CEAW004101
Field Assembly
Manual
DUMP TRUCK
SERIAL NUMBERS
A30427 & UP
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu 730E dump truck. Variations of design required for specific truck orders may require some modification of the general procedures 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 the current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated 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.
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.
TABLE OF CONTENTS
SUBJECT
PAGE NUMBER
FOREWORD . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . 1-1
MAJOR COMPONENTS AND SPECIFICATIONS . . . 2-1
MAJOR COMPONENT WEIGHTS . . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . . 5-1
CHASSIS ASSEMBLY. . . 6-1
DUMP BODY ASSEMBLY . . . 7-1
DUMP BODY INSTALLATION . . . 8-1
FINAL CHECK-OUT . . . 9-1
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 blocks between 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 your customer support manager for further informa-tion.
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, with high lift capability.
4. Two, 300 amp portable welding units and an oxy-acetylene cutting set.
5. One, propane torches for weld preheating. 6. Portable air compressor - 3.5 cmm (125 cfm)
and 690 kPa (100 psi) capacity. Two, 15 m (50 ft) air hoses.
7. Metal stands and a sufficient amount of wood cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm (4 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm (4 ft. x 6 in. x 6 in.) - such as railway cross ties
8. Tire handler - Wiggins/Iowa Mold Tooling. 9. Miscellaneous air tools
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft) 11. Chains, lifting cables, slings:
•
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 rope12. 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, 6mm to 36mm.•
Inch sockets and open end wrenches up to 1 3/4 in.•
Torque wrenches - 339 N·m (250 ft lb) with 18:1 multiplier. Torque wrenches - 339 N·m (600 ft lb) with 4:1 multiplier. Hydrotorque - 1 1/2 in. drive with capability of 5559 N·m (4100 ft lb) or greater.•
Box wrench 1 3/8 in. (Snap-On p/n X440B) with 12 inch extension to tighten ROPS cap screws.•
Sockets: 2 1/4 in. (Snap-On P/N J15036) and 2 5/8 in. (Snap-On P/N J15042) to tighten front suspension hardware.15. Heavy duty 3/4 in. & 1 in. square drive impact wrench sets.
16. Impact sockets for 3/4 in. & 1 in. square drive tools.
17. Special tools (see list, following pages)
18. Two, hydraulic or pneumatic porta-power jacks, 4.5 and 9 metric ton (5 and 10 ton)
19. Various hooks and shackles
20. Miscellaneous: i.e. grinders, containers, rags. 21. Spreader bars for cab and decks.
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
LIFTING SLING GENERAL
INFORMATION
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
Part Number Description Use
PB8326 Offset Box End Wrench, 1 7/16”
Miscellaneous and Cab Mounting
Part Number Description Use
TZ2734 3/4” Torque Adapter
Miscellaneous
Part Number Description Use
TZ2733 Tubular Handle Use with PB8326 and TZ2734
Part Number Description Use
TY2150 Seal Installa-tion Tool
Installation of Front Wheel Bearing Face Seals
Part Number Description Use
EC1741 EC1742 TZ0992 Sleeve Alignment Tool Steering Linkage and Tie Rod Assembly. Refer to Section G.
Part Number Description Use
AK4720 Payload Data Manger Payload Meter Download. Refer to Section D. EF9160 PLM Download Harness
Part Number Description Use
PB6039 Hydraulic Coupling
Miscellaneous
Part Number Description Use
TG1106 Eye Bolt Miscellaneous
Lifting Requirements
Part Number Description Use
TW9425 Special Wrench Accumulator Gland Nut
PART NO. DESCRIPTION USE
PC2061 Belt Tension Tester
Part Number Description Use TZ8968 Socket 3-1/2” Miscellaneous TZ2726 Socket 1-1/8” Miscellaneous TZ2729 Socket 1-1/4” Miscellaneous TV7567 Socket 1-5/16” Miscellaneous PB6825 Impact Socket 1-5/8” Miscellaneous TR0529 Socket 1-3/4” Miscellaneous TZ2100 Socket 1-7/8” Miscellaneous TZ2727 Socket 2-1/4” Miscellaneous TZ2728 Socket 2-3/4” Miscellaneous PB6824 Impact Socket 3-1/8” Miscellaneous TZ8968 Socket 3-1/2” Miscellaneous TR0532 Square Drive Extension 8” Miscellaneous TR0533 Square Drive Extension 17” Miscellaneous TV1186 Extension 3-1/2” Miscellaneous TR0546 Sliding T-Handle Miscellaneous TZ2730 Adapter 1” x 1-1/2” Miscellaneous TZ2731 Adapter 3/4” x 1” Miscellaneous PB6851 Locking Steel Pin (for
use with 1-1/2” square drive sockets)
Miscellaneous
PB6852 Locking Rubber Ring (for use with 1-1/2” square drive sockets)
Miscellaneous
PART NO. DESCRIPTION USE
EL8868 V-Belt Align-ment Tool
Aligning A/C pulleys
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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 electrical energy back to mechanical energy through built-in gear trains within the wheel motor assembly. The direction of the wheel motors is controlled by a 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 CAB
The operator's cab for the Komatsu 730E dump truck has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab provides for wide visibility, with an integral four-post Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS), and an advanced analog operator environment. It includes a tinted safety-glass windshield and power-operated side windows, a deluxe interior with a fully adjustable seat with lumbar support, a fully adjustable/tilt 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 cab and by setting the RSC (Retarder Speed Control). Dynamic retarding is automatically activated if the truck goes to a preset overspeed setting.
BRAKE SYSTEM
The wheel service brakes are caliper/dry disc brakes applied by an all hydraulic actuation system. Depressing the brake pedal actuates wheel-speed single disc front brakes and armature-speed dual disc rear brakes. The rear brakes can also be acti-vated by operating a switch on the instrument panel. All wheel brakes will be applied automatically if the system 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.
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/Wheel
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 to provide constant rate steering.
Emergency power steering automatically provided by accumulators (meets SAE J1511).
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 Kilograms (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.
MAJOR COMPONENT WEIGHTS
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before each use. Lifting equipment must be in good condition and rated for approximately two times the weight being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result. Optional equipment added onto the truck may cause an increase to the component weights listed in this chapter. Contact your customer support manager for concerns or questions about lifting truck 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
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
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 AND
TRAINING
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 of highly stressed structural members such as castings, torque tubes, top and bottom plates on the frame rails, and the curved intersection points of frames should be done with the specific detailed instructions from Komatsu Product Service. See Annex A for repair procedures. These repair procedures are detailed instructions for most high stressed structural members.
APPROVED CONSUMABLES
GMAW - LW102-15 or ER80S-D2 FCAW - E70T-5, E71T-8, or E71T8-NI1 SMAW - E7018-1, E8018-C1, or E8018-C3WELD QUALITY REQUIREMENTS
1. Each weld must be homogeneous with lowporosity, free from cracks, and slag inclusions. 2. Each weld must have complete fusion between
the base metal and weld metal added by the electrode.
3. All welds must be reasonably smooth, without excessive deformity, and all craters filled. No cracks are permitted.
4. The toe of a weld to a stressed member must have a smooth transition. Excessive convexity in multi-pass fillet welds is not permitted. 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.
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 required that all slag is removed and tie in all areas. Grind all welds where a weld crosses or inter-sects with another weld.
MATERIALS, CONTROLS, AND
PRECAUTIONS
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 a grinder 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.
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 and test results are normally recorded.
6. X-Ray Inspection - This process provides a view of the weld and base materials but it is highly specialized. This procedure provides a permanent visual record, but is more expensive than most other inspection techniques.
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 joint preparation complete, with backer bars installed, etc. just prior to welding. These photos easily identify if the required preheating and post heating have been done with a three inch circumference around the weld repair area. Without this documentation, Komatsu will not cover any weld repair claim made under warranty. No exceptions will be made.
ANNEX A
The following are general repair procedures, which must be followed for all repair and rework of major load carrying members on Komatsu equipment.
1. The repair or rework area must be protected from wind and moisture during the entire 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. All welding should be done at an ambient tempera-ture of 10°C (50°F) or above.
2. Clean and grind the entire repair area to remove all rust, grease, oils, paint, and any other foreign materials likely to contaminate the weld.
3. Air arc the entire crack leaving a V-shape joint. The depth of the V (or U shaped) joint will be determined by the depth of the crack. The width to depth ratio should be approximately 1.25:1 and never less than 1:1. All cracks through the parent material will require a slightly wider root opening than the original, usually 6 mm (0.25 in.) to allow the installation of a backup strip. Backup strips are required for all cracks that have gone through the parent material and 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.
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 weld acceptance 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 the direction of travel. This will normally require approximately four passes of the peening tool with the pressure of near full operator weight being applied. The depth of the indentation must be between 0.6 mm to 0.8 mm (0.02 to 0.03 in.).
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 for the burr tool resulting in the material removed being approximately equally divided between the base material and the weld metal face to the specified depth and not exceed 8 mm (0.31 in.) in width. Refer to Figure 4-2.
2. The weld must have a smooth profile and the toe must have a good transition to the parent material (no overlap) before the 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 at about 45° to the parent plate and inclined at about 45° to the direction of travel. The depth of the grinding must be between 0.8 mm to 1.0 mm (0.030 to 0.040 in.). The final surface must be clean, smooth and free of all traces of under-cut or slag.
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 CarCar-bon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The Welding Institute, F. R. Coe, Author
SPECIAL PRECAUTIONS WHEN
SERVICING AN A/C DRIVE SYSTEM
TRUCK
Consult a qualified technician, specifically trained for servicing the A/C drive system, before welding on the truck.
The following procedures must be followed to ensure the safety of maintenance personnel and to help pre-vent damage to the equipment.
Anytime the engine is on:
• Do not open any of the cabinet doors or remove any covers.
• Do not use power cables for hand holds or foot steps.
• Do not touch retarder grid elements.
Before opening any cabinets or touching a grid element or a power cable, the engine and all warning lights must be off.
Engine Stop Procedure Prior To Maintenance
Perform the following procedure prior to maintenance to ensure that no hazardous voltages are present in the A/C drive system.
1. Before turning off the engine, verify the status of all the drive system warning lights on the overhead display panel. Use the lamp test switch to verify that all lamps are functioning properly.
2. If all red drive system warning lights are off, turn the engine off.
3. After the engine has been off for at least five minutes, inspect the link voltage lights. The lights are located on the exterior of the main control cabinet and back wall of the operator's cab (DID panel). If all lights are off, the retard-ing grids, wheel motors, alternator, and power cables connecting these devices are safe to work on.
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 creatre-energiz-ing system voltage until the switch is returned to its former position.
After repairs, replace all covers and doors and place the GF cutout switch and battery 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 disconnect any 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 strap from the ECS.
3. Fasten the welding machine ground (-) lead to the piece being welded. The grounding clamp must be attached as near as possible to the weld area.
4. DO NOT weld on the rear of the control cabinet! The metal panels on the back of the cabinet are part of the capacitors and cannot be heated. 5. DO NOT weld on the retard grid exhaust
lou-vers.
6. Some power cable panels throughout the truck are made of aluminum or stainless steel. They must be repaired with the same material or the power cables may be damaged.
7. Power cables must be cleated in wood or other non-ferrous materials. DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Inspect power cable 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 the vehicle electrical harnesses. Welding voltage may be induced into the electrical harnesses and cause damage to components.
10. DO NOT allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders.
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 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.
ASSEMBL
Y
LA
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 preparation2. Unload truck components 3. Assemble the chassis 4. Weld the body
NOTE: Chassis assembly and body welding may be done in either order, or simultaneously. The most logical order depends on available resources such as cranes, welders, assemblers, etc.
5. Static checkout (electrical & mechanical) 6. Install the body
7. Dynamic checkout (electrical & mechanical) 8. Site cleanup
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, and cables used for lifting components must be inspected daily for serviceable condition. Refer to the manufacturer’s guidelines for correct capacities and safety procedures when lifting components. Replace any questionable items.
• Slings, chains and cables used for lifting must be rated for approximately two times the intended load.
• When in doubt as to the weight of components or any assembly procedure, contact your customer support manager for further information.
• Lifting eyes and hooks must be fabricated from the proper materials and rated to lift the intended load.
• Never stand beneath a suspended load. Guy ropes are recommended for guiding and positioning a suspended load.
• Before lifting, ensure there is adequate clearance 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 wire before welding on the frame or its components. Fasten the welding machine ground cable to the component being welded.
DO NOT allow welding current to pass through bearings.
DO NOT lay welding cables over truck electrical cables and harnesses. Welding voltages could be induced into the truck wiring and cause damage to components.
DO NOT weld on the fuel tank or the hydraulic tank unless they have been properly cleaned and ventilated.
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.
GENERAL PRECAUTIONS AND
INSTRUCTION
1. Clean and remove all foreign material from component mounting surfaces.
2. DO NOT weld the front uprights until all upper decks are installed.
3. Torque the deck mounting bolts before the exhaust tubes, etc. are installed.
4. Verify all electrical connectors are free from paint and/or corrosion. Clean any connector that may be questionable.
5. Do not torque the diagonal ROPS beam until after the operator cab & LH air intake tubes are in place.
6. Before installing the cab, tap all threaded holes to remove paint.
7. Verify all wiring is properly connected before attempting to start the engine.
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 pressureand 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 of this manual.
13. Use the battery disconnect switch when arc welding. Connect the weld ground near the weld area.
1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each. Lift the chassis onto adequate support blocks or stands. The weight of the chassis, as shipped, is approximately 38,555 kg (85,000 lb).
The support blocks/stands must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm (12 in.) high under the rear axle housing. Placement of the chassis at this height will allow easy installation of truck components.
FIGURE 6-1.
FIGURE 6-3.
3. Lift the LH deck support into position. The weight of the deck support is approximately 408 kg (900 lb). a. Bolt the support into place.
b. Weld the support to the frame. The four tapped pads on each support and the corresponding blocks on the horsecollar must be removed to allow for a complete weld around the joint. Follow the specifications shown in Figure 6-7.
c. Grind all areas, and clean. Paint after welding is complete.
If the tapped pads are not removed, a complete weld around the support can not be achieved. Gaps in the weld around the support may result in premature frame cracking in this area.
FIGURE 6-5.
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 6-9.
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 6-12.
FIGURE 6-14.
FIGURE 6-16.
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 prevent damage to the fillet between the cap screw head and the shank. Refer to Figure 6-23.
Alternately tighten the wheel motor mounting cap screws to 2007 ± 201 N·m (1480 ± 148 ft lb).
NOTE: When lifting the wheel motors, do not lift under the brake assembly. Shipping fasteners installed in the outboard rim bolt circle must remain in place during lifting and installation of wheel motors.
FIGURE 6-19.
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.
FIGURE 6-21.
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 threads 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 Standard Oil 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 the Southwest Grease and Oil Company
NOTE: If none of the rust preventive greases listed above are available for field assembly, use one of the following lubricants:
• SAE 30 weight oil
• 5% Molybdenum - Disulphide Grease DO NOT use anti-seize compounds.
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. The weight of each front suspension cylinder is approximately 2228 kg (4,912 lb). Install the mounting hardware and tighten according to the "turn-of-the-nut" method outlined on the follow-ing pages.
FIGURE 6-23. INSTALLATION OF HARDENED FLAT WASHER
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 corner cap screws and the bottom, outer four cap screws (without spacers).
c. Loosen the eight remaining cap screws and then tighten again as follows:
d. Initially tighten the four cap screws (1) at the upper mount to 95 N·m (70 ft lb). Then, advance the cap screw heads 60° as 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° as outlined 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 Washers 3. Housing
4. Mounting Surface 5. Shear Bar
6. Cap Screws and Washers
7. Piston
8. Cap Screws and Washers
9. Spacer
10. Nuts and Washers
FIGURE 6-25. 60 DEGREE ADVANCE
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 wrench during the tightening procedure.
e. Loosen the top two corner cap screws (1, Figure 6-24) and the bottom outer four cap screws (8), (without spacers).
1.) Tighten the top two corner cap screws to
95 N·m (70 ft lb), then advance the cap
screw heads 60°.
2.) Tighten the bottom, outer four cap screws to 203 N·m (150 ft lb), then advance the cap screw heads 90°.
NOTE: If for any reason, these fasteners need to be checked for tightness after completing this procedure, loosen and inspect all 14 cap screws and repeat the entire process. The hardware must be cleaned and lubricated.
FIGURE 6-27.
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.
FIGURE 6-29.
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
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.
FIGURE 6-33.
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.
FIGURE 6-35.
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).
FIGURE 6-37.
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.
FIGURE 6-39.
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.
FIGURE 6-41.
27. Tighten the cap screws that secure the diagonal ROPS beam and the decks. Tighten the cap screws to stan-dard torque.Refer to Stanstan-dard Tables in Section 10, Appendix.
FIGURE 6-43.
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 to
407 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 mainmain-tained, daily checking is no longer required. Check intermittently to ensure torque is maintained.
FIGURE 6-46. FRONT WHEEL TIGHTENING SEQUENCE
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 in place with the lubricated wheel nuts. Evenly tighten each nut in an alternating pattern, as shown in Figure 6-48, to 407 N·m (300 ft lbs). 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 inflation lines to the bracket on the outer rim. Tighten the cap screws to standard torque.
42. Install the wheel cover. Remove the blocks from under the truck and lower the truck to the ground.
43. After truck assembly is complete, operate the truck for one load and retighten the wheel nuts in the proper sequence. Recheck the nut torque daily (each 24 hours of operation) to ensure proper torque is maintained on each nut. Once the torque is maintained, daily checking is no longer required. Check intermittently to ensure torque is maintained.
FIGURE 6-48. REAR WHEEL TIGHTENING SEQUENCE
FIGURE 6-49.
FIGURE 6-51.
44. Complete the wiring for the control cabinet and retarding grid.
FIGURE 6-54.
45. Install the exhaust system.
FIGURE 6-56.
46. Install the blower hose and clamps to the control cabinet and alternator.
47. LIft the air intake ductwork into position and install the mounting hardware. The weight of the inlet duct is approximately 214 kg (472 lb). Tighten the cap screws to standard torque. Refer to Standard Tables in Section 10, Appendix.
FIGURE 6-59.
FIGURE 6-61.
FIGURE 6-63.
FIGURE 6-65.
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 6-68.
FIGURE 6-70.
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. After 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
