Shop -" Manual IO 320M DUMP TRUCK KOMATSUA WARNING Reems Cue ce Pega aT Peano Unsafe use of this machine may cause serious injury or death. Operators and maintenance personne! must read and understand this manual before operating or maintaining this machine. This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it. This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written authorization from KAC, Itis the policy of the Company to improve products whenever it is possible and practical to do so. The ‘Company reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Because of continuous research and development, periodic revisions may be made to this publication. Customers should contact their local Komatsu distributor for information on the latest revision. CALIFORNIA Proposition 65 Warning Diese! engine exhaust, some of iis constituents, and certain vehicle components contain or emit chemicels known tothe State of California to cause cancer, bith defects or other reproductive harm. CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead ‘compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.FOREWORD ‘This Service Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings ‘and cautions should be understood and followed when accomplishing repairs on the truck. ‘The first section covers component descriptions, truck specifications and safe work practices, as well ‘as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine ‘and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be cartied only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and do not necessarily refer to any one particular truck model ‘This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all location references “right” or “left” are made in respect to the operator's normal seated position. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specications have ++10% tolerance unless otherwise specified. ‘The HAULPAK® model designation is based on maximum Gross Vehicle Weight (GVW). Model numbers consist of three numbers and one letter (Le. 325M). The three numbers represent the maximum gross vehicle weight (GVW) in thousands of pounds. This number reflects the maximum loaded weight of the vehicle rounded to the nearest 5,000 Ibs. (2 268 kg). The letter “M" or “E” stands for Mechanical or Electrical drive system. This model designation is a job rating or range rating concept which establishes well defined maximum gross vehicle weights. The GVW is used for both design and application guidelines in determining the load on the drivetrain, frame, ties, and other components. Maximum GVW means the total weight, which is: the Empty Vehicle Weight (EV) + the fuel + the payload. To determine allowable payload: Fil fuel tank of empty truck and weigh truck. Record this value and subtract from GVW rating, The result isthe allowable payload. Exceeding the allowable payload will reduce expected life of truck components. ‘A00002 2/91 IntroductionAz 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. A DANGER "DANGER" identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken. AWARNING "WARNING" identifies a specific potential hazard WHICH MAY RESULT in either INJURY OR DEATH if proper precautions are not taken. ACAUTION "CAUTION" is used for general reminders of proper safety practices OR to direct the reader's attention to avoid unsafe or improper practices which may resutt in damage to the equipment. Introduction ‘Anoo02 2/91TABLE OF CONTENTS SUBJECT «1... eee eee eee ee » » . SECTION GENERAL INFORMATION . . - sete eee eee eee eee A ‘STRUCTURES . wee te eee eee ENGINE, FUEL, COOLING AND AIR CLEANER . eee eee .c ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) ... 2. - 2-2-2 ee ee eee 2. D TRANSMISSIONAND PTO ........-- see es iF DRIVE AXLE, SPINDLES AND WHEELS: wee tees . G HYDRAIR® Il SUSPENSIONS Peer Peer) -. H BRAKE CIRCUIT AIR SYSTEM becca veces kK HYDRAULIC SYSTEM wae ae see e eee eens cn OPTIONS AND SPECIAL TOOLS: eee ae M OPERATOR'S CAB eee dee e ee eee renee eee N LUBRICATION AND SERVICE beeen ee eee eee eee ALPHABETICALINDEX ...... Bees ae eeeee 11. @ SYSTEM SCHEMATICS ween cee eR ‘A00002 2/91 Introduction325M HAULPAK® TRUCK Introduction ‘An0002 2/91SECTION A GENERAL INFORMATION INDEX ‘TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS. GENERAL SAFETY AND TRUCK OPERATICN WARNINGS AND CAUTIONS CHARTS AND TABLES Agt001 AttNOTES 01001MAJOR COMPONENT DESCRIPTION ENGINE ‘The standard 325M HAULPAK® is powered by a Cummins KT-38-C diesel engine. Other optional en- gines may be specie. TRANSMISSION ‘The diesel engine supplies power through an Allison P8963 transmission. ‘The transmission is equipped with a lock-up TC-860 torque converter, hydraulic retarder, and Allison Trans- mission Electronic Controls (ATEC) for automatic shilt- ing, FINAL DRIVE ASSEMBLY ‘The final drive consists of a plug-in differential assem- bly with planetary wheel drive. OPERATOR'S CAB The HAULPAK® Operator's Cab has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab is rubber mounted to reduce noise and vibration. It includes a tinted safety- {lass windshield and sliding side windows for excellent Visibility, a deluxe interior, controls mounted within easy reach of the operator, and an instrument panel which provides the operator with all instruments and «gauges whichare necessary to control and monitor the truck's operating systems. ‘A02002 8/90 POWER STEERING ‘The HAULPAK® truckis equipped with a fulltime power steering system which provides positive steering con- trol with a minimum of effort by the operator. The system includes a nitrogen-charged accumulator which automatically provides emergency power ifthe steering hydraulic pressure is reduced below an estab- lished minimum HYDRAULIC RETARDER The hydraulic retarder is an integral part of the trans- mission. It is controlled by the operator through the activation ot the retarder pedal in the operator cab. During normal operation, the hydraulic retarder is used to slow the truck and to control speed coming down a ‘grade without use of service brakes. BRAKE SYSTEM The service brake system is an air-over-hydraulic, wedge actuated shoe and drum type. Depressing the brake pedal actuates front and rear drum brakes. Au- tomatic emergency application as well as manual con- trol for “Dry” and “Slippery” road conditions are provided. SUSPENSION HYDRAIR® Il suspension cylinders located at each wheel provide a smooth and comfortable ride for the operator and dampens shock loads to the chassis during loading. Properly maintained suspensions will extend the service life of both tires and main frame. Major Component Description AaAIR CLEANER: HYDRAULIC TANK: STEERING ‘ACCUMULATOR HYDRAULIC PUMP HOIST CYLINDERS. In /AIR CLEANER ENGINE - CUMMINS KT-28-¢ FRONT HYDRAIR ‘SUSPENSIONS. TRANSMISSION “ALLISON DPaSe3. o ree Tans FINAL DRIVE TIRES. 27.00-49, 42PR Rock (E3) REAR HYDRUIR 1 SUSPENSIONS, 0050 325M MAJOR COMPONENTS 2-2 Major Component Description ‘A02002 8/90SPECIFICATIONS ENGINE Cummins KT-38-C Number of Cylinders. 2 Operating OYC!e enn . 4Stroke Rated Brake HP... 925 HP(690 KW) @ 2100 RPM Flywheel HP... 876 HP (653 KW) @ 2100 RPM Maximum torque ... : . ne 93050 lb-ft (4136 N.m) @ 1250 RPN TRANSMISSION Alison DP-8963 with TC-860 Lock-Up Torque Con: verter, Hydraulic Retarder and Allison Transmission Electronic Controls (ATEC) for Automatic Shifting. With CUMMINS KT-38-C Gear mph (kph) 1St (FORWAD) rr 65 (105) 2nd. 120 (19.3) ard. 164 (264) 4th.. 212 (34.1) sth. 277 (448) 6th.. 382 (61.5) Reverse, 48 (77) FINAL DRIVE ASSEMBLY Plugin Differential with vw Planetary Wheel Drive 9.88:1 6.00:1 23.28:1 ELECTRIC SYSTEM .~. Two 12 Volt Batteries in Series . 24 Volt, 50 Ampere Output .. 24 Volt Electric ‘A02002 8/90 TIRES Rock Service.. . (E-3) Tubeless Standard. 27.00-49 42 Ply Rating Rim Size..... 19.5 in. X 49 in. (60 cm X 124.4 cm) Separable Tire Rims SERVICE CAPACITIES U.S. Gallons Liters (Cummins Crankcase .. 34 129 (Includes Lube Oil Filters) Cooling System (Total) 82 310 Fuel Tani 32001211 Transmission 28 106 Hydraulic System (Total) . 96 (363 Final Drive... 62285 AIR SYSTEM Compressor: Cummins. Main Air Tank Capacity. 90 cfm (0.85 m®/ min) 15 0u.ft (4251) HYDRAULIC SYSTEM (Closed System) Double Vane Pump... .. 96 GPM (363 l/min.) @ 2100 RPI Cylinders Pressurized 65 U.S.Std. Gallon (246 !) ‘Accessible, Replaceable, Elements . Single, Full Flow, 100 Mesh Return... Dual, Full Flow, 3 Micron - Nominal SERVICE BRAKES ‘Actuation: v Air-Over-Hydraulic Type (Shoe) Front Rear 80x 10 in 30x 12in. (76.2x25.4 cm) (76.2 x 30.5 cm) STEERING Turing Circle (Front Wheel Track)....... 691. (21 m) Emergency Power Steering With AccUMUAOE nn Standard Major Component Description 23DUMP BODY CAPACITY (Standard) Struck. Heaped @ 2:1 (SAE) 47.3 cu. yds. (96.2 m°) 67.1 cu. yds. (51.3 m>) WEIGHT DISTRIBUTION (wIKT38-C engine, 27.00-49 Tires and standard body) EMPTY Pounds Front Axle.. . 65,920 Rear Axe... . 66,980 Total 192,900 LOADED 85 tons (77.11) Payload Pounds Front Axle. 102,190 Rear Axe.. 200,710 Total * 302,900 Kilograms 29.901 90.383 60.283 Kilograms 46353 91 040 197 393 * Not to Exceed 325,000 Ibs. (147 420 kg) on 27.00-49, Tires including Options, Fuel, & Payload OVERALL TRUCK DIMENSIONS aw ot ey Fir (ean, TT [es 35 1005 a) 35° (041 ma} 18S" (470 Sr Mm A24 711" 9m 175 626.0) Major Component Description ‘A02002 8/90SAFETY RULES Safety records of most organizations will show that the (greatest percentage of accidents are caused by unsafe acts of persons while the remainder are caused by unsafe mechanical or physical conditions. The following safety rules are intended to instruct the HAULPAK® operator on what to do and not to do while ‘operating the truck. However, all situations cannot be covered by these safety rules; local conditions and regulations may add many more to ths lis. GENERAL 1. Prevention is the best safety program. Prevent accidents by knowing all the safety regulations required by the employer. all necessary precau- tions at the job site, and the manufacturer's recommendations for the truck. Report any con- ditions that need attention to the proper authorities, 2, Wear proper clothing. Loose fiting clothing, un- buttoned jackets and sleeves, jewelery, etc. can ‘catch on a protrusion and cause a potential haz- zard. 3, Always use personal safety equipment such as safety shoes, safety glasses and hard hat. There may be conditions when ear protective devices should also be worn. 4, When walking to or from the truck, keep a sale distance from all machines even ifthe operator is visible, Before Starting Engine 1. Carefully study the Operator Handbook before starting engine or driving truck. Give particular attention to safety material and caution and warn- ing decals. Only qualified operators or technicians, should attempt to operate the HAULPAK®. 2. Before operating truck, a careful visual inspection as well as operational checks should be com- pleted. Report any items that need attention to the proper authority. 1. Inspect entire truck for oil or coolant leaks, ‘A03002 2/90 Wf engine has been running, allow coolant to cool before removing the fill cap or draining radiator. ‘Any operating fluid, such as hydraulic oil, or engine coolant escaping under pressure, can have suff- cient force to enter a person's body by penetrating the skin and cause serious injury and possibly death, if proper medical treatment by a physician who is familiar with this type of injury is not received immediately. b. When checking coolant in radiator, relieve pressure before removing radiator cap. . Check tires for cuts, damage or "bubbies’. Check tires for proper inflation. If tire is warm, from operation, allow tire to cool before adjust- ing tire pressure. I inflation is needed, use an air chuck with extension hose clipped on the tire inflation valve to allow service away from front of wheel d. Visually inspect all headlights, worklights, clearance lights, and tailights for damage and be certain lenses are clean. Good visibility may prevent an accident. . Upon completion of an exterior inspection of the truck, clean mud, grease, ice or snow from shoes and ladder before climbing access lad- der. f. Always use handrails and ladder when mount- ing or dismounting truck. Always mount and dismount facing the truck. Never attempt to mount or dismount while the truck is in motion. g. Check the deck areas for debris or loose hardware. h. When getting in or out of truck cab, face the cab and use handrails provided. Safety Rules Ati. Become familar with all protective equipment devices on the truck and insure that these items (Geat belts, grab bars, anti-skid material, canopies, etc.) are securely in place. j. Check on-board fire extinguishers. Do not use a fire extinguisher for any purpose other than extinguishing a fire. If extinguisher is used, report the occurrence so it may be refilled or replaced Starting Engine And General Operation 1. Make sure all persons are clear of truck before starting engine. Always sound the hon asa warn- ing device before activating any controls. When backing the truck, give backup signal (three blasts ‘on horn); when starting forward, two blasts on hom. These signals must be given each time the truck is moved forward or backward. 2. Insure adequate ventilation before startup if the truck is in an enclosure. Exhaust fumes are dangerous. 3, If cold weather starting aid is used, read and follow the manufacturers instructions for use and disposal ‘Starting fluid is highly flammable. Use with extreme care. 4, Check windshield wipers, lights, windows and horn for proper operation and cleanliness. 5. Operate each of the truck brake circuits at least twice prior to operating and moving the truck. ‘These checks should include individual activa- tions of the service brake, parking brake, and brake lock with the engine running, Itany applica tion/release of any brake circuit does not appear Proper, or if sluggishness is apparent on applica- tion/release, shut the truck down and notify main- tenance personnel. DO NOT operate truck until brake circuit in question is fully operational AXCAUTION Use brake lock at dump or loading site ONLY. DO NOT use brake lock to park the truck with engine shut down or to stop the truck during routine operation. 432 Safety Rules 6. Check parking brake periodically during shift. Use parking brake for parking only. 7. Observe safety and warning decals on the truck at all times. 8, Keepall unauthorized reading material out of truck cab, 8. Do not carry tools and supplies in cab of truck or allow trash to accumulate in cab. 10, Do not allow anyone to ride on decks or steps of truck. Riders should be in cab only. 11. Only authorized persons are allowed to ride in the truck cab. Wear seat belts at all times. 12, Do not allow anyone to get on or off truck while it is in motion, 18. Do not move truck into or out of a building without a signal person present. 14, DO NOT leave truck unattended while engine is running, 15. Check for flat tires periodically during shift. Iftruck has been run on a ‘fiat’, it must not be parked in building until the tire cools. If tire must be changed, do not stand in front of rim and locking ring when inflating tire mounted on the machine. Initial inflation to required pres- sure must be done with a safety cage or rack enclosing the tire and rim assembly. Observers should not be permitted in the area and should be kept at least 1500 ft. (457 m) away from the side of such tres. AWARNING Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the tire may ignite causing explosion of tire and AWARNING In the event of fire in the tire and wheel area (including brake fires), stay away from the truck until the tire and whee! are cool. Tire and rim assembly may explode if subjected to excessive heat. Personnel should move to a remote or protected location if sensing excessively hot brakes, smell of rubber burning or evidence of fire near tire and wheel area. ‘03002 2/90Itthe truck must be approached to extinguish afire, those personnel should do so only from the front or the back of the tire, unless protected by use of large heavy equipment as a shield. Stay at least 50 feet (15 m) from the tread of the tire. 16, Report haul road, pit or dump conditions which may present hazzards (muddy roads, ice, snow, Pot holes, spilled debris, etc.) immediately to su- pervisor. Loading 1. Pull into the loading area with caution. Remain at a safe distance while truck ahead of you is being loaded. 2. Do not drive over unprotected power cables. 3, When approaching or leaving a loading arez, ‘watch out for other trucks and for personnel work- ing in the area, 4. When positioning truck under shovel, follow "Spot- ter" oF "Shovel Operator’ signals. Operator may speed up loading operations by watching truck position ahead of him in order to judge where he Is to place his unit. 6, While truck is being loaded, operator should stay in cab of truck. Apply brake lock during loading operation. 6, After truck is loaded, pull away from shovel witn caution. ‘A03002 2/90 Hauling 1. Stay alert! Govern truck speed by the road condi- tions, weather and visibility. 2. Always operate truck so it is under control at all times. 3. Use extreme caution when approaching a haul road intersection. Be prepared to avoid collisions with other vehicles. Watch for oncoming vehicles and be prepared to slow down and move aside if haul road is restricted. 4. Obey all road signs. 5. unfamiliar with the road, drive with extra caution. 6. Always dim headlights when meeting oncoming vehicles. 7. Maintain a safe distance when following another truck. Never approach another truck from the rear, in the same lane, closer than 50 ft. (15 m). When operating on a down grade, this distance should be no closer than 100 ft. (20 m). 8. Before starting up or down a grade, maintain a speed that will insure safe driving and provide effective retarding under all conditions. Refer to speedigrade decal in operator cab. 9, When operating truckin darkness or when visibility is poor, do not move truck unless headlights are ‘on. Do not back truck without a spotter if backup horn or lights are inoperative. 10. When backing the truck, give backup signal (three blasts on horn); when starting forward, two blasts on horn. These signals must be given each time the truck is moved forward or backward. 11. Do not stop or park on a haul road unless un- avoidable. If you must stop, move truck to a safe place, apply parking brake, block wheels securely ‘and notify maintenance personnel for assistance. 12, Cab doors should remain closed at all times while truck is in motion or unattended. Safety Rules 433Passing 1. Use only the areas designated for passing. Before passing, make sure the road ahead is clear. 2. Donot pass another vehicle on a hill or blind curve. 3. fadisabled truck is blocking yourlane, slowdown ‘and pass with extreme caution. Dumping 1. Pull into dump area using caution. Carefully maneuver truck into dump position. Obey signals as directed by the spotter, if present. 2. When in dump position, apply wheel brake lock and move selector switch to "Neutral" position. 3. Put hoist control lever in "Hoist" position and depress throttle pedal. 4. Remove foot from throttle pedal as last stage of hoist cylinder starts to extend. 5. After load has been dumped, place hoist control lever in the down position and release the lever allowing the body to return to the frame. 6. With body completely down against frame, leave the dump area. ACAUTION The HAULPAK® is not to be moved with the dump body raised EXCEPT IN EMERGENCIES. Failure to follow this CAUTION may result in hoist cylinder, frame, and/or body hinge pin damage. 134 Safety Rues Parking 1. When parking, park only in designated parking areas and at a safe distance from other vehicles as determined by supervisor. 2. If parking truck in other than designated parking area is necessary, select a level area, apply park- ing brake and block wheels front and rear. Do not use brake lock as a parking brake. 3. fnecessary to park ona slope, parkat rightangles to the incline and block wheels securely. 4, When parking do not leave truck unattended if engine is left running or dump body is raised. 5. If engine is to be shut down, follow procedure outlined under "Shutting Down Engine’. ‘Shutting Down Engine 1. Bring truck to complete stop, move range selector to the ‘Neutral" position and apply parking brake, 2. Allow engine to run from 3 to § minutes at idle to provide cooling of the engine. Do not leave truck unattended during engine idle coo! down period. ‘3. Turn off all lights and accessories. 4. Engine shutdown may be activated when key- switch is moved to the "Off" position on some trucks: other trucks may require depressing and holding a shutdown button until the engine stops. Refer to the Operator Handbook for specific ‘mode! information. Some trucks may inolude an ‘optional "Ground Level Shutdown’ button 8. Close and lock all windows, remove key from key-switch and lock cab to prevent unauthorized truck operation. Dismount truck property. ‘A03002 2/90‘When Service Is Necessary 1. If truck is to be towed for any reason, use a rigtt towbar. Checktruck cab for decal recommending special towing precautions. Refer to "Towing" instructions for further precautions. 2. When truck body is in the dump position, do not allow anyone beneath it unless "body-up" retain- ing cable or pins are installed. 3. Do not repair or service truck while engine s running, except when adjustments can only be made under such conditions. Keep a safe dis- tance from moving parts. 4, When servicing air conditioning system with refrigerant (Freon), wear a face shield and cold resistant gloves for protection against freezing 5, Follow package directions carefully when using cleaning solvents. 6. Ifan auxiliary battery assist is needed, turn off all accessories and be sure area is well ventilated. NOTE: HAULPAK® Trucks are generally equipped with two 12 volt batteries connected in series to provide 24 volt output. Be sure to maintain correct voltage and polarity when connecting booster cables. Damage 10 electrical components may result if voltage and polarity are not correct. AWARNING Lead-sulphate batteries will give off hydrogen gas! Sparks or flame near these batteries may cause @ violent explosion which will expe! debris and ex- tremely toxic and corrosive sulphuric acid! Use the following procedure to minimize the pos- sibility of sparks in the vicinity of the battery: ‘a. Connect one lead of booster cable to 24V posi tive (+) post of battery needing assist, ard other lead of the booster cable to the 24V positive (+) post of auxiliary battery. b. Connect one lead of second booster cable to 24V negative (-) post of auxiliary battery and then connect other lead of the booster cable to a good frame ground on the disabled truck away from the battery needing assist. ‘A002 2/90 Towing Prior to towing a truck, many factors must be carefully considered. Serious personal injury and/or significant property damage may result if important safety prac- tices, procedures and preparation for moving heavy equipment are not observed. CAUTION Both right and left planetary sun gearé/drive axles, should be removed before any towing. Refer to Section G" for these instructions. Extensive secon- dary damage can occur to final drive components and/or transmission, if truck is towed without first removing sun gears/drive axles. A disabled truck may be towed after the following MINIMUM precautions have been taken, 1. Shut down engine. 2, Refer to operator's cab for towing decal for any special instructions. 3. If truck is equipped, install hydraulic connections for steering and dumping between towing and towed vehicles. 4, Inspect tow bar for adequacy (approximately 1.5, times the gross vehicle weight of truck being towed). 5, Determine that towing vehicle has adequate capacity to both move and stop the towed truck under all conditions, 6. Protect both operators in the event of tow bar failure. 7. Block disabled truck to prevent movement while attaching tow bar. 8, Release disabled truck brakes and remove block- Do not tow the truck any faster than 5 MPH (8 kph). 9. Sudden movernent may cause tow bar failure. ‘Smooth and gradual truck movementis preferred. 10. Minimize tow angle at all times - NEVER EXCEED 30°. The towed truck must be steered in the direc- tion of the tow bar. Safety Rules 35A386 NOTES Safety ules ‘A03002 2/90WARNINGS AND CAUTIONS The following paragraphs give an explanation of the Waring, Caution, and Service Instruction plates and decals attached to the HAULPAK® truck. The piates and decals listed here are typical of this HAULPAK® ‘model, but because of customer options, individual trucks may have plates and decals that are different from those shown here. The plates and decals must be kept clean and legible. If any decal or plate becomes worn or unable to be read, it should be replaced with a new one. ‘A warning plate is mounted around the key switch on the instrument panel The warming stresses the importance of reading and Understanding the operator's manual before operation, DO NOT OPERATE VEHICLE BEFORE READING AND UNDERSTANDING’ OPERATION MANUALS. essa ‘A warning plate is mounted directly under the red warning lights in the instrument panel. The warning plate stresses that if any of the red wamning lights are Cn, the truck should be safely stopped and the engine shut down. Truck should not be operated with ary red warning lights on. WARNING DO NOT OPERATE MACHINE IF ANY OF THE RED WARNING LIGHTS ARE ON. In the HAULPAK® cab, located above the windshield is a “Caution” to idle the engine before shutdown. Damage may result to the turbocharger if the engine has not idled the minimum three minutes. The tur- bocharger needs at least three minutes at engine idle to cool toa safe temperature. CAUTION IDLE THIS ENGINE 3 MINUTES BEFORE SHUTDOWN IF THIS ENGINE IS SHUTDOWN WITHOUT IDLING SERIOUS DAMAGE MAY RESULT ‘TO THE TURBOCHARGER. wastes ‘An OPTIONAL engine shutdown plate is mounted on the front left hand comer by the ladder and locates the {ground level engine shutdown switch. ENGINE SHUTDOWN ‘A04004 7/91 Warnings and Cautions Ae‘A warning plate is mounted on the instrument pane! around the “Dry/Slippery Road” switch and the “Whee! Brake Lock” switch. Z\WARNING The dry/sippery road control switch permits the oper- ator to select either ful braking capability at all wheels, for “dry road” or reduced braking at the front wheels, with full braking at the rear wheels for “slippery road’ ‘When the switch is placed in the “slippery road” posi- tion, more of the braking is done by the rear wheels than the front wheels to provide better steering control. The “Whee! Brake Lock” should be used with the engine running for dumping and loading operations only. DO NOT use for parking the truck with engine shutdown, Use of the wheel brake lock control with the engine shut down will permit the brakes to release. ‘A waming plate is mounted directly over the parking brake and the emergency brake switch which stresses the parking brake switch is only for parking and the emergency brake switch for emergency stopping only. NOTE: Do not use at shovel or dump. PARKING BRAKE EMERGENCY BRAKE ‘USEONLY wen TABLE Sree 9 © OFF oH cs on ® ® STSTEN Wit AEE3 Ob RiusAswa bia M2 Warnings and Cautions ‘Awarning plate is located inside the operator's cab and provides transmission range/speed guidelines to be used when descending various grades with a loaded truck. AWARNING 10 NOT DESCEND GRADES AT SPEEDS GREATER THAN LISTED WHEN VEHICLE IS LOADED MAX. G .W. 325,000. LBS. TRANS. GRADE SPEED << Sy GEAR XM, 16 The Automatic Transmission Electronic Control (ATEC) plate is installed on the right side of the passen- ‘ger seat base. This plate lists cautions which must be observed if welding repairs are required. CAUTION PRIOR TO WELDING ON TRUCK 1) DISCONNECT BATTERY CONNECTIONS 2) DISCONNECT PLUGS TO ELECTRONIC. CONTROL UNIT (ECU) 3) COVER ATEC COMPONENTS AND WIRING FOR PROTECTION FROM HOT SPARKS, 4) DO NOT CONNECT WELDING CABLES TO ATEC COMPONENTS 5) DO NOT WELD ATEC COMPONENTS 6) REMOVE THE ATEC COMPONENTS IF WELDING IS TO BE DONE WITHIN 10 IN OF COMPONENTS ‘A04004 8/90The engine cooling systemis controlled by thermostats which keep coolant temperature between 160 -190°F (71'-89'C) during operation. Unless the pressure is fist released, removing the radiator cap after engine has been running for a time will result in the hot coolant beeing expelled from the radiator. Serious scalding and touring can result. A plate warning the service person of this danger is mounted on top ofthe radiator grille near the radiator cap. WARNING ‘SYSTEM IS PRESSURIZED BECAUSE OF THERMAL EXPANSION OF COOLANT. “DO NOT” REMOVE RADIATOR CAP WHILE ENGINE IS HOT. SEVERE BURNS MAY RESULT. ‘The ATEC (Automatic Transmission Electronic Con- trol) shift instruction plate is located above the ‘windshield. ‘The instruction plate provides a brief description of each shift selector position and Cautions the operator that the range selector lever may be moved toa lower range position at any speed, but the transmission WILL NOT DOWNSHIFT UNTIL MACHINE GROUND SPEED 1S REDUCED. Use the retarder and/or service brakes to reduce speed, "AUTOMATIC TRANSMISSION DRIVING INSTRUCTIONS AXCAUTION ‘A04004 7/91 ‘The transmission temperature plate is located in the ‘cab above the windshield. When the indicator passes from yellow to red, the truck must be stopped in a safe place, the range selector placed in Neutral, and engine ‘operated at 1500 RPM until normal operating tempera- ture is reached. TRANSMISSION TEMPERATURE GAUGE SHIFT TO NEUTRAL AND OPERATE ENGINE AT 1500 RPM TO REDUCE TRANSMISSION TEMPERATURE The towing caution decal is located above the windshield. Do not tow truck unless both sun ‘gears/drive axles are removed. Internal transmission and/or final drive damage may result if these precau- tions are not followed. Refer to “Towing” in the General Safety Rules for additional precautions. A CAUTION ‘ORES ur ra coven ATEN nanos SS ‘Warnings and Cautions Ag‘A Cauttion plate is attached to the hydraulic tank alert- ing personnel that the hydraulic oil level must be checked with the body down. Z\ CAUTION WITH BODY DOWN, OIL MUST BE VISIBLE IN GLASS. IF NOT, FOLLOW. ADD OIL PROCEDURE LOCATED ON TOP OF TANK. An instruction plate for filing the hydraulic tank is attached to the hydraulic tank. it Cautions that the system is pressurized and must be relieved before opening. Have replacement fitter elements on hand when the tank cover is removed. Keep the system open to the atmosphere only as long as absolutely necessary to lessen chances of system contamination. Service the tank with clean Type C-3 hydraulic ol. All oil being put into the hydraulic tank should be fittered through 3 micron fiters. CoAT TelN PRESSURIZED SYSTEM INITIAL FILLING AND ADDING OIL PROCEDURE: 1, DEPRESS VALVE TO RELIEVE TANK PRESSURE, ‘THEN REMOVE CAP. 2. FILL UNTIL OIL LEVEL IS AT TOP OF FILL TUBE. (APPROXIMATELY 65 GALS, INITIAL FILL). 13. START ENGINE, STEER LOCK TO LOCK 3 TIMES, 4, RAISE BODY AT LOW IDLE UNTIL CYLINDERS. ARE FULLY EXTENDED, THEN LOWER BODY. S.WITH ENGINE RUNNING AND BODY DOWN, ADD. ‘OIL TO TOP OF FILL TUBE. 6. RAISE BODY AT LOW IDLE UNTIL CYLINDERS ARE FULLY EXTENDED, 7.REPLACE CAP AND LOWER BODY. ‘Attached to the hydraulic tank is a Caution plate alert- ing the service person of hot oll under pressure. Hy- Craulic ol becomes heated during operation and care must be taken to avoid bums when it is necessary to open the hydraulic system. There is always a chance of residual pressure being present even after the pres- sure is released. CAUTION HOT OIL UNDER PRESSURE. DEPRESS BUTTON TO RELEASE AIR PRESSURE BEFORE REMOVING CAP OR TANK TOP. Hydraulic fluid escapes under pressure can have sufficient force to enter a person's body by pene- trating the skin and cause serious injury and pos- sibly death if proper medical treatment by a physician familiar with this injury is not received immediately. A Caution plate is located on the hydraulic brake res- ervoirto alertthe service personto use only SAE J-1703 rated brake fluid. Brake system components are not compatible with other fluids and will deteriorate. Z\ CAUTION USE ONLY SAE J-1703 HYD. BRAKE FLUID OR EQUAL IN RESERVOIR. OTHERWISE BRAKE SYSTEMS COMPONENTS WILL DETERIORATE. Abd Warnings and Cautions ‘A04004 8/90‘A warning plate is attached to both fuel tanks warin technicians NOT to work on the truck with the body in thé raised position unless safety cables or body props are in posttion. WARNING DO NOT WORK UNDER RAISED BODY UNLESS SAFETY DEVICE(S) ARE IN POSITION OPTIONAL - On HAULPAK® trucks equipped with this, option, a decal is located on the hydraulic tank which states that the body may be lowered in a controlled ‘manner by opening the valve adjacent to the decal and allowing the hoist cylinders to slowly lower the body. FOR CONTROLLED BODY CREEP DOWN OPEN VALVE. ‘804004 8/90 OPTIONAL - On HAULPAK® trucks equipped with ‘option, a plate is located on the hydraulic tank which provides the operator or technician the proper hook-up procedure for dumping the load from a disabled truck. EMERGENCY DUMP PROCEDURE {NOOR ur SUCK OCOMCTE: NE Ue fnow Lance HotsT cross {owe on csuautp Tauck 79 SUALt WOU enoas Tune Ue Go0D ‘wuex Te TER UME Fao MHL otsT enoss TURE OH ‘IsunaD TAUCK To. LANGE NolsT Cnose TUBE ox coop TRC 2 PLACE HUST VAIE OF DIABLED THUCK Ut WOLE POSTION, ‘Tartan ths Postion TanoUen Blur cee 1 DUMP LOAD OF DISHBLED TRUCK BY ACTUATING WOisT YALE OF ooo Fauex To “Powen bow poston. 44 AFTEN LOAD wis nEEu pouPeD, PLACE WONT YALE ‘RUG Yo"lor"poumow Ab Aow Taek oo OPTIONAL - On HAULPAK® trucks equipped with this option, a waming plate provides instructions to the operator or technician on the emergency steering pro- cedure. This plate states the proper procedure and hook-up instructions for steering a disabled truck using the hydraulic system of a good truck. A\WARNING EMERGENCY STEERING PROCEDURE *- ENGINE Musy BE STOPPED ANO ACCUMULATOR 2 SGNNEEY EctenNat suprty HOSETO 7S NCH > FRANC CRE REE RUT ose ro sone ee aes ESE SUne Semcon SSS Warnings and Cautions AS‘Attached to the exterior ofthe battery compartment is. ‘a danger plate. This plate stresses the need to keep from making any sparks near the battery. When an- other battery or 24VDC power source is used for aux- iiary power, al switches must be “Off prior to making any connections. When connecting auxiliary power cables, positively maintain correct polarity; connect the posttive (+) posts together and then connect the negative () lead ofthe auxiliary power cable to a good frame ground. Do not connect to the negative posts of the truck battery or near the battery box. This hookup completes the circuit but minimizes danger of sparks near the batteries. Sulfuric acid is corrosive and toxic. Use proper safety {gear, goggles, rubber gloves and rubber apron when handling and servicing batteries. POISON / DANGER CAUSES SEVERE BURNS Pee memes SL ea Ran PINS Scd fanmncaarnas Te cewcoretts ant Crusis 7 cota Emre a) On top of the battery box is a decal which outlines the correct procedure for disconnecting the batteries. CAUTION WHEN DISCONNECTING BATTERY DISCONNECT +12V TERMINAL FIRST. (DO NOT LET TERMINAL TOUCH CHASIS GROUND.) DISCONNECT +26V TERMINAL, SECOND. IF DISCONNECTING GROUND TERMINAL, DISCONNECT GROUND RECONNECT IN REVERSE ORDER. Ass Warnings and Cautions Warning plates are mounted on the truck frame in front of and to the rear of both front tires to alert all persons to stay clear when truck is being steered. WARNING STAY CLEAR. CLEARANCE REDUCED WHEN MACHINE IS STEERED. MOVING COMPONENTS MAY CAUSE CRUSHING. wasoz DANGER plates which contain instructions for releas- ing internal pressure prior to any disassembly of com- ponents are attached to each suspension cylinder. ‘04004 8/90‘ADANGER plate which contains instructions forreleas- ing internal pressure prior to disassembly of com- Ponents is attached to the steering accumulator. ° [A\ pancerR | ° WIGH PRESSURE CYLIDER READ WARMING LABEL MOUNTED ON SIDE OF ACCUMULATOR HOUSING BEFORE LOOSENING ° (OR DISASSEMBLING ANY PARTS, ‘A Product identification plate located on the frame in front of the right side front wheel gives the Model Number, Maximum G.V.W. and Product Identification Number. = LUBRICATION =— CHART = ® @® © = ® @ The Lubrication Chart is located on the right hand side of the radiator grille. Refer to the Service Manual for more complete lubrication instructions. 04004 7/91 Warnings and Cautions MerMe NOTES Warnings and Cautions ‘A04004 8/90STANDARD CHARTS AND TABLES This manual provides dual dimensioning for most specifications. U.S. standard units are specified firs, with metric (SI) units in parentheses. References ‘throughout the manual to standard torques or other standard values will be to one of the following Chars or Tables. For values not shown in any of the charts or tables, standard conversion factors for most common- ly used measurements are provided in TABLE Xill, Page A5-6. INDEX OF TABLES TABLE | .... Standard Torque Chart (SAE) AS TABLE I Standard Torque, 12-Point, Grade 9 5.2 TABLE Ill . Standard Metric Assembly Torque A52 TABLE IV ..... JIC Swivel Nuts Torque Chart A53 TABLE V.. Pipe Thread Torque Chart A53 TABLE VI ‘O-Ring Boss Torque Chan. ASS TABLE Vil... .O-Ring Face Seal Torque Chart AS3 TABLEVIII . .Torque Conversions (ft.lbs—N.m) A5-4 TABLE IX . Torque Conversions (ft.lbs ~ kg.) A5-4 TABLE X .. Pressure Conversions (psi- kPa) A5-4 TABLE XI . .Pressure Conversions (psi-MPa) AS-4 TABLE XII ........ Temperature Conversions A55 TABLEXIII ... Common Conversion Multipliers A5-5 TABLE 1 STANDARD TORQUE CHART ‘SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY (LUBRICATED THREADS) TOLERANCES 10% EFFECT OF SPECIAL LUBRICANTS (On Fasteners And Standard Torque Values Haulpak Division does NOT recommend the use of special “riction-reducing” lubricants such as, "Copper Coat’, "Never Seize’, and other similar products on the threads of standard fasteners where “standard torque" values are applied. The use of special “riction-reducing’ lubricants will significantly alter the clamping force being applied to fasteners during the tightening process. If special “ric- tion-reducing’ lubricants are used with the "Standard Torque" values listed below in Table | (and most Haul- pak service manuals), excessive stress and possible breakage of the fasteners may result. ‘Where Torque Tables specify Lubricated Threads" for the Standard Torque values listed. these standard torque values are to be used with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust- preventive grease (see list, page AS-2) onthe threads and seats, unless specified otherwise. NOTE: Always be sure threads of fasteners and tapped holes are free of burrs or other imperfections before assembling. Standard Torque values are not to be used when *Turn-of-the-Nut" tightening procedures are recommended. TonQUE™ GRADES | TOROIE > GHpOEE[OUSONSN] TOROUE > GRADES tute | tom | Nm [ree [som | xm | "2 Pam | mam | nm [aoe | tom | nem Taser et sen [ tes tae a ee tea aber ee poe veo [ ae bee tos [om Pas tos siete [os baer ae fo fen [ ae Pate oe to te eae te eee eae ee Ln Ps ee seis [ steep ee tee Dae Peete eee seats test pet temp weet soe te ae meee beet pa tes oe mes[= esa ts pee a taba tee pe ner [-oo bese tot eo teat bere pet Tues [ ae Pes Lise feet oe oe wee bebe oe et woes [ame [ese Pee | ofa siete tee tees is mtb toe oo sen [es Lae st Tie [ew tae ave | oe ote seep tee eet Tee Die basa [oe foe Seba bee bs te bs He elena A05001 8/96 ‘Standard Torque Charts and Tables ASAStandard Assembly Torques For 12-Point, Grade 9, Capscrews (SAE) ‘The following specifications appy torequired assembly torques for all 12-Point, Grade 9 (170,000 psi minimum, tensile), Capscrews. © Capscrew threads and seats SHALL belubricated when assembled. Unless instructions specifically recommend otherwise, these standard torque values are to be used with simple lithium base chassis grease (mutti-purpose EP NLGI) or a rust- preventive grease (see list, this page) on the threads. © Torques are calculated to give a clamping force of approximately 75% of proof load. ‘© The maximum torque tolerance shall be +10% of the torque value shown. Standard Metric Assembly Torque For Class 10.9 Capscrews & Class 10 Nuts The following specifications appy to required assembly torques for all meteric Class 10.9 finished hexagon head capscrews and Class 10 nuts. © Capscrews threads and seats SHALL NOT be lubricated when assembled. These specifications are based on all capscrews, nuts, and hardened washers being phosphate and oil coated. NOTE: If zinc-plated hardware is used, each piece must be lubricated with a Rust Preventive Grease or Lithium-base grease to achieve the same clamping forces provided below. ‘© Torques are calculated to give a clamping force of approximately 75% of proof load. ‘© The maximum torque tolerance shall be 10% of the torque value shown. TANDARD METRIC ASSEMBLY TORQUE TABLE- STANDARD ASSEMBLY TORQUE ‘Torauve | TORQUE | TORQUE for 12-Polt, Grade 8, Capscrows um ‘capscnew | TORQUE | TORQUE | TOROUE Mext 2 1 sae | "nies um ‘am Maxis [3 Zz 305 0250-25 2 6 17 moras = 2 rr 0312-18 24 33. 33 M12x 1.75. ES 70 9.69 0.375 - 16 42 ST $8 Mid x2 155 14 15.81 0.49814 70 35 97 Mi6x2 240 Era Pass (0500-13 | 105 a2 4s wane | ase 3s eras 0562-12 150 203 207 M26x 3. "200, ‘590 816 0625-11 | 205 ze | 283 M20x35 | 1600 180 7632 0780-10_[ 60 488 07 Ms6x4 | 2750 7028 2005 0878-9 S75. 70. a4 * Shank Diameter (mm) x Threads per mm. 1000-8 860 1168 19 This Table represents standard valves ony. 7000-12 | 915 1240 126 Do not use these values to replace torque values which are 1125-7 | 1290 1670 170 ‘sbeciied in assembly insrucions. 5.125.12 | 10 1800 184 4250-7 W715, 2325, 237 SUGGESTED* SOURCES FOR ro = a aa RUST PREVENTIVE GREASE: figre=1om ere ea ea ‘@ AMERICAN ANTI-RUST GREASE #3-X from cE an ape rm ‘Standard Oil Company (also American Oil Co.) 41.500 - 12 3225 4375, 445, @ GULF NORUST #3 from Gulf Oil Company. This Table represents standard values onl, ‘Do not use these values to replace torque values which are ecified in assembly instructions, SSS A522 Standard Torque Charts and Tables ‘® MOBILARMA 955, Product No. 68708 from Mobil Oil Corporation, ‘¢ RUST BAN 326 from Humble Oil Company. ‘¢ RUSTOLENE B GREASE from Sinclair Ol Company. ¢ RUST PREVENTIVE GREASE - CODE 312 from the Southwest Grease and Oil Company. * NOTE: This list represents the current Engineering approved sources for use in Haulpak manufacture. It |s not exclusive. Other products may meet the same specifications of this list. ‘A05001 8/96Taste TORQUE chant FoR G'S SWIVEL NUTS Tonave HAT FOR rt onwmnour om Sea onnna goes Fives ae Bae wuae sz] Trmeacs | ToRauE cove goor_| “eos | twess | ies we [ois [ose [est =e [ores | ostape [te =a] aes [egress [os =a [one [ose se |e =a | “ae nase | ps =a | age [oases | —o8 =e} este [aso —ss ss [ose [oases [19s =e [osm [ose | 88 =e] ears | assets [93 | ose [oreo | ca | 9m0 | ozeeie [ss =i | “oes oars | aos =o | aes | oarete [sre =i | “oro [sets | as S| aso | oes | se =| oe [here] as S| oars | tieete|st =16 1,000. 131212 20 +5 16 1.000 131212, wezs_ | =a [1am [Tiss | “oto Sa [ie ee [se Sa so tert st Sa | ~ts00 | terete] ee sae] 0m 1 asomie [a0 a8 [2g Ten Tose tb TABLE V | TABLE Vil Tonal chant FoR TonaUe Chant FoR Pe TuneAD FTN o-nma act Seat FTG wit —]winouT See] ae sve] Tineacs | TORoUE ERE [Prezaneno| sexu | Soccawt cooe_| oo) | tnress | wre rres_| ‘Frise = cased [st <2 ass] ms 3 ogee <4 [oaso-1e [aos | as 8 33 cane =e [oare-is[psss | se 8 a0 oars se [cosine [ose] ees 3 toe =iz[orsmia[ ages | ge 8 He ise mie | tasosriso-[ sss [es 8 = ee a = ieee Sas [1-t180-| 905 | os == [amos [ees [ms L=2 _20rso | sssi0 | zor | SSS ‘A05001 8/96 Standard Torque Charts and Tables A533TABLE Vill TORQUE CONVERSIONS Foot Pound ft. bs. To Newton.meters (N.m) (reso 4s a Ts sl 7s 2 o [wm [1368 _[ ei ar | 5a] ere | a8 | 90 | 088 | a jo [1386 | iast_| i627 | ares | tase | 3038 | a1s9 | 20s] 24e0 | as7r6 z0_|zr12| sear | aoa sese_| aso0 | 9525 | 951 _| eras | soa g0| aos | a20s_| 439 | ea7e | 4610 | eras | apt | e017 | sts | sar ao _|sazs [sss [ses | s800 | spe6 | 6x01 | 2a | e370 | eno | saa so [errs | ees | roso | 716 | 7az1_|ras7 | 7508 | rr.28 | rues | 0.00 eo [eras [e270 | see | 542 | 0677 | ens | os | ona | e270 | oass yo [ sia: [e625 | o72 | o8s7 | 10038 | 10169 | 1004 108.40 | “10578 | or. ao [sonar [tose [1nnt6 | 11259 | sae [11528 | 11660 | 117906 | 1031 | 12067 so | vze03 [tease | 12474 | 12500 | v2ras | vzae0 | 19016 | 10181 | taea7 [1945 ‘See NOTE on page ASS "TABLE 1 TORQUE CONVERSIONS Foot Pounds -f. bs. To klogram.meter (kgm) Fries | _o z 2 3 4 5 z 2 2 oT ecgmy [0.138 [0277 [041s | 0858 | 062 | 0.690 | 0968 | 1108 | 1205 70 sze [ssa [165 | 10 | 196 | 207 | 2at 295 | 249 | 269 20 27 {290 [aoe | 318 | ase | a6 360 | 373 | se7 | a0 30 415 [429 [44s [ase [470 | aaa | 498 | 512 | 525 | 529 0 553 | se7_| sav sas | 60s | 622 | 635 | 650 | 66s | 678 50 ese [70s | 7s | 733 | rar | 7.61 zis | 798 | 802 | 6.16 0 sao | sas |" esr [er | ees | a00 | 013 | 027 | 040 | asa, 70. ass_| ea | a6 [1010 [1023 | 1037 | 1051 | i065 | 1079 | 1093, 20. 1105 [i120 | ig4 | an48 | ang2 | 3.76 | 11.80 | 1203 | 1217 | 12.30 20. seas | r2s9 [1272 | 1205 | 1300 | 1314 | 1328 | 1342 | 1355 | 1069, ‘See NOTE on page AES TABLE X PRESSURE CONVERSIONS: Pounds/sq, in. [pel] To. kilopascals (kPa) Formula: psi x 6.895 = kPa (om 2 z 273 2 ss 2 oT wea) Ten0s [1370 [206s [arse | maar | a1s7 | 0825 | 55.10] e205, so | e805 |" 750s [e274 [e063 | 0653 | 1042 |_11098 | 11720 | 1241 | 131.0 20. sag [teas [1517 | 586 | 1655 | 1724 | 1703 | 182 | 1931 | 2000 so_{ 2068 |" 2is7 [2006 | ae7s | asa4 | 2613 | 2082 | 2551 | 2520 | 208.9 4o__| ase |" 2s27 |" aso6 | aes | soa | 3103 | 372 | 24s | aa10 | s379 so__| ssa7_ | ss16 | ssas | ses4 [sas | ava2 | 2861 | 2930 | sen9 | eons so_| 4137 | 206 [aos | asea | asia | eaa2 | 4551 | 4620 | 468.9 | e758 70 asz6 [4005 [sos [5038 | st02 | si71_| 5240 | 5009 | 5078 | sea 20 20 100 oso [076 [083 | 090 | 097 | 1.03 | 1.10] 1.7 | 124] 1.3 200 18 [nas [ssa [159 [165 | 472 | 179 | 1.86 | 198 | 200, 300 | 207 | 214 | 22 225 | 2as | 241 [248 | 25s | 262 | 269 400__|" are | 283 | 290 [298 | 30s | 310 | 17 | aoe | ast | ae. soo_|' sas [ase [aso [36s [372 | 379 | 386 | a3 | 400 | aor. soo_[ 416 [421 [427 4a | aer| aaa | 45s | 462 | 469 | a76 zoo__|"4a3 [490 [498 | 503 | s10_| si] 28 | 51 538 | 545 soo | ssa_[ sss [ses s7e | 570 | 56 | sas | 600 | er | 614 soo | e21 | sz | ess | 641 | 648 | 655 | 662 | 669 | 676 | 683. ‘See NOTE on page ASS 54 Standard Torque Charts and Tables ‘805001 8/96NOTE: Tables such as Table Vill, IX, X, and XI may be used as in the following example: Example: Convert 975 psi to kilopascals (kPa). 1. Select Table Vil 2. Goto PSI row 80, column 7; read 668.8 97 psi = 668.8 kPa. 3. Multiply by 10: 970 psi = 6688 kPa, 4, Goto PSI row 0, column 5; read 34.47 5 psi = 94.47 kPa. Add to step 3. 5.970 + 5 psi = 6688 + 94 = 6722 kPa, 975 psi = 6722 kPa. TABLE Xil_ TEMPERATURE CONVERSIONS CELSIUS. [FAHRENHET] CELSIUS JFAHRENHEIT] CELSIUS [annexe —___ — — a == = aes a Ss es Be a3 Eee =e —— 2 ee — — —— —s :— Sa ae ce ts te Se caaan Sala Nee mre, eae faccgta ane toecertsstco asec jeman tenon er fsceencner on ‘A05001 8/96 Standard Torque Charts and TablesTABLE XIll - COMMON CONVERSION MULTIPLIERS [COMMON CONVERSION MULTIPLIERS ‘COMMON CONVERSION MULTIPLIERS ENGLISH to METRIC METRIC to ENGLISH TO CONVERT MOLTIPOY ‘wOLTIPLY FROM to ey 10 ey neh — in. lier (mr) 2540 ineh~ i 0.0964 nen = i centimeter (7) 258 ine — in (03957 foot = 8. meter (n) 2.2048 foot = 3.2008 yard_— ya meter (n) 0914 yars= ye 1.0995 mile = mi oreter Gen) 1.81 kometer Gen) ile — ‘o.210 sq. in. — in 29. centimeters (em?) 6.45 sq. centimeters (em?) [sq. in. _— in? 0.1550 sa. contimetes (om?) | 029 29. centimeters (em?) |sa. ft 0.001 eu. centimeters om?) | 1639 ou. contmetors (en) eu. n= in 00st ters Ql) 0.016 liters () jeu. in. — in? 81.02 feu. motos =) onze eu. metre?) eu tt = 8° 35314 tes) 733 ners ext — a2 00353 kilogram (ka) 0.028 jarams (a) ounce = oz, ome =i (a) 20573 iter (ot [nic ounce — fez | 0.0038 pound (ass) ogra tg) 0454 ogram eg) pound (mass) 2206 pound (ores) — Tes | Nowon () ase Nevo (N) [pound (ores) — fos. | 0z24a nos. force) Newor.meers Rim) | 0.18 Nowtonzmeters Rum) | klogram.meters gm) | 0.102 os. tore) Newn.neters Nm) | 1.258 [Newson meters (Num) [fs force) 7376 tbs. tore) kogram.meters (xan) | 0.198. [ogram meters 6g.) [fos force) 7.2009 elogram.metars hen) [Newton.meters (Nn) | 9807 kiogram.meters hg.) | Nowon.meters (um) | 9.807 (pressure) Klopascals (MPa) 5895 lopascals kPa) [psi ressue) 0.1450 ps (oessue) imogapascals (MPa) | 0.007 megapascals(MPa)_[psi (ressue) 145.099 pe (pressure) Kiogramsiem? (gion) | 00704 [legramsien? fag/en*| [pst (pressure) 14.2091 ton nen gram (eg) 9072 klopascals Pa) 9.9068 ton ener) mewiston 0907 tn chon) o0or4 quar = ot iors) 0.06 ton chon) 1.1023 |galon— ga ites) 3725 quan = 1.0557 HP norepowe) [watts 7457 galon gal 254 HP torseoower) [kilowatts a) ors HP rotsepower) ‘200104 HP (horsepower 43610 AA SSSSSSSSSSSSSSSSsSSsSsSssssssssssse 156 Standard Torque Charts and Tables ‘A05001 8/96SECTION B STRUCTURES INDEX ‘STRUCTURAL COMPONENTS Pee Eee Grille & Hood... Peer Decks DUMP BODY Removal Instaltation Body Pad Body Guide. . Body Position Indicator . . . Body Sling Rock Ejectors FUEL TANKS Removal Installation Vent... Gauge 801008 9/90 Index BitNOTES B12 Index 801008 9190STRUCTURAL COMPONENTS GRILLE AND HOOD Removal 1. Attach liting device to lifting loops (1, Figure 2-1) located on top of the grille. 2. Disconnect upper headlight wiring, unciamp wit- ing from grille and tie wiring clear of gril. 8, Remove upper mounting capscrews (2) from the grille. Remove side and lower mounting capscrews (4) from the gril. 4. Lift grille (3) off of truck and remove to work area. Installation 1. Reverse Steps 2, 3, and 4. ose FIGURE 2-1. GRILLE REMOVAL DECKS ‘The HAULPAK® truck left deck is mounted tothe frame structure using rubber mounting pads. These pads are placed between the deck and the mounting structure to reduce noise and vibration. These rubber mounts should be checked periodically and worn or defective mounts should be replaced. When tightening ccapscrews, torque to 94 in (23.5 mm) installed dimen- sion shown in Figure 2-2. FIGURE 2-2. RUBBER MOUNTING PADS. 1. Capscrew 5. Lockwasher 2. Flatwasher 6 Nut 3. Deck 7. Frame Structure 4, Rubber Mounting Pad 8 Washer MOUNTING PAD REPLACEMENT Removal 1. Remove capscrews (1, Figure 2-2), washers (2, 5 & 8) and nuts (6). 2. Raise comer of deck (8) a sufficient distance approximately 2 in. (60.8 mm) to remove worn or damaged mounting pad. 3, Remove mounting pad (4) and discard. Installation 1. Install new mounting pad (4). 2. Lower deck structure (3) onto pad and align 1. Lifting Bracket 3. Grille capscrew holes with mounting pad. 2. Upper Mounting 4, Side & Lower Capscrews Mounting Capscrews 3. Install capscrews (1), washers (2, 5 & 8) and nuts (6). Tighen nut (6) unti0.94 in. (23.5 mm) dimen- sion shown in Figure 2-2 is obtained. 02002 7/90 ‘Structural Components Bot