Shop
Manual
730E
DUMP TRUCK
with TROLLEY ASSIST
SERIAL NUMBER
A30197 - A30200
and upThis material is proprietary to Komatsu Mining Systems, Inc. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Systems, Inc.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The Company reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication. Customers should contact their local distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read and understand this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
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This safety section also contains precautions forop-tional equipment and attachments.
SAFETY RULES
• ONLY trained and authorized personnel can oper-ate and maintain the machine.
• Follow all safety rules, precautions and instruc-tions when operating or performing maintenance on the machine.
• When working with another operator or a person on worksite traffic duty, be sure all personnel un-derstand all hand signals that are to be used.
•
SAFETY FEATURES
• Be sure all guards and covers are in their proper position. Have guards and covers repaired if dam-aged. (Refer to "Walk-Around Inspection, Operat-ing Instructions", later in this section.)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety features properly.
• NEVER remove any safety features. ALWAYS keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.
•
UNAUTHORIZED MODIFICATION
• Any modification made without authorization from Komatsu can create hazards.
• Before making a modification, consult your Komatsu distributor. Komatsu will not be respon-sible for any injury or damage caused by any unauthorized modification.
CLOTHING AND PERSONAL PROTECTIVE ITEMS • Avoid loose clothing, jewelry, and loose long hair.
They can catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothes because they are flammable.
• Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering metal chips or minute materials—this is so particu-larly when driving pins with a hammer and when cleaning the air cleaner element with compressed air. Check also that there is no one near the ma-chine.
STANDING UP FROM THE SEAT
• To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the following before standing up from the operator’s seat.
• Place the shift control lever at neutral (N) and set the parking lever to the PARKING position.
• Lower the dump body, set the dump lever to the HOLD position, then apply the lock.
• Stop the engine. When leaving the machine, al-ways lock everything. Alal-ways remember to take the key with you. If the machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or death.
MOUNTING AND DISMOUNTING
• NEVER jump on or off the machine. NEVER get on or off a moving machine.
• When getting on or off the machine, face the ma-chine and use the handhold and steps.
• Never hold any control levers when getting on or off the machine.
Read and follow all safety precautions. Serious injury or death may result, if all safety precautions are not followed.
• Always maintain three-point contact with the hand-holds and steps to ensure that you support your-self.
• When bringing tools to the operator’s compart-ment, always pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.
• Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
A: For use when getting on or off the machine from the left door.
B: For use when getting on or off the machine from the engine hood or right door.
FIRE PREVENTION FOR FUEL AND OIL • Fuel, oil, and antifreeze can be
ignited by a flame.
Fuel is extremely FLAMMABLE and can be HAZARDOUS.
• Keep flame away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil tank caps securely.
• Refueling and oiling should be made in well venti-lated areas.
• Keep oil and fuel in its specified place and do not allow unauthorized per-sons to enter.
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
• Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature and are under pressure. If the cap is removed or the oil or water is drained or the filters are replaced, there is danger
of serious burns. Always wait for the temperature to go down, and carry out the opera-tion according to the specified procedure.
• To prevent hot water from spurting out: 1) Stop the engine.
2) Wait for the water temperature to go down. 3) Turn the cap slowly to release the pressure
before removing the cap.
• To prevent hot oil from spurting out: 1) Stop the engine.
2) Wait for the oil temperature to go down. 3) Turn the cap slowly to release the pressure
before removing the cap.
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials contain-ing asbestos fibers, follow these guidelines as given below:
• NEVER use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Operate the machine with the wind to your back, whenever possible.
• Use an approved respirator if necessary.
PREVENTION OF INJURY BY WORK EQUIPMENT • Never enter or put your hand or arm or any other
part of your body between movable parts such as the dump body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead to serious bodily injury or death.
FIRE EXTINGUISHER AND FIRST AID KIT • Be sure fire extinguishers
have been provided and know how to use them.
• Provide a first aid kit at the storage point.
• Know what to do in the event of a fire.
• Be sure you know the phone numbers of persons you should contact in case of an emergency.
PRECAUTIONS WHEN USING ROPS
• If ROPS is installed, the ROPS must never be removed when operating the machine.
• The ROPS is installed to protect the operator if the machine should roll over. If is designed not only to support the load if the machine should roll over, but also to absorb the impact energy.
• The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its function properly. It can only display its performance if it is repaired or modified in the specified way.
• When modifying or repairing the ROPS, always contact your Komatsu distributor.
• Even if the ROPS is installed, it cannot show its full effect if the operator does not fasten the seat belt properly. Always fasten the seat belt when operat-ing.
PRECAUTIONS FOR ATTACHMENTS
• When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this man-ual.
• Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of un-authorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
• Any injuries, accidents, and product failures result-ing from the use of unauthorized attachments will not be the responsibility of Komatsu.
PRECAUTIONS DURING OPERATION
BEFORE STARTING ENGINE
SAFETY AT WORKSITE
• Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
• Examine the road surface in the jobsite and deter-mine the best and safest method of operation.
• Choose an area where the ground is as horizontal and firm as possible before carrying out the opera-tion.
• If you need to operate on a road, protect pedestri-ans and cars by designating a person for worksite traffic duty or by installing fences around the work-site.
• Check the river bed condition, and depth and flow of water before crossing shallow parts of river. NEVER be in water which is in excess of the per-missible water depth.
• The operator must check personally the work po-sition, roads to be used, and existence of obstacles before starting operations.
• Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines to travel.
FIRE PREVENTION
• Th o r o u g h l y r em o ve w o o d chips, leaves, paper and other flammable things accumulated in the engine compartment. They could cause a fire.
• Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks repaired. Wipe up any ex-cess oil, fuel or other flammable fluids.
• Be sure a fire extinguisher is present and working.
• Do not operate the machine near any flame.
IN OPERATOR’S CAB
• Do not leave tools or spare parts lying around in the operator’s compartment. They may damage or break the control levers or switches. Always put them in the tool box on the right side of the ma-chine.
• Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
• Check the seat belt, buckle and hardware for dam-age or wear. Replace any worn or damdam-aged parts. Always use seat belts when operating your ma-chine.
VENTILATION FOR ENCLOSED AREAS • If it is necessary to start the
engine within an enclosed area, provide adequate ven-tilation. Exhaust fumes from the engine can KILL.
KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN • Remove any dirt from the surface of the windows
or lights to ensure good visibility.
• Adjust the rear view mirror to a position where the operator can see best from the operator’s seat, and keep the surface of the mirror clean. If any glass should break, replace it with a new part.
• Check that the machine is equipped with the head lamps and working lamps needed for the operating conditions. Check that all the lamps light up prop-erly.
OPERATING MACHINE
WHEN STARTING ENGINE
• Walk around your machine again just before mounting it, checking for people and objects that might be in the way.
• NEVER start the engine if a warning tag has been attached to the control.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.
• Do not allow any person other than the operator in the operator’s compartment or any other place on the machine.
• For machines equipped with a back-up alarm buzzer, check that the alarm buzzer works prop-erly.
CHECK WHEN TRAVELING IN REVERSE • Before operating
the machine or work equipment, do as follows:
• Sound the horn to warn people in the area.
• Check that there is no one near the machine. Be particularly careful to check behind the machine.
• If necessary, designate a person to check the safety. This is particularly necessary when travel-ing in reverse.
• When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic.
• Do not allow any one to enter the line of travel of the machine. This rule must be strictly observed even on machines equipped with a back-up alarm or rear view mirror.
TRAVELING
• When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is traveling, the steering wheel will not work, and it will be dangerous to drive the machine. Apply the brakes immediately and stop the machine.
TRAVELING ON SLOPES
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, go down to level ground before turning.
• Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine slip on even the slightest slope. Take all possible steps to avoid traveling sideways, and always keep the travel speed low.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel sud-denly. Do not use the foot brake except in an emergency.
• If the engine should stop on a slope, apply the brakes fully and apply the parking brake, also, to stop the machine.
ENSURE GOOD VISIBILITY
• When working in dark places, install working lamps and head lamps, and set up lighting in the work area if necessary.
• Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a condition that allows the operation to be carried out safely.
OPERATE CAREFULLY ON SNOW
• When working on snowy or icy roads, there is danger that the machine may slip to the side on even the slightest slope, so always travel slowly and avoid sudden starting, turning, or stopping.
• Be extremely careful when carrying out snow-clearing operations. The road shoulder and other objects are buried in the snow and cannot be seen.
• When traveling on snow-covered roads, always install tire chains.
AVOID DAMAGE TO DUMP BODY
• When working in tunnels, on bridges, under elec-tric cables, or when entering a parking place or any other place where there are height limits, always drive extremely carefully and lower the dump body completely before driving the machine.
WHEN DUMPING
• Before starting the dumping operation, check that there is no person or object behind the machine.
• Stop the machine in the correct position, and check again that there is no person or object behind the machine. Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position a flagman.
• When carrying out dumping operations on slopes, the machine stability will become poor and there is danger that it may tip over. Always carry out such operations extremely carefully.
• Do not travel with the dump body raised.
WORKING ON LOOSE GROUND
• Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse, your machine could fall or tip over and result in serious injury or death. Remem-ber that the soil after heavy rain or blasting is weakened in these areas.
• Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight or vibration of your machine.
• When operating in places where there is danger of falling rocks or danger of the machine turning over, always install ROPS and a seat belt.
WHEN LOADING
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body uniformly.
• Do not leave the operator’s seat during the loading operation.
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES • Going close to high-voltage cables can cause
elec-tric shock. Always maintain the safe distance given below between the machine and the electric cable.
Voltage Minimum Safety Distance
6.6 kV 3 m 10 ft
33.0 kV 4 m 14 ft
66.0 kV 5 m 17 ft
154.0 kV 8 m 27 ft
275.0 kV 10 m 33 ft
• The following actions are effective in preventing accidents:
1) Wear shoes with rubber or leather soles. 2) Use a signalman to give warning if the
ma-chine approaches too close to the electric cable.
• If the work equipment should touch the electric cable, the operator should not leave the operator’s compartment.
• When carrying out operations near high voltage cables, do not let anyone come close to the ma-chine.
• Check with the electricity company about the volt-age of the cables before starting operations.
PARKING THE MACHINE
• Choose a horizontal road surface to park the ma-chine. If the machine has to be parked on a slope, always put blocks under all the wheels to prevent the machine from moving.
• When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
• Before leaving the machine, lower the dump body fully, set the parking lever to the PARKING position, stop the engine, then lock everything. Always take the key with you.
BATTERY
BATTERY HAZARD PREVENTION
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.
• Bat tery ac id c o uld c ause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.
• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegeta-ble oil. Call a doctor or poison prevention center immediately.
• When working with batteries ALWAYS wear safety glasses or goggles.
• Batteries generate hy-drogen gas. Hyhy-drogen gas is very EXPLOSIVE, and is easily ignited with a small spark of flame.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.
• When removing or installing, check which is the positive (+ ) terminal and negative (-) terminal.
• Tighten the battery cap securely.
• Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.
STARTING WITH BOOSTER CABLES
• ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
• When starting from another machine, do not allow the two machines to touch.
• Be sure to connect the positive (+ ) cable first when installing the booster cables.
Disconnect the ground or negative (-) cable first when removing them.
• If any tool touches between the positive (+ ) termi-nal and the chassis, it will cause sparks. This is dangerous, so be sure to work carefully.
• Connect the batteries in parallel: positive to posi-tive and negaposi-tive to negaposi-tive.
• When connecting the ground cable to the frame of the ma-chine to be started, be sure to connect it as far as possi-ble from the battery.
TOWING
WHEN TOWING, FIX WIRE TO HOOK
• Towing in the wrong way may lead to serious personal injury or damage.
• When using another machine to tow this machine, use a wire rope with ample strength for the weight of this machine.
• Never tow a machine on a slope.
• Do not use any towing rope that has kinks or is twisted.
• Do not stand astride the towing cable or wire rope.
• When connecting a machine that is to be towed, do not let any one come between the towing ma-chine and the mama-chine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing portion of the machine, and secure it in position. (For towing method, see "Operating Instructions" later in this section.)
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE
WARNING TAG
• If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death.
• ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary.
• These tags are avail-ab le f r o m y o u r Komatsu distributor. (Part No.
09963-03000)
PROPER TOOLS
• Use only tools suited to the task. Using dam-aged, low quality, faulty, or makeshift tools could cause personal injury.
PERIODIC REPLACEMENT OF CRITICAL PARTS • Periodically replace parts used to insure safety or
prevent accident. (See “Periodic Replacement Of Component Parts For Safety Devices”, Section 4, of the "Operation & Maintenance Manual".)
• Replace these components periodically with new ones, regardless of whether or not they appear to be defective. These components deteriorate over time.
• Replace or repair any such components if any defect is found, even though they have not reached the time specified.
STOPPING THE ENGINE BEFORE SERVICE • When carrying out inspection or maintenance,
al-ways stop the machine on firm flat ground, lower the dump body, then stop the engine.
• If the engine must be run during service, such as when cleaning the radiator, always set the shift control lever to the neutral position (N) and the parking brake lever to the PARKING position. Al-ways carry out the work with two people. One person should sit on the operator’s seat so that he can stop the engine if necessary. NEVER move any controls you do not need to operate.
• When servicing the machine, be careful not to touch any moving part or get your clothes caught.
• Put blocks under the wheels.
• When carrying out service with the dump body raised, always place the dump lever at the HOLD position, apply the lock, and insert the safety pins securely.
DURING MAINTENANCE
PERSONNEL
• Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-ham-mer.
ATTACHMENTS
• Plac e attac hments that have been removed from the machine in a safe place so that they do not fall. If they fall on you or others, serious injury could result.
WORK UNDER THE MACHINE • Always lower all movable
wo rk eq uip m ent to the ground or to their lowest position before performing service or repairs under the machine.
• Always block the tires of the machine securely.
• Never work under the machine if the machine is poorly supported.
KEEP THE MACHINE CLEAN
• Spilled oil or grease, or scattered tools or broken pieces are dangerous because they may cause you to slip or trip.
Always keep your machine clean and tidy.
• If water gets into the electrical system, there is danger that the machine may not move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the operator’s com-partment.
RULES TO FOLLOW WHEN ADDING FUEL OR OIL • Spilled fuel and oil may cause you to slip, so always
wipe it up immediately.
• Always tighten the cap of the fuel and oil fillers securely.
• Never use fuel for washing any parts.
• Always add fuel and oil in a well-ventilated place.
RADIATOR WATER LEVEL • If it is necessary to add
water to the radiator, stop the engine and allow the engine and radiator to cool down before adding the water.
• Slowly loosen the cap to relieve pressure before removing the cap.
USE OF LIGHTING
• When checking fuel, oil, coolant, or battery elec-trolyte, always use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger or explosion.
PRECAUTIONS WITH BATTERY
• When repairing the electrical system or when car-rying out electrical welding, remove the negative (-) terminal of the battery to stop the flow of current.
HANDLING HIGH-PRESSURE HOSES
• Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or hoses. They may burst during use.
• Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
PRECAUTIONS WITH HIGH PRESSURE OIL • Do not forget that the work equipment circuits are
always under pressure.
• Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the inter-nal pressure.
• If oil is leaking under hig h p ressure fro m small holes, it is dan-gerous if the jet of high-pressure oil hits your skin or enters your eyes.
• If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
• Alw ay s w ear safety g lasses and thick gloves, and use a piece of cardboard or a sheet of wood to c h ec k fo r o il leakage.
PRECAUTIONS WHEN PERFORMING
MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE
• Immediately after stopping op-erations, the engine cooling water and oil at all parts are at high temperature and under high pressure.
• In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced, it may result in burns or other injury. Wait for the tempera-ture to go down, then carry out the inspection and maintenance in accordance with the procedures given in this manual.
ROTATING FAN AND BELT • Keep away from rotating
parts and be careful not t o l et an y t h in g g et caught in them.
• If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying, so never touch any rotating parts.
WASTE MATERIALS • Never dump waste
oil in a sewer sys-tem, rivers, etc.
• Alw ay s p u t o il drained from your machine in contain-ers. Never drain oil d ir ec t ly o n t h e ground.
• Obey appropriate laws and regulations when dis-posing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and others.
TIRES
HANDLING TIRES
• If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones on rough road surfaces. This may lead to serious injury or damage.
• To maintain safety, always keep to the following conditions:
• Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is too low.
• Use the specified tires.
The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual values may differ depending on the type of tire and the condition under which they are used. For details, please contact your Komatsu distributor or tire maker.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly dangerous if the tires become overheated when the tires are under pressure. If the gas generated inside the tire ignites, the internal pressure will suddenly rise, and the tire will explode, and this may lead to serious personal injury. Explosions differ from punctures or tire bursts, be-cause the destructive force is extremely large. There-fore, the following operations are strictly prohibited when the tire is under high internal pressure:
• Welding the rim
• Building fires or carrying out welding near the wheel or tire.
If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult your Komatsu distributor or tire maker.
STORING TIRES AFTER REMOVAL
• As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up “No Entry” and other warning signs that even young children can understand.
• Stand the tire on level ground, and block it se-curely so that it cannot roll or fall over.
• If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy, so trying to hold the tire may lead to seri-ous injury.
ADDITIONAL JOB SITE RULES
Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions.
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DUMP BODY
Removal
1. Park truck on a hard, level surface and block all the wheels. Connect cables and lifting device to the dump body and take up the slack as shown in Figure 3-1.
Before raising or lifting the body, be sure there is adequate clearance between the body and over-head structures or electric power lines.
Body weight can vary substantially depending on liner plate installation, etc. Be certain the lifting device is rated for at least a 45 ton capacity.
2. Remove mud flaps and rock ejectors from both sides of the body. Remove electrical cables, lubri-cation hoses etc. attached to the body.
3. Attach chains around upper end of hoist cylinders to support them after the mounting pins are re-moved.
4. Remove pin retainer capscrew (4, Figure 3-2) from each of the upper hoist cylinder mounting eyes. With adequate means of supporting the hoist cyl-inders in place, remove each of the mounting pins (2).
5. Remove capscrews (4, Figure 3-3) from each pivot pin.
6. Remove body pivot pins (6). The spacer shims (3) will drop out as the pin is removed.
7. Lift dump body clear of the chassis and move to storage or work area. Block the body to prevent damage to the body guide, pads, etc.
8. Inspect bushings (2) and pivot pins; replace bush-ings and/or body pivot pins if damaged or worn excessively.
Installation
1. Attach lifting device to dump body and lower over the truck frame. Align body pivot and frame pivot holes.
2. Install shims (3, Figure 3-3) as required to center the body on the frame pivot.
NOTE: A minimum of 1 shim is required at the outside end of the frame pivot. Do not install shims at the inside.
3. Align the pin retainer capscrew hole and push the pivot pin through the spacers and into the pivot bushings in each side of the frame.
4. Install capscrew through each pin and tighten the nuts to standard torque.
FIGURE 3-1. DUMP BODY REMOVAL 1. Lifting Cables 2. Guide Rope
FIGURE 3-2. HOIST CYLINDER MOUNT (UPPER) 1. Dump Body
2. Hoist Cylinder Pin 3. Hoist Cylinder4. Pin Retainer
5. Align hoist cylinder upper mounting eye bushings with the hole through the body, align retaining capscrew hole (4, Figure 3-2)and install the pin. 6. Install the pin retaining capscrews and nuts and
tighten to standard torque.
7. Install mud flaps, rock ejectors, electrical cables and lubrication hoses if installed.
BODY PADS
It is not necessary to remove the dump body to replace body pads. Pads should be inspected during sched-uled maintenance inspections and replaced if worn excessively.
1. Raise the body to a height sufficient to allow access to all pads.
Place blocks between the body and frame. Secure blocks in place.
2. Remove hardware attaching pads to the dump body. (Refer to Figure 3-4)
3. Remove body pad and shims. Note number of shims installed at each pad location. (The rear pad on each side should have one less shim than the other pads)
4. Install new pads with the same number of shims as removed in step 3.
5. Install the mounting hardware and tighten to 25 ft.
lbs. (34 N.m) torque.
6. Raise body, remove blocks supporting body and lower body onto the frame.
Adjustment
1. All pads, except the rear pad on each side, should contact the frame with approximately equal com-pression of the rubber. A gap of approximately 0.06 in. (1.5 mm) is required at each rear pad. This can be accomplished by using one less shim at each rear pad. If pad contact appears to be un-equal, repeat the above procedure. (Vehicle must be parked on a flat, level surface for inspection.) Proper body pad to frame contact is required to assure maximum pad life.
FIGURE 3-3 DUMP BODY PIVOT PIN (RH Side Shown) 1. Body
2. Bushing 3. Shim
4. Pin Retainer Capscrew 5. Frame
6. Body Pivot Pin
FIGURE 3-4. BODY PAD 1. Dump Body
2. Shim
2. Pad Mounting Hardware
4. Body Pad 4. Frame
BODY GUIDE
The body guide is designed to ensure the body is positioned properly on the frame to prevent excessive body pad and pivot pin bushing wear during truck operation.
1. Body guide wear points should be inspected each time a body pad inspection is performed. (Refer to Figure 3-5) The body guide should be centered between the wear plates (3), with a gap of 0.19 in. (5.0 mm) at each side when new.
2. If gap becomes excessive, the wear plates (4) should be replaced. (Refer to the Parts Catalog)
BODY SLING
Any time personnel are required to perform main-tenance on the vehicle with the dump body in the raised position, the body MUST be supported in the raised position with the body sling cable. Always inspect cable and mounting brackets for signs of fatigue or wear before use.
1. To lock the dump body in the up position, raise the body to it’s maximum height.
2. Remove pins storing sling in the storage position and place cable clevis over eye below rear sus-pension mount and eye on body. Reinsert pins and retainers.
3. Slowly lower the body until the cable is tight. 4. After work has been completed, raise body,
un-hook cable and reattach to its storage position.
BODY POSITION INDICATOR
The Body Position Indicator is a device mounted on the canopy of the dump body. When the body is lowered, the indicator is visible to the operator. This device should be inspected daily and repairs made if required. FIGURE 3-5. BODY GUIDE
1. Dump Body
2. Body Guide 3. Frame4. Body Guide Wear Plates
