Komatsu Dump Trucks 830E-AC Field Assembly Manual - PDF DOWNLOAD

CEAW004503

Field Assembly Manual

DUMP TRUCK SERIAL NUMBERS

A30043 - A30108

®

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

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

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

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

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

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

FAM0012

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

FAM0012

TABLE OF CONTENTS

SUBJECT

PAGE NUMBER

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

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

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

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

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

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

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

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

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

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

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

FAM0012

Introduction

iii

KOMATSU 830E-AC

iv

Introduction

FAM0012

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

FAM0110 5/08

Safety Rules, Tools, & Equipment

Page 1-1

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

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

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

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

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

5. One, propane torches for weld preheating.

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

Two, 15 m (50 ft) air hoses.

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

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

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

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

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

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

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

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

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

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

8. Tire handler - Wiggins/Iowa Mold Tooling.

17. Special tools (see list, following pages)

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

18. Two, hydraulic or pneumatic porta-power jacks, 4.5 and 9 metric ton (5 and 10 ton)

11. Chains, lifting cables, slings:

19. Various hooks and shackles

• • • • •

Two, 4 point slings, 3 m (10 ft) in length Two, 4 point slings, 2 m (6 ft) in length

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

21. Spreader bars for cab and decks.

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

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

Two, 3 m (10 ft) nylon straps

23. Pry bars

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

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

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Safety Rules, Tools, & Equipment

5/08 FAM0110

LIFTING SLING GENERAL INFORMATION

FAM0110 5/08

Safety Rules, Tools, & Equipment

Page 1-3

Part Number

Description

Use

EB1759

Nitrogen Charging Kit

Suspension & Accumulator Nitrogen Charging

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

Part Number

Description

Use

EJ2627 (No longer available as complete unit)

Roller Assy.

Power Module Remove & Install

EJ2629

Roller Mount

PC0706

Bearing

TH9449

Bearing Retainer Ring

TG1680

Roller Retainer Ring

C1645

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

C1542

Lockwasher 0.75 in.

EH8686

Roller Ring

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Safety Rules, Tools, & Equipment

5/08 FAM0110

Part Number

Description

Use

TZ3535

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

Miscellaneous

Part Number

Description

Use

TZ2734

3/4 in. Torque Adapter

Miscellaneous

Part Number

Description

Use

TZ2733

Tubular Handle

Use with TZ2734 & TZ3535

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Safety Rules, Tools, & Equipment

Page 1-5

Part Number

Description

Use

TY2150

Seal Installation Tool

Front Face Seals

Part Number

Description

Use

TY4576

Sleeve Alignment Tool

Steering Linkage and Tie Rod

TZ0992

Sleeve Alignment Tool

Rear Suspension & AntiSway Bar

Part Number

Description

Use

PB6039

Hydraulic Coupling

Miscellaneous

Part Number

Description

Use

PC2061

Belt Tension Tester

A/C Belt Tension

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Safety Rules, Tools, & Equipment

5/08 FAM0110

Part Number

Description

Use

EL8868

V-Belt Alignment Tool

Aligning A/C pulleys

Part Number

Description

Use

PC2525

Harness

Payload Meter Download

AK4720

Software

Payload Meter Data Manager

Part Number

Description

Use

EH7817

Alignment Tool

Upper Hoist Pin

FAM0110 5/08

Safety Rules, Tools, & Equipment

Page 1-7

Part Number

Description

Use

TZ2100 TZ2726 TZ2727 TZ2728 TZ2729 TV7567 PB6825

Socket (1 7/8 in.)

Socket (1 1/8 in.)

Socket (2 1/4 in.)

Socket (2 3/4 in.)

Socket (1 1/4 in.)

Socket (1 5/16 in.)

Impact Socket (1 5/8 in.)

Part Number

Description

Use

TZ2730 TZ2731

Adapter (1-1 1/2 in.)

Adapter (3/4-1 in.)

Socket adapter

Part Number

Description

Use

WA4826 TG1106

Lifting Eye Bolt

Miscellaneous

Miscellaneous

Part Number

Description

Use

TV1186 TR0532 TR0533

Extension (3 1/2 in.)

Extension (8 in.)

Extension (17 in.)

Miscellaneous

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Safety Rules, Tools, & Equipment

5/08 FAM0110

FAM0110 5/08

Safety Rules, Tools, & Equipment

Page 1-9

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Safety Rules, Tools, & Equipment

5/08 FAM0110

TRUCK COMPONENTS AND SPECIFICATIONS Truck And Engine

Operator's Cab

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

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

Alternator (G.E. GTA-41) The diesel engine drives an in-line alternator at engine speed. The alternator produces AC current which is rectified to DC within the main control cabinet. The rectified DC power is converted back to AC by groups of devices called "inverters", also within the main control cabinet. Each inverter consists of six "phase modules" under the control of a "gate drive unit" (GDU). The GDU controls the operation of each phase module.

Cooling air for the control / power group and wheel motors, as well as the alternator itself, is provided by dual fans mounted on the alternator shaft.

AC Induction Traction Motorized Wheels The alternator output supplies electrical energy to the two wheel motors attached to the rear axle housing.

The motorized wheels use three-phase AC induction motors with full-wave AC power.

The two wheel motors convert electrical energy back to mechanical energy through built-in gear trains within the wheel motor assembly. The direction of the wheel motors is controlled by the directional control lever located on the center console.

Suspension

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

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

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

Brake System

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

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

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

FAM0211

Truck Components And Specifications

Page 2-1

830E MAJOR COMPONENTS Page 2-2

Truck Components And Specifications

FAM0211

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

ENGINE Komatsu SDA16V160 (Optional SSDA16V160) No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke Rated Brake HP. . . . 1865 kW (2500 hp)@ 1900 rpm Flywheel HP . . . . . 1761 kW (2360 hp) @ 1900 rpm Weight* (Wet) 9 608 kg (21,182 lbs) * Weight does not include Radiator, Sub-frame, or Alternator

AC ELECTRIC DRIVE SYSTEM (AC/DC Current)

SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters. (U.S. Gal.) Crankcase * . . . . . . . . . . . . . . . . . 280.0. . . . . (74.0) * Includes Lube Oil Filters Cooling System . . . . . . . . . . . . . . . . 568. . . . . (150) Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542. . . . (1200) Hydraulic System . . . . . . . . . . . . . . . 946. . . . . (250) Hydraulic Tank . . . . . . . . . . . . . . . . . 901. . . . . (238) Wheel Motor Gear Box (each) . . . . . . 38. . . . . . (10) HYDRAULIC SYSTEMS* Pumps Hoist . . . . . . . . . . . . . . . . . . . . . Tandem Gear Pump Rated @ . . . . . 851 lpm (225 gpm) @ 1900 rpm and . . . . . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi) Steering/Brake . . . . . Pressure Compensating Piston Rated @ . . . . . . .246 lpm (65 gpm) @ 1900 rpm and . . . . . . . . . . . . . . . . . . . . . . . .18 961 kPa (2,750 psi) System Relief Pressures

Alternator . . . . . . . . . . . . . General Electric GTA - 41 Dual Impeller, In-Line Blower 255 m3/min (9000 cfm) Motorized Wheels . . . .GEB25 AC Induction Traction Motors Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1 Maximum Speed* . . . . . . . . . 64.5 km/h (40 mph) (*w/40.00-57 Tires and 31.875:1 gear train) *NOTE: Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.

Komatsu & G.E. must analyze each job condition to assure proper application.

DYNAMIC RETARDING Electric Dynamic Retarding . . . . . . . . . . . . . Standard Maximum Rating . . . . . . . . . . . . . 2983 kW (4000 hp) 24 VDC ELECTRIC SYSTEM Batteries . . . . 4 x 8D 1450 CCA, 12 volt batteries in Series/Parallel w/Disconnect Switch Alternator . . . . . . . . . . . 24 Volt, 260 Ampere Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt Cranking Motors (2). . . . . . . . . . . . . . . . . . . . .24 Volt

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

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

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

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

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

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Truck Components And Specifications

Page 2-3

DUMP BODY CAPACITIES AND DIMENSIONS Standard, Heaped @ 2:1 (SAE) . . 147 m3 (193 yd3) Struck . . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd3) Loading Height Empty . . . . . . . . 6.61 m (21 ft. 8 in.)

Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Non-heated body w/exhaust mufflers . . . . . Standard TIRES Radial Tires (standard) . . . . . . . . . . . . . . . 40.00 R57 Optional Tires . . . . . . . . . . . . . . . . . . . . . . 46/90 R57 Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless Rims, standard 5 piece. . Rated to 827 kPa (120 psi)

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

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

OVERALL TRUCK DIMENSIONS (Empty with Standard Body)

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

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

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

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

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

Page 2-4

14.4 m (47 ft. 3 in.)

7.32 m (24 ft. 0 in.)

6.96 m (22 ft. 10 in.)

13.52 m (44 ft. 4 in.)

28.4 m (93 ft. 0 in.)

Truck Components And Specifications

FAM0211

MAJOR COMPONENT WEIGHTS

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

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

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

ITEM

KILOGRAMS

POUNDS

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

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

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Major Component Weights

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ITEM

KILOGRAMS

POUNDS

POWER MODULE Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 . . . . . . . . . . . . . . . . . . . . . . . . 421 Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788 . . . . . . . . . . . . . . . . . . . . . . .1,737 Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340 Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,364 . . . . . . . . . . . . . . . . . . . . . . .5,212 Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,176 . . . . . . . . . . . . . . . . . . . . . . .7,002 Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 . . . . . . . . . . . . . . . . . . . . . . . . 445 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,993 . . . . . . . . . . . . . . . . . . . . . . .8,803 Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,558 . . . . . . . . . . . . . . . . . . . . . . 18,867 Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,905 . . . . . . . . . . . . . . . . . . . . . . .4,200

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

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

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

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Major Component Weights

FAM0311

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

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

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

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

APPROVED CONSUMABLES WELDER QUALIFICATION AND TRAINING

GMAW - LW102-15 or ER80S-D2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

WELD INSPECTION

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

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

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

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

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

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Field Welding Procedures

FAM0403

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

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

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

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

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

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

Komatsu requires record keeping of all welding work.

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

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

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

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

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

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

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

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

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

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

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

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

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

FAM0403

ANNEX B 2.0 TOE GRINDING WITH A ROTARY BURR

1.0 TOE HAMMER PEENING Equipment:

Equipment:

1. Hand held pneumatic hammer 2. Adequate air supply

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

3. Adequate lighting

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

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

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

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

Procedure

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

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

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

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

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

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

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FIGURE 4-1. TOE HAMMER PEENING

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FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

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BIBLIOGRAPHY American Welding Society Bulletin No. D14.3-94/ D1.1 - Specification for Welding Earthmoving and Construction Equipment Metals and How to Weld Them - James F. Lincoln Arc Welding Foundation. Cleveland, Ohio Procedure Handbook of Arc Welding - Lincoln Electric Company, Cleveland, Ohio American Welding Society - Welding Handbook

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

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

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

Anytime the engine is on: • Do not open any of the cabinet doors or remove any covers.

• Do not use power cables for hand holds or foot steps.

• Do not touch retarder grid elements.

Before opening any cabinets or touching a grid element or a power cable, the engine and all warning lights must be off.

Engine Stop Procedure Prior To Maintenance Perform the following procedure prior to maintenance to ensure that no hazardous voltages are present in the A/C drive system.

1. Before turning off the engine, verify the status of all the drive system warning lights on the overhead display panel. Use the lamp test switch to verify that all lamps are functioning properly.

2. If all red drive system warning lights are off, turn the engine off.

3. After the engine has been off for at least five minutes, inspect the link voltage lights. The lights are located on the exterior of the main control cabinet and back wall of the operator's cab (DID panel). If all lights are off, the retarding grids, wheel motors, alternator, and power cables connecting these devices are safe to work on.

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Field Welding Procedures

FAM0403

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

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

After repairs, replace all covers and doors and place the GF cutout switch and battery disconnect switches in their original positions. Reconnect all harnesses prior to starting the truck.

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

4. If the red lights on the exterior of the control cabinet and/or the back wall of the operator's cab continue to be illuminated, a fault has occurred.

Leave all cabinet doors in place. DO NOT touch the retard grid elements. DO NOT disconnect any power cables or use them as hand or foot holds.

Notify your Komatsu customer service manager immediately. Only qualified personnel, specifically trained for servicing the A/C drive system, may perform this service.

General Welding Guidelines 1. Open the battery disconnect switches and disconnect the battery charging alternator lead wire.

2. Disconnect all electrical harnesses from the Engine Control System (ECS). The ECS is located inside the electrical cabinet behind the operator's cab. Disconnect the ground strap from the ECS. 3. Fasten the welding machine ground (-) lead to the piece being welded. The grounding clamp must be attached as near as possible to the weld area.

4. DO NOT weld on the rear of the control cabinet!

The metal panels on the back of the cabinet are part of the capacitors and cannot be heated.

5. DO NOT weld on the retard grid exhaust louvers.

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

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

8. Protect power cables and wiring harnesses from weld spatter and heat.

9. DO NOT lay welding cables over or near the vehicle electrical harnesses. Welding voltage may be induced into the electrical harnesses and cause damage to components.

10. DO NOT allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders.

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NOTES

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

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

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

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.

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

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ASSEMBLY LAYOUT Page 5-2

Receiving & Assembly Preparation

FAM0503

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

RECOMMENDED ASSEMBLY DATA

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

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Chassis Assembly

Page 6-1

ORDER OF ASSEMBLY

LEVEL 5

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

However, all tasks in that level must be completed before proceeding to the next higher level. Each level depends on the installation of components from the previous level.

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

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

LEVEL 6 1. Weld Uprights

LEVEL 8 Dump Body Installation

LEVEL 7 LEVEL 1

1. Hoist Cylinders

1. Chassis - Unload and crib for assembly.

2. Rock Ejectors

2. Deck Supports

3. Mud Flaps

NOTE: It is easier to install and weld the deck supports before the front suspensions are installed.

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

3. Hydraulic Tank

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

LEVEL 8 1. Clean the Truck

4. Fuel Tank

2. Lighting Wiring

5. Front Suspensions

3. Charge Suspensions

6. Uprights/Air Cleaners

4. Charge Accumulators

7. Diagonal Support Beam

5. Add Fluids 6. Charge the Air Conditioning System

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

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

LEVEL 2

LEVEL 9

1. Air Cleaner Piping

1. System Checkouts

2. Spindles/Hubs

2. Decals

3. Diagonal Ladder

3. Touch Up Paint

LEVEL 3

4. Train Operators 5. Optional - Install Fire Suppression System

1. Control Cabinet 2. Auxiliary Control Cabinet 3. Center Deck 4. Steering Cylinders 5. Tie Rod 6. LH Deck 7. RH Deck/Grid Box 8. Wheel Motors

Page 6-2

Chassis Assembly

5/08 FAM0611

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

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

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

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

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

DO NOT allow welding current to pass through bearings.

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

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

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

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

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

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

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

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

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

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

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

FAM0611 5/08

Chassis Assembly

Page 6-3

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

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

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

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

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

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

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

Page 6-4

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

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

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

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

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

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

Chassis Assembly

5/08 FAM0611

NOTES

FAM0611 5/08

Chassis Assembly

Page 6-5

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

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

Thoroughly clean the chassis.

Page 6-6

Chassis Assembly

5/08 FAM0611

FIGURE 6-1.

FAM0611 5/08

Chassis Assembly

Page 6-7

2. On domestic trucks, the auxiliary control cabinet (Figure 6-2) is attached to the frame of the truck and wired.

The electrical wiring cannot easily be disconnected. Lift the cabinet onto the control cabinet support to allow the installation of other components (Figure 6-3). The weight of the auxiliary control cabinet is approximately 202 kg (445 lb).

Use caution when moving the auxiliary control cabinet. Lifting the cabinet too high may cause damage to the wiring and electrical connections. DO NOT pull the wiring taut when lifting.

NOTE: On international trucks, the auxiliary control cabinets are not attached to the chassis. The cabinets are installed on the main control cabinet, separate from the chassis.

Page 6-8

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5/08 FAM0611

FIGURE 6-2.

FIGURE 6-3.

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Chassis Assembly

Page 6-9

3. Clean the mating surfaces for the deck supports to prepare for installation. (Figures 6-4 & 6-5)

Page 6-10

Chassis Assembly

5/08 FAM0611

FIGURE 6-4.

FIGURE 6-5.

FAM0611 5/08

Chassis Assembly

Page 6-11

4. Lift the LH deck support into position. The weight of the deck support is approximately 490 kg (1080 lb). a. Bolt the support into place. b. Tack weld the support. c. The four tapped pads on each support and the corresponding blocks on the horsecollar must be removed to allow for a complete weld around the joint. d. Grind all areas, and clean. Paint after welding is complete.

Refer to Figures 6-6 thru 6-7.

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

5. Repeat for the RH deck support. The weight of the deck support is approximately 222 kg (489 lb).

Page 6-12

Chassis Assembly

5/08 FAM0611

FIGURE 6-6.

FIGURE 6-7.

FAM0611 5/08

Chassis Assembly

Page 6-13

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

11. Clean the mounts for the hydraulic tank and the fuel tank.

Page 6-14

Chassis Assembly

5/08 FAM0611

FIGURE 6-8.

FIGURE 6-9.

FAM0611 5/08

Chassis Assembly

Page 6-15

12. Lift the hydraulic tank into position on the cradles. (Figure 6-10). The weight of the hydraulic tank is approximately 325 kg (717 lb).

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

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

13. Lift the fuel tank into position on the cradles. (Figure 6-11) The weight of the fuel tank is approximately 1711 kg (3772 lb).

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

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

Page 6-16

Chassis Assembly

5/08 FAM0611

FIGURE 6-10.

FIGURE 6-11.

FAM0611 5/08

Chassis Assembly

Page 6-17

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

Refer to Figures 6-12.

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

11. Install the hydraulic filters onto the bracket at the rear of the fuel tank. Refer to Figure 6-13.

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

Page 6-18

Chassis Assembly

5/08 FAM0611

FIGURE 6-12.

FIGURE 6-13.

FAM0611 5/08

Chassis Assembly

Page 6-19

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

Refer to Figure 6-14 & 6-15.

Page 6-20

Chassis Assembly

5/08 FAM0611

FIGURE 6-14.

FIGURE 6-15.

FAM0611 5/08

Chassis Assembly

Page 6-21

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

14. Lubricate the cap screw threads, cap screw head seats, washer faces, and nut seats with a rust preventive compound.

High tightening torque is required to load the front suspension mounting cap screws.

Repeated tightening will result in cap screw fatigue and damage. DO NOT reuse mounting cap screws, washers and nuts. Replace the hardware after each use.

Suspension mounting cap screws are specially hardened to meet or exceed grade 8 specifications. Replace only with cap screws of correct hardness. Refer to the appropriate parts book for the correct part numbers. .

FIGURE 6-16. INSTALLATION OF HARDENED FLAT WASHER 1. Hardened Flat Washer

2. Cap Screw

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

15. The hardened flat washers use on the front suspensions are punched during the manufacturing process. Assemble the cap screws and washers, and position the punch lip away from the cap screw head to prevent damage. See Figure 6-16.

• American Anti-Rust Grease #3-X from Standard Oil Division of American Oil Company

16. Lift the front suspension into position. Refer to Figure 6-17. The weight of each front suspension cylinder is approximately 2228 kg (4,912 lb). Install the mounting hardware and tighten according to the "turn-of-the-nut" method outlined on the following pages.

• Rustolene D grease from Sinclair Oil Company • Gulf NoRust #3 from Gulf Oil Company • Rust Ban 326 from Humble Oil Company • 1973 Rustproof from the Texas Company • Rust Preventive Grease-Code 312 from the Southwest Grease and Oil Company NOTE: If none of the rust preventive greases listed above are available for field assembly, use one of the following lubricants: • SAE 30 weight oil • 5% Molybdenum - Disulphide Grease DO NOT use anti-seize compounds.

Page 6-22

Chassis Assembly

5/08 FAM0611

FIGURE 6-17.

FAM0611 5/08

Chassis Assembly

Page 6-23

"Turn-Of-The-Nut" Tightening Procedure 1.) Mark a reference line on a corner of the hexagonal cap screw head or nut and the mounting surface opposite this corner, as shown. Then mark the position located 60° or 90° clockwise relative to the first reference line on the mounting surface.

Refer to Figures 6-18 and 6-19.

a. Tighten all 14 cap screws (1, 6, 8, Figure 620) to 542 ± 5 N·m (400 ± 40 ft lb). b. Maintain this torque on the top two corner cap screws and the bottom, outer four cap screws (without spacers). c. Loosen the eight remaining cap screws and then tighten again as follows:

2.) Scribe a reference mark at the opposite end of the turning member to ensure that either the cap screw head or nut, remains stationary.

d. Initially tighten the four cap screws (1) at the upper mount to 95 N·m (70 ft lb). Then, advance the cap screw heads 60° as outlined in Steps d-1 through d-3. Refer to Figure 6-18.

3.) Each corner of a hexagon represents 60°.

The turning member, either the cap screw head or nut, is turned until the marked corner is adjacent with the marked reference line. Prevent the opposite end of the turning member from turning during the tightening procedure.

NOTE: Do not exceed 4 rpm tightening speed. Do not hammer or jerk the wrench while tightening. e. Loosen the top two corner cap screws (1, Figure 6-20) and the bottom outer four cap screws (8), (without spacers).

FIGURE 6-18. 60 DEGREE ADVANCE

1.) Tighten the top two corner cap screws to 95 N·m (70 ft lb), then advance the cap screw heads 60°.

Initially tighten the bottom four cap screws (6, Figure 6-20) to 136 N·m (100 ft lb).

Then, advance the cap screw heads 120° as outlined in Steps d-1 through d-3. Refer to Figure 6-19.

2.) Tighten the bottom, outer four cap screws to 203 N·m (150 ft lb), then advance the cap screw heads 90°.

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

FIGURE 6-19. 90 DEGREE ADVANCE

Page 6-24

Chassis Assembly

5/08 FAM0611

FIGURE 6-20. SUSPENSION INSTALLATION 1. Cap Screws, Washers 2. Nuts, Washers 3. Housing 4. Mounting Surface 5. Shear Bar

FAM0611 5/08

6. Cap Screws, Washers 7. Piston 8. Cap Screws, Washers 9. Spacer 10. Nuts, Washers

Chassis Assembly

Page 6-25

17. Remove the center deck to enable easy installation of the air intake tubing and the diagonal cross tube (Figure 6-21). The weight of the center deck is approximately 250 kg (550 lb).

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

Page 6-26

Chassis Assembly

5/08 FAM0611

FIGURE 6-21.

FAM0611 5/08

Chassis Assembly

Page 6-27

18. Prepare the upright mating surfaces for installation. Refer to Figure 6-22.

19. Attach either upright to a crane using adequate lifting apparatus. Attach a ratchet hoist to the lifting apparatus to enable the upright to pivot for proper alignment. Refer to Figure 6-23.

Page 6-28

Chassis Assembly

5/08 FAM0611

FIGURE 6-22.

FIGURE 6-23.

FAM0611 5/08

Chassis Assembly

Page 6-29

20. Lift the LH & RH uprights into position and install the four cap screws for each upright. Tighten to standard torque. Refer to Standard Tables in Section 10, Appendix. The weight of the RH upright is approximately 530 kg (1169 lb). The weight of the LH upright is approximately 668 kg (1472 lb).

Refer to Figure 6-24.

DO NOT weld the torque tubes on the uprights until the decks are installed.

21. Attach the upper radiator stabilizers rods to the uprights. Refer to Figure 6-25. After the decks are installed and the uprights welded, adjust the stabilizers to vertically level the radiator.

Page 6-30

Chassis Assembly

5/08 FAM0611

FIGURE 6-24.

FIGURE 6-25.

FAM0611 5/08

Chassis Assembly

Page 6-31

22. Prepare the mounting surfaces for the LH diagonal tube (Figure 6-26).

23. Lift the tube into position (Figure 6-27). The weight of the diagonal tube is approximately 120 kg (265 lb).

Do not tighten the cap screws until the deck and the cab are in place.

Page 6-32

Chassis Assembly

5/08 FAM0611

FIGURE 6-26.

FIGURE 6-27.

FAM0611 5/08

Chassis Assembly

Page 6-33

24. Install the hanger brackets for the intake tubes. Refer to Figure 6-28.

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

Refer to Figure 6-29 - 6-31. The intake tubes are assembled and adjusted for installation on the truck. DO NOT loosen any of the connections during installation.

Page 6-34

Chassis Assembly

5/08 FAM0611

FIGURE 6-28.

FIGURE 6-29.

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Chassis Assembly

Page 6-35

FIGURE 6-30.

Page 6-36

Chassis Assembly

5/08 FAM0611

FIGURE 6-31.

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Chassis Assembly

Page 6-37

26. Lift the center deck into position (Figure 6-32). Install the mounting hardware and tighten to standard torque.

Refer to Standard Tables in Section 10, Appendix.

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

Lubricate the two surfaces with multi purpose grease number 2 (5% molybdenum disulphide). Refer to Figure 6-33.

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

Products containing copper will contribute to corrosion in this area.

Page 6-38

Chassis Assembly

5/08 FAM0611

FIGURE 6-32.

FIGURE 6-33.

FAM0611 5/08

Chassis Assembly

Page 6-39

28. Lift the retainer plate into position under the spindle. The weight of the retainer plate is approximately 48 kg (106 lb). Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brake assembly is approximately 3216 kg (7090 lb). Refer to Figure 6-34.

29. Install the twelve retainer plate cap screws. Refer to Figure 6-35. Tighten cap screws using the following procedure: a. Tighten cap screws uniformly to 678 N·m (500 ft lbs) torque. b. Continue to uniformly tighten the cap screws in increments of 339 N·m (250 ft lbs) to obtain a final torque of 2142 N·m (1580 ft lbs).

30. Repeat the previous steps for the remaining wheel.

Page 6-40

Chassis Assembly

5/08 FAM0611

FIGURE 6-34.

FIGURE 6-35.

FAM0611 5/08

Chassis Assembly

Page 6-41

31. Prepare the steering cylinder and tie rod mounting surfaces. Refer to Figure 6-36.

Page 6-42

Chassis Assembly

5/08 FAM0611

FIGURE 6-36.

FAM0611 5/08

Chassis Assembly

Page 6-43

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

Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 ± 71 N·m (525 ± 53 ft lb). Refer to Figures 6-37 & 6-38.

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

33. Lift the tie into position on the steering arms. The weight of the tie rod is 165 kg (364 lb). Lubricate the mounting pins with grease. Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 ± 71 N·m (525 ± 53 ft lb).

The tie rod toe-in must be adjusted once the tires and the body are installed. The toe-in adjustment procedure is located in Section 10, Appendix.

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

Page 6-44

Chassis Assembly

5/08 FAM0611

FIGURE 6-37.

FIGURE 6-38.

FAM0611 5/08

Chassis Assembly

Page 6-45

34. Install the handrails onto the LH deck and lift the deck into place (Figure 6-39). The weight of the LH deck with handrails is approximately 802 kg (1768 lb). Loosely install the eight deck mounting cap screws.

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

35. Lift the operator cab into position. The weight of the cab is approximately 2177 kg (4800 lb). Refer to Figure 640.

Tap the cab mounting holes to remove any paint.

Install and tighten the forty cap screws to standard torque.

36. Tighten the hardware for the LH diagonals tube to standard torque. Refer to Standard Tables in Section 10, Appendix.

Page 6-46

Chassis Assembly

5/08 FAM0611

FIGURE 6-39.

FIGURE 6-40.

FAM0611 5/08

Chassis Assembly

Page 6-47

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

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

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

38. Install the handrails on the RH deck.

39. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approximately 3100 kg (6834 lb). Refer to Figure 6-41.

40. Weld the LH & RH uprights to the front frame tube. Refer to Figure 6-42.

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

Page 6-48

Chassis Assembly

5/08 FAM0611

FIGURE 6-41.

FIGURE 6-42.

FAM0611 5/08

Chassis Assembly

Page 6-49

41. Lift the two bumper extensions into place. The weight of each bumper extension is approximately 123 kg (271 lb). Refer to Figure 6-43 & 6-44.

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

Page 6-50

Chassis Assembly

5/08 FAM0611

FIGURE 6-43.

FIGURE 6-44.

FAM0611 5/08

Chassis Assembly

Page 6-51

42. Domestic trucks only - Lift the auxiliary control cabinet out of the way to allow placement of the control cabinet. The weight of the auxiliary control cabinet is approximately 202 kg (445 lb). Refer to Figure 6-45.

43. Lift the control cabinet into position. The weight of the cabinet is approximately 3176 kg (7002 lb). On international trucks, the auxiliary control cabinet is already attached to the main control cabinet. The weight of this assembly is 3378 kg (7447 lb) Install the mounting hardware. Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

Refer to Figures 6-46.

44. Domestic trucks only - Lift the auxiliary control cabinet into position on the LH side of the main electrical control cabinet on domestic trucks. Refer to Figure 6-48.

Install the six cap screws to the cabinet and tighten the cap screws to standard torque.

Page 6-52

Chassis Assembly

5/08 FAM0611

FIGURE 6-45.

FIGURE 6-46.

FAM0611 5/08

Chassis Assembly

Page 6-53

FIGURE 6-47.

FIGURE 6-48.

Page 6-54

Chassis Assembly

5/08 FAM0611

FIGURE 6-49.

NOTE: Figure 6-50 shows the international configuration with the auxiliary cabinet already attached to the control cabinet.

FAM0611 5/08

Chassis Assembly

Page 6-55

45. Install the mounting bracket for the control cabinet vent cover and install the cover. Figure 6-50 & 6-51.

Connect the wiring for the electrical control cabinet, auxiliary control cabinet, and grid box.

Lift the transition duct into place on the alternator, and install the mounting hardware. Clamp all wiring.

Refer to FIgures 6-52- 6-58.

Page 6-56

Chassis Assembly

5/08 FAM0611

FIGURE 6-50.

FIGURE 6-51.

FAM0611 5/08

Chassis Assembly

Page 6-57

FIGURE 6-52.

FIGURE 6-53.

Page 6-58

Chassis Assembly

5/08 FAM0611

FIGURE 6-54.

FIGURE 6-55.

FAM0611 5/08

Chassis Assembly

Page 6-59

FIGURE 6-56.

FIGURE 6-57.

Page 6-60

Chassis Assembly

5/08 FAM0611

FIGURE 6-58.

FAM0611 5/08

Chassis Assembly

Page 6-61

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

Refer to Figure 6-59 & 60.

Page 6-62

Chassis Assembly

5/08 FAM0611

FIGURE 6-59.

FIGURE 6-60.

FAM0611 5/08

Chassis Assembly

Page 6-63

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

Refer to Figure 6-61 & 6-62.

Page 6-64

Chassis Assembly

5/08 FAM0611

FIGURE 6-61.

FIGURE 6-62.

FAM0611 5/08

Chassis Assembly

Page 6-65

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

Refer to Figure 6-63.

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

Page 6-66

Chassis Assembly

5/08 FAM0611

FIGURE 6-63.

FAM0611 5/08

Chassis Assembly

Page 6-67

49. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assemblies installed is approximately 12,201 kg (26,899 lb). Refer to Figure 6-64 &6-65.

The hardened flat washers used in this application are punched during the manufacturing process. Therefore, the washers must be installed with the punched lip away from the head of the mounting cap screws to prevent damage to the fillet between the cap screw head and the shank. Refer to Figure 6-67.

Tighten the wheel motor mounting cap screws to 2007 ± 201 N·m (1480 ± 148 ft lb).

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

FIGURE 6-64.

FIGURE 6-65.

Page 6-68

Chassis Assembly

5/08 FAM0611

FIGURE 6-66.

FIGURE 6-67.

1. Washer

FAM0611 5/08

2. Cap Screw

Chassis Assembly

Page 6-69

50. Connect the power cables and the speed sensors to each of the wheel motors. Connect the apply lines, brake cooling supply lines, and return lines to each wheel.

Refer to Figures 6-68.

Page 6-70

Chassis Assembly

5/08 FAM0611

FIGURE 6-68.

FAM0611 5/08

Chassis Assembly

Page 6-71

FIGURE 6-69. FRONT WHEEL ASSEMBLY 1. Valve Assembly 2. Bead Seat Band 3. Rim 4. O-Ring 5. Side Flange

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

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

16. Lockwasher 17. Bent Plate 18. Hub

51. Use a tire handler to lift the front wheel into position on the wheel hub. Install wheel retainer lugs (7, Figure 6-69 and lubricated nuts (8). Evenly tighten each nut to 407 N·m (300 ft lb). Tighten the nuts in the sequence shown in Figure 6-60.

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

If run-out is within specifications, tighten each nut to 746 N·m (550 ft lb). Tighten the nuts in the sequence shown in Figure 6-70.

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

Page 6-72

Chassis Assembly

FIGURE 6-70. TIGHTENING SEQUENCE

5/08 FAM0611

FIGURE 6-71.

FIGURE 6-72.

FAM0611 5/08

Chassis Assembly

Page 6-73

FIGURE 6-73. REAR WHEEL ASSEMBLY 1. Side Flange 2. Outer Wheel Rim 3. Bead Seat Band 4. O-Ring

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

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

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

54. Use a lifting device to install spacer (6, Figure 6-73) onto wheel motor hub. The weight of the spacer is approximately 88 kg (194 lb). Tap the spacer against the inner dual.

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

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

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

Page 6-74

Chassis Assembly

5/08 FAM0611

56. Install the wedges onto the studs and secure in place with the lubricated wheel nuts. Evenly tighten each nut in an alternating (criss-cross) pattern as shown in Figure 6-74. Tighten the nuts to 407 N¡m (300 ft lb).

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

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

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

Check the torque at regular intervals, thereafter.

FIGURE 6-74. TIGHTENING SEQUENCE

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

FIGURE 6-75.

FAM0611 5/08

Chassis Assembly

Page 6-75

60. Attach a lifting device to the radiator surge tank. Lift the tank into position on the radiator (Figure 6-76). Install the mounting hardware to the surge tank.

Install the hoses to the radiator and the surge tank. (Figure 6-77)

Page 6-76

Chassis Assembly

5/08 FAM0611

FIGURE 6-76.

FIGURE 6-77.

FAM0611 5/08

Chassis Assembly

Page 6-77

61. Lift the surge tank cover into position and install the mounting hardware (Figure 6-78). The weight of the cover is approximately 98 kg (216 lb).

Page 6-78

Chassis Assembly

5/08 FAM0611

FIGURE 6-78.

FAM0611 5/08

Chassis Assembly

Page 6-79

62. Connect the electrical harnesses and hydraulic hoses below the operator’s cab. Refer to Figure 6-79 & 6-80.

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

FIGURE 6-79.

FIGURE 6-80.

Page 6-80

Chassis Assembly

5/08 FAM0611

FIGURE 6-81.

FIGURE 6-82.

FAM0611 5/08

Chassis Assembly

Page 6-81

64. Install the mud-flaps and mud guards.

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

66. The truck is now ready for body installation.

Page 6-82

Chassis Assembly

5/08 FAM0611

FIGURE 6-80.

FIGURE 6-81.

FAM0611

Chassis Assembly

Page 6-83

62. Install the mud-flaps and mud guards.

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

64. The truck is now ready for body installation.

Page 6-84

Chassis Assembly

FAM0611

DUMP BODY ASSEMBLY GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

FAM0710

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 1492 kg (3289 lb). DO NOT damage the bores.

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

Dump Body Assembly

FAM0710

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

FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE

FIGURE 7-6. BODY PIVOT INSTALLATION

FAM0710

Dump Body Assembly

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

FAM0710

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

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

FIGURE 7-10.

FIGURE 7-8.

FIGURE 7-11.

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

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

FIGURE 7-9.

FAM0710

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

Dump Body Assembly

7-5

FIGURE 7-12.

FIGURE 7-14.

FIGURE 7-15.

FIGURE 7-13.

FIGURE 7-16.

7-6

Dump Body Assembly

FAM0710

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

FIGURE 7-17.

FIGURE 7-19.

FIGURE 7-18.

FIGURE 7-20.

FAM0710

Dump Body Assembly

7-7

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

7. Install any optional equipment such as body liners and side boards (Figure 7-22).

8. Clean the weld joints and paint.

FIGURE 7-21.

7-8

Dump Body Assembly

FAM0710

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

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

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

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

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

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

FAM0811

Final Assembly

Page 8-1

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

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

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

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

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

4. Install cap screw (1) through the pin and tighten nut (2) to 407 N¡m (300 ft lb). Use washers, as necessary on the nut side only, to provide proper thread contact.

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

Page 8-2

Final Assembly

FAM0811

FIGURE 8-1.

FIGURE 8-2.

FAM0811

Final Assembly

Page 8-3

FIGURE 8-3.

Page 8-4

Final Assembly

FAM0811

FIGURE 8-4. DUMP BODY PIVOT PIN 1. Cap Screw 2. Lock Nut 3. Body Pivot Pin 4. Body Ear 5. Body Pivot Bushing

FAM0811

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

Final Assembly

Page 8-5

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

Install the pin retaining cap screws and nuts. Tighten to 407 N¡m (300 ft lbs).

Page 8-6

Final Assembly

FAM0811

FIGURE 8-5.

FIGURE 8-6. HOIST CYLINDER UPPER MOUNT 1. Dump Body 3. Hoist Cylinder 2. Hoist Cylinder Pin 4. Pin Retainer

FAM0811

Final Assembly

Page 8-7

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

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

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

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

Page 8-8

Final Assembly

FAM0811

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

FAM0811

Final Assembly

Page 8-9

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

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

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

Page 8-10

Final Assembly

FAM0811

FIGURE 8-8.

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

3. Stop Block 4. Mounting Bracket

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

FAM0811

Final Assembly

Page 8-11

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

Page 8-12

Final Assembly

FAM0811

FIGURE 8-11.

FIGURE 8-12.

FAM0811

Final Assembly

Page 8-13

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

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

Page 8-14

Final Assembly

FAM0811

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

FAM0811

3. Body Guide Wear Plates

Final Assembly

Page 8-15

12. Adjust the body up limit switch.

Adjust the switch bracket to maintain an air gap between the sensing area and target of 12.7 mm (0.50 in.) to 15.7 mm (0.62 in.). Adjust the switch to cover the bottom 53.8 mm (2.12 in.) of the target. Secure the components in place.

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

Page 8-16

Final Assembly

FAM0811

FIGURE 8-14. BODY-UP SWITCH ADJUSTMENT

FAM0811

Final Assembly

Page 8-17

14. Install the exhaust system piping and hangers. The deck mounted muffler exhaust is shown Figure 8-15.

Refer to the installation prints for other optional exhaust systems.

Page 8-18

Final Assembly

FAM0811

FIGURE 8-15.

FAM0811

Final Assembly

Page 8-19

15. With the body in the raised position, adjust the body hoist limit switch. Position the target so that it covers the entire switch sensing area. Adjust the gap between the target and the switch to 12.7 - 14.7 mm (0.50 - 0.58 in.). Secure the target into position.

The switch should activate 152 mm (6 in.) before maximum cylinder stroke.

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

Page 8-20

Final Assembly

FAM0811

FIGURE 8-16.

FIGURE 8-17.

FAM0811

Final Assembly

Page 8-21

17. Install add-on components such as the lubrication system. Verify that all electrical and hydraulic connections are correct. Refer to Figure 8-19.

FIGURE 8-18.

Page 8-22

Final Assembly

FAM0811

FIGURE 8-19.

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

FAM0811

13. R.H. Anti-Sway Bar Bearing 14. R.H. Suspension, Top Bearing 15. Truck Frame 16. Vent Hose 17. Pipe Plug (Oil Level) 18. Pressure Switch, N.O., 17 237 kPa (2500 psi) 19. Grease Pump 20. Vent Valve 21. Filter 22. Grease Supply to Injectors 23. Injectors 24. Pressure Switch, N.O., 13 790 kPa (2000 psi)

Final Assembly

Page 8-23

18. Install the fire system. Refer to Figures 8-20 & 8-21.

This installation is normally performed by the fire system distributor.

Page 8-24

Final Assembly

FAM0811

FIGURE 8-20.

FIGURE 8-21.

FAM0811

Final Assembly

Page 8-25

19. Paint the truck as needed.

20. Install the anti-skid strips at the designated areas on the decks (Figure 8-22).

21. Install all decals on their designated areas (Figure 8-23).

Page 8-26

Final Assembly

FAM0811

FIGURE 8-22.

FIGURE 8-23.

FAM0811

Final Assembly

Page 8-27

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

Check all hydraulic lines and electrical connections for secure installation.

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

Page 8-28

Final Assembly

FAM0811

FIGURE 8-24.

FAM0811

Final Assembly

Page 8-29

NOTES

Page 8-30

Final Assembly

FAM0811

FINAL CHECKOUT Final checkout requires truck operation.

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

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

1. Complete delivery and warranty forms.

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

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

FAM0903

4. Purge any 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.

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

Final Checkout

Page 9-1

NOTES

Page 9-2

Final Checkout

FAM0903

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

1. Lubrication Chart - WB2790 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 - EL2603 8. Brake Checkout Procedure - EL6704 9. VHMS Checkout Procedure - EK8480

10. Payload Meter III Checkout Procedure - EJ3061

11. Electrical Checkout Procedure - EF9650

12. Standard Torque Charts and Conversion Tables

13. Field Assembly Inspection Report

14. 50 Hour Post Commissioning Checksheet

FAM1007

Appendix

Page 10-1

NOTES

Page 10-2

Appendix

FAM1007

LUBRICATION CHART

NOTES

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

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

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

®

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

Proper charging of HYDRAIR®II suspensions requires that three basic conditions be established in the following order: 1. Oil level must be correct.

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

3. Nitrogen charge pressure must be correct.

5/08

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

NOTE: For longer life of suspension components, a Friction Modifier should be added to the suspension oil. See Specifications Chart, Figure 4-5 at the end of this chapter.

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

EQUIPMENT LIST •

HYDRAIR® Charging Kit

•

Jacks and/or Overhead Crane

•

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

•

HYDRAIR® Oil (See Specifications Chart)

•

Friction Modifier (See Specifications Chart)

•

Dry Nitrogen (See Specifications Chart)

HYDRAIR® CHARGING KIT Assemble service kit as shown in Figure 4-1 and attach to container of pure dry nitrogen (8).

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

2. Turn "T" handles (1, Figure 4-1) of adapters (2) completely counterclockwise.

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

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

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

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

7. Open both outlet valves (3).

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

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

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

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

4. Tighten swivel nut (small hex) on charging valve. If a new charging valve is being used, tighten swivel nut to 14.2 N·m (10.5 ft lbs) torque, then loosen and retighten swivel nut to 14.2 N·m (10.5 ft lbs) torque. Again loosen swivel nut and retighten to 5.4 N·m (4 ft lbs) torque. Replace valve cap (1) and tighten to 3.3 N·m (2.5 ft lbs) torque (finger tight).

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

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

5/08

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

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

Exposed piston rod extensions are specified for both oil level and nitrogen charging for HYDRAIRÂŽII suspensions. These dimensions are listed in the Tables below Figures 4-2 and 4-4. Measure dimensions from the face of the cylinder gland to the machined surface on the spindle at the front suspension. Measure from the face of the cylinder gland to the piston flange at the rear suspension.

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

FRONT SUSPENSION 1. Park the unloaded truck on a hard, level surface. Place the directional control lever in PARK. Place chock in front and behind two sets of wheels to prevent roll away.

NOTE: Do not place wheel chocks around front tires.

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

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

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

Front Suspension Oiling

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

NOTE: For longer life of suspension components, a Friction Modifier should be added to the suspension oil. See Specifications Chart, Figure 4-5 at the end of this chapter.

5/08

1. Position and secure oiling height dimension blocks in place (Figure 4-2). When nitrogen pressure is released, suspensions will lower to rest on the blocks. Ensure the blocks do not mar or scratch the plated surfaces of the pistons or damage wiper seals in the lower bearing retainer. Support blocks must seat on the spindle and the cylinder housing. The blocks should be positioned 180° apart to provide stability.

Wear a face mask or goggles while relieving nitrogen pressure.

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

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

FIGURE 4-2. FRONT SUSPENSION

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

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

FRONT SUSPENSION DIMENSIONS (EMPTY) TRUCK MODEL & OPTIONS

OILING HEIGHT mm (IN.)

CHARGING HEIGHT mm (IN.)

CHARGING PRESSURE kPa (psi)

830E*

25.4 (1.0)

229 (9.0)

2689 (390)

830E**

25.4 (1.0)

229 (9.0)

2827 (410)

* with standard Rock Body ** with Combination Body / Tailgate Note: If truck starts to lift off blocks before charging pressure is attained, STOP CHARGING.

5/08

Front Suspension Nitrogen Charging

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

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

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

2. Tighten valve body (large hex, 6) to 16.5 ft lbs (22.4 N·m) torque. The valve swivel nut (small hex, 4) must be unseated by turning counterclockwise three full turns.

Dry nitrogen is the only gas approved for use in HYDRAIR®II suspensions.Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in chart (Figure 4-5).

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

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

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

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

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

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

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

7. Open inlet valve (4) until the pressure has dropped below the pressure listed in Figure 4-2, and then close the valve.

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

5/08

9. Charge the suspensions to the pressure listed in Figure 4-2. DO NOT use an overcharge of nitrogen to lift the suspensions off of the charging blocks.

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

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

11. Close outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit. 12. If charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs) torque.

13. If a new charging valve is being used, tighten swivel nut to 14.2 N·m (10.5 ft lbs) torque, then loosen and retighten swivel nut to 14.2 N·m (10.5 ft lbs) torque. Again loosen swivel nut and retighten to 5.4 N·m (4 ft lbs) torque. Replace valve cap (1) and tighten to 3.3 N·m (2.5 ft lbs) torque (finger tight).

14. Install protective guard over charging valve.

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

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

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

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

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

NOTE: Do not place wheel chocks around front tires.

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

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

When the blocks are in place on a suspension, they must be secured in place with a strap or other means to insure the blocks staying in place while being used. An unsecured block could fly loose as weight is applied, presenting the possibility of serious injury and/or damage.

NOTE: For longer life of suspension components, a Friction Modifier must be added to the suspension oil. See Specifications Chart, Figure 4-5 at the end of this chapter.

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

5/08

Rear Suspension Oiling 1. If the suspensions are extended, position and secure oiling height dimension blocks (supports) in place (See Figure 4-4) so the blocks are seated between the piston flange and the cylinder housing. Ensure the blocks do not mar or scratch the plated surfaces on the piston or damage the wiper seals in the cylinder barrel.

Support blocks must seat on the piston flange and the cylinder housing. The blocks should be positioned 180° apart to provide stability.

REAR SUSPENSION DIMENSIONS (EMPTY) TRUCK MODEL & OPTIONS

OILING HEIGHT mm (IN.)

CHARGING HEIGHT mm (IN.)

*CHARGING PRESSURE kPa (psi)

830E

25.4 (1.0)

241 (9.5)

1724 (250)

830E

25.4 (1.0)

241 (9.5)

2172 (315)

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

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

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

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

4. Use a plastic tube to help bleed off trapped air inside the piston. Remove vent plugs and the bleeder screw. Service the suspension with clean HYDRAIRÂŽ Oil (with 6% friction modifier) until clean oil comes out of the port where the bleeder screw and plug were removed from the side of the housing. Drip pans should be used and all spillage cleaned from the outside of the suspension. Install the bleeder and vent plugs.

Continue to fill the oil until it reaches the fill port.

Allow the suspension to stand for at least 15 minutes to clear any trapped nitrogen and/or air bubbles from the oil. Add oil if necessary, and install the fill plug.

5/08

FIGURE 4-4. REAR SUSPENSION

Rear Suspension Nitrogen Charging

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

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

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

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

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

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

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

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

2. Tighten valve body (large hex, 6) to 22.4 N·m (16.5 ft lbs) torque. The valve swivel nut (small hex, 4) must be unseated by turning counterclockwise three full turns.

Dry nitrogen is the only gas approved for use in HYDRAIR®II suspensions. Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities, serious injuries and/or major property damage. Use only nitrogen gas meeting the specifications shown in chart (Figure 4-5).

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

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

8. Close outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit. 9. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs) torque.

10. If a new charging valve is being used, tighten swivel nut to 14.2 N·m (10.5 ft lbs) torque, then loosen and retighten the swivel nut to 14.2 N·m (10.5 ft lbs) torque. Again, loosen the swivel nut and retighten to 5.4 N·m (4 ft lbs) torque.

Replace valve cap (1) and tighten to 3.3 N·m (2.5 ft lbs) torque (finger tight).

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

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

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

5/08

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

-30°F & above (-34.5°C & above)

Part No.

Approved Sources

VJ3911 (need to add 6% of AK3761)

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

AK4063

Suspension Oil (premixed with 6% Friction Modifier)

AK4064

-55°F & above (-48.5°C & above)

5 Gallon container 55 Gallon container

VJ5925 (need to add 6% of AK3761)

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

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

AK4065

Suspension Oil (premixed with 6% Friction Modifier)

5 Gallon container

AK4066

55 Gallon container

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

FRICTION MODIFIER

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

Part Number

Suspension Oil

Amount of Friction Modifier to add

AK3761 (5 Gallon container of 100% Friction Modifier)

1 gallon of suspension oil

add 7.7 oz.

5 gallons of suspension oil

add 38.4 oz.

55 gallons of suspension oil

add 3.3 gal.

NITROGEN GAS (N2)SPECIFICATIONS HYDRAIR®

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

Property

Value

Nitrogen

99.9% Minimum

Water

32 PPM Maximum

Dew Point

-68°F (-55°C) Maximum

Oxygen

0.1% Maximum

FIGURE 4-5. SPECIFICATIONS CHART

5/08

NOTES

5/08

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

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

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

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

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

3658 mm (144.0 in.)

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

5. When the adjustment is complete, tighten the locknuts on the tie rod to 420 ± 42 N·m (310 ± 31 ft lb).

6. Remove the wheel chocks from the rear wheels.

FIGURE 3-1. MEASURING TOE-IN

NOTES

AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE GREASE REQUIREMENTS Grease requirements will depend on ambient temperatures encountered during truck operation: •

Above 32°C (90°F) - Use multipurpose grease (MPG).

NLGI

No.2

•

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

•

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

PUMP HOUSING OIL The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level every 1000 hours. To add oil, remove oil level plug (4, Figure 3-2) and fill the housing to the bottom of the plug hole.

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

1. Fill lube reservoir with lubricant, if necessary.

2. To purge air from the main supply line, remove the main supply line at the canister 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 grease appears at the group of injectors and re-install the pipe plug. Repeat for remaining injector groups.

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

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. Manual Override Switch

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

PRESSURE AND FLOW CONTROL High pressure hydraulic fluid from the truck steering system is reduced to 2 240 to 2 413 kPa (325 to 350 psi) by pressure reducing valve (4, Figure 3-1) located on the manifold on top of the pump motor.

This pressure can be observed on the gauge installed on the manifold. Occasionally check to verify that pressure is within the above limits. The pressure reducing valve is factory adjusted. DO NOT tamper with this setting.

Flow control valve (5) controls oil flow through the pump. The valve is factory adjusted to 2.5 gpm (9.5 L/min.). DO NOT tamper with this setting.

SYSTEM CHECKOUT To check system operation (not including timer), proceed as follows: 1. Turn key switch ON and start the engine.

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

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

4. Once the required pressure is reached, the pump motor should turn off and the system should vent.

5. Check for pump, hose or injector damage or leakage with the system pressurized.

FIGURE 3-2. PUMP CONTROLS 3. Pressure Gauge 1. Pressure Reducing 4. Oil Level Plug Valve 2. Manual Override Switch 5. Flow Control Valve (Test)

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

Repair the lube system as necessary.

PREVENTATIVE MAINTENANCE PROCEDURES The following maintenance procedures should be used to insure 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-today operations. •

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

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

3. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points. a. Repair or replace all damaged feed line hoses. b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service.

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

250 Hour Inspection 1. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points (see, Figure 31). a. Repair or replace all worn / broken feed line hoses. b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service.

2. Check all grease supply line hoses from the pump to the SL-1 injectors.

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

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

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.

5. System Checkout a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation. b. Start truck engine. c. Actuate the manual override switch (6, Figure 3-1). The hydraulic motor and grease pump should operate. d. With the grease under pressure, check each SL-1 injector assembly. The cycle indicator pin should be retracted inside the injector body. e. When the system attains 17,237 kPa (2500 psi), the pump should shut off and 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 timer operation.

NOTE: With engine running, lube system should activate within 5 minutes. The system should build 13,790 to17,237 kPa (2000 to 2500 psi) within 25-40 seconds.

a. Repair or replace all worn / broken supply lines. b. Make sure that all air is purged and all new supply line hoses are filled with grease before sending the truck back into service.

3. Check grease reservoir level.

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

a. Fill reservoir if low. b. Check reservoir for contaminants. Clean, if required.

1000 Hour Inspection 1. Check pump housing oil level and correct if necessary.

NOTES

NOTES:

NOTES:

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CHECKOUT PROCEDURE

IEL6704-0 PaQe 1 of 8

NAME: BRAKE SYSTEM CHECKOUT

WRITTEN Mike RabasBY:

MACHINE & MODEL: 830E wi Rear Combo Brake

~:04/08/05 DATE: 5/~/ClS" DATE:

~I )/0 \ Necessarv

DASH A SIZE

Eauipment:

1. Checkout procedure and hydraulic system schematic.

2. Accumulator charging outfit with good gauges and either K type bottles of dry nitrogen or T type bottles with a gas intensifier.

3. Clear plastic hose and bucket for bleeding brakes or simulators of air.

4. If truck is only partially assembled and this checkout is to be done without brakes installed, brake simulators are required in order to simulate the brake volume.

5. At least 3 calibrated gauges with quick-disconnect couplings, capable of measuring up to 5000 PSI.

Assumptions: 1. All components used within the brake system are to specification.

2. Any parts that do not function as described, will be replaced or adjusted.

Note: Notify Quality Control Department for problems or to obtain adjusting procedures for individual components.

3. The hydraulic source for the brake system (the steering system) is in proper operation and the compensator has been adjusted.

Note: Refer to steering and hoist for check-out procedures and specifications.

WARNING! Block wheels of truck to prevent a possible rollaway BEFORE performing this procedure

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IEL6704-0 PaQe 2 of 8

Brake Accumulators Precharae Note: Permanent damage to bladder accumulators will result if the engine is started without the accumulators being properly precharged Note: Use only dry Nitrogen to precharge accumulators Note: Precharge rates of all bladder accumulators must follow details in step (c) or permanent damage to bladders will result a. Open both needle valves in brake cabinet to vent oil side of all brake accumulators to tank. This will also vent the oil side of the front steering accumulator to tank.

CAUTION!

The rear steerina accumulator is not vented to tank thru the opened needlevalves! b. Be certain that hydraulic pressure is relieved from the steering system by activating the bleed down solenoid. The solenoid will vent the rear steering accumulator to tank since it is not vented when the needle valves are opened in step (a). c. Accumulators are to be precharged only with dry Nitrogen as follows: I. Check Nitrogen precharge of each accumulator. The precharge pressure of each brake accumulator should be 1400 PSI. Follow Steps II, III and IV below for each accumulator.

Note:

Precharge Pressure is 1400 PSI at 70 degrees (F) II. If the precharge is below 100 PSI, The accumulator's bladder will not be fully expanded. To fully expand the bladder precharge must be slowly applied. To do this, set the regulator 25 PSI above the pressure measured in step I. Slowly increase precharge pressure to the regulator setting so that it takes 3 minutes to initially increase the precharge pressure 25 PSI Note: Failure to add Nitrogen precharge slowly at the rate listed above will result in permanent damage to the accumulator's bladder

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IEL6704-0 PaQe 3 of 8

If the precharge pressure is still below 100 PSI after adding the additional Nitrogen at the rate listed above, slowly raise the precharge pressure until 100 PSI is obtained.

Once the pressure is above 100 PSI, follow step III. III. If the precharge pressure is 100 PSI or above, the accumulator bladder is fully expanded and the precharging rate can be safely increased until 1400 PSI is reached. Allow the precharge to set for 15 minutes. Adjust the precharge pressure to 1400 PSI as necessary.

IV. * Record Final precharqe pressure for each Brake Accumulator

Initial System Set Up: 1. Install pressure measuring instruments at: a. Test Port BR (Brake Cabinet) b. Test Port BF (Brake Cabinet) c. Test Port LAP1 (Brake Manifold) 2. Close both brake accumulator bleed down valves. If brakes have not been assembled to truck when checkout is performed, attach a brake simulator to each brake application line.

3. * Start engine to fill accumulators with oil. Observe rising brake pressures as system charges. Brake pressure should begin to fall when the AUTO APPLY valve releases.

The brake pressures when AUTO APPLY releases should be approximately 2100 +/- 100 PSI front and 1580 +/-75 PSI rear. Record the brake pressures when AUTO APPLY releases (BR & BF).

4. Partially depress brake pedal and bleed air from each brake or brake simulator.

* Asterisk denotes item to be recorded

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IEL6704-0 Page 4 of 8

Parkina Brake Note: Move one of the pressure measuring instruments from either the BR or BF locations to the park brake test port (PK2) on the Brake Manifold.

5. * Apply BRAKE LOCK. Release parking brake with PARK BRAKE switch. Verify that PARK BRAKE Status Lamp indicates that the parking brake is released. Record parkinq brake release pressure. (pressure should be 2500 :t 100 PSI) 6. Cycle PARK BRAKE switches several times to assure crisp applications and release of pressure and proper function of status light.

7. Apply PARKING BRAKE and release BRAKE LOCK

Service Brake Note:

Return the pressure measuring device to the port (BRor BF)from which it was

removed

8. Slowly depress brake pedal. Rear Brake pressure should begin to rise before the Front Brake Pressure. Rear Brake Pressure should be between 45 and 205 PSI when the Front Brake Pressure begins to rise. Force feedback of pedal on foot should be smooth with no abnormal noise or mechanical roughness.

9. * Slowly depress brake pedal and record the rear brake pressure (BR) at which the stop lights energize. Record Rear Brake Pressure (BR). (This pressure should be 75 :t 5 PSI.).

10. * Quickly and completely depress pedal and check to see that front brake pressure is 3000 :t 150 PSI (BF) and that the rear brake pressure is 1580 :t 75 PSI (BR) within 1 second. Holding pedal fully applied, both pressures should remain above their minimum values for a minimum of 20 seconds. Record Front and Rear Brake pressures (BF and_BR).

11. * Release pedal. Brake pressure should return to zero within two seconds and there should be no residual pressure trapped in brakes. Record Front and Rear Brake pressures (~ and B~

* Asterisk denotes item to be recorded

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IEL6704-0 PaQe 5 of 8

BRAKE LOCK/Secondary 12. Disconnect lead wire on BRAKE LOCK solenoid, located on brake manifold in hydraulic cabinet and to the immediate right of the PK2 port. Install jumper to connect lead wires to timer

13.* Apply BRAKE LOCK. BRAKE LOCK pressure degradation switch should sound warning buzzer. Depress brake pedal until warning stops and then very slowly release pedal until warning resumes. Record Rear Brake pressure (BR) when warninq resumes.

Note: BRAKE LOCK degradation switch should trigger when BR pressure drops to 1000 :t 25 PSI, however, there is a two second delay between the time the switch makes and the lamp/buzzer activates.

14. Connect lead wire on BRAKE LOCK solenoid.

15. * Cycle BRAKE LOCK several times to assure crisp application of and release of pressure and proper function of status light. Record rear brake pressure (BR) (BRAKE LOCK pressure should be 1500::!: 100 PSI.)

Low Brake Pressure and AUTO APPLY 16. Allow engine to run until/ow brake accumulator pressure stabilizes at or above 3200 PSI. 17. * Shut engine down. Allow the steering accumulators to bleed completely down.

Disable steering pressure switch from the brake warning circuit by unplugging the diode between circuits 33 and 33F. Turn key switch on. After 2 minutes, record the low accumulator pressure, (LAP1 port) If LAP1 pressure is below 2600 PSI, then leakage in the system is excessive and the source of the leakage needs to be identified.

18. * Crack the front brake accumulator bleed down valve and observe LAP1 pressure.

The Low Brake Pressure Lamp and buzzer must actuate at 2300 ::!:75 PSI. Record this pressure (LAP1). Brake pressures should begin to rise (AUTO APPLY) when LAP1 reaches 2100::!:100PSI. Record the LAP1 pressure. the Front Brake pressure and the Rear Brake pressure (BR). Close front brake accumulator bleed down valve.

m 19. Start engine to recharge hydraulic system. Allow engine to run until low brake accumulator pressure stabilizes at or above 3200 PSI. * Asterisk denotes item to be recorded

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IEL6704-0 Page 6 of 8

20. Shut engine down. Allow the steering accumulators to bleed completely down. Turn key switch on. Crack the rear brake accumulator bleed down valve and observe LAP1 pressure. Verify that the Low Brake Pressure Lamp and buzzer, and AUTO APPLY set point are within 100 PSI of those recorded in Step 18. Record the LAP1 pressures for Low Brake Pressure Lamp& Buzzer. LAP1 pressure for AUTO APPLY, the Front Brake pressure and the Rear Brake pressure (BR). Close the rear brake accumulator bleed down valve.

21. Enable the steering pressure switch by plugging in the diode removed between circuits 33 and 33F. Reapplications 22. Start engine to recharge hydraulic system. Allow engine to run until low brake accumulator pressure stabilizes at or above 3200PSI. 23. * Shut engine down. Do not allow steering accumulator to bleed down. Make repeated slow, complete brake applications with pedal until Low Brake Pressure warning comes on. Record the number of brake applications prior to Low Brake Pressure warninq.

Low Brake Pressure warning must not actuate prior to the sixth pedal application.

AUTO APPLY must not occur until after Low Brake Pressure warning.

24. Shut engine down and turn off keyswitch. Open each brake accumulator bleed down valve. Remove all instrumentation and simulators. Close Brake accumulator bleed down valve. This concludes the brake system checkout.

* Asterisk denotes item to be recorded

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IEL6704-o PaQ8 7 of 8

830E- wI Rear Combo Brake Hydraulic Brake System Checkout Data Sheet ACCUMULATORPRECHARGE Step c -IV

Front Brake Accumulator Precharge Pressure Rear Brake Accumulator Precharge Pressure

Initial System Set Up: Step 3

Rear brake (BR) pressure when AUTO APPLY releases.

Front brake (BF) pressure when AUTO APPLY releases.

Parkina Brake System Step 5

Parking brake release pressure.

Service Brake System Step 9

Rear brake (BR) pressure when stop lights energize.

Step 10

Rear brake (BR) pressure (pedal applied).

Front brake (BF) pressure (pedal applied).

Step 11

Rear brake pressure (pedal released).

Front brake pressure (pedal released).

BRAKE LOCK/Secondarv System Step 13

Rear Brake (BR) pressure when brake degradation fault occurs.

Step 15

Rear Brake (BR) pressure when BRAKE LOCK is applied.

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IEL6704-0 Page 8 of 8

Low Brake Pressure and AUTO APPLY Step 17

LAP1 pressure after 2 minutes.

Step 18

LAP1 pressure when Low Brake Pressure Lamp and Buzzer activate.

LAP1 pressure when AUTO APPLY occurs.

Front brake apply (BF) pressure after AUTO APPLY Rear brake apply (BR) pressure after AUTO APPLY

Step 20

LAP1 pressure when AUTO APPLY occurs.

Front brake apply (BF) pressure after AUTO APPLY Rear brake apply (BR) pressure after AUTO APPLY

Reapplications Step 23

Machine

Number of applications prior to Low Brake Pressure Lamp and Buzzer activating.

Unit No.

SIN

Name of Mechanic or Inspector doing Check Out

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CHECKOUT PROCEDURE I

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NAME: VHMS System Checkout Procedure WRITTEN BY:

MACHINE & MODEL: 930E, 960E, 830E

DATE:

07/17/04 CHECKED BY:

DATE:

APPROVED G. Horst

DATE:

BY:

1 0 DASH A SIZE

INTEGRATED INTERFACEMODULECHECKOUT 8/18/04 \\\"'\4 NEWRELEASE DATE ECN DESCRIPTION OFCHANGE MICROFILM

I I I I I I I I I I I I I

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BY

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Structure and purpose: This procedure is in two parts. The first part verifies the installation of the VHMScontroller,The Interface module, the OrbComm communicator, the sensors, and all associated wiring.

The second part ofthe procedure setsup VHMSfor time of day, time zone, fault,trendand payloaddata transmission,and OrbCommcommunicationsettings.

Preliminarv procedures (can be done before ac~nstallationt 1. WebCARE Machine registration must be completed. Fill out the "WebCARE Machine registration request" (a copy is attached to this document) and FAX to the VHMSlWebCARE support team (FAX number is on the form).

2. The "Orbcomm activation request" must be completed (a copy is also attached to this document). If this is a field installation, one of the serial number stickers should be placed on the form (be sure to place the other on the Orbcomm modem itself). When complete, FAX the form to the KOMTRAX Service Hotline (FAX number is on the form).

It will take a week or two to complete this activation.

Necessarv Eauipment: 1.

Checkout procedure and system schematic.

2.

Laptop computer with VHMS PC software installed (VHMS Technical Analysis Toolbox), and VHMS Watcher software.

3.

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

4.

You will need the correct CGCDatcsv file for use with the specific truck model you are checking out This .csv file is used with the VHMS Watcher software to identify by name the input signals that the Interface Module (1M)sends to VHMS. Installina the CGCDat.csv File: 1.

The file names take this form: CGCDat930E.csv, CGCDat830E.csv, etc. They will be found in the same file folder as the VhmsWatcher.exe program.

2.

The active file is always named CGCDatcsv. If you have the wrong file active, you must rename it (OLDCGCDatcsv). Then make a copy of the correct file and change the copy's name to CGCDatcsv.

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

Application code must match the truck model for Interface Module installation.

Use EJ9098-1 software for 930E trucks and EL0355-0 software for 830E trucks.

Go to the Interface Module web site www.kac-peoria.com/interfacemodule/ to get the necessary files and instructions.

PLM3 NOTE Use the Payload Data Manager software to verify the PLM3 installed software.

PLM3 software EJ0575-3 or later is required for the Interface Module to properly acquire truck speed on model 830E and 930E trucks. Go to PLM3 web site, www.kac-peoria.com navload'for software and instructions.

PART 1 - Installation

and wirin(:l verification

CHECK FOR FAULT CODES ASSOCIATED WITH THE INTERFACE MODULE Look at a recent download (with the VHMS Technical Analysis Toolbox) and view fault history.

Confirm that there are no fault codes associated with the Interface Module. If any are found, these circuits should be analyzed to determine the cause of the fault and should be repaired.

CHECK INPUT TO THE INTERFACE MODULE Use the VHMS Watcher software.

1. Double click the shortcut VHMSWatcher on the Desktop screen. The program begins with a blank window. On the menu bar, there are five items: File, VHMS, Settings, Interaction, Help.

Only use the VHMS pull down menu.

2. Click on VHMS on the menu bar. A small menu pops up, showing two items: Read Table Data and Port Setting. Click Read Table Data.

3. Click VHMS on menu bar again, this time click Port Setting. A small window shows up to allow selection of Port Setting. Select the appropriate port (COM1,COM2), and select the baud rate to be 19.2K. 4. Click VHMS on menu bar again. Click Open Connection.

5. Click VHMS on menu bar again, click Start. A window will open as shown: m

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CHECKOUT PROCEDURE I

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IDOxc120: Seq# Ox2:Args Hello sent (rpc_senUnspector) IDOxfffe: Seq# Ox2: acked by receiver (rpc_ack_inspector) ID Oxfffd: Seq# OxO: sentto

COM.dll (rpc_tx_inspector)

ID Oxc121: Seq#OxO: Ver.11030100181

kind.930E:

Cold Start!

Ready

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We must see 4 lines of message like shown above, if 2 or 3 lines then it did not work. If it does not work, the problem is with serial communication (maybe the key switch is off, or the serial port is wrong, or is assigned to other software).

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6. Next, click VHMS item on menu bar again, when the menu pops up, this time click Regist&Display, then a screen like this will show up:

Iii BtaSelectMenu"

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CLOSE

301: 2 s: En9-Speed: rpm 0

301: 2 s: Eng_Speed: rpm 354: 2 s: Cool_Temp: degC

354: 2 s: Cool_Temp: degC

355: Eng_OilJemp 385:AmblenCair _temp 386: Blow_by-press 387: Eng_oil-press 388: Boost-press 389: Exh_gas_temp 500: FueUnjection 501: Ave_Min_ldle_On 502:Auto_Lube_Sw 503: BatC 12V_A 504: BatU 2V_B 505: BatU 2V- C

0

0 Delete 0

0 START/STOP

12s

Sampling

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2:10PM

That is the main screen of the Watcher program. On the table list on the right, click to highlight the selected item we want to view the value, then click the "Add" bar. The selected item will show up in the 6 slots on the left of the screen (so we can view up to 6 items at a time). The screen shows an example when only two items are selected to view: Eng_Speed and CooL Temp. After finishing selecting items to view, click on the START/STOP button, the values of the items will show up. This button is like a toggle switch, click it a second time, then the data capture is disabled. When 6 items are selected, to view another item, we have to remove one item by clicking the Delete button, then repeat the process of Add a new item to view. Remember, before Delete, need to click the START/STOP button, so that the data capture is disabled, after removing an item and replacing with a new item by ADD, need to click the START/STOP button again to enable data capture. m

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CHECKOUT PROCEDURE I

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For all trucks: 1. Ambient Air Temperature - should read close to actual ambient. (Ambient air temp 385) 2. Steering Pressure - Insert 1330 :t20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Steer Press 574) 3. BrakePressure- Insert1330:t20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Brake_Press 515) 4. HoistPressure1 - Insert1330:t20 ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Hoist_Press_1 529) 5. Hoist Pressure 2 - Insert 1330 :1:20ohm resistor in place of the sensor and read 12140 :t1000 kPa. (Hoist_Press_2 530) 6. Pump Filter Switches - short wire 39 to ground at the switches for 3 seconds and confirm state change (zero to one). (Pump_Filter_Sw 559) 7. Low Steering Precharge - short wire 51A to ground at the switches and confirm state change (zero to one). The warning state should be sustained until the key switch is turned off and back on. (Low_Str_Precharg_Sw 538) 8. Hydraulic Tank Level- disconnect wire 34L from tank probe and confirm state change (zero to one). (Hydraulic_Level 532) 9. Auto Lube Switch - short wire 68LLP1 to ground at RB6 (830E models) or RB7 (930E models) or at the Lincoln Lube Timer (960E models) for and confirm state change (zero to one). The warning state should be sustained until the key switch is turned off and back on.

(Auto_Lube 502) For 930E and 960E GE trucks, but not 830E trucks: 1. Brake Oil Temperature RR - confirm as being near ambient on a cold truck. (564) 2. Brake Oil Temperature LR - confirm as being near ambient on a cold truck. (536) 3. Brake Oil Temperature RF - confirm as being near ambient on a cold truck. (563) 4. Brake Oil Temperature LF - confirm as being near ambient on a cold truck. (535) 5. No Propel/Retard - short wire 75-6P to ground at TB26-C momentarily and confirm state change (zero to one).

6. No Propel - short wire 75NP to ground at TB25-P momentarily and confirm state change (zero to one).

7. Propel System Caution - short wire 79W to ground at TB26-D momentarily and confirm state change (zero to one).

8. Propel System Temp Caution - short wire 34TW to ground at TB26-B momentarily and confirm state change (zero to one).

9. Propel System Reduced Level - short wire 72LP to ground at TB25-W momentarily and confirm state change (zero to one).

10. Reduced Retard - short wire 76LR to ground at TB25-T momentarily and confirm state change (zero to one). m ,;: CO ~ CO QI ~ Page 5 of 15

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CHECKOUT PROCEDURE I

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For 830E trucks only: 1.

2.

3.

4.

5.

6.

Hydraulic Tank Temperature (RR Hydraulic Oil Temp on VHMS Watcher) - confirm as being near ambient on a cold truck. (564) Motor Temperature High - short wire 722L to ground at TB21E-B momentarily and confirm state change (zero to one). (558) Motor Blower Off - short wire 32B to ground at TB21E-E momentarily and confirm state change (zero to one). (555) Diode Fault - short wire 79VD to ground at TB21D-G momentarily and confirm state change (zero to one). (551) Electric Drive System Fault - short wire 79VS to ground at TB21D-E momentarily and confirm state change (zero to one). (516) Ground Fault - short wire 79VG to ground at TB21D-F momentarily and confirm state change (zero to one). (557)

For 960E trucks only: 1.

Park Brake Set Switch - with engine running, toggle Park Brake Switch and confirm state change (zero to one).

2. Engine Speed 1M- with engine running observe reported speed.

3. Vehicle Speed - observe reported speed while testing the speedometer with the GE DID panel. Set to 20 mph and observe 20mph on speedometer as well as within VHMS. 4. Battery 12V A - check with batteries fully charged or being charged. Voltage should be about 12 volts.

5. Battery 12V B - check with batteries fully charged or being charged. Voltage should be about 12 volts.

6. Battery 12V C - check with batteries fully charged or being charged. Voltage should be about 12 volts.

CHECK OUTPUTS FROM THE INTERFACE MODULE For 830E only: 1. Check the High Hydraulic Temperature Lamp by pressing the lamp test rocker switch. The lamp should light.

For 930E and 960E: 1. Check the output of Brake Cooling RPM Advance 1, Brake Cooling RPM Advance 2, Brake Oil Temperature Gauge (930E only), and High Brake Oil Temp Lamp by placing a 169 ohm resistor (a range of 1520 to 1860 should work) in place of any of the four input temperature probes.

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CHECKOUT PROCEDURE I

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2.

3.

4.

5.

6.

7.

8.

9.

Brake Cooling RPM Advance 1 should go to 24 volts (check at TB40-B).

Brake Cooling RPM Advance 2 should go to 24 volts (check at TB40-C).

The Brake Oil Temperature Gauge (930E only) should read near the middle of the red band.

The High Brake Oil Temp light should come on.

If the output functions do not turn on, read the value of the temperature for the selected input in VHMS Watcher. It should be between 126 and 140 C. If the temperature reading is low check wiring for high resistance between the probe and Interface Module.

If the temperature reading is high check for shorts in the wiring.

It the temperature is in the right range but the output functions do not work, check the Interface Module output circuit and wiring associated with any non-working function.

For 960E only: Actuate and hold the lamp test switch in the operator's cab. The following lamps are driven by the Interface Module and should come on (along with all the other lamps): 1. Park Brake Lamp 2. Low Fuel Lamp 3. Batt Charge Alt Failure Lamp 4. 1MWarning Lamp 5. High Brake Oil Temp Lamp

The functionality of the Fuel Level output can be confirmed by observing the needle position of the gauge when the low fuel lamp comes on.

1.

2.

3.

Dismount the sending unit only from the tank and position the gauge to a low level with a screwdriver. The shaft of the screwdriver will turn this magnetically coupled sending unit to any position you desire.

Set the gauge to empty. After 15 seconds, the Low Fuel Light should come on.

Return the gauge to the approximate position of the actual fuel in the tank before remounting it.

The Park Brake Solenoid and Brake Apply output can be checked with the following procedure.

1. Turn parking brake off. Park brake valve should be energized and brake auto apply valve should not. Energization of these valves can be determined by checking voltage across the valves or check for magnetism in the valve with a screwdriver.

2. Use the GE DID panel to set the truck speed to some elevated value such as is used to calibrate the speedometer. The park brake valve should continue to be energized. The auto apply valve should continue to be off.

3. With the truck speed signal still high, turn the park brake on. The park brake valve should m continue to be energized, and the auto apply valve should stay off.

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4.

Now remove the high truck speed signal. The auto apply valve should pulse on for about 1.5 seconds, and the park brake valve should turn off after the auto apply valve has been on for 1 second.

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PART 2 - VHMS setup VHMSCheckout and WebCARE ReQistration 1. It is vitally important that each item in the checkout procedure be checked-off before continuing on to the next.

2. The information recorded in form 3 at the back of this procedure will be needed for full registration and commission of VHMS. After completion of the form 3, Fax to the number indicated on the form.

3. Email thefilescreatedbyperformingaVHMSdownloadtowebcare@komatsu.co.jp

BeQin VHMS Checkout and Setup Key Switch off 1. Record the the following on Form 3: a. Truck serial number (item 2). b. VHMS box serial number (item 3). c. OrbComm box serial number (item 4).

2. Verify the seven segment LED display on the VHMS controller are off.

3. Disconnect the OrbComm antenna. (WebCARE must be ready to receive data before connecting the antenna.)

Key Switch on. DO NOT START Engine.

4. Watch the seven segment red LED display on the VHMS box. After a short time the display should start counting up. Verify and record (item 5) on Form 3.

5. Connect a lap top PC to the VHMS RS232 serial port.

6. Start the VHMS Setting Tool software.

7. Type the VHMS part number into the "Service 10"field. (If VHMS has test software installed enter "0".

8. Select "Data Clear & Setup" 9. Select EDIT and set the VHMS time of day clock. a. Fill in all entries in item 6 on Form 3. b. Enter the correct time zone. (the UTC or GMT setting) c. Select DST (Daylight Savings Time) if appropriate) 10.Set the truck model, type, variation, and serial number. Fill in all entries in item 7 on Form 3.

11.Set the engine serial number and record in item 8 on Form 3.

12.Select "Apply", accept the confirmation prompts, select no to the download data question and then select "Exit". Completely exit the Setting Tool program. Check YES to reboot the controller.

13.Restart the Setting Tool program.

14.Before entering the Service 10,activate the TEST mode by holding down the "ALT" key and m typing 'TEST". The heading "TEST" should appear at the top of 10 screen. " 15.Enter the Service 10field as in step 7 above.

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16.Select "Setup". (DO NOT select "Data Clear & Setup" this time.)

17.Hold down the "ALT" key and press "S". Set the service meter reading hours. (SMR). Record in Item 10 on Form 3.

18.Select "Apply" and accept the confirmation prompts.

19.Configure the OrbComm settings. Select "EDIT" in the Communication Settings window.

20.Set the file transfer settings as follows and record in Item 11 on Form 3.

Item Short Trend Analysis Short Load Map

Send ON ON

Short FaultHistory ShortPayloadmeter

ON ON

Occurrence Day

for PLM3 Short Brake Load Map

ON

SMR

Timer SMR SMR

Number 1

-

Interval 20 (SMR) 160 (SMR)

6 1

-

-

160

21. Set GCC (Ground Control Center) to the appropriate setting and record in item 12 on From 3 GCC code 1 120 121 122 123 130

Territory (country) USA ITALY MALAYSIA KOREA BRAZIL JAPAN

22.Check address boxes 1, 2 and 3 and record in item 12 on Form 3.

23.Select "Apply" and exit the Setting Tool program. Answer "YES" when prompted to reset the controller.

24.Start the Payload Data Manager program and select connect to the Payload Meter. (This can be done with the serial cable still connected to the VHMS data port.)

25.Set the PLM3 time of day and date to be the same as VHMS date and time. (:t2 minutes) Record item13 on From 3.

26. Exit the Payload Data Manager program.

Key Switch on. START Engine. Wait 30 seconds. Record item 14 on Form 3.

27. Press and hold the GE data store switch (this will trigger a VHMS Manual Snapshot) for 3 seconds, and then release. (The GE DataStore switch is located on the bottom rear of the console to the right of the driver's seat.) The white "Data Store in Progress" LED should light solid and bright. The LED may glow dim (not completely off) before the GE DatStore switch is pushed. The white LED will begin a slow flash after 5 minutes, then flash rapidly for 30 secorJOSm ~ co ~

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beginning at 7 minutes. Record proper operation of the manual data store in item 15 on Form 3 28.Wait until the Data Store in Progress LED has finished flashing. Wait another minute, then turn the key switch off and stop the engine. Record item 17 on Form 3.

Key Switch on. DO NOT START Engine. Record item 18 on Form 3.

29. Start the VHMS Technical Analysis Tool Box program. (user name = 'usr' and password = '1') 30.Select the Download icon and select the correct comm port when prompted, usually COM1.

31.Select "Connection" 32.Verify that the date & time displayed on the download screen are correct for the current local date/time and that the displayed Service Meter hours are equal to the value entered previously.

Record in item 19 Form 3.

33.Verify that a Manual Snapshot (MFAO)has been recorded. The display should show an item named 'Snapshot' with code MFAOand text "Manual Trigger". Record in item 20 on Form 3.

34.Select the 'Select All' option (from the bottom right of window) and perform a download. Record in item 21 on Form 3.

35.Verify that the 'Download Completed' message is displayed. Click on "exit". Record item 22 on Form 3.

36. From the Technical Analysis Tool Box launch the View program.

37. Find the data from the download performed in step 31. The data can be identified by the file name which has the date in which it was created. Select the correct file and click "OK".

38.Verify that a Manual Snapshot (MFAO)was recorded by selecting "Fault History" on the upper left corner of the screen. The MFAOfault should be recorded with the time of the manual snapshot and SMR hours entered previously.

39. Select the MACHINE HISTORY option from the list on the left side of the screen.

40.Verify that the Key ON/OFF and Engine ON/OFF records are recorded correctly.

41. Exit the VHMS Technical Analysis Toolboxsoftware. Record in item 23 on Form 3.

42. Start the Setting Tool program. Enter the Service ID field as in step 7 above.

43. Select the radio button labeled 'Setup and Clear'.

44.Accept all the current settings, then Apply and Exit. Record in item 24 on Form 3.

45. Record remaining items on Form 3 and Fax a copy of Form 3 to VHMS/WebCARE support center FAX: 81-3-5561-4766.

46. Email a copy of the download files to VHMSlWebCARE supoort center webcare@komatsu.co.jp. The files are found in folder C:\VHMS_DATA\930E\(truck serial number)\(date of download)\CHKOO01 47.Wait 24 hours. Reconnect the antenna.

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CHECKOUT PROCEDURE I

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To : VHMSlWebCARE support FAX: 81-3-5561-4766

WebCARE

machine

Ref. No. Date Name

team

registration

Fonn

request

( DB information] 1. Distributor name

2. Branch

3. Person

4. E-mail address

in Charge

"An

Name

5. DB code (GCPS)

[ Customer

information]

6. Customer

name

7. Site name

[ Machine information] 8. Model Name

9. Serial No.

10. Unit No. 11. Item to be registered in WebCARE. VHMS

.. Retro-klt Installed on new machine 0 0

PM Clinic

D

KUC

D

[ Orbcomm Activation] 12. Date of Orbcomm activation

[ Remark]

WebC.,ARE

.1

VHMS/WebCARE Support team TEL 81-3-5561-2765 FAX 81-3-5561-4766 E-mail webcare@komatsu.co.jp

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CHECKOUT PROCEDURE I

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TO: Customer support Gr.,Solution Div.,Komatsu Ltd. (KOMTRAX Service Hotline) Phone: +81-463-22-8780 Fax: +81-463-22-8448 Address: 3-25-1 Shinomiya, Hiratsuka-shi, kanagawa 2548555,Japan E-mail: cs_kom@komatsu.co.jp

I

Important

Request for Orbcomm Terminal Activation Please fill in the form below and fax or send by mail to Customer Support Gr., Kltd. to activate Orbcomm terminal.

Terminal Terminal Part Number

(Pleasefillin terminal PIN&S/Nor put on enclosedsticker here)

Terminal SIN

PIN:

Terminal Activation Date

(YY/MM/DD)

SIN: I

I

Country where used Machine Information

Model-Type-S/N#

Customer's Contact Address Company (or Plant) Phone Number

(Country-Area-number>

FAX Number

(Country. Area-number)

e-mail address Name (please print)

First Middle Family

Signature

Note: It will take one or two weeks to activate after being received this sheet.

Orbcomm terminal is unable to communicate before activation being completed.

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NOTES:

NOTES:

STANDARD TORQUE CHARTS AND CONVERSION TABLES This manual provides dual dimensioning for most specifications. U.S. standard units are specified first, with metric (SI) units in parentheses.

References throughout the manual to standard torques or other standard values will be to one of the following charts or tables. For values not shown in these charts or tables, standard conversion factors for most commonly used measurements are provided in TABLE XIII, page A5-6.

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

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

Grade 5

Cap Screw Thread Size

kg•m

1/4-20

7

1/4-28

8

5/16-18

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

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

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

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

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

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

TORQUE GRADE 5 ft lbs

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

EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values

TORQUE GRADE 8

Cap Screw Thread Size

Grade 8

TORQUE GRADE 5

TORQUE GRADE 8

N•m

ft lbs

kg•m

N•m

ft lbs

kg•m

N•m

ft lbs

kg•m

N•m

0.97

9.5

10

1.38

13.6

1.11

10.8

11

1.52

14.9

3/4-16

235

32.5

319

335

46.3

454

7/8-9

350

48.4

475

500

69.2

15

2.07

20.3

21

2.90

28

678

7/8-14

375

51.9

508

530

73.3

719

5/16-24

16

2.21

22

22

3.04

3/8-16

25

3.46

34

35

4.84

30

1.0-8

525

72.6

712

750

103.7

1017

47

1.0-12

560

77.4

759

790

109.3

3/8-24

30

4.15

41

40

1071

5.5

54

1.0-14

570

78.8

773

800

110.6

1085

7/16-14

40

5.5

54

7/16-20

45

6.2

61

58

8.0

79

1 1/8-7

650

89.9

881

1050

145

1424

62

8.57

84

1 1/8-12

700

96.8

949

1140

158

1546

1/2-13

65

9

88

90

12.4

122

1 1/4-7

910

125.9

1234

1480

205

2007

1/2-20

70

9.7

95

95

13.1

129

1 1/4-12

975

134.8

1322

1580

219

2142

9/16-12

90

12.4

122

125

17.3

169

1 3/8-6

1200

166

1627

1940

268

2630

9/16-18

95

13.1

129

135

18.7

183

1 3/8-12

1310

181

1776

2120

293

2874

5/8-11

125

17.3

169

175

24.2

237

1 1/2-6

1580

219

2142

2560

354

3471

5/8-18

135

18.7

183

190

26.2

258

1 1/2-12

1700

235

2305

2770

383

3756

3/4-10

220

30.4

298

310

42.8

420

1 ft lbs = 0.138 kg•m = 1.356 N•m

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CAP SCREW SIZE*

TORQUE ft lbs

TORQUE N•m

TORQUE kg•m

0.250 - 20

12

16

1.7

0.312 - 18

24

33

3.3

M6 x1

12

9

1.22

0.375 - 16

42

57

5.8

M8 x 1.25

30

22

3.06

CAP SCREW SIZE*

TORQUE N•m

TORQUE ft lbs

TORQUE kg•m

0.438 -14

70

95

9.7

M10 x 1.5

55

40

5.61

0.500 -13

105

142

14.5

M12 x 1.75

95

70

9.69 15.81

0.562 - 12

150

203

20.7

M14 x 2

155

114

0.625 - 11

205

278

28.3

M16 x 2

240

177

24.48

0.750 - 10

360

488

49.7

M20 x 2.25

465

343

47.43

0.875 - 9

575

780

79.4

M24 x 3

800

590

81.6

1.000 - 8

860

1166

119

M30 x 3.5

1600

1180

163.2

1.000 - 12

915

1240

126

M36 x 4

2750

2028

280.5

1.125 - 7

1230

1670

170

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

1.125 - 12

1330

1800

184

1.250 - 7

1715

2325

237

1.250 - 12

1840

2495

254

1.375 - 6

2270

3080

313

1.375 - 12

2475

3355

342

1.500 - 6

2980

4040

411

1.500 - 12

3225

4375

445

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

Suggested* Sources for Rust Preventive Grease: • AMERICAN ANTI-RUST GREASE #3-X from Standard Oil Company (also American Oil Co.) • GULF NORUST #3 from Gulf Oil Company.

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

• RUST BAN 326 from Humble Oil Company.

• RUSTOLENE B GREASE from Sinclair Oil Co. • RUST PREVENTIVE GREASE - CODE 312 from the Southwest Grease and Oil Company.

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

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

TABLE VI. TORQUE CHART FOR O-RING BOSS FITTINGS

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

–2

0.125

0.312 – 24

4 ±1

–2

0.125

0.312 – 24

4 ±2

–3

0.188

0.375 – 24

8 ±3

–3

0.188

0.375 – 24

5 ±2

–4

0.250

0.438 – 20

12 ±3

–4

0.250

0.438 – 20

8 ±3

–5

0.312

0.500 – 20

15 ±3

–5

0.312

0.500 – 20

10 ±3

–6

0.375

0.562 – 18

18 ±5

–6

0.375

0.562 – 18

13 ±3

–8

0.500

0.750 – 16

30 ±5

–8

0.500

0.750 – 16

24 ±5

– 10

0.625

0.875 – 14

40 ±5

– 10

0.625

0.875 – 14

32 ±5

– 12

0.750

1.062 – 12

55 ±5

– 12

0.750

1.062 – 12

48 ±5

– 14

0.875

1.188 – 12

65 ±5

– 14

0.875

1.188 – 12

54 ±5

– 16

1.000

1.312 – 12

80 ±5

– 16

1.000

1.312 – 12

72 ±5

– 20

1.250

1.625 – 12

100 ±10

– 20

1.250

1.625 – 12

80 ±5

– 24

1.500

1.875 – 12

120 ±10

– 24

1.500

1.875 – 12

80 ±5

– 32

2.000

2.500 – 12

230 ±20

– 32

2.000

2.500 – 12

96 ±10

TABLE V. TORQUE CHART FOR PIPE THREAD FITTINGS

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

SIZE CODE

PIPE THREAD SIZE

WITH SEALANT ft lbs

WITHOUT SEALANT ft lbs

–2

0.125 – 27

15 ±3

20 ±5

–4

0.250 – 18

20 ±5

25 ±5

–6

0.375 – 18

25 ±5

35 ±5

–8

0.500 – 14

35 ±5

45 ±5

– 12

0.750 – 14

45 ±5

55 ±5

– 16

1.000 – 11.50

55 ±5

65 ±5

– 20

1.250 – 11.50

70 ±5

80 ±5

– 24

1.500 – 11.50

80 ±5

95 ±10

– 32

2.000 – 11.50

95 ±10

120 ±10

SIZE CODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE ft lbs

–4

0.250

0.438 – 20

11 ±1

–6

0.375

0.562 – 18

18 ±2

–8

0.500

0.750 – 16

35 ±4

– 10

0.625

0.875 – 14

51 ±5

– 12

0.750

1.062 – 12

71 ±7

– 16

1.000

1.312 – 12

98 ±6

– 20

1.250

1.625 – 12

132 ±7

– 24

1.500

1.875 – 12

165 ±15

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

0

1

2

3

4

5

6

7

8

9

0

(N.m)

1.36

2.71

4.07

5.42

6.78

8.14

9.49

10.85

12.20

10

13.56

14.91

16.27

17.63

18.98

20.34

21.69

23.05

24.40

25.76

20

27.12

28.47

29.83

31.18

32.54

33.90

35.25

36.61

37.96

39.32

30

40.67

42.03

43.39

44.74

46.10

47.45

48.81

50.17

51.52

52.87

40

54.23

55.59

56.94

58.30

59.66

60.01

62.37

63.72

65.08

66.44

50

67.79

69.15

70.50

71.86

73.21

74.57

75.93

77.28

78.64

80.00

60

81.35

82.70

84.06

85.42

86.77

88.13

89.48

90.84

92.20

93.55

70

94.91

96.26

97.62

98.97

100.33

101.69

103.04

104.40

105.75

107.11

80

108.47

109.82

111.18

112.53

113.89

115.24

116.60

117.96

119.31

120.67

90

122.03

123.38

124.74

126.09

127.45

128.80

130.16

131.51

132.87

134.23

See NOTE on page A5-5 regarding Table usage

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

0

1

2

3

4

5

6

7

8

9

0

(kg.m)

0.138

0.277

0.415

0.553

0.692

0.830

0.968

1.106

1.245

10

1.38

1.52

1.66

1.80

1.94

2.07

2.21

2.35

2.49

2.63

20

2.77

2.90

3.04

3.18

3.32

3.46

3.60

3.73

3.87

4.01

30

4.15

4.29

4.43

4.56

4.70

4.84

4.98

5.12

5.26

5.39

40

5.53

5.67

5.81

5.95

6.09

6.22

6.36

6.50

6.64

6.78

50

6.92

7.05

7.19

7.33

7.47

7.61

7.74

7.88

8.02

8.16

60

8.30

8.44

8.57

8.71

8.85

8.99

9.13

9.27

9.40

9.54

70

9.68

9.82

9.96

10.10

10.23

10.37

10.51

10.65

10.79

10.93

80

11.06

11.20

11.34

11.48

11.62

11.76

11.89

12.03

12.17

12.30

90

12.45

12.59

12.72

12.86

13.00

13.14

13.28

13.42

13.55

13.69

See NOTE on page A5-5 regarding Table usage

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

0

1

2

3

4

5

6

7

8

9

0

(kPa)

6.895

13.79

20.68

27.58

34.47

41.37

48.26

55.16

62.05

10

68.95

75.84

82.74

89.63

96.53

103.42

110.32

117.21

124.1

131.0

20

137.9

144.8

151.7

158.6

165.5

172.4

179.3

186.2

193.1

200.0

30

206.8

213.7

220.6

227.5

234.4

241.3

248.2

255.1

262.0

268.9

40

275.8

282.7

289.6

296.5

303.4

310.3

317.2

324.1

331.0

337.9

50

344.7

351.6

358.5

365.4

372.3

379.2

386.1

393.0

399.9

406.8

60

413.7

420.6

427.5

434.4

441.3

448.2

455.1

462.0

468.9

475.8

70

482.6

489.5

496.4

503.3

510.2

517.1

524.0

530.9

537.8

544.7

80

551.6

558.5

565.4

572.3

579.2

586.1

593.0

599.9

606.8

613.7

90

620.5

627.4

634.3

641.2

648.1

655.0

661.9

668.8

675.7

682.6

See NOTE on page A5-5 regarding Table usage

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

0

10

20

30

40

50

60

70

80

90

0

(MPa)

0.069

0.14

0.21

0.28

0.34

0.41

0.48

0.55

0.62

100

0.69

0.76

0.83

0.90

0.97

1.03

1.10

1.17

1.24

1.31

200

1.38

1.45

1.52

1.59

1.65

1.72

1.79

1.86

1.93

2.00

300

2.07

2.14

2.21

2.28

2.34

2.41

2.48

2.55

2.62

2.69

400

2.76

2.83

2.90

2.96

3.03

3.10

3.17

3.24

3.31

3.38

500

3.45

3.52

3.59

3.65

3.72

3.79

3.86

3.93

4.00

4.07

600

4.14

4.21

4.27

4.34

4.41

4.48

4.55

4.62

4.69

4.76

700

4.83

4.90

4.96

5.03

5.10

5.17

5.24

5.31

5.38

5.45

800

5.52

5.58

5.65

5.72

5.79

5.86

5.93

6.00

6.07

6.14

900

6.21

6.27

6.34

6.41

6.48

6.55

6.62

6.69

6.76

6.83

See NOTE below regarding Table usage

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

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

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

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

TABLE XII. TEMPERATURE CONVERSIONS Formula: F° - 32 / 1.8 = C° or C° x 1.8 + 32 = F° FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS 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 XIII COMMON CONVERSION MULTIPLIERS

COMMON CONVERSION MULTIPLIERS METRIC TO ENGLISH

COMMON CONVERSION MULTIPLIERS ENGLISH TO METRIC To Convert From

Multiply By

TO

Multiply By

inch – in.

millimeter (mm)

25.40

millimeter (mm)

inch – in.

0.0394

inch – in.

centimeter (cm)

2.54

centimeter (cm)

inch – in.

0.3937

foot – ft

meter (m)

0.3048

meter (m)

foot – ft

3.2808

yard – yd

meter (m)

0.914

meter (m)

yard – yd

1.0936

1.61

kilometer (km)

mile – mi.

0.6210

mile – mi.

kilometer (km)

To Convert From

2)

TO

in.2

0.1550

sq. centimeters (cm )

6.45

sq. centimeters (cm

sq. ft. – ft2

sq. centimeters (cm2)

929

sq. centimeters (cm2)

sq. ft. – ft2

0.001

cu. in. – in.3

cu. centimeters (cm3)

16.39

cu. centimeters (cm3)

cu in – in.3

0.061

cu. in. – in.3

liters (l)

0.016

liters (l)

cu in – in.3

61.02

cu. ft. – ft3

cu. meters (m3)

0.028

cu. meters (m3)

cu ft – ft3

35.314

cu. ft. – ft3

liters (l)

28.3

liters (l)

cu ft – ft3

0.0353

ounce – oz

kilogram (kg)

0.028

grams (g)

ounce – oz.

0.0353

fluid ounce – fl oz

milliliter (ml)

29.573

milliliter (ml)

fluid ounce – fl oz.

0.0338

pound (mass)

kilogram (kg)

0.454

kilogram (kg)

pound (mass)

2.2046

Newton (N)

4.448

Newton (N)

pound (force) – lbs

0.2248

Newton meters (N•m)

0.113

Newton-meters (N•m)

kilogram meters (kg•m)

0.102

sq. in. – in.

2

pound (force) – lbs in. lbs. (force)

2

sq. in. –

ft lbs (force)

Newton meters (N•m)

1.356

Newton-meters (N.m)

ft lbs

0.7376

ft lbs (force)

kilogram meters (kg•m)

0.138

kilogram-meters (kg•m)

ft lbs

7.2329

psi (pressure)

kilopascals (kPa)

6.895

kilogram-meters (kg•m)

Newton meters (N•m)

9.807

psi (pressure)

megapascals (MPa)

0.007

kilopascals (kPa)

psi

0.1450

psi (pressure)

kilograms/cm2 (kg/cm2)

0.0704

megapascals (MPa)

psi

145.038

psi

14.2231

kilopascals (kPa)

98.068

ton

0.0011

2

(kg/cm2)

ton (short)

kilogram (kg)

907.2

kilograms/cm

ton (short)

metric ton

0.0907

kilograms/cm2 (kg/cm2)

quart – qt

liters (l)

0.946

kilogram (kg)

gallon – gal

liters (l)

3.785

metric ton

HP (horsepower)

Watts

745.7

liters (l)

HP (horsepower)

kilowatts (kw)

0.745

liters (l)

ton

1.1023

quart – qt

1.0567

gallon – gal

0.2642

Watts

Horsepower HP

0.00134

kilowatts (kw)

Horsepower HP

1.3410

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

MACHINE MODEL (Circle One) 730E 830E

830E-1AC

930E-4

930E-4SE

Service Meter Reading

MACHINE SERIAL NUMBER

ENGINE MODEL

Date of Inspection

Wheel Motor Serial Numbers

Location of Machine at Inspection

ENGINE SERIAL NUMBER

LH

Dump Body Manufacturer Komatsu

CUSTOMER UNIT NUMBER

RH Other

Distributor’s Name

Dump Body Style

Customer’s Name

KAC Area Service Manager Signature

Date

Customer’s Address

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

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

All four copies are to be distributed as shown below.

Send White Reports to

Manager of Technical Support Komatsu America Corp.

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

Send Canary Reports to

Manager of Field Assembly Komatsu America Corp.

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

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

Mark each item with the appropriate symbol as shown below.

CEAW003211

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

Page 1 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Inspection Around Machine 1

Parts

Visual inspection of unit for loose parts and debris

2

Hardware

Visual inspection of unit for missing and/or loose mounting hardware

3

Hoses and Cables

Visual inspection of hydraulic hoses and electric cables to ensure they are securely clamped and clear from sharp edges and not rubbing each other

4

Ground Straps

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

5

Engine Oil Level

Verify engine oil level is in operating range

6

Engine Fan

Inspect fan-to-shroud clearance and belt alignment

7

Hydraulic Oil Level

Oil level visible through the upper sight glass with body down

8

Hatch Door (730E, 830E, 830E-1AC)

Verify adequate latch seal on the rear axle hatch door to prevent dust entry

9

Anchor Pin

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

10

Wheel Motors

Inspect oil specification and proper oil level

11

Fuel Tank

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

12

Radiator

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

13

Decks and Ladders

Inspect all ladders and handrails are secure and hardware is tight Visual inspection of installation of grid blower, rectifier assembly and control box for correct assembly of components and proper clamping, no loose contacts, no damaged or poorly crimped cables

14

Battery

Inspect all wiring and connections in battery box - no rubbing or chafing Verify battery mounting hardware is secure Verify electrolyte at proper level and caps are securely installed Verify all battery terminals are secure

15

Frame

Visually inspect installation of steering cylinders, tie rod, and accumulators per print Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations (all hardware secure, no leaks)

Hardware Torque 1

Suspension

2

Wheels

Verify front suspension mounting cap screws have been properly tightened per appropriate service manual procedure using the “turn-of-the-nut” method 730E

Verify torque on all wedge nuts at 746 N·m (550 ft lbs)

(See Note below chart) 830E, 830E-1AC

Verify torque on all wedge nuts at 746 N·m (550 ft lbs)

(See Note below chart) 930E-4, 930E-4SE (See Note below chart)

Verify torque on front wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs) Verify torque on rear inside wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs) Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft lbs)

3

Rops

Verify torque on left rops beam cap screws at 949 N·m (700 ft lbs) Verify torque on right cross beam cap screws at 240 N·m (177 ft lbs)

4

Cab

Verify torque on cab mounting cap screws at 949 N·m (700 ft lbs)

5

Wheel Motor

Verify torque on wheel motor mounting cap screws at 2007 N·m (1480 ft lbs)

NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mounting tightening procedure.

CEAW003211

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

No.

Cab Compartment 1

Cab Doors

Verify doors open and close smoothly, latch works properly, O&M manual in door

2

Cab Windows

Verify windows can be opened and closed smoothly

3

Door Locks

Verify left and right door locks work properly with key

4

Interior

Visually inspect interior for completeness of assembly

5

Cab Seats

Inspect operators seat adjustments (slide lever, back rest operation, seat inclination, seat height etc.)

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

Inspect seat belt for proper installation (and seat tethers) 6

Passenger Seat

Verify back rest operates without interference

7

Steering Wheel

Check tilt and telescoping functions

8

Wiper

Verify wiper works all speeds, & range does not extend beyond glass surface

9

Cigarette Lighter

Check lighter operation, should pop up after 10 seconds and be hot (730E,830E only)

10

Horn

Check for proper sound, no looseness in horn button

11

Back Up Horn

Check for proper sound, and function

12

Shift Tower

Check for proper function, no binding or looseness

13

Gauges

Verify gauges are installed straight and operating correctly

14

Hydraulic Fittings

Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet

15

Hoist

Check operation of the hoist lever in all four positions

Headlights

Verify all headlights working, high and low beams

Check adjustable lever can be locked securely

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

Lights 1

Verify high beam indicators are functional Verify lights at proper angle 2

Instrument Panel

Check switch depresses and all lights function

2a

Dimmer Switch

Verify dimmer operates properly

2b

Turn Signal

Visually inspect front and rear turn signal operation on left and right sides Directional indicators operate properly Switch turns off after turn is completed

3

Hazard Flashers

Verify flasher operates properly

4

Back Up Light

Verify back up light operates properly when shifter is in R position

5

Manual Back Up Light

Verify switch and light work properly

6

Fog Light (optional)

Verify fog lights and indicator lights operating properly

Verify hazard indicator lights operating properly

Brake Lights 1

Service Brake

Verify service brake lights operating properly

2

Brake Lock

Verify brake lock light operating properly

3

Emergency Brake

Verify emergency brake light operating properly

4

Parking Brake

Verified parking brake light operating properly

5

Dome Light

Verify dome light is on when the switch is ON

6

Retarder Lights

Verify retard light operating properly

CEAW003211

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

Page 3 of 5

Acceptance Procedures

Maintenance

Inspection Item

Accepted

No.

Service Inspection 1

Suspension

730E

(See Note below chart)

Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear Front charge height, 229 mm (9 in.) at 2758 kPa (400 psi) Rear charge height, 276 mm (10.9 in. ) at 1420 kPa (206 psi)

830E, 830E-1AC (See Note below chart)

Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear Front charge height, 229 mm (9 in.) at 2689 kPa (390 psi) Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)

930E-4, 930E-4SE (See Note below chart)

Suspension oiling height at 25.4 mm (1 in.) front and 53.0 mm (2.1 in.) rear Front charge height, 229 mm (9 in.) at 2930 kPa (425 psi) Rear charge height, 218 mm (8.6 in.) at 1482 kPa (215 psi)

2

Accumulators

Verify nitrogen charge in accumulators is at 9653 kPa (1400 psi) for all models, for both steering and brakes (charge pressure will vary with ambient temperature, refer to chart in SM)

3

Engine Prelube

If equipped, ensure prelube is working prior to engine starting

4

Engine Starting

Ensure engine starts easily

5

Engine Noise

No abnormal noise from engine

6

Brake Lock

Verify when switch is ON, brakes are applied and light is illuminated. Must be in Neutral.

7a

Parking Brake

Verify when switch is ON, brakes are applied and light is illuminated

730E, 830E 7b 8

830E-1AC, 930E-4, 930E-4SE Brake Pressure

730E

Verify when directional control lever is in PARK, brakes are applied and light is illuminated Verify with pedal depressed, front brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi) Verify with pedal depressed, rear brake pressure is 11,721 ± 517 kPa (1700 ± 75 psi) Verify brake lock pressure is 10,342 ± 689 kPa (1500 ± 100 psi) Verify parking brake pressure is 17,926 ± 689 kPa (2600 ± 100 psi)

830E, 830E-1AC

Verify with pedal depressed, front brake pressure is 20,684 ± 1034 kPa (3000 ± 150 psi) Verify with pedal depressed, rear brake pressure is 13,652 ± 689 kPa (1980 ± 100 psi) Verify brake lock pressure is 10,342 ± 689 kPa (1500 ± 100 psi) Verify parking brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)

930E-4, 930E-4SE

Verify with pedal depressed, front brake pressure (BF) is 17,236 ± 517 kPa (2500 ± 75 psi) Verify with pedal depressed, rear brake pressure (BR) is 17,236 ± 517 kPa (2500 ± 75 psi) Verify brake lock pressure is 13,790 ± 689 kPa (2000 ± 100 psi) Verify parking brake release pressure is 18,616 ± 689 kPa (2700 ± 100 psi)

9

Steering

Verify that steering system is operating smoothly, turning from lock to lock Verify steering system is free of noise and vibration

10

Hoist

Verify hoist pressure is 17,236 kPa (2500 psi) power up, and 10,342 kPa (1500 psi) power down Verify hoist limit switch is operational and is set correctly (measure on the hoist cylinder - 3rd stage), cylinder should stop 6 inches before full extension Verify that the hoist hold position operates properly Verify that there is no heavy shock when the body returns to the frame in float

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

CEAW003211

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

11

730E

Acceptance Procedures

Maintenance

Inspection Item Hoist Times

Accepted

No.

Power up loaded - 21-23 seconds Power down - 15-17 seconds Float down empty - 22-24 seconds

830E, 830E-1AC

Power up loaded - 25-27 seconds Power down - 15-17 seconds Float down empty - 23-25 seconds

930E-4, 930E-4SE

Power up loaded - 21-23 seconds Power down - 23-25 seconds Float down empty - 24-26 seconds

All Trucks

Ensure body up switch activates the body up alarm and light in the cab

12

Lubrication

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

13

Payload Meter Sys.

Calibrate and check payload meter operation per O&M manual

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

14

Error Codes

Troubleshoot any error codes and delete

15

Machine

Record machine model-type, machine serial number and engine serial number

16

Dump Body

Ensure the dump body is shimmed correctly prior to truck release

17

Electrical Checks

Ensure the electrical checkout procedure has been completed and signed off on, including megger testing (see appropriate Field Assembly Manual or Shop Manual for procedure)

18

Truck Programming

Ensure the truck is programed with itâ&#x20AC;&#x2122;s own unique configuration file and a copy of the file saved

ADDITIONAL COMMENTS__________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW003211

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

(Circle One) 730E 830E

ENGINE MODEL

ENGINE SERIAL NUMBER

CUSTOMER UNIT NUMBER

830E1-AC

930E-4

930E-4SE

Service Meter Reading

Date of Inspection

Wheel Motor Serial Numbers

Location of Machine at Inspection

LH

Dump Body Manufacturer Komatsu

RH Other

Distributor’s Name

Dump Body Style

Customer’s Name

KAC Area Service Manager Signature

Date

Customer’s Address

Inspector’s Comments:

Inspector’s Name

KOMATSU USE ONLY: Sheet receiving Date:

Title

By:

Signature

Remark:

Send white reports to:

Manager of Technical Support Komatsu America Corp.

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

Send canary reports to:

Manager of Field Assembly Komatsu America Corp.

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

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

CEAW004203

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

Page 1 of 5

No.

Inspection Item

Acceptance Procedures

As Found Condition

Corrective Action

Inspection Around Machine 1

Parts

Visually inspect the truck for loose parts and debris.

2

Hardware

Visually inspect the truck for missing and/or loose mounting hardware.

3

Hoses and Cables

Visually inspect hydraulic hoses and electric cables to ensure they are securely clamped and clear of sharp edges and other objects that may cause chaffing.

4

Engine Oil Level

Verify the engine oil level is at the proper operating range.

5

Hydraulic Oil Level

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

6

Anchor Pin

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

7

Wheel Motors

Verify the correct oil is being used and oil is at the proper level.

8

Fuel Tank

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

9

Radiator

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

10

Steering Components

Verify proper installation of the steering cylinders, tie rod, and accumulators.

11

Hydraulic Components

Visually inspect the hoist valve, pumps, filters, hydraulic tank and hoist cylinder installations. All hardware must be secure, and no leaks evident.

12

Leakage

Visually inspect the entire machine for leaks.

Hardware Torque 1

Steering Arm To Suspension

730E - Verify hardware torque Target: 2705 N·m (1995 ft lbs) 830E, 830E-1AC- Verify hardware torque Target: 2705 N·m (1995 ft lbs) 930E-4, 930E-4SE - Verify hardware torque Target: 2705 N·m (1995 ft lbs)

2

Steering Cylinder To Frame

730E - Verify hardware torque Target: 464 N·m (342 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 712 N·m (525 ft lbs) 930E-4, 930E-4SE - Verify hardware torque Target: 1017 N·m (750 ft lbs)

3

Steering Cylinder To Steering Arm

730E - Verify hardware torque Target: 464 N·m (342 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 712 N·m (525 ft lbs) 930E-4, 930E-4SE - Verify hardware torque Target: 1017 N·m (750 ft lbs)

CEAW004203

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

Page 2 of 5

No.

Inspection Item

Acceptance Procedures

4

Tie Rod Pin Retainer

730E - Verify hardware torque -

As Found Condition

Corrective Action

Target: 464 N·m (342 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 712 N·m (525 ft lbs) 930E-4, 930E-4SE - Verify hardware torque Target: 1017 N·m (750 ft lbs) 5

Front Brake Caliper Mounting

730E - Verify hardware torque -

(Capscrew with Nut)

830E, 830E-1AC - Verify hardware torque -

Target: 1085 N·m (800 ft lbs) Target: 1085 N·m (800 ft lbs)

6

Front Brake Caliper Mounting (Capscrew Only)

730E - Verify hardware torque Target: 1166 N·m (860 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 1166 N·m (860 ft lbs)

7

Rear Service Brake Caliper Mounting

730E - Verify hardware torque Target: 780 N·m (575 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 780 N·m (575 ft lbs)

8

Rear Brake Adapter Mounting

730E - Verify hardware torque Target: 488 N·m (360 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 488 N·m (360 ft lbs)

9

Brake Disc To Adapter Mounting

730E - Verify hardware torque Target: 278 N·m (205 ft lbs) 830E, 830E-1AC - Verify hardware torque Target: 278 N·m (205 ft lbs)

Cab Compartment 1

Horn

Check for proper tone and volume. Ensure there is no looseness in the horn button.

2

Back Up Horn

Check for proper tone, volume, and function.

3

Gauges

Verify all gauges are installed straight and are operating correctly.

4

Glass

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

5

Seat/Seat belts

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

CEAW004203

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

Page 3 of 5

No.

Inspection Item

Acceptance Procedures

As Found Condition

Corrective Action

Service Inspection 1

Suspension

730E

(See Note below)

Suspension oiling height: 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear Front charge height: 229 mm (9 in.) at 2758 kPa (400 psi) Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206 psi)

830E, 830E-1AC (See Note below)

Suspension oiling height: 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear Front charge height: 229 mm (9 in.) at 2689 kPa (390 psi) Rear charge height: 241 mm (9.5 in.) at 1724 kPa (250 psi)

930E-4, 930E-4SE (See Note below)

Suspension oiling height: 25.4 mm (1 in.) front and 53.0 mm (2.1 in.) rear Front charge height: 229 mm (9 in.) at 2930 kPa (425 psi) Rear charge height: 218 mm (8.6 in.) at 1482 kPa (215 psi)

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

2

Accumulators

Verify the nitrogen charge in the accumulators is at 9653 kPa (1400 psi) for all models, for both steering and brakes. (Charge pressure will vary with ambient temperature, refer to chart in SM)

3

Steering

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

4

Lubrication

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.

5

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.

6

Tires

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

Pressure Size Manufacturer

7

Payload Meter System

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

8

GE Drive/Control System

Check drive control system operation per O&M manual.

Troubleshoot, correct and delete any error codes.

9

GE Rotating

Visually inspect wheel motor armature condition - brush wear, commutator color, etc.

Components (Wheel Motors, MTA, Grid Blower)

Inspect MTA slip rings and brushes.

10

Wheel Motor Sun Pinion End Play

Measure and record sun pinion end play for both RH and LH wheel motors

11

VHMS

Verify the VHMS system is functioning properly per O&M manual. Troubleshoot and repair any problems.

CEAW004203

Inspect grid blower motor commutator condition, brush wear, etc.

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

Page 4 of 5

MINE OPTIONS - List any mine/site specific options or modifications made to the unit.

No.

Description of Modification

Reason For Installation

1 2 3 4 5 6

ADDITIONAL COMMENTS:______________________________________________________________

__________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

CEAW004203

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: