manual de armado 830e1 a-c.pdf

CEAW006801

Field AssemblyManual

830E-1ACDUMP TRUCK

SERIAL NUMBERS A30566 & UP

FAM0019 Introduction i

FOREWORD

This manual is provided to aid assemblers during field assembly of the standard Komatsu 830E-AC dump truck.Variations of design required for specific truck orders may require some modification of the general proceduresoutlined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assemblingthe truck.

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

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

All location references to front, rear, right, or left, are given in respect to the operator's normal seated posi-tion.

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

ii Introduction FAM0019

This alert symbol is used with the signal words, CAUTION, DANGER, andWARNING in this manual to alert the reader to hazards arising from improperoperating and maintenance practices.

DANGER Identifies a specific potential hazard which will result in either injury or death if proper precautions are not used.

CAUTION is used for general reminders of proper safety practices or to direct the readers attention to avoid unsafe or improper practices which may result in damage to the equipment.

WARNING identifies a specific potential hazard which may result in either injury or death if proper precautions are not used.

FAM0019 Introduction iii

TABLE OF CONTENTS

SUBJECT PAGE NUMBER

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

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

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

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

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

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

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

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

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

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

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

iv Introduction FAM0019

KOMATSU 830E-AC

FAM0115 Safety Rules, Tools, & Equipment F01-1

SAFETY RULES, TOOLS & EQUIPMENT

SAFETY RULESThe following list of safety practices is intended for useby personnel during field assembly of the truck.

This list of safety rules is not intended to replace localsafety rules or regulations and federal, state, or locallaws. The safety precautions recommended here aregeneral and must be used in conjunction with all pre-vailing local rules and regulations.

1. All personnel must be properly trained for theassembly process.

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

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

4. Use only solid, hard wood for supports. Whenusing metal support stands, place wood blocksbetween the support and the frame to preventmetal to metal contact.

5. Inspect all lifting devices. Refer to the manufac-turer's specifications for correct capacities andsafety procedures when lifting components.

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

7. DO NOT stand beneath a suspended load. Use ofguy ropes are recommended for guiding and posi-tioning a suspended load.

8. Maintain fire control equipment. Inspect fire extin-guishers regularly to ensure they are fully chargedand in good working condition.

9. Cap screws and/or nuts being replaced must bethe same grade as originally supplied.

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

10. Disconnect the battery charging alternator leadwire before welding on the frame or its compo-nents.

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

12. DO NOT weld the fuel tank or hydraulic tankunless the tanks have been properly purged andventilated.

13. Use the proper tools for the job to be performed.Never improvise wrenches, screw drivers, sock-ets, etc. unless specified.

14. Lifting eyes and hooks must be fabricated fromthe proper materials and rated to lift the intendedload.

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

BODY-UP RETENTION CABLE

To avoid serious personal injury or death, the bodyup retention cable must be installed anytime per-sonnel are required to perform maintenance on thevehicle with the dump body in the raised position.

The Komatsu body-up safety sling can only beused with a Komatsu body. Non-OEM body may notaccommodate the Komatsu body-up safety sling.The end user must ensure that a proper cable/slingis used.

F01-2 Safety Rules, Tools, & Equipment FAM0115

TOOLS AND EQUIPMENT FOR ASSEMBLYThe following equipment is recommended for fieldassembly of the truck.

1. Equipment and tool storage trailer with a lockabledoor. Approximately 12 x 2.5 m (40 x 8 ft)

2. Cranes

a. Two, 45 metric ton (50 ton) cranes to removethe chassis from the freight trailer and place oncribbing. These cranes can also be used to liftthe assembled body onto to the chassis.

b. One, 109-136 metric tons (120-150 ton) crane.The crane is needed to turn the body over aftercompletion of the underside welding. A 45 met-ric ton (50 ton) crane is also required for thistask.

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

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

5. One, propane torches for weld preheating.6. Portable air compressor - 3.5 cmm (125 cfm) and

690 kPa (100 psi) capacity.

Two, 15 m (50 ft) air hoses. 7. Metal stands and a sufficient amount of wood

cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm(14 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 cm(4 ft. x 6 in. x 6 in.) - such as railway cross ties

8. Tire handler - Wiggins/Iowa Mold Tooling.9. Miscellaneous air tools

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

11. Chains, lifting cables, slings:

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

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

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

Two, 3 m (10 ft) nylon straps

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

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

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

14. Set of standard master mechanics hand tools.

Thread taps and dies of both inch and metric sizes.

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

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

Torque wrenches - 339 Nm (250 ft lb) with 18:1 multiplier. Torque wrenches - 339 Nm (600 ft lb) with 4:1 multiplier. Hydrotorque - 1 1/2 in. drive with capability of 5559 Nm (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 impactwrench sets.

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

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) capac-ity.

23. Pry bars

24. Solvent - 38 liters (10 gal)

25. Paint remover - 19 liters (5 gal)

26. Rust preventive grease

27. Body sling if a non OEM body is installed.


LIFTING SLING GENERAL INFORMATION


1. T Handle Valve2. Charging Valve Adapter3. Manifold Outlet Valves (from gauge)4. Inlet Valve (from regulator)5. Regulator Valve (Nitrogen Pressure)6. Manifold7. Charging Pressure Gauge (Suspensions)8. Dry Nitrogen Gas

Part Number Description UseEB1759 Nitrogen

Charging KitSuspension & Accumulator Nitrogen Charging

Part Number Description UseEJ2627(No longer available as complete unit)

Roller Assy. Power Module Remove & Install

EJ2629 Roller MountPC0706 BearingTH9449 Bearing

Retainer Ring

TG1680 Roller Retainer Ring

C1645 Cap screw0.75 -10 NC x 2 1/4 in.

C1542 Lockwasher0.75 in.

EH8686 Roller Ring


Part Number Description UseTZ3535 Offset Box End

Wrench, 1, 1/2 in.

Miscellaneous

Part Number Description UseTZ2734 3/4 in. Torque

AdapterMiscellaneous

Part Number Description UseTZ2733 Tubular Handle Use with TZ2734

& TZ3535


Part Number Description UseTY2150 Seal Installa-

tion ToolFront Face Seals

Part Number Description UseTY4576 Sleeve

Alignment ToolSteering Linkage and Tie Rod

TZ0992 Sleeve Alignment Tool

Rear Suspen-sion & Anti-Sway Bar

Part Number Description UsePB6039 Hydraulic

CouplingHydraulic Flushing


Part Number Description UsePC2525 Harness Payload Meter

DownloadDownload from Komatsu America Extranet

Software Payload Meter Data Manager

Part Number Description UseEH7817 Alignment Tool Upper Hoist Pin

Part Number Description UseTZ2100TZ2726TZ2727TZ2728TZ2729TV7567PB6825

Socket (1 7/8 in.)Socket (1 1/8 in.)Socket (2 1/4 in.)Socket (2 3/4 in.)Socket (1 1/4 in.)Socket (1 5/16 in.)Impact Socket (1 5/8 in.)

Miscellaneous


Part Number Description UseTZ2730TZ2731

Adapter (1-1 1/2 in.)Adapter (3/4-1 in.)

Socket adapter

Part Number Description UseWA4826TG1106

Lifting Eye Bolt Miscellaneous

Part Number Description UseTV1186TR0532TR0533

Extension (3 1/2 in.)Extension (8 in.)Extension (17 in.)

Miscellaneous


HYDRAULIC SYSTEM FLUSHING TOOLS

HYDRAULIC SYSTEM VACUUM PUMP

Part Number Description UseXB5776 Hose Assembly Flush Steering

CircuitPC3074 Flushing Block

(bypass hoist cylinders)

Flush Hoist Circuit

Part Number Description UseXB0887 Vacuum Pump To hold oil back

while the system is open.


NOTES:

FAM0220 Truck Components And Specifications Page 2-1

TRUCK COMPONENTS AND SPECIFICATIONS

Truck And EngineThe 830E-AC dump truck is an off-highway, reardump truck with AC electric drive. The gross vehicleweight is 385 852 kg (850,650 lbs.). The engine is aKomatsu SDA16V160 rated @ 1865 kW (2500 hp).

Alternator (G.E. GTA-41)The diesel engine drives an in-line alternator atengine speed. The alternator produces AC currentwhich is rectified to DC within the main control cabi-net. The rectified DC power is converted back to ACby groups of devices called "inverters", also withinthe main control cabinet. Each inverter consists of six"phase modules" under the control of a "gate driveunit" (GDU). The GDU controls the operation of eachphase module.

Cooling air for the control / power group and wheelmotors, as well as the alternator itself, is provided bydual fans mounted on the alternator shaft.

AC Induction Traction Motorized WheelsThe alternator output supplies electrical energy to thetwo wheel motors attached to the rear axle housing.The motorized wheels use three-phase AC inductionmotors with full-wave AC power.

The two wheel motors convert electrical energy backto mechanical energy through built-in gear trainswithin the wheel motor assembly. The direction of thewheel motors is controlled by the directional controllever located on the center console.

SuspensionHydrairII suspension cylinders located at eachwheel provide a smooth and comfortable ride for theoperator and dampens shock loads to the chassisduring loading and operation.

Operator's CabThe operator cab has been engineered for operatorcomfort and to allow for efficient and safe operationof the truck. The cab provides wide visibility, with anintegral 4-post ROPS/FOPS structure, and anadvanced analog operator environment. It includes atinted safety-glass windshield and power-operatedside windows, a deluxe interior with a fully adjustableseat with lumbar support, a fully adjustable tilt/tele-scope steering wheel, controls mounted within easyreach of the operator, and an analog instrumentpanel which provides the operator with all instru-ments and gauges which are necessary to controland/or monitor the truck's operating systems.

Power SteeringThe truck is equipped with a full time power steeringsystem which provides positive steering control withminimum operator effort. The system includes nitro-gen-charged accumulators which automatically pro-vide emergency power if the steering hydraulicpressure is reduced below an established minimum.

Dynamic RetardingThe dynamic retarding is used to slow the truck dur-ing normal operation or control speed coming down agrade. The dynamic retarding ability of the electricsystem is controlled by the operator through the acti-vation of the retarder pedal in the operators cab andby setting the RSC (Retarder Speed Control).Dynamic retarding is automatically activated, if thetruck speed goes to a preset overspeed setting.

Brake SystemThe braking system consists of an all hydraulic actu-ation system. Depressing the brake pedal actuateswheel-speed single disc front brakes and armature-speed dual disc rear brakes. The brakes can also beactivated by operating a switch on the instrumentpanel. The brakes will be applied automatically if sys-tem pressure decreases below a preset minimum.

The parking brake is integral with the service brakecaliper, and is spring-applied and hydraulically-released. The park brake is applied by moving thedirectional control lever to the PARK position.

2 Truck Components And Specifications FAM0220

1. Operator Cab2. Reserve Oil System3. Steps and Ladder4. Radiator5. Auto Lubrication6. Engine7. Suspension

8. Wheel Hub9. Disc Brake

10. Steering Linkage11. Alternator12. Hoist Filters13. Steering Filter14. Fuel Tank

15. Hoist Cylinder16. Rear Axle Housing17. Disc Brake18. Rear Tires19. Rear Suspension20. Rear Axle Hatch

21. Hydraulic Tank22. Hoist and Steering

Pump23. Steering

Accumulators

FIGURE 2-1. TRUCK COMPONENTS

FAM0220 Truck Components And Specifications Page 2-3

SPECIFICATIONSThese specifications are for the standard Komatsu830E-AC Truck. Customer options may change thislisting.

ENGINE

Komatsu SDA16V160 (Optional SSDA16V160)No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-StrokeRated Brake HP. . . . 1865 kW (2500 hp)@ 1900 rpmFlywheel HP . . . . . 1761 kW (2360 hp) @ 1900 rpm

Weight* (Wet) 8 558 kg (18,867 lbs)

* Weight does not include Radiator, Sub-frame, orAlternator

AC ELECTRIC DRIVE SYSTEM

(AC/DC Current)

Alternator . . . . . . . . . . . . .General Electric GTA - 41Dual Impeller, In-Line Blower 255 m3/min (9000 cfm)Motorized Wheels . . . .GEB25 AC Induction Traction Motors

Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1Maximum Speed* . . . . . . . . . 64.5 km/h (40 mph)(*w/40.00-57 Tires and 31.875:1 gear train)

*NOTE: Wheel motor application depends upon GVW, haul roadgrade and length, rolling resistance, and other parameters. Kom-atsu & G.E. must analyze each job condition to assure properapplication.

DYNAMIC RETARDINGElectric Dynamic Retarding . . . . . . . . . . . . . StandardMaximum Rating . . . . . . . . . . . . 3 207 kW (4,300 hp)

24 VDC ELECTRIC SYSTEMBatteries . . . . 4 x 8D 1450 CCA, 12 volt batteries in Series/Parallel w/Disconnect SwitchAlternator . . . . . . . . . . . 24 Volt, 140 Ampere OutputLighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 VoltCranking Motors (2). . . . . . . . . . . . . . . . . . . . .24 Volt

SERVICE CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . Liters. (U.S. Gal.)Crankcase * . . . . . . . . . . . . . . . . . 280.0. . . . . (74.0) * Includes Lube Oil FiltersCooling System . . . . . . . . . . . . . . . . 568. . . . . (150)Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542. . . . (1200)Hydraulic System . . . . . . . . . . . . . . . 946. . . . . (250)Hydraulic Tank . . . . . . . . . . . . . . . . . 946. . . . . (250)Wheel Motor Gear Box (each) . . . . . . 38. . . . . . (10)

HYDRAULIC SYSTEMS*

Pumps

Hoist . . . . . . . . . . . . . . . . . . . . . Tandem Gear PumpRated @ . . . . . 851 lpm (225 gpm) @ 1900 rpm and. . . . . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi)Steering/Brake . . . . . Pressure Compensating PistonRated @ . . . . . . .246 lpm (65 gpm) @ 1900 rpm and. . . . . . . . . . . . . . . . . . . . . . . .18 961 kPa (2,750 psi)

System Relief Pressures

Hoist . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi)Steering/Brakes . . . . . . . . . . .27 580 kPa (4,000 psi)Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . 3-StageTank (Vertical/Cylindrical) . . . . . . . . Non-PressurizedFiltration . . . . . . . . . . . . in-line replaceable elements Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh

Hoist & Steering . . . . . . . . Full Flow, Dual In-Line, . . . . . . . . . . . High Pressure Beta 12 Rating =200

*With Quick Disconnects for powering disabled truckand system diagnostics.

SERVICE BRAKESActuation . . . . . . . . . . . . . . . . . . . . . . . .All HydraulicFront . . . . . . . . . . . . . . . . Wheel Speed, Single Disc

Inboard Mounted . . . . . . . . . . . . . . . . . 3 CalipersDisc Diameter, O.D. . . . . . . . 1213 mm (47.75 in.)

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

Emergency Brake- .Automatically Applied (Standard)Wheel Brake Lock . . . . . . . Manual Switch on Panel. . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping)

DISC PARKING BRAKEEach Rear Wheel . . . . . Integral with Service Caliper. . . . . . . . . . .Spring Applied, Hydraulically Released

STEERING Turning Circle - Front Wheel Track. . . 28.4 m (93 ft.)Twin hydraulic cylinders with accumulator assist to provide constant rate steering. Emergency power steering automatically provided by accumulators.

4 Truck Components And Specifications FAM0220

DUMP BODY CAPACITIES AND DIMENSIONSStandard, Heaped @ 2:1 (SAE) . . 147 m3 (193 yd3)

Struck . . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd3)Loading Height Empty . . . . . . . . 6.61 m (21 ft. 8 in.)Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Non-heated body w/exhaust mufflers . . . . . Standard

TIRESRadial Tires (standard) . . . . . . . . . . . . . . . 40.00 R57Optional Tires . . . . . . . . . . . . . . . . . . . . . . 46/90 R57Rock Service, Deep Tread . . . . . . . . . . . . . TubelessRims, standard 5 piece. . Rated to 827 kPa (120 psi)

WEIGHT DISTRIBUTION

Empty Vehicle . . . . Kilograms. . . . . . . . (Pounds)Front Axle . . . . . . . . . . . 82 747. . . . . . . . (182,426)Rear Axle. . . . . . . . . . . . 82 902. . . . . . . . (182,768)Total (100% fuel) . . . . . 165 649. . . . . . . . (365,194)Standard Komatsu body 27 669. . . . . . . . . (61,000)Standard tire weight. . . . 21 081. . . . . . . . . (46,476)

Loaded Vehicle . . . Kilograms. . . . . . . . (Pounds)Front Axle . . . . . . . . . . 127 330. . . . . . . . (280,715)Rear Axle. . . . . . . . . . . 258 522. . . . . . . . (569,935)Total * . . . . . . . . . . . . . 385 852. . . . . . . . (850,650)Nominal Payload *. . . . 220 199. . . . . . . . (485,456) . . . . . . . . . . . . . (242 U.S. Ton)

*Nominal payload is defined by Komatsu AmericaCorporations payload policy documentation. In gen-eral, the nominal payload must be adjusted for thespecific vehicle configuration and site application.The figures above are provided for basic productdescription purposes. Please contact your Komatsudistributor for specific application requirements.

OVERALL TRUCK DIMENSIONS(Empty with Standard Body)Length . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 m (47 ft. 3 in.)Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32 m (24 ft. 0 in.)Height with Canopy . . . . . . . . . . . . . . . . 6.96 m (22 ft. 10 in.)Height with Dump Body Up . . . . . . . . . . 13.52 m (44 ft. 4 in.)Turning Circle (on front track) . . . . . . . . 28.4 m (93 ft. 0 in.)

FAM0317 Major Component Weights Page 3-1

MAJOR COMPONENT WEIGHTS

The condition of lifting slings, chains, and/or cables used for lifting components must be inspected beforeeach use. Lifting equipment must be in good condition and rated for approximately two times the weightbeing 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 thischapter. 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 thecomponents are not calculated into this list.

ITEM KILOGRAMS POUNDS

CHASSISWheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 306 . . . . . . . . . . . . . . . . . . . . . . 2,879

Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 309 . . . . . . . . . . . . . . . . . . . . . . 9,500

Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 615 . . . . . . . . . . . . . . . . . . . . . 12,379

Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 288 . . . . . . . . . . . . . . . . . . . . . 40,318

DECK AND DECK SUPPORT COMPONENTSCab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 177 . . . . . . . . . . . . . . . . . . . . . . 4,800

RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604 . . . . . . . . . . . . . . . . . . . . . . 1,331

LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 . . . . . . . . . . . . . . . . . . . . . . 1,568

Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 . . . . . . . . . . . . . . . . . . . . . . . .474

Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 . . . . . . . . . . . . . . . . . . . . . . 1,080

Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 . . . . . . . . . . . . . . . . . . . . . . . .489

LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668 . . . . . . . . . . . . . . . . . . . . . . 1,472

RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 . . . . . . . . . . . . . . . . . . . . . . 1,169

LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 . . . . . . . . . . . . . . . . . . . . . . . .265

Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 . . . . . . . . . . . . . . . . . . . . . . . .388

Vertical Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . .77

2 Major Component Weights FAM0317

ITEM KILOGRAMS POUNDS

POWER MODULEAir Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 . . . . . . . . . . . . . . . . . . . . . . . . 421

Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788 . . . . . . . . . . . . . . . . . . . . . . .1,737

Air Cleaner Assembly (Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 . . . . . . . . . . . . . . . . . . . . . . . . 340

Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 080 . . . . . . . . . . . . . . . . . . . . . . .4,585

Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 176 . . . . . . . . . . . . . . . . . . . . . . .7,002

Auxiliary Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 . . . . . . . . . . . . . . . . . . . . . . . . 445

Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 993 . . . . . . . . . . . . . . . . . . . . . . .8,803

Engine (Komatsu SDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 558 . . . . . . . . . . . . . . . . . . . . . .18,867

Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 905 . . . . . . . . . . . . . . . . . . . . . . .4,200

FLUID COMPONENTSSteering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 . . . . . . . . . . . . . . . . . . . . . . . . 309

Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .796 . . . . . . . . . . . . . . . . . . . . . . .1,755

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 . . . . . . . . . . . . . . . . . . . . . . . . 278

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 . . . . . . . . . . . . . . . . . . . . . . . . 717

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 711 . . . . . . . . . . . . . . . . . . . . . . .3,772

FRONT AXLE COMPONENTSSpindle And Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 216 . . . . . . . . . . . . . . . . . . . . . . .7,090

Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 . . . . . . . . . . . . . . . . . . . . . . . . 496

Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 228 . . . . . . . . . . . . . . . . . . . . . . .4,912

Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 . . . . . . . . . . . . . . . . . . . . . . . . 364

REAR AXLE COMPONENTSRear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 146 . . . . . . . . . . . . . . . . . . . . . . .2,527

Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 . . . . . . . . . . . . . . . . . . . . . . . . 763

Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 086 . . . . . . . . . . . . . . . . . . . . . . 11,213

Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 . . . . . . . . . . . . . . . . . . . . . . . . 330

Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12 201 . . . . . . . . . . . . . . . . . . . . . .26,899

FAM0403 Field Welding For Assembly Or Repair Page 4-1

FIELD WELDING FOR ASSEMBLY OR REPAIRWhen welding on Komatsu equipment, whether atinitial field assembly or during normal maintenancerepairs, special procedures must be followed.

Due to the continuous program of research anddevelopment, periodic revisions may be made to thispublication. It is recommended that customers con-tact their distributors for information on the latest revi-sion.

The welding information contained in this chapter isgeneral information that must be followed unless oth-erwise specified in a detailed repair procedure pro-vided on an engineering drawing or a detailedspecific repair procedure. Additional specific informa-tion, or detailed instructions can be obtained throughyour local Komatsu customer support manager.

WELDER QUALIFICATION AND TRAININGThe welding technique must be of the highest stan-dard to produce the soundest weld possible. Onlywelders who have been trained and qualified forstructural steel welding in all positions, in conform-ance with the American Welding Society (AWS) D1.1or (AWS) D14.3 only, are allowed to perform thewelding. The welding instructions for field assemblyof Komatsu components are normally provided byengineering drawings. Additional detailed weldinginstructions for field repairs are provided in the fieldrepair manual SEB14001. A full understanding of theAWS standard welding symbols is necessary to per-form and inspect such field welds. Weld sizes speci-fied on the drawings are intended to reflect minimumrequirements.

WELD PROCEDURESElectric arc welding, either the semi-automatic MIG(GMAW), Flux Core (FCAW), or Stick electrodewelding (SMAW), are approved processes for fieldinstallation and maintenance welding. Welding ofhighly stressed structural members such as castings,torque tubes, top and bottom plates on the framerails, and the curved intersection points of framesshould be done with the specific detailed instructionsfrom Komatsu Product Service. See Annex A forrepair procedures. These repair procedures aredetailed instructions for most high stressed structuralmembers.

APPROVED CONSUMABLESGMAW - LW102-15 or ER80S-D2

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

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

WELD QUALITY REQUIREMENTS1. Each weld must be homogeneous with low

porosity, free from cracks, and slag inclusions.2. Each weld must have complete fusion between

the base metal and weld metal added by theelectrode.

3. All welds must be reasonably smooth, withoutexcessive deformity, and all craters filled. Nocracks are permitted.

4. The toe of a weld to a stressed member musthave a smooth transition. Excessive convexityin multi-pass fillet welds is not permitted. Exces-sive convexity produces high residual stress inthe 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 applicationof welding an additional cover pass. It is impor-tant that this pass is blended with the existingweld.

2 Field Welding For Assembly Or Repair FAM0403

6. When welding in the vertical position, alwaysweld using the vertical up technique. Largewash weld weaves should not be used whenwelding on truck frames. Properly applied multi-ple pass welding is the required procedure ontruck frames.

7. Slag is to be removed from all weld beads, andmust be completely removed before each passin a multiple pass procedure. It is also requiredthat all slag is removed and tie in all areas.Grind all welds where a weld crosses or inter-sects with another weld.

MATERIALS, CONTROLS, AND PRECAUTIONSThe steel used in the fabrication of all Komatsuequipment is of high strength low alloy (HSLA) mate-rial of different grades. The standard dump bodymain plates are made from abrasion resistant materi-als. These materials offer themselves very well towelding during fabrication, and repair.

The welding consumables are often supplied byKomatsu America Corp. with the new equipment aspart of the field welding / assembly package. For fieldwelding and repairs, the approved consumables asdetailed, should be procured from a local, reliablesupplier. Other highly specialized welding consum-ables are available but have limited use on Komatsustructural components. Approval is required fromyour Komatsu customer support manager.

Control of the welding area environment is essentialfor 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 shieldinggas is being used as part of the welding pro-cess.

2. Low Ambient Temperature - DO NOT weld intemperatures below 50F (10C). At low tem-perature conditions, preheating of all weldingjoint work areas is required. See preheat andpost heating requirements as detailed in AnnexA.

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

4. Moisture - Any moisture on the steel surfaces tobe welded must be removed before welding.Electrodes must be stored in sealed containersuntil needed. Electrodes must be kept in awarming oven at the work location until used toprevent any moisture absorption which mightaffect weld quality.

5. Foreign Materials - Any foreign substances(dirt, paint, rust, scale, and carbon depositsfrom cuttings) must be removed prior to weld-ing. Clean all weld areas and surfaces with agrinder to ensure that all foreign materials havebeen removed.

WELD INSPECTIONAll welding repairs are subject to inspection by aKomatsu appointed inspector or laboratory to insurequality. After the weld has been made it can beinspected by a number of non-destructive evaluationtechniques. The inspections can include any of themethods listed below. All assembly welds and weldrepairs that are deemed unacceptable by the inspec-tor must be corrected at no additional cost to Kom-atsu. All weld repairs are also subject to additionalinspection.

1. Visual Inspection - This is the process of look-ing for potential defects such as undersizedwelds that can be checked with weld gaugesfor, surface cracks, surface porosity, craters,and undercuts.


2. Dye Penetrant Inspection - This is an easilyapplied process which indicates cracks or sur-face conditions. The process is relatively inex-pensive, but does not produce a permanentrecord except by normal photography.

3. Fluorescent Penetrant Inspection - Similar todye penetrant inspection. This process uses ablack (ultraviolet) light for increased efficiencyand accuracy.

4. Magnetic Particle Inspection - This processrequires special equipment that is usually morecostly than the dye penetrant inspections. Thisprocess does not provide a permanent recordexcept by normal photography.

5. Ultrasonic Inspection - This is a popular methodof examining weld discontinuities. Specializedequipment and operator certification is required.With some equipment printed data is availableof the test providing a permanent record. Also,operator records with equipment settings andtest results are normally recorded.

6. X-Ray Inspection - This process provides aview of the weld and base materials but it ishighly specialized. This procedure provides apermanent visual record, but is more expensivethan most other inspection techniques.

RECORDSKomatsu requires record keeping of all welding work.This information is valuable when personnel or jobconditions change. The service and warranty depart-ments of Komatsu must be provided with inspectionreports and photographs of the weld area before,during, and after the repair. The photographs mustbe clear and close enough to show the weld jointpreparation complete, with backer bars installed, etc.just prior to welding. These photos easily identify ifthe required preheating and post heating have beendone with a three inch circumference around theweld repair area. Without this documentation, Kom-atsu will not cover any weld repair claim made underwarranty. No exceptions will be made.

ANNEX AThe following are general repair procedures, whichmust be followed for all repair and rework of majorload carrying members on Komatsu equipment.

1. The repair or rework area must be protectedfrom wind and moisture during the entire proce-dure. If the repair work is to done outside addi-tional precautions must be taken to protect theweld repair process from outside elements. Allwelding should be done at an ambient tempera-ture of 10C (50F) or above.

2. Clean and grind the entire repair area toremove all rust, grease, oils, paint, and anyother foreign materials likely to contaminate theweld.


3. Air arc the entire crack leaving a V-shape joint.The depth of the V (or U shaped) joint will bedetermined by the depth of the crack. The widthto depth ratio should be approximately 1.25:1and never less than 1:1. All cracks through theparent material will require a slightly wider rootopening than the original, usually 6 mm (0.25in.) to allow the installation of a backup strip.Backup strips are required for all cracks thathave gone through the parent material and can-not be welded from both sides. If a weld repairallows access to both sides of the plate, nobackup strip is required as long as completeweld penetration is achieved. If backup stripsare not used, the surface profile on both sidesmust be ground smooth with no undercut. Doc-umentation must support this repair. Photo-graphs of surface condition are required by theservice and warranty departments of Komatsu.

4. Use dye penetrant to ensure the cracks arecompletely removed.

5. After air arcing and inspections (Steps 3 & 4) allareas 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 surfacessmooth to avoid defects in the new weld.

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

8. Preheat the entire weld joint area until the sur-rounding surface area reaches 150C (300F)at a distance of 76 mm (3 in.) from all areas tobe welded.

9. All welds are to be made with approved con-sumables only. The SMAW (Stick) welding rodmust be used within four hours after beingremoved from a new sealed container or from a52C (125F) minimum drying oven. Any rodthat exceeds this exposure time must be driedfor one hour at 427C (800F) before beingused. Keep all weld starts and stops to a mini-mum.

10. When the weld is complete, immediately (beforethe weldment cools) post heat the entire weldarea to 150C (300F). Even if the area is over150C (300F) heat must be applied to maintainthis temperature for 15 minutes, and then allowit to cool slowly. In some cases this mightrequire wrapping with insulation blankets.

11. Grind all butt-welded repairs smooth using 36 orfiner grit grinding material. All grinding marksshould be parallel to the direction of primarystress if possible (and if known).

12. Hammer peen the toes of repair fillet welds asdetailed in Annex B, see attached.

13. Inspect repaired areas (for surface defects)using magnetic particle or dye penetrant inspec-tion procedures.

14. If surface defects are found, remove all defectsby grinding to a maximum depth of 1.5 mm(0.06 in.). Larger defects must be removed asper the above mentioned procedures. All spotwelding also requires preheating and post heat-ing.


ANNEX B

1.0 TOE HAMMER PEENINGEquipment:

1. Hand held pneumatic hammer2. Adequate air supply3. Adequate lighting4. 6 mm (0.25 in.) diameter spherical tip bit5. Protective clothing, gloves, includes eye, face,

and ear protection.

Procedure1. The toe of the weld should serve as a guide for

the peening tool resulting in the area of defor-mation being approximately equally dividedbetween the base material and the weld metalface to the specified depth and not to exceed 5mm (0.19 in.) in width. Refer to Figure 4-1.

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

2. The weld must have a smooth profile and thetoe must have a good transition to the parentmaterial (no overlap) before the peening opera-tion is performed. Grinding the weld face andtoe area is permitted to correct unacceptableconditions. Visual inspection/acceptance is tobe done after peening with the appropriateradius and depth gauge.

3. Hold the hammer tool at approximately one halfthe included angle between the weld face andthe parent material and perpendicular to thedirection of travel. This will normally requireapproximately four passes of the peening toolwith the pressure of near full operator weightbeing applied. The depth of the indentationmust be between 0.6 mm to 0.8 mm (0.02 to0.03 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 tip3. Adequate air supply4. Adequate lighting5. Protective clothing, gloves, includes eye, face,

and ear protection

Procedure1. The toe of the weld should serve as a guide for

the burr tool resulting in the material removedbeing approximately equally divided betweenthe base material and the weld metal face to thespecified 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 thetoe must have a good transition to the parentmaterial (no overlap) before the grinding opera-tion is performed. Grinding the weld face andtoe area is permitted to correct unacceptableconditions. Visual inspection/acceptance to bedone after grinding with the appropriate radiusand depth gauge.

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


FIGURE 4-1. TOE HAMMER PEENING


FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR


BIBLIOGRAPHYAmerican Welding Society Bulletin No. D14.3-94/D1.1 - Specification for Welding Earthmoving andConstruction Equipment

Metals and How to Weld Them - James F. LincolnArc Welding Foundation. Cleveland, Ohio

Procedure Handbook of Arc Welding - Lincoln Elec-tric Company, Cleveland, Ohio

American Welding Society - Welding Handbook

British Standard BS5135 - Metal Arc Welding of Car-bon and Carbon-Manganese Steels

Welding Steels Without Hydrogen Cracking - TheWelding Institute, F. R. Coe, Author

SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK

Consult a qualified technician, specifically trained forservicing the AC drive system, before welding on thetruck.

The following procedures must be followed to ensurethe 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 gridelement or a power cable, the engine and allwarning lights must be off.

Engine Stop Procedure Prior To Maintenance

Perform the following procedure prior to maintenanceto ensure that no hazardous voltages are present inthe AC drive system.

1. Before turning off the engine, verify the statusof all the drive system warning lights on theoverhead display panel. Use the lamp testswitch to verify that all lamps are functioningproperly.

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

3. After the engine has been off for at least fiveminutes, inspect the link voltage lights. Thelights are located on the exterior of the maincontrol cabinet and back wall of the operator'scab (DID panel). If all lights are off, the retard-ing grids, wheel motors, alternator, and powercables connecting these devices are safe towork on.


Locate the GF cut-out switch in the accesspanel on the left side of the main control cabi-net. Place the switch in the CUTOUT position.This will prevent the alternator from re-energiz-ing and creating system voltage until the switchis returned to its former position.

After repairs, replace all covers and doors andplace the GF cutout switch and battery discon-nect switches in their original positions. Recon-nect all harnesses prior to starting the truck.

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

4. If the red lights on the exterior of the controlcabinet and/or the back wall of the operator'scab continue to be illuminated, a fault hasoccurred.

Leave all cabinet doors in place. DO NOT touchthe retard grid elements. DO NOT disconnectany power cables or use them as hand or footholds.

Notify your Komatsu customer service managerimmediately. Only qualified personnel, specifi-cally trained for servicing the AC drive system,may perform this service.

General Welding Guidelines1. Open the battery disconnect switches and dis-

connect the battery charging alternator leadwire.

2. Disconnect all electrical harnesses from theEngine Control System (ECS). The ECS islocated inside the electrical cabinet behind theoperator's cab. Disconnect the ground strapfrom the ECS.

3. Fasten the welding machine ground (-) lead tothe piece being welded. The grounding clampmust be attached as near as possible to theweld area.

4. DO NOT weld on the rear of the control cabinet!The metal panels on the back of the cabinet arepart 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 truckare made of aluminum or stainless steel. Theymust be repaired with the same material or thepower cables may be damaged.

7. Power cables must be cleated in wood or othernon-ferrous materials. DO NOT repair cablecleats by encircling the power cables with metalclamps or hardware. Inspect power cable insu-lation prior to servicing the cables and prior toreturning the truck to service. Discard cableswith broken insulation.

8. Protect power cables and wiring harnessesfrom weld spatter and heat.

9. DO NOT lay welding cables over or near thevehicle electrical harnesses. Welding voltagemay be induced into the electrical harnessesand cause damage to components.

10. DO NOT allow welding current to pass throughball bearings, roller bearings, suspensions, orhydraulic cylinders.


NOTES

FAM0508 Receiving & Assembly Preparation Page 5-1

RECEIVING & ASSEMBLY PREPARATION

Preparation

Inspection, Cleaning, Setup1. Inspect all components for possible shipping

damages. Note any damage found and report toshipping agent.

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

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

4. Install support blocks under the rear axle hous-ing. The support blocks must be approximately30 cm (12 in.) high and spread out along theaxle. The support blocks must be a minimum of51 mm (2 in.) away from the wheel motormounting face.

5. Clean all mounting surfaces on the chassis andon the individual components.

6. Check all electrical connectors and verify theyare free of paint and/or corrosion. Clean anyconnector with questionable electrical continu-ity.

7. Check all factory installed components for theproper tightening torque.

8. Arrange the work site as shown on the followingpage.

Color Coded BoxesA parts check list will be included in each shippingcrate that is shipped with the truck. The list consistsof several color coded tables that represent a portionof the assembly process. The parts listed in eachtable will be packed in waterproof corrugated PVCboxes that match the color of the header row of thattable.

The colored boxes, shown in Figure 5-1, will bepacked into shipping crates and shipped with thetruck. Assembly technicians can then locate the col-ored boxes that match the color of the operation(table) being performed. The boxes will be packedinto the crate in chronological order. Parts neededearly in the assembly process will be located nearthe top of the crates.

To allow for maximum flexibility, the color code maydiffer from unit to unit. However, colors shown on thecheck sheet will still match the color of the packingboxes used.

Due to the limited amount of different colored boxesavailable, some colors may be repeated.

Tables in the checklist that have no color code con-tain parts that are not boxed. Similarly, tables that arecolor coded may also contain parts that are notboxed. These parts are highlighted in yellow.

FIGURE 5-1. COLOR CODED BOXES

2 Receiving & Assembly Preparation FAM0508

ASS

EMB

LY L

AYO

UT

FAM0621 Chassis Assembly Page 6-1

CHASSIS ASSEMBLYDue to differences in machine configurations andshipping restrictions/requirements throughout theworld, the shipping and packaging of large machinesvaries. Photographs or illustrations used in the fol-lowing procedures are provided as general guide-lines only. Actual assembly may be different, but thisgeneral procedure provides a basic outline forassembly.

Items like the hydraulic tank and the accumulatorsmay have been removed for shipping and will have tobe locally installed.

Each shipment may be different, depending on thetruck configuration and destination.

RECOMMENDED ASSEMBLY DATA1. Service Report (Pre-Delivery) 2. Acknowledgement of Receipt of Company War-

ranty 3. Assembly Blueprints & Schematics4. 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. Hydraulic System Flushing Procedure (Section

10 Appendix)8. Toe-In Adjustment Procedure (Section 10,

Appendix)9. Hydraulic Checkout Procedure (Section 10,

Appendix)

10. Brake Checkout Procedure (Section 10, Appen-dix)

11. Propulsion System Checkout Procedure (avail-able in Section 10 of this manual)

12. Filter List (available in parts book)

13. Lubrication & Service PM Forms (available inthe operation and maintenance manual)

14. Component Weights - for crane reference(available in Section 3 of this manual)

15. Standard Torque Chart (available in Section 10of this manual)

16. Field Assembly Inspection Report Form (avail-able in Section 10 of this manual)

BASIC ASSEMBLY PROCEDURE1. Site preparation2. Unload truck components3. Assemble the chassis4. Weld the body

NOTE: Chassis assembly and body welding may bedone in either order, or simultaneously. The mostlogical order depends on available resources such ascranes, welders, assemblers, etc.

5. Static checkout (electrical & mechanical)6. Hydraulic Flushing7. Install the body8. Dynamic checkout (electrical & mechanical)9. Site cleanup

2 Chassis Assembly FAM0621

ORDER OF ASSEMBLY

The assembly procedure is organized in levels. Gen-erally, the tasks to be done at a given level may beperformed in any convenient order or simultaneously.However, all tasks in that level must be completedbefore proceeding to the next higher level. Each leveldepends on the installation of components from theprevious level.

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

LEVEL 11. Chassis - Unload and crib for assembly.2. Deck Supports

NOTE: It is easier to install and weld the decksupports before the front suspensions are installed.However, do not install the deck supports first, unlessthere is a suitable means of installing the suspensionwith the deck support in place.

3. Hydraulic Tank4. Fuel Tank5. Front Suspensions6. Uprights/Air Cleaners7. Diagonal Support Beam8. Platform

NOTE: Do not weld the air cleaner / uprights until alldecks and the operator cab are installed. Ratchethoists may be required to help tie all the structurestogether for a proper fit.

LEVEL 21. Air Cleaner Piping2. Spindles/Hubs3. Diagonal Ladder

LEVEL 31. Control Cabinet2. Auxiliary Control Cabinet3. Center Deck4. Steering Cylinders5. Tie Rod6. LH Deck7. RH Deck/Grid Box8. Wheel Motors

LEVEL 51. Operator Cab2. Blower Inlet Duct3. Front Tires4. Rear Tires

LEVEL 61. Weld Uprights

LEVEL 8

Dump Body Installation

LEVEL 71. Hoist Cylinders2. Rock Ejectors3. Mud Flaps4. Clearance Lights5. Body Pads/Shims/Guides6. Exhaust Blankets

LEVEL 81. Clean the Truck2. Lighting Wiring3. Charge Suspensions4. Charge Accumulators5. Add Fluids

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

6. Hydraulic System Flushing

LEVEL 91. System Checkouts2. Charge the Air Conditioning System3. Decals4. Touch Up Paint5. Train Operators6. Optional - Install Fire Suppression System


CHASSIS ASSEMBLYThe photographs referenced in this procedure depictan 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 andsecured.

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

Slings, chains and cables used for liftingmust be rated for approximately two times theintended load.

When in doubt as to the weight ofcomponents or any assembly procedure,contact your customer support manager forfurther information.

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

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

Before lifting, ensure there is adequateclearance from overhead structures orelectric power lines.

Disconnect the battery cables before arc weldingon the truck. Failure to do so may seriously dam-age the batteries and electrical equipment. Dis-connect the battery charging alternator lead wirebefore welding on the frame or its components.Fasten the welding machine ground cable to thecomponent being welded.DO NOT allow welding current to pass throughbearings.DO NOT lay welding cables over truck electricalcables and harnesses. Welding voltages could beinduced into the truck wiring and cause damageto components.DO NOT weld on the fuel tank or the hydraulictank unless they have been properly cleaned andventilated.Maintain fire control equipment. Inspect fireextinguishers regularly to ensure they are fullycharged and in good working condition.

Mark cap screws and nuts with paint or inkbefore tightening to the specified torque. Thismethod provides verification that the hardwarehas been properly tightened.


GENERAL PRECAUTIONS AND INSTRUCTION

1. Clean and remove all foreign material fromcomponent mounting surfaces.

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

3. Tighten the deck mounting cap screws beforethe exhaust tubes, etc. are installed.

4. Verify all electrical connectors are free frompaint and/or corrosion. Clean any connectorthat may be questionable.

5. Do not tighten the diagonal ROPS beam capscrews until after the operator cab & LH airintake tubes are in place.

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

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

8. Recheck the torque on hardware installed at thefactory.

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

10. Use the proper precautions when checking thenitrogen pressure and oil level in the accumula-tors.

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

12. Purge air from the steering pump before truckoperation. Pressure will not build in the brakeand steering circuit if air is present. Air in thesystem may damage the pump. Refer to theHydraulic Checkout Procedure in Section 10 ofthis manual.

13. Use the battery disconnect switch when arcwelding. Connect the weld ground near theweld area.

14. Before the truck is started for the first time, thehydraulic system must be flushed. Refer to thehydraulic system flushing procedure in theAppendix.


NOTES:


1. Lift the chassis off the truck/trailer or rail car using two cranes with a minimum capacity of 50 tons each. Liftthe chassis onto adequate support blocks or stands. The weight of the chassis, as shipped, is approximately48,943 kg (107,900 lb).

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

Thoroughly clean the chassis.


FIGURE 6-1.


2. Clean the mating surfaces for the deck supports and the frame to prepare for installation. The surfaces mustbe free of paint, rust, dirt, grease and oil. (Figure 6-2 & Figure 6-3)


FIGURE 6-2.

FIGURE 6-3.


NOTE: If more than one truck is being assembled at one time, ensure the uprights, deck supports and diagonalbraces are installed on the correct chassis. These parts are marked with the truck serial number to ensure properassembly.

3. Lift the LH deck support into position. The weight of the deck support is approximately 490 kg (1,080 lb). Boltthe support into place. Refer to Figure 6-4. Do not weld the left hand deck support in place at this time.

4. Lift the RH deck support into position. The weight of the right hand deck support is approximately 222 kg (489lb).

a. Bolt the deck support into place.

b. Tack weld the deck support in place.

c. The four tapped pads on the deck support and the corresponding blocks on the horsecollar must beremoved to allow for a complete weld around the joint.

d. Completely weld all around the deck support as described on the assembly drawing.

e. Grind all areas smooth and clean. Paint the weld and surrounding area after welding is complete.

5. Remove the center deck to enable easy installation of the air intake tubing and the diagonal cross tube (Fig-ure 6-5). The weight of the center deck is approximately 250 kg (550 lb).

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


FIGURE 6-4.

FIGURE 6-5.


6. Prepare the upright mating surfaces and the frame for installation. The surfaces must be free of paint, rust, dirt,grease and oil. Refer to Figure 6-6.

7. Attach the left upright to a crane using adequate lifting apparatus. Attach a ratchet hoist to the lifting apparatus(on the front side) to enable the upright to pivot for proper alignment during installation. Install the four capscrews to mount the upright. Tighten the cap screws to standard torque. The weight of the LH upright isapproximately 668 kg (1472 lb). Refer to Figure 6-7.

DO NOT weld the torque tubes on the uprights at this time.


FIGURE 6-6.

FIGURE 6-7.


8. Lift the right hand upright into position and install the four cap screws to mount the upright. Tighten to standardtorque. Refer to Standard Tables in Section 10, Appendix. The weight of the RH upright is approximately 530kg (1169 lb). Refer to Figure 6-8.

DO NOT weld the torque tubes on the uprights at this time.

10. Attach the upper radiator stabilizers rods to the uprights. Refer to Figure 6-9. Do not tighten at this time.Adjustment will come after the decks and uprights are fully installed.


FIGURE 6-8.

FIGURE 6-9.


11. Clean both mounting surfaces for the left hand diagonal tube (Figure 6-10). The surfaces must be free ofpaint, rust, dirt, grease and oil.

12. Lift the left hand diagonal tube into position (Figure 6-11). The weight of the diagonal tube is approximately120 kg (265 lb). Leave the cap screws loose.

13. Tap the cab mounting holes to remove any paint from the threads. Tap size is 1.00 x 8NC. Lift the cab onto thedeck supports and install 1/2 of the mounting hardware. Verify no gaps exist between the mounting pads ofthe cab. If gaps are present, the upright and/or deck support may need to be repositioned. Tighten the cabmounting hardware to standard torque. Refer to Standard Tables in Section 10, Appendix.

14. Tighten all of the hardware for the left hand diagonal tube to standard torque.

15. Securely tack weld the left upright and the left deck support in place.

16. Remove the cab mounting hardware and remove the cab.


FIGURE 6-10.

1. Cab2. Deck Support

3. Diagonal Beam4. Left Upright

FIGURE 6-12.

FIGURE 6-11.


17. Completely weld the left hand deck support in place. Refer to Figure 6-13.

a. The four tapped pads on the left deck support and the corresponding blocks on the horsecollar must beremoved to allow for a complete weld around the joint.

b. Completely weld all around the left deck support as described on the assembly drawing.

c. Grind all areas smooth and clean. Paint the weld and surrounding area.

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

18. Completely weld the left hand upright to the front frame tube. Refer to Figure 6-14. After the upright issecurely tack welded in place, remove the cap screws. Also cut the cap screw blocks off of the frame. Finishwelding the uprights in place as instructed per the assembly drawing provided with the truck.


FIGURE 6-13.

FIGURE 6-14.


19. Remove all paint from the mounts for the hydraulic tank and the fuel tank. Refer to Figure 6-15.

20. Lift the hydraulic tank into position on the cradles. (Figure 6-16). The weight of the hydraulic tank is approxi-mately 325 kg (717 lb).

Install the four cap screws with special flat washers and the cradle caps at the top of the tank. Tighten capscrews to 616 61 Nm (454 45 ft lb).

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


FIGURE 6-15.

FIGURE 6-16.


21. Lift the fuel tank into position on the cradles. (Figure 6-17) The weight of the fuel tank is approximately 1 711kg (3,772 lb).

Install the four cap screws with special flat washers and the cradle caps at the top of the tank. Tighten to stan-dard 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 tostandard torque.

22. Prepare the hydraulic filters for mounting on the fuel tank. Ensure all filter hardware is properly tightened.Refer to Figure 6-18.


FIGURE 6-17.

FIGURE 6-18.


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

Refer to Figure 6-19.

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

24. Install the hydraulic filters onto the bracket at the rear of the fuel tank. Refer to Figure 6-20.

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


FIGURE 6-19.

FIGURE 6-20.


25. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.Refer to Figure 6-21 & Figure 6-22.


FIGURE 6-21.

FIGURE 6-22.


26. Clean and dry the mounting surfaces on both the suspension and the frame. Use a cleaning agent that doesnot leave a film after evaporation, such as trichlorethylene, tetrachlorethylene, acetone or lacquer thinner.

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

.

27. The use of dry threads in this application is not recommended. Due to the high tightening forcesrequired to load these cap screws, dry threads or threads lubricated with anti-seize compounds mayresult in damage. Only use a lithium based chassis grease (multi-purpose, EP, NLGI #2, with a maxi-mum moly content of 5%).

28. Lubricate the cap screw threads, cap screw head seats, washer faces, and nut seats with a lithium basedchassis grease (multi-purpose, EP, NLGI #2, with a maximum moly content of 5%).


29. The hardened flat washers used on the front suspensions may be punched during the manufacturing process.If there is a punch lip on the flat washer, install the flat washer to position the punch lip away from the capscrew head to prevent damage. See Figure 6-23.

30. Lift the front suspension into position. Refer to Figure 6-24. The weight of each front suspension cylinder isapproximately 2 228 kg (4,912 lb). Install the mounting hardware and tighten according to the "turn-of-the-nut"method outlined on the following pages.

FIGURE 6-23. INSTALLATION OF HARDENED FLAT WASHER

1. Hardened Flat Washer 2. Cap Screw


"Turn-Of-The-Nut" Tightening Procedurea. Initially tighten the hardware to 1 356 136

Nm (1,000 100 lb ft) in the sequenceshown in Figure 6-27. Use a properly cali-brated torque wrench to ensure accuracy.

NOTE: Do not exceed 4 rpm tightening speed. Donot hammer or jerk the wrench while tightening.

The mounting cap screws will now need to be loos-ened and then tightened using turn-of-the-nutmethod. The first set of cap screws to be adjustedwill be at the upper mounting joint. The cap screwsmust be loosened one at time and then tightened byadvancing a specified rotational degree. Use themap shown in Figure 6-27 for proper tighteningsequence.

Upper Mounting Joint - 60 Advance

The proper sequence for the upper mounting joint is1-2-3-4-9-10. Refer to Figure 6-27.

b. Loosen only the first cap screw. All other capscrews must be maintained at 1 356 136Nm (1,000 100 lb ft).

c. Tighten the cap screw to 95 Nm (70 lb ft).d. Mark a corner of the cap screw head with a

paint marker as shown in Figure 6-25. Drawa reference line on the suspension surfacenext to the marked corner on the cap screw.Draw a second reference line on the suspen-sion 60 degrees in advance of the markedcorner on the cap screw.

e. Hold the nut at the rear of the joint stationarywhile tightening. Advance the cap screw tothe 60 advance mark.

f. Make new reference lines along the capscrew, nut and frame at the rear of the jointas shown in Figure 6-26. These referencelines will be used to verify the cap screwshave maintained their torque.

g. Repeat this process in sequence for theremaining five cap screws in the uppermounting joint.

FIGURE 6-24.


NOTE: If for any reason these fasteners need to bechecked for tightness after completing thisprocedure, loosen and inspect all 14 cap screws andrepeat the entire process. The hardware, again, mustbe cleaned and lubricated before repeating.

Lower Mounting Joint - 90 Advance

The proper sequence for the lower mounting joint is5-6-7-8-11-12-13-14. Refer to Figure 6-27.

h. Loosen the first cap screw. All other capscrews must remain tight.

i. Tighten the cap screw to 203 Nm (150 lb ft).

NOTE: Do not exceed 4 rpm tightening speed. Donot hammer or jerk the wrench while tightening.

FIGURE 6-25. 60 DEGREE

FIGURE 6-26. MAKING REFERENCE LINES

FIGURE 6-27. SUSPENSION INSTALLATION


j. Mark a corner of the cap screw head with apaint marker as shown in Figure 6-28. Drawa reference line on the suspension surface(or frame) next to the marked corner on thecap screw. Draw a second reference line onthe suspension surface (or frame) 90degrees in advance of the marked corner onthe cap screw.

k. Hold the nut stationary at the rear of the joint(where applicable) while tightening. Thenadvance the cap screw to the 90 advancemark.

l. Make new reference lines along the capscrew, nut and frame at the rear of the jointas shown in Figure 6-26. For the four capscrews with spacers, refer to Figure 6-29.These reference lines will be used to verifythe cap screws have maintained their torque.

m.Repeat this process in sequence for theremaining cap screws in the lower mountingjoint.

NOTE: If for any reason these fasteners need to bechecked for tightness after completing thisprocedure, loosen and inspect all 14 cap screws andrepeat the entire process. The hardware, again, mustbe cleaned and lubricated before repeating.

Inspection

Visual inspections of the bolted joints are necessaryafter the truck has been released for use. Inspect thejoints at each front suspension at the following inter-vals: 8 hours, 50 hours, 250 hours, and 500 hours.

If the reference lines on the hardware (Figure 6-26and Figure 6-29) have remained in alignment, thetruck may remain in use.

If at least one of the cap screws has shown signs ofmovement, the truck must be taken out of service.The suspension mounting cap screws must beremoved, cleaned, and inspected. If any cap screwshave any signs of damage, replace all cap screws.Install the cap screws again, according to this instal-lation procedure.

FIGURE 6-28. 90 DEGREE ADVANCE

FIGURE 6-29. 90 DEGREE ADVANCE


31. Install the hanger brackets for the intake tubes.Refer to Figure 6-30.

32. Lift the air intake tubes into place. Install andtighten the clamps that secure the hoses.

Refer to Figure 6-31 - Figure 6-33. The intaketubes are assembled and adjusted for installa-tion on the truck. DO NOT loosen any of theconnections during installation.

FIGURE 6-30.

FIGURE 6-31.


FIGURE 6-32.


FIGURE 6-33.


33. Lift the center deck into position (Figure 6-34). Install the mounting hardware and tighten to standard torque.Refer to Standard Tables in Section 10, Appendix.

34. Clean the tapered portion of the suspension rod and the bore of the spindle. Clean and check the tappedholes in bottom of Hydrair piston for damaged threads. Retap holes, if necessary, with 1.250 in. - 12NF tap.Lubricate spindle bore and suspension rod taper with a lithium based chassis grease (multi-purpose, EP,NLGI #2). Refer to Figure 6-35.

NOTE: Never use any lubricants on the spindle bore containing copper, such as many anti-seize compounds.Products containing copper will contribute to corrosion in this area.


FIGURE 6-34.

FIGURE 6-35.


35. Lift the retainer plate into position under the spindle. The weight of the retainer plate is approximately 48 kg(106 lb). Lift the spindle/brake assembly and retainer plate into position. The weight of each spindle/brakeassembly is approximately 3 216 kg (7,090 lb). Refer to Figure 6-36.

NOTE: The use of dry threads in this application is not recommended. Due to the high tightening forces required toload these cap screws, dry threads may cause damage to tools.

36. Lubricate cap screw threads, cap screw head seats and washer face with lithium based chassis grease (multi-purpose, EP, NLGI #2, with a maximum moly content of 5%). Install the twelve retainer plate cap screws.Refer to Figure 6-37. Tighten cap screws using the following procedure:

a. Tighten cap screws uniformly to 678 Nm (500 ft lb) torque. b. Continue to uniformly tighten the cap screws in increments of 339 Nm (250 ft lb) to obtain a final torque of

2 142 Nm (1,580 ft lb).

37. Repeat the previous steps for the remaining wheel.

38. Check cap screw torque on steering arm cap screws. Cap screw torque is 2 705 271 Nm (1,995 200 ftlb).

NOTE: If the steering arms have to be installed, lubricate cap screw threads, cap screw head seats and washerswith a lithium based chassis grease (multi-purpose EP, NLGI #2).


FIGURE 6-36.

FIGURE 6-37.


39. Prepare the steering cylinder and tie rod mounting surfaces. Refer to Figure 6-38.


FIGURE 6-38.


40. Move the steering cylinder rod eye into position on the steering arm. Lubricate the mounting pin with grease.Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 71 Nm (525 53 ftlb). Refer to Figure 6-39 & Figure 6-40.

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

41. Lift the tie rod into position on the steering arms. Ensure the anti-rotation tabs on the tie rod ends are on thebottom side of the tie rod when installed. The weight of the tie rod is 165 kg (364 lb). Lubricate the mountingpins with grease. Install the spacers, the mounting pin, and hardware. Tighten the pin cap screw to 712 71Nm (525 53 ft lb).

The tie rod toe-in must be adjusted once the tires and the body are installed. The toe-in adjustment procedureis located in Section 10, Appendix. Ensure the clamping cap screws on tie rod are tight after adjusting toe-in.

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


FIGURE 6-39.

FIGURE 6-40.


42. Install the handrails onto the LH deck and lift the deck into place (Figure 6-41). The weight of the LH deck withhandrails is approximately 802 kg (1,768 lb). Loosely install the eight deck mounting cap screws.

NOTE: After each deck is in place, tighten the cap screws to standard torque. Refer to Standard Tables in Section10, Appendix.

43. Cab Mounting

a. Tap the cab mounting holes to remove any paint from the threads. Tap size is 1.00 x 8NC.

b. Lift the operator cab into position (Figure 6-42). The weight of the cab is approximately 2 177 kg (4,800 lb).

c. Check for any gaps between cab mounting plates and the frame mounting plates. Use shims EL1949(front) or EL1950 (rear) as required to reduce the gap to less than 1.0 mm (0.04 in.).

d. Install and tighten the 32 cab mounting cap screws to 1 017 Nm (750 ft lb) torque.


FIGURE 6-41.

FIGURE 6-42.


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

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

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

45. Install the handrails on the RH deck.

46. Lift the RH deck into position and install the six cap screws. The weight of the assembly is approximately3 100 kg (6,834 lb). Tighten the mounting cap screws to standard torque. Refer to Figure 6-43.

47. After the right deck is bolted in place, weld the right hand upright to the front frame tube. Refer to Figure 6-44.After the upright is securely tack welded in place, remove the cap screws. Also cut the cap screw blocks off ofthe frame. Finish welding the uprights in place as instructed per the assembly drawing provided with the truck.

48. After both left hand and right hand decks are installed and both uprights welded, adjust the stabilizers to verti-cally level the radiator.

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


FIGURE 6-43.

FIGURE 6-44.


50. Lift the two bumper extensions into place. The weight of each bumper extension is approximately 123 kg (271lb). Refer to Figure 6-45 & Figure 6-46. The left hand bumper extension supports the isolation box. Ensure allwires are out of the way before installation.

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


FIGURE 6-45.

FIGURE 6-46.


51. Lift the control cabinet into position. The weight of the control cabinet is approximately 3 400 kg (7,500 lb).

Install the mounting hardware. Tighten the cap screws to standard torque. Refer to Standard Tables in Section10, Appendix.

Refer to Figure 6-47 and Figure 6-48.


FIGURE 6-47.

FIGURE 6-48.


52. Install the mounting bracket for the control cabinet vent cover and install the cover. Figure 6-49 & Figure 6-50.

Connect the wiring for the electrical control cabinet, auxiliary control cabinet, and grid box. Refer to Figure 6-51 through Figure 6-55.


FIGURE 6-49.

FIGURE 6-50.


FIGURE 6-51.

FIGURE 6-52.


FIGURE 6-53.

FIGURE 6-54.


FIGURE 6-55.


NOTES:


53. Lift the transition duct into place on the alternator, and install the mounting hardware, Figure 6-56. Install flex-ible duct to connect transition duct to alternator.

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

Refer to Figure 6-57 & Figure 6-58.

FIGURE 6-56.


FIGURE 6-57.

FIGURE 6-58.


55. LIft the air intake ductwork into position and install the mounting hardware, Figure 6-59. The weight of the inletduct is approximately 191 kg (421 lb). Tighten the cap screws to standard torque. Refer to Standard Tables inSection 10, Appendix.

Install the flexible duct with cap screws, flat washers and lock washers, Figure 6-60.


FIGURE 6-59.

FIGURE 6-60.


56. Install the power cables with mounting blocks on the air inlet duct, Figure 6-61.


FIGURE 6-61.


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

Refer to Figure 6-62.

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

NOTE: The diagonal ladder may not always be installed in the direction (R to L) as shown in Figure 6-62.


FIGURE 6-62.


58. Install both engine access ladders on the truck frame. Tighten mounting hardware to standard torque. Refer toFigure 6-63 and Figure 6-64.


FIGURE 6-63.

FIGURE 6-64.


59. Thoroughly clean the threaded holes and the mounting faces of the rear axle housing and wheel motor. Referto Figure 6-65.

60. Inspect the threaded holes in the rear axle housing for damage. Re-tap any holes that have damaged threads.Thoroughly clean any threaded holes that have been re-tapped.

61. Apply a lithium based chassis grease (multi-purpose, EP NLGI #2, with a maximum of 5% moly) to thethreaded cap screw holes in the rear axle housing.

62. Install two guide pins 180 apart (3 oclock and 9 oclock positions) in the rear axle housing.

Each complete wheel motor assembly weighs approximately 12 201 kg (26,899 lb). Ensure that the liftingdevices are capable of handling the load safely.

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

63. Lift the wheel motor into position on the rear axle housing. Ensure that all cables and hoses are clear beforeinstallation. Refer to Figure 6-66.


FIGURE 6-65.

FIGURE 6-66.


64. Select the hardware to be installed in Group 1 of the tightening sequence. Refer to Figure 6-68. Inspect eachcap screw for rust, corrosion and surface defects on any seat or thread. Do not use any cap screw if a defectis suspected.

65. Lubricate the cap screw threads, cap screw head seats and washer faces with a lithium based chassis grease(multi-purpose, EP NLGI #2, with a maximum of 5% moly).

NOTE: The hardened flat washers used in this application may have a punch lip on one side due to themanufacturing process. Therefore, the washers must be installed with the punched lip away from the head of themounting cap screws to prevent damage to the fillet between the cap screw head and the shank. Refer to Figure 6-67.

66. Install the hardware for Group 1. Tighten each cap screw to 542 Nm (400 ft lb).

67. Repeat Steps 64 - 66 for each remaining group in the tightening sequence. Refer to Figure 6-68.

Install and tighten all of the hardware in a group before proceeding to the next group in the tighteningsequence. Remove the guide pins that were installed in Step 62 when installing the hardware for Groups 3and 4.

68. After all of the hardware in all of the groups has been installed and tightened to 542 Nm (400 ft lb), moveback to Group 1. Increase the torque on each cap screw in Group 1 to 2 006 Nm (1,480 ft lb). Repeat thisstep for each remaining group in the tightening sequence. Refer to Figure 6-68.


FIGURE 6-67. FLAT WASHER1. Washer 2. Cap Screw

FIGURE 6-68. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE


69. Connect the power cables and the speed sensors to each

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