Ce Aw 004101

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CEAW004101

Field Assembly

Manual

DUMP TRUCK

SERIAL NUMBERS A30427 & UP

®

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FAM0011 Introduction

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 out

lined 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 thecurrent 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 posi-

tion.

It is recommended that all maintenance personnel read and understand the materials in the service manual before

performing maintenance and/or operational checks on the assembled truck.

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ii Introduction FAM0011

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 oper-

ating 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.

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FAM0011 Introduction ii

TABLE OF CONTENTS

SUBJECT PAGE NUMBER

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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iv Introduction FAM0011

KOMATSU MODEL 730E DUMP TRUCK

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FAM0109 Safety Rules, Tools, & Equipment Page 1-1

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 pre-

vailing local rules and regulations.

1. All personnel must be properly trained for the

assembly operation.

2. Wear safety equipment such as safety glasses,

hard toe shoes and hard hats at all times during

assembly.

3. Thoroughly inspect the assembly site. Remove

weeds, debris and other flammable material.

4. Use only solid, hard wood for supports. When

using metal support stands, place wood blocksbetween the support and the frame to prevent

metal to metal contact.

5. Inspect all lifting devices. Refer to the manufac-

turer'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 compo-

nents.

11. When welding, connect the ground cable to the

part being welded. DO NOT allow welding cur-

rent 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, sock-

ets, etc. unless specified.

15. Lifting eyes and hooks must be fabricated from

the proper materials and rated to lift the

intended load.

16. When the weight of any component(s) or any

assembly procedure is not known, contact yourcustomer support manager for further informa-

tion.

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Page1-2 Safety Rules, Tools, & Equipment FAM0109

TOOLS AND EQUIPMENT FOR ASSEMBLY

The following equipment is recommended for field

assembly of the truck.

1. Equipment and tool storage trailer with a lock-

able door. Approximately 12 x 2.5 m (40 x 8 ft)2. Cranes

a. Two, 45 metric ton (50 ton) cranes to remove

the chassis from the freight trailer and place

on cribbing. These cranes can also be used

to lift the assembled body onto to the chas-

sis.

b. One, 109-136 metric tons (120-150 ton)

crane. The crane is needed to turn the body

over after completion of the underside weld-

ing. A 45 metric ton (50 ton) crane is also

required for this task.

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

4. Two, 300 amp portable welding units and an

oxy-acetylene cutting set.

5. One, propane torches for weld preheating.

6. Portable air compressor - 3.5 cmm (125 cfm)

and 690 kPa (100 psi) capacity.

Two, 15 m (50 ft) air hoses.

7. Metal stands and a sufficient amount of wood

cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm

(4 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15

cm (4 ft. x 6 in. x 6 in.) - such as railway crossties

8. Tire handler - Wiggins/Iowa Mold Tooling.

9. Miscellaneous air tools

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

11. Chains, lifting cables, slings:

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

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

• Two, 1 m (4 ft) and two, 2 m (6 ft)

• Two, 3 m (10 ft) nylon straps

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

of rope

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

13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)

14. Set of standard master mechanics hand tools.

• Thread taps and dies of both inch and metric

sizes.

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

• Inch sockets and open end wrenches up to 1

3/4 in.

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

18:1 multiplier. Torque wrenches - 339 N·m

(600 ft lb) with 4:1 multiplier. Hydrotorque - 1

1/2 in. drive with capability of 5559 N·m

(4100 ft lb) or greater.

• Box wrench 1 3/8 in. (Snap-On p/n X440B)

with 12 inch extension to tighten ROPS cap

screws.

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

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

front suspension hardware.

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

wrench sets.

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

tools.

17. Special tools (see list, following pages)

18. Two, hydraulic or pneumatic porta-power jacks,

4.5 and 9 metric ton (5 and 10 ton)

19. Various hooks and shackles

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

21. Spreader bars for cab and decks.

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

capacity.

23. Pry bars

24. Solvent - 38 liters (10 gal)

25. Paint remover - 19 liters (5 gal)

26. Rust preventive grease

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LIFTING SLING GENERALINFORMATION

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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

NOTE: Arrangement of parts may vary from the

illustration shown, depending on the charging kit P/N

Part

Number

Description Use

EB1759 Nitrogen

Charging Kit

Suspension and

Accumulator

Nitrogen

Charging

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


PB8326 Offset Box End

Wrench,

1 7/16”

Miscellaneous

and Cab

Mounting

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TZ2734 3/4” Torque

Adapter

Miscellaneous


TZ2733 Tubular Handle Use with

PB8326 and

TZ2734


TY2150 Seal Installa-

tion Tool

Installation of

Front Wheel

Bearing FaceSeals


EC1741

EC1742

TZ0992

Sleeve

Alignment Tool

Steering Linkage

and Tie Rod

Assembly. Refer

to Section G.

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AK4720 Payload Data

Manger

Payload Meter

Download. Refer

to Section D.EF9160 PLM Download

Harness


PB6039 Hydraulic

Coupling

Miscellaneous

Part Number Description UseTG1106 Eye Bolt Miscellaneous

Lifting

Requirements


TW9425 Special Wrench Accumulator

Gland Nut

PART NO. DESCRIPTION USEPC2061 Belt Tension

Tester

A/C Belt Tension

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Part

Number

Description Use

TZ8968 Socket 3-1/2” Miscellaneous



TV7567 Socket 1-5/16” Miscellaneous

PB6825 Impact Socket 1-5/8” Miscellaneous

TR0529 Socket 1-3/4” Miscellaneous




PB6824 Impact Socket 3-1/8” Miscellaneous

TZ8968 Socket 3-1/2” MiscellaneousTR0532 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 drivesockets)

Miscellaneous

PB6852 Locking Rubber Ring

(for use with 1-1/2”

square drive

sockets)

Miscellaneous

PART NO. DESCRIPTION USE

EL8868 V-Belt Align-

ment Tool

Aligning A/C

pulleys

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A S S E M B L Y S C

H E D U L E A N D

R E S O U R C E

L A Y O U T

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NOTES

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FAM0210 Major Components & Specifications FAM2-1

MAJOR COMPONENTS AND SPECIFICATIONS

The Komatsu model 730E dump truck is an electric drive, off-highway, rear dump truck. Standard 730E gross vehi

cle 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

The Komatsu 730E dump truck is powered by a

Komatsu SSA16V159 engine rated at 2000 HP(1492 kW).

ALTERNATOR (GE GTA-22)

The diesel engine drives an alternator mounted in-

line 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 electricalenergy back to mechanical energy through built-in

gear trains within the wheel motor assembly. The

direction of the wheel motors is controlled by a for-

ward 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 CABThe 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 steer-

ing wheel, controls mounted within easy reach of the

operator, and an analog instrument panel which pro-vides the operator with all instruments and gauges,

which are necessary to control and/or monitor the

truck's operating systems.

POWER STEERING

The Komatsu 730E dump truck is equipped with a

full-time power steering system, which provides posi-tive steering control with a minimum of effort by the

operator. The system includes nitrogen-charged

accumulators which automatically provide emer

gency power if the steering hydraulic pressure is

reduced below an established minimum.

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 elec

tric system is controlled by the operator through the

activation of the retarder pedal in the operator’s caband 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 dua

disc rear brakes. The rear brakes can also be acti

vated by operating a switch on the instrument panel.

All wheel brakes will be applied automatically if thesystem pressure decreases below a preset mini-

mum.

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.

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FAM2-2 Major Components & Specifications FAM0210

730E MAJOR COMPONENTS

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FAM0210 Major Components & Specifications FAM2-3

SPECIFICATIONS

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

ENGINE

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)

ELECTRIC DRIVE SYSTEM

STATEX III w/Fuelsaver . . . . . . . . . AC/DC Current

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

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

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

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

*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.

DYNAMIC RETARDING

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

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

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

. .Two-Speed Overspeed & Extended Range Retard-

ing

. . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Retarding

BATTERY ELECTRIC SYSTEM

Batteries . Bumper-Mounted in Polyethylene Boxes

. . . . . . . . . . Four 12-Volt Batteries in Series/Parallel

. . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity

. . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch

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

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-Volt

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

SERVICE CAPACITIES

Liters . . . U.S. Gallons

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/Whee

HYDRAULIC SYSTEM

Pumps:

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

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

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

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

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

Relief Pressure-Steering . . . . .27580 kPa (4000 psi

Hoist . . . . . . . . Two Three-Stage Hydraulic Cylinders

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

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

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

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

Hoist and Steering High-Pressure Filters

. . . . . . . . . . . . . . . . . Dual, Full Flow, Seven Micron

. . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 rating = 200

SERVICE BRAKES

Actuation . . . . . . . All Hydraulic - Caliper/Disc

. . . . . . . . . . . . . . . (Front) . . . . . . . . . . . . . . . .(Rear

Type . . . . . . . . .Single Disc. . . . . . . . . . . . Dual Disc

. . . . . . . . . . . . Wheel Speed. . . . . .Armature Speed

STEERING

Turning Circle (SAE). . . . . . . . . . . . . . . 28.0 m (92 ft

Twin hydraulic cylinders with accumulator assist toprovide constant rate steering.

Emergency power steering automatically provided by

accumulators (meets SAE J1511).

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FAM2-4 Major Components & Specifications FAM0210

These specifications are for the 730E dump truck without trolley assist. Specifications for trolley trucks will be dif-

ferent.

STANDARD DUMP BODY*

Capacity:

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°

*Optional capacity dump bodies are available.

TIRES

Radial Tires (standard) . . . . . . . . . . . . . . 37.00 R57

Rock Service, Deep Tread . . . . . . . . . . . . Tubeless

Rims . (Patented Phase II New Generation™ Rims)

Tires and Rims . . . . . . . . . . . . . . . Interchangeable

WEIGHT DISTRIBUTION

Empty Vehicle Kilog rams (Pounds)

Front Axle . . . . . . . . . . . . 66,840 . . . . (147,357)

Rear Axle . . . . . . . . . . . .73,752 . . . . . . .(162,593)

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)

Front Axle . . . . . . . . . . 107,026. . . . . . . 235,950)

Rear Axle. . . . . . . . . . . . 217,296. . . . . . . 479,050)

Total * . . . . . . . . . . . . . 324,322 . . . . . .(715,000)

Nominal Payload . . . . . 183,730. . . . . . . (405,050)

*Nominal payload is defined by Komatsu America

Corporation’s payload policy documentation. In gen-

eral, 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.

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FAM0310 Major Component Weights Page 3-1

MAJOR COMPONENT WEIGHTS

The condition of lifti ng 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 lif ted. DO NOT use worn o r damaged lifting equipment. Serious in jury 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 compo-

nents.

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

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Page 3-2 Major Component Weights FAM0310

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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FAM0406 Field Welding For Assembly Or Repair 4-1

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 con-

tact their distributors for information on the latest revi-

sion.

The welding information contained in this chapter is

general information that must be followed unless oth-

erwise specified in a detailed repair procedure pro-

vided on an engineering drawing or a detailed

specific repair procedure. Additional specific informa-

tion, or detailed instructions can be obtained through

your local Komatsu customer support manager.

WELDER QUALIFICATION ANDTRAINING

The welding technique must be of the highest stan-

dard to produce the soundest weld possible. Only

welders who have been trained and qualified for

structural steel welding in all positions, in conform-

ance 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 per-

form and inspect such field welds. Weld sizes speci-

fied on the drawings are intended to reflect minimum

requirements.

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 o

highly stressed structural members such as castingstorque 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 fo

repair procedures. These repair procedures are

detailed instructions for most high stressed structura

members.

APPROVED CONSUMABLES

GMAW - LW102-15 or ER80S-D2

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

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

WELD QUALITY REQUIREMENTS

1. Each weld must be homogeneous with low

porosity, free from cracks, and slag inclusions.

2. Each weld must have complete fusion between

the base metal and weld metal added by the

electrode.

3. All welds must be reasonably smooth, withouexcessive deformity, and all craters filled. No

cracks are permitted.

4. The toe of a weld to a stressed member mus

have a smooth transition. Excessive convexity

in multi-pass fillet welds is not permitted. Exces-

sive 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 criti-

cal welds must be reworked by the application

of welding an additional cover pass. It is impor-

tant that this pass is blended with the existing

weld.

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4-2 Field Welding For Assembly Or Repair FAM0406

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 multi-

ple pass welding is the required procedure on

truck frames.

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 requiredthat all slag is removed and tie in all areas.

Grind all welds where a weld crosses or inter-

sects with another weld.

MATERIALS, CONTROLS, ANDPRECAUTIONS

The steel used in the fabrication of all Komatsu

equipment is of high strength low alloy (HSLA) mate-

rial of different grades. The standard dump body

main plates are made from abrasion resistant materi-

als. 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 consum-

ables are available but have limited use on Komatsu

structural components. Approval is required from

your Komatsu customer support manager.

Control of the welding area environment is essential

for producing proper and sound welds. Essentially,

five areas require attention and control.

1. Air Movement - Avoid areas where air move-

ment from wind, drafts, or blowers is prevalent.

This is particularly important when a shielding

gas is being used as part of the welding pro-

cess.

2. Low Ambient Temperature - DO NOT weld in

temperatures below 50°F (10°C). At low tem-

perature conditions, preheating of all welding

joint work areas is required. See preheat and

post heating requirements as detailed in Annex

A.

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.

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 weld-

ing. Clean all weld areas and surfaces with agrinder to ensure that all foreign materials have

been removed.

WELD INSPECTION

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 inspec-

tor must be corrected at no additional cost to

Komatsu. All weld repairs are also subject to addi-

tional inspection.

1. Visual Inspection - This is the process of look-

ing 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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2. Dye Penetrant Inspection - This is an easily

applied process which indicates cracks or sur-

face conditions. The process is relatively inex-

pensive, 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 andtest 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.

RECORDS

Komatsu requires record keeping of all welding work

This information is valuable when personnel or job

conditions change. The service and warranty depart

ments 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 joinpreparation complete, with backer bars installed, etc

just prior to welding. These photos easily identify i

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 proce-

dure. If the repair work is to done outside addi-

tional precautions must be taken to protect the

weld repair process from outside elements. Al

welding should be done at an ambient tempera

ture of 10°C (50°F) or above.

2. Clean and grind the entire repair area toremove 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 thathave gone through the parent material and can-

not 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. Doc-

umentation must support this repair. Photo-

graphs 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 thor-

oughly with a grinder to remove all possible car-

bon 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 sur-

rounding surface area reaches 150°C (300°F)

at a distance of 76 mm (3 in.) from all areas to

be welded.

9. All welds are to be made with approved con-

sumables 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 mini-

mum.

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 heat-

ing.

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ANNEX B

1.0 TOE HAMMER PEENING

Equipment:

1. Hand held pneumatic hammer

2. Adequate air supply

3. Adequate lighting

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

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 defor-

mation 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.

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

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 opera-

tion 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.

3. Hold the hammer tool at approximately one half

the included angle between the weld face and

the parent material and perpendicular to thedirection 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.).

2.0 TOE GRINDING WITH A ROTARY BURR

Equipment:

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

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

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 fo

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 paren

material (no overlap) before the grinding opera-

tion 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. The axis of the tool should be maintained a

about 45° to the parent plate and inclined a

about 45° to the direction of travel. The depth ofthe grinding must be between 0.8 mm to 1.0

mm (0.030 to 0.040 in.). The final surface mus

be clean, smooth and free of all traces of under

cut 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 Elec-tric Company, Cleveland, Ohio

American Welding Society - Welding Handbook

British Standard BS5135 - Metal Arc Welding of Car-

bon and Carbon-Manganese Steels

Welding Steels Without Hydrogen Cracking - The

Welding Institute, F. R. Coe, Author

SPECIAL PRECAUTIONS WHENSERVICING AN A/C DRIVE SYSTEMTRUCK

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 ensurethe safety of maintenance personnel and to help pre-

vent damage to the equipment.

Anyt ime 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 retard-ing grids, wheel motors, alternator, and power

cables connecting these devices are safe to

work on.

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Locate the GF cut-out switch in the access

panel on the left side of the main control cabi-

net. Place the switch in the CUTOUT position.

This will prevent the alternator from re-energiz-

ing and creating system voltage until the switch

is returned to its former position.

After repairs, replace all covers and doors andplace the GF cutout switch and battery discon-

nect switches in their original positions. Recon-

nect 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 disconnectany power cables or use them as hand or foot

holds.

Notify your Komatsu customer service manager

immediately. Only qualified personnel, specifi-

cally trained for servicing the A/C drive system,

may perform this service.

General Welding Guidelines

1. Open the battery disconnect switches and dis

connect 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 strapfrom 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 lou-

vers.

6. Some power cable panels throughout the truck

are made of aluminum or stainless steel. Theymust be repaired with the same material or the

power cables may be damaged.

7. Power cables must be cleated in wood or othe

non-ferrous materials. DO NOT repair cable

cleats by encircling the power cables with meta

clamps or hardware. Inspect power cable insu-

lation 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 thevehicle 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, o

hydraulic cylinders.

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NOTES

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FAM0506 Receiving & Assembly Preparation Page 5-1

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 num-

ber. Check for missing parts. List the unit num-ber of all major components. Verify the cab and

decks are with the correct chassis.

3. Install support blocks under the chassis. The

support blocks must be approximately 84 cm

(33 in.) high.

4. Install support blocks under the rear axle hous-

ing. The support blocks must be approximately

30 cm (12 in.) high and spread out along the

axle. The support blocks must be a minimum of

51 mm (2 in.) away from the wheel motor

mounting face.

5. Clean all mounting surfaces on the chassis and

on the individual components.

6. Check all electrical connectors and verify they

are free of paint and/or corrosion. Clean any

connector with questionable electrical continu-

ity.

7. Check all factory installed components for the

proper tightening torque.

8. Arrange the work site as shown on the following

page.

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Page 5-2 Receiving & Assembly Preparation FAM0506

A S S E M B L Y L A Y O U T

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FAM0610 10/07 Chassis Assembly Page 6-1

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 fol-

lowing procedures are provided as general guide-

lines 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.

RECOMMENDED ASSEMBLY DATA

1. Service Report (Pre-Delivery)

2. Acknowledgement of Receipt of Company War-

ranty

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, Appen-

dix)

10. Propulsion System Checkout Procedure (avail-

able 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 (avail-

able in Section 10 of this manual)

BASIC ASSEMBLY PROCEDURE

1. Site preparation

2. Unload truck components

3. Assemble the chassis4. 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)

8. Site cleanup

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Page 6-2 Chassis Assembly 10/07 FAM0610

CHASSIS ASSEMBLY

The photographs referenced in this procedure depict

an actual truck assembly. Assembly at other loca-

tions may be different. However, this outline will pro-

vide a general basis for assembly.

Follow all safety recommendations in this man-

ual. Follow all local, state, and federal regula-

tions.

In the procedures that follow, many very heavy com-

ponents will be required to be lifted into place and

secured.

• Inspect all lifting devices. Slings, chains, andcables used for lifting components must beinspected daily for serviceable condition.Refer to the manufacturer’s guidelines for correct capacities and safety procedureswhen lifting components. Replace anyquestionable items.

• Slings, chains and cables used for liftingmust be rated for approx imately two times the

intended load.

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

• Lifting eyes and hooks must be fabricatedfrom the proper materials and rated to lift theintended load.

• Never stand beneath a suspended load. Guyropes are recommended for guiding andpositioning a suspended load.

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

Disconnect the battery cables before arc welding

on the truck . Failure to do so may seriously dam-

age the batteries and electrical equipment. Dis-

connect the battery charging alternator lead wirebefore 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 vo ltages 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 cl eaned andventilated.

Maintain fire control equipment. Inspect fire

extinguishers regularly to ensure they are fully

charged and in good working condition.

Mark cap screws and nuts with paint or ink after

tightening to the specified torque. This method

provides verification that the hardware has been

properly tightened.

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GENERAL PRECAUTIONS ANDINSTRUCTION

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.

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 accumula-tors.

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 o

this manual.

13. Use the battery disconnect switch when arc

welding. Connect the weld ground near the

weld area.

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1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each. Liftthe 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 suppor t can not be achieved. Gaps in the

weld around the support may result in premature frame cracking in th is 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 assem-

blies 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 preventdamage 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 evapora-

tion, such as trichlorethylene, tetrachlorethyl-

ene, acetone or lacquer thinner.

High tightening torque is required to load the

front suspension mounting cap screws.

Repeated tightening will result in cap screw

fatigue and damage. DO NOT reuse mounting

cap screws, washers and nuts. Replace the

hardware after each use.

Suspension mounting cap screws are specially

hardened to meet or exceed grade 8

specifications. Replace only with cap screws of

correct hardness. Refer to the appropriate parts

book for the correct part numbers..

The use of dry threads in this application is not

recommended. Due to the high tightening forces

required to load these cap screws, dry th reads or

threads lubricated with anti-seize compounds

may result in damage. Only use the approved

lubricants listed below.

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

• 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 theSouthwest 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.

16. Lubricate the cap screw threads, cap screw

head seats, washer faces, and nut seats with a

rust preventive compound.

17. The hardened flat washers use on the front sus-

pensions are punched during the manufacturing

process. Assemble the cap screws and wash-

ers, and position the punch lip away from the

cap screw head to prevent damage. See Figure

6-23.

18. Lift the front suspension into position. Theweight 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 follow-

ing pages.

FIGURE 6-23. INSTALLATION OF HARDENEDFLAT WASHER

1. Hardened Flat Washer 2. Cap Screw

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Turn-Of-The-Nut Tightening Procedure

a. Tighten all 14 cap screws (1, 6, 8, Figure 6

24) to 542 ± 5 N·m (400 ± 40 ft lb).

b. Maintain this torque on the top two corne

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 out

lined in Steps d-1 through d-3. Refer to Fig

ure 6-25.

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° asoutlined in Steps d-1 through d-3. Refer to

Figure 6-26.

FIGURE 6-24. SUSPENSION INSTALLATION

1. Cap Screws and

Washers

2. Nuts and Washers3. Housing

4. Mounting Surface

5. Shear Bar

6. Cap Screws and

Washers

7. Piston8. Cap Screws and

Washers

9. Spacer

10. Nuts and Washers

FIGURE 6-25. 60 DEGREE ADVANCE

FIGURE 6-26. 90 DEGREE ADVANCE

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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 refer-

ence 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 wrenchduring 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 bechecked 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.

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FIGURE 6-27.

FIGURE 6-28.

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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). Con-

tinue 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.

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FIGURE 6-29.

FIGURE 6-30.

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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.

1. Steering Cylinder

2. Tie Rod Assembly

3. Retainer

4. Locknut

5. Spacer

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

16. Cap Screw

17. Retainer Plate

18. Flat Washer

Refer to the illustration on the following page.

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FIGURE 6-32.

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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.

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FIGURE 6-33.

FIGURE 6-34.

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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.

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FIGURE 6-35.

FIGURE 6-36.

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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.

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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.

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FIGURE 6-39.

FIGURE 6-40.

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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, Appen-

dix.

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.

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FIGURE 6-41.

FIGURE 6-42.

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27. Tighten the cap screws that secure the diagonal ROPS beam and the decks. Tighten the cap screws to stan-

dard torque.Refer to Standard Tables in Section 10, Appendix.

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

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FIGURE 6-43.

FIGURE 6-44.

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FIGURE 6-45.

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NOTES

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29. Raise the front of the truck for front wheel instal-

lation.

NOTE: Clean the mating surfaces before installing

the wheels.

30. Using a tire handler, lift the front wheel into posi-

tion on the wheel hub. Install the wheel retainer

lugs and lubricated nuts. Evenly tighten each

nut using the sequence shown in Figure 6-46 to407 N·m (300 ft lbs).

31. Spin the wheel and check the rim run-out. Maxi-

mum run-out is 5 mm (0.20 in.). If run-out

exceeds specifications, loosen all nuts and re-

tighten 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 main-

tained 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.

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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 infla-

tion 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 inplace 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).

39. Spin the wheel and check the rim run-out. Maxi-

mum 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 inflationlines 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 ensuretorque is maintained.

FIGURE 6-48. REAR WHEEL TIGHTENING

SEQUENCE

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FIGURE 6-49.

FIGURE 6-50.

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FIGURE 6-51.

FIGURE 6-52.

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

FIGURE 6-53.

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FIGURE 6-54.

FIGURE 6-55.

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45. Install the exhaust system.

FIGURE 6-56.

FIGURE 6-57.

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FIGURE 6-59.

FIGURE 6-60.

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FIGURE 6-61.

FIGURE 6-62.

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NOTES

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

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FIGURE 6-63.

FIGURE 6-64.

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

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FIGURE 6-65.

FIGURE 6-66.

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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.

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FIGURE 6-68.

FIGURE 6-69.

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FAM0710 Dump Body Assembly 7-1

DUMP BODY ASSEMBLY

GENERAL INFORMATION

The total weight of the body is approximately

26,853 kg (59,201 lb). Use two cranes for assem-

bling 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 ter-

rain with an adequate area for welding machines and

for maneuvering lifting equipment.

Body sections must be assembled as originally

manufactured. Match the shipping numbers sten-

ciled on the body sections to mate the correct

parts. DO NOT mix components.

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. Afte

the pivot, guide pin, and body pads are welded in

place, the body can be turned over and the remain-

der of the assembly can be completed.

All paint must be removed from surfaces to be

welded. Use a wire brush or paint removal equip-

ment.

Refer to the assembly blueprints shipped with the

truck for specific welding details and the parts

required for assembly.

1. Canopy

2. Front Sheet

3. RH Side Sheet

4. Lift Hole

5. Floor

6. Pivot

7. LH Side Sheet

FIGURE 7-1. BODY PARTS NOMENCLATURE

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7-2 Dump Body Assembly FAM0710

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 theyare properly oriented for assembly. Refer to

Figure 7-2 for domestic configuration, and 7-3

for international configuration.

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 sup-

port the floor at the rear. Refer to Figure 7-5.

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) aremarked 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.

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 can-

opy. Install cap screws (4, 5 & 6).

9. Install cap screw (7) and the sleeve in the frontof 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.

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).

14. Attach appropriate lifting apparatus to the bodypivot. Insert the lifting apparatus through the

body pin bores. The weight of the pivot is

approximately 1492 kg (3289 lb). DO NOT dam-

age 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.

FIGURE 7-2. DOMESTIC LAYOUT

FIGURE 7-3. INTERNATIONAL LAYOUT

FIGURE 7-4.

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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 (three-

piece), lift the canopy into position at this time.

Install the canopy cap screws and tighten.

18. Tighten all floor, front sheet, and canopy capscrews. 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 thefront sheet:

First Pass: Back step and skip weld in 10increments along the entire length of the joint.Refer to Figure 7-7.

Repeat the same procedure until the entire jointis filled. DO NOT stop welding until entire joint iscomplete.

• The body floor “V” groove must also be weldedusing the same procedure as the front sheet.Weld from the front to the rear. Refer to Figure 7-7.

1. Complete the welds at the center seam, the

front sheet and the canopy. Refer to the assem-

bly blueprints for welding requirements.

2. Remove the canopy alignment blocks.

FIGURE 7-7. FRONT SHEET & FLOOR JOINT

WELDING SEQUENCE

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FAM0710 Dump Body Assembly 7-5

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.

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 typicaexample of a body being inverted with two

cranes.

Position the body onto support blocks as shown

in Figure 7-18.

FIGURE 7-8.

FIGURE 7-9.

FIGURE 7-10.

FIGURE 7-11.

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FIGURE 7-12.

FIGURE 7-13.

FIGURE 7-14.

FIGURE 7-15.

FIGURE 7-16.

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7. Install any optional equipment such as body lin-

ers and side boards.

8. Clean the weld joints and paint.

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FAM0809 Dump Body Installation Page 8-1

DUMP BODY INSTALLATION

Installation

Before raising or lifting the body, ensure there is adequate clearance between the body and overhead

structures or electric power l ines.

Body weight can vary substantially, depending on liner plate installation, etc. Ensure the lifting device is

rated for at l east 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 pivo

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.

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Page 8-2 Dump Body Installation FAM0809

FIGURE 8-2.

FIGURE 8-3. DUMP BODY PIVOT PIN

(RH Side Shown)

1. Body

2. Bushing

3. Shim

4. Pin Retainer Capscrew

5. Frame

6. Body Pivot Pin

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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.

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FIGURE 8-4.

FIGURE 8-5. HOIST CYLINDER MOUNT (UPPER)

1. Dump Body

2. Hoist Cylinder Pin

3. Hoist Cylinder

4. Pin Retainer

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BODY SLING

Any t ime personnel are required to per form main-

tenance on the vehicle with the dump body in the

raised position, the body must be supported in

the raised position with t he body sling cable.

Inspect the cable and mounting brackets for

signs o f 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 stor-

age position.

BODY PADS

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.

Place the blocks between the body and frame

Secure the blocks in place.

2. Place the pad and shims into position. Instal

the mounting hardware and tighten to 34 N·m

(25 ft lbs). Repeat at each pad location.

3. Raise the body, remove the blocks supportingthe body, and lower the body onto the frame.

FIGURE 8-6. BODY PAD

1. Dump Body

2. Shim

3. Pad Mounting Hardware

4. Body Pad

5. Frame

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Ad justment

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 proce-

dure. 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.

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BODY SWITCHES

Refer to Figure 8-10 to properly position the body

switches.

FINAL ASSEMBLY

Install the remaining items to the body and associ-ated components including: lubrication lines, mud

flaps, decals, body position indicator, etc.

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F I G U R E

8 - 1 0 .

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NOTES

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FAM0903 Final Checkout Page 9-1

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 operat-

ing instructions in the operation and maintenance man-ual.

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.

4. Purge any air from the pumps. Pressure will no

build if air is present. Operating the pumps with ai

in the system will result in damage.

5. Perform a final check of all systems and prepare

for operation. Several checks and tasks are out-

lined in Section 10, Appendix.

6. Complete the checks listed in the Field Assembly

Inspection Report Form. A copy of the form is pro

vided with the truck and is also available in Sec-

tion 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.

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Page 9-2 Final Checkout FAM0903

NOTES

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FAM1005 Appendix Page 10-1

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

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Page 10-2 Appendix FAM1005

NOTES

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L U B R I C A T I O N

C H A R T

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NOTES

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Suspension Oiling and Charging

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, willprovide 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.

Al l Hydrai r ®II suspensions are charged with com-

pressed nitrogen gas with sufficient pressure to

cause injury and/or damage if improperly han-

dled. Follow all safety instructions, cautions, and

warnings provided in the following procedures to

prevent any accidents during oi ling and charging.

Proper charging of Hydrair ®II suspensions requires

that three basic conditions be established in the fol-

lowing order:

1. The oil level must be correct.

2. The suspension piston rod extension for nitro-

gen charging must be correct.

3. The nitrogen charge pressure must be correct.

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 othis 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)

Charging Height Dimensions (Front Only)

• Hydrair ® Oil (See Specifications Chart)

• Friction Modifier (See Specifications Chart)

• Dry Nitrogen (See Specifications Chart)

•

Hydrair ® Charging K it

Assemble service kit, as shown in Figure 4-1, and

attach to container of pure dry nitrogen gas (8).

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 chargingvalve adapters (2) completely counterclockwise

3. Ensure manifold outlet valves (3) and inlet valve

(4) are closed (turned completely clockwise).

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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 sus-

pension 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 Ki t

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 cov-

ers 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.

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 suspen-

sions. 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 cylin-

der gland to the piston flange.

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)

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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 proce-

dures 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

Al l Hydrair ®II suspensions are charged with com-

pressed nit rogen gas with sufficient pressure to

cause injury and/or damage if improperly han-dled. Follow all the safety notes, cautions, and

warnings in these procedures to prevent acci-

dents during servicing and charging.

1. Park the unloaded truck on a hard, level sur-

face. Apply the parking brake, and chock the

wheels.

2. Thoroughly clean the area around the charging

valve on the suspensions. Remove the protec-

tive covers from the charging valves.

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, pre-

senting the possibility of serious injury to nearby

personnel and/or damage to the equipment.

Overhead clearance may be reduced rapid ly and

suddenly when nitrogen pressure is released!

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 torest on the blocks. Ensure the blocks do no

mar or scratch the plated surfaces of the pis-

tons or damage wiper seals in the lower bearing

retainer. Support blocks must seat on the spin

dle 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 nitro

gen pressure has been vented from the suspen-

sion.

3. Depress the charging valve core to release the

nitrogen pressure from the suspension. Whenall 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).

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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 moresuspension oil if necessary. Install a new fill

plug O-ring, and install the plug.

Front Suspension Nitrogen Charging

Lifti ng equipment (crane or hydraulic jacks) must

be of sufficient capacity to lift the weight of the

truck. Ensure that all personnel are clear of thelift 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.

FRONT SUSPENSION DIMENSIONS (EMPTY)

TRUCK MODEL AND OPTIONS

OILINGHEIGHT

IN. (mm)

CHARGINGHEIGHT

IN. (mm)

CHARGINGPRESSUREpsi (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 isattained, stop ch arging.

FIGURE 4-2. FRONT SUSPENSION

FIGURE 4-3. CHARGING VALVE

1. Valve Cap

2. Seal

3. Valve Core

4. Swivel Nut

5. Rubber Washer

6. Valve Body

7. O-Ring

8. Valve Stem

9. O-Ring

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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 counter-

clockwise three full turns.

Dry nitrogen is the only gas approved for use in

Hydrair ®II suspensions. Charging of these com-

ponents with oxygen or other gases may result in

an explosion which could cause fatalities, seri-

ous 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 to50.8 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 cyl-

inder 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.

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 charg-

ing blocks.

10. Close inlet valve (4, Figure 4-1). Leave manifold

outlet valves (3) open for five minutes in orde

to allow the pressures in the suspensions to

equalize.

11. Close manifold outlet valves (3) and remove

charging kit components. Refer to Removal o

Charging Kit.

12. If the charging valve is being reused, tightenswivel nut (4, Figure 4-3) to 5.4 N·m (4 ft lbs).


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 f

lbs). Again loosen the swivel nut and retighten

to 5.4 N·m (4 ft lbs). Install valve cap (1) and


14. Install a protective guard over the charging

valve.

15. Raise the truck body in order to extend the fron

suspensions and allow for removal of the nitro-

gen charging blocks. Ensure that sufficien

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 remova

of the blocks, use a crane or floor jacks to raise

the truck and remove the blocks.

The front suspensions are now ready for opera

tion. Visually check the extension with the truck

both empty and loaded. Record the extension

dimensions. Maximum downward travel is indi-

cated by the dirt ring at the base of the pistonOperator comments on steering response and

suspension rebound will also be noted.

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REAR SUSPENSION

1. Park the unloaded truck on a hard, level sur-

face. Apply the parking brake, and chock the

wheels.

2. Thoroughly clean the area around the charging

valve on the suspensions. Remove the protec-

tive 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 pres-

sure 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 atmo-

sphere, 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, andcharging 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).

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Rear Suspension Nitrogen Charging

Lifting equipment (overhead or mobile cranes, or

hydraulic jacks) must be of sufficient capacity to

lift the weight of the truck. Ensure that all person-nel are clear of the lift area before the lift is

started. Clearances under the truck may be sud-

denly reduced.

Ensure the automatic apply circuit has not

applied the service brakes during truck mainte-

nance. If the front b rakes 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 O-

ring (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 counter-

clockwise three full turns.

Dry nitrogen is the only gas approved for use in

Hydrair ®II suspensions. Charging of these com-

ponents with oxygen or other gases may result in

an explosion, which could cause fatalities, seri-

ous 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.

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 suspensionsmatch 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 suspen-

sions for equal extension. Adjust the front as

necessary.

NOTE: A low left front suspension will cause the rightrear 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).


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


11. Install the protective guards over the charging

valves. Install the rubber covers over the piston

rods.

The rear suspensions are now ready for opera-

tion. Visually check piston extension both with

the truck loaded and empty. Record the exten-

sion dimensions. Maximum downward travel is

indicated by the dirt ring at the base of the pis-

ton rod. Operator comments on steeringresponse and suspension rebound will also be

noted.

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G03027 Front Wheel Hub and Spindle G3-1

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 pre-

vent 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 cen-

terlines at the front and rear of the front tires.

3. For trucks equipped with radial tires, the mea-

surements 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 therear 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 cor-

rect toe-in setting. Refer to Table 2 for addi-

tional information.

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.

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

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G3-2 Front Wheel Hub and Spindle G03027

NOTES

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Automatic Lubrication System

AUTOMATIC LUBRICATION SYSTEM

LUBRICANT REQUIRED FOR SYSTEM

Grease requirements will depend on ambient tem-

peratures encountered during truck operation:

• Above 32°C (90°F) - Use NLGI No.2multipurpose grease (MPG).

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

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

SYSTEM PRIMING

The system must be full of grease and free of air

pockets to function properly. After maintenance, if

the primary or secondary lubrication lines were

replaced, it will be necessary to prime the system to

eject all entrapped air.

1. Fill lubrication reservoir with lubricant, if neces-

sary.

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 remain-

ing injector groups.

5. Remove the caps from each injector and con-

nect 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.

LUBRICANT PUMP

Pump Housing Oil Level

The pump housing must be filled to the proper leve

with SAE 10W30 motor oil. Oil level must be checked

at 1000 hour intervals. To add oil, remove oil leveplug (4, Figure 3-1) and fill the housing to the bottom

of the plug hole.

Pump Pressure Control

High pressure hydraulic fluid from the truck steering

system is reduced to 2240 to 2413 kPa (325 to 350

psi) by 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.

FIGURE 3-1. PUMP CONTROLS

1. Pump Pressure

Control

2. Manifold

3. Pressure Gauge

4. Oil Level Plug

5. Flow Control Valve

6. Outlet Port

7. Manual Override

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INJECTORS (SL-1 Series H)

Injector Specifications

• Each lubrication injector services only onegrease point. In case of pump malfunction, eachinjector is equipped with a covered grease fittingto allow the use of external lubricatingequipment.

• 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 con-

trolled by an adjusting screw in the top of the injector

housing.

Turn adjusting screw (1, Figure 3-2) counterclock-

wise to increase lubricant amount delivered and

clockwise to decrease the lubricant amount.

When the injector is not pressurized, maximum injec-

tor delivery volume is attained by turning adjustingscrew (1) fully counterclockwise until piston assembly

(8) touches the adjusting screw. At the maximumdelivery point, about 9.7 mm (0.38 in.) adjusting screwthreads must be showing. Decrease the delivered

lubricant amount by turning the adjusting screw clock-wise to limit injector piston travel. If only half the lubri-

cant is needed, turn the adjusting screw to the pointwhere 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 beadjusted to less than one-fourth capacity.

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).

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

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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 sys-

tem attains 20685 kPa (3000 psi).

4. Once the required pressure is achieved, thepump 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 CheckTo check the solid-state timer operation without wait-

ing 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.

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 toread the voltage between the positive andnegative posts on the solid-state timer. A nor-

mal reading must be 18 to 26VDC, depend-ing upon whether the engine is on or not.

.

FIGURE 3-3. LOCATION OF LUBRICATION CYCLE

TIMER1. Cab Interface

Compartment Under

Passenger Seat

2. Lubrication Cycle

Timer

FIGURE 3-4. LUBRICATION CYCLE TIMER

(SHOWN WITH COVER REMOVED)

1. Timer Enclosure

2. Red LED

3. Timer Selector

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Lubrication Cycle Timer Adjustment

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 themaximum limit of 80 minutes is reached.

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

disassemble it.

PREVENTIVE MAINTENANCE INSPECTION

Use the following maintenance procedures to ensure

proper system operation.

10 Hour Lubri cation System Inspection

1. Check the grease reservoir level.

Inspect the grease level height after each shift

of operation. The grease usage must be consis-

tent from day-to-day operations.

Lack of lubricant usage would indicate an inop-

erative system. Excessive usage would indicate

a broken supply line.

2. Check the filter bypass indicator when fill ing the

reservoir. Replace the element if bypassing.

3. Check all the grease hoses from the SL-1 injec-

tors to the lubrication points.a. Repair or replace all damaged feed line

hoses.

b. Ensure all air is purged and all new feed line

hoses are filled with grease before sending

the truck back into service.

4. Inspect the key lubrication points for a bead of

lubricant around the seal. If a lubrication point

appears dry, troubleshoot and repair the prob-

lem.

100 Hour Inspection

1. Check the oil after every 100 hours of opera-

tion. The crankcase must be filled to the cente

of the drain plug located on the back of the

crankcase.

250 Hour Inspection1. 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 send-

ing the truck back into service.

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 send-

ing the truck back into service.

3. Check the grease reservoir level.

a. Fill the reservoir if low. Check the filte

bypass indicator when filling the reservoir

Replace the element if bypassing.

b. Check the reservoir for contaminants. Clean

if required.

c. Check that all filler plugs, covers, and

breather vents on the reservoir are intact and

free of contaminants.

4. Inspect all bearing points for a bead of lubricant

around the bearing seal.

It is good practice to manually 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.

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5. System Checkout.

a. Remove all SL-1 injector cover caps to allow

visual inspection of the injector cycle indica-

tor pins during system operation.

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.

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 thetroubleshooting chart.

500 Hour Inspection

1. Change the oil after every 500 hours of opera-

tion. Use SAE 10W30 motor oil.

1000 Hour Inspection

1. Check the pump housing oil level. Refill to the

bottom of the level plug with SAE 10W30 motooil, if necessary.

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NOTES

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NOTES:

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NOTES:

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HE K OUT PRO EDURE

L

EF5761

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Necessary Equipment

1. Check-out procedure and systemschematic

2. Accumulator charging outfitwith good gauges and eitherK type bottles of dry

nitrogen or T type bottleswith 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 donewithout 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 systemare to specification.

2. Any parts that do not function as describedwill be replaced or adjusted. (Notify

Quality Control Department for problemsor 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 steeringand 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 (brakemanifold)

2. Open each brake accumulator bleed downvalve and precharge both accumulators

to 1400 psi. Allow gas temperature to approachambient temperature before

completing precharge process.

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Komatsu Mining Systems, Inc.

Peoria Operations

+

'aS8 1 of 7

NAME

MACHINE& HODEL

BRAKE SYSTEM CHECKOUT 730E

WRITTEN BY

DATE

I

D. D. Smith

6/20/95

4

PlIrkin2:

Brk Note: P2:2

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D-Ddate 1t14 tor Mt2:.

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CHECKED BY

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DATE

DASH D£SCRIPTIOHOF CMANCiE

DATE

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6/26/95

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EF5761

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HE K OUT PRO EDURE

Note: For best performance, charge accumulators in the ambient conditions in

which the machine will be operating.

3. Close both accumulator bleed downvalves. Ifbrakes have not been assembled to

truck when check-out is performed, attachbrake simulators to the brake

application lines.

*

4. Start engine to fill accumulatorswith oil. Observe risingbrake pressures as

system charges. Brake pressure shouldbegin to fallwhen Auto Apply Valve

releases. The brake pressures when auto apply releases should be approximately

1750psi front and 1700psi rear. Record the brake pressures at auto apply release.

5. Partially depress brake pedal and bleed air frombleeders located at each brake or

brake simulators.

Parking Brake

Note: Move one of the pressuremeasuring instruments from the BF or BR

locations to port PK2 on the brake manifold.

*

6. Apply brake lock. Release parking brakewith park brake switch. Verify that

park brake status light indicates parking brake is released. Record parking brake

release pressure. (pressure shouldbe 2600=t100psi).

*

7. Ifparking brakes are onvehicle, thenmeasure the lining to discclearance with

feeler gauge and record the clearances.

8. Cycle park brake switch several times to assure crisp application and release of

pressure and proper functionof status light.

9. Apply parking brake and release brake lock.

Note: Return the pressure measuringdevice 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 pressurebegins to rise. Force feedback

of pedal on foot shouldbe smoothwith no abnormalnoise or mechanical

roughness.

*

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

lights energize. (Thisshouldbe 75=tpsi). . .


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HE K OUT PRO EDURE

EF5761 - 4

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*

12. Quickly and completely depress pedal and check to see that front brake pressure

is 2500 i: 100psi 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 minimumof 20 seconds.

*

13.Release peda1. Brake pressure shouldreturn to zerowith a couple of seconds and

there should be no residualpressure trapped inbrakes. If the vehicle is equipped

with rear brakes check to see if rear brake linings are retracted frombrake discs

and are free and loose inbrake calipers.

Note: If step 13is incorrect, perform deadbandadjustment as follows: Insert a

O.025 shimbetween valve and pedal return stop. Loosenjam nut. Adjust set

screw until pressure begins to rise in one or both circuits. Back set screw off 1/8

turn and lock set screwwith jam nut. Remove the shim.

Brake Lock/Secondary

14. (A) Disconnect leadwire 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. RecordBR pressure at which warning resumes.

16. Connect leadwire on brake lock solenoidand removejumper from leadwires to

timer.

*

17. Cycle brake lock several times to assurecrisp application of and release of

pressure and proper functionof status light. Record rear brake pressure, which

should be 1500i: 100psi.

Low Brake Pressure and Auto Apply

I

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

2700psi.

*

19. Shut engine down. Allow the steeringaccumulator to bleed completely down.

Disable steering pressure switch fromthe brakewarning circuit by unplugging the

diode between circuits 33 and 33F. (Thisis diode 22 on diode board 1) Turn key

switch on. After 2 minutes record the low accumulator pressure. (LAP1port) 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 accumulatorbleed down valve and observe LAP1 pressure.

The low brake pressure lampand buzzermust actuate at 1850:: ::5 psi. Record

this value. Brake pressures shouldbegin to rise (auto apply)when LAP1 reaches

1650

100psi. Recordthisvalue. 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 steeringaccumulator to bleed completely down.

Turn key switch on. Crack the rear brake accumulatorbleed down valve and

observe LAP1pressure. Verifythat the low brake pressure lampand buzzer, and

auto apply set points are within a 100psi of those recorded in step 20. Close the

rear brake accumulator bleed downvalve.

*

24. Record auto apply brake pressures. Enable the steeringpressure switch by

plugging in the diode removed between circuits 33 and 33F.

Reapplications

25. Start engine to rechargehydraulic system. Allow engine to run until low brake

accumulator pressure stabilizes at or above2700 psi.

*

26. Shut engine down. Do not allow steeringaccumulatorto bleed down. Make

repeated slow, completebrake applicationswith pedal until auto apply comes on.

Record the number of brake applicationsprior 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 sureto leave end of hosevented to atmosphere.

29. Start engine. Allow the engineto run until LAP1pressure stabilizes at or above

2700 psi.

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Peoria Operations

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EF5761

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HE K OUT PRO EDURE

30. Very slowly depressthe brake pedaluntil the brake differential switch has

activated the low brake pressurelamp andthe 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

switchoff. Openeach 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 incab. Disconnectthe 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:: ::

5 psi).

Release the pedal.

. .

34. Shut engine down and turn key switchoff Openeach brake accumulator bleed

down valve and bleed downthe entirebrake 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 recordedData Sheet.


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HE K OUT PRO EDURE

I EF5761 ~

Pau of

HYDRAULICBRAKE SYSTEM

CHECK-OUTDATA SHEET

STEP 4

Front brake pressurewhen Auto Apply releases.

Rear brake pressurewhen Auto Apply releases.

PARKING BRAKE SYSTEM

STEP 6

Parking brake releasepressure.

STEP 7

Left outboard lining/discgap.

Left inboard lining/disc gap.

Right outboardlining/discgap.

Right inboard lining/discgap.

SERVICE BRAKE SYSTEM

STEP 11

Rear brake pressurewhen stop lights energize.

STEP 12

Front brake pressure. pedal applied

Rear brake pressure pedalapplied

STEP 13

Front brake pressure pedal released

Rear brake pressure pedal released


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P..e 7 of 7

BRAKE LOCK/SECONDARY SYSTEM

Rear brake pressurewhen brake lock degradation fault

occurs.

STEP 15

Rear brake pressurewhen brake lock is applied.

TEP 17

LOW BRAKE PRESSUREAND AUTOAPPLY

LAP pressure after 2 minutes.

TEP 19

LAP pressurewhen low brake pressure fault occurs.

TEP 20

LAP pressurewhen auto applyoccurs.

STEP 21

Front brake pressure after auto apply.

Rear brake pressure after auto apply.

STEP 24

Front brake pressureafter auto apply.

Rear brake pressureafter auto apply.

REAPPLICATIONS

STEP 26

Number of applicationsprior 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.

MACHINE

UNITNO.

SIN

NAME OFMECHANIC OR INSPECTORDOINGCHECK-OUT


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OM TSU CHECKOUT PROCEDURE

I EK8480-1

Paqe 1 of 15

Structure and purpose:

This procedure is in two parts. The first part verifiesthe installationof the VHMScontroller,The

Interface module, the OrbCommcommunicator, the sensors, and all associated wiring.

The second partofthe proceduresetsupVHMSfortimeof day,timezone,fault,trendand

payloaddata transmission,andOrbCommcommunicationsettings.

Preliminarv procedures (can be done before ac~nstallationt

1. WebCARE Machine registrationmust be completed. Fill out the WebCARE Machine

registration request (a copy is attached to this document) and FAX to the

VHMSlWebCARE support team (FAX number is on the form).

2. The Orbcomm activation request must becompleted (a copy is also attached to this

document). If this is a field installation, one of the serial number stickers should be

placed on the form (be sure to place the other on the Orbcomm modem itself). When

complete, FAX the form to the KOMTRAXService Hotline (FAX number is on the form).

Itwill take a week or two to complete this activation.

Necessarv

Eauipment:

1. Checkout procedure and system schematic.

2. Laptop computer with VHMS PC software installed VHMS Technical Analysis

Toolbox , and VHMS Watcher software.

RS232 serial cable with a male DB9connector on one end and a female connector

on the other end.

You will need the correctCGCDatcsv file for use with the specific truck model you

are checking out This .csv file is used with the VHMS Watcher software to identify

by name the input signals that the Interface Module (1M)sends to VHMS.

3.

4.

Installina the CGCDat.csv File:

1. The file

names take this form: CGCDat930E.csv, CGCDat830E.csv, etc. They

will be found in the same file folder as the VhmsWatcher.exe program.

The activefile is always named CGCDatcsv. If you have the wrong file active,

you must rename it (OLDCGCDatcsv). Then make a copy of the correct file

and change the copy's name to CGCDatcsv.

2.

Page

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NAME:

MACHINE MODEL:

VHMS System Checkout Procedure

930E, 960E, 830E

WRITTEN BY: DATE:

07/17/04

CHECKED BY: DATE:

1 INTEGRATEDNTERFACEMODULECHECKOUT 8/18/04

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GGH SK

APPROVED BY: DATE:

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NEWRELEASE

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DESCRIPTIONOFCHANGE

DATE ECN BY

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EK8480 1

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INSTALL THE APPLICATION CODE

Before the Interface Module can be put to work, the application code must be installed.

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

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

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

necessary files and instructions.

PLM3 NOTE

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

PLM3 software EJ0575-3or later is required for the Interface Module to properly acquire

truck speed on model 830E and 930E trucks. Go to PLM3 web site,

www.kac peoria.com

navload for software and instructions.

PART 1 - Installation and wirin :l verification

CHECK FOR FAULT CODES ASSOCIATED WITH THE INTERFACE

MODULE

Look at a recent download with the VHMS Technical Analysis Toolbox) and view fault history.

Confirm that there are no fault codes associated with the Interface Module. If any are found, these

circuits should be analyzed to determine the cause of the fault and should be repaired.

CHECK INPUT TO THE INTERFACE MODULE

Use the VHMS Watcher software.

1. Double click the shortcut VHMSWatcher on the Desktop screen. The program begins with a

blank window. On the menu bar, there are five items: File, VHMS, Settings, Interaction, Help.

Only use the VHMS pull down menu.

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

Data and Port Setting. Click Read Table Data.

3. Click VHMS on menu bar again, this time click Port Setting. A small window shows up to

allow selection of Port Setting. Select the appropriate port COM1,COM2), and select the

baud rate to be 19.2K.

4. Click VHMS on menu bar again. Click Open Connection.

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

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I EK8480-1

PaQe 3 of 15

_~r012~:::~~~i~~{~~ '.:~-':::~ :=:~~ ~ - ~'~~'~- :t:s'$~~1:: :7~='~' '

::;:'2 ..HMS :ielp

; If

IDOxc120:Seq# Ox2:Args Hello sent (rpc_senUnspector)

IDOxfffe: Seq# Ox2: acked by receiver (rpc_ack_inspector)

IDOxfffd: Seq# OxO: sentto COM.dll (rpc_tx_inspector)

IDOxc121: Seq#OxO: Ver.11030100181 kind.930E: Cold Start

Ready

fi ltart I; : :iI~

t) lJ

I~~

Interface Module Re. ..1

J;J

Can8anFF J ~

Untitled

-VhmsWatc...1

We must see 4 lines of message like shown above, if 2 or 3 lines then it did not work. If it does not

work, the problem is with serial communication maybe the key switch is off, or the serial port is

wrong, or is assigned to other software .

Page 3 of 15

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CHECKOUT PROCEDURE

I EK8480-1

Paqe4 of 15

6. Next, click VHMS item on menu bar again, when the menu pops up, this time click

Regist Display, then a screen like this will show up:

Iii

BtaSelectMenu ., ,,'; :-'.;:.';' -;;:~;<i,-::'<:',:' ,~ '~'Hl~ ;.. ,,,~:.--

OM TSU

301: 2s: En9-Speed: rpm

CLOSE I

0

301: 2 s: Eng_Speed: rpm

354: 2 s: Cool_Temp:degC

354: 2 s: Cool_Temp: degC

Delete

355:Eng_OilJemp

385:AmblenCair_temp

386:Blow_by-press

387:Eng_oil-press

388:Boost-press

389:Exh_gas_temp

500:FueUnjection

501:Ave_Min_ldle_On

502:Auto_Lube_Sw

503:BatC 12V_A

504:BatU 2V_B

505:BatU 2V- C

0

0

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START/STOP

~

12s .:J

ll ~_. ---J

Sampling

0

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Rel .dy

:J

ForHelp. press F1

::EllStart I : I ~

t1 JJ . r,

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Interll .ce Module Reml JJ CanBI .nFF

j @ Document. . WordPl .d

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r~ Untitled - VhmsW...

I;NUM

I~~; 2:10PM

That is the main screen of the Watcher program.On the table list on the right, click to highlight the

selected item we want to view the value, then click the Add bar. The selected item will show up in

the 6 slots on the left of the screen (so we can view up to 6 items at a time). The screen shows an

example when only two items are selected to view: Eng_Speed and CooLTemp. After finishing

selecting items to view, click on the START/STOPbutton, the values of the items will show up. This

button is like a toggle switch, click it a second time, then the data capture is disabled. When6 items

are selected, to view another item, we have to remove one item by clicking the Delete button, then

repeat the process of Add a new item to view. Remember, before Delete, need to click the

START/STOP button, so that the data capture is disabled, after removing an item and replacingwith

a new item by ADD, need to click the START/STOP button again to enable data capture.

Page 4 of IS

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OM TSU

CHECKOUT PROCEDURE

I EK8480 1

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For all trucks:

1. Ambient Air Temperature - should read close to actual ambient. Ambient air temp 385

2. Steering Pressure - Insert 1330 :t20 ohm resistor in place of the sensor and read 12140

:t1000

kPa. Steer Press 574

3. BrakePressure- Insert1330:t20 ohm resistor in place of the sensor and read 12140 :t1000

kPa. Brake_Press 515

4. HoistPressure1- Insert1330

:t20 ohm resistor in place of the sensor and read 12140

:t1000 kPa. Hoist_Press_1 529

5. Hoist Pressure 2 - Insert 1330 :1:20ohm resistor in place of the sensor and read

12140

:t1000

kPa. Hoist_Press_2 530

6. Pump Filter Switches - short wire 39 to ground at the switches for 3 seconds and confirm

state change zero to one . Pump_Filter_Sw 559

7. Low Steering Precharge - short wire 51A to ground at the switches and confirm state

change zero to one . The warning state should be sustained until the key switch is turned

off and backon. Low_Str_Precharg_Sw 538

8. Hydraulic Tank Level- disconnect wire 34L from tank probe and confirm state change zero

to one . Hydraulic_Level 532

9. Auto Lube Switch - short wire 68LLP1 to ground at RB6 830E models or RB7 930E

models or at the Lincoln LubeTimer 960Emodels for and confirm state change zero to

one . The warning state should besustained until the key switch is turned off and back on.

Auto_Lube 502

For 930E

and

960E GE

trucks but not 830E trucks:

1. Brake Oil Temperature RR

-

confirm as being near ambient on a cold truck. 564

2. Brake Oil Temperature LR - confirm as being near ambient on a cold truck. 536

3. Brake Oil Temperature RF

-

confirm as being nearambient on a cold truck. 563

4. Brake Oil Temperature LF - confirm as being near ambient on a cold truck. 535

5. No Propel/Retard - short wire 75-6P to ground at TB26-C momentarily and confirm state

change zero to one .

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

zero to one .

7. Propel System Caution - short wire 79W to ground at TB26-D momentarily and confirm state


8. Propel System Temp Caution

-

short wire 34TW to ground at TB26-B momentarily and

confirm state change zero to one .

9. Propel System Reduced Level - short wire 72LP to ground at TB25-W momentarily and

confirm state change zero to one .

10. Reduced Retard- shortwire 76LR to groundat TB25-T momentarily and confirm state


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CHECKOUT PROCEDURE

I EK8480 1

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

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

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

5. The High Brake Oil Temp light should come on.

6. If the output functions do not turn on, read the value of the temperature for the selected input

in VHMS Watcher. It should be between 126 and 140 C.

7. If the temperature reading is low check wiring for high resistance between the probe and

Interface Module.

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

9. It the temperature is in the right range but the output functions do not work, check the

Interface Module output circuit and wiring associated with any non-working function.

For 960E only:

Actuate and hold the lamp test switch in the operator s cab. The following lamps are driven by

the Interface Module and should come on along with all the other lamps):

1. Park Brake Lamp

2. Low Fuel Lamp

3. Batt Charge Alt Failure Lamp

4. 1MWarning Lamp

5. High Brake Oil Temp Lamp

The functionality of the Fuel Level output can be confirmed by observing the needle position of the

gauge when the low fuel lamp comes on.

1. Dismount the sending unit only from the tank and position the gauge to a low level with a

screwdriver. The shaft of the screwdriver will turn this magnetically coupled sending unit

to any position you desire.

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

3. Return the gauge to the approximateposition of the actual fuel in the tank before remounting

it.

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

1. Turn parking brake off. Park brake valve should be energized and brake auto apply valve

should not. Energizationof these valves can be determined by checking voltage across

the valves or check for magnetism in the valve with a screwdriver.

2. Use the GE DID panel to set the truck speed to some elevated value such as is used to

calibrate the speedometer. The park brake valve should continue to be energized. The

auto apply valve should continue to be off.

3. With the truck speed signal still high, turn the park brake on. The park brake valve should

continue to be energized, and the auto apply valve should stay off.

Page 7 of 15

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CHECKOUT PROCEDURE

I EK848 1

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4 Now remove the high truck speed signal The auto apply valve should pulse on for about 1 5

seconds and the park brake valve should turn off after the auto apply valve has been on

for 1 second

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CHECKOUT PROCEDURE

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PART 2

-

VHMS setup

VHMS

Checkout

and WebCARE ReQistration

1. It is vitally important that each item in the checkout procedure be checked-off before continuing

on to the next.

2. The information recorded in form 3 at the back of this procedure will be needed for full

registration and commissionof VHMS. After completion of the form 3, Fax to the number

indicated on the form.

3. Email [email protected]

BeQin

VHMS

Checkout and Setup

Key Switch

off

1. Record the the following on Form 3:

a. Truck serial number (item 2).

b. VHMS box serial number (item 3).

c. OrbComm box serial number (item4).

2. Verify the seven segment LEDdisplay on the VHMS controller are off.

3. Disconnect the OrbCommantenna. (WebCAREmust be ready to receive data before

connecting the antenna.)

KeySwitch on. DO NOT START

Engine.

4. Watch the seven segment red LED display on the VHMS box. After a short time the display

should start counting up. Verify and record (item 5) on Form 3.

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

6. Start the VHMS Setting Tool software.

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

enter 0 .

8. Select Data Clear Setup

9. Select EDIT and set the VHMS time of day clock.

a. Fill in all entries in item 6 on Form 3.

b. Enter the correct time zone. (the UTCor GMT setting)

c. Select DST (Daylight Savings Time) if appropriate)

10.Set the truck model,type, variation, and serial number. Fill in all entries in item 7 on Form3.

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

12.Select Apply , accept the confirmation prompts, select no to the download data question and

then select Exit . Completely exit the SettingTool program. Check YES to reboot the

controller.

13.Restart the Setting Tool program.

14.Before entering the Service 10,activate the TEST mode by holding down the ALT key and

typing 'TEST . The heading TEST should appear at the top of 10screen.

15.Enter the Service 10field as in step 7 above.

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I

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

17.Hold down the ALT key and press S . Set the service meter reading hours. (SMR). Record in

Item 10 on Form 3.

18.Select Apply and accept the confirmation prompts.

19.Configure the OrbComm settings. Select EDIT in the Communication Settingswindow.

20.Set the file transfer settings as follows and record in Item 11 on Form3.

21.Set GCC (Ground Control Center) to the appropriate setting and record in item 12on From3

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

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

controller.

24.Start the Payload Data Manager program and select connect to the Payload Meter. (This can be

done with the serial cable still connected to the VHMS data port.)

25.Set the PLM3 time of day and date to be the same as VHMS date and time.

:t2

minutes)

Record item13 on From 3.

26.Exit the Payload Data Manager program.

Key Switch

on. START Engine.

Wait

30 seconds. Record item 14 on Form 3.

27.Press and hold the GE data store switch (thiswill trigger a VHMS Manual Snapshot) for 3

seconds, and then release. (The GE DataStoreswitch is located on the bottom rear of the

console to the right of the driver's seat.) The white Data Store in Progress LED should light

solid and bright. The LED may glow dim (not completely off) before the GE DatStore switch is

pushed. The white LEDwill begin a slow flash after 5 minutes, then flash rapidly for 30 secorJOSm

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Item en Timer

Number Interval

Short Trend Analysis

ON SMR 1

20 (SMR)

Short LoadMap

ON

SMR

-

160 (SMR)

ShortFaultHistory

ON

Occurrence 6

-

ShortPayloadmeter

ON

Day

1

-

for PLM3

Short Brake Load Map

ON

SMR

160

GCC code

Territory

(country)

1 USA

120 ITALY

121

MALAYSIA

122

KOREA

123

BRAZIL

130

JAPAN

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CHECKOUT PROCEDURE

I

EK8480 1

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beginning at 7 minutes. Record properoperation of the manual data store in item 15on Form3

28.Wait until the DataStore in ProgressLED has finished flashing. Wait another minute, then turn

the key switch off and stop the engine. Recorditem 17 on Form 3.

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

29.Start the VHMS Technical Analysis Tool Box program. (user name = 'usr' and password= '1')

30.Select the Download icon and select the correct comm portwhen prompted, usually COM1.

31.Select Connection

32.Verify that the date time displayed on the download screen are correct for the current local

date/time and that the displayed Service Meter hours are equal to the value entered previously.

Record in item 19 Form3.

33.Verify that a ManualSnapshot (MFAO)has been recorded. The display should showan item

named 'Snapshot' with code MFAOand text Manual Trigger . Record in item 20 on Form3.

34.Select the 'Select All' option (from the bottom right of window) and perform a download. Record

in item 21 on Form3.

35.Verify that the 'Download Completed'message is displayed. Click on exit . Record item22 on

Form 3.

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

37.Find the data from the download performed in step 31. The data can be identified by the file

name which has the date inwhich it was created. Select the correct file and click OK .

38.Verify that a Manual Snapshot (MFAO)was recorded by selecting Fault History on the upper

left corner of the screen. The MFAOfault should be recorded with the time of the manual

snapshot and SMR hours entered previously.

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

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

41.Exit the V MS Technical nalysis Toolboxsoftware. Record in item 23 on Form 3.

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

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

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

45.Record remaining items on Form3 and Fax a copy of Form3 to VHMS/WebCARE support

center FAX: 81-3-5561-4766.

46. Email a copy of the download files to VHMSlWebCARE supoort center

[email protected]. The files are found in folder C:\VHMS_DATA\930E\(truck serial

number)\(date of download)\CHKOO01

47.Wait 24 hours. Reconnect the antenna.

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HE KOUT PRO E URE

I EK8480-1

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To : VHMSlWebCARE support team

FAX: 81-3-5561-4766

Ref. No.

Date

Name

WebCARE machine registration request

Fonn An

DB information]

1. Distributor name

2. Branch Name

3. Person in Charge

4. E-mail address

5. DB code GCPS)

[ Customer information]

6. Customer name 7. Site name

[ Orbcomm Activation]

12. Date of Orbcomm activation

[ Remark]

WebC ARE

VHMS/WebCARE Support team

TEL 81-3-5561-2765

FAX 81-3-5561-4766

E-mail [email protected]

1

.

~

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Page 12of 15

.

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[ Machine information]

8. Model Name 9. Serial No.

10. Unit No.

11. Item to be registered in WebCARE.

VHMS PM Clinic

D

KUC

D

.

Installed on new machine

0

. Retro-klt

0

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I EK8480-1

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13 of 15

TO: Customer support Gr.,SolutionDiv.,Komatsu Ltd.

(KOMTRAX Service Hotline)

Phone: +81-463-22-8780

Fax: +81-463-22-8448

Address: 3-25-1 Shinomiya, Hiratsuka-shi, kanagawa254-

8555,Japan

E-mail: [email protected]

I Important

Request for Orbcomm Terminal Activation

Please fill in the form below and fax or send by mail to Customer Support Gr., Kltd. to activate

Orbcomm terminal.

Note:

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

Orbcomm terminal is unable to communicate before activation being completed.

Page 13of 15

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Terminal

Terminal Part Number

Pleasefillin terminalPIN S Nor put onenclosedstickerhere)

Terminal S N PIN: S N

Terminal Activation Date

(YY/MM/DD)

Country where used

Machine Information

Model-Type-S/N

Customer s Contact Address

Company (or Plant)

Phone Number

Country-Area-number>

FAXNumber

Country.Area-number)

e-mail address

Name (please print)

First MiddleFamily

Signature

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HE KOUT PRO E URE

I EK8480-1

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8/17/2019 Ce Aw 004101


NOTES:

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STANDARD TORQUE CHARTS AND CONVERSION TABLES

This manual provides dual dimensioning for most

specifications. U.S. standard units are specified first,

with metric (SI) units in parentheses.

References throughout the manual to standard torques

or other standard values will be to one of the following

charts or tables. For values not shown in these chartsor tables, standard conversion factors for most

commonly used measurements are provided in TABLE

XIII, page A5-6.

Standard torque values are not to be used when “turn-

of-the-nut” tightening procedures are recommended.

INDEX OF TABLES

TABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1

TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2

TABLE III . . Standard Metric Assembly Torque . . A5-2

TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . A5-3

TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3

TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3

TABLE VIII. Torque Conversions (ft lbs to N•m) . . A5-4

TABLE IX . Torque Conversions (ft lbs to kg•m) . . A5-4

TABLE X . . Pressure Conversions (psi to kPa) . . A5-4

TABLE XI. Pressure Conversions (psi to MPa) . . A5-5

TABLE XII . . . . . . . .Temperature Conversions . . A5-5

TABLE XIII . . .Common Conversion Multipliers . . A5-6

EFFECT OF SPECIAL LUBRICANTSOn Fasteners and Standard Torque Values

The Komatsu engineering department does no

recommend the use of special friction-reducing

lubricants, such as Copper Coat, Never-Seez®, and

other similar products, on the threads of standardfasteners where standard torque values are applied

The use of special friction-reducing lubricants wil

significantly alter the clamping force being applied to

fasteners during the tightening process.

If special friction-reducing lubricants are used with the

standard torque values listed below in Table I

excessive stress and possible breakage of the

fasteners may result.

Where the torque tables specify “Lubricated Threads

for the standard torque values listed, these standard

torque values are to be used with simple lithium base

chassis grease (multi-purpose EP NLGI) or a rustpreventive grease (see list, page A5-2) on the threads

and seats unless specified otherwise.

NOTE: Ensure the threads of fasteners and tapped

holes are free of burrs and other imperfections before

assembling.

TABLE I. -STANDARD TORQUE CHARTSAE HEX HEAD CAP SCREW AND NUT ASSEMBLY

(LUBRICATED THREADS) - TOLERANCES ±10%

Cap

Screw

Thread

Size

TORQUE -

GRADE 5

TORQUE -

GRADE 8

Cap

Screw

Thread

Size

TORQUE -

GRADE 5

TORQUE -

GRADE 8

ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m

1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454

1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678

5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719

5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017

3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071

3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085

7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 14247/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546

1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007

1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142

9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630

9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874

5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471

5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756

3/4-10 220 30.4 298 310 42.8 420

1 ft lbs = 0.138 kg•m = 1.356 N•m

Grade 5 Grade 8

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

The following specifications apply to required assembly

torques for all 12-point, grade 9 (170,000 psi minimum

tensile) cap screws.

• Cap screw threads and seats shall be lubricatedwhen assembled.

NOTE: Unless the instructions specifically recommend

otherwise, these standard torque values are to be used

with simple lithium base chassis grease (multi-purpose

EP NLGI) or a rust preventive grease (see list, this

page) on the threads.

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

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

STANDARD ASSEMBLY TORQUESFor Class 10.9 Cap screws & Class 10 Nuts

The following specifications apply to required assembly

torques for all metric Class 10.9 finished hexagon head

cap screws and Class 10 nuts.

• Cap screw threads and seats shall not belubricated when assembled. These specifications

are based on all cap screws, nuts, and hardenedwashers being phosphate and oil coated.

NOTE: If zinc-plated hardware is used, each piece

must be lubricated with simple lithium base chassis

grease (multi-purpose EP NLGI) or a rust preventive

grease (see list, this page) to achieve the same

clamping forces provided below.

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

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

Suggested* Sources for Rust Preventive Grease:

• AMERICAN ANTI-RUST GREASE #3-X fromStandard Oil Company (also American Oil Co.)

• GULF NORUST #3 from Gulf Oil Company.

• MOBILARMA 355, Product No. 66705 from MobilOil Corporation.

• RUST BAN 326 from Humble Oil Company.

• RUSTOLENE B GREASE from Sinclair Oil Co.

• RUST PREVENTIVE GREASE - CODE 312 fromthe Southwest Grease and Oil Company.

NOTE: This list represents the current engineering

approved sources for use in Komatsu manufacture. It is

not exclusive. Other products may meet the same

specifications of this list.

TABLE II. STANDARD ASSEMBLY TORQUE

for 12-Point, Grade 9 Cap screws

CAP SCREW

SIZE*

TORQUE

ft lbs

TORQUE

N•m

TORQUE

kg•m

0.250 - 20 12 16 1.7

0.312 - 18 24 33 3.3

0.375 - 16 42 57 5.8

0.438 -14 70 95 9.7

0.500 -13 105 142 14.5

0.562 - 12 150 203 20.7

0.625 - 11 205 278 28.3

0.750 - 10 360 488 49.7

0.875 - 9 575 780 79.4

1.000 - 8 860 1166 119

1.000 - 12 915 1240 126

1.125 - 7 1230 1670 170

1.125 - 12 1330 1800 184

1.250 - 7 1715 2325 237

1.250 - 12 1840 2495 254

1.375 - 6 2270 3080 313

1.375 - 12 2475 3355 342

1.500 - 6 2980 4040 411

1.500 - 12 3225 4375 445

* Shank Diameter (in.) - Threads per inch

This table represents standard values only. Do not use these

values to replace torque values which are specified in assembly

instructions.

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

CAP SCREW

SIZE*

TORQUE

N•m

TORQUE

ft lbs

TORQUE

kg•m

M6 x1 12 9 1.22

M8 x 1.25 30 22 3.06

M10 x 1.5 55 40 5.61

M12 x 1.75 95 70 9.69

M14 x 2 155 114 15.81

M16 x 2 240 177 24.48

M20 x 2.25 465 343 47.43

M24 x 3 800 590 81.6

M30 x 3.5 1600 1180 163.2

M36 x 4 2750 2028 280.5

* Shank Diameter (mm) - Threads per millimeter

This table represents standard values only. Do not use these

values to replace torque values which are specified in assembly

instructions.

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TABLE IV.TORQUE CHART FOR JIC 37° SWIVEL NUTS

WITH OR WITHOUT O-RING SEALS

SIZE

CODE

TUBE SIZE

(O.D.)

THREADS

UNF-2B

TORQUE

ft lbs

– 2 0.125 0.312 – 24 4 ±1

– 3 0.188 0.375 – 24 8 ±3

– 4 0.250 0.438 – 20 12 ±3

– 5 0.312 0.500 – 20 15 ±3

– 6 0.375 0.562 – 18 18 ±5

– 8 0.500 0.750 – 16 30 ±5

– 10 0.625 0.875 – 14 40 ±5

– 12 0.750 1.062 – 12 55 ±5

– 14 0.875 1.188 – 12 65 ±5

– 16 1.000 1.312 – 12 80 ±5

– 20 1.250 1.625 – 12 100 ±10

– 24 1.500 1.875 – 12 120 ±10

– 32 2.000 2.500 – 12 230 ±20

TABLE V.

TORQUE CHART FOR

PIPE THREAD FITTINGS

SIZE

CODE

PIPE

THREAD

SIZE

WITH

SEALANT

ft lbs

WITHOUT

SEALANT

ft lbs

– 2 0.125 – 27 15 ±3 20 ±5

– 4 0.250 – 18 20 ±5 25 ±5

– 6 0.375 – 18 25 ±5 35 ±5 – 8 0.500 – 14 35 ±5 45 ±5

– 12 0.750 – 14 45 ±5 55 ±5

– 16 1.000 – 11.50 55 ±5 65 ±5

– 20 1.250 – 11.50 70 ±5 80 ±5

– 24 1.500 – 11.50 80 ±5 95 ±10

– 32 2.000 – 11.50 95 ±10 120 ±10

TABLE VI.TORQUE CHART FOR

O-RING BOSS FITTINGS

SIZE

CODE

TUBE SIZE

(O.D.)

THREADS

UNF-2B

TORQUE

ft lbs

– 2 0.125 0.312 – 24 4 ±2

– 3 0.188 0.375 – 24 5 ±2

– 4 0.250 0.438 – 20 8 ±3

– 5 0.312 0.500 – 20 10 ±3

– 6 0.375 0.562 – 18 13 ±3

– 8 0.500 0.750 – 16 24 ±5

– 10 0.625 0.875 – 14 32 ±5

– 12 0.750 1.062 – 12 48 ±5

– 14 0.875 1.188 – 12 54 ±5

– 16 1.000 1.312 – 12 72 ±5

– 20 1.250 1.625 – 12 80 ±5

– 24 1.500 1.875 – 12 80 ±5

– 32 2.000 2.500 – 12 96 ±10

TABLE VII.

TORQUE CHART FOR

O-RING FACE SEAL FITTINGS

SIZE

CODE

TUBE SIZE

(O.D.)

THREADS

UNF-2B

TORQUE ft

lbs

– 4 0.250 0.438 – 20 11 ±1

– 6 0.375 0.562 – 18 18 ±2

– 8 0.500 0.750 – 16 35 ±4

– 10 0.625 0.875 – 14 51 ±5

– 12 0.750 1.062 – 12 71 ±7

– 16 1.000 1.312 – 12 98 ±6

– 20 1.250 1.625 – 12 132 ±7

– 24 1.500 1.875 – 12 165 ±15

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TABLE VIII. TORQUE CONVERSIONS

Foot Pounds (ft lbs) to Newton-meters (N•m)

ft lbs 0 1 2 3 4 5 6 7 8 9

0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20

10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76

20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32

30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87

40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44

50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00

60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55

70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11

80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67

90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23

See NOTE on page A5-5 regarding Table usage

TABLE IX. TORQUE CONVERSIONS

Foot Pounds (ft lbs) to ki logram-meters (kg•m)

ft lbs 0 1 2 3 4 5 6 7 8 9

0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245

10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63

20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01

30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39

40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78

50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16

60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54

70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93

80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30

90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69


TABLE X. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Kil opascals (kPa)

Formula: psi x 6.895 = kPa

psi 0 1 2 3 4 5 6 7 8 9

0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05

10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0

20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0

30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9

40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9

50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8

60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8

70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7

80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7

90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6


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TABLE XI. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Megapascals (MPa)

Formula: ps i x 0.0069 = MPa

psi 0 10 20 30 40 50 60 70 80 90

0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62

100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31

200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00

300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69

400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38

500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07

600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76

700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45

800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14

900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83

See NOTE below regarding Table usage

TABLE XII. TEMPERATURE CONVERSIONS

Formula: F° - 32 / 1.8 = C° or C° x 1.8 + 32 = F°

CELSIUSC°

FAHRENHEITF°

CELSIUSC°

FAHRENHEITF°

CELSIUSC°

FAHRENHEITF°

121 250 482 63 145 293 4 40 104

118 245 473 60 140 284 2 35 95

116 240 464 57 135 275 – 1 30 86113 235 455 54 130 266 – 4 25 77

110 230 446 52 125 257 – 7 20 68

107 225 437 49 120 248 – 9 15 59

104 220 428 46 115 239 – 12 10 50

102 215 419 43 110 230 – 15 5 41

99 210 410 41 105 221 – 18 0 32

96 205 401 38 100 212 – 21 – 5 23

93 200 392 35 95 293 – 23 – 10 14

91 195 383 32 90 194 – 26 – 15 5

88 190 374 29 85 185 – 29 – 20 – 4

85 185 365 27 80 176 – 32 – 25 – 13

82 180 356 24 75 167 – 34 – 30 – 22

79 175 347 21 70 158 – 37 – 35 – 31

77 170 338 18 65 149 – 40 – 40 – 4074 165 329 15 60 140 – 43 – 45 – 49

71 160 320 13 55 131 – 46 – 50 – 58

68 155 311 10 50 122 – 48 – 55 – 67

66 150 302 7 45 113 – 51 – 60 – 76

NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in

this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If

starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the

center, unmarked column.

NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:

Example: Convert 975 psi to kilopascals (kPa).

1. Select Table X.

2. Go to psi row 90, column 7; read 668.8

97 psi = 668.8 kPa.

3. Multiply by 10:970 psi = 6688 kPa.

4. Go to psi row 0, column 5; read 34.475

psi = 34.47 kPa. Add to step 3.

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

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TABLE XIII

COMMON CONVERSION MULTIPLIERS


ENGLISH TO METRIC

To Convert

From TO

Multiply

By

inch – in. millimeter (mm) 25.40

inch – in. centimeter (cm) 2.54

foot – ft meter (m) 0.3048

yard – yd meter (m) 0.914

mile – mi. kilometer (km) 1.61

sq. in. – in.2 sq. centimeters (cm2) 6.45

sq. ft. – ft2 sq. centimeters (cm2) 929

cu. in. – in.3 cu. centimeters (cm3) 16.39

cu. in. – in.3 liters (l) 0.016

cu. ft. – ft3 cu. meters (m3) 0.028

cu. ft. – ft3 liters (l) 28.3

ounce – oz kilogram (kg) 0.028

fluid ounce – fl oz milliliter (ml) 29.573

pound (mass) kilogram (kg) 0.454

pound (force) – lbs Newton (N) 4.448

in. lbs. (force) Newton meters (N•m) 0.113

ft lbs (force) Newton meters (N•m) 1.356

ft lbs (force) kilogram meters (kg•m) 0.138

psi (pressure) kilopascals (kPa) 6.895

psi (pressure) megapascals (MPa) 0.007

psi (pressure) kilograms/cm2 (kg/cm2) 0.0704

ton (short) kilogram (kg) 907.2

ton (short) metric ton 0.0907

quart – qt liters (l) 0.946

gallon – gal liters (l) 3.785

HP (horsepower) Watts 745.7

HP (horsepower) kilowatts (kw) 0.745


METRIC TO ENGLISH

To Convert From TO

Multiply

By

millimeter (mm) inch – in. 0.0394

centimeter (cm) inch – in. 0.3937

meter (m) foot – ft 3.2808

meter (m) yard – yd 1.0936

kilometer (km) mile – mi. 0.6210

sq. centimeters (cm2) sq. in. – in.2 0.1550

sq. centimeters (cm2) sq. ft. – ft2 0.001

cu. centimeters (cm3) cu in – in.3 0.061

liters (l) cu in – in.3 61.02

cu. meters (m3) cu ft – ft3 35.314

liters (l) cu ft – ft3 0.0353

grams (g) ounce – oz. 0.0353

milliliter (ml) fluid ounce – fl oz. 0.0338

kilogram (kg) pound (mass) 2.2046

Newton (N) pound (force) – lbs 0.2248

Newton-meters (N•m) kilogram meters (kg•m) 0.102

Newton-meters (N.m) ft lbs 0.7376

kilogram-meters (kg•m) ft lbs 7.2329

kilogram-meters (kg•m) Newton meters (N•m) 9.807

kilopascals (kPa) psi 0.1450

megapascals (MPa) psi 145.038

kilograms/cm2 (kg/cm2) psi 14.2231

kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068

kilogram (kg) ton 0.0011

metric ton ton 1.1023

liters (l) quart – qt 1.0567

liters (l) gallon – gal 0.2642

Watts Horsepower HP 0.00134

kilowatts (kw) Horsepower HP 1.3410

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CEAW003209 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5

Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager

FIELD ASSEMBLY INSPECTION REPORT

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

Inspector’s Comments:

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

Al l four copies are to be distr ibuted as shown below.

Send White Reports to Manager of Technical Support

Komatsu America Corp.

2300 N.E. Adams St, P.O. Box 240

Peoria, IL 61650-0240 U.S.A.

Send Canary Reports to Manager of Field Assembly

Komatsu America Corp.2300 N.E. Adams St, P.O. Box 240

Peoria, IL 61650-0240 U.S.A.

Send Pink Reports to your KAC Regional Service Manager

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

Mark each item with the appropriate symbol as shown below.

MACHINE MODEL(Circle One)

730E 830E

830E-AC 930E-4

MACHINE

SERIAL NUMBER

ENGINE MODEL ENGINE

SERIAL NUMBER

CUSTOMER UNIT

NUMBER

Service Meter Reading Date of Inspection Wheel Motor

Serial Numbers LH RH

Location of Machine at Inspection

Dump Body Manufacturer

Komatsu Other

Distributor’s Name Dump Body Style

Customer’s Name KAC Area Service Manager Signature Date

Customer’s Address

Inspector’s Name

KOMATSU USE ONLY:

Sheet receiving Date:

Title

By:

Signature

Remark:

8/17/2019 Ce Aw 004101




NOTE: Refer to Section G, Tires and Rims, in the appropriate service manual for the complete wheel mount-

ing ti ghtening procedure.

No. Inspection Item Acceptance Procedures A c c e p t e d

M a i n t e n a n c e

Inspection Around Machine

1 Parts Visual inspection of unit for loose parts and debris

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

3 Hoses and Cables Visual inspection of hydraulic hoses and electric cables to ensure they are securely

clamped and clear from sharp edges and not rubbing each other

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

5 Engine Oil Level Verify engine oil level is in operating range

6 Engine Fan Inspect fan-to-shroud clearance and belt alignment

7 Hydraulic Oil Level Oil level visible through the upper sight glass with body down

8 Hatch Door

(730E, 830E)

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

9 Anchor Pin Visually inspect anchor hitch pin and anti-sway bar assembly for proper assembly and prop-

erly tightened hardware10 Wheel Motors Inspect oil specification and proper oil level

11 Fuel Tank Verify fuel tank mounting is secure and there are no fuel leaks

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

13 Decks and Ladders Inspect all ladders and handrails are secure and hardware is tight

Visual inspection of installation of grid blower, rectifier assembly and control box for correct

assembly of components and proper clamping, no loose contacts, no damaged or poorly

crimped cables

14 Battery Inspect all wiring and connections in battery box - no rubbing or chafing

Verify battery mounting hardware is secure

Verify electrolyte at proper level and caps are securely installed

Verify all battery terminals are secure

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

Visually inspect hoist valve, pumps, filters, hydraulic tank and hoist cylinder

installations (all hardware secure, no leaks)

Hardware Torque

1 Suspension Verify front suspension mounting cap screws have been properly tightened per appropriate

service manual procedure using the “turn-of-the-nut” method

2 Wheels 730E

(See Note below chart)

Verify torque on all wedge nuts at 746 N·m (550 ft l bs)

830E, 830E-AC


Verify torque on all wedge nuts at 746 N·m (550 ft l bs)

930E-4


Verify torque on front wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs)

Verify torque on rear inside wheel nuts at 2326 ± 136 N·m (1715 ± 100 ft lbs)

Verify torque on rear outside wheel nuts and adapter ring at 2326 ± 136 N·m (1715 ± 100 ft

lbs)

3 Rops Verify torque on left rops beam cap screws at 949 N·m (700 ft lbs)

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

4 Cab Verify torque on cab mounting cap screws at 949 N·m (700 ft lbs)

5 Wheel Motor Verify torque on wheel motor mounting cap screws at 2007 N·m (1480 ft lbs)

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Cab Compartment1 Cab Doors Verify doors open and close smoothly, latch works properly, O&M manual in door

2 Cab Windows Verify windows can be opened and closed smoothly

3 Door Locks Verify left and right door locks work properly with key

4 Interior Visually inspect interior for completeness of assembly

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

5 Cab Seats Inspect operators seat adjustments (slide lever, back rest operation,

seat inclination, seat height etc.)

Inspect seat belt for proper installation (and seat tethers)

6 Passenger Seat Verify back rest operates without interference

7 Steering Wheel Check tilt and telescoping functions

Check adjustable lever can be locked securely

8 Wiper Verify wiper works all speeds, & range does not extend beyond glass surface

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

9 Cigarette Lighter Check lighter operation, should pop up after 10 seconds and be hot

10 Horn Check for proper sound, no looseness in horn button

11 Back Up Horn Check for proper sound, and function

12 Shift Tower Check for proper function, no binding or looseness

13 Gauges Verify gauges are installed straight and operating correctly

14 Hydraulic Fittings Visually inspect all hydraulic fittings in front of cab, rear of cab, and hydraulic brake cabinet

15 Hoist Check operation of the hoist lever in all four positions

Lights

1 Headlights Verify all headlights working, high and low beams

Verify high beam indicators are functional

Verify lights at proper angle

2 Instrument Panel Check switch depresses and all lights function

2a Dimmer Switch Verify dimmer operates properly

2b Turn Signal Visually inspect front and rear turn signal operation on left and right sides

Directional indicators operate properly

Switch turns off after turn is completed

3 Hazard Flashers Verify flasher operates properly

Verify hazard indicator lights operating properly

4 Back Up Light Verify back up light operates properly when shifter is in R position

5 Manual Back Up Light Verify switch and light work properly

6 Fog Light (optional) Verify fog l ights and indicator lights operating properly

Brake Lights

1 Service Brake Verify service brake lights operating properly

2 Brake Lock Verify brake lock light operating properly

3 Emergency Brake Verify emergency brake light operating properly

4 Parking Brake Verified parking brake light operating properly

5 Dome Light Verify dome light is on when the switch is ON

6 Retarder Lights Verify retard light operating properly

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NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropr iate service manual for complete

suspension oiling and charging instructi ons.



Service Inspection1 Suspension 730E


Suspension oiling height, 38.1 mm (1.5 in.) front and 72.6 mm (2.9 in.) rear

Front charge height, 229 mm (9 in.) at 2758 kPa (400 psi)

Rear charge height, 276 mm (10.9 in. ) at 1420 kPa (206 psi)

830E, 830E-AC


Suspension oiling height, 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear


Rear charge height, 241 mm (9.5 in.) at 1724 kPa (250 psi)

930E-4


Suspension oiling height at 25.4 mm (1 in.) front and 25.4 mm (1 in.) rear


Rear charge height, 190 mm (7.5 in.) at 1482 kPa (215 psi)

2 Accumulators Verify nitrogen charge in accumulators is at 9653 kPa (1400 psi) for all models, for both

steering and brakes

3 Engine Prelube If equipped, ensure prelube is working prior to engine starting

4 Engine Starting Ensure engine starts easily

5 Engine Noise No abnormal noise from engine

6 Brake Lock Verify when switch is ON, brakes are applied and light is illuminated

7 Parking Brake Verify when switch is ON, brakes are applied and light is illuminated

8 Brake Pressure 730E Verify with pedal depressed, front brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)

Verify with pedal depressed, rear brake pressure is 11,721 ± 517 kPa (1700 ± 75 psi)

Verify brake lock pressure is 10,342 ± 689 kPa (1500 ± 100 psi)

Verify parking brake pressure is 17,926 ± 689 kPa (2600 ± 100 psi)

830E, 830E-AC Verify with pedal depressed, front brake pressure is 20,684 ± 1034 kPa (3000 ± 150 psi)

Verify with pedal depressed, rear brake pressure is 13,652 ± 689 kPa (1980 ± 100 psi)


Verify parking brake pressure is 17,236 ± 689 kPa (2500 ± 100 psi)

930E-4 Verify with pedal depressed, front brake pressure (BF) is 17,236 ± 517 kPa (2500 ± 75 psi)

Verify with pedal depressed, rear brake pressure (BR) is 17,236 ± 517 kPa (2500 ± 75 psi)


Verify parking brake release pressure is 18,616 ± 689 kPa (2700 ± 100 psi)

9 Steering Verify that steering system is operating smoothly, turning from lock to lock

Verify steering system is free of noise and vibration

10 Hoist Verify hoist pressure is 17,236 kPa (2500 psi) power up, and 10,342 kPa (1500 psi) power

down

Verify hoist limit switch is operational and is set correctly (measure on the hoist cylinder - 3rd

stage), cylinder should stop 6 inches before full extension

Verify that the hoist hold position operates properly

Verify that there is no heavy shock when the body returns to the frame in float

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ADDITIONAL COMMENTS__________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________



11 Hoist Times 730E Power up loaded - 21-23 secondsPower down - 15-17 seconds

Float down empty - 22-24 seconds

830E, 830E-AC Power up loaded - 25-27 seconds

Power down - 15-17 seconds


930E-4 Power up loaded - 21-23 seconds

Power down - 23-25 seconds


All Trucks Ensure body up switch activates the body up alarm and light in the cab

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

Ensure automatic lube system is operating properly and timer is set as desired13 Payload Meter Sys. Calibrate and check payload meter operation per O&M manual

14 Error Codes Troubleshoot any error codes and delete

15 Machine Record machine model-type, machine serial number and engine serial number

16 Dump Body Ensure the dump body is shimmed correctly prior to truck release

17 Electrical Checks Ensure the electrical checkout procedure has been completed and signed off on, including

megger testing (see appropriate shop manual for procedure)

18 Truck Programming Ensure the truck is programed with it’s own unique configuration file and a copy of the file

saved

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NOTES:

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50 HOUR POST-COMMISSIONING CHECKSHEET

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

Inspector’s Comments:

Send white reports to: Manager of Technical Support

Komatsu America Corp.

2300 N.E. Adams St., P.O. Box 240

Peoria, IL 61650-0240 U.S.A.

Send canary reports to: Manager of Field Assembly

Komatsu America Corp.2300 N.E. Adams St., P.O. Box 240

Peoria, IL 61650-0240 U.S.A.

Send pink reports to your KAC Regional Service Manager

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

MACHINE MODEL(Circle One)

730E 830E

830E-AC 930E-4

MACHINE

SERIAL NUMBER

ENGINE MODEL ENGINE

SERIAL NUMBER

CUSTOMER UNIT

NUMBER

Service Meter Reading Date of Inspection Wheel Motor

Serial Numbers LH RH

Location of Machine at Inspection

Dump Body Manufacturer

Komatsu Other

Distributor’s Name Dump Body Style

Customer’s Name KAC Area Service Manager Signature Date

Customer’s Address

Inspector’s Name

KOMATSU USE ONLY:

Sheet receiving Date:

Title

By:

Signature

Remark:

8/17/2019 Ce Aw 004101


8/17/2019 Ce Aw 004101




4 Tie Rod Pin Retainer 730E - Verify hardware torque -

Target: 464 N·m (342 ft lbs)

830E, 830E-AC - Verify hardware torque -


930E-4 - Verify hardware torque -

Target: 1017 N·m (750 ft l bs)

5 Front Brake Caliper

Mounting

(Capscrew with Nut)

730E - Verify hardware torque -




6 Front Brake Caliper

Mounting

(Capscrew Only)





7 Rear Service Brake

Caliper Mounting





8 Rear Brake Adapter

Mounting





9 Brake Disc To Adapter

Mounting





Cab Compartment

1 Horn Check for proper tone and volume. Ensure there is no

looseness in the horn button.

2 Back Up Horn Check for proper tone, volume, and function.

3 Gauges Verify all gauges are installed straight and are operating

correctly.

4 Glass Verify no cracks exist on cab windows. Ensure all win-

dows are properly sealed.

5 Seat/Seat belts Verify the cab seats and seat belts are in proper working

condition.

No. Inspection Item Acceptance Procedures As Found

Condition

Corrective

Acti on

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Service Inspection

1 Suspension 730E

(See Note below)

Suspension oiling height: 38.1 mm (1.5 in.) front and

72.6 mm (2.9 in.) rear

Front charge height: 229 mm (9 in.) at 2758 kPa (400

psi)

Rear charge height: 276 mm (10.9 in.) at 1420 kPa (206

psi)

830E, 830E-AC

(See Note below)

Suspension oiling height: 25.4 mm (1 in.) front and 25.4

mm (1 in.) rear


psi)


psi)

930E-4

(See Note below)

Suspension oiling height: 25.4 mm (1 in.) front and 25.4

mm (1 in.) rear


psi)


psi)

NOTE: Refer to Section H, Oiling and Charging Procedure, in the appropr iate service manual for complete suspension oi ling

and charging instructions.

2 Accumulators Verify the nitrogen charge in the accumulators is at 9653

kPa (1400 psi) for all models, for both steering and

brakes.

3 Steering Verify that steering system is operating smoothly while

turning from lock to lock.

Verify the steering system is free of noise and vibration.

4 Lubrication Ensure the automatic lube system contains no air and is

filled to the proper level.

Ensure the automatic lube system is operating properly

and the timer is set as desired.

5 Hydraulic Filters Verify the 50 hour change of all hydraulic filters has been

completed.

NOTE: Elements are supplied from the factory in the

parts crate.

6 Tires Check and record the tire pressure/size/manufacturer for

future reference

Pressure

Size

Manufacturer

7 Payload Meter System Calibrate and check payload meter operation per O&M

manual. Troubleshoot any error codes and delete after

repair.

8 GE Drive/Control

System

Check drive control system operation per O&M manual.

Troubleshoot, correct and delete any error codes.

9 GE RotatingComponents

(Wheel Motors, MTA,

Grid Blower)

Visually inspect wheel motor armature condition - brushwear, commutator color, etc.

Inspect MTA slip rings and brushes.

Inspect grid blower motor commutator condition, brush

wear, etc.

10 Wheel Motor Sun Pinion

End Play

Measure and record sun pinion end play for both RH and

LH wheel motors

11 VHMS Verify the VHMS system is functioning properly per O&M

manual. Troubleshoot and repair any problems.

No. Inspection Item Acceptance Procedures As Found

Condition

Corrective

Acti on

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MINE OPTIONS - List any mine/site specifi c options or modifi cations made to the unit.

ADDITIONAL COMMENTS: ______________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

No. Description of Modification Reason For Installation

1

2

3

4

5

6

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Ce Aw 004101

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