Ce Aw 004101

Field Assembly Manual

CEAW004101

DUMP TRUCK SERIAL NUMBERS

A30427 & UP

®

FOREWARD This manual is provided to aid assemblers during field assembly of the standard Komatsu 730E 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.

FAM0011

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 taken.

“WARNING” identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken.

“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

FAM0011

TABLE OF CONTENTS

SUBJECT

PAGE NUMBER

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

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

MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

DUMP BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

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

FAM0011

Introduction

iii

KOMATSU MODEL 730E DUMP TRUCK

iv

Introduction

FAM0011

SAFETY RULES, TOOLS & EQUIPMENT SAFETY RULES The following list of safety practices is intended for use by personnel during field assembly of the truck. This list of safety rules is not intended to replace local safety rules or regulations and federal, state, or local laws. The safety precautions recommended here are general and must be used in conjunction with all prevailing local rules and regulations. 1. All personnel must be properly trained for the assembly operation. 2. Wear safety equipment such as safety glasses, hard toe shoes and hard hats at all times during assembly.

11. When welding, connect the ground cable to the part being welded. DO NOT allow welding current to pass through bearings, engine, etc. 12. DO NOT weld the transmission housing unless it has been completely disassembled. 13. DO NOT weld the fuel tank or hydraulic tank unless the tanks have been properly purged and ventilated. 14. Use the proper tools for the job to be performed. Never improvise wrenches, screw drivers, sockets, etc. unless specified.

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

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

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.

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

5. Inspect all lifting devices. Refer to the manufacturer's specifications for correct capacities and safety procedures when lifting components. 6. Perform a daily inspection of all lifting cables and chains. Replace any questionable items. Use cables and chains that are properly rated for the load to be lifted. 7. DO NOT stand beneath a suspended load. Use of guy ropes are recommended for guiding and positioning a suspended load. 8. Maintain fire control equipment. Inspect fire extinguishers regularly to ensure they are fully charged and in good working condition. 9. Cap screws and/or nuts being replaced must be the same grade as originally supplied. 10. Disconnect the battery charging alternator lead wire before welding on the frame or its components.

FAM0109

Safety Rules, Tools, & Equipment

Page 1-1

TOOLS AND EQUIPMENT FOR ASSEMBLY

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

The following equipment is recommended for field assembly of the truck.

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

sizes.

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

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.

• 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.

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

• Sockets: 2 1/4 in. (Snap-On P/N J15036) and

4. Two, 300 amp portable welding units and an oxy-acetylene cutting set.

2 5/8 in. (Snap-On P/N J15042) to tighten front suspension hardware.

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.

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.

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

17. Special tools (see list, following pages)

8. Tire handler - Wiggins/Iowa Mold Tooling.

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

9. Miscellaneous air tools

21. Spreader bars for cab and decks.

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

• • • • •

18. Two, hydraulic or pneumatic porta-power jacks, 4.5 and 9 metric ton (5 and 10 ton) 19. Various hooks and shackles

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

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

23. Pry bars

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

24. Solvent - 38 liters (10 gal)

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

25. Paint remover - 19 liters (5 gal) 26. Rust preventive grease

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

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Safety Rules, Tools, & Equipment

FAM0109

LIFTING SLING GENERAL INFORMATION

FAM0109

Safety Rules, Tools, & Equipment

Page 1-3

Part Number

Description

EB1759

Nitrogen Charging Kit

Use Suspension and Accumulator Nitrogen Charging

1. T-Handle Valve 2. Charging Valve Adapter

Part Number

Description

Use

EC7852

Roll-Out Assembly

Power Module Remove and Install

EG2298

Roller Assembly

MM0055

Cap Screw M20 x 2.5 x 50

MM0465

Flat Washer M20

Part Number

Description

Use

PB8326

Offset Box End Wrench, 1 7/16”

Miscellaneous and Cab Mounting

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

NOTE: Arrangement of parts may vary from the illustration shown, depending on the charging kit P/N

Page1-4

Safety Rules, Tools, & Equipment

FAM0109

Part Number

Description

Use

TZ2734

3/4” Torque Adapter

Miscellaneous

Part Number

Description

Use

TZ2733

Tubular Handle

Use with PB8326 and TZ2734

FAM0109

Part Number

Description

Use

TY2150

Seal Installation Tool

Installation of Front Wheel Bearing Face Seals

Part Number

Description

EC1741 EC1742 TZ0992

Sleeve Alignment Tool

Safety Rules, Tools, & Equipment

Use Steering Linkage and Tie Rod Assembly. Refer to Section G.

Page 1-5

Part Number

Description

Use

AK4720

Payload Data Manger

EF9160

PLM Download Harness

Payload Meter Download. Refer to Section D.

Part Number

Description

PB6039

Hydraulic Coupling

Part Number

Description

TW9425

Special Wrench

Accumulator Gland Nut

Use Miscellaneous PART NO. PC2061

Part Number

Description

Use

TG1106

Eye Bolt

Miscellaneous Lifting Requirements

Page1-6

Use

Safety Rules, Tools, & Equipment

DESCRIPTION Belt Tension Tester

USE A/C Belt Tension

FAM0109

Part Number

Description

Use

EL8868

TZ8968

Socket 3-1/2”

Miscellaneous

TZ2726

Socket 1-1/8”

Miscellaneous

TZ2729

Socket 1-1/4”

Miscellaneous

TV7567

Socket 1-5/16”

Miscellaneous

PB6825

Impact Socket 1-5/8”

Miscellaneous

TR0529

Socket 1-3/4”

Miscellaneous

TZ2100

Socket 1-7/8”

Miscellaneous

TZ2727

Socket 2-1/4”

Miscellaneous

TZ2728

Socket 2-3/4”

Miscellaneous

PB6824

Impact Socket 3-1/8”

Miscellaneous

TZ8968

Socket 3-1/2”

Miscellaneous

TR0532

Square Drive Extension 8”

Miscellaneous

TR0533

Square Drive Extension 17”

Miscellaneous

TV1186

Extension 3-1/2”

Miscellaneous

TR0546

Sliding T-Handle

Miscellaneous

TZ2730

Adapter 1” x 1-1/2”

Miscellaneous

TZ2731

Adapter 3/4” x 1”

Miscellaneous

PB6851

Locking Steel Pin (for use with 1-1/2” square drive sockets)

Miscellaneous

PB6852

Locking Rubber Ring (for use with 1-1/2” square drive sockets)

Miscellaneous

FAM0109

PART NO.

Safety Rules, Tools, & Equipment

DESCRIPTION V-Belt Alignment Tool

USE Aligning A/C pulleys

Page 1-7

ASSEMBLY SCHEDULE AND RESOURCE LAYOUT Page1-8

Safety Rules, Tools, & Equipment

FAM0109

FAM0109

Safety Rules, Tools, & Equipment

Page 1-9

NOTES

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Safety Rules, Tools, & Equipment

FAM0109

MAJOR COMPONENTS AND SPECIFICATIONS The Komatsu model 730E dump truck is an electric drive, off-highway, rear dump truck. Standard 730E gross vehicle weight is 324,322 kg (715,000 lbs) rated for a nominal payload of 185 t (203 tons). Some Trolley versions may have a higher GVW. Refer to the grade/speed chart in the operator’s cab for the appropriate GVW. ENGINE

POWER STEERING

The Komatsu 730E dump truck is powered by a Komatsu SSA16V159 engine rated at 2000 HP (1492 kW).

The Komatsu 730E dump truck is equipped with a full-time power steering system, which provides positive steering control with a minimum of effort by the operator. The system includes nitrogen-charged accumulators which automatically provide emergency power if the steering hydraulic pressure is reduced below an established minimum.

ALTERNATOR (GE GTA-22) The diesel engine drives an alternator mounted inline with the engine. The Alternating Current (AC) output of the alternator is rectified to Direct Current (DC) and sent to the DC drive wheel motors. WHEEL MOTORS (GE 788) The output of the alternator supplies electrical energy to the two wheel motors attached to the rear axle housing. The two wheel motors convert electrical energy back to mechanical energy through built-in gear trains within the wheel motor assembly. The direction of the wheel motors is controlled by a forward or reverse hand selector switch located on a console to the right side of the operator. BLOWER The blower supplies cooling air for the rectifiers, AC alternator, and to both wheel motors, where it is then exhausted to the atmosphere. OPERATOR'S CAB The operator's cab for the Komatsu 730E dump truck has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab provides for wide visibility, with an integral four-post Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS), and an advanced analog operator environment. It includes a tinted safety-glass windshield and power-operated side windows, a deluxe interior with a fully adjustable seat with lumbar support, a fully adjustable/tilt steering wheel, controls mounted within easy reach of the operator, and an analog instrument panel which provides the operator with all instruments and gauges, which are necessary to control and/or monitor the truck's operating systems.

FAM0210

DYNAMIC RETARDING Dynamic retarding is used to slow the truck during normal operation or control the speed coming down a grade. The dynamic retarding ability of the DC electric system is controlled by the operator through the activation of the retarder pedal in the operator’s cab and by setting the RSC (Retarder Speed Control). Dynamic retarding is automatically activated if the truck goes to a preset overspeed setting. BRAKE SYSTEM The wheel service brakes are caliper/dry disc brakes applied by an all hydraulic actuation system. Depressing the brake pedal actuates wheel-speed single disc front brakes and armature-speed dual disc rear brakes. The rear brakes can also be activated by operating a switch on the instrument panel. All wheel brakes will be applied automatically if the system pressure decreases below a preset minimum. The parking brake is a caliper/disc type, mounted on each rear wheel motor, and is spring-applied and hydraulically-released with wheel speed application protection (will not apply with the truck moving.) SUSPENSION Hydrair®II 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.

Major Components & Specifications

FAM2-1

730E MAJOR COMPONENTS FAM2-2

Major Components & Specifications

FAM0210

SPECIFICATIONS These specifications are for the standard 730E dump truck. Customer options may change this listing. SERVICE CAPACITIES

ENGINE

Liters. . . U.S. Gallons

Komatsu SSA16V159 Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 16 Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke Rated Brake HP. . 1491 kW (2000 HP) @ 1900 RPM Flywheel HP . . . . 1388 kW (1860 HP) @ 1900 RPM Weight (Wet) . . . . . . . . . . . . . . . 5294 kg (11,670 lbs)

Crankcase (includes lube oil filters) Komatsu . . . . . . . . . . . . . . . . . 223. . . . . . . . . . . . .59 Cooling System . . . . . . . . . . . 409. . . . . . . . . . . .108 Fuel . . . . . . . . . . . . . . . . . . . 3217 . . . . . . . . . . .850 Hydraulic System . . . . . . . . . . 731 . . . . . . . . . . .193 Wheel Motor Gear Box. . . .40/Wheel . . .10.5/Wheel

ELECTRIC DRIVE SYSTEM HYDRAULIC SYSTEM STATEX III w/Fuelsaver . . . . . . . . . AC/DC Current

Pumps:

Alternator . . . . . . . . . . . . . General Electric GTA - 22

Hoist (gear-type). . . . . . . . . . .513 l/min (135.6 GPM)

Motorized Wheels . . . . . . . . . . General Electric 788*

. . . . . . . . . . . . at 17240 kPa (2500 psi) @ 1900 rpm

Standard Gear Ratio* . . . . . . . . . . . . . . . . . 26.825:1

Steering/Brake (vane-type). . . . . 235 l/min (62 GPM)

Maximum Speed . . . . . . . . . . . 34.6 mph (55.7 km/h)

. . . . . . . . . . . at 18960 kPa (2750 psi) @ 1900 RPM

*NOTE: Wheel motor application depends upon GVW, haul road grade, haul road length, rolling resistance, and other parameters. KOMATSU & G.E. must analyze each job condition to assure proper application.

Relief Pressure-Hoist . . . . . . . .17240 kPa (2500 psi)

DYNAMIC RETARDING

Tank . . . . . . . Vertical - Cylindrical, Non-Pressurized

Electric Dynamic Retarding . . . . . . . . . . . . Standard

Service Capacity . . . . . . . . 731 Liters (193 U.S. Gal)

Maximum Retarding . . . . . . . . . 2759 kW (3700 HP)

Filtration . . . . . . . . . . . In-line Replaceable Elements

. . . . . . . . . . . . . With Continuous Rated Blown Grids

Suction . . . . . . . . . . . . . Single, Full Flow, 100 Mesh

. . Two-Speed Overspeed & Extended Range Retarding

Hoist and Steering High-Pressure Filters

. . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Retarding BATTERY ELECTRIC SYSTEM

Relief Pressure-Steering . . . . .27580 kPa (4000 psi) Hoist . . . . . . . . Two Three-Stage Hydraulic Cylinders

. . . . . . . . . . . . . . . . . Dual, Full Flow, Seven Micron . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 rating = 200 SERVICE BRAKES

Batteries . Bumper-Mounted in Polyethylene Boxes . . . . . . . . . . Four 12-Volt Batteries in Series/Parallel . . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity . . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch

Actuation . . . . . . . All Hydraulic - Caliper/Disc . . . . . . . . . . . . . . .(Front) . . . . . . . . . . . . . . . .(Rear) Type . . . . . . . . . Single Disc. . . . . . . . . . . . Dual Disc . . . . . . . . . . . . Wheel Speed . . . . . .Armature Speed

Alternator . . . . . . . . . . . 24-Volt, 220 Ampere Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt

STEERING

Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt

Turning Circle (SAE). . . . . . . . . . . . . . . 28.0 m (92 ft) Twin hydraulic cylinders with accumulator assist to provide constant rate steering. Emergency power steering automatically provided by accumulators (meets SAE J1511).

FAM0210

Major Components & Specifications

FAM2-3

These specifications are for the 730E dump truck without trolley assist. Specifications for trolley trucks will be different. STANDARD DUMP BODY*

WEIGHT DISTRIBUTION

Capacity:

Empty Vehicle Kilograms (Pounds) Front Axle . . . . . . . . . . . . 66,840 . . . . (147,357) Rear Axle . . . . . . . . . . . . 73,752 . . . . . . .(162,593)

Struck . . . . . . . . . . . . . . . . 77 m³ . . . . . 101 yds³ Heaped @ 2:1 (SAE) . . . . 111 m³ . . . . 145 yds³ Width (inside) . . . . . . . . . . . . . . . 5.61 m (22 ft 6 in.) Depth . . . . . . . . . . . . . . . . . . . . . 2.08 m (6 ft 10 in.) Loading Height . . . . . . . . . . . . . . 5.61 m (18 ft 5 in.) Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

Total (100% fuel) . . . . . . 140,592. . . . . . .(309,950) Standard Komatsu Body . 25,612. . . . . . . .(61,000) Standard Tire Weight. . . . 18,371. . . . . . . .(40,500) Loaded Vehicle

Kilograms . . .

(Pounds)

*Optional capacity dump bodies are available.

Front Axle . . . . . . . . . . 107,026. . . . . . . 235,950) Rear Axle. . . . . . . . . . . . 217,296. . . . . . . 479,050)

TIRES

Total * . . . . . . . . . . . . . 324,322 . . . . . .(715,000) Nominal Payload . . . . . 183,730. . . . . . .(405,050)

Radial Tires (standard) . . . . . . . . . . . . . . 37.00 R57 Rock Service, Deep Tread . . . . . . . . . . . . Tubeless Rims . (Patented Phase II New Generation™ Rims) Tires and Rims . . . . . . . . . . . . . . . Interchangeable

FAM2-4

*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.

Major Components & Specifications

FAM0210

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 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38,555 . . . . . . . . . . . . . . . . . . . . . 85,000 Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,586 . . . . . . . . . . . . . . . . . . . . . . 5,700 Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,404 . . . . . . . . . . . . . . . . . . . . . . 5,300 Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,990 . . . . . . . . . . . . . . . . . . . . . 11,000

DECK AND DECK SUPPORT COMPONENTS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,449 . . . . . . . . . . . . . . . . . . . . . . 5,400 RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 . . . . . . . . . . . . . . . . . . . . . . 1,596 LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 . . . . . . . . . . . . . . . . . . . . . . 1,400 Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 . . . . . . . . . . . . . . . . . . . . . . . .514 Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 . . . . . . . . . . . . . . . . . . . . . . . .900 Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 . . . . . . . . . . . . . . . . . . . . . . . .650 LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 . . . . . . . . . . . . . . . . . . . . . . 1,700 RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907 . . . . . . . . . . . . . . . . . . . . . . 2,000 LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 . . . . . . . . . . . . . . . . . . . . . . . .216 Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 . . . . . . . . . . . . . . . . . . . . . . . .287

FAM0310

Major Component Weights

Page 3-1

ITEM

KILOGRAMS

POUNDS

DRIVE SYSTEM Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214 . . . . . . . . . . . . . . . . . . . . . . . . 472 Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,833 . . . . . . . . . . . . . . . . . . . . . . .8,450 Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,678 . . . . . . . . . . . . . . . . . . . . . . .3,700 Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10,569 . . . . . . . . . . . . . . . . . . . . . . 23,300

FLUID COMPONENTS Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .698 . . . . . . . . . . . . . . . . . . . . . . .1,539 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 . . . . . . . . . . . . . . . . . . . . . . . . 796 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,270 . . . . . . . . . . . . . . . . . . . . . . .2,800

FRONT AXLE COMPONENTS Spindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,330 . . . . . . . . . . . . . . . . . . . . . . .7,340 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 . . . . . . . . . . . . . . . . . . . . . . . . 423 Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,964 . . . . . . . . . . . . . . . . . . . . . . .4,330 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 . . . . . . . . . . . . . . . . . . . . . . . . 300

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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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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.

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FAM0406

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 For Assembly Or Repair

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General Welding Guidelines 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.

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

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CHASSIS ASSEMBLY Due to differences in machine configurations and shipping restrictions/requirements throughout the world, the shipping and packaging of large machines varies. Photographs or illustrations used in the following procedures are provided as general guidelines only. Actual assembly may be different, but this general procedure provides a basic outline for assembly. Items like the hydraulic tank and the accumulators may have been removed for shipping and will have to be locally installed. Each shipment may be different, depending on the truck configuration and destination.

BASIC ASSEMBLY PROCEDURE 1. Site preparation 2. Unload truck components 3. Assemble the chassis 4. Weld the body NOTE: Chassis assembly and body welding may be done in either order, or simultaneously. The most logical order depends on available resources such as cranes, welders, assemblers, etc. 5. Static checkout (electrical & mechanical) 6. Install the body 7. Dynamic checkout (electrical & mechanical)

RECOMMENDED ASSEMBLY DATA

8. Site cleanup

1. Service Report (Pre-Delivery) 2. Acknowledgement of Receipt of Company Warranty 3. Assembly Blueprints & Schematics 4. Fluid Specifications (refer to the lubrication chart in Section 10, Appendix) 5. Suspension Oiling & Charging Procedure (available in Section 10, Appendix) 6. 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 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.

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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, tap all threaded holes to remove paint. 7. Verify all wiring is properly connected before attempting to start the engine.

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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

Page 6-3

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 38,555 kg (85,000 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. Placement of the chassis at this height will allow easy installation of truck components. Thoroughly clean the chassis.

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FIGURE 6-1.

FIGURE 6-2.

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2. Clean the mating surfaces for the deck supports to prepare for installation.

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FIGURE 6-3.

FIGURE 6-4.

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3. Lift the LH deck support into position. The weight of the deck support is approximately 408 kg (900 lb). a. Bolt the support into place. b. Weld the support to the frame. 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. Follow the specifications shown in Figure 6-7. c. Grind all areas, and clean. Paint after welding is complete.

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.

4. Install and weld the RH deck support. The weight of the deck support is approximately 295 kg (650 lb).

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FIGURE 6-5.

FIGURE 6-6.

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FIGURE 6-7.

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NOTES

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5. Clean the mounting surfaces for the hydraulic tank and the fuel tank. 6. Lift the fuel tank into position on the cradles. The weight of the fuel tank is approximately 1270 kg (2800 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. 7. Connect the fuel supply and fuel return hoses to the ports on the fuel tank. 8. Install the filters to the rear of the tank and secure the wiring harness.

FIGURE 6-8.

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FIGURE 6-9.

FIGURE 6-10.

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9. Clean the mating surfaces for the LH and RH uprights. 10. 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. 11. 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 907 kg (2000 lb). The weight of the LH upright is approximately 771 kg (1,700 lb). DO NOT weld the torque tubes on the uprights until the decks are installed. 12. Attach the upper radiator stabilizers rods to the uprights. After the decks are installed and the uprights welded, adjust the stabilizers to vertically level the radiator.

FIGURE 6-11.

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FIGURE 6-12.

FIGURE 6-13.

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FIGURE 6-14.

FIGURE 6-15.

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FIGURE 6-16.

FIGURE 6-17.

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13. Install both wheel motors. The weight of each wheel motor with the service brake and parking brake assemblies installed is approximately 10,569 kg (23,300 lb). 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 6-23. Alternately 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 6-18.

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FIGURE 6-19.

FIGURE 6-20.

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14. Prepare the mounting surfaces for the LH diagonal tube. Lift the tube into position. The weight of the diagonal tube is approximately 98 kg (216 lb). Do not tighten the cap screws until the deck and the cab are in place.

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FIGURE 6-21.

FIGURE 6-22.

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15. 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.

16. 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 6-23. 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.

17. 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 6-23.

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

18. Lift the front suspension into position. 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

10/07 FAM0610

Turn-Of-The-Nut Tightening Procedure a. Tighten all 14 cap screws (1, 6, 8, Figure 624) 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: 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 6-25.

FIGURE 6-25. 60 DEGREE ADVANCE FIGURE 6-24. SUSPENSION INSTALLATION 1. Cap Screws and Washers 2. Nuts and Washers 3. Housing 4. Mounting Surface 5. Shear Bar

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

Initially tighten the bottom four cap screws (6, Figure 6-24) to 203 N·m (150 ft lb). Then, advance the cap screw heads 90° as outlined in Steps d-1 through d-3. Refer to Figure 6-26.

FIGURE 6-26. 90 DEGREE ADVANCE

FAM0610

10/07

Chassis Assembly

Page 6-23

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 6-28 and 6-29. 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. 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 during the tightening procedure. e. Loosen the top two corner cap screws (1, Figure 6-24) and the bottom outer four cap screws (8), (without spacers). 1.) Tighten the top two corner cap screws to 95 N·m (70 ft lb), then advance the cap screw heads 60°. 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.

Page 6-24

Chassis Assembly

10/07 FAM0610

FIGURE 6-27.

FIGURE 6-28.

FAM0610

10/07

Chassis Assembly

Page 6-25

19. Clean the tapered portion of the suspension rod and the bore of the spindle. Lubricate the two surfaces with multi purpose grease number 2 (5% molybdenum disulphide).

20. Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brake assembly is approximately 3300 kg (7340 lb). 21. Lift the retainer plate into position under the spindle. The weight of the plate is approximately 30 kg (66 lb). Install the twelve retainer plate cap screws. Alternately tighten the cap screws to 678 N·m (500 ft lb). Continue to tighten the cap screws in increments of 330 N·m (250 ft lb) until 2705 ± 270 N·m (1,995 ± 200 ft lb) is reached. Repeat the previous steps for the remaining wheel.

Page 6-26

Chassis Assembly

10/07 FAM0610

FIGURE 6-29.

FIGURE 6-30.

FAM0610

10/07

Chassis Assembly

Page 6-27

22. Clean and prepare the steering cylinder and tie rod mounting surfaces. 23. Move the steering cylinders into position in the steering arms bores. Lubricate the pin and pin bore surfaces with multi purpose grease number 2 (5% molybdenum disulphide). Install the pin, spacers, bearing seals and hardware to each joint. Tighten the pin retainer cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix. NOTE: Use alignment sleeve (TY4576) to aid in assembly of the steering cylinder joints.

24. Lift the tie rod into position. The weight of the tie rod is approximately 136 kg (300 lb). Lubricate the pin and pin bore surfaces with multi purpose grease number 2 (5% molybdenum disulphide). Install the pin, spacers, bearing seals and hardware to each joint. Tighten the pin retainer cap screws to standard torque. 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.

FIGURE 6-31.

Refer to the illustration on the following page. 1. Steering Cylinder 2. Tie Rod Assembly 3. Retainer 4. Locknut 5. Spacer

Page 6-28

6. Bearing Seal 7. Spherical Bearing 8. Steering Arm 9. Cap Screw 10. Bearing Retainer

11. Cap Screw 12. Lockwasher 13. Washer 14. Cap Screw 15. Pin

Chassis Assembly

16. Cap Screw 17. Retainer Plate 18. Flat Washer

10/07 FAM0610

FIGURE 6-32.

FAM0610

10/07

Chassis Assembly

Page 6-29

19. Lift the contactor box into position on the retarding grid. Install the mounting hardware and tighten to standard torque. Refer to Standard Tables in Section 10, Appendix.

20. Lift the RH deck into position on the truck. The weight of the assembly is approximately 4600 kg (10,141 lb). Loosely install the deck mounting hardware. NOTE: Do not torque the hardware until after all decks are in place.

Page 6-30

Chassis Assembly

10/07 FAM0610

FIGURE 6-33.

FIGURE 6-34.

FAM0610

10/07

Chassis Assembly

Page 6-31

21. Install the handrails onto the LH deck and lift the deck into place. The weight of the LH deck with handrails is approximately 635 kg (1400 lb). Loosely install the eight deck mounting cap screws. NOTE: Do not torque the hardware until after all decks are in place.

Page 6-32

Chassis Assembly

10/07 FAM0610

FIGURE 6-35.

FIGURE 6-36.

FAM0610

10/07

Chassis Assembly

Page 6-33

22. Tap the cab mounting holes to remove any paint before cab installation.

23. Lift the operator cab into position. The weight of the cab is approximately 2449 kg (5400 lb). Install and tighten the forty cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

Page 6-34

Chassis Assembly

10/07 FAM0610

FIGURE 6-37.

FIGURE 6-38.

FAM0610

10/07

Chassis Assembly

Page 6-35

24. Lift the air intake tubes into place. The weight of the LH tube is approximately 15 kg (33 lb). The weight of the RH tube is approximately 28 kg (62 lb). Secure the tubes in place with the hump hoses and clamps.

Page 6-36

Chassis Assembly

10/07 FAM0610

FIGURE 6-39.

FIGURE 6-40.

FAM0610

10/07

Chassis Assembly

Page 6-37

25. Lift the center deck into position on the truck. The weight of the deck is approximately 233 kg (514 lb). Install the deck mounting cap screws and tighten to standard torque. Refer to Standard Tables in Section 10, Appendix.

26. Lift the diagonal ladder into position on the truck. The weight of the ladder is approximately 130 kg (287 lb). Install the ladder mounting hardware and tighten to standard torque.

Page 6-38

Chassis Assembly

10/07 FAM0610

FIGURE 6-41.

FIGURE 6-42.

FAM0610

10/07

Chassis Assembly

Page 6-39

27. Tighten the cap screws that secure the diagonal ROPS beam and the decks. Tighten the cap screws to standard torque.Refer to Standard Tables in Section 10, Appendix.

28. Weld the uprights in place. Refer to Figure 6-45 for welding specifications.

Page 6-40

Chassis Assembly

10/07 FAM0610

FIGURE 6-43.

FIGURE 6-44.

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10/07

Chassis Assembly

Page 6-41

FIGURE 6-45.

Page 6-42

Chassis Assembly

10/07 FAM0610

NOTES

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10/07

Chassis Assembly

Page 6-43

29. Raise the front of the truck for front wheel installation. NOTE: Clean the mating surfaces before installing the wheels. 30. Using a tire handler, lift the front wheel into position on the wheel hub. Install the wheel retainer lugs and lubricated nuts. Evenly tighten each nut using the sequence shown in Figure 6-46 to 407 N·m (300 ft lbs). 31. Spin the wheel and check the rim run-out. Maximum run-out is 5 mm (0.20 in.). If run-out exceeds specifications, loosen all nuts and retighten them in the proper sequence. 32. If run-out is within specifications, then tighten each nut in the proper sequence to 746 N·m. (550 ft lbs). 33. Connect the valve stem to the wheel hub. 34. After truck assembly operate the truck for one load and retighten the wheel nuts, as specified. Recheck the nut torque daily (each 24 hours of operation) to ensure proper torque is maintained on each nut. Once torque is maintained, daily checking is no longer required. Check intermittently to ensure torque is maintained.

FIGURE 6-46. FRONT WHEEL TIGHTENING SEQUENCE

FIGURE 6-47.

Page 6-44

Chassis Assembly

10/07 FAM0610

35. Attach the tire handler (or lifting device) to the inner dual and install the inner dual onto the wheel motor hub. Do not damage the tire inflation extension line. NOTE: During inner wheel installation, ensure the air inflation line lays in the channel on the wheel hub assembly.

36. Using a lifting device, install the rear wheel spacer onto the wheel motor hub. Tap the spacer up against the inner dual. 37. Attach the tire handler to the outer dual and position onto the wheel motor hub. NOTE: Position the outer dual wheel so that the tire valve bracket aligns with the inner wheel inflation line.

38. Install the wedges onto the studs and secure in place with the lubricated wheel nuts. Evenly tighten each nut in an alternating pattern, as shown in Figure 6-48, to 407 N·m (300 ft lbs).

FIGURE 6-48. REAR WHEEL TIGHTENING SEQUENCE

39. Spin the wheel and check the rim run-out. Maximum run-out is 5 mm (0.20 in.). If the run-out exceeds specifications, then loosen all the nuts and re-tighten them evenly in the proper sequence. 40. If run-out is within specifications, tighten each nut in the proper sequence to 746 N·m (550 ft lbs). 41. Secure the inner and outer dual tire inflation lines to the bracket on the outer rim. Tighten the cap screws to standard torque. 42. Install the wheel cover. Remove the blocks from under the truck and lower the truck to the ground. 43. After truck assembly is complete, operate the truck for one load and retighten the wheel nuts in the proper sequence. Recheck the nut torque daily (each 24 hours of operation) to ensure proper torque is maintained on each nut. Once the torque is maintained, daily checking is no longer required. Check intermittently to ensure torque is maintained.

FAM0610

10/07

Chassis Assembly

Page 6-45

FIGURE 6-49.

FIGURE 6-50.

Page 6-46

Chassis Assembly

10/07 FAM0610

FIGURE 6-51.

FIGURE 6-52.

FAM0610

10/07

Chassis Assembly

Page 6-47

44. Complete the wiring for the control cabinet and retarding grid.

FIGURE 6-53.

Page 6-48

Chassis Assembly

10/07 FAM0610

FIGURE 6-54.

FIGURE 6-55.

FAM0610

10/07

Chassis Assembly

Page 6-49

45. Install the exhaust system.

FIGURE 6-56.

FIGURE 6-57.

Page 6-50

Chassis Assembly

10/07 FAM0610

FAM0610

10/07

Chassis Assembly

Page 6-51

46. Install the blower hose and clamps to the control cabinet and alternator.

47. LIft the air intake ductwork into position and install the mounting hardware. The weight of the inlet duct is approximately 214 kg (472 lb). Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.

FIGURE 6-58.

Page 6-52

Chassis Assembly

10/07 FAM0610

FIGURE 6-59.

FIGURE 6-60.

FAM0610

10/07

Chassis Assembly

Page 6-53

FIGURE 6-61.

FIGURE 6-62.

Page 6-54

Chassis Assembly

10/07 FAM0610

NOTES

FAM0610

10/07

Chassis Assembly

Page 6-55

48. Install the hangers to the intake and exhaust tubes.

Page 6-56

Chassis Assembly

10/07 FAM0610

FIGURE 6-63.

FIGURE 6-64.

FAM0610

10/07

Chassis Assembly

Page 6-57

49. Install and wire the battery boxes. Refer to the electrical schematic for reference.

Page 6-58

Chassis Assembly

10/07 FAM0610

FIGURE 6-65.

FIGURE 6-66.

FAM0610

10/07

Chassis Assembly

Page 6-59

50. Finish routing and connecting remaining hydraulic, electric, and lubrication connections. Install the clamping for each component. 51. After the chassis assembly is complete, the body can be installed. Refer to Section 8 for more information.

FIGURE 6-67.

Page 6-60

Chassis Assembly

10/07 FAM0610

FIGURE 6-68.

FIGURE 6-69.

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10/07

Chassis Assembly

Page 6-61

FIGURE 6-70.

FIGURE 6-71.

Page 6-62

Chassis Assembly

10/07 FAM0610

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.

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

FIGURE 7-18.

FIGURE 7-20.

FAM0710

Dump Body Assembly

7-7

7. Install any optional equipment such as body liners and side boards. 8. Clean the weld joints and paint.

7-8

Dump Body Assembly

FAM0710

DUMP BODY INSTALLATION Installation

Before raising or lifting the body, ensure there is adequate clearance between the body and overhead structures or electric power lines. Body weight can vary substantially, depending on liner plate installation, etc. Ensure the lifting device is rated for at least a 45 ton capacity.

1. Attach the lifting device to the dump body and lower over the truck frame. Align the body pivot and frame pivot holes. 2. Install shims (3, Figure 8-3), as required, to center the body on the frame pivot. NOTE: A minimum of one shim is required at the outside end of the frame pivot. DO NOT install shims at the inside.

FIGURE 8-1.

FAM0809

Dump Body Installation

Page 8-1

FIGURE 8-2.

FIGURE 8-3. DUMP BODY PIVOT PIN (RH Side Shown) 1. Body 2. Bushing 3. Shim

Page 8-2

4. Pin Retainer Capscrew 5. Frame 6. Body Pivot Pin

Dump Body Installation

FAM0809

3. Align the pin retainer cap screw hole and push the pivot pin through the spacers and into the pivot bushings in each side of the frame. 4. Install the cap screw through each pin and tighten the nuts to standard torque.

5. Align the hoist cylinder upper mounting eye with the body. Align the retaining cap screw hole and install the pin. 6. Install the pin retaining cap screws and nuts and tighten to standard torque.

FAM0809

Dump Body Installation

Page 8-3

FIGURE 8-4.

FIGURE 8-5. HOIST CYLINDER MOUNT (UPPER) 1. Dump Body 2. Hoist Cylinder Pin

Page 8-4

3. Hoist Cylinder 4. Pin Retainer

Dump Body Installation

FAM0809

BODY SLING

BODY PADS

Any time personnel are required to perform maintenance on the vehicle with the dump body in the raised position, the body must be supported in the raised position with the body sling cable.

NOTE: It is not necessary to remove the dump body to replace the body pads. The pads must be inspected during scheduled maintenance inspections and replaced if worn excessively.

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

Inspect the cable and mounting brackets for signs of fatigue or wear before use.

1. To lock the dump body in the UP position, raise the body to its maximum height. 2. Remove the pins storing the sling in the storage position and place the cable clevis over the eye below the rear suspension mount and eye on the body. Reinsert the pins and retainers. 3. Slowly lower the body until the cable is tight. 4. After the work has been completed, raise the body, unhook the cable, and reattach to its storage position.

Place the blocks between the body and frame. Secure the blocks in place. 2. Place the pad and shims into position. Install the mounting hardware and tighten to 34 N·m (25 ft lbs). Repeat at each pad location. 3. Raise the body, remove the blocks supporting the body, and lower the body onto the frame.

FIGURE 8-6. BODY PAD 4. Body Pad 1. Dump Body 5. Frame 2. Shim 3. Pad Mounting Hardware

FAM0809

Dump Body Installation

Page 8-5

Adjustment 1. All pads, except the rear pad on each side, must contact the frame with approximately equal compression of the rubber. 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. If the pad contact appears to be unequal, repeat the above procedure. The vehicle must be parked on a flat, level surface for inspection. Proper body pad to frame contact is required to ensure maximum pad life.

FIGURE 8-7.

Page 8-6

Dump Body Installation

FAM0809

BODY GUIDE

ROCK EJECTORS

The body guide is designed to ensure the body is positioned properly on the frame to prevent excessive body pad and pivot pin bushing wear during truck operation.

Rock ejectors are placed between the rear dual wheels to keep rocks or other material from lodging between the tires.

1. Body guide wear points must be inspected each time a body pad inspection is performed. Refer to Figure 8-8. The body guide must be centered between wear plates (4), with a gap of 5.0 mm (0.19 in.) at each side when new. 2. If the gap becomes excessive, wear plates (4) must be replaced.

The rock ejectors must be inspected during tire inspections. If the ejectors are bent or worn excessively, they must be repaired or replaced to prevent possible tire damage. Inspection 1. The ejectors must be positioned on the vertical center line between the rear tires within 5.0 mm (0.19 in.). 2. With the truck parked on a level surface, arm (2, Figure 8-9) must be approximately 80 mm (3.15 in.) from wheel spacer ring (3). 3. If arm (1) becomes bent, it must be removed and straightened. 4. Wear plates (2) must be replaced if severely worn. 5. Inspect the mounting brackets, pins, and stops for wear and/or damage, and repair as necessary.

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

3. Frame 4. Wear Plate

FIGURE 8-9. ROCK EJECTOR INSTALLATION 1. Rock Ejector Arm 2. Wear Plate

FAM0809

Dump Body Installation

3. Rear Wheel Spacer Ring

Page 8-7

BODY SWITCHES Refer to Figure 8-10 to properly position the body switches.

FINAL ASSEMBLY Install the remaining items to the body and associated components including: lubrication lines, mud flaps, decals, body position indicator, etc.

Page 8-8

Dump Body Installation

FAM0809

FIGURE 8-10. FAM0809

Dump Body Installation

Page 8-9

NOTES

Page 8-10

Dump Body Installation

FAM0809

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 and prepare for operation. Several checks and tasks are outlined in Section 10, Appendix. 6. Complete the checks listed in the Field Assembly Inspection Report Form. A copy of the form is provided with the truck and is also available in Section 10, Appendix. 7. Operate the truck in a traffic-free area until safe operation has been validated. 8. Release the truck for use after all checks have been completed and all deficiencies corrected.

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 3. Toe In Adjustment 4. Automatic Lubrication System Checkout 5. Air Conditioning Checkout Procedure - EL4302 6. Air Conditioning Drive Belt Adjustment Procedure - EL9330 7. Hydraulic Checkout Procedure - EL2601 8. Brake Checkout Procedure - EF5761 9. VHMS Checkout Procedure - EK8480

10. Payload Meter III Checkout Procedure - EJ3061

11. Electrical Checkout Procedure - EK8477

12. Standard Torque Charts and Conversion Tables

13. Field Assembly Inspection Report

14. 50 Hour Post Commissioning Checksheet

FAM1005

Appendix

Page 10-1

NOTES

Page 10-2

Appendix

FAM1005

LUBRICATION CHART

NOTES

SUSPENSION OILING AND CHARGING GENERAL These procedures cover the oiling and charging of Hydrair®II suspensions on Komatsu 730E 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. will 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.

For best results, charge Hydrair® II suspensions in pairs (fronts together and rears together). If rears are to be charged, the fronts must be charged first. NOTE: For longer life of the suspension components, a friction modifier must be added to the suspension oil. See Specifications chart, Figure 4-6, at the end of this chapter. NOTE: Set up dimensions specified in the charts must be maintained during oiling and charging procedures. However, after the truck has been operated, these dimensions may vary.

EQUIPMENT LIST • Hydrair® Charging Kit • Jacks and/or Overhead Crane • Support Blocks for: Oiling Height Dimensions (Front and Rear)

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.

Charging Height Dimensions (Front Only) • Hydrair® Oil (See Specifications Chart) • Friction Modifier (See Specifications Chart) • Dry Nitrogen (See Specifications Chart) •

®

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

Hydrair® Charging Kit Assemble service kit, as shown in Figure 4-1, and attach to container of pure dry nitrogen gas (8).

2. The suspension piston rod extension for nitrogen charging must be correct. 3. The nitrogen charge pressure must be correct.

Installation of Charging Kit 1. Remove protective covers and charging valve caps from suspensions to be charged. 2. Turn T handle valve (1, Figure 4-1) of charging valve adapters (2) completely counterclockwise. 3. Ensure manifold outlet valves (3) and inlet valve (4) are closed (turned completely clockwise).

Suspension Oiling and Charging

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 handle valve (1) clockwise. This will depress the core of the charging valve and open the gas chamber of the suspension. 7. Open both manifold outlet valves (3). NOTE: By selective opening and closing of manifold outlet valves (3) and inlet valve (4), suspensions may be charged separately or together.

Removal of Charging Kit 1. Close both manifold outlet valves (3). 2. Turn T handle valve (1) counterclockwise to release charging valve cores. 3. Remove charging valve adapters (2) from the charging valves. 4. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs). 5. If a new charging valve is being used, tighten the swivel nut to 14.2 N·m (10.5 ft lbs). Loosen and retighten swivel nut to 14.2 N·m (10.5 ft lbs). Again loosen the swivel nut and retighten to 5.4 N·m (4 ft lbs). Install valve cap (1) and tighten to 3.3 N·m (2.5 ft lbs). 6. Install charging valve caps and protective covers on both suspensions.

Support Blocks For Oiling and Charging Dimensions Prior to starting the oiling and charging procedures, supports must be fabricated which will maintain the correct exposed piston rod extensions.

FIGURE 4-1. HYDRAIR® CHARGING KIT NOTE: The arrangement of parts may vary from the illustration above, depending on the 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 4-6)

Nitrogen charging support blocks for the rear suspension are not longer necessary. However, oiling blocks are necessary to properly set the oiling height. Exposed piston rod extensions are specified for both oil level and nitrogen charging for Hydrair®II suspensions. These dimensions are listed in the tables below Figures 4-2 and 4-5. Measure the dimensions from the face of the cylinder gland to the machined surface on the spindle at the front suspension. At the rear suspension, measure from the face of the cylinder gland to the piston flange.

Suspension Oiling and Charging

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

All Hydrair®II suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury and/or damage if improperly handled. Follow all the safety notes, cautions, and warnings in these procedures to prevent accidents during servicing and charging. 1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the wheels. 2. Thoroughly clean the area around the charging valve on the suspensions. Remove the protective covers from the charging valves.

NOTE: For longer life of suspension components, a friction modifier must be added to the suspension oil. See the Oil and Nitrogen Specifications chart, Figure 4-6, at the end of this chapter.

1. Position and secure the 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 must 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 the valve seal. DO NOT turn the large hex. The charging valve body has a bleeder groove in its mounting threads, but for the 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 the nitrogen pressure from the suspension. When all nitrogen has been vented to the atmosphere, the suspension will have collapsed slowly and be seated solidly on the support blocks. Remove the top fill plug next to the charging valve (Figure 4-2).

Front Suspension Oiling

When the 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!

Suspension Oiling and Charging

Front Suspension Nitrogen Charging

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

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

FIGURE 4-2. FRONT SUSPENSION FRONT SUSPENSION DIMENSIONS (EMPTY) TRUCK MODEL AND OPTIONS

OILING HEIGHT IN. (mm)

CHARGING HEIGHT IN. (mm)

CHARGING PRESSURE psi (kPa)

730E*

1.5 (38.1)

9.0 (229)

400 (2758)

* with standard rock body Note: If truck starts to lift off blocks before charging pressure is attained, stop charging.

FIGURE 4-3. CHARGING VALVE 4. Fill the suspension with clean Hydrair® oil, with 6% friction modifier, until the cylinder is full to the top of the fill plug bore. Drip pans must be used and all spillage cleaned from outside of the suspension. Allow the suspension to settle 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.

1. Valve Cap 2. Seal 3. Valve Core 4. Swivel Nut 5. Rubber Washer

Suspension Oiling and Charging

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

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

10. Close inlet valve (4, Figure 4-1). Leave manifold outlet valves (3) open for five minutes in order to allow the pressures in the suspensions to equalize. 11. Close manifold outlet valves (3) and remove charging kit components. Refer to Removal of Charging Kit.

Dry nitrogen is the only gas approved for use in Hydrair®II suspensions. 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 4-6). 3. Install Hydrair® charging kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit in this chapter. 4. Charge the suspensions with nitrogen gas to 50.8 mm (2 in.) greater than the charging height listed in Figure 4-2. 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. 6. Remove the center hose from manifold (6). 7. Open inlet valve (4) until the pressure has dropped below the pressure listed in Figure 4-2, and then close the valve.

12. If the charging valve is being reused, tighten swivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs). 13. If a new charging valve is being used, tighten the swivel nut to 14.2 N·m (10.5 ft lbs). Loosen and retighten the swivel nut to 14.2 N·m (10.5 ft lbs). Again loosen the swivel nut and retighten to 5.4 N·m (4 ft lbs). Install valve cap (1) and tighten to 3.3 N·m (2.5 ft lbs). 14. Install a protective guard over the charging valve. 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 from stop to stop several times. If the suspensions still do not extend enough to allow for removal of the blocks, use a crane or floor jacks to raise the truck and remove the blocks. The front suspensions are now ready for operation. Visually check 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 will also be noted.

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

Suspension Oiling and Charging

REAR SUSPENSION 1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the wheels. 2. Thoroughly clean the area around the charging valve on the suspensions. Remove the protective covers from the charging valves and the rubber covers from the suspension piston.

When oiling blocks are used, they must be secured in place with a strap or some other means. An unsecured block can fly loose as weight is applied, presenting the possibility of serious injury and/or damage.

Rear Suspension Oiling NOTE: For longer life of suspension components, a friction modifier must be added to the suspension oil. See Specifications chart, Figure 4-6, at the end of this chapter. 1. Position and secure the oiling blocks in place (Figure 4-4) so the blocks are seated between the frame and the rear axle housing. A block must be used on both the left and right sides of the truck.

Ensure 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 the valve seal. DO NOT turn the large hex. The charging valve body has a bleeder groove in its mounting threads, but for safety of all personnel, the valve body must not be loosened until all nitrogen pressure has been vented from the suspension. 3. Depress the charging valve core to release nitrogen pressure from the suspension. When nitrogen pressure has been vented to the atmosphere, loosen and remove the fill plug. The suspension will have collapsed slowly as gas pressure was released. The weight of the truck is now supported by the support blocks. NOTE: A plastic tube may be used to help bleed off trapped air inside the piston. 4. Remove the vent plug, pressure sensor, and charging valve. Refer to Figure 4-5. Use one of the open ports to fill the suspension with clean Hydrair® oil, with 6% friction modifier. Fill until clean oil seeps from the open ports. Drip pans must be used, and all spillage cleaned from the outside of the suspension. 5. Allow the suspension to settle for at least 15 minutes to clear any trapped nitrogen and/or air bubbles from the oil. Add oil if necessary. 6. Install the vent plug and pressure sensor onto the suspension. 7. Installation a new O-ring onto the charging valve. Lubricate the O-ring with clean Hydrair® oil. Install the charging valve onto the suspension and tighten valve body (6, Figure 4-3) to 22.4 N·m (16.5 ft lbs).

Suspension Oiling and Charging

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

3. Rear Axle Housing

FIGURE 4-5. REAR SUSPENSION

REAR SUSPENSION DIMENSIONS (EMPTY) TRUCK MODEL AND OPTIONS

OILING HEIGHT IN. (mm)

CHARGING HEIGHT IN. (mm)

*CHARGING PRESSURE psi (kPa)

730E

2.9 (72.6)

10.9 (276)

206 (1420)

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

Suspension Oiling and Charging

Rear Suspension Nitrogen Charging 3. Install Hydrair® charging kit and a bottle of pure dry nitrogen. Refer to Installation of Charging Kit. Lifting equipment (overhead or mobile cranes, or hydraulic jacks) must be of sufficient capacity to lift the weight of the truck. Ensure that all personnel are clear of the lift area before the lift is started. Clearances under the truck may be suddenly reduced.

Ensure the automatic apply circuit has not applied the service brakes during truck maintenance. If the front brakes are applied during rear suspension charging, the axle cannot pivot for frame raising/lowering, and the rear suspension may be unable to move up or down. 1. If removed, install charging valve with new Oring (9, Figure 4-3). Lubricate the O-ring with clean Hydrair®oil. 2. Tighten the valve body (large hex, 6) to 22.4 N·m (16.5 ft lbs). 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 4-6).

4. Charge the suspensions with nitrogen gas to 50.8 mm (2 in.) greater than the charging height listed in Figure 4-5. 5. Slowly release the gas until the suspensions match the charging height listed in Figure 4-5. 6. Close inlet valve (4, Figure 4-1). Leave manifold outlet valves (3) open for five minutes in order to allow the pressures in the suspensions to equalize. 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, check the front suspensions for equal extension. Adjust the front as necessary. NOTE: A low left front suspension will cause the right rear suspension to be high. A low right front suspension will cause the left rear suspension to be high. 8. Close manifold outlet valves (3) and remove the 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). 10. If a new charging valve is being used, tighten swivel nut to 14.2 N·m (10.5 ft lbs). Loosen and retighten the swivel nut to 14.2 N·m (10.5 ft lbs). Again, loosen the swivel nut and retighten to 5.4 N·m (4 ft lbs). Replace valve cap (1) and tighten to 3.3 N·m (2.5 ft lbs). 11. Install the protective guards over the charging valves. Install the rubber covers over the piston rods. The rear suspensions are now ready for operation. Visually check piston extension 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 will also be noted.

Suspension Oiling and Charging

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

-34.5°C- and above (30°F and above)

Part No.

Approved Sources

VJ3911 (need to add 6% of AK3761)

Mobil 424 Mobil D.T.E. 15 Texaco TDH Oil Amoco Ultimate Motor Oil 5W-30

Sunfleet TH Universal Tractor Fluid Chevron Tractor Hydraulic FluidConoco Power Tran III Fluid Petro Canada Duratran Fluid Shell Canada Donax TDL

AK4063

Suspension Oil (premixed with 6% friction modifier)

5 Gallon container

AK4064

-48.5°C and above (-55°F and above)

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 19 Liter (5 gallon) cans.

FRICTION MODIFIER

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

Part No.

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

-55°C (-68°F) maximum

Oxygen

0.1% maximum

FIGURE 4-6. SPECIFICATIONS CHART

Suspension Oiling and Charging

NOTES

Suspension Oiling and Charging

TOE-IN ADJUSTMENT 1. Move the truck to a flat, level surface. Align the front wheels in a straight ahead position and then turn the key switch to the OFF position. Allow at least 90 seconds for the steering circuit to depressurize. DO NOT turn the steering wheel during this time. After 90 seconds, verify that the circuit is depressurized by turning the steering wheel. If the wheels do not turn, the truck is safe to adjust. Chock the wheels to prevent truck movement. 2. Check the toe-in by measuring the distance between the centers of the front tires. Refer to Figure 3-1. Measure along the horizontal centerlines at the front and rear of the front tires. 3. For trucks equipped with radial tires, the measurements at the front and rear of the tires must be equal. Equal measurements at the front and rear result in 0 toe-in. If the measurements are not equal, the tie rod must be adjusted. Proceed to the next step. The nominal front measurement for bias ply tires is 1.9 ± 0.6 (0.75 ± 0.25 in) less than the rear measurement. If the measurement is not within this range, the tie rod must be applied. Proceed to the next step. 4. Loosen the clamp locknuts on the tie rod and rotate the tie rod as necessary to obtain the correct toe-in setting. Refer to Table 2 for additional information. TOE-IN DATA

cm (in.)

Nominal tie-rod length, radial tires. (Zero toe-in)

349.2 (137.48)

Nominal tie-rod length, bias ply tires 1.9 mm (0.75 in. toe-in)

349.6 (137.63)

Change in toe-in dimension with one full turn of tie rod

2.0 (0.79)

FIGURE 3-1 MEASURING TOE-IN

5. When the adjustment is complete, tighten the clamp locknuts on the tie rod to 430 N·m (310 ft lbs). 6. Remove the chocks from the rear wheels.

G03027

Front Wheel Hub and Spindle

G3-1

NOTES

G3-2

Front Wheel Hub and Spindle

G03027

AUTOMATIC LUBRICATION SYSTEM LUBRICANT REQUIRED FOR SYSTEM

LUBRICANT PUMP

Grease requirements will depend on ambient temperatures encountered during truck operation:

Pump Housing Oil Level

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

The pump housing must be filled to the proper level with SAE 10W30 motor oil. Oil level must be checked at 1000 hour intervals. To add oil, remove oil level plug (4, Figure 3-1) and fill the housing to the bottom of the plug hole.

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

Pump Pressure Control

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

NLGI

No.2

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.

High pressure hydraulic fluid from the truck steering system is reduced to 2240 to 2413 kPa (325 to 350 psi) by the pressure reducing valve located on the manifold on top of the pump motor. This pressure can be read on the gauge installed on the manifold and must be checked occasionally to verify pressure is within the above limits.

1. Fill lubrication reservoir with lubricant, if necessary. 2. To purge air from the main supply line, remove the main supply line at outlet port (6, Figure 3-1) 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 an 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 CONTROLS 1. Pump Pressure Control 2. Manifold 3. Pressure Gauge

Automatic Lubrication System

4. Oil Level Plug 5. Flow Control Valve 6. Outlet Port 7. Manual Override

INJECTORS (SL-1 Series H) Injector Specifications • Each lubrication injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of external lubricating equipment. • Injector Output Volume: Maximum Output =1.31 cc (0.08 in3) Minimum Output = 0.13 cc (0.008 in3) • Operating Pressure: Minimum - 12755 kPa (1850 psi) Maximum- 24133 kPa (3500 psi) Recommended - 17238 kPa (2500 psi) • Maximum Vent Pressure (Recharge): 4137 kPa (600 psi) Injector Adjustment The injectors may be adjusted to supply from 0.13 1.31 cc (0.008 - 0.08 in3) of lubricant per injection cycle. The injector piston travel distance determines the amount of lubricant supplied. This travel is controlled by an adjusting screw in the top of the injector housing. Turn adjusting screw (1, Figure 3-2) counterclockwise to increase lubricant amount delivered and clockwise to decrease the lubricant amount. When the injector is not pressurized, maximum injector delivery volume is attained by turning adjusting screw (1) fully counterclockwise until piston assembly (8) touches the adjusting screw. At the maximum delivery point, about 9.7 mm (0.38 in.) adjusting screw threads must be showing. Decrease the delivered lubricant amount by turning the adjusting screw clockwise to limit injector piston travel. If only half the lubricant is needed, turn the adjusting screw to the point where about 4.8 mm (0.19 in.) threads are showing. The injector will be set at the minimum delivery point with about 0.22 mm (0.009 in.) thread showing. NOTE: The above information concerns adjustment of injector delivery volume. The timer adjustment must also be changed if overall lubricant delivery is too little or too much. Injector output must not be adjusted to less than one-fourth capacity.

FIGURE 3-2. TYPE SL-1 INJECTOR 1. Adjusting Screw 2. Locknut 3. Piston Stop Plug 4. Gasket 5. Washer 6. Viton O-Ring 7. Injector Body Assembly 8. Piston Assembly 9. Fitting Assembly 10. Plunger Spring

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

NOTE: Piston assembly (8) has a visible indicator pin at the top of the assembly to verify injector operation. NOTE: Piston stop plug (3) must be tightened to 34-41 N·m (25-30 ft lbs). Adapter (19) must be tightened to 61-68 N·m (45-50 ft lbs).

Automatic Lubrication System

SYSTEM CHECKOUT To check system operation, not including the timer, proceed as follows: 1. Start the engine. 2. Actuate the test switch at the reservoir/pump assembly. 3. The motor and pump will operate until the system attains 20685 kPa (3000 psi). 4. Once the required pressure is achieved, the pump motor will turn off and the system will vent. 5. Check for pump, hose, or injector damage or leakage when the system is pressurized. 6. After checking the system, shut the engine off. Observe normal precautions regarding high voltage present in the propulsion system before attempting to repair the lubrication system.

Lubrication Cycle Timer Check To check the solid-state timer operation without waiting for the normal timer setting, proceed as follows: NOTE: The timer incorporates a liquid and dust-tight cover which must be in place and secured at all times during truck operation. 1. Remove the dust cover. 2. Adjust timer selector (3, Figure 3-4) to the five minute interval setting. 3. The timer must cycle in five minutes if the truck is operating.

FIGURE 3-3. LOCATION OF LUBRICATION CYCLE TIMER 2. Lubrication Cycle 1. Cab Interface Timer Compartment Under Passenger Seat .

NOTE: If the timer check is being made on a cold start, the first cycle will be approximately double the nominal setting. All subsequent cycles must be within the selected time tolerance. 4. Perform voltage checks at the timer if the above checks do not identify the problem. a. Ensure that the timer ground connection is clean and tight. b. With the key switch on, use a voltmeter to read the voltage between the positive and negative posts on the solid-state timer. A normal reading must be 18 to 26VDC, depending upon whether the engine is on or not.

FIGURE 3-4. LUBRICATION CYCLE TIMER (SHOWN WITH COVER REMOVED) 1. Timer Enclosure 2. Red LED

Automatic Lubrication System

3. Timer Selector

Lubrication Cycle Timer Adjustment

100 Hour Inspection 1. Check the oil after every 100 hours of operation. The crankcase must be filled to the center of the drain plug located on the back of the crankcase.

The timer is set at the factory for a nominal 2.5 minute (off time) interval. Dwell time is approximately 75 seconds. A longer interval (off time) is obtained by turning the timer selector to the desired position. Set the timer by turning the timer selector to the 2.5 minute setting. Then turn the selector clockwise one detent at a time to the desired setting, or until the maximum limit of 80 minutes is reached.

250 Hour Inspection

NOTE: The timer is a sealed unit. DO NOT attempt to disassemble it.

1. Check all grease hoses from the SL-1 injectors to the lubrication points. a. Repair or replace all worn and broken hoses. b. Ensure all the air is purged and all new feed line hoses are filled with grease before sending the truck back into service.

PREVENTIVE MAINTENANCE INSPECTION Use the following maintenance procedures to ensure proper system operation. 10 Hour Lubrication System Inspection 1. Check the grease reservoir level. Inspect the grease level height after each shift of operation. The grease usage must be consistent from day-to-day operations. Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate a broken supply line. 2. Check the filter bypass indicator when filling the reservoir. Replace the element if bypassing.

2. Check all grease supply line hoses from the pump to the SL-1 injectors. a. Repair or replace all worn and broken supply lines. b. Ensure all air is purged and all new supply line hoses are filled with grease before sending the truck back into service. 3. Check the grease reservoir level. a. Fill the reservoir if low. Check the filter bypass indicator when filling the reservoir. Replace the element if bypassing. b. Check the reservoir for contaminants. Clean, if required.

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

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

a. Repair or replace all damaged feed line hoses.

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

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

It is good practice to manually lubricate 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.

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

Automatic Lubrication System

500 Hour Inspection

5. System Checkout. a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation.

1. Change the oil after every 500 hours of operation. Use SAE 10W30 motor oil.

b. Start the truck engine. c. Actuate manual override (7, Figure 3-1). The hydraulic motor and grease pump should operate. d. With the system pressurized, check each SL-1 injector assembly. The cycle indicator pin will be retracted inside the injector body.

1000 Hour Inspection 1. Check the pump housing oil level. Refill to the bottom of the level plug with SAE 10W30 motor oil, if necessary.

e. When the system attains 20685 kPa (3000 psi), the pump will shut off and the pressure in the system will 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 must be visible. Replace or repair the injectors, if defective. g. Reinstall all the injector cover caps. h. Check the timer operation.

NOTE: With the engine on, the lubrication system will activate within five minutes. System pressure will build to 20685 kPa (3000 psi) within 25-40 seconds.

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

Automatic Lubrication System

NOTES

Automatic Lubrication System

NOTES:

NOTES:

NOTES:

KOMAtsu CHECK-OUT PROCEDURE NAME BRAKE SYSTEM CHECKOUT WRITTEN BY DATE D. D. Smith 6/20/95 CHECKED

tH

n.

R.

DATE

BY

DATE

J. McClone

6/26/95

MACHINE& HODEL

L EF5761 'a,-

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Necessary Equipment 1. Check-out procedure and 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 of air. 4. If truck is only partially assembled and this check-out is to be done without brakes installed, brake simulators are required in order to simulate the brake volumes. 5. At least 3, calibrated gauges with quick-connect 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. (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 check-out group for procedures and specifications. Initial System Set-up 1. Install pressure measuring instruments at: (a) Test Port BF (brake cabinet) (b) Test Port BR (brake cabinet) (c) Test Port LAP1 (brake manifold)

2. Open each brake accumulator bleed down valve and precharge both accumulators to 1400 psi. Allow gas temperature to approach ambient temperature before completing precharge process.

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Komatsu Mining Systems, Inc. Peoria Operations

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Note: For best performance, charge accumulators in the ambient conditions in which the machine will be operating. 3. Close both accumulator bleed down valves. Ifbrakes have not been assembled to truck when check-out is performed, attach brake simulators to the brake application lines. *

4. Start engine to fill accumulators with oil. Observe rising brake pressures as system charges. Brake pressure should begin to fall when Auto Apply Valve releases. The brake pressures when auto apply releases should be approximately 1750 psi front and 1700 psi rear. Record the brake pressures at auto apply release. 5. Partially depress brake pedal and bleed air from bleeders located at each brake or brake simulators.

Parking Brake Note: Move one of the pressure measuring instruments from the BF or BR locations to port PK2 on the brake manifold. *

6. Apply brake lock. Release parking brake with park brake switch. Verify that park brake status light indicates parking brake is released. Record parking brake release pressure. (pressure should be 2600 =t100 psi).

*

7. Ifparking brakes are on vehicle, then measure the lining to disc clearance with feeler gauge and record the clearances. 8. Cycle park brake switch several times to assure crisp application and release of pressure and proper function of status light. 9. Apply parking brake and release brake lock. Note: Return the pressure measuring device to the BF or BR location.

Service Brakes 10. Very slowly depress brake pedal to check circuit tracking. Rear brake pressure must begin to rise before front brake pressure. Rear brake pressure should be between 45 and 205 psi when front brake pressure begins to rise. Force feedback of pedal on foot should be smooth with no abnormal noise or mechanical roughness. *

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11. Slowly depress brake pedal and record the rear brake pressure at which the stop

lights energize. (Thisshouldbe 75 =tpsi).

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12. Quickly and completely depress pedal and check to see that front brake pressure is 2500 i: 100 psi and that rear brake pressure is 1700i: 75 psi within 1 second. Holding pedal fully applied, both pressures should remain above their minimum values for a minimum of 20 seconds.

*

13. Release peda1. Brake pressure should return to zero with a couple of seconds and there should be no residual pressure trapped in brakes. If the vehicle is equipped with rear brakes check to see if rear brake linings are retracted from brake discs and are free and loose in brake calipers.

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Note: If step 13 is incorrect, perform deadband adjustment as follows: Insert a 'O.025"shimbetween valve and pedal return stop. Loosen jam nut. Adjust set screw until pressure begins to rise in one or both circuits. Back set screw off 1/8 turn and lock set screw with jam nut. Remove the shim. Brake Lock/Secondary 14. (A) Disconnect lead wire on brake lock solenoid, located on brake manifold in hydraulic cabinet and to the immediate right of the PK2 port. (B) Install jumper to connect delay timer wires together. 15. 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 BR pressure at which warning resumes. 16. Connect lead wire on brake lock solenoid and remove jumper from lead wires to timer. *

17. Cycle brake lock several times to assure crisp application of and release of pressure and proper function of status light. Record rear brake pressure, which should be 1500 i: 100 psi.

Low Brake Pressure and Auto Apply I

18. Allow engine to run until low brake accumulator pressure stabilizes at or above

2700 psi. *

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19. Shut engine down. Allow the steering accumulator to bleed completely down. Disable steering pressure switch from the brake warning circuit by unplugging the diode between circuits 33 and 33F. (This is diode 22 on diode board 1) Turn key switch on. After 2 minutes record the low accumulator pressure. (LAP1 port) If LAPI pressure is below 2100 psi, then leakage in the system is excessive and the source of the leakage needs to be identified.

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20. Crack the front brake accumulator bleed down valve and observe LAP 1 pressure. The low brake pressure lamp and buzzer must actuate at 1850::!::75 psi. Record this value. Brake pressures should begin to rise (auto apply) when LAP 1 reaches

1650::!:: 100psi. Recordthis value. Closefrontbrakeaccumulatorbleeddown valve. *

21. Record auto apply brake pressures. 22. Start engine to recharge hydraulic system. Allow e.qgineto run until low brake accumulator pressure stabilizes at or above 2700 psi. 23. Shut engine down. Allow the steering accumulator to bleed completely down. Turn key switch on. Crack the rear brake accumulator bleed down valve and observe LAP 1 pressure. Verify that the low brake pressure lamp and buzzer, and auto apply set points are within a 100 psi of those recorded in step 20. Close the rear brake accumulator bleed down valve.

*

24. Record auto apply brake pressures. Enable the steering pressure switch by plugging in the diode removed between circuits 33 and 33F.

Reapplications

25. Start engine to recharge hydraulic system. Allow engine to run until low brake accumulator pressure stabilizes at or above 2700 psi. *

26. Shut engine down. Do not allow steering accumulator to bleed down. Make repeated slow, complete brake applications with pedal until auto apply comes on. Record the number of brake applications prior to auto apply.

Differential Pressure Switch 27. Open each brake accumulator bleed down valve and bleed down the entire brake system. 28. Outside the brake cabinet, disconnect the hose that supplies oil from the front brake accumulator to the brake pedalinthe cab for the front brakes and plug the tube end at the cabinet. Be sure to leave end of hose vented to atmosphere. 29. Start engine. Allow the engine to run until LAP1 pressure stabilizes at or above 2700 psi. I:"-'i

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30. Very slowly depressthe brake pedal until the brake differential switch has activated the low brake pressurelamp and the buzzer. Record the rear brake pressure at the point this occurs. (The fault should occur @ 600 ~ 50 psi). Release the pedal.

31. Shut engine down and turn key switch off. Open each brake accumulator bleed down valve and bleed down entire brake system.

32. Outside the brake cabinet, reconnect the hose that connects the front brake accumulator to the brake pedal in cab. Disconnect the hose that supplies oil from the rear brake accumulator to the brake pedal in the cab for the rear brakes and plug the tube end at the cabinet. Be sure to leave end of hose vented to atmosphere. 33. Very slowly depress the brake pedal until the rear brake differential switch has activated the low brake pressure lamp and the buzzer. Record the front brake pressure at the point this occurs. (The fault should occur at 1O00::!:: 75 psi).

Release the pedal. .

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34. Shut engine down and turn key switch off Open each brake accumulator bleed down valve and bleed down the entire brake system. Outsidethe brake cabinet, reconnect the hose that connects the rear brake accumulator to.the brake pedal in cab. Remove all instrumentation and simulators. This concludes the brake system check-out.

*Asterisk denotes item to be recorded Data Sheet.

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HYDRAULIC BRAKE SYSTEM CHECK-OUT DATA SHEET

STEP 4

Front brake pressure when Auto Apply releases. Rear brake pressure when Auto Apply releases.

PARKING BRAKE SYSTEM

STEP 6

Parking brake release pressure.

STEP 7

Left outboard lining/disc gap. Left inboard lining/disc gap. Right outboard lining/disc gap. Right inboard lining/disc gap.

SERVICE BRAKE SYSTEM STEP 11

Rear brake pressure when stop lights energize.

STEP 12

Front brake pressure. (pedal applied) Rear brake pressure (pedal applied)

STEP 13

Front brake pressure (pedal released) ~ fTj \J1 ~ 0-, .......

Rear brake pressure (pedal released)

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BRAKE LOCK/SECONDARY SYSTEM STEP 15

Rear brake pressure when brake lock degradation fault occurs.

STEP 17

Rear brake pressure when brake lock is applied.

LOW BRAKE PRESSURE AND AUTO APPLY STEP 19

LAP pressure after 2 minutes.

STEP 20

LAP pressure when low brake pressure fault occurs. LAP pressure when auto apply occurs.

STEP 21

Front brake pressure after auto apply. Rear brake pressure after auto apply.

STEP 24

Front brake pressure after auto apply. Rear brake pressure after auto apply.

REAPPLICATIONS STEP 26

Number of applications prior to auto apply.

DIFFERENTIAL PRESSURE SWITCH STEP 30

Rear brake pressure at which the front differential fault occurs.

STEP 33

Front brake pressure at which the rear differential fault occurs.

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