

9

0

(kPa)

6.895

13.79

20.68

27.58

34.47

41.37

48.26

55.16

62.05

10

68.95

75.84

82.74

89.63

96.53

103.42

110.32

117.21

124.1

131.0

20

137.9

144.8

151.7

158.6

165.5

172.4

179.3

186.2

193.1

200.0

30

206.8

213.7

220.6

227.5

234.4

241.3

248.2

255.1

262.0

268.9

40

275.8

282.7

289.6

296.5

303.4

310.3

317.2

324.1

331.0

337.9

50

344.7

351.6

358.5

365.4

372.3

379.2

386.1

393.0

399.9

406.8

60

413.7

420.6

427.5

434.4

441.3

448.2

455.1

462.0

468.9

475.8

70

482.6

489.5

496.4

503.3

510.2

517.1

524.0

530.9

537.8

544.7

80

551.6

558.5

565.4

572.3

579.2

586.1

593.0

599.9

606.8

613.7

90

620.5

627.4

634.3

641.2

648.1

655.0

661.9

668.8

675.7

682.6

See NOTE on page A5-5 regarding Table usage

F15-4

Standard Torque Charts and Conversion Tables

11/05 FAM1501

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

0

10

20

30

40

50

60

70

80

90

0

(MPa)

0.069

0.14

0.21

0.28

0.34

0.41

0.48

0.55

0.62

100

0.69

0.76

0.83

0.90

0.97

1.03

1.10

1.17

1.24

1.31

200

1.38

1.45

1.52

1.59

1.65

1.72

1.79

1.86

1.93

2.00

300

2.07

2.14

2.21

2.28

2.34

2.41

2.48

2.55

2.62

2.69

400

2.76

2.83

2.90

2.96

3.03

3.10

3.17

3.24

3.31

3.38

500

3.45

3.52

3.59

3.65

3.72

3.79

3.86

3.93

4.00

4.07

600

4.14

4.21

4.27

4.34

4.41

4.48

4.55

4.62

4.69

4.76

700

4.83

4.90

4.96

5.03

5.10

5.17

5.24

5.31

5.38

5.45

800

5.52

5.58

5.65

5.72

5.79

5.86

5.93

6.00

6.07

6.14

900

6.21

6.27

6.34

6.41

6.48

6.55

6.62

6.69

6.76

6.83

See NOTE below regarding Table usage

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

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

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

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

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

FAM1501 11/05

Standard Torque Charts and Conversion Tables

F15-5

TABLE XIII COMMON CONVERSION MULTIPLIERS

COMMON CONVERSION MULTIPLIERS METRIC TO ENGLISH

COMMON CONVERSION MULTIPLIERS ENGLISH TO METRIC To Convert From

Multiply By

TO

Multiply By

inch – in.

millimeter (mm)

25.40

millimeter (mm)

inch – in.

0.0394

inch – in.

centimeter (cm)

2.54

centimeter (cm)

inch – in.

0.3937

foot – ft

meter (m)

0.3048

meter (m)

foot – ft

3.2808

yard – yd

meter (m)

0.914

meter (m)

yard – yd

1.0936

1.61

kilometer (km)

mile – mi.

kilometer (km) 2

sq. in. – in. sq. ft. –

ft2

To Convert From

TO

mile – mi.

0.6210

2

sq. in. – in.

0.1550

2

2

sq. centimeters (cm )

6.45

(cm2)

929

sq. centimeters (cm )

sq. ft. – ft2

0.001

2

sq. centimeters

sq. centimeters (cm )

cu. in. – in.3

cu. centimeters (cm3)

16.39

cu. centimeters (cm3)

cu in – in.3

0.061

cu. in. – in.3

liters (l)

0.016

liters (l)

cu in – in.3

61.02

cu. ft. – ft3

cu. meters (m3)

0.028

cu. meters (m3)

cu ft – ft3

35.314

cu. ft. – ft3

liters (l)

28.3

liters (l)

cu ft – ft3

0.0353

ounce – oz

kilogram (kg)

0.028

grams (g)

ounce – oz.

0.0353

fluid ounce – fl oz

milliliter (ml)

29.573

milliliter (ml)

fluid ounce – fl oz.

0.0338

pound (mass)

kilogram (kg)

0.454

kilogram (kg)

pound (mass)

2.2046

Newton (N)

4.448

Newton (N)

pound (force) – lbs

0.2248

Newton meters (N•m)

0.113

Newton-meters (N•m)

kilogram meters (kg•m)

0.102

ft lbs (force)

Newton meters (N•m)

1.356

Newton-meters (N·m)

ft lbs

0.7376

ft lbs (force)

kilogram meters (kg•m)

0.138

kilogram-meters (kg•m)

ft lbs

7.2329

Newton meters (N•m)

9.807

psi

0.1450

pound (force) – lbs in. lbs. (force)

psi (pressure)

kilopascals (kPa)

6.895

kilogram-meters (kg•m)

psi (pressure)

megapascals (MPa)

0.007

kilopascals (kPa)

psi (pressure)

kilograms/cm2 (kg/cm2)

0.0704

ton (short)

kilogram (kg)

907.2

ton (short)

metric ton

0.0907

megapascals (MPa) kilograms/cm

(kg/cm2)

kilograms/cm2 (kg/cm2)

quart – qt

liters (l)

0.946

kilogram (kg)

gallon – gal

liters (l)

3.785

metric ton

HP (horsepower)

Watts

745.7

liters (l)

HP (horsepower)

kilowatts (kw)

0.745

liters (l)

F15-6

2

psi

145.038

psi

14.2231

kilopascals (kPa)

98.068

ton

0.0011

ton

1.1023

quart – qt

1.0567

gallon – gal

0.2642

Watts

Horsepower HP

0.00134

kilowatts (kw)

Horsepower HP

1.3410

Standard Torque Charts and Conversion Tables

11/05 FAM1501

HYDRAULIC SYSTEM FLUSHING PROCEDURE Hydraulic System Flushing Procedure

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

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

Hoist system bypass blocks (PC3074), steering system flushing hose (XB5777) and fitting assembly (XB7075) must be on-site before or during field assembly, so when the truck is started for the first time, the hydraulic system can be flushed and any debris can be removed from the hydraulic system.

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

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

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

3. 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.

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: • Pressure test port “TP3” (4, Figure 16-1) on the bleed down manifold - 35 000 kPa (5,000 psi).

• Pressure test port (1, Figure 16-2) for the front brake cooling circuit - 3 450 kPa (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.

FAM1602 5/11

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

• Pressure test port (1, Figure 16-3) for the rear brake cooling circuits - 3 450 kPa (500 psi).

• Pressure test port “GPA” (2, Figure 16-4) located on the steering pump - 35 000 kPa (5,000 psi).

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

Hydraulic System Flushing

F16-1

7. Ensure pressure gauge connected at "TP3" reads 0 kPa (0 psi) before removing plugs (1 & 2, Figure 16-1). 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.

9. Connect the four hoist cylinder hoses (3, Figure 16-2) 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.

8. If the hydraulic tank has already been filled with oil, a vacuum pump (XB0887) must be installed on the hydraulic tank to prevent oil spillage before disconnecting any brake cooling hoses.

FIGURE 16-2. TEST PORT LOCATIONS AND HOIST FLUSHING HOOKUP 1. Test Port (Front Brake Cooling Circuit) 2. Test Port (Hoist Filters) 3. Hoist Cylinder Hoses 4. Bypass Blocks (PC3074)

FIGURE 16-1. BLEED DOWN MANIFOLD 4. Test Port (TP3) 1. Plug - QD Supply Port 5. Test Port (TP2) 2. Plug - QD Return Port 3. Bleed Down Manifold

F16-2

Hydraulic System Flushing

5/11 FAM1602

10. At the rear axle housing, connect brake cooling lines (1, 2 & 3, Figure 16-5) together using fitting assembly (3, Figure 16-7). 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 16-6) 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.

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

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 16-4). 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.

FIGURE 16-3. BRAKE COOLING MANIFOLD 1. Test Port (Rear Brake Cooling Pressure) 2. Test Port (Front Brake Supply Pressure) 3. Test Port (Front Brake Return Pressure) 4. Test Port (Hoist Return Pressure) 5. Test Port (Rear Brake Return Pressure)

FIGURE 16-4. STEERING PUMP & HOIST SYSTEM QUICK DISCONNECTS 1. Fitting (Pump Case Drain) 2. Test Port (GPA)

FAM1602 5/11

Hydraulic System Flushing

F16-3

12. If a vacuum pump was installed on the hydraulic tank, remove it after all of the hose connections are complete.

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

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

14. To bleed trapped air from inside the 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.

FIGURE 16-6. FRONT WHEEL BRAKE LINES 1. Cooling Hose 2. Adapter (EG1794)

FIGURE 16-5. REAR AXLE BRAKE COOLING LINES 1. LBCR - Left Brake Cooling Return 2. BCS - Brake Cooling Supply 3. RBCR - Right Brake Cooling Return

F16-4

3. Cooling Hose 4. Brake Apply Hose

FIGURE 16-7. FITTING ASSEMBLY 1. 90° Swivel Elbow (PC3062) 2. T-Fitting (WB0426) 3. Fitting Assembly (XB7075)

Hydraulic System Flushing

5/11 FAM1602

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

16. Ensure both brake accumulator bleed down valves (1, Figure 16-8) are open.

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

18. 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.

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

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.

20. If the oil pressure readings in Step 19 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 16-2) and rear brake cooling test port (1, Figure 16-3) 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.

• 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).

FIGURE 16-8. BRAKE MANIFOLD 1. Accumulator Bleed Down Valves 2. Brake Manifold

FAM1602 5/11

Hydraulic System Flushing

F16-5

21. If all pump pressures and brake cooling oil supply pressures are correct as stated in Steps 18 and 19, increase engine speed to 1500 rpm and flush 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.

22. 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.

23. Install a vacuum pump on the hydraulic tank to prevent oil leakage before disconnecting hoses.

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

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

25. Check 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 16-1) previously removed back into the bleed down manifold.

26. Remove the vacuum pump from the hydraulic tank. Check the hydraulic tank oil level. If necessary, add oil.

27. Close both brake accumulator bleed down valves (1, Figure 16-8).

28. 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 21 200 kPa (3,075 psi). This is the pressure where the steering pump unloader valve shifts and unloads the pump.

• If the accumulator pressure exceeds 21 546 kPa (3,125 psi), immediately turn the engine off and open the brake accumulator bleed down valves.

Refer to Steering pump pressure control adjustments in the shop manual, then repeat Step 27.

• If the accumulator pressure does not reach 20 856 kPa (3,025 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.

29. When the pressure gauge connected to "TP3" reads approximately 21 200 kPa (3,075 psi): a. For the first time only through this step: • Leave the key switch in the ON position, and use the 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.

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

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

F16-6

Hydraulic System Flushing

5/11 FAM1602

30. If Step 28-b results are satisfactory, open both brake accumulator bleed down valves (1, Figure 16- 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.

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

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

32. If the truck is sitting on cribbing and no wheels are installed, skip this step. If the tires are installed, apply the service brake and move the directional control lever to neutral. Apply the wheel brake lock, then release the service brakes. This will release the parking brake to allow the front wheels to be steered.

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

34. If the truck was sitting on tires, apply the service brakes and move the directional control lever to the PARK position. Turn the wheel brake lock switch to OFF, then release the service brakes.

35. 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.

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

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

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

40. After the steering and brake system checkout procedures are completed, remove hoist cylinder bypass blocks (4, Figure 16-2) 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.

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

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

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

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

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

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

45. 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.

a. Close both hoist pump suction line shutoff valves and the steering pump suction line shutoff valve.

b. Remove the hoist and steering hydraulic filter elements. Clean the housings and install new filter elements.

b. Remove the hoist and steering hydraulic filter elements. Clean the housings and install new filter elements.

c. If installed, remove the vacuum pump.

c. Open both hoist pump suction line shutoff valves and the steering pump suction line shutoff valve.

FAM1602 5/11

Hydraulic System Flushing

F16-7

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

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

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

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

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

F16-8

Hydraulic System Flushing

5/11 FAM1602

FIELD ASSEMBLY INSPECTION REPORT After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.

MACHINE MODEL

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

Date of Inspection

Wheel Motor Traction Motor

CUSTOMER UNIT NUMBER

860E-1K 860E-1KT Service Meter Reading

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.

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 1 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Inspection Around Machine 1

Parts

Visually inspect unit for loose parts and debris.

2

Hardware

Visually inspect unit for missing and/or loose mounting hardware.

3

Hoses and Cables

Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped and clear from sharp edges and not rubbing each other.

4

Ground Straps

Verify all ground straps are secure (sub-frame, anchor, etc).

5

Engine Oil Level

Verify engine oil level is in operating range.

6

Engine Fan

Inspect fan-to-shroud clearance and belt alignment.

7

Hydraulic Oil Level

Verify oil level is visible through upper sight glass with dump body down.

8

Anchor Pin

Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and properly tightened hardware.

9

Wheel Motors

Inspect oil specification and proper oil level.

10

Fuel Tank

Verify fuel tank mounting is secure and there are no fuel leaks.

11

Radiator

Inspect coolant fill level, cold temperature protection, and DCA additive.

Verify all ladders and handrails are secure and hardware is tight.

12

Decks and Ladders

Visually inspect installation of grid blower, rectifier assembly and control box for correct assembly of components and proper clamping, no loose contacts, no damaged or poorly crimped cables.

Inspect all wiring and connections in battery box and ensure there is no rubbing or chafing.

13

Verify battery mounting hardware is secure.

Battery

Verify electrolyte is at proper level and caps are securely installed.

Verify all battery terminals are secure.

14

Steering Components

Visually inspect installation of steering cylinders, tie rod, and accumulators per print.

15

Hydraulic Components

Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations to ensure all hardware is secure and there are no leaks.

Hardware Torque 1

Suspension

2

Verify front suspension mounting cap screws have been properly tightened per appropriate shop manual procedure.

Verify torque on front wheel nuts is at 1 166 ± 136 N·m (860 ± 100 ft lb).

Wheels (See Note below.)

Verify torque on rear inside wheel nuts and outer wheel nuts are 1 166 ± 136 N·m (860 ± 100 ft lb).

Verify torque on rear outside adapter ring is at 2 326 ± 136 N·m (1,715 ± 100 ft lb).

Verify torque on left rops beam cap screws is at 800 N·m (590 ft lb).

3

Rops

4

Center Beam

If equipped with trolley option, verify torque on center beam cap screws is 240 N·m (177 ft lb).

5

Cab

Verify torque on cab mounting cap screws is at 800 N·m (590 ft lb).

6

Wheel Motor

Verify torque on wheel motor to axle housing mounting cap screws is at 2 007 N·m (1,480 ft lb).

7

Tie Rod Clamp Nuts

Verify torque on tie rod clamp nuts is at 420 ± 42 N·m (310 ± 31 ft lb).

Verify torque on right cross beam cap screws is at 240 N·m (177 ft lb).

NOTE: Refer to the appropriate Disassembly and Assembly section in the shop manual for the complete wheel mounting tightening procedure.

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 2 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Cab Compartment 1

Cab Doors

Verify doors open and close smoothly and latch works properly.

2

Cab Windows

Verify windows can be opened and closed smoothly.

3

Door Locks

4

Interior

5

Document Holder

6

Cab Seats

7

Steering Wheel

8

Wiper

9 10

Verify left and right door locks work properly with key.

Visually inspect interior for completeness of assembly.

Visually inspect for cracked glass, torn upholstery, dirt, stains, holes, etc.

Verify O&M manual and safety manual are in the holder.

Inspect operatorâ&#x20AC;&#x2122;s seat adjustments.

Inspect seat belts and tethers for proper installation.

Check tilt and telescoping functions.

Verify adjustable lever can be locked securely.

Verify wiper functions at all speeds and range does not extend beyond glass surface.

Verify windshield washer functions properly and washer fluid bottle is full.

Cigarette Lighter

Check lighter operation, should pop out after 10 seconds and be hot.

Horn

Check for proper sound and no looseness in horn button.

11

Backup Horn

Check for proper sound and function.

12

Shift Lever

Check for proper function and no binding or looseness.

13

Gauges

Verify gauges are installed straight and operating correctly.

14

Hydraulic Fittings

Visually inspect all hydraulic fittings under cab and hydraulic brake cabinet for leaks. If equipped, inspect all pantograph fittings for leaks.

15

Hoist

Check operation of hoist lever in all four positions.

1

Dome Light

Verify dome light operates properly.

2

Dimmer Switch

Lights

Verify dimmer operates properly.

Verify all headlights (high and low beams) and fog lights are functional.

3

Headlights/Fog Lights

Verify high beam indicators on instrument panel are functional.

Verify lights are at proper angle.

Visually inspect front and rear turn signal operation on left and right sides.

4

Turn Signal

Verify turn signal indicators on instrument panel operate properly.

Verify switch turns off after turn is completed.

Verify flasher operates properly.

5

Hazard Flashers

6

Backup Light

Verify backup lights operate properly when shift lever is in REVERSE.

7

Manual Backup Light

Verify switch and light function properly.

8

Service Brake

Verify service brake lights and indicator operate properly.

9

Retarder Lights

Verify retarder lights operate properly.

CEAW005902

Verify hazard indicator on instrument panel operates properly.

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 3 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Service Inspection 1

Hydraulic System

Perform hydraulic flushing procedure at initial start up.

Front suspension oiling height is 25.4 mm (1 in.).

2

Suspensions

Rear suspension oiling height is 54.0 mm (2.1 in.).

(See Note below.)

Front charging height is 229 mm (9.01 in.) at 3 365 kPa (488 psi).

Rear charging height is 270 mm (10.63 in.) at 1 467 kPa (213 psi).

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 17 235 ± 517 kPa (2,500 ± 75 psi).

9

Brake Pressures

Verify with pedal depressed, rear brake pressure (BR) is 17 235 ± 517 kPa (2,500 ± 75 psi).

Verify brake lock pressure is 13 790 ± 689 kPa (2,000 ± 100 psi).

Verify parking brake release pressure is 11 480 ± 1 275 kPa (1,665 ± 185 psi).

10

Verify steering wheel turns smoothly from lock to lock.

Steering

Verify steering system is free of noise and vibrations.

Verify POWER UP relief pressure is 17 237 kPa (2,500 psi).

Verify POWER DOWN relief pressure is 10 340 kPa (1,500 psi).

11

Verify hoist limit switch is operational and set correctly. (Measure on hoist cylinder 3rd stage.

Cylinder should stop 152 mm (6 in.) before full extension.)

Hoist

Verify hoist HOLD position operates properly.

Verify there is no heavy shock when dump body returns to frame in FLOAT. POWER UP with loaded dump body is 20-24 seconds.

12

Hoist Times

POWER DOWN with empty dump body is 13-15 seconds.

FLOAT to frame with empty dump body is 22-26 seconds.

Ensure body up switch activates body up alarm and indicator.

Ensure automatic lubrication system is serviced, tank is full and air is purged from system.

13

Lubrication

14

Payload Meter

Calibrate and check payload meter operation per shop/O&M manual instructions.

15

Error Codes

Troubleshoot any error codes and delete.

16

Machine

Record machine model type, machine serial number and engine serial number.

17

Dump Body

Ensure dump body is shimmed correctly prior to truck release.

18

Electrical Checks

19

IM Programming

Ensure automatic lubrication system is operating properly and timer is set as desired.

Ensure electrical checkout procedure has been completed and signed off.

(See appropriate field assembly manual or shop manual for procedure.)

Ensure IM is programmed with its own unique configuration file and copy of file is saved.

NOTE: Refer to the appropriate Testing and Adjusting section in the shop manual for complete suspension oiling and charging instructions.

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 4 of 5

ADDITIONAL COMMENTS ________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW005902

White - Komatsu, Manager of Technical Support Pink - Komatsu, Regional Service Manager

Canary - Komatsu, Manager of Field Assembly Gold - Komatsu Distributor, Service Manager

Page 5 of 5

NOTES:

50 HOUR POST-COMMISSIONING CHECKSHEET Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.

MACHINE MODEL 860E-1K 960E-1K

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

Date of Inspection

Wheel Motor Traction Motor

CUSTOMER UNIT NUMBER

860E-1KT 960E-2K

Service Meter Reading

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

CEAW006004

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.

CEAW006004

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 Suspensions

Rear suspension oiling height is 53.0 mm (2.1 in.).

Front charging height is 219 mm (8.62 in.) at 3 282 kPa (476 psi).

960E-1K 960E-2K

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

KOMTRAX Plus

CEAW006004

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 KOMTRAX Plus 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:______________________________________________________________

__________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW006004

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

®

www.komatsuamerica.com

Komatsu America Corp.

2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072

Copyright 2011 Komatsu Printed in USA