930E-4 field Assembly.pdf

7/16/2019 930E-4 field Assembly.pdf

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CEAW004600

Field Assembly

Manual

DUMP TRUCK

SERIAL NUMBERS A30462 & UP


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FAM0013 Introduction

FOREWARD

This manual is provided to aid assemblers during field assembly of the standard Komatsu 930E-4 dump truck. Vari

ations of design required for specific truck orders may require some modification of the general procedures out

lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the

truck.

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

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

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

tion.

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

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


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ii Introduction FAM0013

This alert symbol is used with the signal words, CAUTION, DANGER, and

WARNING in this manual to alert the reader to hazards arising from improper

operating and maintenance practices.

DANGER Identifies a specific potential hazard

which will result

in either injury or death

if proper precautions are not used.

CAUTION is used for general reminders

of proper safety practices

orto 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.


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FAM0013 Introduction i

TABLE OF CONTENTS

SUBJECT PAGE NUMBER

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

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


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iv Introduction FAM0013

NOTES


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FAM0108 Safety Rules, Tools, & Equipment Page 1-1

SAFETY RULES, TOOLS & EQUIPMENT

SAFETY RULES

The following list of safety practices is intended for use

by personnel during field assembly of the truck.

This list of safety rules is not intended to replace local

safety rules or regulations and federal, state, or local

laws. The safety precautions recommended here are

general and must be used in conjunction with all pre-

vailing local rules and regulations.

1. All personnel must be properly trained for the

assembly process.

2. Wear safety equipment such as safety glasses,

hard toe shoes and hard hats at all times during

assembly.

3. Thoroughly inspect the assembly site. Remove

weeds, debris and other flammable material.

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

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

metal to metal contact.

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

turer's specifications for correct capacities and

safety procedures when lifting components.

6. Perform a daily inspection of all lifting cables and

chains. Replace any questionable items. Use

cables and chains that are properly rated for the

load to be lifted.

7. DO NOT stand beneath a suspended load. Use of

guy ropes are recommended for guiding and posi-

tioning a suspended load.8. Maintain fire control equipment. Inspect fire extin-

guishers 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.

Before welding, refer to Special Precautions When

Servicing A 930E Truck, in Section 4.

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 curren

to pass through bearings, engine, etc.

12. DO NOT weld the fuel tank or hydraulic tank

unless the tanks have been properly purged and

ventilated.

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 from

the proper materials and rated to lift the intended

load.

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

assembly procedure is not known, contact you

customer support manager for further information.


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Page1-2 Safety Rules, Tools, & Equipment FAM0108

TOOLS AND EQUIPMENT FOR ASSEMBLY

The following equipment is recommended for field

assembly of the truck.

1. Equipment and tool storage trailer with a lockable

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

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

the chassis from the freight trailer and place on

cribbing. These cranes can also be used to lift

the assembled body onto to the chassis.

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

The crane is needed to turn the body over after

completion of the underside welding. A 45 met-

ric 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

(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 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) capac-

ity.

23. Pry bars

24. Solvent - 38 liters (10 gal)

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


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LIFTING SLING GENERAL INFORMATION


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1. T Handle Valve2. 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

Part Number Description Use

EB1759 Nitrogen

Charging Kit

Suspension &

Accumulator

Nitrogen

Charging


EJ2626

(No longer

available as

complete unit)

Roller Assy. Power Module

Remove & Install

EJ2271 Roller Mount

PC0706 Bearing

TH9449 BearingRetainer

Ring

TG1680 Roller

Retainer

Ring

C1645 Cap screw

0.75 -10 NC

x 2 1/4 in.

C1542 Lockwasher

0.75 in.

EH8686 Roller Ring


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PB8326 Offset Box End

Wrench,

1, 7/16 in.

Miscellaneous


TZ2734 3/4 in. Torque

Adapter

Miscellaneous


TZ2733 Tubular Handle Use with

PB8326 &

TZ2734


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BF4117 Seal Installa-

tion Tool

Front & Rear

Disc Brake

Floating Ring

Seal Installation

ED3347 Seal Installa-

tion Tool

Rear Axle/Hub

Adaptor Float-

ing Ring Seal

Installation


EH4638 Sleeve

Alignment Tool

Steering Linkage

and Tie Rod


EF9302 Wear Indicator Brake Disc Wear

EB1723 Cap, Indicator

EF9301 Pin Indicator

WA0010 O-ring, Indica-

tor Pin

TL3995 O-ring, Indica-

tor Cap

EB4813 Housing, Indi-

cator

SV9812 O-ring, housing


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EF9160 Harness Payload Meter

Download


EH7817 Alignment Tool Upper Hoist Pin


PB4684 Hydraulic

Coupling

Miscellaneous


PB9067 Bulkhead

Connector

Battery Jumper


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P t N b D i ti U


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TZ2100

TZ2727

TZ2729

Socket (1 7/8 in.)

Socket (2 1/4 in.)

Socket (1 1/4 in.)

Misc.


TZ2730

TZ2731

Adapter (1-1 1/2 in.)

Adapter (3/4-1 in.)

Socket adapter


WA4826 Lifting Eye Bolt Miscellaneous


PC0370 Sling Body Retention


PC0367 Shackle Miscellaneous


TR0532

TR0533

Extension (8 in.)

Extension (17 in.)

Miscellaneous


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TRUCK COMPONENTS AND SPECIFICATIONS

Truck And Engine Operator's Cab


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FAM0212 Truck Components And Specifications Page 2-1

Truck And Engine

The 930E-4 dump truck is an off-highway, rear dump

truck with A/C electric drive. The gross vehicle weight

is 1,106,000 lbs. (501 673 kg). The engine is a

Komatsu SSDA16V160 rated @ 2700 HP (2014 kW).

Alternator (GE-GTA41)

The diesel engine drives an in-line alternator at

engine speed. The alternator produces A/C current

which is rectified to DC within the main control cabi-

net. The rectified DC power is converted back to A/C

by groups of devices called "inverters", also within

the main control cabinet. Each inverter consists of six

"phase modules" under the control of a "gate drive

unit" (GDU). The GDU controls the operation of each

phase module.

Each phase module contains an air-cooled solid-

state switch referred to as a "gate turn-off thyristor"(GTO). The GTO cycles on and off at varying fre-

quencies to create an A/C power signal from the DC

supply.

The A/C power signal produced by each inverter is a

variable-voltage, variable-frequency signal (VVVF).

Frequency and voltage are changed to suit the oper-

ating conditions.

Cooling air for the control / power group and wheel

motors, as well as the alternator itself, is provided by

dual fans mounted on the alternator shaft.

A/C Induction Traction Motorized Wheels

The alternator output supplies electrical energy to the

two wheel motors attached to the rear axle housing.

The motorized wheels use three-phase A/C induction

motors with full-wave A/C power.

The two wheel motors convert electrical energy back

to mechanical energy through built-in gear trains

within the wheel motor assembly. The direction of the

wheel motors is controlled by a forward or reverse

hand selector switch located on the center console.

Suspension

HydrairII 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.

Operator s Cab

The operator cab has been engineered for operato

comfort and to allow for efficient and safe operation

of the truck. The cab provides wide visibility, with an

integral 4-post ROPS/FOPS, and an advanced ana

log operator environment. It includes a tinted safetyglass windshield and power-operated side windows

a deluxe interior with a fully adjustable seat with lum-

bar support, a fully adjustable/tilt steering wheel, con

trols mounted within easy reach of the operator, and

an analog instrument panel which provides the oper

ator with all instruments and gauges which are nec

essary to control and/or monitor the truck's operating

systems.

Power Steering

The truck is equipped with a full time power steering

system which provides positive steering control withminimum operator effort. The system includes nitro

gen-charged accumulators which automatically pro

vide emergency power if the steering hydraulic

pressure is reduced below an established minimum.

Dynamic Retarding

The dynamic retarding is used to slow the truck dur

ing normal operation or control speed coming down a

grade. The dynamic retarding ability of the electric

system is controlled by the operator through the acti

vation of the retarder pedal (or by operating a leve

on the steering wheel) in the operators cab and bysetting the RSC (Retarder Speed Control). Dynamic

Retarding is automatically activated, if the truck

speed goes to a preset overspeed setting.

Brake System

Service brakes at each wheel are oil-cooled multiple

disc brakes applied by an all-hydraulic actuation sys

tem. Depressing the brake pedal actuates both fron

and rear brakes, after first applying the retarder. Al

wheel brakes will be applied automatically, if system

pressure decreases below a preset minimum.

The parking brake is a dry disc type, mounted

inboard on each rear wheel motor, and is spring

applied/hydraulically-released with wheel speed

application protection (will not apply with truck mov

ing).


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Page 2-2 Truck Components And Specifications FAM0212

930E-3 MAJOR COMPONENTS


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SPECIFICATIONS

These specifications are for the standard Komatsu 930E Truck. Customer Options may change this listing.

ENGINE SERVICE CAPACITIES


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FAM0212 Truck Components And Specifications Page 2-3

ENGINE

Komatsu SSDA16V160

No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke

Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rpmHigh Idle . . . . . . . . . . . . . . . . . . . . . . . . . . 1910 rpm

Rated Full Load . . . . . . . . . . . . . . . . . . . . . 1900 rpm

Rated Brake HP. . . 2700 HP (2014 kW) @ 1900 rpm

Flywheel HP . . . . . 2550 HP (1902 kW) @ 1900 rpm

Weight* (Wet) . . . . . . . . 21,182 pounds (9608 kg)* Weight does not include Radiator, Sub-frame, or Alternator

A/C ELECTRIC DRIVE SYSTEM

(AC/DC Current)

Alternator . . . . . . . . . . . . . General Electric GTA - 41

Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . 12,000 cfm (340 m/ min)Motorized Wheels . . GDY106 A/C Induction Traction

Standard Gear Ratio*. . . . . . . . . . . . . . . . . 32.62:1

Maximum Speed . . . . . . . . . . 40 mph (64.5 km/h)*NOTE: Wheel motor application depends upon GVW, haul road

grade and 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 Rating . . . . . . . . . . . . 5400 HP (4026 kW)

Continuous . . . . . . . . . . . . . . . . 3300 HP (2460 kW)

Continuously rated high-density blown grids with retard at engineidle and retard in reverse propulsion.

BATTERY ELECTRIC SYSTEM

Batteries 4 x 8D 1450CCA, 12 volt, in series/parallel,

. . . . and 2x30H 800CCA, 220-ampre-hour batteries,

. . . . . . . . . . bumper mounted with disconnect switch

Alternator . . . . . . . . . . . 24 Volt, 260 Ampere Output

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

Cranking Motors (2). . . . . . . . . . . . . . . . . . . . 24 Volt

SERVICE CAPACITIES

. . . . . . . . . . . . . . . . . . U.S. Gallons . . . . . . . Liters

Crankcase * . . . . . . . . . . . . . . . . 74 . . . . . . . . . .280

* Includes Lube Oil Filters

Cooling System . . . . . . . . . . . . .157 . . . . . . . . . .594Fuel . . . . . . . . . . . . . . . . . . . . .1200. . . . . . . . .4542

Hydraulic System . . . . . . . . . . . .350 . . . . . . . . 1325

Wheel Motor Gear Box. . . 25/Wheel . . . . . 95/Whee

HYDRAULIC SYSTEMS

Hoist & Brake Cooling Pump:. . . . . . . . Tandem Gea

Rated @ . . . . . . 270 GPM (1022 l/min.) @ 1900 rpm

. . . . . . . . . . . . . . . . . . . . .and 2500 psi (17 237 kPa

Steering/Brake Pump:Pressure Compensated Piston

Rated @ . . . . . . . 65 GPM (246 l/min.) @ 1900 rpm

. . . . . . . . . . . . . . . . . . . . .and 2750 psi (18 961 kPa

Relief Pressure-Hoist . . . . . . . 2500 psi (17 237 KPa

Relief Pressure-Steering . . . . 4000 psi (27 579 KPa

Hoist Cylinders (2) . . . . . . . . . . . . 3-Stage Hydraulic

Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized

Tank Capacity . . . . . . . . 250 US Gal. (947 Liters

Filtration . . . . . . . . . . . . In-line replaceable elements

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

Hoist & Steering Filters . . . . . .Beta 12 Rating =200

. . . . . . . . . . . . . . . . . . .Dual In-Line, High Pressure

SERVICE BRAKES

All Hydraulic Actuation . . . . . . . with Traction System

. . . . . . . . . . . . . . . . . . . . . Wheel Slip / Slide ControFront and Rear Oil-Cooled Multiple Discs-each whee

Total Friction Area / Brake . . 15,038 in (97 025 cm

Maximum Apply Pressure . . . 2500 psi (17 238 kPa

STEERING

Turning Circle (SAE). . . . . . . . . . .97 ft. 7 in. (29.7 m

Twin hydraulic cylinders with accumulator assist to

provide constant rate steering.


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STANDARD DUMP BODY CAPACITIESAND DIMENSIONS

Capacity,

Heaped @ 2:1 (SAE) . . . . . . . . . 276 yd3 (211 m3)

WEIGHT DISTRIBUTION

Empty Vehicle . . . . . . . . Pounds . . . . (Kilograms)

Front Axle (49.3%) . . . . . 227,738 . . . . . . . 103 301

Rear Axle (50.7%). . . . . .237,034 . . . . . . . 107 518


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Page 2-4 Truck Components And Specifications FAM0212

p @ ( ) y ( )

Struck . . . . . . . . . . . . . . . . . . . . .224 yd3 (171 m3)

Width (Inside) . . . . . . . . . . . . . . . 26 ft. 9 in. (8.15 m)

Depth . . . . . . . . . . . . . . . . . . . . . . 10 ft. 7 in. (3.2 m)

Loading Height . . . . . . . . . . . . . . 23 ft. 2in. (7.06 m)Dumping Angle. . . . . . . . . . . . . . . . . . . . . . . . . . 45

*OPTIONAL capacity dump bodies are available.

TIRES

Radial Tires (standard) . . . . . . . . . . . . . . . 53/80 R63

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

Rims . . . .(patented Phase I New Generation rims)

Total (50% Fuel) . . . . . . 464,772 . . . . . . . 210 819

Standard Komatsu body . . 66,936 . . . . . . . . 30,362

Standard tire weight. . . . . . 57,600 . . . . . . . . 26,127

Loaded Vehicle . . . . . . .Pounds Kilograms

Front Axle (33.9%) . . . . . 363,000 164 656

Rear Axle (66.1%). . . . . .737 000 . . . . . . . 334 301

Total * . . . . . . . . . . . . . 1,106,000 . . . . . . . 501 673

Nominal Payload* . . . . . . 641,228 . . . . . . . 290,859

* Nominal payload is as defined within Komatsu

America Corporations payload policy documenta-

tion. Nominal payload must be adjusted should the

weight of any customized body or tires fitted vary

from that of the standard Komatsu body and tires as

shown above. Nominal payload must also beadjusted to take into account the additional weight of

any custom/optional extras fitted to the truck which

are not stated within the Standard Features list of the

applicable specification sheet.

OVERALL TRUCK DIMENSIONS


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MAJOR COMPONENT WEIGHTS


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FAM0312 Major Component Weights Page 3-1

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 weigh

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

Wheel Rim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,813 . . . . . . . . . . . . . . . . . . . . . . 6,202

Tire 53/80 R63 (148" OD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,309 . . . . . . . . . . . . . . . . . . . . . . 9,500

Rim & Tire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,122 . . . . . . . . . . . . . . . . . . . . . 15,702

Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21,866 . . . . . . . . . . . . . . . . . . . . . 48,206

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

DECK AND DECK SUPPORT COMPONENTSCab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,725 . . . . . . . . . . . . . . . . . . . . . . 6,008

RH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937 . . . . . . . . . . . . . . . . . . . . . . 2,066

LH Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 . . . . . . . . . . . . . . . . . . . . . . 1,455

Center Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . .551

Left Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654 . . . . . . . . . . . . . . . . . . . . . . 1,442

Right Deck Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 . . . . . . . . . . . . . . . . . . . . . . . .602

LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 . . . . . . . . . . . . . . . . . . . . . . 1,60

RH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578 . . . . . . . . . . . . . . . . . . . . . . 1,274

LH Diagonal Beam (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 . . . . . . . . . . . . . . . . . . . . . . . .298

RH Diagonal Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . .150

Diagonal Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 . . . . . . . . . . . . . . . . . . . . . . . .397

Diagonal Ladder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . . . . . . . . . . . . 119


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ITEM KILOGRAMS POUNDS

POWER MODULE

Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 . . . . . . . . . . . . . . . . . . . . . . . . 613


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Page 3-2 Major Component Weights FAM0312

Engine Sub-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891 . . . . . . . . . . . . . . . . . . . . . . .1,964

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

Retard Grid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,082 . . . . . . . . . . . . . . . . . . . . . . .6,795

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

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

Engine (Komatsu SSDA16V160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9305 . . . . . . . . . . . . . . . . . . . . . . 20,514

Radiator & Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1996 . . . . . . . . . . . . . . . . . . . . . . .4,400

HYDRAULIC COMPONENTS

Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . . . . . . . . . . . . . . . 379Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .932 . . . . . . . . . . . . . . . . . . . . . . .2,055

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . . . . . . . . . . . . . . . . . . . . . . . 322

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731 . . . . . . . . . . . . . . . . . . . . . . .1,612

FRONT AXLE COMPONENTS

Front Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,496 . . . . . . . . . . . . . . . . . . . . . . .3,298

Spindle, Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,803 . . . . . . . . . . . . . . . . . . . . . .10,589

Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331 . . . . . . . . . . . . . . . . . . . . . . . . 730

Front Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,790 . . . . . . . . . . . . . . . . . . . . . . .6,151

REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,242 . . . . . . . . . . . . . . . . . . . . . . .4,943

Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 . . . . . . . . . . . . . . . . . . . . . . . . 351

Pivot Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371 . . . . . . . . . . . . . . . . . . . . . . . . 818

Rear Axle Housing w/Pivot Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,568 . . . . . . . . . . . . . . . . . . . . . .14,480

Anti-Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 . . . . . . . . . . . . . . . . . . . . . . . . 324

Wheel Motor & Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 . . . . . . . . . . . . . . . . . . . . . .39,683

Wheel Ring Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 . . . . . . . . . . . . . . . . . . . . . . . . 675


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FIELD WELDING FOR ASSEMBLY OR REPAIR

When welding on Komatsu equipment, whether at

initial field assembly or during normal maintenance

repairs, special procedures must be followed.

Due to the continuous program of research and

WELD PROCEDURES

Electric arc welding, either the semi-automatic MIG

(GMAW), Flux Core (FCAW), or Stick electrode

welding (SMAW) are approved processes for field


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FAM0403 Field Welding For Assembly Or Repair 4-1

Due to the continuous program of research and

development, periodic revisions may be made to this

publication. It is recommended that customers con-

tact their distributors for information on the latest revi-

sion.

The welding information contained in this chapter is

general information that must be followed unless oth-

erwise specified in a detailed repair procedure pro-

vided on an engineering drawing or a detailed

specific repair procedure. Additional specific informa-

tion, or detailed instructions can be obtained through

your local Komatsu customer support manager.

WELDER QUALIFICATION ANDTRAINING

The welding technique must be of the highest stan-

dard to produce the soundest weld possible. Only

welders who have been trained and qualified for

structural steel welding in all positions, in conform-

ance with the American Welding Society (AWS) D1.1

or (AWS) D14.3 only, are allowed to perform the

welding. The welding instructions for field assembly

of Komatsu components are normally provided by

engineering drawings. Additional detailed welding

instructions for field repairs are provided in the field

repair manual SEB14001. A full understanding of 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 minimum

requirements.

welding (SMAW), are approved processes for field

installation and maintenance welding. Welding o

highly stressed structural members such as castingstorque tubes, top and bottom plates on the frame

rails, and the curved intersection points of frames

should be done with the specific detailed instructions

from Komatsu Product Service. See Annex A fo

repair procedures. These repair procedures are

detailed instructions for most high stressed structura

members.

APPROVED CONSUMABLES

GMAW - LW102-15 or ER80S-D2

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

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

WELD QUALITY REQUIREMENTS

1. Each weld must be homogeneous with low

porosity, free from cracks, and slag inclusions.

2. Each weld must have complete fusion between

the base metal and weld metal added by the

electrode.

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

cracks are permitted.

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

have a smooth transition. Excessive convexity

in multi-pass fillet welds is not permitted. Exces

sive convexity produces high residual stress in

the throat of the weld, and is not permitted.

5. Undercut in excess of 0.8 mm (0.03 in.) on criti

cal welds must be reworked by the application

of welding an additional cover pass. It is impor

tant that this pass is blended with the existing

weld.


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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 Sl i t b d f ll ld b d d

2. Low Ambient Temperature - DO NOT weld in

temperatures below 50F (10C). 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 W ld C li P t t th ld f


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4-2 Field Welding For Assembly Or Repair FAM0403

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, ANDPRECAUTIONS

The steel used in the fabrication of all Komatsu

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

rial of different grades. The standard dump body

main plates are made from abrasion resistant materi-

als. These materials offer themselves very well to

welding during fabrication, and repair.

The welding consumables are often supplied by

Komatsu America Corp. with the new equipment as

part of the field welding / assembly package. For field

welding and repairs, the approved consumables as

detailed, should be procured from a local, reliable

supplier. Other highly specialized welding consum-

ables are available but have limited use on Komatsu

structural components. Approval is required from

your Komatsu customer support manager.

Control of the welding area environment is essential

for producing proper and sound welds. Essentially,

five areas require attention and control.

1. Air Movement - Avoid areas where air move-

ment from wind, drafts, or blowers is prevalent.

This is particularly important when a shielding

gas is being used as part of the welding pro-

cess.

3. Weld Cooling - Protect the weld area from a

rapid cooling rate. Heat retardation may be

accomplished through the use of heat lamps,

torches, insulating blankets, etc.

4. Moisture - Any moisture on the steel surfaces to

be welded must be removed before welding.

Electrodes must be stored in sealed containers

until needed. Electrodes must be kept in a

warming oven at the work location until used to

prevent any moisture absorption which might

affect weld quality.

5. Foreign Materials - Any foreign substances

(dirt, paint, rust, scale, and carbon deposits

from cuttings) must be removed prior to weld-

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

been removed.

WELD INSPECTION

All welding repairs are subject to inspection by a

Komatsu appointed inspector or laboratory to insure

quality. After the weld has been made it can be

inspected by a number of non-destructive evaluation

techniques. The inspections can include any of the

methods listed below. All assembly welds and weldrepairs 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.


48/335

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

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 mus


49/335


3. Fluorescent Penetrant Inspection - Similar to

dye penetrant inspection. This process uses ablack (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.

during, and after the repair. The photographs mus

be clear and close enough to show the weld joinpreparation complete, with backer bars installed, etc

just prior to welding. These photos easily identify i

the required preheating and post heating have been

done with a three inch circumference around the

weld repair area. Without this documentation

Komatsu will not cover any weld repair claim made

under warranty. No exceptions will be made.

ANNEX A

The following are general repair procedures, which

must be followed for all repair and rework of majo

load carrying members on Komatsu equipment.

1. The repair or rework area must be protected

from wind and moisture during the entire proce

dure. If the repair work is to done outside addi

tional precautions must be taken to protect the

weld repair process from outside elements. Al

welding should be done at an ambient tempera

ture of 10C (50F) or above.

2. Clean and grind the entire repair area toremove all rust, grease, oils, paint, and any

other foreign materials likely to contaminate the

weld.


50/335

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

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

52C (125F) minimum drying oven. Any rod

that exceeds this exposure time must be dried

for one hour at 427C (800F) before being

used Keep all weld starts and stops to a mini


51/335


in.) to allow the installation of a backup strip.

Backup strips are required for all cracks thathave gone through the parent material and can-

not be welded from both sides. If a weld repair

allows access to both sides of the plate, no

backup strip is required as long as complete

weld penetration is achieved. If backup strips

are not used, the surface profile on both sides

must be ground smooth with no undercut. Doc-

umentation must support this repair. Photo-

graphs of surface condition are required by the

service and warranty departments of Komatsu.

4. Use dye penetrant to ensure the cracks are

completely removed.5. After air arcing and inspections (Steps 3 & 4) all

areas cut by the air arc should be cleaned thor-

oughly with a grinder to remove all possible car-

bon deposits and dye penetrant.

6. Fill gouges with weld and grind all surfaces

smooth to avoid defects in the new weld.

7. Grind all surfaces to be welded so they are free

of slag, rust, and any other foreign materials.

8. Preheat the entire weld joint area until the sur-

rounding surface area reaches 150C (300F)

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

be welded.

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 150C (300F). Even if the area is over

150C (300F) 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 inspec-

tion 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.


52/335

ANNEX B

1.0 TOE HAMMER PEENING

Equipment:

1. Hand held pneumatic hammer

2. Adequate air supply

3 Adequate lighting

2.0 TOE GRINDING WITH A ROTARY BURR

Equipment:

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


53/335


3. Adequate lighting

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

5. Protective clothing, gloves, includes eye, face,

and ear protection.

Procedure

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

the peening tool resulting in the area of defor-

mation being approximately equally divided

between the base material and the weld metal

face to the specified depth and not to exceed 5

mm (0.19 in.) in width. Refer to Figure 4-1.

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

2. The weld must have a smooth profile and the

toe must have a good transition to the parent

material (no overlap) before the peening opera-

tion is performed. Grinding the weld face and

toe area is permitted to correct unacceptable

conditions. Visual inspection/acceptance is to

be done after peening with the appropriate

radius and depth gauge.

3. Hold the hammer tool at approximately one half

the included angle between the weld face and

the parent material and perpendicular to thedirection of travel. This will normally require

approximately four passes of the peening tool

with the pressure of near full operator weight

being applied. The depth of the indentation

must be between 0.6 mm to 0.8 mm (0.02 to

0.03 in.).

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

3. Adequate air supply

4. Adequate lighting

5. Protective clothing, gloves, includes eye, face

and ear protection

Procedure

1. The toe of the weld should serve as a guide fo

the burr tool resulting in the material removed

being approximately equally divided between

the base material and the weld metal face to the

specified depth and not exceed 8 mm (0.31 in.in width. Refer to Figure 4-2.

2. The weld must have a smooth profile and the

toe must have a good transition to the paren

material (no overlap) before the grinding opera

tion is performed. Grinding the weld face and

toe area is permitted to correct unacceptable

conditions. Visual inspection/acceptance to be

done after grinding with the appropriate radius

and depth gauge.

3. The axis of the tool should be maintained a

about 45 to the parent plate and inclined a

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

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

be clean, smooth and free of all traces of under-

cut or slag.


54/335


55/335


FIGURE 4-1. TOE HAMMER PEENING


56/335


57/335


FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR


58/335

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

SPECIAL PRECAUTIONS WHENSERVICING AN A/C DRIVE SYSTEMTRUCK

Consult a qualified technician, specifically trained for

servicing the A/C drive system, before welding on the

truck.

The following procedures must be followed to ensurethe safety of maintenance personnel and to help pre-


59/335


tric Company, Cleveland, Ohio

American Welding Society - Welding Handbook

British Standard BS5135 - Metal Arc Welding of Car-

bon and Carbon-Manganese Steels

Welding Steels Without Hydrogen Cracking - The

Welding Institute, F. R. Coe, Author

y p p p

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.


60/335

Locate the GF cut-out switch in the access

panel on the left side of the main control cabi-

net. Place the switch in the CUTOUT position.

This will prevent the alternator from re-energiz-

ing and creating system voltage until the switch

is returned to its former position.

After repairs, replace all covers and doors and

place the GF cutout switch and battery discon-nect switches in their original positions. Recon-

t ll h i t t ti th t k

General Welding Guidelines

1. Open the battery disconnect switches and dis

connect the battery charging alternator lead

wire.

2. Disconnect all electrical harnesses from the

Engine Control System (ECS). The ECS is

located inside the electrical cabinet behind the

operator's cab. Disconnect the ground strapfrom the ECS.


61/335


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.

3. Fasten the welding machine ground (-) lead to

the piece being welded. The grounding clamp

must be attached as near as possible to the

weld area.

4. DO NOT weld on the rear of the control cabinet

The metal panels on the back of the cabinet are

part of the capacitors and cannot be heated.

5. DO NOT weld on the retard grid exhaust lou

vers.

6. Some power cable panels throughout the truck

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

power cables may be damaged.

7. Power cables must be cleated in wood or othe

non-ferrous materials. DO NOT repair cable

cleats by encircling the power cables with meta

clamps or hardware. Inspect power cable insu

lation prior to servicing the cables and prior to

returning the truck to service. Discard cables

with broken insulation.

8. Protect power cables and wiring harnesses

from weld spatter and heat.

9. DO NOT lay welding cables over or near thevehicle electrical harnesses. Welding voltage

may be induced into the electrical harnesses

and cause damage to components.

10. DO NOT allow welding current to pass through

ball bearings, roller bearings, suspensions, o

hydraulic cylinders.


62/335

NOTES


63/335



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RECEIVING & ASSEMBLY PREPARATION

1. Inspect all components for possible shipping

damages. Note any damage found and report to

shipping agent.

2. Spread out all parts and organize per unit num-

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

decks are with the correct chassis.

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


65/335

FAM0503 Receiving & Assembly Preparation Page 5-1

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.

proper tightening torque.

8. Arrange the work site as shown on the following

page.


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Page 5-2 Receiving & Assembly Preparation FAM0503

ASSEMBLYLAYOUT


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CHASSIS ASSEMBLY

Due to differences in machine configurations and

shipping restrictions/requirements throughout the

world, the shipping and packaging of large machines

varies. Photographs or illustrations used in the fol-

lowing procedures are provided as general guide-

lines only. Actual assembly may be different, but this

general procedure provides a basic outline forassembly.

Items like the hydraulic tank and the accumulators

h b d f hi i d ill h t

BASIC ASSEMBLY PROCEDURE

1. Site preparation

2. Unload truck components

3. Assemble the chassis

4. Weld the body

NOTE: Chassis assembly and body welding may be


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FAM0612 Chassis Assembly Page 6-1

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)

done in either order, or simultaneously. The mos

logical order depends on available resources such as

cranes, welders, assemblers, etc.

5. Static checkout (electrical & mechanical)

6. Install the body

7. Dynamic checkout (electrical & mechanical)

8. Site cleanup


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ORDER OF ASSEMBLY

The assembly procedure is organized in levels. Gen-

erally, the tasks to be done at a given level may be

performed in any convenient order or simultaneously.

However, all tasks in that level must be completed

before proceeding to the next higher level. Each level

depends on the installation of components from the

previous level.

NOTE: As stated earlier, shipping and packaging of

large machines will vary. Some of these steps may

change due to different shipping configurations and/

LEVEL 3

1. Spindles/Hubs

2. Steering Cylinders

3. Tie Rod

LEVEL 41. LH Deck

2. RH Deck/Grid Box

3 Operator Cab


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Page 6-2 Chassis Assembly FAM0612

g pp g g

or truck options.

LEVEL 1

1. Chassis - Unload and crib for assembly.

2. Auxiliary Control Cabinet (temporary)

3. Deck Support (on horsecollar over suspension).

NOTE: It is easier to install and weld the deck

supports before the front suspensions are installed.

However, do not install the deck supports first, unless

there is a suitable means of installing the suspension

with the deck support in place.

4. Rear Suspension

5. Hydraulic Tank

6. Fuel Tank

7. Front Suspensions

8. Diagonal Ladder

9. Uprights/Air Cleaners10. Diagonal Support Beams (leave loose until left

deck is bolted in place)

NOTE: Do not weld the air cleaner / uprights until all

decks and the operator cab are installed. Ratchet

hoists may be required to help tie all the structures

together for a proper fit.

LEVEL 2

1. Air Cleaner Piping

2. Center Deck

3. Control Cabinet

4. Auxiliary Control Cabinet

3. Operator Cab

LEVEL 5

1. Exhaust Pipes

2. Weld Uprights

3. Blower - Air Intake Ductwork

4. Wheel Motors

LEVEL 6

1. Front Tires

2. Rear Tires

3. Hoist Cylinders

LEVEL 7

1. Clearance Lights

2. Body Pads/Shims/Guides

3. Front Mud Flaps

LEVEL 81. Dump Body Installation

LEVEL 9

1. Hoist Cylinders

2. Rock Ejectors

3. Rear Mud Flaps


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LEVEL 10

1. Clean the Truck

2. Decals

3. Lighting Wiring

4. Charge Suspensions

5. Charge Accumulators

6. Add Fluids

7. Charge the Air Conditioning System

CHASSIS ASSEMBLY

The photographs referenced in this procedure depic

an actual truck assembly. Assembly at another loca

tion 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


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NOTE: Prior to starting the engine, verify that the

steering pump case is full of oil.

LEVEL 11

1. System Checkouts

2. Exhaust Blankets

3. Clean Assembly Rear4. Touch Up Paint

5. Train Operators

6. Optional - Install Fire Suppression System

ual. Follow all local, state, and federal regula

tions.

In the procedures that follow, many very heavy com

ponents will be required to be lifted into place and

secured.

Inspect all lifting devices. Slings, chains, andcables used for lifting components must beinspected daily for serviceable conditionRefer 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 ocomponents or any assembly procedurecontact your customer support manager fofurther 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 oelectric power lines.


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Disconnect the battery cables before welding on

the truck. Failure to do so may seriously damage

the batteries and electrical equipment. Discon-

nect the battery charging alternator lead wirebefore welding on the frame or its components.

Fasten the welding machine ground cable to the

component being welded.

GENERAL PRECAUTIONS ANDINSTRUCTION

1. Clean and remove all foreign material from

component mounting surfaces.

2. Mount the front suspensions first so that deck

substructures can be installed while other com-

ponents are installed.

3. DO NOT weld the front uprights until all upper

decks are installed.

4. Install the fuel return hose on the rearward most

fitting on the fuel tank.

5 Torque the deck mounting bolts before the


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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 purged andventilated.

Maintain fire control equipment. Inspect fire

extinguishers regularly to ensure they are fully

charged and in good working condition.

Mark cap screws and nuts with paint or ink after

tightening to the specified torque. This method

provides verification that the hardware has been

properly tightened.

5. Torque the deck mounting bolts before the

exhaust tubes, etc. are installed.

6. Verify all electrical connectors are free from

paint and/or corrosion. Clean any connector

that may be questionable.

7. Do not torque the diagonal ROPS beam until

after the operator cab & LH air intake tubes are

in place.8. Before installing the cab to the substructure, tap

all threaded holes to remove paint.

9. Verify all wiring is properly connected before

attempting to start the engine.

10. Recheck the torque on hardware installed at the

factory.

11. Use blocks for charging the suspension (oil &

nitrogen). Follow the procedures outlined in

Section 10, Appendix.

12. Steering accumulators are normally not charged

with nitrogen when shipped from the factory.Use proper precautions when checking the

nitrogen pressureand oil level in the cylinder.

13. Brake accumulators are normally charged with

nitrogen when shipped from the factory. Use

proper precautions when checking pressures.

14. Verify the lube system is lubricated, purged and

all levels full prior to start up.

15. 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 ofthis manual.

16. Use the battery disconnect switch when arc

welding. Connect the weld ground near the

weld area.


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NOTES


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1. Lift the chassis off the truck/trailer (Figure 6-1) or rail car using two cranes with a minimum capacity of 50 tons

each. Place the chassis on adequate support blocks in a level position. The weight of the chassis, asshipped, is approximately 60,382 kg (133,000 lb).

The support blocks must be approximately 84 cm (33 in.) high at the front, and approximately 30 cm (12 in.)

high under the rear axle housing (Figure 6-2). Placement of the chassis at this height will allow easy installa-

tion of truck components.

Thoroughly clean the chassis.


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FIGURE 6-1.

FIGURE 6-2.


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2. Lift the LH deck support into position. The weight of the deck support is approximately 654 kg (1442 lb).

a. Bolt the support into place.

b. Tack weld the support.

c. 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.


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d. Remove the plate and backer strip from the back of the LH deck support (see inset in Figure 6-7). Install

the backer strip at the end of the deck support. Install the plate at the end of the deck support.

e. Weld completely around the support without leaving any gaps. Finish welding around the plate.

f. 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. The gaps in

the weld around the support may result in premature frame cracking in this area.

Refer to Figures 6-3 thru 6-8.

Repeat for the RH deck support. The weight of the deck support is approximately 273 kg (602 lb).


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FIGURE 6-3.

FIGURE 6-4.


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FIGURE 6-5.

FIGURE 6-6.


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FIGURE 6-7.

FIGURE 6-8.


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3. Position the top rear suspension eye between the ears on the frame, as shown in Figure 6-9.

4. Lubricate pin (1). Align the retaining cap screw hole with the hole in the mounting bore, and partially push the

pin in until secure.

5. Insert spacer (4) and continue to push the pin in through the spherical bearing. Insert the remaining spacer

and continue to install the pin in until the retaining cap screw hole is aligned with the hole in the pin.

NOTE: Note the proper orientation of the spacers as shown in Figure 6-9.

6. Install cap screw (2) and locknut (3). Tighten to 465 Nm (343 ft lb).


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FIGURE 6-9. REAR SUSPENSION MOUNTING PIN

(Typical, Top and Bottom)

1. Pin

2. Retainer Cap Screw3. Locknut

4. Bearing Spacer

5. Retainer Ring

6. Bearing

7. Cap Screw8. Washer

9. Sleeve


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7. Clean the mounts for the hydraulic tank.

8. Lift the tank into position. (Figure 6-10). The weight of the hydraulic tank is approximately 731 kg (1612 lb).

Tighten the four mounting cap screws near the top of the tank to 622 62 Nm (459 46 ft lb).

Tighten the two mounting cap screws near the bottom of the tank to 800 80 Nm (590 59 ft lb).


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10. Clean the mounts for the fuel tank and lift the tank into position. (Figure 6-11) The weight of the fuel tank is

approximately 1690 kg (3725 lb).

Tighten the four mounting cap screws near the top of the tank to 712 71 Nm (525 52 ft lb).

Tighten the four mounting cap screws near the bottom of the tank to 298 30 Nm (220 22 ft lb).


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FIGURE 6-10.

FIGURE 6-11.


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

Refer to Figures 6-12 and 6-13.

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

are open when the handles are parallel with the hoses.


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FIGURE 6-12.

FIGURE 6-13.


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11. Install the two hoist filters onto the bracket at the inner side of the fuel tank. Connect the fuel supply and return

lines to the fuel tank.

Refer to Figure 6-14.


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12. Clean the front suspension mounting surfaces. The surfaces must be free of paint, rust, dirt, grease and oil.



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FIGURE 6-14.

FIGURE 6-15.


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13. Lift the front suspension into position. Refer to Figure 6-18. The weight of each front suspension cylinder is

approximately 2790 kg (6150 lb). Lubricate the cap screw threads, cap screw head seats and nut seats with

rust preventive grease. The hardware for the front suspension must be tightened according to the "turn-of-

the-nut" method as described below.

"Turn-Of-The-Nut" Tightening Procedure

a. Tighten all 14 cap screws (1, 6, 8, Figure 6-19) to 542 5 Nm (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. For the four cap screws (1, Figure 6-19) at

the upper mount, initially tighten the cap

screws to 95 Nm (70 ft lb), then advance

the cap screw head 60 as outlined in Steps

d-1 through d-3 Refer to Figure 6-16

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 120 clockwise relative to the first

reference line on the mounting surface.


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.


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d 1 through d 3. Refer to Figure 6 16.

For the bottom four cap screws (6, Figure

6-19), initially tighten the cap screws to 136

Nm (100 ft lb), then advance the cap

screw head 120 as outlined in Steps d-1

through d-3. Refer to Figure 6-17.

The turning member, either the cap screwhead or nut, is turned until the marked

corner is adjacent with the marked refer-

ence line. Ensure that the opposite end of

the turning member has NOT turned dur-

ing 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)

and the bottom outer four cap screws (8),

(without spacers).

1.) Tighten the top two corner cap screws to95 Nm (70 ft lb), then advance the cap

screw heads 60.

2.) Tighten the bottom, outer four cap screws

to 271 Nm (200 ft lb), then advance the

cap screw heads 120.

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 6-16. 60 DEGREE ADVANCE

FIGURE 6-17. 120 DEGREE ADVANCE


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FIGURE 6-18.

FIGURE 6-19. SUSPENSION INSTALLATION

1. Cap Screws, Washers

2. Nuts, Washers

3. Housing

4. Mounting Surface

5. Shear Bar


7. Piston


9. Spacer

10. Nuts, Washers


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14. Install the diagonal ladder. The weight of the diagonal ladder is approximately 180 kg (397 lb).


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


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FIGURE 6-20.


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15. Lift LH & RH uprights into position and install the four cap screws for each upright. Tighten to 465 47 Nm

(343 34 ft lb). The weight of the LH upright is approximately 726 kg (1601 lb). The weight of the RH upright

is approximately 578 kg (1274 lb).


NOTE: DO NOT weld the torque tubes on the uprights until the decks are installed.


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FIGURE 6-21.

FIGURE 6-22.


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16. If installed (some trucks are shipped with the center deck not installed), remove the center deck to enable

easy installation of the air intake tubing and the two diagonal cross tubes. The weight of the center deck is

approximately 250 kg (550 lb).



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17. Lift the LH diagonal tube into position (Figure 6-24). The weight of the tube is approximately 135 kg (298 lb).

Do not tighten the cap screws until the deck and the cab are in place.


120/335FIGURE 6-23.


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FIGURE 6-24.


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18. Lift the RH diagonal tube into position (Figure 6-25). The weight of the tube is 68 kg (150 lb). Do not tighten

the cap screws until the decks are in place.


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19. Lift the six air intake tubes and hump hoses into place. Install and tighten the clamps that secure the hoses.



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FIGURE 6 25


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FIGURE 6-25.

FIGURE 6-26.


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20. Lift the center deck into position. (Figure 6-27). Tighten the four cap screws to 465 47 Nm (343 34 ft lb).


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FIGURE 6-27.


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21. Lift the electrical control cabinet into position. The weight of the cabinet is approximately 3045 kg (6714 lb).

Install the mounting hardware and shims. Tighten the 10 cap screws to 1600 160 Nm (1180 118 ft lb).



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FIGURE 6-28.


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22. 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).

Lift the spindle/brake assembly into position. The weight of each spindle/brake assembly is approximately

5393 kg (11,890 lb). Refer to Figures 6-29 thru 6-33.

A ratchet hoist may be used at the lower portion of the steering arm to the lifting hook to aid in leveling the

assembly for easier mounting to the suspension.

Lift the retainer plates to the bottom of each suspension using blocks and a hydraulic jack.

Install the fourteen cap screws.

E l ti ht th t 678 N (500 ft lb) C ti t ti ht th i i t f 330


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Evenly tighten the cap screws to 678 Nm (500 ft lb). Continue to tighten the cap screws in increments of330

Nm (250 ft lb) until 2705 270 Nm (1,995 200 ft lb) is reached.

After installation is complete, connect the brake piping to each brake.


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FIGURE 6-29.


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FIGURE 6-30.

FIGURE 6-34

FIGURE 6-31.


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FIGURE 6-32.

FIGURE 6-33.


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23. Connect the steering cylinders and the tie rod to the steering arms.

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.



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FIGURE 6-34.


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24. Install the handrails and lift the LH deck into place (Figure 6-35). The weight of the LH deck with handrails is

approximately 720 kg (1587 lb). Loosely install the eight cap screws.

After all decking is in place, tighten the cap screws on each deck to 465 47 Nm (343 34 ft lb).


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25. Lift the retarding grids into place on the RH deck. The weight of the grids is approximately 3082 kg (6795 lb).

Tighten the eight cap screws to 800 80 Nm (590 59 ft lb).

26. Install the handrails on the RH deck.

27. Lift the RH deck into position and loosely install the six cap screws. The weight of the assembly is approxi-

mately 4100 kg (9039 lb). Refer to Figure 6-36.


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FIGURE 6-35.


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FIGURE 6-36.


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28. Lift the operator cab into position. The weight of the cab is approximately 2725 kg (6008 lb). Refer to Figures

6-37 and 6-38.

Remove any paint from the cab mounting holes.

Determine if shims are required at each mounting pad. The gap between the cab and the ROPS support must

not exceed 1 mm (0.039 in.). Install shims at each mounting pad as required.

Install and tighten the thirty two cap screws to 800 80 Nm (590 59 ft lb).

29. Tighten the hardware for the diagnonal tubes. For the RH tube, tighten the 12 cap screws to 240 24 Nm

(177 17 ft lb). For the LH tube, tighten the 16 cap screws to 800 80 Nm (590 59 ft lb).


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FIGURE 6-37.


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FIGURE 6-38.


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30. Weld the LH & RH uprights to the front frame tube. Refer to Figure 6-39.


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31. Lift the two bumper extensions into place. Refer to Figure 6-40.

Tighten the cap screws to standard torque.


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FIGURE 6-39.


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FIGURE 6-40.


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32. Install any remaining handrails. Tighten the cap screws to standard torque.


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FIGURE 6-41.

Documents

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