KOMATSU HD1500-7 DUMP TRUCK Field Assembly Manual (SERIAL NUMBERS A30001 – A30108) – PDF DOWNLOAD

CEAW004902

Field Assembly Manual

DUMP TRUCK SERIAL NUMBERS

A30001 - A30108

®

FOREWARD This manual is provided to aid assemblers during field assembly of the standard Komatsu HD1500-7 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.

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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

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TABLE OF CONTENTS

SUBJECT

PAGE NUMBER

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 DUMP BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

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Introduction

iii

KOMATSU HD1500-7 DUMP TRUCK

iv

Introduction

FAM0014

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 operation.

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.

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 transmission housing unless it has been completely disassembled.

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

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

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

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

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

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.

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

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Safety Rules, Tools, & Equipment

Page 1-1

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

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

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

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 oxy-acetylene cutting set.

5. One, propane torches for weld preheating.

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

Two, 15 m (50 ft) air hoses.

7. Metal stands and a sufficient amount of wood cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm (4 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm (4 ft. x 6 in. x 6 in.) - such as railway cross ties 8. Tire handler - Wiggins/Iowa Mold Tooling.

9. Miscellaneous air tools 10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft) 11. Chains, lifting cables, slings:

• • • • •

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

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

sizes.

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

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

• Torque wrenches - 339 N·m (250 ft lb) with

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

• Box wrench 1 3/8 in. (Snap-On p/n X440B) with 12 inch extension to tighten ROPS cap screws.

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

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

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

17. Special tools (see list, following pages) 18. Two, hydraulic or pneumatic porta-power jacks, 4.5 and 9 metric ton (5 and 10 ton) 19. Various hooks and shackles 20. Miscellaneous: i.e. grinders, containers, rags.

21. Spreader bars for cab and decks.

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

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

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

23. Pry bars

Two, 3 m (10 ft) nylon straps

24. Solvent - 38 liters (10 gal)

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

25. Paint remover - 19 liters (5 gal)

Page1-2

26. Rust preventive grease

Safety Rules, Tools, & Equipment

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LIFTING SLING GENERAL INFORMATION

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Safety Rules, Tools, & Equipment

Page 1-3

PART NO.

DESCRIPTION

562-98-31301 Disc Gauge

PART NO. EC3331

DESCRIPTION NItrogen Charging Kit

USE Brake Disc Wear Tool

USE Suspension & accumulator nitrogen charging

NOTE: Not included with all trucks.

PART NO. PC2061 PART NO.

DESCRIPTION

569-86-87361 Download Harness

Page1-4

USE

DESCRIPTION Belt Tension Tester

USE A/C Belt Tension

PLM Download Data

Safety Rules, Tools, & Equipment

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PART NO. EL8868

PART NO. SE21188

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DESCRIPTION V-Belt Alignment Tool

DESCRIPTION Driveshaft Alignment Tool

USE Aligning A/C pulleys

USE Aligning driveline components

Safety Rules, Tools, & Equipment

Page 1-5

ASSEMBLY SCHEDULE AND RESOURCE LAYOUT Page1-6

Safety Rules, Tools, & Equipment

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MAJOR COMPONENTS AND SPECIFICATIONS Engine

Power Steering

The Komatsu HD1500-7 dump truck is powered by a Komatsu SDA12V160 diesel engine. This engine is Tier 1 compliant.

The HD1500-7 truck is equipped with a full time power steering system. The system provides positive steering control with minimum effort by the operator.

Nitrogen-charged accumulators automatically provide emergency power if steering pressure is reduced below an established minimum.

Transmission The Torqflow transmission is a planetary gear, multiple disc clutch transmission. The transmission is hydraulically actuated and force-lubricated for optimum heat dissipation. consists A three-element, single-stage, two-phase torque converter is mounted to the front of the transmission.

The Torqflow transmission is capable of seven forward speeds and one reverse speed. Automatic shifting is controlled by an electronic shift control system with automatic clutch modulation in all gears. A lockup system consisting of a wet, double-disc clutch, is activated in F1-F7 gears for increased fuel savings.

Depressing the brake pedal, or operating the retarder, actuates the hydraulic front and rear service brakes. Both front and rear service brakes are oilcooled, multiple-disc brakes. The brakes are automatically applied when engine speed exceeds the rated revolutions for the shift range. The system includes two nitrogen-charged accumulators for quick response. The accumulators provide emergency braking if a problem occurs in the primary braking circuit.

Retarder

Final Drive The final drive consists of a plug-in differential with planetary wheel drive.

Operator’s Cab The HD1500-7 operator's cab has been engineered for maximum operator comfort and to allow for efficient and safe operation of the truck.

The cab provides for wide visibility, with an integral four-post ROPS/FOPS, and an advanced analog operator environment. It includes the following: tinted safety-glass windshield, power-operated side windows, deluxe interior with a fully adjustable seat with lumbar support, fully adjustable tilt steering wheel, controls mounted within easy reach of the operator, and an electronic display/monitoring panel to keep the operator informed of the truck's operating circuits.

Audible alarms and indicator lights warn the operator of system malfunctions.

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Brake System

The operator can manually apply both the front and rear oil-cooled, multiple-disc brakes by actuating the retarding system. The retarder control lever is mounted on the steering column.

The retarding system is also equipped with an Automatic Retard Speed Control (ARSC) system. The system automatically applies the retarder to maintain the set speed as initiated by the operator. Refer to Section 32, Operator Cab and Controls, for more information on the ARSC system.

Suspension Hydro-pneumatic suspension cylinders are mounted at each wheel to reduce shock. The suspensions provide riding comfort for the operator and machine stability for safe travel.

Major Components and Specifications

2-1

MAJOR COMPONENT LOCATION

2-2

Major Components and Specifications

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SPECIFICATIONS Engine

Service Capacities

Komatsu . . . . . . . . . . . . . . . . . . . . . . . SDA12V160*

. . . . . . . . . . . . . . . . . . . . . . . .Liters . . U.S Gallons

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 12

Engine . . . . . . . . . . . . . . . . . . 193 . . . . . . (51) (Includes Lube Oil Filters)

Operating Cycle (diesel) . . . . . . . . . . . . . . . 4-Stroke Rated . 1108 kW (1486 SAE Brake HP) @ 1900 rpm Flywheel . . . 1048 kW (1406 SAE HP) @ 1900 rpm Weight (dry) . . . . . . . . . . . . . . . .5813 kg (12,815 lbs) * Tier 1 Compliant

Cooling System . . . . . . . . . . . 532 . . . . . . (141) Fuel Tank . . . . . . . . . . . . . . . . 2120 . . . . . (560) Transmission . . . . . . . . . . . . . 153 . . . . . . .(41) And Torque Converter Hydraulic System . . . . . . . . . 900 . . . . . . (238)

Transmission Automatic Electronic Shift Control with Automatic Clutch Modulation In All Gears.

Torque Converter. . . . . . . . 3-Element, Single-stage, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-phase Lockup Clutch . . . . . . . . . . . . . . . Wet, Double-disc, . . . . . . . . . . . . . . . . . . . . . . Activated in F1-F7 gears.

Transmission . . . . . . . 7 Forward Speeds, 1 Reverse . . . . . . . . . . . . .Planetary Gear, Multiple Disc Clutch, . . . . . . . . . . Hydraulically Actuated, Force-lubricated Gear . . . . . . . . . . . . . . . . . . . . . kph . . . . . . . . mph 1 . . . . . . . . . . . . . . . . . . . . . . 11.0 . . . . . . . . . 6.8 2 . . . . . . . . . . . . . . . . . . . . . . 14.6 . . . . . . . . . 9.1 3 . . . . . . . . . . . . . . . . . . . . . . 19.5 . . . . . . . . 12.1

Differential . . . . . . . . . . . . . . . 297 . . . . . . .(78) Final Drive (each planetary) . 120 . . . . . . .(32) Hydraulic System Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . (3) Hoist (Tandem Gear) . . . . 805 l/min. (213 gpm) @ 18 960 kPa (2,750 psi) Steering (Piston) . . . 221 l/min. (58.5 gpm) @ 18 960 kPa (2,750 psi) Brake (Tandem Gear) . . . . . 1512 l/min. (400 gpm) Hoist Control Valve . . . . . . . . . . . . . . . . . Spool Type Positions. . . . . . . . . . Raise, Hold, Float, and Lower

5 . . . . . . . . . . . . . . . . . . . . . . 32.6 . . . . . . . . 20.3

Hydraulic Cylinders Hoist . . . . . . . . . . . . . 3-Stage Telescoping Piston Steering . . . . . . . . . . . Twin - Double Acting Piston

6 . . . . . . . . . . . . . . . . . . . . . . 44.2 . . . . . . . . 27.5

Relief Valve Setting . . . . . . . .18 960 kPa (2,750 psi)

7 . . . . . . . . . . . . . . . . . . . . . . 58.0 . . . . . . . . 36.0

Filtration . . . . . . . . . . . In-line Replaceable Elements Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh Hoist & Steering . . . . . . . . . Dual, Full Flow, In-line . . . . . . . . . . . . High Pressure. Beta 12 Rating = 200

4 . . . . . . . . . . . . . . . . . . . . . . 24.5 . . . . . . . . 15.2

Reverse . . . . . . . . . . . . . . . . . . . 10.6 . . . . . . . . . 6.6

Transmission . . . . . . . . . . . . . .Dual, High Pressure

Final Drive Final Drive . . . . . . . . . . . . . . . . . Plug-in Differential . . . . . . . . . . . . . . . . . . . . with Planetary Wheel Drive Reduction Ratios: Bevel Set . . . . . . . . . . . . . . . . . . . . . . . . . 2.647:1 Planetary Final Drive . . . . . . . . . . . . . . . . . 7.235:1 Total Reduction . . . . . . . . . . . . . . . . . . . 19.151:1

Electrical System Batteries (series-parallel). . 4 x 12V / 140 Amp-Hour Alternator . . . . . . . . . . . . . . 24 Volt, 140 Amp Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt Cranking Motors . . . . . . . . . . . Two - 24 Volt Electric

Service Brakes Actuation: . . . . . . . . . . . . . . . . . . . . . . . All-Hydraulic Front . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc Rear . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc . . . . . . . . . . Both act as service and retarder brakes Retarder Brakes: Normally Applied . . . . . . . . Manually By Operator. . . . . . . . . . . . . . . . . . . . . . . . . . . (w/ ARSC control) Automatically Actuated . . . . . . . . . . . . . . . . . . . . . . when engine speed exceeds the rated revolutions of the shift position for the transmission.

Parking Brake: . . . . . . Spring-Applied, Oil Released . . . . Dry Caliper Disc Actuates On Rear Drive Shaft Emergency Brakes: Manual or automatic operation.

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Major Components and Specifications

2-3

Steering Turning Circle Diameter (SAE) . . . . . . . 24.4 m (80 ft) Automatic Emergency Steering . . . . 2 Accumulators

Tires Rock Service (E-3) . . . . . . . . . . . . . . . . . . . Tubeless Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 33.00 R51 Rim Size . . . . . 61x 12.95 x 12.7 cm (24 x 51 x 5 in.)

Phase II Generationâ„¢ . . . . . . . Separable Tire Rims

Dump Body Capacity (Standard) Struck . . . . . . . . . . . . . . . . . . . . . . . 54 m3 (71 yds3) Heaped @ 2:1 (SAE) . . . . . . . . . . 78 m3 (102 yds3)

Overall Truck Dimensions Loading Height . . . . . . . . . . . . . . . . 4.965 m (16' 3") Minimum Clearance Height . . . . . . . . 5.85 m (19' 2") Overall Length . . . . . . . . . . . . . . . . . 11.37 m (37' 4") Maximum Width. . . . . . . . . . . . . . . . . 6.62 m (21' 9") Weight Distribution Empty . . . . . . . . . . . . . . . Kilograms . . . . .Pounds Front Axle . . . . . . . . . . . . . . 51,714. . . . . . 114,008 Rear Axle . . . . . . . . . . . . . . 54,041 . . . . . . . 119,140 Total . . . . . . . . . . . . . . . . . . 105,755 . . . . . 233,148 Loaded (150 Ton Payload) . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . .Pounds Front Axle . . . . . . . . . . . . . . 83,824 . . . . . . .184,800 Rear Axle . . . . . . . . . . . . . . 165,651 . . . . . .365,199 Total * . . . . . . . . . . . . . . . . . 249 475 . . . . . .550,000 *Not to Exceed 249 475 kg (550,000 lbs.).

Including Options, Fuel & Payload

2-4

Major Components and Specifications

FAM0214

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 AND CAB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32,228 . . . . . . . . . . . . . . . . . . . . . 71,050 Wheel Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003 . . . . . . . . . . . . . . . . . . . . . . . 2211 Tire 33R51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2177 . . . . . . . . . . . . . . . . . . . . . . .4800 Wheel & Tire Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3180 . . . . . . . . . . . . . . . . . . . . . . . 7011 Center Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 . . . . . . . . . . . . . . . . . . . . . . . .527 Left Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 . . . . . . . . . . . . . . . . . . . . . . .1000 Right Deck with Battery Box and Handrails. . . . . . . . . . . . . . . . . . . . . . . . . 1021 . . . . . . . . . . . . . . . . . . . . . . .2250 RH Deck Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 . . . . . . . . . . . . . . . . . . . . . . . .350 LH ROPS Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590 . . . . . . . . . . . . . . . . . . . . . . .1300 RH Upright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 . . . . . . . . . . . . . . . . . . . . . . .1000 LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 . . . . . . . . . . . . . . . . . . . . . . . .825 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2019 . . . . . . . . . . . . . . . . . . . . . . .4450 RH/LH Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . . . . . . . . . . .100 Rear Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . . . . . . . . . . .100 Fire Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . . . . . . . . . . . . . . . . . . . . .175

FAM0313

Major Component Weights

3-1

ITEM

KILOGRAMS

POUNDS

ENGINE, TRANSMISSION AND RELATED COMPONENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6431 . . . . . . . . . . . . . . . . . . . . . . 14,178 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1191 . . . . . . . . . . . . . . . . . . . . . . . 2626 Upper Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 . . . . . . . . . . . . . . . . . . . . . . . . . 66 Lower Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 . . . . . . . . . . . . . . . . . . . . . . . . . 51 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3268 . . . . . . . . . . . . . . . . . . . . . . . 7205 Battery Box with batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363 . . . . . . . . . . . . . . . . . . . . . . . . 800

FRONT AXLE COMPONENTS Front Wheel Hub, Suspension Cylinder & A-arm . . . . . . . . . . . . . . . . . . . .3629 . . . . . . . . . . . . . . . . . . . . . . . 8000 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 . . . . . . . . . . . . . . . . . . . . . . . . 289

FLUID COMPONENTS Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 . . . . . . . . . . . . . . . . . . . . . . . . 309 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685 . . . . . . . . . . . . . . . . . . . . . . . 1510 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .975 . . . . . . . . . . . . . . . . . . . . . . . 2150 Hydraulic Brake Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343 . . . . . . . . . . . . . . . . . . . . . . . . 756

REAR AXLE COMPONENTS Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455 . . . . . . . . . . . . . . . . . . . . . . . 1003 Rear Axle Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 . . . . . . . . . . . . . . . . . . . . . . . . 243 Anti-Sway Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 . . . . . . . . . . . . . . . . . . . . . . . . 201 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,288 . . . . . . . . . . . . . . . . . . . . . . 31,500

3-2

Major Component Weights

FAM0313

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 GMAW - LW102-15 or ER80S-D2

WELDER QUALIFICATION AND TRAINING

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

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

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 Procedures

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 Procedures

FAM0404

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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Field Welding Procedures

4-3

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.

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 Procedures

FAM0404

ANNEX B 2.0 TOE GRINDING WITH A ROTARY BURR

1.0 TOE HAMMER PEENING Equipment:

Equipment:

1. Hand held pneumatic hammer 2. Adequate air supply

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

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

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

5. Protective clothing, gloves, includes eye, face, and ear protection.

4. Adequate lighting

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.

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

FAM0404

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.

Field Welding Procedures

4-5

FIGURE 4-1. TOE HAMMER PEENING

4-6

Field Welding Procedures

FAM0404

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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Field Welding Procedures

4-7

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

4-8

Field Welding Procedures

FAM0404

RECEIVING & ASSEMBLY PREPARATION 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. Inspect rear suspension spherical bearings to ensure proper pin fit and movement.

4. Install support blocks under the frame at the hoist cylinder mounts. The support blocks must be approximately 76 cm (30 in.) high.

FAM0504

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.

Receiving & Assembly Preparation

5-1

ASSEMBLY LAYOUT 5-2

Receiving & Assembly Preparation

FAM0504

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

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

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

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

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

RECOMMENDED ASSEMBLY DATA

8. Site cleanup

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

FAM0614

Chassis Assembly

6-1

ORDER OF ASSEMBLY The following list outlines a general assembly order for building the truck. It is possible for some of these tasks to be performed out of order depending on factors such as manpower and location on the truck.

Before changing the order of assembly, however, consider the impact on subsequent tasks.

15. Weld both uprights

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.

20. Install body accessories - mud flaps, body position switches, etc.

16. Front ladders 17. Wheels and tires 18. Install the dump body 19. Connect hoist cylinders

21. Clean the truck 22. Install decals

1. Chassis - Unload and place on support blocks 2. Connect the rear axle.

3. Front suspension, wheel and brake assembly

23. Install lighting wiring 24. Check and adjust suspension oiling and charging

4. Fuel tank

25. Charge accumulators

5. Fit LH upright

26. Add fluids

6. Fit RH upright NOTE: Prior to starting the engine, ensure the steering pump case is full of oil.

27. Perform system check-outs 28. Clean the assembly area Do not weld the uprights until all decks and the operator cab are installed. Ratchet pullers may be required to help align the structures for a proper fit.

29. Touch up paint 30. Operator training 31. Install fire suppression system, if applicable

7. Fit LH deck/ROPS support 8. Fit RH deck support 9. Weld deck supports 10. Air intake tubes 11. RH deck, handrail and mirrors 12. Hydraulic brake cabinet 13. LH deck and handrails 14. Operator cab

6-2

Chassis Assembly

FAM0614

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.

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.

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

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

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

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

DO NOT allow welding current to pass through bearings.

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

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

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

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

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

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

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

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

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

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

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Chassis Assembly

6-3

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

2. Lubricate all pins with clean NLGI No. 2 (5% molybdenum disulfide) grease prior to installation.

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

4. Open the battery disconnect switch before arc welding. Connect the weld ground near the weld area.

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

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

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

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

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

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

17. Verify that the correct oils and coolant are being used for the operating conditions. Different climates require different fluids. The oils and coolant must be formulated for the correct operating temperatures. Refer to the lubrication chart located in the appendix for different temperature range fluid specifications.

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

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

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

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

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

13. 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.

6-4

Chassis Assembly

FAM0614

NOTES

FAM0614

Chassis Assembly

6-5

1. The weight of the chassis, as shipped, is approximately 32,228 kg (71,050 lb). Lift the chassis off the transport using two cranes. The cranes must be a minimum 45 metric ton (50 ton) capacity. Install support blocks at the front and the rear of the frame to raise the chassis for rear axle installation. The support blocks must be approximately 76 cm (30 in.) high.

Thoroughly clean all mating surfaces if not done prior.

6-6

Chassis Assembly

FAM0614

FIGURE 6-1.

FIGURE 6-2.

FAM0614

Chassis Assembly

6-7

FIGURE 6-3.

FIGURE 6-4.

6-8

Chassis Assembly

FAM0614

FIGURE 6-5.

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Chassis Assembly

6-9

2. The weight of the rear axle, as shipped, is approximately 14 288 kg (31,500 lb). Install the rear axle under the frame. Connect the upper and lower links and the anti-sway bar. Install all pins and keepers. Install the lower suspension mounting pins and keepers.

Lubricate all pins with clean NLGI No. 2 (5% molybdenum disulfide) grease prior to installation.

The normal shipping arrangement for the chassis will include the three final drive attachment links (1 upper center, two lower sides) already installed to the main frame end. However, if for some reason these are shipped separately, then they must be identified by part number and length to be certain that they are installed correctly. • The length of the center, upper link is 1460 mm (57.5 in.). • The length of the lower links is 1490 mm (59 in.).

Misalignment of the rear drive shaft and final drive housing will occur if these parts are not installed correctly.

6-10

Chassis Assembly

FAM0614

FIGURE 6-6.

FIGURE 6-7.

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Chassis Assembly

6-11

FIGURE 6-8.

FIGURE 6-9.

6-12

Chassis Assembly

FAM0614

FIGURE 6-10.

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Chassis Assembly

6-13

3. Lift the rear drive shaft into position between the transmission and the rear axle. The weight of the drive shaft is approximately 220 kg (485 lb). The male end of the slip shaft mounts on the rear axle. The female end mounts on the transmission.

Align the yokes on the drive shaft. The yokes must be positioned in the same phase angle.

4. Apply sealant (09940-00030) (or other available thread lock) to cap screws (2). Install the eight cap screws and tighten to 382 ± 38 N·m (282 ± 28 ft lb).

6-14

Chassis Assembly

FAM0614

FIGURE 6-11.

FAM0614

Chassis Assembly

6-15

5. When installing the rear axle brake cooling hoses, position the hose fittings at a 45° angle facing inward.

Pointing the hose fitting inward positions the hoses away from the frame to prevent chafing. The RH hose must be a minimum distance of 105 ± 5 mm (4.1 ± 0.2 in.) from the frame. The LH hose must be a minimum distance of 80 ± 5 mm (3.2 ± 0.2 in.) from the frame. Verify these measurements after the dump body has been installed.

6-16

Chassis Assembly

FAM0614

FIGURE 6-12.

FAM0614

Chassis Assembly

6-17

6. Lift the front suspension/wheel hub assemblies into position on each side of the truck. Each assembly weighs approximately 3,629 kg (8,000 lb).

Lubricate all pins with clean NLGI No. 2 (5% molybdenum disulfide) grease prior to installation.

Install the suspension pins and keepers, first. Then install the A-arm dust boots, spacers, pins and keepers.

Move the steering cylinders into position and install the dust boots, pins, and keepers.

Finally, move the tie rods into position and install the dust boots, pins and keepers.

6-18

Chassis Assembly

FAM0614

FIGURE 6-13.

FIGURE 6-14.

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Chassis Assembly

6-19

FIGURE 6-15.

FIGURE 6-16.

6-20

Chassis Assembly

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FIGURE 6-17.

FIGURE 6-18.

FAM0614

Chassis Assembly

6-21

7. Thoroughly clean the fuel tank trunnions. Lift the fuel tank into place on the trunnions. The weight of the fuel tank is approximately 975 kg (2,150 lb). Install the trunnion caps. The chamfer on the trunnion caps faces the fuel tank. Install the lower mounts. Tighten all cap screws to standard torque.

8. Attach the filter bracket to the rear of the fuel tank.

FIGURE 6-19.

6-22

Chassis Assembly

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FIGURE 6-20.

FIGURE 6-21.

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Chassis Assembly

6-23

9. Lift the hydraulic brake cabinet into position. The weight of the cabinet is approximately 343 kg (756 lb). Install the mounting hardware and tighten to standard torque.

6-24

Chassis Assembly

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FIGURE 6-22.

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Chassis Assembly

6-25

10. Lift the RH upright into position. The upright weighs approximately 454 kg (1,000 lb). Secure the upright with the mounting cap screws. DO NOT weld the upright at this time.

11. Lift the LH upright into position. This upright weighs approximately 374 kg (825 lb). Secure the upright with the mounting cap screws. DO NOT weld the upright at this time.

FIGURE 6-23.

6-26

Chassis Assembly

FAM0614

FIGURE 6-24.

FIGURE 6-25.

FAM0614

Chassis Assembly

6-27

12. Lift the air intake tubes into position and install on the engine. The weight of the tubes are approximately 21 kg (46 lb). Install the intake tube hangers after the decks are installed.

6-28

Chassis Assembly

FAM0614

FIGURE 6-26.

FIGURE 6-27.

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Chassis Assembly

6-29

13. Lift the ROPS support into place. This support weighs approximately 590 kg (1,300 lb). Secure the support with the mounting cap screws. Weld the support according to the specifications shown if Figure 6-34.

14. Lift the right deck support into place. The support weighs approximately 159 kg (350 lb). Secure the support with the mounting cap screws. Weld the support according to the specifications shown if Figure 6-35.

6-30

Chassis Assembly

FAM0614

FIGURE 6-28.

FIGURE 6-29.

FAM0614

Chassis Assembly

6-31

FIGURE 6-30.

FIGURE 6-31.

6-32

Chassis Assembly

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FIGURE 6-32.

FIGURE 6-33.

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Chassis Assembly

6-33

FIGURE 6-34. LH DECK SUPPORT WELD SPECIFICATIONS

6-34

Chassis Assembly

FAM0614

FIGURE 6-35. RH DECK SUPPORT WELD SPECIFICATIONS

FAM0614

Chassis Assembly

6-35

10. Lift the RH deck into position. The weight of the assembly is approximately 1021 kg (2250 lb). Install the mounting hardware to secure the deck and tighten to standard torque.

6-36

Chassis Assembly

FAM0614

FIGURE 6-36.

FIGURE 6-37.

FAM0614

Chassis Assembly

6-37

11. Lift the LH deck into position. The weight of the deck is approximately 454 kg (1000 lb). Install the mounting hardware to secure the deck and tighten to standard torque.

Install the handrails and mirrors onto the deck. These may be installed prior to deck installation.

6-38

Chassis Assembly

FAM0614

FIGURE 6-38.

FIGURE 6-39.

FAM0614

Chassis Assembly

6-39

12. Lift the operator cab into position on the left deck. The weight of the cab is approximately 2019 kg (4,450 lb).

Install the cab mounting hardware and tighten to 950 N¡m (700 ft lb).

6-40

Chassis Assembly

FAM0614

FIGURE 6-40.

FIGURE 6-41.

FAM0614

Chassis Assembly

6-41

13. Lift the front ladders into position. The weight of each ladder is approximately 45 kg (100 lb). Install the mounting hardware to the ladders and tighten to standard torque.

6-42

Chassis Assembly

FAM0614

FIGURE 6-42.

FIGURE 6-43.

FAM0614

Chassis Assembly

6-43

14. After installation of the decks and the cab, the uprights can be welded into place. Refer to the welding specification in Figure 6-46. To complete the weld, remove the bolt blocks from the bumper and weld the entire groove as shown in Figure 6-45.

FIGURE 6-44.

FIGURE 6-45.

6-44

Chassis Assembly

FAM0614

FIGURE 6-46. UPRIGHT WELDING SPECIFICATIONS

FAM0614

Chassis Assembly

6-45

15. Lift the exhaust into position on the engine. Install the clamps the secure the exhaust in place.

FIGURE 6-47.

6-46

Chassis Assembly

FAM0614

FIGURE 6-48.

FIGURE 6-49.

FAM0614

Chassis Assembly

6-47

16. Remove all dirt, debris and rust from mating parts before installing the wheel.

Grasp the wheel with the tire handler and position the wheel on the wheel hub. Align the notch in the wheel hub with the rim stopper.

Install the wheel clamps and nuts. Moderately tighten the clamp nuts in the sequence specified in Figure 6-48.

Rotate the wheel, then check that the lateral runout of the rim is within 5 mm (0.20 in.). Adjust the wheel as necessary.

Continue tightening the nuts to 2210 ± 245 N·m (1630 ± 181 ft lbs) following the proper sequence.

Adjust the tire inflation to the tire manufacturer's recommended pressure.

After the truck is ready for use, operate the truck for one haul cycle and tighten the wheel nuts again. Use the same torque specifications as previously outlined.

Check the torque daily until the specified torque value listed above is maintained on each nut. Check the torque intermittently, thereafter.

FIGURE 6-50.

6-48

Chassis Assembly

FAM0614

FIGURE 6-51.

FIGURE 6-52. FRONT TIGHTENING SEQUENCE

FAM0614

Chassis Assembly

6-49

17. Clean all tire mounting surfaces. Ensure all contact surfaces are free of damage and debris.

Move the tire handler into position and install the inboard tire. Align the notched groove in the wheel hub with the rim stopper.

NOTE: Use caution when installing the wheel. The air valve is susceptible to damage.

Install the three clamps and nuts that secure the inner wheel. Tighten the nuts to 2210 ± 245 N·m (1630 ± 181 ft lbs).

Install the spacer between the dual wheels. Use the tire handler or other lifting device to lift the spacer. The weight of the spacer is approximately 93 kg (205 lb).

Move the tire handler into position and install the outboard wheel. Align the notched groove in the wheel hub with the rim stopper.Use caution when installing the wheel. The air valve is susceptible to damage.

Install the wedge ring. Position the wedge ring so that the protrusion of the ring from the cover surface is equal around the entire circumference. Install the wheel clamps and nuts. Only tighten the nuts enough to prevent the tire/rim assembly from moving.

Install the air valve lock plate.

Lower the truck to the ground.

Tighten the clamp nuts to 2210 ± 245 N·m (1630 ± 181 ft lbs). Use the sequence shown in Figure 6-54 to tighten the clamps.

Rotate the wheel and verify the lateral runout of the rim is within 5 mm. (0.20 in.)

After assembly of the truck is complete, drive approximately 5 - 6 km (3 - 4 miles) to seat the wheels. Then tighten the clamp nuts again to the specifications listed earlier in this procedure. Check the torque periodically until the specified torque is maintained.

FIGURE 6-53.

6-50

Chassis Assembly

FAM0614

FIGURE 6-54.

FIGURE 6-55.

FAM0614

Chassis Assembly

6-51

FIGURE 6-56.

FIGURE 6-57.

6-52

Chassis Assembly

FAM0614

FIGURE 6-58. REAR TIGHTENING SEQUENCE

FAM0614

Chassis Assembly

6-53

18. Complete all hydraulic piping, electrical wiring, mechanical connections, and clamping.

6-54

Chassis Assembly

FAM0614

FIGURE 6-59. BATTERY DISCONNECT

FIGURE 6-60. FRONT WHEEL / BRAKE

FAM0614

Chassis Assembly

6-55

FIGURE 6-61. FRONT WHEEL LINKAGE

6-56

Chassis Assembly

FAM0614

FIGURE 6-62. FRONT BRAKE

FIGURE 6-63. REAR AXLE

FAM0614

Chassis Assembly

6-57

FIGURE 6-64.

FIGURE 6-65.

6-58

Chassis Assembly

FAM0614

FIGURE 6-66. REAR DRIVE SHAFT

FIGURE 6-67.

FAM0614

Chassis Assembly

6-59

FIGURE 6-68.

FIGURE 6-69.

6-60

Chassis Assembly

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FIGURE 6-70.

FIGURE 6-71.

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Chassis Assembly

6-61

FIGURE 6-72.

FIGURE 6-73.

6-62

Chassis Assembly

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FIGURE 6-74.

FIGURE 6-75.

FAM0614

Chassis Assembly

6-63

FIGURE 6-76.

FIGURE 6-77.

6-64

Chassis Assembly

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FIGURE 6-78.

FIGURE 6-79.

FAM0614

Chassis Assembly

6-65

19. Install remaining ladders.

FIGURE 6-80.

20. Install the dump body. Refer to Sections 7 & 8 for dump body assembly and installation. After the body is installed, all remaining body accessories, mud flaps and covers may be installed.

6-66

Chassis Assembly

FAM0614

DUMP BODY ASSEMBLY GENERAL INFORMATION

The total weight of the body is approximately 20,000 kg (44,082 lb). Use two cranes for assembling the body. A 45 metric ton (50 ton) crane and a 109-136 metric tons (120-150 ton) crane are required. The larger crane is needed to help turn the body over after completion of the underside welding.

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

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

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

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

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

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

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

FIGURE 7-1. BODY PARTS NOMENCLATURE 7. LH Side Sheet 4. Lift Hole 1. Canopy 5. Floor 2. Front Sheet 6. Pivot 3. RH Side Sheet

FAM0704

Dump Body Assembly

7-1

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

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

FIGURE 7-4.

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

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

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

FIGURE 7-2. DOMESTIC LAYOUT

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

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

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

10. Install cap screws (8 & 9).

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

FIGURE 7-3. INTERNATIONAL LAYOUT

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

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

13. Loosen cap screws (1 & 2).

2. Remove the paint from the weld areas.

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

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

7-2

14. Attach appropriate lifting apparatus to the body pivot. Insert the lifting apparatus through the body pin bores. The weight of the pivot is approximately 1317 kg (2904 lb). DO NOT damage the bores.

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

Dump Body Assembly

FAM0704

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

FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE

FIGURE 7-6. BODY PIVOT INSTALLATION

FAM0704

Dump Body Assembly

7-3

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

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

Install the canopy cap screws and tighten.

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

19. Tighten the pivot cap screws.

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

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

BODY WELDING 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.

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

Refer to Figure 7-7.

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

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

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

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

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

2. Remove the canopy alignment blocks.

7-4

Dump Body Assembly

FAM0704

3. Install the remaining gussets, the body guide and the body pad mounts.

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.

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

Position the body onto support blocks as shown in Figure 7-14.

FIGURE 7-9.

The following photographs show a typical example of a body being inverted with two cranes. The pictures were taken from a different model truck and are only used as a reference.

FIGURE 7-10.

FIGURE 7-8.

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Dump Body Assembly

7-5

FIGURE 7-11.

FIGURE 7-13.

FIGURE 7-12.

FIGURE 7-14.

7-6

Dump Body Assembly

FAM0704

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

6. Install any remaining components as specified on the installation blueprints.

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

8. Clean the weld joints and paint.

FIGURE 7-15.

FIGURE 7-16.

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Dump Body Assembly

7-7

NOTES

7-8

Dump Body Assembly

FAM0704

DUMP BODY INSTALLATION • 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.

1. Attach appropriate lifting cables and a hoist of to the dump body. A typical body, as shown in Figure 8-1, weighs approximately 20,000 kg (44,082 lb). Lift the body and lower into position over the truck frame. Align the body pivot and frame pivot holes.

2. Install shims (2 & 3, Figure 8-2) in both body pivots as required to fill the gaps. Center the body on the frame pivot. A minimum of one shim is required at the outside end of both frame pivots.

• 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.

• Use a lifting device that is rated for at least a 25 ton capacity.

FIGURE 8-2. DUMP BODY PIVOT PIN (Section B-B, Figure 8-4) 1. Body Pivot Pin 2. Shim/Spacer 3. Shim/Spacer

4. Pivot Bushing 5. Cap Screw 6. Lock Nut

3. Lift the pivot pin into position and align the pin retainer cap screw hole. The weight of the pin is approximately 49 kg (108 lb). Push pivot pin (1) through the shim(s) and into the pivot bushings in each side of the frame.

FIGURE 8-1. DUMP BODY REMOVAL 1. Lifting Cables

FAM0813

4. Install cap screw (5) through each pin. Install nut (6) and tighten.

2. Guide Rope

Dump Body Installation

8-1

7. Remove the shipping plates from the hoist cylinder ports, and reinstall the hoses onto the ports. New hardware is provided to install the hoses without the plates.

Failure to remove the shipping plates from the hoist cylinder hose ports may result in hose failure, personal injury, or death. Remove the plates and reinstall the hoses before operating the dump body. The shipping plates are installed during factory assembly to prevent inadvertent cylinder extension.

FIGURE 8-3. HOIST CYLINDER UPPER MOUNT 4. Retainer Ring 1. Retainer 5. Bearing 2. Cap screw & Washer 6. Hoist Cylinder 3. Pin 5. Align the hoist cylinder upper mounting eye between the mounting ears. Align the retainer slot in pin (3, Figure 8-3) with retainer (1). Install the pin.

6. Install pin retainer (1) and cap screws (2). Position the retainer to obtain 0.5 mm (0.020 in) clearance between the retainer and the bottom of the slot in body pin (3). Tighten the cap screws to standard torque. Repeat for the remaining cylinder.

FIGURE 8-4. SHIPPING PLATE REMOVAL 1. Shipping Plate

2. Hoses

8. Install the mud flaps, electrical cables and lubrication hoses.

9. Install the rock ejectors. Refer to Rock Ejectors in this chapter for installation information.

8-2

Dump Body Installation

FAM0813

FIGURE 8-5. BODY COMPONENT LOCATIONS 1. Dump Body View A-A. Rock Ejector (See Figure 8-8) 2. Body-Up Retention (Safety) Cable View B-B. Body Pivot Pin (See Figure 8-2) View C-C. Body Guide (See Figure 8-7) View D-D. Body Pads (See Figure 8-6)

BODY PADS Inspect the body pads during scheduled maintenance inspections. Replace if damaged or worn, excessively.

1. Raise the body to a height sufficient to allow access to all body pad mounts.

Place blocks between the body and the frame.

Secure the blocks in place.

2. Remove the hardware attaching the pads to the dump body. Refer to Figure 8-6.

3. Install the body pads and shims, noting the quantity of shims required at each pad. The rear pads have one less shim than the other pads.

4. Install the mounting hardware and tighten.

5. Remove the blocks from between the body and the frame. Lower the body onto the frame.

FAM0813

FIGURE 8-6. BODY PAD INSTALLATION 1. Nut 2. Lock Washer 3. Cap Screw 4. Flat Washer 5. Dump Body

Dump Body Installation

6. Mounting Pad 7. Shims (as required) 8. Body Pad 9. Main Frame

8-3

Body Pad Adjustment

BODY GUIDES

NOTE: The truck must be parked on a flat, level surface for this adjustment.

Install the body guides as shown in Figure 8-7.

Inspect body guide wear plugs (2, Figure 8-7) each time a body pad inspection is performed. If the gap becomes excessive, replacement parts must be installed.

1. All pads, except the rear pads, should contact the frame with approximately equal compression of the rubber.

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

3. If pad contact appears to be unequal, repeat the above procedure.

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

FIGURE 8-7. BODY GUIDE 1. Body Guide 2. Body Guide Wear Plug

8-4

Dump Body Installation

3. Body Rail 4. Main Frame

FAM0813

BODY-UP RETENTION CABLE

ROCK EJECTORS

When performing maintenance on the vehicle with the dump body raised, the body-up retention cable must be installed.

Rock ejectors are placed between the rear dual wheels to keep rocks and other material from lodging between the tires. Failure to maintain the rock ejectors could result in a build up of debris between the dual wheels. Debris build up may lead to tire damage.

Inspection 1. The ejectors must be positioned on the center line between the rear tires within 5 mm (0.20 in.).

To install the cable: 1. Raise the body to it's maximum height. Refer to Figure 8-5.

2. Remove cable (2) from its stored position on the body. Connect the cable between dump body (1) and the axle housing ear.

3. Secure the cable clevis pins with cotter pins.

4. Allow the body to lower until supported by the cable.

5. After maintenance is complete, reverse the above procedure to remove the cable assembly and place it in the storage position.

2. With the truck parked on a level surface, the arm (refer to Figure 8-8) must be approximately 109 mm (4.3 in.) from the wheel spacer ring.

NOTE: With rock ejector arm (1, Figure 8-8) hanging vertical as shown in Figure 8-8, there must not be any gap between the arm and the stop on bracket (2).

3. If arm (1) is bent, remove the arm and straighten.

4. Replace wear plates that are severely worn.

5. Inspect brackets (2) and pins (3) at each shift change for wear and damage. Repair as necessary.

FIGURE 8-8. ROCK EJECTORS 1. Rock Ejector Arm 2. Rock Ejector Bracket 3. Pin

FAM0813

Dump Body Installation

4. Washer 5. Cotter Pin

8-5

HEATED BODY EXHAUST BOX The standard body on HD1500 trucks utilizes a heated body design. Engine exhaust flows through the exhaust piping and enters dump body (1, Figure 8-9) through exhaust coupling (3). From the box, exhaust flows into the front sheet to warm the body and its contents. Exhaust exits the body through the side panels. When the body is raised, the connection to the body is broken. Exhaust is vented to the atmosphere at exhaust tube (4).

The exhaust coupling is mounted on exhaust box (2).

The adjustment of the exhaust coupling is extremely important in ensuring that no exhaust leakage occurs at the coupling-to-exhaust tube joint. The coupling contains a spring mechanism that maintains sufficient force to create a seal between the tubing and the exhaust coupling when the body is lowered. If the exhaust box or the coupling is not properly installed, exhaust leakage will occur.

Because of the many tolerances in the body assembly and installation, it is not possible to attach the exhaust box to the body before installing the body onto the chassis. The dump body, body guides, and body pads must be properly installed and adjusted before welding the exhaust box to the body.

FIGURE 8-9. BODY HEATED EXHAUST COUPLING 1. Dump Body 2. Exhaust Box

3. Exhaust Coupling 4. Exhaust Tube

The details and specifications for installing the exhaust box are located on the installation prints supplied at machine shipment. Follow the exact instructions on the prints to ensure proper installation, operation, and component durability.

8-6

Dump Body Installation

FAM0813

BODY POSITION SWITCHES Two magnetically activated proximity switches sense the position of the truck dump body. The body-up switch (5, Figure 8-12) is located inside the left frame rail, forward of the body pivot. This switch provides a "body seated" signal to the transmission controller when the body is resting on the frame. When the body is raised above the frame rail (magnetic field removed from the switch sensing area), the switch sends a "body float" signal to the transmission controller. A warning lamp on the instrument panel left pod illuminates to inform the operator.

NOTE: The body float lamp will also illuminate if the hoist control is not in the FLOAT position or if there is an open circuit between the switch and the transmission controller.

Inside the body limit switch, there are two magnets of slightly varying strengths in line with one another.

The magnets are located on separate ends of a rocker lever assembly which contains the functional switch contacts. In the non-actuated or rest state, in which there is no disturbance in the internal switch natural magnetic fields, the stronger magnet dominates the rocker into the “normal” position. Refer to Figure 8-10.

When the field of the dominate magnet becomes distracted by a target, (a ferrous plate, or an opposite polarity magnet field (south pole)), the weaker magnet in the switch will then become more dominate and move the rocker lever. The switch is then considered to be actuated or in the “sensed” position.

Hoist limit switch (9) is located on the left frame rail just behind the pivot. The hoist limit switch sends a signal to the hoist limit solenoid (in the hydraulic cabinet), which activates and blocks oil flow from the hoist pilot valve to the hoist valve. The “power up” oil supply is blocked to prevent full hoist cylinder extension, and possible damage to the cylinders. Proper switch adjustment insures the hoist cylinder travel stops slightly before full extension.

If either the body up switch or the hoist limit switch do not function as described above, adjust the switches according to the procedure on the following pages.

Proximity Switch Operation The body position switches on these trucks are magnetic field change operation switches. The switches can sense a ferrous material target, as well as a specific pole (south pole) magnet field. When a switch is activated by ferrous material, the maximum sensing distance is approximately 13 mm (0.5 in.). When a magnet is used instead of ferrous material, maximum sensing distance is approximately 95 mm (3.75 in.).

Therefore, use of a magnet target allows the switch to activate at greater sensing distances.

FIGURE 8-10. SWITCH CONTACTS - NORMAL AND SENSED POSITIONS

FAM0813

Dump Body Installation

8-7

Body-Up Switch Adjustment Figure 8-12 shows two views of the body-up switch (5) and the magnet used to activate the switch.

If switch adjustment is necessary, follow the procedure below: 1. With the body resting completely on the frame, loosen the switch mounting cap screws (6) and/ or the magnet adjustment cap screws (3).

2. Position the lower edge of the magnet near the upper edge of proximity switch (5) as shown in view A-A. 3. Adjust the proximity switch so the passing distance between the two targets is 15 mm (0.59 in). Tighten cap screws (6) and recheck vertical adjustment. If necessary, readjust and tighten cap screws (3).

2. If necessary, loosen the cap screws securing the proximity switch to the mounting bracket and slide the switch in or out until the passing distance between the two targets is 45 mm (1.77 in). Tighten the cap screws after adjusting. Refer to Figure 8-11 for an illustration of optimum setting of the switch.

3. Lower the body onto the frame.

4. Check operation of the switch to verify that the hoist cylinders extend, but stop before reaching maximum cylinder stroke. If the cylinders extend full stroke, adjust the switch, as necessary, to prevent full extension.

Hoist Limit Switch Adjustment Prior to adjustment, the body must be raised to maximum hoist cylinder extension and supported.

1. With the body fully raised, loosen the proximity switch adjustment cap screws (8, Figure 8-12), and slide the switch up or down to position the top of the switch 25 mm (1 in.) away from the lower edge of magnet (10). Tighten the cap screws when adjusted properly.

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. 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 25 mm (1 in.) prior to reaching the edge of the magnet. Therefore, it is crucial that the 25 mm (1 in.) is observed when setting the body limit switch.

FIGURE 8-11. HOIST LIMIT SWITCH OPTIMUM SETTING

8-8

Dump Body Installation

FAM0813

FIGURE 8-12. BODY-UP AND HOIST LIMIT SWITCHES 1. Body - Raised Position 2. Body - Resting on Frame 3. Magnet Adjustment Cap Screws 4. Magnet 5. Proximity Switch (Body-Up)

FAM0813

6. Switch Mounting Cap Screws 7. Mounting Bracket (On Frame) 8. Switch Mounting Cap Screws 9. Proximity Switch (Body Limit) 10. Magnet (Body Limit Switch)

Dump Body Installation

8-9

NOTES

8-10

Dump Body Installation

FAM0813

FINAL CHECKOUT Final checkout requires truck operation.

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

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

4. Purge trapped air from the pumps. Pressure will not build if air is present. Operating the pumps with air in the system will result in damage.

5. Perform a final check of all systems. Several checks are outlined in Section 10, Appendix.

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

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

1. Complete delivery and warranty forms.

2. Check the coolant and all lubricants for proper levels and specifications. Verify that the correct oils and coolant are being used for the operating conditions. Different climates require different fluids. The oils and coolant must be formulated for the correct operating temperatures. Refer to the lubrication chart located in Section 10, Appendix for different temperature range fluid specifications.

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

3. Verify the shut-off valves in the hydraulic cabinet are open.

FAM0906

Final Checkout

9-1

9-2

Final Checkout

FAM0906

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 - EM4499 2. Suspension Oiling And Charging Procedure 3. Toe In Adjustment Procedure 4. Automatic Lubrication System Checkout Procedure 5. Air Conditioning Checkout Procedure - EL4302 6. Air Conditioning Drive Belt Adjustment Procedure - EL9330 7. Hydraulic Checkout Procedure - EM7619 8. Brake Checkout Procedure - EL5358 9. Electrical Checkout Procedure - EM1710 10. VHMS Setup Procedure - EM1711 11. VHMS Checkout Procedure - EM2129 12. Standard Tables 13. Field Assembly Inspection Report - CEAW003506 14. 50 Hour Post-Commissioning Checksheet - CEAW004301

FAM1009

Appendix

10-1

NOTES

10-2

Appendix

FAM1009

NOTES

SUSPENSION OILING AND CHARGING GENERAL INFORMATION

Equipment List

These procedures detail the oiling and charging of the front and rear suspensions. Suspensions which have been properly charged will provide improved handling and a better ride while improving the service life of the suspensions, the truck main frame, and other main components.

1. Service Kits:

NOTE: Inflation pressures and oiling/charging dimensions are calculated for original truck Gross Vehicle Weight (GVW). Any accumulation of dirt/ mud/debris on the truck or in the body must be removed before starting these procedures. Additions to the truck weight (tailgates, water tanks, etc.) must be considered part of the payload. Keeping the truck GVW within the specification will result in a better ride and will extend the service life of the truck main frame and suspensions.

4. Jacks and/or overhead crane

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

2. The suspension piston rod extension for nitrogen charging must be correct, and this dimension maintained during nitrogen charging.

a. EC6027 Oil Charging Kit (Figure 4-5) b. EC3331Nitrogen Charging Kit (Figure 4-6) 2. Jacks and/or overhead crane 3. Two oiling spacers: height - 95 mm (3.7 in.)

5. Spacers (two) for oiling height; 95 mm (3.7 in.)

6. Oil - Refer to Tables 1 & 2 7. Dry nitrogen - Refer to Table 3

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

3. Nitrogen charging pressure must be correct.

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

NOTE: Setup dimensions specified in the charts must be maintained during oiling and charging procedures. However, after the truck has been operated, these dimensions will change.

It is extremely important to properly maintain oil and nitrogen levels on the suspension cylinders.

The oil is not only used to provide dampening, but also to lubricate internal parts. If an oil leak is present, it must be repaired, immediately. Excess nitrogen charging will not compensate for an oil leak. The lack of oil will cause excess friction in the cylinder leading to suspension cylinder failure.

Oiling and Charging Procedures

1

TABLE 1. APPROVED SUSPENSION OILS AND FRICTION MODIFIER Part Number

Description

Comments

VJ3911

Komatsu Suspension Oil - 19 liter (5 gal) container

Add 6% friction modifier. See Table 2.

AK4063

Komatsu Suspension Oil - 19 liter (5 gal) container

Already mixed with 6% friction modifier

AK4064

Komatsu Suspension Oil - 208 liter (55 gal) container

Already mixed with 6% friction modifier

Not Available

Mobil 424

Add 6% friction modifier. See Table 2.

Not Available

Mobil DTE 15

Add 6% friction modifier. See Table 2.

Not Available

Texaco TDH Oil

Add 6% friction modifier. See Table 2.

Not Available

Amoco Ultimate Motor Oil 5W-30

Add 6% friction modifier. See Table 2.

Not Available

Sunfleet TH Universal Tractor Fluid

Add 6% friction modifier. See Table 2.

Not Available

Chevron Tractor Hydraulic Fluid

Add 6% friction modifier. See Table 2.

Not Available

Conoco Power Tran III Fluid

Add 6% friction modifier. See Table 2.

Not Available

Shell Donax TDL

Add 6% friction modifier. See Table 2.

Not Available

Citgo Transgard Tractor Hydraulic Fluid

Add 6% friction modifier. See Table 2.

Not Available

Duratran Fluid - Petro

Add 6% friction modifier. See Table 2.

AK3761

100 % friction modifier - 19 liter (5 gal) container

Mix with suspension oil. See Table 2.

TABLE 2 SUSPENSION OIL / FRICTION MODIFIER MIXING RATIO Proper Ratio = 94% Suspension Oil : 6% Friction Modifier Suspension Oil Quantity

Friction Modifier Quantity

3.8 liter (1 gal) of suspension oil

237 ml (8 oz)

19 liter (5 gal) of suspension oil

1 liter (38 oz)

208 liter (55 gal) of suspension oil

11.4 liter (3 gal)

The following oils may be used as alternatives to those listed in Table 1. DO NOT mix these oils with friction modifier.

• HO-MVK (Koma-Hydro MV) • Shell Tellus T32 • Shell Tellus 46 • Castrol Hyspin AWS 46

TABLE 3. NITROGEN GAS SPECIFICATIONS

Nitrogen gas used in suspension cylinders must meet or exceed CGA Specification G-10.1 for Type 1, Grade F Nitrogen Gas.

2

PROPERTY

VALUE

Nitrogen

99.9% minimum

Water

32 ppm maximum

Dew Point

-55°C(-68°F) maximum

Oxygen

0.1% maximum

Oiling and Charging Procedures

FRONT SUSPENSION

Front Suspension Oiling

1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and block the wheels.

2. Verify that the bottom of each cylinder cover is within the range designated by the arrows (Figure 4-1) signifying correct nitrogen charge.

3. If each suspension is within the area indicated by the arrows, no service is necessary for the front suspensions. See the note below for guidelines. If a suspension is not within the area indicated by the arrows, the front suspensions will have to be serviced.

Lifting equipment (crane or hydraulic jacks) must be capable of lifting the weight of the truck.

Ensure that all personnel are clear of the lift area before the lift is started.

NOTE: The oil level must be checked: • Before charging or adding nitrogen.

• When there are signs of oil leakage.

• After rebuild/repair and installed on the truck

the

suspension

.

FIGURE 4-1. FRONT SUSPENSION HEIGHT

is

A common mistake when adjusting the oiling height is the failure to recognize and/or properly react to oil that contains trapped nitrogen or "foamy oil". Oil, such as this, is common when the truck has recently been operating and the suspension oil and gas haven’t been allowed to settle and separate. This condition needs to be handled properly to ensure that the suspension receives the proper amount of oil. Failure to do so may cause a low oil level resulting in premature component wear. Premature bearing and seal wear can, in many cases, be attributed to this occurrence.

If the truck has been operating, allow three to four hours for the oil and nitrogen gas to separate. An alternative is to purge the foamy oil and replace with new oil. The wrong oiling height will be observed if the oil level is checked/adjusted with foamy oil or with air bubbles present.

Oil Quantity (approximate): 62.4 Liters (16.5 Gallons)

NOTE: DO NOT fill the suspension cylinder with oil based on quantity alone. Oil quantities are given as reference, only. Fill/adjust the oil level in the front suspension to the oiling height listed in Figure 4-3.

Oiling and Charging Procedures

3

1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and block the wheels.

2. Remove the outside suspension covers and thoroughly clean the area around charging valves (3, Figure 4-2).

3. Place a hydraulic jack (1, Figure 4-3) under the main frame, and raise the jack until it contacts the frame. The jack must be rated for a minimum of 50 tons.

4. While wearing a face mask or goggles, discharge the nitrogen pressure from the suspension by loosening pressure sensor valve assembly (2, Figure 4-4) one revolution. DO NOT exceed one revolution. Nitrogen pressure cannot be released by loosening the pressure sensor, itself. The schrader valve in the valve assembly (2) will prevent nitrogen from being released.

FIGURE 4-2. VALVE AND SENSOR LOCATION 1. Air Bleed Valve 2. Pressure Sensor

3. Charging Valve

Releasing the nitrogen gas from the valve core of charging valve (3, Figure 4-2) will damage the valve core. Release the gas by loosening air bleed valve (1, Figure 4-2) or sensor valve assembly (2, Figure 4-4).

Loosening the pressure sensor valve assembly more than three revolutions may result in the component being forced out of the suspension by the gas pressure inside. This can cause serious bodily injury. DO NOT exceed one revolution.

Wear a face mask or goggles while relieving nitrogen pressure.

NOTE: If oil is discharged with the gas, tighten the pressure sensor valve assembly slightly so only the gas will be discharged. If this is not possible, the foamy oil will need to be purged from the suspension during the oiling procedure, prior to charging.

4

FIGURE 4-3. OIL HEIGHT 1. Jack (50 ton min.)

2. Frame

Oiling and Charging Procedures

A: 97 Âą 3 mm (3.8 Âą 0.12 in.)

5. Adjust the hydraulic jack (1, Figure 4-3) so that dimension "A" of the cylinder is 97 ±3 mm (3.8 ± 0.12 in.).

6. After all nitrogen pressure has been relieved, tighten valve assembly (2, FIgure 4-4).

FIGURE 4-4. PRESSURE SENSOR 1. Schrader Valve 2. Valve Assembly

3. Sensor FIGURE 4-5. OIL CHARGING KIT (EC6027)

7. Remove charging valve (5, Figure 4-5), and install fitting (4).

8. Install adapter (3) to fitting (4), then connect the hose and oil pump.

NOTE: Pressure sensor (6) must be installed, and the air bleed valve (7) must be loose to ensure there are no air pockets inside the suspension.

9. Loosen air bleed valve (7), then pump oil into the cylinder until no air bubbles or foamy oil is discharged from air bleed valve hole (8).

1. Hose 2. Connector 3. Adapter 4. Fitting 5. Charging Valve

6. Pressure Sensor 7. Air Bleed Valve 8. Air Bleed Hole 9. Oil Pump Lever 10. Oil Pump

Use caution when tightening the valves and fittings on the suspensions. DO NOT overtighten.

Overtightening can damage the fittings or the suspension housing resulting in gas and oil leaks. Tighten to the specified torque.

10. When no more air bubbles or foamy oil is discharged, tighten air bleed valve (7) to 44 ± 5 N·m (33 ± 3 ft lbs).

11. Remove pressure sensor valve assembly (6), then operate the oil pump until no air bubbles or foamy oil is discharged from the plug hole.

12. After all air and/or foamy oil is discharged, install and tighten the pressure sensor valve assembly to 44 ± 5 N·m (33 ± 3 ft lbs).

13. After filling with oil, remove the oil pump and fittings, then install charging valve (5) and tighten the valve to 44 ± 5 N·m (33 ± 3 ft lbs).

Oiling and Charging Procedures

5

Front Suspension Nitrogen Charging

Dry nitrogen is the only gas approved for use in the suspensions. Charging the suspensions with oxygen or other gases may result in an explosion which could cause serious injuries, fatalities, and/or major property damage. Refer to Nitrogen Gas Specifications at the beginning of this chapter.

6. When the left and right cylinders reach the specified length as shown in Figure 4-7, close valve (4, Figure 4-6) to stop the flow of nitrogen gas. Turn the handle of regulator (11) counterclockwise to close the valve.

1. Remove the caps from charging valves (3, Figure 4-2).

NOTE: Before installing regulator (11, Figure 4-6, blow out the cylinder connector with nitrogen gas, 965 kPa (140 psi) or more, to clean out all dirt or dust. Dirt or dust in the system can cause suspension failures.

2. Connect the regulator to the nitrogen cylinder.

Open the valve on the gas cylinder, and check the pressure reading on regulator gauge (1).

NOTE: The internal pressure of the gas cylinder must be substantially higher than the suspension charging pressure (refer to the chart in Figure 4-7).

3. Install the nitrogen charging kit to the suspensions, as shown in Figure 4-6.

4. Slowly turn the handle of regulator (11) clockwise. Adjust the pressure, shown on gauge (2), to the required charging pressure (refer to the chart in Figure 4-7). Then, open valves (3 & 4, Figure 4-6) to fill the suspension cylinders with nitrogen gas.

5. Fill the left and right cylinders at the same time.

Verify the required charging pressure on gauge (10) by closing valve (4).

FIGURE 4-6. NITROGEN CHARGING KIT (EC3331) 1. Nitrogen Cylinder Gauge 2. Charging System Gauge 3. Manifold Outlet Valves (from gauge) 4. Inlet Valve (from regulator) 5. Connection Valve w/EC2253 Adapter Installed 6. Valve "T" Handle 7. Pressure Sensor/Schrader Valve 8. Air Bleed Valve 9. Manifold 10. Charging Pressure Gauge (Suspensions) 11. Regulator Valve (Nitrogen Pressure) 12. Dry Nitrogen Gas (see Nitrogen Gas Specifications at the beginning of this chapter) NOTE: Parts may vary from the illustration above depending on the charging kit part number.

6

Oiling and Charging Procedures

7. Turn handle (6) on valve adapter (5) fully counterclockwise to close the charging valve. Then, remove the charging equipment, the hydraulic jack, and install the suspension covers.

8. Use soapy water to check the charging valve, the air bleed valve and the pressure sensor fittings for leaks. Repair as necessary.

9. Install the caps and O-rings onto charging valves (3, Figure 4-2).

Dimension "A" is measured from the top of the cover to the top of the suspension cylinder plate. DO NOT include the capscrews in the measurement. The removal of an access panel on the top cover is required.

NOTE: Setup dimensions specified in the charts must be maintained during oiling and charging procedures. However, after the truck has been operated, these dimensions may vary. After charging the suspensions, operate the empty truck over a short course and then park the truck on a level surface.

Record the dimensions again and save for periodic reference.

FIGURE 4-7. FRONT SUSPENSION

DIMENSION

CHARGING HEIGHT

CHARGING PRESSURE

FRONT "A"

287 Âą 10 mm (11.3 Âą 0.4 in.)

2758 kPa (400 psi)

Oiling and Charging Procedures

7

REAR SUSPENSION

Rear Suspension Oiling

GENERAL INFORMATION If the rear suspension is being filled with oil while installed on the truck, the angle in which the rear suspension is positioned coupled with the location of the charging valve port results in a significantly large volume of air being trapped inside the suspension. This has the effect of lowering the oiling height since the rear suspension can not be filled with the correct amount of oil. To compensate for this, all rear suspensions being filled with oil while installed on the truck must use the "Installed On Truck" oiling heights listed in Table 4.

When the suspension is in a vertical position while off the truck, the oiling height will be different. All rear suspensions being filled with oil while off the truck should use the "On Bench" oiling heights listed in Table 4.

NOTE: Refer to Table 4 for the approximate block height. The oiling height of the cylinder must always be determined by using Dimensions A or C, only.

The “final charging height” in Table 4 is for suspensions at normal operating temperature and must not be exceeded. After charging a cold suspension, operate the truck for several hours and check/adjust the charging height at normal operating temperature.

If the suspensions are not checked/adjusted at normal operating temperature, the suspension height may be incorrect, possibly causing excessive driveline angles that could result in damage to powertrain components.

1. Check whether dimension "A" (Figure 4-11) on each suspension cylinder is within the specified value listed in Table 4. If dimension “A” is within specifications, no service is necessary for the rear suspensions. If a suspension is not within the area indicated by the arrows, the front suspensions must be serviced. Continue with this procedure.

NOTE: The oil level must be checked; • Before charging or adding nitrogen.

• When there are signs of oil leakage.

• After repair/rebuilds.

A common mistake when performing oiling procedures is the failure to recognize and/or properly react to oil that contains trapped nitrogen or "foamy oil". Oil, such as this, is common when the truck has recently been operating and the suspension oil and gas haven’t been allowed to settle and separate. This condition must be handled properly to ensure that the suspension receives the proper amount of oil. Failure to do so may cause a low oil level resulting in premature component wear. Premature bearing and seal wear can, in many cases, be attributed to this occurrence.

If the truck has been operating, allow time for the oil and nitrogen gas to separate. This may take several hours. An alternative action is to purge the foamy oil from the cylinder during oiling.

Oil Quantity (approx.): . . . 36.3 Liters (9.6 Gallons) NOTE: DO NOT fill a suspension cylinder with oil based on quantity alone. Oil quantities are given as reference, only. Always fill/adjust the oil level in the suspension cylinders based on the oiling height dimensions given in Table 4.

8

Oiling and Charging Procedures

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

1. Park the truck on a flat level surface. Apply the parking brake, and chock the wheels.

2. Clean the area around charging valves (5, Figure 4-9).

3. Position the oiling spacer between the stopper and the axle housing as shown in Figure 4-8 (if servicing while on the truck). Dimension "A", Figure 4-11, must be equal to the proper dimension listed in Table 4.

NOTE: The proper oiling block dimension is listed in Table 4.

FIGURE 4-9. OIL CHARGING KIT (EC6027) 1. Hose 2. Connector 3. Adapter 4. Fitting

5. Charging Valve 6. Pressure Sensor 7. Oil Pump

FIGURE 4-8. OILING BLOCK INSTALLATION 1. Oiling Block 2. Cylinder

3. Dust Cover

FIGURE 4-10. PRESSURE SENSOR/VALVE ASSY. 1. Schrader Valve 2. Valve Assembly

Oiling and Charging Procedures

3. Pressure Sensor

9

Dimension "A" is measured from the face of the retainer to the bottom flat surface of the cylinder rod. Do not measure from the cap screws or capscrew heads.

Dimension "B" is measured from the top of the housing surface to the mating face for the flange.

Dimension "C" is measured from the center line of the top pin to the center line of the bottom pin.

FIGURE 4-11. REAR SUSPENSION 1. Housing

2. Retainer

TABLE 4. REAR SUSPENSION OILING & CHARGING DIMENSIONS Housing Length (Dimension B) Oiling Height (Dimension A)

Oiling Height (Dimension C) Final Charge Height (At Operating Temperature)

510 mm (20.0 in.)

Installed On Truck

221 ± 3 mm (8.7 ± 0.1 in.)

On Bench

154 ± 3 mm (6.1 ± 0.1in.)

Installed On Truck

1148 ± 3 mm (45.2 ± 0.1 in.)

On Bench

1081 ± 3 mm (42.6 ± 0.1 in.)

Dimension A

234 ± 10 mm (9.2 ± 0.4 in.)

Dimension C

1161 ± 10 mm (45.7 ± 0.4 in.)

Approximate Oiling Spacer Height

10

95 mm (3.7 in.)

Oiling and Charging Procedures

4. Disconnect the pressure sensor harness connectors and remove the clamps securing the harnesses.

6. After all nitrogen pressure has been relieved, remove the pressure sensor/valve assembly.

7. Remove charging valve (5, Figure 4-9), and install fitting (4).

8. Install adapter (3) to fitting (4). Connect the hose and the oil pump.

Releasing the nitrogen gas from the valve core of charging valve (5, Figure 4-9) will damage the valve core. Therefore, remove the gas by loosening pressure sensor/valve assembly (6) one revolution.

Loosening the pressure sensor/valve assembly more than three revolutions may result in the component being forced out of the suspension by the gas pressure inside. DO NOT exceed one revolution.

NOTE: If oil is discharged with the gas, tighten the valve slightly so only the gas will be discharged. If this is not possible, the foamy oil will need to be purged from the suspension during the oiling procedure, prior to charging.

9. Operate the pump until clear oil (containing no air bubbles or foam) is discharged from the plug hole.

10. After all air and foamy oil is discharged, install the pressure sensor valve assembly.

Use caution when tightening the valves and fittings on the suspensions. DO NOT overtighten.

Overtightening can damage the fittings or the suspension housing resulting in gas and oil leaks. Tighten to the specified torque.

11. Tighten the pressure sensor valve assembly to 44 ± 5 N·m (33 ± 3 ft lbs).

12. After the completion of oiling, remove the oil pump, and install charging valve (5). Tighten to 44 ± 5 N·m (33 ± 3 ft lbs).

Verify that all personnel are out of the area and the support blocks are secure before releasing the nitrogen. Use a face mask or goggles when releasing the nitrogen.

5. While wearing a face mask or goggles, discharge the nitrogen pressure from the suspension by loosening pressure sensor/valve assembly (2, Figure 4-10) one revolution. DO NOT loosen more than one revolution.

Oiling and Charging Procedures

11

Rear Suspension Nitrogen Charging

Dry nitrogen is the only gas approved for use in suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause serious injuries, fatalities and/or major property damage. Refer to Nitrogen Gas Specifications at the beginning of this chapter.

1. Remove the caps from charging valves (5, Figure 4-9).

NOTE: Before installing regulator (11, Figure 4-6), blow out the connector with nitrogen gas at 965 kPa (140 psi) or more, to clean out all dirt or dust. (Dirt or dust in the system causes failures.)

2. Open the valve on the gas cylinder, and check the pressure at regulator gauge (1).

NOTE: Internal pressure of the gas cylinder must be substantially higher than the suspension charging pressure, 1882 kPa (273 psi).

3. Slowly turn the handle of regulator (11, Figure 4-6) clockwise, and adjust the pressure at gauge (2) to the required charging pressure, 1882 kPa (273 psi). Open valves (3 & 4) to fill the suspension cylinders with nitrogen gas.

4. Fill the left and right cylinders at the same time.

Verify the required charging pressure is present at gauge (10).

5. When the left and right cylinders reach the specified length, as shown in Figure 4-11, close valve (4) to stop the flow of nitrogen gas. Turn the handle of regulator (11) counterclockwise to close off nitrogen flow.

12

6. When the left and right cylinders reach the specified length, as shown in Figure 4-11 (Table 4), close valves (3 & 4, Figure 4-6) to stop the flow of nitrogen gas. Turn the handle on regulator (11) counterclockwise to close the valve.

7. Turn handle (6) on valve adapter (5) counterclockwise to close the charging valve. After the valve is completely closed, remove the charging equipment.

8. Use soapy water to check the charging valve and pressure sensor joints for leaks. Repair as necessary.

9. Install the caps and O-rings onto the charging valves.

LENGTH ADJUSTMENT - FRONT AND REAR CYLINDERS NOTE: Adjust the installed length of the cylinder with the truck on level ground and the body empty.

Depending on the ambient temperature, the gas in the suspension may expand or contract changing the length of the cylinder. In locations where there are wide differences in temperature throughout the year, inspect the suspension height periodically and adjust to keep the length within the specified range shown in Figures 4-7 and 4-11 (Table 4).

1. To reduce the sliding resistance of the cylinder, drive the truck forward approximately 15 m (50 ft) and stop suddenly, then drive in reverse to the original position and stop suddenly, again.

Repeat this cycle three to four times. Finally, allow the truck to stop slowly without depressing the brake. Then measure the installed length.

Oiling and Charging Procedures

2. If the result of the check shows that the length is too long, release nitrogen gas to adjust the length. Loosen the pressure sensor/valve assembly no more than one revolution to release the nitrogen gas. When doing this, release only a small amount of gas. The cylinder should not move. If too much nitrogen gas is released and the cylinder moves, the installed length may be below the specified length. The cylinders will need to be charged to the correct dimension.

DO NOT release nitrogen pressure by depressing the tip of the valve core. Damage to the valve core may result.

3. After releasing nitrogen gas and adjusting the length, repeat Step 1-2 to check the installed length again.

4. Finally, check that there is no leakage of gas from the valve core, pressure sensor/valve assembly, and piston rod gland.

Use soapy water to check for leakage of gas. If there is any leakage of gas from the valve core, replace the valve core.

5. The rear suspensions are now ready for operation. Visually check piston rod extensions both with truck loaded and empty. Record extension dimensions. Maximum downward travel is indicated by the dirt ring at the base of the piston.

Operator comments on steering and suspension rebound should also be noted.

Oiling and Charging Procedures

13

NOTES

14

Oiling and Charging Procedures

TOE IN ADJUSTMENT The correct toe-in specification for these model trucks is zero with the truck at the empty vehicle weight. As the truck is loaded, the geometry of the suspension and steering will result in minor toe-in angles.

Adjustment Procedure 1. Park the truck on a hard, level surface and chock the rear wheels.

2. Ensure the front and rear suspensions are oiled and charged according to shop manual specifications. Refer to Suspension Oiling and Charging Procedures in this section. The suspensions must be properly charged and oiled to ensure accurate toe adjustment.

3. Inspect steering and suspension components and replace any damaged and/or worn parts.

4. Place a hydraulic jack below the front suspension to A-arm pin on both sides of the truck. Elevate the truck until the lower portions of the tires are no longer bulged, but allow for full tread contact with the ground across each tire.

Ensure the two jacks are at the same height.

Refer to Figure 11-1.

5. Measure the distance from the edge of the tire rim to the flat face of the frame. Measure this distance at both the front and the rear of the left hand wheel. Refer to Figure 11-2.

6. Calculate the average distance from the two measurements obtained in Step 5. Record the measurement.

7. Start the truck and steer the wheels until the average measurement is achieved at the front and rear of the left hand tire.

Keep personnel away from the truck when operating the steering wheel. Personal injury may result. Depressurize the accumulators before making adjustments to the steering linkage.

FIGURE 11-1. RAISING THE TRUCK

FIGURE 11-2. TIRE TO FRAME DISTANCES

8. Mark the centerlines of the tires on the faces of the tread at the front and rear of each tire. The vertical centerline should be a distance of 1220 mm (48 in.) from the ground surface. The horizontal centerline should be exactly half the width of the tire. Refer to Figure 11-3.

13. Check tire wear periodically. If abnormal wear is evident, check for damaged or worn steering components, and verify the toe is properly adjusted. Replace components as necessary, and adjust the toe.

9. Measure the distances between centerlines at the front and rear of the wheels. Record the measurements.

10. Adjust the length of the tie rods until the two measurements obtained in Step 9 are within 3 mm (0.118 in.) of one another. The tie rods must be adjusted equally. One full turn of the tie rods is approximately equal to 25.4 mm (1 in.) of toe adjustment.

11. Record the final distances between the front and rear centerlines for future reference.

12. Remove the jacks and the wheel chocks from the truck. Operate the truck through several complete turn cycles. Recheck the measurements, and readjust if necessary.

Adjust the toe after replacing integral steering system components. Failure to adjust the toe after replacing any components that may effect the steering geometry may cause premature wear to the tires and other components.

14. Check the toe adjustment at every 500 hour interval. If abnormal tire wear is evident, check the adjustment, immediately.

FIGURE 11-3. MARKING CENTERLINES ON THE TIRES

NOTES

AUTOMATIC LUBRICATION SYSTEM CHECKOUT

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

• DO NOT exceed maximum working pressure for any component in the system.

• DO NOT alter or modify any part of this system unless factory authorization.

• DO NOT attempt to repair or disassemble the equipment while the system is pressurized.

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

• Read and follow the fluid manufacturer's recommendations regarding fluid compatibility.

• Check all equipment regularly and repair.

Replace worn or damaged parts immediately.

FIGURE 3-1. PUMP & RESERVOIR COMPONENTS 1. Hose From Filter 2. Outlet to Injectors 3. Hydraulic Motor 4. Pressure Reducing Valve 5. Solenoid Valve 6. Test Switch 7. Vent Valve

8. Pressure Gauge 9. Pump Assembly 10. Flow Control Valve 11. Pressure Switch 12. Grease Reservoir 13. Vent Hose

This equipment generates very high grease pressure. Use extreme caution when operating this equipment. Pressurized grease can pierce the skin causing serious bodily injury. Adequate protection such as safety goggles and protective clothing is recommended.

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

LUBRICANT PUMP Pump Housing Oil Level The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level at 1000 hour intervals. To add oil, remove plug (4, Figure 3-2) and fill the housing to the bottom of the plug hole.

Pump Pressure Control High pressure hydraulic fluid from the truck steering system is reduced to 2240 to 2413 kPa (325 to 350 psi) by pressure reducing valve (1). The reducing valve is located on the manifold on top of the pump motor. Operating pressure can be read on the gauge installed on the manifold. Occasionally check the gauge to verify pressure is within the specified range.

The pressure reducing valve is not adjustable. If operating pressure is not within limits, the pressure reducing valve must be replaced.

FIGURE 3-2. PUMP CONTROLS 1. Pressure Reducing Valve 2. Test Switch

3. Pressure Gauge 4. Oil Level Plug 5. Flow Control Valve

INJECTORS (SL-1 Series “H”)) Injector Specifications • Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of manual lubrication equipment.

• Injector output volume: Maximum output = . . . . . . . . 1.31 cc (0.08 in3) Minimum output = . . . . . . . 0.13 cc (0.008 in3) • Operating Pressure: Minimum - . . . . . . . . . . 12,755 kPa (1850 psi) Maximum - . . . . . . . . . . 24,133 kPa (3500 psi) Recommended - . . . . . 17,238 kPa (2500 psi) • Maximum Vent Pressure - (Recharge) 4,137 kPa (600 psi)

Injector Adjustment The injectors may be adjusted to supply from 0.13 cc to 1.31 cc (0.008 in3 to 0.08 in3) of lubricant per injection cycle. The injector piston travel distance determines the amount of lubricant supplied. Piston travel is controlled by an adjusting screw in the top of the injector housing.

Turn adjusting screw (1, Figure 3-3) counterclockwise to increase injector output and clockwise to decrease injector output.

When the injector is not pressurized, maximum injector delivery volume is attained by turning the adjusting screw (1) fully counterclockwise. Turn until the indicating pin (8) just touches the adjusting screw. At the maximum delivery point, about 9.7 mm (0.38 in.) of adjusting screw threads will be exposed. Decrease the delivered lubricant amount by turning the adjusting screw clockwise to limit injector piston travel. If only half the lubricant is needed, turn the adjusting screw to the point where about 4.8 mm (0.19 in.) threads are exposed. The injector will be set at the minimum delivery point with about 0.22 mm (0.009 in.) thread exposed.

NOTE: The information above relates only to the adjustment of injector delivery volume. The timer adjustment must also be changed if overall lubricant delivery is inadequate or excessive. Do not adjust Injector output to less than one-fourth capacity.

FIGURE 3-3. TYPE SL-1 INJECTOR 1. Adjusting Screw 2. Locknut 3. Piston Stop Plug 4. Gasket 5. Washer 6. Viton O-Ring 7. Injector Body Assy.

8. Piston Assembly 9. Fitting Assembly 10. Plunger Spring

11. Spring Seat 12. Plunger 13. Viton Packing 14. Inlet Disc 15. Viton Packing 16. Washer 17. Gasket 18. Adapter Bolt 19. Adapter 20. Viton Packing

NOTE: Piston assembly (8) has a visible indicator pin at the top of the assembly to verify injector operation.

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 purge entrapped air.

1. Fill the reservoir with lubricant, if necessary.

2. To purge air from the main supply line, remove the main supply line at the reservoir and 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 it reaches the injector group. Install the pipe plug and repeat for the remaining injector groups.

5. Remove the caps from each injector. Connect an external grease supply to the zerk on the injector. Pump until grease reaches the far end of the individual grease hose or the joint being greased.

Filter Assembly Replace element (5, Figure 3-4) if bypass indicator (2) indicates excessive element restriction.

FIGURE 3-4. FILTER ASSEMBLY 1. Housing 2. Bypass Indicator 3. O-Ring 4. Backup Ring 5. Element

6. Spring 7. Bowl 8. O-Ring 9. Plug

SYSTEM CHECK To check system operation (not including timer), proceed as follows: 1. Start the engine.

2. Actuate the lube system test switch at the reservoir/pump assembly.

3. The motor and pump should operate until the system attains 17,237 kPa (2500 psi).

4. Once the required pressure is achieved, turn the pump motor off. The system should vent.

5. Check for pump, hose or injector damage.

Check for leakage with the system pressurized.

6. After checking the system, shut the engine off.

Lubrication Controller Check Pressing the manual lube button on the enclosure cover will initiate a lube event. (See Figure 3-5).

Lubrication Controller Operation

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

When the switch is set to “memory on”, the controller will function as follows: • When power is turned off between lube cycles, the lube cycle will resume at the point of interruption after power is restored. In other words, the controller will remember its position in the cycle.

• When power is turned off during a cycle, the controller will reset to the beginning of the lube cycle after power is restored.

Off time switch (1) is used to select units of time.

Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or 30. The mode switch determines whether the off time units will be minutes or hours.

The time between lube events is determined by the setting of the rotary switch and the dip switch. The rotary switch selects the numeral setting, and the dip switch selects the units in either minutes or hours.

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

Lubrication Controller Components

The manual lube switch, when depressed, will initiate a lube cycle.

Mode switch (2, Figure 3-5) consists of four dip switches. The first dip switch controls the maximum amount of “on time”, either 30 seconds or 120 seconds.

The second dip switch controls the mode, either timer mode or controller mode. When the switch is set to the timer mode, the amount of time that the pump is on will be determined by the setting of the dip switch - 30 seconds or 120 seconds. When the switch is set to the controller mode, a pressure switch must be installed in the lube supply line. The pressure switch will detect supply line pressure, and will reset the timer at a set pressure. If the pump fails to reach the set pressure within the dip switch set time, the controller will initiate an alarm.

The third dip switch is for selecting the units for the “off time”. This setting is to be used in conjunction with off time switch (1). Hours or minutes may be selected.

Lubrication Controller Adjustment The lubrication controller is factory adjusted to the following switch settings: Dip switch 1 . . . . . . . . . . . . . . . . . . . . . 120 seconds Dip switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .timer Dip switch 3 . . . . . . . . . . . . . . . . . . . . . . . . . minutes Dip switch 4 . . . . . . . . . . . . . . . . . . . . . . . memory off Rotary Switch . . . . . . . . . . . . . . . . . . . . . . 15 minutes

FIGURE 3-5. LUBRICATION TIMER 1. Off Time Switch 2. Mode Switch

3. Cover

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

Symptom

Pump Does Not Operate

Pump Will Not Prime

Pump Will Not Build Pressure

Possible Causes

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.

Controller malfunction.

Replace the controller assembly

Solenoid valve malfunctioning.

Replace the solenoid valve assembly

Motor or pump malfunction.

Repair or replace motor and/or pump assembly.

Refer to the service 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 the service manual for rebuild instructions.

NOTE: Normally during operation, the injector indicator stem will move into the body of the injector when pressure builds. When the system vents and releases pressure, 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 the service 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 not functioning properly.

Refer to Pump Pressure Control.

Symptom

Possible Causes

Corrective Action

No signal at solenoid.

Check timer.

No electric power to controller.

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

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

Printed circuit board failure.

Remove and replace.

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

Printed circuit board failure or keypad failure.

Remove and replace.

Controller memory mode is off.

Switch controller memory mode to ON.

Injector output adjustment setting too high.

Readjust to lower setting.

Timer/controller cycle time setting too low.

Set to longer cycle time or reevaluate lube requirements.

Injector output adjustment setting too low.

Readjust injector output setting.

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

Set to shorter cycle time or reevaluate lube requirements.

System too large for pump output.

Calculate system requirements per planning manual.

Pump Pressure Builds Very Slowly Or Not At All

Controller Does Not Operate

Bearing Points Excessively Lubricated

Bearing Points Are Not Sufficiently Lubricated

PREVENTATIVE MAINTENANCE Use the following maintenance procedures to ensure proper system operation.

Daily Lubrication System Inspection 1. Check grease reservoir level.

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

3. Check the grease reservoir level. a. Fill the reservoir as needed. Check the filter bypass indicator when filling the reservoir.

Replace the element if grease is bypassing. b. Check the reservoir for contaminants. Clean, if necessary.

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

c. Ensure all filler plugs, covers and breather vents on the reservoir are intact and free of contaminants.

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

4. Inspect all bearing points for a bead of lubricant around the bearing seal.

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

5. System Checkout

a. Repair or replace all damaged hoses. b. Ensure all air is purged and all new hoses are filled with grease before truck operation.

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

NOTE: It is good practice to manually lube each bearing point at the grease fitting provided on each Injector. This will indicate if there are any frozen or plugged bearings, and will help flush the bearings of contaminants.

250 Hour Inspection 1. Check all grease hoses from the SL-1 injectors to the lubrication points. See Figure 3-2. a. Repair or replace all worn or broken hoses. b. Ensure all air is purged and all new hoses are filled with grease before truck operation.

2. Check all grease hoses from the pump to the SL-1 injectors. a. Repair or replace all worn or broken hoses. b. Ensure all air is purged and all new hoses are filled with grease before truck operation.

a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation. b. Start the engine. c. Actuate manual test switch (17, Figure 3-2).

The hydraulic motor and grease pump should operate. d. With the grease pressurized, check each SL1 injector assembly.

The cycle indicator pin should be retracted inside the injector body. e. When the system reaches 17,237 kPa (2500 psi), the pump should shut off. The pressure in the system should drop to zero, venting back to the grease reservoir. f. With the system vented, check all of the SL-1 injector indicator pins; all of the pins should be visible. Replace or repair injectors, if defective. g. Reinstall all injector cover caps. h. Check controller operation.

NOTE: With the engine on, the lube system should activate within 5 minutes. The system should build 13,790 to 17,237 kPa (2000 to 2500 psi) within 25-40 seconds.

i. If the system is working properly, the machine is ready for operation. j. If the system is malfunctioning, refer to the troubleshooting chart.

1000 Hour Inspection 1. Check the pump housing oil level. Fill to the bottom of the plug hole with SAE 10W-30 motor oil.

NOTES:

NOTES:

NOTES:

STANDARD TABLES This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard units in parentheses. References throughout the manual to standard torques or other standard values will be to one of the following tables. Do not use standard values to replace specific torque values in assembly instructions.

For values not shown in any of the charts or tables, standard conversion factors for most commonly used measurements are provided in Tables 1 and 17.

NOTE: Portions of this truck may be assembled with SAE (US) hardware. Ensure the correct table is referenced when determining the proper torque.

INDEX OF TABLES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page TABLE 1

Common Conversions Multipliers Metric -to- English . . . . . . . . . A5-1

TABLE 2

Standard Tightening Torque For Metric Cap Screws and Nuts . . . . . A5-2

TABLE 3

Standard Tightening Torque For Split Flange Bolts . . . A5-2

TABLE 4

Tightening Torque For Flared Tube And Hose Fittings . . . . . . . A5-2

TABLE 5

Temperature Conversions . . . . . A5-3

TABLE 6

Torque Conversions kg·m to ft lb. . . . . . . . . . . A5-3

TABLE 7 TABLE 8 TABLE 9

Torque Conversions kg·m to N·m . . . . . . . . . . A5-3 Pressure Conversions kg/cm2 to psi . . . . . . . . . . . A5-4 Pressure Conversions kg/cm2 to kPa . . . . . . . . . . . A5-4

TABLE 10

Pressure Conversions psi to kPa . . . . . . . . . . . . . A5-4

TABLE 11

Standard Tightening Torque For SAE Cap Screws and Nuts . . . . A5-5

TABLE 12 Standard Tightening Torque 12-Pt, Grade 9, Cap Screws (SAE). . . . A5-5 TABLE 13

JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . A5-6

TABLE 14

Pipe Thread Torque Chart (SAE) . A5-6

TABLE 15

O-Ring Boss Torque Chart (SAE) . A5-6

TABLE 16

O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . A5-6

TABLE 17 TABLE 18

TABLE1. Common Conversion Multipliers Metric To English

Common Conversions Multipliers English -to- Metric . . . . . . . . . A5-7 Sealants And Adhesives. . . . . . . A5-8

To

Multiply By

millimeter (mm)

inch (in.)

0.0394

centimeter (cm)

To Convert From

inch (in.)

0.3937

meter (m)

foot (ft)

3.2808

meter (m)

yard (yd)

1.0936

kilometer (km)

mile (mi)

0.6210

square inch (in.2)

0.1550

square centimeters (cm2) square centimeters (cm 3

2)

cubic centimeters (cm ) liters (l)

square feet

(ft2)

0.061

3

61.02

cubic inch (in. ) cubic inch (in. )

3

cubic meters (m ) liters (l) grams (g)

0.001

3

3

35.314

3

cubic feet (ft )

0.0353

cubic feet (ft ) ounce (oz)

0.0353

milliliter (ml)

fluid ounce (fl oz)

0.0338

kilogram (kg)

pound (mass)

2.2046

pounds (lb)

0.2248

Newton (N) Newton meters (N·m)

kilogram meters (kg·m)

0.102

Newton meters (N·m)

foot pounds (ft lb)

0.7376

kilogram meters (N·m)

foot pounds (ft lb)

7.2329

kilogram meters (N·m)

Newton meters (N·m)

9.807

kilopascals (kPa)

pounds/square inch (psi)

0.1450

megapascals (MPa)

pounds/square inch (psi)

145.038

kilograms/cm2 (kg/cm2)

pounds/square inch (psi)

14.2231

kilograms/cm2 (kg/cm2)

kilopascals (kPa)

98.068

kilogram (kg)

short ton (tn)

0.0011

metric ton

short ton (tn)

1.1023

liters (l)

quart (qt)

1.0567

liters (l)

gallon (gal)

0.2642

Watts (W)

horsepower (hp)

0.00134

kilowatts (kW)

horsepower (hp)

1.3410

Standard Tables

Page-1

TABLE 2. Standard Tightening Torque For Metric Hex Head Cap Screws And Nut

Cap Screw Thread Diameter (mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Width Across Flat (mm) 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Kilogram meters (kg·m) Tolerances ±10% 1.35 3.2 6.7 11.5 18.0 28.5 39.0 56.0 76.0 94.5 135 175 225 280 335

Newton meters (N·m) Tolerances ±10% 13.2 31.4 65.7 112 177 279 383 549 745 927 1320 1720 2210 2750 3280

Foot Pounds (ft lb) Tolerances ±10% 10 23 48 83 130 206 282 405 550 684 975 1266 1630 2025 2420

Newton meters (N·m) Tolerances ±10% 65.7 112 279

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

Newton meters (N·m) Tolerances ±10% 25 50 80 140 175 195 245 295

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

TABLE 3. Tightening Torque For Split Flange Bolts

Cap Screw Thread Diameter (mm) 10 12 16

Width Across Flat (mm) 14 17 22

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

TABLE 4. Tightening Torque For Flared Tube And Hose Fittings

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

Page-2

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

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

Standard Tables

TABLE 5. 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.

TABLE 6. Torque Conversions kilogram meter (kg·m) to foot pounds - (ft lb) 1 kg·m=7.2339 ft lb kg·m

0

1

2

3

4

5

6

7

8

9

0

(ft lb)

7.23

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.5

303.8

311.0

318.2

325.5

332.7

339.9

347.2

354.4

50

361.6

368.9

376.1

383.3

390.6

397.8

405.0

412.3

419.5

426.7

60

434.0

441.2

448.4

455.7

462.9

470.1

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

TABLE 7. Torque Conversions kilogram meter - kg·m To Newton meters (N·m) 1 kg·m=9.807 N·m kg·m

0

1

2

3

4

5

6

7

8

9

0

(N.m)

9.8

19.6

29.4

39.2

49.0

58.8

68.6

78.5

88.3

10

98.1

107.9

117.7

127.5

137.3

147.1

156.9

166.7

176.5

186.3

20

196.1

205.9

215.8

225.6

235.4

245.2

255.0

264.8

274.6

284.4

30

294.2

304.0

313.8

323.6

333.4

343.2

353.1

362.9

372.7

382.5

40

392.3

402.1

411.9

421.7

431.5

441.3

451.1

460.9

470.7

480.5

50

490.4

500.2

510.0

519.8

529.6

539.4

549.2

559.0

568.8

578.6

60

588.4

598.2

608.0

617.8

627.6

637.5

647.3

657.1

666.9

676.7

70

686.5

696.3

706.1

716.0

725.7

735.5

745.3

755.1

764.9

774.8

80

784.6

794.4

804.2

814.0

823.8

833.6

843.4

853.2

863.0

872.8

90

882.6

892.4

902.2

912.1

921.9

931.7

941.5

951.3

961.1

970.9

Standard Tables

Page-3

TABLE 8. Pressure Conversions kilograms per square centimeter (kg/cm2) to pounds per square inch (psi) 2 1 kg/cm =14.2231 psi kg/cm2

0

1

2

3

4

5

6

7

8

9

0

(psi)

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

185.0

199.1

213.3

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.2

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.1

597.4

611.6

625.8

640.0

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.0

782.3

796.5

810.7

824.9

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

952.9

967.2

981.4

70

995.6

1009.8

1024.1

1038.3

1052.5

1066.7

1081.0

1095.2

1109.4

1123.6

80

1137.8

1152.1

1166.3

1180.5

1194.7

1209.0

1223.2

1237.4

1251.6

1265.9

90

1280.1

1294.3

1308.5

1322.7

1337.0

1351.2

1365.4

1379.6

1393.9

1408.1

7

8

9

TABLE 9. Pressure Conversions 2 kilograms per square centimeter (kg/cm ) to kilopascals (kPa) 2 1 kg·cm =98.068 kPa kg/cm

2

0

1

2

3

4

5

6

0

(kPa)

98

196

294

392

490

588

686

785

883

10

981

1079

1177

1275

1373

1471

1569

1667

1765

1863

20

1961

2059

2157

2256

2354

2452

2550

2648

2746

2844

30

2942

3040

3138

3236

3334

3432

3530

3629

3727

3825

40

3923

4021

4119

4217

4315

4413

4511

4609

4707

4805

50

4903

5001

5100

5198

5296

5394

5492

5590

5688

5786

60

5884

5982

6080

6178

6276

6374

6472

6571

6669

6767

70

6865

6963

7061

7159

7257

7355

7453

7551

7649

7747

80

7845

7944

8042

8140

8238

8336

8434

8532

8630

8728

90

8826

8924

9022

9120

9218

9316

9415

9513

9611

9709

TABLE 10. Pressure Conversions pounds per 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

NOTE: Tables such as Table 6, 7, 8, 9 and 10 may be used as in the following example: 950 kg·m = 6871 ft lb

Example: Convert 955 kg·m to foot pounds (ft lb).

1. Select Table 6.

2. Go to kg·m row 90, column 5; reads 687.1 95 kg·m = 687.1 ft lb 3. Multiply by 10:

Page-4

4. Go to kg·m row 0, column 5; reads 49.0 5 kg·m = 49 ft lb Add to step 3.

5. 950 + 5 kg·m = 6871 + 49 = 6920 ft lb 955 kg·m = 6920 ft lb

Standard Tables

TABLE 11 Standard Torque Chart SAE Hex Head Cap Screw And Nut Assembly (Lubricated Threads) Tolerances ±10%

N·m

ft lb

kg·m

N·m

Cap Screw Thread Size

0.97

9.5

10

1.38

13.6

3/4-16

235

32.5

1.11

10.8

11

1.52

14.9

7/8-9

350

48.4

15

2.07

20.3

21

2.90

28

7/8-14

375

51.9

508

530

73.3

719

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

Cap Screw Thread Size

ft lb

kg·m

1/4-20

7

1/4-28

8

5/16-18 5/16-24

Torque Grade 5

Torque Grade 8

Torque Grade 5 ft lb

kg·m

Torque Grade 8 N·m

ft lb

kg·m

N·m

319

335

46.3

454

475

500

69.2

678

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 lb = 0.138 N·m = 1.356 N.m

TABLE 12 - Standard Tightening Torque for 12-Point, Grade 9 Cap Screws

TABLE 12 - Standard Tightening Torques For 12Point, Grade 9, Cap Screws (SAE) The following specifications apply to required assembly torques for all 12-Point, grade 9 (170,000 psi minimum tensile), cap screws.

Cap Screw Size*

Torque ft lb

Torque N·m

Torque kg·m

0.250 - 20

12

16

1.7

0.312 - 18

24

33

3.3

0.375 - 16

42

57

5.8

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

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

0.438 -14

70

95

9.7

0.500 -13

105

142

14.5

0.562 - 12

150

203

20.7

0.625 - 11

205

278

28.3

0.750 - 10

360

488

49.7

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

0.875 - 9

575

780

79.4

1.000 - 8

860

1166

119

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

1.000 - 12

915

1240

126

1.125 - 7

1230

1670

170

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

Standard Tables

Page-5

TABLE 15.

Torque Chart For O-ring Boss Fittings

TABLE 13.

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

Tube Size (OD)

Threads UNF-2B

Torque ft lb

Size Code

Tube Size (OD)

Threads UNF-2B

Torque ft lb

–2

0.125

0.312 – 24

4 ±1

–2

0.125

0.312 – 24

4 ±2

0.188

0.375 – 24

5 ±2

–3

0.188

0.375 – 24

8 ±3

–3

–4

0.250

0.438 – 20

12 ±3

–4

0.250

0.438 – 20

8 ±3

0.312

0.500 – 20

10 ±3

–5

0.312

0.500 – 20

15 ±3

–5

–6

0.375

0.562 – 18

18 ±5

–6

0.375

0.562 – 18

13 ±3

0.500

0.750 – 16

24 ±5

–8

0.500

0.750 – 16

30 ±5

–8

– 10

0.625

0.875 – 14

40 ±5

– 10

0.625

0.875 – 14

32 ±5

0.750

1.062 – 12

48 ±5

– 12

0.750

1.062 – 12

55 ±5

– 12

– 14

0.875

1.188 – 12

65 ±5

– 14

0.875

1.188 – 12

54 ±5

1.000

1.312 – 12

72 ±5

– 16

1.000

1.312 – 12

80 ±5

– 16

– 20

1.250

1.625 – 12

100 ±10

– 20

1.250

1.625 – 12

80 ±5

1.500

1.875 – 12

80 ±5

2.000

2.500 – 12

96 ±10

– 24

1.500

1.875 – 12

120 ±10

– 24

– 32

2.000

2.500 – 12

230 ±20

– 32

TABLE 16 Torque Chart For O-ring Face Seal Fittings

TABLE 14 Torque Chart For Pipe Thread Fittings

Size Code

Pipe Thread Size

With Sealant ft lb

Without Sealant ft lb

Size Code

Tube Size (O.D.)

Threads UNF-2B

Torque ft lb

–4

0.250

0.438 – 20

11 ±1

–2

0.125 – 27

15 ±3

20 ±5

–6

0.375

0.562 – 18

18 ±2

–4

0.250 – 18

20 ±5

25 ±5

–8

0.500

0.750 – 16

35 ±4

–6

0.375 – 18

25 ±5

35 ±5

– 10

0.625

0.875 – 14

51 ±5

–8

0.500 – 14

35 ±5

45 ±5

– 12

0.750

1.062 – 12

71 ±7

– 12

0.750 – 14

45 ±5

55 ±5

– 16

1.000

1.312 – 12

98 ±6

– 16

1.000 – 11.50

55 ±5

65 ±5

– 20

1.250

1.625 – 12

132 ±7

– 20

1.250 – 11.50

70 ±5

80 ±5

– 24

1.500

1.875 – 12

165 ±15

– 24

1.500 – 11.50

80 ±5

95 ±10

– 32

2.000 – 11.50

95 ±10

120 ±10

Page-6

Standard Tables

TABLE 17 - Common Conversion Multipliers English to Metric To Convert From

To

Multiply By

inch (in.)

millimeter (mm)

25.40

inch (in.)

centimeter (cm)

2.54

foot (ft)

meter (m)

0.3048

yard (yd)

meter (m)

0.914

mile (mi)

kilometer (km)

1.61

2

square inch (in. )

square centimeters (cm )

6.45

square feet (ft2)

square centimeters (cm2)

929

cubic inches (in.3)

cubic centimeters (cm3)

16.39

cubic inches (in.3)

liters (l)

0.016

cubic feet (ft3)

cubic meters (m3)

0.028

cubic feet (ft.3)

liters (l)

28.3

ounce (oz)

kilogram (kg)

0.028

fluid ounce (fl oz)

milliliter (ml)

29.573

pound (lb)

kilogram (kg)

0.454

pound (lb)

Newton (N)

4.448

inch pounds (in. lb)

Newton meters (N·m)

0.113

foot pounds (ft lb)

Newton meters (N·m)

1.356

foot pounds (ft lb)

kilogram meters (kg·m)

0.138

kilogram meters (kg·m)

Newton meters (N·m)

9.807

pounds/square inch (psi)

kilopascals (kPa)

6.895

2

pounds/square inch (psi)

megapascals (MPa)

0.007

pounds/square inch (psi)

kilograms/square centimeter

0.0704

short ton (tn)

kilogram (kg)

907.2

short ton (tn)

metric ton (t)

0.0907

quart (qt)

liters (l)

0.946

gallon (gal)

liters (l)

3.785

(kg/cm2)

horsepower (hp)

Watts (w)

745.7

horsepower (hp)

kilowatts (kw)

0.745

Standard Tables

Page-7

TABLE 18. Sealants And Adhesives Nomenclature

Adhesives

Code

Three Bond *

LT-1A

TB1521

Applications

LT-1B

1000B - 1000W

LT-2

TB1374

Preventing bolts, nuts and plugs from loosening and leaking oil.

LT-2A

TB2411

Preventing bolts, nuts and plugs from loosening and leaking oil. (1)

Used to apply rubber pads, rubber gaskets and cork plugs.

Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.

LT-2B

TB2403

Preventing bolts, nuts and plugs from loosening and leaking oil. (2)

LT-2C

TB2430 or TB2440

Preventing bolts, nuts and plugs from loosening and leaking oil. (2)

LT-3 Main bond Hardening agent

TB2001

LG-1

Provides an airtight, electrically insulating seal. Used for aluminum surfaces.

TB2105 TB1108B

Used with gaskets and packings to increase sealing effect.

LG-3

TB1107

Heat-resistant gasket for precombustion chambers and exhaust piping.

LG-4

TB1104

Used by itself on mounting surfaces on the final drive and transmission cases.

Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)

LG-5

TB1110

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm (2 in) in diameter.

Anti-friction compound

LM-P

-

Applied to bearings and taper shafts to facilitate press-fitting and to prevent sticking, burning or rusting.

Grease

G2-LI

-

Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work.

Vaseline

-

-

Used for protecting battery electrode terminals from corrosion.

Liquid Gasket

* NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations.

(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of 1965 kPa (285 psi) or less.

(2) Used for threaded areas (for example, stud, etc.) which are not removable, and a pressure of 1965 kPa (285 psi) or less.

The sealants and adhesives listed below are manufactured and sold by Three Bond USA, Inc. For information concerning Three Bond products, call or write to:

Page-8

Part Numbers Three Bond

Komatsu

Three Bond USA, Inc. 6184 Schumacher Park Drive West Chester, OH 45069

TB1374

09940-00030

TB1521

790-129-9030

TB1104

790-129-9020

Telephone: (513) 779-7300 Fax: (513) 779-7375

TB1108B

790-129-9010

Standard Tables

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

MACHINE MODEL

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

CUSTOMER UNIT NUMBER

HD1500-7 Service Meter Reading

Date of Inspection

Location of Machine at Inspection

Dump Body Manufacturer Komatsu

Distributor’s Name

Dump Body Style

Customer’s Name

KAC Area Service Manager Signature

Other

Date

Customer’s Address

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation.

All four copies are to be distributed as shown below.

Send White Reports to

Manager of Technical Support Komatsu America Corp.

2300 N.E. Adams St, P.O. Box 240 Peoria, IL 61650-0240 U.S.A.

Send Canary Reports to

Manager of Field Assembly Komatsu America Corp.

2300 N.E. Adams St, P.O. Box 240 Peoria, IL 61650-0240 U.S.A.

Send Pink Reports to your KAC Regional Service Manager Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.

Mark each item with the appropriate symbol as shown below.

CEAW003506

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 1 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

N o.

Inspection Around Machine 1

Parts

Visually inspect the unit for loose parts and debris.

2

Hardware

Check for missing hardware.

3

Hoses & Cables

Verify hoses and cables are free from kinks, sharp edges, chafing, and are properly attached.

4

Ground Straps

Check all ground straps for secure connections.

5

Engine Fan

Inspect the fan to shroud clearance and belt alignment.

6

Decks and Ladders

Check for proper installation of decks, ladders, handrails, and anti-skid strips.

7

Belt Tension

Verify correct tension on engine accessory belts.

8

Tire Inflation

Verify tire pressure is within specifications.

9

Tire Flaw

Check tires for visible damage or flaws.

10

Cylinders

Verify that cylinder plated surfaces are free from rust and other flaws.

Battery

Verify that battery connections are clean and tight.

11 12

Verify that batteries are mounted tightly.

13

Verify that caps are tight and electrolyte solution is at the proper level.

Cab Compartment 1

Cab Doors

Inspect doors open and close smoothly, latch works properly, O. & M. Manual in door

2

Cab Windows

Check window operation. Should open and close smoothly.

3

Door Locks

Verify left and right door locks work properly with key.

4

Interior

Visually inspect interior for completeness of assembly.

5

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

6

Verify operators seat adjusts properly (slide lever, back rest operation, seat inclination, seat height etc.).

Cab Seats 7

Inspect seat belt for proper installation (and seat tethers).

8

Passenger Seat

Verify back rest tilts forward and back.

9

Steering Wheel

Check tilt and telescoping functions.

Wiper

Verify wiper works in all speeds, and range does not extend beyond glass surface.

13

Cigarette Lighter

Inspect lighter operation; should pop up hot after 10 seconds.

14

Horn

Check for proper sound, no looseness in horn button.

15

Back Up Alarm

Check for proper sound and function.

16

Gauges

Verify that gauges operate properly.

17

Indicator Lights

Verify that indicator lights illuminate properly.

18

Character Display

Verify the character display in the electronic display panel functions properly.

19

Hydraulic Fittings

Inspect all hydraulic fittings in front of cab and rear of cab.

20

HVAC System

Verify heater and air conditioning systems function properly.

21

Radio

Verify all radio functions operate properly.

10 11

Verify adjustable lever can be locked securely.

12

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

CEAW003506

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 2 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

N o.

Lights 1 2

Verify headlights work, high and low beams.

Headlights

Verify high beam indicator is functional.

Panel Dimmer Switch

Verify dimmer controls brightness of display panel.

Turn Signal

Directional indicators operate properly.

3 4

Verify lights are at proper angle.

5 6

Verify front and rear turn signals operate properly on both sides of the truck.

7 8

Switch turns off after turn is completed.

Hazard Flashers

Verify flasher operates properly.

10

Back Up Light

Verify back up lights operates properly when transmission control is in R position.

11

Ladder Light

Verify ladder lights illuminate with switch ON.

12

Dome Light

Verify dome light operates with the switch ON.

9

Indicator lights operate properly.

13

Backup/Deck Lights

Verify backup lights illuminate with switch ON.

14

Engine Compartment Lights

Verify the engine compartment lights illuminate with switch ON

Brake Lights 1

Service Brake Lights

Verify service brake lights and indicator illuminate with service brake pedal depressed.

2

Brake Lock

Verify brake lock indicator light illuminates when activated.

3

Auxiliary Brake

Verify auxiliary brake indicator light illuminates when activated.

4

Parking Brake

Verify parking brake indicator light illuminates with the parking brake on.

5

Retarder Lights

Verify retard indicator light illuminates when activated.

Fluid Levels 1

Fluid Levels

Check all fluid levels and observe condition of fluids.

Bolt Torque Checks 1

Drive Shaft (Engine to Transmission)

Verify capscrews are tightened to specified torque.

2

Drive Shaft (Transmission to Differential)

Verify capscrews are tightened to specified torque.

3

Engine Mount

Verify capscrews are tightened to specified torque.

4

Transmission Mount

Verify capscrews are tightened to specified torque.

5

Cab Mount

Verify capscrews are tightened to specified torque.

6

Front Support (LH & RH)

Verify capscrews are tightened to specified torque.

7

Hydraulic Tank

Verify capscrews are tightened to specified torque.

8

Fuel Tank

Verify capscrews are tightened to specified torque.

9

Wheels

Verify capscrews are tightened to specified torque.

10

Steering Wheel

Verify capscrews are tightened to specified torque.

Leakage 1

Machine

CEAW003506

Verify that no oil leaks are found throughout the machine.

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 3 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

N o.

Safety Functions 1

Transmission Range Selector

Verify transmission control will not shift out of N without pressing the release button

2

Neutral Safety

Verify engine will not start in any position unless transmission range selector is in N. In this position, centralized warning lamp illuminates, and buzzer sounds.

3

Parking Brake (ON)

When parking brake is ON and transmission range selector is in any position other than N, centralized warning lamp illuminates, and buzzer sounds.

4

Hoist Control

When hoist control is any position other than FLOAT and transmission range selector is in any position other than N, centralized warning lamp illuminates, and buzzer sounds.

5

When hoist control is any position other than FLOAT and transmission range selector is in R, the truck will not move.

Suspension Cylinders 1

Front Suspension

Verify that front suspension cylinder oiling height is 97 ± 3 mm (3.8 ± 0.12 in.). Refer to the note below.

2

Rear Suspension

Verify that rear suspension cylinder oiling height is 221 ± 3 mm (8.7 ± 0.12 in.). Refer to the note below.

NOTE: Refer to Section H, Oiling And Charging Procedures, in the shop manual for the proper procedures for servicing front and rear suspensions.

Engine Performance 1

Engine Starting

Verify that engine starts without difficulty.

2

Engine Noise

Verify that no abnormal engine noise exists.

3

Exhaust Gas Color

Check for abnormal exhaust colorations during operation.

4

Exhaust Gas Leakage

Inspect all exhaust joints for leakage.

Transmission Performance 1

Transmission Noise

Verify that no abnormal transmission noise exists.

2

Transmission Shifting

Verify transmission shifts smoothly in all speeds.

Braking 1

Service Brake

2 3

Verify that service brakes do not pull to either side and steering wheel does not vibrate.

Check rpm required to overcome the service brakes with the transmission in F5.

Measurement__________rpm

Retarder

Verify that machine does not pull to either side and steering wheel does not vibrate during retardation.

4

Check rpm required to overcome the retarder with the transmission in F5.

Measurement__________rpm

5

Emergency Brake

Verify that the machine will not move with the transmission range selector in F5.

6

Parking Brake

Check rpm required to overcome the parking brake with the transmission in F5.

Measurement__________rpm

7

Brake Lock

Verify brake lock actuates the rear brakes.

Steering 1

Steering Wheel

Check steering wheel mounting. Should not have any play on mount.

2

Steering

Verify that steering wheel turns easily, steering is smooth, and free from noise or vibration.

3

Emergency Steering

Verify that emergency steering functions properly.

CEAW003506

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 4 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

N o.

Hoist / Dump Body 1

Hoist Control Lever

Verify that control lever functions properly.

2

Hoist Limit

Verify that hoist limit functions properly by preventing full cylinder extension.

3

Body Raise Speed

Check body raise speed with the dump body empty.

4

Body Lower Speed

Check body lower speed with the dump body empty.

Hydraulic Oil Temperature_________ Engine Speed________ Body Raise Time ________ Hydraulic Oil Temperature_________ Engine Speed________ Body Raise Time ________ Service Inspection 1

Lubrication

Ensure automatic lube system is serviced and full (and air bled from system)

2

Error Codes

Check the machine monitor on the (EDP) for action codes and/or fault codes. Troubleshoot if codes exist.

3

Payload Meter System

Calibrate and check payload meter operation per Operation and Maintenance Manual.

Ensure automatic lube system is operating properly and timer is set as desired

Additional Comments:

CEAW003506

White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

Page 5 of 5

NOTES:

50 HOUR POST-COMMISSIONING CHECKSHEET Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.

MACHINE MODEL

MACHINE SERIAL NUMBER

ENGINE MODEL

ENGINE SERIAL NUMBER

CUSTOMER UNIT NUMBER

HD1500-7 Service Meter Reading

Date of Inspection

Location of Machine at Inspection

Dump Body Manufacturer Komatsu

Distributor’s Name

Dump Body Style

Customer’s Name

KAC Area Service Manager Signature

Other

Date

Customer’s Address

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Send white reports to:

Manager of Technical Support Komatsu America Corp.

2300 N.E. Adams St, P.O. Box 240 Peoria, IL 61650-0240 U.S.A.

Send canary reports to:

Manager of Field Assembly Komatsu America Corp.

2300 N.E. Adams St, P.O. Box 240 Peoria, IL 61650-0240 U.S.A.

Send pink reports to your KAC Regional Service Manager Send gold reports to the Service Manager at the KAC Distributor who sold the truck

CEAW004301

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

Engine Checks

Check the air intake system and verify all intake tube clamps are tightened securely. Ensure no leaks exist.

Inspect the entire engine. Ensure there are no fluid leaks or abnormalities.

6

Transmission Oil Level

Verify the transmission oil level is in the proper operating range. (Overfilling may lead to overheating.)

7

Hydraulic Oil Level

Verify hydraulic oils are filled to the proper levels.

8

Rear Axle

Visually inspect axle mounting rods and rear suspensions for proper installation and proper tightening torque.

Verify the correct oil is being used and the housing filled to the proper oil level.

9

Fuel Tank

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

10

Radiator

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

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 Lever Assembly To Frame

Verify hardware torque -

2

Steering Cylinder To Center Lever

Verify hardware torque -

3

Steering Cylinder To Frame

Verify hardware torque -

4

Tie Rod Pin Retainer

Verify hardware torque -

5

Front Brake To Spindle

Verify hardware torque -

Target: 177 N·m (131 ft lb) Target: 177 N·m (131 ft lb) Target: 177 N·m (131 ft lb) Target: 177 N·m (131 ft lb) Target: 927 N·m (684 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 operating correctly.

4

Glass

Verify no cracks exist on cab windows. Ensure all windows are properly sealed.

CEAW004301

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

Acceptance Procedures

5

Seat/Seat belts

Verify the cab seats and seat belts are in proper working condition.

As Found Condition

Corrective Action

Service Inspection 1

Front Suspension

Verify that the front suspension cylinder heights are within the arrows on the cylinder decal.

Rear Suspension

Verify that the rear suspension cylinder heights are within specifications.

NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropriate service manual for complete suspension oiling and charging instructions.

2

Steering

3

Lubrication

Verify that steering system is operating smoothly while turning from lock to lock.

Verify the steering system is free of noise and vibration.

Ensure the automatic lube system contains no air and is filled to the proper level.

Ensure the automatic lube system is operating properly and the timer is set as desired.

4

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

5

Tires

Check and record the tire pressure/size/manufacturer for future reference

6

Machine Monitor (EDP)

Check the machine monitor on the EDP for proper operation. Verify that no action codes and/or fault codes are present. Troubleshoot any codes that exist.

7

Payload Meter System

Calibrate and check payload meter operation per O&M manual. Troubleshoot any error codes and delete after repair.

8

Dump Body

Check the dump body for proper alignment, shimming, and for any abnormal body pad wear. Verify that the body limit switch and the hoist control lever are adjusted correctly and working as intended.

Size Manufacturer

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

CEAW004301

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

ADDITIONAL COMMENTS ___________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CEAW004301

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